Mechanical Behavior of the Weld Joints of Thick Steel Plates Produced by Various Welding Processes
The effect of a welding process (electrogas welding (EGW) and flux cored arc welding (FCAW)) on the fracture toughness, CTOD (crack tip opening displacement), and mechanical properties (tensile, bending, impact strengths and hardness) of thick weld joints is examined. The CTOD value of the FCAW weld...
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Інститут проблем міцності ім. Г.С. Писаренко НАН України
2015
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irk-123456789-1732872020-11-29T01:27:06Z Mechanical Behavior of the Weld Joints of Thick Steel Plates Produced by Various Welding Processes Bang, HanSur Bang, HeeSeon Ro, ChanSeung Jeong, SuOk Научно-технический раздел The effect of a welding process (electrogas welding (EGW) and flux cored arc welding (FCAW)) on the fracture toughness, CTOD (crack tip opening displacement), and mechanical properties (tensile, bending, impact strengths and hardness) of thick weld joints is examined. The CTOD value of the FCAW weld joints was higher than that of the EGW ones. The fractured welded specimen after the CTOD test reveals ductile and cleavage fractures of the weld joint faces after flux cored arc and electrogas weldings, respectively. The mechanical properties of the EGW welded specimens satisfied relevant classification rules. These results suggest that the EGW process is an effective substitute for the current welding process (FCAW) used for high-strength thick steel plates. Рассмотрено влияние способа сварки (электрогазовая и дуговая порошковой проволокой) на вязкость разрушения, раскрытие вершины трещины и механические свойства (предел прочности при растяжении, изгибе, ударная вязкость и твердость) сварных швов. Значение раскрытия вершины трещины для швов, полученных дуговой сваркой, было выше такового для швов, полученных электрогазовой сваркой. Разрушенный сварной образец после испытания по определению раскрытия вершины трещины обнаруживает вязкое разрушение и хрупкий излом лицевых поверхностей швов после дуговой и электрогазовой сварки соответственно. Механические свойства сварных образцов после электрогазовой сварки удовлетворяют соответствующим критериям классификации. Эти результаты свидетельствуют о том, что электрогазовая сварка может эффективно заменять используемую в настоящее время дуговую сварку для высокопрочной толстолистовой стали. 2015 Article Mechanical Behavior of the Weld Joints of Thick Steel Plates Produced by Various Welding Processes / HanSur Bang, HeeSeon Bang, ChanSeung Ro, SuOk Jeong // Проблемы прочности. — 2015. — № 1. — С. 240-249. — Бібліогр.: 14 назв. — англ. 0556-171X http://dspace.nbuv.gov.ua/handle/123456789/173287 539.4 en Проблемы прочности Інститут проблем міцності ім. Г.С. Писаренко НАН України |
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Научно-технический раздел Научно-технический раздел Bang, HanSur Bang, HeeSeon Ro, ChanSeung Jeong, SuOk Mechanical Behavior of the Weld Joints of Thick Steel Plates Produced by Various Welding Processes Проблемы прочности |
| description |
The effect of a welding process (electrogas welding (EGW) and flux cored arc welding (FCAW)) on the fracture toughness, CTOD (crack tip opening displacement), and mechanical properties (tensile, bending, impact strengths and hardness) of thick weld joints is examined. The CTOD value of the FCAW weld joints was higher than that of the EGW ones. The fractured welded specimen after the CTOD test reveals ductile and cleavage fractures of the weld joint faces after flux cored arc and electrogas weldings, respectively. The mechanical properties of the EGW welded specimens satisfied relevant classification rules. These results suggest that the EGW process is an effective substitute for the current welding process (FCAW) used for high-strength thick steel plates. |
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Article |
| author |
Bang, HanSur Bang, HeeSeon Ro, ChanSeung Jeong, SuOk |
| author_facet |
Bang, HanSur Bang, HeeSeon Ro, ChanSeung Jeong, SuOk |
| author_sort |
Bang, HanSur |
| title |
Mechanical Behavior of the Weld Joints of Thick Steel Plates Produced by Various Welding Processes |
| title_short |
Mechanical Behavior of the Weld Joints of Thick Steel Plates Produced by Various Welding Processes |
| title_full |
Mechanical Behavior of the Weld Joints of Thick Steel Plates Produced by Various Welding Processes |
| title_fullStr |
Mechanical Behavior of the Weld Joints of Thick Steel Plates Produced by Various Welding Processes |
| title_full_unstemmed |
Mechanical Behavior of the Weld Joints of Thick Steel Plates Produced by Various Welding Processes |
| title_sort |
mechanical behavior of the weld joints of thick steel plates produced by various welding processes |
