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TRANSPORT PROBLEMS                                                                                2016 Volume 11 Issue 4 
PROBLEMY TRANSPORTU                                                                   DOI: 10.20858/tp.2016.11.4.3 
 
truck frames; exploitation and safety conditions; 
welding; electrodes; alloy elements 
 
Michał MIROS* 
Humanitas University in Sosnowiec 
Kilinskiego 43, 41-200 Sosnowiec, Poland 
Wojciech MAJEWSKI 
AM&HP 
Lutostanskiego 6 /13, 16-400 Suwałki, Poland 
Jan PIWNIK 
Bialystok University of Technology 
Wiejska 45C, 15-351 Bialystok, Poland 
Tomasz WĘGRZYN  
Silesian University of Technology 
Krasinskiego 8, 40-019 Katowice, Poland 
Adam KONOPKA 
Kofama 
Portowa 47, 47-205 Kedzierzyn-Kozle, Poland 
*Corresponding author. E-mail: michalmiros@humanitas.edu.pl 
 
 
 
ELECTRODES WITH VARIOUS AMOUNT OF NICKEL FOR TRUCK 
FRAME REPAIRS 
 
Summary. The goal of this paper is to analyze the exploitation and safety conditions of 
weld steel structure of car body truck frames after welding repairs made by covered 
electrodes. The main role of conditions in connected with materials, alloy elements in 
steel and filer materials, welding technology, state of stress and temperature. Because of 
that, good selection of steel and choice of welding method for proper steel structure 
repairs are very important. For responsible steel, structures like truck frames and low 
alloy steel are used, very often with small amounts of carbon and some amounts of alloy 
elements such as Ni and Mo in low alloy steel and their welds. To study the frame’s 
flexibility and resistance, welded joints have been analyzed. Samples have been welded 
by steel electrodes with various amounts of Ni. 
 
 
 
ELEKTRODY OTULONE DO NAPRAW RAM POJAZDÓW CIĘŻAROWYCH 
 
Streszczenie. Celem artykułu jest analiza właściwości eksploatacyjnych oraz 
bezpieczeństwa naprawianych ram pojazdów ciężarowych z użyciem spawania. Ważną 
rolę odgrywają połączenia materiałów, pierwiastki stopowe, materiały dodatkowe, 
technologia spawania, stan naprężeń oraz temperatura. Bardzo istotne są odpowiedni 
dobór stali oraz metody spawalniczej. Na odpowiedzialne konstrukcje stalowe, jak  
np. ramy pojazdów ciężarowych, jest używana niskostopowa stal, często z niską 
zawartością węgla oraz dodatkiem pierwiastków stopowych, takich jak Ni oraz Mo. Do 
oceny elastyczności oraz wytrzymałości połączeń spawanych w ramach pojazdów 
ciężarowych, analizowano właściwości połączeń wykonanych elektrodami o różnej 
zawartości Ni. 
 
22 M. Miros, W. Majewski, J. Piwnik, T. Węgrzyn, A. Konopka 
 
1. INTRODUCTION 
 
The frame of vehicles has a lot of impact on their safety in traffic. Safety and durability of vehicles 
largely depend on the fatigue strength of the framework that welded the joints within [8-11].  There 
are still tested new techniques and materials used for car body frames [4-10]. In the last 5 years, 
important publications were presented about welding with micro-jet cooling [3-4, 12] that could also 
be used in car body repairs. In the frame of truck vehicles in addition to major impulse forces during 
exploitation, they are stresses much smaller but very often repeated. Such forces may cause the 
occurrence of fatigue cracks [11-13]. This type of damage is considered to be common and to cause 
the transition of welded frame into a state of unfitness for operation. There are known cases of damage 
to the framework of trucks due to fatigue cracking [6, 10, 15]. 
 
 
 
Fig. 1. Fatigue cracking in truck vehicle frame 
Rys. 1. Pęknięcia zmęczeniowe w ramie pojazdu 
 
Welded steel frame is still one of the most frequently encountered structures carrying truck 
vehicles. Properties of steel welded structures depend on many factors such as welding technology, 
filler materials and state of stress. The chemical composition of welded metal deposit could be 
regarded as a very important factor influencing properties of weld metal deposit (WMD). The 
influence of nickel content in weld metal deposit on plastic properties was well analysed by many 
researchers in the last 15 years [1-3, 11-15]. The influence of nickel on impact toughness of welds is 
presented below (fig. 2). 
Analysing figure 2 it is possible to observe that impact toughness of weld metal deposit (WMD) is 
positively affected by the amount of nickel [1]. Frame vehicles are made of steel with good strength 
and plastic properties. Regardless of the analysis of the impact toughness properties, it is important to 
understand the characteristics of fatigue. These are usually constantly type S355J0 (EN). Welded 
joints are located in the framework of this type and should have the good strength and plastic 
properties too. 
 
