Welding Procedures Specification for

Flux Cored Arc Welding of Wind Towers

By Nelson da Cunha de Matos, Instituto Superior Técnico

Abstract Leading the renewable technologies is wind

The main objective of the study concerns the energy conversion. Wind energy is an attractive
development of a welding procedure using flux alternative to fossil fuels mainly because is a
cored wire in order to allow a new design clean, renewable, plentiful and widely distributed
concept for large wind energy towers with source of energy.
increased base diameters. The innovation of this Nowadays, conventional WEC towers have
concept is the replacement of ring flanges by reached road transportation limits in dimension
onsite welds which improves the fatigue and weight. Limited accessibility conditions of
resistance, enables the introduction of higher onshore remote areas, where best wind
steel grades and erection of wind energy conditions exist, do not permit the installation of
converters (WEC) in remote areas with limited larger and more efficient WEC. This requires
accessibility. transport of parts, assembly and erection on site.
Welding trials and preparation of Welding This study targeted the ability to use
Procedure Specifications Flux Cored Arc mechanized Flux Cored Arc Welding (FCAW) to
Welding (FCAW) tests were carried out, a wide connect tower sections onsite made with S355J2
selection of self-shielded and gas-shielded wires and S460M steels maintaining mechanical
were tested and evaluated for their overall properties required for this type of construction.
weldability, especially. In the vertical-up position, Manual and mechanized trials were
since it is the most relevant for FCAW during the performed in S355J2 and S460M steels using
erection of the tower. self-shielded and gas-shielded wires.
Welded samples in S355J2 and S460M steel All welded samples were visual inspected and
were subjected to mechanical tests and micro- submitted to Radiographic and Ultrasonic testing
structural analysis in order to ascertain their according to ISO5817.
suitability for the efforts expected in a WEC.
WEC innovation
Introduction Replacing Submerged Arc Welding done in
Due to environmental constraints greenhouse factory by mechanized FCAW onsite and using
gas emissions must be reduced according to the higher steel grades such as S460M will enable
Kyoto Protocol[1] and new methods to gather onsite manufacturing of the lower tower sections
energy with lower levels of pollution and to in a mobile factory overcoming transportation
reduce the carbon footprint have been restrictions and allowing larger bottom diameters
developed. The new technologies emerging from and thinner walls. By allowing larger diameters
this effort are called Green Energy. [2] and having a lighter structure total WEC height,
Renewable technologies are essential weight of the nacelle and rotor can be increased
contributors to sustainable energy as they and in consequence energy conversion
generally contribute to world energy safety, efficiency will also increase.
reducing dependence on fossil fuel resources, Another positive feature, of this alternate
and providing opportunities for mitigating means of manufacture, is the expected improved
greenhouse gases.
1
fatigue behavior due to the replacement of bolted Coreshield 8(1.6mm); Coreshield 8 Ni1
connections by welding. H5(1.6mm)
FCAW characteristics Gas-Shielded: ESAB PZ6113(1.2mm);
Flux Cored Arc Welding has developed PZ6113S(1.2mm); PZ6114S(1.2mm);
significantly since 1950, having overcome many PZ6116S(1.2mm); PZ6138(1.2mm)
of the restrictions associated with Shielded Metal For the selected wire a Preliminary
Arc Welding and becoming a competing Specification of Welding Procedures was defined
technology of Gas Metal Arc Welding. FCAW for the 10mm and 30mm thickness joints. The
was developed primarily for welding thick and second stage was initiated after obtaining a
out-of-position structural steels both in closed satisfactory welding procedure. Microstructural
shop environment and outdoors. properties analysis and hardness tests were
For this study self-shielded wires are of conducted on S460M steel for different heat
particular interest since all welding work shall input (HI).
occur outdoor at the mercy of nature. This type of In the third step fully mechanized welding
wire does not require externally supplied trials were performed on smaller sample test
protection gas for shielding, unlike gas-shielded pieces to check the welding settings. Non
wires, vaporization and decomposition of core Destructive Testing (NDT) such as Ultrasonic
ingredients provide protection to the weld and Radiographic testing were used to assess
creating their own shielding gas. the existence of any welding imperfection.
Gas-shielded wires are easier to work with, In the last trial all knowledge from the
and do not require such an accurate technique previous trials was used to produce flawless test
as with self-shielded, however if used in a windy pieces that later underwent to confirm
environment without any additional protection of mechanical properties required.
the welding area the loss of protection of the gas
from air flow can lead to weld imperfection Results
namely porosity. 1. First trial
Best results of the first trial were obtained with
Experimental procedure NR-203Ni1 and PZ6113S self-shielded and gas-
The main purpose of this work was guarantee shielded type respectively.
a mechanized FCAW alternative to SAW
providing defect-free welds and mechanical
properties required for WEC towers.
The trials were divided in four stages. In the
first stage the most appropriate filler wire was
selected to the task at hand, which was welding
vertical up joints. The wire with best results in
welding parameters optimization was then used
for the remaining trials.
The parameters to be studied and optimized
were: Wire feed speed, current, arc voltage,
stickout, travel speed, torch angle and weaving
frequency / trajectory.
The wires tested in selection trials
differentiated themselves by shielding/gas type,
diameter and mechanical properties. Chosen Figure 1 - Example of a semi-automatic
wires for selection trials welding joint using a self-shielded wire (NR-
Self-Shielded: Lincoln Electric NR-233 (1.6mm); 203Ni1.Left: front side of welded joint; right:
NR203Ni1(2.0mm);NR-Offshore(2.0mm); ESAB back side of welded joint.

