Mechanical Properties Evaluation according to Welding Conditions of TMCP Steel for Offshore Wind Power Substructures (Part III: SAW for 60 mm Thick S420ML Steel)
As the capacity of offshore wind turbines continues to scale up, their massive substructures increasingly require thick TMCP steel plates exceeding 60 mm. While submerged arc welding (SAW) is preferred for its high deposition rate, ensuring root pass quality and low-temperature toughness in the heat-affected zone (HAZ) remains challenging. Following previous studies on S355ML (Part I) and 40 mm S420ML (Part II), this study (Part III) investigated a process using Flux-Cored Arc Welding (FCAW) for the root pass and SAW for the fill and cap passes. This approach aims to ensure root soundness while maximizing productivity for 60 mm thick S420ML steel. The welded joints demonstrated excellent mechanical integrity. Despite SAW’s high heat input, the joints achieved an average tensile strength of 548.5 MPa, meeting design requirements. Charpy V-notch tests at 50 °C revealed superior toughness in the SAW fill (70 J) and stable toughness in the FCAW root (57 J), both significantly exceeding the 27 J standard. These results confirm that the combined FCAW/SAW process effectively overcomes the thickness effect, providing an optimal balance between productivity and fracture toughness for offshore substructures.