Welding
276 International
Maruyama2003 17 (4) 276–281
Selected from Journal of the Japan Welding Society 2002 71 (6) 25–29; Reference JJ/02/6/25; Translation 3113
Arc welding technology for dissimilar joints
T MARUYAMA
Kobe Steel KK
Introduction
The most widely used metal underpinning modern industry
is steel (carbon steel). Low-alloy steel designed to increase
the strength and heat resistance of basic carbon steel
and stainless steel to offer improved corrosion resistance
and oxidation resistance are extensively used in the
manufacture of thermal and nuclear power plants, chemical
plants, etc. An extremely important and unavoidable
practical requirement in modern steel construction
technology is to be able to perform dissimilar welding of
stainless steel to carbon and low-alloy steels (welding
of dissimilar metals). This article profiles the basic
principles and noteworthy features of dissimilar welding
of stainless steel to carbon and low-alloy steels.
Dissimilar welding methods and welding
additives
Various welding processes, such as butt welding, steel
cladding, overlay welding, etc. are currently available
for welding of dissimilar metals. Welding additives with
a composition differing from that of each base metal are
normally used for welding of dissimilar metals, and the
weld metal produced by welding obtains a composition
through both base metals and welding additives being
mixed at some specific ratio. An important point to note
during welding of dissimilar metals is that special
investigations – based on prior assumptions about the
composition of the weld metal emerging from the base
metals and welding additive compositions – may be
Table 1 Typical examples of arc welding wires available for use during conventional
submerged arc welding of dissimilar metals
Ba se me ta l c o mp o sitio n e xa mp le s
C a rb o n/lo w– a llo y ste e ls S ta inle ss ste e ls
Mild ste e l Auste nitic sta inle ss ste e ls
Lo w– a llo y ste e l S US 3 0 4 /3 0 4 L/3 4 7
(High– stre ngth ste e l) S US 3 1 6 / 3 1 6 L
(C r– Mo ste e l)
C a st ste e l/c a stings Ma rte nsitic sta inle ss ste e l a nd fe rritic
sta inle ss ste e l S US 4 0 5 , 4 1 0 , 4 3 0
* * F o r use und e r high– te mp e ra ture /inte nse the rma l c yc le c o nd itio ns.
performed to ascertain whether or not welding defects,
such as weld cracking, can be prevented and whether or
not the weld metal properties can be satisfactorily arranged
to correspond to the properties required after post-weld
heat treatment or those required by the operating
environment. Table 1 lists typical examples of arc welding
wires available for use during conventional submerged
arc welding of dissimilar metals. Conventional welding
of dissimilar metals involves application of submerged
arc welding, MIG/MAG welding, TIG welding, band
electrode overlay welding, etc. The welding additives
generally used are austenitic materials containing a
relatively large amount of ferrite. However, if welds are
exposed to elevated temperatures or subjected to an
intense thermal cycle, Ni-base alloy welding additives,
such as Inconel 600, are used. During dissimilar welding
to ferritic stainless steel, on the other hand, ferritic
stainless steel welding additives, such as D430Nb and
D410Nb, are used in addition to those specified above.
Welding-induced dilution of base metal and
constitutional changes
Various constitutional changes occur during welding of
dissimilar metals, such as changes in the dilution
(penetration) ratio of the base metal affected by the welding
conditions or the weld metal composition depending on
the types of welding additives used. The weld metal
structure and properties also significantly change.
Welding of dissimilar metals therefore faces various
characteristic problems raised by these structural changes.
Typ e s o f a p p lie d we ld ing a d d itive s
o r sp e c ific a tio ns
D3 0 9 / 3 0 9 L
D3 0 9 M o L
D3 1 2 Inc o ne l
typ e * *
D4 3 0 N b 5 0 N i* *
D3 0 9 / 3 0 9 L
 Arc welding dissimilar joints 277

Ni equivalent = Ni + 30 x C +
D309 weld metal

Austenite (A)
Dilution ratio
0.5Mn

Sigma embrittlement Schematic illustration of welding of dissimilar metals

Nickel equivalent = %Ni + 30 x %C + 0.5 x %Mn

Hot cracking
Low- )
temperature t (%
Stable zone en
cracking Austenite (A) nt
co
Martensite (M) ite
rr
Ferrite (F) Fe
Dilution ratio (33 %)

