Escolar Documentos
Profissional Documentos
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For
CostmEffective Welding
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11
4 Modular Construction.................................................................................................................................. 17
7 Fatigue Considerations................................................................................................................................. 45
13 Nondestructive Examination....................................................................................................................... 93
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17 Arc StudWelding ........................................................................................................................................ 129
...
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iv
SECTION I
Primary Concepts
of Weldability
Contents
Weldability .......................................................................................................................................................................... 2
...........................................................................
Personnel Concerns about Fabrication Projects ..................................... 2
.........,.............................._........ .. ..............................4
._......_........
Weldability Can Be Determined by the Manufacturer
1
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SECTION 1-PRIMARY CONCEPTS OF WELDABILITY
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SECTION 1-PRIMARY CONCEPTS OF WELDABILITY
failures are more likely caused by poor decisionson the Recognize the cause of existing and potential produc-
part of engineers orcompany management due to a lack tion problems.
of knowledgeor training.
Improperly selected joint designs, welding processes, Properly utilize, coordinate, and develop cooperation of
locations of welds, and filler metals are frequently asso- available expertise to make sound welding decisions.
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SECTION 2
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Accepting Metal
Fabrication Projects
Contents
Background ........................................................................................................................................................................ 6
.........................................................................
Establish a Prebid Review Group (Before Accepting Special Projects) 6
................................................................................
Establish a Detail Planning Group(Prior to Issuing Job Orders) 7
5
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Section 2-Accepting Metal Fabrication Projects
The critical question asked by a metals fabricator for a (1) Not a repetitive project, even though a company
completed project to be considered successful is: Did the may have procedures that are applicable to the work.
project make a profit and was it completed on time? This includes work that the company has accomplished
When large or small companies have repetitive work, before but has notdone for a long period of time.
they are usually quite successful. They also know the pit- ( 2 ) Any type of field work thatis away from the com-
falls. They know what their minimum bid should be and pany’s home ofice, and involves a significant number of
what delivery or schedule times can be met. They proba- man hours. Field work limits the company’s flexibility for
bly have experienced the normal day-to-day items that scheduling work accurately. Inaddition, field work limits
threaten their profit and thequality of their work. Know- the company’s ability to combine work activitiesfor eco-
ing these pitfalls, they can make allowancesfor them. nomical use of materials, man hours and equipment.
However, for a companytobe successful whenit (3) Any projectthat requires manydifferent disci-
accepts work that can be defined as a special project plines from the same company to accomplishits task.
(meaning adifferent type of work for the company), the (4) Unusual or complex work requirements (includ-
engineer, the fabricator, and the welder need a funda- ing inspections, paperwork, and records).
mental understanding of the weldability of metals and the
basics of sound welding decisions. During the accep-
tance of work, many decisions that seem innocuous to
welding end upjeopardizing the weldability of materials
and the service suitability of the completed weldment.
Establish a Prebid Review Group
(Before Accepting Special Projects)
Since a special project is a nonrepetitive project that
may include multiple workshopshaving new or unusual
Defining Special Projects requirements, the acceptance of such work should be re-
The critical first step for
a company is the ability to recog- viewed by a small prebid review group before accepting
nize a special project. Nearly all special projects require
high special projects. It cannot be expected that a single per-
up-front costs. Thereare increased costs in determining: son who plans and estimates jobscan assemble and un-
derstand all the technical, quality, material, and process
Should the company bid on the project?
requirements of unusual work. When the structure of a
What should the bid be?
company permits, it is recommended that the member-
To what extent are production instructions required?
ship of the preacceptance bid review group consistof
What are the costs to establish these instructions?
comptroller, planner and estimator, design, production
How and when to monitor the work in production?
lead shop, and quality assurance representatives.
Are the company resources adequate?
A comptroller or planner and estimator should over-
Do company equipment and personnel capabilities ad-
see this group. The primary goalof the group should be
equately meet projectrequirements?
to assess the company’s limitations andcapabilities in re-
Whatadditionaltraining/equipmentisrequiredto
gard to technical, quality, and special process require-
meet project objectives?
ments before accepting
. .work. The group should also
Resolvingtheseissuesshould be accomplishedwith determine the limitations andconditions that should be
smallreviewgroupswith specific tasks in mind.placedontheproject for bid acceptance.
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SECTION 2-ACCEPTING METAL FABRICATION PROJECTS
SECTION 3
Production Welding
Cost Analysis
Contents
Introduction ..................................................................................................................................................................... 10
Rework .............................................................................................................................................................................. 11
Joint Designs.................................................................................................................................................................... 12
.............................................................
AutomatiodMechanization ofNew or Existing Thermal Joining Processes 12
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......................................................................................
Cost Considerations of Nondestructive Examination (NDE) 13
Summary .......................................................................................................................................................................... 14
9
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STD-AWS DPW-ENGL 3999 m 07842b5 O539509543 m
SECTION 3-PRODUCTION WELDING COST ANALYSIS
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10
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STDoAWS
DPW-ENGL L999 D
SECTION 3-PRODUCTION WELDING COST ANALYSIS
In his discussion about estimating welding costs, in sary down timeto replace the spooled filler metal contain-
the Design of Weldments (published by the James F. Lin- ers during the welding operation. Also, ordering filler
coln Arc Welding Foundation), Omer W. Blodgett states metal in large quantities, whether it be covered or bare
the following: electrodes, decreases the basic costs per pound. Proper
planning regarding future needs of specific electrode
“The cost of welding i s directly affected by the types, and their proper storage
is required here.
amount of weld metal required.Veryfew peoplere-
alize the great increase in weld metal and cost that
results from a slight increasein weld size.”
AutomatiodMechanization of New or
Existing Thermal Joining Processes
Joint Designs Another aspect of controlling manufacturing/welding
costs, although it involves long-range preplanningwith
In a further representation of Mr. Blodgett’s words, it the possibility of only long-term payback on investment,
has been shown thata decrease of 30” in joint design bev- is the introduction of automation or mechanization of
els can result in a savings of almost 50%, which includes new/existing thermal joining processes. However, before
the welding time, reduction infiller metal and distortion! serious consideration is given to automate (i.e., use of
In the inverse scenario, anincrease in fillet weld sizes by robots), or to mechanize specific welding processes
a factor of 50% will require a significant increase in all (GMAW, FCAW), it is critical that fabrication projects
the above factors. For example,an increase in fillet weld exist to support its development. Purchase of complex
sizes from 1/4 in. to 5/8 in. (using 1/4 in. as 100%)will equipment is a large capital cost, not including associated
increase the labor costs by a factor of 500%! This does operator training, engineering support,or maintenance. A
not include the potential problem of weldment distortion projected return must exist. As an example, at one naval
due to the additional welding. shipyard, after a successful development program involv-
Another factor involving design decisions,or joint de- ing a new welding process (Flux Core-Twisted wire),
sign selections, involves the decision of when to utilize specific production applications were identified. Utiliza-
fillet or groove welds.There is obviously a significant dif- tion of this new process resulted in major labor savings
ference between these designs, and equally so in costs. over the previous welding method in reduced joint design
Based on deposited filler metal costs alone, it is evident preparation, and increased welding depositionrate. The
that for 1/2 in. plate, fillet welds are the cheapest design savings can be realized on future thick section weldments.
per foot, but as the plate thickness increases up to three In addition to the variables previously mentioned dur-
inches, a 45” double bevel groove joint design becomes ing the preplanning section regarding the utilization of
the least expensive. The responsibility of the design engi- welding processes, othervariables need to be evaluated
neer is very significant in controlling welding or manu- prior to making decisions on adapting or purchasing
facturing costs. automated welding equipment. Additional criteria for
Following a review of joint designs, another “tool” that consideration are:
needs to be evaluated is the applicable welding proce-
dure/process to support fabrication. A welding procedure Processing speed of parts per unit of time.
provides the welding foremadwelder with the essential Economic requirements: initial investment and opera-
welding elements including required gas shielding/flow tion costs, and payback period.
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12
I
After review of the abovecriteria, one of the most cru- provides assurance that the quality level
for the productor
cial decisions remains: is there a high degree of assurance weldment is being met for critical applications.
that utilization of the automated welding equipment or Specific definitiondapplications of NDE are covered
new processes will bring abouta positive rate of return on in another section, however, a brief overview of the six
the investment? available nondestructive inspection/testing methods in-
cludes the following: Visual Testing (VT), Eddy Current
(ET), Magnetic Particle(MT), Dye Penetrant(PT), Radio-
graphic (RT), and Ultrasonic Testing(UT).
13
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although more time consuming thanMT. However, PT manent record as the radiograph, improved equipment
requires a better surface finish than MT for satisfactory provides computerized printoutsfor records.
inspection to be accomplished.
Summary
Radiographic Testing
Withever-shrinkingbudgets,andstrongcompetition
Of the six NDE methods, radiographic inspection is from abroad, controlling costs in the public and private
the most expensive. This nondestructive method uses the industry is a major concern. As we have seen, there are
penetrating radiation of X-rays, or the gamma rays of a several variables to consider when welding and related
radioactive source, to penetrate a specific object to reveal nondestructive testing is involved. This section has at-
discontinuities. It is verylabor intensive for the following tempted to describe some of the welding variables that
reasons: need to be considered. Table 3.1is a condensed review. It
High cost of equipment and film. is not intended to be all inclusive, rathera brief narrative
Stringent controls of the radiation source. about some of the major subjects which should be re-
Skilled personnel capable of producing exposed film. viewed. Table 3.2 is a check-off sheet of costs to remem-
Required chemical processing of the exposed film. ber priorto the bid process.
Trained personnel to reviewhnterpret the film.
Restriction of production efforts in the area of inspec-
tion, due tothe presence of harmful radiation. Bibliography/Recommended Reading
This method can be used on most materials, and pro- List
vides a permanent record of most surface or internal de-
Blodgett, O. W. 1963. Design of Weldments. The James F.
fects or flaws. RT is widely utilized in inspection of pipe
Lincoln Arc Welding Foundation, Cleveland, Ohio.
and structural butt welds.
Boyer, H., ed. 1976. ASM Handbook, 8th ed., vol. 1, Fun-
damentals of Quality Controland Quality Assurance.
Ultrasonic Inspection ASM International, Metals Park, Ohio.
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One of the most versatile NDE methods is ultrasonic Cary, H. 1997. Modern Welding Technology. Englewood
inspection. UT has several advantages including location Cliffs: Prentice-Hall.
of internal flaws in components, and abilityto be used on
most materials. However, in termsof ease of operation, it Cooper, N., Davis, W. J., and Pandjiris, A. K. 1968. Know
is fairly complex, and requires the interpretative skills of costs then weld. Welding Journal 47(7): 561-568.
trained technicians. In regard to cost, one individual can
Procedure Handbook of Arc Welding, sec. 12. 1973. The
operate the machine and interpret the ultrasound wave
Lincoln Electric Company, Cleveland,Ohio.
signals. This makes UT considerably less expensive than
RT. Because UT produces no radiation, inspection areas Welding Handbook, 8th ed., vol. 1, Welding Technology
need not be evacuated. Thoughunable to provide a per- (WHB-1.8).Miami, Ra.: American Welding Society.
Table 3.1
Review of Production WeldingCosts I
1. Job preplanning, definition of scope, and accurate scheduling are three critical and necessary steps that must be accomplished
prior to any project bid submittal or start of production.
2. Maintaining accountability of work accomplishments or inspections via the use of formal records is a necessary overhead cost
that must be factored into the bid.
3. If at all possible, it is preferable to accomplish the majority of fabrication or welding in the shop vs. in the field.
4. Increasing fillet weld sizes beyond what is required can be detrimental. Aside from raising the filler metal and labor costs, the
additional welding may contribute to serious distortion of the weldment.
5. Choosing the correct joint design for the particular plate thickness is very important. For example, for thicknesses over
1-1/2 in., the double bevel ‘T’joint design is more economical to employ than increasing the fillet weld size.
6. There are several factors that affect the efficient utilization of the many welding processes, ¡.e., deposition rates, joint geome-
try, fixturing. etc. Careful considerations must be made prior to utilizing a particular welding process or mode.
7. The selection of automated equipment requires a close review of several variables, including long-term preplanning and costs.
There must be a projected positive rate of return, which will justify the capital expenditures.
8. Fireheat protection costs have significantly increased. It has been estimated that for every hour of welding time, an equal
amount of time is required for related fireheat protection.
9. Weld procedurelpersonnel qualifications pose two problems. Both are expensive, and can require considerable time to accom-
plish. Early identification of specific needs is required.
10. Inexperienced welders or craftsman can affect the reject rates. Maintaining a skilled workforce should be a high priority.
1 1 . Nondestructive testing during the manufacturing process has potential for increasing costs. However, it ensures that a quality
product is being produced, and may in the long run actually reduce costs.
12. The roles of the design engineer, welding engineer, supervisor, welder, etc., are all varied, with each being critical for success-
ful project accomplishment. Joint meetings to discuss particular attributes or suspected problem areas are necessary for uni-
fied direction. The results of these meetings will decrease costs and enhance the product quality.
15
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O Receipt inspection costs; i.e., issue instructions for base and filler metal inspections, etc.
O Costs for preparation prior to welding; i.e., base metal cleaning, joint designs, fitting, etc.
O Rigging or crane costs in the movement of the materials during and after the weldments are completed.
O Overhead costs (vacation, electric power, medical insurance, etc,) associated with labor and operation of the required equip-
ment for the fabrication of weldments.
SECTION
Modular
Construction
Contents
Introduction .....................................................................................................................................................................
18
I
Dimensional Accuracy (Process Control)
...................................................................................................................... 19
.....................................................................................................
Designing for Zone and Preoutfitting Construction 21
Summary ......................................................................................................................................................................... . 21
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SECTION 4-MODULAR CONSTRUCTION
Section 4 M o d u l a r Construction
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Two of the more common methods of displaying the
data for accuracy control measurements are the histo-
Dimensional Accuracy (process Control) gram and the process control chart. Each of these meth-
Successful preoutfitting is greatly dependent on struc- ods utilizes basic statistical analysis.
tural dimensional accuracy. Proper implementation of
these advanced concepts requires all structural members
and platforms tobe within predetermined tolerances. The
(1) Histogram. Figure 4.1is a typical histogram. The
data shown represent a series of actual measurements
I
20 MEASUREMENTS
i ALL DIMENSIONS
IN INCHES
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STDsAWS DPW-ENGL 1999 9 0784265 0539539 492 W
SECTION 4"ODULAR CONSTRUCTION
taken over a period of time. By collecting the data in the sure that productivity is being improved andthe effects
histogram format, the variations in the process can be on baseline performance can be determined.
collected and displayed toprovide ameaningful analysis. An accuracy control program providesessential infor-
The histogram can beusedto approximate a "bell mation for successful implementation of modular con-
curve." The bell curve is a standard statistical representa- struction. When sequencing work byzones, it is essential
tion of predictable variations in a process. By utilizing that the systems continuing from one zone to another
the bell curve, normal process inconsistencies can be properly align at the boundaries. The structure must be
estimated and a process can be evaluated to determine accurate and within predefined tolerances to ensure that
the frequency and magnitude of deviation from perfor- the matching systems in two zones are within dimen-
mance to established tolerances. sional tolerances to allow for proper connections.
"""""""""""""""
+ UPPER
CONTROL
LIMIT
PROCESS
AVERAGE
LOWER
CONTROL
LIMIT
- i.5 l
- . O L H + H - H J
0 1 2 3 4 5 6 7 8 9 1 0 1 1
TIME UNITS
20
to perform their tasks without interfering with other The design effort must support a zone approach.
work. Similarly, compatible tasks can be scheduled to be Planning must be directed toward a zone work pack-
performed in unison, and considerations of conflicting age that is producible, to ensure the proper balance of
efforts must be discouraged. For example, it is not eff- the key variables (time, resources, and quality).
cient to have a blast or paint operation being performed 9 An accuracy control program must be implemented to
in the same zone asa pipe-fitting operation. adequately monitor the fabrication process to ensure
that the blocks and distributive systems align properly. I
Designing for Zoneand Preoutfitting Some of the benefits of preoutfitting include:
Construction (1) A higherpercentage of shop fabrication and
assembly.
Effective use of modular construction must incorpo- (2) Less congestion andworker interference for
ratedesign efforts that enhance zonedefinition for mate- structure installation.
rial and productionplanning. Design by system has value (3) Reduction in lost material.
in defining the capability of each functional individual
(4)Less on-site rigging and material handling.
system and in demonstrating the location and path of the
(5) Less on-site cleaning and reduction
in
fire
distributive systems. However, the optimum base of zone
hazards.
planning and work packages requires a zone approach to
(6) Improved worlung conditions on the assemblies.
design.