 
2. EXPERIMENTAL PROCEDURE 
 
Truck during exploitation is subjected to considerable dynamic loads. These charges are the result 
of driving on uneven surfaces, sharp curves, hard braking. The size of the typical stresses during 
Electrodes with various amount of nickel for truck frame repairs 23 
 
operation of the truck is shown in fig. 3. The stress value allows us to assess the fatigue strength of 
welded track frames. Examples of the stress value registered on the elements of the frame of the truck 
during unloading shows in fig. 3. 
 
 
 
Fig. 2. Relations between the amount of Ni in MWD and the impact toughness of WMD [1] 
Rys. 2. Wpływ niklu na udarność stopiwa MWD [1] 
 
 
 
Fig. 3. Intensity of stresses in stringers of the frame while unloading 
Rys. 3. Naprężenia w podłużnicach naczepy podczas rozładunku 
 
At the same time welded connections located within the frame of the truck are periodically 
occurring strains that can cause damage in the form of fatigue cracks. It was decided to examine the 
effect of nickel (element strongly affecting the impact strength) on essential property connection 
vehicle frames. To assess the effect of nickel on mechanical properties of deposited metals, basic 
electrodes prepared in an experimental way were used. The electrode contained constant or variable 
proportions of the following components in powder form. 
The oxygen content was in the range from 340 to 470 ppm, and the nitrogen content was in the 
range from 70 up to 85 ppm. The acicular ferrite content in weld metal deposit was above 45%. This 
principal composition was modified by separate additions of ferronickel (up to 8%, at the expense of 
iron powder). A variation in the nickel amount in the deposited metal was respectively tested from 1% 
up to 3% Ni. 
 
  
24 M. Miros, W. Majewski, J. Piwnik, T. Węgrzyn, A. Konopka 
 
                                                                  Table 1 
Composition of basic electrodes 
 
technical grade chalk 30% 
fluorite 20% 
rutile 4% 
quartzite 3% 
ferrosilicon (45%Si) 6% 
ferromanganese (80%Mn) 4% 
ferronickel (20%Ti) up to 8% 
iron powder up to24% 
The principal diameter of the electrodes was 4 mm. The standard current was 180 A, and the 
voltage was 22 V. A typical weld metal deposited had the following chemical composition. 
                                                               Table 2 
Composition of typical weld metal deposit 
 
C 0.08% 
Mn 0.8% 
Si 0.37% 
P 0.018% 
S 0.019% 
Ni 1-3% 
 
3. RESULTS AND DISCUSSION 
 
After the welding process using basic coated electrodes, there were gettable weld metal deposits 
with the variable amounts of tested elements (Ni) in it. After that procedure, the chemical analysis, 
micrograph tests, and fatigue strength tests were carried out. The tests were done at +20°C and 20 
specimens having been tested from each weld metal. Fatigue strength was tested for four load constant 
levels (stress ratio R ≠0). The fatigue strength results are given in figures 4-6. Fatigue strength was 
tested in bending rotation (sinusoidal waves). 
 
Fig. 4. Fatigue strength of WMD with 1% Ni 
Rys. 4. Wytrzymałość zmęczeniowa stopiwa z dodatkiem 1% Ni 
Electrodes with various amount of nickel for truck frame repairs 25 
 
 
Fig. 5. Fatigue strength of WMD with 2 % Ni 
Rys. 5. Wytrzymałość zmęczeniowa stopiwa z dodatkiem 2% Ni 
 
Fig. 6. Fatigue strength of WMD with 3% Ni 
Rys. 6. Wytrzymałość zmęczeniowa stopiwa z dodatkiem 3% Ni 
 
