CARBON STEEL & ALLOY STEEL

CLASSIFICATION SYSTEM
SAE & AISI DEVELOPED MOST COMMON
NUMBERING & CLASSIFICATION
OF STEEL

4 DIGIT NUMBERING SYSTEM

1ST DIGIT TYPE OF STEEL

2ND DIGIT % OF ALLOYING ELEMENT

LAST TWO CARBON CONTENT IN HUNDRED

DIGITS OF A PERCENT
 CARBON STEEL & ALLOY STEEL
CLASSIFICATION SYSTEM

4 DIGIT NUMBERING SYSTEM

EXAMPLE

AISI 2315 NICKEL STEEL

ABOUT 3% NICKEL (Ni)

0.15 % CARBON (C)

 CARBON STEEL & ALLOY STEEL
CLASSIFICATION SYSTEM
MATERIAL CODE TYPE OF STEEL
1XXX CARBON STEELS
12XX SPECIAL SULPHUR – CARBON STEEL
12XX PHOSPHOROUS – CARBON STEEL
13XX MANGNESE STEEL
2XXX NICKEL STEELS
3XXX NICKEL – CHROMIUM STEELS
4XXX MOLYBDENUM STEELS
5XXX CHROMIUM STEELS
6XXX CHROMIUM – VANADIUM STEELS
7XXX TUGSTEN STEELS
9XXX SILICON – MANGANESE STEELS
 PERCENTAGE OF CARBON

ALLOY % OF CARBON
WROUGHT IRON NO CARBON ( < 0.08%)
LOW CARBON STEELS 0.15 % CARBON (MAX)
0.25 - 1.5 % MANGANESE
MILD STEEL 0.15 - 0.29 % CARBON

MEDIUM CARBON STEEL 0.25 - 0.50 % CARBON

0.60 - 1.65 % MANGANESE
HIGH CARBON STEELS 0.50 - 1.03 % CARBON
0.30 - 1.00% MANGANESE
LOW ALLOY STEELS 0.29 % CARBON (MAX.)
TOTAL METAL ALLOYS <= 2.0 %
CAST IRON 2.1 % CARBON
 CARBON EQUIVALENT

%C % Mn % Ni % Cr + % Mo % Cu
C.E. = + + + +
6 20 10 40

if C.E. < 0.40% MATERIAL IS READILY WELDABLE

C.E. > 0.40% SPECIAL CONTROLS REQUIRED

PREHEATING

LOW HYDROGEN PROCESSES

PROCEDURE SHOULD BE QUALIFIED

AWS ELECTRODE CLASSIFICATION SYSTEM
ELECTRODES FOR CARBON & LOW - ALLOY STEEL (SMAW)

AWS SPECIFICATION A 5.1

E 60 1 0
TYPE OF COATING
& CURRENT
ELECTRODE

STRENGTH IN KSI POSITION

AWS ELECTRODE CLASSIFICATION SYSTEM

E 80 1 8 - B1
ELECTRODE

80 KSI Min.

ALL POSITION

AC OR DCEP

CHEMICAL COMPOSITION
OF WELD METAL DEPOSIT
AWS ELECTRODE CLASSIFICATION SYSTEM
E XX X X

POSITION

SIGNIFICANCE OF 3RD DIGIT - POSITION

3RD DIGIT POSITION

1 FLAT, HORIZONTAL, VERTICAL, OVERHEAD

2 FLAT AND HORIZONTAL ONLY

3 FLAT, HORIZONTAL, VERTICAL DOWN,

OVERHEAD
AWS ELECTRODE CLASSIFICATION SYSTEM
E XX X X TYPE OF COATING &
CURRENT

SIGNIFICANCE OF 4TH DIGIT

4TH DIGIT TYPE OF COATING CURRENT

0 CELLULOSE SODIUM DCEP
1 CELLULOSE POTASSIUM AC or DCEP or DCEN
2 TITANIA SODIUM AC OR DCEN
3 TITANIA POTASSIUM AC OR DCEP
4 IRON POWDER TITANIA AC or DCEP or DCEN
5 LOW HYDROGEN SODIUM DCEP
6 LOW HYDROGEN POTASSIUM AC or DCEP
7 IRON POWDER IRON OXIDE AC or DCEP or DCEN
8 IRON POWDER LOW HYDROGEN AC or DCEP
AWS ELECTRODE CLASSIFICATION SYSTEM
E XXXX - XX
SUFFIX

