Etals Nternational Imited: Significant Welding Variables Brazing References

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Significant Welding Variables

Brazing
References
Introduction
Although the complex shapes produced by the casting process have enabled castings to replace many fabricated
components, there are many applications in which, for economic or engineering reasons, castings themselves become
part of a fabrication and are joined to other castings or other materials. Although often more cost-effective than steel
castings and forgings, Ductile Irons have not been used in some applications requiring joining by welding because they
have been considered difficult to weld. This poor weldability of Ductile Iron is partly fact but primarily misconception.
When Ductile Iron castings are repaired or joined by fusion welding their high carbon content can cause the formation
of carbides in the fusion zone (FZ) and martensite in both the FZ and heat affected zone (HAZ) adjacent to the FZ. The
formation of hard brittle phases in the FZ and HAZ can cause a significant deterioration in both machinability and
mechanical properties.
Following an investigation into the weldability of various types of cast irons, the American Welding Society Committee
on Welding Cast Irons has developed both a weldability test and a set of recommended practices for welding cast irons.
The weldability test consists of the production of carefully controlled autogenous welds (an autogenous weld is one
made without filler metal) on test castings preheated to various temperatures and the determination of a minimum
temperature, called the "no-crack temperature" above which there is no cracking in the test weld. The committee found
no correlation between the no-crack temperature and the carbon equivalent (CE) formula used to determine the
weldability of steels and the following formula for CE was developed.
CECI = %C + 0.31 (%Si) + 0.33 (%P) + 0.45 (%S) +

0.028 (%Mn + %Mo + %Cr) - 0.02 (%Ni) - 0.01 (%Cu)
Figure 8.1 shows that there is a good correlation between CEC, and the no-crack temperature for Gray, Ductile and
Malleable irons. The autogenous welding method used to obtain this correlation was chosen to simplify and
standardize test procedures and is not considered good welding practice for cast irons. For this reason CECI should be
used only to rank weldability rather than determine either absolute weldability or specific preheating conditions.
Through the use of welding practices and consumables described in the Guide for Welding Castings and other
references used in this Section, Ductile Iron castings have been joined successfully to other Ductile Iron castings and to
steel in the fabrication of automotive and other engineering components. In addition, nonfusion joining processes such
as brazing, diffusion bonding and adhesive bonding can be used to produce high quality joints between Ductile Iron and
a wide variety of other materials.
WELDING
Welding involves the fusion of both a filler metal (welding consumable) and the base metal adjacent to the weld zone.
The high carbon content of Ductile Iron can lead to the formation of carbides in the fusion zone (FZ) and martensite in
both the FZ and heat affected zone (HAZ) adjacent to the FZ unless correct procedures are followed. However, with the
100
METALS INTERNATIONAL LIMITED
Tel: +86-21-6090-0836/37 Fax:+86-21-6090-0838
www.klsteel.com Email: metalsintl@yahoo.com
use of appropriate materials and procedures, Ductile Iron castings can be successfully joined to other Ductile Iron
castings and to steel by fusion welding.
ARC WELDING
Several methods have been employed successfully to arc-weld Ductile Iron to itself and other materials with acceptable
properties in both the weld and base metal. The properties of shielded metal arc welded Ductile Irons were greatly
improved by the introduction over 30 years ago of the high-Ni and Ni-Fe electrodes (AWS Ni-CI and ENi-Fe-CI). These
electrodes produce high-nickel fusion zones that are relatively soft and machinable but have adequate tensile strength,
ductility and fatigue strength. The short arc, or dip transfer MIG welding process, by virtue of its controlled, low heat
input, reduced harmful structural changes in the base metal HAZ. Combining the benefits of Ni-base filler wire with the
short-arc MIG process has resulted in welds with tensile properties that are equivalent to the base Ductile Iron (Table 8.
1) and fatigue strengths that are 65% and 75% respectively of the fatigue limits of unwelded pearlitic and ferritic Ductile
Irons (Figures 8.2 and 8.3). Although suffering from the disadvantages of high consumable costs, low deposit rate
(1.8-3.2 kg/h (4-7 lb/h)) and a tendency toward lack-of-fusion defects, short-arc MIG welding has been used
successfully for the joining of Ductile Iron castings for commercial applications. Recent work at BCIRA has shown that
short-arc MIG welds made with high Ni filler wire have Charpy fracture energies that are superior to those of
MIG-welded joints made with Ni-Fe and Ni-Fe-Mn wires and flux-core arc welded joints produced with Ni-Fe wire.
Table 8.1 Average transverse tensile properties of short-arc mig-welds between 25mm (1 inch) thick plates.
Matrix 0.2% yield strength, Tensile strength, Elongation, %

Filler metal
structure N/mm2 (ksi) N/mm2 (ksi) in 50 mm (2 in.)
Ferritic Unwelded 232-309 (34-45) 386-541 (56-78) 15-25
Nickel 61 (44) 422 (61) 11.5
Monel 60 (44) 400 (58) 8.7
Nilo 55 (44) 412 (60) 12.7
Pearlitic Unwelded 386-463 (56-67) 618-772 (90-112) 1-3
Nickel 61 358 (52) 550 (80) 3.5
Monel 60 346 (50) 495 (72) 2.5
Nilo 55 339 (49) 425 (62) 5.7
Flux Cored Arc Welding

Flux cored arc welding (FCAW), utilizing a flux cored wire developed specially for the welding of cast irons, has
improved upon the metallurgical advantages provided by the Ni-rich consumables and offers the additional advantage
of much higher metal deposit rates (6-9 kg/h (13-20 lb/h)). The key to the success of the FCAW process is the
consumable, marketed under the trade name "Ni-Rod FC55", which consists of a nickel-iron tubular wire filled with
carbon, slagging ingredients, and deoxidizers. In addition to the advantages offered by the high nickel content, Ni-Rod
FC55 provides the additional benefits of a high carbon content, which produce graphite precipitates during the
solidification of the weld metal. It has been claimed that the expansion resulting from the formation of graphite
counteracts weld-metal shrinkage, reducing stress-induced cracking of the weld. The high productivity of the FCAW
101

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METALS INTERNATIONAL LIMITED

Tel: +86-21-6090-0836/37 Fax:+86-21-6090-0838

Significant Welding Variables

CECI = %C + 0.31 (%Si) + 0.33 (%P) + 0.45 (%S) +

Matrix 0.2% yield strength, Tensile strength, Elongation, %

Ferritic Unwelded 232-309 (34-45) 386-541 (56-78) 15-25

Nickel 61 (44) 422 (61) 11.5

Monel 60 (44) 400 (58) 8.7

Nilo 55 (44) 412 (60) 12.7

Pearlitic Unwelded 386-463 (56-67) 618-772 (90-112) 1-3

Nickel 61 358 (52) 550 (80) 3.5

Monel 60 346 (50) 495 (72) 2.5

Nilo 55 339 (49) 425 (62) 5.7

Flux Cored Arc Welding

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