Welding International

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Fracture toughness of CA6NM alloy, quenched and

tempered, and of its welded joint without PWHT

Walter Jesus Paucar Casas , Sérgio Luiz Henke & Nilceu Novicki

To cite this article: Walter Jesus Paucar Casas , Sérgio Luiz Henke & Nilceu Novicki (2009)
Fracture toughness of CA6NM alloy, quenched and tempered, and of its welded joint without
PWHT, Welding International, 23:3, 166-172, DOI: 10.1080/09507110802543344

To link to this article: http://dx.doi.org/10.1080/09507110802543344

Published online: 11 Mar 2009.

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 Welding International
Vol. 23, No. 3, March 2009, 166–172
Selected from Soldagem & Inspecao 2008 13(1) 25 – 31

Fracture toughness of CA6NM alloy, quenched and tempered, and of its welded joint
without PWHT
Walter Jesus Paucar Casasa1, Sérgio Luiz Henkeb and Nilceu Novickic
a
Department of Mechanical Engineering, Federal University of Rio Grande do Sul, Porto Alegre, Rio Grande do Sul, Brazil;
b
Department of Materials Technology, Institute of Technology for Development (LACTEC), 2 Curitiba, Curitiba, Paraná, Brazil;
c
Department of Electro-mechanics, Federal University of Technology for Paraná, Medianei, Paraná, Brazil
(Received 9 January 2007; final version received 30 August 2007 )

CA6NM quenched and tempered steel is used in hydraulic turbine rotors, pumps and compressors. The objective of this
research is to determine the fracture toughness of tempered and quenched CA6NM alloy, and of its welded joints without
post-welded heat treatment (PWHT). To this end, compact tension (CT) test pieces are milled from pieces of CA6NM steel
for evaluation of the toughness of the alloy used in a hydraulic turbine. Due to the elasto-plastic condition of the material, the
test pieces are tested by means of the J integral concept, setting out the resistance curve J – R and the crack initiation JIC.
Downloaded by [University of Regina] at 19:22 09 June 2016

In welded joints produced from ingots, without PWHT, the fragility they show does not allow the J – R curve for the CT test
pieces to be drawn up, and the toughness is characterized by means of the KIC concept. The welding procedure looks at the
probable conditions for repair of cavitation wear to the turbine, where PWHT cannot be carried out. The results confirmed
the higher toughness for the CA6NM steel, with values approximately three times higher than those obtained in the welded
joints without PWHT. In terms of the fracture, the CA6NM steel shows ductile behaviour while the welded joint without
PWHT shows fragile behaviour.
Keywords: fracture toughness; CA6NM steel; welded joint

