Welding Defects: BY BY

WELDING DEFECTS
BY
SURENDRA SINGH
Energy for the World
Discussion P i t Di i Points
Classification of metals Effect of alloying elements Weld Defects
Classification of Metals
Metals M l Ferrous metals Steels Plain carbon steels Low carbon steels Medium carbon steels High carbon steels Low alloy steels
High alloy steels Stainless & T l steels St i l Tool t l
Non-ferrous metals Cast Irons Grey Iron y White Iron Malleable & Ductile Irons
Cast Iron
Alloy of iron and carbon content 2 4% 2-4%. Higher strength and hardness but ductility is low. Cannot be rolled in the from plate or sheet. Can be made ductile by addition of element Mg. Higher fluidity
Types of Cast Iron

Gray cast iron y
Ferrite
Contain 2.5 - 4% C and 1.0 3% Si Pearlite ASTM A48
Graphite Nodules
Ductile cast iron

Contain 2.5 - 4% C, 1.02.5% 2 5% Si and 1 0 2% Mg 1.0 ASTM A536
Ferrite
White cast iron

No graphite, white in colour. Cementite It contain upto 2-4% C, 3% Cr, 0.9 1.40% Si Pearlite and 0 25 0 55 % M d 0.25 0.55 Mn
Tampered Nodules
Malleable cast iron

Produced by annealing HT of white cast iron ASTM A47
Ferrite
Classification of Steel
Steel: An alloy of the metal iron with carbon. 0.01 1.4% C is considered as the general range for steels Steels are classified into 1. 1 Low Carbon Steel 0 01 0 3% Carbon 0.01 0.3% 2. Medium Carbon Steel 0.3 0.6% Carbon 3. High Carbon Steel 0.6 1.4% Carbon Plain carbon steels contain only iron & carbon as main alloying elements, traces of Mn, Si, Al, S & P may also be present
Low Carbon Steel

It contain upto 0 3%C often 0.3%C, alloyed with 0.4%Mn Weak due to ferrite and pearlite microstructure. Flat rolled product such as sheet and plate. Easily formable, weldable formable weldable, machinable. ASTM A36
Medium Carbon Steel

It contain upto 0 3 0 6%C 0.3-0.6%C, with 0.6-1.65%Mn Higher strength and hardness but ductility is low Microstructure shows 50 50% 50-50% ferrite and pearlite phase. Used in shaft axles gears shaft, axles, gears, crankshaft, railways wheels and axles etc.
High Carbon Steel

It contain upto 0 6 1 4%C 0.6-1.4%C and alloyed with 0.30.9%Mn 0 9%Mn Highest hardness and strength but low ductility ductility. Microstructure shows cementite (white portion) in the matrix of pearlite. Screw drivers, hammers, rope wires, springs etc.
Stainless Steel
Types
Austenitic Stainless Steel Ferritic Stainless Steel Duplex Stainless Steel Martensitic Stainless Steel Precipitation Hardened Stainless Steel
Austenitic Stainless Steel

Face Centered Cubic Face-Centered structure (FCC), also called 18 8 SS 18-8 SS. Non-magnetic, S f but extremely workSoft hardenable. P Prone to SCC and IGC t d Widely used ASS is 304, 316, 347, 316 347 321 etc t
Electrolytic Oxalic Acid
ASTM No. 7
Ferritic Stainless Steel

Body Centered Cubic Body-Centered (BCC) structure, Major alloying element are 14-28 %Cr and 0.1% C. Ferromagnetic Ferromagnetic, Soft and not very workhardenable, hardenable Resistance to SCC and IGC. IGC Best suited for high temperature application
Duplex Stainless Steel

Contain 50 50 % 50-50 austenite and ferrite Phase Major alloying element 18 28% 18-28% Cr and 4 5-8% Ni 4.5 8% Ferromagnetic Highly corrosion resistant in marine environment Type 329 widely used
NaOH + Potassium Ferricyanide 100X
Martensitic Stainless Steel

Body Centered Cubic Body-Centered (BCC) structure, Major alloying elements 11.5-18% Cr and higher C upto 0 1% 0.1%. Ferromagnetic, Hard and brittle brittle, Type 410 and 416 widely used MSS MSS.
HCl+Picric Acid+Ethanol
100X
Effect of alloying elements

Carbon
Prime and essential element in steel Increase in carbon content will increase hardness and strength but reduce ductility
Aluminum
Alloyed to steel mainly as grain refiner. Also act as de-oxidised agent upto some extent.
Chromium
Sharply increases corrosion resistance at high concentrations (> 12%). Improves hardenability, strength and wear resistance upto some extent (<5%). (<5%)
Titanium
Carbide stabilisation to form titanium carbide, more resistant to IGC. Added upto 0 23 to 0 60 in SS 321. 0.23 0.60 321
Molybdenum
Improves resistance to pitting corrosion (2-3%) Provides high temperature strength, hardness and creep resistant. resistant
Nickel
Increases s e g , impact s e g a d toughness a low c eases strength, pac strength and oug ess at o and high temperature, it also act as grain refiner(>8%). Provide ductility, formability as well as weldability in small concentration. t ti
Manganese g
Improves the depth of hardness, toughness and wear resistance. (<1.6%). Control solidification cracking. Substitute for Ni.
Sulphur
It improve the machinability but high concentration cause brittleness or solidification cracking (<0 030%) (<0.030%).
Silicon
Act as deoxidizer agent (<0.8%) and provide machinability. Increases strength but excessive amount reduce ductility
Phosphorus
Added with sulphur to improve machinability (<0.045%). It greatly reduce ductility and toughness
Vanadium
Used as a de-oxidant
Tungsten
Mainly alloyed to high speed tool steels for providing wear resistance at high temperature temperature.
Weldability W ld bilit
Weldability can be defined as the ability of a material to be welded by most of the common welding processes, Poor weldability generally results in the occurrence of some sort of cracking problem CEN = C + Mn + Cr + Mo + V + Cu + Ni
6 5 15
If CEN 0.45 : Good Weldability 0 45 If CEN > 0.45 : Poor Weldability

