Materials Sciences and Applications, 2013, 4, 198-204

doi:10.4236/msa.2013.43024 Published Online March 2013 (http://www.scirp.org/journal/msa)

The Influence of Welding Parameters on Brittle Fracture

of Liquefied Natural Gas Storage Tank Welded Joint
Abd El Fattah Mustafa Khourshid, Mohamed Ahmed Ghanem
Production Engineering and Mechanical Design Department, Faculty of Engineering, Tanta University, Tanta, Egypt.
Email: engmghanem66@yahoo.com

Received December 9th, 2012; revised January 11th, 2013; accepted February 9th, 2013

ABSTRACT
Many applications operate at sufficiently low temperature conditions where most structural steels become very brittle
and, therefore, unsuitable for use in safety-critical structures. So the materials used in the vessels or storage tanks which
keep the natural gas at liquefaction temperatures need to remain ductile and crack resistant with a high level of safety.
The material also needs to have high strength in order to reduce the wall thickness of the container and it must permit
welding without any risk of brittle fracture. 9% Ni steel plates are one of most common used materials in the LNG
storage tank application. However, the welding procedure for 9% Ni steel plates requires high level of skills of welding
that is strictly controlled welding parameter for balancing avoidance of cold and hot cracking and maintenance of high
strength. Mechanical properties are important characteristics of the weldment that must confirm to the application feasi-
bility as well as functional requirements of the welded joint. The only way to enhanced the mechanical properties of
welded joint by controlling the parameters of using welding process. From the main variables of the arc welding process
are the heat input and interpass temperature where the two variables control the thermal cycle of welding process. The
experiment show that for thin test specimen with thickness ≤ 14 mm, the heat input range from 1.4 to 2 KJ/mm and con-
trolling interpass temperature within 80˚C give high tensile strength with improving the toughness properties of welded
joint and reduce the probability of brittle fracture happened by increase the ductility and reduce the yield strength and
increased the transition temperature.

Keywords: 9% Ni Steel Plate; LNG Tank; Heat Input; Mechanical Properties; Welding Process and Brittle Fracture

1. Introduction grained structure of tough nickel-ferrite free from em-

brittling carbide networks. The optimum microstructure
Metallurgical characteristics of the weld metal as well as
and mechanical properties are obtained by a carefully
heat affected zone (HAZ) are very important because this
controlled heat-treatment in the production of the steel
directly influence the weld mechanical properties and [2].
joint performances. It is well known that the micro These unique properties of the 9% Ni steel plates have
structure of the weld metal is different from the micro- resulted from the microstructure where consist mainly
structure of base metal as well as HAZ. The weld micro- from fine martensite and from 5% - 15% retained austen-
structures, however, are somewhat different with respect ite. This microstructure is existing due to quenching and
to distributions of martensite and austenite, their amounts, tempering [3-5].
grain sizes etc. depending upon the welding conditions The welding is widely used in construction these ap-
adopted. From more important application is (LNG) that plications, controlling the parameters which affect the
will be liquefy at −163˚C and is therefore stored or trans- weldability of 9% Ni steels is critical to the successful
ported around −170˚C. At this low temperature quenched implementation of these engineering materials [6].
and tempered 9% nickel steels have the fracture tough- The weldability of 9% nickel steel is excellent and the
ness and crack arrest properties required for safe con- steel is not susceptible to cracking and shows little or no
struction of tanks and vessels [1]. detoriation of the properties by the heat inputs normally
Combination of high strength and good toughness is used during the welding with procedures. Heat input
essential for the steels used in liquefied natural gas epi- should not exceed 3 kJ/mm and interpass temperature
cally there is a high risk assessment of probability of must be limited to max 100˚C - 150˚C [1,2].
leakage done. The excellent low temperature notch im- The strength and toughness required for the weld
pact properties of 9% nickel steels arise from the fine metal differs greatly depending upon the application for

