Advanced Steel Design - Welds

3/11/2019
ADVANCED STEEL COURSE
WELDS AND WELDING
AMANUEL GEBREMESKEL
UNIVERSITY OF WITWATERSRAND
CHAPTER 4:
WELDING ISSUES
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Chapter 4: WELDING
 Overview
 Welding processes
 Welding consumables
 Weld positions and joint types
 Weld preparations
 Weld procedure specifications & welder
qualifications
 Minimum size welds to plate thickness
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Chapter 4: WELDING
 Preheating
 Weld defects
 Non destructive testing
 Weld symbols
 Access for welding
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Overview
 Fusion welding –apply intense heat to a
joint between 2 parts to melt and
intermix the constituent parts .Upon
cooling and solidification a bond occurs.
 4 main types are commonly used in
structures.
 Many others for special applications
such as mixed metals, stainless steels
etc.
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ARC WELDING TYPES
 Shielded Metal Arc Welding (SMAW)
 Gas Metal Arc Welding (CO2
Mig/Mag)(GMAW)
 Submerged Arc Welding (SAW)
 Flux Cored arc welding (FCAW)
• Electro Slag Oxy Acetylene Gas
• Gas Tungsten Arc (TIG)
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WELD POOL PROTECTION
The basic objective of any weld
process is to protect the molten pool
from contamination by Not
Desirables either from within the
Molten pool or from “the
atmosphere”
WELD POOL PROTECTION
“The atmosphere” by not letting the air
(especially hydrogen ) come into contact
with the pool till the “fused” weld
solidifies from the molten weld pool.
We do this by means of chemical
reactions and gas barriers
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WELDING SPEED‐CURRENT
 The higher the current the greater will
be the rate of deposit of weld
 The following processes are discussed
in order of speed of weld deposit from
slowest to fastest
WELDING SPEED‐CURRENT
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SMAW THE PROCESS
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MIG/MAG or CO2CO2
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GMAW THE DETAIL
GMAW AUTOMATIC
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FCAW THE DETAIL
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SAW –SUBMERGED ARC
 Good quality weld‐good penetration
 Highest deposition rates due to high
currents
 Limited to flat uses due to granular flux
 Specialist equipment necessary
SAW THE PROCESS
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SAW THE DETAIL
SUBMERGED ARC PROCESS
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CONSUMABLES
 We recommend E70xx wire the so called
“Low Hydrogen” welding wire for steel
S355JR.
 Ensure that if flux coated E70 rods are
used that they are stored in a dry
environment.
 Ensure that they are kept in a warming
oven once removed from the original
plastic packing
 Do not be scared to look at the welding
wires packaging all the information is on
it
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Welding electrode types
• E6013 In SA
used only for
non‐ structural
• E7018 used
for
structures
Summary of consumables for
main structural weld processes
Process AWS Specification Electrode European

