Development of High Strength Steel ConsumablesFrom Project to Product.

Vincent van der Mee, Fred Neessen. Lincoln Smitweld bv, The Netherlands

IntroductionApplication of high strength steels may offer many advantages. Today, high strength steels areincreasingly applied in pipelines, cranes, offshore construction, bridges, minesweepers, etc. In order tomeet market requirements for a wider range of steel grades, consumables for applicable processes needto be available, whether it is for manual or mechanized welding.In this paper, an overview is given of criteria and results in the development process of FCAW,SMAW, GMAW and SAW consumables for steel grades up to S690.Initially, weldability is the feature to be met. Next, chemical composition and mechanical properties inthe as welded and/or post weld heat treated condition need to be demonstrated, followed by aconsumable classification according to AWS, EN or other. Influence of individual elements (like Mn,Ni, Mo, Ti or B) on weld metal toughness and strength level is discussed.An important issue for end-users is the working range of a consumable that still delivers requiredproperties. Restrictions in operability, heat input, welding position, joint configuration or heattreatment, do limit the application of a specific consumable and should be minimized. Consistency inobtained mechanical properties is an essential development criterion.Finally, welding procedures will be discussed using consumables that demonstrated fitness for purpose.

Steel gradesIn European Standards, construction steel grades are classified according to method of production.

� Normalized fine grain steel grades (EN 10113 part 2)� TMCP fine grain steel grades (EN 10113 part 3)� Q&T high strength steel grades (EN10137 part 2)

The application of these steel grades is in table 1, sub-divided in two main groups: EN 10113 part 2 & 3, EN 10137 part 2

Steels in these groups are used in more severe constructions like offshore, bridges, cranes,storage tanks, minesweepers, etc. Application can be at low temperatures.

Table 1: Classification of steel grades EN standard "Current" Classification "Old" Classification EN 10113 part 2: Normalized fine grain steel grades

S 275 N S 355 N S 420 N S 460 N

StE 285 StE 355 StE 420 StE 460

EN 10113 part 3: TMCP fine grain steel grades

S 275 M S 355 M S 420 M S 460 M

--- StE 355 TM StE 420 TM StE 460 TM

EN10137 part 2: Q&T high strength steel grades

S 460 Q S 500 Q S 550 Q S 620 Q S 690 Q S 890 Q S 960 Q

--- StE 500 V StE 550 V StE 620 V StE 690 V StE 890 V StE 960 V

In this paper, high strength steels are defined as structural steels from S420 up to S690 . High strengthsteel grades, defined in EN 10137 part 2 are weldable, relatively low carbon, low-alloyed steel grades.The excellent mechanical properties of these grades are obtained by a well-balanced chemicalcomposition in combination with a well-controlled heat treatment. Within one chemical composition, itis possible to supply different strength levels. Depending on manufacturer, production method, andplate thickness, one or more of the elements mentioned in table 2 can be present.

Most Q&T steels contain manganese, nickel, molybdenum, chromium, with additional hardening bysmall amounts of boron. Normally some micro alloying elements are present also, to obtain a finemartensite microstructure after quenching, however vanadium should be avoided when any heattreatment is applied. Table 2: Chemical composition (max. %) according to EN 10137 part 2

C Mn Si Cr Ni Mo Cu Ti B N Nb V Zr 0.2 1.7 0.8 1.5 2.0 0.7 0.5 0.05 0.005 0.015 0.06 0.12 0.15

