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Ohio Sea Grant College ProgramThc Ohio State University
1314 Kinncar Road
Cohimbus, Ohio 43212-1194614/292-8949
Executive Committee
Jeffrey M. Reutter, Directorfvlaran Brainard, Comm«nicatorfEditor
Kcith W, Bedford, Engineering and Physical Science CoordinatorDavid A. Cu1 ver, Biological Sciences Coordinator
Rosa nne W. For tner, Ed«cation CoordinatorLeroy J. Hushak, Social Sciences Coordinator
District SpecialistsDavid O. Kelch, Elyria
Frank R. Lichtkoppler, PainesvilleFred L. Snydcr, Port Clinton
Office Staff
Jo Ann Damon, Office ManagerJean Lewis, B«siness Manager
Arleen Pined a, SecretaryNancy Rausch, Information Clerk
Suc Abbati, Graphic Artist
1'hc Ohi<> Sca Grant College Program is part of the Lake Erie Programs administered by the College<if Biological Sciciices at The Ohio State University. The other programs are thc Center for Lake Eric
Area Research CLEAR! and Franz I'hcodore Stone Laboratory: Ohio's freshwater field biologystation.
funding Support
'1'his publication is a result of work from project R/OE-4. Ohio Sea Grant College Program ispartiaBy supported through grant NA88AA-D-SG094 from the National Sea Grant College Program<if the National Oceanic and Atmospheric Administration NOAA!, U.S Department of Commcrce.Support is provided by the Ohio Board oF Regents, The Ohio State University, other universities
and indu stries.
'<~ 1987 by The Ohio State University.
FLEXIBLE PAD CONCEPT IN UNDERWATER WELDED CONNECTIONS
A Thesis
Presented in Partial Fulfillment of the Requirements for
the degree Master of Science in the
Graduate School of The Ohio State University
by
Laurence R. Z i rker J r
The Ohio State University
1987
Approved by:Master's Examination Committee;
Chan L. Tsai
William L. Green
Adviser
Department of WeldingEngineering
THESIS hBSTRhCT
THE OHIO SThTE UNIVERSITY
GRADUhTR SCHOOL
NhMR: Zirker, Laurence H. Jr. QUhRTER/YRhR: Spring/1987
DRPhRTHENT: Welding Engineering DEGREE: Master of Science
ADVISER'S NhME: Tsai, Chon L.
TITLE OF THESIS: Flexible Pad Concept for Underwater WeldedConnections
The focus of this research was to investigate theperformance characteristics of Type B underwater welds wetwelds!. The wet. test welds--vee groove and tee fillet--weregiven a series of mechanical tests to determine theirmechanical properties' .hardness, ductility, CVN, andtensile tests with macro and microstructure analysis.Through these tests, the flexible pad connection concept wasdeveloped. The flexible pad connect.ion circumvents theproblems of degraded mechanical properties and low fatiguelife by allowing the joint to flex and dissipate loadingenergy before the loading stress reaches the welds. Thisconcept not only allows for increased fatigue life, but is aviable economic solution to the high cost of underwaterwelding.
The flexible pad connections--tubular tee welds--veregiven static and impact loading tests for a comparativeanalysis with tubular tee welds made in air, on a fitness-for-purpose basis.
DEDICATION
To my faithful and constant companion, Margie,
who unceasingly supported me through this project.
May it be for the better life of which
we dream.
hCKNOWLRDGHMHNTS
The researcher would like to thank Prof. Chon L. Tsaifor his encouragement, enthusiasm, and guidance through thisresearch. Were it not for his insight and knowledge, thisidea would not yet be conceived. Also appreciation to thehrcair Company in Lancaster, Ohio must be expressed fortheir unceasing willingness to give time, facilities,advice, and help in testing and support. In particular to:Bob Strohl--the welder/diver for the consistent quality inunderwater fielding; Lance Soisson--the computer expert- � forthe patience in teaching me Lotus; Paul Moore � -the gadget-eer for problem solving and arranging for testing; andWilber Moore--the photographer--who willingly photographedand printed for this research. I extend heartfelt thanks toWhitty Grubbs of Global Diving, for assistance with obtain-ing valuable data and guidance throughout this project.Also for the help in mechanical testing to Ted, Don, andLen, who willingly gave of their time and talents. ToMargie, my proofreader, who constantly proofread andcorrected the many pages over and over again. And not leastmy parents, who have supported me in times of discouragementand given me courage to continue my education.
111
VITA
February 5, 1947
1966-71
1971-74
1976-78
1978-79
1980-85
1986-Present
FIELDS OF STUDY
Studies in Underwater Welding Technologywith Dr. Chon L. Tsai
Major Field: Welding Engineering
Born--Salt Lake C ity, Utah
B.S. of IndustrialEducation, NorthernArizona University,Flagstaff, Arizona
Teacher, Santa RitaHigh School, Tucson,Arizona
Course Work, WeldingTechnology, ArizonaState University,Tempe, Arizona
Welding Engineer,Bechtel Power Corp.Palo Verde, Arizona
Owner, Arc FlashWelding, Fvanston,Wyoming
Graduate Student of
Welding Engineering, TheOhio State University
TABLE OF CONTENTS
DBDICATlON
ACKNOWLEDGEMENTS.
VITA 1 V
TAB LR OF CONTENTS
vi 1
Vl
I I. BACKGROUND
21
23
2427
27
28
30
32
TAB LF, OF TAB LES
TABLE OF FIGURES'
TABLE OF PLATES
CHAPTER
I. INTRODUCTION
Methods of Underwater WeldingTypes of Welds
Wet WeldingWelding ProcessMaterial Selection and Weldability
Carbon Equi valen t.Weld Condition
Macro and Micro Analysis of Welds.Weld Metal and HAZ Mechanical Properties
Ductility.Charpy Vee Notch.Ultimate Tensile Strength Testing.Hardness Tests.
Development of Algorithm TablesDesign Philosophy
Welding Considerations.Tubular Test Model
Butt Joints.
Stress Loading of Flexible Pad Concept.Impact LoadingFitness for Purpose Testing.
III. EXPERIMENTAL PROCEDURR.
4 68 9
11
13
14
1517
18
1819
1920
32
32
33
3435
36
36
IV. RESULTS
82
82
88
93
93
95
VI. FUTURE WORK
102BIBLIOGRAPHY.
105APPENDIN.
V1
Underwater Welding SurveyReview of Up-Dated LiteratureParameter IdentificationWelding Tes ts Under S iaulated Sub-SeaConditions
Test Welds.Welding Techniques.
Test Material SelectionMill Certifications.
Degraded Weld Properties on StructuralReliability
Fillet Weld Dimensional Data,Fillet Break Calculations.Vee Groove Helds.Macro Analysis.Micro Analysis.Hardness Value Surveys.
Fabrication of Flexible Pad ConnectionsTesting the Flexible Pad Concept
Shear Strength Loading.Static Loading.Impact Loading.
Underwater Welding SurveyLiterature Search and FFPI Data Bases
Statistical Analysis.Underwater Welding Teats
Welding Procedure.Test Weld Nomenclature.
Mechanical Properties of Test WeldsHardness Tests'Macrostructure Analysis.Mictostructure Analysis.Fillet Weld Shape and Break Data.Fillet Weld Break Profiles.Plots of Nechanical Properties andThroat Size.CVN Test Data.
Development of Algorithm TablesTesting of Tee Joints
Static Loading.Impact Loading.
V. DISCUSSION AND CONCLUSIONS.
38
38
41
43
44
44
44
45
48
48
49
53
55
5558
58
64
64
64
65
68
72
79
79
TABLE OF TABLES
TABLE PAGE
56
Appendix
593. FFPI Data Base
62
80
S7
9. Algorithm Tables. 90
Underwater Welding Survey Responses
2. Weld Properties from Current Literature
4. Welding Procedure.
Hardness Values of Test Welds.
DPH Values of Weld Traverses
7. Fillet Weld Shape and Fracture Data
8. CVN Test Results.
.Appendix
.Appendix
TABLE OF FIGURES
PAGF.FIGURE
1. The Research Approach
Basic Joint Configurations.2.
3. Fillet Weld Shapes 15
Structures af a Single and Multipass WeldWeld
16
5. Correlation of Temperature in the HAZ
6, Fitness for Purpose Index FFPI! 2
Connect i an Pad Concept7.
268. Multi Pad Concept.
Tube-ta-Tube Cannect ion 269.
10. Impact Energy.
ll. Analysis of Structure Connection. 29
12.37
13. Locations of Test Coupons.
14. Details of Typical Fillet Weld
15. Tee Fillet Weld Break Test.
16. Effective Throat Area.
17. Locations of Hardness Itnpressions.
18. Details of Pad Connectian.
19. Static Loading af Tee Joints,
20. Literature Search Data Base
39
40
42
42
60
Joint details and Welding Sequence of Testwelds.
21. FFPI Data Base 62
22. DPH Numbering System. 66
23. Plots o f DPH Values
24. Macro Photographs. 69
25. Horizontal and Vertical Traverses. 71
7326. VTU
7327. HTU
28. Photographs of Fillet Weld Cracks.
29. Fracture Limit vs Throat Size.
30. Stress Fracture vs Throat Size.
83
89
89
9233. FFPI
34. Plastic Deformation from Impact Loading
35. Impact Cracking of Root Bead.
96
92
31, Current Location of CVN Test
32. Improved Joint Design for True HA7. Toughness
TABLE OF PLATES
50
Plate II Photograph of Tee Connection.
Plate III Impact Testing.
Plate IV Underwater Weld Refined Region VTU!
5
54
75
Plate V Underwater Weld Traverse HTU!
Plate VI Air Weld Refined Region VTA!
Plate VII Air Weld Traverse HTA!
Plate VIII Local Plastic Deformation.
76
77
78
94
Plate I Photograph of Flexible Pad Tee Connection.
CHAPTER
INTRODUCTION
Welding engineering is a composite of many fields--an
exciting blend of mechanical, metallurgical, computer, and
the scientific disciplines. As such, the solving of
problems is not limited tv one area, but is accomplished by
analysis and investigation through many mediums and techniq-
ues. This is particularly true in this research project in
underwater welding.
The primary impetus in developing underwater welding
has been from the offshore petroleum industry. Other
fields--marine salvage, ocean mining or the military--may
also benefit from or add to the technological developments.
Underwater welding has made spectacular developments over
the last two decades, because of magnified understanding of
the capacities and limitations of individual welds in
structures. �!
The definition of underwater welding has been enhanced
through the American Welding Society AWS! by implementing
the underwater welding code D3.6 in 1S83. The 03.6 specifi-
cationss were prep'ared in response to the need for a specifi-
cation that would allow users of underxnter welding to
conveniently specify and produce welds of a predictable
performance level. l! Until this time underwater welding
had been cursed with an industry stigma that has sometimes
classified it as "black magic". �!
There are two basic forms of underwater welding � -wet
and dry. Dry welding is underwater, but the welding is
performed in a dry, protected atmosphere, whereas wet
welding exposes both the welding are and the diver/welder to
water. Net welding has some maj or limitations. First, the
rapid quenching of the weld metal and heat affected zone
HAZ! is a limitation. Second, disassociation of water in
the arc atmosphere creates a high ri sk of hydrogen cracking.
Thirdly, arc stability in water may be inferior and gross
defects may occur. �! All three of these limitations
contribute to the degraded mechanical properties of wet
welds. However, wet welding has a distinct economic
advantage over dry welding with its ease of use and low
operating and equipment cost. With increased technological
advances and knowledge of the total industry rising, the
need to identify the bounds of wet welding has arisen.
The thrust of this research is to I--Investigate wet
welds. 2--Characterize the mechanical properties af wet
welds on a fitness-for-purpose basis. 3--Design a tubular
connection to circumvent the problems of degraded mechanical
properties and service life. 4--Test the tubular pad
connections on s fitness-for-purpose basis. The method used
to solve and investigate the problems will be a researchapproach method. This is shown graphically in Fig. l The
Research Approach.
This research, sponsored by the Ohio Sea Grant program,
is a university and industry partnership for the advancementof underwater welding technology.
The University: The Ohio State UniversityThe Industry: The hrcair Company of Lancaster, OhioThe Sponsor: The U.S. and Ohio Sea Grant Programs.
The Arcair Company has directed its research anddevelopment department to assist with this project, not onlywith the making of underwater welds, technical andsecretarial services, but also in funding the independentmechanical testing of the simulated sub-sea test welds andthe plate and pipe material for the tests.
Fig. l The Research Approach
CHAPTER II
BACKGROUND
To better understand the breadth and complexity of
underwater welding, a background discusrion of the subject
is in order to prepare the reader for the topic, testing
procedures and results of ihe findings.
Methods of Underwater Weldin
There are several bas ic methods o f underwater we 1 ding
currently in use. �,5,6!
1. Welding in a pressure vessel in which thepressure is reduced to approximately one �!atmosphere, independent of depth one atmospherewelding};
2. Welding at ambient pressure in a large chamberfrom which water has been displaced, in anatmosphere when the welder/diver does not. work indiving equipment habitat welding!;
3. Welding at ambient pressure in a simple open-bottomed, dry chamber that accommodates, as a
minimis, the head and shoulders of the welder!diver in full diving equipment dry chamberwelding!;
4. 'Welding at ambient pressure in a small,transparent, gas-filled enclosure with thewelderjdiver outside in the water dry spotwelding!; and
5. Welding at ambient pressure with the.welderjdiver in water without any physic al barrierbetween the water and the welding arc wet
welding!
Welds achieved in an air atmosphere, typically exhibit
a higher quality of mechanical properties, while wet welds
are of lesser quality. A trade-off between the high
operating cost of a hyperbaric welding vessel snd degraded
properties must be made. The quality of the welds are
higher in a hyperbaric vessel, in dry welding, but it is
seldom practical if complex structures are being weidecl.
�!
The economic differential between wet end habitat
welding is significant. A typical Gulf coast! wet welding
repair operation costs $500.00 per l2-hour shift. This cost
is generally 75% less expensive than a habitat welding
operation. 8!
lds
Before welding begins on any structure, the
welder/diver must be certified or qualified to perform the
welding. The welder must demonstrate abilities to
satisfactorily weld a test coupon, defined by D3.6, similar
to the actual production weld. The test coupon is subject
to destructive and non-destructive evaluations NDE!, and if
the coupon meets the mechanical and NDF. requirements, the
welder becomes qualified and may undertake the welding.
However, before the welder can be quHlified, the
production welding procedure must also he qualified. The
welding procedure includes the types of base materials,
electrodes, joint designs, etc. h test coupon, welded with
the prescribed welding procedure, is subject to destructive
mechanical tests which qualify it to certain standards of
quality. These standards are divided by D3.6 into four
types of weld qualities. The state-of-the-art wet weld is
classified as a Type B weld. Although Type B or wet welds
are the major focus of this research, other weld types
defined by D3.6 are: �!
1. Type "h" underwater welds are intended to besuitable for appl.ications and design stressescomparable to their above-water counterparts byvirtue of specifying comparable properties andtesting requirements;
2. Type "8" underwater welds are intended forless critical applications where lower ductility,greater porosity, and other l.arger discontinuitiescan be tolerated;
3. Type "C" underwater welds need only satisfylesser requirements than Types A, B, and 0, andare intended for applications where the load-bearing function is not a primary consideration,and
4. Type "0" underwater welds meet therequirements of another designated code orspecification, as well as additional requirements,defined herein, to cope with the underwaterwelding environment and working conditions.
