BY

RAHUL J. PATEL (106440319068)

MAULIK S. PATEL (106440319050)

JAY Y. SHUKLA (106440319030)

ABHI V. PATEL (106440319067)

GUIDE

Mr. A. M. PATEL Mr. J. A. PATEL

B. S. PATEL POLYTECHNIC, GANPAT UNIVERSITY, MEHSANA

WHAT IS WELDING DEFECT?

A Discontinuity or Discontinuities that by a nature or accumulated defect (e.g. total crack length) render a part or a product unable to meet the minimum acceptance standard or specifications.
They are excessive conditions, outside the acceptance limits, which risks to compromise the stability or the functionality of the welded structure.
They are also called rejectable discontinuities.

This means that the same type of discontinuity of a lesser degree, might be considered harmless and acceptable.

: WELDING DEFECT (con.) :

This means DISCONTUITY is not a defect if it is acceptable within the limitation of applicable codes and standards.

Whereas DEFECT is definitely discontinuity and defines rejectability of a part or product. Defects are otherwise called as Flaw or Imperfections that are to be repaired so that the material is made more homogeneous as assumed in the design.

: Significance of defects depends on :

Microstructure in which defect occurs. Mechanical properties of the material. Type of loading (static, cyclic or shock) The environment (corrosive or non corrosive) Section thickness Type and size of defect Stress pattern local to the defect.

: Classification of Defects :

Distortion

Gas inclusion

Slag inclusion

Lack of Fusion

Incomplete Penetration

Lamellar tearing

Undercut

Types of Cracks

: Types of Crakes :
Arc Strikes crack
Cold cracking Crater crack

Cold cracking
Fusionline crack

Crater crack
Hat crack

Fusion-line crack Hat crack

Hot cracking

Hot cracking
Underbe ad crack

Underbead crack
Longitudi nal crack

Longitudinal crack Reheat cracking Root and toe cracks Transverse crack

Reheat cracking

Root and toe cracks

Transver se crack

Arc strike cracking

Cold cracking

Crater crack

Hat crack

Hot cracking

Under bead crack

Longitudinal crack

Reheat cracking

Fusion-line crack

Root and toe cracks

Transverse crack

Spatter

Distortion

Gas inclusion

Slag inclusion

Lack of Fusion

Incomplete Penetration

Lamellar tearing

Undercut

Lack of Penetration

Misalignment

Overlap

Concave-Conwax

Porosity

Method of Non-destructive Weld Examination

Visual Inspection (VT) Radiographic Inspection (RT) Magnetic Particle Inspection (MT) Liquid Penetrant Inspection (PT)

Ultrasonic Inspection (UT)

Eddy Current Inspection

Leak Inspection

Welding Procedure Qualification Inspection

Positive Material Identification

Hydrostatic Inspection

Ground Penetrating Radar Inspection

Digital Imaging Inspection

Method of Non-destructive Weld Examination Whatever the standard of quality, all welds should be inspected
Non-destructive examination (NDE) methods of inspection make it possible to verify compliance to the standards on an on-going basis by examining the surface and subsurface of the weld and surrounding base material. Five basic methods are commonly used to examine finished welds: visual, liquid penetrant,

magnetic particle, ultrasonic and radiographic

Visual Inspection (VT)

"Visual inspection is the best buy in NDE, but it must take place prior to, during and after welding"

Radiographic Inspection (RT)

"Radiography is one of the most widely accepted NDE methods."

Magnetic Particle Inspection (MT)

"MT may have an advantage over RT and UT in detecting tight cracks and surface disconfinuifies."

Magnetic particle inspection is a method of locating and defining discontinuities in magnetic materials It is excellent for detecting surface defects in welds, including discontinuities that are too small to be seen with the naked eye, and those that are slightly subsurface

Liquid Penetrant Inspection (PT)

Surface cracks and pinholes that are not visible to the naked eye can be located by liquid penetrant inspection. It is widely used to locate leaks in welds and can be applied with austenitic steels and nonferrous materials where magnetic particle inspection would be useless. Liquid penetrant inspection is often referred to as an extension of the visual inspection method.

Ultrasonic Inspection (UT)

Ultrasonic Inspection is a method of detecting discontinuities by directing a high-frequency sound beam through the base plate and weld on a predictable path. When the sound beam's path strikes an interruption in the material continuity, some of the sound is reflected back. The sound is collected by the instrument, amplified and displayed as a vertical trace on a video screen - Fig.

Eddy Current Inspection

Eddy current inspection is one of several methods that use the principal of electromagnetism as the basis for conducting examinations Eddy current inspection is used extensively to inspect tubing at power generation and petrochemical facilities for corrosion and erosion.

Digital Imaging Inspection

Radiography is used when volumetric inspections are necessary to insure part reliability. We have added Digital Imaging capabilities to enhance inspection needs. The "x-ray" is now captured on a plate which is scanned and digitized by computer. This enables us to instantly share files with many individuals by email, CD, DVD and/or flash memory.