CHEMICAL COMPOSITION OF WELD DEPOSIT

SUFFIX % Mn %Ni %Cr %Mo %V

A1 ½

B1 ½ ½

B2 1¼ ½

B3 2¼ 1

C1 2½

C2 3¼

C3 1 0.15 0.35

D1 & D2 1.25 – 2.00 0.25 – 0.45

G 0.50 0.30 Min. 0.20 Min. 0.10 Min.

AWS ELECTRODE CLASSIFICATION SYSTEM

AWS SPECIFICATIONS FOR GMAW ELECTRODES

BASE MATERIAL AWS SPECIFICATION

CARBON STEEL A 5.18
LOW ALLOY STEEL A 5.28
ALUMINIUM ALLOY A 5.10
COPPER ALLOY A 5.7
MAGNESIUM A 5.19
NICKEL ALLOYS A 5.14
STAINLESS STEEL A 5.9
TITANIUM A 5.16
AWS ELECTRODE CLASSIFICATION SYSTEM

CARBON STEEL ELECTRODES (GMAW)

ER 70 S- X
ELECTRODE OR ROD CHEMICAL COMPOSITION
& SHIELDING

SOLID ELECTRODE WIRE

STRENGTH IN KSI
 CARBON STEEL ELECTRODES FOR GMAW

CHEMICAL COMPOSITION

AWS %C %Mn %Si % OTHER

CLASSIFICATION
Ti Zi Al

E 70S – 2 0.6 0.40 – 0.70 0.05 0.02 0.05

E 70S – 3 0.06 – 0.15 0.90 – 1.40 0.45 – 0.70

E 70S – 4 0.07 – 0.15 0.65 – 0.85

E 70S – 5 0.07 – 0.19 0.30 – 0.60 0.50 –

0.90

E 70S – 6 0.07 – 0.15 1.40 – 1.85 0.80 – 1.15

E 70S – 7 0.07 – 0.15 1.50 – 2.00 0.50 – 0.80

 CARBON STEEL ELECTRODES FOR GMAW
MECHANICAL PROPERTIES
AWS WELDING ELECTRODE STRENGTH REQUIREMENTS
CLASS. (AS WELDED)

POLARITY EXTERNAL TENSILE YIELD %

GAS SHIELD STRENGTH STRENGTH ELONGATION
MIN. MIN. MIN.

KSI KSI

E 70S – 2 DCEP CO2 72 60 22

E 70S – 3 DCEP CO2 72 60 22

E 70S – 4 DCEP CO2 72 60 22

E 70S – 5 DCEP CO2 72 60 22

E 70S – 6 DCEP CO2 72 60 22

E 70S – 7 DCEP CO2 72 60 22

SHIELDING GAS MAY BE ARGON– CO2 OR ARGON – O2 MIXTURE

AWS ELECTRODE CLASSIFICATION SYSTEM
GTAW ELECTRODES

AWS CHEMICAL COMPOSITION COLOR

CLASS. CODE
EWP PURE TUNGSTEN GREEN
EWCe – 2 97.3% TUNGSTEN, 2% CERIUM OXIDE ORANGE
EWLa - 1 98.3% TUNGSTEN, 1% LANTHANUM OXIDE BLACK
EWTh - 1 98.3% TUNGSTEN, 1% THORIUM OXIDE YELLOW
EWTh - 2 97.3% TUNGSTEN, 2% THORIUM OXIDE RED
EWZr - 1 99.1% TUNGSTEN, 0.25% ZIRCONIUM OXIDE BROWN
EWG 94.5% TUNGSTEN, REMAINED NOT GRAY
SPECIFIED
 ALLOY STEEL – FILLER METAL
AWS FILLER METAL SPECIFICATIONS
SUFFIX LETTER DESIGNATE THE CHEMICAL COMPOSITION OF
THE DEPOSITED WELD METAL

