Science and Technology of Welding and Joining

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Multipass pulsed current gas metal arc welding of

P91 steel

S. Krishnan, D. V. Kulkarni & A. De

To cite this article: S. Krishnan, D. V. Kulkarni & A. De (2016) Multipass pulsed current gas
metal arc welding of P91 steel, Science and Technology of Welding and Joining, 21:3, 171-177,
DOI: 10.1179/1362171815Y.0000000080

To link to this article: http://dx.doi.org/10.1179/1362171815Y.0000000080

Published online: 30 Mar 2016.

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 Multipass pulsed current gas metal arc
welding of P91 steel
S. Krishnan1, D. V. Kulkarni1 and A. De*2
Conventional gas metal arc welding of modified 9Cr1Mo steels referred to as P91 steels is
considered difficult due to loss of alloying elements and degradation of weld joint properties. In
comparison to the conventional process, pulsed current gas metal arc welding allows more
accurate control of heat input per unit length and electrode deposition and, thus, can be more
suitable for the joining of P91 steel. A detailed experimental study is therefore undertaken to
examine the roles of welding current, speed and groove angle in the weld bead profiles and joint
properties in multipass pulsed current gas metal arc welding of 12 mm thick P91 steel. The results
show that the joint properties are strongly influenced by the heat input per unit length and the
groove angle. A groove angle of 758 and an appropriate choice of process conditions resulted in
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fairly acceptable bead profiles and joint properties.

Keywords: Modified 9Cr 1Mo steel, Pulsed current gas metal arc welding, Multipass welding, Bead profile, Weld quality

Introduction and high level of oxygen content and non-metallic

The creep strength enhanced ferritic steels contain
912%Cr, small amounts of Mo, V, and Nb, and
varying additions of W, Co, B, N, and Ni.13 The modified
9Cr1Mo grade steel that is referred to as P91 steel belongs
to the family of creep strength enhanced ferritic steel and is a
promising material for high temperature piping components
in modern power plants.17 However, the weldability of P91
steel is a major concern due to the loss of alloying elements,
degradation of weld joint mechanical properties, its sus-
ceptibility to type IV cracking16,8,9 and the formation of
delta ferrite.5,1013 A careful control of the heat input per
unit length and suitable choice of welding procedure, tech-
nique and post-weld heat treatment (PWHT) cycles are
reported to minimise some of these problems.811,1417
Furthermore, reducing the level of non-metallic inclusions
and weld metal oxygen content is found to improve weld
toughness in welds of P91 steels with consumable
electrodes.1,7,11,12
Several processes are attempted for joining of P91
steels depending on the original joint geometry, welding
position, and the required rate of electrode depo-
sition.1,2,14,18,19 Gas tungsten arc welding (GTAW)
could provide the joint toughness of around 100 J at
room temperature although the lower rate of filler metal
deposition remained a concern.1,2,13,14,18,19 Convention-
al welding processes with consumable electrode could
improve the deposition rate, but the welds commonly
suffered from loss of alloying elements, low toughness,
1
Larson & Toubro Limited, Heavy Engineering IC, Powai Campus,
Mumbai 400 072, India
2
Department of Mechanical Engineering, Indian Institute of Technology
Bombay, Mumbai 400072, India
*Corresponding author, email amit@iitb.ac.in
2016 Institute of Materials, Minerals and Mining
Published by Taylor & Francis on behalf of the Institute
Received 08 June 2015; accepted 28 July 2015
DOI 10.1179/1362171815Y.0000000080
inclusions.13,14,1822 Newell reported severe lack of fusion
(LF) and oxide inclusions in conventional gas metal arc
welding (GMAW) of P91 steels with a solid wire
electrode.23 The author could reduce the level of
inclusions using the metal cored wire electrode.12 Laser
beam welds in P91 steel could improve the joint tough-
ness due to fine microstructure and reduce the size of heat
affected zone (HAZ), but the formation of delta ferrite
remained a concern.10,24 Kundu et al.25 reported the
presence of high tensile residual stress especially in the
region susceptible to type IV cracks in electron beam
welds of 9 mm thick P91 steels. Albert et al.13 proposed
that a reduction in the HAZ width could enhance the
creep rupture life. Rothwell and Abson15 reported
smaller residual stress and distortion in electron beam
welding of 28 mm thick pipes of P91 steel. Aravinda
et al.26 used GTAW of P91 steel with hot- and cold-wire
electrodes and found significant deterioration of weld
joint impact toughness with the hot-wire fed GTAW
process. The use of an advanced GTAW process with
activating flux on the workpiece surface, referred to as A-
TIG, showed the presence of delta ferrite in welds of
P91 steel.27 In summary, appropriate welding schedule
with consumable electrodes has consistently remained a
challenge for the joining of medium to thick P91 steels.
Pulsed current gas metal arc welding (GMAW-P)
has advanced significantly to facilitate high electrode
deposition rate with accurate control of heat input by
the use of current pulses at moderate to high
frequency.28,29 GMAW-P of high strength low alloy
(HSLA) steels could provide superior tensile, impact
and fatigue properties over the other conventional
joining techniques.30 However, the application of
GMAW-P for the joining of medium to thick P91
steels in single-pass and multipass is rare. In comparison
to the conventional process, GMAW-P could reduce
HAZ width, weld porosity and facilitate favourable weld
Science and Technology of Welding and Joining 2016 VOL 21 NO 3 171
 Krishnan et al. Multipass pulsed current gas metal arc welding of P91 steel