With quenched and tempered steel grades, the high tempered martensite will result in good ductility andhigh yield and tensile strength. When welding these steel grades, the heat input needs to be such thatforming of ferrite and perlite is avoided, because of lower strength and toughness level. At a particular plate thickness, the cooling time▲t800-500, is a function of heat input. When cooling toofast, the presence of some alloying elements could result in high HAZ hardness. An optimal ▲t800-500needs to be established (~10-15 seconds). Development issues Consumables Recent advances in thermo-mechanical controlled processing of steel have resulted in low carbonequivalent, higher strength pipe steel, with limited the risk of HAZ cracking. The predominantstrengthening mechanism in the weld metal, however, is through alloy additions. The weld metal thusbecomes the “weakest link" with increased susceptibility to hydrogen cracking. Consumables forwelding high strength steels have been developed parallel with base material. Optimization of theseconsumables has been a continuous process. With this background, defining the limits of consumablesbecomes relevant. Empirical carbon equivalent expressions have been developed that weigh the relative effects of alloyingelements on material hardenability. One frequently used equation is the IIW carbon equivalent Ceq = C + Mn/6 + (Cr + Mo + V)/5 + (Ni + Cu)/15 Based on the coefficients it is clear that Mn, Cr, Mo and V have a significant effect on the carbonequivalent and thus the hardenability. The carbon content in the Ceq formula however, has the largestinfluence. Most initial studies in the area of alloying effects concentrated on SMAW electrodes and theabove mentioned elements. Hart1 looked at the effects of carbon, iron powder and basicity, molybdenum and nickel on theproperties of welds. He used basic electrodes to do gapped-bead-on-plate (GBOP) welds. This GBOPtest gives an evaluation of weld metal hydrogen cracking without involving influences of the basemetal. Molybdenum up to 0.4% was seen to improve the crack resistance at intermediate levels (5ml/100g) ofhydrogen in deposited metal, and was deleterious at high levels (10ml/100g) of hydrogen in weld metal.With basic electrodes, a preheat of 100°C was always adequate to prevent hydrogen cracking. Evans2 pointed out that molybdenum was beneficial for toughness up to 0.25% when the manganesecontent remained low in basic electrodes. The role of molybdenum was speculated to be the restrictionof pro-eutectoid ferrite formation at grain boundaries either due to pinning or dragging effects ofmolybdenum carbides. The effect of chromium on C-Mn welds has also been studied. The toughnesswas adversely affected, especially when chromium was increased beyond 1%. There is very little literature available regarding the effect of vanadium on weld metal microstructure.Vanadium, apparently has a very complex and unpredictable effect on transformation behavior.Generally, vanadium is considered to reduce the development of ferrite side plates. It has beensuggested that this is due to the pinning effect of interphase precipitates of V4C3. Studies on individual and some specific trace elements are mostly done by consumable manufacturersand often treated as confidential information. Further in this document we will illustrate some moreeffects. SMAW: Cellulosic electrodes The traditional method of circumferential girth welding of pipes, cellulosic electrodes, still standsbecause of versatility, albeit with limitations at high strength levels. In the case of root and hot passes,

this still has been mentioned as the recommended procedure, while fill and cap passes can be weldedwhen proper precautions are taken, particularly on thin wall pipes. High strength (E9010G) cellulosic electrodes also serve a niche because of the increasing emphasis onweld metal strength overmatching the pipe strength. Pipe is manufactured with certain specifiedminimum yield strength, but in practice can be much stronger than this specified minimum. The effect of various alloying elements to obtain high strength cellulosic electrodes has been evaluated.The relative effects of chromium, vanadium, and manganese have been compared to that ofmolybdenum. The approach taken was to compare all these alloying additions at a similar strength level(to match X-80 pipe strength) and sufficient resistance to hydrogen cracking. For instance for welding X-80 pipe,� Weld strength should be over 560N/mm2 yield strength, realistically a minimum of 580 N/mm2 for

transverse tensile tests requirement. The tensile strength should correspondingly be 660N/mm2 toexpect to match the pipe strength.

� Similarly, the toughness should be as high as possible at any temperature in the transition region� Resistance to hydrogen cracking should be optimized. Optimizing chemical compositions Depending on the presence of other elements, manganese could have a detrimental effect on the CVNproperties at levels above 560 N/mm2 yield strength. Chromium also has poor impact propertiesattributed to the extensive perlitic regions seen in the reheat regions. Chromium additions also do notnecessarily improve the yield strength to match requirements. Vanadium additions appear to be themost potent of the alloying elements for strengthening, but give a low resistance to hydrogen crackingand PWHT. A means of selecting optimal composition could be as illustrated by Dallam3 in Figure 1. Figure 1: Relation between 50% Shear Transition Temperature, GBOP results and Yield Here, the critical design is a yield strength of 80 ksi, while toughness and resistance to hydrogencracking are maximized. The 50% shear transition temperature is plotted in this figure to represent thefracture appearance of the impact specimen. Apparent in this figure is that the optimal molybdenumconcentration for the GBOP testing coincides with the optimal point for 50% shear, both occurring atjust below 0.4% molybdenum. The strength of weld metal at that composition is also adequate forwelding X-80 pipe. Any “optimal” point from a testing procedure is valid only for that welding condition. This point couldbe altered dramatically with welding conditions resulting in different cooling rates or different baseformula compositions. On pipe, the effects of the cooling rate and weld composition resulting from thepipe welding procedure and base metal dilution would control the optimal composition. Weld metal behavior is ultimately dependent on the microstructure. The limits for using any sort ofconsumable will be determined by the ability to consistently produce the desired microstructure. The solution seems to be to minimize formation of any phase on prior austenite grain boundaries. Thisdirectly or indirectly seems to provide the best resistance to hydrogen cracking. It is apparent from earlier investigations that molybdenum hinders the grain boundary phase formationuntil the driving force to form shear transformation products becomes overwhelming. This unique effectof molybdenum seems to give it an advantage over other alloying elements studied, to produce high