Analysing fig. 4-6, it is possible to deduce that fatigue strength of weld metal deposit is very 
positively affected by the amount of nickel. Nickel could be treated as a very important element 
influencing WMD fatigue strength properties. The amount of 2% Ni could be treated as optimal. The 
influence of nickel content in weld metal deposit on impact toughness was well analysed by many 
researchers [1-3, 11-15]. Literature data on the fatigue properties of frames after welding with various 
amounts of nickel were not given so explicitly [3, 12]. For a fuller explanation of the fatigue properties 
of frames after welding with various amounts of nickel it was decided to carry out observations of the 
microstructure. The microstructure of weld metal deposit having various amounts of nickel were 
precisely analysed. Acicular ferrite and MAC phases (self-tempered martensite, upper and lower 
26 M. Miros, W. Majewski, J. Piwnik, T. Węgrzyn, A. Konopka 
 
bainite, rest austenite, carbides) were analysed and counted for each weld metal deposit. The amount 
of AF and MAC phases were on the similar level in all tested deposits with various amounts of Ni  
(fig. 7). 
 
Fig. 7. Estimation of grain size in WMD with 2% Ni, 55% of acicular ferrite, 3% of MAC, 200× 
Rys. 7. Szacowanie wielkości ziaren w stopiwie elektrodowym zawierającym 2% Ni, 55% drobnoziarnistego 
ferrytu, 3% faz MAC, 200× 
 
Analysing figures regarding fatigue strength of WMD with various amounts of Ni and 
microstructure, it is possible to conclude that nickel could be treated as a very positive element in low 
alloy weld metal deposit. Good impact toughness and very good fatigue strength of car body frames 
correspond with the chemical composition of WMD (especially with the proper amount of Ni). 
 
 
4. CONCLUSIONS 
 
1. Nickel could be treated as a positive element in low alloy weld metal deposits. 
2. Amount of 2% Ni could be treated as optimal. 
3. Nickel should be added into car body frame WMD because of its good fatigue strength and 
impact toughness. 
4. WMD with 2% Ni allows us to get high amounts of acicular ferrite that corresponds with good 
mechanical properties of truck frames after welding. 
 
 
References 
 
1. Węgrzyn, T. & Hadrys, D. & Miros, M. Optimization of operational properties of steel welded 
structures. Conference materials CEFOM 2007. Central European Forum of Maintenance 2007. 
Wrocław. 21-23 October 2007. 
2. Piwnik, J. & Hadryś, D. & Skorulski, G. Plastic properties of weld after micro-jet cooling. 
Journal of Achievements in Material and Manufacturing Engineering. 2013. Vol. 59. No. 1. 
P. 20-25. 
3. Kurc-Lisiecka, A. & Ozgowicz, W. & Ratuszek, W. & Kowalska, J. Analysis of Deformation 
Texture in AISI 304 Steel Sheets. Solid State Phenomena. 2013. Vol. 203-204. P. 105-110. 
Available at: http://www.scientific.net/SSP. 
4. Formanek, B. & Szymański, K. & Szczucka-Lasota, B. New generation of protective coatings 
intended for the power industry. Journal of Materials Processing Technology. 2005. Vol. 164-
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5. Lisiecki, A. Welding of thermomechanically rolled fine-grain steel by different types of lasers. 
Arch. Metall. Mater. 2014. Vol. 59. No. 4. P. 1625-1631. 
6. Sourmail, T. & Bhadesia, H. Microstructural evolution in two variants of NF709 at 1023 and 
1073K. Mettal Mater Trans. 2005. Vol. 36A. P. 23-34. 
7. Tanaka, H. & Maruta, M. Microstructural evolution and change in hardness in type 304H 
stainless steel during long-term creep. Materials Science and Engineering. 2001. Vol 1A. P. 788-
791. 
8. Golański, G. & Zieliński, A. & Słania, J. & Jasak, J. Mechanical Properties of VM12 steel after 
30 000hrs of ageing at 600°C temperature. Archives of Metallurgy and Materials. 2014. Vol. 59. 
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9. Tarasiuk, W. & Gordirnko, A.I. & Wolocko, A.T. & Piwnik, J. & Szczucka-Lasota, B. The 
tribological properties of laser hardened steel 42CrMo4. Archives of Metallurgy and Materials. 
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10. Węgrzyn, T. & Piwnik, J. & Łazarz, B. & Tarasiuk, W. Mechanical properties of shaft surfacing 
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Received 23.04.2015; accepted in revised form 18.10.2016 
 


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