Weldability Characteristics of Torr and Corrosion-Resistant TMT Bars Using SMAW Process

Abstract

Torr steel rebars, also known as cold twisted deformed (CTD) rebars, are used extensively for the construction of reinforced cement concrete (RCC) structures. These steels, which are characterized by a high carbon content and are subjected to a cold twisting operation to attain the desired strength level and bond strength, suffer from low ductility and poor bendability properties. Furthermore, these rebars are not suitable for coastal, humid, and industrial conditions where corrosion rates are very high. To combat these problems, recent efforts at the Steel Authority of India Limited (SAIL) have led to the successful development of corrosion-resistant thermomechanically treated (TMT) rebars with a minimum yield strength of 500 MPa. These rebars are characterized by a low carbon content, exhibit excellent strength-ductility-corrosion properties, and are rapidly replacing traditional torr rebars in corrosion-prone areas for a wide range of applications, namely, concrete reinforcement structures, bridges, flyovers on dams, etc. A comprehensive evaluation of the weldability properties of corrosion-resistant Cu-TMT rebars was carried out, and they were compared with those made of torr steel in order to assess their suitability for various structural applications. Implant and restraint cracking (RC) tests were carried out to assess the cold-cracking resistance of the weld joint under different welding conditions. The static fatigue limit (SFL) values were found to be similar, namely, 640 MPa (torr steel) and 625 MPa (Cu-TMT steel) under condition of no preheating and no rebaking using a heat input of 7.5 KJ/cm, indicating adequate cold-cracking resistance for both the steels. Restraint cracking tests yielded critical restraint intensities (Kcr) in excess of 16,800 MPa for both of the steels. Based on the weldability tests, the optimized conditions for welding were formulated and extensive tests were carried out on the welded joints. Both of the steels exhibited adequate strength levels (tensile strength (TS): torr rebars, 524 Mpa; Cu-TMT rebars, 630 MPa) and adequate low-temperature impact toughness properties, ensuring a high integrity of the fabricated products.