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    Welding Imperfections

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    Anonymous
    The document discusses various types of cracks and welding imperfections, classified by their shape, location, and cause. Cracks are categorized as longitudinal, transverse, chevron, or lamellar tears and occur in locations like the heat-affected zone, centerline, or fusion zone. Welding imperfections include lack of fusion, porosity, overlap, undercut, and concave roots, which can result from issues like contamination, incorrect parameters, or poor technique.

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    Welding Imperfections

    Uploaded by

    Anonymous
    187 views39 pages
    The document discusses various types of cracks and welding imperfections, classified by their shape, location, and cause. Cracks are categorized as longitudinal, transverse, chevron, or lamellar tears and occur in locations like the heat-affected zone, centerline, or fusion zone. Welding imperfections include lack of fusion, porosity, overlap, undercut, and concave roots, which can result from issues like contamination, incorrect parameters, or poor technique.

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    The document discusses various types of cracks and welding imperfections, classified by their shape, location, and cause. Cracks are categorized as longitudinal, transverse, chevron, or lamellar tears and occur in locations like the heat-affected zone, centerline, or fusion zone. Welding imperfections include lack of fusion, porosity, overlap, undercut, and concave roots, which can result from issues like contamination, incorrect parameters, or poor technique.

    Copyright:

    © All Rights Reserved
    Download as PPSX, PDF, TXT or read online from Scribd
    Download as ppsx, pdf, or txt
    187 views39 pages

    Welding Imperfections

    Uploaded by

    Anonymous
    The document discusses various types of cracks and welding imperfections, classified by their shape, location, and cause. Cracks are categorized as longitudinal, transverse, chevron, or lamellar tears and occur in locations like the heat-affected zone, centerline, or fusion zone. Welding imperfections include lack of fusion, porosity, overlap, undercut, and concave roots, which can result from issues like contamination, incorrect parameters, or poor technique.

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    Cracks

    Cracks that may occur in welded materials


    are caused generally by many factors and
    may be classified by shape and position.
    Classified by Shape Classified by Position
    •Longitudinal •HAZ
    •Transverse •Centerline
    •Chevron •Crater
    •Lamellar Tear •Fusion zone
    •Parent metal

    Note: Cracks are classed as Planar


    Defects.
    Cracks

    Longitudinal parent metal Transverse weld metal

    Longitudinal weld metal


    Lamellar tearing
    Cracks

    Transverse crack Longitudinal crack


    Cracks

    Main Crack Types


    Solidification Cracks
    Hydrogen Induced Cracks
    Lamellar Tearing
    Reheat cracks
    Cracks
    Solidification Cracking
    Occurs during weld solidification process
    Steels with high sulphur impurities content (low
    ductility at elevated temperature)
    Requires high tensile stress
    Occur longitudinally down centre of weld
    Cracks
    Hydrogen Induced Cold Cracking
    Requires susceptible hard grain structure, stress, low
    temperature and hydrogen
    Hydrogen enters weld via welding arc mainly as
    result of contaminated electrode or preparation
    Hydrogen diffuses out into parent metal on cooling
    Cracking developing most likely in HAZ
    Lamellar Tearing
    Location: Parent metal
    Steel Type: Any steel type possible
    Susceptible Microstructure: Poor through thickness
    ductility
    • Lamellar tearing has a step like appearance due to the
    solid inclusions in the parent material (e.g. sulphides
    and silicates) linking up under the influence of welding
    stresses
    • Low ductile materials in the short transverse direction
    containing high levels of impurities are very susceptible
    to lamellar tearing
    • It forms when the welding stresses act in the short
    transverse direction of the material (through thickness
    direction)
    Gas Cavities
    Gas pore Cluster porosity
    Causes:
    •Loss of gas shield
    •Damp electrodes
    •Contamination
    Blow hole •Arc length too large
    Herringbone porosity
    •Damaged electrode flux
    •Moisture on parent material
    •Welding current too low

    Gas pore <1.5mm


    Root piping Blow hole.>1.6mm
    Gas Cavities

    Porosity

    Root piping
    Gas Cavities

    Cluster porosity Herringbone porosity


    Crater Pipe

    Weld crater

    Crater pipe
    Crater Pipe
    Crater pipe is a shrinkage defect and not a gas defect, it has
    the appearance of a gas pore in the weld crater

    Crater cracks Causes:


    (Star cracks)
    • Too fast a cooling
    rate
    • Deoxidization
    reactions and
    liquid to solid
    Crater pipe volume change
    • Contamination
    Solid Inclusions
    Slag inclusions are defined as a non-metallic inclusion
    caused by some welding process
    Causes:
    •Slag originates from
    welding flux