Cr equivalent = Cr + 1.5Si + Mo + 0.5Nb Dilution ratio (50 %)

1 Schäffler constitution diagram and problems facing welding
of dissimilar metals.
During welding of dissimilar metals, much as during
conventional similar welding of austenitic stainless steels,
stable fabrication with good cracking resistance can be
performed through the weld metal being arranged to have
an austenitic structure containing several % ferrite phase.
As base metal dilution increases during welding of
dissimilar metals, the ferrite content decreases. If the
structure then becomes single austenite, hot cracking
readily occurs. As dilution further increases with
martensite formation, the low-temperature cracking
susceptibility is also heightened. If the ferrite content
increases to excess, thermal ageing during post-weld heat
treatment or operation at elevated temperature may
conversely lead to formation of the sigma phase from
the ferrite structure together with heavy embrittlement.
For this reason welds used in machinery and other systems
operated at elevated temperatures are required to have
as low a ferrite content as possible. The Schäffler
constitution diagram in Fig. 1 1 shows the relationship
between the weld metal constitution and structure and
the problems facing this structure. For prediction of the
structure from the weld metal composition, it is also
effective to use the Delong constitution diagram or the
WRC-1992 constitution diagram2 in addition to the Schäffle
constitution diagram.
Without dwelling on an explanation of its arrangement,
Fig. 23 gives a reference example of a method for prediction
of the relationship between the constitutional changes
of the weld metal and its structure in response to base
metal dilution during actual welding of dissimilar metals.
(Base metal
penetration
50-50)
Martensite (M)
Ferrite (F)
Chromium equivalent = %Cr + %Mo + 1.5 x %Si
+ 0.5 x %Nb
2 Schäffler constitution diagram used to predict composition
of dissimilar joint weld metal.
the solid and liquid phases during weld metal solidification
and the shrinkage stress generated during solidification
at these locations operating to initiate cracking. During
such solidification cracking, a major cracking improvement
effect is well-known to be obtained through the weld
metal in the case of austenitic stainless steel being
arranged to contain several % ferrite, as shown in Fig.
3.4 Application of conventional type 309 welding additives
is aimed at achieving several % ferrite being retained
after completion of solidification in a state of carbon/
low-alloy steel base metal dilution when solidification
takes place with delta ferrite as the prior grains during
the solidification process. In the case of a partner base
metal such as high-carbon casting steel, however, it cannot
always be ensured that type 309 welding additives will
contain a sufficient quantity of ferrite, and type 309MoL
WRC fissuring bend test
(Submerged arc welded overlay zone)
Cracking ratio (%)

Basic problems facing welding of dissimilar

metals

Various important aspects to be noted during dissimilar

welding of stainless steel to carbon and low-alloy steels
are highlighted below.

