High Yield (HY),
HIGH STRENGTH STEELS PLUS
& AISI (SAE CSA) STEELS

ALL WELDS SHOULD FIRST BE QUALIFIED BEFORE
THE WELD PROCEDUTRES / CONSUMABLES ARE APPROVED.

SMAW and GMAW Mechanical Strength
E6010 Minimum Yield 50,000 psi Minimum Tensile 62,000 psi.
E6011 Minimum Yield 50,000 psi Minimum Tensile 62,000 psi.
E7010 Minimum Yield 60,000 psi Minimum Tensile 72,000 psi.
E7018 Minimum Yield 60,000 psi Minimum Tensile 72,000 psi.

MIG E70S-3-6 Minimum Yield 60,000 psi Minimum Tensile 72,000 psi.

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Mechanical Strength of Gas Shielded Flux Cored Electrodes from the
ANSI/AWS A5.29. 1198 Specification
Low Alloy Steel Electrodes for Flux Cored Arc Welding

Brittleness?
The ease at which the weld or metal will break or crack without appreciable deformation. When a metal gets harder it becomes more brittle. Preheat, inter-pass temp controls and post heat all are designed to reduce the potential for brittleness.

Welding alloy steels often may require unique weld or heat treat considerations. Compare the low alloy steels chemistry and mechanicals with a standard A36 steel. Remember this site is only a guide, weld responsibility starts with "you" First verify the weld consumable and then the material heat treat recommendations.

The "yield strength". The stress that can be applied to a base metal or weld without "permanent deformation" of the metal.
The "tensile strength". The ultimate tensile strength, the maximum tensile strength that the metal or weld can with stand before "failure occurs".

Metric Conversion 1000 psi = ksi x 6.894 = MPa

AISI SAE DATA AS A GUIDE FOR WELDING ONLY.
ALL WELDS REQUIRE PRE-QUALIFICATION.
ONLY NOMINAL ALLOY CONTENT MAY BE PROVIDED, (NOT VERIFIED).

AISI steels. When selecting electrodes take note of
[a] the carbon content and the primary alloys.
[b] Over 0.03 carbon ensure low hydrogen electrodes.
[c] Over 0.35% carbon give SPECIAL consideration to
pre-heat / inter-pass temp control and post heat.

THE FOLLOWING IS A RANDOM SELECTION OF AISI STEELS. THE DATA PROVIDED IS TO ASSIST WITH YOUR WELDING DECISIONS. TAKE NOTE OF THE PRIMARY ALLOYS THE CARBON CONTENT AND THEIR RELATIONSHIP BETWEEN THE PRE AND POST HEAT RECOMMENDATIONS.

AISI 1040 / 1050, 18 Weld Procedures. Intended for weld repairs on AISI 1040 / 1050, 18 " forged steel components.

The intention of these weld repairs is to fill cracks surface scratches or indentations
With the SMAW (stick) weld process the following recommendations apply.
If cracks occur clean area with wire wheel. Drill two 1/8 hole within 1/16 of the weld crack start / stop. Pre heat and inter pass temp control is critical to slow down the weld cooling rate to reduce the hardening effect in the welds and heat affected zone. A minimum preheat and inter-pass temperature of 600 to 700 F. is required.

Provide the preheat with a "propane or natural gas " torch, do not use acetylene as its conentrated and localized. Provide the preheat on the general area surrounding the weld repair. Use a temp stick to measure the preheat. Measure the temp at least 3 to 4 inches from either side of the weld. Caution, preheat may cause lubricants to be drawn from shaft, the shaft surface has to be dry and clean before welding.

 

 

SMAW Electrode Guide lines: With carbon steel electrodes use an E7018 low hydrogen electrodes. Polarity DC Reverse Polarity (electrode positive) or AC. If cracking occurs with the E7018 consider an E312 stainless wire, or the use of MIG short circuit.
Only use SMAW electrodes if they are new and in a sealed sealed container. Use a small electrode diameter to minimize the required weld current and heat input. 1/8 or 5/32. No arc strikes are allowed on the part surface, use a scrap strike plate to establish an arc. Once electrode is warm its easier to start on shaft. Use stringer, small beads, no weld weaves. At weld completion gently peen weld bead surface with pointed end of slag hammer to assist in stress reduction. Maintain preheat during weld. At weld completion wrap insulated blanket around weld to allow slow controlled cool without drafts to shaft.

ELECTRODE E7018 DCRP 1/8 130 - 140 AMPS, first choice.
ELECTRODE E7018 DCRP 5/32 140 - 160 AMPS second choice.