Table 1 Chemical composition of BM and electrode wire

Elements (wt-%) C Cr Mo V Ni Si Mn Al Nb N

Base metal (P91 steel) 0.10 9.01 0.89 0.21 0.24 0.21 0.41 0.02 0.08 0.05
Electrode (ER90S-B9) 0.11 8.93 0.94 0.20 0.66 0.23 0.55 ... 0.06 0.03

microstructure and mechanical properties.30,31 A recent
study on single-pass GMAW-P of P91 steel showed a
fair improvement of the weld chemistry and mechanical
properties over the similar joints prepared using con-
ventional GMAW.32
A detailed investigation on multipass GMAW-P of
12 mm thick P91 steel is undertaken in the present work.
The effects of welding current, speed and groove geo-
metry on the bead profile, weld chemistry and oxygen
content, weld toughness and tensile strengths and
susceptibility to the formation of delta ferrite and non-
metallic inclusions are examined. The multipass weld
cross-sections are examined critically for adequacy of
the side-wall and inter-bead fusions. The hardness dis-
tribution is tested across the weld and HAZ regions both
in as-welded and after PWHT.
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(Graphtec made, model no. GL 900-4) with simultaneous
sampling rate of 0.1 MHz is used to monitor the current and
the voltage transients. The corresponding time-averaged
current IAV and voltage VAV are estimated as
I P tP I B tB
I AV 1
tP tB
V P tP V B tB
V AV 2
tP tB
where IP, IB, VP, VB, tP and tB refer respectively to the peak
pulse and base current, peak and base voltage and the cor-
responding time durations in a currentvoltage cycle. For a
current setting, the variability in the time-averaged current
and voltage are estimated over 20 currentvoltage pulses.
Table 2 documents the measured values of the pulse
parameters and the estimated values of the time-averaged