Implementation of preoutfitting will not be optimized If properly implemented, preoutfittingandmodular
without the corollary design package. As stated in the construction will be cost effective and improve quality
introduction, there are differences between the systems and productivity.
21
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I
SECTION 5
Welding Process I
Selection
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Contents
...........................................................................................................................................
Common Welding Processes
Process Selection............................................................................................................................................................
24
24
I
SMAW............................................................................................................................................................................... 26
GMAW .............................................................................................................................................................................. 27
GTAW ........_.................I............................,.,..................................,.,.,..............................................................................30
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SECTION +WELDING PROCESS SELECTION
Common Welding Processes cess the weld metal composition is an alloy combination
of filler metal and remelted base metal. Weld metal com-
The most common welding processes used in industry position varies with each process. Itis diffkult to predict
involve arc welding. The electric arc is a very effective weld metal composition since many elements are diluted
and portable heat source for melting most metals quickly. when crossing the welding arc.
When the base metal and filler metal become molten, Figures 5.1-5.5 describethemostcommonwelding
they mix together then solidify to produce one solid processes and summarize their advantages and limitations.
piece. Most welding processesutilize a consumableelec-
trode, which conductsthe welding current and melts as it
is continuously fed into the arc and deposited into the Process Selection
joint. The most common manual arc welding process is
When selecting a welding process for a specific appli-
the Shielded Metal Arc Welding (SMAW) process (see
cation, several factors that affect productivity and weld
Figure 5. l), in which a fixed length of electrode is hand
quality must be balanced. This can become a compli-
fed into the joint. Typical semi-automatic arc welding
cated decision, due to the number of conflicting advan-
processes includethe Gas Metal Arc Welding (GMAW)
tages and disadvantages which each process possesses in
process (see Figure 5.2) and the Flux Cored Arc Welding
each situation.
(FCAW) process (see Figure 5.3), which automatically
Productivity is usually a very important consideration
feed a spooled electrodefiller wire into the joint while
on most jobs. The depositionrate is a significant part of
the welder manipulates the torch manually. The Sub-
this factor. Each process can be ranked in terms of its dep-
merged Arc Welding (SAW) process (see Figure 5.4) is
osition rate in pounds of weld metal deposited per hour.
an automatic processwhereby both filler wire and travel
speed are controlled by the machine which runs along a However, there are other factors that must be considered.
For example, it usually takes time for a shop to become
preset track. The Gas Tungsten Arc Welding (GTAW)
familiar with a new welding process, new equipment, or
process (see Figure 5.5) uses a nonconsumabletungsten
even a new brand of filler metal. Until adequate training
electrode to establish an arc in the weld joint, and typi-
and acceptance by the shop personnelare accomplished,
cally, a separate hand-held filler wire is melted inthe arc
the actual productivity rate will be less than the average.
and depositedin the joint.
Reject rates also have a significant impact on actual pro-
The molten weld pool created with all arc processes ductivity, since a considerable amount of time is required
must be shielded from oxidationand contamination dur- to remove defective weld metal, replace it, and reinspect
ing the welding process. SMAW electrodes have a thick it. Therefore, many factors must be taken into account be-
dry flux coating, whichcreates a gasshield and also pro- fore determining which is the best process for a specific
vides many of the alloying elements to the weld. The application. Process selection must be made by someone
SAW process obtains shielding and alloying witha simi- who is very familiar not only with the various processes,
lar type of dry flux in a granular form that coversthe but more importantly with the shop’scapabilities and the
welding arc and molten pool. Spooled FCAW electrodes job requirements. As a minimum, the following items
also use a dry flux contained in the center of a tubular should be considered prior to selecting a welding process.
wire and typically obtain additional shielding from an
inert gas shield similar to the GMAW process. Both
Base Metal Type
GMAW and GTAW utilize inert shielding gases that flow
around the molten weld pool, while all alloying elements Some processes are better suited tocertain base mate-
are supplied by the wire electrode alone. For each pro- rials than others. The maximum heat input must be
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SECTION %WELDING PROCESS SELECTION
I
tor has to frequently stop the process toset up for the next
certain materials, and also may limit the maximum heat
pass, as would be necessary with a small repair. Since
input used to ensure that specific mechanical properties
some processes require more access to the joint root to
are met. A high-productivity process suchas SAW would
avoid lack of fusion defects, the selection of some pro-
lose much of its advantage if the heat input were re-
cesses may also requirea joint design change.
stricted down to the range achievable by GMAW.
Table 5.1 is a general comparison guide for the most
Welding Position
commonly used processes in the industry, relative to
The weld joint position plays a very important part some of the factors discussed above. While some of the
when selecting a process, since many processes are lim- ratings are subjective, they do provide a general cornpar-
ited to onlya few positions. Whenever possible, thejoint ison for many applications.
should be in the flat position, since the highest productiv- It can be seen from thischart that many variables must
ity and weld qualityare attained when weldingis accom- be taken into account when selecting the best welding
plished in this position. Since most repair work is done
I
process for a given job. In practice, it takes experience to
on large weldments that cannot be repositioned and ac- identify and accurately weigh all of the variables in-
cess to the joint is limited, use of high-productivity pro- volved. Some factors, such as the attitude and perception
cesses and filler materials is limited. of shop employees toward a new process or procedure
The four basic welding positions are: flat, horizontal, change, may be more difficultto analyze than others.
vertical, and overhead, as shown in Figure 5.6.
Anotherfactorcomplicatingprocessselection is the
rapid change brought on by the computer age, which is
Environmental Conditions taking place in the electrical power sources used for arc
Wind and rain are the two field conditions that typi- welding. It takes a considerable amountof study to take
cally affect welding. It takes very
little wind to disturb the full advantage of the wide variety of machines available
gas shield that is critical for high-quality GMAW and today and all of thefunctions each one is capable of per-
GTAW welding. This restricts their use outside of shel- forming. TheGMAW and FCAW processes are probably
tered containments. The SMAW and FCAW processes the most influenced by these advances, in the form of
can also be affected by wind, but to a lesser degree. No “synergic” power sources that manipulate the waveform of
process is tolerantof direct rain. Proper placement of the welding current through complex electrical circuits.
tarps, dams, or other temporary containments can rectify These advanced machines automatically adjust all of the
this situation. Due to the many problems associated with waveform parameters to optimize the mode of metal trans-
welding outside (i.e., being exposed to the elements or fer across the arc with simple operator controls. Since pro-
cramped inside of a structure), shop prefabrication is rec- ductivity and weld quality are greatly affected by many
ommended where practical. Studies have shown that re- aspects of the metal transfer across the arc, these machines
ject rates for field welding increased from 100% to offer a significant advantage over the previous generations
greater than 400% over those forshop welding. of power sources.
25
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DIRECTION OF WELDING
Advantages Limitations
All-position capability. Higher potential for weld contamination than for other
processes.
Many alloys are weldable.
Welding is frequently interrupted due to the short, fixed
Thick sections are weldable. length of electrodes.
Excellent for field and repair work. The process creates spatter and smoke fumes and leaves
a slag that must be removedbefore the next layer can be
Equipment is simple, low cost, low maintenance, and is deposited.
easy to set up.
Not suitable for thin material but issuitable for thin-wall
Good accessibility in space-restricted areas. repairs on thick material.
Arc visibility is good. Poor usability for aluminum and most bronzes.
The process is fairly tolerantof environmental conditions. Special electrode care is required since most fluxcoat-
ings absorb moisture.
Electrode travel, which helps to control heat input, is
required. Foreign material exclusion for nuclear applications is
poor.
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SECTION %WELDING PROCESS SELECTION
GMAW
Gasmetalarcwelding is a semiautomatic or auto-
~~~ ~
I
matic process. A small-diameter, continuous consumable
electrode is melted in the arc and deposited in the joint.
Shielding is provided by a gas that flows through the
weld torch. Depending on the amperage and wave form
used, four modesof metal transfer are possible: short cir-
cuiting, globular, pulsed spray, and spray transfer.
CONSUMABLE
'WELD
METAL
--``,``-`-`,,`,,`,`,,`---
Advantages Limitations
of SMAW).
H.igh deposit rates (three times that Handling gas bottles for field work can be expensive.
All-position welding with someGMAW processes. Excessive weld spatter with COz, shielding.
No slag removal and minimum interpass cleaning. Not used for thin metals except with pulsed spray and
short-circuit transfer welding.
Easily adapted to robotics.
Limited accessibility.
Good weld puddle visibility.
Spray transfer limited to the flat position.
27
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SECTION >WELDING PROCESS SELECTION
FCAW
WIRE GUIDE AND
Flux cored arc welding usesequipment CONTACT TUBE
L WELDPOOL
L ARC AND METAL
TRANSFER
--``,``-`-`,,`,,`,`,,`---
Advantages Limitations
28
SAW
Submerged arc welding is very similar to
I
GMAW exceptthe weldpool is shielded, Slag
deoxidized, and alloyed with a granulated
flux that melts in the arc. The flux is fed
through a hopper and a guide tube and de-
posited in the joint ahead of the welding arc.
Two or more electrode wires can be used in
tandem or metal powders can be added toin-
crease deposition rate toobtain optimum me-
chanical properties.
Metal
Weld
Metal
Weld Path
Direction of Travel ____t
I
Advantages Limitations
Excellent weld quality. Limited to ferrous metals and high-nickel alloys(no age-
hardenable alloys).
No flash bums.
Best suited to long welds and thicksections.
Less angular weld distortion.
Special care required for the flux, since it absorbs mois-
Weld appearance excellent. ture easily.
Maintenance
relatively low. Slag
unfused
and removed.
flux
bemust
Smoke and fume quantities are low. High toughness properties are hard toobtain.
Penetration is excellent. Joint fit-up and design are critical to penetration control.
--``,``-`-`,,`,,`,`,,`---
29
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SECTION 5-WELDING PROCESS SELECTION
GTAW 4
DIRECTION OF WELDING
LlDlFlED
WELD METAL WELD METAL
Advantages Limitations
Wide rangeof thicknesses canbe welded. Both hands must be used to hold
the torch and filler wire,
which limits accessibility.
Very clean welds can be achieved withno significant slag,
spatter, or smoke. Shielding gas is easily disturbed by gusts of wind.
Excellent weld quality on most metals. Flash burns are easily obtained.
Amperage can be controlled by remote foot or hand Very limited for outdoor field work.
switches.
Difficult to monitor heat input.
The process can be used either manual or automatic.
30
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SECTION 5-WELDING PROCESS SELECTION
(B) HORIZONTAL
I
1
--``,``-`-`,,`,,`,`,,`---
I
EAD (D) (C) VERTICAL
Table 5.1
Process Comparison Chart
Process SMAW GTAW GMAW FCAW SAW
Arc Visibility and Filler Metal Placement Good Excellent Satisfactory Satisfactory Poor
31
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SECTION 5-WELDING PROCESS SELECTION
--``,``-`-`,,`,,`,`,,`---
32
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STDaAWS DPW-ENGL 1999 m 07842b5 05B953L T9T m
SECTION 6
Primary Concepts I
--``,``-`-`,,`,,`,`,,`---
of Welding Design
Contents
Introduction ..................................................................................................................................................................... 34
Know about Welding.........................................................................................................
What the Designer Should 34
Service Requirements...................................................................................................................................................... 34
........................................................................................................................................................ 35
Base Metal Selection
Welds Create a Discontinuity in the Base Material
...................................................................................................... 35
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STDOAWS DPW-ENGL 1999 9 07842b5 05L9532 92b
SECTION GPRIMARY CONCEPTS OF WELDING DESIGN
34
--``,``-`-`,,`,,`,`,,`---
I
expensive to purchase andto fabricate than the quenched weldment to have:
and tempered steel alloys or the heat-treatable steels and Lower fatigue resistance than the base metal.
will usually require considerably less rework. Steels de- Lower impact properties than the base metal.
signed for special applications frequently require pre-
Higher residual stress than the base metal.
heat, and interpass temperature controls during welding,
and sometimes stress relief. Special electrodes and elec- The weld is a discontinuity which is both a geometric
trode care may also be required. Since fabrication is and metallurgical notch that decreases the suitability for
much more expensive with quenched and tempered service below thatof the base metal alone.
steels, special consideration should be givento their use.
From a design prospective,
in some instances,
quenched and tempered steels offer little advantage. Fa- Keep Weldment Designs Simple
tigue stress ranges are not improved with these steels,
only the maximum allowable fatigue stress or static loads. Weldment design should be kept as simple as possible.
If complete reversal of service stress is expected, these Weldments that involve multiple crossing of stiffeners on
steels offer little advantage for fatigue. These steels also the same plane, multiple intersecting “I” beams, or com-
have lower buckling stabilityfor similar cross sections of plex patterns of stress flow should be minimized. Com-
mild steel, because they are typically used for higher plex designs are expensive to fabricate and can lose
loads and will most likely require additional stiffening. serviceability, due to high residual stress and distortion.
Complex designs also limit welding access and may cause
the inability to meet post-weld inspection requirements.
relative to other fabrication processes. Service areas Welding and its related processing is one of the most
where welds can perform favorably toward base metals expensive operations in fabrication. Shaping plate by
are: pressing or breaking is usually preferable to welding one
35
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SECTION G P R I M A R Y CONCEPTS OF WELDING DESIGN
36
--``,``-`-`,,`,,`,`,,`---
o\
--``,``-`-`,,`,,`,`,,`---
314
37
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STD.AWS DPW-ENGL 1999 E 07842b5 051953b 5 7 1 E
SECTION &PRIMARY CONCEPTS OF WELDING DESIGN
compression loads normal to a weld (see Figure 6.2). Full Penetration Welds
Making full penetration welds on very thick material for
these types of loads can cause higherresidual stress than
A full penetration weld penetrates through the thick-
the anticipated service loads. In some cases, particularly
ness of a joint (see Figure 6.3). Groove weldsare used on
on heavy sections, weld failures will be experienced dur-
butts, corners, and tees. Full penetration welds should be
ing fabrication before service loads are imposed. Often
welds that are subject toshear stresses can be designed to used only where requiredby the design service require-
be 50% efficient, thereby allowing partial penetration ments. Services involving high shock, high temperatures,
joint designs orlower-strength welds to be used. axial or bending cyclic loading (fatigue), and pressure
vessels often require full penetration welds. Fullpenetra-
Welding defects thatareplaced in compression or
tion welds are expensive, often cause the largest distor-
shear while in service are much less critical than those
tion and have high residual stress. However, they are
placed in tension by service loads. In a practical sense,
permitted the highest allowable stresses for design ser-
partial penetration welds have crackstarters and continu-
ous lack of fusion conditions at their roots. Openroots of vice by all codes.
partial penetration weldsmay be subjectto crevice corro- Full penetration welds on heavy sections require spe-
sion. They should not be used in corrosive environments cial joint design consideration to minimizeresidual stress
unless the metal is resistant to crevice corrosion. These and the possibility of cracking and lamellar tearing (see
joints have poor resistance to fatigue and impact loading, Figure 6.4). Mild steel structural plate has low ductility
and they should not be used whenthe weld roots are sub- through its thickness and it cannot accommodate high
ject to transverse cyclic tensionor bending tension loads. through thickness strains. Lamellar tearing and cracking
Partial penetration welds are less expensive and cause of the base metal adjacent tothe weld is a common result
less distortion thanfull penetration welds. of poor weldingjoint details on heavy structural steels.
t
PARTIAL JOINT PENETRATION FILLET WELD PARTIAL PENETRATION
GROOVE WELD GROOVE WELD
--``,``-`-`,,`,,`,`,,`---
38
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SECTION GPRIMARY CONCEPTS OF WELDING DESIGN
--``,``-`-`,,`,,`,`,,`---
Figure 6.3-Full Penetration Groove Welds
I
Fillet Welds penetration, the actual mechanical properties of the weld
deposit and HAZ, the amountof weld reinforcement, and
Fillet welds are generally triangular in cross section the actual failure path. These varying conditions lead to
and are used to join two relatively perpendicular sec- some conservative positions by design engineers. How-
tions. Small fillet welds result in low residual stress and ever, it is extremely rare that fillet welds resultin service
weld distortion. A 5/16-in. fillet weld can be readily failures unless unanticipated service fatigue or impact
achieved in one pass. loads are experienced. Great care should be taken by de-
Larger fillets will require a minimum of three passes,
which greatly increases the cost of welding. If possible, it
is better to keep the fillet size down to one pass and
signers in not applying liberal safety factors and over-
sizing fillet welds. Oversize fillet welds are very expen-
sive and can result in excessive distortion, welding time,
I
extend the length of the weld to achieve joint efticiency. filler metal, and possibly the need for flame straighten-
The smallest typical production welds are generally ing. Fillet weld sizing formulas and tables can be found
1/8-in. fillet welds, because a 1/16-in. fillet weld isnearly in AWS D l . 1, Structural Welding Code-Steel, or see
impossible to produce. Since fillet welds are used prima- AWS Design Handbook for Calculating Fillet Weld Size.
rily in shear, they are unlikely to propagate weld defects
into failures except under fatigue service applications.
