Ferrite Number for Austenite SS welding

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THE DEFINITION OF FERRITE NUMBER

ASME Section IX_Welding and Brazing Qualification EN ISO 8294_ Determination of Ferrite Number(FN) in austenitic and
duplex ferritic-austenitic CR-Ni stainless steel weld metals

ASM Metals Handbook Vol.6_Welding, Brazing, and Soldering

AWS A4.2_ Standard Procedures for Calibrating Magnetic Instruments to Measure to the Delta Ferrite Content of Austentie and Duplex Austenitic-Ferritic Stainless Steel Weld Metal

WRC, establishing the lack of a standard calibration procedure(1972)

% ferrite in austenite SS weld metals in the past has too often been regarded as a firm fixed value But each lab gives different ferrite % with same specimen : Average 5%, 3.5-8%, Average 10%, 7-16% The term FN to replace % ferrite to clearly indicate that the measuring instrument was calibrated to the procedure

AWS, to extend WRCs calibration procedure and prepared AWS 4.2(1974)

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HOT CRACKING
Hot cracking
Referring to cracking that occurs during welding, casting, hot working at temp. close to the melting point Not completely understood, but generally accepted as following ;
Segregation during solidification & form low-melting-point liquid films on GB Tensile stresses(building up during solidification & cooling) cause cracking along the liquid films

Mechanism of cracking(Liquid film + shrinkage stress + thermal contraction)

Metallurgy of welding(Sixth Edition) / J.F.Lancaster

From Solidification and Liquation Cracking Issues in Welding / Sindo Kou

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HOT CRACKING IN AUSTENITE STAINLESS STEEL

Solidification cracking
Intergranular cracking in fusion zone Revealing fracture surface as dendritic morphology Intergranular cracking in PMZ(Partially Melted Zone) No fracture surface as dendritic morphology
Solidification cracking

Liquation cracking

Liquation cracking

From Solidification and Liquation Cracking Issues in Welding / Sindo Kou

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COMPOSITIONAL EFFECT TO ASS SOLIDIFICATION CRACKING

Two major effects with composition
Mode of solidification from liquid by the amounts of ferrite stabilizing elements Segregation(S, P, Ti, Nb, B, Si) : determining the wetting characteristic & constitutional in the interdendritic region Acc. to several studies, Creq/Nieq ratio >1.5 or with P+S < 0.01wt% were not susceptible for cracking

1979

1988

From Solidification cracking in austenitic Stainless Steel welds / V Shankar

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EFFECT OF DETAL-FERRITE ON SOLIDIFICATION MODE

Different solidification modes depending on ferrite content(Creq/Nieq)
A, AF mode(less than 3 FN) : Primary austenitie solidification process FA mode(3 45 FN) : Primary ferrite solidification process, reducing the susceptibility of cracking effectively

Less than 3 FN

3 45 FN

From AWS Welding Handbook Volume 4, part2

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BENEFICIAL EFFECTS OF PRIMARY FERRITE SOLIDIFICATION

Major effects
Higher solubility of S, P etc., in the ferrite that introduces less of the harmful solute in the interdendritic regions Lower wettability of grain boundaries in a duplex structure Grain refinement during FA mode solidification Smaller solidification temp. range : Providing a smaller critical temp. range for crack formation Higher ductility of ferrite at high temp. : Allowing relaxation of thermal stresses Lower thermal expansion coefficient of ferrite : Less contraction stresses and fissuring tendency

Minor or negligible effects

From Welding Metallurgy and Weldability of Stainless Steels / John C. Lippold From Welding Metallurgy / Sindo Kou

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FERRITE MEASUREMENT TECHNIQUES

Metallographic Point Counting
ASTM E562, Standard Practice for Determining Volume Fraction by Systematic Manual Point Count. Destructive method, applying to any microconstituent or phase which is metallographically identifiable Schaeffler(1949), DeLong(1974), WRC Diagram(1992) Non-destructive method Magnetic Indicators(Severn Gage), Attractive Force(Magne Gage), Magnetic Permeability(Feritescope) Non-destructive method, using ferromagnetic at room temp. for ferrite while austenite is not X-ray Diffraction, Magnetic Saturation, Mossbauer Not being readily applied to field engineering situations due to the use of laboratory confined equipment or variations in material so far
Austenitic SS Duplex SS

Constitution Diagram

Magnetic Instrumentation

Experimental Trials

Ferrite Austenite

X600

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METALLOGRAPHIC POINT COUNTING

