How To Weld 4140 Steel

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L et’s keep it simple. 4140 steel can be welded without

problems as long as you follow some simple guidelines. We will

not be discussing the metallurgical properties of 4140 or trying to
explain what happens to its microstructure when it cools too
rapidly. 4140 steel is alloyed with chromium and molybdenum,
hence the term chromoly steel. The addition of these alloying
elements and its relatively high carbon content (around 0.40%)
provide this low-alloy steel with excellent strength to weight ratio
and make it a lot stronger and harder than standard 1018 and
1020 steels. The disadvantage is the need to be more careful
when welding 414, or other medium to high carbon steels for that
matter, as compared to low carbon steel.
 When welding 4140 material it is absolutely necessary to preheat.

4140 is typically supplied in either the hardened and tempered condition (referred
to as 4140HT) or in the annealed condition. For welding it is recommended that
you use the latter. Welding on 4140HT is not recommended due to the high
susceptibility for cracking, even when using preheat. If you must weld 4140HT it is
absolutely necessary that you stress relieve the part at a temperature 15C below
the original tempering temperature. Typically, if you have to weld on 4140HT you
are making a repair. 4140HT should never be used for standard fabricationif
possible.

If you are manufacturing parts out of 4140 we can assume that it is in the annealed
condition. 4140 will weld very similar to your low carbon steels. The difference is
that its high carbon content can screw things up. To avoid cracking you need to
preheat 4140 prior to welding. This is done to slow the cooling rate after we are
done welding and avoid embrittlement, which can lead to cracking.

Steps to weld 4140:

1. Preheat
Per Table 6-13 in page 6.1-29 of The Procedure Handbook of Arc Welding we need
to preheat as follows:
Up 1/2″ thickness 400-500F

1/2″ – 2″ thickness 600-700F

Other publications recommend a preheat of only 350F up to 1/2″, 450F from 1/2″
to 1″, and 500F for 1″ to 2″. Keep in mind that when a part is preheated over
500F it becomes extremely uncomfortable for the welder. These lower preheat
temperature are used with success, but go with the higher ones is you want to play
it extra safe. The higher temperatures will produce slower cooling rates.

It is important that the interpass temperature not be below the minimum preheat
temperature. If more than one pass is required make sure the part is above that
minimum temperature, if not, get that rose bud and heat the part.

Developing Welding Procedures for 4140 and

Other High Carbon Steels

Step-by-step instructions for developing welding procedures for 4140 and other high carbon
steels. Get this guide for FREE!

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2. Use a low-hydrogen electrode (whether using GTAW, GMAW or SMAW)
The filler metal recommended for welding 4140 steel is ER80S-D2. ER70S-2 can
be used but you will be undermatching the base material. Low-hydrogen
electrodes minimize the amount of diffusible hydrogen in the weld. With the
elevated carbon content even low levels of hydrogen can wreck havoc. A common
problem with medium to high carbon steels is their susceptibility to hydrogen-
induced cracking.
3. Slow cool the part. Preheating will take care of this most times; however, using
heating blankets to assure a slow cooling rate is good practice. As mentioned
above, a slow cooling rate prevents or reduces embrittlement (crack sensitive area
in the heat affected zone). It also allows hydrogen more time to leave the weld,
thus reducing the possibility of hydrogen-induced cracking.
Do you typically weld 4140 or other high carbon steel? Please include your
thoughts and any tips in welding these materials.