1. Introduction neutrons and corrosion under tension. This weakening may

The variations of the microstructure in the welded joints,
caused by the heat cycles of welding, result in different
values of fracture toughness, reflecting the influence of
a number of variables such as correlated mechanical
properties, grain size, formation of high-carbon marten-
site islands and residual stresses. The activation of these
items are shown in the heat affected zone (HAZ) as zones
of localized weakening (ZFL), which by definition are
areas that present low toughness1,2. There are also other
factors such as anisotropy, geometrical appearance and
rate of load application that lead to variations in the
toughness.
The ZFLs are separate microstructural regions in the
HAZ that present lower resistance to the start of the
fracture than the matrix in which it sits. The size of a ZFL
is a function of the heat input to the welding and of the
behaviour of the base metal, with typical peak values
lower than 1 mm and extending parallel to the weld for a
distance of tenths of millimetres3. The length depends on
the welding procedure, weld angle and frequency of stops
when carrying out the weld.
The loss of toughness is also associated with the action
of some mechanisms that cause a change in the
microstructure, or by the interaction of the method with
the material4. In the first group, we can highlight the
weakening of the tempering and weakening of the tempered
martensite, also known as 3508C weakening, and in the
second group, hydrogen weakening, bombardment of
ISSN 0950-7116 print/ISSN 1754-2138 online
q 2009 Taylor & Francis
DOI: 10.1080/09507110802543344
http://www.informaworld.com
arise as a consequence of metallurgical operations, such as
welding and heat treatment.
The establishment of the micro hardness profile
throughout the HAZ helps in the definition of the most
fragile region, but the majority of the works involving
fracture toughness in welded joints opt for a pre-crack
along the line of fusion (LF) or close to it, in the HAZ. The
small size of the HAZ makes it hard to ensure that the pre-
fatigue crack falls totally within the desired region. One
way of minimizing this risk is the utilization of chamfer
K geometry, which aims to obtain a HAZ that is more
rectilinear and perpendicular to the surface of the plate,
facilitating the positioning of the groove and subsequent
pre-cracking by fatigue in the affected area.
The normal situation when a test of fracture toughness
is carried out in the HAZ is that the crack crosses a series
of regions with different mechanical properties, located
around the ZFL. In general, the determination of toughness
in an HAZ involving multiple passes becomes complex,
and simulations of the heat cycles of welding in Gleeble
machines are used for a more specific analysis. Developed
in the 1960s, as part of research that was trying to find a
new type of steel for the manufacture of hydraulic turbine
rotors5, mild martensitic stainless steels (AIMM) were
introduced as an alternative to the limited weldability of
conventional martensitic stainless steels (AIMC), which
have a high susceptibility to cold cracking and demand
rigorous preventive measures during welding. With this in
 Welding International
mind, steel was developed with lower levels of C and the
addition of 4 –6% of Ni-AIMM.
The formation of cold cracks, caused by the presence
of hydrogen close to the weld metal (MS) and in the HAZ,
that compromized the weldability of the AIMC, made
it necessary to reduce the level of C, which in steels
containing 13% of Cr led to a contraction of the austenitic
field. This issue required the addition of Ni in order to keep
the ability to maintain a martensitic structure, with a low
level of retained ferrite and austenite.
Cast stainless steels are specified, according to the
Alloy Casting Institute, as a function of their chemical
composition and utilization; the first letter indicates the
use of the material C – resistance to corrosion and H –
resistance to high temperatures; and the second letter
denotes the levels of Cr and Ni. The number(s) that follow
the two letters indicate the maximum level of C ( £ 100%)
allowed, and the final letters represent the initials of the
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alloy elements. CA6NM steel is an AIMM alloy that is
resistant to corrosion, with 11.5– 14% of Cr, a maximum
level of C of 0.06% and containing Ni (3.5 – 4.5%), and Mo
as elements of the alloy.
For CA6NM in its welded condition, post-welded heat
treatment (PWHT) is recommended to obtain suitable
toughness values in the ZFL. Quenching between 950 and
10508C enables homogenization of the structure by
dissolving the retained ferrite and austenite, which are not
in equilibrium after the solidification, and a later tempering
at 6008C produces a soft martensite and a stable austenite
finely distributed throughout the microstructure (Au2),
which do not transform into martensite after the cooling,
contributing to the excellent tenacity of the alloy6,7.
Some researchers8 – 10 have suggested double temper-
ing to reduce hardness and avoid corrosion under tension,
with the first at 6708C and the second between 550 and
6008C. Other works11,12 show the effects of tempering and
double tempering, with and without prior quenching, in
an AIMM 13Cr–4NiMo alloy with 0.07% of C. In the
quenched condition after double tempering the best
toughness values were obtained, given that the decrease
in the yield point and tensile resistance are not relevant in
relation to the gains in toughness.
Previous works have tried to apply welding techniques
to the CA6NM steel that would enable the tempering of the
previous passes without application of the PWHT. The
results obtained in Henke13, with the addition of austenitic
metal, demonstrate that the tempering occurs in a small
band at around 25%, and the welded joint shows low
toughness close to the LF, 26 J at ambient temperature.
The analyses realized in Pereira14 concluded that the AWS
E410NiMo tubular wire used in welding the CA6NM
alloy, shows better flexibility than the solid, although with
lower toughness values.
CA6NM alloy has a high-yield point, good resistance
to corrosion and cavitation, and better weldability than the
167
AIMC; it is increasingly used in rotors, in hydraulic
turbines, pumps, and compressors, as well as in
components in the chemical and petrochemical industries.
However, its behaviour in terms of fracture and fatigue,
and in welded joints has not always been explored.
In regard to hydraulic turbines, the weld is used in two
distinct situations: (i) in joining the blades to the turbine
axle during its manufacture, and (ii) in the repair of
cracked areas, or those that suffer cavitation. After
welding the blades, heat treatment is intended to guarantee
suitable levels of toughness. For repair welds carried out
in the hydraulic workshop, PWHT is not always practical
with heat blankets or viable due to the lack of
infrastructure, and as a result the welding procedure
needs to implicitly guarantee levels of toughness that are
sufficient for the turbine to be used. Knowledge about the
toughness of an alloy is necessary for an evaluation of its
fracture and fatigue behaviour.
As a result, the objective of this work is to establish the
fracture toughness of the CA6NM alloy with a 0.020%
level of C, similar to that used in a hydraulic turbine
quenched at 10508C and tempered at 5908C, and of its
welded joint without PWHT, thereby reproducing a
situation of a repair of cracked regions or those eroded
by cavitation. As an additional contribution, the results
allow evaluation of the use of the consumable and of the
probable welding procedure to be used for repairs to the
components that use this alloy.
2. Materials and methods
2.1 Materials
The base metal for the tests was supplied by The Institute
of Technology for Development (LACTEC), from ingots
cast together with the hydraulic turbines at the
Hydroelectric Workshop of Salto Caxias, PR, in Rio
Iguaçú.
The base metal, CA6NM steel, after being quenched at
10508C and tempered at 5908C, has a tensile resistance of
799.70 MPa, a yield point of 666.60 MPa, and hardness
HV0.4 value of 266, with a chemical composition as shown
in Table 1. The rates of recooling used, did not allow the
total dissolution of the retained ferrite and austenite, with
these constituents remaining in small quantities. The
microstructure of the CA6NM alloy, made up of tempered
martensite containing islands of ferrite, may be visualized
in Figure 1.
The solidification of a 13/4 Cr –Ni alloy in conditions
of equilibrium, is totally ferritic between 1300 and
12008C. During cooling in any welding procedure, small
quantities of ferrite, d are recooled in the d – g
transformation. In the subsequent cooling, the austenite
transforms into martensite between 250 and 2008C, and
with a high level of Cr, this transformation is possible even
 168 W.J.P. Casas et al.