Method : ASTM E 562

Metallurgical sections shall be polished and etched to clearly reveal the two-phase Examining and photographing under a microscope at a sufficient magnification (Recommending X400 for parent plate & weld metal, X700-1000 for HAZ) Overlaying with a grid of at least 100 points Calculating ferrite % by counting the number of points that fall on the ferrite phase and the total number of points

Limitation
Destructive : Requiring sections to be removed from an actual weldment Time consuming & inherently inaccurate unless many sections in various locations & orientations are examined Poor reproducibility : Among a number of laboratories shown to be poor
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CONSTITUTION DIAGRAM 1 : SCHAEFFLER DIAGRAM

Firstly proposing quantitative relationship between the composition & ferrite content : 1949
Reasonable accurateness for Types 308, 309, 309Cb, 310, 312, 316, 317, 318 and 347 with 4% ferrite No Mn in WRC-1992 diagram
Mn has no effect on the high-temp. transformation( ) during cooling, but has significant effect on the low-temp. transformation ( martensite) during further cooling by stabilize austenite at low temp.

Still retaining because of reasonably accurate predictions martensite in lean stainless steel

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CONSTITUTION DIAGRAM 2 : DELONG DIAGRAM

The second diagram to related chemical composition and ferrite content : 1956
Focusing on 300 series austenitic stainless steel Recognition of the important of the element nitrogen as a strong austenizer Having the difficulty of measuring the ferrite content quantitatively by volume in welds Using magnetic measurements : BCC delta ferrite is ferromagnetic, FCC austenite is not

Being modified to show FN after the adoption of a standardized method in AWS A4.2 : 1974

Effect of N on ferrite content in TIG welds of DSS / Welding metallurgy, Sindo Kou

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CONSTITUTION DIAGRAM 3 : WRC DIAGRAM

Needing new diagram due to the limitation of DeLong Diagram : WRC-1988 Diagram
DeLong Diagram, underestimating ferrite content with high Mn & overestimating FN of highly alloyed(309)
Mn promotes to a lesser degree as its content is increased, & at very high levels, it promotes the formation of ferrite

1,000 measurements based on AWS A4.2 from manufacturers, research institutes, fabricators Expanding FN range : 0-18 0-100
Schaeffler Creq Nieq Delong WRC

Modification with WRC-1988 Diagram by adding Cu coefficient to Nieq : WRC-1992 Diagram

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FURTHER DEVELOPMENT OF CONSTITUTION DIAGRAM

Some limitations for WRC Diagram
Depending on the quality of the chemical analysis and a cooling rate Levels of Mn up to 10% and N levels up to 0.25%, giving lower prediction accuracy over 1% Si or 3% Mo No recommendation for extrapolation() outside the area of lines on the diagram since the iso-ferrite lines become non-linear at high alloy contents Ti(similar to Nb), a potent carbide former & promoting ferrite in the absence of carbon Termed neural because they mimic the function of the human brain Being reported to be more accurate than the WRC-1992 diagram(WRC-1992 diagram + date from other sources) Incorporating cooling rate effect

More study preceding for Titanium

Neural Network Ferrite Prediction

From Welding Metallurgy and Weldability of Stainless Steels / John C. Lippold

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FERRITE MEASUREMENT : MAGNETIC INSTRUMENTATION

Advantages of magnetic measurement
Using ferromagnetic at room temp. for ferrite while austenite is not Non-destructive & proving useful in creating reliable, reproducible and user-friendly Magnetic indicators(e.g., : Severn Gage)
Go/no go type : comparing the relative magnetic attraction between the magnet & the material to be tested Continuous-reading type utilizing a spring to measure the attraction between a magnetic & the material to be tested Reading relative force of the spring required to break the contact between specimen and magnet Operating on the magneto-induction principle where the relative magnetic permeability of specimen is measured Measuring a voltage when a magnetic field is induced in the probe upon contact with the material to be tested
Magne Gage Feritescope

Magnetic Instrumentation

Attractive Force(e.g., : Magne Gage)

Magnetic Permeability()(e.g., : Feritscope)

Severn Gage

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FERRITE NUMBER VS FERRITE %

History
Initial concept(1974) : Ferrite number = Percent Ferrite Further research revealing : the 1:1 correlation of FN to volume percent is only acceptable for low FN(0-10)
Majority of ASS weld metals was in the range of 0-10FN

Requiring the measurement of higher FN(e.g., duplex stainless steel) Acc. many standard, FN = Ferrite volume 0-8(or 10) % Acc. to Welding Journal 61

