WELDING

KAMAL KUMAR VISHOI Assistant Engineer M6V089

INTRODUCTION TO WELDING
Welding or fabrication is a metallurgical fusion process. Here, the interface of two parts to be joined are brought to a temperature above the melting point and then allowed to solidify so as to permanent joint takes place.

H=f VI/v

f is heat transfer efficiency. V is voltage I is current v is travel speed of electrode

GTAW

GTAW EQUIPMENT
THORIATED ELECTRODE CUP

WELDING TORCH

COLLET BODY

TUNGSTEN ELCTRODE a. Tungsten electrodes are non-consumable. b. There may be thorium oxide mixed with the tungsten. e. Thoriated tungsten electrode can carry more current and maintain stable arc. f. Tungsten has melting point of 3410C.

1.This type is used with DCEP. 2. For AC welding with high Frequency. 3.This type is used with DCEN.

SHEILDING GAS
Argon is the most commonly used shielding gas for GTAW, since it helps prevent defects due to a varying arc length. The use of argon results in high weld quality and good appearance over HELIUM due to density difference.

POWER SUPPLY
The preferred polarity of the GTAW system depends largely on the type of metal being welded. There are two type of polarity which are used:1.DCEN(direct current electrode negative) 2.DCEP (direct current electrode positve)

ELECTRODE

Contd. Welding chart Advantage of coating Electrode baking procedure

ADVANTAGES OF COATING
a. b. c. d. The coating provides inert gas ,which shields the molten metal pool and protect it from the atmosphere. Coating introduced special alloying material to the molten pool. Some elements are added in the coating to stabilized the arc. Coating consumes at the slower rate than the core,this helps in concentrating the arc and directing the filer metal in the joint.

ELECTRODE BAKING PROCEDURE

HOLDING TEMPERATURE (C) 220C DRYING

PORTABLE OVEN

2hr TIME(hr.)

100C(any case should not less than 65C)

Welding Defects
porosity slag inclusion incomplete fusion undercut spatter excess penetration unacceptable weld profile

Welding procedure of P91 Prerequisite

a. Edge preparation only done by machining, in special case grinding be allowed in the supervision of welding engineer. b. Edge preparation at the site is subjected to LPT. c. Root gap should be within the specified range ,as well the ID mismatch. d. Thermocouple should be in required number.

PREHEATING
a. The surface should be free from grease oil and dirt. b. Two thermocouple should be spot welded at 0 and 180 position on both the pipes, 50mm away from the EP. c. Preheating temperature should be maintained above 220

CONTD.. d. Root welding should start 5min after the start of argon purging. e. The inter pass temperature shall not exceed 350 c. after completing the welding bring down the temperature to 80-100c and hold at this temperature for minimum one hour.

PWHT
a. Four thermocouple two at weld and two at the base metal should be spot welded. b. The width of the heated circumferential band on either side of the weld must be at least 5 times the thickness of the weld. c. The rate of heating should be 110C/hr. up to 60mm thickness.

CONTD.. d. The PWHT temperature for P91 material shall be 76010C and the soaking time shall be 2.5 minutes per mm of weld thickness, subjected to a minimum of two hours. e. The width of the insulation band beyond the heating band shall be at least two times the heating band with on either side of the weldment.

 Heat treatment graph

PWHT preheating

FIT-UP 65-70
1.5 to 2.5; T<10 2.5 to 4 ;T>10 Similarly for J groove, except the included angle is 55

ALIGNMENT OF I/L REHEATER HEADER

Contd.

Contd.

THANK YOU

THAN K YOU