Welcome to Preheat Calculation Program

In this help file you will find information and background of this program.
The program itself is self explanatory. Nevertheless if you have some questions, problems or
suggestions, you can send me an e-mail, so I can improve this program
c.brak@it.fnt.hvu.nl
The subjects discussed in this file are:

Avoidance of hydrogen cracking in ferritic steels

Method to determine preheat temperature
Weld temperature cycle
Heat input
Carbon equivalent
Combined Thickness
Diffusible H Content
Transition thickness
Calculating preheating temperature according AWS D1.1
Weld shape factor
Grouping system for steels (groups 1-4)
Disclaimer
All information obtained from this program shall be considered as a guideline. Under
no circumstances, the author can be hold liable for any situation
resulting from using this program.
All rights reserved, including the right of reproduction in whole or in part in any form.

Avoidance of cracking in ferritic steels

The scope of this program is to give guidance for avoiding hydrogen cracking (cold cracking)
in unalloyed and low-alloyed ferritic steels.
Cold cracking in ferritic steels can occur when there are three combined factors:
Hydrogen generated by the welding process
A microstructure, susceptible to cracking
Residual stresses in the welded joint
In unalloyed en low alloyed steels, most of the hydrogen cracks are in the HAZ, however
cracks can also occur in the weld metal, especially in low alloyed steel.
To avoid this cracking you can minimize the combined contribution of the factors.
Weld metal hydrogen content
The principal source of hydrogen is the moisture in the consumables.
Basic stick electrodes normally generated less hydrogen than rutile or cellulosic types.
For cored wires, basic0, rutile- and metal cored wires, all can deposit weld metal with low
hydrogen. In sub arc welding, basic fluxes typically give a low hydrogen weld metal.
Parent metal composition
The hardenability of a material is usually expressed in terms of its carbon content or, when
other elements are taken into account its carbon equivalent (like CE).
The higher the carbon equivalent the greater the risk of hydrogen cracking.
Generally, steels with a CE < 0,4 are not susceptible to hydrogen cracking, as long as low
hydrogen welding consumables are used.

Parent material thickness

The parent material thickness influences the cooling rate, and therefore the hardness of the
HAZ, but also the amount of hydrogen retained in the weld and the residual stresses.

Stresses acting on the weld

The stresses generated across the welded joint will be greatly influenced by external
restraint, material thickness, joint geometry and fit up.
Areas of stress concentration are more likely to initiate a crack at the toe and root of the
weld.
Heat input
The heat input, together with the material thickness and the preheat temperature will
determine the thermal cycle and the resulting microstructure, the hardness and the remaining
hydrogen content.
A high heat input will reduce the hardness and hydrogen content, but increases the width of
the heat affected zone and decreases the Charpy toughness.
Preheating
When it is not possible to avoid cold cracks by lowering the hydrogen content, preheat is a
necessity.
In EN 1011-2 (2001) recommendations for the preheating temperature of ferritic steels are
given.

typical cold crack, due to high stresses in the root

(misalignment), as well as high hardness in the HAZ
(from: Bailey, Welding of ferritic steels)

Method to determine preheat temperature of ferritic steels

The methods, described in EN 1011-2:2001, are recommendations to avoid hydrogen
cracking (also known as cold cracking) in ferritic steels.
Many methods have been proposed for predicting preheat temperature to avoid hydrogen
cracking in non-alloyed, fine grained and low alloy steel weldments.
Examples are given in IIW documents.
Two of those methods are described in this standard:
Method A is based on extensive experience and data which is mainly, but not exclusively, for
carbon-manganese type steels.
Method B is based on experience and data which is mainly, but not exclusively for low alloy
high strength steels.
Beside these two methods there are tables which shall be used for creep resisting and low
temperature steels. (method C).
The recommendations apply only to normal fabrication restraint condition.
Higher restraint situations may need higher preheat temperature or other precautions to
prevent hydrogen cracking.
The methods A and B refer to welding of parent metal at temperatures above 0 C. When
welding is carried out below this temperature it is possible that special requirements will be
needed.
Otherwise lower preheat temperatures are possible, if this is supported by procedures.
To calculate the preheat temperature for method A or B you have to know
The hydrogen content of the consumable (HD)
The composition of the parent metal (CE of CET);
The plate thickness and joint geometry
The heat input
In this program, a method D is added, based on the standard AWS D1.1
To calculate the preheat temperature for this method you have to know
The hydrogen content of the consumable (HD)
The composition of the parent metal (Pcm);
The plate thickness
The restraint level

Weld temperature cycle

The calculation of the welding temperature cycle is based upon the simplified formulas of
Rykalin. The formulas used here for respectively 3- and 2-dimensional cooling of a bead on
plate are the following.

