W HAT T O C ONSIDER W HEN W ELDING S TAINLESS S TEEL

W.F. Garth Stapon Praxair, Inc. Marketing Manager Metal Fabrication

Novem

ber 1999

Vol. 29

No.11

Reprinted from The Fabricator November 1999

What to consider when welding

stainless steel
Process, filler, and gas selection

Article reprinted with permission from the November 1999 issue of The FABRICATOR.

By W.F. Garth Stapon

n North America, use of stainless steel grew about 5.5 percent annually from 1988 to 1997.1 The techniques for joining and cutting this popular metal are numerous. This article discusses gas and filler metal selection and process options to achieve high-quality joining and cutting operations. Because most of the stainless that is welded commercially is of the 300 series, this article focuses on those alloys.

Welding Process Selection

The two most common production methods for joining stainless steel are gas tungsten arc welding (GTAW) and gas metal arc welding (GMAW). Base metal thickness is the primary factor in determining the more economical method of welding. A rule of thumb is that materials less than 116 inch thick usually are joined with GTAW, although recent developments in GMAW power supplies allow it to be used for thicknesses that previously were dominated by GTAW. By carefully matching the shielding gas, welding power supply, and filler metal diameter and composition, materials as thin as 22 gauge thickness can be joined using a lap joint.
Because labor and overhead represent more than 80 percent of total welding costs, the increased cost for the shielding gas can be offset by improved productivity.

GTAW Gas Selections

Shielding gases used for GTAW of stainless steel include pure argon, argon/helium, and argon/hydrogen blends. The selection of the shielding gas is based on welding productivity, distortion levels, and desired color match. Purge gases can include pure argon, argon/hydrogen, argon/helium, and

nitrogen/hydrogen. Factors such as desired color match and corrosion resistance are important criteria when selecting a purge gas for GTAW of stainless. Argon is the most widely used shielding gas for GTAW of stainless steel. It offers excellent arc-starting characteristics and has mild heat conductivity, making it suitable for joining thin materials. Gas purity is essential (99.995 percent minimum) to achieve high-quality results. By blending helium (as much as 50 percent) or hydrogen (as much as 10 percent) with argon, heat conductivity of the shielding gas increases, which usually permits faster travel speeds. With improved travel speed, distortion levels also are reduced, although operating voltage is increased compared to that of argon. This makes these blends an option for mechanized welding. If maintaining color match is critical when welding a 300 series alloy, the reducing effect of the argon/hydrogen

blend can leave less residual oxide on the completed weld deposit. In many cases, a postweld cleaning operation can be avoided. The mixture ratio with GTAW is typically argon/2 percent to 10 percent hydrogen. As base metal thickness increases, the hydrogen content also must increase to achieve the desired finish.

To Purge or Not to Purge

Pure argon, argon/hydrogen, and nitrogen/hydrogen blends have been used as the purge gases for welding stainless steel pipe. When working with 300 series alloys, a nitrogen/ hydrogen mix can be used as a more economical alternative to argon, although lower concentrations of hydrogen in nitrogen can cause crack susceptibility. Argon/hydrogen is recommended for the 300 series alloys because of its color match capabilities at lower flow rates, without compromising corrosion resistance.

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Shielding Gases for GMAW

Shielding gas selection depends on the base metal thickness, welding position, and operating current. For shortcircuit transfer on thin material, a helium/argon/CO 2 blend is a good selection because it produces little spatter while maintaining proper weld puddle fluidity. Some success has been achieved with argon/10 percent CO 2 blends, although CO2 content should be controlled carefully to prevent carbon pickup. In applications in which preventing carbon pickup and corrosion resistance are critical, CO 2 levels should be limited to 3 percent. Surface color match also will improve as the CO 2 level in the shielding gas is reduced. Hydrogen (1 to 2 percent) can be added to an argon/CO2 blend to improve the heat conductivity of the gas as well as to lower the residual oxide on the finished weld deposit. For spray arc welding of thicker material, argon/oxygen or argon/helium/CO2 is recommended.

flat slope and low inductance. Because puddle fluidity improves generally with inductance, the amount of inductance should be run at a lower level when welding out of position to promote a faster freeze of the weld puddle.

Torch Design
Most gas-cooled GMAW guns are rated for use with CO2 and derated by 40 to 50 percent when used with mixed gas. Water-cooled guns perform well when welding with mixed gases, but there is a cost penalty. A minimum 400-amp rating should be selected when performing pulsed or spray arc transfer. Because the expansion rate of stainless steel is greater than that of mild steel, a slightly oversized contact tip also will enhance wire feeding. A rule of thumb is that the contact tip should be oversized 0.002 to 0.005 inch. Tips dedicated for use with aluminum alloys are a good selection to minimize burnback and improve wire feeding at currents greater than 150 amps. For GTAW, a water-cooled torch allows greater operating currents to be used and is well-suited to production welding applications. The use of gas-cooled torches typically is limited to a maximum of 200 amps. With argon/helium or argon/ hydrogen blends, a water-cooled torch is essential to prevent premature melting of the tungsten.

