ISSN (Online) 2456-1290

International Journal of Engineering Research in Mechanical and Civil Engineering

(IJERMCE)
Vol 3, Issue 2,February 2018

Effect of FCAW & SAW Welding Process on the

Tensile, Impact and All Weld Properties of
Multipass Butt Welded Joints of High Carbon Steel
[1]
Navdeep Singh, [2] Jagtar Singh
[1]
Asst. Professor mechanical department .KCCIET ,Nawashahar (PB),
[2]
Manager Cheema Boilers Ltd.Kurali (PB)

Abstract: -- Flux cored arc welding and submerged arc welding are widely known as high quality, high deposition rate processes,
commonly used to join the plates of higher thickness in pressure vessel components. These processes provide a pure and cleaner,
high volume weldment that has a relatively high material deposition than other traditional welding methods. In this research work
high carbon steel plate SA 516 Gr. 70 was used to evaluate the best welding process for heavy thickness and good impact & tensile
properties of HAZ and weld metal. Two test coupons were welded with FCAW and SAW welding separately. After welding the
coupons were subjected to radiography testing and destructive testing such as tensile and impact test. There was significant
difference found between the results and it was concluded that SAW welding is the best method which enhance the tensile and
impact properties of butt weld joints of high carbon steel.

Keywords — FCAW, HAZ, Impact Strength,SAW.

under all the welding conditions. Impact of initial metal

I. INTRODUCTION
preheat on mechanical properties diminishes with increased
temperature in the heat affected zone. Microstructures of
Boiler and pressure vessel plate SA-516 grade 70 have been
preheated specimens differ from the no preheat specimen,
widely used in boilers and pressure vessels, boats, bridges,
showing traces of precipitation of bainite [4]. Studied that
wind turbine towers, oil and gas pipelines. Boiler and
increased in heat input the percentage of graphitic phase was
pressure vessel plate are the most important structural
slightly decreased whereas the percentage of ferrite sharply
materials for construction because of their high strength and
increased and finally the ferrite structures were observed. The
toughness and relatively low cost. Welding is the most
proportionate value of transverse value were observed The
reliable, efficient and practical metal joining process which is
influence of the submerged arc welding (SAW) process
widely used in industries such as nuclear, aerospace,
parameter on the transverse tensile, toughness and all weld
automobile, transportation, and off-shore[1, 2]. Submerged
test of high carbon steel of butt welded joints. The Toughness
arc welding (SAW) and flux cored arc welding (FCAW) are
was found higher at high welding speed compared to that at
the welding process which produce high quality, high
low welding speed for a given welding current [6]. In
deposition rate provided a purer and high volume weldment.
multilayer welds partial or complete re-crystallization of
Use of this technology has huge economic and social
weld metal occurs depending upon the heat input, bead
implications in the national perspective. It is observed that a
dimensions and time interval between successive deposition
refined microstructure of HAZ imparts largely the intended
with the exception of final layer the structure is refined with
properties of the welded joints [ 1, 3] . In submerged arc
corresponding improvement in ductility and toughness [7,8].
welding (SAW) and flux cored arc welding (FCAW) welding
With a view to achieving the above mentioned aim design of
process, the parameters are current, arc voltage, travel speed
experiment based on to evaluate the best welding process to
and nozzle to plate distance. They affect the microstructure
enhance the tensile and impact value of heavy thickness butt
and mechanical properties of the welded joints as well as
welded joints in carbon steel on as well as reduce the cost,
welding process also affects the mechanical properties of the
time and obtain the welding data for production weld with
welded joints they all affect the microstructure and
study of tensile properties and impact properties of weld
mechanical property of the welded joints. Mechanical
metal and heat affected zone in multipass, submerged arc
properties such as tensile strength, toughness and all weld in
welding (SAW) and flux cored arc welding (FCAW) are the
arc welded mild steel plates were found to be higher in the
welding process. This paper presents the experimental results
submerged arc welding(SAW) reduce to the base metal value
of the affect of the welding process on the tensile, impact and

