Welding of Alloy Steels

Alloy steels of these family contain 0.5 to 9.0 % of Chromium and 0.5 or 1 % Molybdenum. The carbon content is normally less than 0.20 % for good weldability, but the alloys have high hardenability. The chromium provides improved oxidation and corrosion resistance and molybdenum increases strength at elevated temperatures. Chromium-Molybdenum (Cr-Mo) Steels are widely used in petroleum industries and in steam power generation and elevated temperature application. The Cr-Mo steels are readily joined by arc welding and brazing processes commonly used for carbon steels. The combined carbon and alloy content of these steels is sufficient to promote the formation of Martensite from austenite on rapid cooling which may be hard and brittle. Steels in this group are also very sensitive to hydrogen induced cracking. Therefore, the welding process and procedures should minimize the presence of hydrogen during welding as well as the formation of Martensite. To avoid these problems preheating and post weld heat treatment are done. Extents of preheat and post weld heating is decided by "Carbon Equivalent" in the particular steel. CARBON EQUIVALENT: Although Carbon is the most significant alloying element affecting weldability. The effects of other elements can be estimated by equating them to an equivalent amount of carbon. Thus the effect of total alloy content can be expressed in terms of carbon equivalency (CE)

CE = %C + %Mn + {%Cr+%Mo+%V} + {%Si + %Ni + %Cu} 6 5 15

Steels having CE less than 0.35 usually require no preheating and post heating. Steels having CE between 0.35 and 0.55 usually require preheating, and steels with CE more than 0.55 require both preheating and post heating. Because the carbon equivalent is calculated from base metal composition and includes no other variable, it is only an approximate measure of weldability or susceptibility to weld cracking. Section thickness or weldment restraints are of equal or greater importance. Three major steps are involved in the welding of the Low Alloy Steels. These are: a. Preheating Preheating is required in most cases to prevent hardening and cracking. Recommended minimum preheat and inter pass temperatures for various thickness of Cr-Mo steels are given bellows.

Base Metal Group Alloy Steel Cr <0.5% <12.7 mm >12.7 mm Alloy Steel 0.5% < 2%< td> Alloy Steel 2.25% < td 10%<>

Nominal Wall Thickness (mm)

Minimum Preheat & Interpass Temperature (0C)

10 80 All All 150 175

b. The method of heating should be one that will provide a uniform temperature along the entire joint length before welding is started. Also the width of the heated area should be sufficient to ensure that the temperature is nearly uniform through out the thickness. c. Selection of Electrode/Filler Material The filler metal should have the same nominal composition as the base metal, except for the carbon content. Normally the carbon content is lower than that of the base metal. Suggested welding consumables are given below. Electrode for SMAW Electrode for GTAW * # E80XX-B1 E80XX-B2 E80XX-B2L E90XX-B3 E90XX-B3L E90XX-B3 E502-XX E502-XX E7Cr-XX ER80X-B2L ER80X-B2 ER80X-B2L ER90X-B3 ER90X-B3L ER90X-B3 ER502 ER502 ER502 ER505

Alloy Steel
1

/2Cr - 1/2Mo

1Cr -1/2Mo, 11/4Cr -1/2Mo 2Cr -1/2Mo, 21/4Cr - 1Mo 3Cr-1Mo 5Cr-1Mo 7Cr-1/2Mo

9Cr-1Mo E505-XX ER505 d. * Shielded Metal Arc Welding Electrodes from AWS Specification A5.4-78 or A5.5-81. # Welding Rod or Filler material from AWS Specification A5.9-77 or A5.28-79. e. Post Weld Heat Treatment A stress relief heat treatment is used to reduce welding stresses and also to increase the ductility and toughness of the weld metal and heat affected zone (HAZ). The welded joint or the entire weldment is heated to some temperature below the temperature at which the steel will begin transformation to austenite. Recommended temperature and holding time for alloy steels are given below:

Base Metal Group Alloy Steel Cr 1/2 %

Nominal Wall thickness (mm) <19

Recommended Temperature Range None 595-720 OC None 705-745 OC 705 OC

Holding Time (hr/Inch of wall Thk) None 1 None 1 1

Minimum Holding Time None 1 None 2 2

>19
<12.7

Alloy Steel 1 /2% < 2%< td> Alloy Steel 21/4<CR<10%< td>

>12.7
All