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 The Influence of Welding Parameters on Brittle Fracture of Liquefied Natural Gas Storage Tank Welded Joint 199

which the structure is employed and according to the drogen diffusion from the weld and is a major factor
type of steel and welding materials. Depending upon the when avoiding hydrogen cracking [16].
welding processes the thermal conditions differ greatly As interpass temperature is increased, the main micro-
up to the time when the weld metal is formed, solidifies structural effect is that the amount of columnar structure
and is cooled. The properties will differ according to the within a reheated weld bead is reduced and an increase in
difference in welding conditions and especial without the the amount of re-austerities and tempered areas is seen
postweld heat treatment (PWHT) even when identical especially within the central beads of a welded joint. Lit-
welding processes and welding materials are employed. tle effects are seen on the cross sectional area of each
[7]. weld bead deposited with increase in interpass tempera-
Both strength and toughness are critical properties ture but the proportion of recrystallised area increases
since failure may occur through either ductile rupture or [17]. By eliminating the columnar microstructure, hard-
fracture. The combination is important since strength and ness becomes more uniform and is reduced. There is also
toughness have an inverse relation to one another; an a reduction in strength by increasing interpass tempera-
increase in strength at given temperature almost invaria- ture however toughness at low temperatures increases.
bly leads to a decrease in fracture toughness. While there To conclude, control of welding parameters such as
is no reliable quantitative theory of the strength—tough- interpass temperature is important. The Recent work [18]
ness relation of structural alloys [8]. analyzed the variation of mechanical properties of high
For such inhomogeneous systems, measurement of the strength weld metals and concluded that variations in
toughness alone has little meaning if it is not related to yield strength were not alone due to compositional varia-
the tensile properties of the material system. It has been tions, but also to process parameters such as the weld
demonstrated that the apparent fracture toughness of the metal interpass temperature.
same HAZ microstructure can be changed dramatically Previous investigations have demonstrated the effec-
by just changing the tensile properties in the adjacent tive welding parameters on both of weld metal and heat
weld metal [9]. affected zones as a function of the cooling rate from peak
The cooling rate is a primary factor that determines the temperature [19-22]. Consequently, it concern on the
final metallurgical structure of the weld and heat affected improving of the toughness properties and the micro-
zone (HAZ), and is especially important with heat- structure of welded joint for thickness plate is more
treated steels. Especially during welding quenched and than 20 mm to be in good condition by using heat input
tempered steels, the slow cooling rates (resulting from in the range from 1 - 3 KJ/mm and the interpass tem-
high heat inputs) can soften the material adjacent to the perature no more 150˚C.
weld, reducing the load-carrying capacity of the connec- More recent work identified that heat input affects on
tion. [10]. the microstructure to improve the toughness of welded
Weldment toughness tends to deteriorate with increase joint by controlling the cooling rates and creates types of
in welding heat input. It is said that this tendency is ferrite phase and the effect of creation of ferrite types on
caused by the austenite grain growth at the heat-affected the tensile strength of welded joint [23-25].
zone (HAZ) during the welding thermal cycle [11,12]. However, this paper concern on heat input and inter-
Although With the increase of heat input, the impact pass temperature as the main factors for affecting the
toughness of weld zone and heat affected zone decrease, embrittlement of weld joints, when the heat input is in
whereas the tensile strength of the weld joints does not suitable range and controlling the interpass temperature
change at all [13]. the in order to improve the tensile strength and toughness
Under different weld heat inputs, the impact energy of properties of welded joint. By using shield metal arc
the HAZ has a larger difference, indicating a tendency welding process with heat input rang from 1.3 - 2.5
for a change in the fine structure of the HAZ. By control- KJ/mm, interpass temperature within 80˚C and test
ling weld heat input = 20 kJ/cm, the presence of carbide specimens of 9% Ni steel plate with thickness 6, 10 & 14
in the HAZ can be removed, and therefore the impact mm in vertical position.
toughness in this zone can be assured [10,11].
A specific maximum interpass temperature in welding 2. Experimental Procedure
procedure is sometimes required e.g., in order to avoid
2.1. Base Metal
hot cracking. In this case using a higher interpass tem-
perature will increase the time spent in the critical tem- The SA553 type 1 (9% Ni) steel is the used material for
perature range [14,15]. the liquefied natural gas (LNG) tank application. Its
This is also an issue with high strength steel weld met- microstructure content from martensite and retained
als but using a high interpass temperature normally plays austenite about (5% to 15% of structure size) as shown in
a more important role. Longer cooling times allows hy- (Figure 1), so this posses tensile strength range from 620

