Professional Documents
Culture Documents
KO-111-01
URL:http://www.hitachi-kenki.co.jp
KO-111-01
Forward
If construction machines work under severe conditions for long period, cracks may occur in the structure due to metal
fatigue.
To reduce down time and to extend the life of the machine, it is imperative to check for cracks and to repair as soon as
possible. Repairing cracks by appropriate welding techniques (crack detection, restraint, preheating, gouging, repair
welding, after heating, reinforcement, and finishing) are most important and effective measures.
However, if inadequate repair welding is applied, cracks will develop again in a shorter period of operation than before,
making it difficult to trace the cause of the repeated crack. If appropriate welding techniques are not performed, this will
allow cracks to develop repeatedly.
This manual aims to introduce the correct method of repair welding to prevent cracks from developing repeatedly.
This manual is intended for welders who have completed technical training of welding (American Welding Society
Class 3 or up, or equivalent), Hitachi sales support servicemen and Hitachi Dealer servicemen who are in the position
to supervise repair welding.
Repair works shall be implemented according to the countermeasures diagram issued by Hitachi; this manual shall be
used as a supplementary reader.
Be sure to thoroughly read this manual for correct repair welding information and procedure.
Information and specifications in this manual are for repair welding purpose only. They may be different from those of
Hitachi construction machinery factory procedures and standards.
All information, illustrations and specifications in this manual are based on the latest
information available at the time of publication. The right is reserved to make changes at
any time without notice.
COPYRIGHT ©2019
Hitachi Construction Machinery Co., Ltd.
Tokyo, Japan
All rights reserved
FORWARD
The answers to the questions or useful information on the above items are contained in the following sections. Hitachi
servicemen who are in position to supervise welding should have this information in advance.
TOOLS & INSPECTION RESTRAIN PREHEA GOUGING REPAIR REINFOR FINISHING APPENDIX
AUXILIARY OF CRACKS ING TING WELDING CEMENT
EQUIPMENT
SECTION AND GROUP
CONTENTS Group 1 SAFETY
Group 2 DON’T’S: FUNDAMENTALS
Group 3 DON’T’S: EXAMPLES
Group 4 TOOLS & AUXILIARY EQUIPMENT
Group 5 INSPECTION OF CRACKS
Group 6 RESTRAINING
REPAIR WELDING MANUAL
Group 7 PREHEATING
Group 8 GOUGING
Group 9 REPAIR WELDING
Group 10 REINFORCEMENT
Group 11 FINISHING
Group 12 APPENDIX
COPYRIGHT ©2019
Hitachi Construction Machinery Co., Ltd.
Tokyo, Japan
All rights reserved
(Blank)
SECTION 1
SAFETY
– CONTENTS –
1-1. Safety......................................................................................1-1
(Blank)
SECTION 1 SAFETY
1-1. Safety
Follow Safety Instructions
Safety first
Allow only trained, qualified, authorized personnel to
perform repair welding.
(American Welding Society Class 3 or up, or equivalent)
Carefully read and follow the instructions in this manual.
Also, read the safety section of the operator's manual
before performing any welding work.
Be sure to follow your local safety regulations.
SA-003
SA-022
1-1
SECTION 1 SAFETY
1-2
SECTION 1 SAFETY
1-3
SECTION 1 SAFETY
SA-016
SA-037
1-4
SECTION 2
DON’T’S: FUNDAMENTALS
– CONTENTS –
2-1. Don’t’s: Fundamentals......................................................2-1
(Blank)
SECTION 2 DON'T'S: FUNDAMENTALS
2-1
SECTION 2 DON'T'S: FUNDAMENTALS
Restraining
DO NOT work without restraint fixture where restraint
fixture is required.
Heat is applied when gouging or welding. When the heat
falls, the base material shrinks, causing distortion (falling
down and twisting).
DO NOT use restraints fixture that cannot withstand
deformation.
If the restraint fixture material is weak, the restraint fixture
material itself will be deformed and useless.
DO NOT weld a restraint fixture to machined surfaces.
If a restraint fixture is welded on a machined surface, the
machined surface must be machined again.
DO NOT attach restraint fixtures without checking the
dimensions.
If welding is performed without first measuring the
dimensions of the matching parts, the match may not fit;
welding-induced distortion cannot be corrected without
knowing the original dimensions.
DO NOT apply preheating work without attaching
restraint fixtures.
Similar to the case of welding work, as the temperature
of preheated parts goes down, the preheated parts may
distort.
Preheating
DO NOT perform welding on high tensile strength steel or
on special steel without preheating it.
Welding without preheating can cause cracks. Preheating
prevents cracks, hardening and embrittlement.
DO NOT perform welding work when the temperature is
lower than 10 °C (50 °F).