Conversion

Acc. to ASM Metal HandBook, 50-90FN

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FERRITE OPTIMIZATION
Ferrite in ASS
Should contain a small but controlled amount of ferrite Too much -ferrite(10 vol%) : Reducing the ductility, toughness, corrosion resistance Too little -ferrite(5 vol%) : hot cracking

7075 Al

From Welding Metallurgy and Weldability of Stainless Steels / John C. Lippold

SS310
From Welding Metallurgy / Sindo Kou

Ferrite in DSS
Phase balance is important to optimize their mechanical & corrosion properties Too much -ferrite(>70 vol%) : Low ductility, loss of corrosion resistance, HE susceptability Too less -ferrite(<20 vol%) : Low strength, low SCC resistance
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FERRITE NUMBER LIMITATION BY SPECIFICATION

API 582, Austenitic stainless steel welding(P8 Group 1)
Weld metal(PWHT or high temp. service) : < 10FN prior to PWHT
Measurement : Instrument acc. to AWS A4.2 or actual composition with WRC1992(FN) or DeLong(FN) Diagram SS347 : 5FN, 16-8-2 weld deposits : 1-5FN Cryogenic service, non-magnetic application or special corrosive service : lower FN required

Filler metal : > 4FN, except for the following ;

High temp. service(above 538) with FCAW weld material : < 9FN Final layer overlay : 3-10FN(except 347 : 511FN) Base metal, HAZ and weld metal : 30-65% Weld deposit : 3-15FN Acceptable corrosion resistance : 30-100FN, Delayed cracking can be formed : >110FN No FN for ASS welding DSS Welding : 35-65% by ASTM E562 for each PQR

API 582, Austenitic SS overlay API 582/938-C, Duplex stainless steel welding(P10H) BS EN 1011-3:2000, Standard austenitic stainless steels BS EN 1011-3:2000, Duplex stainless steels NACE 0103-2010, Appendix D

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FERRITE NUMBER LIMITATION BY PROJECT

NSRP, Foster Wheeler Energy
Ferrite determination : prior to PWHT, either magnetic instrument(AWS A4.2) or chemical analysis(WRC-1992) FN requirements
308L/316L/308H/316H : 3-10FN 347 : 6-10FN 16-8-2 : 2-5FN DSS : 35-65(ASTM E562) ASS cladding : 4-10(347, 5-10FN)

Barrancabermeja, Foster Wheeler USA

Ferrite determination : Either magnetic instrument(AWS A4.2, ISO 8249) or chemical analysis(WRC-1992) FN requirements
Above 350 : 4-8FN DSS : 35-65% ASS cladding :

And others,

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DISCUSSION
Dilution
In general, arc welding dilution : 15%(cladding) 40%(thin plate), 60%(GTAW root) How can we calculate or expect the dilution in field?

4 5

1 3 2

Hot cracking for nickel alloy

How can we avoid the hot cracking for nickel alloy?

FN limitation
Any more FN limitation by spec. from this presentation
1 5

Say 30% Dilution 2

More questions??

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REFERENCES
Welding Metallurgy / Sindo Kou Solidification and Liquation Cracking Issues in Welding / Sindo Kou Welding Metallurgy and Weldability of Stainless Steels / John C.Lippold, Damian J.Kotecki Welding integrity and performance : Chapter 14 / ASM International Metallurgy of welding(Sixth Edition) / J.F.Lancaster A new constitution diagram for predicting ferrite content of stainless steel weld metals Ferrite Measurement in Austenitic and Duplex Stainless Steel Castings / C.D.Lundin Stainless Steel Castings Improved Ferrite Number Prediction Model / Welding Research BS EN 1011-3:2000, Welding Recommendations for welding of metallic materials, Part 3 : Arc welding of stainless steels ASM Metal HandBook Vol.6 Welding, Brazing, and Soldering / ASM International AWS 4.2 Standard Procedures for Calibrating Magnetic Instruments to Measure to the Delta Ferrite Content of Austentie and Duplex Austenitic-Ferritic Stainless Steel Weld Metal ISO 8249 : 2000, Welding Determination of Ferrite Number(FN) in austenitic and duplex ferriticaustenitic CR-Ni stainless steel weld metals / ISO ASTM E562, Standard Practice for Determining Volume Fraction by Systematic Manual Point Count. / ASTM ASME Section II, Part C, ASME Section IX API582, 938, NACE 0103
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