SUFFIX LETTER CHEMISTRY

A C – Mo STEEL

B Cr – Mo STEEL

C or Ni Ni STEEL

D Mn – Mo STEEL

NM NI – Mo STEEL

G,K,M and W OTHER LOW ALLOY STEEL

 ALLOY STEEL WELDING

FOUR FACTORS FOR SUCCESSFUL ALLOY STEEL WELDING

1. ALWAYS USE A LOW - HYDROGEN WELDING PROCEDURE,

PROCESS & FILLER METAL

2. SELECT A FILLER METAL THAT MATCHES THE STRENGTH

LEVEL OF THE ALLOY STEEL

3. SELECT A FILLER METAL THAT COMES CLOSE TO

MATCHING THE COMPOSITION OF ALLOY STEEL

4. USE PROPER WELDING PROCEDURE

 LOW CARBON STEEL WELDING

LOW CARBON STEEL

AISI CARBON WELDING SPECIAL ELECTRODE

GRADE EQUIVALENT PROCESS PRECAUTION
(% CE) (IF ANY)

C-1008 < 0.40% SMAW NIL E 60XX

C - 1025 E 70XX
 MEDIUM CARBON STEEL WELDING

MEDIUM CARBON STEEL

AISI CARBON WELDING SPECIAL ELECTRODE

GRADE EQUIVALENT PROCESS PRECAUTION
(% CE) (IF ANY)

C-1030 < 0.40% SMAW NIL E 70XX

C - 1050
 HIGH CARBON STEEL WELDING

HIGH CARBON STEEL

AISI CARBON WELDING SPECIAL ELECTRODE

GRADE EQUIVALENT PROCESS PRECAUTION
(% CE) (IF ANY)

C-1055 > 0.40% SMAW PRE E 70XX

C - 1095 HEATING
(200 – 310OC)

PWHT
 LOW ALLOY STEEL WELDING
LOW NICKEL STEEL AISI 2315, 2515, 2517

MAJOR ALLOYING ELEMENT % COMPOSITION

CARBON (C) 0.12 – 0.30%
MANGANESE (Mn) 0.40 - 0.60%
SILICON (Si) 0.20 - 0.45%
NICKEL (Ni) 3.25 – 5.25%

WELDING ELECTRODE SPECIAL PRECAUTION

PROCESS (IF ANY)
SMAW E 80XX, C < 0.15% NO PREHEAT
(EXCEPT FOR HEAVY SECTION)
E 90XX
WITH C1, C2 C > 0.15% PREHEAT UP TO 260OC
SUFFIX STRESS RELIEVING -
ADVISABLE
 LOW ALLOY STEEL WELDING
LOW Ni - Cr STEEL AISI 3130, 3135, 3140, 3310, 3316
MAJOR ALLOYING ELEMENT % COMPOSITION
CARBON (C) 0.14 – 0.34%
MANGANESE (Mn) 0.40 – 0.90%
SILICON (Si) 0.20 – 0.35%
NICKEL (Ni) 1.10 – 3.75%
CHROMIUM (Cr) 0.55 – 0.75%
WELDING ELECTRODE SPECIAL PRECAUTION
PROCESS (IF ANY)
SMAW E 80XX, C < 0.15% NO PREHEAT
(EXCEPT FOR HEAVY SECTION)
E 90XX
C > 0.15% PREHEAT UP TO 316OC
STRESS RELIEVING -
ADVISABLE
 LOW ALLOY STEEL WELDING
LOW Mn STEEL AISI 1320, 1330, 1335, 1340, 1345
MAJOR ALLOYING ELEMENT % COMPOSITION
CARBON (C) 0.18 – 0.48%
MANGANESE (Mn) 1.60 – 1.90%
SILICON (Si) 0.20 – 0.30%

WELDING ELECTRODE SPECIAL PRECAUTION (IF ANY)