Intermittentfilletweldsandcontinuousfilletwelds
made from one side only should be avoided where fa- Design Considerations for Change of
tigue, corrosion, or debris and contamination traps are a
concern.
Cross Sections
One of the common mistakes of engineers is that they One of the fundamental errors made by design engi-
will frequently increase the fillet weld by one size neers is not allowing for stress and strain to take place
(1/16 in.) above their calculated values to play it safe. It through gradual changes of the cross section. Failures
also is not uncommon for production personnel to be commonly occur as a result of thermal and/or mechanical
conservative and go oversize due to increased attention fatigue associated with rapid changes of the cross section.
being given to visual inspection. Increasing fillet weld Changes of the cross section must be gradual in both the
sizes by two sizes (1/8 in.) has the potential of increasing weld metal and the base metal when fatigue isof primary
welding time, distortion, and cost of filler metals by concern (see Figures 6.5 and 6.6). It is preferable to have
more than 100%. changes in the cross section take place in the base metal
Fillet weld sizing is not strictly based on engineering instead of in the weld metal through a weld joint. It should
calculations that are backed up by extensive laboratory also be noted that, in general, those items that affect fa-
tests. The various codes and standards each have differ- if impact loading is expected.
tigue life are also of concern
ent requirements based on different theories and assump- Some common design practices allow tapered sections or
tions. Laboratory tests and calculations can also vary by changes of cross sectionto be a 2 : I ratio. However, a 4: I
the selection of the welding process, the depth of weld ratio is consideredto be the most desirable.
39
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STDmAWS DPW-ENGL 1999
SECTION 6-PRIMARY CONCEPTS OF WELDING DESIGN
40
I
W
m
æ
c
8O h
I
O
*m a
W
n
â
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cw
O
h
O
I
m
I W
o m
L
L
O
41
--``,``-`-`,,`,,`,`,,`---
--``,``-`-`,,`,,`,`,,`---
+-b ‘II
I
. ...
c.
i,p,
..,”_
i
i,,-I
”“ ,*
“i ,L
Ii r
^”
””
”
REMOVE REMOVE
1 AFTER WELDING 1 WELDING AFTER
AFTER WELDING
CHAMFER CHAMFER
BEFORE WELDING 1 WELDING BEFORE
CHAMFER
BEFORE WELDING
42
--``,``-`-`,,`,,`,`,,`---
(14) Use the lowest yield strength filler metal compat- List
ible with the design. This reduces costs, residual stress,
distortion, and cracking.
(15) Use the least amount of weld metal necessary to
meet design requirements. A 1/8-in. fillet is typically the
American Welding Society.Design Handbook for Calcu-
lating Fillet Weld Sizes (FWSH). Miami, Fla.: Ameri-
can Welding Society.
I
smallest practical fillet size. "- . Structural Welding Code-Reinforcing Steel
(1 6) Use partial penetration welds in lieu of full pene- (Dl .4).Miami, Ra.: American Welding Society.
tration when the design permits (i.e., all compression
. Structural Welding Code-Sheet Steel ( D 1.3).
loads, tension and shear loads that act parallel to the axis
Miami, Fla.: American Welding Society.
of the weld).
(17) Use full penetration welds only when required by . Structural Welding Code-Stuinless Steel (D 1.6).
the service requirements. Miami, Ra.: American Welding Society.
(18) Use fillet welds when practical. Use single pass
. Structural Welding Code-Steel (D 1 . I). Miami,
fillet welds where possible (5/16-in. to 3/8-in. maximum
Fla.: American Welding Society.
leg sizes depending on the welding process). Some stan-
dards require a two-layer minimum for leak tightness if
they are tobe used for fluid containment.
(19) Balance welding about the neutral axis.
-" . Welding Handbook, 8th ed., vol. 1, Welding
Technology (WHB- 1.8). Miami, Ha.: American Weld-
ing Society.
I
43
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I
SECTION 7
Fatigue I
Considerations
--``,``-`-`,,`,,`,`,,`---
Contents
.
Introduction ..................................................................................................................................................................... 46
.
Loading ............................................................................................................................................................................. 46
Stress Concentrations...................................................................................................................................................... 46
Inspection ......................................................................................................................................................................... 48
Peening.............................................................................................................................................................................. 48
Grinding ........................................................................................................................................................................... 49
................................................................................................
Base Metal andWeld Metal Changes in Cross Section 49
Thermal Fatigue.............................................................................................................................................................. 49
.
Checklist for Fatigue Considerations............................................................................................................................. 50
.
BibliographyIRecommendedReading List ................................................................................................................... 50
45
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STD*AWS DPW-ENGL 3999 0784Sb5 0539543 701 W
SECTION 7-FATIGUE CONSIDERATIONS
--``,``-`-`,,`,,`,`,,`---
46
m
I
I
I
I
II
/ \
LEGEND:
1 CRATER
2 FACE
CRACK
CRACK
3 HEAT-AFFECTEDZONECRACK
4 LAMELLARTEAR
5 LONGITUDINAL
CRACK
6 ROOTCRACK
7 ROOTSURFACECRACK
8 THROATCRACK
9 TOE
CRACK
10 TRANSVERSECRACK
11 UNDERBEADCRACK
12 WELDINTERFACECRACK
13 WELDMETALCRACK
14 LAMINATION
Figure 7.1-Cracks
47
--``,``-`-`,,`,,`,`,,`---
area, typically associated with lack of fusion, cracks or loading, the rate of loading, or the number of cycles
slag, open to or very close to a weld surface, are most should be examined. Welds should be kept in low-
likely to progress into cracksif undesirable loading is stressed areas. Reverse cyclic loading (tension-compres-
present. Fatigue crack growth fromthe toes of welds will sion) should be avoided. High-yield base metals havelit-
typically progress from the edgeof the weld and through tle advantage if reverse cyclic loading
is experienced.
the heat-affected zone (HAZ)into the base metal at right
angles to the fluctuating primary stress in the weldment.
By proper examination of fatigue fracture surfaces, il
can be determined where the failure initiation sites were:
Surface Finishing to Improve Fatigue
and the direction and amount of primarystress. Life
Since surface shapes can directly affect fatigue life, it
is necessary to know how surface conditioning can im-
Inspection prove fatigue life. A simple example of this is that a
--``,``-`-`,,`,,`,`,,`---
Fatigue cracks aredifficulttofindduring the early finely finished smooth machined plate or shaft will have
stage of growth since they are tight and exhibit no defor- an improved fatigue performance (numberof cycles and
mation. Visual inspection is of limited value during this stress limit) over base metal with mill scale. Also, plates
stage of crack growth. The magnetic particle (MT), pene- or shafts with mill scale will have considerably better fa-
trant (PT), and eddy current (ET) tests would be the best tigue resistance than the same base metal that has been
inspection processes for discovering fatigue cracks. subject to surface pittingby corrosion.
48
The following weld geometry attributes are stress ris- gles is very beneficial for improving the fatigue life of a
ers that directly lead to a lower fatigue life (see Figure
7.2).
It isimportantto realize that the onlythingthatis
component. In every case,fatigue life should be expected
to be improved over the as-welded condition by proper
grinding. Grinding that is properly accomplished can im-
I
being addressed here is the shape of the surface and not prove fatigue performance by at least 20%. However,
differences due to a weld deposit being present, such as grinding should not leave gouges or heavy grind marks.
residual stress or different mechanical properties. Reduc- Also, removal of weld reinforcement to nearlyzero with-
tion in fatigue life due to these surface conditions would out creating a noticeable angle between the reinforce-
be present regardless of whether a weld were present or ment and the base metal improves fatigue life. Contour
not. If all base metal fatigue samples are machined into grinding of welds should be performed prior to stress re-
different shapes, such as increasing amounts of rein- lief on components, such as pressure vessels. Since con-
forcement or increasing re-entrant angles or machined in touring of welds is very expensive, and in some cases it
simulated weld ripples, thefatigue life will be decreased. is more expensive than making the weld, it should only
For example, if simulated undercut is machined into the be accomplished for critical applications, or where
surface of a plate it will reduce the fatigue life of the
plate even thougha weld is not present.
known service problems exist.
I
Base Metal and Weld Metal Changes
Grinding in Cross Section
Contourgrinding of weldsand the adjacentbase
metal to remove undercut, excessive weld reinforcement, Improper change in cross section is one of the most
weld ripples, weld defects and sharp weld re-entrant an- common causes of reduced fatigue life. Abrupt changes
in the cross section (stress concentrations) must be
avoided or minimized for improved fatigue resistances.
Poor transitions in thicknesses cause higherlocal cyclic
fatigue stresses, and consequently, lower fatigue life.
$
, r Reinforcement A- Removed By
.<Grinding These localized stresses and strains can be induced in the
component by different sources. Fatigue is often experi-
enced due to differential thermal expansion or vibration
I
of structural and machinery components. Piping system
A
Excess Weld Reinforcement B Improper Treatment 01 Reinforcement
fatigue failures are often caused by vibration of nearby
--``,``-`-`,,`,,`,`,,`---
machinery components, not allowing systems to freely
Removed By
.- - ~ ,f- Grinrlinn expand during heating periods, or improperly installed
pipe hangers that were used to support service loads and
dampen the number of fatigue cycles.
C Acceptable Treatment of Weld Reinforcement
Thermal Fatigue
h When a component is comprised of thick and thinsec-
tions and is subject to transient changes in temperatures,
high thermal strains can easily develop at abruptchanges
of the cross section without considering other external
loads. Duringthe heat-up cycle the thin material will heat
up much more rapidly than the thick sections. The hot
thin sections must thermally expand, but will be re-
strained by the thicker cooler sections. During the cool-
down cycle, the thinner sectionswill cool-down much
more rapidly than the thick sections, causing high ther-
mal strains, again due to differences in temperature. Fur-
ther, thermal strains can be induced as a result of the
Figure 7.2-Surface Geometry Effects difference in thermal conductivity between materials
on Fatigue Life used in a given joint configuration.
49
Checklist for Fatigue Considerations (1 3) Continuous fillet welds have betterfatigue perfor-
mance than intermittent filletwelds.
(1) Keep welds in low-stressed areas. (14) Full penetration welds have better fatigue perfor-
(2) Keepthemaximum stress andthenumberof mance than partial penetration welds.
cycles as low as is practical. (15) Avoidthe
use of welds on external cor-
(3) Avoid reverse cycles (tension and compression). ners or plate edges when practical for critical fatigue
(4) Avoid rapid or abrupt changes in cross-sectional applications.
thicknesses especially in weld-associated areas.
(16) Avoid welding transverse to primary tension fa-
(5) Keep weld reinforcement and re-entrant angles to
tigue stress (i.e., across tension flanges of beams).
a minimum.
(17) Flame-cutedges on heat-treatable basemetal
( 6 ) Contour grinding or peening will improve fatigue
should be ground to a smooth surface to remove peak
performance.
hardness residualhtresses and stress concentrations.
(7) Keep components painted;itimproves fatigue
performance and minimizessurface corrosion. (18) Avoid forcedalignment of flanged joints and
weld joints, as this may result in fatigue cracks adjacent
(8) Reverse thermal strains are common in piping and
to welds during service.
machinery components where abrupt changesof thick-
ness are present or components' piping systems are not
allowed to freely expand. Theseinternal loads can be re-
duced by providing gradual changes in cross sections, Bibliography/Recommended Reading
flexible supports, sliding foundations or bends in piping List
systems to allow gradual strain distributions over larger
areas. American Welding Society. Structural Welding Code-
(9) When repairing a fatigue crack, be sure the crack Steel (Dl.1). Miami, Fla.: American Welding Society.
is completely removed. Contour grindthe weld and in- "_ . Welding Handbook, 8th ed., vol. 1, Welding
spect the weldfor critical applications. Technology (WHB-1,8). Miami, Fla.: American
(10) Unless the stress pattern, the rate of loading, the Welding Society.
number of cycles, or the basic design is changed, re-
paired fatigue cracks will redevelop (usually at a more Fatigue Assessment of WeldedJoints Using Local Ap-
rapid rate). proaches. England: Abington Publishing. (Available
(1 1) Avoid the use of doubler or cover plates where through AWS.)
fatigue considerations are critical.
Fatigue Strength of Welded Structures, 2nd ed. England:
(12) For dissimilarmetalweldsinvolvingthermal
Abington Publishing. (Available through AWS.)
fatigue applications, the filler metal should have a ther-
mal expansion rate approximatelymidway between the Proceedings of the International Conferenceon Fatigue.
two base metals selected. Miami, Fla.: American Welding Society.
50
--``,``-`-`,,`,,`,`,,`---
SECTION 8
Welding
Considerations
Contents
Introduction ..................................................................................................................................................................... 52
Design................................................................................................................................................................................ 52
Production ........................................................................................................................................................................ 53
51
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STD.AWS DPW-ENGL 3779 m 07842b5 0539549 L2T W
SECTION &WELDING SAFETY CONSIDERATIONS
--``,``-`-`,,`,,`,`,,`---
overlooked. All too often, hazardous conditions are Processsafety.
present and overlooked or not properly considered. This Allof the above are important aspects of a well-
results in unnecessary risk to personnel, equipment,and formulated plan. While these items do not directly ad-
product. dress safety, it can be seen that several of the items will
It can be said, with reasonable certainty, that no de- greatly impact the safety of the production personnel per-
signer, planner, production superintendent, or mechanic forming the specified task.
ever plans to have an accident. Accidents are, by defini- The designer must use knowledge and experience to
tion, unplanned occurrences, sometimes resulting in loss weigh production techniques against worker safety re-
of life, serious collateral damage, orboth. quirements. For example, are theweld joint design and
The information provided anddiscussed in the follow- component configuration consistent with the intended
ing pages is not intended to address all of the potential weld process, i.e., will a joint’s backside accessibility be
hazards associated with welding fabrication, or the sub- in a tank, with a single access at the top of the tank, jeop-
sequent safety precautions necessary to resolve every po- ardizing a welder’s safety by asphyxiation due to lack of
tential problem. This reference guide is intended to oxygen? Thisresulting from the plan-specified weld pro-
stimulate the imagination of everyone, from the designer cess, “gas metal arc” welding which incorporates an inert
to the mechanic, to look for potential hazards and elimi- shielding gas. It cannot be assumed by the designer that
nate them before an accident occurs and it becomes a production personnel will takethis type of potential haz-
costly lesson learned the hard way. ard into consideration beforestarting work.
Safety, as related to weldingfabrication, must be con- There are manyindustrypublicationsavailablethat
sidered from three specific points of view: design, plan- cover industry-associated health and safetyhazards, e.g.,
ning, and production fabrication. Each area has specific AWS 249.1, Safety in Welding, Cutting, and AlliedPm-
responsibilities and concerns and will be looked at indi- cesses, and AWS Effects of Welding on Health I-X.
vidually in this section. These and other industryreference materials can bevalu-
able sources of information if your organization is not
fabricating under some other safety standard, such as
those of the Occupational Safety and Health Administra-
Design tion (OSHA).
Safety during the design phase is usually not a field The following are specific areas that designers should
that is given independent consideration. Safetyis usually consider prior to issue of plans and instructions:
limited to general areas of consideration, and more often
(1) Design and lay out welds which will allowfor ad-
than not, related to production capabilities and costs,
equate and safe welder accessibility.
more than safety, such as:
(2) Design assemblies so that fabrication welds can
Canthecomponentbehandled or positioned for be performed in areas where adequate ventilation can be
fabrication? provided.
52
53 --``,``-`-`,,`,,`,`,,`---
the base metal or the presence of volatile solvents in Use of Inert Gases
the air.
Due to the serious nature of the potential hazards as-
Zinc and magnesiumoxide inhalation. sociated with the use of inert and other gas mixturesre-
quired during welding, additional emphasis is warranted.