Table 1. Chemical composition of the CA6NM steel. Table 2. Chemical composition of the AWS E410NiMo T1
wire.
CA6NM% ASTM A743-93%
Chemical element by weight by weight Chemical Obtained% Manufacturer%
element by weight by weight
Carbon 0.02 0.06 (max)
Manganese 0.64 1.00 (max) Carbon 0.026 0.023
Chrome 12.4 ^ 0.7 11.5 – 14.0 Manganese 0.33 0.30
Nickel 3.7 ^ 0.1 3.5– 4.5 Chrome 10.2 11.5
Molybdenum 0.42 0.40– 1.00 Nickel 3.6 4.3
Phosphor 0.008 0.040 (max) Molybdenum 0.45 0.59
Sulphur 0.0018 0.0300 (max) Silicon 0.38 0.38

with low rates of cooling. After the cooling, the structure by Equation (1), which allows the martensitic structure
in the MS and HAZ consists of a soft and resilient low- obtained in a pass to be re-coated by the later pass and
carbon martensite with residual austenite and the presence reduces the possibility of cracking7.
of islands of ferrite.
AIMM shows better weldability due to two factors5,7 – 11; M s ¼ 492–125% C 2 65:5% Mn 2 10% Cr 2 29% Ni: ð1Þ
the first relates to reduction of the risk of grain growth due to
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the low quantity of ferrite and the second is related to the

lower tendency to fissures by hydrogen due to the presence
of the residual austenite after cooling. This condition
provides the AIMM with suitable tenacity and hardness
values of between 350 and 400 HV7. Finally, stabilization of
the ferrite, which tends to reduce the toughness, is a
consequence of the increase in Mo to improve the resistance
to corrosion.
2.3 Consumable
The consumable used for manufacture of the welded joint,
AWS E410NiMo T1 wire, allows welding in all positions.
The chemical composition and mechanical properties of
the consumable, which are very similar to the base metal,
are presented in Tables 2 and 3.