Performing welding when the temperature is lower
than 10 °C (50 °F) may cause a state of rapid heating and
cooling, resulting in cracks around the welded part.
DO NOT start welding without measuring preheat
temperature.
Low preheat temperature may cause cracks. High preheat
temperature may cause brittling of the base metal which
may result in cracks in the base metal.
DO NOT heat high tensile strength steel or special steel to
more than 400 °C (752 °F) and rapidly cool it.
Base metal becomes brittle. In some cases, cracks may
develop in a few days.
DO NOT heat metals to temperatures more than required
and DO NOT expand the heating area.
Base metal becomes brittle and resulting distortion
increases.
2-2
SECTION 2 DON'T'S: FUNDAMENTALS
Repair welding
DO NOT ground far away from the welding part.
For example, do NOT ground at a hydraulic cylinder when
welding on the frame.
As a gap exists between the cylinder tube and the piston,
sparks will be generated at the gap, causing damage to
the cylinder.
DO NOT use an inappropriate gouging rod.
Relatively large rod diameter compared to the plate
thickness may cause the plate to be penetrated.
DO NOT use a faulty holder (torch) or gas burner.
Electrocution or burns may result. Also, appropriate
heating or welding cannot be done with it.
DO NOT perform gouging using a gas burner on high
tensile strength steel or on special steel.
As the temperature excessively rises, base metal becomes
brittle, causing cracks.
DO NOT perform any gouging without confirming the
thickness of plate first.
If it is penetrated during gouging, a notch will be left if
the back side cannot be welded.
DO NOT generate arc strikes (sparks) on places other than
the welding part.
Arc strike parts harden. Even after grind finishing, cracks
may appear at the bent areas of plates or rounded areas.
DO NOT weld the gouged part as it is.
A weld defect occurs inside or becomes brittle. Therefore,
after gouging, grinder finishing must be performed
before welding.
DO NOT use flux cored wire or coated electrode which is
not dry.
When welding with a damp electrode, especially with
that of low hydrogen type, the weld metal may become
brittle, causing cracks as well as other failures, such as
blowholes.
DO NOT use any electrodes or welding wires except for
those specified.
Desired strength may not be obtained. Also,
inappropriate bead forms may result, causing cracks.
DO NOT weld with defects.
Cracks will appear in a short time after completion of
repair welding.
DO NOT weld on high tensile strength steel or on special
steel, surpassing interpass temperature.
Base metal around welded parts becomes brittle. Also,
it may cause distortion to increase. Keep interpass
temperature higher than preheating temperature and
lower than 400 °C (752 °F).
DO NOT rapidly cool (or quench) high tensile strength
steel or special steel.
The steel may become brittle. For this reason, toughness
may decrease, eventually leading to breakage.
2-3
SECTION 2 DON'T'S: FUNDAMENTALS
DO NOT perform welding work without taking into
account crack propagation (progression).
If no appropriate corrective measure is taken, cracks may
not be completely removed, or cracks may propagate.
DO NOT perform welding heavily on one side when
performing welding on both back and front surfaces or
performing left and right symmetrical welding.
If the work is done unevenly, excessive distortion will
result.
DO NOT weld the gas cut surface without grind finishing.
Poor penetration caused by notches on cut surface
will result. Also, weld defect caused by slag inclusion
may result.
DO NOT close manholes without first confirming and
recording what was done inside of a box type structure.
Required welding inside or grind finishing might have
been omitted.
Straightening
DO NOT perform straightening with welding fixtures
removed.
Amount of distortion may increase and distortion
directions may become multi-dimensional, causing
straightening to become very difficult.
DO NOT heat high tensile strength steel or special steel to
more than 400 °C (752 °F) and rapidly cool it.
Base metal becomes brittle. In some cases, cracks may
develop in a few days.
DO NOT heat metals to temperatures more than required
and DO NOT expand the heating area.
Base metal becomes brittle and resulting distortion to be
increased.
DO NOT perform straightening on one side only.
Amount of distortion increases and distortion directions
may become multi-dimentsonal.
DO NOT heat and then rapidly cool machined surfaces.
Distortion will develop on machined surfaces.
2-4
SECTION 2 DON'T'S: FUNDAMENTALS
Reinforcement
DO NOT add reinforcing plate carelessly.
If a reinforcing plate is carelessly added, it may inversely
increase stress concentration, leading to the occurrence
of new cracks.
Finishing
DO NOT finish rougher than the standard.
If the finished surface is rough, or if there is a notch due
to grinder finish in the surface, stress will concentrate and
break.
DO NOT omit grind finishing on any specified areas.
Although weld bead or ends of bead may look smooth
and flat, there always are undercuts and/or overlaps,
causing stress concentration.