If the weld draws lubricant from the shaft and creates a porous weld, grind out weld, preheat and weld again.
After the weld is complete, cooled and ground, test weld surface area with dye pen.

MIG Alternative procedures.

If crack issues occur with SMAW, consider MIG short circuit. Lower weld energy
Use an E70S-3 or E70S-6 wire, size 0.035.
Use argon with 10 CO2.
Set the wire feed at 280 ipm, around 11 0'clock. You can measure the wire ipm by the length attained for 10 sec x 6.
Set the weld voltage at 17 to 18 volts, to achieve crisp, consistent crisp crackle.
Use stinger bead and use the preheat and other applicable weld data from SMAW procedure.

 

 

 

E-Mail Feb 2007.

Hi Ed, Would you offer some advice on welding 4130 plate and tubing using GMAW? I have looked in the books that we have of yours and have searched the discussion group and didn’t find similar enough situations for reference. The weldment consists of 4130 sheet/plate and pipe that is heat treated to 125-145 KSI ultimate tensile strength prior to welding. The sheet/plates range from .125”-.625” thick and the tubes range from .188”-.250” wall thickness. I will be using a 120 KSI UTS filler metal and the weldment will be post weld stress relieved. Do you have any suggestions on the parameters and techniques that should be applied? Thanks, Steve


From Mike. Why not use a 4130 filler metal. I have been involved with welding a structural component for the last four years. We have had excellent results. The base metal is supplied in the annealed condition. The component is pre-heated to 400F and then subjected to post weld hest treatment. In a few instances, due to engineering changes after the pwht, some minor welds were made and a local pwht was applied.

From Ed. Steve welding with or without heat treatment, its logical to use low end parameters, use stringers, avoid weaves and maintain an interpass temp of 300F max.

STRESS RELIEVING (SR) BASIC GUIDELINES:

• STRESS RELIEF - CONTROLLED HEATING & COOLING TO REDUCE STRESS.
• STRESS RELIEF MACHINED PARTS FOR DIMENSIONAL STABILITY.
• STRESS RELIEF SLOW HEATING AND COOLING REQUIRED
• CONFIRM WITH CODE SPECIFICAIONS FOR STRESS RELIEF REQUIREMENTS.
  
  
  

If steels are quenched and tempered to match properties electrode selection and
heat treatment recommendations critical.

Fatigue?
The ability of a metal or weld to withstand repeated loads. Fatigue failures occur at stress levels less than the metal or weld yield strength. Some things that can influence fatigue failure:

• Excess weld profiles.
• Welds which cause undercut.
• FCAW or SMAW slag inclusions.
• Lack of weld penetration.
• Excess weld heat, typically from multi-pass welds without inter-pass temp controls.
• Items to a part that adds restraint while welding.
• Items added to a part that can concentrate stresses in a specific location.
• Incorrect selection of filler metal, weld too weak or weld too strong.|
  
  
  
  

Steels	Yield  ksi  MPa	Tensile  ksi MPa	Description	Preheat Post heat	UNS	Chemistry weld data
AISI/SAE 44XX			Moly Steel	4419 preheat >13mm 100F .>25mm 200F 4419/4422/4427 post heat required FOR 4419/4422/4427 at 1200-1350F		SAE 4419 carb 0.18-0.23 Mn 0.45-0.65 Si 0.15-0.3 Mo0.45 - 0.6
AISI/SAE 46XX	4620 53-55	4620 75-85	Ni-Moly	4615 - 4617- 4620 preheat >13mm 200F >25 mm 250 F post heat desirable 1100-1250F		4615 carb 0.12-0.18 Mn 0.4/0.65 Si 0.3 Ni 1.65/2 Mo 0.2/0.3 weld 4620 E8018-C1 E80S-D2 E81T1-Ni2
AISI/SAE 47XX			Ni - Cr - Mo			carb 0.16-0.22 Ni 0.9-1.2 Cr0.35-0.55 Mo 0.15/0.4
AISI/SAE 48XX			Ni- Mo			carb 0.13-0.23 Ni 3.25-3.75 Mo 0.2 /0.3
AISI/SAE 50XX			Carb/Chrome	AISI 5046 preheat <13mm 300 F <25MM 350F >25mm 400F		50xx range carb 0.12-0.48 Mn 0.3/1 Si 0.15-0.35 Cr 0.2-0.6
AISI/SAE 51XX			Carb/Chrome HIGHER CHROME THAN 50XX	AISI 5120 E8016-B2 E80T1-B2 >13mm 250F post heat desirable 1100 to 1250F		51xx range carb 0.13-0.53 Mn 0.6/0.9 Si 0.15-0.35 Cr 0.7-1.15
AISI/SAE 61XX			Cr / V			carb 0.16-0.54 Mn 0.5/0.9 Cr 0.5-1.15 V 0.1-0.15
AISI/SAE 81XX			Ni / Cr / Mo			carb 0.13-0.18 Ni 0.2/0.4 Mo.0.08-0.15 Cr 0.3-0.5
AISI/SAE 86XX			Ni Cr Mo			carb 0.12 / 0.48 Ni 0.4/0.7 Mo.0.15-0.25 Cr 0.35-0.6
AISI/SAE 87XX			Ni Cr Mo			carb 0.18-0.46 Ni 0.4/0.7 Mo.0.2-0.3 Cr 0.35-0.6
AISI/SAE 88XX			Ni Cr Mo			carb 0.2-0.25 Ni 0.4/0.7 Mo.0.3-0.4 Cr 0.4-0.6
AISI/SAE 93XX			Ni Cr Mo			Ni 3.25 Cr 1.2 Mo 0.12
AISI/SAE 94XX			Ni Cr Mo			Ni 0.45 Cr 0.4 Mo 0.12
AISI/SAE 97XX AISI/SAE 98 XX			Ni Cr Mo			Ni 0.55 Cr 0.2 Mo 0.2 Ni 1 Cr 0.8 Mo 0.25