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Інститут проблем міцності ім. Г.С. Писаренко НАН України |
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2015 |
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Научно-технический раздел |
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http://dspace.nbuv.gov.ua/handle/123456789/173287 |
| citation_txt |
Mechanical Behavior of the Weld Joints of Thick Steel Plates Produced by Various Welding Processes / HanSur Bang, HeeSeon Bang, ChanSeung Ro, SuOk Jeong // Проблемы прочности. — 2015. — № 1. — С. 240-249. — Бібліогр.: 14 назв. — англ. |
| series |
Проблемы прочности |
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| first_indexed |
2025-07-15T09:55:42Z |
| last_indexed |
2025-07-15T09:55:42Z |
| _version_ |
1837706358298771456 |
| fulltext |
UDC 539.4
Mechanical Behavior of the Weld Joints of Thick Steel Plates Produced by
Various Welding Processes
HanSur Bang,
a
HeeSeon Bang,
a,1
ChanSeung Ro,
b
and SuOk Jeong
c
a Department of Welding and Joining Science Engineering, Chosun University, Gwangju, Republic of
Korea
b Department of Naval Architecture & Mechanics, Chosun College of Science & Technology,
Gwangju, Republic of Korea
c Department of Welding and Joining Science Engineering, Graduate School, Chosun University,
Gwangju, Republic of Korea
1 banghs@chosun.ac.kr
The effect of a welding process (electrogas welding (EGW) and flux cored arc welding (FCAW)) on
the fracture toughness, CTOD (crack tip opening displacement), and mechanical properties (tensile,
bending, impact strengths and hardness) of thick weld joints is examined. The CTOD value of the
FCAW weld joints was higher than that of the EGW ones. The fractured welded specimen after the
CTOD test reveals ductile and cleavage fractures of the weld joint faces after flux cored arc and
electrogas weldings, respectively. The mechanical properties of the EGW welded specimens satisfied
relevant classification rules. These results suggest that the EGW process is an effective substitute for
the current welding process (FCAW) used for high-strength thick steel plates.
Keywords: heavy thick steel, electro gas welding, flux cored arc welding, fracture
toughness, mechanical properties.
Introduction. The enlargement of container ships offers many economic benefits,
such as a reduction in investment costs and shipping expenses [1–4]. In the case of
container ships, which possess several holds specifically for loading containers, heavy thick
steel plate is generally used for the upper deck and hatch coating because they withstand
stress concentrations to achieve stability in their structures [5–8]. In manufacturing the
heavy thick steel member, the highly efficient manufacturing technique of the electro gas
welding (EGW) process, which involves a large heat input process, is practically unavoidable
due to the limitations of the current flux cored arc welding (FCAW) process of the
conventional multilayer welding process in terms of productivity [9–14]. On the other
hand, EGW is expected to have weaker fatigue strength and undergo brittle fracture due to
its large heat input. Some classification societies are considering the relevant requirements
to estimate and improve the fracture toughness of large-sized welding constructions using
high strength heavy thick steel plates. Therefore, for the application of EGW to a heavy
thick hull, the fracture behavior and mechanical characteristics of its welded joints should
be clarified in advance. In this study, the fracture toughness (CTOD) was measured and
mechanical tests (tensile, impact, bending strength and hardness) were performed to
evaluate the strength of the welded joints with high strength (355 MPa) and thick steel
plates EH36-TMCP (78 mm). The results of EGW are compared with those of the current
FCAW process.
1. Experimental. In this study, shipbuilding steel plate EH36-TMCP (Classification
Grade) with a 78 mm thickness, which is used in large container ships, was used to
fabricate welded specimens by large heat input welding (EGW), and existing multi-layer
welding (FCAW). Tables 1 and 2 provide the chemical composition and mechanical
properties of the EH36-TMCP and welding electrodes. The specimen dimensions were
© HanSur BANG, HeeSeon BANG, ChanSeung RO, SuOk JEONG, 2015
240 ISSN 0556-171X. Ïðîáëåìû ïðî÷íîñòè, 2015, ¹ 1
1200 mm in length, 400 mm in breadth and complied with the requirements of the WPQT
(welding procedure qualification test) of the classification societies. The shape and angle of
the welding groove were chosen to have an X shape in both sides, 30� in the bevel angle
and an 8 mm gap, considering the field conditions of welding. Figure 1, as well as Tables 3
and 4 provide the details of the welding joint shape and the number of layers for the EGW
and FCAW welded joints, respectively.