- Toxicity produces chills, fevers,nausea four to The use of nonflammable (inert) gases within structural
eight hours after exposure. enclosures, piping systems, etc., creates a potential per-
- Toxicity disappears almostinvariably,within 24 sonnel hazard. The inherent danger in the use of inert
hours. gases is that sufficient quantities may be released into an
occupied compartment or space to reduce the oxygen
Copper fumes toxicity. content of the atmosphere below that required to support
human life.
- Toxicity symptoms similar to zinc and magnesium Inert gases are used in many production methods in
except it is more severe, longer lasting and is pre- the building and repair of ships, argon (Ar) for purging
cipitated by less exposure. piping systems, nitrogen (N2) for drying air piping,
Nickel (1 mg per cubic meter), cobalt(O. 1 mg per cubic helium (He) for some types of welding and carbondiox-
meter), and mercury(O. 1 mg per cubic meter) are: ide (COz) for inerting tanks containing flammables, to
name a few.
- Strongly suspected of causing a chemical pneu- An atmosphere deficient in oxygen ( 0 2 ) usually gives
monitis which may have severe or even fatal little or no warning, particularly if the gas that has dis-
results. placed the oxygen is odorless. A trained observer may
notice an increase in pulse or breathing rate intime to es-
Cadmium oxide and beryllium oxide. cape; however, the average individual may fail to recog-
- These oxidesproduce severe fume pneumonitis.
nize the lackof oxygen until he istoo confused and weak
to save himself, especially when a considerabledistance
- They are extremely dangerous. must be traveled to reach fresh air.
To minimize the hazards, the use of inert gas must be
Iron and aluminum apparently do not cause a metal closely controlled. Positive exhaust systems must be in
fume fever although inhalation of very large amounts operation to reduce the possibility of an inert gas
of iron fumes for a period of years maycause a condi- buildup, should accidental leakage occur. Low areas
tion known as siderosis, a deposit of iron in the lungs. where heavier gases tend to accumulate require special
attention. In addition to general ventilation requirements
Materials coated, even accidentally, with toxic materi-
to reduce this hazard, localexhaust ventilation should be
als such as lead, cadmium, mercury or paints contain-
ing toxic materials produce what is probably the installed in such a manner as to exhaust the inert gas.
Each opening from which the inert gas is flowing must
greatest health hazard in welding or cutting. Any such
coatings should be removed prior to welding, or rigid have individual ventilation.
ventilation control measures should beestablished. Personnel usingandor having access to inert gas should
receive additional training about its potential hazards and
Welding on materials containing lead, or other toxic the appropriate methods for handling and working with it.
materials such as high-lead bronze, may produce a harm-
ful exposure, depending largely on the amount of such
material present and the amount of metal melted. Pro- Planning for Safety
fessional safety advice should be consulted prior to It is often the case during the planning and funding
welding. phase of a project, that safety is assumed to be a normal
Welding on materials containing Beryllium may pro- work practice and is just another unaccounted for ex-
duce an extremelydangerous condition. No such welding pense of completing a project. This can be a dangerous
should be undertaken until completecontrol of fumes has approach to doing business. This attitude or lack of
been provided. awareness of what is required to ensure the safety of the
Welding on tanks, pipelines or containers of any sort workers places an unnecessary burden on those produc-
from which the contents have not been completely re- tion people trying to meet the schedules. Not properly
moved may introduce a serious hazard by volatilization identifying and subsequently funding safety require-
or decomposition of the residue. This is particularly ments may cause production personnel, in their efforts to
true when halogenated materials or plating solutions are complete a job in a timely, cost-effective manner, to
involved. overlook serious safety considerations. Safe working
54 --``,``-`-`,,`,,`,`,,`---
55
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SECTION 9
Weld Joint Design
Considerations
Contents
Introduction ..................................................................................................................................................................... 58
Design................................................................................................................................................................................ 58
Accessibhty ....................................................................................................................................................................... 59
1 .
Environmental Conditions.............................................................................................................................................. 60
Temperature Control....................................................................................................................................................... 60
.......................................................................................................................................... 60
Pipe Welding Considerations
Summary ............................................................................................................................................................................ 61
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SECTION %WELD JOINT DESIGN CONSIDERATIONS
58
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Welding Processes
When selecting a weld joint design, it is necessary to
lack of penetration or weld surface roughness should all
be avoided to maximize fatigue life. Weld reinforcement
sized to the members being joined will increase fatigue
I
consider what welding processes are to be used. Will the life. Welds are often designed as full penetration and fil-
welding be accomplished in the field or in the shop? let welds designed as continuous instead of intermittent
Each welding process has its limitations. Gas Tungsten in order to maximize fatigue life.
Arc Welding (GTAW) should not be usedon heavy struc-
tural sections, but rather on piping or sheet metal. Sub- Impact Resistance
merged Arc Welding (SAW) will only be used in the flat
or horizontal position preferably in a shop-type environ- Impact loading may result from any sudden applica-
ment. If weld deposition rates are of concern in the field tion of a load. During impact loading, a member is re-
then the Flux Cored Arc Welding (FCAW) process quired to absorb energy rapidly. Designs that are
should be considered rather then Shielded Metal Arc susceptible to fatigue failures are often also subject to
Welding (SMAW). Joint access and position may deter-
mine which welding process can be used.
termines the weld jointdesign.
This in turn de-
impact failure. The weld and base material should be
ductile and have suitable impact resistance at the lowest
possible service temperature. Weld joints subject to im-
I
pact loading will gain increased resistance by design in-
Corrosion Resistance corporating many of the guidelines used for “Fatigue
Resistance.”
What type of service (operating media such as high-
temperature steam, seawater, acidic fluids, etc.) will the Distortion Control
joint experience? Weld joints with backing strips or
backing rings and partial penetration joints with open There are a number of distortion origins during the
roots will be subject to crevice corrosion and should not manufacture of structural sections and piping systems.
be used in the above-mentioned service without specific Distortion is primarily due to restricted expansion when
consideration. the heat of welding is applied. With preplanning, distor-
tion can be kept to a minimum. Design factors of distor-
Joint Efficiency tion control include:
Joint efficiency is the abilityof the weld joint totrans- (1) Minimize welding by using standard shapes.
fer stresses between the members being welded and the ( 2 ) Use
partial-penetration joints when design
weldment. Weld joint efficiency requirements will, to a permits.
(3) Balanceweldingaroundtheneutralaxis.Use
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59
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SECTION %WELD JOINT DESIGN CONSIDERATIONS
construction or repair? Can component subassemblies be (4) What physical and chemical properties need to be
accomplished in the shop? Shop assemblyincreases ac- considered?
cessibility by permitting plates to be turned, and piping ( 5 ) What material types and thicknesses are available?
to be rolled. To assist in making sound desigdplanning (6) Are dissimilar metals to be joined? (Some filler
decisions, the design engineershould visit and review the metals are extremely crack sensitive depending on the
job site prior to issuing work instructions. base metaufiller metal combination.)
Fabricatedcomponents, throughout their life span,
may have to be weld repaired. The designer shouldkeep
Environmental Conditions this in mind for weldability and welding access in the
field. Components that will be weld repaired orreplaced
A jobsite and work condition review willassist in se-
often should be designed for ease of welder access and
lection of weld process and associated joint design. Ad-
ease of weldability (i.e., process to be used, base material
verse weatherconditions and contaminates such as water,
type, andjoint design).
paint, and oil in or nearan existing weld joint are factors
to consider when designing new weld joints, or specify-
ing repairs and welding processes. Windy conditions re-
quire additional sheltering if a gas-shielded welding Pipe Welding Considerations
process is selected.
Pipe Joint Design
Design criteria for welded pipe joints are set forth in
Temperature Control specifications. These criteria are dependent upon the
piping system. The designer is guided in selection of a
Heat transfer from the welding process into the weld
particular joint design by one or more of the following
and the adjacent base metalcan cause damageto compo-
nents. When welding a component with finished ma- factors:
chined surfaces control of temperatures before, during (1) Contractual requirements.
and after welding has to be addressed so as to keep dis- (2) System application (pressure, temperature, corro-
tortion of those surfaces to an acceptable level. There sion, erosion, etc.).
may be paint that needs to be protected on the inaccessi- (3) Piping material.
ble backside of a component that requires weld repair. (4) Piping wall thickness.
Material thickness and maximum temperature the paint ( 5 ) Specifications.
can withstand have to be known before welding. A (6) Classification of joint (i.e., consumable insert,
mock-up of thejob may have to be done. backing ring, socket,or square butt).
O-ring seating surfaces located near weld repair areas (7) Availability of fittings.
require heat input control for distortion protection. Some (8) Welding accessibility for butt or socket joints vary
considerations for controlling heat to a desired areacan with location. Butt welds usually requiregreater working
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60
Summary
When designing weldments,the designengineer
Bibliography/Recommended Reading
List I
American Welding Society. Standard Symbols for Weld-
needs to know the properties of the materials selected, ing, Brazing, and Nondestructive Examination
the service requirements of the weldments, and the fun- (A2.4). Miami, Fla.: American Welding Society.
damentals of the fabrication processes. "_ . Welding Handbook, 8th ed., vol. 1, Welding
Engineersdesigning welded components need to Technology (WHB- 1.8). Miami, Fla.: American
know basic mathematical formulas for calculating forces Welding Society.
and their effects. The calculations need direct application Blodgett, O. W., Design of Weldments. The JamesF. Lin-
to the specific weld joint design that is selected for join- coln Arc WeldingFoundation, Cleveland, Ohio.
ing component parts. Cary, H. 1997. Modern Welding Technology. Englewood
I
Weldment design should always be based on the thin- Cliffs: Prentice-Hall, Inc. (Available through AWS.)
ner member beingjoined. The minimum amount of weld Metals Handbook, 9th ed. vol. 6 , Welding, Brazing, and
metal should be used while maintaining weld joint Soldering. American Society for Metals, Metals
strength requirements. Park, Ohio.
61
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Weld Distortion
and Control
Contents
Introduction ..................................................................................................................................................................... 64
................................................................................................... 66
Considerations for Minimization of Weld Distortion
63
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Introduction
UNWELDED PLATE
Control of distortion during fabrication is essential.
Weld distortion is evident on practically all weldments.It n
is readily visible on thin plate and sheet metal when
welded. In addition to lowering stress-carrying capabili-
ties, distortion can make it extremely difficult to fit sub- ARC IS STRUCK
assembly parts together to complete a fabrication. Weld
distortion can be extremely expensive tocorrect and it is
easier to prevent than tocorrect for critical applications.
Fabrication distortion is caused by:
HEATED PORTION
Volumetric shrinkage of molten metal solidifying to EXPANDS
ambient temperature.
Thermal shortening of metaladjacent to a weld.
Filler metal with higher yieldstrengths than their base
metals. ARC IS
EXTINGUISHED
The metallurgicalandmechanicalproperties of the
base metal greatly influence the degree of distortion ex-
perienced. Because of their different mechanical and
CONTRACTING
metallurgical properties, different base metals exhibit SHAPE WITH
varying amounts of distortion for the same amount of COOLING
heat input. The following base metalsare listed in order
of increasing distortion problems: HY-100, HY-80, high-
strength steel, mild steel, Monel@, copper-nickel and300 RESOLIDIFIED
Series stainless steel. WITH RESIDUAL
STRESS
64
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SECTION 10-WELD DISTORTION AND CONTROL
causing large thermal expansion in this localized area. A double “V’ groove requires less welding than a sin-
Plastic flow occurs in this restricted expansion area, re- gle “V” in the same plate thickness and will help bal-
sulting in distortion. Stainless steel has much lower ther- ance angulardistortion.
mal conductivity than mild steel and this is partially why Use partial penetration joints whenever possible.
it is much more susceptible to distortion than mild steel.
Use smallest weld size possible to meet the strength
requirements. Oversized welds increase distortion.
Modulus of Elasticity
Use flanged comers instead of welded comers.
Modulus of elasticity is a measure of the stiffness of a Use intermittent welds to reduce welding where prac-
metal. A material with a higher modulus is more resistant tical (see Figure 10.2).
to distortion, since increased stress is required to strain or
stretch the material. However, it should be noted that the Balance Welding
mild steel and most alloy steels have nearly the same
modulus of elasticity. Weld in a sequence that offsets one shrinkage stress
against a previously deposited weld on the opposite side
Yield StrengtWStrain (see Figure 10.3). However, the resultant shrinkage of the
second weld will not equal the distortionof the first weld.
Yield strength or yield strain is an indication of the Distortion is best controlled by welding both sides simul-
metal’s resistance to permanent deformation. A lower
taneously such asdouble fillet welds where practical.
yield strength filler metal accommodates someof the dy-
namic weld joint stresses by stretching rather than creat-
ing distortion. Conversely, base metals with high yield
Joint Design
strain are less susceptible to distortion due to their in- Joint designs shouldhave minimum rootopenings and
creased strength. bevel angles, yet provide adequate joint accessfor good
fusion for the welding process used. Joint designs need
Manufacturing Residual Stresses to be selected that will balance welding (see Figure
10.4).
Components have their own residual stress patterns
that can affect the resultant distortion of the finished
product after welding. Because of different cooling pat- Restraint
terns, castings, plate, and shapes have varying residual Reduce distortion by restraining assemblies in fixtures
stress patterns that directly affect distortion. For exam- or to other assemblies. When practical weld toward max-
ple, the flanges of rolled I-beams are typically under ten- imum restraint; weld away from edges; weld toward the
sion, while the webs are under compression, because centroid or the center of gravity when practical.
during manufacture the thinner cross section of the webs
cool first followed by the flanges. The cooling and short-
ening of the flanges place the webs under compression.
Neutral Axis
Position weld joints at a neutral axis to provide less
leverage for shrinkage forces, or balance welding around
Considerations for Minimization of the neutral axis.
Weld Distortion
Structural Tacks
Minimize Welding
Structural tacks help force the welds to deform rather
Avoid welding when practical. Use standard shapesor than distorting the base metal. Structural tacks are usu-
rolled sections, use castings or breakho11 material into ally a minimum of two inches long andare often two lay-
different shapes rather than welding several pieces ers thick. These tacks will restrain the root opening from
together. closing during welding and will help force the root weld
pass to deform instead of pulling the plates together. It
Minimize root openings and bevel angles of full pene- should be kept in mind that any restraint that can be
tration joints. However, adequate accessfor the weld- placed on hot weld metal will be very effective, dueto its
ing process andoperator must be provided. low yield strength at high temperatures. The structural
A “J” or “U’ grooverequireslessweldingthan a tacks need to be thick enough so that they cannot be
bevel or “V” groove and will result in less distortion fused through by subsequent passes, as this will reduce
of thicker metals. some of their effectiveness.
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-
(A) Double Sided Single Pass Fillet Welds -
(B) Single Sided Multiple Pass Fillet Welds
on a Lap Joint on a Corner Joint
-
(C)DoubleSided MultiplePassFilletWelds(D)FilletWeldsaroundtheDiameter of aHole
on a T-Joint
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(E) StaggeredIntermittentFilletWelds,TopView(F)ChainIntermittentFilletWelds,TopView
67
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SECTION IO-WELD DISTORTION AND CONTROL
Preset
Figure 10.3-Sequence Welds
Alignmentof the joint is setupout of position to
allow for anticipated shrinkage during weldingto bring
the assembly to the desired position (see Figure 10.6).
Use mockup test assemblies to estimate amountof preset
necessary as the amount of preset will vary with each
BACKGOUGE
welding process andthe parameters used.
Overwelding
J- Weld convexity increases shrinkage but does not in-
1 crease strength. Use intermittent welds or partial penetra-
tion welds where practical. Do not oversize fillet welds.
Excessive distortion can result from oversizing small fil-
let welds by one size on thin material.
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Weld Process Selection
Figure 10.4-Joint Designs
The greater the total heat input by conventional weld-
to Minimize Distortion
ing processesthe greater the distortion. Weld process se-
lection should consider weld deposition, amperage, and
travel speed. Use of largest suitable electrode is fre-
quently recommended as transverse weld stresses are
somewhat cumulative and distortion can be increased by
Fit Up multiple passes.
Properedgepreparationwith joint alignmentand
minimum root openings decrease weldingand result in Prefabrication
less weld distortion. Do not use excessive forceto align Welds made in the flat position or with joint rotation
joints for welding. Highresidual stress will be induced allow use of larger electrodes and deeper-penetrating
into the weld joint resulting in weld distortion. weld processes with less joint preparation. The result is
less weld distortion.
