BARC Newsletter

Post-Weld Heat Treatment Case Studies

Khaleel Ahmed and J. Krishnan
Centre for Design and Manufacture
Bhabha Atomic Research Centre

Introduction

EAT TREATMENT IS AN IMPORTANT

operation in the final fabrication process
of many engineering components. Only
by heat treatment it is possible to impart high
mechanical properties to steel parts and tools for
sophisticated applications.
Heat treatment is considered to be very
important tool of the metallurgist by which he
can alter the properties of steel easily. The
same steel can have a very wide range of
mechanical properties if subjected to different
heat treatment.
Today when science and
technology are advancing very rapidly in pursuit
of higher and higher properties in materials,
heat treatment plays a very important role.

Principles of Heat Treatment

Heat treatment may be defined as a sequence of
heating and cooling designed to get the desired
combination of properties in the steel. The
changes in the properties of steel after heat
treatment are due to the phase transformations
and structural changes that occur during the
heat treatment. The factors, which determine
and control these structural changes, are called
the principles of heat treatment. The important
principles of heat treatment are as follows:
1.
2.
3.

When combined with normal load stresses these

may exceed the design stresses. The removal of
residual stresses takes place due to the fact that
the thermal energy received by the metal allows
for grain boundary sliding and removal of
metallurgical defects like dislocations, vacancies
and slip planes. A most important aspect of Post
Weld Heat treatment is the prevention of Brittle
Fracture. Post weld heat treatment softens the
hardened zones and makes the machining easy.
Removal of residual stresses becomes necessary
where dimensional stability is required. The
heat treatment consists of the stress-relief,
annealing or solution annealing depending upon
the requirements.

Thermal Stress Relief

Residual stresses resulting from welding are
reduced by a post weld thermal stress relief heat
treatment. The residual stress remaining in a
material after stress relief treatment will depend
on rate of cooling.
The percentage relief of internal stress is
independent of steel type, composition or yield
strength. The effect of varying time and temper
are shown in the graph below:

Phase transformations during heating.

Effect of cooling rate on structural changes
during cooling.
Effect of carbon content and alloying
elements.

Post Weld Heat Treatment

High level residual stresses can occur in
weldment due to restraint by the parent metal
during weld solidification. The stresses may be
as high as the yield strength of material itself.

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Stress relieving temperature 0C

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The temperature reached during the stress relief
treatment has a far greater effect in relieving
stresses than the length of time the specimen is
held at that temp. The closer the temperature is
to the critical or re-crystallization temperature,
the more effective it is in the removal of residual
stresses.
When a thermal stress relief treatment is
employed to reduce residual stresses, other
important properties must be taken into
account.
The micro-structure, tensile and
impact strength are among the properties
affected by the Stress relief treatment.
A post weld heat treatment at 1040 C 1090
C, spheroidizes the ferrite present in type 347 SS
weldments, which effectively reduces sigma
formation. This treatment also takes some of
the ferrite into solution. An intermediate hold at
595 C is recommended for those weldments to
relieve residual stresses and to reduce the
susecptibity to cracking during post weld heat
treatment.
The heat affected zone (HAZ) in the vicinity of
welded joints are aided considerably by post
weld heat treatments. The properties of those
zones are improved by the reduction of residual
stresses together with the metallurgical changes
brought about by the H.T. If any dissolved
hydrogen is present it is given an aided
opportunity to escape.
The necessity for post heating increases with
higher carbon content, increased alloy content
and cross-sectional thickness of the part.
The temperatures recommended for stress
relieving low carbon steels are 595 C to 675 C.
One hour per inch of thickness is the basis used
to determine the length of time at the desired
temperature.
Larger periods of time are
required at 595 C to achieve the same degree
of stress relief as of 675 C.
Thermal stress relief can be conducted in any
furnace suitable for heating of the entire
weldment. Same time only a portion of the
weldment is heated if the structure is uniform in
cross-section and the unheated ends are free to

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move and do not restrict the expansion of the

heated part.
The heating and cooling must be gradual and at
a rate that will ensure approx. uniform
temperature across wall thickness. In general,
the greater the difference between max. and
min. thickness, the slower should be the rate of
temperature change.
Because of variable
factors such as strength characteristics of the
metal and geometry of the parts, it is not
possible to recommend formula for max. heating
or cooling rates. The following rules can be
used as an approx. guide for simple cases:
Case 1
Where the ratio of max. to min. thickness does
not exceed 4 to 1 heating or cooling rate should
not exceed 200 C/hr divided by the max.
thickness in inches at the weld.
Case 2
Where the ratio of maximum to minimum
thickness exceeds 4 to 1, heating or cooling
rates should not exceed
1
2
3
4
5
6

inch
inch
inch
inch
inch
inch

thick
thick
thick
thick
thick
thick

95
65
38
27
16
10

C/hr
C/hr
C/hr
C/hr
C/hr
C/hr

For complicated structures with members of

widely varying thickness the safest procedure is
to attach thermo-couples to all critical sections
and not permit more than 42C difference
between any two sections
In this paper six case studies of post weld heat
treatment for nuclear components have been
discussed.

Case Studies
12 NB Carbon Steel Pipe: 12 NB Carbon
Steel pipe have been welded by GTAW required
for Kaiga Atomic Power Project.
After
joining/welding, thermal stress is developed, to
reduce their thermal stresses post weld heat
treatment done.

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The welded pipe, after cleaning the joint has
been loaded in a localised set up furnace and
pre-heated to 300 C and then Temp. raised to
625C to 650 C at the rate of 150 C/hr (max.)
Soaking time: 45 minutes
Rate of cooling 150 /hr cool up to 300 C and
then still air cool. The treatment has been done
to achieve full strength.