T a b l e 1
Chemical Composition of EH36-TMCP and Wire (wt.%)
Material C Si Mn P S Ni Cu Ti
EH36-TMCP 0.18 0.1–0.5 0.9–1.6 0.035 0.035 0.40 0.35 0.02
Wire for EGW 0.05 0.25 1.6 0.009 0.007 1.40 – 0.05
Wire for FCAW 0.04 0.38 1.1 0.012 0.010 1.55 – –
T a b l e 2
Mechanical Properties of EH36-TMCP and Wire
Material Yield strength (MPa) Tensile strength (MPa) Elongation (%)
EH36-TMCP 355 490–620 21
Wire for EGW 500 615 25
Wire for FCAW 560 620 29
T a b l e 3
Welding Condition for the EGW Specimens
Number
of pass
Current
(A)
Voltage
(V)
Arc time
(s)
Speed
(cm/min)
Interpass
temperature
(�C)
Heat input
(kJ/cm)
Top (1 pass) 400 42 1589 4.5 116 235.2
Bottom (1 pass) 430 44 1310 5.5 162 206.4
a b
Fig. 1. Welding joint shape and number of layers for the EGW (a) and FCAW (b) process.
ISSN 0556-171X. Ïðîáëåìû ïðî÷íîñòè, 2015, ¹ 1 241
Mechanical Behavior of the Weld Joints of Thick Steel Plates ...
The CTOD test of the B B� type using a 3-point bending test was carried out in
accordance with the BS7448 Standard to examine the fracture toughness in the fusion line
where lowest fracture toughness might be encountered [11–14]. The CTOD test was
performed for two types of surface notch and through thickness notch, which are located on
CGHAZ, as shown in Fig. 2. Furthermore, tests for the mechanical properties, i.e., tensile,
bending, impact strength, and hardness were performed and evaluated according to the
class rules. The tensile strength tests were conducted on the half-thickness specimens with
a size of 25 mm (W)�39 mm (t). Side bending tests were carried out with an angle of 180�.
A Charpy impact test was performed at each notch location of the face and middle part,
such as the weld metal, fusion line, fusion line �1, �2, �3, and �5 mm at � �20 C.
Figures 3 and 4 show the procedure for the CTOD test by the 3-point bending
specimen and a schematic diagram of the CTOD values calculation, respectively. The test
procedure requires that the radius of the milled notch and band swan notch shall not exceed
0.1 mm in radius and 0.15 mm in breadth. This means that if the dimensions of the
specimen failed to satisfy the dimension requirements, no further test is performed, and the
test will be invalidated if the fatigue crack size including the notch length exceeds 60% of
the breadth (W), which was fixed by the specimen thickness (B), in the base metal and 70%
in the weld metal. During the test, a fatigue crack induced by a 500 ton class universal
fatigue test machine was initiated with a stress ratio R � 0.1.
T a b l e 4
Welding Conditions for the FCAW Specimens
Number of pass Current
(A)
Voltage
(V)
Arc time
(s)
Interpass
temperature (�C)Top Bottom
1 1 240 300 30 31 405 373 119 119
2 2 280 300 31 31 352 361 123 135
3 3 300 300 31 31 365 359 114 157
4 4 300 280 31 32 143 223 123 128
5 5 300 280 31 32 182 209 141 147
6 6 300 280 31 32 193 262 137 130
7 7 300 280 31 32 172 191 131 112
8 8 300 310 31 31 151 265 115 129
9 9 300 310 31 31 174 262 119 145
10 10 300 320 31 31 147 244 131 125
11 11 300 320 31 31 199 226 149 136
12 12 300 320 31 31 151 237 127 115
13 13 300 320 31 31 201 246 139 118
14 14 260 320 29 31 131 212 152 124
15 15 260 320 29 31 171 187 121 131
16 16 260 320 29 31 121 257 147 135
17 17 260 275 29 31 117 213 114 105
18 18 260 275 29 31 153 227 127 111
– 19 – 275 – 31 – 176 – 125
242 ISSN 0556-171X. Ïðîáëåìû ïðî÷íîñòè, 2015, ¹ 1
HanSur Bang, HeeSeon Bang, ChanSeung Ro, and SuOk Jeong
After the fatigue crack formation, the 3-point bending test was carried out after
maintaining the specimen in the refrigerant chamber at a test temperature� �20 C of E grade
steel. In order to create test temperature � �20 C, refrigerant liquid nitrogen in chamber was
maintained in the temperature range � � �20 2 C and specimen was dipped into refrigerant
a b
c d
Fig. 2. Notch locations of the EGW (a, b) and FCAW (c, d) welded specimens: (a, c) through-thickness
notch; (b, d) surface notch.