2.2 Recommendations for welding 2.4 Welding

To guarantee suitable weldability of the CA6NM steel,
some recommendations had to be followed: with the aim of
not exceeding 5% of finely dispersed ferrite9, the chemical
composition of the addition metal is lower than 0.040% of
C, 12% of Cr and 4– 6% of Ni, as seen in Table 2; as the
thickness of the joint is more than 20 mm (Figure 2) pre-
heating is required7; the pre-heating and the temperature
inter-passes are carried out at lower values than the
martensitic transformation temperature, Ms, as defined
The ingots were cut to a size of 240 £ 65 £ 27 mm,
Figure 2, with subsequent milling of the joint with a
K chamfer of 408, with the aim of obtaining a rectilinear
HAZ and facilitating the positioning of the pre-fatigue
crack parallel to the weld. The joints were welded with
a energy equivalent to 18 kJ/cm, with pre-heating and
temperature inter-passes at 1608C. Table 4 shows the
welding parameters used, in which the values for voltages
are those given by the wire manufacturer to avoid splatter.
Initially, to obtain an accurate HAZ that was parallel to
the weld, an ingot with its chamfer perpendicular to the
surface was covered with three layers of weld, resulting in
a cladding of approximately 8 mm (Figure 2). The passes
to complete the chamfer – a total of eleven – were carried
out using the clad ingot in the direction of the inclined
chamfer, with the objective of maintaining the rectilinear
character of the HAZ. The procedure was shown to be
suitable, despite showing a lack of fusion at some points
close to the inclined chamfer, meaning the passes had to be
redone, and the occurrence of localized splatter, close to
the root pass (weld bead 6).

Figure 1. Microstructure of the CA6NM steel quenched at 2.5 Test pieces

10508C and tempered at 5908C showing tempered martensite and
islands of ferrite indicated by the arrows. Attack: Vilella’s The test pieces for the fracture toughness test were milled
reagent. by wire electro-erosion, providing the finish needed
 Welding International 169

Figure 2. Welded joint showing the geometry, cladding, and distribution of the passes.

without heating them to a sufficient extent to alter the
mechanical properties locally, something which is
compromized with conventional milling.
The grooves were machined directly onto the base
metal of the CA6NM steel quenched at 10508C and
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determination of the fracture toughness. The dA/dN
module of the fast track programme and a 10 mm COD
extension meter were used to monitor the growth of the
pre-fatigue crack, in a condition with DK constant at
35 MPa m1/2, R ¼ 0.1 and a loading frequency of 20 Hz.

