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I - WE Chapter 9 - Controlling Distortion - 3RD
I - WE Chapter 9 - Controlling Distortion - 3RD
Controlling Distortion
Wise men learn from other mens mistakes,
fools by their own.
H.G. Bohn
Introduction
Since welding processes expose the workpiece to high temperatures, weldinduced distortion is always present. We will investigate how distortion
affects workpieces and present several methods to reduce its effects. These
methods are often simple, but without them many workpieces would be
ruined.
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Elevated
Temperature Outline
Room
Temperature Outline
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X
Z
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221
rapidly and prevents the unheated edge from heating and expanding as the
heat flows across the plate. Note that what happens during the cooling period
is seldom what happens during the heating period. See Figure 94.
Figure 94. Sheet metal before heating (left) and while hot (right).
What happens to the shape of a plate after a partial cut is made in it with
OFC?
Because of differential heating and the restraint offered by the uncut portion
of the plate, the hinge effect occurs, see Figure 95. If two parallel cuts were
made simultaneously, the metal between the cuts would show little distortion,
as heating and expansion would be balanced. Dual torches are available to
make such cuts.
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CONTROLLING DISTORTION
side?
See Figure 96. As the bead is applied, one side of the bar is heated and
expands. When the bar and the filler metal on top of it cool, they contract
much more than the cooler metal on the bars opposite side. Applying the
weld bead makes the bar bend toward the side of the weld bead.
Figure 96. Effect of applying a weld bead on one side of a steel bar. Straight
bar, no bead applied (left). Bar bends toward bead side with weld bead
applied when cool (right).
What are the residual stresses and shape changes caused by welding in a
V-groove butt weld?
There are residual stresses both along the weld axis (longitudinally) and
across the weld (transversely), Figure 97 (left). When cooled, the weldment
has permanent deformation away from the side where heat was applied along
the weld line. Because this is a V-groove butt joint that has more filler metal
at its top than at its root, there is more shrinkage along the top of the joint in
both directions. This makes the plate dish or bend upwards, Figure 97
(right).
T
L
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223
Because the longitudinal stresses on each side of the joint balance each other,
the vertical member of the T-joint remains straight. See Figure 98 (right) for
the distortion these residual stresses cause.
Figure 98. Longitudinal and transverse stresses in a T-joint (left) and the
distortion they cause (right).
Controlling Distortion
How can we eliminate the effects of distortion from welding?
There are several steps that can reduce its effect, but we can never completely
eliminate distortion.
What is a simple way to reduce the effects of distortion that pulls a butt
joint or V-groove joint out of alignment?
First, preset the parts. Then tack weld the parts slightly out of position and let
residual forces bring them into proper position. See Figure 99 showing how
a T-joint and V-groove joint are handled.
Figure 99. Presetting and tack welding work out of position lets weld
shrinkage bring parts back into alignment.
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CONTROLLING DISTORTION
Weld
Wedge
Figure 910. Using tack-welded restraints and wedges to hold joint in position
while welding.
How can we limit heat flow from the weld joint to limit distortion?
Use chill bars. Chill bars consist of steel or copper bars clamped beside and
parallel to the weld bead. They draw heat away from the weld and reduce its
flow to the rest of the part. They also limit distortion to upsetting metal close
to the weld line and eliminate ripples completely by exerting a clamping force
which prevents ripples from forming when the work is hot, see Figure 911.
A groove in the lower chill bar permits the weld itself to remain hot and not
have its heat drained away by the chill bar. This groove could be flooded with
shielding gas for GTAW.
Work
Chill Bars
Chill Bar
Figure 911. Chill bars reduce distortion by confining heat to the weld area
and by preventing work from forming ripples when hot.
Excellent part alignment is needed. How can this be accomplished?
Use prestressing. Use clamps to bend the joint members in opposite direction
to the weld forces and let weld-shrinkage forces bring the parts back into
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position. This method works well when a jig or fixture can be used and test
runs are made to determine the amount of prestress needed. See Figure 912.
Leg
Span
Figure 913. Initial joint designs (left) and balanced force designs (right).
How can we reduce total weld distortion forces as well as balance them?
Use chain intermittent or staggered intermittent weld beads. Intermittent
beads not only balance one another, but also by reducing the total amount of
weld bead, reduce total residual force, see Figure 914. Even a single
intermittent weld bead will have less distortion than a single continuous weld
bead and often the strength of a continuous bead is not needed.
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Figure 915. Redesigned joint can balance residual stress and reduce
distortion.
What method can be used to reduce the distortion in a long continuous
bead?
Use backstep welding. Apply short increments of beads in the direction
opposite of the end point of the weld. When applying multiple passes, start
and stop the beads of each layer at different points. See Figure 916.
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Direction
of Welding
Average
Length
8 to 10
Inches
Direction
of Travel
of
Electrode
Direction of Welding
Direction of Contraction
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