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 ISSN (Online) 2456-1290

International Journal of Engineering Research in Mechanical and Civil Engineering

(IJERMCE)
Vol 3, Issue 2, February 2018
all weld metal properties of the boiler and pressure vessel properties of the SAW wire and saw flux is shown in table 3
plates. and table no 4.
Table 3 Chemical Compositions for solid SAW wire
II. EXPERIMENTATION
AWS Chemical Composition by weight
Class
The material of plate used for present work is SA 516 Gr. 70
used for making boiler and pressure vessel plate. The C Mn Si S P
EH-14
chemical composition and mechanical properties of the plate 0.10-0.20 1.70-2.20 0.10 0.030 0.030
material is shown in table 1 and table no 2. Table 4 Mechanical Properties for solid SAW wire & Flux
Tensile Min.Yield
AWS Elongation Min. Average
Table 1Chemical Compositions for Base Metal Strength Strength
Class (%) Energy Level
Material Chemical Composition by weight (psi) (psi)
EH-14+ 70000-
C Mn. P S Si 58000 22 20 ft-lbf
Carbon F7A4 95000
The interpass temperature considered for experimental work
Steel 0.30 0.79-1.30 0.035 0.035 0.13-0.45 is 150° C as per ASME section IX 5.17. After completion of
one side of welding the SMAW deposited metal is gouged
Table 2 Mechanical Properties for Base Metal and removed from the joint and then subsequently filled by
SAW welding. Second specimen is made by using multipass
FCAW welding using ADOR Champ multi 400 with filler
wire E71T-1. During making of this specimen the interpass
temperature is again considered 150 °C as per ASME section
IX 5.17. the chemical composition and mechanical properties
of the filler wire and saw flux is shown in table 3 and table
no 4 The second side of the plate is welded and vee groove is
Total four plates of size 500 x 150 x 63 mm were used for
filled completely. The duration of welding was noted down
two test pieces with double vee groove joint on each test
for each passes. After welding both test coupon was subject
pieces, prepared with the help of shaper machine as shown in
to stress relieving process up to 620ºc to remove the internal
figure no-1.
stress and fine the grains of weld metal and heat affected
zones. After stress reliving both test coupons were tested
with radiography to check the internal defect of weldment
and there was no defect was found. The specimens for tensile
strength are impact machined by using lathe machine and
facing machine. Tensile and impact tests coupons were
prepared also to evaluate the tensile and toughness properties
of the joint made by flux arc welding (FCAW) and
submerged arc welding (SAW)welding. Second specimen is
made by using multipass FCAW welding using Ador Champ
multi 400 with filler wire E71T-1. The chemical composition
Before the welding start, preheat the both test coupons with & mechanical properties of the FCAW wire is given in table
heating burner up to 100ºc and measured by thermal chalk to 5 & 6 respectively.
reduce the temperature difference as result to avoid cracks
and distortion in butt welded joints and then the first test Table 5 Chemical Compositions for FCAW Electrode
piece was welded by root run was done by using SMAW
using the electrode E-7018-1. Then the subsequent filling of AWS Chemical Composition by weight
weld metal is done by using automatic submerged arc Class
welding (SAW) machine by using EH-14 saw wire with 4mm C Mn Si S P
dia. and granular saw flux having grade F7A4 is used for E-71T-1
0.12 1.75 0.90 0.03 0.03
welding. The chemical composition and mechanical

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 ISSN (Online) 2456-1290

International Journal of Engineering Research in Mechanical and Civil Engineering

(IJERMCE)
Vol 3, Issue 2, February 2018
is most important in the case of multipass welding to control
Table 6 Mechanical Properties for FCAW Electrode the distortion.
Tensile Min. Yield Min.
AWS Min. Impact
Strength Strength Elongation
Class Energy
(ksi) (ksi) (%)
20 ft-lbf
E71T-1 70- 95 58 22
at 0°C
During making of this specimen the interpass temperature is
again considered 150 °C AS PER ASME SECTION IX 5.17.
The second side of the plate is welded and vee groove is
filled completely. The specimen for tensile strength is
machined by using lathe machine for conducting tensile test.
Specimens of impact tests are also prepared to evaluate the
toughness properties of the joint made by both flux cored arc
welding (FCAW) and submerged arc welding (SAW).

