A C++ algorithm was used to metallurgically design high-performance GMAW electrodes for joining HSLA-65 steel. The electrode
design was based on: (1) a carbon content ≤0.06 wt.% for improved weldability, (2) a 5-15% lower A
r3 transformation temperature than HSLA-65 steel for enhanced strength and toughness, and (3) a desirable range of carbon equivalent
number (CEN) for consistently overmatching the minimum specified tensile strength of HSLA-65 steel. The algorithm utilized
a set of boundary conditions that included calculated A
r3, B
S, B
F, and M
S transformation temperatures besides CEN. Numerical ranges for boundary conditions were derived from chemical compositions
of commercial HSLA-65 steel, substituting thermomechanical effects with weld solidification effects. The boundary conditions
were applied in evaluating chemical composition ranges of the following three prospective welding electrode specification
groups that offered to provide ≤0.06 wt.% carbon, a minimum transverse-weld tensile strength of 552 MPa (80 ksi), and a minimum
CVN impact toughness of 27 J at −29 °C through −51 °C (20 ft lbf at −20 °F through −60 °F) in the as-welded condition: (1)
ER80S-Ni1, (2) E90C-K3, and (3) E80C-W2. At ≤0.06 wt.% carbon, the algorithm returned over 3100 results for E90C-K3 that satisfied
the boundary conditions, but returned no acceptable results for other two electrode specification groups. Results revealed
that welding electrode designs based on an Fe-C-Mn-Ni-Mo system, containing 0.06 wt.% C, 1.6 wt.% Mn, 0.8 wt.% Ni, and 0.3 wt.%
Mo that provide weld metals characterized by an A
r3 of 690 °C, a CEN of 0.29, and a (B
F − M
S) of 30 °C are expected to consistently overmatch the minimum specified tensile strength of HSLA-65 steel while offering a
minimum CVN impact toughness of 41 J at −40 °C (30 ft lbf at −40 °F).
Keywords C++ algorithm - carbon equivalent number - chemical composition limits - ER 80 type electrodes - ER 90 type electrodes - GMAW process - HSLA-65 Steel - overmatching - transformation temperatures - welding electrode specifications