Backstep Welding
Backstep welding uses the restraint of a previously Subassemblies
deposited weld to minimize the tendency of the two Fabrication of subassemblies provides additional dis-
plates from pulling together as the welding progresses. tortion control, since each subassembly becanadjusted for
distortion before being matchedto another subassembly.
Controlled Wandering (Backstep) Weld
Peening
A backstepweld is usedinwandering sequence.
Welds made in short segments, distributed along the Weld shrinkage may becounteracted by peening,
length of the joint, cause less distortion than continuous which stretches the weld in the area peened. Peening is
welding (see Figure 10.5). most effective at higher temperatures. A blunt tool
should be used to plastically deform (stretch) the weld
after slag is removed. However, a root bead should only
Prestressing and Interference Fits
be peened lightly or not at all because of the danger of
Prestressing surfaces to be welded by bending or by causing a root crack. Peening marks shouldbe removed
interference fits develops tensile stresses
on surfaces to be from the final weld surface if they are expected to inter-
68
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-
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69
SECTION II
Checklist for
Sound Welding
Decisions
Contents
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71
No itemhas a greater effect on weldabilitythan O Tensile and compressive stresses and strains (axial/
the common everyday decisions made by the designer, bending).
welding engineer, shop supervisor, and the journeyman O Corrosion resistance.
mechanic. O Erosion resistance.
Before making a weldingdecision, there are three O Abrasion resistance.
basic areas that should receiveconsideration: O Impact resistance (stress and temperature dependent).
O Creep resistance.
The intended service requirements. O Temperature (high- or low-temperature physical
The base metal and weld metal properties. properties).
The fabrication conditions imposed. O Fatigue resistance (thermal and mechanical).
O Aesthetics (color match, anodizing, and appearance).
As an aid, to make sure you have checked items that
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72
--``,``-`-`,,`,,`,`,,`---
-
O Purging requirements.
O Skilled, qualified mechanics (experience and good O Thermal stress developed Restraint Safety of men
- morale). and equipment.
O Schedule. O Quality control evaluations (defects vs. failures
O Available equipment, materials, and facilities. and cost to meet NDE).
O Welding process characteristics. O Weld procedure (various welding parameters).
73
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I
.
Defects and Discontinuities
of Welding
Contents
Introduction ..................................................................................................................................................................... 76
Weld Acceptance Standards........................................................................................................................................... 76
The Causeof Welding Defects ........................................................................................................................................ 76
Weld Discontinuities ........................................................................................................................................................ 77
Cracking ........................................................................................................................................................................... 77
Delayed Cracking-Hydrogen Embrittlement ............................................................................................................. 83
Techniques for Allowing Hydrogen to Escape from Welds ......................................................................................... 84
Minimizing theAvailable Amount of Hydrogen to theWeld Deposit ........................................................................ 84
Welding Processes and their Available Hydrogen ........................................................................................................ 84
Summary of Rules to Minimize Hydrogen Embrittlement Cracking ........................................................................ 85
Slag Inclusions................................................................................................................................................................. 85
Lack of Fusion or Incomplete Fusion............................................................................................................................ 85
Lack of Penetration ......................................................................................................................................................... 86
Porosity ............................................................................................................................................................................. 87
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Undercut (Including Root Undercut) ............................................................................................................................ 88
fingsten Inclusions ......................................................................................................................................................... 88
Arc Strikes........................................................................................................................................................................ 89
Spatter .............................................................................................................................................................................. 90
Crater Pit.......................................................................................................................................................................... 90
Burn-Through .................................................................................................................................................................. 91
Incomplete Insert Melting.............................................................................................................................................. 91
Root Centerline Crease................................................................................................................................................... 91
Melt-Through ................................................................................................................................................................... 91
Oxidation .......................................................................................................................................................................... 91
Root Concavity................................................................................................................................................................. 91
Root Convexity ................................................................................................................................................................. 92
Bibliography/RecommendedReading List ................................................................................................................... 92
75
76
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Porosity
Uniformly scattered la 12.2, 12.6 W Weld only as discussed herein
Cluster lb 12.1, 12.2, 12.3, 12.5, 12.6 W Weld only as discussed herein
Incomplete fusion 3 12.1, 12.2, 12.3, 12.4, 12.5 W At joint boundaries or between passes
Inadequate4joint
penetration
1 12.2,
12.1, 12.3, 12.4, 12.5
I W
I Root weld
of preparation
~ ~~_________
Undercut 5 12.1, 12.2, 12.3, 12.4, 12.5, 12.6 HAZ Junction of weld and base metal at
surface
Overlap 7 12.1, 12.2, 12.3, 12.4, 12.5, 12.6 W/HAZ Junction of weld and base metal at
surface
Laminations S 12.1, 12.2, 12.3, 12.4, 12.5, 12.6 BM Base metal, generally near
midthickness of section
Delamination 9 12.1, 12.2, 12.3, 12.4, 12.5, 12.6 BM Basemetal, generally near
midthickness of section
Seams and laps 10 12.1, 12.3, 12.4, 12.5, 12.6 BM Base metal surface, almost always
longitudinal
Transverse
Crater
I
12.3, 12.2,
12b
12c
I 12.1, 12.4, 12.5, 12.6
Throat 12d 12.1, 12.2, 12.3, 12.4, 12.5, 12.6 W Weld axis
Toe 12e 12.1, 12.4, 12.5, 12.6 HAZ Junction between face of weld and base
metal
Root 1 12f I 12.1, 12.2, 12.3, 12.4, 12.5, 12.6 I W I Weldmetal, at root
Underbead and
heat-affected zone
1 12g 1 12.1, 12.2, 12.4, 12.5,
12.6 I HAZ 1 Base metal, in HAZ
78
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SECTION 12-DEFECTS AND DISCONTINUITIES OF WELDING
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80
--``,``-`-`,,`,,`,`,,`--- 81
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SECTION 12-DEFECTS AND DISCONTINUITIES OF WELDING
(B)
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Figure 12.7-Potential Weld Crack Locations
82
Cold Cracking
Cold cracking generally occurs below 400°F. Marten-
sitic base metals are subject to high stresses and have a
I
microstructure that is susceptible to low-temperature
cracking. Cold cracks are predominately transgranular,
occurring across metal grains, while hot cracking usually
occurs between grains or interdendritically.
Lamellar Tearing
Some mild steel base metals are subject to cracking
adjacent to welds due to their inability to withstand high
through-thickness stresses, because their through-thick-
ness ductility is low. This low ductility is the result of
- non-metallic inclusions thatdeveloped during the initial
pouring of the ingot to make the material. These inclu-
sions are i n the form of oxides, silicates, sulfides, etc.
When the plates are rolled, some of these inclusions are
rolled out into thin, lamellar plate inclusions lying paral-
lel to the plate surface at different depths throughoutthe
thickness of the material. When high through-thickness
stresses are placed on the plate by welding, cracking oc-
curs by shearing from one inclusion in the plate to an-
other inclusion within the base metal. This cracking
pattern has a stair-step appearance in the base metal (see
Figure 12.1I). Comer welds that involve welding across
--``,``-`-`,,`,,`,`,,`---
the end of both members and butt welded joints, mini-
mize through-thicknessstrains and are most desirable be-
cause in some applications they place the metal under
through-thickness compression.TEE welds are examples
of unavoidable through-thicknessstresses. In these cases,
the most successful remedy is clad welding the plate in
the area of the groove’s reinforcement fillet or fillet weld
or peen each weld pass.
Recommendations to prevent lamellar tearingare:
( I ) Select weldjoints that minimize through-thickness
stresses.
(2) Peen all weld layers.
(3) Keep weld sizes down.
(4) Use low-strength filler metals.
(5) Use thin plate (less than one half inch).
(6) Provide for slight root openings under “T” welds.
(7) Select fine-grain steels with stabilized inclusions
than cannot be rolled out into lamellar inclusions.
Figure 12.11-Examples of
Lamellar Tearing
Delayed Cracking-Hydrogen
Embrittlement
The presence of hydrogencan develop tremendous presence and the effects of hydrogen during welding can
stress when present i n welds and their heat-affected cause cracking of the base metal (under-bead cracking)
zones in low-alloy steels (heat treatable) such as HY-80, or weld metal immediately or several days after the weld
HY-100, AISI-4130, AISI-8630, and AISI-4340. The was completed. Thus comes the term delayed cracking.
83
The presence of hydrogen causes a drastically localized 200°F minimum preheats and interpass temperatures are
loss of ductility in ferritic weldsand their heat-affected not suitable for all base metals.
zones. Classical cracks are transverse across the weld de-
posit. Hydrogen may also contribute to other types of Hold the Weld at Interpass Temperature
cracks such as longitudinal cracksand localized cluster
cracks depending on the restraint and environmental con-
after Welding
ditions. Techniques and procedures that a welder must The weld and the adjacent base metal should be held
use to minimize cracks are: near the maximum interpass temperature for at least one
(1) Minimize the amount of hydrogen available to the hour after welding; and on heavy sections, 24 hours is
molten weld metal. highly desirabre to permithydrogen to diffuse from the
weld without developing cracks.
(2) Allow hydrogen to escape from the weld and the
HAZ.
84 --``,``-`-`,,`,,`,`,,`---
--``,``-`-`,,`,,`,`,,`---
very thick layers. Slag inclusions can be microscopic in as a crack, since slag is usually globular in shape. It is
size or very much larger, extending through the entire more closely allied to porosity in its effects on service,
thickness of a weld or across a completelayer of weld(as except that slag, when its area becomes significant or its
can be found in submerged arc welds). shape is not globular, will probably affectfatigue perfor-
mance to agreater degree than porosity.
Location
The most common area for slag entrapment is in the Lack of Fusion or Incomplete Fusion
first layer and between the root layer and the second
layer. Slag is also found at sharp re-entrant angles be-
tween weld passes and between weld passes and the base
Definition
metal. Overhead weldingis most proneto slag inclusions, This condition exists when there is incomplete fusion
due to the quick freezing slag of
smaller weld beads. between the weld metal and a precedingweld deposit or
the weld metal and base metal (fusion that is less than
Sources of Slag complete). Frequently, incomplete fusion appears as
metal-to-metal contact with a thin line between beads
The majorsourceofslag is thefluxand electrode
with no metallurgicalbonding.
coating used in SMAW, FCAW, and SAW processes.
However, GMAW and GTAW processes may contain
slag inclusions due to metal and silicon oxides. As the Shape
amount of oxygen increases in GMAW shielding gases, Onweld cross sections, lackof fusion is usually a
the amount of slag produced increases. Slag can also curved line. On a radiographic image, lack of fusion will
occur with GTAW process, when the molten end of the frequently appear to have a straight portion with a curved
filler metal is removed from the shielding gas and oxides end (a tail).
are formed. The oxidesare introduced into the weld pud-
dle when the filler metal is added. Another source of slag
Location
is the base metals themselves, since nonmetallic oxides
and nitrides are available to form slag fromthese materi- Lackoffusion occurs betweenweldpasses,orbe-
als. Shop dirt in the form of oxides of burning and goug- tween weld passes andthe base metal (see Figure 12.12).
85
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SECTION 12"DEFECTS AND DISCONTINUITIES OF WELDING
INCOMPLETE
FUSION 1 (B)
n
INCOMPLETE FUSION
f
metal and to allow sufficient timefor thin surface oxides Melting Melting
to be removed.Other causesof incomplete fusion are im- Temperature Temperature
Metal ("F) Oxide
proper travel speeds (too fast or too slow), insufficient
electrode size, improper joint design selection, improper Aluminum 1100 A1203
electrode or torch manipulation, impropersurface clean-
ing, and improper removal of refractory oxides. Monel@ 2400 Ni0
Refractory oxides melt at much higher temperatures InconeP 2525 cr203 4109
than their base metals and are a major causeof incom-
plete fusion, particularly in high-nickel or aluminum al- Titanium 3137 Ti02
loys. The only oxide that melts at a lower temperature
than its metal constituent is iron oxide. Also some filler
metals are alloyed with elements that form refractoryox-
ides, such as: titanium, aluminum, nickel, magnesium
any lack of fusion. Lack of fusion is considered a serious
and chromium. Base metalsthat readily form refractory
defect when it is open to the surface ofa joint. In general,
oxides are: aluminum, Inconel@,copper-nickel, Monel@,
lack of fusion is considered a higher stress concentration
and K-Monel@(see Table 12.2).
--``,``-`-`,,`,,`,`,,`---
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SECTION 12-DEFECTS AND DlSCONTlNUlTlES OF WELDING
I
INCOMPLETE JOINT PENETRATION
INCOMPLETE
PENETRATION
JOINT
--``,``-`-`,,`,,`,`,,`---
Cause
Lack of penetration is most commonly caused by im-
proper weld joint selection for the weld process used, or
the use of improper welding parameters such as: welding
amperage too low, improper travel speeds, improper po-
larity, improper filler metal selection, improper filler
metal manipulation, or improper backgouging. Another
error is sometimes just forgetting to weld the opposite
side of a weldjoint. Weld joint designs must be properly
selected for the base metal,filler metal, and welding pro-
cess used. The welding arc penetration and the weld pud-
dle fluidity depend on these conditions. Unlike mild
steel, low-alloy steels, and stainless steels, high-nickel
and copper alloys do not spread or wet easily.
Figure 12.14-Locations of Porosity
Service Impact
Few codes permit lack of penetration when afull pen-
etration weld is required. Lackof penetration is a veryse-
rious discontinuity when fatigue is involved (particularly
when the axis of the discontinuity is transverseto primary Location
stress). Lack of penetration has resulted in a large per-
Porosityisalwayslocatedwithinthewelddeposit.
centage of service failures involving ship hulls, piping Lack of visual porosity on a weld surface is not an indi-
systems, pressure vessels, and machinery components. cation of a porosity-free weld.
Lack of fusion that is totally enclosed within a weld is not
nearly as hazardous as lack of penetration open to a joint
surface (¡.e., a one-sided joint weld). However, when Cause
properly selected for service, partial penetration joints
welded from one side are desirablejoint designs. Porosity is caused when there is not enough time for
the gas bubble to escape the molten weld metal before
the puddle solidifies. Porosity can be formed by any vol-
Porosity atile material being trapped within molten metal; gas
evolving out of the weld from elements that were in solu-
Definition tion at a higher temperature; the reduction of metal ox-
ides or nitrides; chemical reactions that create sulfur
Porosity is a void or gaspocketcontainedwithin a dioxide or carbon monoxide gas; and entrapment of
weld. The gasis entrapped within the weld during the
so- shielding gas. In some metals like aluminum, gaseousel-
lidification process (see Figure 12.14). ements (most likely hydrogen) will come out of solution
near the solidifying dendrites growing into the liquid
Shape metal. The liquid metal cannot keep the element in
The most common shape is spherical; however, poros- solution as thepuddle cools and solidifies, so the element
ity can be elongated and extend from one weld pass into collects into a gas pocket. Hydrogen is 20 timesmore
another. soluble in molten aluminum than in solid aluminum.
X7
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SECTION 12-DEFECTS AND DISCONTINUITIES OF WELDING
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- ~~ ~~
Service . .
Arc Strikes
Definition
Anarcstrike is caused by unintentionalmelting or
heating of a finished weld or base metal surface by an
electric current. It results in a localized weld and heat-
zone affected 12.17-ArcFigure Strikes
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SECTION 12-DEFECTS AND DISCONTINUITIES OF WELDING
Cause
Arc strikes may be caused by improper manipulation
of the electrode, loose ground clamps, and lowamperage
that causes sticking and dragging of the welding elec-
trode. Even magnetic particleinspection prods can cause
arc strikes, if improperly used.
Service Impact
Arc strikes are critical on heat-treatable steels. An arc
strike area creates a hardened weld and HAZ due to the
extremely rapid quenching caused by the surrounding
metal. Arc strikes should not be permitted on high-speed Figure 12.18-Spatter
rotating shafts particularly if they are made of quench-
hardenable steel. Some standardsmay require that all arc
strikes and associated HAZ be removed by grinding.
Arc strike protection of the base metal adjacent to the
weld joint is agood practice and should be maintained
for critical applications. Service Impact
Excessive spatter could maska defect during weld in-
spections and in those areas it must be removed. Some
Spatter standards exclude the presence of weld spatter. Spatter
should be considered similar to arc strikes for highly
hardenable heat-treatable metals thatare subject to severe
Definition fatigue loads, such as high-speed rotatingshafts.
