iiw -welding defects
DESCRIPTION
WELDING DEFECTS POWER POINT PRESENTATION.TRANSCRIPT
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Definition :
The change in the geometry or composition of an
object, it may be intentional or unintentional.
Such changes inherently affect the physical propertiesof the object and may in turn have an effect on the
objects ability to fulfill its intended use or service life.
Every discontinuity is not a defect but every defect is adiscontinuity.
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Discontinuity is categorized in four stages
Inherent discontinuities.
Primary processing discontinuities.
Secondary processing discontinuities.
Service induced discontinuities.
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Porosity
Location : Surface or Subsurface
Cause : Vaporized constituents in the molten eld metal are entrapped
during solidification.
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Cluster Porosity
Location : Surface or Subsurface
Cause : Vaporized constituents in the molten eld metal are entrapped
during solidification.
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Slag nclusion
Location : Subsurface
Cause : Improper cleaning of previous eld pass and mi!ing of o!ides
on the base metal surface into the eld pool
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!ac" of Penetration
Location : Surface or Subsurface
Cause : Inade"uate penetration of the eld #oint root by the
eld metal.
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!ac" of #usion
Location : SubsurfaceCause : $ailure of filler metal to coalese ith the base metal
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joint groove can be characterised as follo$
% i& The distance that fusion e'tends into the
base metal is called depth of side$all
fusion
% ii& Depth of $eld bead in previous $eld
bead is called penetration depth,
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()*+ : ead to ead Penetration
(-*+ : Side (all #usion
d : Penetration depth
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#actors affecting Side$all #usion
% (elding oltage
% (elding Current
% (elding Speed% Shielding gas
% Cast of Electrode
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%ider $used &one
Sideall
'ndercutting
Slag (ntrapments
)urn )ac* of the +ip
,ptimal
Voltage
Loer -eat Input
Lesser -eat Into the Sideall
Incomplete $usion into the Sideall
Intensive Spatter Short Circuiting
(elding oltage
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(elding Current
%Deposition rate, arc stability and bead geometry $ill effectby $elding current. (eld bead depth $ill increase $ithincreasing $elding current. Current is basically directfunction of the $ire feed rate. Deposition rate $ill increase$ith increasing the $ire feed rate. ncreasing current
results into deep penetration into the bottom of the jointmuch faster than into side$alls and there $ill beunfavorable bead configuration.
% To over come this problem the current is "ept proportional
to travel speed.
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(elding Speed
% (elding speed is set accordance $ith other$elding parameters /namely $elding current,$elding voltage&.
%(eld bead $idth is inversely related to travelspeed. 0t lo$ travel speed, a large molten poolmay be created, $hich $ill flo$ under the arc. tmay cause incomplete fusion into the side$allsand bet$een layers of deposited metal.
% 0t high $elding speed, heat input $ill beminimum and it $ill leads to incomplete fusion tothe side$alls.
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% Shielding gas : Penetration pattern
/0r,C1- and 2i'ture&
% C1- have higher thermal conductivity than argon. #or a
given $elding current and arc voltage, the heat input is
higher for more thermally conductive gas, $hich resultsinto deeper penetration and higher deposition rates. The
greater penetration of C1- usually allo$s the use of
higher $elding speed. Thus, higher $elding speed and
higher deposition rate provides higher productivity in$elding
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% The addition of C1- gas /in argon& dissociates $ith increasingtemperature into carbon mono'ide and o'ygen. This liberated o'ygenreact $ith iron and forms #e1. This #e1 is easily melted at higher
temperature and remain fluid. This increases the fluidity of the $eldpool and the ease $ith $hich it $ets the side$alls and also improvedthe bead shapes, the height of over fill is greatly reduced and $eld$idth is increased. This change in bead shape may be because ofreduction in surface tension of molten metal in the $eld pool
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% Suc" ac"
Location : Surface or Subsurface
Cause : here the eld metal has contracted as it cools and has been
dran up into the root of the eld.
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nternal 3ndercut
Location : Surface
Cause : ,ver sized eld pool /related to e!cessive amperage0 travel
speed and electrode size.1
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E'ternal 3ndercut
Location : Surface
Cause : ,ver sized eld pool /related to e!cessive amperage0 travel
speed and electrode size.1
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1ffset or mismatch
Location : Surface
Cause : here to pieces being elded together are not properly
aligned.
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Cold 4 5ot Crac"
Location : Surface or Subsurface.
Cause : 2 combination of atomic hydrogen0 hardenable material
and high residual stress.
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nade6uate $eld reinforcement!ocation : Surface
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E'cessive $eld reinforcement
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Tungsten nclusion
Location : Subsurface
3olten pool or filler metal comes in contact ith +ip of +ungsten
(lectrode
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urn Through
Location : Subsurface
Cause : +oo much heat causes e!cessive eld metal to penetrate
the eld zone
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Secondary processing Dis.
+rinding Crac"s!ocation : Surface
Cause : !ocali7ed overheating of the material due toimproper grinding procedures.
5eat Treating Crac"s!ocation : Surface
Cause : 3neven heating and cooling that producesstresses e'ceeding the tensile strength of the material.
8uench Crac"s
!ocation : Surface
Cause : Sudden cooling from elevated temperature
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Service induced discont.
#atigue
Location : Surface
Cause : Cyclically applied stress belo the ultimate tensile strength.
Creep
Location : Surface
Cause : 3aterial sub#ected to elevated temperatures and stress belothe yield strength.
Stress Corrosion Crac"ing
Location : Surface
Cause : Combined effect of static tensile load and corrosiveenvironment.
5ydrogen Crac"ing
Location : Surface
Cause : Combined effect of applied tensile or residual stress andhydrogen enriched environment.