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Heat input and metal transfer inuences on the weld geometry and
microstructure during underwater wet FCAW
Yong Zhang, Chuanbao Jia , Bo Zhao, Jiakun Hu, Chuansong Wu
Key Laboratory for Liquid-Solid Structural Evolution and Processing of Materials Ministry of Education, Shandong University, Jinan 250061, PR China
a r t i c l e
i n f o
Article history:
Received 14 March 2016
Received in revised form 27 June 2016
Accepted 13 July 2016
Available online 15 July 2016
Keywords:
Underwater wet welding
FCAW
Heat input
Weld geometry
Microstructure
Metal transfer
a b s t r a c t
FCAW experiments were conducted under water and in the air. Inuences of surrounding water on the
weld geometry and weld metal microstructure were investigated through analyzing the heat input and
metal transfer. The underwater welds have a lower proportion of acicular ferrite and pro-eutectoid ferrite.
Two metal transfer modes in wet FCAW were observed, i.e. repelled globular transfer and surface tension
based quasi-short-circuit transfer. The former one is the main cause of asymmetric and less uniform weld
appearance.
2016 Elsevier B.V. All rights reserved.
1. Introduction
Characterized by low cost, good adaptability, simple equipment,
the underwater wet welding has been widely applied. Particularly,
the underwater wet ux-cored arc welding (FCAW) has been developed for automatic and semi-automatic welding processes in deep
water. It has a great potential to be applied to repair or even to
construct oceanographic structures.
Liu et al. (1993) mentioned that the harsh underwater environment has signicant effect on the welding process, which
dramatically alters the cooling rate during welding and further
affects the nature of the weld-metal phase transformation. The
behavior of the welding arc, metal transfer and weld pool is
seriously inuenced by the special environment which results in
completely different metallurgical process with weld geometry and
micro-structure changes. Consequently the weld joint quality and
mechanical properties might be lowered.
Tsai and Masubuchi (1979) investigated the bubbles dynamics,
arc heat distribution, and heat input mechanism. They concluded
that a fast cooling of the weld zone during underwater welding
was the result of surface heat losses in weld area behind the arc.
Liu et al. (1993) found that the much lower cooling time t8/5 (from
800 C to 500 C) during underwater wet shielded metal arc welding
Corresponding author.
E-mail address: jiachuanbao@sdu.edu.cn (C. Jia).
http://dx.doi.org/10.1016/j.jmatprotec.2016.07.024
0924-0136/ 2016 Elsevier B.V. All rights reserved.
374
and ferrite side plate decreased, acicular ferrite increased accompanied with rened grain. Their ndings suggested that rapid cooling
rate can improve the impact toughness and tensile strength of
weld metal in local dry underwater welding. Gao et al. (2015a)
obtained martensitic dominated coarse grain heat affected zone in
wet shielded metal-arc welding. They improved the fatigue property by the combination of grinding and underwater ultrasonic
impact treatment. Garasic et al. (2009) carried out research to
determine optimum parameters that minimize the generation of
cold cracks in wet SMAW and self-shielding FCAW at three levels of
heat input. They concluded that FCAW provided better conditions
for reducing the risk of cold cracks occurrence.
Zhang et al. (2004) observed that direct wet underwater laser
welding produced a kind of plasma with strong ultraviolet emission and obtained smaller penetration when the water depth is
less than 3 millimeters. Cui et al. (2014) conducted friction taper
plug welding experiments in wet conditions. They found a large
volume of lath bainite, small amounts of acicular ferrite, polygonal ferrite, martensite in HAZ and the lower region of the weld
metal. Meanwhile, they observed mainly lath martensite in the
upper weld metal region.Yin et al. (2015) investigated the material
ow inuence on the weld formation and mechanical performance
in underwater friction taper plug welds. They indicated that the
microstructure of both weld zone and HAZ mainly consists of lath
bainite which results in an overmatching condition (i.e. specimen
breaks in the base material far away from the plug area and HAZ
during tensile testing) through the weld.
However, only few of the studies mentioned above analyzed
the physics of FCAW welding process in underwater environment,
especially metal transfer and arc behaviors. This partly owing to the
difculty to acquire visual images as evidence. Guo et al. (2015a)
acquired clear images of droplets transfer via X-ray photographing. They (Guo et al., 2016) also analyzed the effect of boric acid
concentration on the arc stability but the bubbles and welding
arc could hardly be recognized from the images they provided.
Actually, the generation and burst of bubbles are signicant factors to determine the welding arc stability and metal transfer. Jia
et al. (2014) obtained clear images of droplets and welding arc
during underwater FCAW. They found a typical repelled globular
droplet transfer mode and a wandering compressed welding arc
behavior.