Globularmetal particles that are ejectedfromthe
welding arc area. Weld spatter does not form an inten-
tional part of the weld.
Crater Pit
Shape
Spatter is usually spherical or globular in shape.
Definition, Shape, and Location
A crater pit is usually a circular-shaped depression. I t
is a cavity that extends down into a weld at its termina-
Location tion site (weld stop).
Weld spatter may or may not attach or weld itself to
the existing weld or the adjacent base metal (see Figure
12.18). Cause
Crater pits are caused by a volumetric contraction of
Cause molten metal during solidification andlack of filler metal
to fill the void. It is usually the result of abruptly remov-
The most frequent causesof weld spatter include: ex- ing the welding arc or not using current decay with
cessive welding current; arc length too long; or short cir- GTAW. It may be minimized by gradually reducing the
cuiting the welding arc causing a high surge of welding weld current (current decay) at the weld stop, increasing
current that will expel weld spatter. Some spatter is nor- the travel speed, gradually withdrawingthe welding arc,
mal with most welding processes except submergedarc or adding additional filler metal at the termination site of
welding and gas tungsten arc welding. GTAW welds.
90 --``,``-`-`,,`,,`,`,,`---
Crease
Centerline
Root
I
--``,``-`-`,,`,,`,`,,`---
Service Impact
Unless crater pits have cracks or other associated weld An intermittent or continuous shallow linear groove
defects, they are not expected to cause in-service failures. (centerline crease) concavity formed by distortion or up-
Crater pits are not addressedby most acceptance standards. setting of the root surface by subsequent weld passes.
Burn-Through Melt-Through
A root surface or base metal irregularityon a consum-
A 'Oid Or fused and extendinginto the On able insert or closed root full penetration joint resulting
the back side Of a a backing in fusion completely
through a localized region
without
strap weld, or open root weld. Droplets of metal may
development of a void or opening. The melt-through
may
stick out from this bum-througharea.
or may not be associated with the weld root.
W c ORIGINAL INSERT
NOT MELTED
Root Concavity
A root surface depression or concavity that may be
due to gravity (weld segment in the overhead position),
surface tension, or too high of an internal purge pressure
on the molten metal. Also, distortion caused by subse-
quent weld passes can causeconcavity of the root pass. It
W L INSERT
NOT
COMPLETELY MELTED
is controlled by using the proper joint design, the correct
c WELDJOINTINSERT
COMPLETELY MELTED
12.19-Incomplete
Figure
12.20-Oxidation
Figure
Melting
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SECTION 12-DEFECTS AND DISCONTINUITIES OF WELDING
Root Convexity
Root weld reinforcement (convexity) that is beyond
the base metal surface which may bedue to gravity (weld
segment in the flat position), surface tension, or low in-
ternal purge pressure effects on molten metal (see Figure
12.21). Also, distortion causedby subsequent weld passes
can cause convexity of the root pass. It is controlled by
using the proper joint design, the correct size consum-
able insert, and proper welding parameters(Le., amper-
--``,``-`-`,,`,,`,`,,`---
age, travel speed, and purge pressure).
Figure 12.21-Convexity
ReferencesKRecommended Reading
List
American Welding Society.Guide for Nondestructive In- . The Everyday Pocket Handbook for Visual In-
spection of Welds (Bl.10). Miami, Fla.: American spection and Weld Discontinuities (PHB-2). Miami,
Welding Society. Fla.: American Welding Society.
. Guide f o r Visual Inspection of Welds (B1.11). " . Welding Handbook, 8th ed., vol. 1, Welding
Miami, Fla.: American Welding Society. Technology (WHB-1.8). Miami, Ha.: American Weld-
ing Society.
. Practical Reference Guidefor Radiographic In-
spection Acceptance Criteria (PRG). Miami, Fla.: . Welding Inspection (WI-80). Miami, Ha.: Amer-
American Welding Society. ican Welding Society.
_" . Standard Methods f o r Mechanical Testing of . Welding Inspection Technology(WIT). Miami,
Welds (B4.0). Miami, Fla.: American Welding Society. Ha.: American Welding Society.
92
SECTION 13
Nondestructive
Examination
Contents
Introduction ..................................................................................................................................................................... 94
................................................................................................................................
When Should NDE Be Performed? 94
93
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--``,``-`-`,,`,,`,`,,`---
Introduction repair, base metal defect repair, and other repair welding
should be inspected prior to welding. A nondestructive
The field of Nondestructive Examination (NDE) pro- test of the repair area and surrounding material can be
vides methods to measure or detect soundness criteria used to determine the extent of defects and ensure part
placed on materialby design requirements. soundness before repair welding begins.
NDE gathers this information through testing, in such
a way as to not adversely affect the serviceability of the Finished Product Inspection
material; hence, the term nondestructive testing.
Quality cannot be inspected into a material; however, With the proper selection and application of various
NDE can ensure that the material has acquired quality at- NDE methods, NDE can provide overall quality assur-
tributes. The proper selection and application of NDE to ance of the finished product.
key phases of fabrication or assembly can save time, ma-
terial, and money, as well as provide assurance that de-
In-Service Inspection
sign requirements are met. Maintenance inspection can be scheduled to meet the
service needs of a product. Monitoring of known and
suspected wear and stress areas with NDE can determine
When Should NDE be Performed? the frequency ofservice required.
When to perform aninspection can be as important as
selecting an NDE method. After a designer has com-
pleted the selection of materials and determined an as- Nondestructive Test Methods
sembly design, it becomes the fabricator’s responsibility There is a wide variety of NDE methods available to-
to meet those requirements. To do this, inspection mile day. More than one may be used on the same weldment.
markers are essential. The various test methods do not necessarily compete
with each other. For detailed military requirements see
Receipt Inspection MIL-STD-271 and MIL-STD-278. The following sec-
Raw materials thatmeetspecification requirements tions present a brief overview ofmajor NDE methods.
are essential for high-quality fabrication. Various NDE
methods often provide a quick and relatively inexpensive Visual Inspection Testing (VT)
way to verify the material’s properties or identification. VT provides important information about weld con-
When material problems or discrepancies are caught at
formance and practical quality control. VT uses trained
this stage, rather than during fabrication or in service, observation and attention to requirements as the primary
savings of time and money can be immense. inspection criteria. Although visual inspection is exclu-
sively a surface application, experience and training can
In-Process Inspection reveal discontinuities such as surface porosity and some
During fabrication, visual inspection of the joint de- types of surface cracks, weld bead contour and rough-
signs, weld preparations, and the deposited weld metal ness, bead placement, residual slag and oxide films, un-
provides evidence of a quality product. In-processin- dercut, joint misalignment, and other indicators of
spection ensures that quality is built into an assembly and potential inferior quality. Adequate lighting, cleaning of
can reduce final inspection requirements. Welding appli- inspection area, and specific inspection standards are re-
cations that involve weld buildup for corrosionor wear quired to effectively ensure quality. See Table 13.l.
94
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SECTION 13”NONDESTRUCTIVE EXAMINATION
Table 13.1
Visual Inspection Testing
developer is applied, the dye that bleeds out of the dis-
continuities provides a visible indication of the flaw.
PT is typically used to inspect forgings, castings, ex-
I
trusions, and weldments of most solid, nonporous mate-
Advantages Disadvantages
rials. The surface being inspected must be sufficiently
Best method for detecting weld Limited to surface and smooth to allow removal of excess dye without over
bead contour and roughness, weld alignment attributes. cleaning the test surface. If open to the inspection sur-
bead placement, residual slag, face, all weld and base metal defects can be detected in-
undercut, and joint misalignment. No easily recordable
permanent record. cluding cracks, lack of bond,cold shuts, edge lamination,
Minimal equipment required. shrinkage areas, laps, and open porosity. The portability
Cannot reliably detect of PT materials make them an ideal toolfor field inspec-
Very fast and economical to use. some types of surface tion. See Table 13.2.
cracks.
Results are obtained immediately.
Precleaning
~
- Does not interfere with other work The test surface must be cleaned (usually with isopro-
in the area.
pyl alcohol) to remove contaminants to allow the pene-
Results are obtained immediately. (see Figure 13.1).
trant to penetrate surface discontinuities
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SECTION 13”NONDESTRUCTIVE EXAMINATION
Applying Penetrant
--``,``-`-`,,`,,`,`,,`---
Applying Developer
The developer is evenly applied on the test surface.
Adequate time is allowed for it to act as a “blotter” for
the discontinuity (see Figure 13.4). The test surface is
then examined with visible light, when color contrast
dyes are used, or with ultraviolet light, when fluorescent
dyes are used.
Postcleaning
After the test surface has been evaluated, it is cleaned
(usually with isopropyl alcohol) to remove the developer Figure 13.4-Visible Indication after
and any remaining penetrant. Application of Developer
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SECTION 13”NONDESTRUCTIVE EXAMINATION
Precleanìng
Usuallygrinding or “needle gunning” to remove
paint, slag, and scale is sufficient precleaning. The iron
particles must be allowed to migrate freely across the in- Figure 13.6Throat Crack in a
spection surface.
Fillet Weld Root
Applying the Magnetic Particles
The iron oxide particles are applied to the surface of
the test area while the electrical current is still producing
the magnetic field. There are two widely used methods of
doing this:
(1) Dry Method-in which a thin, even coat of dry
Lines of forca
iron oxide particles are sprinkled or dusted ontothe sur- wwin and on
face. There are a choice of colors available to provide a surface ol the part
97
98
--``,``-`-`,,`,,`,`,,`---
SURCH
switched to receive (or another searchunit can be desig- used for ultrasonic inspection. Longitudinal waves are
nated to receive) the reflected pulses which have been al- propagated into the test material at an angle normal to its
99
--``,``-`-`,,`,,`,`,,`---
the proper orientation are If the eddy current field moves within range of a disconti-
easily detected. The test surface must physically nuity or change in material properties, the magnitude and
conform to the search unit
Accurate location of the contact surface, grinding and direction of the eddy currents are altered. This change of
discontinuity. paint removal may be necessary. eddy current density changesthe inductive reactance of
the primary coil.These variations are registered on anout-
Access is required from Poor surface and near-surface put device and,depending on the sensitivity of theelectri-
one sideonly. resolution. cal instrumentation, can be used to locate discontinuities
Excellent sensitivity. Linear discontinuities lying or variations in the test material. Due to the “skin effect”
parallel to the plate surface are of both the eddy currents and the primary current, the coil
Process can be automated readily detected. is limited todetecting surface and near-surface parameters.
for rapid inspection of The depth of effective penetrationis determined by the pri-
plate and bar stock. No easily recordable permanent mary coil power output and frequency. See Table 13.5.
record.
Linear discontinuities
lying perpendicular to the Large grain metal castings
plate surface are readily (i.e., 300 series stainless) can be
detected. difficult to inspect.
100
-
practical depth of detection, which is typically no more
Table 13.5 than 114 in.
- Eddy Current Testing
Limitations
Applications
The application of RT for weld inspection is largely
ET can be used to identify and classify materials by dependent on thelocation of the joint in the weldment,
comparing them to a standard. Thickness measurements the joint configuration, and section thickness. These fac-
of thin sheet materials and nonconductive coatings are tors may combine to limit the best use of RT and favor
also common. Surface and subsurface discontinuities can another method. Oneof the primary limitations of RT is
also be detected which may be related to welding or its difficulty in detecting cracks or other closeddisconti-
other fabrication processes. nuities which are not aligned with the source beam. Mul-
tiple shots at various angles can be used to detect most
Advantages
The primary advantage of ET over other methods is
that it canbe completely automated and produce accurate
results at high speeds without ever contacting thepart
being tested. ET is, therefore, especially well suited to
continuous production lines. Another advantage is that
the signal generated by ET is often proportional to the
size of the discontinuity detected.
Limitations
Surface cleanliness is important for accurate results,
since any magnetic particles on the surface may cause
nonrelevant indications. The majorlimitation of ET is
FILM
that the primary coil design must be compatible with the
part geometry and defect or attribute type being investi-
gated. Care must also be used when calibrating the ET
equipment with a reference standard as this will deter-
Figure 13.12-Orientation of Radiation
mine the accuracyof the results.Another limitation is the Source, Test Plate, and RadiographicFilm
101
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--``,``-`-`,,`,,`,`,,`---
detect. . Guide f o r Visual Inspection of Welds (B1.11).
Linear discontinuities lying
perpendicular to the plate Considerable time required Miami, Fla.: American Welding Society.
surface are easily detected. for setup, exposure, and . Practical Reference Guidefor Radiographic In-
interpretation of results.
I spection Acceptance Criteria (PRG). Miami, Fla.:
American Welding Society.
. Standard Methods f o r Mechanical Testing of
Welds (B4.0). Miami, Fla.: American Welding Society.
discontinuities; however, due to limited accessibility,
multiple shots are often not possible. When cracks are
. The Everyday Pocket Handbookf o r Visual In-
spection and Weld Discontinuities-Causes and Rem-
suspected to occur in a critical applications, another
edies (PHB-2). Miami, Fla.: American Welding
NDE method such as UT may be a better choice.
Society.
102
Contents
Introduction ................................................................................................................................................................... 104
Material ..........................................................................................................................................................................
104
.................. 105
Welding Department Required Information Facilitated by the Design Engineer/Technical Support
103
--``,``-`-`,,`,,`,`,,`---
and base material grades. Because of this, details of the mechanical and corrosion-resistant properties.
procedure should be clarified to the welding department
by the design engineer. Documentation requirements
should be detailed on the engineering instruction with Filler Material
clear direction to access forms or with copies of forms to
be filled out and attached. In most organizations, the The filler material should be specified by the welding
quality assurance requirements are buried deep in corpo- procedure or the engineering instruction. The welding
rate procedures and difficult for the welder to uncover. procedure should be reviewed to ensure that it is clearin
The procedures should be interpreted by the engineer, selecting the correct filler material. Some welding proce-
and details provided to the welder. The term “welder” as dures are written to cover a variety of materials and situ-
used in this section refers to the actual production welder ations and need to be clarified for the welder at time of
or his immediate supervisor. use.
104
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SECTION 14-INFORMATION FOR THE WELDER
PREHEAT
Preheat
Temperature,
Minimum: Interpass Temperature,
maximum
Pass or Filler Metals Current Travel Joint D I-
Layers Process Class Dia. Type Amps Volts Speed
We, the undersigned, certify that this Welding Procedure Specification meets the requirementsof
ANSI/AWS D1 . l .
Company
BY Date
106
American Welding Society. WELDPERFECT The Easy . The Everyday Pocket Handbook f o r Visual In-
Guide to Perfect Welding (WPERF). Miami, Fla.: spection and Weld Discontinuities-Causes and Rem-
American Welding Society. edies (PB-2). Miami, Ha.: American Welding Society.
. The Everyday Pocket Handbook for Visual In-
. Joint Weld Terminology and Standard Welding
spection of AWS Dl.1, Structural Welding Code-
Symbol Interpretation (textbook). Miami, Ha.: Amer-
Steel, Fabrication and Welding Requirements (PHB-6).
ican Welding Society.
Miami, Fla.: American Welding Society.
. Lens Shade Selector(F2.2). Miami, Ha.: Ameri- . The EverydayPocket Handbook on Metric Prac-
can Welding Society. tices f o r the Welding Industry (PHB-5). Miami, Fla.:
. Prequalified Joint Details in AWS D 1.1, Struc- American Welding Society.
tural Welding Code-Steel (chart). Miami, Ha.: Amer- . The Everyday Pocket Handbook on Welded Joint
ican Welding Society. Details for Structural Applications (PHB-3). Miami,
Fla.: American Welding Society.
. Standard f o r Welding Procedure and Perfor-
mance Qualification (B2.1). Miami, Fla.: American . Welding Symbols (chart). Miami,Fla.: Ameri-
Welding Society. can Welding Society.
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~~
Fitting Aids
Contents
Background .................................................................................................................................................................... 1 10
.................................................................................................................................
Current Problems in Fabrication 1 10
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SECTION 15"FIlTING AIDS
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SECTION 15-FIlTING AIDS
Fitting AidCategories
The fitting aid devices documented herein are classi-
I
fied by their primary method of mechanical advantagein
their design. Some of the aids shown use a combination
of methods for force application.
Wedge devices (see Figures 15.1-15.4).
Threaded devices (see Figures 15.5-15.8). Figure 15.2-Weld-On Saddle
Hydraulic devices (see Figures 15.9-15.10).
Pneumatic devices (see Figure 15.11).
Gear-pulley devices (see Figures 15.12-15.13).
