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BY H. K. D. H. BHADESHIA
We depend in our everyday life on the defect that has to be managed. One way which a joint is deposited such that sam-
performance of vast quantities of steel, of doing this is through a deep under- ples can be obtained without dilution with
which we use without giving it a second standing of metallurgy, thereby avoiding the base plates. It is fortunate that the lit-
thought. This is possible because the ma- the engineering disasters of the kind that erature is rich in data from tests of this
terial is reliable and cheap (weight for plagued for example, the Liberty ships. A kind, data which have been liberally ex-
weight, some 1000 times cheaper than weld consists of distinct zones, each of ploited in the development of models.
potato chips). Yet, there are remarkable which is the consequence of a particular
technologies and sciences working behind interaction between heat flow and the Defining Characteristics of a
the scenes to create ever better steels that phase transformation characteristics of Weld Metal
can be assembled into awe inspiring struc- the weld metal and the base metal.
tures. Out of all these zones, the weld metal The essential variables n e e d e d in
Examples include the giant oil rigs that is particularly challenging to design be- order to be able to calculate the mi-
p e p p e r the North Sea, the oil and gas cause there is little that can be done once crostructure and properties of steel weld
pipelines that traverse the frozen wastes, the weld is completed (Refs. 1-3). This metal are illustrated in the top row of Fig.
and the 101 Tower in Taiwan, which is now contrasts with wrought steel, which can be 2 (Refs. 4, 5). The chemical composition,
the tallest building in the world - - Fig. 1. processed and manicured using all the fa- cooling conditions, and austenite grain
These are all made from steel and rely on cilities available in a modern steel plant. size capture all the essential features of
welding for their assembly. There is, therefore, a major industry de- weld metal. The essence of the welding
voted to the design and manufacture of process and joint geometry is expressed
Weld Design: Experiment or welding alloys. Academic activity has sup- via the cooling curve and there are many
Model? ported this industry, both in terms of the models with varying levels of sophistica-
underlying science and in the creation of tion capable of predicting the change in
A weld is a heterogeneity introduced quantitative methods for alloy design. temperature as a function of time and po-
into a carefully manufactured steel. It is a Given all this effort, I shall use this lecture sition. As will be seen later, the chemical
to explore whether it is any longer neces- composition defines the thermodynamics
HARSHAD K. D. H. BHADESHIA was se- sary to conduct experiments when devel- of transformation and the nature of the
lected to present the 2004 Comfort A. Adams lec- oping welding consumables. Are the heterogeneities that arise.
ture at the A WS Annual Meeting, Chicago, IlL He models sufficiently robust to be exploited The austenite grain structure, a para-
is a professor of physical metallurgy in the Depart- meter sometimes ignored in the interpre-
by industry without supervision?
ment of Materials Science and Metallurgy at the
The focus of this paper is on ferritic tation of microstructures, has a profound
University of Cambridge, U.K., where he received
his Ph.D. He has held the positions of university steels, which form the bulk of the billion effect.
demonstrator, university lecturer, reader in physi- or so tons of steel consumed annually.
cal metallurgy, and Royal Society Leverhume The development of welding consum- Cooling Curve
Trust Senior Fellow. ables involves all weld-metal tests in
He specializes in the theory of solid-state trans- There is a huge amount of research
formations with emphasis on the prediction of mi- that has been devoted solely to the calcu-
crostructural development in complex metallic al- lation of the thermal cycle associated with
loys, particularly for multicomponent steels as KEY WORDS welding. The most sophisticated of mod-
applied to engineering applications.
els account for joint geometry, gravita-
He was elected a Fellow of the Royal Society,
the Institute of Physics, the Institute of Materials, Consumables tional forces, surface tension effects,
and the Royal Academy of Engineering, and this Cooling Curve buoyancy forces, electromagnetic forces,
year was awarded Consulting Professorship by Experimentation metal transfer, changes in thermophysical
Harbin Institute of Technology, China. He has re- Ferritic Steel properties with temperature and turbu-
ceived other honors from institutions in Brazil, Modeling lence, etc. (Ref. 6). Weld pool shapes can
Japan, India, and the United States. He can be Solid-State Transformation be fairly accurately calculated and when
contacted at www.msm.cam.ac.uk/phase-trans. there are deviations, empirical correc-
1
' | Widmanst~Rtenferrite i
growth rate I
|
MS' BS' WS' Th' TI I
I Impingement effects I
Microp,a,esI I Acicu'ar'er"toI
Fig. 1 - - The 101 Tower in Taiwan, made from steel and +
glass. Photograph courtesy of Thomas Sourmail.