DO NOT leave any notches on finished surfaces.
Even a notch on a smooth finished surface causes stress
concentration on it, eventually leading to breakage. Be
careful not to leave any notches on finished surfaces.
Especially check toe of bead.
DO NOT grind finish any machined surfaces.
Precise dimensions cannot be obtained by grinding. For
this reason, oil leakage or excessive wear may result.
2-5
SECTION 2 DON'T'S: FUNDAMENTALS
MEMO
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2-6
SECTION 3
DON’T’S: EXAMPLES
– CONTENTS –
3-1. Don’t’s: Examples................................................................3-1
(Blank)
SECTION 3 DON’T’S: EXAMPLES
RIGHT WRONG
DO NOT tack-weld ends of the backing plate.
When using a flat-bar-type backing plate, avoid
performing tack welding in the range approx. 40 to 50
mm (1-1/2 to 2 in) from the contacting end, as illustrated.
Tack welding close to the end may cause stress
concentration, leading to premature breakage of the End
welded joint. Maintain Backing Plate
40 to 50 mm (1-1/2 to 2”)
distance TDC-26
Completely
DO NOT tack-weld the backing plate from the inside. remove the
When installing the backing plate for covering an access RIGHT tack welding WRONG
hole by tack welding, weld the back plate at the weld beads using Base Metal
a grinder Outside
groove, as illustrated. just before
Then, remove the tack welding beads one by one just the regular
before regular welding is performed on the tack welded welding.
part.
Inside
Backing Plate
TDC-25
3-1
SECTION 3 DON’T’S: EXAMPLES
DO NOT let the root gap for backing plate welding be too RIGHT WRONG
wide or too narrow.
Narrow root gap results in incomplete penetration,
leading to bead cracking.
Wide root gap induces stress concentration at the joint.
Backing Plate
Wide Root
Correct Root Gap Gap
4 to 6 mm
(1/8 to 1/4”) Deep Penetration
WRONG
Incomplete
Penetration
Narrow
Root Gap TDC-27
DO NOT leave any gap between the base metal and the
reinforcing plate.
If any gap is left between them, the reinforcing plate will
not function. Be sure to reduce gap to less than 0.5 mm
(20/1 000 in), as illustrated below.
Wedge
Tighten with the bolt RF-005 Press the plate using the wedge RF-006
Reinforcing Plates
RF-009
3-2
SECTION 3 DON’T’S: EXAMPLES
DO NOT plug-weld any reinforcing plates.
If a reinforcing plate is installed by plug welding, it will RIGHT
NOT function properly.
Anti-Wear
Moreover, it may induce new cracks at plug welded parts. Plate
Use plug welding method only when installing anti-wear
materials.
RW-03-03-002
WRONG
Reinforcing Plate
RW-03-03-003
DO NOT penetrate through base metal when removing a
through crack by gouging. α
Repair work will be extremely difficult once the base
metal is penetrated by gouging.
Refer to the illustration right to remove through cracks.
t
3 mm (1/8”)
or more
4 mm (5/32”)
or more
10 mm (13/32”)
or more
GA-008
DO NOT commence grinding without first considering the
lengthwise direction of the crack.
Since notches and scratches that occur in the direction
of grinder disk rotation will cause cracks to recur, finish
them securely so that they do NOT exist.
Grinder-Left
Rings (Lines)
Crack Grinder
SA-006A
3-3
SECTION 3 DON’T’S: EXAMPLES
DO NOT weld plate edges.
In general, plate edges are stress concentrated. For this
reason, notches may be left at stress concentrated places
if plate edges are welded.
Be sure to avoid welding plate edges.
When the restraint material is attached, remove it
completely and finish the surface so that notches and
scratches does not remain after removal.
TDC-55
RIGHT WRONG
Restraint Fixture
Weld
TDC-56
TDC-58
WRONG
RF-013
3-4
SECTION 3 DON’T’S: EXAMPLES
DO NOT lay welding bead perpendicular to the force
applied direction.
Bead laying perpendicular to the force applied direction
acts as a large notch, inducing stress concentration.
RIGHT WRONG
Force Applied Force Applied
Direction Direction To Front Attachment
or
RIGHT
SA-007A
2A or more
Bead A
RW-03-01-001
RIGHT WRONG
EX-002
3-5
SECTION 3 DON’T’S: EXAMPLES
DO NOT lay weld lines close together.
If weld lines are laid close together, the combined
residual welding stress will make the welded joints and
surroundings brittle.
