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VIJAYAN M G
Qualmet Services 1
Welding v casting
Weld must adhere to mould wall
Heat is added continually to welds
● High temperature gradient
Welds solidify much faster than castings
In welds, the surface shape is constant
There is strong mixing of weld pools
Qualmet Services 2
Fusion weld structure
Fusion line
Weld preparation
Base Weld metal
HAZ HAZ
metal
Qualmet Services 3
Thermal gradients in HAZ
Temperature
Fusion line
Fusion line + 2mm
Fusion line + 5 mm
Time
Qualmet Services 4
HAZ structure
High peak temperature
High temperature gradient
● Variable cooling rate
Superimposed HAZs in multipass welds
Welding stresses affect transformation
Qualmet Services 5
Multipass fusion weld
Last weld run
Previous weld run
Qualmet Services 6
Weld properties
Weld metal has different composition &
thermal history to base metal
Welding heat modifies adjacent base metal
(HAZ)
Variation in strength, ductility & corrosion
resistance across welds
Qualmet Services 7
Welding procedure
Selection of process conditions &
consumables for a weld
Designed to match base material properties
as closely as possible & avoid weld defects
Needs to consider service conditions of the
weld
Qualmet Services 8
Definition of weldability
The capacity of a material to be welded
under the imposed fabrication conditions
into a specific, suitably designed structure &
to perform satisfactorily in intended service.
• (ANSI / AWS A3.0)
Qualmet Services 9
Factors affecting weldability
Weldability is often considered to be a
material property, however the effect of other
variables should not be ignored.
Design of weldment
Its service conditions
Choice of welding process
Qualmet Services 10
Material properties
Melting & vaporisation temperatures
Electrical & thermal properties
● Conductivity, expansion coefficient, thermal
capacity, latent heat
Affinity of weld metal for O, N & H
● Susceptibility to porosity, embrittlement or wetting
problems
Presence of a surface film on base metal
● Oxide, paint or metallic surface coating
Qualmet Services 11
Service environment
Extreme environments
● Corrosive
● Low temperature (brittle failure)
● High temperature (oxidation, creep, embrittlement)
● Others (wear, fatigue, nuclear)
The more extreme the environment
● The more difficult it is to find suitable materials
● The more restricted the welding procedure becomes to
avoid service failure
Qualmet Services 12
Welding Defects
Cracks
● In weld metal or HAZ
Porosity
● Gas bubbles entrapped in weld metal
Incomplete fusion (interrun or at preparation edge)
Inclusions
● Slag or other matter entrapped in weld
Defective profile
● Underweld, overweld, lack of penetration, overlap,
undercut
Qualmet Services 13
Causes of weld defects
Poor design of weldment
● Lack of access to make weld
Mistakes by welder
● Lack of skill
● Poor placement of weld metal
● Inadequate cleaning
Poor welding procedure
Qualmet Services 14
Weld defects Slag
inclusion
Wormhole
porosity
Incomplete
fusion
Overlap
Solidification cracking
Contraction strains
cause rupture of the
weld at the point where
the last material
solidifies.
● Solidification range
● Weld pool size & shape
Qualmet Services 16
Residual stress & distortion
Uneven heating leads to constrained thermal
expansion
At completion of the weld thermal cycle the
weldment either distorts or if restrained will
contain residual stress
Residual stress fields are complex, but
stresses as high as yield often occur
Stresses may need to be removed by a stress
relief heat treatment
Qualmet Services 17
Residual stress in a butt weld
sy
σ
sx
σ
X X sx
σ
Compression 0 Tension
σy Tension
X X
Compression
Qualmet Services 18
Weld detailing
Qualmet Services 19
Weld positions plate
Qualmet Services 21
Weld details
Joints Arrangements of members being
joined
● Butt, tee, lap, corner, flare
Welds Geometry of weld detail selected to
make the joint
● Butt, fillet, plug & slot
Joint types
Butt Tee
Edge
Lap Corner
Qualmet Services 23
Weld types
Butt weld
● Between mating members
● Best quality
● High weld preparation cost
Fillet weld
● Easy preparation
● Asymmetric loads, lower design loads
Plug & slot welds
● Modified fillet welds in lap joints, using
holes through one member
Qualmet Services 24
Fillet welds
Simple & cheap to assemble & weld
Stress concentrations at toes & root
Notch at root (fatigue, toughness)
Critical dimension is throat thickness
Root gap affects throat thickness
Radiography & ultrasonic testing is of
limited use
Large fillets use a lot of weld metal &
therefore are uneconomic
Qualmet Services 25
Fillet weld terms
Toe
Weld face
Toe
Root Throat
thickness
Gap
Apparent leg length
Butt welds
Types:
● Double welded butt
● Permanent or temporary backing
● Single welded butt
Lower stress concentration
Easier ultrasonic testing or radiography
Expensive preparation
Qualmet Services 27
Butt weld types
Single vee
Single bevel Double vee
can be single
or double welded
Backed butt (permanent or temporary)
Butt weld terms
Fusion face Included angle
Bevel angle
Reinforcement
Toe
Root face
Root
gap
Root run Toe
Weld preparation dimensions
Compromise
● Weld cross sectional area
• Cost
• Ease of welding (risk of defects)
Standard preparations
● AS1554, AWS D1.1, ANSI B31.3
Fabricator’s risk
Qualmet Services 30
Single welded butt joints
Access to one side only
● Pipe & hollow section butt joints
Root run forms inside surface
High fitup tolerances required
High skill required
● Special welder qualification
Root may be contaminated
Inside is difficult to inspect
Qualmet Services 31
‘J’ & ‘U’ Preparations
“U” preparation
Root radius
Land
Double “U” butt
Qualmet Services 32
AS1101.2 drawing symbols
OTHER SIDE
Tail Reference line
ARROW SIDE
Arrow points to weld
location
Weld type symbol
Qualmet Services 33
Typical AS1101.2 symbols
6mm
CJP
6
Qualmet Services 34