Properties I
Fig. 2 - - Flowchart showing the progress of weld metal microsmwmre and property calcu-
lations.
tions are made in a manner constrained by equiaxed grains found in most steels and multiphase steels, using proprietary or
the physics. From the present point of requires a different approach in defining free software.
view, it is really the cooling curve that is the amount of austenite grain surface per 2) The second effect is more subtle be-
important, particularly in the regime unit volume (Sv). It has been demon- cause it depends on the rate at which
where solid-state transformations occur, strated that the columnar grains can be de- change occurs. The equilibrium solubility
i.e., between about 900°C and the marten- scribed as hexagonal prisms (length c and of an alloying element is never identical in
site-start temperature; this must be the side a) in three dimensions. It follows that austenite and ferrite. If circumstances per-
reason why the time Ats00_500is a popular two stereological parameters, the mean mit, the solute will therefore tend to par-
measure in the welding industry. This lineal and mean areal intercepts, are tition between the phases during the
greatly simplifies the problem because the needed to quantify this anisotropic grain course of transformation. The required
cooling rate (dT/dt) within the weld metal structure. However, because the grains diffusion may then limit the kinetics of the
can, to a high level of accuracy, be repre- are much longer than they are wide, a process. This is a gross effect involving
sented independently of position with a good approximation is that the mean lin- large numbers of atoms and distances
simple equation (Refs. 7, 8). eal intercept measured on transverse sec- comparable to the size of the transformed
tions of the weld (Ltn), in a direction nor- product. Another kinetic effect of equal
mal to the columns, adequately describes importance can be triggered by minute
. r = c,(r-r,.) C'
S v (Ref. 9). There exist equations that concentrations of solute; misfitting atoms
a, o. (1) then relate S v t o the chemical composition can segregate to interfaces. In doing so,
of the weld metal and the heat input. they reduce the interfacial energy per unit
where Q is the heat input per unit length, area. This is the mechanism by which
11 is the transfer efficiency, and T i the pre- The Alloying Elements boron renders austenite grain boundaries
heat or interpass temperature. There are less effective as heterogeneous nucleation
numerous weld cooling curves available in A weld metal may contain twenty or sites for ferrite. Traces of boron can there-
the welding literature; for a particular more deliberate solutes, and others that fore have a huge influence on hardenabil-
process and weld geometry, this equation are introduced accidentally during deposi- ity, far in excess of that expected from its
can be fitted to derive the empirical con- tion: C, Mn, Si, Ni, Mo, Cr, V, Co, B, N, O influence on G a - Gr.
stants C t and (72. Such constants are avail- ..... Some of these, such as boron, may be
able for a large variety of welding present in minute quantities and yet can Solid-State Transformations
processes and this simple procedure works have a profound effect on the microstruc-
rather well in practice. Rigorous calcula- ture. Solutes act on steels by two essential AIIotriomorphic Ferrite
tions in which the weld pool is properly mechanisms:
modeled make only a small difference to 1) The relative stabilities of austenite Having described the three parameters
the calculated microstructure. This is be- (7) and ferrite (ct) are affected via a ther- that are seminal in the development of weld
cause the cooling rate in the transforma- modynamic effect, which can be expressed metal microstructure, we now address the
tion range is relatively insensitive to fluid rigorously in terms of the difference in complex array of phase changes that occur
flow phenomena. Gibbs free energies, G a - Gr, often called as the weld metal cools (Refs. 1-5). The es-
the "driving force" for transformation. sential features of the transformed mi-
The Austenite Grain Structure This thermodynamic quantity feeds di- crostructure are illustrated schematically in
rectly into rate theory, for example in the Fig. 3. It consists of allotriomorphic ferrite
The columnar austenite grains in the equations governing classical nucleation. et, Widmanst~itten ferrite Ctw,acicular ferrite
weld deposit derive, in most cases, from It is now routinely possible to calculate ct, and the so-called microphases, which
columnar &ferrite grains that grow epi- these free energies and, of course, to ex- might include small amounts of martensite,
taxially from the fusion surface during the press them in terms of equilibrium phase retained austenite, or degenerate pearlite.
early stages of solidification. The colum- diagrams. Such calculations can now be Bainite consisting of sheaves of parallel
nar shape is quite different from the conducted routinely for multicomponent, platelets is also found in some weld de-
.c 10
.,.j.- " c 3 :
.,..,.:.,""" ~1. _0.05
o m
,,-" ~--.'-' 0.07 N8
........ .jJ 2 ~L_L,--o.o, 2
.../,.. / -]_., _............... O. I 1
. , ~ :::,.LL .........
w. / / ....
