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XIV International Conference on Building Pathology and Constructions Repair – CINPAR 2018
XIV International Conference on Building Pathology and Constructions Repair – CINPAR 2018

Damages in weld joint of water elevated reservoir steel structures

Damages in weld joint of water elevated reservoir steel structures
XV Konferensi Portugis di Patah, PCF 2016, 10-12 Februari 2016, Paco de Arcos, Portugal
Hizadora Constanza Medina D'Ambros a*, Thiago Dias De Araújo Silva a, Esequiel
Hizadora Constanza Medina D'Ambros a*, Thiago Dias De Araújo Silva a, Esequiel
Fernandes Teixeira Mesquita b, Renato Ferreira Barros a
pemodelan termo-mekanis
Fernandes Teixeira dari turbin
Mesquita blade
b, Renato tekanan
Ferreira Barros a tinggi dari
a Instituto Federal de Educação, Ciência e Tecnologia do Tocantins, AE 310 Sul Avenida LO 05 s/n, Palmas 77021-090, Brazil
a Institutob Federal
b
Fundaçãode Núcleo
Educação,
de Tecnologia mesin turbin gas pesawat
Ciência e Tecnologia doCeará,
Industrial do Tocantins,
Rua AE 310
Prof. Sul Avenida
Rômulo LO Fortaleza
Proença, 05 s/n, Palmas 77021-090,
60440-552, BrasilBrazil
Fundação Núcleo de Tecnologia Industrial do Ceará, Rua Prof. Rômulo Proença, Fortaleza 60440-552, Brasil

P. Brandão Sebuah, V. Infante b, AM Deus c *

Abstract Sebuah Departemen Teknik Mesin, Instituto Superior Técnico, Universidade de Lisboa, Av. Rovisco Pais, 1, 1049-001 Lisboa,
Abstract
Portugal
Waterb IDMEC,
elevatedJurusan Teknik
reservoirs areMesin, Instituto
commonly Superior
designed forTécnico,
drinkingUniversidade deinLisboa,
water storage Av. Rovisco Pais,
small communities. 1, 1049-001
Usually Lisboa, prefabricated steel structures of
they comprise
Water elevated reservoirs are commonly designed for drinking water storage in
elevated tanks, especially due to fast assembly of the component parts oncePortugal small communities. Usually they comprise prefabricated
parts of the structure just need to be connected. steelthe
That one was structures of
construction
c CeFEMA, Department of Mechanical Engineering, Instituto Superior Técnico, Universidade de Lisboa, Av. Rovisco Pais, 1, 1049-001 Lisboa,
elevated tanks,
system used especially
in small due to fast
communities assembly
in the State ofofTocantins,
the component
Brazil.parts once parts
However, weld of thefailures
joint structure
havejustcaused
need todegradation
be connected.
and That one occurrence
damage was the construction
in the
systemelevated
used in reservoir
small communities in the StatebyofShielded
Tocantins, Brazil. Portugal
water components welded Metal ArcHowever, weld jointprocess
Welding (SMAW) failuresthat
have caused
uses degradation
a flux-coated and damage
electrode to formoccurrence
the weld. Ininthis
thework,
water
an elevated reservoir
investigation components
was carried welded
out in order by Shielded
to analyze Metal Arc
the existence Welding (SMAW)
of pathologies in the process that uses
welded joints a water
in the flux-coated electrode
elevated to form
reservoir the in
located weld. In this work,
Tocantins.
an investigation
Following, was carriedwere
the components out intested
orderto
totensile
analyze the existence
strength of pathologies
(NBR 6892-1: 2013) ininplates
the welded
equal joints in the
to those water
used elevated
in water reservoir
elevated located
reservoirs in with
and Tocantins.
joints
Abstract
Following, the components
welded intentionally with thewere
same tested to tensile
identified strength
pathology. The(NBR 6892-1:
damages 2013)
found by in plates
visual equal to
analysis werethose usedtoinfast
related water elevated
cooling, slagreservoirs
inclusions, and with
high joints
and low
welded intentionally
welding amperage and withmoist
the same
weldingidentified pathology.
electrodes. The damages
Concerning found
the tensile by visual
strength test, analysis werewith
joint welded related to fast cooling,
low welding amperage slagand
inclusions, high with
joint welded and low
moist
During their operation, modern aircraft engine components are subjected to increasingly demanding operating conditions, especially the high pressure turbine
welding electrodes
welding amperage and moist welding
presented more electrodes.
damages, Concerning
results that the tensile
evidenced the strength
importance test,
of joint
the weldedcontrol
quality with low
of welding
the weldamperage
in this and joint welded
construction system. with moist
(HPT) blades. Such conditions cause these parts to undergo different types of time-dependent degradation, one of which is creep. A model using the finite
welding electrodes presented more damages, results that evidenced the importance of the quality control of the weld in this construction system.
element method (FEM) was developed, in order to be able to predict the creep behaviour of HPT blades. Flight data records (FDR) for a specific aircraft,
provided by a commercial aviation company, were used to obtain thermal and mechanical data for three different flight cycles. In order to create the 3D model
needed for the FEM analysis, a HPT blade scrap was scanned, and its chemical composition and material properties were obtained. The data that was
Copyright
gathered© 2018
was fedElsevier B.V.
into the FEMAll model
rights reserved. Peer-review
and different under
simulations were run, first with a simplified 3D rectangular block shape, in order to better establish the
Copyright © 2018 Elsevier B.V. All rights reserved. Peer-review under
Copyright
model, ©and
responsibility2018theElsevier
ofthen with theB.V.
CINPAR realAll
2018 rights
meshreserved.
obtainedPeer-review
3Dorganizers under
from the blade scrap. The overall expected behaviour in terms of displacement was observed, in particular at
responsibility of the CINPAR 2018 organizers
responsibility
the trailing of the of
edge CINPAR 2018Therefore
the blade. organizers
such a model can be useful in the goal of predicting turbine blade life, given a set of FDR data.
Keywords: Damages; Steel structures; Weld joint; Water elevated reservoir
Keywords: Damages; Steel structures; Weld joint; Water elevated reservoir