Type B structural components, in D3.6, are either
welded using a vee groove or fillet weld joint design. ln
Fig. 2 Basic Joint Configurations, samples of both joints
and typical components are shown.
WELI3 METAL
HAZ BASE METAL
Vee Groove Joint
BASE METAL
TAL
Tee Fillet JointFig. 2 Basic Joint Configurations.
the welder are exposed to the surrounding water environment.
Wet welding is the most widely used method in producing
underwater welds. 9! The welding are is not protected by
any external means except by its own gas or bubble
generation during welding. A type B weld is intended for
less critical applications where lower mechanical properties
can be tolerated as determined by D3.6. �! A list of its
advantages would include: �,9,10!
l. The diver can go into areas that, due todesign and location, cannot be satisfactorilywelded by another method;
2. Available standard welding machines andequipment can be easily mobilized;
3, There is more latitude in the design and fit-up of repair sections;
4. Freedom of movement allows for more efficientweld repairs; and
5. Underwater arc cutting can easily beadapted for use through minor alterations in thewelding equipment.
The major disadvantages of wet welds are the
dissociation of water in the welding arc, hydrogen
embrittlement conditions and the rapid quenching rate of the
weld metal and HAZ. These creates detrimental metallurgical
and mechanical properties in the weld area. The HAZ is that
part of the base material that was not melted, but was
metallurgically altered hy the heat of welding. The harmful
ef fects include a larger amount of hydrogen, oxygen and
porosity in the weld metal and higher HAZ hardness. �,11!
Often Type S welds are associated with repair welding.
This possibility must be examined and accommodated when
selecting materials and designing an offshore or underwater
structure. Regular inspection of these structures may
reveal damage which necessitates repair, and repair by
welding is an attractive option, because it allows the
structure to be repaired to its near original condition.
�0!
One researcher has outlined what must be considered
when a repair weld i.s attempted.
The engineer who must make an underwater weldrepair should analyze the situation as completelyas possible. He not only must determine thestresses which will be imposed on the completedweld, but he should also know what caused thedamage and how to repair it to assure durableservice. He should be familiar with potentialmetallurgical effects and must thoroughly under-stand the current and future use of the structureso he can choose the correct safety factor. Heshould be a~are of factors that affect diving suchas depth, current, visibility, and watertemperature. Finally, he must know all he canexpect under the conditions faced bywelder/divers. Once the designer determines howmechanical connections compare with welds made dryand wet, he Should calculate costs to determinethe most economical approach. l2!
<~<eldis Process
The most widely used welding pr<><:<.ss I or wet we'I d ing is
shielded metal arc welding SMAW! . With underwater SNAW,
the welding power supplies may he the same as thos< used in
above water welding. They must have st least: a 300 ampere
10
rating with direct current capabilities. �3! The
remaining equipment must be designed for underwater use, as
in the case of insulated cables and electrode halders. The
advantages of SMAW include ease in use, low cost af
aperation, and the variety af both welding and cutting
electrodes available. Other processes are also used in wet
welding, although not as extensively as SMAW.
Not only is the visibility great1y reduced in
underwater welding from the bubble generation af the arc,
but far unrelated causes, the water can be muddy or fouied.
Typically, welding is a skill requiring a high degree of
hand and eye coordinatian. To produce sound welds, a
welder needs to see the arc in order to maintain a short,
but constant, arc length and follow the joint or seam being
welded. The drag technique is used by underwater weldeis
to campensate for the inability ta clear1y see the are.
The drag technique allows the welder to physically drag or
touch the electrode along the joint. The arc length is
self-maintaining, because the steel core of the electrode
burns up into the coating of flux and creates a constant
arc length between the electrode and base material. �, 14!
The arc characteri stics can also vary considerab]y if the
arc length alters. As the arc length increases, so does
the voltage, and as the voltage increases, the amperage
decreases. Increased arc length decrease in amperage!
causes a myriad of welding defects to occur- lack of
11
fusion, porosity, and lack of penetration,
Material Selection and Weldabilii~
Weldability is the ease in which the material can be
welded without defects. �5! The material selected for the
simulated welds was a structural quality steel--ASTM A 36.
This steel is a low grade carbon steel with the typical
chemical and mechanical properties: �6!
Compositions in percent:C--O.Z9 max; Mn--0.80-1.20; P--0.04 max; S--0.056max' �Si--0.15-0.3.
Tensile Strength--58-80 ksi �00-500 MPa!Yield Point, min--36 ksi �50 MPa!Elongation in 2 inches �0 mm!--23
Because of the low carbon and alloy content in A 36,
many of the inherent problems associated with welding
underwater are reduced. �7! However, A 36 presents a
dilemma in that although it is the most commonly available
structural steel, the degree of latitude in the mechanical
properties and chemical quantities is great. This is
readily shown when comparing the carbon contents of the
material used for making the test welds �.11 and 0.19%! to
the amount allowable of 0.29%. If the carbon content of the
material were at the maximum, then the weldability and
hardenability characteristics would change. As the carbon
content of a steel increases, the hardenability increases,
and as the hardenability increases the weldahiliiy
decreases. �8! The hardenabi1 ity and weldai>ility ar e
12
directly related to cracking in under~ster welds. 1t is an
advisable engineering practice, when ordering materia1, to
obtain mill certifications of material chemistry to verify
the carbon and alloying contents in order to avoid any
surprises in fabrication or service.
hs earlier stated, hydrogen cracking one of the problem
areas of underwater welding. Three elements need to be
present for hydrogen cracking to occur: hydrogen, a stress
condition, and a hard microstructure, �0,16,18! Hydrogen
is readily disassociated from the water during the welding
process, and absorbed into the molten pool. The rapid
quenching of the weld metal retards the diffusion of
hydrogen out of the weld metal. A stress point or stressed
condition on the weld in an underwater welded structure can
occur from the fabrication process a forced fit or welding
stresses! or a service loading candii.ion a storm or
excessive loading!. The normal hard zones HAZ! of the weld
are intensified because of the rapid quenching affect of the
water. This hardening is also enhanced with higher allaying
of the material.
The fabricator or engineer must eliminate one of the
three elements to insure protection from cracking. �7! A
logical variable for manipulation is the material selection.
Selection of a material with a low carbon content will often
eliminate or limit the hardened microstructure constituent
martens ite. Nartensite is the structure most susceptible t.o
13
cracking and high hardness. Kith a low carbon material, t.he
martensite will be eliminated or its detrimental effect. will
be limited. Often the onus falls on the fabricator to
achieve satisfactory joint toughness when the parent
material is supplied by the client, The options available
are then welding process, joint design, consumable
selection, and welding procedure. �9!
Consideration of the composition of the filler material
must be made. The molten weld metal in the fusion process
is subject to similar metallurgical responses, as is t.he
base metal. The electrode must also have low carbon and
alloying content, because of the rapid cooling of underwater
welding, in order to prevent the formation of martensite in
the weld metal, and to avoid the problems of the HAZ--high
hardness and cracking. �0!
Carbon E uivalent. Another device which gives a rough
measurement of weldability is the carbon equivalent CE!.
The CE considers not only the effect carbon has on the
hardenability, but all the combined alloying elements.
Materials with a CE of less than 0.40 are often considered
safe from hydrogen cracking. In D3.6, in t;he requirements
for base materials section, two formulas are given for
determination of CE. �!
CE = C + Mn/6 + Cr + Mo + V!/6 + Ni + Cu!/L5 eq. 1
CE = C + Mn/6 + 0.05
Weld Condition
Weld properties can be divided into two parts; we1d
conditions and mechanical properties. Each has its own
values and characteristics.
The weld shapes have a direct relationship to the weld
condition. Through D3.6, AWS has made advancements in
specifying underwater weld shapes or geometries to reduce
the local stress concentrations, and thereby improving
service life. Fillet weld shapes or macro geometries have
direct relationship to the service life fatigue! of an
underwater structure. �l!
The electrode and its welding characteristics directly
affect the weld shape. The electrode flux coating and water.
proofing have a major effect on arc stability, weld profile
and slag removal, �2! A smooth running underwater
electrode, which features easy slag removal and weld metal
profile, can greatly assist the welder in achieving weld
quality and the fillet weld shapes defined hy D3.6. These
shapes are shown in Fig. 3. The toe region of the weld
should be a smooth transition angle between the bead shape
and the base material in order to reduce the mechanical
notch effect that the toe naturally causes.
Besides making a physical notch, the toe region also
has higher hardness and larger grain size, which represents
a metallurgical notch.
15
L~ Erre C Erne CEue
Srus ~ Crurrecur C erase nes uaceeE 0 92 Snarls acruel reE use. lu lru seueu rse rulee ~ el ec uraerruel reE hlars uucr acus 0 06 cl ll 0 rruul.
IEI ~ IrEer eurEI EsurEseIEI 0eauaNe irene cruel Esrrlslaa
Insul I reruns Iueeeeucl errenel r er cruE ~
~ arneecueEauuuereul4rurruunr
ICI Usesrcaspsaase s~ ssalE eresrssa
Fig. 3 Fillet Held Shapes. �!
Macro and Micro Anal sis of Welds. A typical macro
structure of these welds will display a !ayered effect from
the multipass welds, and the presence of porosity or
cracking. The heat of fusion from a following weld layer
will refine or temper the earlier layers. These over-layers
are often called temper beads. The last layers or capping
beads may be placed to temper the toe region of the weld to
reduce its high hardness. This effect can be shown on Fig.
4 Structures of a Single and Nultipass Weld.
These two schematics show the basic layers of a single
and multipass weld cross section. The course grained layers
in "a" correspond to the hardest constituent of the HAZ,
which lays next to the fusion line. These large grains
typically exhibit the highest hardness and consequently the
lowest toughness. �7,23! The multipass weld metal has a
more composite structure than the single pass in that the
fallowing layers anneal out some of the residual stress and
16
o 'I
We I<Imerel
rioor offecred
b--Hu 1 t i passa--Single Pass
Fi g. 4 Structures of a Single and Hultipass Held
Fig. 5 Correlation of Temperature in tbe HAZ �!
Cootre Qroirrecl
Fice p oirorI
irrlercriricol
Coorre col
Iiecryrra I Ii
iiecryrrolli
17
will refine same of the weld metal structure. �7! The
annealing or refining effect gives a polygonal structure a
small eguiaxed grain! which has improved toughness. �4!
Although both schematics show the structure of air welds,
the same basic feature would exist for underwater welds.
The microstructure is a product of many factors:
amperage, travel speed, material, and thickness. These
factors determine the extent of the thermal treatment peak
temperature and cooling rates!. The thermal cycle becomes
less pronounced with greater distance from the fusion line.
ln essence, the microstructural changes are a function of
distance. �5! This is well shown in Fig. 5. The points
on this f.igure correspond to a steel with 0.2'4 carbon, on
the iron-carbon phase diagram, which is comparable to the
test weld material used for this research,
Weld Metal and HAZ Mechanical Pr~a erties
In order to determine the minimum specific d mechanical
properties of weld metals, base metals, and HAZ's,
mechanical tests are conducted. These mechanical properties
determine the range of usefulness of the metal and establish
the service that can be expected. 15! With the mechanicai
properties, there exist trade--offs between ductility/
toughness and the hardness/ultimate tensile strength E,'VTS!.
One often increases at the expense of another. DB.fi defines
the four tests to determine the properties of each.
Many tests are indirect indi.cators of
ductility, but it is evaluated directly with bend tests.
The bend test evenly stresses the outer fiber layers of the
bend specimen to a set strain �0% for type A and 7.7% for
Type 8! established by the specification, without major
cracking. I! ln a homogeneous material, the outer fibers
stretch evenly, but with a composite of structures, as xn a
weld, the harder zones do not stretch as the softer zones
do. This worst case condition truly tests the ductility
strength of a joint in that the hardest zones are less
ductile than the softer zones. The finite point, joining
the two zones, experiences the greatest stress, and
represents the true performance of the welded joint.
~Char Vee Notch. The Charyy Vee Notch CVN! measures
impact loadi.ng ductility of a material. The CVN test
measures the amount of impact energy needed to break a
material. A hard or brittle material will easily fracture
whereas a softer material wil1 bend or tear and resist
breaking and hence, require more energy to break. Details
for machining these samples are found in D3.6, including the
requirements for both HAZ and weld metal CVN tests. A
Problem inherent with the CVN HAZ test is locating the exact
placement for machining of the vee notch at the hardest
structure of the HAZ. A notch is machined into the coupon
at a prescribed location in order to initiate u fracture
point upon impact. The CVN test results sometimes have
limited fundamental significance. It has meaning in terms
of correlation with brittle or ductile behavior under impact
conditions.
Ultimate Tens i le Stree th Test i~et. The rednced section
tensile test is a standard method of establishing the
ultimate tensile strength UTS! of a joint. With this test,
the percent of elongation is also evaluated. This percent
of elongation is another indirect function of ductility, bui.
the results are often misleading. It measutes the ductility
of the reduced section of the test coupon, but typically the
weld and HAZ are not affected,
Hardness Tests, These tests are easily performed and
are a direct link to the microstructure. Hardness is a
measure of how a material resists denting. The larger the
dent, the softer the material. A weld is a composite non-
homogeneous! of microstructures which vary in hardness. The
Vickers hardness Hv! system with a micro� � indenter Diamond
Pyramid Hardness--DPH! will be used, because of the si.ze of
the micro � indenture and the ease of placing the indenter
within the proper microstructure. An integrated microscope
in the testing unit allows for exact placement of the
indentor within a microstructure. The HAZ impressions
should be made nn the base metal sidt of the fusion line, as
close to the weld/HA7. interface as possible tn obtain
20
accurate the hardest! readings. The DFH system implants a
micro diamond shaped indenture in the material, and the
diagonal of the indenture is measured using a number.ed scale
located in the eye piece of the microscope. The diagonal
value is set into the following equation to obtain the DFH
value.
1856.4 X 500 / diagonal eq. 3
A Rockwe 1 1 C or B macro ha r dness sys terna ! inden te r' is
too large and can not measure the small or narrow zones of 8
weld microstructure. The hardest zone on A 36 steel can be
0.5 mm from the fusion line, �6! making the Vickers system
ideal for these measurements. According to D3.6, a macro
Vickers testing unit with a 10 kg 1oad is specified. Such n
unit was not available in the OSU laboratories, and the
factory representative for the OSlJ unit stated that the
variance of hardness values between the macro and micro
units for A 36 material was slight.
To better relate to the hardness of DPH, divide it by
10 and the new value is an approximation of Rockwell C Hc!.
Develo ment of Al orithm Tables
This activity summarized the true performance .level of
Joints with Type B welds in comparison with Type A welds.