0.0 0.2 0.4 0.6 0.8 1.0 1.2% Molybdenum

-0.2

0.0

0.2

0.4

0.6

0.8

1.0

GBO

P(u

ncra

cked

)

YS

GBOP

50% Shear

60

70

80

90

100

110

-75.0

-62.0

-49.0

-36.0

-23.0

-10.0

X-80 YS reference line

50%

She

ar T

rans

ition

tem

pera

ture

YS (K

si) Limitation of cellulosic electrodes

strength welds with a relatively better hydrogen cracking resistance. It is the most effective element forstrengthening weld metal while incurring the smallest loss in impact toughness, simultaneouslyminimizing the risk of hydrogen cracking. From the point of view of a manufacturer of electrodes, theoptimal designs can be utilized as a baseline for designing cellulosic electrodes for X-80 high strengthpipes. Certain limits/constraints, particularly hydrogen concerns, will eventually limit the use of theseelectrodes. SMAW: Basic vertical down electrodes Alternatively, basic vertical down electrodes can be applied for pipe welding. These type of electrodesare designed to weld single and multiple pass fillet and butt welds on high strength, medium and highcarbon or low alloy steel, as well as for all types of heavy restrained mild steel joints. They arerecommended for pipe grades up to X90. Although the travel speed is slower than with cellulosicelectrodes, the joint will fill faster due to the higher deposition rate of the basic vertical downelectrodes. Small size electrodes can be used for open gap root pass welding, although joint fit-up ismore critical. Due to the deeper penetrating characteristics, cellulosic electrodes are preferred for root and hot-pass.For open gap root pass welding, also a basic vertical-up electrode can be used when low hydrogen rootpass is required as an example for Tie-in's. Strength level and toughness requirements are met throughan alloy system based on manganese, nickel and molybdenum. SMAW: Basic (high recovery) electrodes Traditionally, basic electrodes have been the first choice in high strength applications. These electrodesare to a certain extend readily available, together with solid wires for GMAW. A common range ofbasic coated electrodes for high strength steel applications is again with the alloy system including Mn,Ni, Mo and in some occasions small amounts of Cr (See WPAR Conarc 80.01). There is however anincreasing need for higher deposition, downhand as well as out-of position. With the introduction of a150% efficiency basic coated electrode, there is a good alternative for high deposition filling of jointsas well as fillet welds in horizontal-vertical position. With a yield of >750 MPa and a toughness of >50 J @ -50°C, mechanical properties are similar totraditional basic electrodes. For higher efficiency out-of-position welding the best process is FCAW. FCAW: Rutile and Metal cored wires For gas-shielded flux cored wires, the optimal chemical composition is not necessarily the same as forcoated electrodes. Most important is the resulting micro-structure that is obtained. Because of weldability and positional welding requirements, only rutile flux cored wires are taken inconsideration. Specifically when post weld heat treatment is required, basic flux cored wires arefavorable in mechanical properties, however these wires do not exhibit a preferred weldability.Although not widely popular, metal cored wires can be chosen also. Still, out-of-position welding(vertical-up) with basic or metal-cored wires, is very difficult and not the most economical solution.Modern rutile flux cored wires offer the best out-of-position weldability and combine this with fit-for-purpose mechanical properties. The strength level can be obtained through several routes. Relatively low carbon in combination withmanganese and molybdenum additions for strength and nickel additions for toughness works best.Additions of vanadium and chromium did not result in optimum toughness properties, although theyworked well for strength level. Other than with coated electrodes micro-alloying with boron works wellfor strength and impact properties with rutile cored wires, provided the Ti/B ratio is optimized.Titanium and boron containing wires do show a shift in the yield-to-tensile ratio and need to be wellbalanced to avoid hydrogen cracking susceptibility. When no boron is present in the weld metal, theyield-to-tensile ratio improves, but the strength level decreases. Looking at weldability, it is preferredthat a welding procedure is for instance not limited to stringer beads. Some wires available in themarket do not allow the use of a weaving technique, while maintaining the mechanical properties. Wirespresented in this report were specifically developed on this issue (See WPAR OS690.01). Next there is an increased demand for wires that can be used when a post weld heat treatment needs tobe applied. This heat treatment depends of course on the manufacture procedure of the steel. Typically,a post weld heat treatment should be at least 30°C below the actual tempering temperature of the plate.Baring this in mind, a PWHT of max. 550°C is common for S690 where max. 600°C could be morecommon for S420.