© 2016 The Authors. Published by Elsevier B.V.

Peer-review under responsibility of the Scientific Committee of PCF 2016.

Keywords: High Pressure Turbine Blade; Creep; Finite Element Method; 3D Model; Simulation.

* Corresponding author. Tel.: +55 63 981388459.

* E-mail
Corresponding
address:author. Tel.: +55 63 981388459.
hizadoraconstanza@hotmail.com
E-mail address: hizadoraconstanza@hotmail.com

2452-3216 Copyright © 2018 Elsevier B.V. All rights reserved. Peer-review under
2452-3216 Copyright
responsibility © 2018 2018
of the CINPAR Elsevier B.V. All rights reserved. Peer-review under
organizers.
* Corresponding
responsibility of the CINPAR 2018+351
author. Tel.: organizers.
218419991.
E-mail address: amd@tecnico.ulisboa.pt

2452-3216 © 2016 The Authors. Diterbitkan oleh Elsevier

Peer-review di bawah tanggung jawab Komite Ilmiah PCF 2016.
2452-3216 Copyright • 2018 Elsevier B.V. All rights reserved. Peer-review under
responsibility of the CINPAR 2018 organizers
10.1016/j.prostr.2018.11.016
 Hizadora Constanza Medina D’Ambros et al. / Procedia Structural Integrity 11 (2018) 114–121 115
2 Author name / Structural Integrity Procedia 00 (2018) 000 – 000

1. Introduction

Welding is a joining process of two or more metallic components involving melting of the metal adjacent to the joint to establish an atom-to-atom
bond (Hellier, 2003). In the Shielded Metal Arc Welding (SMAW) process an arc welding process produces coalescence of metal by heating them
with an arc between a covered metal electrode and the working surface (Ranjan, 2014).

