Abstract
Welding of shipbuilding steels is considered a challenge. First, because of the requirement to keep the metallurgical continuity that gives the material mechanical strength and toughness. Second, due to the great thickness that is involved, the selection of welding parameters usually occurs empirically, without understanding the thickness effects. Therefore, this work aims to develop and validate a practical methodology for welding A131 DH36 naval steel plates with different thicknesses (7 mm, 10 mm, 12.7 mm, 19 mm, and 25.4 mm) by applying the multipass gas metal arc welding (GMAW) process. For this purpose, five plates were welded and qualified based on the AWS D1.1/D1.1 M:2020 standard. After being processed in the vertical up position, the effect of plate thickness on the number of passes and electrical parameters was studied, as well as the resulting microstructure. It was noticed, differently from expected, that the root and filling passes did not show large variations of electrical parameters as a function of thickness, while the finish passes required different energy levels for each one in order to meet the standard requirements. The cooling rates were estimated through the classical equations from Rosenthal and Rikalin, which enabled the prediction of the initial microstructure (without the effects of multipass), using the CCT diagram. The influence of thickness and welding energy on the cooling rate was studied. Then, microhardness and the resultant multipass microstructure were analyzed. The predicted fuzion zone (FZ) hardness varied from 195 to 339 HV depending on the thickness and type of pass. On the other hand, the measured hardness varied from 192 to 267 HV. The differences between the predicted and measured results can be explained based on the divergences caused by the assumptions used in the analytical equations and the peak temperature of the CCT diagram available, besides the divergences caused by the subsequent passes. The joints did not present defects and were within the required specifications in all tests performed: hardness, tensile, Charpy, and bending.
Graphical Abstract
Similar content being viewed by others
Availability of data and material
Not applicable.
Code availability
Not applicable.
References
Messias T, Borba D, Flores WD, Oliveira L (2017) Assessment of the weldability of EH36 TMCP shipbuilding steel welded by high heat input submerged arc welding. Weld Int 31:184–195. https://doi.org/10.1080/09507116.2016.1218619
Ribeiro ACN (2015) Evaluate the welding microalloyed steel AH36 by submerged arc process with one and two wires. USP, São Paulo
ASTM International (2019) Standard specification for structural steel for ships. ASTM International, West Conshohocken
Yang L, Wang Y, Sun T et al (2020) Microstructure and mechanical properties of FCTIG-welded DH36 steel with rutile-type and basic-type flux cored wires. J Mater Process Tech 275:1–9. https://doi.org/10.1016/j.jmatprotec.2019.116363
Chen S, Wang D, Wang Z et al (2017) Microstructure and mechanical properties of friction stitch welds of DH36 steel in local dry conditions. Int J Adv Manuf Technol 93:3615–3624. https://doi.org/10.1007/s00170-017-0745-8
Almoussawi M, Smith AJ, Young A, Cater S, Faraji M (2017) Modelling of friction stir welding of DH36 steel. Int J Adv Manuf Technol 92:341–360. https://doi.org/10.1007/s00170-017-0147-y
Teng J, Wang D, Wang Z et al (2017) Repair of arc welded DH36 joint by underwater friction stitch welding. Mater Des 118:266–278. https://doi.org/10.1016/j.matdes.2017.01.016