Weld cracking

Hot cracking
Ferrite content (%)
Hot cracking involves low-melting point impurities, such
as P, S, etc., being segregated at the boundary between 3 Relationship between material ferrite content and cracking.
278 Maruyama
Molten zone
Weldpool formed formed by
weldpool
by arc ignition
heat
Component concentration
Component element (B)
Component element (A)
Bond centre
Weld bead
Weld boundary
Bond transition layer
4 Schematic illustration of component concentration
distribution in bond (transition layer) of dissimilar welds.
or 312 welding additives designed with a high ferrite
content are therefore used in many instances rather than
type 309 welding additives.
Low-temperature cracking
As dilution of the base metal on the carbon/low-alloy
steel side increases during welding of dissimilar metals,
the weld metal contains a hard martensite phase despite
type 309 welding additives being used. This hard
martensite phase has an extremely high hydrogen-induced
delayed cracking (low-temperature cracking)
susceptibility, consequently being readily prone to low-
temperature cracking. To prevent this cracking, it is
necessary either to ensure that, through appropriate
selection of used welding additives, welding method,
and welding conditions, no martensite phase is formed
or else to apply thermal control measures, such as adequate
pre- or post-heating.
Although welds may escape the problem of dilution
during welding of dissimilar metals, the phenomenon of
‘bond martensite formation’ may be an unavoidable
consequence of this process. The schematic illustration
in Fig. 45 shows that bond martensite extends over a
width of around several tens to several hundreds of ¼m
on the weld metal side of the dissimilar joint bond
o Without preheating (penetration
ratio: 40 %)
Maximum bond martensite
l Preheating at 823 K (penetration
formation width ( µ )
ratio: 40 %)
F Preheating at 823 K (penetration
ratio: 50 %)
Weld metal Ni content (%)
5 Bond martensite formation during bead welding with
welding wires having different Ni contents.
Mark Welding additive
OInconel 132
Welding after buttering
Component
on A387 Gr11
analysis position
Stress (MPa)
Inconel
Base metal HAZ
Time to rupture (hr)
6 Typical results obtained during tensile restraint cracking
(TRC) test.
boundary, representing the transition zone within which
the twin compositions of the base metal and weld metal
significantly change and where an extremely hard
martensitic structure is formed. With regard to bond
martensite formation, Fig. 5 6 shows that bond martensite
tends to occur less readily with an increasing weld metal
Ni content. Despite Ni-base alloy welding additives being
used, however, bond martensite may still occur in the
transition zone depending on dilution conditions. The
results of TRC tests shown in Fig. 6 7 suggest that, if
bond martensite is present, cracking of delayed cracking
type may occur when joints operate under heavy restraint.
When welding is performed with austenitic welding
additives, pre- or post-heating is usually unnecessary.
During welding of dissimilar metals, however, adequate
thermal control measures must be exercised depending
on base metal type and restraint conditions.
Structural changes due to post-weld heat
treatment
Post-weld heat treatment may be applied during welding
HAZ Weld metal
Micro-Vickers hardness (Hv20)
Fusion line
Hardness
measurement position
7 Example of hardness change during heat treatment of
dissimilar welds.
 Arc welding dissimilar joints 279

of dissimilar metals for purposes of residual stress removal No cracking

or structural improvement. Depending on circumstances, Cracking
i.e., applied conditions, such as heat treatment

Ferrite content (%)

temperature, etc., however, it must be noted that, although
residual stress may be removed, welds may be affected
by a number of other adverse phenomena, such as
‘decarburised/cemented layer formation’ at the weld bond
boundary, precipitation of carbides in the weld metal,
‘sigma phase formation’, etc.
Figure 7, 1 referring to dissimilar welding of carbon to
stainless steel joints with D309, shows the hardness of
the bond zone after post-weld heat treatment. Figure 8 1
shows the microstructure of the bond zone in a dissimilar
joint after post-weld heat treatment. Heat treatment leads
to decarburisation in the HAZ on the carbon steel side
and to cementation on the stainless steel weld metal side,
causing the hardness in the cemented region to rise
sharply. Figure 9 8 shows the post-weld heat treatment
conditions of test plates overlay-welded with D309 on
carbon steel and the extent of cracking in the cemented
region in side bending tests. This diagram suggests that
cracking increases with a rising heat treatment temperature
and increasing heat treatment time. Figure 10 shows the
post-weld heat treatment conditions applied during
2.25Cr-1Mo steel D309 weld metal
Decarburised layer Cemented layer region
Tempering constant P = (T + 273) x (logt + 20)×
× 10 -3 where T: temperature ( o C), t: time (hr)
10 Effects of SR conditions and ferrite content on bend
cracking of YF-309L double-layer overlay weld metal.
double-layer overlay welding with D309 on
2.25 % Cr–1 % Mo steel and the extent of cracking in the
second-layer weld metal in side bending tests. This diagram
suggests that the initial-layer D309 weld metal is free
from cracking and that cracking only occurs in the second-
layer D309 weld metal. This is due to the fact that brittle
intermetallic compounds appearing as sigma phase are
formed from the ferrite phase in the second-layer D309
weld metal with high ferrite content. Such embrittlement-
induced cracking can be eliminated by use of D308 as
the second-layer welding additive in this case. During
heat treatment of dissimilar joints, it is important to exercise
suitable selection and control of welding additives and
conditions in such a way that the weld metal ferrite content
can be kept at a low level within the hot cracking-free
range.