SAW: Flux and wire combinations In welding high strength steel using the SAW process, neutral aluminate-basic or fluorid-basic fluxesare the only option. With higher strength, the lowest diffusible hydrogen level is preferred. There arepatented sub-arc fluxes available that guarantee a diffusible hydrogen content of less than 2 ml/100gdeposited weld metal. This low level can be achieved due to the use of hydrogen scavengers. Typically, solid wires are used when the SA process is applied. The chemical composition of these solidwires is also on a Mn, Ni, Mo and in some cases Cr alloy basis (See WPAR P230.09). Today, moreoften cored wires (m etal cored) are used for increased deposition. The most important issue from amanufacturers point of view is the possibility of making any desired alloy. With this fine-tuning, nocomplete heats need to be produced in a steel mill, but small quantities of 100 kg could be supplied. Hydrogen cracking The three well-known relevant factors in hydrogen induced cold cracking are:

� Sufficient amount of diffusible hydrogen� Susceptible microstructure� Stress

The microstructure of the weld metal is clearly a function of cooling rates, thermal history and chemicalcomposition. The weld procedure thus can change the microstructure drastically. A wide range ofmicrostructures is possible using the same electrode and machine parameters when changing from avertical up position weld to a vertical down position. The optimal formulation for an electrode is veryclosely linked with a defined operating procedure, and changing either the formulation or the procedurecan alter the properties of the weld metal. For the root, it is often preferred to use a consumable that isone grade lower than the base material. Due to dilution, the weld metal strength will increase anyway.

Figure 2: Susceptibility for hydrogen cracking

With increasing strength level, the risk for hydrogen induced cracking increases. A lower carbonequivalent will help in minimizing the hydrogen induced cracking. Depending on diffusible hydrogenlevel in the weld metal, microstructure after welding, strain level of the construction, chemistry andplate thickness, preheating is often recommended in order to reduce the susceptibility for hydrogeninduced cracking.Florian4 calculated the required preheat temperature (Tp) for weld metal, based on five differentconcepts (Thyssen, Okuda, Nippon, Hart and Chakravarti). With the exception of the Okuda andNippon concept, which are based on Rm, they are all based on carbon equivalent. The formula forcalculating the necessary preheating temperature to avoid cold cracking in high strength weld metal (forsteel grades S450-S690) is:

Tp = 0.25Rm + 62HIIW0.35 - 154

Using this formula, the calculated preheat temperature is found to be appropriate for diffusiblehydrogen levels of around 5 ml/100g deposited weld metal.High restraint cracking tests have been performed on fillet welds (t=30/15mm) using flux cored wiresup to 800MPa yield strength. An optimized micro-alloy system was used in order test the designs onsusceptibility to cracking at room temperature, as indicated in figure 3. Even at 6°C, no crackingoccurred in 2 of the 3 wires tested. At this strength level (700-800MPa) a minimum preheat of 100°C isstill recommended for base metal thickness over 10mm.

mL

of d

iffus

ible

hyd

roge

n

X-65 X-80 X-100 X-120

Basic SMAW & FCAW-S

Acceptable

Unacceptable

Susceptibility to Hydrogen Cracking

2

5

40

100

gram

s of

dep

osite

d m

etal

GMAW & FCAW-G

Cellulosic SMAW

Figure 3: Cold cracking tests using high strength flux cored wires

0

2

4

0 10 20 30 40 50 60 70 80 90 100

Preheat temperature.°C

OS81K2-HOS550-HOS690-HOS690-H cracked

no cracking

230A, 24.5V

200A, 21Vonly weld that cracked

Mechanical PropertiesTypical chemical composition and all weld metal mechanical properties of the processes / consumablesdiscussed are shown in tables 3 through 6.