Experimental investigation
Table 1 presents the composition of workpiece and electrode
materials. The base material conforms to 12 mm thick
modified 9Cr1Mo (P91) steel with impact toughness, ulti-
mate tensile strength and yield strength of respectively 220 J,
670 MPa and 550 MPa at room temperature. Figure 1
schematically shows the joint geometry. Multipass bead-in-
groove welds are prepared in flat (1G) position with
Ar+2%CO2 shielding gas using a backhand technique at
multiple combinations of current, speed and groove angle
following a three-level full factorial design with three
repetitions at each welding condition. Three levels of weld-
ing speed and current setting are chosen as follows: 310, 320,
and 330 mm min21 and 255, 263, 270 A respectively. Three
different groove angles of 45u, 60u and 75u are considered as
shown in Fig. 1. A microprocessor controlled synergic
GMAW-P power source is used to prepare the weld
samples. A four-channel transient recorder
current and the heat input per unit length. The time-aver-
aged value of voltage remains around 26 V for all the three
current settings.
The welded coupons were subjected to PWHT for
stress relieving at 760108C for 4 h. The transverse
weld cross-sections were examined after polishing and
etching with Villellas reagent (1 g picric acid, 5 mL
hydrochloric acid, and 100 mL methanol). The bead
microstructures are examined under a scanning electron
microscope (SEM) in as-welded condition and after
PWHT. The microhardness distribution was measured
in as-welded condition and after PWHT at various lo-
cations as shown in Fig. 2. The tensile strength was
evaluated using all-weld sub-size specimens as per
ASTM E8:2013.33 The weld toughness was evaluated
using sub-size specimens as per ASTM A370:2014.34
A spectrometer based weld bead chemical analysis was
carried out as per ASTM E415:2014.35 The oxygen
content in the weld was studied by wet analysis following
ASTM E1019:2011.36 The weld inclusion level was
examined using energy dispersive spectroscopy analysis.

Results and discussion

1 Schematic view of groove geometry for sample multipass
Figure 3ac shows the transverse weld macrographs for
the three groove angles of 45u, 60u and 75u for a given
welding condition. In each case, the number of requisite
passes to fill the groove is shown by black lines.
Although the number of required passes is the same as
six for both the 60u and 75u groove angles, the corre-
sponding bead profiles differ significantly
(Fig. 3b and c). The bead width and height are measured

Table 2 Details of pulse parameters and corresponding heat input per unit length (superscripts a, b, and c refer to estimated
heat input at welding speeds of 310, 320 and 330 mm min21)

Current Peak Base Pulse on-time Pulse off-time Heat input

setting/A current IP/A current IB/A tP/ms tB/ms IAV/A Frequency/Hz per unit length/kJ mm21

255 343 (10) 91 (5) 2.24 (1) 3.98 (1) 182 (6) 160 0.91a, 0.88b, 0.85c
263 351 (15) 104 (3) 2.25 (1) 3.49 (1) 199 (7) 175 1.01a, 0.99b, 0.96c
270 357 (8) 114 (3) 2.27 (1) 3.38 (1) 212 (5) 178 1.10a, 1.07b, 1.04c

