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7 Ways To Control Distortion in Welding

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D
istortion is a nasty problem we experience in welding. Understanding what causes distortion is important in
order to be able to minimize or eliminate it completely. There are physical and mechanical properties that affect
distortion susceptibility of materials. To learn more about this you can read 4 Material Properties That Affect
Distortion.

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 Larger weld nuggets in butt joints can help in minimizing
distortion

As fabricators we hardly ever get to pick the base material of the welded structure. However, regardless of a material’s mechanical and physical
properties, we can follow a set of rules to minimize or eliminate distortion altogether. Follow these steps and you’ll be on your way to controlling
weldment distortion.

1. Don’t overweld – the more weld metal we put in the joint the higher the forces causing shrinkage. Don’t lay a 5/32” fillet when a ¼” fillet will
do. If there is a drawing calling out welds stick to the sized called for. If necessary, invest in weld gages. You can learn how to use them in Proper
Use of Weld Gages.

2. Use intermittent welding – using intermittent welds rather than continuous welds, where design allows it, you can save as much as 75% weld
metal and significantly reduce shrinkage and distortion. Welding stiffeners to plate is a great place to do this.

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 3. Minimize the number of weld passes – the shrinkage caused by each pass is cumulative, thus making it better to fill the same volume in fewer
passes, especially when we are dealing with transverse distortion.

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4. Weld near the neutral axis – as you can see in the image below the location of the weld relative to the neutral axis will determine which way the
structure will distort. If we can place the weld right at the neutral axis we can effectively control distortion.

Source: Haynes International – Welding and Joining

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 5. Balance welds around the neutral axis – we can’t always change material thickness to affect where the neutral axis is. In this case, whenever
possible, balance the welds around the neutral axis. This means trying to achieve symmetry.

When designing consider the

location of the welds based on the
neutral axis

6. Use backstep technique – this is helpful since the previous weld create a restraint minimizing distortion. This technique may not be feasible in
all situations

7. Preset parts to offset distortion – if we anticipate distortion and can predict which way the welded structure will bend, we can pre-bend the
part so that after welding the part is straight.

There are other methods for reducing distortion such as planning the welding sequence accordingly to counteract shrinkage forces. Peening can also
reduce some of the residual stresses. Preheating and other thermal methods can help as well.

Sources: The Procedure Handbook of Arc Welding, 14th Edition

Haynes International – Welding and Joining (Weld Defects)

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Category: Theory and Education Posted on Friday, November 25, 2016

Disclosure of Material Connection: Some of the links in the post above are “affiliate links.” This means if you click on the link and purchase the item, we will receive an affiliate commission. Regardless, we only recommend products or services we use
personally and believe will add value to our readers. I am disclosing this in accordance with the Federal Trade Commission’s 16 CFR, Part 255: “Guides Concerning the Use of Endorsements and Testimonials in Advertising.”

4 Material Properties That Affect... How To Calculate Heat Input From Welding

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5 thoughts on “7 Ways To Control Distortion in Welding”

Pingback: 4 Material Properties That Affect Distortion | WELDING ANSWERS

Gerald Austin says: Reply

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 February 1, 2017 at 10:37 pm

How about preheat. When properly applied, angular distortion and residual stress are reduced.

Pingback: 5 Common Mistakes Made Welding Stainless Steel | WELDING ANSWERS

philani says: Reply
March 22, 2018 at 11:22 am

minimizing distortion after welding

Sydney kapindula says: Reply

September 1, 2019 at 2:18 pm

I could like to know more about welding

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