RIGHT WRONG
Bead
EX-003
Gas-Cut Surface
Access Hole
RIGHT WRONG
EX-004
3-6
SECTION 4
1. Preparation
Movable Scaffold
Footing
Protectors
Refractory cover for cylinder rod protection
Cover binding wire
Grounding wire
Wind screen Movable scaffold RW-04-01-001
Crack Report
Crack report form
Repair welding report form
Photo-camera with close-up function
2. Crack Check
Checking Tool
Ultrasonic flaw detection device
Development solution for liquid penetrant inspection
(Dye check)
Linear Measure
Tape measure, ruler, etc.
RW-04-01-002
Liquid penetrant inspection solution
Others
Plate thickness gauge
Cleaning solvent
Shop towel
Illumination
3. Restraining
Restraining Material and Tools
Material for restraining member (Fixture)
Hydraulic jack
Journal jack
Linear Measure
Tape measure, ruler, etc.
Welding machine
4-1
SECTION 4 TOOLS & AUXILIARY EQUIPMENT
4. Preheating
Preheating Equipment
Gas torch, gas burner
Thermometer
Thermal chalk, surface thermometer
5. Gouging
Gouging Machine
Arc-air gouging machine
Inspection Equipment
Liquid penetrant inspection solution (Dye check)
Ruler
4-2
SECTION 4 TOOLS & AUXILIARY EQUIPMENT
7. Reinforcement
8. Finishing
Finishing Tool
Pencil grinder (Tungsten carbide cutter)
Straight grinder
Angle grinder
Others
R gauge, template, compressor
4-3
SECTION 4 TOOLS & AUXILIARY EQUIPMENT
MEMO
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4-4
SECTION 5
INSPECTION OF CRACKS
– CONTENTS –
5-1. Importance of Inspection................................................5-1
5-2. Record and Report.............................................................5-2
5-3. Visual Inspection.................................................................5-4
5-4. Liquid Penetrant Inspection...........................................5-5
5-5. Ultrasonic Flaw Detection Method..............................5-7
5-6. Magnetic Powder Method..............................................5-8
(Blank)
SECTION 5 INSPECTION OF CRACKS
RW-05-01-002
5-1
SECTION 5 INSPECTION OF CRACKS
2. Information on Crack
Be sure to indicate the location of any cracks using
“Drawing”, “Parts Catalog”, or “Visual Check List”.
Be sure to indicate the distance from a reference position
to the crack and the crack length to correctly locate the
cracked position, as illustrated to the right (L1, L2, L3, and
L4).
Check and report if more than one of the base metals are
cracked.
In case that crack (s) develop in the weld joint, make it
clear that either the toe of weld is cracked or the weld
bead is, as shown by (a), (b), and (c) in the table to the
below.
In case that crack (s) have developed, check the starting
point of the crack and be sure to report the starting point.
Report the weld appearance at the cracked section
regarding if any weld defects such as short-bead-leg
length, undercut, overlap, and blowhole on the weld
bead surface are noticeable.
If a crack has developed on a box type section, report if
the crack was started from the outer surface or from the
inner surface. However, when such judgement is difficult,
avoid making a hasty conclusion. Be sure to report only
the points actually recognized.
Be sure to report the serial No. of the front attachment.
(The stamp location of the serial No. is illustrated below.)
L2
L1
Manufacturing
No. (stamped).
No crack.
5-2
SECTION 5 INSPECTION OF CRACKS
3. Photograph
Be sure to take three kinds of photographs of the crack as
illustrated below.
Arm
bulkhead
Bottom
plate Rib
Crack
RW-05-02-002E
5-3
SECTION 5 INSPECTION OF CRACKS
5-4
SECTION 5 INSPECTION OF CRACKS
RW-05-04-002
3. Application of Penetrant
(1) After pre-treatment with cleaner, apply penetrant to
the inspection surface.
(2) Leave at room temperature for about 10 minutes.
Application of Penetrant
RW-05-04-003
5-5
SECTION 5 INSPECTION OF CRACKS
4. Excess Penetrant Removal
(1) Let the waste cloth soak in the cleaner.
(2) Wipe off the excess penetrant on the inspection
surface.
DO NOT spray the solvent on the test surface directly, because
this can remove the penetrant from the flaws.
5. Agitation of Developer
(1) Shake the developer can.
(2) Shake the can several times after the agitating ball in it
sounds.
6. Application of Developer
(1) Keep the developer about 30 cm away from the
inspection surface.
(2) Evenly spray the developer onto the inspection
surface.