Magnetic devices (see Figures 15.14-15.15).
Strongbacks (see Figure15.16).
Padeyes, stays, and cables (see Figures 15.17-15.19).
--``,``-`-`,,`,,`,`,,`---
Figure 15.4-Pulldown
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Figure 15.5-Push-Pull Jack
112
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-
Figure 15.8-Clip and Bolt
Figure 15.10-Portable Hydraulic Ram
Come-Along, a devicehavingaratchetinggear-
pulley arrangement to change the effective length of a
Pneumatic Devices(Figure 15.11) chain for lifting or pulling.
~~ -
Vacuum Saddle, also known as vacuum jacking
clamp, an air-operated devicehavingsuctionpadsfor Magnetic Devices ( ~15.14-15.15)
i ~ ~ ~ ~
gripping relatively smooth surfaces and a “U”- or “L”-
shaped metal structureforstraddlingand holding parts MagneticSaddle, also known as magnetic jacking
together. This device is used in conjunction with a screw clamp, a device employing an electrically induced or per-
and thread or hydraulic ram for applying pushing force. rnanent magnetic field(s) and a “U”- or “L”-shaped metal
--``,``-`-`,,`,,`,`,,`--- 113
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SECTION 15"FIlTING AIDS
Figure 15.12-Chainfall
Figure 15.14"agnetic Saddle
--``,``-`-`,,`,,`,`,,`---
U
Figure 15.13-Come-Along Figure 15.15-Fitting Magnet
structure for straddling andholding ferrous metal parts Strongbacks (Figure 15.16)
together. This device is used in conjunction with a screw
and thread or hydraulic ram for applying pushing force. Strongback, any number of devices used to restrain
applied forces and/or hold alignment. Thesedevices may
FittingMagnet, a deviceemploying an electricallyin- be welded or mechanically fastened and are used with
duced magnetic field(s) for drawing ferrous metals together. many other tools for applying forces to parts.
114
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SECTION 15"FITTING AIDS
II
II
II
II
, m
af i ,
II
II
II
II
II
II
II
II
II II II II II II
1
el
Figure 15.16Strongback
11.5 --``,``-`-`,,`,,`,`,,`---
--``,``-`-`,,`,,`,`,,`---
Figure 15.1s"stay
Figure 15.19-Cable
Figure 15.21-Fixture
116
-
Specialized Devices PanelLinewithOne-SideButtWelding Station,
-
stiffener attachment and welding station, web frame at-
One-Side Welding System, a system that consists of tachment and welding station, and bulkhead attachment
a heavy structural frame hydraulic magnetic or pneu- and final welding station.
matic clamping rams, plate positioning and/or feeding
PanelLinewithTacking Station, two-side butt
conveyors, weld backing bar and weldingequipment.
welding station, stiffener attachment and weldingstation,
web frame attachmentand welding station, and bulkhead
Stiffener Positioning System, a system that consists
attachment and final welding station.
of a heavy structural beak and/or gantry, hydraulic, mag-
netic and/or pneumatic stiffener clamping and position-
ing equipment and tack weldingequipment. Bibliography/Recommended Reading
Web Positioning System, a system that consists of a
List
heavy structural beam and/or gantry, hydraulic magnetic, American Welding Society. Welding Handbook, 8th ed.,
pneumatic, and/or gear-pulley equipment and tack weld- vol. 1, Welding Processes (WHB-1.8). Miami, Fla.:
ing equipment. American Welding Society.
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SECTION 16
Welding Metallurgy:
Practical Aspects
Contents
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Introduction ................................................................................................................................................................... 120
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SECTION 16-WELDING METALLURGY: PRACTICAL ASPECTS
(1) Mild steel (ferrous alloys not strengthened by heat Mild steel, with typically well less than 0.29%carbon,
treatment) [i.e., ordinary steel (OS),ASTM A 361. has a relatively low hardenability and is not typically
(2) High-strength, low-alloy, structural steel (normal- strengthened by heat treatment. Its primary yield and ten-
ized) (i.e., HSof MIL-S-22698, ASTM A 242, A 441, sile strength properties are primarily developed from its
A 572, and A 588Grade 50). microstructure of pearlite and ferrite. Mild steel’s chemis-
(3) Low-alloy steel with quench hardening and tem- try is basically carbon up to approximately 0.30%, man-
pering heat treatment before welding (i.e., T-1, HY-80, ganese up to approximately 1.5%, and a small amount of
HY-100, HY-130, ASTM A 514). silicon, with residuals ofphosphorous and sulfur.
120
-
High-strengthlow-alloy steels have similar micro- 6. What Special Treatmentsor Actions are Necessary
-
structures and chemistries as mild steel and they are to Maintain Base andWeld Metal Properties
strengthened by a fine-grained (small) crystal structure
There are no special routine treatments of these steels
created from small additions of elements such as vana-
other than when heavy sections are cut and welded. Due
dium, nickel, chromium, or molybdenum and frequently
to the rapid cooling rate of heavy sections, preheating in
receive normalizing heattreatment. This process consists
the range of 150°F to 200°F is sometimes advisable.
of heating the steel to approximately 1550°F and air
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SECTION IGWELDING METALLURGY: PRACTICAL ASPECTS
are pressure vessels, bridges, ballistic protection, ships, similar to those of the base metal. Filler metal carbon
mining, penstocks, and buildings. contents are typically less than 0.12%.
The designershould keep in mind that if mild steel or
grain-refined mild steel will meet the service require- 6. What Special Treatments or Actions are Necessary
ments, they should be used since they are easier and to Maintain Base and Weld Metal Properties?
more economical to fabricate.
Strict adherence to the manufacturer’s recommenda-
tions or code requirements is essential if the desired
2. Base Metal Corrosion Resistanceof Quenched and properties of these base metals are to be preserved. Pre-
Tempered Steels before Welding heat and interpass temperatures that are too low during
The quenched and tempered steels have only slightly the welding process can result in base metal and weld
better corrosion resistance than mild steel. They are rou- metal cracking. Probably the most frequent cause of
tinely painted for corrosion protection. Improved corro- cracking of these metals while welding is lack of ade-
sion resistance of these steels comes from the small quate preheat. When preheats are required they should be
amount of alloyingelements present. They are rarely gal- soaking preheats. Preheat is frequently required to pre-
vanized probably due to their susceptibility to hydrogen vent restraint cracking on heavier sections. Soaking pre-
embrittlement. heats can be verified by measuring the preheat on the
opposite (back side) of the weld joint.
3. Welding Effects on the Base Metal Properties of Preheats that are too highwill produce undesirable
Steels that are Quenched and Tempered before nonuniform microstructure. Preheat and interpass tem-
Welding peratures that are too high will result in low impact prop-
erties. This can cause adrastic loss in the ability toarrest
Weldingcanhave drastic effectsonthemechanical crack propagation during impact loadingparticularly at
properties of the base metal and their heat-affected zone low temperatures.
(HAZ). The heat-affected zone is the unmelted base Heat input that is too high is detrimental for good im-
metal area next to the weld having any noticeable effects pact resistance. Excessively high preheats, high interpass
from the heat of welding. These effects may include temperatures, high amperage, and slow travel speeds can
changes in mechanical properties.These steels are some- cause a retarded cooling rate. All in-process welding
what difficult to weld and special precautions must be conditions causingexcessive heatinput result in the same
observed if the yieldstrength, impact resistance and duc- outcome: aretarded cooling rate from peak welding tem-
tility are to be maintained. Improper welding techniques peratures. Retarded coolingrates cause a heterogeneous
can result in hidden cracks and cracking that may not microstructure that is more susceptible to fracture on im-
occur until many hoursafter welding is complete (hydro- pact loading.
gen embrittlement cracking). Welding heavy sections
without preheat and/or low interpass temperatures can Heat Input (J/in.) = Volts x Amps x60
result in extensive HAZ/fusion line cracking. Welding Travel Speed (ipm)
with excessive preheat andinterpass temperatures can re-
The maximumheat inputs shouldbe in accordance
sult in a loss of impact toughness.
with the applicable code, standard or qualified welding
procedure. Aserious loss of the metal’s ability to absorb
4. What Effects Does Welding have on the Base Metal energy without cracking canresult if excessive heat in-
Corrosion Resistance? puts are permitted. Stringer beads (straight-line progres-
Welding has little effect on the corrosion resistance of sion) having higher travel speeds than weaving beads
the base metal. (oscillating progression) are preferred, since this reduces
the heat input into the base metal and previously depos-
ited weld metal. It is importantto protect the weld metal
5. How Welds Develop their Mechanical Properties
properties. One of the most limiting factors in welding
Filler metalstypicallyhavechemical compositions these quenched and tempered steels is the marginal abil-
similar to base metals except they are not micro alloy ity of weld metal to match base metal toughness.
hardened by elements such as boron. They are frequently Stress relief as previously mentioned is generally not
alloyed with elements such as nickel, chromium, molyb- recommended. However, it is sometimes accomplished
denum and manganese. The carbon content is kept much for dimensional stability of weldments thatare to receive
lower thanthe base metal carboncontent. This is because close tolerance machining. Stress relief should only be
the weld metal goes through an extremely rapid quench accomplished if permitted by the manufacturer or the
and would be susceptible to cracking at carbon contents governing code or standard. The manufacturer’s or code
122
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-
requirements should be strictly followed. Usuallythis in- improve hardenability (the depth of hardening). These
volves stress relieving the part 50°F below the tempering metals often do not have mechanical property require-
-
temperature, if known, and sometimes it requires forced ments in their applicable base metal specification. Vary-
cooling to minimize the loss of fabrication impact prop- ing mechanical properties canbe selected by the user and
erties. Also, it is essential that the weld metal contain less are achieved by varying the heat treatment. These alloys
that 0.05% vanadium or the weld will be subject to seri- are used for machinery applications suchas gears, shafts,
--``,``-`-`,,`,,`,`,,`---
ous temper embrittlement. Since these alloys are subject and fasteners for increased wear, tensile strength, or
to serious embrittlement by improper heat treatment, sometimes for improved fatigue resistance.
post-weld stress relief should be under the direction of a The designer should keep in mind that if mild steel, or
welding engineer or a metallurgist. even the steels that are quenched and tempered before
welding (Le., HY-X0/100) will meet the service require-
7. Detrimental Elements that Reduce Weldability ments, they should always be used in lieu of these post-
weld heat treatable steels.
The most common element on earth, hydrogen, isalso
the most hazardous to welding quenched and tempered 2. Base Metal Corrosion Resistance of Quenched and
steels. Hydrogen is commonly produced when water, oil Tempered Steels after Welding
and rust are broken down in the arc. Procedures and tech-
niques to avoid hydrogen embrittlement cracking are dis- The quenched and tempered steels have only slightly
cussed in Section 12 of this manual. Other hazardous better corrosion resistance than mild steel. Theyare rou-
elements are those such as lead, tin, zinc, phosphorous, tinely painted for corrosion protection. Improved corrosion
sulfur, etc., that will form low melting temperature resistance of these steels comes from the small amountof
constituents. alloying elements. They are not typically galvanized.
123
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SECTION 16-WELDING METALLURGY: PRACTICAL ASPECTS
content is usually kept much lower than the base metal. frequently cause unacceptable distortionand scaling of
This is because the weld metal goes through an ex- close-tolerance machined components.
tremely rapid quench and is very susceptible tocracking
at carbon contents approaching the base metal. Under 7. Detrimental Elements that Reduce Weldability
special circumstances base metal or filler metals that
One of the most common elements on earth, hydro-
nearly match the base metal are used for welding.It is
gen, is also the most hazardous to welding these
common to use undermatching filler metal and rarely do
quenched hardenable steels. Proceduresand techniques
welds match the base metal mechanical properties, un-
to avoid hydrogen embrittlement cracking are discussed
less unique and specialized procedures are developed. in Section 12 of this manual. Other hazardous elements
However, post-weld heat treatment (PWHT) can be se- are those such as lead, tin, zinc, phosphorous, sulfur, etc.,
lected so that the resultant basemetal properties nearly that will form low melting temperature constituents.
approximate those attainable by the weld. In most cases,
designers must take into account that the welds will typi-
cally undermatch the base metal properties.
300 Series Austenitic Stainless Steel (An-
nealed) [304,310,316,321, 347 Corrosion-
6. What Special Treatments or Actions are Necessary Resistant Steel (CRES)]
to Maintain Base and Weld Metal Properties?
1. Strengthening Mechanisms of Austenitic Stainless
Strict adherence to manufacturer’s recommendations, Steel Base Metal
special developed procedures, or code requirements is Typical austenitic stainless steels usedin industry
absolutely essential if the desirable properties of these have 18% or more chromium and 8% or more nickel,
metals are to be achieved. Preheat and interpass tempera- with the remaining balance of approximately 50 to 60%
tures that are too low during the welding process can re- iron, and are sometimes calledthe 18-8 stainless steels.
sult in base metal and weld metal cracks. Preheats as Depending on the alloy type and application, the carbon
high as 600°F may be required. Qpically, these metals content will be 0.20% and less. Typically carbon is less
may require soaking times after welding at preheat tem- than 0.08% for corrosion resistance. Higher carbon con-
peratures to minimize cracking or they may require to be tent metals (309, 310) are commonly used where high-
immediately stress relieved, if post heat treatment for temperature strength is required. Austenitic stainless
mechanical properties will not occur until later in the steels are not strengthened by quench hardening, since
fabrication process. Probably the most frequent causeof their primary phase and structure do not change with
cracks while welding these metals is lack of adequate temperature as with the quenched and tempered steel al-
preheat. When preheats are required, they should be loys. Theirprimary yield and tensile strength properties
soaking preheats. Soaking preheats can be verified by are developed from what is called substitutionaland in-
measuring the preheat on the opposite (back side) of the terstitial alloy strengthening. The microstructure is auste-
weld joint. nitic at all temperatures with small amounts of carbides.
Generally, there are no welding heat input restrictions Austenitic stainless steels containing nickel, chrome, and
on these metals like those required on metals that are manganese with small amounts of silicon are sometimes
--``,``-`-`,,`,,`,`,,`---
quenched and tempered metals before welding. The rea- alloyed with molybdenum, titanium, niobium, or copper
son for this is the mechanical properties are achieved with residuals of unwanted sulfur and phosphorous. Aus-
through heat treatment after welding and the weld and tenitic 300 Series stainless steels typically have yield
HAZ are recrystallized during heat treatment. strengths of 35 ksi at room temperature, with very little
Since these metals are heat treated after welding, they loss of strength even atrelatively high temperatures. Ten-
are not usually stress relieved unless they are welded in sile strengths of 75-80 ksi are common with ductility of
30-35%. These steels are typicallyused for their high-
the heat-treated condition or following manufacturing
temperature yield strength, oxidation resistance forboth
processes makes it necessary to dimensionally stabilize
high- and low-temperature applications, and excellent
the metal or to reduce the hardness of the material (as
toughness. These steels are nonmagnetic.
might be neededfor machining). The manufacturer’s rec-
ommendations or code requirements should be strictly Galvanic Series. When any of these 300 series stainless
followed. When components are welded in the heat- steels are used in combination with a dissimilar metal for
treated condition, stress relieving is usually accom- sea-water service the galvanic series should be examined.
plished 50°F below the tempering temperature. It should This will help determine if accelerated corrosion can be
always be kept in mind that the temperatures reached expected due to the different metal being brought used in
during the heat treatment and the quenching process will the same system.The surface areas of the dissimilar met-
124
-
als can also greatly affect the amount and extent of corro- carbides, leaving the chrome available to form its protec-
sion. In general austenitic stainless steels are not tive oxide film. Stressed stainless alloys that have exten-
-
recommended for sea-water service environments. sive depletion of chrome by sensitization and are in a
corrosive halogen product environment, such as salt wa-
2. Corrosion Resistance of Austenitic Stainless Steel ter, may be subject to stress corrosion cracking. Stress
corrosion cracking can be extensive, penetrating com-
Austenitic stainless steels have excellent atmospheric
pletely through the base material thickness in a short pe-
corrosion resistance and resist corrosion very well at
--``,``-`-`,,`,,`,`,,`---
riod of time.
high temperatures. When alloyed with copper (320) it
has good corrosion and erosion resistance in sea water.