To best approximate the true character of the Type B weld in
2l
question, a data base was used. The data base was the
actual values from the simulated sub-sea test welds
conducted for this research, and those tests from the
literature search that fit the criteria of: A 36 base
material with tensile, CVN and hardness tests. A three-axis
quality index was used to show the relationship of the three
tests in order to determine the true performance of Type B
welds. Each axis corresponds to one of t.he tests. Each
test was divided into six ranges along the axis. An example
of this concept is shown in Fig. 6 Fitness-for-Purpose-
Index FFPI!
The algorithm tables were derived by inserting data
points which fall into test range cells in the planes along
the hardness axis.
Desi n Philoso h
One of the research goals was to develop s design
concept to circumvent the problems of degraded mechanical
properties and service life of wet welds. To date, wet.
welding has not been used in critical situations on a
permanent basis because of degraded properties and in
particular- � poor service life fatigue life!. But there is
a driving economic pressure to establish methods of using
wet welding with its degraded propert.ies. It. is a common
plea of some users for des igners and eng i neera t,o co<!r <t i na t.e
their effort for the probable need for underwat,er welding,
22
I LANE ~
PL 5 Z N ANGE I2 AXI ~ C'VN
Fig. 6 Fitness-for-Purpose index FFPl!
23
sometime during the life of the structure, in the early
stages of design, to maintain structural integrity while
circumventing the degraded property problem. �! A typical
solution would be to scallop the edges of a sleeve t.o
increase actual weld area, or eliminate overhead underwater
welding which inherent1y gives rough or out of specificat.ion
bead profiles. Both of these solutions would improve the
usage of a wet weld, if planned for through proper joint.
design. It maybe also be possible to compensate for lost
mechanical strength and toughness by increasing the amount
of weld metal. However this approach must be used with
caution, because of the surface condition affects or
geometery of the as-deposited wel<i. � I!
Weidin~ Considerations. The aim of t.he design
philosophy was to blueprint or devise a tubular joint that
could be fabricated using underwater welding wit.h its
inherent degraded properties, and through fitness � for-
purpose tests, prove t.hat it was worthy to stand by it. self.
This would be possible because the underwater welds will be
placed on the joint in a non-critical, but struct.urally
sound, location.
Obviously, defect free underwater welding would be
ideal, but is presently unfeasible. The ability to avoid
welding defects is best stasted as a level of degrees. Th»
use of vee groove joints is not < on<tuc i ve to <i.-. feet fr ee
underwater w"lding, especially for pipe or tubing. The
24
groove welds are inherently difficult, but the underwater.
environment and the overhead parts of the joint make the
weld even more difficult. For thise reason, the chaice of
fillet welds was more desirable as they are more defect
free, easier to see and weld.
Tubular Test Madel
The design solution was the use of a flexible
intermediate connection pad between the main and branch
members, This idea is shown in Fig. 7 Connection Pad
Concept, this concept could be expanded even further for
conditions requiring increased flexibility by using a multi-
layer pad design. A multi-layer pad design is shown in Fig.
8. In Fig. 7, a combination of two joint connections, butt
and alphabet, is shown on the same structure.
Typical alphabet connections are the tee, K, Y and X.
Of ten these connect iona in of fshore st r.un tur es are braced i rr
multiple planes, and the use or analysis of such a structure
would be beyond the scope af this resear ch. The tee jai<rt
shown in Fig. 7 cauld be modified to include other joint
connections, but for simplicity, the tee joint. was used for
this study.
25
Fig. 7 Connection Pad Concept
Fig. 8 Multi Pad Concept
Fig. 9 Tube-to � Tube Connection
27
Butt Joints. Typical butt or tube-to � tube joints
joints two elements or pieces of the same shape in order to
extend the structure. A vee groove weld is a common method
used to join tubing together, but a vee groove joint is
avoided in underwater welds, because of the difficulty i.n
achieving 100% penetration and sound weld metal. To
minimize the welding difficulty of a vee groove weld, a
sleeve with machined slots would slide over the ends of tube
and plug fillet welds would be used instead of groove welds
in joining the tubes. An example of a tube-to � tube joint is
shown in Fig. 9 Tube-to-Tube Connection.
Stress Loading of flexible Pad Conduce t.
A joint must carry the applied design 1oad to be
considered efficient. Initial design must be strong enough
to withstand the applied loads. In the traditional
allowable-stress method, the calculated maximum stress,
assuming elastic behavior is up to anticipated maximum
loads, is kept lower than a specified allowable stress.
This allowable stress is intended to be less than the
calculated stress at failure by a factor of safety. �7!
The allowable-stress method is not always valid. This
is particularly true with fatigue or repetitive loading-�
failure may occur much below the yield point. For the most
part, the allowable stress method gives the designer values
28
to begin making assumptions for design calculations. With
the flexible pad concept, the joint was tested on a fitness-
for-purpose basis to compare with the actual proof load
values.
~fm act toed~to . To comparativeiy qualify the impact
strength of the joint, several specimens were tested in an
impact loading mode. This clearly tested the toughness arid
ductility of the joint in a fitness-for-purpose mode.
Ductility of wet welds is typically low due to the rapid
quenching effect. These tests quantified the strer!gth of
the connections.
In the theory of strength of materials, this t:onr ept
was demonstrated by BIodgett �8! In designing for impact
loads, Rlogett states that it is possible to determine the
impact force by finding the amount of kinetic Ek! or.
potential Ep! energy that must be absorbed by the member.
E> = Wjg V~ eq. 3
eq. 4Ep = Wh
These energy formulas are then set equal to the energy
U! absorbed by the member within a given stress, se« Rig.
10 Impact energy.
In the above equations, the mass of the member has been
neglected. Some energy is lost due to the ine,-ria of th»
member and less energy is left to stress the member under
29
Fig. lO Impact Energy. �8!
1670
Fig. il Analysis of Structure Connection. �8!
impact. Combining this loss of energy with energy absorbing
devices such as springs or rubber shock absorbers, the tota]
energy absorbed by the connecting welds will be less. This
is shown further in Fig. ll Analysis of Structure
Connection. With this design, the energy dissipates in the
connection pad before it reaches the underwater welds, and
the energy stress in the welds is minimal The stress in the
underwater welds is, therefore, kept below the plastic
limit.
There are some elements to reconsider when insta11ing
this flexible connection: 1--possible reduction of
structural rigidity, 2 � � change of natural frequency, ;»><i 3-
increase in structural value requirements.
Fi tnes se Tea~tin . Because of the
conservative nature of the calculations of stresses and
strengths, the fitness-for-purpose concept was adopted for
the testing of the connections. Additionallly, a weldment
is not a homogeneous structure, and different mechanical
properties are apparent in the separate zones. These zones
interact in a complex manner, and through fitness-for-
purpose testing actual service strength of the structure may
be approximated. Laboratory tests may project results that
are less applicable to field conditions than are fitness-
for-purpose tests. �2! Stout explains further that the
best procedure for testing seems to be to devi.-.. � a test so
that .it involves actual welding, permits testing conditions
31
approaching those of service, and provides quantitative
evaluation of pertinent properties of the steel.
Considering these thoughts, the most complete mode of
testing the flexible pad connection is accomplished fitness
for-purpose testing.
CHAPTER III
EXPERIMENTAL PROCEDURE
Underwater Weldin Surve
A survey instrument was designed to extract information
pertaining to the goals of this research, and submitted to
international and domestic industrial users of underwater
welding. A list of users was obtained from the marketing
division of Arcair Company. A cover letter and the survey
was sent to 126 users of underwater welding. A copy of the
cover letter and survey are in the appendix,
Review of U -Dated Literature
The literature review was divided into three time
frames: 1930 to 1976, 1976 to 1982, and 1976 to 1985. The
compiled bibliography of all underwater welding literature
published since 1930 was found in an earlier Sea Grant
report �977! by Tsai. �! Hattelle Laboratories conducted
a title search in 1983, as part of a report for the Navy
�4!, through the Weldasearch data base system developed by
The Welding Institute in England. The data base system to
date �985! has 120,000 abstracts. Yor t.his research,
another Weldasearch was used to find other new titles.
32
33
Initially, the last time period was between 1982 and 1985.
Because the Battelle report used different key words, the
search for this study was expanded to include a longer time
span �976 to 1985! and other key words. Boih of these
searches provided the requisite data to conduct a survey of
current liierat.ure.
Parameter Identification
The objective of this activity was to identify the
important parameters from the literature search data which
define weld quality. Weld quality is classified by two
categories: weld condi.tion and mechanical properties, Weld
conditions would include weld bead profile and interna1
discontinuities as defined by 03.6. The mechanical
properties should include tension, bend, hardness, and CVN
tests of u»derwatet welds. The data from these tests
defined the performance level of underwater welds, and aided
in comparing results of the newly generated data to the
underwater test welds. It was not a goal of this research
to qualify these welds to a Type A cl.assificatio», but to
subject them to the Type A tests in order to assess Type B
we 1 ds for f undamen t a 1 knowledge.
Prior research publications did not always provide
clear explanations of testing procedures or results. Vor
this r easo», 1 osis were conduct ed on «xper imeni a1 sub- sea
welds to ver ify the properties of Type 8 we1ds
34
Through statistical means and standard deviations, the
true performance level of Type 8 welds can be identified. A
comparison of the data generated from the literature search
and the newly developed data were compared.
Weldin Tests Under Simulated Sub � Sea Conditions
The objective of this task was to determine the effects
of degraded weld properties on structural reliability from
which the performance levels wer e established.
The task of underwater welding was accomplished at the
Arcair Company of Lancaster, Ohio. Arcair Company, a co-
sponsor of this research, has a diving tank on their
premises and employs diver/welders. Diver/welder, Bob
Strohl, welded all of the tests to minimize operator welding
variations. All tee fillet and vee groove welds were
supervised by the researcher. Another test set combination
was attempted using a fillet weld to join a pipe to a plate.
The joint orientation placed the pipe horizontally and the
plate welded on one end of the: pipe. The results of them ar
not presented because the fillet leg sizes varied greatly
and the weld condition excessive roughness! of the overhead
underneath! portion of the weld was unacceptable.
In a private communication with Whitey Grubbs of Global
Divers Inc., he expl,ained that "...welds in the splash zone
on an offshore structure, are. the hardest to do well. This
is not fr oui the water action, but from the la~ ~. of pressure
from the water. Welds at 60 feet are much smoother and
better in quality than those made at the splash zone." 8!
He concluded that this pipe to plate test might be easier to
do in salt water and at greater depths, The water depth of
the Arcair tank is l0 feet. This shallow depth and the uae
of fresh water are limiting factors to this research,
Test Welds. The tee fillet joint test welds were
divided into 3 equal groups. Each group was welded with a
dif ferent electrode. Two groups were welded with
domestically available underwater welding electrodes:
electrodes A and B. The third group--electrode C--was
fielded wii.h an E-7014 electrode in the air.
For the tee fillet; welds, two welds were made for each
electrode in the horizontal and vertical positions, The
direction of welding for the vertical welds was down. All
welding was done with dc negative dc-! current and straight
polority. Four evaluations--weld bead profile analysis,
bending fracture limit, hardness test.s with macro and mxcro
analysis were conducted in the engineering laboratories at
The Ohio State University OSU! in Columbus, Ohio.
When testing the vee groove welds, the welding position
was flat, and only one was completed for each of ihe
e lect rode t ypes. A f ter t he vee groove we 1ds w~. r e comp le ted,
they were sent out to a pr'ivaie test ing ] aboraiory for.
tensile, bend and CVN tests. Only hat dness, ma. r o and micro
at OSU.ana i ys i s w~ r comp le tc. d
36
Weldin Techni ues. The test welds were multiple pass
welds using the generally accepted stringer bead technique.
�4! A stringer bead technique implies that the deposited
weld metal or bead is narrow--about 3 times wider than the
electrode diameter, and the electrode is not oscillated
during use. A weave technique, with side to side
osci1 lat iona was not pract iced in underwater welding,
because the intense bubble generation hinders the visibility
of the arc, The welding sequence of the test weld joints
are illustrated in Fig. 12 Joint Details and Welding
Sequence of Test Welds,
Test Material Se1.ection
The materia1 selected for the test welds was th»
structural s'teel--A 36.
Mill Certifications. 1n compliance with D3.6, mil1
certificates of chemical composition of the material were
requested for sll steel ordered for underwater welding. Two
forms of material were received: plate and bar. The plate
material �8" X 96" X 0.375"! was used for both the vee
groove and fillet welds and the bar materiai �" X 244" X
0.375"! was used for the te» fi11et welds. Wi,h each form
of material, a mill certification of chemical composition
and mechanical properties was requested and i ~:-. iv=d, Thea»
37
0,3
4
Tee Fillet Weld
0.3
Vee Groove Weld
Fig. 52 Joint details and Welding Sequ.-. e of Test~'e 1 ds .
38
certifications are included in the appendix for reference.
De raded Weld Pro erties on Structural Reliabili~t
The objective of this activity determined the
significance of weld defects on joint strength and the
effect of degraded weld properties on structural
reliability. The reliability was analyzed with respect to
weld conditions and mechariical properties. The composite
result of this activity is presented by algorithm tables. A
joint strength index was developed from the tables arid was
related to weld quality indices.
Part of this activity included the destructive
evaluation of t.ee fillet and vee groove welds. The. test
welds were saw cut in a prescribed manner and locat iori, and
then the coupons were tested. These destructive tests are
outlined in D3.6. Ln Fig. 13 I.ocations of Test Coupons,
the locations of the various coupons are identified and
defined.
Fillet Weld Dimensional Data. Two sets of the 6 test
weld combinations were made, From each of the 12 test
welds, 3-one inch wide coupons were saw cut for a total of
36. One coupon was inadvertently destroyed.! The
remaining 35 coupons were characterized by measuring t.h< leg
and throat
sizes and describing the weld profile, These L'. mensions ,ire
described :n Fig. l4 Details of Typical Fillet Held. A
39
I!~~ ttxaaa aaaaxaaaa taacxa alch aha haxthxxax axacneteh
al the xaartcx laca
Tee Fillet fields
10" m~h 10" mm
Vee Groove fields
Fig. 13 Locations of Test Coupons.
Fig. i4 Details of Typical Fillet Held.
visual comparison between the two underwater electrodes was
made. Two characteristics of underwater weld quality were
noted--the surface roughness and bead contour.
Fillet Break Calculations. The mathematical elements
of the fi11et break test are shown in Vig. 15 Fillet Break
Test. The fracture limit value indicated on the two dial
gauges of the Tinus-Olsen tensile machine was recorded
during testing. The bending moment and stress was
calculated from this load and the dimensional data. The
initial dimensions of the pieces were the same, and
therefore the only variable was that of "P"--the fracture
load. The bending moment was calculated by the. following
method.
P X 1.34 � Ry X 4.38
Bz = 0.31 P then R2 = 0.69 P
Moment M! = 0.69 P X 0.94" =- 0.65 P in-lb!
The fracture initiation point was the root of the we1d
and not the toe. Weld stress was calculated by the
following equation:
Weld Stress = 8 / S! f< + R2 / Acr<
P � Vt actus e For<.e
42
Fig. 15 Fillet Breek Test.
Fig. 6 deflective 'Throat Area
Rz = 0.69 P
Seer = Section Modulus = 1" X Throat > / 6
Rp = 0.69 P
Sqff = Section Modulus = 1" X Throat ~ / 6
Aer< = Affective Throat Area = Throat X 1"
The Aeff is shown in Fig. 16 Effective Throat
Area.