2
 Wire
Current Weld Heat Deposition
feed Voltage
(typical) speed input rate
Pass speed
no.

[m/mi
[V] [A] [cm/min] [kJ/mm] [kg/h]
n]

1 6.0 23 160 11 2.0 2.1

2, 3 8.0 25 190 18 1.7 2.8

Figure 3 - Welding joints (10mm), sequences

and parameters for vertical-up (PF) position
with PZ6113S.

Figure 2 - Example of a semi-automatic

welding joint using a gas-shielded wire
(PZ6113S): Left: front side of welded joint;
right: back side of welded joint.

Deposition rate (Kg/h)

Wire Root Fill & Cap Wire
Current Weld Heat Deposition
NR233 1,6 2,3 feed Voltage
Pass (typical) speed input rate
speed
NR203Ni1 1,4 1,7 no.
NR Offshore 1,3 1,7
[m/min] [V] [A] [cm/min] [kJ/mm] [kg/h]
Coreshield 8 1,4 1,4
Coreshield 8 Ni1 1,1 1,6
1 6.0 23 160 10 2.2 2.1
PZ6113 2,1 3,2
PZ6113S 2,1 3,2 2-8 9.0 27 210 17 2.0 3.2
PZ6114S 2,1 3,2
PZ6116S 2,1 3,2 Figure 4 - Welding joints (30mm), sequences
PZ6138 2,1 3,2 and parameters for vertical-up (PF) position
Table 1 - Deposition rate of all tested wires. with PZ6113S.

From visual inspections, deposit rates and 2. Second trial

overall weldability the best wire tested was With all the objectives and results of the first
PZ6113S. test completed the second trial began by
obtaining the desired heat input with two different
approaches. The first approach combined
different values of wire feed speed (WFS) with
welding speed (WS), This was used for test
specimens from A to G, the remaining specimens
were welded with the other approach consisted
on maintaining the WFS value constant and
varying only the WS.

3
 HV10 One parameter of paramount importance is the
400 angle of the torch in all passes but especially on
350 root and cap passes, by controlling the torch
300 angle a good penetration or fill can be obtained.
For root passes it was found that a downward
250
angle, about 15º with horizontal plane, provided
200 the correct amount of penetration and good joint

