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Frontiers in Automobile and Mechanical Engineering IOP Publishing
IOP Conf. Series: Materials Science and Engineering 197 (2017) 012067 doi:10.1088/1757-899X/197/1/012067
1234567890

Experimental Investigation of Mechanical Properties of

Welded Corten Steel A588 Grade Plate Using ER70S - 6 Filler
Material for Construction Application
J.R.Deepak1*, V.K.Bupesh Raja2, Mittapalli Janardhan Guptha3 Palaparthi Hari
Durga Prasad4, V.Sriram 5
School of Mechanical Engineering, Sathyabama University Chennai- 600119

deepakcape@gmail.com

Abstract. ASTM A588 Grade A steel plate is a high strength, low alloy structural steel with
0.19 % of carbon content. When exposed to the atmosphere, A588 Grade A is suitable for
construction in the bare (paint – free) condition. The main problems are lack of fusion, lack of
penetration and corrosion on heat affected zone. In this research work Corten ASTM A588
Grade steel of 3mm thickness is electroplated with copper and then both raw and copper
electroplated are welded by GMAW welding process with ER70S-6 as a filler material. The
welded ASTM A588 is cut according to ASTM size for further testing of mechanical
properties. Considering its welding strength after the process of electroplating, this research
clearly states the metal can be utilized for better results in any given field. Here both the tensile
and hardness are higher in copper electroplated welded when compare to raw welded.

Key words: Corten A588 Grade, ER70S – 6, Welding, Electroplating

1. Introduction:
Corten steel is also called as weathering steel which belongs to a steel alloy. Basically it is a high strength low
alloy steel were it is used as a paint free material. It also forms rust like top layer called patina with good
corrosion stability. The metallurgical properties varies from weathering steel and ordinary structural steel is the
addition of chromium, copper and nickel alloying elements by which weathering steel has high resistance
to corrosion. It is available in different standards like ASTM A242, ASTM A588 and ASTM A606. In this work
corten A588 is used as base metal.

1.1. Base metal Corten A588:

HSLA (High-strength low-alloy) steels are mainly used for their higher strength and corrosion resistance. It has
atmospheric corrosion resistance than carbon steels. Using shear cutting process the base metals are cut into
300*150*3 (all dimensions are in mm)

Table 1. Chemical composition of Corten ASTM A588 Grade Steel

Elements C Si Mn P S Cr Ni Cu

Composition % 0.120 0.298 0.391 0.087 0.013 0.546 0.218 0.302

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Frontiers in Automobile and Mechanical Engineering IOP Publishing
IOP Conf. Series: Materials Science and Engineering 197 (2017) 012067 doi:10.1088/1757-899X/197/1/012067
1234567890

1.2. Filler material (ER70S-6):

Abbreviation for ER70S-6:
ER: An electrode or filler rod
70: A minimum of 70000 pounds of tensile strength per square inch of weld.
S: Solid wire
6: The amount of deoxidizing agent, cleaning agent and copper coating on the electrode.
It is a mild steel solid wire used for good strength, proper welds and problem free in high temperature, high
speed etc. it is basically used for the gas mixture of 100% co2 and 80% co2 & 20% Ar.

Table 2. Chemical composition of ER70S-6

Elements C Si Mo S Cr Ni Cu

Composition, % 0.1 0.8 0.12 0.03 0.15 0.13 0.5

2. Problems definition
Lack of fusion, lack of penetration, cracks on heat affected zone and corrosion in heat affected zone
are the main problems in welded corten A588 Grade steel plates

3. Experimental work

3.1. Electroplating of Corten A588 Grade steel plate coated with copper:
In this research work the raw milled corten steel A588 plates is electroplated with copper. Firstly,
degreasing is done for removal of dirt and dust and pickling is followed for removing the rust. Pre
copper coating is done and then rinsed in water followed by drying process.

Figure 1. Raw milled Corten A588 Grade steel Plate

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Frontiers in Automobile and Mechanical Engineering IOP Publishing
IOP Conf. Series: Materials Science and Engineering 197 (2017) 012067 doi:10.1088/1757-899X/197/1/012067
1234567890

Figure 2. Corten A588 Grade steel Plate Electroplated with Copper

3.2. Welding Process:

GMAW (Gas Metal Arc Welding) process is also called as MIG Welding (Metal Inert Gas welding).
This helps to produce good weld due to the smaller thickness of filler material. Gas used for welding is
80% C02 and 20% Ar.

3.3. EDM Cutting Process:

After the welding is done these are cut in ASTM E8/E8-M-11 standards for tensile and hardness
testing using EDM cutting process.

4. Results
4.1. Tensile test:
The tensile testing is carried out in Micro Tensile testing setup as shown in figure which is used to find
the capacity of the material with varying loads.