PROCESS

SMAW E 80XX, LOW RANGE OF NO PREHEAT

C & Mn
E 90XX
C >= 0.25% PREHEAT DESIRABLE
WITH A-1,D- (121OC TO 149OC)
1,D-2 SUFFIX
HIGH RANGE Mn PREHEAT – MANDATORY
THICKER SECTION - DO- (240OC TO 290OC)
STRESS RELIEVING ADVISABLE
 LOW ALLOY STEEL WELDING
LOW ALLOY Cr STEEL AISI 5015 to 5160
MAJOR ALLOYING ELEMENT % COMPOSITION
CARBON (C) 0.12 – 1.10%
MANGANESE (Mn) 0.30 – 1.00%
SILICON (Si) 0.20 – 0.35%
CHROMIUM (Cr) 0.20 – 1.60%

WELDING ELECTRODE SPECIAL PRECAUTION (IF ANY)

PROCESS
SMAW E 80XX, LOW RANGE OF NO PREHEAT
C & Cr
E 90XX
HIGH RANGE OF PREHEAT MANDATORY
WITH B C & Cr (399OC )
SUFFIX THICKER SECTION - DO- (240OC TO 290OC)
STRESS RELIEVING ADVISABLE
 STAINLESS STEEL
 ALSO CALLED CORROSION - RESISTANT STEELS

 THEY DO NOT RUST

 STRONGLY RESIST ATTACK BY GREAT MANY LIQUIDS,

GASES & CHEMICALS

 GOOD LOW - TEMPERATURE TOUGHNESS & DUCTILITY

 GOOD STRENGTH & RESISTANCE TO HIGH TEMP.

 IRON AS MAIN ELEMENT, CHROMIUM - 11 TO 30 %

STAINLESS STEEL IDENTIFICATION SYSTEM
AISI IDENTIFICATION SYSTEM

 IDENTIFICATION BY 3 DIGIT NUMBERS

EXAMPLE - AISI 304

 FIRST DIGIT INDICATES GROUP

 LAST TWO INDICATES SPECIFIC ALLOY

STAINLESS STEEL IDENTIFICATION SYSTEM
AISI IDENTIFICATION SYSTEM

SERIES METALLURGICAL PRINCIPLE MAGNETIC

DESIGNATION GROUP ELEMENTS PROPERTY
2XX AUSTENITIC Cr – Ni – Mn NON MAGNETIC

3XX AUSTENITIC Cr – Ni -DO-

4XX MARTENSITIC Cr MAGNETIC

4XX FERRITIC Cr -DO-

5XX MARTENSITIC Cr – Mo -DO-

 STAINLESS STEEL WELDING
STAINLESS STEEL IS DIFFICULT TO WELD
COMPARE TO CARBON - STEELS

THIS IS BECAUSE OF DIFFERENCE IN

PHYSICAL PROPERTIES.

THESE DIFFERENCES ARE

 LOWER MELTING TEMPERATURE
 LOWER THERMAL CONDUCTIVITY
 HIGHER COEFFICIENT OF THERMAL EXPANSION
 HIGHER ELECTRICAL RESISTANCE
 STAINLESS STEEL WELDING

MOST POPULAR PROCESSES FOR WELDING STAINLESS

STEEL ARE

 SMAW

 GTAW

 GMAW
 STAINLESS STEEL WELDING
AUSTENITIC TYPE STAINLESS STEEL – 2XX, 3XX
PROPERTIES

 45% HIGHER MANGANESE

 NOT HARDENABLE BY HEAT TREATMENT
 NON MAGNETIC
 MAY BECOME MAGNETIC WHEN COLD WORKED
OR WELDED
 ALL AUSTENITIC SS ARE WELDABLE
 EXCEPTION – TYPE 303 (CONTAINS HIGH SULPHUR)
TYPE 303Se (CONTAINS SELIUM)
 STAINLESS STEEL WELDING
AUSTENITIC TYPE STAINLESS STEEL – 2XX, 3XX