The quality of the weld and its mechanical strength depends on the interaction of variables, as joint temperature and pression. In SWAN process
not all of the properties are related with materials properties (Ranjan, 2014). Since that, parameters of interest in arc welding include: welding
current, welding voltage, welding speed, torch position, gas protection, filler material addition and wire feed speed (Sun et al., 2005). However, is
difficult control and maintain these parameters constant when the welding outside the laboratorial environment.

The difficulty of completely controlling the welding process predict the presence of defects at welds (Rogerson,
1983), the failures will inevitably exist in welded structures (Maddox, 1974). According to Rogerson (1983), there are two groups of defects:
technological and workmanship defects. The first defect results from inconsistency in the welding operations, and the second defect are from the
inherent variability of the welding process.
Because of this is necessary define reliable methods of assessing the significance of failures and also acceptance levels of weld defects
(Boulton, 1976). Some non-destructive testing (NDT) techniques used to assurance quality in weld joint are: visual inspection, dye penetrant
inspection, magnetic particle testing, radiographic inspection, ultrasonic testing. The quality levels for imperfections are determined by
standardizations as BS EN ISO 5817:2014 (ISO, 2014).

The damage caused by the defects in butt-welded joints were evaluated by authors as Chang and Teng (2004) who investigated the residual
stresses of this type of weld, considering a no uniform temperature distribution, thermal strains and localized plastic deformation causes by the
welding process. In the same way, the effect of weld geometry and residual stresses on fatigue in butt-welded joints was the object of Teng et al
d
(2002) in order to predict the effects of important butt weld geometry parameters.
d

Steel water elevated reservoir localized in the state of Tocantins, Brazil, was visited to discover the existence of welded joints pathologies by
visual analysis. The study was carried out by water supplier company's invitation which aimed to reduce the failures numbers in these structures
once several times the loss of water in steel water elevated reservoir had happened at the weld joint. Structures in the communities Paraíso do
Tocantins, Porto Nacional and Araguatins were visited, the Fig. 1 show the location of these cities.

Fig. 1. Location of visited cities with steel water elevated reservoir and the welder in Paraíso do Tocantins, Porto Nacional and Araguatins.

Damages found at welded joints by visual analysis were related to slag inclusions, high and low welding amperage and also moist welding
electrodes, the Fig. 2 and 3 show the aspects of this pathologies. The presence of slag inclusions characterized this pathology, but also defects as
overlap, excess weld metal, porosity were identified (Fig. 2).
116 Hizadora Constanza Medina D’Ambros et al. / Procedia Structural Integrity 11 (2018) 114–121
Author name / Structural Integrity Procedia 00 (2018) 000 – 000 3

Fig. 2. Pathologies in weld joint at steel water elevated reservoir: slag inclusions.

The weld joint with weld spatter, porosity and solidification cracking indicated the weld in high welding amperage (Fig. 3a). In opposite, excess
weld metal, overlap, undercut were recognized as the joint in low welding amperage (Fig. 3b). At least, the incorrect storage of the welding
electrodes indicated the use of moist welding electrodes (Fig. 3c).

Fig. 3. Pathologies in weld joint at steel water elevated reservoir: (a) high welding amperage; (b) low welding amperage; (c) moist welding

electrodes indicated by incorrect storage of the welding electrodes.

 Hizadora Constanza Medina D’Ambros et al. / Procedia Structural Integrity 11 (2018) 114–121 117
4 Author name / Structural Integrity Procedia 00 (2018) 000 – 000

The damage caused by this pathologies in the steel were measured by an experimental investigations with weld joint samples intentionally
welded with the same identified pathology previously created with materials equals to those l used in the water elevated reservoir.