Almoussawi M, Smith AJ, Faraji M, Cater S (2017) Segregation of Mn, Si, Al, and oxygen during the friction stir welding of DH36 steel. Metallogr, Microstruct, Anal 6:569–576. https://doi.org/10.1007/s13632-017-0401-6
Camilleri D, Micallef D, Mollicone P (2015) Thermal stresses and distortion developed in mild steel DH36 friction stir-welded plates: an experimental and numerical assessment. J Therm Stresses 38:405–508. https://doi.org/10.1080/01495739.2015.1015856
Toumpis AI, Galloway AM, Arbaoui L, Poletz N (2014) Thermomechanical deformation behaviour of DH36 steel during friction stir welding by experimental validation and modelling. Sci Technol Weld Joining 19:653–663. https://doi.org/10.1179/1362171814Y.0000000239
Tiwari A, Pankaj P, Biswas P, Kore SD, Rao AG (2019) Tool performance evaluation of friction stir welded shipbuilding grade DH36 steel butt joints. Int J Adv Manuf Technol 103:1989–2005
Zhang J, Coetsee T, Dong H, Wang C (2020) Element transfer behaviors of fused CaF2-TiO2 fluxes in EH36 shipbuilding steel during high heat input submerged arc welding. Metall Mater Trans B 51:1953–1957. https://doi.org/10.1007/s11663-020-01936-3
Zhang J, Coetsee T, Dong H, Wang C (2020) Elucidating the Roles of SiO 2 and MnO upon decarburization during submerged arc welding : a thermodynamic study into EH36 shipbuilding steel. Metall Mater Trans B 51:1805–1812. https://doi.org/10.1007/s11663-020-01869-x
Bai Y, Chaudhari A, Wang H (2020) Investigation on the microstructure and machinability of ASTM A131 steel manufactured by directed energy deposition. J Mater Process Tech 276:1–13. https://doi.org/10.1016/j.jmatprotec.2019.116410
Wang J, Zhang M, Tan X et al (2020) Fatigue behavior of ASTM A131 EH36 steel samples additively manufactured with selective laser melting. Mater Sci Eng, A 777:1–15. https://doi.org/10.1016/j.msea.2020.139049
Wang J, Wu WJ, Jing W et al (2019) Improvement of densification and microstructure of ASTM A131 EH36 steel samples additively manufactured via selective laser melting with varying laser scanning speed and hatch spacing. Mater Sci Eng, A 746:300–313. https://doi.org/10.1016/j.msea.2019.01.019
Wang J, Zhang M, Wang B et al (2021) Influence of surface porosity on fatigue life of additively manufactured. Int J Fatigue 142:1–20. https://doi.org/10.1016/j.ijfatigue.2020.105894
Zou X, Zhao D, Sun J et al (2018) An integrated study on the evolution of inclusions in EH36 shipbuilding steel with Mg addition : from casting to welding. Metall Mater Trans B 49:481–489. https://doi.org/10.1007/s11663-017-1163-x
Rong Y, Mi G, Xu J et al (2018) Laser penetration welding of ship steel EH36: a new heat source and application to predict residual stress considering martensite phase transformation. Mar Struct 61:256–267. https://doi.org/10.1016/j.marstruc.2018.06.003
Barbosa LHS, Modenesi PJ, Godefroid LB et al (2018) Microstructure and mechanical characteristics of the welding zone of a shipbuilding steel welded in submerged arc welding with very high heat input. Soldagem Inspeção 23:168–179
Zhang J, Leng J, Wang C (2019) Tuning weld metal mechanical responses via welding flux optimization of TiO2 content: application into EH36 shipbuilding steel. Metall Mater Trans B 50:2083–2087. https://doi.org/10.1007/s11663-019-01645-6
Pereira DHM, Pereira DHM, Rolim TL et al (2020) Residual stress analysis using CPD method in ASTM A131 AH36 steel multipass welding by SMAW and FCAW processes. Soldagem Inspeção 25:1–9
Toumpis A, Galloway A, Cater S, Mcpherson N (2014) Development of a process envelope for friction stir welding of DH36 steel – a step change. Mater Des 62:64–75. https://doi.org/10.1016/j.matdes.2014.04.066