The strength reserve factor SRF! is determined by
dividing the weld stress by 21000.
SRF = Weld Stress / �.3 X 70000!
0.3 = Reduction Factor
70000 = Ultimate Tensile Strength of Weld Metal psi!
Uee Groove Welds. Kn accordance with D3.6, the 16
separate mechanical tests were conducted on each vee groove
test specimen. These include: 2 � � toot bends, 2 face bends,
2 � � reduced section tensiles, 5 � � weld metal impacts, and
HAZ impacts along with macro and hard»ess a»alyses. For
these tests, the groove weld plates were tested in an
independent laboratory. Because this research did not
intend to qualify any person or group, departure from the
actual location prescribed by code was taken. Tl.e goal was
to quanti y the weld and joint, and not qua!i.~ the welder.
Identifyi»~ the actual locatio»s af the specimen»s from the
test coupons was determined by examination of '.I.';; � ray film
of t:.e tes ~ ou o», The res~-archer 'hen selec, " thl mos
defect free locations for testing. If gross internal
defects were located in the weld metal, that section was
omitted, because the defects would cause lower than normal
test values to occur during the testing of the specimens.
The other macro, micro and hardness tests were done in the
engineering laboratories.
Macro An~al sis. Macro analysis was conducted l.o
traverse.
Micro An~al sis. An analysis of the microstructure was
conducted along the path of the hardness points. A series
of micro photographs were arranged in a montage to show the
structure along the hardness traverse paths.
Hardness Value Surveys. Samples from each set of welds
were sectioned and metallographically prepared for hardness
tests. The polished samples were tested using a Vickers
mici ohardness DPH! testing apparatus with p. v ' jrams 1oad.
The inst.rJment, with the attached microscope, - .A>ws the
place t.".e m1ct 0user to re. ognize the microst t ucture and
indenture in the proper location as des< rihe;.
test~D3.C give~ t' » . ~ca t icnB Iot d i h'i' d;t srd
determine cracking or porosity. An expansion of this
analysis included taking hardness traverses of a typical tee
fillet to show the tempering effect of the multipass weld on
the hardness of the nonhomogeneous weld metal structure.
Two welds were analyzed with a vertical and horizontal
45
conducted on each specimen. See Fig. 17, Locations of
Hardness Impressions, for this specificat.ion.
Fig. 17 Locations of Hardness Impressions.�!
Fabrication of Flexible Psd Connections
A total of 21 tee connections were fabricated. Of this
total 6 were used for static loading and 7 for impact
loading. There were 4 types of tubular tee connections:
thin flexible pad, thick flexible pad, air welded and
and underwater welded tee. The pad connections varied only
in the thickness of the pad, and the regular tee connections
varied only in that some were welded in the air and some
were welded underwater. The fabrication of the pad
connections followed the basic design shown in Fig. 18
Details of Pad Connection. The fabrication of the regular
tee connection was without the pad.
The ~ee connection parts were cut using ~ oxyacetylene
torch. The 6 � inch piping was cut into 11 inc~i »'eces and
then sliced longitudinally for 2 pad pieces. The inside
diamete» I"} of the schedule 8G ;ipe closely tched the
Fig. lR Details of Pad Connect>on.
47
outside diameter {OD! of the 5-inch pipe and did not require
much deflection to force the sides of the pad to touch the
5 � inch pipe. The ID of the schedule 40 pipe is larger than
the 5 inch pipe and required more deflection to have s snug
fit on the 5-inch. The schedule 80 pieces were heated
slightly to aid in the compression of the pad, and because
of the thickness �.432!, it was harder to bend.
The pad was tacked onto the main pipe, and then as the
sides were compressed in a vise onto the main pipe, the pad
was tack welded 4 places. After the pad was tacked in
place, the 3 inch branch pipe was welded to the pad. The 3
inch piece was saddled and beveled to allow for a full
penetration weld. The saddle was custom cut to allow 0.125
inch root opening with a 45 degree bevel.
This weld was accomplished using an open butt joint.
The root and hot pass were welded with 0.125 inch H60{0
electrodes, and the fill and cap beads with 3/32 inch E7018.
Between the root and hot passes, the weld was ground out and
brushed. The remainder of the welds were wire brushed
between the layers.
After the tee weld was finished, the pad � to � main-pipe
underwater welds were made, Each side of the pad was welded
with 3 stringer beads. The top and bottom of the fillet
welds were rounded to give a slight eud-return. The
underwater welds--pad to main pipe-- were fillet welds. The
fi.rst hatt",.m; v ~s made wi' h 0.125 electrodes ' .. ;sore
satisfactory results were achieved with 5/32 inch
electrodes. See Plates I and II for photographs of the
finished tee welds.
Testin the Flexible Pad Conce t
After the fundamental knowledge was obtained from the
testing of fillet and groove welds, testing of the pad
concept began. The joints were tested it> a fitness � for-
purpose concept. The joints were tested as an integral part
and not dissected into finite element parts.
Before testing began, the connections were numbered,
visually examined and characterized. The testing inc1uded a
static and impact loading condition. The connections for
each test were selected by its weld quality. The static
loading placed the bottom half of the tee in tension while
the impact loading test stressed the top half. Therefore,
the regions of the underwater welds with the best quality
were selected for the particular test. The goal of the
testing is to verify the fitness � for-purpose and not to see
if a defect will cause or add to a failure.
Shear Stren th Loadin . Considering the flexible joint
design shown in Fig. 18, the pad to branch connec tion was
made ir. air, end the pad to main member was mv .':. underwater.
The pad length was determined by the allowvb1.e strength
of the underwater welds The joint shear str-.-i~i.', was not
comorumi;=~' bcc-use more 1ength w'='s «'id-'d to «* oad to
P j.at.e I PhoLogr aph of Flexible Pad Tee
Connection.
50
Plate II Photograph of Air Weld Tee Connection,
51
compensate for the degraded properties.
the following calculations.
This is shown in
eq. 7
q = 0.3 X 70,000 X 0.707 X 0.375 = 5.57 unitstrength per inch!
qb = 6pL/2 l2 bending stress!
qv = p/2 1!~ shear stress!
5.57 = 6pL/2 1 ~ + p/2 1! ~ sum of the forces!
1 = 5.93 inches length of side of pad!
Adjusted length is 10 inches because impactstrength of underwater welds are 60% of air welds.
l ad X 0. 60 = 1 actual = 6. 0 inches
1 a v~ = 10. 0 inches
Static Loadin . The joints were tested under a static
shown. But'ng the first test, the sharp corner edges of the
joint gouged into the fixture and the fixture failed by
bending under a 140 Kzp Load. The joint did not bend,
because the structure had become as a rigid frame.
A second attempt was made using roller b..=.;'ngs �0!
sandwi 1 e-' between two 4 0" X 6 0" X 0 625 in, ibad k
machined p a".es beneath the tee joint during Loading. Thxs
rolling base would allow the ends of the tee . > iove or roll
loading condition to compare the strength of the pad and
fillet welds to the in-the-air welded structure. The static
loading induced both a bending and shear stress. In Vig. 19
Static Loading, the method of testing the tee joints is
52
Fir;. T3 Static Loading of Tee Joints.
53
A fixture device was designed toIm act Loadin
secure and hold a test joint in place while a weight was
dropped on the end of the branch tube. The branch tube had
a clamped striking pad bolted 11 inches from the main
tube. This strike point served to concentrate the impact at
the end of the tube. Through calculations, it was
determined that four pounds dropped from 6 feet would cause
a plastic deformation in the branch tube of 0.1 inch. The
hypothesis was that if the plastic limit of the tube was
reached before the welds failed, then the strength level of
the joint exceeded the strength of the material, and the
welds passed on a fitness-for-purpose test.
The first trial joint gave a 0,125 inch deflection with
33 pounds from 5 feet in height. In order to achieve
greater deflection and see a greater discrepancy between the
regular tee and the pad concept tee, the weight was doubled
and raised to 7 feet high. Each joint was fitted and bolted
in place, the distance between the base plate and a gauge
mark was measured. The weight was dropped and impacted the
tube. It was then lifted off the end of the tube before
measuring the deformation. An example of the testing is
shown on Plate III Impact Testing. This photograph at the
instant of impact, also shows portions of the testing
fixture. The welds were later tested with dye penetrant
inspection to check for cracks from the impact loading.
Plate i I I Inipar t 'I'est in>.
CHAPTER IV
RESULTS
Underwater Wetdin~Snrve
From the compiled list of users, !20 questionnaire
surveys were mailed. Of these 38 were retu<ned. Of the 38,
l8 were completed, and 20 were returned because of address
changes. A compilation of questions a»d responses is found
on the following two pages as Table l.
The users can be organized into two groups � -oil
companies and service organizations. Trends pertinent to
this study were established--the high use of fil.let welds,
A 36 material, and wet welding with SHAW, Two users
indicated that they use another material--A 633. The
material has a 30% lo~er maximum carbon content �.19!, hut
slight.fy higher alloying by other elements. This material
has more exacting limits on chemical composition, thus
giving a consistent low hardness in the wells.
Literatvre Search and FFPI Data Bases
The .~'.~»i i f icat ion of impar t a» t pa< amete"'~ whi ch def ine
w<.l d qu<." ' i ty have been <ol !ected from <vrre»t I tt rat ure en<i
the t est i t of underwater welds. Tb is compi lat < =n of data
56
Table 1 Uzzclerwater Welding Survey Res purses
KS4 X IRK RC R C Sv
SURVEY REPDNSESQUESTIONS
16 YES 1 ND
10 YES 6 ND
ls this vork prinarily for:
5. Prinary type of naterial used?
6. Basic joint desiqns?
7. General uelding depths?
SMAN}0 ranked at 51 ranked at 3 and 4
GffAN2 ran'ked at 4
ranked at 3. i,
STAN1 r anked at 4 , and 13 ranked at l
Does your conpany's activities include undervatervelding?
2. Do your activities include fabrication of offshorestructures
3 ~ Nhat geographical area is your uork?
B. Nelding processes? RANK ON THE SCALE Of USE:5 TS THE ffQST!
12 Gulf of Mexico3 North Sea2 Great Lakes7 East coast5 Nest coast5 inland rivers2 Ilany of the above locations4 Other � Japan, Carribean and North
Africa
13 Offshore drilling6 Transniss<on lines7 General oil field construction
Salvage10 Offshore structure fabrication12 Actual undervater velding2 Other-Repair
12 A-362 A 1062 A-533 Other � Apl 2H 6r 50, A 633 Gr b and
c
10 Tee Joints9 'K' joints6 'Y' Joints
Plates--sean lap joints5 Plates � sean butt jo>nts12 Fillet velds1 Other � Tube butt joints
6 Al 1 depths15 Splash zone16 10 to 50 feet12 50 to 300 feet5 300+ feet
57
Table 1 Underwater Welding Survey Responses � � continued
FCIN1 ranked at 5 4, and 12 ranked at k
9. ln vhat types of conditions? Net velding11 ranked at 51 ranked at 4,2, and 1
Kini-habitat3 ranked at '5 and 11 ranked at 3
5 YES 5 ffO
10. Can you list any technical difficulties vithundervater velding in vhich you are associated vith?
11. The second phase of our project is to investigatejoint details and configurations. Mould youassist or allov us to reviev the joint details andconfigurations of sone of your undervater structures?
Hyperbaric2 ra~ked at 53 ranked at 3
ranked at 4,2 and 1
Ifost responces vere related to problensconnon to undervater velding: Porosityhardness, ductility, fit-up pressureeffects, 'testing and inspection. Otherconnents included: Finding good velders,velding on old naterials and stoppingthe vave action
58
sis. The statist. ical analysis vf theStatis'ti
data base consists of two bar chart graphs. The similar
trends established from the two data bases are clearly shown
in bar graphs on the fallowing pages. See Fig. 20 and 2]
with accompanying data charts.
Ud nrewater W~e1dtn Tests
Before welding could begin, the weldability of material
used for the test welds needed to be investigated. The CE
was determined and found to be within specificat.ion. The CF.
f » the o..' material was 0 35 using K<I. 1 and <, '.'.< us ing Eq.
The CE i or the plat e was 0. 19 and 0. 24, P t h <>f these
values ar e below the CE level �. 40! t at has - 'n si>own to
includes in part the mechanical properties of--yield
strength, tensile strength, reduction in area, hardness
values, CVN and crack tip opening displacement CTOD!. The
data base consisted of two paris, The first part was
derived from the literature search data base, and the second
from the FFPI data base. The FFPI data base consisted of
test results from actual mechanical tests from the test
welds and from other test data that exact.ly matched the
welding procedure for this research. The compilation of t!ie
literature search data base is shown in the appendix on
Table 2 Weld Properties from Current Literature.
�,12,14,2'3! The FFPI data hase is listed in Table 3.
59
Table 3 FFP I Data Base
ULT IffATE TENSILE CHARPY IIIPACTSTREIGTH HELD NETALkpsi ffpa! ft-lb J!
HARONESS +IVICKER5
0PH
alhis data base vas derived froe the literature searchand test results.All of the velds vere cade vith 4-36 naterial aud includedthe above eechanical tests.+a Haxiuuu hardness of HAl vith a 500 8 !oad on Vickers: GPH
7271747570717169707171696972576871
496.4489. 5510,2517.1482.6489.'5489.'5475.7482.6489.5489.5475.7475.7496.4393.0468.8489.5
2832352914 82030232627242226Ie3033
38.043.447.539.319 ' 010.827.140.73l.235.336 ' 632.529.83'5. 321. 740,744. 7
333405228376480340350350440365365365400236177417357
61
LEBEND:
QUALITV OF UNDERNATER MELDOUALITT INDEX =
QUALITV IF AIR HELD
QUALITY REFEREHCE FOR AIR lELOS
UTS = 71.0 kpsi 498,0 NPaCVN = 44.0 ff-Ib 59,0 J
HARDNESS NH * 180 DPH VICKERSIQIRONESS HAZ = 440 DPH VICKERSDHARONESS NN ~ IB HRC
tHARONESS HAZ * 23 HRC~ ELONSATION = 259
tUSKD ONLY IIITH THE LITKRATURK SEARCH DATA BASE+aNDTE: HITH HARDNESS THE HARDER THE IMMATERIAL,
THE LESS DES I4BLE ARE THE PROPER I TIES.THEREFORE THE SHALLER THE VALUE, THE NOREF IT fOR SERVICE IT IS.
L'ITERATURE SEARCH DATA BASE
YS UTS ELUH6. CVN HRCkpsi HPA kpsf IIPA ! ff-Ib J HII
HRC IIjhl
I
49,0;115.7 771.0 33.7 61.2 83.0 48.097.0llIAX IIIUH 669.0
356.0 38.9 259.0 5,0 f0.3 14.0 14.5 20.0 ILNININUH l '53. 4
72.0 13.6 9f.0 10.1 17.0 23.0 8.3 8.2 lf0.8'S N-f!