1 dC~ I I
0 0 0,1 0,2 0.3
o IO
Time / s Volume fraction (x
Fig. 3 - - Schematic representation o f the mi- Fig. 4- - A Isothermal thickening of ferrite layers as a function o f the carbon concentration; B
-- -- cor-
crostructure o f weld metal relation of parabolic rate constant against va for a variety o f welds.
posits, particularly of the type used in the thickness is most sensitive to the carbon grains within a fraction of a second is typ-
power generation industry. concentration when the latter is close to ical - - Fig. 6A. The theory used here is rig-
These phases all evolve during cooling, the solubility of carbon in ferrite; this is orous and proven, but the volume fraction
beginning with the decoration of austenite because the need to partition carbon de- of Widmanst~itten ferrite (vw) hardly cor-
grain boundaries with layers of allotri- creases as the average concentration relates with G - - Fig. 6B.
omorphic ferrite. They seem to nucleate ~--~xCq'. We shall see later that this explains The discrepancy arises because by the
readily and then thicken at a rate con- some of the carbon equivalent equations time the weld has cooled to induce Wid-
trolled by the diffusion of carbon in the prevalent in industry. Figure 4B shows manst~itten ferrite, acicular ferrite sprouts
austenite (T) ahead of the (x/'/ interface. that the the nucleation stage of the layers from inclusions dispersed within the
The substitutional elements do not parti- of ferrite can justifiably be neglected be- austenite grains. There is, therefore, com-
tion; this kind of transformation is said to cause the volume fraction v a correlates petition for the austenite that remains and
occur under paraequilibrium conditions. strongly with cq for a large variety of weld a strong possibility of impingement be-
Theory shows that the thickness (q) of the metals. tween intragranularly nucleated acicular
ferrite varies parabolically with time (t) Welds cool continuously, so the above ferrite and Widmansffttten ferrite. As il-
equations need to be integrated over the lustrated in Fig. 7, when the alloy content
q = a l tl/2
temperature range Th to 7"l, the start and is small, the rapid growth ofct and c~wcon-
(2) stop temperatures for tx. T h is estimated sumes much of the austenite, thereby re-
using calculated time-temperature-trans- ducing the ability to form ~a" By contrast,
where cq, the parabolic thickening rate formation ( T I T ) diagrams (Ref. 10) (Fig. in high-hardenability welding alloys, the
constant, is given by the solution of 5) and Scheil's rule. 7"/is taken to be the acicular ferrite has an opportunity to de-
point where displacive transformations velop and indeed to stifle the penetration
become kinetically favored. Once the of Widmanst~itten ferrite into the austen-
2/~=D x ~ - 2 _
thickness of the layers of 0~ has been cal- ite grains.
~21" X ~ --Xa)'
culated, it is straightforward to relate it to The volume fraction of Widmanst~itten
] f<,,] p
al e x p 4 - - p e r f c 4 ~
the volume fraction of ferrite using the ferrite that can form is therefore a func-
geometry of the austenite grains tion not just of the growth rate, but also of
I.4---DJ I.2V__DJ (3) the thickness of allotriomorphic ferrite,
the time required for it to grow across an
andx~xC'Yare the paraequilibrium carbon austenite grain, and the geometry of the
concentrations in austenite and ferrite re- ,,o=LI2a__2,,,+,emJ'a austenite grains.
spectively at the interface (obtained using (5)
the thermodynamic calculations de-
scribed earlier), E is the average carbon so that the dependence on austenite grain
concentration in the alloy and D is a size becomes obvious.
weighted average diffusivity of carbon in
austenite, given by Widmanst~tten Ferrite (6)
WELDING J O U R N A L P.gizl~l
A
800
3 4 5
oo 6 0 0 "~ Fe-1 Mn-C w t . %
700
_ _
(-
6
ot,J
600
o
<.9
V
,.=
SO0 1. Fe-0.4C =~ 4 0 0
- -
2. Fe-0.4C-2Si
E o
N,~'X.~ X 3. Fe-0.4C-1 Ni ._.
400 - \x.~ 4. Fe-0.4C-1 Mn
E
I- "~,~ 5. Fe-O.4C-q Mn-] Cr
300
-- " " 6. Fe-0.4C-2Mn 200
(D
c- C)
I I I I I ~O
200 0 1 2 3 4 5 x2_ %
10 10 10 10 10 10 i i
form during solidification and subsequent proposing two different tween volume fraction and growth rate o f Widmanstdtten ferrite.
cooling. The quantitative details of the equations for the carbon
calculation of acicular ferrite are dis- equivalent.
cussed elsewhere (Ref. 11).