WELDING IS DIFFICULT COMPARING TO CARBON STEEL

REASONS

 45% HIGHER THERMAL COEFFICIENT OF EXPANSION TO CS

 HIGHER ELECTRICAL RESISTANCE TO CS
 LOWER THERMAL CONDUCTIVITY TO CS
 LOWER MELTING POINT THAN CS
 STAINLESS STEEL WELDING
AUSTENITIC TYPE STAINLESS STEEL – 2XX, 3XX
RECOMMENDATIONS:-

 USE HIGH TRAVEL SPEED

 IT REDUCES HEAT INPUT

 IT REDUCES CARBIDE PRECIPITATION

 IT MINIMIZES DISTORTION

 SPECIAL PRECAUTION AGAINST WRAPAGE &

DISTORTION
(TACK WELDS SHALL BE TWICE AS NORMAL)

THIN MATERIAL - DIFFICULT TO COMPLETELY AVOID BUCKLING

 STAINLESS STEEL WELDING
FERRITIC TYPE STAINLESS STEEL – 4XX

 WELDABLE EXCEPT 430F (CONTAINS HIGH SULFUR)

 COEFFICIENT OF THERMAL EXPANSION SAME AS CS
 TENDENCY OF GRAIN GROWTH AT T >= 871O C
 WELDING PROCESSES THAT TEND TO INCREASE
CARBON PICK UP ARE NOT RECOMMENDED e.g.
 GMAW WITH CO2
SHIELDING
 OXYFUEL PROCESS
 STAINLESS STEEL WELDING
FERRITIC TYPE STAINLESS STEEL – 4XX

RECOMMENDATIONS
 HEAVIER SECTION - PREHEAT 205O C TO 210O C

 ANNEALING - 760O C TO 816O C FOLLOWED BY

WATER OR AIR QUENCH

 PEENING THE WELD (TO IMPROVE TOUGHNESS)

 USE AUSTENITIC SS FILLER METAL (IF HT IS

NOT POSSIBLE)
 STAINLESS STEEL WELDING
MARTENSITIC TYPE STAINLESS STEEL – 4XX, 5XX

 HARDENABLE BY HEAT TREATMENT

 MAGNETIC

 LOW CARBON TYPE CAN BE WELDED WITHOUT ANY

PRECAUTION

 WELDING PROCESSES THAT TEND TO INCREASE CARBON

PICK – UP ARE NOT RECOMMENDED

 INCREASED CARBON CONTENT INCREASES CRACK

SENSITIVITY IN WELD AREA
 STAINLESS STEEL WELDING
MARTENSITIC TYPE STAINLESS STEEL – 4XX, 5XX

LOW - CARBON TYPE WELDABLE

(WITHOUT PRECAUTIONS)

%C > 0.15 PREHEAT, POST-HEAT REQD.

PREHEAT TEMP. 230O C - 290O C

POSTHEAT TEMP. 650O C - 760O C

(FOLLOWED BY SLOW COOLING)
 STAINLESS STEEL WELDING
RECOMMENDED FILLER METAL
SERIES AISI POPULAR RECOMMENDED FILLER METAL
DESIGNATION NO. NAME FIRST CHOICE SECOND CHOICE

Cr – Ni – Mn 201 308 308L

Austenitic 202 308 308L
Cr – Ni Austenitic 301 308 308L
302 308 308L
302B 308 309
303 - -
303Se - -
304 18/8 308 308L
304L 18/8 ELC 308L 347
305 308
309 25/12 309
 STAINLESS STEEL WELDING
RECOMMENDED FILLER METAL

SERIES AISI POPULAR RECOMMENDED FILLER METAL

DESIGNATION NO. NAME FIRST CHOICE SECOND CHOICE

Cr – Ni Austenitic 309S 309 -

310 25/20 310 -
310S 310 -
314 310 -
316 18/12 Mo 316 309Cb
316L 18/12 ELC 316L 309Cb
317 19/14 Mo 317 309Cb
321 347 308L
347 19/9 Cb 347 308L
348 19/9CbLTa 347 -
 STAINLESS STEEL WELDING
RECOMMENDED FILLER METAL
SERIES AISI POPULAR RECOMMENDED FILLER METAL
DESIGNATION NO. NAME FIRST CHOICE SECOND CHOICE

