Defects In Fusion Welding.ppt 3o5e13

Slide 4 of 81

COMMONLY OBSERVED DISCONTINUITIES IN FUSION WELDING TYPE

EXISTS

REMARKS

Lamination

Pm

Delamination

Pm

Seams & laps

Pm

Base metal surface, often at all times longitudinal.

Lamellar tears

Pm

Invariably near the HAZ in flange plate of T-butt t.

Cracks

Pm, Wm Wm/Pm

Base metal, genarally near mid thickness of section. ,,

Restraint, Hot, Brittle & Under bead cold cracks; which may be either in longitudinal or transvers direction.

Crater cracks

Wm

Usually with multi axial cracks at the point of termination.

Fissures

Wm

Micro cracks generally in fully austenitic stainless steel & less ductile metal.

Stray flash

Pm

Appears away from the weld seam as a trail of arc spots with micro fissures, excesively brittle & hard character.

Spatters

Pm

Globular weld particles ejected out of an arc zone & scattered shabbily around over the base metal.

Pm = Parent metal; Wm = Weld metal; Pm/Wm = Junction of weld & base metal Continued...

Pm = Parent metal; Wm = Weld metal; Pm/Wm = Junction of weld & base metal Weld decay & Pm Precipitation of chromium carbide in austenitic stainless stress corrossteels & severely degrading the corrosion resistance ion cracks property in HAZ; which may also be associated with the stress corrosion cracks. Oxidation

Wm

Inadequacy in gas shield or gas purge from the root side causes a heavy black scale or an extremely rough crinkled appearance.

Craters

Wm

An unfilled concave crater causes a point of stress raiser.

Underfill

Wm

Inadequate weld metal filling and causing weakness.

Undercut

Wm/Pm Groove made by the arc force & left unfilled, causes severe stress concentration.

Overlap

Wm/Pm Accumulation of weld, without fusion, causes an extremely voilent point of sstress raiser.

Lack of fusion

Wm, Lack of union between the two weld beads or weld & base Wm/Pm metal causes stress concentration.

Lack of penetration

Pm

Inadequacy of through thickness fusion depth.

Solid particle inclusion

Wm

Trapped slag particle, tungsten or oxide (Al2O3) in weld.

Gas inclusion

Wm

Gas voids contained within the weld causes: Blow hole, Gas pore, Piping, Worm holes, Linear, Clustered or Scattered

- due to segregation

Lamellar Tearing:

• Dilution • Heat input

The dilution: Dilution% = Pm / Wm X 100 Wm

Fm

Wm = Fm + Pm Pm = Melted Parent metal Fm = Melted Filler metal

Pm

The heat input: Kj /

mm = I.V./ S.1000

I = Current across the arc. V = Voltage across the arc. S = The rate of arc motion mm/Sec.

‘‘Too low or high heat input both may equally be proved detrimental.’’

Solidification cracks due to the bead factor:

That is

W

W/P

W = Bead Width P = Bead Depth

W

P

P

W/P>1

W/P<1

Cracks is detected in a radiograph, only when it produces a change in thickness that is parallel to the x-ray beam. It appears often zig-jagged with faint irregular line. Cracks can also appear sometime as "tail" to an inclusion or porosity.

Undercut is an erosion of the base metal next to the toe of the weld face. It appears in radiograph as a dark irregular line on outer edge of the weld.

Root undercut is an erosion of the base metal next to the root of the weld. It appears in radiographic images as a dark irregular line offset from the centerline of the weldment. Undercutting is not as straight edged as LOP because it does not follow the straight edge

Root concavity or suck back is a condition where the weld metal has contracted as it cools down & has been drawn up into the root of the weld. On a film it appears similar to the lack of root penetration but the line has irregular wide edges and placed in the middle.

Cold lap is a condition where the weld metal does not fuse with the base metal or the previous weld bead (inter cold lap). The arc does not melt the base metal and causes the molten puddle to flow into the base metl without the proper bonding.