Yield Strength
Solidification-Induced Segregation IIW >0.18wt-% C
C E = C + Mn+Si + Ni+Cu + For an individual phase, the strength
In the discussion above, it has been as- 6 15 can be factorized into a number of intrin-
sumed that the chemical composition of Cr+Mo+V sic components (Ref. 12).
weld metal is uniform. This is not the case wt-%
5 (7)
in practice because welds cool rapidly and (9"----fTFe + Z Xl~Tssi q- XcO'c +
there may be uncontrolled variations in i
the welding conditions. A good estimate
of the magnitude of segregation comes Ito-Besseyo <0.18wt-% C K'{~'}+KDP°~ (9)
from the partition coefficient ki, which is
CE=c+Si M n + C u + C r ~-
the ratio of solute concentration i in the where x i is the concentration of a substitu-
solid to that in the liquid. The coefficient 30 20 tional solute which is represented here by
can easily be calculated, and used to give Ni Mo V a subscript i. The other terms in this equa-
--+ +--+5B wt-%
the compositions of the solute-rich and 60 15 10 tion can be listed as follows:
solute-poor regions of the weld (carbon is (8) KL strengthening due to grain size,
very mobile so it is assumed to be uni- 115 MN m -1.
formly distributed). This information can KD dislocation strengthening, 7.34
then be used to estimate the effect on T h For the IIW version, the dependence of x 10-6 MN m -1
for allotriomorphic ferrite, which then in- CE on substitutional solutes such as man- OFe pure, annealed Fe, 219 MN m -2
fluences all subsequent transformations. ganese is greater than for the CE reserved at 300 K
To summarize, virtually every compo- for low-carbon steels. This is because in Oss i substitutional solute (i) strength-
nent of weld microstructure is amenable the low-carbon steels, it is the carbon that ening
to calculation. Some examples are pre- has a greater influence on the kinetics of oC solid solution strengthening due
sented in Fig. 8. Predictions like these transformation. to carbon
I | | I
high alloy0ontent 0.2 0./. 0.6 0.8 1.0
Experimentalvolumefraction
Fig. 7 - - The hexagons are cross sections o f columnar austenite grains and the Fig. 8 - - A n example o f the agreement achieved between the measured and
dots represent inclusions, calculated weM metal microstructures.
Fig. 9 - - Illustration o f the complexity of the function (of two inputs) that can be created using a simple neural network with just four hidden units. The two fig-
ures are generated for the same mathematical function but different weights.
PD dislocation density, typically ness, stress-corrosion resistance, creep re- the input dataxj are multiplied by weights,
1016 m-2 sistance, etc. are routine considerations in but the sum of all these products forms the
L measure of the ferrite plate size, typ- the design process (Ref. 13). These proper- argument of a hyperbolic tangent (Refs.
ically 0.2/xm ties are "complex" in the sense that they can 14, 15). The output y is therefore a non-
Given the microstructure, the yield be measured and used in design but cannot linear function of xj, the function usually
strength can be estimated from that of the be predicted. There is no theory that has the chosen being the hyperbolic tangent be-
individual phases, either as a rule of mix- rigor or sophistication to handle the large cause of its flexibility. Combining many of
tures, i.e., cy= Y~i~i V/where Vi is the frac- number of variables that are known to con- these functions increases the available
tion of phase i, and a/the corresponding trol such properties. flexibility. A few of the advantages of the
strength. More sophisticated methods for The conventional way to approach network over conventional regression can
combining the effects of the different such problems is to apply regression analy- be listed as follows:
phases are also available, but suffice it to say sis in which experimental data are best-fit- 1. There is no need to specify a function
that given the microstructure, it is possible, ted to some function, which is usually lin- to which the data are to be fitted. The
using well-established strengthening the- ear. The result is an equation in which function is an outcome of the process of
ory, to estimate the weld metal yield each of the inputs xj is multiplied by a creating a network.
strength. weight wj; the sum of all such products and 2. The network is able to capture al-
a constant 0 then gives an estimate of the most arbitrarily nonlinear relationships.
Complex Properties output y = Y.j wj xj + O. This is precisely 3. With Bayesian methods, it is possible
how the carbon-equivalent equations are to estimate the uncertainty of extrapolation.
The fabrication of useful devices and derived. We shall now discuss these last two
structures is based on more than just the A neural network is a more general points in detail.The complexity and flexi-
strength. Properties such as fatigue, tough- method of regression analysis. As before, bility of the relationship that can be cre-
WELDING JOURNALP/.~lil~.'l
14
14
I inear
12
12 experimental ~
10
~. 8 Cl. 8
4.,I
:3 6 :3 6
O 0
4 "~ ' " a4 4
--~ + -i-i- + " E
0
0 2 4 6 8 2 4 6 8
Input Input
Fig. 10 - - Two functions that exactly match the experimental data (2, 4, 6) "extrapolate differently.