3-Dimensional:
The temperature as a function of time and place is given by

R2
Q
+ T0 .
T(t , R ) =
exp
2 t
4at
The cooling time from 800C to 500C then is

t 8 / 5 =

1
1

500 T0 800 T0

2-Dimensional:
The temperature as a function of time and place is given by

T(t , R ) =

R2
+ T0 .
exp
d 4 c t
4at
Q

The cooling time from 800C to 500C then is

t 8 / 5 =

Q2
1
1

2
2
4 cd
( 800 T0 ) 2
( 500 T0 )

Here R represents the distance to the center of a point (3D) or line (2D) shaped heat source,
, c en are the physical constants, d is the plate thickness and T 0 the preheat and
interpass temperature.

The relations for the cooling time t8/5 have been empirically adapted to steel by Uwer et. al.
(IIW doc. IX 1631-91), obtaining the formulas below. Here there is no need for the values of
, en c, which are often difficult to obtain. Furthermore the weld shape factor for three- or
two-dimensional heat flow (F3 respectively F2) has been introduced. This enables one to
calculate more situations than a bead on plate. These new formulas for t8/5 are described in
EN 1011-2.

3-Dimensional:

1
1
F3 .
t 8 / 5 = (6700 5 T0 ) Q

500

T
800

T
0
0

2-Dimensional:
t 8 / 5 = (4300 4, 3 T0 ) 10 5

Q2
2
d

1
1

( 500 T ) 2 ( 800 T ) 2 F2 .
0
0

The transition thickness dt is the plate thickness at which the transition from threedimensional to two-dimensional heat flow takes place. In that case F2 = F3 and both values
of t8/5 are equal, also:

dt =

( 4300 4,3 T0 ) 10 5

1
1

Q
+
6700 5 T0
500

T
800

0
0

Some values of the transition thickness are below:

Preheating temperature

Q.
0,5
1
1,5
2
2,5
3

20C.

100C.

200C.

10.4
14.7
18
20.7
23.2
25.4

11.1
15.7
19.2
22.2
24.8
27.1

12.3
17.4
21.3
24.6
27.5
30.1

Heat Input
The heat input is defined as

Q =k

UI
v

(kJ/mm)

where
k = relative thermal efficiency for the applicable process (see table);
U = arc voltage in V
I = welding current in mm/s
v = welding speed in mm/s;
Often the welding speed is given in cm/min.
In case of shielded metal arc welding; it may be difficult to use the above formula, so you
can use the data of the tables listed in EN 1011-2, in which the run out length is expressed in
terms of electrode diameter and heat input, by different efficiencies and a consumed
electrode length of 410 mm (when the electrode length is 450 mm).
Otherwise you can use the following formula:

D2 L F
Q=
rol

(kJ/mm)

where
D
= electrode diameter
L
= the consumed length of the electrode (mm). Normally this is the originally length
less 40 mm for the stub end
rol
= run out length
F
= factor in kJ/mm3 depending on the electrode efficiency
Efficiency approx. 95%
F = 0,0368
95% < efficiency 110%
F = 0,0408
110%< efficiency 130%
F = 0.0472
efficiency > 130%
F = 0,0608
This formula is normally used when the electrode length differs from 450 mm, but is also
used in this program

Carbon equivalent
Hardness and hardness penetration of steel (the hardenability) depends on the carbon
content, the alloying elements, the cooling rate and the grain size.
The effect of the alloying elements on the hardenability, and thus on the weldability of steel
is usually expressed in a carbon equivalent.
In a carbon equivalent formula the hardening effect of each alloying element is compared to
that of carbon.
Because it is an empirical formula, there are a number of carbon equivalents.
In this program there are three formulas used (CE, CET and Pcm).

1.

CE = C +

Mn Cr + Mo + V Ni + Cu
+
+
6
5
15

in %

This carbon equivalent is applicable in the range of 0,30 to 0,70 and may be used for
unalloyed, fine grained and low alloy steels within the following range of composition
(weight %)
Carbon
0,05 to 0,25 %
Silicium
0,8% max.
Manganese
1,7% max.
Chromium
0,9% max.
Copper
1,0% max.
Nickel
2,5% max.
Molybdenum 0,75% max.
Vanadium
0.20% max.
The formula is not suitable for boron-containing steels
When, of the elements in this formula, only carbon and manganese are stated on the
mill sheet, then 0,03 should be added to the calculated value. (This is corrected in the
program)

2.