12 NB C.S. Elbow: 12 NB C.S. Elbows

welded by GTAW required for Kaiga Atomic
Power Project. After welding post weld heat
treatment have been done.

arm magnets) out of Aluminium Alloy 6061 T6.

Each of these structures consists of 4 Front and
4 Rear chambers and each of these chambers
is made up of a pair of Al. Alloy Frames.
To develop the manufacturing procedure, one
North side Front chamber was built on prototype
basis, adopting weldment route for Aluminimum
structures, welded structure calls for post-weld
heat treatment (Stress relief) for which a special
furnace, of triangular shape with 2.5 m long
slides was built. The prototype chamber was
inspected and approved by Los Alamos National
Labs, USA at CDM.

The job loaded in BHF and pre-heated to 300 C

Temp. raised to 625 C to 650 C at the rate of
150/hr
Soaking time: 45 minutes
Rate of cooling 150 C/hr cooled up to 300 C
then still air cool.
The purpose of the treatment was to achieve full
strength.

Phenix aluminium frame

Solution annealing of the frame carried out (Fr.

Stress relieving to effect solid solution of alloying
constituents (e.g. Mg, Cr, and Si) and to improve
mechanical properties of Aluminium alloy.
Material: Al 6061 (Al, 1.0 Mg, 0.25% Cu, 0.6%
Si, 0.20% Cr)
Soaked for 2 hrs at 55 C 5 C and then water
quenched.
Aging (precipitation hardening) (to be done
within 18 Hrs of solution treatment) at temp.
170 C 5 C
Soaked for 12 hrs and still air-cooled.
(Hardness obtained 100 120 BHN).
During this process precipitation of soluble
constituents (e.g. Mg, Cr, Si) from Super
saturated solid solution takes place. As this
precipitation progress the strength of material
increases.
12" NB C.S. elbow

Detector Frames for Station II

PHENIX
CDM was assigned to develop and manufacture
North and South hanging structures (for N & S

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Stress Relieving of SS 316 Pipe

after Stellite Deposition
Pipe loaded in furnace at 300C pre heat temp.
of and heated to 900C (rate 150C/hr) soaked

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for 30 minutes at 900C and allowed to cool at
rate of 150C/hr up to 400C and then furnace
cool. This operation was carried out to obtain
full hardness and uniform stresses.

consists of a disc made of 17-4 PH heat treated

to H 1100 condition to which is bonded an
annular disc of nickel, about 1.5 mm thick by
electro deposition from an aqueous bath.
Sealing is accomplished by deflecting the sealing
disc on the face of the end fitting of the coolant
channel and then locking the deflection. Nickel
serves as a sealing gasket. For efficient sealing
the nickel should be soft (hardness not more
than 170 HV) and the bond between nickel and
SS should be adequately strong.

Seal Disc
PFBR sleeve

Post Weld Heat treatment of

Aluminium Servo-Drive Housing
Material: Al LM-14
Composition: Al, Cu: 3.5% to 4.5%
Si: 0.7 %
Mg 1.2 to 1.8%
Cr < 0.21%
Solution Heat treatment
Temp. 515 C 5 C for 6 hrs and then Air blast
quenching
Aging (Precipitation Hardening)
Temp: 232 C 5 C for 1 to 3 hrs
And cool in still air
T.S: 215 to 280 Mpa
Hardness: 100 BHN (approx.)
This has been done for stress relieving of the
housing.

Post Weld Heat Treatment of SS

430 (Martensitic) + SS 304
(Austenitic) Weld
Job heated at the rate of 100 C/hr up to 700 C
20 C and soaked at this temp. for 5 hrs.
Furnace cool at rate of 30 C/hr up to 595 C
and then cool in still air. This operation carried
out to achieve impact properties.

Seal Disc
Seal disc is used to prevent escape of heavy
water from the coolant channel. The seal disc

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SS 17-4PH
Disc

Nickel
Ring

Seal disc

The seal disc is heat treated after Nickel

diffusion bonding as per procedure stipulated
below.
Seal disc are given solution treatment and
precipitation hardening. Seal disc are heated in
furnace to 1050C at the rate of 25-50 C/hr and
held for 30 minutes. Thermo-couples are fitted
at the ends and the middle zone. The job then
quenched in oil at room temp. 30 C.
Subsequently quenched in cold water at 5-10 C.
Then precipitation hardening at H1075 (570 to
585 C) carried out.
This has been done to achieve appropriate
conditions prior to diffusion bonding.

Conclusion
Post weld heat treatment is necessary to satisfy
one or more end requirements. Every case has
to be independently treated.

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This paper was adjudged as the Best Paper presented at the International Symposium
on Thermal Spray held at Mumbai during May 2-4, 2002
About the author
Mr Khaleel Ahmed, F.I.E, is working as Engineer-in-charge of Surface Treatment and FHT
group of Manufacturing Section of Centre for Design and Manufacture, BARC. He is a B.E
(Mechanical) from College of Engineering, Guindy (University of Madras).

Dr J. Krishnan is heading the Manufacturing Section of Centre for Design and

Manufacture, BARC. He is a Ph.D in Welding from I.I.T Mumbai and a Fellow of
Indian Institution of Welding. Apart from welding and fabrication, surface
engineering is also a part of Manufacturing Section. He has 50 technical papers
presented / published. He is actively involved in various programmes of IIW,
ISNDT, ASM and various educational institutions.

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