1,5
1,03
0,49
0,51

1,05

2,17
2,58

3,11
3,82
3
filling.
Heat Input KJ/mm For cap passes the decision of what angle
was more appropriate was difficult because not
Figure 5 - Maximum Hardness for each
only the welding speed and torch angle
heat input value tested.
influenced the cap but also weaving frequency
400 Max. y = 364,35e-0,062x
Hardness and amplitude.
R² = 0,9715
350 The preferred angle for fill and cap pass was
an angle of 0º with horizontal plane, with a 0.2
300
seconds dwelling right and left with a frequency
250 of 1Hz, as for the width of the weaving was
normally 2mm shorter than the gap of the joint in
200
1,57 3,13 4,70 6,26 7,83 9,39 11,90 the actual pass.
Cooling times T8-5 Mechanized test pieces were subjected to
ultrasonic testing and if any imperfection was
Figure 6 - Max. hardness relation with cooling detected welding parameters and procedures
times obtained with Rosenthal analytical solution. were refined until flawless welding bead was
achieved.
All specimens presented acicular ferrite,
polygonal ferrite, in the weld material, in the low
heat input specimens some formations of
martensite, and bainite were detected. The
unaffected parent material presented ferritic and
perlitic structures.
Microstructural differences were best seen in
the heat affected zone as it was expected.
Specimens with lower heat input (A, B, C, H, I) Figure 7 - Completed welding joint. Left: front
have martensitic and bainite structures in the side, right: back side of welded joint.
grain growth and in the refined grain areas as
Most problematic imperfection found was
well. Traces of perlite and some aggregated
porosity. Welding parameters and conditions
carbides are present in the subcritical region. In
were check and arrived at the conclusion that
the specimens with Hi higher than 2.5KJ the
that the cause was incorrect gas flow rate. By
grain growth region has ferrite with aligned M-A-
consulting gas flow efficiency information in “
C and ferrite carbide aggregates, in the
Wilkinson, M. E., Direct Gas Shield Analysis to
subcritical region ferrite and spheroidized pearlite
Determine Shielding Efficiency. Report of The
are present.
Welding Institute (TWI), Cambridge, England;”
3. Third trial and applying, the Reynolds number (Re) from
The first and second trials gave the fluid mechanics, a flow line was plotted which
opportunity to initiate mechanized welding with facilitated the establishment of a new and more
well-defined parameter boundaries. Few efficient flow rate however the exact transition
changes were needed to achieve sound welding will be dependent on the diameter of torch used,
beads with good penetration and morphology.

4
this study provided some perspective and There are two hypotheses to explain the slag
cautions on the use of too high a flow rate. inclusion:
Flow Rate 1st used flow 1- The cut made by the grinder entrapped
30 (l/min) 2nd used flow slag in the small groove of the cut and the
25 Flow Line 26 26,9 second pass did not melted adequately the root
22,7 pass leaving slag embedded in the bead.
20 20
17,5 2- The cut originated a small groove that
15 Turbulent
was enough to entrap the slag of the second
10 Laminar pass by disturbing the weld flow.
5 6,6
Not being sure which one was the defect
0 cause, slag removal procedure and welding
1 3 5 7 9 11 13 15 17 19 21 procedures were altered in order to eliminate all
Nozzle Size (mm)
possible causes. Conventional slag cut was
Figure 8 - Shielding gas flow regions.
made on left and on right instead of being
4. Fourth trial centered, the cut did not touch the weld bead.
Similarly to the third trial mechanized samples Welding speeds were increased in order to avoid
with no imperfections were welded with the a cushion effect and provide a better penetration
purpose of being submitted to mechanical tests. by the arc travelling on the edge of the molten
Even with all the trials done before and welding material.
procedure well established some imperfections After all welds quality was confirmed by
were detected in some samples. In twenty nine ultrasonic and radiographic testing, Charpy and
samples four showed presence of imperfections tensile tests were also carried out on several test
such as intermittent undercut, slag inclusions pieces.
and gas pores. Yield Tensile Elongation
Test
Strength Strength after
Three test pieces, despite the imperfections Reference
Mpa MPa fracture %
found, are classified by ISO 5817 as class B ST004_T1 531 614 25,3
(highest quality level). Only one test piece had ST004_T2 540 650 27,1

imperfections not permitted by the standard, ST004_T3 610 695 27,7

none of the other three test pieces with ST006_T1 476 596 29,0
ST006_T2 524 644 26,2
imperfections required repair.
ST006_T3 496 599 24,8
The case of the test piece with not
ST013_T1 552 680 27,5
acceptable is present below.
ST013_T2 559 699 27,4
ST013_T3 558 715 29,9
ST020_T1 495 625 28,1
ST020_T2 516 632 28,8
ST020_T3 536 664 27,6

