Standard

2557
FUSION WELDINGS
ed.: 1 Mod.
Page: 1/8
Date:01-04-1998

Object Index
To define the characteristics, prescriptions and 1. General .................................................................2
testing methods relating to steel joints welded by 2. Fusion welding with weld material. ......................2
fusion (which is a welding procedure that brings 3. Fusion welding without weld material ...................8
about a localized fusion of base materials without 4. After welding thermal treatment............................8
the use of pressure and with or without weld
material).

Modification Date Description of the modification

01-04-1998 Ed. 1 – New edition

Date of applicability:
Author: P. Mariani
Checked: A. Mantini
Approved: E.Cazzamani

Distribution List (codes): 27, 31, 33, 34, 35, 36, 39, 40, 41, 42, 43, 44, 66, 67, 68, 71, 72, 76, 80, 81, 86, 91,
108, 143, 190, 447, 554, 559, 567, 569, 571, 573, 582, 584, 591, 619, 621, 622, 636, 644.

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 Standard 2557 Page: 2 / 8 Mod.: Ed.: 1

C) Thermically altered area – these are the portions

1. General
of base material (adjacent to the fusion area)
This Standard specifies the characteristics, structurally altered by the heat induced by welding.
prescriptions and testing methods relating to
steel joints welded by fusion (which is a welding
procedure that brings about a localized fusion of
base materials without the use of pressure and
with or without weld material).
For the definition of the various fusion welding C A
st
treatments (f.e. arc, gas, etc.) see UNI 1307, 1
part.
Resistance welding (f.e. spot, ultrasonic, etc.)
and brazing are excluded from this Standard.
Fusion welding has been further subdivided into B
the following two classes for better definition of
its characteristics, prescriptions and testing
methods: A
- Fusion welding with weld material
- Fusion welding without weld material
Note: The various welded joints are defined by
nd
UNI 1307, 2 part.
For the conventional representation on technical
B C
drawings see UNI 1310.

2. Fusion welding with weld material. A

2.1 Terminology

On every joint welded by fusion with weld

material the following areas are defined (see
C B
examples at Fig.1):
A) Weld bead – this is the area outside the base
A Weld bead
materials produced by the weld material.
B Fusion area
B) Fusion area – these are the parts of the base C Thermically altered area (Z.T.A.)
material fused by welding.

Fig. 1

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 Standard 2557 Page: 3 / 8 Mod.: Ed.: 1

2.2 Prescriptions and test methods p1

2.2.1 Surface appearance

The welding examination must be performed

visually, in good lighting conditions and with the h1 a p2

aid of a lens if possible.

By reference to UNI EN 26520, the welded h2
surface must be homogeneous, without slag and Fig. 3 3
Figura
marginal incisions.
Pores and surface blowholes are permissible as
p
long as they are slight and do not prejudice the
functionality of the joint.
Cracks are not permissible. h
The welded section may have only slight defects
such as small craters at the beginning and the Fig. 44
Figura
end of the weld.
These defects are tolerable provided they are
L
concentrated in a short section (≤ 10% of the
weld bead total length).

2.2.2 Dimensions and tolerance

The measurement of the welding area

dimensions must be performed by observing the
appropriate sections of the welded joint Fig. 5
Figura 5
(prepared and etched in accordance with the
C
prescriptions in Standard 2571/LT ).

p2

Figura
Fig. 66
a
p1
h1

Fig. 2

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 Standard 2557 Page: 4 / 8 Mod.: Ed.: 1

C V ≥ 10% of the thickness of the thinnest

joint component
p1,p2 between 15 and 60% of the thickness of
the thinnest joint component

Figura 7
Fig. 7 2.2.3 Shape defects and internal compactness

In accordance with the illustration in Fig.10, and UNI

EN 26520, the following defects and acceptance
limits must be shown on the joint section.

Fig. 8
Figura 8
V
Figura 9
Fig. 9
By reference to Figs. 2, 3, 4, 5, 6, 7, 8, 9
(pages 3 and 4 /7) the following characteristic
joint components float, prior to welding (g): must
dimensions can be defined.
be ≤20% of the thickness of the thinnest joint
h1,h2 = weld bead sides
component.
L = weld bead length

marginal incisions: are permitted within the
a = weld bead height
following limits unless otherwise specified on the
C = weld bead convexity
drawing:
V = welding root penetration
- they are not permissible on welded safety joints
p1,p2 = fusion area depth
D
These dimensions, measured with a low (symbols and ).

magnification microscope equipped with a - for all other welded joints: of a depth ≤10% of the
micrometric eyepiece, must fall within the thickness of the thinnest joint components.
following limits: ¯ internal compactness: cracks or lack of fusion
h1,h2 ,L = in accordance with drawing (stuck weld) of the weld bead are not admitted;
prescriptions slag inclusions and porosity are tolerated so long
a ≥ 60% of the thickness of the thinnest as they are slight and do not prejudice the
joint component functionality of the joint; cracks in the thermally
C ≤ 20% of the shorter side of the weld altered area (T.A.A.) are not permissible.
bead

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 Standard 2557 Page: 5 / 8 Mod.: Ed.: 1

Fig. 11

g marginal
incisioni incisions
marginali

2 mm max

Fig.10 ≥ 5 mm
Figura 10

2.2.4 Hardness test

The hardness test on safety joints (symbols

2 mm m ax
D
and ) is performed on appropriate sections
of the joint, prepared by smoothing them off with
grain 600 abrasive paper, using the Vickers Base m etal Base m etal

method and load = 1 Kg ( HV1 ).

