Metallurgical failure analysis of cold cracking in a structural steel weldment: Revisiting a classic failure mechanism

Cold cracking of structural steel weldments is a well-characterized, well-documented, and well-understood failure mechanism. Extensive effort has been put forth to recognize the welding and materials selection parameters that are conducive to cold cracking; however, these engineering efforts have not fully eliminated the occurrence of such failures. This article describes cold cracking failure specifically related to the construction industry. This particular failure was successfully identified prior to final erection of the structural member, and the weld was successfully reworked. These actions potentially prevented a serious catastrophic event that could have occurred have occurred either later in the construction process or possibly during the use of the building. Individual welding parameters, such as electrode/wire selection, joint design, and pre/postheating, played a role in the failure, and a number of human factors relating to the actual fabrication practices also contributed to the failure process.