Table 2 – Tensile test results

ST013 & ST014

Temp. Weld Fusion
FL+2mm FL+5mm
(ºC) Metal Line
Figure 9 – Welding Imperfection Radiography 22 91 67 48 56
parameters of ST005, 170mm to 335mm; -20 69 60 28 40
Macrograph of ST005 weld bead showing a slag -50 47 20 19 17
channel Table 3 – Charpy test
The defect was a slag inclusion. Analysis of results
After evaluating the defect the most probable Filler wire selection
cause found for this to happen was due to the Self-shielded wires seemed to have good
method of removing the root slag. potential for application in the scope of the

5
project. These wires were valid choices as they besides stickout (which is limited) is wire feed
are all-position wires for structural welding of mild speed that also has a limit. More current implies
and some alloy steels but also suitable for single- hotter molten metal and more wire fed, in these
and multi-pass welding however self-shielded conditions it is impossible to the molten metal
wires were not capable of matching mechanical solidify quickly enough to sustain the following
properties of S460M steel. metal deposited by the weaving motion.
All gas-shielded filler materials that have Pure carbon dioxide is not an inert gas
been tested are 1.2mm diameter all-position because the heat of the arc breaks down the
rutile wires which differ among them mainly on CO2 into carbon monoxide and free oxygen. The
nickel content and corresponding toughness use of pure CO2 as welding gas, instead of 20%
properties of the weld metal. All gas-protected CO2 argon-based mixtures, results normally in
rutile flux-cored wires tested, PZ6113 (with lower values of hydrogen as CO2 react at these
Ar/CO2), PZ6113S, PZ6114S, PZ6116S and high welding temperatures producing a hotter
PZ6138, all match entirely the properties of puddle than truly inert atmospheres. The thermal
S460M steel. conductivity of the gas at arc temperatures
Not only gas-shielded wires are capable of a influences the arc voltage as well as the thermal
much better overall weldability but also have energy delivered to the weld. As thermal
deposition rates notoriously higher than their conductivity increases, greater welding voltage is
self-shielded counterparts. necessary to sustain the arc. For example, the
It is known that as the cross sectional area thermal conductivity of helium and CO2 is much
of a conductor decreases, the resistance to higher than that of argon, because of this they
current flow increases. This resistance to current deliver more heat to the weld. As result the use
flow will cause considerable heating of the of CO2 improves the molten puddle flow
conductor if the current is relatively high and the characteristics and hydrogen diffusion, since the
conductor is small in cross sectional area. In elevated solubility of hydrogen allows hydrogen
other words, at a given current in amperes, the to diffuse out of the metal while this is at elevated
current density within the conductor will increase temperatures.
as the diameter of the conductor is reduced. In spite of the need to provide protection
It is this high current density that makes flux from wind in the immediate vicinity of the welding
cored wires the success they are. The high area, gas-shielded wires are strongly
resistance heating of the wire is confined to a recommended for mechanized FCAW
small area, and the electrode reaches its' melting applications within the scope of the project, the
point very quickly, producing a concentrated final choice of FCAW filler material fell on
deep penetrating arc. The deposition rate and PZ6113S due to lower cost related to welding
the efficiency are very high. (gas type) and very similar properties with the
The current density is considerably higher in remaining PZ wires.
the small diameter flux cored wire and therefore S460M Weldability Test
the deposition rate will also be somewhat higher. The microstructural changes between
For example the smallest self-shielded (SS) wire different heat input samples can be explained by
tested was 1.6mm and gas-shielded (GS) was the cooling time. A high heat input will result in a
1.2mm, the resistive area of SS is 77% bigger slow cooling rate, for a carbon steel, a slow
than GS and even increasing the stickout length cooling time over the temperature range of 800
to its limit it was proven impossible to to 500º C, results in a predominantly ferrite and
compensate the resistance difference, as it can pearlite microstructure.
be seen in Table1 were the best SS wire has a A low heat input will result in a high cooling
deposition rate of about 75% of any GS. rate. A fast cooling time over the temperature
To match GS wires performance SS wires range of 800 to 500º C, results in a
must increase its welding current however the predominantly ferrite and equal quantities of
only parameter which increases the current bainite and pearlite in the microstructure.