Zhao W, Feng G, Zhang M et al (2020) Effect of low temperature on fatigue crack propagation rates of DH36 steel and its butt weld. Ocean Eng 196:1–12. https://doi.org/10.1016/j.oceaneng.2019.106803
Tiwari A, Pankaj P, Suman S, et al (2021) Effect of plasma preheating on weld quality and tool life during friction stir welding of DH36 steel. J Eng Manuf 235:1–15. https://doi.org/10.1177/0954405421990139
Tingey C, Galloway A, Toumpis A, Cater S (2015) Effect of tool centreline deviation on the mechanical properties of friction stir welded DH36 steel. Mater Des 65:896–906. https://doi.org/10.1016/j.matdes.2014.10.017
Pankaj P, Tiwari A, Biswas P et al (2020) Experimental studies on controlling of process parameters in dissimilar friction stir welding of DH36 shipbuilding steel – AISI 1008 steel. Weld World 64:963–986
Fowler S, Toumpis A, Galloway A (2016) Fatigue and bending behaviour of friction stir welded DH36 steel. Int J Adv Manuf Technol 84:2659–2669. https://doi.org/10.1007/s00170-015-7879-3
Paes LES, Pereira M, de Souza Pinto Pereira A et al (2019) Power and welding speed influence on bead quality for overlapped joint laser welding. Journal of Laser Applications 31:1–6. https://doi.org/10.2351/1.5096110
Paes LES, Pereira M, Weingaertner WL et al (2019) Comparison of methods to correlate input parameters with depth of penetration in LASER welding. Int J Adv Manuf Technol 101:1157–1169. https://doi.org/10.1007/s00170-018-3018-2
Cavilha Neto F, Pereira M, dos Santos Paes LE et al (2021) Effect of power modulation frequency on porosity formation in laser welding of SAE 1020 steels. Int J Adv Manuf Technol 112:2509–2517. https://doi.org/10.1007/s00170-020-06482-5
Neto FC, Fredel MC, Pereira M, Paes LES (2020) Laser power modulation to grain refinement of SAE 1045 steel welds. J Laser Appl 32:1–7. https://doi.org/10.2351/7.0000096
Silva RHG, Paes LES, Sousa GL et al (2019) Design of a wire measurement system for dynamic feeding TIG welding using instantaneous angular speed. Int J Adv Manuf Technol 101:1651–1660. https://doi.org/10.1007/s00170-018-3026-2
Gook S, Midik A, Biegler M et al (2022) Joining 30 mm thick shipbuilding steel plates EH36 using a process combination of hybrid laser arc welding and submerged arc welding. Journal of Manufacturing and Materials Processing 6:1–11. https://doi.org/10.3390/jmmp6040084
Hosseini VA, Hurtig K, Karlsson L (2020) Bead by bead study of a multipass shielded metal arc-welded super-duplex stainless steel. Welding in the World 64:283–299
Gao H, Dutta RK, Huizenga RM et al (2014) Pass-by-pass stress evolution in multipass welds. Sci Technol Weld Joining 19:256–264. https://doi.org/10.1179/1362171813Y.0000000191
Turichin G, Kuznetsov M, Tsibulskiy I, Firsova A (2017) Hybrid laser-arc welding of the high-strength shipbuilding steels: equipment and technology. In: Physics Procedia. Elsevier B.V., pp 156–163
Batista GZ, Carvalho LP, Silva MS, Souza MP (2016) Girth welding of API 5L X70 and X80 sour service pipes. Weld J 95:363–370
Krishnan S, Kulkarni DV, De A (2016) Multipass pulsed current gas metal arc welding of Multipass pulsed current gas metal arc welding of P91 steel. Sci Technol Weld Joining 21:171–177. https://doi.org/10.1179/1362171815Y.0000000080
Trindade VB, Alves SMS, Cândido LC et al (2017) Microstructural and mechanical characterization across the cross section of multipass GMAW weld joints of an API5L X65Q. Soldagem Inspeção 22:217–228
Xu X, West GD, Siefert JD et al (2018) Microstructural characterization of the heat-affected zones in grade 92 steel welds : double-pass and multipass welds. Metall Mater Trans A 49:1211–1230. https://doi.org/10.1007/s11661-017-4446-6
