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Indian Institute of Welding - ANB Refresher Course Module 02
Indian Institute of Welding - ANB Refresher Course Module 02
4
Illustration:
Weld deposited
on grey iron
with Nickel
Filler Metal
Composite Zone
Austenite
Unmixed Zone
White Iron
HAZ
martensite
&un-dissolved
graphite
5
Segregation
Equiaxed
dendrite
equiaxed
dendritic Columnar
dendritic
cellular
% Solute
dendritic
cellular
planar
HS
Low speed
LS
Martensite TS = f(%C)
Brittle & unstable
M No ppt.
Needle (lens) shape
Microstructure & hardness of HAZ in
steel
CG FG
coarse
fine
Stress relief
Dimensional stability
Resistance to stress corrosion
Improved toughness and mechanical
properties
16
Common Heat Treatment Processes
19
c. Temperature just exceeds A3, thereby causing
full Austenite transformation.
a. On cooling all grains will be normalized.
d. Temperature significantly exceeds A3 line
permitting grains to grow.
1. On cooling, ferrite will form at the grain boundaries,
and a coarse pearlite will form inside the grains.
2. A coarse grain structure is more readily hardened
than a finer one, therefore if the cooling rate
between 800C to 500C is rapid, a hard
microstructure will be formed (brittle fracture may
occur in this region)
20
Welding versus heat treatment
23
Stress Relieving
4 hours
1 hour
6 hours
Full Annealing
Elongation
L L0
100 0.02% Proof Stress
L = L-L0 L0
Proportional limit: YS Fracture
A A
RA 0 100 stress
Stress
A0
Stress
E if stress YS
Strain
P % Elongation
Plastic deformation
Tertiary
Primary Secondary /
Steady state
Strain
l
s Steady state creep rate
l l0
tr = time to rupture
Strain
time
l0
Creep is a slow time dependent deformation. All metals & alloys under go creep. It
is measurable if test temperature is > 0.5TM (melting point in deg Kelvin). It is a
strong function of stress & temperature. Creep test at a given temperature and
stress gives us time to rupture, steady state (minimum) creep rate, rupture strain
Stress & temperature dependence of creep
stress Temp.
strain
strain
time time
Master rupture plot
Safe stress
Stress
tr
Brinell P Fe : P 30 D 2
P
BHN
D D / 2 ( D D2 d 2 ) Al : P 5D 2
d
Mild steel
max
Endurance limit
1234
min
S-N curve
Al alloy
Corrosive
environment
Log Nf
Fatigue strength = Endurance limit = f (size, surface finish, surface
prop, residual stress, UTS, inclusion content, environment)
Jack hammer component,
shows no yielding before
fracture.
Fracture zone
Propagation zone, striation
Hydrogen embrittlement test
Steel picks up hydrogen during welding, pickling, heat treatment,
electroplating or corrosion due to cathodic charging. This makes the
steel notch sensitive and makes it susceptible to delayed fracture.
P
There is a critical stress below which delayed fracture
does not take place.
Stress corrosion tests
P
Chemical species Alloy Temperature
Chlorides in water Austenitic steel Above room temp
NaOH, KOH soln. Carbon steel 100 deg C
Nitrates in water Carbon steel 100 deg C
NH3 or ammonium Copper alloys Room temp. P
salts in water
fracture
KIC III
II
KI
da/dt
KISCC I
threshold
Log tr
K
Charpy Impact Test
CVN, J
Temp.
HAZ has coarse grain & high transition temperature. This
was the cause for failure of Liberty ship.
Fracture mechanics
P
K
B w
P
w
f a Kc LEFM
B = thickness
For most commercial alloys do not exhibit such plots.
EPFM Variation of fracture
a dU toughness with plate
J Kc thickness.
Bda 2
P
J K
a+a J KIC = material property
E
B
NB. Normal design: if a plate deforms, increase thickness. FM based
design: if a plate cracks, reduce thickness.
Acknowledgements
We gratefully acknowledge the contributions of
the following faculty members for developing
this module
Dr.R.N.Ghosh
Mr.R.Banerjee
Mr.A.A.Deshpande
Dr.Shaju Albert
THANK YOU