71.0 13.4 90.0 9,7 16.5 22.0 B." 7.6 l<S NiI
10.2
I NlpiBER10 I pt "7 10 l
10624
Fig. 20--continued
aHEAN l 70 2 468 0 74,0 4930 223 31 7 430 350 40 5 I
Statistical analysis of fitness for pmpose Rata
h;ih V
6911M 3NHZ15
Fi~. c'> Statist icai Ane lysis of FFPI D-.: ..~~a
63
LEGEND'.
OIIL'.TTY OF UNDERNATER HELDDOALETY ENDER ~
IBIALITY OF AlR NELO
QUALITY REFT.E FOR llR VELDS
FIEHEBS FOR PURPOSE FFP! DATA BASEUES CVK HAROIIFSS t
psi IIPa ft-1b J DPII70.0 466.5 24.9 33.8 352.0
I
49'9. 8 35.0 47. 5 480. 0 i75. 0
10.8 177. 057.0 379.8 8.0
3. 8 25 ~ 3 7.2 9.7 76,9
24.8 7. 0 9.5 74.63,7
I
}7 II1717
UTS ~ 71.0 k si 498.0 HPaCVK 44.0 rt-Ib 59,0 J
HARDNESS NK < 180 DPH VICKERSHARDNESS Hhl ~ 440 DPH VICI,'ERSaHARDKES"; NII 18 HRC
~ HARDHESS HAl ~ 23 HRC«ELOHBATIOK ~ 257
IUSED OIR.Y VETM THE LITERATURE SEARCH DATA BASENOTE: VlTH HAR'OIFSS THE HlRDER THE IIATER'I AL!
THE LESS DESIRABLE ARE THE PROPER'IEIES,THEREFORE THE SIIALLER THE VALUE., TH: IIOREFll FOR S4%ECE lT 15.
Weldin Procedure. Initially, tI>e welding parameters
T48LE 4 � HELD IH6 PROCEDURE
'. ELECTRODE I AHPERh6E I POLARITY I EL'ECTRODEI 'IIELD POS1TIQH I EHVIROHIIENTI IIATERIAL I TIIICKHESS,'TYPE SIR I FILLETS 6 6ROOVESl INCHES '.< 3F AIID 2F 16I 3F AND 2F 16l 3F AND 2F 16
0. 125'I 0.125'I 0.125'
DC-K-DC-
IELECTRODE A I 130-160IELECTRODE B I 135-175IELECTRGDE C 3 140-165
MET I 4-36IIET I 4-36DRY I 4-36
0.3750.3750.375
LE6EHD: ELECTRODES A AND 8 ARE DOIIESTIC ELECTORDES3F--TFE JOINT HELD IH VERTICAL POSITIOH � MELDII46 DIRECTION IS DOlIII2F � TEE JOINT IIELD ll4 HGRTIOHTAI. POSITIOI416 � VEE 6RGOVE JOINT IN FLAT POSlTION
Test Weld Nomenclature. Before welding, each weld was
given a descriptive identification number. Examples wouldinclude:
Test Weld--TVAU--T = tee fillet weld jointV = vertical positionA = electrode AU = underwater weld
vee groove butt weld jointflat positionelectrode Cair weld
BFCA � -BFC
A complete list of all the test weld nom~:nclature willbe g ~ ve~. xo conjunction with the hardness valises in Table 5!
Mechanical Pro erties of Test Welds
The t o ' in' .n~< portion of th s 4 tudy wi 1' 'i. divided
was derived from existing data and from past experience, butafter several of the test welds were completed, theparameters were identified and are listed below in Table 4Welding Procedure.
into various segments representing the mechanical properties
and weld condition of the test welds: hardness va1ues and
plots, macro and micro analyses of both tee and groove
welds, mechanical properties of tee fillet weld fracture
tests, tee fillet weld bead profiles with crack directio»,
and tests of the vee groove welds--CVN, tensile, and bend--
done by an independent third party.
Hardness Tests. A special technique was developed to
better illustrate the weld area hardness. See Fig. 22 DFH
Numbering System. With this numbering sequence, the values
were plotted and a relationship between the hardness found
in the different location was sho~n. This is demonstrated
in Fig. 23 Plot of DPH Va1ues. With this numbering
sequence, the left half of the hardness plot is in effect a
mirror image of the right half with point "14" as the center
or pivot point. Notice that most of the 1ines converge on
point 14, This point represents the weld metal DPH of the
samples. With this unique plotting system, a comparison of
the hardness between the regions is easily shown. Note that
the HAZ near the veld toe is the hardest points 4 and 25!.
The base material averaged about a DPH value of 180 or
about Rockwell C of 18. The HAZ hardness in une uf the toe
reg io»s h~d a maximum DPH of 439. The max imum <~ 1 1 owab 1 » for
a Typ» A wc.l d i s 325 Hv 10, The DPH vu I ue i s or i h<
Vickers mxcro � indenter whereas the Hv 10 is t. h< den i gnat i<>»
for ".ickes ~., a< . o-ind< nt er with 1000 gram 1oa<j. ', i «Lh<.
Tee Fillet Welds
Vee Groove We 1ds
Fzg, ."? DPH Number ing Sys tern.
Ei7
Fll LET '"ELP0
4 vL'v
42I't
' ~ 4. !
'vf0
eav
24!
I4 t
0 7'Et '+ TPIst Ix
� Tvxt.!0 ~V
--Tee Fillet WeldBUTT WELD'
.205'I 0
27026!
t4
210
0 6'!
b--Vee Groove Welds
Fi<. ~0." Plots of DPH Velues
t vt0190IP0I 0I c.0
2 5 4 5 6 7 5 '9 I 'I l 121514 151617161920212 25242526 27
I 2 0 4 5 6 7 6 9 1011 I21>I4 I5161718 19 0 'I '24 5262.
68
appendix, a complete list of the hai dness values is found in
Table 5 Hardness Values of Test Welds.
Macrostructure Anal sis. A macrostructure analysis af
the base and weld metals was co~ducted. No cracking or
porosity was observed. All of the test welds were multipass
welds and were, therefore, more complicated than a single
pass weld. The welding sequence was shown earlier in Fig.
To see the effect of welding on the structures, macro
photographs were taken of both a typical tee and groove
underwater welds and one groove air weld. In the following
photographs in Fig. 24, a--Tee Joint, Underwater weld, b--
Vee Groove, Underwater Weld, and c--Vee Groove, Air Weld,
the HAZ, weld metal, and base metals are clearly seen.
Notice that the weld metal of the first or root I>ass
has been affected or refined by the following weld 1ayers.
The affected, long columnar grains of the weld metal have
been refined. It is readily apparent that the preferential
etch of the weld metal by the etchant �R Nital! is more
pronounced than the air weld. The depth or thickness of the
refined HAZ is greater on the air weld. The rapid cooling
of the wet weld shortened the heat transfer zone and reduced
the H47 size. The placing of beads or layers over 1>revious
beads for the purpose of iefining the weld meta1 is cailed
temper beads, This is a common technique used in underwater
welshing no .n'y to iefine or temper t1ie course, weld metal
a � - Tee Joint
Undersea ter We 1 d
b � � Vee Groove
Underwater WeEd
c--Vee Groove
Air Weld
Fig. 24 Macro Photograph,
70
grains, but to refine the hard microstructure of the toe
region of the HAZ. From the photographs it is obvious that
the refining action was not complete. To rely totally on
temper beads to soften the toe region would be an error,
because the exact weld placement would be hard to accomplish
underwater. From a quality control aspect, temper bead
placement is hard to police and verify. �,8!
To show the effect of a temper bead on the hardness of
weld metal, traverse DPH impressions were taken of both
underwater and air welds, See Fig. 2S Horizonta'l and
Vertical Traverses, for locations and orientations of the
impressions
The horizontal traverse of points trave1 from an
unaffected base metal through the HAZ and into the weld
metal. This is representative of a single underwater weld.
The vertical traverse also begins in the unaffected base
metal and travels through the HAZ and into weld metal, but
continues into a refined portion of the weld metal. in the
Appendix, Table 6 DPH Values of Weld Traverses, lists the
values of the four traverses--two from an air we!d and two
from an underwater weld. The values of the two underwater
welds we re plotted to better show the effects of temper
beads on the macrostructure. Figure 26 Vertical Traverse
VTU!, si uws the softening of the middle zone «id the n a
hardening from the temper bead. Figurc 27 JiorizuntaI
Traverse 8i''i;, demonstrates the hardness of r i 'ld without
HORIZONTAL TRA VE
OF OPH IMPRESSIONS
HAZ VERTICAL TRAVERSEOF DPH IMPRESSIONS
Fi g. 25 Horizontal and Vertical Traverses
72
a temper bead. This would be typical of a single pass weld.
These trends were similar to those demonstrated by Tsai in
1977. �! No hardness traverses were taken on the vee
groove welds, because the same basic effect would be present
as demonstrated with the temper beads on the tee fillet:
welds.
These plots were made to show the composit.e or non-
homogeneous structure of a weld on a macro scale and how the
heat of welding changes the structure and the mechanical
properties.
Micros tree tore Aper~sic. The micros troct ore coo iysiis
of underwater welds is not a requirement of D3. 6.
Nevertheless, it was conducted, because microstructure
determines the material properties. The typical
microstructures of air and underw«ter welds are shown as s
montage of photographs which follow the same path as the
vertical and horizontal t.raverse surveys. These photographs
Plates I <t to VI I ! or, montages, show the thermal ly irrduced
allotropic phase changes in the structure caused by welding.
All of the test welds were examined, but only two were
photographed. The metallurgical response from welding was
the same with each underwater electrode.
The sequence of photographs begins in the h~se metal
and pre<-.e<s s through t he HA7 and i rr t<i the we 1<l met a t . The
path fol iowa the DPH in<tent urea--which are se<r~c»f i«1 ' y
size of ttr<' irrdenture in<ticates tr e r e lativ<.
VTU 73
DPH VALVES F1%OIA THE BASC TO WELCH LIET.4L330. 00
&0.00
m~1 O. 00
300,00
290. 00
290. 00
270,00
260,00
250. 00
240. 00
230,00
0.00
210.00
200. OC'
190,00
Ieo.co 1 2 0 0 6 6 7 6 9 10 11 12 I> 14 15 'IC 17DISW4CE f11944 EI4SE 44ET4L- -0.5 mm
0 VTLIFig. 26 VTU
HTU
VALI!ES ET[0M THE 8.4SE TCI WELP 44ET4iv 30.00
320. 00
~1 O.CO
290,00
290. 0!
27G OG
260 00
2 A>. 00
240. 00
Elo 00
220. 00
2'IO.CO
200, 00
190.07
'I 00.004 5 6 7 0 9
VSSE F11044 ~ METAL--O,5 mm0 HT4I
F i g. '7 HTU
74
hardness of the material. In the underwater welds, it is
apparent that the indentures get smaller which means the
structure is getting harder! as they proceed into the HAZ
and weld metal, The superimposed dialogue describes the
morphology of the structure,
The air weld clearly shows the classic regions of a
welded microstructure. The underwater welds show a similar
structure, but because of the rapid quenching effect., the
microstructure regions near the fusion line are not as
discernable or pronounced as the air weld, The base meta1
shows a banded structure of ferrite and pearlite typical to
hot rolled structural steels. With welding, the banded
structure begin to spheriodize and refine into a smaller.
grain structure or size, Nearer the heat source, the grai.n
structure begins to grow as it enters into the austenite
region. Immediately prior to melting, the structure is
austenitic, and the austenite grains are very large. The
grains, in the HAZ, adjacent to the fusion line, typically
remain large be» ause the r apid cooling rate does not allow
the structure to refine. This material on the base metal
side of the fusion line has almost melted and the material
has been heated above the critical temperature range end
The austenite has a high solubility for carbon, and wh» n it
cools rapidly, the austenite does not have the time to
change into pearlite and ferrite, under equilibrium
conditx» ns. 'i».t it forms martensite. There is »»l~o
75
P1ate IV Underwater Weld Refined Region VTU!
UNDERWATER WELD REFINED REGIONzaax
REFINED WELD METALREHEATED /BOVE 875'C
FUSION LINE
POLYGONAL FER~Cv
4~-'J
HEATED ABOVE;,+pi"',875 C ' c ,<' '
LUMNAR GRAI
WELD METAL
DPH INDENT
.',:,'-�',-0�"44<'j; '
BASE METAL
Plate V Underwater Weld Traver se HTU!
UNDERWATER WELD TRAVERSE
200 XHEATED
4 ABOYE 575 C
COL UMNA R GRA INED WELD ME TAL
/
FUSION LINE
WIDMANSTATTEN ~ 45
HEATED
ABOVE 'F80'C
PRIOR AUSTENIT AINS
k Ft DPH INDENTi 4
FERRITE
PEARLITEvt
P g'..2
BASE METAL
77
Plate VI Air Weld Refined Region VTA!
AIR WELD REFINED REGION200X
POLYOONAL FERRITE
REFINED WELD 'METALREHEATED ABOVE
51$'C COLUIMHAR ORAIHEDWELD METAL
FUSION LINE
HEATED ABOVE 875'C
2
DPII BC!EHT
BABE METAL
79
has become austenite oi face centered cubic in structure.
relationship between the hardness of martensite to the
carbon content.
With A 36 material the carbon is low � � 0.19% and the
martensite is softer and the problems of cracking are
lessened. Martensite is characterized by an acicular
structure, and is the hardest of the decomposition products
of austenite. There is some martensite present because the
hardness af the structure is above 40 Rc, but it is a low
carbon martensite. With the tempering affect shown in the
macro photographs, the martensite becomes tempered,
generally having a beneficia] affect on toughness. This
softening is also shown in the difference between the
hardnesses of the weld metal within the same weld. See Fig.
26 and Fig, 27 for this comparison. The last bead on the
weld slightly tempered the second bead even though the
microstructure appears to be unchanged, but the hardness is
higher in the 1ast weld metal deposited.
Fillet Weld Sha e and Fracture Data, The fillet weld
shape and fracture data is listed on Table 7. The fracture
limit was the actual force in pounds required to either
break the coupon and/or bend the material is found in the
fracture .immit column.
Fillet Weld Fracture Profiles. From the 35 break
tests, sevei.»i common fracture patterns appeare ~.
80
Crr
Sr
C C
C C.SI Sr 0
&'CIW SESS 'Ct Sr StSr 4 SrSt aCI
Sr SJ Sr Sl
Sr Sr Sr Sl0 0
vvvuvvvv4444ODODDOOOXTXZScr 0 % SS O D SS '0 000 CIErr0 0a Sr 4 Sr St C C C: C« ~
SI SI SrV V v v ~ a h~ S tS S rSa a LJ LJ v v~ tr rs tc0000vr-a-sC C
rS rSSt SI 4 Sl~ p- a v v vrSav V v v V»ra tSh v ~ 0
'V aJ V Vtc JS tSv k.Sr SI 4 4 Sr 4 SI 4 SJ SI 4 SJI ~ & ~ r a w a a I
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Figure 28 Photographs of Fi 1 let We 1<1 F r act ur.e <iisplays
photographs a to d! of fillet weld breaks wh.ich show
several trends. There were multiple modes of fracture,
however most of the coupons broke through the HAZ or through
the weld metal towards the notch formed between the two
cover passes
The smooth transition bead profiles, with no «r sm<rll
notches, on the weld surface were less prone to failure
Plots of Mechanical Pr~o erties and Throat Size. Two
comparisons of mechanical properties � � fracture limit <rrrd
stress fracture--were plotted against throat size in Fig. 29
Fracture Limit vs. Throat Size and Fig. 30 Stress Fracture
vs. Throat Size. The trend in Fig. 2'9 shows that as the
throat size incr eases, so does the fracture limi t. Figure
30 shows that air welds have about the same fracture stress,
but with one half of the throat size.