Table 3: Typical results for optimal (high strength) cellulosic electrode for pipeAWS C

%Mn%

Si%

Ni%

Cr%

Mo%

V%

YieldN/mm2

TensileN/mm2

CVN (J)

-29°C -46°CE6010 0.15 0.50 0.25 --- --- --- --- 440 520 65 ---E7010 0.12 0.35 0.12 --- --- 0.35 0.02 450 550 80 ---E8010 0.12 0.90 0.20 0.85 0.10 --- 0.03 510 570 75 ---E9010 0.13 0.60 0.15 0.70 --- 0.60 --- 550 640 50 45

E10010 0.18 0.85 0.20 0.75 0.02 0.40 0.003 630 720 75 57

Table 4: Typical results for basic vertical down electrodes for pipe welding

AWSC%

Mn%

Si%

Ni%

Mo%

YieldN/mm2

TensileN/mm2

CVN (J)

-29°C -46°CE8018 0.06 1.30 0.45 0.02 --- 530 620 115 80E9018 0.06 1.45 0.45 0.75 --- 610 675 110 75

E10018 0.06 1.65 0.55 0.80 0.2 680 730 100 70

Table 5: Typical results for basic (150% recovery) high strength electrodesAWS C

%Mn%

Si%

Ni%

Cr%

Mo%

Nppm

YieldN/mm2

TensileN/mm2

CVN (J)

-40°C -50°CE9018 0.06 1.00 0.35 1.60 0.01 0.30 80 600 670 100 75

E10018 0.06 1.40 0.40 1.00 0.02 0.40 80 650 730 95 70E11018 0.06 1.50 0.30 2.20 0.20 0.40 80 710 785 90 80E12018 0.06 1.70 0.30 1.90 0.40 0.40 90 790 850 80 60E12028 0.05 1.50 0.40 2.50 --- 1.00 80 770 840 75 55

Table 6: Typical results for high strength flux cored wiresAWS C

%Mn%

Si%

Ni%

Mo%

Ti%

B%

YieldN/mm2

TensileN/mm2

CVN (J)

-40°C -50°CE71T-1 0.04 1.40 0.55 --- --- 0.035 0.003 500 570 45 ---

E81T1Ni1 0.05 1.40 0.25 0.90 --- 0.040 0.004 530 600 90 60E81T1K2 0.04 1.40 0.20 1.40 0.040 0.004 590 630 130 100

E101T1K3 0.04 1.40 0.20 2.00 0.30 0.035 0.025 700 730 60 ---E111T1K3 0.06 1.50 0.20 2.00 0.50 0.035 0.025 800 830 60 50

In some applications, CTOD and wide plate tests are required. For a number of consumables, these areavailable but is probably out of the scope of this paper.

ApplicationsIn general, consumables are selected on strength and toughness, which is normally a "matching"consumable. The yield strength of the deposited weld metal in that case is slightly higher than thespecified minimum yield strength of the steel applied. In some applications, an overmatching of 15-20%is prescribed, which means a significant higher yield strength than the base metal. For instance steelgrade S500, with a minimum yield strength of 500MPa would require a minimum yield of the weldedjoint of 580MPa.With increasing yield strength, the elongation will decrease. In order to handle shrinkage and distortion,this elongation is important. Preheat, in combination with a "softer" weld metal for the root, could bebeneficial. In table 7, an overview is given of recommended consumables for welding high strengthsteels and pipes.

Table 7: Recommended consumables for welding high strength steelEN standard Grade SMAW

EN499 / 757FCAWEN758

SAW flux/wireEN756

PlateEN 10113 part 2:(Normalized)

S 420 NS 460 N

E50 6 1NiB32H5E55 6 ZB32H5

T50 6 1NiPM2H5T50 6 1.5Ni-PM2H5

S426FBS3SiS506FBS0

EN 10113 part 3:(TMCP)

S 420 MS 460 M

E50 6 1NiB32H5E55 6 ZB32H5

T50 6 1NiPM2H5T50 6 1.5Ni-PM2H5

S426FBS3SiS506FBS0

EN10137 part 2:(Q&T)

