Prior to T/TS welding, it is often desirable

to expand the tube into the tubesheet, for

example by a ‘light roll’ to ensure the tube
is centred in the hole for good tracking in
automatic welding. A ‘hard roll’ prior to
welding increases the chance of producing
a weld defect from escaping gas as the
weld is being made. After welding on
thicker tubesheets, the tube is often given
a ‘hard roll’ stopping about 25mm short of
the back side.

The completed T/TS weld should be

inspected visually for defects. A liquid
penetrant inspection is also quite standard.
Other inspections might be imposed - a
leak test and, in some T/TS designs, a
radiographic inspection can be made of
selected areas. Defects such as cracks or
porosity should be ground out and repaired
by TIG (GTAW) with filler metal. Large heat exchanger

Flush tube weld Cladding Fillet weld Cladding

A1 A2 D1 D2
Tube wall Tubesheet Tube wall Tubesheet
ligament ligament
Trepanned tubesheet fillet weld Recessed tube weld

B1 B2 E1 E2

Added-ring weld Explosive tube weld

C F1 F2

Figure 3 – Typical tube weld joint preparations showing finished weld on the right side. 1st and 3rd columns are solid copper-nickel tubesheet; the
2nd and 4th columns are clad plate (ex Reynolds et al - see Bibligraphy)

16 | Copper-Nickel Welding and Fabrication

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