CVN Test Data. The CVN test data results from the
first three vee groove welds were Low, and did not refLect
established results. The impact properties of the HAZ were
2 to 3 times greater better! than the normally tougher weld
metal A possible explanation for this trend was the
corrsi der ab Le amount of f iire porosity in the wel d meial. Tire
f inc po<'.i". i ty, i n comb inat ion with the oxyger«<intent,
wou 1 d <-ause the weld metal to exh i bit lower tougliness.
Yhoto a:
Weld cracked throughthe HAZ o f air weld.Note th» notch fromt,he lack of penetration,but i t st'i.1 k fai 1 ed i nthe HAZ.
Yhoto h:
;racked towards thenotch located
between the two."-urfac» beads.
I''xg. 20 Photographs of Fi 1 lct W» Id Cracks. Phot.ographs cand d are continued on the next page!
Phot.o
C r a <. k e d t, h r o u g h t. h ~t Eri lit!es t, see t ion
the throa t..
Photo d:
No bred>h
h''ig. HEI I'hotagrwpI<s of F'j I Ii I H< lc! ;<;t< I s
85
AACfIÃ LlN!t It. lNNII SfXL'
IRACHRt L18IT: roasts af ant
Fig. 29 Fractur e Limit vs Throat Size.
NGk STRXSS 0$: lllR041 hl?I
KELl SIRES: kgb i
Fig 39 Stress FractUre vs Throat Size
86
The radiographic film of the electrode A weld sho~ed a
substantially greater amount of fine porosity than electrode
B. The notch for the HAZ impact samples may have been
placed incorrectly, However, the weld metal of the air
welds also showed degraded properties, and thxs error may
lay with absorbed moisture in the flux coating of the E7014
electrodes. These electrodes were not baked before using
and the moisture content could have been high.
Because of these deficiencies, another set of vee
groove coupons were welded and resubmitted for CVN testing.
The new results showed a marked improvement of values which
parallel established results. Copies of both test reports
ate found in the appendix. The CVN test was conducted using
10 samples from each weld--5 impact specimens from the weld
metal and 5 from the HAZ, Table 8 CVN Results shows the
improved test results.
These values are much closer to test results from
industry, however the values of the HAZ are still better
than the weld metal. The HAZ had a higher hardness and
larger grain size, but better CVN properties--an obvious
contradiction.
With the plate thickness of 0.375 inch 'JJ.5 mm! and the
sub sized CVN specimen � mm!, incongruities occur because
of the 'oint design and orientation of HAZ to the note:h in
the GVVi sample. To better evaluate the CVM values of the
HAZ, an aiiernate joint design should be consid.-ted.
87
LOCATION OF CVN TEST RESULTSWELD METAL HAZ
f t-I b f t-lbWELD ID
IlUHA � UNDERWATER WELD WITH "A" ELECTRODEUWB--UNDERWATER WELD WITH "8" ELECTRODE*W--AIR WELD WITH E-7014 ELECTRODE
Table 8 C VN Resul ts.
UW* l 28I 201 r g4
I 3n4
UWS l 26I ,�
28
I 26t 26
514 3
49
47'45
313'9
54
44
46
45'74
40
61
46
58
88
Presently, for a typical vee groove, the notch for or>.
impact test is located in only part of the HAZ. This is
shown in Fig. 31 Current Location of CVN Test. The figure
shows the location of the machined notch in re!ationship to
the HAZ according to D3.6. The machined notch is designed
to provide the crack initiation point for failure on these
coupons. But as Fig. 31 shows, only one por.tion �5%! of
the high hardness area of the HAZ is tested. The crack path
can now propagate through tougher structure base metal! of
the joint and give incorrect higher! values. A better
design to test the HA7, of a material would be to use a
single bevel joint. This would allow for the true character
of HRZ toughness to be determined. Figure 32 Improved
Joint Design shows the notch orientation to the HAZ in an
improved joint design.
Develoymeot of Allforilhm Tables
TIl rough t he development of al gor fthm tab I as, the we1d
condi to on and mechanical properties of Type 8 welds can be
characterised. These 17 data points ar e listed in Table 3
FFPI data base.
Tob".e 9 shows the six algorithm tah]es. 'The va ues of
each of' '.4'= 17 data points was plod ed in the «r»r»priate
cell wit:;'n one of the tables. Each table corresponds to
one o t t1r» r anges on the "/" or har»ines s ax i s i n I he 3.-ax is
VFPI i n l -" s~» wr- in Fi g.
89
TOP VIEW
f
WELD COUPON CHARPY SAMPLE
SiDE VIEW
Fig. 31 Current Location of CVN Test
TOP VIEW
CHARPY SAMPLE
WELD COUPON
SIDE VIEWHAZ
Fig. 32 Improved Joint Design for True HAZ Toughness
90
Table 9 Algorithm Tables
PLANE 4HARDNESS INDEX RANGE: 240.0 TO 320.0 DPH
PLANE IHARDNESS INDEX RANGE: 0,0 TO 60.0 DPH
I 6I I
5I
I 4I
I I I I I I I II II III III I
II IIIII II I
II II III II
I II I II I II I I
II II
'I I 3
I I I II
II II II II II
I
I II II II II I
II III I
IIIII I
, '5 2 l 3 l 4 l 53 6
RANGES OF CHARPY UEE NOTCH DATA
PLANE 2HARDNESS INDEX RAN6E: 80.0 TO l60.0 DPH
RANGES OF CHARPY VEE NOTCH DATA
PLANE 5HARDNESS IND'El RANK. '320.0 TO 400.0 DPH
I II II III I'I
ItttttII I I 'I rI
II II I I I I II 6 I
I I 'I5 'I
I 'I
92 I II I II II I
I
l4lI I I I
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I 3
I I I I I I I I I II I I I I I I I I I I I I II I I I I I
3 I 4 ' 5I I
II 4 I 5 ! f II I 2 l 3
RANGES Of CMARPY UEE NOTCH DATA RANGES OF CHARPY VEE NOTCH DATA
PLANE 6HARDNESS INDEX RANGE: 400.0 TO 480.0 DPH
PLAlli 3HARDNESS INDEX: l60.0 TO 240,0 DPH
I t II II I I I I I I Il61 I I I 92
I I I'I'I I I I I I I
5
I I I I I I I III 'I
I I
I I III II II I I
I II II I I I
I II II
II 1.II
rI
II II I II I I II I II I I I II
l l 2I I I
5 II 3 I 4 I4 l 5 l 62 I 3 6
FIr'rHGEs of CHARPY UEE NOTCH DATA RANGES OF CHARPY VE'E NOTCH DATA
vithin the plane,A-tr:.1..'., nar >s the cell as a data point
RANGESIN THEULT IHATETENSILESTRENGTHINDEX
RANKSIN THEOLTIHATETENSILESTREN6THINDEX
RAN6ESIN THEULTIHATETENSILFSTRErrB:HINDEX
I I
I I I I I I I I I I I I I I I I I I
I I I I I I I I II I II
RANGESIN THEOLT IIIATETENSILESTREN6THINDEX
RANGESIN THEULTIN ATETENSILESTRENGTHINDEX
RAIIGESIN THEULT IIIATETENSILESTRENGTHINDEX
I 3I
I 2III IIII
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l 2
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I I I I I I I I 92 'I I I I I 1 I I I I I I I I I I I I I I II I I I I I I
I I I t I I I I I I CCI I I I I LNI ~I SCI I LI
I I I I gtI I 1 I I I I I I OI IAI I I I I I I I I II I I I SiI I NlI I StI CI 1S1 I I 0I I
~ IllIIIlII III IIt CD IIl II I St IIl SN INll lS IIl ~Il11 III I11tl11 Itl I11 III IN ISII ICC III III Sl IN CIC III I III NI III 1 IIlII III III III tIIllIIII Ill Ill Ilt ~ Ill Itl StIIll C: Ill St III t- 'IS IS IIlNlt INN III ~II III III I11 III CD III I11 Ot Itl Stt IIl K II I NiII ~ III III II Ill III ItlI! Ill Ill IN IN IN IIlN IIl tif III SN III D IIl tS III t I III IN IIl IN IIIII III IIIII III Ilt IIl ~ IIl IIt StIl SN Itl K IIl ClNN IN IN IN III IIIIl III IIl III II I Cfl III III NN Ill ~ Ill IIl K IItIIN
IIIII a&iI PII CtIII COII CCIIIIIII
I PI OIIIIIIII1IIIII ECII OII CtII CCII IPJIIIIIII 4I CSI IAII loIIIItIII
III CVI IPCo
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II IONI e
Z
? C Z O !C
The points within the plane cells were plotted on the
three way FYP axis. By way of comparison, a superimposed
box shows the approximate quality range for a Type A weld.
Confidence factors were computed from the Type 8 data
points, and llX of the data points fall within the Type A
range along the hardness axis. However, 90% of the FVP
welds fell within the Type A range when considering UTS and
CVN values. The hardness limitation of 325 Vickers is t.he
most difficult of the mechanical properties to achieve.
Testin of Tee Joints
The data contained thus far in this chapter showed the
results of testing a finite part of a welded specimen. The
testing of the flexible pad and regular tee was conducted on
a global or total concept basis. The tee connections were
tested by static and impact loading.
Six of the tee connections were givenStat
shows th» «x t.»nsi ve 1<><.a t def<>rmat. i o»
a compressive load of 96 kips. None of the connections
failed from the loading. The loading condition was two
times higher than the calculated yield point. The contact.
points of the tee connections were severely deformed, but »o
plastic deformation of the branch tube at the weld was
obser ~e<i, Tab le 8 Pl ast ic De f ormat i o» f < om S t. «t i < Loa<! i »g
94
Plate 8 I.ocul Deformatioo
Im act Loadin . The results from the impact loading
are shown in Fig. 34 Plastic Deformation from Impact
Loading. None of the connections showed any cracking after
testing. The weld areas were checked with dye penet.rant by
the NDE department of Arcair Company, and no cracking was
present. Because the deformation of the underwater welded
tee joint was greater than the padded tees, it was suspected
that this tee was internally cracked. Upon a macro
examination of the weld cross-section, two root bead cracks
were noticed see Fig. 35 Impact Cracking of Root Beads!.
The top crack not very clear in the photograph! traversed
one third of the thickness of the brarrch tube. These cracks
may explai» why the deformation from impact was greater than
with the air weld tees when it should have been the same.
96
I'IASTIC DKFONNTION FRN INFACT L04DING
TKK COINIKTION TYI'ER
Fig. 34 Plot of Impact Loading of Tee Connections.
97
Fig. 35 Impact Cracking of Root Bead,
CHAPTER V
DISCUSSION AND CONCLUSIONS
The most significant finding nf this study was the
flexible pad concept for a joint connection. The energy
dissipates in the connection pad before it reaches the welds
made underwater, and the energy stress in the welds is
minimal. The stress in the underwater welds is kept. helow
the endurance limit for infinite fatigue life. The joint
performance under impact loading would also be improved.
Several other advantages with this connection would include
quick installatio~, little or no fit-up time, hetter weld
quality with fillet welds and no groove welds, which
typically are of poor quality in sub-sea conditions, premade
parts for ready installation, and viable for new
construction or fabrication. This concept appears to be a
feasible method of circumventing the expected pejorative
consequences of degraded mechanical properties in
connection, maintaining performance limits, an~J economically
benefiting from connections which are less expensive and
easier to install.
Through t his research on the degraded Type }I weJd
properties and underwater welding, several specific
99
conc lus ious can be made
1. The toe regions of the welds have the highesthardness and largest g'rain structure size, As aresult, the toe region has both a mechanical aridmetallurgical notch effect,
3. Defects in the fillet weld shapes causestress risers and degraded weld properties.
4. Charpy impact values of the HAZ can bemisleading because of the narrow HAZ band,misplacement of notch, and following the AWSguidelines for a vee groove joint.
5. Charpy impact values of the weld metaL can bemisleading because of porosity and gases in thewe1d metal.
6. New structural steel alloys are beingselected because of lower maximum limit oncarbon, which would lover the hardenabilitycharacteristics of the steel and facilitatebetter properties on underwater repair welds.
7. The throat thickness of underwater welds isdouble those of air we1ds at the same st.ressfracture limit.
8. Statistically, 11% of Type B welds meet TypeA hardness criteria; whereas 90% of Type B weldsmeet Type A CVN and UTS requirements.
9. With an improved joint design groove angleadjustment!, the true character of' HAZ and weldmetal CVN properties for material qualificationcan be determined.
10. 'The UTS of an underwater weld is equal t<>that of an air weld, but the CVN va1ues are 6~%to 7.>w iess.
11. The metallurgy<:a] response inf r om w.- 1 <1 > ng is has icall y th<- sameun<]<.i w;, i. «ei «":i rodes.
L h< t n~~, m< ta.l
with bokh
2. Temper beads over the years have been used toreduce the weld metal and toe hardness, butwithout a precise placement of the temper bead,the high hardness at the toes will still exist.The proper placement of these beads is hard toverify or insure.
100
12. The variables available to the welder forbetter weld quality are determined by followingthe AWK guideline for bead shape- � this can beaided by using electrodes with smooth runningeasy slag removal characteristics.
13. Because the material selection is oftenpredetermined, the variables available to thewelder are limited to altering the joint designfor better or easier welding avoiding vee grooveor butt joints!, and keeping a smooth transitionweld bead shape for better fatigue life!.
14. ln a stat:ic loading condition, the flexiblspad tees were as strong as the air welded tees.
16. The impact stress caused cracking in theunderwater welded tee, but riot the othe< tees.
15. The flexible paddeflection than the aireducing the amount ofon the welds.
tees displayed morer weld tees, hereby
stress affecting or acting
FUTURE WORK
This research had laid the ground work for future
studies. Example of other work to be considered would
include. 'l. Finite element study; 2. Fatigue tests; 3,
Investigation into a water cushion concept; and 4.
Electrode development for improved wet weld bead contours,
surface smoothness, and reduced porosity.
101
BIBLIOGRAPHY
"Specs Add Confidence in Use of Wet Welding" Feb. 1984,Offshore
2.
Gooch, T.G., April 1983, "Properties of UnderwaterWelds: Part 2--Mechanical Properties", MetalsConstruction, pp 206-215
S ecification for Underwater Weldin , 1982, AWS D3.6�83, American Welding Society AWS!: Miami
Grubbs, C.E. and O.W. Seth, 1977, Underwater WetWelding With Manual Arc Electrodes", Conf. Proc.Underwater Weldin for Offshore Installations, TheWelding Institute TWI!: Cambridge U. K. pp 17-34
Thomas, W.J.F., Jan. 1983, Underwater Welding-�Principles and Practices", Metals Construction, pp26-29
Tsai, et al, April 1977, "Development of New ImprovedTechniques for Underwater Welding", Re ort No. MITSG77-9, MIT: Cambridge, Mass.