172 Science and Technology of Welding and Joining 2016 VOL 21 NO 3


2 Locations for measurement of microhardness distribution
to be 8.0 and 6.5 mm and 9.5 and 5.5 mm respectively
for the 60u and 75u groove angles. The wider and thinner
weld beads with the 75u groove angle could facilitate
efficient bead tempering and improve weld toughness as
commonly noted in multipass welds.1,23 Furthermore,
the macro-examination of the weld coupons show LF of
the side walls for several cases with the 45u and in few
cases with 60u groove angles. Figure 3d shows the pre-
sence of an LF defect in a typical weld cross-section with
the 60u groove angle. However, all the weld coupons
with the 75u groove angle exhibited sound bead profiles
without any LF defect. Although a higher groove angle
such as 75u would result in a nominal increase in the
deposit volume, the elimination of the LF defect is
considered to be a significant achievement in multipass
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GMAW.1,21,37
Table 3 shows the measured weld metal chemical
composition (in wt-%) and indicates no appreciable loss
of the alloying elements for the range of welding con-
ditions considered here. The chemical analysis is con-
ducted for different weld passes in order to verify the
consistency of the measured results. The weld metal
oxygen content was found to be in the range of 490 to
530 ppm that is significantly lower than the same
reported in P91 welds with conventional GMAW (*780
ppm)23, flux cored arc welding (FCAW) (600980
ppm)11,22 and submerged arc welding (SAW) (*580
ppm)23 processes. The measured values of the weld metal
compositions are utilised to estimate the corresponding
values of chromium equivalent (Creq) and the
Kaltenhauser ferrite factor (KFF) that provide a
measure of the tendency to ferrite retention and delta
3 Macrographs of weld transverse sections at welding speed of 320 mm min21 and current setting of 263 A at groove angles
of a 458, b 608, c 758 and d 608 showing typical LF defect
Science and Technology of Welding and Joining
Krishnan et al. Multipass pulsed current gas metal arc welding of P91 steel
ferrite formation in weld.1,5,11 The recommended maxi-
mum values of Creq and KFF to avoid delta ferrite are
respectively specified as 10 and 8 in the contemporary
literature.7 The estimated values of Creq and KFF of the
P91 sample welds remain in the range of respectively
7.45 to 7.52 and 4.55 to 4.84 that indicates little chance
of delta ferrite formation.
Figure 4a and b shows the microstructure of the base
metal (BM) and fusion zone (FZ) in as-welded condition
for a sample P91 weld, while Fig. 4cf show the micro-
structures of the FZ and HAZ after PWHT at 760uC for
4 h. The microstructure of the base material consists of
tempered martensite with small precipitates of carbide
particles within and around the prior austenite grain
boundaries (Fig. 4a). Figure 4b shows the presence of
freshly formed martensite in a typical as-welded micro-
structure of the FZ before PWHT. The FZ microstruc-
ture after PWHT is devoid of any trace of delta ferrite
and depicts a uniform and distinct distribution of car-
bide precipitates in the tempered weld (Fig. 4c). The
HAZ in the welds of P91 steel commonly consists of
coarse grain (CGHAZ), fine grain (FGHAZ) and inter-
critical (ICHAZ) regions.1 The CGHAZ starts from the
FZ boundary and experiences peak temperature well
above the Ac3 temperature. As a result, the carbides that
impede the austenite grain growth gets dissolved
resulting in coarse austenite grains and transforms to
martensite on cooling.1 Figure 4d shows a similar
microstructure of the CGHAZ with coarse prior auste-
nitic grains. The FGHAZ undergoes a peak temperature
just above the Ac3 temperature resulting in fine prior-
austenite grains as shown in Fig. 4e. The ICHAZ is the
furthest from the FZ boundary and experiences a peak
temperature between Ac1 and Ac3 resulting in partial
transformation of austenite. Figure 4f shows a mixture
of austenitemartensite phases in the ICHAZ micro-
structure. Similar FZ and HAZ microstructures in welds
of P91 steel are also observed in GTAW, SMAW and
SAW processes.1,711
The variation in FZ and HAZ microstructures is exam-
ined further by the characteristic microhardness
2016 VOL 21 NO 3 173
 Krishnan et al. Multipass pulsed current gas metal arc welding of P91 steel