    Slag inclusions Lack of sidewall •MAG and TIG welding


    fusion with process produce silica
    associated slag inclusions
    •Slag is caused by
    inadequate cleaning
    •Other inclusions include
    Parallel slag lines Lack of interun tungsten and copper
    fusion + slag inclusions from the TIG
    and MAG welding process
    Solid Inclusions

    Interpass slag inclusions Elongated slag lines


    Welding Imperfections
    Typical Causes of Lack of Fusion:
    • welding current too low
    • bevel angle too steep
    • root face too large (single-sided weld)
    • root gap too small (single-sided weld)
    • incorrect electrode angle
    • linear misalignment
    • welding speed too high
    • welding process related – particularly dip-transfer GMAW
    • flooding the joint with too much weld metal (blocking Out)
    Lack of Fusion
    Causes:
    •Poor welder skill
    • Incorrect electrode
    Incomplete filled groove +
    manipulation
    Lack of sidewall fusion
    • Arc blow
    • Incorrect welding
    1 current/voltage
    2 • Incorrect travel speed

    1. Lack of sidewall fusion • Incorrect inter-run cleaning


    2. Lack of inter-run fusion
    Lack of Fusion

    Lack of sidewall fusion + incomplete filled groove


    Weld Root Imperfections

    Lack of Root Fusion Lack of Root Penetration


    Cap Undercut

    Intermittent Cap Undercut


    Undercut

    Root undercut Cap undercut


    Surface and Profile

    Incomplete filled groove Poor cap profile

    Poor cap profiles and


    excessive cap reinforcements
    may lead to stress
    concentration points at the
    weld toes and will also
    contribute to overall poor toe
    blend Excessive cap height
    Surface and Profile

    Excess cap reinforcement Incomplete filled groove


    Weld Root Imperfections

    Excessive root
    penetration
    Overlap
    An imperfection at the toe or root of a weld caused by metal
    flowing on to the surface of the parent metal without fusing to it

    Causes:
    •Contamination
    •Slow travel speed
    •Incorrect welding
    technique
    •Current too low
    Overlap

    Toe Overlap

    Toe Overlap
    Set-Up Irregularities
    Linear misalignment is
    measured from the lowest
    plate to the highest point.

    Plate/pipe Linear Misalignment


    (Hi-Lo)

    Angular misalignment is
    measured in degrees

    Angular Misalignment
    Set-Up Irregularities

    Linear Misalignment
    Set-Up Irregularities

    Linear Misalignment
    Incomplete Groove

    Lack of sidewall fusion + incomplete filled groove


    Weld Root Imperfections
    A shallow groove, which may occur in the root of a butt weld

    Causes:
    • Excessive back purge
    pressure during TIG welding
    Excessive root bead grinding
    before the application of the
    second pass
    Concave Root
    welding current too high for
    2nd pass overhead welding
    root gap too large - excessive
    ‘weaving’
    Weld Root Imperfections

    Concave Root
    Weld Root Imperfections

    Concave root Excess root penetration


    Weld Root Imperfections
    A localized collapse of the weld pool due to excessive
    penetration resulting in a hole in the root run

    Causes:
    • High Amps/volts
    • Small Root face
    • Large Root Gap
    • Slow Travel
    Burn through Speed
    Weld Root Imperfections

    Burn Through
    Oxidized Root (Root Coking)
    Causes:
    • Loss or insufficient
    back purging gas (TIG)

    • Most commonly occurs


    when welding stainless
    steels

    • Purging gases include


    argon, helium and
    occasionally nitrogen
    Miscellaneous Imperfections

    Causes:
    • Accidental striking of the
    arc onto the parent
    material
    • Faulty electrode holder
    • Poor cable insulation
    • Poor return lead
    clamping

    Arc strike
    Miscellaneous Imperfections
    Causes:
    • Excessive current
    • Damp electrodes
    • Contamination
    • Incorrect wire feed
    speed when welding
    with the MAG welding
    process
    Spatter • Arc blow
    Mechanical Damage
    Mechanical damage can be defined as any surface
    material
    damage cause during the manufacturing process.

    • Grinding
    • Hammering
    • Chiselling
    • Chipping
    • Breaking off welded attachments
    (torn surfaces)
    • Using needle guns to compress
    weld capping runs
    Mechanical Damage
    Chipping Marks

    Mechanical Damage/Grinding Mark

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