Digital Imaging Inspection

Positive Material Identification

Hydrostatic Inspection

Ground Penetrating Radar Inspection

&

Welding Procedure Qualification Inspection

Inspection by following Instrument

Flashlight Gauge

Magnifying Glass

Undercut Gauge

Palmgrin Gauge

Arc Strike Cracking

Causes
Improper welding technique Rapidly Cooling of welding area Remedies Use proper welding technique Proper Cooling of welding area

Cold Cracking
Causes
high thermal severity Hydrogen in the weld metal Presence of impurities Weld of insufficient sectional area High welding speeds and low current density Remedies Preheat as per Welding Procedure Specification Welding consumables must be hydrogen controlled Remove impurities Proper weld of sufficient sectional area As per requirement Use of welding speeds and current density Preheat as per WPS

Crater Cracking
Causes
Unfilled Crater Crater crack in sub-merged arc welding Remedies Filler crater with proper technique Utilize run out tab

Hot Cracking
Causes
high welding current poor joint design that does not diffuse heat impurities (such as sulphur and phosphorus) Preheating speed fast & long arcs Base metal contamination Remedies Medium welding current Proper weld joint design Remove impurities Dont Preheating Speed medium & medium arcs Avoid contamination of base metal

Hat Cracking
Causes
Not enough speed Much voltage Remedies Increase welding speed Proper voltage

Under Bead Crack

Causes
More presence of Hydrogen Unequal contraction of base metal & weld metal Remedies Reduce presence of Hydrogen Equal contraction of base metal & weld metal

Longitudinal Crack
Causes
Rapid cooling of weld Improper joint preparation High restraint of joint Remedies Use Proper or matched electrode Reduce Rigidity of weldment Use higher ductile welding filler metal Use Preheat or Reduce cooling rate

Reheat Crack
Causes
Less cooling rate Improper Preheating Remedies Increase cooling rate Proper Preheating

Porosity
Causes
Improper coating on the electrode. Improper Preheating Longer arcs Too low and too high arc currents Faster arc travel speeds Incorrect welding technique Unclean job surface Improper base metal composition Remedies Use low hydrogen welding process Use preheat Increase heat input Clean joint surfaces and Reduce arc travel speeds Use proper welding technique Adjacent surfaces Reducing excessive moisture

Distortion
Causes
Excessive layers & faulty joint preparation Improper bead sequence Improper set-up and fixture Excessive weld size Over-heating of base metal (thin plate) Remedies Tack weld parts with allowance for distortion Use proper bead sequence Tack or clamp parts securely Make weld of specify size

Gas Inclusion
Causes
high sulphur content in the work piece or electrode excessive moisture from the electrode or workpiece too short of an arc wrong welding current or polarity Remedies Reduce sulphur content Avoid moisture Use proper welding current or polarity

Slag Inclusion
Causes
Improper cleaning Presence of grease & dirt Incomplete slag removal from previous bead Gap & Improper preparation of groove Remedies Proper cleaning Avoid grease & dirt Complete remove slag from previous bead Avoid more Gap

Lack of Fusion
Causes
Improper manipulation of welding electrode Weld joint design. Improper heat input Surface contamination which leads slag formation prevents fusion Remedies Minimum heat input to be maintained Avoid molten pool flooding the arc Proper cleaning of oxides slag Correct Electrode angle

Lack of Penetration
Causes
Improper joint ( U joint give better than J butt joint ) Less welding current Root gap too small Too large root face Faster arc travel speed Large electrode diameter Misalignment Remedies Use proper joint geometry Follow current WPS ( welding procedure specification ) Use small electrode in root Increase root opening Reduce arc travel speed Medium electrode diameter Proper alignment

Lamellar Tearing
Causes
Poor ductility of weld metal High Sulphur content of the base metal Hydrogen in the weld Tensile stresses in thickness direction Remedies Use the base metal which has higher ductility Low sulphur & Low inclusions in base metal Use low hydrogen in welding Decrease the stress by Modification

Under Cut
Causes
Excessive welding current Wrong electrode angle Excessive side manipulation Remedies Use the right adequate welding current Proper electrode angle

Welding Methods
Mostly use following welding methods to joint Steam pipe of power plant :

Tungsten Inert Gas (TIG) arc welding Submerged arc welding (SAW) Shielded Metal Arc Welding (SMAW) Resistance Flash Butt Welding

Clear-cut structuring Intuitive operation Uncompromising performance Excellent price /performance ratio Simple installation & Available languages

Welding process done by Specify specification as per Requirement. New add or change in Welding process specification (WPS). All affected parameter also consider in WPS. Creating of Welding joint Sketch is very easy and also Modify them. All details are given like welding process, no. of passes, filler material, shielding gas, current and polarity, welding Voltage, material transfer, wire feed rate, travel speed, distance or gap, heat input, etc WPQR option also given in this software so we can get Qualified welding process. By welder Administration, controlling work and management of Welder. Survey of welder. Easily find out contact information of each welder is easy by Welder Administration Cost Calculation is very easy, not require hard work. We get three types Cost Calculation of like per Meter, per Hour, per Weld. Valuable parameters fill by market value and then we get automatic calculation of Costs. Easily operate by Technician. And Stationary is not required. Record can be store for a long-time period. Manual Calculation is not necessary, so no chance of Mistake. Time for Calculation is less, so Time Savings.

According to the American Society of Mechanical Engineers (ASME) welding defect causes are broken down into the following percentages, And we are Comparison of our project solution with this theory.
41% poor process conditions 32% operator error 12% wrong technique 10% incorrect consumables 5% bad weld grooves Details Description of Problem Welding Defects Causes & Remedies Welding Methods Welding Technology Weld Assistant Software

With the help of our project study and reports : They reduce 85% welding defects as compare to last year Records Maintenance Cost of welding reduce 50%. Improvement in welding joint. Increase Life of Welded pipes. Prevention Accident case & other damage by welding defects Standardization in welding process by welding assistant software. Automatic Economical Cost Calculation & Estimation of welding process. Welding Team having more knowledge of weld examination NDT methods.

The main objective this study is to Reduce welding defects in steam pipes. And we are successful in our project.