Table 3 Weld metal compositions (in wt-%) in GMAW-P to examine the consistency of the measured values across
the weld bead. In general, the toughness along location 1
Groove angle
are found to be slightly higher that is attributed to the
effective tempering of this region during subsequent
Elements 458 608 758
weld passes and resulting finer microstructure. Figure 6b
Mn 0.440.49 0.430.50 0.460.51 shows the effect of heat input per unit length on the
Si 0.160.21 0.170.22 0.180.21 average weld bead toughness (at +20uC) for different
Cr 8.709.00 8.759.10 8.809.08 welding conditions. The weld bead toughness is found to
Ni 0.350.40 0.350.40 0.380.40 reduce with an increase in the heat input per unit length
Mo 0.850.96 0.830.98 0.890.96 for the 75u and 60u groove angles. The measured
Nb 0.0600.065 0.0580.065 0.0600.065
S 0.0020.004 0.0020.004 0.0020.004
toughness values for the welds with the 45u groove angle
O2 0.0490.053 0.0490.052 0.0490.053 are not plotted as the same are found to be scattered
C 0.1150.120 0.1160.120 0.1150.120 within a range of 42 to 55 J that is attributed to the large
V 0.190.20 0.190.20 0.180.20 number of defects in these welds. The decrease in the
N 0.0500.051 0.0500.051 0.0490.051 weld toughness with an increase in the heat input per
unit length is attributed primarily to the reduced cooling
rate and resulting coarser grain structure. Further, the
distribution across the P91 welds before and after PWHT. weld bead toughness is found to increase with an
Figure 5 shows the FZ microhardness to be higher increase in the groove angle for a given heat input per
compared to that in base material and HAZ regions in unit length that is attributed to the decrease in weld
as-welded condition. The FZ depicts a cast structure in the defects at higher groove angles. The weld bead tough-
as-welded condition leading to higher hardness in com- ness is also affected by the size and density of the micro-
parison to the same in the normalised and tempered inclusions in the bead microstructure. Figure 7 shows
structure of the base material.10 The microhardness the distribution of spherical micro-inclusions with Al, Si,
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becomes nearly uniform after PWHT except a softer region
in ICHAZ due to partial transformation of austenite
structure and subsequent tempering during PWHT.1 The
overall width of the HAZ remains between 3.0 and 3.5 mm
in contrast to 4.5 to 5.0 mm as observed in GTAW and
SMAW of P91 steels.14 The reduction in HAZ width in
GMAW-P can be considered significantly beneficial
towards reducing the susceptibility to type IV cracking in
welds of P91 steel.1,13
The weld bead toughness for each sample weld is
evaluated at three different locations as shown in Fig. 6a
Mn and Fe respectively around 5.96%, 5.77%, 7.86%
and 79.59% as obtained from an SEMenergy dispersive
spectroscopy analysis. An inclusion rating analysis as
per ASTM E-45:201338 has shown that the size of these
inclusions is lesser than 2 mm that is significantly lower
than those obtained in FCAW11 and single-pass
GMAW-P.32 The smaller size of inclusions in multipass
GMAW-P of P91 welds is attributed to the remelting of
the underneath weld beads during multiple weld passes
and resulting disintegration of the coarser micro-in-
clusions and formation of numerous finer particles.

4 a Base metal, b FZ in as-welded condition, and c FZ, d CGHAZ, e FGHAZ, and f ICHAZ microstructures after PWHT at 7608C
for 4 h for sample welds at current setting of 263 A, welding speed of 320 mm min21 and groove angle of 758

174 Science and Technology of Welding and Joining 2016 VOL 21 NO 3

 Krishnan et al. Multipass pulsed current gas metal arc welding of P91 steel

5 Microhardness variation across weld bead at current setting of 263 A, welding speed of 320 mm min21 and groove angle of
758 in as-welded condition and after PWHT
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6 a Notch locations for weld toughness measurement, b measured values of weld toughness as function of heat input per unit
length and at two different groove angles of 608 and 758

7 Micrograph (SEM) of weld showing inclusion distribution

for current setting of 263 A, welding speed of 8 Measured values of weld bead ultimate tensile strength as
320 mm min21 and groove angle of 758 in as-welded function of heat input per unit length and at two different
condition groove angles of 608 and 758

