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Re: [MW:36034] SS304/304L Tubes to CS Tubesheet Mock Weld -Cracks found

By Materials & Welding
Dear Sirs, 

As per my below mail history and your recommendation for low Amps to avoid high heat input, 
After performing the new MOCKUPs for 15.85, & 19.05 OD SS304L tubes to CS SA-516-70N tubesheet of 50mm with GTAW ER309LMO 1.6 Dia only of 3 passes for 19.05 ID tube, 82 A for 1st pass, 95A for 2nd, 100A for 3rd pass. Only 2 passes given for 15.85 OD tube.

We got incomplete penetration aa per the attached macro photo., almost for all the tube welds for both sized tube welds.

Please see the groove design for your reference. 

Also, please give me suggestions to make sound complete penetration on root pass and to avoid cracks too.

Thanks and regards, 
Saravanan Sornam, 
Ansan city,
S.Korea 




On Thu, 16 Apr 2026, 2:51 pm 'Ahmed Osman' via Materials & Welding, <materials-welding@googlegroups.com> wrote:
sure, 309LMO will be helpful as low carbon and MO are increasing delta ferrite for avoiding hot cracks
also reduce heat input for controlling dilution from CS sheet

Best Regards ,
Ahmed Osman



On Thursday, April 16, 2026 at 08:32:05 a.m. GMT+3, PARAI Reaction Channel <saravanshyla@gmail.com> wrote:


Dear Sir, 

Thank you for your advice for root welding parameters. 

Can i use ER309LMO  instead of ER309 ?

Please confirm. 

Thanks and regards, 
Saravanan Sornam, 
ANSAN,
S.KOREA 


On Thu, 16 Apr 2026, 12:06 pm Vanchinath S.A., <vanchinaths@gmail.com> wrote:
Weld root with 80-90 amps. 
Vanchi

On Wed, 15 Apr, 2026, 7:18 pm PARAI Reaction Channel, <saravanshyla@gmail.com> wrote:
Dear Sirs,

We have made 2 MockUp PQRs as per ASME Sec IX QW-193.

The Tube sizes are 19.05OD x2.11T and 15.88OD x2.11T, the
tubesheet plate is SA-516-70, 50T.

Amps used Max 145, Volts Max 13, welded with GTAW AWS Class ER309 with 1.6mm Filler , 2 passes.

We found minor cracks on the weld root and some on the surface too, but not for all the 10 tubes welded, but randomly found these cracks

When we did PT after welding on the surface, no cracks were found. But found after Macro etching at the test lab.

Can I switch the filler to ER309LMo for this MockUp weld ?

Are these cracks called Hot cracks ?

Please give me some advice.

With best regards,
Saravanan Sornam,
Ansan city,
S.Korea.


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