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200 The Influence of Welding Parameters on Brittle Fracture of Liquefied Natural Gas Storage Tank Welded Joint

omy is also offered when using high recovery electrodes.

So by using SMAW as welding process, electrode E
NiCrFe4 with 2.5, 3.2 and 4.0 mm diameter to weld
SA553 type I steel test specimen with thickness 6, 10 and
14 mm. The interpass temperature controlled to no more
Figure 1. Present the microstructure of 9% Ni steel plate. than 80˚C with using low ampere and increasing the travel
speed to reduce the heat input.
to 850 MPa, impact energy at −196˚C reach to 100 J and The chemical composition and mechanical properties
more. [26]. of electrode ENiCrFe4 according to construction code
The test specimens are three crews with different standard and actual electrode certificates as shown in
thickness size 6, 10 and 14 mm thickness. The chemical Tables 3 and 4 [28].
and mechanical properties of 9% Ni steel plate according The geometry of welded joints as shown in (Figure 2)
to standards and the actual used according to material with different root opening according to the using of
certificate as shown in Tables 1 and 2 [27]. electrode diameter.

2.2. The Welding Process 2.3. The Mechanical Tests

Welding with stick electrodes however, is still a very  Tensile tests have been done on 2 test samples from
flexible and viable process for welding under site condi- each welded joint .The test conducted according to
tions, all positions and all materials. A respected econ- the requirements of ASME IX [29] & ASME II part A,

Table 1. The chemical composition of 9% Ni steel.

Chemical composition (%)

Designation material
C Mn Si P S Ni Mo Cr Ti Cu Nb

A553 Type I (Standard) ≤0.13 ≤0.9 0.15 - 0.3 ≤0.035 ≤0.04 8.5 - 9.5 0.12 0.3 0.03 0.4 0.02
Test specimen
0.05 0.56 0.25 0.002 0.001 9.18 0.01 0.01 0.002 0.01 0.001
10 &14 mm THK
Test specimen
0.06 0.55 0.2 0.004 0.001 9.11 0.1 0.02 0.005 0.01 0.004
6 mm THK

Table 2. The mechanical properties of 9% Ni steel according standards and actual parent metal.

Mechanical properties
Material Specification
Y.S. [R.T*] (MPa) UTS [R.T*] (MPa) El.5d [20˚C] (%) Kv [−196˚C]
KvT ≥ 27 J
ASTM A553-1 ≥585 690 - 825 ≥20.0 Exp. > 0.381 mm
KvL ≥ 34 J
Test specimen 14/10 mm 665 715 44 KvT 205 - 226 - 236 1.7 - 1.72 - 1.76
Test specimen 6 mm 650 700 34 KvT 34 - 40 - 40 1.41 - 1.56 - 1.54

Table 3. The chemical compositions of ENiCrFe4 from code and actual values.

Chemical analysis %
Electrode designation
C Mn Fe P S Si Cu Ni Cr Nb Plus Ta Mo
ENiCrFe4 [21] standard 0.2 1.0 - 3.5 12 3 0.02 1 0.5 60 min 13 - 17 1.0 - 3.5 1.0 - 3.5
Weld metal 0.09 2.66 11.08 0.01 0.002 0.26 0.02 65.52 15.79 1.76 2.57

Table 4. The mechanical properties as standard and actual value of ENiCrFe4.

Mechanical properties
Electrode designation
Units standards Test temperature ˚C Tensile strength MPa Yield strength MPa Elongation (%)
EniCrFe4 (standard) Room temp. 660 (Min.) 360 (Min) 20 (Min.)
All weld metal 20˚C 689 419 41.7

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 The Influence of Welding Parameters on Brittle Fracture of Liquefied Natural Gas Storage Tank Welded Joint 201

Figure 3. The test sample of tensile stress.