5-6
SECTION 5 INSPECTION OF CRACKS
5-7
SECTION 5 INSPECTION OF CRACKS
Weld Joint
Defect
Yoke Method
Electromagnet
Current
Specimen
Magnetic Force
Line
Defect
Weld Joint
Prod Method
TDC-64
5-8
SECTION 6
RESTRAINING
– CONTENTS –
6-1. Importance of Restraining Work...................................6-1
6-2. Precautions for Restraining Work.................................6-2
6-3. Examples of Attaching Restraining Fixtures.............6-4
6-4. Precautions for Removing Restraining Fixure..........6-6
(Blank)
SECTION 6 RESTRAINING
6-1
SECTION 6 RESTRAINING
TDC-47
WRONG RIGHT
Welding
Machined Surface
TDC-50
6-2
SECTION 6 RESTRAINING
Attach a restraining fixture before preheating for regular
welding. Preheating will also cause distortion when it is
cooled.
Burner
Preheating RW-06-03-001
6-3
SECTION 6 RESTRAINING
Welding
Access Hole
TDC-54
6-4
SECTION 6 RESTRAINING
Restraining Methods for Ribs inside Boom & Arm and Yoke-
type Bracket
Ribs inside Boom and Arm
If an arc strike impression is left on the upper section of
the rib provided inside the boom and arm, cracks may
develop from that point. Thus, welding a restraining
fixture in this section should be avoided.
TDC-55
RIGHT WRONG
Restraining Fixture
TDC-56
If an arc strike impression is left at the plate fringe of the
yoke bracket provided at the tip end of the boom and
arm, cracks may develop from that point. Thus, welding a
restraining fixture in this section should be avoided. RIGHT WRONG
TDC-57
6-5
SECTION 6 RESTRAINING
6-4. Precautions for Removing Restraining Fixure Small Notch Finish by Grinding
TDC-58
6-6
SECTION 7
PREHEATING
– CONTENTS –
7-1. Preheating.............................................................................7-1
7-2. Temperature Between Welding Paths.........................7-2
7-3. Warming Up.........................................................................7-3
7-4. Postheating..........................................................................7-4
7-5. Selection of Preheating Temperature.........................7-5
7-6. Preheating Method............................................................7-6
7-7. Temperature Checking Method....................................7-7
(Blank)
SECTION 7 PREHEATING
7-1. Preheating
Weld joint and its vicinity are heated to a specified
temperature before welding. The purpose of preheating is to
allow the diffusive hydrogen in the weld metal to have enough
time to be released while cooling as the cooling speeds of
preheated base metal are slower than untreated base metal.
The additional effects of preheating are:
Prevention of weld cracks and to ensure complete
penetration when welding base metals having self-
hardening properties.
To help recover ductility and notch brittleness of weld
metal.
Generally, preheating for the first layer is most effective. Measuring Position of Preheating Temperature
However, it is sometimes performed to intermediate or final
RW-07-01-001
layers.
Preheating RW-07-01-002
7-1
SECTION 7 PREHEATING
Appropriate Temperature
Too High Temperature
RW-07-02-004 RW-07-02-005
7-2
SECTION 7 PREHEATING
7-3. Warming Up
The purpose of warming up are to dehydrate the surface of
the base metal and to heat the vicinity of the weld joint up to
approx. 40 °C (104 °F) before welding even if material of the
base metal is normally not preheated.
RW-07-03-001
7-3
SECTION 7 PREHEATING
7-4. Postheating
After welding, the weld joint is heated again. This is called
“Postheating.” The postheating is usually applied to high
carbon steels to prevent the heat affected zone from
hardening too quickly. Slow cooling after welding allows
hydrogen to be released, reduces residual stress, and prevents
the occurrence of cracks.
However, strength or toughness may be reduced by
postheating. Therefore, postheating temperature must be
correctly controlled.
RW-07-04-001
7-4
SECTION 7 PREHEATING
Generally:
When single-bevel groove is called for, the preheating
temperature for them is 50 °C (90 °F) higher than that for
double-V, single-V, or double-U groove.
The higher the alloy elements such as carbon, the higher
the preheating temperature. (Degree of restraint depends
on groove shape)
The thicker the plate, the higher the preheating
temperature.
Manual welding requires higher preheating temperature
than semi-automatic welding.
T: Plate Thickness
Weld steel T<25 mm 25<T<38 38<T<50
JIS ASTM/AISI (T<1”) (1”<T<1-1/2”) (1-1/2”<T<2”)
SS400 36 Not required* Not required* Not required*
SM490 70 Not required* 70 °C or less 50-100 °C
High tensile steel (158 °F)
50 kg/mm2
(70 000 psi)
Class
SM570 - 50-100 °C 70-120 °C 100-150 °C
High tensile steel (122-212 °F) (158-248 °F) (212-302 °F)
60 kg/mm2
(85 000 psi)
Class
High tensile steel 70-120 °C 100-150 °C 120-180 °C
70 kg/mm2 (158-248 °F) (212-302 °F) (248-356 °F)
(100 000 psi)
Class
High tensile steel 100-150 °C 120-180 °C 150-200 °C
80 kg/mm2 (212-302 °F) (248-356 °F) (302-392 °F)
(115 000 psi)
Class
*: When ambient temperature is lower than 10 °C (50 °F), be sure to preheat base metal to 30-50 °C (86-122 °F ).