Thermal stresses of welds

During welding of dissimilar metals, thermal stresses due

to the difference in the thermal expansion coefficients of
both base metals and weld metal are superposed in addition
8 Example of microstructure in bond boundary zone of to the normal residual stresses imposed by welding
heat-treated dissimilar weld. fabrication. Table 2 gives typical examples of the thermal
expansion coefficients of various base metals and welding
additives, and Fig. 11 9 presents the results obtained in
Heat treatment temperature ( o C)

With microcracking Table 2 Thermal expansion coefficients of stainless steels and

Ni-base alloys

Without microcracking The rma l e xp a nsio n

Ma te ria l Re ma rk s
c o e ffic ie nt (1 0 –6/°C )

C a rb o n/lo w– a llo y ste e l 14.3 0 . 5 M o s te e l

We ld ing N i– b a se 15.2 Inc o ne l 6 0 0

a d d itive s a llo ys

Heat treatment time (hr) S ta inle ss 18.7 3 0 8 typ e

ste e l typ e
9 Relationship between heat treatment conditions and
S ta inle ss ste e l 18.7 S US 3 0 4
microcracking in side bending test.
280 Maruyama

Welding fabrication technology

Joint shape and welding additives

Thermal stress (MPa)

Thermal stress (ksi)

Table 3 3 shows a number of typical butt joint shapes

produced by dissimilar welding. They include those
involving welding with buttering of the carbon/low-alloy
steel base metal and those involving direct welding. Proper
A = Austenitic steel joint use, however, will always be arranged depending
F = Ferritic steel on the degree of base metal restraint. When welding is
N = Inconel 600
I = Alloy 800
performed with buttering, heat treatment is applied at
this point, although, since welding with buttering involves
joining of austenitic stainless steel partners, heat treatment
Radius may be altogether omitted.
11 Thermal stress analysis results of dissimilar joints. Welding fabrication

an analysis of the thermal stress distribution at 866 K in
the plate thickness direction near the weld metal boundary
of ferritic steel and austenitic steel pipes. This diagram
suggests that application of welding additives whose
thermal expansion coefficient gently varies in the joint
axis direction generates lower thermal stresses.
To solve problems of thermal stress generation and
formation of carbides and decarburised/cemented layers
described above, dissimilar joints are either used in the
temperature range above 700 K, or else Inconel type Ni-
base alloy welding additives are mostly used when joints
are exposed to a rigorous thermal cycle.
Welding of dissimilar metals involves application of much
the same fabrication techniques as employed during
conventional welding. In the case of SMAW welding
that readily leads to heavy base metal dilution, however,
it is important to ensure pre-selection of optimum welding
conditions in such a way that excess dilution is prevented.
Preheating
The preheating temperature should be essentially selected
to give a higher temperature than normally required by
each base metal. It should be noted, however, that, if the

Table 3 Typical examples of butt joint shapes produced by dissimilar welding

S ymb o ls Typ e I Typ e II Typ e III Typ e IV

Buttering
Joint welding
Joint welding Inconel Joint welding Joint welding with 308 Buttering
with 309
Jo int with Inconel buttering with Inconel with 308 with 309
me tho d Stainless
Stainless Carbon Carbon Carbon
typ e steel
Stainless steel
steel Stainless Carbon
steel steel steel (SUS304) steel steel

P ro c e d ure 1 ) Inc o ne l b utte ring 1 ) Jo int we ld ing with 1 ) Butte ring with 3 0 9 1 ) Jo int we ld ing with
2) SR Inc o ne l with typ e we ld ing a d d itive 3 0 9 typ e we ld ing
3 ) Jo int we ld ing p re he a ting 2 ) Butte ring with 3 0 8 a d d itive with
(Inc o ne l) 2 ) With o r witho ut typ e we ld ing a d d itive p re he a ting
SR 3) SR 2 ) With o r witho ut
4 ) Jo int we ld ing (with SR
3 0 8 typ e we ld ing
a d d itive )