Slope and Inductance

For short-circuit welding of stainless steel, the power supply should have steep slope and variable inductance. By controlling the slope, the short-circuit current spike is lowered, which helps to smooth the molten metal droplet transfer. This helps to limit spatter. Inductance can be described simply as a shock absorber for the arc. Unlike slope, inductance does not limit the total current available. Rather, it limits the rate at which the current rises. This is very useful in increasing arc on time and can improve puddle fluidity substantially when working on light materials at low operating currents. The use of slope and inductance hampers arc-starting characteristics. If multiple short welds are required, more positive arc starts can be achieved with

Tungsten Selection
Thoriated tungsten (EWTh-1 and EWTh-2) is a common selection because it improves the electrical conductivity of the nonconsumable tungsten electrode. These alloys are available in 1 and 2 percent grades and provide easy arc starting, arc stability, and current-carrying capacity. They are used primarily with direct current straight polarity (DCSPelectrode negative). Care should be taken in storing and

grinding these electrodes because they are radioactive. No firm guidelines exist, and thorium is a naturally occurring element. Inventory should be kept low, and an operator should keep only one days supply on hand. The tungsten manufacturers recommendations on the correct operating and storage requirements should be followed. Other options are available. For example, lanthanum-alloyed tungsten (EWG) is a nonradioactive substitute for thoriated tungsten. These alloys operate in a fashion similar to thoriated tungsten and are designed primarily for use with DCSP. They allow arc striking at lower levels than does pure tungsten, and they have slightly less current-carrying capacity than do thoriated tungsten electrodes. Cerium dioxide-alloyed tungsten (Ce EWCe-2) is nonradioactive and offers increased service life and good arc starting and stability. This tungsten allows arc striking at lower current levels than does pure tungsten. It also provides longer service life than a thoriated tungsten electrode. Zirconium dioxide-alloyed tungsten (ZirconEWZr-1) is designed for use in AC welding of aluminum alloys and offers increased current-carrying capacity when compared to pure tungsten. Pure tungsten (99.5 percent EWP) can be used for AC or DC welding and is suitable for use in a variety of operating conditions. Its current-carrying capacity is lower than that of thoriated and lanthanum-, cerium-, and zirconium-alloyed tungsten.

Stainless FCAW Wire

The use of stainless steel flux-cored wire continues to grow. When performing out-of-position welding or when welding materials greater than 12 inch in thickness, it offers improved productivity and weld appearance. Shielding gas selection is based on the welding position, operating conditions, and filler metal.

The filler metals are divided into two categoriesthose for all-position welding and those for flat-position welding. For all-position welding, argon/25 percent CO2 is recommended. Pure CO2 shielding gas can be used for flat-position welding, although spatter, fume, and distortion rates typically increase because of the greater heat conductivity and poor electrical conductivity of pure CO2. The argon/25 percent CO2 blend commonly is used for flat-position welding and may offer increased travel speed because of its electrical conductivity compared to that of pure CO 2 . Typically, operating parameters can be increased from 5 to 15 percent while maintaining control of weld spatter. Because labor and overhead represent more than 80 percent of total welding costs, the increased cost for the shielding gas can be offset by improved productivity. Metal-cored stainless wires have been used for highdeposition welding without arc stability problems.

SMAW
SMAW remains a common method of joining stainless steels. The electrodes used can be divided into two categoriesall-position and flat-position styles. Many flat-position electrodes use a slightly magnetic low-alloy steel core and produce the stainless steel weld deposit from alloys added to the flux of the electrode. These jet-style electrodes offer the ability to run at higher operating currents and can increase the weld deposition rate by as much as 20 percent compared to conventional electrodes. When using jet electrodes, a backstep welding technique is required to ensure that the arc starting point is a stainless deposit. The alloy that is deposited is determined by the flux-tocore wire ratio. This ratio is calculated at the design stage of the manufacturing process. Electrode starts can be rich in iron and chromium-deficient because the end of the electrode has a tapered flux coating. The core-to-flux ratio is greater than that in the electrode itself and causes a lower chromium deposit at arc initiation. Welding back over the start of the deposit is known as back-stepping and will prevent this potential problem. A meat plant processor once built a 316L stainless floor that was welded using a jet-style electrode. The floor corroded after two months at locations about 8 inches apart along the entire length of the weld seam. The cause was low-alloy deposits in the arc initiation zones because the operator failed to use back-stepping. Although conventional stainless core electrodes operate at lower current levels during welding (to prevent electrode overheating), it is sometimes beneficial to use these alloys because they maintain their corrosion-resistant properties along the entire weld seam, including the arc starting point.

Carbide Precipitation
When 300 series stainless is heated and cooled during the welding operation, given sufficient time, the carbon that is present in the arc zone can combine with chromium to form chromium carbides. Because the chromium is tied up and precipitates out of the stainless in the form of dark, granular particles, corrosion resistance is compromised. Small areas are left rich in iron and depleted of chromium and are no longer stainless steel because these areas can corrode or rust. Peppering, as the condition is commonly called, can be prevented by using a low-carbon filler material. Additional techniques that will prevent carbide precipitation include high-productivity/low-heat input processes and rapid cooling following the weld procedure. Carbide precipitation should be avoided at all costs because it compromises the corrosion qualities of the welded part.