7-5
SECTION 7 PREHEATING
Heat, not only the range close to the weld joint but both sides (2-4”)
of the weld joint ranging from 50 to 100 mm (2 to 4 in) (or 3 Weld Joint
times the plate thickness), to the 50-100 mm 50-100 mm
specified temperature. (2-4”) (2-4”)
TDC-69
7-6
SECTION 7 PREHEATING
Thermal Chalk
Utilizing change in color or state due to thermal
decomposition or fusion of compounds, temperature
is checked. This method is convenient to check if the
temperature of the preheated area is over or below the
specified temperature. However, this method cannot
measure exactly what the temperature is. Thermal chalks
are grouped and available depending on temperature
ranges to be measured. Use thermal chalk appropriate to
the application.
The following are thermal chalks recommended to have
in stock for repairing construction machineries.
Thermal Chalk RW-07-07-001
Applicable Temperature of Thermal Chalk
°C 50, 70, 100, 120, 150, 180, 200, 250
°F 120, 160, 200, 250, 300, 350, 400, 450
7-7
SECTION 7 PREHEATING
Surface Thermometer
There are two types of surface thermometers, non-
contact type and contact type. The contact type is usually
comprised of a temperature sensor and a display. When
the temperature sensor is pushed against the base metal,
the temperature of the base metal is indicated on the
display.
Temperature range and sensing response vary depending
on kind of material used for the sensor. Depending
on the surface roughness of the base metal and the
contact condition of the sensor with the base metal, the
sensitivity of the contact type surface thermometer may
be affected. Take care to correctly push the contact type Contact Type Surface Thermometer
surface thermometer sensor against the base metal. Take RW-07-07-002
care to correctly push the thermometer sensor against
the base metal.
The non-contact type surface thermometer is simple and
easy to use. However, as the accuracy is relatively low
compared to the contact type surface thermometer, take
care to use it.
7-8
SECTION 8
GOUGING
– CONTENTS –
8-1. Gouging.................................................................................8-1
8-2. Preparation for Gouging..................................................8-3
8-3. Gouging Procedure...........................................................8-4
8-4. Finishing............................................................................. 8-12
(Blank)
SECTION 8 GOUGING
8-1. Gouging
Crack Gouging
The purpose of gouging is to completely remove defects from
the section to be welded and to prevent defects in the weld
bead of the repair welding.
If any defect should remain in the weld bead, cracks may
result.
Since gouging sparks can scatter over 10 m, be sure to
confirm safety of the surrounding workers and there are no
flammables around the area before starting work.
GO-001
1. Kinds of Gouging
Gouging methods are grouped as follows:
Arc-air gouging
Gas gouging
Plasma gouging
Generally, when repairing cracks on structures for
construction machineries, arc-air gouging finished by
grinder is employed.
The arc-air gouging work method is explained in this
section.
8-1
SECTION 8 GOUGING
3. Kinds of Gouging Rods
Gouging rods for mild steel are as follows:
Carbon Size mm (in) Copper Applying Groove Shape mm (in) Plate
Gouging Speed
Thickness
Diameter Length Coating Current (A) mm/min (in/min) Depth Width mm (in)
5.0 (3/16) 305 (12) Coated 100-200 900-1200 (35-50) 3-4 (1/8-5/32) 7-9 (9/32-11/32) -9 (11/32)
6.5 (1/4) 200-350 900-1200 (35-50) 4-5 (5/32-3/16) 9-11 (11/32-13/32) -12 (15/32)
8.0 (5/16) 250-400 700-1000 (30-40) 5-6 (3/16-1/4) 10-12 (3/8-15/32) 12 (15/32)-
9.0 (3/8) 300-450 400-700 (15-30) 6-7 (1/4-8/32) 11-13 (13/32-1/2)
11.0 (7/16) 400-550 300-400 (12-15) 8-9 (5/16-11/32) 13-15 (1/2-19/32)
13.0 (1/2) 450-600 200-300 (8-12) 9-10 (11/32-3/8) 15-17 (19/32-21/32)
4. Fundamental Precautions
Use a dried gouging rod.
Whenever a gouging rod comes in contact with steel, arc Carbon Electrode Air Valve Handle
will appear. Protect the environment from damage.
Connect the torch holder to the positive terminal of the D.C.
D.C. machine. Machine
Extend the gouging rod approx. 150 mm (6 in) from the
holder head.