The iron in these austenitic stainless steels is protected 5. How Welds Develop their Mechanical Properties
from corrosion oroxidation by the formation ofa protec- and Corrosion Resistance
tive stable refractory chrome-oxide film. This tenacious
Stainless steel filler metals havechemistries similar to
film develops whenthe surface of the metal is exposed to
the base metals they are intended to weld. They develop
an oxidizing atmosphereand once formed prevents con-
their mechanical properties and corrosion resistance due
tinuing corrosion or oxidation. The continued presence
to their similar base metal chemistryand metallurgy.
of this oxide film is imperative to maintain corrosion
There is no significant improved corrosion resistance of
resistance. If service conditions cause the loss of this
the stainless steel weld metals over the base metal.
film, the material will be susceptible to corrosion. Also,
the effects of welding heat cancause aloss of the metal's Some stainless steel filler metals haveslight chemistry
ability to form these protective oxides. These metals are modifications to permit the development of delta femte
frequently used without painting. in the weld deposit. Fully austenitic welds have aten-
dency to fissure (develop smallcracks). When delta fer-
3. WeldingEffectsonStainlessSteelBaseMetal rite is present in the weld deposit the tendency for
Mechanical Properties fissuring is reduced. Stainless steel filler metals such as
308, 309, 316, all may contain small amounts (usually
Welding has very little effect on the mechanical prop- less than 10%)of delta femte when deposited. The stain-
erties of austenitic stainless steel base metals. Since less filler metal 312 typically has 40% ferrite and is very
austenitic stainless steels are not quench hardenable, the crack resistant. However, it should not be used for high-
HAZ does not exhibit increased hardness as a result temperature applications, as the soft and ductile delta fer-
of welding. These steels are readily weldable but do re- rite will change to a hard and brittle phase called sigma
quire some special controls to maintain their corrosion ferrire that is extremely crack sensitive.
resistance.
If the stainless steel has
been cold worked prior to weld-
6. What Special "keatmentsor Actions are Necessary
ing to increase its yield strength, the effects of welding
to Maintain Base and Weld Metal Properties
may cause a drastic loss of the base metal's yield strength
in the HAZ to approximately its annealed condition. Austenitic stainless steel welds are somewhat subject
to high-temperature fissuring. They are also subject to re-
4. Welding
Effects on Base Metal Corrosion duced corrosion resistance with increased potential of
Resistance stress corrosion cracking when sensitized. Sensitization
The effects of welding cancause aserious loss of cor- by chromium carbide precipitation takes place at 900°F
rosion resistance of the base metal adjacent to the weld. to 1500°F and is time dependent. Themore time spent in
For some service applications, the presence of carbon the sensitizing temperature range the greater the degree
and the heat of welding can result in reduced corrosion of chromium carbide precipitation. To minimize fissuring
resistance of some stainless steel alloys by the preferen- and sensitization, minimum preheats are used and inter-
tial formation of chromium carbidesin lieu of the protec- pass temperatures are kept low (350°F maximum). By
tive chrome-oxide films. This depletion of available keeping the preheat and interpass temperature low, less
chromium for oxidation resistance by the formation of time is spent at sensitizing temperatures and the amount
chromium carbides is called sensitization. Therefore, for of the base metal and degree of sensitization will be re-
special applications the carbon content may be held to duced. Avoiding high heat input welding processes will
0.04% or less (extra low carbon 308L or 316L) or addi- also lower the amount of time at sensitizing temperatures
tions of titanium (321) orniobium (347) may be made to and the amountof base metal subjectto sensitization. The
the base metal. The stabilizing elements of titanium and use of stringer beads is recommendedinstead of weave
niobium will form carbides, preferentially chromium beads, which minimizes heat input and sensitization.
125
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SECTION 16-WELDING METALLURGY: PRACTICAL ASPECTS
7. Detrimental Elements that Reduce Weldability 70:30 CuNi (70% copper-30%nickel) wrought metals
typically have yield strengths of 18,000-20,000 psi, and
Some stainless steels have selenium, phosphorous, or tensile strength of 45,000-50,000 psi with elongation of
sulfur additions to improve machining operations. These 20-35%. It is considered a hot short material having re-
steels are frequentlycalledfree machining steels (303-Se, duced ductility at temperatures above 1100-1400°F and
316F, 347F). These additions may cause porosity and/or is subject to high-temperature cracking while under
develop low melting temperature constituents that result stress.
in hot short cracking during welding. Welding of these al- NiCu (70% nickel-30% copper alloy), commonly
loys is not recommended. The contamination of weld called Monel@,has the highest tensile and yield strength
joints by low melting constituents cancause serious weld- of any ratio of nickel-to-copper contents. Its minimum
associated cracking. Lead contaminationfi-om radioactive tensile strength is 70-85 ksi and its yield strength is 23-
shielding or from machinists' hammers, sulfur from sulfu- 25 ksi with 35% minimum ductility.
rized cutting fluids, lead and tin from soft solder contami-
nation, and cadmium from silver brazing alloys, etc., are 2. Corrosion Resistanceof Copper and Nickel Alloys
examples of potential sourcesof contamination.
Carbon contamination can havea serious effect on the These alloys haveexcellent atmospheric and corro-
sion resistance. These metals are frequently used without
corrosion resistance of stainless steels; therefore, it must
be considered a detrimental contaminate. Its potential painting.
sources are shop dirt, grease, oil, paint, shellac, antispatter
compounds, and carbon arcing slag. CuNi-90:lO
It is typically used for water corrosion resistance with
Copper-Nickel and Nickel-Copper Base good antifouling resistance. This alloy has a higher iron
Metals [90:10 CuNi, 70:30 CuNi, and content than the 70:30CuNi alloys, which improves its
strength and corrosion protection. This alloy performs
--``,``-`-`,,`,,`,`,,`---
126
affect the amount and extent of corrosion. These alloys ations. These are frequently calledfree machining alloys.
are frequently recommended and used for water-service These additions may cause porosity and/or develop low
environments. melting temperature constituents thatjeopardize welding
due to hot short cracking. Welding of these alloys is not
3. Welding
Effects
on
Base
Metal
Mechanical recommended.
Properties The contamination of aweld joint bylowmelting
Welding has very little effect on the mechanical prop- constituents can cause seriousweld-associated cracking.
erties of nickel alloys and copper base metals. Since Lead contamination from radioactive shielding or from
these alloys are not quench hardenable the HAZ does not machinists' hammers, sulfur from sulfurized cutting flu-
exhibit increased hardness as a result of welding. These ids, lead, tin or zinc from soft solder contamination, and
alloys are readily weldable but do require some special cadmium from silver solder,etc., are all potential sources
controls to minimize cracking and weld porosity. If any of contamination.
of these alloys have been cold worked prior to welding to
increase its yield strength, the effects of welding may
cause a drastic loss of the base metal's yield strength in Castings
the HAZ, approximating its annealed condition.
Copper and nickel alloy components that are castings
4. Welding Effects on
Base
Metal
Corrosion and are not made by weld fabrication should always have
Resistance suspected poor weldability. Because of the ironcontents
permitted in these castings and the higher silicon con-
The effects of welding have little effect on the corro- tents to facilitate pouring operations, some of these cast-
sion resistance of the adjacent base metal. ings have extremely limited weldability. Unless properly
alloyed for weldability, they may experience extensive
5. How Welds ObtainMetalStrengthening
and fusion line cracking.
Corrosion Resistance
For Monel@ castings, iron and silicon contents must
Filler metals for welding alloys of nickel and copper be held low, preferably at 1.7%. Niobium is also required
have chemistries/compositions similar to the base metals to minimize the harmful effects that silicon hason the
they are intended to weld. They develop their mechanical weldability of Monel@". Niobium-to-siliconratios of 1.S
properties and corrosion resistance due to their similar to 1.8 are believed to be adequate to minimize weld
base metal metallurgy. There is no significant improved cracking caused by silicon. A Nb/Si ratio of 1.7 is con-
corrosion resistance of weld metals over the base metal. sidered optimum. Iron content above 2% is a major con-
In the case of Monel*filler metal (70% Ni/30% Cu), it is tributor to both weld metal and heat-affected zone
found that under some wet conditions, thesefiller metals cracking. Also, shielded metal arc welding (SMAW) has
will preferentially corrode over similar composition base slight advantages overgas tungsten arc welding (GTAW)
metals. Monel* welds on wetted surfaces of Monel@ for casting repairs.
castings will often preferentially corrode in lieu of the
base metal.
Some copper and nickel alloys have selenium, phos- . Welding Metallurgy, 4th ed., vol. 1, Fundamen-
phorous, or sulfur additions to improve Machining oper- tals (WM1.4). Miami, Fla.: American Welding Society.
127
--``,``-`-`,,`,,`,`,,`---
^‘^TION 17
Arc Stud
Welding
Contents
Introduction ............................................................................................................................. ............................-.-........130
--``,``-`-`,,`,,`,`,,`---
How a Stud is Welded ..................................................................................................................................... ............... 130
.._................,........_........_..........._................................................................................ .. ......... 130
Elements of a Stud Weld
..........................................................................................................
Testing and Judging Welds .............................-.-..131
Operating Instructions ..._._.
....._... ..._._. ....................,................._...
..._._. ....................................................................... ...13 1
Setting Up to Weld ............................................................................................ .................................. .......................... 132
Gun ......................._.
How to Handle the Stud Welding ........,..... ........................................................ ........... 132
..._._.
....._.
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SECTION 17- ARC STUD WELDING
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130
make sure that the stud moves freely through the ferrule.
If there is any binding, readjust foot assembly until free
Figure 17.2-Gun Accessories action is obtained.
--``,``-`-`,,`,,`,`,,`---
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SECTION 17- ARC STUD WELDING
Setting u p to Weld (See Figure 17.3) proximate and will vary with the type of application.
Note that the power supply may not be
calibrated to indi-
Turn power OFF when making connections. cate actual welding current.
(1) Position the control unit and the power supply as
near the work area as possible. Excessive cable lengths
adversely affect stud welding. How to Handle the Stud Welding Gun
(2) Connect the ground cable to the terminal of the (1) Hold the gun firmly with your hand placedso that
power supply (positive or negative ground orientation you can readily press the trigger.
must be determined by the weld procedure test data). (2) Keep your handoff the side cable.
Secure the c-clamp to the work plate. Make sure both (3) Hold the gun square/perpendicularto the work.
connections are tight and eradicate any paint or rust at (4) Be sure the ferrule is seated firmly against the
the connection points. workpiece.
(3) Connect the timer input cable to the other termi- ( 5 ) Pressthegun’s trigger onlyonce andrelease.
nal of the power supply and to the connector marked Pressing the trigger a second time will damage the chuck
“power supply” on thecontrol unit. or stud threads.
(4)Connect the control unit ground clamp tothe (6) Do not move the gun duringthe welding action.
work plate. This completesthe electrical path needed to (7) After welding the stud, draw the gun straight back
supply power to the control unit. away from the workpiece. Avoid pressing the trigger
( 5 ) Connect the combination cable(control and weld- again.
ing cable) to the control unit and the gun.
(6) Make sure the power supply is set for required po-
larity, and that the input cable and the ground cable is Bibliography/Recommended Reading
properly connected. The power supply is typically a con- List
stant voltage (CV) type and should have a minimum
open circuit voltage of 65 volts dc. American Welding Society. Recommended Practicesfor
--``,``-`-`,,`,,`,`,,`---
Stud Welding ((25.4). Miami, Fla.: American Welding
(7) Turn on the power supply and the control unit. The
Society.
light onthe control unit should lightindicating that power
is available andis connected for the required polarity. . Welding Handbook, 8th ed., vol. 1, Welding
(8) Adjust the time on the control unit and current Technology (WHB-1.8). Miami, Fla.: American
setting of the power supply.The settings provided are ap- Welding Society.
132
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SECTION 18
Thermal Spray
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Fundamentals
Contents
Why Use the Thermal Spray Process?........................................................................................................................ 134
Fundamentals................................................................................................................................................................. 134
133
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Section 18-Thermal Spray Fundamentals
WhyUsetheThermalSprayProcess?Fundamentals
The thermal spray process is used primarily for two Before a machinerycomponent is repaired (¡.e., to
reasons: build up worn areas) using a thermal spray process,the
repair area is undercut. Standardpractice is first to clean
(1) Corrosion control. the component to be thermal sprayed, and then use an
(2) Machinery component refurbishment. aluminum oxide grit blast to create an anchor tooth pat-
tem for the coating to lock into. When repairing machin-
ery components, thermal spray materials are used as
Corrosion Control Applications bond coats to create a mechanical interaction between
the substrate and the coating.
More than 20 years of corrosion protection of steel
and iron can be obtained by applying thermal sprayed
aluminum or zinc coatings. In a wet environment, these Thermal Spray Processes
coatings can serve as anexpendable anode,preventing or
minimizing corrosion of steel and ironsubstrates. By definition, thermal spray is heating a metallic or a
Because of the portability of arc and flame spraysys- nonmetallic material, in a heating zone to a molten or
tems, many components can receivea corrosion-preventing semi-molten state, and then propelling that material onto
coating either in the shop or in the field. Examples of a substrate to form a coating. There are four primary
some of the items that have received this corrosion control spray processes used by fabricators at this time: plasma
method are valves and piping. powder process, arc wire process, flame powder process,
and flame wire process.
Plasma Powder
Machinery Component Applications
With the plasma powder process, the heating zone is
The thermalsprayprocesscanbe a cost-effective produced by an arc that is created inside the plasma pow-
method for dimensional restoration. The processis an ex- der gun between a tungstenelectrode and the nozzle. A
cellent repair method and should be considered, when gas or gasmixture is passed throughthe arc. This excites
appropriate, in lieu of other processes, suchas weld re- the gas into a plasma state, creating temperatures higher
pair, chrome plating, or instead of manufacturing of a than can be obtained with just oxygen fuel flame mix-
new component. tures. The gas or gasmixture exits the nozzle, forcing the
Thermal spray is also used to enhance the service life plasma flame outside the gun. A powder is fed intothe
of many machinery components. Ceramics can be flame, melted, and propelledto the substrate by the force
sprayed on packing areas of valve stems andpump shafts of the gas or gas mixture(see Figure 18.1). The plasma
to give those areas a smoother, longer-lasting surface powder process is used primarily forthe refurbishment
than the substrate material. This will also cause less dam- of machinery components.
age to the packing msterial and provide better operation
of the component. Thermal sprayed metallic coatings Arc Wire
that will resist wear, erosion, corrosion, heat, and chemi-
cal attack better than the substrate material can be ap- The heating zone of the arc wire process is produced
plied to machinery components. by creating an arc between two continuously fed metallic
134
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-'I
NOZZLE SPRAY DEPOSIT
TUNGSTEN (COPPER
NODE) CATHODE
/
f PLASMA "
2
--``,``-`-`,,`,,`,`,,`---
b U l Y 1 V L bIIWIV
4TER IN'
AND
WATER OUT AND
wires. The heating zone meltsthe wires and the molten Flame Powder
material is atomized and propelled to the substrate by The flame powder process uses an oxygen fuel flame
compressed air or an inert gas (see Figure 18.2). The arc to create the heating zone. Powder is fed into the heating
wire process can be used for corrosion control and ma- zone and melted, The molten material is then atomized
chinery refurbishment applications. and propelled to the substrate by the force of the burning
gasses and compressed air (see Figure 18.4). The flame
Flame Wire powder process is used primarily for machinery refur-
bishment applications.
The flame wire process uses an oxygen fuel flame to
create the heating zone. A wire is then continuously fed
into the heating zone where it is melted and then pro- Finishing Thermal Sprayed Coatings
pelled onto the substrate by the force of the burning gas-
ses and compressed air (see Figure 18.3). The flamewire The structure of a thermalsprayedcoatingmaybe
process can be used for corrosion control and machinery different than the structure of that same material in
refurbishment applications. wrought form, Sometimesthis different structure creates
SPARK PLUG
7 SPRAY
SPRAYED-
MATERIAL
POWDER -
INERT P U R G E GAS
SUBSTRATE
U
FUEL GAS
135
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STD*AWS DPW-ENGL 1999 m 07842b5 0519b2b 503 9
SECTION 18-THERMAL SPRAY FUNDAMENTALS
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GAS
SPRAY DEPOSIT
BURNING GASES
SPRAY STREAM
ATOMIZINGAIR J
PREPARED~
SUBSTRATE
136
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STDmAWS DPW-ENGL 1999 9 07842b5 05Lqb27 4 4 T
SECTION 18-THERMAL SPRAY FUNDAMENTALS
-
problems in finishing. If personnel are unfamiliar with with the mating part. This makes it possible to form a
the finishing of coatings, they should follow the thermal precise seal.
spray equipment and material manufacturer's recommen-
~
137