Cr – Martensitic 403 410 -

410 12 Cr 410 430
414 410 -
416 410 -
416 Se - -
420 12 Cr HC 410 -
431 430 -
440A High carbon welding not recommended
440B High carbon welding not recommended
440C High carbon welding not recommended
 STAINLESS STEEL WELDING
RECOMMENDED FILLER METAL

SERIES AISI POPULAR RECOMMENDED FILLER METAL

DESIGNATION NO. NAME FIRST CHOICE SECOND CHOICE

Cr – Ferritic 405 410 405Cb

430 16 Cr 430 309
430F - -
430FSe - -
446 309 310
501 5 Cr - ½ Mo 502 -
502 5 Cr - ½ Mo 502 -
 ALUMINIUM & ALUMINIUM ALLOY
PROPERTIES

LIGHT WEIGHT

RELATIVELY HIGH STRENGTH

Al WELDING IS DIFFERENT FROM STEEL WELDING

 ALUMINIUM & ALUMINIUM ALLOY

DESIGNATION OF ALUMINIUM ALLOY GROUPS

MAJOR ALLOYING ELEMENT DESIGNATION

99% MINIMUM Al AND OVER 1XXX
COPPER 2XXX

MANGANESE 3XXX

SILICON 4XXX
MAGNESIUM 5XXX
MAGNESIUM AND SILICON 6XXX

ZINC 7XXX
OTHER ELEMENT 8XXX
 ALUMINIUM & ALUMINIUM ALLOY

SERIES PROPERTIES USE

1XXX Al – 99% OR HIGHER PURITY PRIMARY USED IN
ELECTRICAL &
CHEMICAL
INDUSTRY
2XXX PRINCIPAL ALLOYING ELEMENT – Cu
HIGH STRENGTH (WHEN PROPERLY
HEAT TREATED)
LESS CORROSION RESISTANCE
OFTEN CLAD WITH Al OR SPECIAL Al
ALLOY
 ALUMINIUM & ALUMINIUM ALLOY

SERIES PROPERTIES USE

3XXX

4XXX

5XXX

6XXX

7XXX

8XXX
ALUMINIUM & ALUMINIUM ALLOY WELDING

Al welding is different from steel welding because of

following properties of steel
 Al Oxide Surface Coating
 Al reacts with O2 in air to produce thin
hard film of Al - oxide on the surface
 Melting point of oxide film  1926o C
(3 times melting of Al)
 Oxide film absorb moisture from air
 Moisture - source of H2 causing
porosity
 Al - Oxide film must be removed prior
to welding
 Small particles of un-melted Al - Oxide
will
ALUMINIUM & ALUMINIUM ALLOY WELDING

 Al Oxide Surface Coating

 Can be removed by
Mechanical Method - Grinding
etc
Chemical - Cleaning Solution
Welding Fluxes
Electrical - Cathodic
Bombardment
half cycle of AC
GTAW
 Oxide film immediately start to form
(Weld with 8 hr. of cleaning)
 High Thermal Conductivity
 High Thermal Expansion Coefficient
 Low Melting Temperature
ALUMINIUM & ALUMINIUM ALLOY WELDING

 GTAW - Used for welding thinner

section (Use AC)

 GMAW - Thicker Section

 SMAW - Not Popular

 OxyAcetylene - Not Popular

 Resistance - Used
Welding

 Solid State - Used

 DISSIMILAR METAL WELDING

 SHOULD BE AS STRONG AS WEAKER OF TWO

METALS JOINED

 IMPORTANT TO INVESTIGATE PHASE DIAGRAM

 IF MUTUALLY SOLUBLE - JT. CAN BE MADE

SUCCESSFULLY

 IF MUTUALLY NOT SOLUBLE - USE THIRD METAL

WHICH IS SOLUBLE TO BOTH
 DISSIMILAR METAL WELDING

IMPORTANT CONSIDERATIONS
 COEFFICIENT OF THERMAL EXPANSION OF
BOTH MATERIALS

 DIFFERENCE IN MELTING TEMPERATURE

 INTERMETALLIC COMPOUNDS FORMED

BETWEEN THE DISSIMILAR METALS

- CRACK SENSITIVITY
- DUCTILITY
- SUSCEPTIBILITY TO CORROSION
 DISSIMILAR METAL WELDING
EFFECTIVE WELDING PROCESSES
 ARC WELDING

