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THE WELDING OF

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.

TABLE 1: TYPICAL PHYSICAL PROPERTIES FOR DIFFERENT TYPES OF STEEL

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

AUSTENITIC technology, have virtually eradicated cracking occur:


STAINLESS STEELS the two major problems associated 1. Solidification Cracking
These are also known as the 200 or with the welding of austenitic stainless takes place during and just after
300 series, as outlined in the previous steel. solidification. It is due to weld metal
module. These are: not being able to accommodate the
Their weldability is generally Hot cracking within the weld zone. thermal stresses during cooling.
excellent, except for the free machining Weld metal cracking. Mechanical failure takes place along
grades such as 303 or 303Se. HAZ cracking. the grain boundaries (intergranular
They may be readily welded by any Loss of corrosion resistance through cracking). This failure is more often
of the standard welding processes sensitization. than not the result of poor technique
such as manual metal arc (MMA), or poor consumable selection. Welding
tungsten inert gas (TIG), metal active HOT CRACKING WITHIN THE procedures suitable for mild steel are
gas (MAG), submerged arc welding WELD ZONE NOT directly applicable to stainless
(SAW), resistance welding, friction Weld metal cracking steel.
welding, plasma arc, laser welding Resistance across the weld and the 2. Micro-fissuring occurs at
and electron beam welding. crystal structure development in the temperatures very close to that of
Advances in welding technology weld metal are the major influencing final solidification. It is intergranular
(particularly those associated with factors. Fully austenitic weld metals in nature and is due to low melting
developments in the field of welding are more prone to cracking. point compounds segregating out at
consumables) and in steel making Two forms of closely related hot the grain boundaries. It is more

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difficult to avoid entirely and is not as temperature applications are two The steel has therefor become
dependent on welding conditions. further such end-uses. SENSITISED and is prone to localised
The presence of impurities, notably Whereas generally there is a corrosion occurring close to the weld
sulphur (S) and phosphorus (P) and to preference for the utilisation of ferrite deposit and along an intergranular
a slightly lesser extent silicon (Si) and containing weld metal, it must be path, due to the lower corrosion
niobium (Nb), has a marked influence stressed that significant amounts of resistance of these Cr depleted grain
on hot cracking. Modern steelmaking fully austenitic (theoretically crack- boundary areas. Note that this localised
processes and impurity control have prone) weld metal are successfully corrosion may only occur in specific
largely eliminated these problems deposited (e.g. 310, ferrite-free 316). conditions.
Resistance to hot cracking is However, the necessary precautions This corrosion is termed WELD
improved if the weld metal solidifies should be taken in these instances to: DECAY and is typified by a rough
as two-phase austenite plus a small Minimise stress/restraint. granular appearance of the corroded
amount of retained ferrite. Use narrow weld/smaller stringer surface (like grains of sugar, as
This is due to three factors: beads. illustrated in Figure 3).
1. The ferrite dissolves and retains The above factors demonstrate the Two methods are used to prevent
in solution the impurities that would importance of the correct composition weld decay:
otherwise separate out. of the weld deposit. 1. Stabilising alloying elements,
2. The ferrite present increases the Electrodes often have the necessary such as titanium (Ti) and niobium
grain boundary area available and alloys content contained in the flux, and (Nb), are added to the steel. These have
thereby “dilutes” any grain boundary filler wires are specifically produced to a higher affinity for C than Cr does.
segregates that may occur. close chemical composition limits. Provided they are present in sufficient
3. The ferrite fraction has a lower Therefore the following precautions quantities, they preferentially combine
high temperature strength and should be noted: with and lock up the carbon to form
therefore deforms without inducing DO NOT use electrodes if the flux stable Ti or Nb carbides. Therefore,
cracking to accommodate the stresses. coating is damaged. Cr carbides cannot form and the steel
The chemical composition of most DO NOT strip electrodes of the flux retains its corrosion resistance.
filler metals is therefore adjusted to coating and use as filler wires. The typical stabilised grades of
result in a weld metal that contains DO NOT use trimmings off sheet austenitic stainless steel are 321, 316 Ti
6-10% ferrite. This is indicated by the or random pieces of ordinary stainless (containing Ti) and 347 (containing Nb).
ferrite number (FN) normally given by steel wire as filler wire. In the welding of these stabilised
the suppliers of welding consumables. (N.B. These rules apply to the grades, it is generally recommended
(At low levels the FN may be taken to welding of ALL stainless steel and that a stabilised welding consumable
be equal to the ferrite percentage). highly alloyed materials). be used. As Ti tends to be lost in the arc,
Nb is used for stabilised consumables.
HAZ cracking LOSS OF CORROSION 2. The carbon content is reduced to
This is also largely related to the RESISTANCE THROUGH very low levels. The carbon content of
impurity level. Ferrite, if present, has a SENSITISATION the steels is held to the very low level of
beneficial effect. Fine grain sizes are less Chromium has a high affinity for 0,03% max C.
susceptible. carbon at elevated temperatures. In addition to temperature,
Wrought plate and sheet has a Heating the parent metal within the sensitisation is also dependent on
negligible ferrite content, but its fine temperature of 450° - 850°C, can cause carbon content and the time within the
grain size and low impurity levels are Cr and C to combine as a complex sensitisation temperature range.
beneficial factors. chromium carbide, Cr23C6. The Referring to Figure 4, note that a
Cast materials usually have a higher HAZ is unavoidably subjected to this 0,08% C steel can start to sensitise in
ferrite content that counteracts the temperature range during welding. under a minute, whereas a 0,03% C
normally associated higher impurity These carbides form preferentially steel takes well over an hour.
levels and coarser grain sizes. on the grain boundaries, causing these The typical low carbon grades (“L”
areas to be depleted in Cr. grades) are 304L, 316L and 317L.
CRACKING IN PERSPECTIVE
An understanding of this has resulted HAZ
WELD
in modifications to the composition of PARENT
DEPOSIT
welding consumables and has virtually METAL