6
Martensite is rare in weldments with 0.1 to 0.25% Consulting the standard ISO TR 15608 –
C and 1.0 to 2.0% Mn carbon steel welded with 2005 the steel S460M belongs to the group 2.1
suitable fillers, a cooling time of less than 1 as it is a thermomechanically treated fine-grain
second over the temperature range of 800 to steel with a specified minimum yield strength 360
500º C would be necessary to form martensite. /mm2 < ReH ≤460 /mm2 and consulting ISO
The application of Rosenthal analytical 15614-1 2004 section 7.4.6 Table 2 the
solutions for this kind of experimental work is maximum permitted hardness value (HV10) for
always a rough approximation to real welding this type of joint and steel group cannot exceed
conditions, however with the necessary 380HV10.
precautions when analyzing the data obtained Even with the lowest heat input the
some conclusions can be associated with the maximum HV value obtained was 363 therefore
real case. according to the standards any of the welding
The predicted range of cooling times for a parameters used are acceptable, however lower
0.5 kJ/mm weld sample was found to be around values of hardness ensure a less brittle structure
1.6s, this translates to mean cooling rates of and HI higher than 1.5KJ/mm should be used to
approximately 192ºC/s. On the opposite for a safeguard a more ductile fracture.
heat input of 3.8KJ/mm the cooling time As expected test pieces with lowest HI such
increased to 12s and the cooling rate was about as A, B, E,I with microstructures rich in bainite
25°C/s. and martensite which has limited slip possibilities
In Figure 6 the maximum hardness versus and a high yield strength, these test pieces also
cooling times were plotted and a trend lines was show higher hardness and brittleness in WM up
added using an exponential equation, this trend to refined grain growth than all the others test
line has a R2=0.9715 which is a fairly good pieces. The other test pieces with higher HI and
accuracy to the values plotted. slower cooling rates have small amount of
( ( polygonal ferrite and acicular ferrite,
This equation can be used to back track characterized by needle shaped crystallites with
from a hardness value desired up to the HI chaotic ordering, in the WM which confers a
necessary to achieve it. more ductile microstructure than martensite.
With cooling times less than 4.7s there is a Ferrite with aligned M-A-C was also found and
high probability to find martensite on the weld although this kind of microstructures is not
metal and also on the HAZ, these hard beneficial due to the presence of martensite and
microstructures are above de 300HV since the carbides which contribute to the embrittlement,
supersaturated solid solution of carbon and hardness values were very alike to test pieces
alpha ferrite are not maintained between 800 and without this type of microstructures which leads
500ºC have enough time to promote the grain to think that there is only a small amount of M-A-
growth and carbon diffusion. C.
Test pieces C, D and M had cooling times It was also found that for same values of
between 5 and 9s, this higher cooling time heat input obtained by higher wire feed speed
translated in the complete microstructural result in slight lower values of hardness. This can
transformation of the weld metal in acicular and be seen in Figure 5 where hardness values of
polygonal ferrite and long enough cooling time to 0.49 KJ/mm and 1.03KJ/mm, respectively test
transform austenite in bainite, avoiding pieces H and I welded at 9cm/min, were 20HV10
martensite, in the HAZ. lower than when the two test pieces welded at
For the remaining test pieces, G and N, 6cm/min. One reason for this to happen is the
with cooling time, above 9s, allowed the cushion effect, at a slower welding speed the arc
attainment of ferrite and spheroidized perlite in force is damped by the extra weld metal
the subcritical zone very similar with the parent deposited this translate to a lower heat
material whilst in the grain growth zone was transmission to the piece as heat is partly
identified ferrite with aligned M-A-C. dispersed by the weld bead itself, although the