 ULTRASONIC WELDING

 COLD WELDING

 EXPLOSION WELDING

 ELECTRON BEAM WELDING

 LASER BEAM WELDING

 DISSIMILAR METAL WELDING

POPULAR DISSIMILAR METAL COMBINATIONS

BASE METALS SMAW GTAW GMAW

Al to Mild Steel Use a transition insert of these metals

Al to Low - Alloy Steel - do -
Al to S.S. - do -
SS(Ferritic) to Low-Alloy ENiCrFe-3 RNiCrFe-3 ENiCrFe-3
Steel
SS(Aus.) to Low-Alloy ENiCrFe-3 RNiCrFe-3 ENiCrFe-3
Steel
Mild Steel to Low Alloy E7018 E70S-X E70S-X
Steel
 HEAT AND WELDING

Heat is employed in most Welding Processes

1. Electric Arc
2. Resistance Heating
3. High Temperature Flame
4. Mechanical Sources - Friction, Ultrasonic
5. Exothermic Chemical Reaction

Most Common is Electric Arc

Temperature 5000oC - 20,000oC

 EFFECTS OF WELDING HEAT

1. High Residual Stresses Distortion

2. Reduction in ductility & Cracking
change in hardness in HAZ
3. Deterioration in toughness
in HAZ
4. Loss of Strength in HAZ in
certain work - hardened, quenched & tempered
steel.
 WELDING METALLURGY

Science of Welding closely relates to metallurgy

Metallurgy involves Producing metals from ore

Making & Compounding Alloys
Reaction of metals to many
different activities & situations

Extensive Use of Heat-treatment

Metallurgy in Steel Making & Processing
Forging
Foundry
 WELDING METALLURGY

Welding Metallurgy Special branch of metallurgy

Reaction time - minute/second

Changes of physical properties
in short period

It deals with Interaction of different metals

Interaction of metals with

gases
 WELDING METALLURGY

Metal in Liquid State No Distinct Structure

Atoms move freely among

themselves
As Molten Metal cools Heat Energy decreases
Less mobility of atoms

Near to Solidification Atoms attracted together in a

definite patterns
Three Dimensional lattice
Also called “Space Lattices”
“Crystal”
 WELDING METALLURGY

Most Metals in Common Use are in the form of Alloy

• Substitutional Solid Solution
• Interstitial Solid Solution
• Inter-metallic Compound

PHASE Each grouping with its own

crystalline structure
Microstructure Overall arrangement of grains, grain
boundaries & phases present in alloy
 ALLOTROPES

Allotropic change
• Substitutional Solid Solution
• Interstitial Solid Solution
• Inter-metallic Compound

PHASE Each grouping with its own

crystalline structure
Microstructure Overall arrangement of grains, grain
boundaries & phases present in alloy
 WELDING METALLURGY

TEMERATURE DISTRIBUTION AROUND A WELD

 WELDING METALLURGY

STEPS IN THE SOLIDIFICATION OF MOLTEN METAL

 WELDING METALLURGY

SOLIDIFICATION PATTERN OF GROOVE WELD

 WELDING METALLURGY

CHARACTERISTICS OF WELDED JOINT IN PURE METAL

CHARACTERISTICS OF WELDED JOINT IN PRECIPITATION HARDENED ALLOY

 WELDING METALLURGY

MICROSTRUCTURE OF DIFFERENT PARTS OF WELD

 WELDING METALLURGY

WELD SHOWING WELD METAL, HEAT AFFECTED ZONE & BASE METAL