Q ua lity 1 ) C a rb o n migra tio n Exc e lle nt Exc e lle nt Go o d Go o d

e va lua tio n

2 ) The rma l stre ss Exc e lle nt Exc e lle nt Go o d Go o d

3 ) C o rro sio n Exc e lle nt Go o d Exc e lle nt Go o d

re sista nc e

4 ) Disb o nd ing Exc e lle nt Go o d Exc e lle nt Go o d

c ra c k ing o f b o nd

Wire diameter: 1.6 mm
)
min
0 cm/
( 4
ed
Penetration ratio (%)
spe
l d ing
We
Base metal
Welding current (A)
12 Effects of welding current and welding speed on
penetration ratio of initial-layer overlay welds produced with
gas shielding type flux-containing wire.
preheating temperature is too high, this readily leads to
increased base metal dilution. When austenitic welding
additives are used, the preheating temperature applied
to each base metal can be set at a lower level. When the
base metal is of normal carbon steel type, it is also routine
practice to fabricate without preheating. However, when
joints operate under heavy restraint or when the base
metal composition may readily lead to hardening,
preheating is performed to address the risk of low-
temperature cracking or disbonding cracking, or else the
joints may be pre-buttered.
Welding conditions
It is important to exercise proper controls to ensure that
welding conditions are within the prescribed range in
order to avoid excessive dilution of the carbon/low-alloy
steel base metal. Factors strongly affecting dilution
include the welding method, welding current, welding
speed, welding position, bead overlap position (overlay
welding), etc. Figure 123 shows the effects of the welding
current and welding speed on the degree of dilution.
This diagram suggests that dilution readily increases
under higher-current and higher-speed conditions.
Consideration must therefore be given to these factors
where higher-performance fabrication is being sought.
It should also be noted that, when manual fabrication is
performed by SMAW, as shown in Fig. 13, 5 dilution
significantly changes depending on the degree of bead
overlapping.
Post-weld heat treatment
The purpose of post-weld heat treatment is to relieve
residual stress and release hydrogen. A temperature range
of 873–1023 K is normally selected for post-weld heat
treatment. Dissimilar joints treated in this temperature
range, however, face the problem of Cr carbide precipitation
and attendant corrosion resistance impairment, sigma
phase embrittlement, and de-cementation. It is therefore
desirable wherever possible to omit post-weld heat
treatment of dissimilar joints. Where heat treatment is
performed, the temperature should be selected as low as
possible, post-weld heat treatment should be performed
with austenitic steel preliminarily overlaid on the low-
alloy steel side, and no heat treatment should preferably
Arc welding dissimilar joints 281
Welding wire: 4.0 mm dia D309
Current: 130 A (DC-RP)
Interpass temperature: 100–150 oC
Wire feed ratio: 1.5
Wire
Stringer bead
Dilution ratio (%)
(Target position of wire)
A: Half lap with somewhat large bead overlap
B: Normal half lap
C: Half lap with somewhat small bead overlap
Number of passes per 100 overlay width
13 Relationship between initial-layer dilution ratio and
amount of bead overlapping during submerged arc welding.
be performed after welding. During dissimilar welding of
ferritic/martensitic stainless steel to carbon steel, however,
it is of the utmost importance to perform post-weld heat
treatment from the perspective of performance
enhancement of welds when welding the stainless steel
base metal with a co-metallic welding additive. Post-weld
heat treatment should then never be omitted. In cases
where post-weld heat treatment cannot be applied, it is
important to perform heat treatment immediately thereafter
to ensure ductile recovery of welds.
Conclusions
During dissimilar welding of stainless steel to carbon
and low-alloy steels, it is of the utmost importance to
predict the nature of the mixed-composition weld metal
and to understand the weld metal properties. Key aspects
to be considered in this context are appropriate selection
of welding additives and setting of welding conditions.
This article profiles the basic principles and noteworthy
features of dissimilar welding of stainless steel to carbon
and low-alloy steels and will have served its purpose
through having provided a useful reference guide for
factors to be considered during production of actual
dissimilar joints.
References
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