Plasma Cutting and Welding

Plasma cutting and welding can be performed on stainless materials. For welding, the constricted plasma arc is suited to joining thin materials. Argon/hydrogen commonly is used as the plasma gas. For cutting, the plasma gas can be air or nitrogen. Oxides on the cut surface are more prevalent when air is used. Choosing nitrogen improves consumable life (tips) by 20 to 50 percent, although the capacity of the system will be derated by 25 percent compared to the use of air. Oxides on the surface of the cut will be reduced, requiring less preparation before the welding operation. Wet shop air is the primary cause of premature torch failure with plasma cutting operations. By selecting nitrogen, moisture content is controlled closely in the manufacturing operation to enhance torch life further.

GMAW Filler Metal Selection

For GMAW of stainless, the filler metal should be matched to the alloy being welded. There are two common types of filler metal grades high-silicon (hi-sil) and conventional alloys. The hi-sil alloys commonly are used because they offer good weld puddle fluidity. For out-of-position welding and when the weld joint is under severe restraint, standard-grade alloys should be used because they produce a faster freezing puddle for improved control and offer increased crack resistance. To join stainless steel to mild steel, a 309 or 312 alloy should be used. A low-carbon or extra-low-carbon filler alloy can help prevent carbide precipitation. This also applies with shielded metal arc welding (SMAW) and flux cored arc welding (FCAW).

For plasma arc gouging, air or argon/hydrogen blends are used. As a torch cooling gas, nitrogen or argon helps to suppress fume production from the gouging operation.

Base Metal Cleanliness

In stainless fabrication, clean base material is essential to achieve highquality results. Any addition of hydrocarbons such as oil, grease, ink markers, or paint can cause an increase in the carbon level that, in turn, can cause carbide precipitation. As pointed out earlier, carbide precipitation can cause small areas to corrode or rust. Because of the high cost of rework and scrap, time spent on cleaning material will pay off later through lower distortion, better weld bead shape, and reduced porosity.

Operating currents should be 20 to 25 percent lower than those for mild steel. For example, a 18-inch steel SMAW electrode can be operated at 125 amps when joining 14-inch mild steel. With stainless, the same diameter stainless electrode is operated at 90 to 100 amps.

Pulsed GMAW
Pulsed GMAW is being used increasingly to achieve high-quality stainless steel weldments. It offers control of operating conditions, limited heat input, and versatility for allposition welding on a large variety of base metal thicknesses. In addition to producing spatter-free weldments, this process is suited to stainless steel because it offers the ability to control heat input, an essential variable when trying to lower base metal distortion levels. The rapid freeze rates associated with pulsed GMAW also allow good control when welding out of position. Fume and spatter are reduced when compared to conventional methods. Shielding gas selection ranges from argon/1 to 2 percent O2 to helium/ argon/CO2 to argon/3 percent CO2.

3. Corrosion resistance 4. Base metal composition 5. Desired magnetic properties 6. Desired crack resistance 7. Output of available power supply As with most welding operations, the shielding gas selection should be matched closely to the filler metals selected and type of metal transfer.

Summary
With the expanded use of stainless alloys, todays fabricator must look at changing technology and incorporate welding processes that meet quality demands while improving the productivity of the process. Factors such as color match, weld bead shape, penetration properties, corrosion resistance, and distortion levels must be considered when making a process selection. With careful consideration, the reward will be a highquality, defect-free joining operation. s
1. International Nickel Company (INCO) Stainless Steel Report, World Bureau of Metal Statistics document ISSN 0141-0806. W.F. Garth Stapon is Marketing ManagerMetal Fabrication for Praxair, Inc., 39 Old Ridgebury Road, Danbury, Connecticut 06810, phone 800-PRAXAIR or 716-8794077, fax 800-772-9985 or 716-879-2040, e-mail garth_stapon@praxair. com, Web site praxair.com. Praxair, Inc., produces, sells, and distributes atmospheric, process, and specialty gases and surface coatings. Photos courtesy of ESAB Welding & Cutting, Florence, South Carolina.

Distortion
Distortion rates in stainless are greater than those encountered when welding on mild steel. For this reason, tacking operations should be three to four times as frequent as they are for steel. A tack every 4 to 6 inches helps to ensure lower distortion rates. Heat input should be kept to a minimum to achieve the desired results. Argonbased shielding gases help to lower distortion rates because of improved travel speeds and moderate heat conductivity associated with these mixtures.

Filler Metal Selection

Filler metal should be selected based on the following criteria: 1. Base metal thickness 2. Welding position

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Praxair and the Flowing Airstream design are trademarks or registered trademarks of Praxair Technology, Inc. in the United States and/or other countries. The information contained herein is offered for use by technically qualified personnel at their discretion and risk without warranty of any kind. Printed in the United States of America 2-2000 P-8451 3M