Figure 2. The joint shape for different thickness (6, 10 & 14
mm).

SA370 [30] at room temperature and the samples

shape with dimensions as shown in (Figure 3).
 Bend tests applied on 4 test samples from each
welded joint with keeping in the consideration the
requirements of ASME IX & ASME II part A, SA370
(2 test samples for root bends and 2 for face bend)
 Charpy impact tests have been done in two zones of
welded joint weld metal and HAZ zones, 3 test sam-
ples for each zone according to ASME IX &ASME II
part A, SA370. The test temperature at −196˚C.
 Lateral expansion test conducted according to
ASME IX & ASME II part A, SA370.

3. Results and Discussion Figure 4. The results of tensile strength test of 6 mm at dif-
ferent H.I.
3.1. Tension Tests
The tensile properties of the specimens obtained from the
welded joints with three different heat input levels are
shown in Figures 4-6. The tensile test results show that
different heat input levels are all above 690 MPa, which
is higher value of the material standards.
From the metallurgical aspects the microstructure of
solidification weld deposit can be determine by deter-
mine the time of cooling process between 800˚C to
500˚C. So from the heat transfer the next equation to
calculate the time of cooling from 800˚C to 500˚C de-
pend on the heat input have been used during the welding
of test specimen in 3 dimension.
 t8 5   H.I 2 * K * π  * 1 500  1 800 (1)
where Figure 5. The results of tensile strength test of 10 mm at
H.I = heat input different H.I.
K = coefficient of thermal conductivity (w/m.K).
According to the Equation (1) the time of cooling from the lower the interpass temperature effect with still low
800˚C/500˚C the time range is between 7.2 to 13.6 sec cooling time.
that related to H.I range from 13.4 to 25.2 KJ/mm. The initial weld passes preheat the base metal of mul-
Where the max tensile strength value exist with ap- tipass welds. The effects are greatest on the second pass.
plying welding with the lowest heat input, this is due to As the preheating conditions after the second pass are
higher cooling rate that is permission to austenite crystals stabilized, the resultant change in thermal cycle and cool-
structure to transform to martensite during welding so- ing rate is big significant.
lidification [25]. Although the fracture of test specimens done in weld
The different relation tensile strength and the heat in- metal zones in some test specimens but with strength
put is shown in Figure 5, where the development of ten- values higher than the minimum value of base metal.
sile strength value with increase the heat input because The compared results show that heat input has a big

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202 The Influence of Welding Parameters on Brittle Fracture of Liquefied Natural Gas Storage Tank Welded Joint

Figure 6. The results of tensile strength test of 14 mm at

Figure 7. The impact tests results of 6 mm at different H.I.
different H.I.

effect on the tensile properties, with the increase of heat

input, the tensile strength of welding joint only increases
little.

3.2. Notch-Toughness Tests

The Charpy V notch impact toughness data obtained at
−196˚C from the WM and HAZ regions of three weld
joints welded with heat inputs levels are presented in
Figure 7 which the figure with underline shows the av-
erage value of the impact absorbed energy. It is clear that
the impact toughness of every zone of the weld joints
with three different heat input levels all satisfy the de-
mand of 27 J at −196˚C as required by standard, even Figure 8. The impact test results of 10 mm at different H.I.
when the heat input is in the range of 13.4 - 25.2 kJ/cm.
The results of toughness in HAZ and W.M zones were
increased as H.I decreased. Austenite-rich and ferrite-
rich bands are formed during socking because of the re-
distribution of element C, N and Ni. The austenite en-
riched of C, N and Ni is still stable [24].
On the other hand from Figures 8 and 9 the toughness
results increase as heat input increase to 2.1 KJ this is
shown as a results of HAZ & W.M zones and after that
the impact value decrease as H.I increase. This return to
increase in the cooling rate that increase the probability
of present lower binate phase.
The Max. toughness results exist in HAZ zone than the
results of W.M zone where the structure of HAZ is
mainly martensite and retained austenite affected by the
heat input only and W.M is mainly Ni base alloy and has Figure 9. The impact test results of 14 mm at different H.I.
coarse grains.
All results of impact tests related to full size test side bend (S.B). The results showed good ductility for all
specimen 10 × 10 × 55 mm. joints & all were free of surface crack or any other sur-
face defect as the following Table 5.
3.3. Guided -Bend Tests
3.4. Lateral Tests
The bending test at room temperature, all test samples for
6 & 10 thickness were tested for root bend (R.B) and As in Figures 10 and 11 the Lateral test results show that
face bend (F.B) but for 14 mm and the bend test were there are different relation between lateral expansion

