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3.7.2 Increasing Chances For Successful Welding: Chap. 2

This document discusses determining whether existing steel can be welded to. It states that steel produced before 1923 should be tested for weldability, steel from 1923-1936 is generally weldable, and steel after 1936 is normally weldable. It recommends conducting chemical testing of steel samples to determine carbon equivalent and weldability. It also describes an in-place fillet bend test to check weld ductility without removing samples. Proper welding techniques like preheating thicker members and using low-hydrogen electrodes can increase the chances of successful welding to existing steel structures.

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31 views1 page

3.7.2 Increasing Chances For Successful Welding: Chap. 2

This document discusses determining whether existing steel can be welded to. It states that steel produced before 1923 should be tested for weldability, steel from 1923-1936 is generally weldable, and steel after 1936 is normally weldable. It recommends conducting chemical testing of steel samples to determine carbon equivalent and weldability. It also describes an in-place fillet bend test to check weld ductility without removing samples. Proper welding techniques like preheating thicker members and using low-hydrogen electrodes can increase the chances of successful welding to existing steel structures.

Uploaded by

jcvalencia
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© © All Rights Reserved
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weld to the existing structure?

To answer this question, one must determine whether the existing steel is weldable. Some
early steels had large concentrations of carbon, sulfur, and phosphorus, and welding them may
be problematic. Too much carbon and phosphorus result in a steel that is overly brittle; high
sulfur content often produces porous welds. As a rough guide, steel made prior to 1923 should be
tested for weldability. Weldability of steel produced between 1923 and 1936 is generally good,
and steel made after 1936 is normally weldable.26 The reason for the qualifiers in this statement
is that the ASTM A7 allowed for a wider range of chemical composition than the later ASTM
A36 steel.
Unless the material specifications or mill certifications for the steel in question are available,
the best method of arriving at an intelligent answer is to conduct chemical testing of the steel by
removing coupons, as described in Chap. 2. This relatively inexpensive service, which can be
performed by many testing laboratories, can determine the mechanical and chemical properties
of steel. The critical chemical property for determination of weldability is carbon equivalent, a
number that combines the percentage of pure carbon and certain fractions of several other
elements present in steel. There are a number of formulas for computing the carbon equivalent.
When the carbon equivalent is less than a certain value, which depends on the formula, the steel
is considered to be weldable.
Of course, prior to embarking on any such testing, one should first examine the existing
structure for the presence of any welded connections: If the steel was successfully welded before,
the answer is obvious. If still unconvinced, the engineer may order an in-place test for
weldability, which will provide information about weld ductility and hardening of the base
metal. This “fillet bend test” is specified in AWS D1.1.27 Essentially, it involves welding a small
steel plate tab to the existing member and hitting it with a hammer. If the existing steel is
weldable, the fillet weld will deform without breaking; if it is not, the weld will separate from the
base material. This method is rather crude; for critical applications, there is no substitute for
laboratory testing.

3.7.2 Increasing Chances for Successful Welding


In his classic article “Field Welding to Existing Steel Structures,”6 which should be read by
everyone involved in specifying this type of work, David T. Ricker lists some of the precautions
that can be taken to increase the chances of successful welding to the existing framing. Some of
these steps that the design engineer can take include:

• Specifying proper welding electrodes, typically E60XX or E70XX series for ASTM A7,
A9, A36, and A500. Low-hydrogen welding electrodes used for manual welding can help.
• Using preheating, especially for thicker members. Both the AISC manual and AWS D1.1
contain tables for minimum preheat and interpass temperatures for various material
thicknesses joined by regular or low-hydrogen electrodes. Thicker members require higher
preheat and interpass temperatures because they absorb more heat from the welds and
make them cool too fast, potentially resulting in increased internal stresses and
embrittlement. The welds should be allowed to cool down between the passes.
• Positioning the welds properly, especially avoiding welding perpendicular to the existing
stress lines, which usually run along the longitudinal axis of the member. If transverse

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