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CSWIP 3.0 / 3.1 / 3.2, WELDING FIELD

CSWIP 3.1: Question with Answer and

Explanation – Part 16
Date: November 11, 2017 Author: Thanh ( QC ) Nguyen Le 1 Comment
1) Which of the following processes is most prone to solidification cracks?

a. MMA with basic coated electrodes

b. MMA with rutile coated electrodes
c. TIG
d. ( answer ) SAW
Solidification also referred as Hot Cracking.

Solidification Cracking (hot crack) can occur when:

-Weld metal has a high carbon or impurity (sulphur) content

-The depth-to-width ratio of the solidifying weld bead is large (deep & narrow)

-Disruption of the heat flow condition occurs, stop/start condition

2) Which of the following could be used to minimise the occurrence of
solidification cracks in steels welds?

a. Increase sulphur levels to a minimum of 0.5%

b. ( answer ) Reduce the dilution into the base metal
c. Increase carbon content in the weld metal
d. Reduce the manganese content in the weld metal

3) Hydrogen cracking is considered a cold crack as it will not form till the
weldment cools to below:

a. 500oC
b. ( answer ) 300oC
c. 300oF

d. 730oC
300oF = 149oC

400oF = 205oC

HYDROGEN INDUCED CRACKS:  As know cold cracking, delayed cracking or

underbead/toe cracking.

4)  In a heavy plate fabrication where S is residual @0.3%, which may cause
problems in the welded joint, additions of Mn may be added to prevent:

a. Laminations in the plate through thickness

b. Stress corrosion cracks
c. Manganese sulphides (MnS)
d. ( answer ) Solidification cracking
Solidification Cracking (hot crack) can occur when: Weld metal has a high carbon or
impurity (sulphur) content.

Precautions for controlling solidification cracking:

Add Manganese to the electrode to form spherical Mn/S which form between the
grain and maintain grain cohesion.

As carbon increases the Mn/S ratio required increases exponentially and is a major
factor. Carbon content % should be a minimised by careful control in electrode and
dilution.

5) Inspection for hydrogen cracking is often specified to be done between 48 to 72

hrs after completion of the weld, this is because?

a. The stress level will have reduced by then

 b. ( answer ) It is the maximum time it taken for all the H2 to
diffuse out of the weld
c. Usually after 48 hrs such cracking is unlikely to occur
It is to ensure the weld has property cooled down to
d.
ambient temperature
Typically, hydrogen-induced cracking occurs at temperatures below 600 degrees
Fahrenheit (more commonly around or below 300 degrees Fahrenheit) and within 48
hours of completing the weld. In some cases, it can occur as much a week after
welding.

In applications with greater contributing factors — highly restrained joints; high

levels of hydrogen; or rapid cooling after weld completion — hydrogen-induced
cracking can occur much sooner, even immediately.

6) Preheats are used on steel joints of high hardenability mainly to:

a. ( answer ) Slow the cooling rate of the steel

b. Remove surface moisture from the joint
c. Reduce the formation of surface oxides
d. Increase the diffusion rate of hydrogen into the HAZ
There are four primary reasons to utilize preheat:

(1) it lowers the cooling rate in the weld metal and base metal, producing a more
ductile metallurgical structure with greater resistant to cracking

(2) the slower cooling rate provides an opportunity for any hydrogen that may be
present to diffuse out harmlessly without causing cracking

(3) it reduces the shrinkage stresses in the weld and adjacent base metal, which is
especially important in highly restrained joints and

(4) it raises some steels above the temperature at which brittle fracture would occur
in fabrication. Additionally, preheat can be used to help ensure specific mechanical
properties, such as notch toughness.

7)  Sensitisation is a term applied to the formation of which intermetallic

compound at the grain boundaries in the HAZ of austenitic stainless steels?

a. ( answer ) Chromium carbide

b. Titanium carbide
c. Niobium carbide
d. Molybdenum carbide

Crack type:  Inter-granular corrosion

Location:  Weld HAZ. (longitudinal)

Steel types:  Stainless steels

Microstructure:  Sensitised grain boundaries*

Occurs when:

An area in the HAZ has been sensitised by the formation of chromium carbides. This
area is in the form of a line running parallel to and on both sides of the weld. This
depletion of chromium will leave the effected grains low in chromium oxide which is
what produces the corrosion resisting effect of stainless steels. If left untreated
corrosion and failure will be rapid*

8) When comparing the properties of plain carbon steels and austenitic stainless
steels … which of the following statements is true?

a.  ( answer ) Carbon steels have better thermal conductivity

b. Stainless steels have low expansion and contraction
Carbon steels have higher expansion rates in the Z
c.
direction
d. Stainless steels have lower chromium
Austenitic stainless steels have high ductility, low yield stress and relatively high
ultimate tensile strength, when compare to a typical carbon steel.

Plain Carbon Steels:

Low Carbon Steel 0.01 – 0.3% Carbon

Medium Carbon Steel 0.3 – 0.6% Carbon
High Carbon Steel 0.6 – 1.4% Carbon

Plain carbon steels contain only Iron & Carbon as main alloying elements, but traces
of Mn, Si, Al, S & P may also be present.

Austenitic Grades:

Non-magnetic
Low thermal conductivity (‘hold’ the heat during welding)
High coefficient of expansion – more distortion during welding

9) Weld decay occurs in which of the following steel types:

a. Carbon Manganese
b. Low alloy
c. Any stainless steels
d.  ( answer ) Austenitic stainless steels
Inter-Granular Corrosion Also known as Weld Decay

Location: Weld HAZ. (longitudinal

 Steel Type: Austenitic stainless steels
Susceptible Microstructure: Sensitised HAZ grain boundaries

10) Which of the following materials is most susceptible to hydrogen cracking?

a. Low carbon steel

b. Austenitic stainless steel
c.  (answer) High strength low alloy steel
d. Aluminium

Pls see next part:

Thanks!!!

Published by Thanh ( QC ) Nguyen Le

-QA/QC in offshore / ship building / welding field -Worked at Triyards -Worked at

Hyundai Vinashin View all posts by Thanh ( QC ) Nguyen Le
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