eliminated weld metal cracking (if a SENSITIZED


REGION
ferrite containing weld metal can be
allowed). GRAINS ACTUALLY
Relatively few end-uses require DISSOLVED OUT

ferrite-free, or very low ferrite content,


weld deposits.
The chemical industry sometimes
considers the presence of ferrite an
adverse factor because it can be prone CORROSION ALONG AND
to localised corrosion (e.g. in urea AROUND THE GRAIN
BOUNDARIES
manufacture).
Cryogenic and continuous high Figure 3 Schematic illustration of sensitisation within the HAZ; with associated chrome carbide
and chromium depletion at the grain boundaries

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better than that of standard ferritic
900
steels.
0,08 %C 0,05 %C Their corrosion resistance remains
TEMPERATURE (ºC)

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

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lowering of the corrosion resistance. Pure CO2 should NOT be used. These steels consist of a two-
These steels develop a two-phase If TIG welding is being carried out phase crystal structure of ferrite and
(i.e. mixed) crystal structure on HIGH purity argon should be used. austenite, The ferrite:austenite ratio
heating to high temperatures. is now generally controlled to about
The presence of this mixed crystal MARTENSITIC 50:50.
structure strongly inhibits grain STAINLESS STEEL A wide range of new duplex grades
growth; any martensite formed is very Martensitic stainless steels are typified containing manganese as a partial
low in carbon and is therefore tough. by those contained within the AISI replacement for nickel are now
On cooling, the crystal structure 400 series. Details of grades and known as “lean duplex grades” and
retains the mixed and small grained chemical content have been covered in the addition of nitrogen to increase
structure of the parent material. Some previous modules. These steels have both the stability of the austenite
increase of hardness and strength been specifically formulated to render and improvements in mechanical
occurs. them amenable to heat treatment by properties is now common across all
The net result is that corrosion quenching and tempering to produce the duplex grades.
resistance is maintained and high strength and harness levels. Control of the nitrogen content in the
the properties are adequate for The thermal cycle of heating and weld metal is now considered crucial
all applications, except severe rapid cooling that occurs in the and a variety of nitrogen containing
engineering such as pressure vessels welding process HAZ is equivalent shielding gases are now available to
and highly stressed cyclic loading. to a quenching cycle. A high carbon assist.
Thin gauge steels can be resistance martensite crystal structure is As a result of continuous
welded. produced, which is highly stressed modification and development by the
However, as most applications and extremely brittle. Therefore there manufacturers the weldability of the
involve the use of thicker sheet and is a strong tendency for cracking in the duplex steels is now considered to be
plate, MMA and MIG processes are HAZ. good, with engineering quality welds
most often used, TIG to a lesser extent. Martensitic stainless steel therefore being achievable up to 50mm.
SAW is not recommended as the heat possesses very poor weldability. The weldability of these grades is
input is too high. In general the applications that determined by:
In the welding procedures it is of utilise martensitic stainless steel The austenite changing to ferrite at
paramount importance to: seldom involve the necessity for high temperatures and subsequently
Ensure cleanliness, especially welding. However, if they have to reverting to austenite on cooling.
prevent any carbon contamination. be welded, the following courses of The effect of the high temperatures
Minimise N pick-up by ensuring action may be adopted to limit failure on both the ferrite formed from the
good arc shielding, especially in MIG by cracking; austenite and the ferrite fraction
and TIG processes. Preheat to between 200ºC and 300ºC. existing in the steel.
Ensure close control of heat input This prevents rapid cooling of the In welding the aim is to obtain
and minimise interpass temperatures. HAZ by surrounding parent metal. conditions that maximise the
In this respect positional welding Interpass temperature should be at the reformation of austenite on cooling.
should be avoided if possible. same level. The 50:50 ferrite:austenite crystal
If unavoidable, use multipass Weld the steels in the annealed structure should be maintained after
narrow stringer bead welds (smaller condition and subsequently give the welding. Nitrogen (N) is an alloying
gauge electrodes with lower current) necessary heat treatment to produce element often used to attain this
to minimise heat input. the required properties. higher austenite content.
For MMA and MAG welding, Use an austenitic (e.g. 308, 309) Duplex stainless steel has better heat
austenitic consumables are consumable to improve ductility conductivity than austenitic stainless
recommended. in the weld metal, but note that the steel. Faster cooling rates of the HAZ
The austenitic welding consumable mechanical properties in the weld therefore occur. However, fast cooling
gives an austenite/ferrite weld metal will not match those of the retards the required re-formation of
deposit, depending on the FN of the parent metal. Matching consumables austenite. The mechanical properties
consumable and the degree of dilution. are available and if used, require (particularly toughness) are critically
Fabricator experience indicates extremely closely controlled dependant on achieving a sufficiently
a preference for grade 309L. It is of conditions to prevent segregation and high austenite content. Therefore, in
sufficiently high alloy content to cater cracking of the weld metal. comparison to the welding of other
for dilution by the parent metal, but stainless steel, higher heat input and
not so highly alloyed to result in a DUPLEX STAINLESS interpass temperatures are used when
fully austenitic weld metal that could STEEL welding duplex stainless steels.
be prone to hot cracking. Many of the duplex stainless steels On the other hand, excessive heat
If utility ferritic steel is being welded available are proprietary grades inputs and slow cooling rates can
to austenitic stainless steel, or to plain developed and produced by different promote an increase in the grain size
carbon (mild) or low alloy steel, an steel makers, but several are now of the ferrite and the formation of
austenitic grade consumable MUST included in international standards. carbides that cause brittleness and loss
be used. The shielding gases used for Details of their constitution and of corrosion resistance.
MAG welding are either 98/argon 2% properties have been covered in A closely controlled balance between
CO2 mixtures. previous modules. these two conditions has to be