Science and Technology of Welding and Joining 2016 VOL 21 NO 3 175

 Krishnan et al. Multipass pulsed current gas metal arc welding of P91 steel
Table 4 Compositions (average) and properties of P91 weld for current of 255 A and welding speeds of 310, 320 and
330 mm min21 with 758 groove angle in conventional GMAW
Elements Mn Si Cr Ni Mo
wt-% 0.38 0.19 8.68 0.30 0.85
HAZ width/mm 4.204.95 Toughness/J
Figure 8 presents the all-weld tensile strength of the
sample welds. The measured ultimate tensile strength
(UTS) indicates a similar trend as noticed in the weld
bead toughness in Fig. 6b. The measured values of
UTS reduce with an increase in the heat input per unit
length for the welds made with the 60u and 75u groove
angles. In contrast, the measured strengths for the welds
produced with 45u groove angle exhibited a wide
scatter in between 650 and 720 MPa that is attributed
to the inherent defects and were not plotted. The
maximum all-weld UTS is obtained as 760 MPa
with the 75u groove angle for a current setting of 255 A
and welding speed of 330 mm s21 that con-forms to
a low heat input per unit length of 0.85 kJ
mm21. An increase in all-weld UTS at lower heat input
per unit length can be attributed to the
smaller dendrite sizes and lesser interdendritic spacing
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in the FZ.
An attempt is made further to evaluate multipass welds
in 12 mm thick P91 steel with a 75u groove angle using
conventional GMAW at a current setting of 255 A and
welding speeds of 310, 320 and 330 mm s21 as similar
conditions in GMAW-P have provided better welds. The
corresponding values of heat input are estimated as 1.369,
1.297 and 1.243 kJ mm21 in conventional GMAW com-
pared to 0.91, 0.88 and 0.85 kJ mm21 in GMAW-P
(Table 2). Table 4 shows the measured values of average
weld metal composition and the ranges of HAZ width,
toughness and all-weld UTS for the welds made using
conventional GMAW. A comparison of Tables 3 and 4
shows relatively greater loss of alloying elements, e.g. Mn,
Cr, Ni and Mo, and higher weld metal oxygen content in
conventional GMAW compared to that in GMAW-P. The
measured HAZ width in conventional GMAW is found to
be in the range of 4.204.95 mm in contrast to 3.03.5 mm
in GMAW-P. The ranges of weld bead toughness and all-
weld UTS in conventional GMAW are respectively 2642 J
and 675692 MPa that are far inferior to those obtained in
GMAW-P for similar welding conditions (Figs. 6 and 8).
The reduced loss of alloying elements, smaller HAZ width
and superior weld properties in GMAW-P of P91 steels are
attributed primarily to the pulsating nature of current and
voltage and the resulting decrease in effective heat input in
comparison to that in conventional GMAW.
The role of the key welding conditions such as current,
speed and groove angle in the bead morphology and
joint properties in multipass GMAW-P of P91 steels are
studied in detail that have been scarce in the literature.
The present work shows that P91 steels can be welded in
multipass GMAW-P with fairly acceptable bead mor-
phology and joint properties at high welding speed and
electrode deposition rate in comparison to the conven-
tional GMAW, FCAW and SMAW processes.
Conclusion
GMAW-P facilitates a more accurate control of the heat
input per unit length compared to the conventional
GMAW and a greater rate of electrode deposition than
GTAW with external electrode wire and does not pose
176 Science and Technology of Welding and Joining 2016 VOL 21
Nb O2 C V N Al
0.05 0.063 0.12 0.19 0.04 0.02
2642 UTS/MPa 675692
flux related problems similar to SMAW, FCAW and
SAW processes. A detailed investigation of the suit-
ability of GMAW-P for the joining of P91 steels is
therefore requisite and currently scarce in the literature.
The work presented here demonstrates a critical exam-
ination of the effects of the key welding variables on the
final weld bead quality in multipass GMAW-P of 12 mm
thick P91 steel. The welds are found to be fairly accep-
table based on the visual inspection of the bead profile,
composition analysis, oxygen and inclusion levels, and
the examination of microhardness distribution, micro-
structure, mechanical strength and toughness. An
appropriate selection of the heat input per unit length
and groove geometry is found to be critical. In par-
ticular, the groove angle should be sufficiently large to
get a defect free weld. An average heat input per unit
length of 0.85 kJ mm21 with a groove angle of 75u
provided the best results.
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