Fig. 3. CTOD test procedure.
ISSN 0556-171X. Ïðîáëåìû ïðî÷íîñòè, 2015, ¹ 1 243
Mechanical Behavior of the Weld Joints of Thick Steel Plates ...
liquid nitrogen for 30 s per thickness of specimen. During and after the test, a measurement
of the crack opening displacement (COD) with plastic component of the clip gauge
displacement Vp , Pm value and evaluation of the fractured surface and crack length a0
were conducted. Figure 3 schematically depicts the test procedure. In addition, the fatigue
crack length should comply with the following criteria: (i) crack length to specimen breadth
ratio a W0 should be within the range from 0.45 to 0.55; (ii) the crack length increment
(difference between any two sets of values) should not exceed 10% of a0; and (iii) crack
propagated angle from the notch direction should not exceed 10�.
From the available methods for the CTOD test conduction, an estimation method by
the displacement of a clip gauge was selected, which is based on a rotating center. In this
method, the specimen is treated as a rotating rigid body on r W a( )� as the central axis
from the crack tip when a bending load is applied, and using relationships between the
resulting � and Vg , the CTOD can be estimated as follows:
�
�
� � �
r W a V
a z r W a
V
p
g
( )
( )
, (1)
where r is the rotation factor. In accordance with the BS 5762 for the 3-point bending test,
the CTOD( ) for r� 0 can be described as follows:
�
�
�
�
�
�
� �
K
E
W a V
W a zY
p
2 21
2
04
04 06
( ) . ( )
. .
, (2)
where K is stress intensity factor,
is Poisson’s ratio, �Y is the yield strength, E is the
Young modulus, a is the effective crack length, Vp is the plastic component of the clip
gauge displacement, and z is the distance between the clip gauge location from the test
piece surface.
Fig. 4. Schematic diagram of the CTOD values calculation.
244 ISSN 0556-171X. Ïðîáëåìû ïðî÷íîñòè, 2015, ¹ 1
HanSur Bang, HeeSeon Bang, ChanSeung Ro, and SuOk Jeong
2. Results and Discussion.
2.1. Fracture Toughness. Table 5 presents the results of the CTOD test of the EGW
and FCAW welded specimens with a surface notch and through thickness notch, whose
locations in the welded specimens are shown in Fig. 2. Figures 5 and 6 show the fractured
welded specimens after the CTOD test. The CTOD values of the EGW for the surface notch
and through thickness notch, which are located on CGHAZ, were 0.212 and 0.687 mm,
respectively, whereas the values of the FCAW were 0.403 and 0.939 mm. The CTOD value
in FCAW was higher than that of EGW and the values on the surface notch, where the
microstructure is weak at the crack tip, was less than those of the through thickness notch.
The fractured surface after the CTOD test for the EGW and FCAW welded specimens were
observed by SEM (scanning electron microscopy), as shown in Figs. 7 and 8. The shape of
the fracture face in EGW shows that facet fracture occurs, as observed from the plain
surface on the fractured face, whereas the FCAW shows the facet fracture together with the
partial dimple fracture. This means that the FCAW shows ductile fracture due to the low
heat input and small grain boundary but EGW shows cleavage fracture due to the high heat
input, large granule sand brittleness. In the case of EGW, there was no difference in the
fractured faces between the surface and through thickness notch.
2.2. Mechanical Properties. Table 6 lists the results of the tensile tests for the EGW
and FCAW welded specimens. All specimens were fractured by the base metal and the
mean tensile strengths were measured to be approximately 540 MPa for the EGW and
FCAW specimens, which satisfied the classification requirements (min. 470 MPa) for
EH36-TMCP. The hardness test for each welding process was carried out using a Vickers
hardness tester throughout 22 points for the weld metal (WM), heat affected zone (HAZ),
and base metal (BM), as shown in the photos embedded into Table 7. A comparison of the
hardness between the front and the backward welding regions revealed the value of the
T a b l e 5
Results of the CTOD Test
Welding process Location of crack CTOD value (mm)
EGW Surface notch 0.212
Through-thickness notch 0.687
FCAW Surface notch 0.403
Through-thickness notch 0.939
a b
Fig. 5. Fractured EGW welded specimen after the CTOD test: surface notch (a) and through-thickness
notch (b).
ISSN 0556-171X. Ïðîáëåìû ïðî÷íîñòè, 2015, ¹ 1 245
Mechanical Behavior of the Weld Joints of Thick Steel Plates ...
