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Welding Operations Defects
Welding Operations Defects
:Process Definition .1
Commonly called stick or covered electrode welding and it is manual process whereby an arc is generated between a flux-covered consumable electrode and .the work piece
:Process Principles .2
The arc generated when the electrode touches "scratches" the base metal. The .resulting arc melts both the base metal and the tip of the electrode The molten electrode metal/flux is transferred across the arc to the base-metal .pool that results the weld covered by slag from the electrode flux
:Equipments .3
The equipments consists of a power supply, electrode holder, electrode , welding .cables and work piece as shown in the figure below
:Process Capabilities .4
:(Materials (alloys
Carbon steel, stainless steel , low alloy carbon steel , cast iron , cupper, nickel & .aluminum
:Shape Limitation
.Un limited shape
:Dimensions Range
.Thickness from 1.6 inch to unlimited thickness
:Advantages .5
.Easily implemented. 2. Inexpensive. 3. Flexible. .Filler metal protect the weld because of flux .5 .can be used for many materials .6 4. Easy to use .1
:Limitations .6
.Low productivity. 2. Low Deposition rate. 3. Operator dependant .1 .Heat of welding are too high for lead , tin , zinc and their alloys .4
:Process variables .2
.(Welding current (electrode feed speed .1 .polarity. 3. Arc voltage (arc length). .electrode extension. 6. Electrode orientation. 4. Travel speed .2 7. Electrode diameter .5
3. Equipment:
The arc (1) is struck between the work piece and a metal wire electrode (2) that is continually fed forward into the arc. The wire is supplied on a reel (3), and is fed to the welding gun by the drive rollers (4), which push the wire through a flexible conduit (5) in the hose package (6) to the gun (7). Electrical energy for the arc is passed to the electrode through the contact tube (9) in the welding gun. This contact tube is normally connected to the positive pole of the power source, and the work piece to the negative pole. Striking the arc completes the circuit. The gas nozzle (11) that surrounds the contact tube (9) supplies shielding gas (10) for protection of the arc and the weld pool (12).
4. Advantages:
1. Deposition rates higher than SMAW. 2. Productivity higher than SMAW. 3. No slag remove and continuous.
4. Easily automated.
5. Limitations:
1. 2. 3. 4. More expensive than SMAW. The process more complex to control. Restricted access. Its gun is larger than electrode holder in SMAW.
:Process Features .2
Flux-cored arc welding has two major variations. FCAW uses an externally supplied gas to protect the arc from N2 , O2 in the atmosphere . The core ingredients in gas- shielded electrodes are slag formers, deoxidizers, arc stabilizers, and elements.
3. Process Equipments:
1. Contactor control . 4.welding gun. .wire driver motor .7 2. wire feed control . 5. work piece. 3. voltage control. 6. shielding gas source.
:Advantages .5
High deposition rates. Deeper penetration than SMAW. High quality. Less pre-cleaning than GMAW. Slag covering helps with larger out-of-position welds. Self-shielded FCAW is draft tolerant.
6. Limitations:
Slag must be removed. More smoke and fumes than GMAW & SMAW. Spatter. FCAW wire is more expensive and complex than for SMAW. Equipments are more expensive and complex than for SMAW.
:Process Variables .2
Continuously-fed like FCAW.
Higher deposition by using a larger diameter. Higher current. The process can be utilized such as multiple torches and arrow gap welding.
3. Process Equipments:
1. Automatic wire feed.
2. 3. 4. 5.
6.
7. 8. 9.
Flux hopper. Welded power. Flux feed tube. Flux shelf. Solid slag . Welding vee. Weld backing plate. Work connection.
5. Process Capabilities:
Materials (alloys):
Steels, low alloying steels, stainless steel, nickel, chromium, and molybdenum steels.
Shape Limitation:
Not suitable for thin material.
6. Advantages:
High deposition rates. No arc flash. Easily automated. Joints can be prepared with narrow grooves.
7. Limitations:
Slag removal required. Flux handling equipments. Flux obstructs view joint. Flux is subject to contamination porosity.
2. Process Variables:
1. The non-consumable guide method. 2. Consumable guide method uses a guide tube to guide the wire.
3. Process Equipments:
Electrode lead. Power source. Wire feed drive. Wire reel. Oscillation. Molten slag. Molten weld pool. Work lead. Retaining shoe. Consumable guide tube.
