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3 Information Series The Welding of Stainless Steel Material
3 Information Series The Welding of Stainless Steel Material
STAINLESS STEEL
AN OVERVIEW OF THE BASIC PRINCIPLES
Welding is the most used method of THE THREE ZONES IN affect its mechanical, physical and
joining stainless steel. It is a special WELDING corrosion resisting properties.
process whereby different pieces In welding there are three zones of
of solid metal are joined, at molten concern, as illustrated in Figure 1. 3. THE SOLIDIFIED WELD
metal temperatures, to produce a joint METAL
that should have the same (or better) 1. THE UNAFFECTED P ARENT The composition of this can be either
mechanical and corrosion resistant (OR BASE) METAL
properties as the base material. The material being welded - at a metal is used (known as autogenous
It is a key element in the fabrication relatively small distance from the welding) or that resulting from a
of many stainless steel products. weld it is only slightly warmed so
Moreover, the welding of stainless steel that there is no change to its crystal (depending on the extent to which the
structure, or to its properties. parent metal has been melted, thereby
Therefore an understanding of
the basic principles will assist in 2. THE HEAT AFFECTED ZONE
greater productivity in fabrication, (HAZ) is a miniature “casting”. Its cast
The area of the parent metal adjacent grain structure will differ from the
and, if required, maintenance. to the weld metal is heated through parent metal. This difference will be
a range of higher temperatures up to
STAINLESS STEEL the melting point, which occurs at the or sheet, but also differs, to a lesser
Stainless steel is not a single material, junction with the weld metal. extent, if the parent metal is a casting.
but a family of different types and The actual temperature attained
grades, based on alloying chromium depends on the distance from the WELDABILITY
(Cr) with iron (Fe). The details of weld, the thermal conductivity of the The utilisation of welding in
steel and the amount of heat input. the fabrication of engineering
and their properties and corrosion The high temperatures reached components depends on the
resistance have been covered in induce changes to the crystal structure weldability of the steel. Weldability
previous modules of this series. of the parent metal, which in turn may
property, but rather implies the
ability of the material to be joined by
standard welding processes, so that
the resultant mechanical, physical
and chemical properties of the weld
zone (i.e. both the weld metal and the
HAZ) are at least equivalent to those
of the parent metal.
Whereas all stainless steels may be
WELD METAL
HEAT AFFECTED ZONE (HAZ) welded, the weldability of the various
PARENT METAL (UNAFFECTED)
WELD ZONE
to a large degree, due both to the
MELTING POINT
different chemical compositions and
crystal structures as well as to the
TEMPERATURE ( ºC) resultant reactions of these to the
thermal cycles of welding.
To a lesser extent the weldability of
ROOM TEMPERATURE
the different grades within any one
Figure 1 Schematic illustration of the three zones of welding and the related confined area of
high temperature.
PHYSICAL PROPERTIES cooling, which can cause weld zone welding, the incorrect use of too
OF STAINLESS STEEL cracking or high levels of residual stress. high a welding current will cause
As outlined in previous modules overheating of the core wire of the
the physical properties of stainless THERMAL CONDUCTIVITY electrode with associated damage to
steel may differ substantially from Austenitic stainless steels, in the flux coating.
carbon and low-alloy steels (e.g. mild particular, will conduct heat more
steels) and also between the various slowly than mild steel. MELTING TEMPERATURES
classifications of stainless steel. This promotes sharp temperature The lower melting temperatures of
The physical properties of major gradients, which, together with the stainless steel compared with mild
influence are: high thermal expansion, will cause steel is an advantage, because less heat
The coefficient of thermal expansion. that distortion to be confined to a is required to produce fusion.
The thermal conductivity. small area. The weld zone will remain This in turn means faster welding
The electrical resistivity. at high temperatures for a longer for the same heat, or conversely less
The melting temperatures. time, which is of critical importance in heat input for the same welding speed.
Typical values of these physical controlling interpass temperatures. These factors demonstrate that a
properties for various types of steel change from welding mild steel to
are given in Table 1. ELECTRICAL RESISTANCE stainless steel should not be made in
The higher electrical resistance of an undisciplined manner.
COEFFICIENT OF THERMAL stainless steel results in the generation With an appreciation of these
EXPANSION of more heat for the same current. differences, appropriate actions
Austenitic stainless steel, in particular, This, together with the low heat should be taken to avoid or minimise
will expand to a greater rate, than conductivity, is an advantage when possible detrimental effects such as
mild steel. resistance welding processes are used. distortion and excessive heat input.
Allowance must be made for this But, in other welding processes These can include using smaller and
expansion and contraction to control it can, if not controlled, result in too more frequent tack welds, the use of
distortion and prevent high levels of great a heat input. copper back-up bars and chill plates or
thermal stress, particularly during In manual metal arc (MMA) step welding.