T a b l e 6
Tensile Test Results for the EGW and FCAW Welded Specimens
Item Size
(W t� , mm)
Area
(mm2)
Total load
(ton)
Tensile strength
(MPa)
Note
EGW 1 25 0 40 2. .� 1005.00 55.60 542.16 Mean
tensile
strength
539.66 MPa
EGW 2 25 6 35 3. .� 903.68 49.80 540.05
EGW 3 25 4 38 5. .� 977.90 53.30 540.25
EGW 4 24 9 37 8. .� 941.22 50.85 536.17
FCAW 1 25 3 38 0. .� 961.40 52.60 536.17 Mean
tensile
strength
540.17 MPa
FCAW 2 35 3 37 5. .� 948.75 51.30 529.89
FCAW 3 25 3 37 3. .� 943.69 51.95 539.48
FCAW 4 24 9 37 8. .� 941.22 52.25 555.13
a b
Fig. 6. Fractured FCAW welded specimen after the CTOD test: surface notch (a) and through-thickness
notch (b).
Fig. 7. SEM images of the fractured surfaces after the CTOD test of the EGW welded specimen.
Fig. 8. SEM images of the fractured surfaces after the CTOD test of the FCAW welded specimen.
246 ISSN 0556-171X. Ïðîáëåìû ïðî÷íîñòè, 2015, ¹ 1
HanSur Bang, HeeSeon Bang, ChanSeung Ro, and SuOk Jeong
T a b l e 7
Hardness Test Results for the EGW and FCAW Welded Specimens
EGW welded specimens Measurement points/EGW
BM HAZ (left) WM HAZ (right) BM
1 2 3 4 5 6 7 8 9 10 11
206 174 185 175 215 215 209 191 187 190 214
BM HAZ (left) WM HAZ (right) BM
12 13 14 15 16 17 18 19 20 21 22
210 199 204 218 232 235 236 207 216 212 211
FCAW welded specimens Measurement points/FCAW
BM HAZ (left) WM HAZ (right) BM
1 2 3 4 5 6 7 8 9 10 11
194 217 212 207 212 218 218 231 223 210 190
BM HAZ (left) WM HAZ (right) BM
12 13 14 15 16 17 18 19 20 21 22
186 229 246 241 204 225 220 232 225 222 198
T a b l e 8
Results of the Bending Test for the EGW and FCAW Welded Specimens
Item Type Angle
(deg)
Requirement Result Welded specimen
after bending test
EGW
1–4
Side
bend
180 Open defect
length � 3 mm
Accepted
FCAW
1–4
Side
bend
180 Open defect
length � 3 mm
Accepted
a b
Fig. 9. Results of the impact test for the EGW (a) and FCAW (b) welded specimens.
ISSN 0556-171X. Ïðîáëåìû ïðî÷íîñòè, 2015, ¹ 1 247
Mechanical Behavior of the Weld Joints of Thick Steel Plates ...
backward side to be higher than the front side. This confirmed that the test results satisfied
the relevant standards, such as HV for the weld and 350 HV for the HAZ, as shown in
Table 7. In addition, this result also complied with the mechanical properties of an
EH36-TMCP steel plate.
Figure 9 shows the absorbed energy, which was tested using the Charpy impact test at
a test temperature of � �20 C. The test results show that the energy absorbed at each notch
location of the face and middle parts, such as the weld metal, fusion line, fusion line �1,
�2,�3, and �5 mm, was sufficient (
150 J). In addition, these results satisfied the relevant
standard, i.e., min. 34 J in the EGW specimens and 47 J in the FCAW specimens. The
bending strength of the EGW and the FCAW welded specimens was estimated. As shown
in Table 8, no open defect occurred, which satisfies the relevant requirements of an open
defect length � 3 mm.
Conclusions. In view of the structural integrity and stability for a welding construction
that uses heavy thick plate, these results show that large heat input welding, such as EGW,
complies with the relevant requirements. The comparison with the traditional welding
process, FCAW, shows that the EGW welded joints are compatible with large welding
constructions.
Acknowledgments. This research was financally supported by the Ministry of
Education, Science Technology (MEST) and National Research Foundation of Korea
(NRF) through the human resource training project for regional innovation
(2012H1B8A2026193).
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Received 20. 10. 2014
ISSN 0556-171X. Ïðîáëåìû ïðî÷íîñòè, 2015, ¹ 1 249
Mechanical Behavior of the Weld Joints of Thick Steel Plates ...
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