Ferrite Determination in Weld Deposit

The austenitic chemically resistant Cr-Ni steels generally exhibit very good weldability. However, the special physical properties of these steels low thermal conductivity and high coefficient of thermal expansion must be taken into account when welding with regard to input of welding heat. Special significance is accorded to the type of primary solidification which subsequently has a crucial effect on hot cracking behaviour. For the practical welder the presence of specific ferrite fractions in the weld metal is an indirect indication of adequate resistance to hot cracking. Generally speaking ferrite in the weld metal is an advantage in welds that do not have the ability to expand freely, those with large weld cross-sections and if cracks have previously impaired their suitability for use. Ferrite increases the weld metal strength but has the opposite effect on corrosion resistance in certain media. Furthermore, it is also a disadvantage in lowtemperature applications and in the high-temperature range where transformation to the brittle -phase is possible. The ferrite content may be determined magnetically in addition to metallurgical estimation. The scale used is not absolute with the result that there will probably be differences in the results of measurements obtained from different laboratories (e.g. variations between 3.5 and 8.0 % in a specimen with approximately 5 % -ferrite). The measured values are usually shown in FN (ferrite numbers). The ferrite number may be equated with the percentage of ferrite up to approx. 10 FN. According to the Welding Research Council (WRC) it is not possible at present to determine the absolute ferrite content in austenitic-ferritic weld metal deposits. Variations resulting from differences in the welding and measuring conditions are to be anticipated even in specimens with pure weld metal deposit. The usual standardisation assumes a 2-sigma variation which means a variation of 2.2 FN for 8 FN. Greater variations are to be anticipated if the welding procedure permits higher absorption of nitrogen from the ambient air. High nitrogen absorption may lead to a weld metal with 8 FN falling to 0 FN in the ferrite content. Absorption of 0.10 % nitrogen typically reduces the ferrite content by 8 FN. In weld metal deposits dilution with the base metal leads to further ferrite reductions since base metals with the same composition usually have lower ferrite contents than the pure weld metal. In addition to measurement, it is also possible to calculate the ferrite content from the chemical composition of the pure weld metal. Various structural diagrams may be referred to for this purpose. They are the WRC-92 diagram, the Schaeffler diagram, the DeLong diagram and the Espy diagram. There may be very great variations between the results of the individual diagrams as they were prepared on the basis of series examinations for different groups of materials. The WRC-92 diagram provides a prediction of the ferrite content in FN. It is the most recent of the diagrams mentioned and exhibits better concurrence between the measured and the calculated ferrite contents than when using the DeLong diagram. It should be noted that the WRC-92 diagram does not take account of the silicon and manganese content which restricts the weldability of weld metals with high-silicon and high-manganese contents (over 8 %). Furthermore, its use should be restricted with nitrogen contents over 0.2 %. The Schaeffler diagram is the oldest of the diagrams referred to and until now has been widely used for calculation of the ferrite content. It has a broad scope of application but does not allow for the highly austenitising effect of nitrogen. The Espy diagram attempts to compensate for these weaknesses. Like the Schaeffler diagram it calculates the ferrite content in percent but also allows for manganese contents up to 15 % and nitrogen contents up to approximately 0.35 %. The DeLong diagram is a modification of the Schaeffler diagram which shows the ferrite content in ferrite numbers up to about 18 FN. The diagram allows for the nitrogen content in calculation and exhibits better concurrence between measurement and calculation than the Schaeffler diagram. It overlaps approximately with the WRC-92 diagram in its applicability.

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WRC-92-diagram for corrosion-resistant steel grades

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Espy-diagram for ferrite determination of corrosion-resistant steel grades

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DeLong-diagram for ferrite determination of corrosion-resistant steel grades

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If the nitrogen content is not known for determining the nickel equivalent then it is possible to assume a content of 0.06 % for TIG welding and manual electrode welding and a content of 0.08 % for gasshielded welding with solid wire electrodes. Using the WRC-92 diagram it is possible to predict the ferrite number within a range of 3 FN in approximately 90 % of the measurements assuming an accurate chemical composition.

Effect of -Ferrite
The following overview provides a summary of the advantages and disadvantages of -ferrite in the austenitic weld metal. In principle the statements apply to the steel material as well. Depending on the practical conditions of use the -ferrite is sometimes undesirable, in most cases beneficial and in some cases even necessary. The reasons for these requirements, which on first sight appear contradictory, are shown in the overview. The consequences of deviations are also highlighted. Reasons -ferrite fraction is undesirable requirement for non-magnetic weld metal special corrosion stresses use at very low temperatures use at high temperatures low -ferrite fraction is beneficial high resistance to hot cracking even in thick-walled components service temperatures between 100 and +400C no unusual chemical stresses high -ferrite content is necessary Consequences of too much or to little -ferrite FN=0 FN<0.5 FN<0.5 FN<0.5 magnetisation selective corrosion loss of ductility phase precipitation danger of hot crack formation loss of ductility phase precipitation selective corrosion reduced resistance to stress corrosion cracking reduced ductility properties reduced strength properties danger of hot cracks as a result of dilution FN<5 FN>15 FN>15 FN>15 FN<30 FN>75 FN<30 FN<15

FN=5-15

FN=30-75 resistance to stress corrosion cracking FN=30-75 increase of strength properties compensation for dilution in dissimilar FN=15-25 welds

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