TYPE OF STEEL Coefficient of Thermal Thermal Conductivity Electrical Resistivity Melting Point
Expansion (µm/m°C) (W/m°C) (µΩm) (°C)
PLAIN CHROMIUM 11,3 24,0 0,060 1 430 to 1 510
FERRITIC & MARTENSITIC
STAINLESS STEEL
AUSTENITIC STAINLESS 18,3 18,5 0,072 1 400 to 1 450
STEEL
UTILITY FERRITIC 12,5 25,0 0,057 1 430 to 1 510
STAINLESS STEEL
PLAIN CARBON AND 13,8 65,0 0,016 1 500 to 1520
LOW-ALLOY STEELS
800
unimpaired and there is a far lower
0,03 %C tendency for brittleness to develop.
700
These improvements are chiefly
600 related to the very low levels of C
and N, plus the usual addition of
500 stabilising elements.
However, grain growth of the ferrite
crystal structure can still detract from
1 MIN 10 MIN 1 HR 10 HRS 100 HRS the properties in the “as-welded”
condition.
TIME Some manufacturers limit “good
weldability” to a maximum thickness of
Figure 4 Schematic illustration of the major effect of carbon content on the time taken for
2,5mm but, in general, the weldability
sensitisation of a typical austenitic stainless steel
may be classed as “moderate” up to
thicknesses of 5-6mm.
In the welding of these grades either This is due to They are best welded by resistance
“L” grade, or Nb stabilised welding Grain boundary breakdown at high welding or autogenous TIG welding
consumables must be used. temperatures (over 1 100°C) forming processes.
Due to either of the above methods, larger, coarser grains. For welding thicker gauges use
coupled with modern welding Formation of Cr carbide and Cr TIG or MAG and high nickel-based
equipment that allows faster, lower heat nitride precipitates and relatively high consumables.
input procedures, the classical form carbon martensite. Matching filler metals tend to
of weld decay through sensitisation, Typically these steels are brittle after produce a coarse grained structure
as explained above, SHOULD NOT welding and prone to corrosion within in the weld metal and are not
OCCUR. Note that even in normal the HAZ. recommended.
carbon grades of austenitic stainless These deleterious properties The inert gas welding processes are
steels, the carbon content is now generally render these steels susceptible to CO2, N, or H2 impurities.
controlled to lower levels than in the unsuitable for engineering end-uses Pure Argon is recommended for TIG
past, thus minimising the incidence of involving welded heavier gauge and Argon +1 -2% O2 for MIG. MMA
this problem. material. welding is not recommended.
However, responsibility rests with Their normal applications as welded Cleanliness is essential, particularly
the welder to ensure that contamination components are therefore limited to with respect to possible contamination
of the weld from sources of carbon such those utilising only thin gauge sheet by C. Heat input and interpass
as dust off the workshop floor, paint, material. temperatures should be restricted to
grease and oil do not occur. Such thin material is usually welded minimise grain growth.
The presence of such carbon using an autogenous welding process
contamination is often overlooked, (TIG or resistance welding), although UTILITY FERRITIC
as the source is not always readily MAG welding is also used in high STAINLESS STEEL
apparent (e.g. a mist of oil contained production processes. These steels were developed to
in the exhaust of air motor machines, If a filler metal is used, or if thicker overcome the problems limiting the
handling electrodes with oily or greasy gauges are welded, the austenitic filler weldability of plain Cr ferritic stainless
gloves). metals, grades 308L and 309L, must be steels for engineering applications, but
used. with sufficient Cr content to impart
FERRITIC It is also necessary to minimise heat useful corrosion resistance.
STAINLESS STEEL input and interpass temperatures. If welded in accordance with
There are three sub-classifications of recommended procedures the
ferritic stainless steel to be considered. SUPER FERRITIC STAINLESS weldability is good in thicknesses up
Standard ferritic stainless steel. STEEL to 25mm to 30mm.
Super ferritic stainless steel. Several of the super-ferritic stainless In the HAZ, the adverse effects
Utility ferritic grades. steels available are proprietary of the thermal cycle of welding are
grades but many are now included minimised due to:
STANDARD FERRITIC in international standards. Noticeable Very low C and N content (which
STAINLESS STEEL features of their chemical composition may be additionally stabilised by the
Standard ferritic stainless steel are: addition of Ti).
contained within the AISI 400 series Increased Cr and additions of Mo to The mixed crystal structure of the
have been detailed previously. improve corrosion resistance. steel at high temperatures.
In general the weldability of these Very low C and N content. The formation of chromium
steels is poor and they suffer from Stabilisation by additions of Ti, or carbides and nitrides are reduced to
inferior properties in the “as-welded” Ti + Nb. a minimum, thereby overcoming both
condition. The weldability of these steels is their embrittling effect and their