tempered at 5908C, as in their welded joints without The pre-crack growth was 5 mm, providing an a0/w value
PWHT, thereby placing the groove close to the LF of the of 0.55; therefore within the band between 0.45 and 0.55
side of the HAZ perpendicular to the surface, character- permitted by the norm for KIC and naturally within the
ized by a macrographic exam. The geometry of the test band between 0.45 and 0.70 permitted by the standard for
pieces complied with ASTM standard E182015, using JIC. The pre-cracking was encouraged by the use of lateral
compact tension (CT), pieces in the proportion B £ 2B, grooves of 20% of the thickness of the test piece, which
where B ¼ 25 mm. To enable it to be extracted from a cast showed no deviation during the propagation.
condition, there was no need to orientate it during milling. The determination of the fracture toughness of the
quenched and tempered CA6NM steel is carried out by
means of the JIC parameter. With the occurrence of the
2.6 Tests and analyses instability in the growth of the crack of the test pieces
corresponding to the welded joint, which characterizes a
By means of the elastic flexibility variation technique in
fragile condition, it was possible to calculate the fracture
the CT test pieces, and following the recommendations of
toughness by means of the KIC in the welded joint without
ASTM standard E182015, the fracture toughness of the
PWHT.
quenched and tempered CA6NM steel will be character-
ized, along with its welded joint without PWHT with a
consumable similar to the CA6NM alloy.
2.7 Analysis by microscope
The tests were carried out in the LACTEC laboratory
in an Instron machine, using the fast track programme Analysis by electron scan microscope (ESM) was carried
for evaluation of the pre-fatigue crack and for the out using a Philips XL30 scan microscope. The fractured
samples from the fracture toughness test were examined
Table 3. Mechanical properties of the AWS E410NiMo T1 using ESM, both for the base metal and for the welded
wire. joint. In the case of the welded joint, the final fracture
occurred in the region close to LF on the side of the MS.
Mechanical property Tempered at 6218C/l h As welded The analyses were carried out in the pre-crack region,
Tensile resistance (MPa) 903.20 1116.26 the interface between the pre-crack and the start of the
Yield point (MPa) 765.30 999.05 fracture, and in the fracture stabilization region.
Lengthening (%) 21 20
Hardness (HV0.4) – 350
3. Results and discussion
The tests carried out on the soft martensitic CA6NM
Table 4. Welding parameters used, with argon gas at 8% CO2 stainless steel, quenched and tempered, showed values of
and a flow rate of 20 l/min.
the JIC parameter at fracture initiation that confirm the
Current Voltage Speed Wire diameter Energy high C toughness in this condition (quenched and
(A) (V) (cm/min) (mm) (kJ/cm) tempered). In an analogous way, the results of KIC found
300 25.60 25.92 1.60 18
the welded condition for C, with pre-cracking close to the
LF of the side of the MS, proving the need for PWHT, or
 170 W.J.P. Casas et al.

Table 5. Values of JIC for CA6NM steel quenched at 10508C 800

and tempered at 5908C.
700
Test piece Fracture toughness, JIC (kJ/m1/2) MB1
600
MB1 345.80
MB2 338.75 500

J, KJ/m2
MB3 343.70
400
MB4 339.05
300

200
a solution that enables recovery of toughness when Linha 0.1
100
necessary, as carried out in prior research13,14.
0
0.25 0.0 0.50 1.00 1.50 2.00 2.50
Growth of crack, mm
3.1 Base metal – CA6NM steel quenched at 10508C
and tempered at 5908C Figure 4. Curve J £ growth of the crack in the base metal.
The values for JIC, set out in Table 5, were obtained in tests
carried out with the control parameters set out above, on
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of clearly visible cavities, an expected characteristic due to

four test pieces, all at 238C. The values for JIC, at an
average 341 kJ/m1/2, and equivalence of KIC ¼ 278
MPa m1/2 (8784 N/mm3/2) confirmed the high toughness
of the tempered and quenched AIMM. To obtain the JIC
value, the load £ displacement curve is generated for the
load line (DLC) and the J £ growth of the crack curve,
known as the J– R resistance curve is generated as shown
in Figures 3 and 4, which enabled the fracture toughness
parameter JIC to be obtained from the intersection of the
curve J –R with the tangent 0.2.
Examination of the fractured surface involved viewing
the micro-mechanisms and characteristics of the fracture,
which developed in the samples MB3 and MB4 in three
stages: in the pre-crack, in the transition between pre-crack
and fracture, and in the actual fracture itself. Figure 5
corresponds to the growth of crack, where the definition of
JIC occurs, that is, in the fracture region, with the presence
90.0
the high toughness value of the material. For the fracture
in the quenched and tempered CA6NM steel; taking into
account the macroscopic rough appearance seen, the
growth in zigzag of the crack, and the presence of cavities;
it is defined as being ductile.
3.2 CA6NM steel welded joint without PWHT
The high toughness values presented by the CA6NM steel
after heat treatment indicate that PWHT must, when
possible, be carried out. One of the purposes of the work
is the characterization of the fracture toughness in the
CA6NM steel welded joint without PWHT, thereby
simulating the situation after repair of cavitation wear or
cracking.
Three samples were tested, LF1ST, LF2ST and
LF3ST, which showed the same toughness value by using
Equation (2), KIC ¼ 89.26 MPa m1/2 (2820 N/mm3/2), a fact