CET = C +

Mn + Mo Cr + Cu Ni
+
+
10
20
40

in %

This carbon equivalent is applicable in the range of 0,30 to 0,70 and may be used for
unalloyed, fine grained and low alloy steels within the following range of composition
(weight %).
Carbon
0,05 to 0,32%
Silicium
0,8% max.
Manganese
0,5 to 1,9%
Chromium
1,5% max.
Copper
0.7% max.
Nickel
2,5% max.
Molybdenum 0,75% max.
Vanadium
0.18% max.
Niobium
0,06% max.
Titanium
0,12% max
Boron
0,005% max

The relationship is valid for structural steels with Rp02 < 1000 N/mm2 , and
CET = 0,2 to 0,5%
The CET of the parent material exceeds that of the weld metal by at least 0,03%
Otherwise the calculation of the preheat temperature has to be based on a CET of the
weld metal, increased by 0,03% (This can not be corrected by the program)

3.

Pcm = C +

Si Mn + Cr + Cu Ni Mo V
+
+
+
+
+ 5B
30
20
60 15 10

This carbon equivalent, according Ito and Bessyo, for low alloyed steels is valid
within the following composition(weight %):
C
0,07 to 0,22%
Mn
0,4 to 1,40 %
Si
0,6% max.
Ni
1,2% max
Cr
1,2% max
Mo
0,7% max
V
0,12% max
Cu
0,5% max.
B
0,005% max.
This formula is used, together with the hydrogen content, plate thickness and
restraint condition to calculate a preheating temperature from a table. (method D in
this program)

Combined thickness
The combined thickness (tg) is the sum of the parent metal thickness averaged over a
distance of 75 mm from the weld line.
Combined thickness is used to assess the heat sink of a joint for the purpose of determining
the cooling rate
In a fillet weld, the heat sink is greater than in a butt weld with the same thickness. The
preheating temperature is higher because of the greater combined thickness.

Tg = d1 + d 2 + d 3

Tg = D1 + D 2

Diffusible H Content
In fusion welding the hydrogen content, immediately after solidification, is very high, but most
of it diffuses out of the weld This diffusible hydrogen moves not only into the air, but also into
the HAZ.
The remaining diffusible hydrogen can be high resulting embrittlement.
It is necessary to know the amount of diffusible hydrogen.
Sources are not only the consumables, but also the plate surface and the atmosphere.
The hydrogen content is usually expressed in ml/100 g deposited weld metal, known as HD .
In setting up welding procedures, the hydrogen content in the weld metal as a result of
supported by the consumable used, is divided in classes: hydrogen scales for A to E
Diffusible hydrogen content
ml/100g of deposited metal
> 15
10 15
5 10
3 5
3

Hydrogen scale
A
B
C
D
E

Transition thickness
The transition thickness dt is the plate thickness at which the transition from threedimensional to two-dimensional heat flow takes place. In that case F2 = F3 and both values
of t8/5 are equal, also:

dt =

( 4300 4,3 T0 ) 10 5

1
1

Q
+
6700 5 T0
500 T0 800 T0

Some values of the transition thickness (in mm) are below:

Preheating temperature

Q.

20 C.

100 C.

200 C.

0,5

10.4

11.1

12.3

14.7

15.7

17.4

1,5

18

19.2

21.3

20.7

22.2

24.6

2,5

23.2

24.8

27.5

25.4

27.1

30.1

Weld shape factor

The influence of the weld shape on the cooling time has been investigated by Uwer et al. and
is used in the calculations given in EN 1011-2.
The shape factor for two dimensional is F2, for three dimensional F3

F2
Form of weld

F3

Two dimensional heat flow Three dimensional heat flow

1

0.9

0.9

0.9-0.67

0.67

0.45-0.67

0.67

Calculating preheating temperature according to AWS D1.1

Here the calculation of the preheating temperature from Pcm (method D) according to
awsD1.1 is explained
First calculate the Pcm value and determine the hydrogen content.
A Susceptibility Index Grouping A-G is then derived from a table, or by calculation.
Then a restraint condition and plate thickness is chosen.
In the second table the advised minimum preheating temperature derived at the crossing of
the Susceptibility Index and the plate thickness by the given restraint factor
To calculate the susceptibility index grouping there are two methods
1. AWS formula method
The formula susceptibility index = 12*Pcm +10log HD
Pcm is the calculated value and the following value of HD, given in ml/100 g of weld
metal: H1 = 5, H2 = 10, H3 =30
This gives values for the SI, which are converted to a susceptibility index grouping:
For greater convenience , the Susceptibility Index Groupings have been expressed in the table by
means of letters A through G, to cover the following range:
susceptibility index
<3
3,1 - 3,5
3,6 -4,0
4,1 - 4,5
4,6 -5,0
5,1 - 5,5
5,6 -7,0

susceptibility index grouping

A
B
C
D
E
F
G

Now table 2 gives the minimum preheat and interpass temperatures.