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attained in the welding procedure. These are complex alloys and the cleaning company or sassda technical
It is therefore recommended that the welding and weldability of these is an staff should be sought.
welding conditions for each grade and extremely complicated subject. It is generally good practice to wash
thickness of material be determined These stainless steels can be down the completed fabrication with
and the optimum be formulated in a successfully welded. However, the a dilute solution of nitric acid in a
qualified welding procedure, which welding procedures are, in general, mild detergent, followed by thorough
thereafter should be closely controlled extremely complex and should not be rinsing in clean water. This will remove
and monitored. entered into lightly without obtaining any dirt and grease, any mild steel
Because of the relatively lower full details from the manufacturer of the contamination and will restore the
coefficient of thermal expansion of specific alloy, training of the welders to passivity of the stainless steel to it’s
duplex stainless steel, the stresses be employed and using fully qualified optimum level.
imposed in the weld zone are less welding procedures.
than those experienced with austenitic CONCLUSION
stainless steel. PICKLING AND As stated earlier, the welding of stainless
The welding processes that may be PASSIVATION steel is not difficult, only different. All
used include MMA, MIG/MAG, TIG After welding of any of the types of people involved in its welding should
and SAW. stainless steel covered above, the heat have an appreciation and understanding
Welding consumables for duplex affected zone will show some degree of of the basic principles, which are
stainless steel are essentially matching oxide discolouration due to exposure to different from those applicable to the
alloys, albeit often slightly modified elevated temperatures. This oxide is not welding of plain carbon and low alloy
in terms of chemical composition to the same as the passive layer and will steels. There are some newer hybrid
ensure an optimum crystal structure actually impair the corrosion resistance welding processes such as pulsed MIG/
of the weld metal. Ordinary austenitic of the underlying stainless steel. It MAG, synergic MIG/MAG CMT (cold
stainless steel consumables are NOT MUST therefore be removed before the metal transfer) and STT, which produce
suitable. fabrication enters service. very high quality welds with complete
Shielding gases used for MIG/ This can be done either by mechanical control of the heat affected zone and
MAG and TIG processes are 98% HP means (grinding, bead/grit blasting distortion on thinner materials.
Argon 2% N2, heat input and interpass or polishing the affected area) or by Stainless steel, by its very nature, is
temperatures must be carefully pickling with suitable acid solutions or often employed in aggressive situations
controlled during the welding process. pastes, or a combination of both. The as critical components, where the
acid mixture generally used for pickling consequence of failure can be significant.
PRECIPITATION of stainless steel is a combination Therefore, those who utilise welding
HARDENING STAINLESS of nitric and hydrofluoric acids, in the fabrication and maintenance of
STEEL normally applied hot. Details of the stainless steel equipment should note:
There are three sub-classifications of concentration, time and temperature The people involved must have the
precipitation hardening stainless steel: will vary depending on the grade of required knowledge, experience and
Martensitic. stainless steel used and the degree ability.
Semi-austenitic. of oxide present and assistance from Simple basic precautions must be
Austenitic. a welding supplier, stainless steel observed.

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