III .METHODLOGY

The experiments carried out in following steps: Fig. 2. Different groove designs shown schematically (all
dimensions in mm).; (A1) Double V butt joint for flux cored
A. Preparation of base plate arc welding process (B1) Welding sequence for Flux cored
B. Select the limit of the process parameters arc welding (C1) Cross sectional view of butt welded joint of
C. Welding the plates using FCAW and SAW. flux cored arc welding(FCAW) (A2) Double V butt joint for
D. Preparing the specimens for tensile and impact test. submerged arc welding process(SAW) (B2) Welding
E. Conducting the tensile and impact test on the sequence for submerged arc welding process (C1) Cross
specimen made from welded plate. sectional view of butt welded joint of submerged arc
F. Comparing the test results of specimens of FCAW welding process(SAW)
and SAW.
G. Optimum welding process and parameter. Table 8 Welding process parameter for SAW
Welding Parameters Parameter Units Lower Higher
The selected process parameters were arc voltage (V), limits limits
welding current(I), welding speed (S), and nozzle to plate Welding Amp 590 610
distance (NTPD).Welding was started as per the selection of Current
welding parameters depending on the diameter of the wire Arc Voltage Volts 31 35
and the maximum and minimum range was selected upon by Nozzle to plate mm 20 25
inspecting the bead for smooth appearance without any distance
visible defects and heat input tolerate by root pass. The upper
limit and lower limit of the current, voltage and nozzle to IV. RESULTS AND DISCUSSION
plate distance with their units and notations are given in table
7 & 8 respectively. A. Macrostructure
Macro test or macro examination is performed on the cross
Table 7 welding process parameter for FCAW section, an independent test to evaluate subsurface conditions
Parameter Units Lower limits Higher limits or as a subsequent step of another test to reveal the effects on
Welding Amp 170 250 the subsurface. Generally macro test. Several semi-finished
Current and samples of finished products are subjected to macro test
Arc Voltage Volts 20 27 to reveal internal discontinuities such as impurities,
Nozzle to plate mm 15 20 inclusions in rolled products or grain flow in forgings after
distance exposure to appropriate preparation and exposure to
The sequence of test procedure, welding sequence and chemicals or heat. Macro test is also performed on the test
welded test piece are shown in figure no-2, welding sequence specimens as shown is figure figure-2-C1 and C2

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 ISSN (Online) 2456-1290

International Journal of Engineering Research in Mechanical and Civil Engineering