Xie X, Zhong M, Zhao T, Wang C (2022) Unravelling microstructure evolution induced mechanical responses in weld metals of EH420 shipbuilding steel subjected to varied high heat inputs. Sci Technol Weld Joining 27:472–478. https://doi.org/10.1080/13621718.2022.2064649
Kolhe KP, Datta CK (2008) Prediction of microstructure and mechanical properties of multipass SAW. J Mater Process Technol 197:241–249
Alipooramirabad H, Ghomashchi R, Paradowska A, Reid M (2016) Residual stress- microstructure- mechanical property interrelationships in multipass HSLA steel welds. J Mater Process Tech 231:456–467. https://doi.org/10.1016/j.jmatprotec.2016.01.020
Murugan S, Kumar PV, Raj B, Bose MSC (1998) Temperature distribution during multipass welding of plates. Pressure Vessels Piping 75:891–905
Westin E (2016) Microstructure and properties of welds in the lean duplex stainless steel LDX 2101. Royal Institute of Technology, Stockholm
Shirali AA, Mills KC (1991) The effect of welding parameters on penetration in GTA welds. Weld J 347s–353s
Mcpherson NA, Galloway AM, Cater SR, Hambling SJ (2013) Friction stir welding of thin DH36 steel plate. Sci Technol Weld Joining 18:441–450. https://doi.org/10.1179/1362171813Y.0000000122
Bechetti DH, Semple JK, Zhang W, Fisher CR (2019) Temperature-dependent material property databases for marine steels-part 1: DH36. West Bethesda, Naval Surface Warfare Center
AWS (2004) AWS D1.1/D1.1M Structural welding code – steel. AWS, Miami
Paes LES, Ferreira HS, Pereira M et al (2021) Modeling layer geometry in directed energy deposition with laser for additive manufacturing. Surf Coat Technol 409:1–9. https://doi.org/10.1016/j.surfcoat.2021.126897
Truppel GH, Angerhausen M, Pipinikas A et al (2019) Stability analysis of the Cold Metal Transfer (CMT) brazing process for galvanized steel plates with ZnAl4 filler metal. Int J Adv Manuf Technol 103:2485–2494. https://doi.org/10.1007/s00170-019-03702-5
Souza D, Rossi ML, Keocheguerians F et al (2011) Influence of the welding parameter setting on the MIG/MAG process stability working with short-circuiting. Soldagem Inspeção 16:22–32
Silva RHG, Paes LES, Marques C et al (2019) Performing higher speeds with dynamic feeding gas tungsten arc welding (GTAW) for pipeline applications. J Braz Soc Mech Sci Eng 41:1–6. https://doi.org/10.1007/s40430-018-1529-2
Kou S (2003) Welding metallurgy. Wiley-Interscience, Hoboken
Moltasov AV, Dyman MM (2022) Stress concentration in butt welded joints made without the use of linings for the formation of the root of the seam. Weld Int 36:181–186. https://doi.org/10.1080/09507116.2022.2033446
Megahed MM, Attia MS (2015) Failure analysis of thermowell weldment cracking. Eng Fail Anal 50:51–61. https://doi.org/10.1016/j.engfailanal.2015.02.002
Eskin DG, Savran VI, Katgerman L (2005) Effects of melt temperature and casting speed on the structure and defect formation during direct-chill casting of an Al-Cu alloy. In: Metallurgical and Materials Transactions A: Physical Metallurgy and Materials Science. Minerals, Metals and Materials Society 36:1965–1976
Walale A, Singh Chauhan A, Satyanarayana A, Pradyumna R (2018) Analysis of shrinkage & warpage in ceramic injection molding of HPT vane leading edge core of a gas turbine casting. Mater Today: Proc 5:19471–19479
Scotti A, Ponomarev V. MIG/MAG Welding: better understanding, better performance. Artliber, São Paulo
Sudnik W, Radaj D, Erofeew W (1998) Computerized simulation of laser beam weld formation comprising joint gaps. J Phys D: Phys 31:3475–3480