Incomplete fusion is a condition where the weld metal does not fuse with the base metal. Appearance on radiograph is usually a darker line or lines oriented in the direction of the weld seam along the weld ing area.

Whiskers are the short lengths of electrode wire, visible on the top or bottom surfaces of the weld or contained within the weld. On radiograph they appear as light, "wire like" indications.

Burn through (icicles) results when too much heat causes weld to pierce through. Lumps of weld metal sag through the seam creating a thick globular condition on the root face. On a radiograph, burn through appears as dark spots surrounded by light globular areas.

Lack of penetration occurs when the weld metal fails to penetrate

through the t. Allows a linear stress riser like discontinuity from which a crack may initiate. The appearance on a radiograph is a dark well-defined straight edges that follows the land or root face down the center of a t.

Gas inclusion •Gas pore _ singular. •Blowhole _ singular. •Scattered Porasity. •Cluster Porasity. •Linear Porasity. •Piping. • Worm holes.

Fine

Severe

Porosity appears often as dark round irregular spots in clusters or rows. Sometimes it is elongated and may have an appearance of a tail. This is the result of gas attempting to escape while the metal is still in a liquid state & is called wormhole porosity. All porosity is indeed a void will have a darker density than the surrounding.

Cluster porosity is caused when electrodes are contaminated with moisture or hydrocarbon. It appears like regular porosity in a film but the indications will be grouped close together.

• Oxide inclusion/ Puckering

Slag inclusions are the nonmetallic solid materials trapped in weld or between the weld and base metal. In a radiograph, dark, jagged asymmetrical shapes within the weld or along the weld t areas are indicative of slag inclusions.

Tungsten inclusions. Tungsten is a brittle and dense material used as an electrode in tungsten inert gas welding. If an incorrect welding procedures & skill is performed, then only the tungsten gets trapped. Radiographically, tungsten is more dense than aluminum or steel; therefore, it shows as a lighter area with a distinct outline on the radiograph

Oxide inclusions are usually visible on the surface of a weld mtal (especially aluminum). Oxide inclusions are less dense than the surr -ounding metals and, thus it appears as dark irregular shaped discon -tinuity in radiograph. This is also referred as puckering in ISO.

The radiographic image is a noticeable difference in density between the two mismatched pieces. The difference in density is caused by the difference in material thickness. The dark, straight line is caused by failure of the weld metal to fuse with the land area.

Excessive reinforcement is an area of a weld added in excess of that specified by the drawings and codes. The appearance on a radiograph is a localized & less darker area. A visual examination will easily determine if the weld reinforcement is in excess.

Underfilling is an area where the deposited weld metal is less than the required thickness. It is easy to determine by RT films, because the image density in the area of inadequacy will be darker than the surrounding image density.

Distortion: Distortion is an unavoidable phenom -enon of fusion welding. Type: • Angular distortion;

• Longitudinal distortion; & •

Transvers distortion.

Distortion:

Remedy:

only to minimise.

• Reduce the cause of shrinkage forces; • Make use of the shrinkage forces; • Balance the shrinkage forces.

&

Reduce the cause of shrinkage forces: 1. Do not weld __ if possible. 2. Reduce the number of ts. 3. Improve the t design & fit-up. 4. Avoid excessive root gap & mismatch. 5. Avoid over welding. 6. Reduce the number of runs. 7. Use larger size electrodes. 8. Use iron powder type electrode. 9. Use semi or fully mechanized welding.

 Obviously the poor fit-up demands more metal to be filled in and thus the more shrinkage / distortion.

GA

©

© 

 RF RO

GA=Groove / Included angle  Fusion faces RF = Root face © Shoulder RO = Root opening

t

Effective throat area gets reduced in proportion to the root gap and an over welding by 1.6mm to a 6 mm given fillet size, the cross section area of weld increases by a margin of 56%.

W W

Make use of shrinkage forces:

Balance the shrinkage forces: Use an appropriate welding scequence. i.e. Back step & intermittent welding techniques.

Use external force: i.e. Tack weld, Jigs, Fixtures & Clamps.