Abstract
Electroslag welding (ESW) is a highly efficient welding process for completing single-pass complete joint penetration welds that offers production gains over conventional welding processes. This gain in productivity requires very high heat inputs, often to the detriment of the base metal's heat-affected zone (HAZ) impact energy. U.S. bridge-welding codes recognize the ESW Narrow Gap (termed ESW-NG) process developed in the early 1980s to remedy the substandard weld and HAZ impact energies found in bridges across the United States fabricated with the original ESW process used roughly from 1967 to 1977. ESW-NG process is limited to certain base metals; particularly, ESW-NG with quenched and tempered (Q&T), and thermo-mechanically controlled processed steels are prohibited because they are not part of the ESW-NG process development. This study was specifically performed to evaluate whether the existing ESW-NG process could be qualified for use with grade HPS 485W (70W) Q&T bridge steel and hybrid weldments between grade HPS 485W (70W) Q&T and conventionally processed grade 345W (50W) bridge steels. None of the weldments met fracture critical impact requirements. The weldment of just Q&T steel and the hybrid weldment met nonfracture critical requirements. However, the weldment of just Q&T had tension and impact resistance results right on the margin, leaving little room for error.
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