7
heat input is equal. As seen before lower to unsettle. Same scenario was found in PF
temperatures are accompanied by higher cooling position with the welding speed limit being
rates which lead to harder structures. 11cm/min.
Mechanized welding trials Mechanized welding samples
It was decided maintain constant the wire Although some defects were detected in the
feed speed, therefore torch alignment, stick-out, ST samples, according to ISO 5817, no repair
welding speed and torch angle would be was mandatory, except for one. The results
adjusted in order to compensate changes in joint obtained by NDT confirmed not only the quality
geometry. The parameters obtained from the of welded joints but also the ability to detect any
manual testing were very accurate working as kind of imperfection.
guide lines needing just some corrections case Methodology and welding parameters were
by case as it is impossible to guarantee identical very alike with the ones used in the mechanized
joint geometry of every test pieces and the trials and in twenty nine test pieces only one
mechanized system does not compensate failed the standard requirements this shows that
unforeseen situations like a skilled technician the welding procedure is robust and easily
does. repeatable with high quality welds.
The most delicate and troublesome pass The major imperfection found on ST005
was the cap, not only because it was the surface reveals that the welding position PA is more
one but also because it was the transitions from prone to develop this kind of imperfection than
a weld bead starting within the joint and ending the PF position, this is related to the less efficient
on the surface of the test piece. convection in the molten pool when welding in
Shielding gas flow rate is often a neglected PA making any failure in the joint preparation is a
factor in FCAW, the assumption that more gas possible triggering defect. The key to eliminate
flow results in better protection is misleading. the imperfection was the homogeneous
High gas flow surge at weld start causes preparation of the joint to receive the second
turbulence in the shielding gas stream. This pass as it is nearly impossible to control weld
turbulence causes air to be mixed into the flow conditions.
shielding gas stream until the flow rate stabilizes The disturbance of the weld flow can be
to the preset level. This entrained air causes, in explained by two types of flow generated.
addition to wasting shielding gas, excess weld The surface temperature of the weld pool
spatter and can cause internal weld porosity. The will usually be maximum in the center of the weld
gas flow required to efficiently protect the molten pool and decreases with increasing distance
puddle cam be directly related to the welding gun from the center creating a temperature gradient
nozzle size and distance to work piece First flow which in turn will generate a surface tension
rate value used, which lead to some porosity, is gradient. The negative gradient of the surface
marked as a red triangle in Figure 8. As can be tension generates outward directed flow called
seen it was not an excessive value however for Marangoni flow (Figure 10), on the opposite side
the gas type and nozzle size being used it was is the Lorentz flow (Figure 11) which generates
too much. After plotting a flow line that separates electromagnetic forces in the weld pool due to
approximately the turbulent regime from the divergency of the electric current causing
laminar a new and conservative flow rate was pressure differences and resulting in downward
tested, marked in the graph with a green square, directed flow.
with this new value the incidence of porosities
cause by inadequate gas flow rate dropped to
virtually zero.
In PA position with 10mm thickness was
found to be impossible to make the root pass
Figure 10- Figure 11-
with welding speed higher than 7cm/min as the
Marangoni flow Lorentz flow
electric arc overtakes the molten bath and begins

8
 As result of these reversals, undesirable One explanation is that longitudinal test
variations in penetration depth can occur and the metal across the grain of steel and have higher
existence of the small groove can be enough to notch toughness than transverse.
produce the imperfection above described. Thermomechanically rolled material possess
Tensile test results confirm the mechanical long grain boundaries in rolling direction and
properties expected when welding with the another reason for the anisotropy is the
chosen wire and these types of steel, the lowest elongation of non-metallic inclusions like
value of yield strength registered was 476MPa manganese sulphide. At high temperatures the
above minimum value in the wire certificate as sulphide inclusions are harder than the matrix
well in the steel certificate. material, but in the temperature regime of the
The values for these properties vary even thermomechanical treatment the inclusions are
between specimens of the same test sample, the softer. During the rolling process they stretch in
maximum variation is about 81 MPa and this can the rolling direction and elongate resulting in
be explained by some changes in the welding anisotropic toughness behavior as a consequent,
parameters to compensate inhomogeneous joint the Charpy impact values in the transverse
zones. These changes modify the heat input and direction are usually inferior to those in the rolling
joint filling, this can originate different direction.
microstructures consequently different
mechanical properties. Ductility can be Conclusions
assessed by the other two parameter, area Although self-shielded FCAW wires have
reduction and elongation after fracture. A evolved greatly they are still a step behind the
material that experiences very little or no plastic gas-shielded wires Self-shielded wires seemed
deformation upon fracture is termed brittle and to have good potential for application in the
the converse is also true. The minimum scope of SAFETOWER as mobility being the
elongation belongs to S460M steel with a value best property however self-shielded FCAW wires
of 17% from tensile test done the lowest of all do not match mechanical properties of S460M
specimens was 24.8%, regarding the values of steel and presented a very harsh and difficult arc
reduction of area and using once again behavior translating into an additional difficulty
ISO6892-1 this type of fracture is considered when trying to mechanize the procedure
ductile. Gas-shielded surpassed in every way their
Charpy impact tests determine the amount self-shielded counterparts, with mechanical
of energy absorbed by a material during fracture. properties similar to S460M, better deposition
All results obtained while testing confirm the rates, steady behavior on ceramic backing
predicted behavior, supplied by the wire and provided a good start point to mechanize.
steel manufacturers, at all temperatures including Parameters found manually needed very
at -50ºC which is an extreme temperature for few corrections when mechanized, nevertheless
both steel and filler wire. All test pieces absorbed constant oversight of the welding procedure is
amounts of energy above the minimum value in mandatory. A good joint preparation minimizes
the wire and steel certificate for all temperatures. the corrections during welding and reduces the
One other aspect of Charpy results is the energy probability of imperfections as shown above.
difference between longitudinal and transverse S460M weldability test demonstrated the
specimen. Generally in the longitudinal specimen steel behavior when subjected to certain heat
the energy absorbed increases along the inputs, results show arising of some detrimental
distance from the weld metal in other words structures like martensite and carbides but in
FL+5 will absorb the most amount of energy of small quantities and the hardness values show
all the locations followed by FL+2 then FL and that even with very low HI, according to ISO
finally WM, on the other and the transverse standard, all welds are acceptable. However the
specimen behaves in the opposite way and has use of HI equal or higher than 1.5KJ/mm will
generally lower values than the longitudinal one.