AISI SAE HIGH STRENGTH SHEET STEEL DESIGNATIONS:

AISI 035SF. First three digits = minimum yield 35 ksi (241 MPa)
035SF First letter after numbers denotes chemistry composition

(S) = structural quality C-Mn-p-n,
(X) = low alloy Cb-Ti-V-Si-Zr
(W) = weathering steels Si-P-Cu-Ni-Cr
(D) = Dual phase Matensite transformation

AISI 035SF Last letter denotes deoxidation practice. (F) Deoxidation Killed Steel Inclusion control. (K) Deoxidation killed steel. (O) Deoxidation is none killed. To find heat treat, chemistry and weld data cross reference these steels with the following ASTM Steels. Go back to the steels program home page to find your ASTM steel.

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Hardnes?
The resistance of the metal or the weld to penetration. Hardness is related to the strength of the metal. A good way to test a weld after the weld and heat treatment are complete, is to test the hardness of weld and the base metal surrounding the weld.

Ductility?
The amount that a metal or weld will deform without breaking. Measured on welds by the % of elongation in a 2 inch 51 mm test piece. An E71T-1 flux cored electrode should result in a minimum of 20% elongation. An E70S--6 MIG weld should produce approx 22%.

Toughness?
The ability of the metal or weld sample at a predetermined temperature to withstand a shock. The test for toughness measures the impact of a pendulum on a notched specimen. You may see that the required impact properties for the metal or weld are 20ft-lbf @ -20 F (27 j @ -29C)

If you are welding a carbon steel and you don't know what the composition is or what the weld consumable should be, try the following:

• If the metal is thicker than 6 mm preheat to 150F.
• Use either an E7018 stick electrode, an 0.035 or 0.045 E70S-6 MIG wire. For your all position welds an E71T-1 electrode wire.
• For MIG welding use an argon 10 to 15% CO2 mix.
• For flux cored use a mix with 20 to 25% CO2.
• Ensure with multi-pass welds you use inter-pass temp control. Ensure the inter-pass temp weld temperature does not exceed 200F.
• If possible do destructive test of a weld sample.
• If possible have the hardness and grain size checked after welding.

 

Dual - Ten manufactured by US Steel

 

 

Dual TEN are dual phase steels with a mix of ferrite matrix and martensite islands decorating grain boundaries with possible addition of bainite. These steels contain approx. 5 - 15% martensite. These steels therefore offer that unique combination of Ferrite = soft phase (ductility) and martensite = hard phase offering high strength.

 

Grades Dual Ten 590 / 600

Grades Dual Ten 780 / 800

 

Dual Ten Strength UTS 72 - 175 ksi 500 - 1200 Mpa

Dual Ten high rate of work hardening

Dual Ten offer weigh reduction even in comparison to high strength steels, this means the auto industry will embrace them and you will be welding parts less than 1.2 mm thick For more information on the unique mechanical properties of this steel vist the US Steel site.

The only information on welding i found at US STEEL on welding, is that these steels meet auto application weld needs. From my perspectice, Its logical with these steels to minimize weld heat input, so short circuit or high weld speeds with the open arc modes of weld transfer would be logical.. No pre-heat on gage and definately look to interpass temp controls, at a guess i would state 200F.