S 460 QS 500 QS 550 QS 620 QS 690 Q

E55 6 ZB32H5E55 4 ZB32H5E55 4 1NiMoB32H5E69 5 ZB32H5E69 5 Mn2NiCrMoB32H5E69 5 Mn2NiMoB53H5

T50 6 1.5Ni-PM2H5T50 6 1.5Ni-PM2H5T55 4 ZPM1H5T69 4 ZPM2H5T69 4 ZPM2H5

S506FBS0S506FBS0S556FBS0S694FBS0S694FBS0

PipeX42/X46 E42 3 C25

E46 5 B35H5T46 3 P M1H5 S38 2 ABS2Si

X52 E42 2 MoC25E46 5 B35H5

T46 3 P M1H5 S38 2 ABS2Si

X56 E42 2 MoC25E46 5 B35H5

T50 6 1NiPM2H5 S42 2 ABS2Mo

X60 E46 4 1NiC25E46 5 B35H5

T50 6 1.5NiPM2H5 S42 2 ABS2Mo

X65 E46 4 1NiC25E55 5 Mn1NiB35H5

T50 6 1.5NiPM2H5 S46 4 FB SO

X70 E46 4 1NiC25E55 5 Mn1NiB35

T55 4 ZPM1H5 S50 6 FB SO

X80 E50 4 1NiMoC25E62 5 Mn1NiB35H5

T55 4 ZPM1H5 S50 6 FB SO

X90 E50 4 1NiMoC25E62 5 Mn1NiB35H5

--- ---

The width of the HAZ is a function of heat input and plate thickness. When welding TMCP steelgrades, a reduction of strength in the HAZ could be possible, depending on the welding procedure. Forthis, the weld metal should be higher in strength than the base metal. The weaker HAZ will yield firstand consequently become stronger, to a level of the base metal.When using Q&T steel grades, the high tempered martensite will result in high yield- and tensilestrength. It will also result in good toughness and low susceptibility to brittle fracture. The formation ofrelatively soft ferrite and perlite should be avoided in order to maintain a higher strength level.Typically, Q&T steel grades do not require overmatching to an extend as the TMCP steel grades.

Welding proceduresIn WPAR Conarc80.01, OS690.01 and P230.09, practical welding procedures for the SMAW, FCAWand SAW processes are shown. These procedures list necessary information regarding weldpreparation, preheat and interpass temperature, heat input, bead sequence etc. in addition to chemicalcomposition and mechanical properties of the weld metal.

References1 Hart P, Welding Journal 14s-22s, Jan 19862 Evans G, Welding Research Abroad, Volume XXXVII no 2/3, 42-69, 19913 Dallam C, Feb 2002, to be published4 Florian W, Cold cracking in high strength weld metal, IIW doc IX-2006-01

Page 1 / WPAR : Conarc 80.01Rev. : 0Ref. WPQ : test report doc. 00892

Procedure Specification Test Results

Base material HRS 650M Radiographic, Magnetic Particle Examination: : AcceptableWelding processes A: SMAW (111) B:Manual or machine Manual Reduced-section tension test

Tensile strength [MPa] Fracture locationWelding position PA (1G) 2/3 Side 793 Base materialFiller metal (trade) 1: Conarc 80 2: 1/3 Side 787 Base materialFlux N.A.Filler metal classific. AWS A5.5: E 11018-M All-weld-metal tension test 2/3 Side 1/3 Side

EN 757: E 69 5 Z B 3 2 H5 Yield point [MPa] : Rp0,2 747 - 753 794 - 792Shielding gas [l/min] N.A. Flow Rp1,0 757 - 764 793 - 792Backing (gas) [l/min] N.A. Flow Tensile strength [MPa] : Rm 815 - 810 833 - 836Gouge method Arc air + grinding Rp0,2/Rm 0,92 - 0,93 0,95 - 0,95

Elongation, A5 [%] : A4 20 - 20 20 - 23Current / polarity DC + A5 17 - 16 17 - 20Preheat temp. [°C] 100 - 150 Reduction [%] : Z 62 - 62 62 - 59Interpass temp. [°C] max. 150 Side bend tests Former diameter: D = 4dPostheat treatment N.A. 2/3 Side 180° No defectsWelder's name Cees de Roij 1/3 Side 180° No defects

