Occurrence and Prevention of Pores

Unlike the phenomena mentioned above, it is only possible to influence pores during welding to a limited extent by means of the chemical composition of the base metal and the weld metal. Basically there are two possible types of pore formation: In the liquid condition steel dissolves gases such as hydrogen, nitrogen and oxygen. In metallurgical pore formation dissolved gases are precipitated as gas bubbles (H2, N2, CO, O2) during the solidification process due to the jump in solubility from the liquid to the solid phase. If the solidification speed is greater than the speed at which the gas bubbles up, then the bubbles are entrained (frozen) and are left behind in the weld as predominantly spherical pores. Depending on the amount of gas available, these pores may also be present in an elongated form. Gas bubbles occur at the phase boundary between liquid and solid and in slag particles floating in the molten weld pool. Mechanical pore formation occurs if gaps or voids filled with gases, e.g. air, are welded over. If gases that expand due to welding heat are unable to escape completely in another direction, a pressure builds up that is reduced by the formation of bubbles in the liquid weld pool. This effect may be intensified still further by gas-forming substances in the gaps and voids (moisture, greases and oils, components of coating materials, metallic coatings). As a rule mechanically formed pores are linked to the voids that led to their formation. defects and causes metallurgical pores
High nitrogen contents in the base metal and the filler metal Increase in nitrogen content due to plasma cuts Inadequate shielding of the arc area against the atmosphere due to: - arc being too long - wrong angle of electrode inclination - damaged electrode coating - arc blow effect Shielding gas flow rate too low due to: - setting being too low - leaking line - capillary hole too small
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countermeasures

Use filler metals matched to the base metal with an increased solvent power for nitrogen (e.g. increased Cr and Mn contents in austenitic alloys) Grind the cut edge

Weld with short arc Weld with steep inclination Take care to use undamaged and centric electrode coating Take care to ensure symmetrical material connection, weld with alternating current if possible Correct setting accordingly Look for and remedy leaks Correct assignment of capillaries and pressure regulators Cylinder and line pressure must correspond to required preliminary pressure of pressure regulator. Prevent drafts, position extraction system differently Allow gas to pre-flow or post-flow longer as appropriate Reduce gas nozzle gap Align wire electrode better, arrange contact tube centrically Match gas nozzle shape to weld preparation If possible arrange gas nozzle downstream of torch seen in direction of welding.

- preliminary pressure too low for pressure regulator Inadequate gas shielding due to: - draft from open windows, doors, etc. - insufficient gas flow at beginning or end of welding - gas nozzle gap too large - eccentric exit of wire electrode - wrong shape of gas nozzle - wrong position of gas nozzle

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defects and causes

Turbulence due to: - shielding gas flow rate being too high - spatter on gas nozzle or contact tube - turbulent arc

countermeasures
Reduce gas flow rate Clean gas nozzle and contact tube during welding breaks Remedy problems with wire feed, increase voltage with stuttering wire electrode, ensure good current transition in contact tube, perfect bonding to earth, remove slag from beads welded previously. Reduce size of weld pool Reduce preheat or interpass temperature (if possible metallurgically) Seal pipes Re-dry electrodes according to manufacturers instructions Equalize temperature of filler metal, store in a dry place Dry weld area by skin-drying or preheating Look for leaks and remedy, dry wire transport hose in case water has got in Check torch cooling for excess capacity Weld over arc strikes Use basic electrode with higher Mn content Reduce penetration by decreasing the arc power or increasing the welding speed. Clean weld area prior to welding

Thermal up-current or chimney effect due to: - weld pool temperature being too high - work piece temperature being too high - unimpeded draft in pipelines Moisture due to: - moist electrode coating (increased H contents) - condensation on wire electrode - moisture on base metal - leaking water-cooled torch - condensation on shielding gas nozzle Incorrect handling of basic electrodes Rounding of segregation zones

Rusty and scaly surfaces

mechanical pores
Inclusion of air in the area immediately surrounding the weld Moisture in welding gap, possibly chemically bonded to rust Layers of grease in welding gap, present either as contamination or to prevent corrosion or applied intentionally for lubrication purposes Metallic coatings (e.g. tin, zinc) Create opportunities for entrained air to escape e.g. increase welding gap, use butt welds instead of fillet or lap welds Remove moisture by preheating, remove rust or layers of scale, use butt welds instead of fillet or lap welds Remove grease using solvents, increase welding gap and dry well, use butt welds instead of fillet or lap welds Comply with recommended layer thicknesses, remove metal coatings if necessary, increase welding gap, use butt welds instead of fillet or lap welds Choose favourable coating material, comply with prescribed coating thickness, remove any layers that are too thick if necessary, ensure good degasification in the gap, use butt welds to replace fillet or lap welds

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Coating materials (e.g. production coatings)

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