Thus, an imaging system was developed to acquire the images
of bubbles, arc and droplets at the same time (Fig. 1). This paper is
Table 1
Chemical composition of Q235 carbon steel mass%.
C
Mn
Si
Fe
0.17
0.350.65
0.28
0.038
0.038
Balance
Parameters
Air 1
Water 1
Air 2
Water 2
30
6.32
240
Air
30
6.32
240
Water
31
6.32
240
Air
31
6.32
240
Water
Table 2
Experimental parameters.
375
of 2 N and loading time of 10 s. Microhardness tests were conducted in longitudinal direction i.e. parallel to the base material
surface.
376
Table 3
Bead geometry parameters.
A
B
Air 1
Water 1
Air 2
Water 2
Table 4
The effective power of the arc and heat input.
W (mm)
P (mm)
R (mm)
13.8
11.8
15.8
10.2
2.1
2.7
1.8
2.6
3.5
3.9
3.2
4.2
A
B
Air 1
Water 1
Air 2
Water 2
5265
4907
5407
4915
1052
980
1080
982
are 35% smaller than air welds. The penetration and reinforcement
differences are 44% and 31%.
The compression and asymmetry of underwater weld beads can
be obviously observed (Fig. 4). Pore defects are discovered both at
the bottom and the top part of the weld metal. The shapes of two
underwater welds HAZ are like a crescent, the widths of which
increase with penetration. This phenomenon can well reect the
much different cooling process in the two directions (i.e. through
the substrate thickness and across the weld seam width).
First, it implies that the arc burning atmosphere (bubbles) and
the water environment cause rapid cooling on the substrate surface.
Second, although the high temperature gradient exist between the
weld pool and the backside surface of the base metal, the thick plate
provides bigger volume for the thermal conduction in the direction
of thickness.
3.2. Microstructure analysis
Grains appear with bigger sizes from the base metal to the
heat affected zone (Fig. 5a). The microstructure of weld zone
(Fig. 5b) is uniform. The pro-eutectoid ferrite (PF) distributes on
the boundary of the columnar grain and ingrown carbon-free bainite grows in parallel to the prior austenite grain boundary. The
other microstructures within the grain are acicular ferrite (AF) plus
a little granular bainite.
Grains of overheated zone are coarse with block or strip PF scattered on the boundary of the coarse prior austenite grain (Fig. 5).
Plenty of side plate ferrite (SPF), a little granular bainite plus mas-
377
Fig. 5. Microstructure of air welds (a shows the whole weld bead; b shows the weld zone; c and d show the HAZ).
Fig. 6. Microstructure of underwater welds (a shows the whole weld bead; b and c show the weld zone and d shows the HAZ).
378
higher carbon content, the underwater weld metal has lower hardness than air welds. Similarly a lower proportion of PF which has
lower carbon content leads to higher microhardness in HAZ.
Different welding thermal processes caused by different surroundings might be responsible for the differences of weld
geometry and microstructure between air and underwater specimens. The effective power and the heat input are calculated to
analyze the effect of thermal processes. The equations are given
below.
1
P=
T
T
u(t) i (t) dt
(1),
PT
P
Q =
=
S
V
Fig. 7. Microhardness test result.
ter together and its proportion is much lower than in air specimens
while the PF in HAZ is also lower.
Different cooling rate could explain the microstructure differences. For underwater specimens HAZ, after the nucleation of PF
at the boundary of the austenite, the rapid cooling rate caused by
the water environment does not provide sufcient time for PF to
grow up. The amount of PF decreases a lot. As for lath martensite, lower alloying content of base metal (i.e. Q235) plus the rapid
cooling rate makes it difcult for undercooled austenite to retain
stable, therefore most of them will transform to lath martensite.
The microhardness value of base material is about 150 HV (Fig. 7).
At the 3 mm test line, the hardness have a sharp increase for both
specimens. It is concluded that due to a lower proportion of AF with
(2),
379
ture of the weld zone is less uniform and the HAZ contains less
PF(Fig. 8).
3.3. Metal transfer process
As being well-know, the metal transfer modes have signicant
effect on the formation of weld bead. Droplets transfer modes were
investigated to reveal the water surroundings effect on droplets
transfer process. Though, two sets of experiments (Groups A and
380
B) were conducted with different parameters, there are no signicant changes in metal transfer modes for both underwater and air
welding conditions. The group A was elected to typically discuss
the metal transfer differences between air and underwater FCAW.
Fig. 9 shows a typical cycle of a droplets formation and detachment from the wire tip during FCAW in air. A newly formed droplet
repelled from the arc center by the upward forces and some spatters are clearly observed ying off the welding area at 1.104 s. The
droplet is not of a regular spherical form due to a complex action
(3),
381
382
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