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 The Influence of Welding Parameters on Brittle Fracture of Liquefied Natural Gas Storage Tank Welded Joint 203

Table 5. Present the locations and results of bend tests.

Thickness Bend test location

of test No. of test Bend Bend Bend Bend
specimen specimen test No.1 test No.2 test No.3 test No.4 Result
1 R.B R.B F.B F.B
6 mm 2 R.B R.B F.B F.B
3 R.B R.B F.B F.B
1 R.B R.B F.B F.B No
surface
10 mm 2 R.B R.B F.B F.B
defect
3 R.B R.B F.B F.B found
1 S.B S.B S.B S.B Figure 12. The lateral test results of 14 mm at different H.I.

14 mm 2 S.B S.B S.B S.B

This is meaning the Welded joint zones are high ductile
3 S.B S.B S.B S.B and for the HAZ zone the structure still uniform and fine
R—Root, B—Bend, F—Face, S—Side. grains. The W.M zone are still low values comparing
with the values of HAZ due to have a different chemical
composition and the main alloy element is Ni.

4. Conclusions
According to the results of this research ,it can be con-
cluded that, the heat input rang from 1.34 to 2.0 KJ/mm
is more suitable range for improve the tensile strength
and toughness properties of welded joint for the thick-
ness base metal ≤14 mm especially in HAZ zone.
The high cooling rate produced by the using of heat
input range has a big effects on the microstructure of
welded joint and improved the mechanical properties by
Figure 10. The lateral test results of 6 mm at different H.I. eliminating the changing in microstructure of HAZ by
creating a martensite and austenite or bainite and austen-
ite. Whilst the effects of cooling rate on the grain of mi-
crostructure is development the grain size as in weld
metal or existing a fine grain in HAZ zone.
On the other hand the improve of the ductility proper-
ties of welded joint increase the transition temperature
and enhanced the resistance of brittle fracture and in-
crease the critical stress required to produce the brittle
fracture so it has gotten more grantee for the welded
joint.
The recommendation is to continue the research for to
improve the mechanical properties of welded joint espe-
Figure 11. The lateral test results of 10 mm at different H.I.
cially the toughness properties more closet to the base
metal and reduce the probability of fracture of welded
values in Weld metal(W.M), HAZ and heat input. Where
joint due to the thermal shock that can be happened due
the lateral expansion of W.M zone are decreased as H.I
to any leakage.
increased, the Lateral test results of HAZ zone are in-
creased as H.I increased.
Although as in Figure 12 the lateral expansion of
5. Acknowledgements
W.M and HAZ zone are increased as H.I increased and There have been many people who helped me to reaching
the values of lateral test results of HAZ are greater than this far, my sincere thanks to the My supervisors, Prof.
the results of W.M zone. ABD El Fatah Kourshid for giving me this great chance
The all results of lateral expansion tests show that the in life. Thanks for employees of PETROJET central
W.M and HAZ zones are more than the value of ASME workshop mechanical lab, for their help in preparing,
standard required (0.38 mm) and with average 0.9 mm. finishing, and processing the mechanical tests.

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204 The Influence of Welding Parameters on Brittle Fracture of Liquefied Natural Gas Storage Tank Welded Joint

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