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BARODA BRANCH
202, Arckie View Complex, Tower-A,
Atmajyoti Ashram Road, Opp. WaterTank,
Vadodara 390 023
STRESS CORROSION :
It may be influenced by weld metal & HAZ,
microstructure & residual stresses, geometric stress
risers & planar discontinuities to the extent they intersect
the surface in the corrosive environment.
Cont..
BRITTLE UNSTABLE FAILURE:
Cause greatest concern.
Indicative of full thickness abrupt failure to normally
ductile materials at applied stresses which do not exceed
the cross section yield stress.
FATIGUE- HIGH CYCLE, LOW CYCLE.
90% of all disruptive failure.
Often precedes the onset of brittle failure.
Discontinuities act as a stress riser thus enhance the
propagation of the crack.
METHODS USED TO DETECT
DISCONTINUTIES.
DESTRUCTIVEW NON DESTRUCTIVE
METHOD: METHOD:
Normally performed Often employed to
to qualify a procedure, ensure the quality of
process consumables the weld which is to
or welder for a be put into service.
particular application.
To verify the
conformance of
mechanical properties
of the weld.
APPLICABLE INSPECTION METHODS Vs
DISCONTINUITIES.
Discontinuities RT UT PT MT VT ET
Porosity A O A O A O
Slag Inclusions A A NA O NA O
Incomplete Fusion O A NA O NA O
Inadequate joint
A A NA NA NA O
preparation
Under cut A O O O A O
Overlap NA O A A O O
Cracks 0 A A A A A
Laminations NA A A A A NA
Porosity . .
SPATTERS
SPATTERS
Spatters
Cause Remedy
1) Low Voltage 1) Increase Voltage
2) Inadequate Inductance 2) Increase Inductance
3) Rusted BM surface 3) Clean BM surface
4) Rusted Core wire 4) Replace By Rust
5) Quality Of Gas Free wire
5) Change Over To
Ar + Co2
Spatters
LACK OF FUSION
This term is
commonly used to
denote conditions
caused by a lack of
complete melting &
coalescence of some
portion of the metal
in a joint.
LACK OF FUSION
LOF may occur
either between weld
beads or between
weld & base metal.
Lack Of Fusion
Cause Remedy
1) Inadequate Current 1) Use Right Current
2) Inadequate Voltage 2) Use Right Voltage
3) Wrong Polarity 3) Connect Ele. + Ve
4) Slow Travel Speed 4) Increase Travel
5) Excessive Oxide On speed
Joint 5) Clean Weld Joint
Lack Of Fusion
UNDERCUT
Undercut is a groove
melted into the base
metal adjacent to the
weld toe or root and UNDERCUT
unfilled by weld
metal.
Undercut
Cause Remedy
1) Excess Voltage 1) Reduce Voltage
2) Excess Current 2) Reduce Current
3) Improper Torch angle 3) Train & Qualify the
4) Excess Travel Speed Welder
4) Reduce Travel Speed
Under cut
OVERLAP
Uneven and
excessive welding
called overlap.
OVERLAP
Cause Remedy
1) Too Long Stick Out 1) Reduce Stick Out
Overlap
SLAG INCLUSION
This term is used to describe the oxides or other
non metallic, solid materials that the entrapped in
weld metal or between the weld metal & base metal.
There are two type of slag inclusions:
LINEAR SLAG INCLUSION: Continuous or broken
lines of slag situated parallel to the axis of weld.
ISOLATED SLAG INCLUSION: (Scattered)
There are slag inclusions of irregular
shape distributed within the weld.
SLAG
Cause Remedy
1) Inadequate Cleaning 1) Clean each bead
2) Inadequate Current 2) Use Right Current
3) Wrong Torch angle 3) Train / Qualify welder
4) Improper bead 4) Train / Qualify
placement Welder
Slag
CRACK
Cracking is frequently caused by metallurgical related
phenomena and many theories exist to account for the
formation of various types of cracks. They can be
broadly placed into two general categories:
COLD CRACKING: Low temp. cracking which
includes weld metal & HAZ hydrogen assisted
cracking and lamellar tearing.
HOT CRACKING: High temp. cracking which
includes solidification cracking, liquidation
cracking, ductility dip cracking and reheat
cracking.
CRACK
Cause Remedy
1) Incorrect Wire 1) Use Right Wire
Chemistry 2) Increase wire Feed
2) Too Small Weld 3) Preheat Uniformly
Bead 4) Post heating or ISR
3) Improper Preheat
4) Excessive Restrain
crack
LACK OF PENETRATION
This term is used to
describe a condition
where failure of filler
metal and base metal
to fuse
integrally.Three
categories of LOP:
LOP at root.
LOP at interpass.
LOP atsidewall.
LOP
Lack Of Penetration*
Cause Remedy
1) Too Narrow Groove 1) Widen The Groove
Angle 2) Increase Current
2) Too Low Welding current 3) Train / Qualify
3) Wrong Torch angle Welder
4) Puddle Roll In Front Of 4) Correct Torch
Arc Angle
5) Excess root face. 5) Reduce root face.
6) Oversize filler wire. 6) Reduce filler wire
size.
* Applicable to SSFPW
LOP
TUNGSTEN INCLUSION
Cause Remedy
1) Ineffective HF 1) Rectify HF Unit
2) Improper Starting of 2) Never Touch Weld
Arc. With Tungsten Rod.
3) Tungsten Tip Comes in 3) Train / Qualify
Contact With Weld welder.
Tungsten Inclusion
SUCK BACK*
Cause Remedy
Suck Back
BURN THROUGH*
Cause Remedy
1) Excess Current 1) Reduce the Current
2) Excess Root opening 2) Reduce root opening
3) Inadequate Root face 3) Increase root face
4) Improper weaving. 4) Train / Qualify
5) Too low travel speed. Welder.
5) increase travel
speed.