(IJERMCE)
Vol 3, Issue 2, February 2018
respectively. The most common test is weld cross section
examination to reveal internal discontinuities, weld profile,
weld passes and sequence, extent of penetration and the
quality of weld. It has been observed from the macro test that
the penetration of the submerged arc welding (SAW) test
coupon was observed wide and as compare to flux cored arc
welding (FCAW) test coupon on other hand the penetration
of flux cored arc welding (FCAW) test coupon appears
narrow different zones of the heat affected zone are Figure 3Transverse tensile butt weld tests results
encountered as shown in Fig.2-C1and C2, which indicates II. Toughness
that the patterns in which the welding heat dissipates from Charpy impact testing was conducted -40ºc temperature total
thirty test sample was taken fifteen form each test pieces
the joints, largely following the conductive mode of heat
these sample were taken from different location from Weld
transfer through the HAZ, lead to micro- structural changes
metal ,heated affected zone and base metal the teat was
in the HAZ. It is observed that adjacent to the fusion
performed on toughness testing machine of the specimens
boundary lies the course grained heat affected zone, also
called under bead zone, which undergoes austenitic prepared with V-notch locations in the main weld pass as
well as the root pass of each joint and the comparison results
transformation range of high temperature thus promoting the
obtained are shown in figure 4 and 5 respectively Toughness
grain growth or recrystallization in this region. A similar
of the carbon steel was checked and increased after the
observation is reported Another important region of the heat
PWHT- Post Weld Heat Treatment.The impact strength has
affected zone as found in these weldment is the region that
been improved by the heat treatment the residual stress is
possesses minimum microhardness, and this zone has been
decreased, the impact value of the welded joint is depends on
named as sub-critical heat affected zone (SCHAZ) .
the heat input given during the welding if the heat input
increase the impact value decrease .heat input is depends
B. Mechanical properties
upon the current, voltage and speed of welding the grain
I. Tensile properties
structure also refined after post weld heat treatment.
Transverse tensile testing was carried out on all the joints to
evaluate for properties such as yield strength, ultimate
strength, percentage elongation, percentage reduction in area
and joint efficiency, and the results of the same are presented
in figure-3 along with the comparison study of both welding
joints welded with flux cored arc welding(FCAW)and
submerged arc welding(SAW) process Total two test coupon
was tested having one test piece of each process .During
transverse tensile testing fracture took place in the base metal
region indicating that the strength of the welded joint is more
than the base metal. It is observed from figure-3 that the
tensile strength of submerged arc welded sample has highest
when compared to flux cored arc welding sample. The
increases in tensile strength is due to high temperature of
welding and good dilution and after heat treatment there is no
internal stress are remaining in the material, so molecule
cohesion increases, refine structure of the material and it Figure 4 Charpy Impact test results of weld Zone
increases the tensile strength of the material. This stresses are
relieved leading to enhance the tensile strength of material.

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 ISSN (Online) 2456-1290

International Journal of Engineering Research in Mechanical and Civil Engineering

(IJERMCE)
Vol 3, Issue 2, February 2018

It is observed from graph, that the yield strength and ultimate

tensile strength of flux cored arc welding found more as
submerged arc welding as result flux cored weldment show
more ultimate strength as compare to submerged arc welding
process.

Figure 5 Charpy Impact test results of Heat affected Zone

Figure no 7 All Weld Metal test results (Ductility)

It has been observed from graph, that the Impact value of
SAW is more as compare to FCAW welding in case of HAZ- It is observed from graph, that the percentage elongation and
Heat affected zone, WZ-Weld zone respectively as shown in reduction in area found more in submerged arc welding as
figure4 and figure 5 compare to flux cored arc welding as result saw welding
shows more ductility in weld metal.
III. All Weld Metal tensile test
The purpose of such testing is to test welding filler metal V .CONCLUSION
mechanical properties for their suitability for the job
concerned and the quality of deposited metal in welded joint. The following conclusions have been drawn based upon the
In the case of SAW to check the mechanical property of weld findings of the present work:
metal with combination of saw wire and saw flux .Total two
test coupon was tested having one test piece of each process. (1) Relatively study of macrostructure of flux cored are
This sample was taken from the pure weld metal to check the welding and submerged arc welding, SAW welded joint
ultimate tensile strength (UTM), yield strength, percentage show deep penetration into the base metal
elongation, and percentage reduction in area of weld metal
only and was performed on universal tensile testing machine. (2) It is observed from the transverse tensile test that the
The comparison study of the both test sample is give in the tensile strength of submerged arc welded sample has highest
figure no -6 and figure no-7 respectively. as compared to flux cored arc welding sample as result the
joint is more efficient as compare to flux cored arc welding

(3) In the case of multipass welding the charpy impact

value observed more in the case of submerged arc welding as
compare to flux cored arc welding

(4) Corresponding to different welding process,

submerged arc welding joints show, highest overall Charpy
impact toughness (including weld zone heat affected zone)

(5) It is observed from the study of all weld metal, that

the percentage elongation and reduction in area found more
in submerged arc welding as compare to flux cored arc
Figure no 6 All Weld Metal test results welding as result saw welding shows more ductility in weld

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Vol 3, Issue 2, February 2018
metal as significantly more efficient welded joint formed by
submerged arc welding. [11] ASME (American Society Of Mechanical Engineering
Section – IX, 2013).

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