Weld: A union b t i between materials caused b h t and or pressure t i l d by heat, d Joint: A configuration of members fi ti f b
Welding Defects f
Common Weld Types
Common Joint Types
Single B tt Weld Preparation Butt
Double sided weld preparation
Weld Defects
Defects detected by visual inspection
Cracks Solid inclusions Surface and profiles g (setMisalignment ( up irregularities) Gas pores and porosity
Lack of fusion Mechanical damage Parent material damage Miscellaneous
Cracks
Cracks that may occur in welded materials are caused generally b many f t ll by factors and may b classified b shape d be l ifi d by h and position, cracks are classed as planar defect.
Classified by Shape Longitudinal Transverse Branched
Classified by Position HAZ Centreline Crater Fusion zone Parent metal
Cracks
Main Cracks T pes in Welding Types

Hydrogen induced cold cracking (HICC) Solidification cracking ( g (hot cracking) g) Lamellar tearing Intercrystalline cracking or corrosion
Hydrogen Induced Cracking

The four essential factors for cracking to occur Susceptible grain structure: Martensite Hydrogen >15ml/100gm of weld f ld Temperature less than 200oC Stress
HIC Macrostructure
Prevention of HIC y g g process Use low hydrogen welding p Bake or heat the welding electrode before welding Preheat the metal to remove moisture Reduce stress by heat treatment
Solidification Cracking
Occurs during weld solidification process Steels with high sulphur impurities content (low strength at elevated temperature) Requires tensile stress Occur longitudinally down the centre of weld
Lamellar Tearing
M i l occur i rolled Mainly in ll d steel plate Higher concentration of impurities or inclusion such as sulphides or silicates Reduction in through thickness ductility y
Intercrystalline cracking
Occur mainly in austenitic stainless steels, due to the formation of chromium carbide along the grain boundary
Line of sensitization
Gas Ca ities Cavities

Gas pore < 1.5mm Dia Blow hole > 1.5mm Dia
Loss of gas shield g Damp electrodes Contamination Arc length too large Damaged electrode flux Moisture on parent material
Gas Cavities
Solid Inclusions Incl sions

Slag inclusions are defined as a non-metallic inclusion caused by b some welding process ldi
Entrapment of slag between passes p Slag is caused by inadequate cleaning q g Other inclusions include tungsten and copper g pp inclusions from the TIG and MAG welding process
Tungsten Incl sion T ngsten Inclusion

Lack of Fusion
Poor welder skill Incorrect welding current/voltage or low t/ lt l heat input. High travel speed Incorrect inter-run inter run cleaning
Lack of root penetration

Low amps/volts Large root face/ small root gap t Fast travel speed p Incorrect electrode angle Contamination
Root Defect
Lack of side wall f sion all fusion

Profile Defects
Poor cap profiles and excessive cap reinforcements may lead to stress concentration points at p the weld toes.
Miscellaneous Miscellaneo s Defects

Excessive current Damp electrodes D l t d g g Long arc length Contamination Wrong selection of shielding gas
Miscellaneous Miscellaneo s Defects

A id t l striking of Accidental t iki f the arc onto the parent material Faulty electrode holder Poor cable insulation Poor access to work
Undercut Underc t
An irregular g g groove at the toe of a weld run in the parent metal
Excessive amps/volts Excessive travel speed d Excessive weaving g Electrode dia too large
Cap Underc t Undercut
Excessive Root Penetration

Root penetration bead in excess in accordance with the relevant specification used
Root faces too small Root gap too large Excessive amps/volts Slow travel speed Lack f L k of welder skill ld kill Use of unsuited electrode in welding position
Burn Through B rn Thro gh

Al localized collapse of th weld pool d t excessive li d ll f the ld l due to i penetration resulting in a hole in the root
High Amps/volts Small S ll root f t face Large root gap Slow Travel Speed Lack of welder skill
Root Defects
Crater Pipe
Crater pipe is a shrinkage defect and not a gas defect
Too fast a cooling rate Lack of welder skill C Contamination i i
Crater Pipe
Set-up Irregularities Set p Irreg larities

Li Linear misalignment i i li t is measured from the lowest lo est plate to the highest point of the cap Angular misalignment is measured in degree g
Linear Misalignment
Exercise 1
Exercise 2
Exercise 3 E i
Thank You

Welding Defects: BY BY

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WELDING DEFECTS

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Types of Cast Iron

Contain 2.5 - 4% C and 1.0 3% Si Pearlite ASTM A48

Ductile cast iron

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White cast iron

Malleable cast iron

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Low Carbon Steel

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Medium Carbon Steel

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High Carbon Steel

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Austenitic Stainless Steel

Electrolytic Oxalic Acid

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Ferritic Stainless Steel

Duplex Stainless Steel

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Martensitic Stainless Steel

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Effect of alloying elements

If CEN 0.45 : Good Weldability 0 45 If CEN > 0.45 : Poor Weldability

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Common Weld Types

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Common Joint Types

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Single B tt Weld Preparation Butt

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Double sided weld preparation

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Lack of fusion Mechanical damage Parent material damage Miscellaneous

Classified by Shape Longitudinal Transverse Branched

Classified by Position HAZ Centreline Crater Fusion zone Parent metal

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Main Cracks T pes in Welding Types

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Hydrogen Induced Cracking

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Gas Ca ities Cavities

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Solid Inclusions Incl sions

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Tungsten Incl sion T ngsten Inclusion

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Lack of root penetration