Weld Technology Defects

Weld Technology and Defects
NDT 2/20 Revision 1 Sep 2004
World Centre for Materials Joining Technology
Welding Terminology
Butt Joints
Closed
Square Edged
Open
Vee
Single Sided Butt
Bevel
Double Sided Butt Bevel Vee
Welding Terminology
Fillet Joints
Tee
Lap
Corner
Welds
An ideal weld must give a strong bond between materials with the interfaces disappearing
To achieve this
Smooth,flat or matching surfaces Surfaces shall be free from contaminants

Metals shall be free from impurities Metals shall have identical crystalline structures
Welding
A union between pieces of metal at faces rendered plastic or liquid by heat,pressure or both. BS 499
Possible energy sources
Ultrasonics Electron beam Friction Electric resistance Electric arc
Electric Arc Welding
Electrode
Power supply
Work piece Clamp(Earth)


Electric discharge produced between cathode and anode by a potential difference (40 to 60 volts) Discharge ionises air and produces -ve electrons and +ve ions Electrons impact upon anode, ions upon cathode
Impact of particles converts kinetic energy to heat (7000o C) and light

Amperage controls number of ions and electrons, Voltage controls their velocity

Arc Welding Processes
Manual metal arc Tungsten Inert Gas Metal Inert Gas Submerged Arc
Differences between them: Methods of shielding the arc Consumable or Non-consumable electrode Degree of automation
Zones in Fusion Welds

Parent Material or Base Metal Heat Affected Zone Fusion Zone
Manual Metal Arc Welding

Shielding provided by decomposition of flux covering Electrode consumable Manual process Welder controls Arc length Angle of electrode Speed of travel Amperage settings
Manual Metal Arc (MMA)

Consumable electrode
Arc
Evolved gas shield
Flux coating
Slag
Core wire Parent metal
Weld metal
Tungsten Inert Gas (TIG)

Gas nozzle Filler wire
Nonconsumable tungsten electrode Arc Gas shield
Parent metal
Weld metal
Metal Inert Gas (MIG)

Gas nozzle Consumable electrode(filler wire) Reel feed
Gas shield
Arc
Parent metal
Weld metal
Submerged Arc
Submerged Arc
Flux retrieval Consumable electrode Reel feed
Slag
Flux feed
Weld metal
Parent metal
Welding Defects
Cracks
Classified by Shape Longitudinal Transverse Branched Chevron Classified by Position HAZ Centreline Crater Fusion zone Parent metal
Welding Defects
Cracks
4 Crack Types Solidification cracks Hydrogen induced cracks Lamellar tearing Reheat cracks
Welding Defects
Cracks
Solidification Occurs during weld solidification process Steels with high sulphur content (low ductility at elevated temperature) Requires high tensile stress Occur longitudinally down centre of weld e.g. Crater cracking
Welding Defects
Solidification Cracking
Welding Defects
Cracks
Hydrogen Induced Requires susceptible grain structure, stress and hydrogen Hydrogen enters via welding arc Hydrogen source - atmosphere or contamination of preparation or electrode Moisture diffuses out into parent metal on cooling Most likely in HAZ
Welding Defects
Hydrogen Cracking
Welding Defects
Cracks
Lamellar Tearing Step like appearance Occurs in parent material or HAZ Only in rolled direction of the parent material Associated with restrained joints subjected to through thickness stresses on corners, tees and fillets Requires high sulphur or non-metallic inclusions
Welding Defects
Lamellar Tearing
Restraint High contractional stress

Lamellar tear
Welding Defects
Cracks
Re-Heat Cracking Occurs mainly in HAZ of low alloy steels during post weld heat treatment or service at elevated temperatures Occurs in areas of high stress and existing defects Prevented by toe grinding, elimination of poor profile material selection and controlled post weld heat treatment
Welding Defects
Incomplete root penetration
Causes Too large or small a root gap Arc too long Wrong polarity Electrode too large for joint preparation Incorrect electrode angle Too fast a speed of travel for current
Welding Defects
Incomplete root Fusion
Causes Too small a root gap Arc too long Wrong polarity Electrode too large for joint preparation Incorrect electrode angle Too fast a speed of travel for current
Welding Defects
Root concavity
Causes Root gap too large Insufficient arc energy Excessive back purge TIG
Welding Defects
Excess Root Penetration
Causes Excessive amperage during welding of root Excessive root gap (poor fit up) Excessive root grinding Improper welding technique
Welding Defects
Root undercut
Causes Root gap too large Excessive arc energy Small or no root face
Welding Defects
Cap Undercut
Causes Excessive welding current Welding speed too high Incorrect electrode angle Excessive weave Electrode too large
Welding Defects
Lack of fusion
Causes Contaminated weld preparation Amperage too low Amperage too high (welder increases speed of travel)
Welding Defects
Incompletely Filled Groove & Lack of Side wall Fusion
Causes Insufficient weld metal deposited Improper welding technique