7.
Priviate communication with Whitty Grubbs, technicaldirecto for Globa1 Divers, 25 Aug 1986.
Bruner, W.K., April 1978, "Generalized Survey of theState-of � the Art of Underwater Welding", 1"avel~En racers Journal, pp 68-74
102
1. Delaune, P. T. Jr., Feb. 1987, Offshore StructuralRepair Using Specification for Underwater Welding, AWSD3.6", Weldin Journal, AWS, Miami
103
Olsen, D.L., and S. Iberra, Feb. 1986, Ener -SourcesTechnolo onf., Paper OMAE-13, New Orleans.
Stout, Robert D. and W. D'orville Dotty, 1978,Weldabilit of Steels, Welding Research Council, 3rdEdition, New York
12.
Tsai, C.L. and K. Masubuchi, Feb. 1977, Inter retiveRe ort on Underwater Weldin , Welding Research CouncilBulletin ¹224i New York, pp 1-37
13.
Easterling, K., 1983, Introduction to the Ph sicalMetallur of 'Weldin , Butterworths: London
14.
Mishler, H. W. and J. K. Myers, hug 1985, "UnderwaterWelding Survey", Battelle: Columbus, Ohio.
Cary, Howard B., 1979, Modern Weldin TechnoloPrentice � Hall Inc., Englewood Cliffs, New Jersey
16.
Metals Handbook: Pro erties and Selections of Metal,1978, Vol 1, 9th Ed., American Society of Metals ASM!:Metals Park, Ohio
Linnert 1967, Weldin Metallur , Vol 2, 3rd Ed. AWS:Miami
18.
Metals Handbook: Weldin and Brazin, 1971, ASM:Metals Park Ohio
19.
Dawsen, G.W., et al,1982, 2nd Inter. Conf. on OffshoreWelded Structures, TWI: Cambridge, U.K.
20.
lntrodnctor to Weldin Metallnr , 1979, AmericanWelding Society, Miami
21.
Mat'lock, D.K., et al, 1982, "hn Evaluation of theFati.gu» Behaviour in Surface, Habitat, and Underwaterlet Yells", 2nd Inter. Conf. on Offshore Welded"t,d-'..I 7 es, TwI; cambr idge, U. K.
22.
Ha~pc »cen, P. J., 1982, "Improving the Fat 1 g! oePerformance of Welded Joints", 2nd Inter. Conf. onOffal- re Welded Structures, TWI: Cambridsye, U. K.3-3F,'3-<3
23.
pp
Pisarsk i. H.G. and R. T. Parget> er, 1984, "1 racture24.
10. Cotton, H.C., 1977, "Why Underwater Welding", Conf.Proc. Underwater Weldin for Offshore InstallationsTWI; Cambridge U. K. pp 3 � 8
104
Toughness of Weld Heat Affected Zones HAZ! in Steels
Ener Related Pro'ects, WIC: Toronto pp 415-428
25. Tandberg, S., 1984, "Offshore Structures for the NorthSea HAZ Hardness Requirements and PracticalImplications", Weldin in Ener Related Pro'ects,Welding Institute of Canada WIC!: Toronto pp 279-288
26. Stevenson, A.W., June 1983, "Offshore OptionsReviewed", Weldin and Metals Fabrication, pp 249-252
27. Pisarski, H.G. and R. T. Pargetter, 1984, "FractureToughness of Weld Heat Affected Zones HAZ! in Steelslined in Construction Of Offshore Plstfores" Welkin in
Kner Related Pro 'ects, WIC: Toronto pp 415-428
28. Blodgett, Omar, 1976, Desi n of Weldments, 8th edition,James F. Lincoln Arc Welding Foundatio~, Cleveland
APPENDIX
105
106
The Ottta State tNtteetetty Oep4rtntent atWelding Engtneenng
190 WeSt 19tn avenueColvmous, Ohio 4321 0-1 1 82
Pnone 6 t 4-422-6841
Dear Si r:
please accept ouz request for input into ouz research prospect.The U.B. Government has funded us, under the Sea Grant program,to use our resources and expertise to computer model underwaterwelded ]oints in current of fshore structures and reevalulate the Lzdesign chazacter istics. The primary ob]ective of this prospect isto develop a design philosophy, with test vezif Lcation, fozunderwater welding of o f fs haze structures� .
The solution to the inherent problems associated with underwaterfielding is found through proper design and planning. ThLsresearch project intends to provide a constructive framework forthe use o f underwater welding techniques uti l ized by any industryinvolved in offshore activities,
The offshore Lndustry is both highly competitive and expensive.we plan to assist the users of these structures Ln their effortsto design the most efficient, cost effective and safe structures.We feel that this is an opportunity foz you to reap the benefit ofyour tax dollar as it returns to assi.st you in keeping thecompetitive edge.
Ve appreciate your time. Please help us to help the industry. Ifyou do not feel you are the right person to complete this, pleasedirect it to those who can. Also, if you desire not to return ourform to us, please remember that The Ohio State University WeldingEngineer ing Department has many facilities and resouzces designedto solve engineer ing problems.
Sincerely,
Chon L. TsaLPrincipal Investigator
LarryGraduate Research Associate
107
SURVEY OF
Ul4DERWATER VELDIHC SPOHSQRED BY THE SEA GRANT PROGRAM
Your name
Title
Company
Do your activities include fabrication of of shore structures? 3-yes 4-no
Vhat geographical area is your vor k? 5-Gulf o f. l4exico6-Horth Sea7-Great Lakes8-East coast9-West coast
10-inland z ivers11-many of he above locations,12-othez
13-offshore drilling14 � transmission lines15-general oil f isld construction16-salvage17-offshore s ruc ure fabr ication18-actua1 undezvater velding19-other
Is th's vcrk pr imarily for:
20-A 3621-A 10622- A. 523 � othez
fr i-.wry type of material used?
24-tee 5cints25-K 5oints26-Y 5oints27-plates--seam lap 5oi nts28-plates--seam butt 5oints29- fillet velds30-other
Basic foist desi qns?
PLFASE CIRCLE THE APPROPRIATE HUl4BER S! OR FILL IH THE BLANKS AS HEEDED.
Does youz company's activities include undervater welding? 1-yes 2-no
108
General welding depths7
Rank on the scale af use: 5 is most
Welding processes7
In vhat types of canditions7
Can you list any technical di f f iculties vith undervatex; welding in vhich youare associated vith7
The second phase of our pro!ect is to investigate ioi.nt deta'ls andconfigurations. Would you assist or allow us to reviev the 3ornt detailsand configurations a some of your underwater structures7 44-yes 45-no
Do you think that proper design of joints for underwater welding could be aI-art.al oluti on ta the curren. problems7 46-yes 47-no. I f you answe NO,; ! e .,e 0 ve you opinions on what should be done o impr ove underwater« ding .. cnnolugy,
31-all depths32-splash rane33-10 to 50 feet34-50 to 300 feet35-300+ fee't
36-SHAW37-GHAV38-GTAV39-FCAV
40-vet welding41-hyperbaric42 mani-habita't43-other
Thank y"o for vous part cipa ion in the Sea Grant program.
55 45 45 4
5 44
5 45 4
3 2 13 23 2 13 2 l
3 2 l3 2 13 2 l3 2
109
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9 >IEATLAND J.<, t..... -;,';�'wsEATLAtvO, Pa 18161
t412I 342 6151
1 umbu s P i pe a n d Equip . Company73 E�Markison Ave.
lumbus, Ohio 43207
ATT: P bbie Bentley
60095AREG. NORE: CUST. ORDER 0 3930
Gentlemen:
This is to certify that al tandard Weight and Extra Heavy WeightBlack or Galvanized Steel Pipe and Coupli ngs manufactured by theWheatland Tube Company at Wheatl nd, Pennsylvania, U.S.A. has beenmanufactured, tested and inspect d in accordance with the applicableprovis ions of the ASTM Standard peci ~ication A-120/A-53 and alsoconforms with the requirements set for n Federa! SpecificationWWP 406/O'IPP 404.
Chief Chemist atIIManager, qua 1 i tg Control
112
LISLE 2-.HEI.0 PROPERTIED PRON CURRENT LLTERITLTRE
451 19393 HD
392ND
4f �77 I aHIITLW
Hd2.30 -10
16 � 0 � �,L2 014 Le 15 -10 C.03,06 .04 -10
�63!IHHw ilh
553495
31 39 3527 37 32
0 � � .10 0-10 . ID . I I . II -ID
3524
HA!IHrJ
0-10
. IO 0
.16 -10
HO ND �63! TihiNN!454
.15 .13 10-�� 30 23 .Ll
�71! 'TWHE,HH
28 0
-1015 17 1612 14 L3 ,07 .05 -LD*C.O4
13NO
DHHTTIAIKIK
669I 8
771426
NHLO 99/7628 46 37 032 43 40 .i0
.09 .20 ~ 17 0
.18 .28 .21 -10
I216! aHHTIHHHHHK
426ND
22842 103 7346 130 87
010
,OO .14 .10 0, 10 . � . 13 - 10
.30 0
.29 -LO35 90 63 0
70 -10HHL 6
�83! THTHHWi
RDAJN HH2! 0-LO
22 26 2521 26 24
kHHTr "f33
aHHT, *f 1.'7
NINLT,'fl 7
AHHTr FL.T
w,'f33
434 406 10
369-437 434 480 12-24
EDDI'!
E6020
pro-auLLLe-Oridt caveripT 472-614 50 Hi 8 5
7OHL-ISCrDT'S -Tha 35 i-463 425-599 10-16
497 41 0Sea Ceo Eli013
ECEC TRODE TERT REchaHLcAL PROPERTLE6 REHIRE 8 RELIHI, NI ~ 14 Tooer! ~ E!onqat!oe CWI IJ! CTOO Ioa! llardneea
~ thoeeth stheo9th I 1! hlh Hei aVE T C! "6 HV2.5!,orIHPa! HPa! lilk hei APE T C! Haa HRC
113
Co~tinued labia 7--hecnanical Properties Iron Current Ctiarntnre
WI, 'I'1. 7E6020
icid-rutil ~-ot!de&eeerine 31 39
27 37480-515 35 0
32 -ID35 024 -IO
Lih ~FI 7WI "F 1.7ha'rIL62r Fl.l
440 463
259-303
Wtr 'F I. 7
WI, Fl.7IDL, F1,7
WI, 'F33
EDOI415 le lf, O12 14 13 -10eci dc inc Corer I et
Bea-Con ehl
TDRI- 15Cr-16ho-F a+V 46-491 42 102
46 130T3 087 -ID6e o38 . IO63 070 -10
llh, *F1. 7IIIL, 7 I. 7Ilr�f 132IS 'F132hit, r1.7I461, F 1.7
35 90
ltlld 5lealElectro4e
i2038 486446409400
Ilh, 15INIDL, f'l02Wi,eer Ftee
27,026.523 025. 0
387404
450-491366
IRL, ReWL, F63WiIS
43,021. D-34. 0
42.2
2S. 5 vh, Re4442-ero
i515-70
0515<i0
430
45146I � 43. 544. 9 IS, R$
23. 0 Vh
37.5 WI, 895141-60
483459
i537 WL,R5> flooLSreer 'T ISO
35. 036. 0
iustrnrtjrE rctrar
5-778C7-9M28-5'5846-57E5C 92!Sfr- II2E73.207FBI-I42F87-27388'1.562886-9226
8-e>9-339IT-IITD
51373136fr5835454644eS6 I573555529297643582399543
41. 932,03e. 529,541. 039. 044.32'9, 739. 741,032. 229. 242. 441.242.BIC
Btt, RBIN, RSINiel, ReVnVhr RBith, ReWlre5r F50Ilh, ReWIIN, F96Vh, "F IieIN, ReWL, RSBh,eeVh, RS
114
2-hechaercal Propert!pe trop Currebt LiterakureCunt!peed Table
32 83023 -1814 -34
66O�
83 -I73 -3483 -51
k!9k picket
26.326.3
560524
477420
Ti-0thhh! FaceRoot
62758e
3tl,o31. 0
I'aceKoot
2. 52K I <!RIA!
Wi28. 831. 0
464405
FeedRoot
tl. SIRE thhh!
31. 532. 5
617541
518416
»or he»i! FaceRa"
31. 433.7 ~Ti -GI9ai �9
431i ic»Root
584SI-hrrh!8! Feed 511
2. Slv! EBOxx
E70!! 550
25-359025-463826~029'515B30.51�32.571041+E43. 5E44-107f44-tOBE44-109f44-ltOE48-104651-94E52-90f52.58E52-91652-11IE53-154E55-390E59-028E6!-904E61-905E649 82E66-'971E76-542F82-923690-29k90-33K
39933537!46i 2276563are'52248354359057952056547D'5295045495014616595763!e417639468432501500458
28 208 222 214 20153 192 16e -5o41 88 59 -70
32 219 232 225 20l� I46 130 -50100 143 121 -70
23. 243.037 038. D36.D40,03!,017. 023,042. 042. 8
39.024.D2G.038.538.338,539.0II ~ 241. 539. 045. 240,0
<20. 044. 042,735. 433. 0036. 5
vh, RSuh, RSIhl, RS
uhuh, RSIPIvh, RSVh, RSVhIrhVhIBivh
IhlVhvhVhIv!, R»vh, RSvh, RSvh, RSvh» RSvh, R6vh, RS
vh, "F 96Vh, F50Wu "F50
ll5
MIDWESTTESTINGLABO RA'10 RIESIrlC
Indeoeoa eelIoII I lieIalwwatooea
LAZGPATG.".YP,EPG."T
DATC: October 27, 19GG27.PGPT TG: I.arry Zirker541 :.'iI!Sard goadCOlumbuS, Ghia 43202 LAD R:POUT liG.: GI 00751
P.G. i/G.. To Arcair Co.lr73072 i.' P G l'. T G: l: S a m p 1 e s S u b cI i t t o d f o r I .' a c h i n i n g
anal Impact Testing.