2. Experimental investigation

All of the butt-welded specimens were fabricated from hot-roll ASTM A36 structural steel with 6,3mm thickness. The chemical compositions
allowing manufacturer's technical catalog is 0,25% of carbon (C), 0,040% of phosphorus (P), 0,050% of sulfur (S) and 0,4% of silicon (Si)
(USIMINAS, 2017). The NBR 6892-1: 2013 (ABNT,
2013) indicate spec imens of proportional size to tensile test because of the plate’s thickness above 3mm. The
Equation 1 determines length of steel plate where O L = original measurement length; k = coefficient of
proportionality (5.65); O S = original cross-sectional area.

O
k L • SO (1)

The length of steel plate for the samples of proportional size was 90mm and a steel plate length of 30mm was request by the test machine. To
determine the steel yield strength and steel ultimate tensile strength of the base metal four plates without weld and size 150x40x6.3 mm were used.

The damages in weld joint were simulated in thirty-six samples, four plates for each weld damage: high welding amperage (E-HIGH), low
welding amperage (E-LOW), slag inclusions (E-SLAG), moist welding electrodes (E- MOIST) and four samples to weld joint reference (E-REF).
Plates with size 150x40x6.3 mm with a single V-groove joint between them were used to make a finished weldment of size 75x40x6.3 mm. The Fig.
4 presents the dimensional details of the specimen used in the experiments and welding parameters.

Fig. 4. Dimensional detail of samples used in the experiment: base metal samples and butt-welded samples.

The welding process was SMAW. The E7018 coated electrode of 4mm conserved free of moisture was used, except for E-MOIST sample. The
electric current used on butt-welded specimens varied according to sample: 175 A for E-REF, E-SLAG and E-MOIST; 230 A for E-HIGH ; 100 A for
E-LOW. For this, a welding machine with rated electric current of 280 A and apparent power of 27.5 KVA was used, the base metal was not heat to
welding process, the ambient temperature was between 40 to 42°C.

The base metal tensile strength and the butt-welded specimen tensile strength were measure by tensile test according with NBR 6892-1: 2013
(ABNT, 2013). In these tests, a hydraulic pressure machine with load limit capacity of 1000 kN was used.
118 Hizadora Constanza Medina D’Ambros et al. / Procedia Structural Integrity 11 (2018) 114–121
Author name / Structural Integrity Procedia 00 (2018) 000 – 000 5

3. Results and discussions

Equations The results of base metal samples present the characterization of the metal base were 365,7MPa steel ultimate tensile strength and
269,7MPa steel yield strength. These values corresponded to those expected according to NBR 8800:2008 (ABNT, 2008). The Fig. 5 and 6
presents the aspect of the samples E-BASE, E-REF, E-HIGH, E-LOW, E-SLAG and E-MOIST after tensile strength results. The crack in all E-HIGH,
E-LOW, ESLAG and E- MOIST samples were inside the weld joint, just in E-REF the crack was on base metal, this is a indicated of defects in the
samples (Kobe Steel, 2015).

Fig. 5. Samples aspect after tensile strength results: (a) E-REF; (b) E-SLAG.

Fig. 6. Samples aspect after tensile strength results: (a) E-HIGH; (b) E-LOW; (c) E-MOIST.

The Table 1 show the defects at weld joint samples E-REF, E-HIGH, E-LOW, E-SLAG and E-MOIST in order to compare the defects presented
in each one. All the samples presented defects, as discussed previously the difficulties to maintain constant the parameters causes weld flaws.
Eleven defects were found, the E-MOIST and E- SLAG presented the larger number of defects (nine and seven defects, respectively) and E-REF
the smaller one (four defects).
 Hizadora Constanza Medina D’Ambros et al. / Procedia Structural Integrity 11 (2018) 114–121 119
6 Author name / Structural Integrity Procedia 00 (2018) 000 – 000

Table 1. Defects identified after the weld at samples E-REF, E-HIGH, E-LOW, E-SLAG and E-MOIST.