80.0

70.0

60.0
Load, kN

50.0

40.0
MBI
30.0

20.0

10.0

0.0
0.0 0.025 0.50 0.75 1.0 1.25 1.50 1.75 2.0 2.25 2.50 2.75 3.0
Displacement, mm
Figure 5. Cross section of the region of growth of the crack in
Figure 3. Curve load £ displacement of the line of load in the the fracture, in the CA6NM steel quenched of 10508C and
base metal. tempered at 5908C.
 Welding International 171

45
LF1ST LF1ST
40
LF2ST P5
35 LF3ST LF2ST

30 LF3ST
Load, kN

25

20

15

10 Secante 5 %

0
0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8
Displacement, mm Figure 8. Cross section of amplification in the MS region
(E410NiMo T1, tubular) of the welded joint of the steel CA6NM
Figure 6. Curves load £ displacement of the line of load in the without PWHT, with greater detail of the inclusions.
welded joint with pre-crack close to LF.
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welded joint developed. The presence of cavities suggests

caused by the 5% drying agent, which crossed the
load £ displacement curves at the same point for all three
samples, as shown in Figure 6, generating the same P5 and
consequent PQ values. Table 6 compares the fracture
toughness in the base metal and in its welded joint.
PQ  a 
K Q ¼ pffiffiffiffiffiffiffiffiffiffi f :
BN W W
Figures 7 and 8 show the appearance of the fracture
in the MS, in the region, where the final fracture of the
Table 6. Values of fracture toughness KIC in the base metal of
CA6NM steel quenched at 10508C and tempered at 5908C, and of
its welded joint without PWHT with AWS E410NiMo T1 wire.
KIC fracture resistance MB
1/2
(Mpa m ) 278
(N/mm3/2) 8784
Figure 7. Cross section of the transition region between the pre-
crack and the MS (E410NiMo T1, tubular) of the welded joint of
the CA6NM steel without PWHT, showing the inclusions.
a micro-mechanism of ductile fracture, but the unstable
propagation of the crack, the macroscopic aspect of the
fractured surface, and the low toughness values observed,
are opposed to an alveolar micro-mechanism.
The nucleation of cavities and the low toughness
shown by the welded joint may be justified by the presence
of inclusions of oxides, arising from the waste from the
ð2Þ
tubular wire used, which does not allow the fracture in the
MS to absorb a great quantity of energy1, showing fragile
behaviour under a macroscopic analysis. The presence
of cavities occurs across the whole-fractured surface, but
they are reduced in size when compared to the cavities
in the fracture in the quenched and tempered condition,
providing proof of the low-fracture toughness of the
welded joint.
LFST
89 4. Conclusions
2820
The CA6NM soft-martensitic stainless steel, with 0.020%
C, quenched at 10508C and tempered at 5908C, presented
JIC toughness values equal to 341 kJ/m1/2 and KIC
equivalent of 278 MPa m1/2. The CA6NM steel welded
joint with wire of a chemical composition similar to AWS
E410NiMo T1 and without PWHT gave a KIC ¼ 89
MPa m1/2, revealing a toughness in the welded condition
approximately three times lower.
The fracture presented ductile behaviour for the
quenched and tempered CA6NM steel and fragile
behaviour in the welded joint without PWHT, which
suggests proper control during the manufacture of the
welded joints. The nucleation of cavities in the fragile
condition is justified by the presence of inclusions of
oxides arsing from splatter from the tubular wire used.
The welded joints, all in MIG/MAG, carried out using
the parameters indicated by the manufacturer of the
wire, with the inter-pass and pre-heating temperatures
 172 W.J.P. Casas et al.
controlled, will need improvements to the welding
procedure to guarantee higher toughness values when
needed for applications without PWHT.
Note
1. Email: walter.paucar.casas@ufrgs.br
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