E Silva RHG, Paes LEDS, Barbosa RC, et al (2018) Assessing the effects of solid wire electrode extension (Stick out) increase in MIG/MAG welding. J Brazilian Soc Mech Sci Eng 40:1-7. https://doi.org/10.1007/s40430-017-0948-9
Sartori F, Silva RHG, Dutra JC et al (2017) A comparative analysis of different versions of the MIG/MAG process modern variants for the root pass in orbital welding. Soldagem Inspeção 22:442–452. https://doi.org/10.1590/0104-9224/SI2204.04
Paes LES, Andrade JR, Lobato FS et al (2022) Sensitivity analysis and multi-objective optimization of tungsten inert gas (TIG) welding based on numerical simulation. Int J Adv Manuf Technol 122:783–797. https://doi.org/10.1007/s00170-022-09934-2
Silva RHG, Schwedersky MB, Rosa AF (2020) Evaluation of toptig technology applied to robotic orbital welding of 304L pipes. Int J Press Vessels Pip 188:1–8. https://doi.org/10.1016/j.ijpvp.2020.104229
Kumar K, Masanta M, Sahoo KS (2019) Microstructure evolution and metallurgical characteristic of bead-on-plate TIG welding of Ti-6Al-4V alloy. J Mater Process Technol 265:34–43. https://doi.org/10.1016/j.jmatprotec.2018.10.002
Rosenthal D (1946) The theory of moving sources and its application to metal treatments. Transactions of the ASME 859–866
Rikalin NN, Nikolaev AV (1971) Welding arc heat flow. Welding in the World 9:112–132
Marques PV, Modenesi PJ (2014) Some handy equations for welding. Soldagem Inspeção 19:91–102
ASTM (2017) E384–17 Standard test method for microidentation hardness of materials. ASTM, West Conshohocken. https://doi.org/10.1520/E0384-17
Tümer M, Yılmaz R (2016) Characterization of microstructure, chemical composition, and toughness of a multipass welded joint of austenitic stainless steel AISI316L. Int J Adv Manuf Technol 87:2567–2579. https://doi.org/10.1007/s00170-016-8614-4
Acknowledgements
The authors would like to acknowledge the technical support from Petrobras and Usiminas.
Funding
This work was supported by Petrobras, ANP, CAPES, CNPq, and FAPEMIG.
Author information
Authors and Affiliations
Contributions
João Marcos Souza Dias: conceptualization, methodology, formal analysis, data curation, investigation, writing—original draft, and writing—review and editing. Luiz Eduardo dos Santos Paes: supervision, conceptualization, methodology, formal analysis, investigation, writing—original draft, and writing—review and editing. Arthur Gustavo Moreira Santos: methodology, formal analysis, data curation, investigation, writing—original draft, and writing—review and editing. Tadeu Messias Donizete Borba: methodology, formal analysis, investigation, and writing—review and editing. Leonardo da Paixão Carvalho: funding acquisition, and writing—review and editing. Louriel Oliveira Vilarinho: project administration, resources, funding acquisition, formal snalysis, and writing—review and editing.
Corresponding author
Ethics declarations
Ethics approval
Not applicable.
Consent to participate
Not applicable.
Consent for publication
Not applicable.
Competing interests
The authors declare no competing interests.
Additional information
Publisher's Note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Rights and permissions
Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.
About this article
Cite this article
Dias, J.M.S., dos Santos Paes, L.E., Santos, A.G.M. et al. A methodology for multipass gas metal arc welding of shipbuilding steel plates with different thicknesses. Int J Adv Manuf Technol 127, 751–773 (2023). https://doi.org/10.1007/s00170-023-11575-y
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-023-11575-y