equivalent
SMAW AWS A5.1 E70XX E48XX *

SAW AWS A5.17 F7XX-EXXX
GMAW AWS A5.18 ER70S-X
FCAW AWS A5.20 E7XT-X
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WELDING POSITIONS
Lousy over head welding
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Lousy over head welding
What do those names of
consumables tell us
 All processes covered in detail in Chapter 6
 E70XX used for SMAW (stick welding)
 E designates Electrode
 70 Ultimate tensile strength in kips x 6.9
gives Mpa
 First X for weld position
• 1= all positions
• 2 = horizontal or down hand only
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What do those names of
consumables tell us
 E70XX continued
 Second X is a number between 1 & 8
 Defines chemical composition of flux.
 8 is the most common
• Low hydrogen
• Iron powder
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Welded joint types
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WELDING TYPES
Butt weld with full penetration
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Fillet weld side on, triangular
in shape
Smooth surface, equal leg
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lengths WWW. SAISC.CO.ZA 35
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SPECIFIYING WELDING
 Suggested code:
 Main structural welding for South Africa
• American welding society
• Structural welding code AWS D1.1.00
Welding process management EN3834
• SABS and BS are not preferred
• Called up in our design codes
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WHY AWS ?
 SAISC has promoted the use of this
specification for nearly 20 years
 Most recognized SA fabricators are using
the code.
 The code is intelligently laid out and user
friendly
 The code has a series of pre‐qualified welds
which can form the basis of a WPS (Weld
Procedure Specification)
Weld Procedure Specification
 What is a pre‐qualified weld procedure
specification ?
• For a given material, weld process, type
and size the pre‐qualified weld defines the
“Weld Procedure specification” i.e. the
preparation, weld wire type and size,
current, (voltage which can be varied in
submerged arc process), speed, number of
runs, gas flow rates etc which would result
in a good quality weld if strictly adhered to
by a qualified welder.
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Welder qualification
 Welder qualification requirements are
clearly defined (coding)
 In SA very few welders are qualified to
do all types of welds in all materials
 So we code welders to weld on WPS’s
 Valid for a year, with ID and picture
 Renewable without test if welder
continues to regularly do this type of
weld
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OTHER COMMENTS
 Good quality welding is a mind set –
unless the welder knows that his welds
are going to be tested they will not be
of the best quality
Minimum weld sizes‐no pre‐heat
to prevent cracking out of weld
Thickness of thicker part (mm) Minimum fillet weld size (mm)

Up to 12 5
Over 12 to 20 6
Over 20 to 40 8
Over 40 to 60 10
Over 60 to 150 12
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Note:
Preheating requirements
Steel Weld process Low Thickness of Minimum

grade hydrogen thicker part preheat
electrodes (mm) temperature
(ºC)
300/S355 SMAW, SAW, E70, F7, 3-20 10
JR GMAW,FCAW ER70, E7
300/S355 SMAW, SAW, E70, F7, +20-38 20
300/S355 SMAW, SAW, E70, F7, +38-65 75
300/S355 SMAW, SAW, E70, F7, +65 100
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Note:
•Notes relating to preheat table

•This table should be read in conjunction
with Table 6.26 which specifies the
combination of minimum size of SMAW
fillet weld and thickness of plating which
will not require preheating.
•When welding materials of unknown
grade or weldability pre-heating to at least
75 °C is recommended (e.g. EN 9 or EN 19
or deformed reinforcing bar etc)
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Note:
•Preheating is measured 75 mm away

from the weld
•It is intended to slow the cooling down to
prevent self cracking
•It is controlled with tempil sticks (crayons
that change colour at the temperature
capacity of the crayon)
•Digital thermometers
•Tack welds do not normally require pre-
heating
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WELDING DEFECTS ‐ CRACKS
 CRACKS 100 series defects
 Cracks Longitudinal.
 Cracks transverse
 Crater cracks
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WELDING DEFECTS ‐
CRACKS CRACKS
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CAVITIES AND POROSITYSITY
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Rusted
plate
Cleaned
plate
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INCLUSIONS
 SOLID INCLUSIONS 300 series defects
 Solids slag inclusions during multi‐pass
welds
 Solid flux inclusions during subarc welds
LACK OF FUSION/PENETRATION
 INCOMPLETE FUSION LACK OF
PENETRATION 400 series defects
 Fusion‐wrong speed, current too low,
wrong diameter welding rods
 Fusion‐bad joint design
 Fusion‐bad fit up during assembly
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INCOMPLETE FUSION
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UNDERCUT/OVERLAP
 BAD SHAPE‐UNDERCUTS‐OVERLAPS
500 Series defects
 Undercut‐bad operator, current too
high, rod diameter too big
 Bad profile‐wrong travel speed,
incorrect electrode type, bad operator
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UNDERCUTS BAD SHAPES
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BADLY SHAPED WELDS
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LAMELLAR TEARING
 3 Conditions required:
• Strains to develop in the “through”
direction of plates –usually by shrinkage
caused by welding
• Weld orientation such that stress acts
through the plate
• Poor ductility for material in “Z”
direction‐usually from sulphide or oxide
crystals
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DISTORTION FROM WELDING
 The rapid high input of heat due to
welding and the subsequent slow
cooling down causes “welding
distortion”
 This is worse when welds are applied
eccentrically to a weldment
 See the attached examples
DISTORTION
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NONDESTRUCTIVE TESTING
METHODS
 Visual inspection before during and
after welding
 Magnetic particle
 Liquid penetrant
 Radiographic
 Ultrasonic
AWS visual inspection summary
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MAGNETIC PARTICLE
MAGNETIC PARTICLE
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LIQUID DYE PENETRANT
Radiography (X rays)
RADIOGRAPHY‐X‐RAY
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ULTRASONIC INSPECTION (UT)
ULTRASONIC
NDT METHODS TO FIND DEFECTS
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HOW MUCH NDT?
• For important full penetration groove
welds (CJP) in tension, 100% of the welds
•For less important CJP welds, 10% testing
to start.
• How to interpret “10%”
• is it the first 10% of all the welds,
• is it 10% on the length of each weld,
• or is it the whole length of every
tenth weld?
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How much NDT ? contd
It is good practice to:

• NDT at least the first two lengths of weld
in their entirety to establish confidence
• Then to reduce it to one of the latter
two 10% interpretations.
• 10% of all important fillet welds should
have magnetic particle.
• Reduce this to 5% when confidence
has been established
• or eliminate it completely
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Weld symbols
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WELDING SYMBOLS
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Weld symbols continued
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Quality plans / QA
Contractors Quality Plan

Prepare a quality plan for every component or
group of similar components.
Containing the following minimum information:
Source of information:
• Reference source documents
•design,
•drawings,
•Code
•specifications, etc.
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Quality plans / QA

Non-welding requirements:
• Confirm correct grade of steel is used.
• Dimensional check components to detail
drawings
• Weld sizes, etc.
• Special requirements e.g. client inspection or
witnessing.
• Corrosion protection, preparation, coating
and records of
thicknesses, etc.
• Erection to line, level and verticality tolerance,
tightening of bolts, etc.
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Quality plans / QA

Welding requirements:
• A weld procedure specification (WPS) for each
type and position of covering details of weld:
• (edge) preparations
• preheating requirements,
• the welding process & consumables,
• current and speed settings,
• gas flows and every other aspect of the weld.
• Current welder qualification papers by
procedure
• This also applies to tack welding. 86
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Quality plans / QA

Welding requirements: continued:
• Visual inspection reports covering the requirements of
AWS D1.1 Table 6.1.
• Weld preparations and set up before welding
commences.
• NDT reports and acceptances.
• Repair procedures for work that is not acceptable, with
WPS’s for the repair procedures.
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Clearances for the welder
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Clearances for the welder
SMAW process,
Welder must hold electrode,
• 4,8 mm dia
• 350mm to 450 mm long,
• in full control,
• in a position so far end of the
rod is in near contact with the
base metal.
• He observe through a dark glass
in a bulky helmet.
• Must keep control of electrical
cable
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Clearances for the welder special
case
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Clearances for the
welder special case
• Special case of minimum clearance (straight

electrode)
• The 20° angle is the minimum to allow good
welding along the bottom of the angle
• It governs the setback to the end of the beam.
• For a 12mm setback / 4.8mm electrode
clearance between the angle and the flange
beam >26 mm 75mm leg >36 mm 100 mm leg
• Optional cut improves the situation.
• The cut costs money.
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3/11/2019

Process AWS Specification Electrode European

SMAW AWS A5.1 E70XX E48XX *

Thickness of thicker part (mm) Minimum fillet weld size (mm)

Steel Weld process Low Thickness of Minimum

•Notes relating to preheat table

•Preheating is measured 75 mm away

It is good practice to:

Contractors Quality Plan

Contractors Quality Plan

Contractors Quality Plan

Contractors Quality Plan

• Special case of minimum clearance (straight

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