SM490A weld to railway

[Pravin Poornachandran]

Dear Expert,

We are doing a weld joint with following base metal combination: 

SM490 weld to railway (alloyed, high tensile material) 

I used E7016 for this welding, after 4 hours, crack was observed on the weld toe,

however there is no crack on the weldment, thus I assume this is cold crack. 

Crack was noticed on the railway material, not on SM490A material. 

Welding condition:

Baking was done 300-350degC x 1hr 

thickness: 16mm both material 

Preheat: 200degC 

Post heating: 250degC x 1hr

Can anyone advise how to solve this crack defects

Best regards,

Pravin Poornachandran

[Vishwas Keskar]

Pl. send MTCs of both the materials 

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[Pravin Poornachandran]

Dear Sir,

 

Enclosed material properties of railway material, while SM490A is ordinary mild steel with low carbon content <0.3%

Along I have enclosed picture of the crack.

 

1^st picture was without preheat, while 2^nd picture was with preheat 230degC & postheating 250degC x1hr.

However, crack still occurs. I’m bit lost at this point.

 

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[Vishwas Keskar]

Railway material is  with High Carbon  so will have  high strength  with  High HAZ hardness .

The electrode deployed - E7016 has less strength .

Use E11018   with pre heating   and 3.15  dia with stringer bead technique.

After full welding , maintain pre ehat maintenance  say 350  Deg C - 2 HRS  and then cool under insulation 

This shall 

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[pravin.n...@gmail.com]

E-7016 not be suitable for SM490A to Rail steel (low alloy steel)

Below suggestion given based on both material Chemical & Mechanical properties.

Sugeested welding consumable for SM490A to Rail steel (low alloy steel) is E-12016-G electrode

Preheat temp. for the rail steel- 200 to 300 Deg.C

Interpass Temp.:- Less than 400 Deg.C

Slow cooling required after welding by insulation covering.

Regards,

Pravin Nimbalkar

Welding Engineer

[Satyaprakash Soni/EM&RBG/MUM]

avoid faster colling rate.

Thanks & Regards,

Satyaprakash Soni,Manager - QA/QC,Mobile +91-9892649099

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[Ramin Kondori]

Is this the new Japanese high-speed rail project in India...?

Ramin  Kondori

Sr. QA/QC & Welding Engineer

-----------------------------------------------------------

PG-Dip. in Welding Engineering (IWE  AT  0070)

BSc. in Civil Engineering (IUT)

BGAS Painting Inspector

ASNT Level I&II

                        

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[Pravin Poornachandran]

Hi Ramin,

 

This is in Malaysia high speed rail project which connects North – East Malaysia.

 

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From: Ramin Kondori
Sent: Saturday, 10 April, 2021 11:05 PM
To: material...@googlegroups.com

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[Pravin Poornachandran]

Hi Pravin,

 

Thank you very much for your valuable inputs.

I shall take note.

 

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[Pravin Poornachandran]

Hi Vishwas,

 

I agree with you on the electrode selection.

Need your advice, using high tensile electrode can lead to brittleness?

The problem im facing now is, client keep on insisting to use E7016 instead of high tensile electrode.

 

Having hard time to convince the client.

 

Anyways appreciate your input.

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[Vishwas Keskar]

Dear Pravin,

Query- 

Need your advice, using high tensile electrode can lead to brittleness?

Response - 

These High Tensile electrodes are with Low alloys addition and have moderate ductility of @20 %-  reasonable ductility during Welding 

Need  to follow  critical Welding parameters  , the welding will be sound .

 

Query-

The problem im facing now is, client keep on insisting to use E7016 instead of high tensile electrode.

  Response - The rail material is High Carbon  so hard HAZ requires strength when  butt  Joint is welded.  So either E110XX, E120XX is chosen

For Fillet welds , E7016 would have been suffice 

Hope the things will  be all clear

  

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