Cracks

Cracks may be detectable in severe cases by eye, or by surface NDT techniques, such as dye penetrant or magnetic
particle inspection (ferritic materials) or eddy current testing. Buried cracks can only be found by volumetric
inspection (radiography or ultrasonic inspection). Hydrogen cracks, in particular, may be tight, and difficult to
detect by radiography if not ideally oriented

Heat Affected Zone (HAZ) Hydrogen cracking

Cause
Heat Affected Zone (HAZ) hydrogen cracking is a problem which may be experienced when welding ferritic and
martensitic steels. It arises when hydrogen embrittles hardened HAZ microstructures. Potential sources of
Hydrogen include moisture, oil or grease, any of which may dissociate in a welding arc, and hydrogen containing
weld process gases, which are only appropriate for austenitic stainless steels. Hydrogen cracking under the
influence of residual stresses generally occurs when the plate cools to ambient temperature. It is most commonly
experienced in thicker section materials.

Steels will crack if the combination of stress, microstructure and hydrogen is too severe.

Stress
This is generally of yield magnitude, from thermal
contraction, and although to some extent dependent
on joint restraint, cannot be easily controlled.
Stress concentrations resulting, for example, from
poor fit up can increase the risk of cracking.

Microstructure
Hard microstructures are generally at greatest
risk, and are produced by:
• rapid cooling due to:
• low heat input
• large heat sink (thick section)
• low preheat
• high carbon content and alloying additions

Hydrogen
The principal source of hydrogen is
decomposition of:
• moisture in:
• fluxes
• poorly maintained gas supply system
• surrounding atmosphere
• grease and dirt on:
• wires
• weld preparations

Hydrogen embrittlement is greatest at around normal ambient temperatures, and cracking does not occur in
most cases until the weld has cooled. Significant delays may be experienced beyond the initial cooling period
before cracks initiate, particularly close to threshold cracking conditions..
Heat Affected Zone (HAZ) Hydrogen cracking
Prevention methods
Minimise hydrogen Use low hydrogen consumables/processes
Ensure wire and preparations are clean and dry
Apply correct preheat (encourages escape by diffusion)

Limit HAZ hardness Ensure high enough heat input

Apply preheat
Limit alloy content /carbon equivalent
Ensure good fit-up

The most powerful control is to reduce hydrogen. Both allowing hydrogen to escape and limiting hydrogen input
are beneficial, as cracking will not occur while the joint is maintained above ambient temperature.

Hydrogen diffusion is faster at higher temperatures. Hence, extending the time the temperature is over about
100°C, by applying preheat (and/or postheat), can encourage hydrogen escape and reduce the risk of cracking.

Weld process gases rich in carbon dioxide, eg. Ferromaxx® Plus and Ferromaxx® 15, may help to limit absorption
of hydrogen by the weld pool. Use of a long stick out and low current with tubular cored wires reduces
hydrogen input.

In carbon and carbon-manganese steels, a higher heat input will reduce the HAZ hardness. This is less beneficial
in alloy steels. Applying preheat can also reduce HAZ hardness to some degree.

Where there is the opportunity to select steels, attempt to minimise the carbon equivalent.

Nomograms for determining safe combinations of hydrogen, heat input, steel composition and preheat for carbon
and carbon manganese steels are available in EN 1011-21, and in Welding Steels Without Hydrogen Cracking2.

Techniques for limiting the risks of cracking in more difficult (hardenable) steels are given in Welding Steels
Without Hydrogen Cracking2.

It is important to ensure that controls are applied to tack welds and temporary attachment welds.

Where possible, minimise joint restraint (eg. modify welding sequence). Where restraint is high, take extra care
with other precautions.

1.
Welding - Recommendations for welding of metallic materials, Part 2: Arc welding of ferritic steels. BS EN 1011-2:2001, Inc.
Amendment 1:2003.
2
Bailey N, Coe FR, Gooch TG, Hart PHM, Jenkins N and Pargeter RJ, 2004: 'Welding Steels Without Hydrogen Cracking', 2nd
edition (revised), Woodhead Publishing, Cambridge.

www.airproducts.co.uk/welding_selector

The information contained in this document is subject to change without notice, and provided as reference material only.
If you require specific advice about your own, your customers’ or your organisations’ position in relation to anything
covered in the document, that advice should always be obtained in person from an Air Products expert.