Tilt the gouging rod approx. 80 to 90°. As soon as arc
appears, blow air and move the gouging rod forward.
Maintain air pressure within 0.6 to 0.7 MPa (85 to 100 psi).
If air pressure becomes lower than 0.4 MPa (55 psi), Torch Holder
Air
melted metal will not be easily blown off.
In case the crack is suspected to extend while gouging is
being performed, make stopholes to prevent the crack GO-002
from propagating. (Refer to “Removal and repair of weld
defect” in section 09 “Repair Welding”)
Carbon
Air
80° to 90°
GO-003
8-2
SECTION 8 GOUGING
WRONG
GO-004
GO-005
Hydraulic Cylinder
GO-012
8-3
SECTION 8 GOUGING
<Features>
(1) The gouging target line is easy to check. However,
small defects are difficult to find.
(2) This method is common.
80° to 90°
Direction of Gouging
RW-08-03-005
RW-08-03-004
RW-08-03-006
8-4
SECTION 8 GOUGING
Work method (B): Looking behind the gouging
<Features>
(1) The defects are easy to find. However, the gouging
target line is difficult to check.
(2) This method is suitable for checking small defects
such as cracks.
About 90°
Direction of Gouging
RW-08-03-011
RW-08-03-010
RW-08-03-012
8-5
SECTION 8 GOUGING
2. Width of Gouging
Gouging width (W) and depth (D) should be 1:1 as much
as possible in order to prevent cracks after welding.
When it becomes deep, lower the current and take care
for cracks.
40° to 45°
Width (W)
Depth (D)
RW-08-03-013
8-6
SECTION 8 GOUGING
2. When crack has broken through: α
When plate thickness is 19 mm (3/4 in) or less:
When penetration is confirmed by ultrasonic flaw
detection, gouge the crack so that 4 mm (5/32 in) or more
bottom thickness is left.
3 mm (1/8”)
Make groove angle α so that torch angle and electrode or more
angle can meet properly. t
After welding the front side, gouge the reverse side 3 mm
(1/8 in) or more
As the first layer is prone to defects after welding, gouge
the back side in order to remove the first layer. 4 mm (5/32”)
or more
Gouge the re-welded part 3 mm (1/8 in) or more. After
gouging, check for defects.
10 mm (13/32”)
or more GO-008
α0
α1
GO-009
8-7
SECTION 8 GOUGING
3. When weld joint with a backing plate is cracked: α
Gouge only the base metal. Never gouge the backing
plate. If the backing plate is gouged and welded with
the base metal, the backing plate functions as an added
member, inducing stress concentration.
Make groove angle α so that torch angle and electrode
angle can meet properly.
GO-010
RW-08-03-014
8-8
SECTION 8 GOUGING
(2) Tack Welding Method
1. Perform tack welding of a length of 50 mm (2 in) or
more at the center of the crack in order to prevent the
extension of cracks.
If the crack width is 2 mm (0.1 in) or more, use a patch
plate.
* 200 (7.9")
Crack opens 2 mm (0.1") or
more.
50 mm (2") or more
Patch Plate
RW-08-03-015
When using a patch plate (cross section)
* Assuming a 200 (7.9 in) mm long crack that does not
penetrate to the back RW-08-03-016
* 200 (7.9")
50 (2") 50(2")
Section A
Section A RW-08-03-018
RW-08-03-017
fNOTE: PT: Penetrant Testing
MT: Magnetic Particle Testing
8-9
SECTION 8 GOUGING
3. Weld part (a) and part (b). When performing multi-layer
welding, the welding start part and crater part should
not be concentrated at the same position.
* Weld until the final welding part. (Section A)
* 200 (7.9")
Section A
RW-08-03-019
* 150 (5.9")
Section B
Part (c)
RW-08-03-022
Section B
RW-08-03-021
8-10
SECTION 8 GOUGING
5. Weld part (a).
The welding start part and crater part should not be
concentrated. (Section A)
Section A
Section A RW-08-03-024
Part (a)
RW-08-03-023
RW-08-03-025
8-11
SECTION 8 GOUGING
8-4. Finishing
After gouging, grind the gouging surface to remove carbon Gouged Surface
adhering to the gouging surface and to smoothly finish the
surface. Grinding work is required to completely remove
melted slag or carbon adhering to the gouged surface.
Otherwise, they will cause weld defects such as an incomplete Surface Finished by Grinding
fusion and weld metal hardening. Remove section shown
with by grinding.