9
result in more favorable microstructures and so it [6] James F. Lincoln Arc Welding Foundation,
is advisable. 2000, The Procedure Handbook of Arc Welding,
The Rosenthal analytical solution applied to 14th Edition, Lincoln Electric
welding proved to be a fairly accurate tool to [7] Quintino, L.; Santos, J.; “Processos de
predict heat behavior in steel however have Soldadura”, Instituto de Soldadura e Qualidade,
some attention must be taken when working with 2.ª Edição, 1998
to intermediate thicknesses. [8] Fernandes, Paulo Eduardo Alves; Evaluation
The NDT chosen to verify the weld quality of fracture toughness of the heat affected zone
will also be important for the future of the project, (HAZ) of API 5L X80 steel welded SMAW and
specially UT as it is safe to operate ( no radiation FCAW. São Paulo,2011
emission) and fairly easy to mechanize, two very [9] Anmol S. Birring, "Ultrasonic Testing in
important properties since it is going to be Electric Power Plants," NDT Handbook,
operated on site. Weld quality was verify not only Ultrasonic Testing, 3rd Edition, ASNT, 2007
by NDT but also by mechanical testing such as [10] Mostafa ; M.N. Khajavi Optimization of
tensile test and impact tests, that ensured welding parameters for weld penetration in
structural integrity of welded joints. The values FCAW 2006 Journal of Achievements in
obtained by these tests were well within the Materials and Manufacturing Engineering
acceptable range of the materials in question [11] STARLING, Cícero Murta Diniz;
and for the use they are intended for. MODENESI, Paulo J. and BORBA, Tadeu
The tensile and Charpy tests performed Messias Donizete. Bead characterization on
proved the mechanical qualities expected of this FCAW welding of a rutilic tubular wire. Soldag.
type of material and process and within the insp. (Impr.) [online]. 2009
range recommended by ISO standards. [12] Krauss, G., 1992, “Heat Treatment and
From this work it can be concluded that use Processing Principles Materials Park” American
of FCAW for onsite build and erection of WEC is Society for Metals.
a good substitute for the current method of [13] Doherty, R.D., Martin J.W. Cantor, B. 1997,
fabrication and erection of WEC using bolted “Stability of Microstructure in Metallic Systems”.
flanges. CTOD, high cycle fatigue, and bending [14] Smith, W. F., Princípios de Ciência e
tests are scheduled to be executed in the near Engenharia de Materiais, 3ª Edição McGraw-Hill
de Portugal, 1998
future to complement the tests already done.
[15] Lopes Dias, E. M.; Miranda R. M.;
“Metalurgia da Soldadura”; Instituto de
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