Defects E-REF E- HIGH E- LOW E-SLAG E-MOIST

Excess weld metal x x x x

Overlap x x x x

Uneven weld bead ripples x x x x

Weld spatter x x x

Porosity x x x

Longitudinal cracking x x x

Slag inclusions x x x

Undercut x x

Lack of fusion x x

Excessive penetration x

Incomplete root fusion or penetration x

The most common defects were excess weld metal, overlap, uneven weld bead ripples (four from five groups of samples). In all this case the
preventive measure are related to welding amperage and the electrode manipulation and also electrode travel and work angle, which correspond to
the samples E-LOW, E-SLAG and E-MOIST. Porosity is related to the environment conditions such as the use of moisture and wind, then it is
expected to be found in E- MOIST samples. Longitudinal cracking and slag inclusions are influenced by the base metal conditions and the incorrect
amperage with correctly correspond to E-HIGH, E-SLAG samples (Kobe Steel, 2015). The Fig. 7 shows the aspect of the defects mentioned at weld
joint samples.

Fig. 7. Defects identified after the weld at samples: (a) porosity, slag inclusions, lack of fusion, overlap; (b) undercut, weld spatter, porosity, lack

of fusion; (c) uneven weld bead ripples, slag inclusions, longitudinal cracking.

In other hand, the less common defects were excessive penetration and incomplete root fusion or penetration (one from five groups of samples
each one). The excessive penetration occurs just in E-HIGH, one cause of this defect is the high heat input to the joint which corresponding to the
joint pathology. Also the incomplete root fusion or penetration was identified at E-SLAG sample because of the slag itself, which trapped in the weld,
when the next layer is deposited, the entrapped slag is not melted out (TWI, 2018). The Fig. 8 show results of tensile strength test of E-REF,
E-HIGH, E-LOW, E-SLAG and E-MOIST samples.
120 Hizadora Constanza Medina D’Ambros et al. / Procedia Structural Integrity 11 (2018) 114–121
Author name / Structural Integrity Procedia 00 (2018) 000 – 000 7

Fig. 8. Tensile strength results of samples E-REF, E-HIGH, E-LOW, E-SLAG and E-MOIST.

The E-REF samples show the large value of steel ultimate tensile strength and steel yield strength above all the other samples. The E-LOW and
E-MOIST presented the smaller value of steel ultimate tensile strength (14,35% and
10,03% below E-REF sample, respectively). The fact repeat for the steel yield strength values, in this case E-LOW and E-MOIST samples present
values 12,77% and 7,11% below E-REF sample. In both characteristic property of steel the E-SLAG and E-HIGH samples show less than 3%
difference from the EREF value.
This results associated with the visual analyses indicate the E-LOW and E-MOIST samples as the most effected by the simulated conditions.
Both are workmanship defect where the skills of the welder have not matched the demands of the weld configuration (Hicks, 2000). The use of
appropriated amperage and the correct storage of the electrode are the preventive measure indicated for avoid weld with the same aspects of
E-LOW and E-MOIST samples.

4. Conclusions

In this work an experimental program was carried out to measure the damage of of welded joints pathologies identified at water elevated
reservoirs in the state of Tocantins, Brazil. The visual analyses determine the presence of pathologies related to slag inclusions, high and low
welding amperage and also moist welding electrodes indicated by the defects present in weld joint.

The samples intentionally welded with pathologies show similar defects to those identified at the water elevated reservoirs. The tensile strength
results evidence significant loss of resistance and the in large number of defects in samples with low welding amperage and moist welding
electrodes. Those damages were identified as workmanship defect, and then is recommended the improvement of welder technique which must
necessarily include the capacitation of welder in order to adequate the materials, equipment and the welder ability to the weld configuration.

Acknowledgements

Hizadora D ’Ambros acknowledge the Civil Engineering Tutorial Education Program of Federal Institute of
Education, Science and Technology of Tocantins (PET Civil IFTO) funded by the Ministry of Education of Brazil. The authors acknowledge the Civil
Engineering Laboratory of Educational Lutheran Association of Brazil.
 Hizadora Constanza Medina D’Ambros et al. / Procedia Structural Integrity 11 (2018) 114–121 121
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