Literature survey and fracture analysis of deep and long cracks in 3" to 12" thick steel weldments. Finite element modeling study was completed in full penetration welds to study the sensitivity of defects in the weld metal. The project lead to specific recommendations to the preheat, interpass and post heat conditions to build tough welds. Forensic analysis of photomicrographs indicated source and subsequent propagation from hot crack formed during the early solidifcation stage of the weld metal melt front. Acoustic stress waves were to cause the origin of the initial defect of a hot crack.
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