Laboratory Test No. VE 54 Impact tests ISO-V [Joule] Test temp. [°C]: see tableRemarks : Lot No.: ø 3,2 mm 646350 Size of specimen: 10 x 10 x 55 mm (2 mm sub-surface)

ø 4,0 mm 842433 Clw 2/3 Side av. Lateral exp. [mm] av.- 20°C 106 107 100 104 1,28 1,10 1,19 1,19

Welding Procedure - 40°C 70 70 78 73 0,95 0,93 0,99 0,96Pass Consumable Welding Current Speed H.I. - 51°C 66 - 55 - 64 - 65 - 65 63 0,82-0,61-0,75-0,80-0,78 0,75No. index Ø [mm] Ampere Volts [mm/min] [kJ/mm] - 60°C 63 - 65 - 68 -37 58 0,86-0,72-0,80-0,46 0,71

Side 11 A1 3,2 75 23 - 24 46 2,29

2 - 16 A1 5,0 220 24 - 26 ± 215 ± 1,5 Clw Root av. Lateral exp. [mm] av.17 A1 3,2 125 23 - 24 122 1,45 - 20°C 84 83 81 83 0,94 0,95 1,04 0,98

18-21 A1 5,0 220 24 - 26 ± 215 ± 1,5 - 40°C 65 65 46 59 0,77 0,61 0,45 0,6122 A1 5,0 220 24 - 26 261 1,26 - 51°C 48 - 36 - 67- 57- 50 52 0,57-0,47-0,80-0,65-0,56 0,61

Side 2 - 60°C 50 - 52 - 44 - 39 46 0,48-0,56-0,46-0,52 0,5123 A1 3,2 125 23 - 24 122 1,45

24-40 A1 5,0 220 24 - 26 ± 215 ± 1,541 A1 5,0 220 24 - 26 246 1,34 Clw 1/3 Side av. Lateral exp. [mm] av.

Joint Detail - 20°C 110 110 92 104 1,20 1,24 1,17 1,20- 40°C 90 88 91 90 0,88 1,04 1,04 0,99- 51°C 65 - 66 - 68 - 74 - 65 68 0,72-0,75-0,77-1,02-0,81 0,81- 60°C 72 - 56 - 64 - 43 59 0,83-0,60-0,60-0,60 0,66

HardnessTest type : Vickers Load: 5 kg

2/3 Side 321 303 303 - 358 271 - 317 313 - 367 265 274

Root 268 274 227 - 229 286 - 303 306 - 332 271 271

1/3 Side 271 268 362 - 367 274 - 325 321 - 371 274 274We hereby, certify that the statements in this record are correct. Project Sub MarineManufacturer or Contractor Lincoln Smitweld bvAuthorized by Frans SpieringsIssued by Fred NeessenDate 29 March 2001

BM WM HAZ BMHAZ

Welding Procedure Approval Record

50°

3

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Procedure Specification Test Results

Base material St 42 buttered with Conarc 80 Radiographic Examination: AcceptableWelding processes A: FCAW B:Manual or machine Manual Reduced-section tension test

Tensile strength [MPa] Fracture locationWelding position PF (3G up) Cap :Filler metal (trade) 1: Outershield 690-H Root :Flux N.A.Filler metal classific. AWS A5.29: E 111 T1-K3 MJ H4 All-weld-metal tension test

EN 12535: T 69 4 Z P M 2 H5 Yield point [MPa] : Rp0,2 781Shielding gas [l/min] 80Ar + 20% CO2 Flow ± 18 Tensile strength [MPa] : Rm 822Backing (gas) [l/min] Ceramic strip Flow - Elongation, A5 [%] : 17Gouge method N.A. Reduction, Z [%] : 63

Bend tests Former diameter:Current / polarity DC + RootPreheat temp. [°C] RT FaceInterpass temp. [°C] 150 ±15 SidePostheat treatment N.A. Impact tests ISO-V [Joule] Test temp. [°C]: see tableWelder's name Edwin Rebel Size of specimen: 10 * 10 * 55 mm, 2 mm sub surface

Clw av. Root av.Laboratory Test No. EX 72 - 20°C 71 77 80 76 0Remarks : Lot No.: 6901213 - 30°C 73 82 77 77 0