4. Advantages:
Used for thick weldments. Produces sound welds. Increased cost effectiveness as thickness increase.
5. Limitations:
Once started , the weld must continue. Coarse grained heat affected zone.
2. Process principles:
A cool & inert gas, such as compressed air, is forced under pressure through a small orifice in the front of cutting torch . This torch is connected by leads to a dc power supply. In the torch, apportion of the inert gas is changed into plasma by heat created by the discharge of high-voltage arc from the power supply. This arc is created between an electrode (-ve) in the torch & the tip nozzle of the torch through which the gas flows.
3. Process Capabilities:
Materials (alloys):
Ferrous & non-ferrous metals.
4. Advantages:
High speed than oxyfuel cutting 5 times approximately. High productivity. Easy to be automated. Good control & more flexible. High energy that cuts higher penetration.
5. Limitations:
More complex torch. High maintenance cost. More parameters need to set up compared with oxyfuel cutting. High capital cost.
6. Applications:
Automobile manufactures , auto body repair shops who must cut highstrength steels. Cutting stainless steel in manufactures of food processing & kitchen equipments. Special & subcontracted items from aluminum , brass , copper , carbon steel , stainless steel ,..etc.
2. Process Principles:
Gun is properly positioned. Trigger is depressed & stud is lifted , creating an arc. Arcing period is completed & stud is plunged into molten pool of metal on base material. Gun is withdrawn from welded stud & ferrule is removed.
3. Process Equipments:
Power cable to work. Power source terminal connections. Control unit. Stud welding gun. Power cable to gun. Control cable to work.
4. Advantages:
Portable. Inexpensive method.
interrupted line indicates a weld on the other side. In this case, the symbol 'hangs' below the interrupted line. See Figure 15.4 and Figure 15.5.
The interrupted reference line is not used for fully symmetrical welds: examples are shown in Figure 15.6.
Dimensioning of welds
The dimensions of the cross-section of the weld are shown to the left of (before) the elementary symbol (e.g. penetration for butt welds, leg length or throat thickness of fillet welds). Write the length of the weld to the right of (after) the basic symbol. E.g. 511300 indicates a square butt weld, with 5 mm penetration and a length of 300mm. indicates a continuous fillet weld with a leg length of 10 mm.
5x200 (100) indicates an intermittent fillet weld with a leg length of 8 mm, divided up into five 200-mm-long welds, spaced 100 mm (end to end) apart.
:Welding Defects
The performance of welded structures or components in service depend on the quality of fabrication , which in turn is based on the presence or absence of defects or discontinuities in . welded joints
: Slag inclusions
Non metallic solid material entrapped in weld metal or between weld metal and . base metal
: Porosity
. Cavity-type discontinuities formed by gas entrapment during solidifications
: Overlap
. The protrusion of weld metal beyond the toe , face , or root of the weld
Tungsten Inclusions
Particles from tungsten electrodes that result from improper gas-tungsten arc . welding procedures
:Shrinkage voids
. cavity-type discontinuities normally formed by shrinkage during solidification
: Oxide Inclusions
. Particles of surface oxide that have not melted and are mixed into the weld metal
: Lack of fusion
. A condition in which fusion is less than complete
: Craters
. Depressions at the termination of a weld bead or in the molten weld pool
: Melt-through
A condition resulting when the arc melts through the bottom of a joint welded from . one side
: Spatter
. Metal particles expelled during welding that do not form a part of the weld
: Under fill
A depression on the face of the weld or root surface extending below the surface of . the adjacent base metal
: Metallurgical Discontinuities .3
: Cracks
Fracture-type discontinuities characterized by sharp tip and high ratio of length
. and width to opening displacement
: Fissures
Small crack-like discontinuities with only a slight separation (opening . displacement) of the fracture surfaces
: Fish eye
A discontinuity found on the fracture surface of a weld in steel that consists of a . small pore or inclusion surrounded by a bright , round area
: Segregation
The non-uniform distribution or concentration of impurities or alloying elements . that arises during the solidification of the weld
: Lamellar tearing
A type of cracking that occurs in the base metal or heat affected zone (HAZ) of restrained weld joints that is the result of inadequate ductility in the through. thickness direction of steel plate
:References*
Welding processes handbook , Klas Weman .