SOLIDIFICATION CRACKS

Solidification cracking (also known as centreline cracking or hot cracking) is a

fracture that occurs in the weld metal of Ferritic steels with a high sulphur or
Phosphorus content or in joints with a large depth/width ratio.
During welding the sulphur joins with iron to form iron sulphide (Fes). This Fes has a
lower melting point than steel and therefore remains as a liquid as the steel solidifies.
The centre of the weld is the last place to cool and the liquid Fes is pushed to the
centre of the weld and forms a liquid film on the grain boundaries causing a lack of
adhesion on the grain boundaries. Weld metal contraction due to cooling leaves a high
tensile stress which can pull the weld apart along the weakened centreline of the weld
bead.
Solidification cracking can be avoided by: Adding Mn to form Mn sulphide which
has a melting point similar to steel which helps to maintain cohesion between the
grain boundaries preventing a crack forming. Specify low Sulphur content material,
less than 0.03% S. Keep surfaces clean from contaminants, oil, paint and grease. Use
a welding process with a low dilution level of parent plate to weld metal. Reduce
restraints, reducing residual stress levels and keep heat inputs low.

Solidification cracking also occurs in Austenitic stainless steels because the austenitic
grain structure is intolerant to contaminants such as Sulphur or Phosphorus between
the grains of weld metal. This cracking can be avoided by making the weld metal 5%
ferritic because the ferrite structure is more accommodating to contaminants.