- 40°C 78 87 94 86 00 0

Welding Procedure Chemical composition all weld metal test (V-45°)Pass Consumable Welding Current Speed H.I.No. index Ø [mm] Ampere Volts [mm/min] [kJ/mm] C 0,061 A1 1,2 160 22 89 2,37 Si 0,252 A1 1,2 200 25 141 2,13 Mn 1,543 A1 1,2 200 25 133 2,26 P 0,0154 A1 1,2 200 25 218 1,38 S 0,0105 A1 1,2 200 25 203 1,48 Cr 0,0106 A1 1,2 200 25 171 1,75 Ni 2,027 A1 1,2 200 25 209 1,44 Mo 0,418 A1 1,2 200 25 166 1,81 V 0,0279 A1 1,2 200 25 209 1,44 Ti 0,044

Al 0,007Joint Detail B 0,0043

N 0,0042

Sketch

We certify that the data in this report are actual test results.Project HSLA steels with min. 690 YieldManufacturer or Contractor Lincoln Smitweld bvWitnessed by QA DepartmentIssued by Fred NeessenDate 7 May 2001

Welding Procedure Approval Record

WPAR : P 230.09Rev. : 0Ref. WPQ :95.098

Procedure Specification Test Results

Base material StE 690 Radiographic-ultrasonic Examination: AcceptableWelding processes A: SMAW B: SAW Dye - Penetrant, Visual Inspection: AcceptableManual or machine Manual and machine Reduced-section tension test

Tensile strength [MPa] Fracture locationWelding position PA (1G) * 1. 19.4 x 34.8 830 Base materialFiller metal (trade) 1: Conarc 70G 2: LNS 168 mod. 2. 19.2 x 35.2 840 Base materialFlux P 230Filler metal classific. 1: EN 757: E 55 4 1Ni Mo B 3 2 H5 All-weld-metal tension test

2: EN 756*: S 70 4 AB S0 ** Yield point [MPa] : Shielding gas [l/min] N.A. Flow Tensile strength [MPa] :Backing (gas) [l/min] N.A. Flow Elongation, A5 [%] :Gouge method Arc air + grinding Reduction, Z [%] :

Bend tests Former diameter: 4 x tCurrent / polarity DC + Side 2x 180° AcceptablePreheat temp. [°C] min. 160 Side 2x 180° AcceptableInterpass temp. [°C] max. 200Postheat treatment Soaking 72h/180°C Impact tests ISO-V [Joule] Test temp. [°C]: - 40 Welder's name -- Size of specimen: 10 x 10 x 55 mm

Mid weld av. Root av.Laboratory Test No. Clw 105 89 81 92Remarks : * Conarc 70G in 3G up (PF) and DC - Fl 95 120 109 108

Fl + 2 171 161 166 166Fl + 5 168 191 168 176

Welding Procedure Micro examination:Pass Consumable Welding Current Speed H.I. C 0.18 0.10No. index Ø [mm] Ampere Volts [mm/min] [kJ/mm] Micro examination of weld Si 0.44 0.62

and HAZ at 100x investigation Mn 0.99 1.741 A1 3.2 120-130 23 - 25 50 - 70 ~ 3.0 shows no unacceptable P 0.007 0.009

2 + 3 B2 4.0 500 28 500 1.68 structures or fissures. S 0.002 0.0064 - 7 B2 4.0 600 30 600 1.8 (Micro test specimen taken Al 0.042 0.0068 + 9 B2 4.0 500 26 450 1.73 from cap area). B 0.003 -

10 B2 4.0 500 26 700 1.11 Cr 0.89 0.2711+12 B2 4.0 550 28 600 1.54 Cu 0.11 0.0813-25 B2 4.0 600 30 600 1.8 Mo 0.42 0.4026-29 B2 4.0 500 26 450 1.73 Ni 0.06 2.43

Ti 0.02 0.09Joint Detail Hardness see sketch

Test type: Vickers Load: 5 kg 1 2 3 4 5 6 7 8 9 ………..

1 = Base 257-269-262-257-271-249-257-262-2572 = HAZ 307-306-293-296-341-341-336-317-299-310-306-303-329-3233 = Weld 265-265-271-271-262-265-283-286-2864 = HAZ 353-296-296-293

Sketch

We hereby, certify that the statements in this record are correct.Project MatanzasManufacturer or Contractor --Authorized by Det Norske VeritasIssued by Fred NeessenDate 29 December 1998

LNS 168 mod.E 690T

ø 10.078589920

Welding Procedure Approval Record

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