Welding Defects
Inter run Incompletely Filled Groove
Causes Insufficient weld metal deposited Improper welding technique
Welding Defects
Gas pores / Porosity
Causes Excessive moisture in flux or preparation Contaminated preparation Low welding current Arc length too long Damaged electrode flux Removal of gas shield
Welding Defects
Inclusions - Slag
Causes

Insufficient cleaning between passes Contaminated weld preparation Welding over irregular profile Incorrect welding speed Arc length too long
Welding Defects
Inclusions - Tungsten
Causes Contamination of weld Caused by tungsten touching weld metal or parent metal during welding using the TIG welding process
Welding Defects
Burn Through
Causes Excessive amperage during welding of root Excessive root grinding Improper welding technique
Welding Defects
Spatter
Causes Excessive arc energy Excessive arc length Damp electrodes Arc blow
Welding Defects
Arc Strikes
Causes Electrode straying onto parent metal
Electrode holder with poor insulation

Poor contact of earth clamp
Welding Defects
Mechanical Damage
Chisel Marks Chisel Marks
Pitting Corrosion
Grinding Marks

Weld Technology Defects

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Weld Technology and Defects

NDT 2/20 Revision 1 Sep 2004

World Centre for Materials Joining Technology

Single Sided Butt

Double Sided Butt Bevel Vee

NDT 2/20 Revision 1 Sep 2004

World Centre for Materials Joining Technology

NDT 2/20 Revision 1 Sep 2004

World Centre for Materials Joining Technology

Smooth,flat or matching surfaces Surfaces shall be free from contaminants

NDT 2/20 Revision 1 Sep 2004

World Centre for Materials Joining Technology

Ultrasonics Electron beam Friction Electric resistance Electric arc

NDT 2/20 Revision 1 Sep 2004

World Centre for Materials Joining Technology

Electric Arc Welding

Work piece Clamp(Earth)

World Centre for Materials Joining Technology

Electric Arc Welding

Impact of particles converts kinetic energy to heat (7000o C) and light

World Centre for Materials Joining Technology

Electric Arc Welding

NDT 2/20 Revision 1 Sep 2004

World Centre for Materials Joining Technology

Zones in Fusion Welds

NDT 2/20 Revision 1 Sep 2004

World Centre for Materials Joining Technology

Manual Metal Arc Welding

NDT 2/20 Revision 1 Sep 2004

World Centre for Materials Joining Technology

Manual Metal Arc (MMA)

Core wire Parent metal

World Centre for Materials Joining Technology

Tungsten Inert Gas (TIG)

World Centre for Materials Joining Technology

Metal Inert Gas (MIG)

NDT 2/20 Revision 1 Sep 2004

World Centre for Materials Joining Technology

NDT 2/20 Revision 1 Sep 2004

World Centre for Materials Joining Technology

NDT 2/20 Revision 1 Sep 2004

World Centre for Materials Joining Technology

NDT 2/20 Revision 1 Sep 2004

World Centre for Materials Joining Technology

NDT 2/20 Revision 1 Sep 2004

World Centre for Materials Joining Technology

NDT 2/20 Revision 1 Sep 2004

World Centre for Materials Joining Technology

NDT 2/20 Revision 1 Sep 2004

World Centre for Materials Joining Technology

NDT 2/20 Revision 1 Sep 2004

World Centre for Materials Joining Technology

Restraint High contractional stress

World Centre for Materials Joining Technology

NDT 2/20 Revision 1 Sep 2004

World Centre for Materials Joining Technology

World Centre for Materials Joining Technology

World Centre for Materials Joining Technology

NDT 2/20 Revision 1 Sep 2004

World Centre for Materials Joining Technology

NDT 2/20 Revision 1 Sep 2004

NDT 2/20 Revision 1 Sep 2004