2. AWS table method
In this case a Susceptibility Index Grouping is found in the table 1.
It is possible that this method gives higher preheat temperatures because of the
big steps of the Pcm value in the table
Hydrogen
content HD
(ml/100 g)

PCM
<0,18

<0,23

<0,28

<0,33

<0.38

H1 5

H2 10

H3 =30

Table 1
Susceptibility Index Grouping A-G as a function of Pcm and HD.

Hydrogen level
H1
Extra-Low Hydrogen
The consumables give a diffusible hydrogen content of less than 5 ml/100 g deposited
weld metal

H2

H3

Low Hydrogen
The consumables give a diffusible hydrogen content of less than 10 ml/100 g
deposited weld metal
Hydrogen not controlled

Restraint
Low restraint
This level describes common fillet and groove welded joints in which a reasonable
freedom of movement of members exists.
Medium restraint
This level describes common fillet and groove welded joints in which, because of
members being already attached to structural work, a reduced freedom of movement
exists.
High restraint
This level describes welds in which there is almost no freedom of movement for
members joined (such as repair welds, especially in thick material).
Example, using the table.
Suppose PCM = 0,24 and HD = 7 ml, Then the susceptibility index is D (Pcm <0,28, H2)
Suppose a high restraint in 18 mm plate, then the advised preheating temperature is 105 C.
When using the formula the preheat temperature is 70 (susceptibility index is C).

Degree of restraint

mm
Low restraint

Medium restraint

High restraint

Advised minimum preheating temperature

Plate
thickness

Temperature in C
A

< 10

< 20

< 20

< 20

< 20

60

140

150

10-20

< 20

< 20

20

60

100

140

150

20-38

< 20

< 20

20

80

110

140

150

38-75

20

20

40

95

120

140

150

>75

20

20

40

95

120

140

150

< 10

< 20

< 20

< 20

< 20

70

140

160

10-20

< 20

< 20

20

80

115

145

160

20-38

< 20

20

75

110

140

150

160

38-75

20

80

110

130

150

150

160

>75

95

120

140

150

160

160

160

< 10

< 20

< 20

< 20

40

110

160

160

10-20

< 20

20

70

105

140

160

160

20-38

20

85

115

140

150

160

160

38-75

115

130

150

150

160

160

160

>75

115

130

150

150

160

160

160

Table 2
Advised minimum preheating temperature as a function of restraint, plate thickness and
Susceptibility Index (Pcm, HD).

Grouping system for steels (groups 1-4)

Method B is valid for steel of groups 1-4 according to CR ISO/ TR 15608
(Welding Guidelines for a metallic material grouping system , 1999)
Groups 1-4 are listed below
Group

Subgroup

Type of steel
2
Steels with a specified minimum yield strength ReH 460 N/mm and with
analysis in %:
C

0.25

Si
Mn

0.60
1.70

Mo*
S

0.70
0.045

0.045

Cu*
Ni*

0.40
0.5

Cr*
Nb

0.3**
0.05

V*

0.12

* A higher value is accepted provided that Cr + Mo + Ni+

Cu + V 0,75 %

** for castings 0,4

1.1

Ti
0.05
2
Steels with a specified minimum yield strength ReH 275 N/mm

1.2

Steels with a specified minimum yield strength 275 N/mm < ReH 360 N/mm

1.3

Normalized fine grain steels with a specified minimum yield strength ReH 360
2
N/mm

1.4

Steels with improved atmospheric corrosion resistance whose analysis may

exceed the requirements for the single elements as indicated under 1

2<

Thermomechanically treated fine grain steels an cast steels with a specified

2
minimum yield strength ReH 360 N/mm

2
2.1

Thermomechanically treated fine grain steels an cast steels with a specified

2
2
minimum yield strength 360 N/mm < ReH 460 N/mm

2.2

Thermomechanically treated fine grain steels an cast steels with a specified

2
minimum yield strength ReH > 460 N/mm
Quenched and tempered steels and precipitation hardened steels except
2
stainless steels with a specified minimum yield strength ReH >360 N/mm

3.1

Quenched and tempered steels and precipitation hardened steels except

2
stainless steels with a specified minimum yield strength 360 N/mm < ReH 690
2
N/mm

3.2

Quenched and tempered steels and precipitation hardened steels except

2
stainless steels with a specified minimum yield strength ReH >690 N/mm

3.3

Precipitation hardened steels except stainless steels

4.1

Low vanadium alloyed Cr-Mo-(Ni) steels with Mo 0,7 % and V 0,1%

Steels with Cr 0,3 % and Ni 0,7 %

4.2

Steels with Cr 0,7 % and Ni 1,5 %