Figure 3. Tensile Testing machine Setup

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Frontiers in Automobile and Mechanical Engineering IOP Publishing
IOP Conf. Series: Materials Science and Engineering 197 (2017) 012067 doi:10.1088/1757-899X/197/1/012067
1234567890

Table 3. Tensile Testing Machine specification

Machine Name Tensile Testing Machine

Testing load range Max 5 Ton Load Condition (HVN(1 kg))
Make Associated Scientific Engineering Works, New Delhi
Digital Encoder make Auto Instruments - Kholapur

Gear rotation speed (for gradual loading) 1.25. 1.5 & 2.5 mm /min

Software details FIE make India

The tensile testing Specimen as per ASTM E8/E8-M-11 is cut by Wire cut EDM process

Figure 4. Tensile Testing Specimen as per ASTM E8/E8-M-11

4.2. Tensile results:
Table 4. Tensile Testing results
Welded Raw milled Welded Corten A588
Description Corten A588 Grade steel Plate
Grade steel Plate Electroplated with Copper
Ultimate Breaking Load (KN) 9.480 12.635
Fracture Location Base Base
Displacement at FMAX (mm) 10.100 11.300
Max Displacement (mm) 12.900 14.000
Area (mm2) 18.000 24.000
Ultimate Stress (KN/mm2) 0.527 0.526
Elongation % 17.143 25.714
Yield stress (KN/mm2) 0.309 0.422
YS / UTS Ratio 0.588 0.801

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Frontiers in Automobile and Mechanical Engineering IOP Publishing
IOP Conf. Series: Materials Science and Engineering 197 (2017) 012067 doi:10.1088/1757-899X/197/1/012067
1234567890

Figure 5. Tensile graph (Load Vs Displacement) of Welded

Raw milled Corten A588 Grade steel Plate

Figure 6. Tensile graph (Load Vs Displacement) of Welded

Corten A588 Grade steel Plate Electroplated with Copper

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Frontiers in Automobile and Mechanical Engineering IOP Publishing
IOP Conf. Series: Materials Science and Engineering 197 (2017) 012067 doi:10.1088/1757-899X/197/1/012067
1234567890

Figure 7. Tensile graph (StressVs Strain) of Welded

Raw milled Corten A588 Grade steel Plate

Figure 8. Tensile graph (StressVs Strain) of Welded

Corten A588 Grade steel Plate Electroplated with Copper

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Frontiers in Automobile and Mechanical Engineering IOP Publishing
IOP Conf. Series: Materials Science and Engineering 197 (2017) 012067 doi:10.1088/1757-899X/197/1/012067
1234567890

4.3. Hardness test:

For metals it is to test resistance of permanent deformation. It is also related to the plastic flow stress
of materials.
Table 5. Micro Hardness Testing Results (HVN)

Base Base
Heat Affected Weld Heat Affected
Samples Material Material
Zone (HAZ) Zone(WZ) Zone (HAZ)
(BM) (BM)
Welded Raw milled
Corten A588 185.85 209.0 216.6 209.6 180.6
Grade steel Plate
Welded Corten A588
Grade steel Plate 188.6 218.1 251.8 246.7 182.2
Electroplated with Copper

300
250
200
150
100
50
0
Base Metal Heat Affected Weld Zone Heat Affected Base Metal
(BM) Zone (HAZ) (WZ) Zone (HAZ) (BM)

Welded Raw Milled Corten Steel A 588 Grade Plate

Welded Corten Steel A 588 Grade Plate Electroplating with Copper

Figure 9. Micro hardness Bar Chart of Welded

Corten A588 Grade steel Plate Electroplated with Copper

5. Conclusion
 Copper Electroplated plate has attained an additional elastic property and ductility with a
maximum displacement of 14.00 (mm).
 Tensile Test Comparison (Load Vs Displacement) the Copper electroplated metal plates has
improved tensile stress compared to the base metal.
 Tensile strength of Copper Electroplated has higher Ultimate Breaking Load 12.635 (KN).
 These changes occur due to electroplating of copper to the parent metal due to which additive
stress has been created so breaking period of metal will increase results in increase in tensile
properties.

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Frontiers in Automobile and Mechanical Engineering IOP Publishing
IOP Conf. Series: Materials Science and Engineering 197 (2017) 012067 doi:10.1088/1757-899X/197/1/012067
1234567890

 Electroplating of Copper in the parent metal has resulted in good improvement in the
mechanical properties as a result of this weld and heat affected zone does not break due to
ductility.
 The welded zone has the highest hardness values. Copper Electroplated plate has the highest
hardness value of 251 (HVN)

References:

[1] ASTM C101-04:2004 Guide for Estimating the Atmospheric Corrosion Resistance of Low-
Alloy Steels. ASTM International, USA.
[2] EN 10025-5:2004 Hot rolled products of structural steels – Part 5: Technical delivery conditions
for structural steels with improved atmospheric corrosion resistance. CEN.
[3] EN 1993-1-1:2005 Eurocode 3: Design of steel structures – Part 1-1: General rules and rules for
buildings. CEN.
[4] EN 1990:2002 Eurocode: Basis for structural design. CEN, 2004.
[5] EN 10025-1:2004 Hot rolled products of structural steels – Part 1: General technical delivery
conditions. CEN.
[6] EN 1993-2:2006 Eurocode 3: Design of steel structures – Part 2: Steel bridges. CEN.
[7] EN 1993-2:2006 Eurocode 3: Design of steel structures – Part 2: Steel bridges. CEN.
[8] Corten weather steel: technical data, archived from the orginal on 13 January 2010, retrieved 13
January 2010.
[9] Elizabeth A. Harris (august 27, 2012). “ Constructing a façade both rugged and rusty” .
nytimes.com. Retrieved 10 September 2012.
[10] Harris , Elizabeth (27 august 2012). “ Constructing a façade both rugged and rusty”. Nytimes.
Retrieved 27 September 2015.
[11] Manual of steel construction, 8th edition second revised printing. Chicago : American institute
of steel construction.