In order to measure and note down the range of
T.A.A..
welded joint hardness values, impressions must
be made in the fused area, the thermally altered
area and on the base metal. The values should
be measured along the row of impressions, one
of which must be situated at a maximum of 2mm
below the surface.
Some typical examples are depicted in Fig.11.
In each row of impressions there must be at
least 3 individual impressions in each welding
area: the fusion area, the thermally altered area
(on both sides) and on the base metal (on both
sides).
In the thermally altered area the first impression
must be made as close as possible to the line of
fusion.
The results of the hardness test must meet the
requirements set out in Table 1.

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 Standard 2557 Page: 6 / 8 Mod.: Ed.: 1

Table 1 Maximum admissible HV1 hardness values

Steel groups Butt and single pass edge joints Butt and multiple pass edge joints

(see Table 2) Not thermally Thermally Not thermally Thermally

treated treated treated treated
1 (1) - 2 380 320 350 320

3 (2) 450 (3) 420 (3)

Alloy hardened and
450 (3) (3) (3)
tempered steels
and (4)
Notes:
(1) If hardness tests are required.
2
(2) For steels with Re > 885 N/mm special agreements are required.
(3) Hardness not lower than the base material.
(4) When the weld material is different to the base material (f.e. group 3 base, group 8 weld material
Table 2).

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 Standard 2557 Page: 7 / 8 Mod.: Ed.: 1

Table 2 Steel grouping system (UNI EN 288 / 3)

Group Steel Type

Steels with a unit yield strength higher than the prescribed minimum Re ≤ 355 N/mm or
2

Rm ≤ 520 N/mm and having a chemical composition % no greater than:

2

C = 0.24
Si = 0.55
Mn = 1.60
1 Mo = 0.65
S = 0.045
P = 0.045
Every other individual element = 0.3
All other elements, in total = 0.8
Normalized or thermomechanical treated fine grain steels, having a unit yield strength higher
2 (1) 2
than the prescribed minimum Re > 355 N/mm .
Hardened and tempered fine grain steels, having a unit yield strength higher than the
3 (1) 2
prescribed Re > 500 N/mm .
4 (2) Steels with Cr max. 0.6 %, Mo max. 0.5 %, V max. 0.25 %.
5 (2) Steels with Cr max. 9 %, Mo max. 1.2 %.
6 (2) Steels with Cr max. 12 %, Mo max. 1 %, V max. 0,5 %.
7 (2) Steels with Ni max. 9 %,
8 (2) Martensitic or ferritic inoxidizable steels from 12 to 20 % Cr.
9 Austenitic inoxidizable steels.

Notes:

(1) Carbon or carbon-manganese steels.

(2) For groups 4 to 8: the alloy content refers to the nominal analysis of the casting.

2.2.5 Micrographic examination

2.2.6 Other tests
The survey of the structure is carried out by
micrographic examination of suitable sections of Any other tests (pressure seal, tensile strength,
the joint, prepared and etched in accordance bending, shock, fatigue strength, etc.) may be
with the prescriptions in Standards 2571/LT and specified depending on the stresses to which the
2572/LT. joint is subjected in operation and its functional
In the thermally altered area the following should importance.
be noted: In these instances, the tests must be prescribed on
a) joints not thermally treated after welding : the drawings and working schedules.
uniform structure with the possible presence of
untempered martensite as long as the hardness 2.3 Repairs
does not exceed that prescribed at point 2.2.4 . The repair of welded safety joints (classified by the
b) joints thermally treated after welding: D
symbols and ) is not permissible.
uniform structure corresponding to the type of
For all other joints repairs by welding are
material in the relevant thermal state.
permissible subject to removal of the defective

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 Standard 2557 Page: 8 / 8 Mod.: Ed.: 1

weld section, provided that the repaired section a) Tempering: is performed at relatively low
meets the requirements set out at point 2. temperatures ( 300 ÷ 600°C ).
Where joints have been subjected to thermal In the case of hardened and tempered material
treatment after welding, the repair obviously (quenching + tempering) welding the post-welding
makes it necessary to repeat the treatment. treatment temperature should be at least 30°C lower
than the tempering and hardening temperature.
2.4 Type of material b) Normalizing: is performed at higher
The type of weld material used (in wire or rod temperatures ( 750 ÷ 950°C ).
form), must comply with the drawing and Both treatments may be performed either in the
manufacturing schedule prescriptions for the furnace or locally by induction heating.
part, it must in any event be compatible with the It must be borne in mind that , in the case of using the
type of material to be welded. furnace the part will be homogeneous after treatment,
whereas in the case of localised heating a structural
variation between the treated and untreated areas
3. Fusion welding without weld may be encountered.
material Note: If there is no specification in this Standard the
prescriptions in the drawing or working schedules
In the case of fusion welding without weld
apply.
material, in addition to complying with the
If the Design or Technology Departments want
requisites for welding with weld material referred
characteristics which are different to those prescribed
to at points 2.2.1 , 2.2.4 ,2.2.5 , 2.2.6 of this
in this Standard, they must be shown on the drawing
Standard, the joint must pass a breaking
and working schedules.
resistance test (or stand up to a minimum of
clamping torque) to be prescribed in the drawing
in relation to different types of welding.
Standards cited
The foregoing particularly applies to safety joints 2571/LT ; 2572/LT

( classified by the symbols and

D
). UNI 1307 / 1:86 - UNI 1307 / 2:87 - UNI 1310:86
UNI EN 288 /3:93 - UNI EN 26520:93
4. After welding thermal treatment

In the event that the welded joint is subjected to

high or repeated mechanical stress(fatigue)
when it is in operation, or where it is safety
D
classified (symbols and ), or prescribed
by the drawing, thermal treatment after welding
should be provided for..

Two types of treatment are possible as a rule:

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