SAiiPLD IDLn 2 IFI GATI GIl: UDA ''Jil
TCST PSGCZDU2"-.: iiachining and impact testing were conducted in accordancewith ASTli E23
Dreal;ing rner y, Ft.-LbsTest Temperature
P c s p c c t 5' u 1 1 y s u b T..i t t e d
Paul Sherman, ilanagetI:cchanic'1 Testin� Laboratoty
PS/lie
TI.ST I'.INSULTS:
Sample lio
85OB inaLoIsy paa ~Pavo Oha e83SO 813! 773-Tol3Dolan Trav kN FreeBe 5-0884Ovtwoe Do@Ion -Oh&IBOOI 621 3eee
<32 degrees+32 de rees+32 oegrecs+32 degrees+32 degrees
FrFFF
28.020.024.023.024.G
23.S avg.
ll6
KECKAN Ca. PROVERT ES FOR OKDERNATER IKL51hq REKARCSTi ~ ld Tonei I ~ Eionqotton cvh 13! CTOD oo! hordnent
tthenqth etnenqth �! NIN KA1 AvE T C! K HV2. '!, or KRAI KIN NA1 NE T C! Nax NRC
ELECTRODE TEST
I'!ND
451393
VFihu I
"C,03
553495
523ND
3927
3532 -ID
.10 0.11 . I I -10.10
.10 0
.16 -1435 024 -10
NDNbhV253IF14 30 23 .10 . 11 . 15 . 13 - 10
27F hV3416 D13 -10
15 1712 14 "C.04 .07 . 05 -14
771426
13Nb
!96/76 hNID
37 040 -10
28 4632 43
�16! ANK Iilh
426ND
503468
1322K
Conttnued Tab! ~ 2--hechanire Probe rt!oe ron Currenl I.sterature
12 16 14 014 16 15 -10
.30 .14
.12 0,06,04 -10
.0'9 .20 .17,18 .28 .21 -10
�77! AVhiKIRI
NAI
�83'I ANKIDNKVhVh
�63! TVNKAI
�7 ! TW,NhIR'
117
Cont>need Ia4ln 2-~cnantcai properties Iron Serrent Literatnro
Hil0 StoolSlee trade
Hild SteelFlee trod» SS 0
10
58 040 -10
Hh ia air 0Ill,in air
Hathi
SHASlitPE-1FE-2IK-IHS 2If.-lHS.1IIS 2I' S-2
HS ~ Hot dstoreieed Sy astaor,n Hot presented ih rslorsncs pepsi ~
IHHI ~ All wld natal tensile.IN ~ Sold natal,
HAI ~ Heat ~ I totted tooo.RS ~ Sestralsl.C r Critical rains.*K ~ Valse at oaiisw load.y n Hater deptrr,
40 HA147 HA144 Hkl40 HA1
HA242 HA I42 KA121 HAt27 Hal22 HA1
WI,rr air 6
HA2,in air 6
HII,in air 7
Table 5 � DPH Values of Traverses
HYAVTA l HTUVTUt
l DI48. I DPHt VALUE
t DIAS t DPH l DIAS t DPH l DIAG ~ l DPHt t VALUE t t VALUE t l VALUE
ILOCAT IONtkO.
LEBENO: VTU � VERTICAL TRANSVERS'E HARDIIESSES ON A TEE FILLET MELD flADE UNDER MATERUT4 � VERTICAL TRANSVERSE HARDHESSES ON A TEE FILLET MELD HADE IN THE AIRHTU--HORIIOHTAL TRANSVERSE HARDNESSES ON 4 TEE FILLET MELD HADE UNDER MATERHTA � HORIIOHTAL TRANSVERSE HARDNESSES Dk A TEE FILLET MELD KADE lk THE AIR
2 l3 I4 t5 I6 l7 I8 t9
10 lll l12 l13 l14 l15 l16 l17 l
6862 l61 l61 l63 l6565 ',es ,'65 I
t
64 t65 l58 l55 l55 l55 t55 l
200.74241.47249.45249.45233 ' 86219.69219,69219.69219,'69219,69226,61219.69275.92306.84306.84306,84306.84
72 l 179.0570 l 189.4369 l 194.9670 l 189.4369 l 194.9668 l 200.7470 l 189.4371 l l84.1371 l 184. 1371 l 184.1371 l 184,1370 l 189.4370 l 189,4368 l 200.74
707064615554545657SB
t 59
l 189,43t 189.43t 226.61l 249.45t 306.84l 318.31l 318.31l 295.98t 285.69l 275.92', 266'.65
I I70 l 189.43 '75 l 16S.01 l71 l 184.13 l71 l 184.13 l72 l 179.05 l70 l 189 43 l66 l 213.09 '70 l 189.43 l
194.96 l69 , '194.96 t
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e~ eveetetee vr ptt peremeeet
petr tr. Letter. p E,Vice ttteNeeer
C.tr. Serveertre et 44tee vere ver tregeeet
L 4reaerr 4~cert t rvite rvetteeet
Report on Sesnple of86- 3291
Report '.44.
Arcai CompanyClient
P,o, Box 405, Route 33 No"thLancaster, Ohio 43130 - Attn. Bo" S~~ohlCharov Imttact Tests
P rtt] eet
Idehtr icetiert
TKS RZSUL"5
D.ll samtrles are sub-s ze 7. 5 x 10 mm.Test Temperature is 32'7,
SUR44, 37, 37, 41, 36 f t/lbs.
104, 108, 78, 95, 201 f /lbs.Weld Netal:BAZ;
21, 6, 8, 7r, 8 ft/Ih ~ .71, 41, 56, 31 f t/lbs.Weld >tetal 4
HAZ:
25, 20, 19, 32 f t/lbs24, 38, 47, 4 7, 37 f. t/IbsWeld Metalr
HAZ;
DBTtnrt Reepec tfuil y ettbrrti tt
D. Bruce Tu reerempereerp Ppltretpp tert. t.-~c ' n oa ' Qc Te t, n -'c ' anALAMIP7 MClMCSMCCMHSIMFAMSCEMSPr~SlrrEMsTItriCAWS
CS CSA: CBO:rC~HSP~OACE:Oprrr CA OCA SAE:VFCAFOrrrterlV CprVrrtpVS rrrrtpq Lptpr4rrtrV tttt Sttter r927
r
4'TZ FiVZ/kFFEfiYZ /NC'CV/VS!'/lTliVLr EiVgiNEERS
TFST/N6' bVSPECTJOIVlAZOHATDHY SFRV/CFS'
ElFZ/PYEggjlYE» kiddo /isn't Eppd ~ ct4reeetttee DNA ld25v ~ 6;r zAwuz
122
4'7l FjVGi5F "Sl/VE /bC'CQiVSDl Jlb'O' FiVZJNEF8$
TFSTN6' /tYZPEC7/Oh'lASOHAT&r'V SF'/CPS
EIFZj/FEB E& ZSSd Fade. Ears' > CrrIrrrrrarrr. ISArrr l~l b'AI- Z% sr'
aWII rrrlli»irrl, Jr., PO.D,. P rmr rrorlrl
Orrr a trnrr r Irr or prOrrrrrrrr
CX. Jrrrrarrrr rr t r fkrrrrr»rr rrrcr prrrrrrrrrr
t. Ore yrrry OrO»rr r!Yrrr nrrrrrrrrir
Report ort Samp1e of86 32ol
»pi w mcc ar cc
CoI.~b-. Obo, '""' 313Report Va.
Area ir Compa nv
P.O. Box 405, Route 33 voCdottt
Lances te», Ogio 4 313rI . rr~r c»
Gu iced Bend Tes tsProI oct
Jderrtrfrcat>on
»»c c T R c B »J L ws
All bend samples were prepa ed and tested per QSE/Vi<SD3.6-83, Fig. 4.4.3A and 4.4.3C.
SUR
Face: No OpeningsFace: 3 8 ! 1/64RoOt: Ho OpeningsRoot: 3. 8 >1/64
troit: ln Roopectftrlly otrbtrrrttod»�
Momoorthrp PortrorooIrorr. Kng1neer - ng . ecnnic anALA AAPTQCIDCS QGC>rVSI QPA&SC~DSIrI DSIII EBS TIrI DWSZCSI GSACICSO ICEi PISPE OACE:OIIhlCA OCA SAF:IIFCA
FacetFace:Root:Root:
Face:FacetRoo t:Root:
Broke in weldBroke in weldBroke in weldBroke in weld
Broke in weldBroke in weld1 0 3/64 + 1 9 1/16 + mulr'pie smal' cracks14ultiple small cracks
Formrnr C Irrmooo tezrrno Lororolor r, Ioc sine» I F27
l23
Inoooonoonl ssos Imuon non onto'Ioinng nnnoa Qno Os}4OLOOOeOSanoI }all} 7}S.IOI3
Oonon }roy Tdl boasoaa8boOwnne Oonen ono@co} F1 ~
L 4 C 0 2 4 ~ 0 11 Y .". r P 0 n T
DCT2: October 27, lr}GGPO:!T TC; l.arrY Zir'er
541 1!id"ard CoedColuIubus, 01Iio 4 202 L4T, CZPC;,I !!C.: 0100702
P. 0.::C.: To Arcair Co.10 07I.'CP03T 0": Samples Subritred for ."achining
end Impact Tcstinp.
Sa.,PL- I~C::TIFIC4TIO:;: .LSUP.-C«
T ST PCCCCllUPi"-: ilachinzn" and impact test jan wer e conducted an accordancewith ASTil a23.
TCST 2CSJLTS:Dree!Iing Knero7 Ft -' baTest TemperatureSanple llo.
447.0 avn
Paul SiIorman, liana or»echonxcu Te tin ' operator 7
PS/lh
oIIDolESITtsnHGIasc}ea}0 RIESINC.
+ + o32 degr
32 de�r32 deCr32 door
ees 'Fees Fees Fees Fees F
51.043.04I}. 047.045.0
l24
L A il 0 g A I 0 .", Y r" E P 0
GrrT' . Gctobcr 27, 1906,.EPG..T TO: Larry 2irker541 !Lid�ord PoodColuovus, Ohio 43202 LAB ..EPGR;lG.: G100750
P.O. BC.I .To Irrcoir Co.19307..EPG-T Gi:: Sarrples Subaitted for iiaclrining
and Inpac t Tao tin
Srilir LE IDE'.:TI FICATIGr': Ui/A ilr'.2
TLST PBOCEDUREI llachining and iepact testin- vere co~ducted in accordancewit h A ST'l E2 3
TEST RESULTS:
Breaking Energy, 'Ft. � l.bs.Test TeoperatureSatIp 1 e llo.
54.4 avC.
Pespectfully subaitrcd
Paul Sheroan, Can'agerliechanicol Testin- Laboratory
PS/lk
MIDWESTTESTIIIGIraacr RAT ORIESINC.
S SOS rrerarrrr Dan Drrrrrrlealrrrs neua One aLISnIaorrrrr~ laISI 11Sena
OOVrrrrr TrOT IOS Iree
Ourrerr Oorrrorr -Ono[SOQI 02I-Sacs
32 degrees32 degrees
2 degrees32 degrees"2 do rees
+ + +F
F F52.061.046.055.050.0
l25
nrttettnneent ES9S Ittttttly nartt tytreTnrnne Ittytrra Onra esSStrttttnrratttnrtn ISTSI TTS-TO%
Oayrttn TrON Tat TyneE45.aesoQuetee Dayton . OntoIEOOI set-artetr
LAJJOPATORV ",."POrT
REPOIT TO: Larry Zirl:er541 Jlidgard PoadColumbus, Ohio 43202
DA. E: October 27, 1 yI66
LAD DEPO!JT iiO.: C100752
P.O, :JG.: To Arceir Co.19307R:?ORT 0!': Samples Submitted for iiechxning
and Tmpact Testing.
SA PLE 1DEir 21FI CATIOIi . 'UUA llAZ
TEST PRGCEDUJ;E: llachining and impact testinn mere conducted in accordattcetyith AST:: E23
T"ST RESULTS:
Breal:ing Ener y, FT..-Lbs.Sample Jlo. Test Temperature
40.2 evg.
Paul Sherman, JianegerIiechenxcaI. Test.'n-� Laboratory
PS<1'
M[trWESTTESTIHCtnsoanTQ RIEsINC.
+3+3+3+3+3
2 degrees2 degrees2 degrees2 degrees2 de ress
r
F FF F
33.031.03rr.O54.044,0
8588 rcumv 4na Dnalashrtg ROwu QnO 88888 aecnotanes 8!S! 778 %76
Drwon 'Irar Ios EtweIQ88886Quate Daven - Qno 8OO! 67u 8888
L A " G F, A T 0 .", " r.' C P 0 ., T
D.',T: Gctoijer 27, lrr06RCi'ORT TO: Larry Zirker541 i idgerd RoadCa 1uobus, Ohio 43202 LAD R "PC I:7 I:C.: G100751
F.O. i;G.I To Arcaer Co.19307RCPORT 0.": Sanplos Subostted for I'achin tug
an J Ilupact Teating.
SAiiPL 2 I DZ STI F? CATIOII: UUA I!ii
TZST PROCCIyVR:: iiechining and i!epact testing were conducted in accord~neowith ASTii S23
TuST RSSVLTS:
Creaking "noz gy, I' t, � Lh sTost TertperetureSar!pie Iio
J AS avg
Respectfully suhotr ted
? o u 1 S h o r tea n,",. s n a g e riiechanical Testis:" i.a'voratory
PS!'ll
M!DWESTrESONCIABORA QRIEEn c
+ + + + +32 degr32 de~r032 degr32 der r32 degr
ees Foes Fees Fees Fees F
2b. 020.024.023.024.0
127
0446'76N8$TTE 516HGlARORATORIEZ0NC.
PelcNN 85688 o66002tr64 PO20 O6044 ~10ll66668 Plnun. Gno 85588u206006636slal 1515! TP5.2O15
Oo446o43 8oT ToP P63PP8854T888Qualna og66o22 . 006@ anQJ 821.58638
L A !I C,. A T C �Y P, P 0 R T
DATC: October 27, l9GG4,I POCT TC: Larry Zirher
$4 I iiidgard IloadColumbus, Ohio 432G2
LAD 2' PO+T;IO.; OIQC703
P.O. IIO.T To Arcair Co.!9307
4.iPC44T Oii; Samples Submit tel. f or ila c:liningand Itlpact Testing.
SAI!PLi IDii:TIFICATIOII1 UVB iiilT-ST P6TCCVDU..E: Ihachining and it;pact testinD acre conducted xn accordanceui th ASTI! C U-
TOST DSSULTS: Sreaking inertly, I' t.-Lbs.Test Temperature
..especttully submitted
P a u l 3 11 e r 4m 8 5, i!a n a g e rI>echanical Testin- Laboratory
Sample tio.
2:2
3
+3+383+3+3
2 de~ressdegrees
2 de"�ress2 de ress2 de~ress
26.024.02'.023.026.0
2'. 4
128
L A D 0 2 n T Q g I .", E P 0 .-. T
DATE: October 27, 10gbF. PO..T TQ: Lar I y Zi r l:or541 liid ard PinedColumbus, QITio 4 202 L43 11EPQ.".T ',10.: 0100701
P,O.:.'0.: To Arcaxr Co.19307SEPO"�T Oil; SarIples SubIsit ted for llachtning
and Impact Te ting.
SA.'lPLZ IDEliTII ICATI0", T UQD UAZ
TEST PHQCEDUUIEI >'schining nnd iapact testing were conducted in accordancewith AST'1 E23
TEST DESULTS:
Test Temperature Eraaksng Energy, Ft.-LbSample llo .
40.0 aug
,",esnecr.fully submitted
Paul Sher .an, !lanngerl;echar:teal ~ osr.'n� aborstory
PS lk
MIDWESTTE STlmaLASOTEATORIESIN C.
m~ ssos inawaN sam gleeTaInne seNa ~ 44aM,Iae~ldraes ISTSI 7TS STI3
Oops %ay RebecsssaB86Due<ac Dms .DnaIaaaj aEl-SeIe
+32 de+32 de+3: de+32 de+32 de
"reesgreesgreesgrees
rees
F F FI'F
46.045. 034.040.035.G
Ohio Sea Grant College PrograznThe Ohio State University
1541 Research Center
1314 Kinnear Road
Columbus, OH 43212-1194614/292-8949
