Multipass self-shielded flux cored arc welding with different heat inputs (1.3-2.0 kJ/mm) was conducted to determine the effects of the heat input on the proportion of the reheated region, impact toughness, and diffusible hydrogen content in the weld
IntrodcuctionSelf-shielded flux cored arc welding (FCAW-S) has advantages over semi-automatic welding processes by virtue of its self-shielding capability, which makes it especially suitable for site erection welding of structural steel, shipbuilding, and in constructing offshore oil production platforms (Keeler, 1981;Rodgers and Lochhead, 1987;Hesbrrok, 1993). Because no external shielding gas is used, strong nitride formers such as Al must be added in the weld metal (Killing, 1980;Kotecki and Narayanan, 2005). This induces a bainitic microstructure in the as-deposited weld metal and results in low impact toughness. As it is known that the reheating of the as-deposited weld metal by successive passes in multipass welding retransforms the brittle bainitic microstructure to the tough fine polygonal ferrite, research works (Dorling et al., 1978;Pisarski et al., 1987;Boniszewski, 1992) have been conducted to find out a suitable welding procedure to get a higher proportion of reheated region in the weld metal.Boniszewski (Boniszewski, 1992) reported that, when welded with a stringer bead technique, the proportion of reheated region becomes higher as travel speed becomes faster, i.e., heat input becomes lower. In contrast, Dorling and Rogerson (Dorling and Rogerson, 1982) reported that, when welded with a weaving technique, the proportion of reheated region becomes higher in higher heat input welding. This suggests that the effect of welding procedure, especially welding technique and heat input, on the proportion of the reheated region and thus the impact toughness of multipass FCAW-S weld metal is complicated.If low heat input welding is performed to get a higher proportion of reheated region, the possibility of hydrogen cracking in the weld metal should be concerned. Hydrogen cracking is one of the most serious welding problems and may result in expensive time consuming repair operations.Hydrogen cracking basically depends upon the following three factors: hydrogen content, residual stress, and hardness of the weld metal (Easterling, 1992). Among these three factors, low heat input welding especially influences following two factors: hydrogen content and hardness. Low heat input welding facilitates fast cooling of the weld metal, giving less time for the hydrogen to diffuse away from the weld metal, and easily hardening the weld metal. This implies that attention should be paid when low heat input welding is utilized to get a higher proportion of reheated region in the weld metal. However, studies on the effect of heat input on 540