8-12
SECTION 9
REPAIR WELDING
– CONTENTS –
9-1. Welding Steel.......................................................................9-1
9-2. Electrode...............................................................................9-3
9-3. Drying of Electrodes..........................................................9-6
9-4. Cleaning of Weld Section Before Welding.................9-7
9-5. Welding Current..................................................................9-8
9-6. Welding Speed....................................................................9-9
9-7. Tack Welding..................................................................... 9-10
9-8. Dimensions of Weld Joints........................................... 9-13
9-9. Precautions for Using Backing Plates....................... 9-15
9-10. Temporarily Welding of Supplementary Parts.... 9-17
9-11. Weld Distortions............................................................ 9-18
9-12. Prevention of Weld Distortion.................................. 9-19
9-13. Types of Weld Defects................................................. 9-22
9-14. Major Types of Weld Defects and
Their Causes......................................................................... 9-23
9-15. Weld Defect Check....................................................... 9-25
9-16. Visual Inspection Standard for Weld Joint........... 9-26
9-17. Removal and Repair of Weld Defect....................... 9-28
9-18. Correction of Weld Distortions................................. 9-29
9-19. Inspection After Repairing Weld Defects............. 9-30
9-20. Precautions for Semi-Automatic Welding............ 9-31
(Blank)
SECTION 9 REPAIR WELDING
Maximum
2. Welding structural steels are preferable to those steels Hardness
that have as low of a carbon content as possible. Carbon
is one of the most influential elements to control
Hardness
characteristics of the heat-affected zone in weld zone.
The higher the carbon content in the steel, the more
liable the heat-affected zone will be to harden when Base
Weld Metal
Metal
cooled quickly, causing cracks and reducing ductility in
the weld zone.
Distance from Bond (mm) RW-09-01-001
Structure and Hardness of Weld Joint (High Tensile Strength Steel:
SM490 A)
9-1
SECTION 9 REPAIR WELDING
3. Sufficient strength of a weld structure will be ensured
only when both base metals and weld zones have
adequate strength. Especially, notch sensitivity of the
material is one of the most important properties to Higher than
Preheating
prevent brittle fracture of the weld structure. Therefore, Temperature
specifications of some weld structural steels prescribe and Lower
the lower limits of Charpy impact values to be taken into than 400 °C (752 °F)
account when selecting kinds of steels.
The more heat is added, the greater the notch sensitivity
of the heat affected zone will be reduced. When high
tensile strength steels are welded with a great deal of
heat input, notch sensitivity is reduced remarkably,
requiring the limitation of heat input as necessary. (Refer
to the section 07 “Preheating”) TDC-03
9-2
SECTION 9 REPAIR WELDING
9-2. Electrode
IMPORTANT: When electrodes are specified in the repair
work drawings, be sure to only use the specified ones.
1. Kinds of Electrodes
Mild Steel
A key point in determining welding quality exists in the
selection of electrodes to be applied.
9-3
SECTION 9 REPAIR WELDING
Shielded Arc Electrode for High Tensile Strength Steel
The shield arc electrode to weld high tensile strength steels
requires the following characteristics:
9-4
SECTION 9 REPAIR WELDING
2. Selection of electrodes
If improper electrodes are selected, the weld bead will not be built up correctly, resulting in weaker strength weld
joints and causing occurrence of cracks in weld joints. The following table lists kinds of electrodes matched to the
properties of steels commonly used for the construction machineries.
fNOTE: JIS: Japanese Standard AISI: American Iron and Steel Institute
ASTM: American Society of Testing and Material AWS: American Welding Society
9-5
SECTION 9 REPAIR WELDING
Dryer
TDC-07
9-6
SECTION 9 REPAIR WELDING
Oil
TDC-09
9-7
SECTION 9 REPAIR WELDING
Low High
TDC-10
9-8
SECTION 9 REPAIR WELDING
Too slow
Enfolding slags
TDC-11
9-9
SECTION 9 REPAIR WELDING
9-10
SECTION 9 REPAIR WELDING
Precautions for Tack Welding
1. Preheat as required depending on kinds of base metals
and atmospheric temperature at the welding site.
Usually, tack-welding-bead length is short so that the
cooling speed is fast. Thus, preheat temperatures for tack
welding are recommended to be set approx. 50 °C (90 °F)
higher than those for regular welding.
RIGHT WRONG
TDC-14
RIGHT WRONG
4. Avoid tack welding to the weld joint corner, end face,
and from the ends as shown below. 50mm (2”)
or more
TDC-15
RW-09-07-001
RIGHT
Tack Welding
TDC-16
9-11
SECTION 9 REPAIR WELDING
6. When specified, tack welding beads placed on important
weld joints must be removed completely, just before the
regular welding. Weld Bead
Chipping
Tack Welding
TDC-17
TDC-18
40 to 50 mm (1-1/2-2”)
(High Tensile Strength Steel)
9-12
SECTION 9 REPAIR WELDING
Leg Size
RW-09-08-001
Unit: mm
Type of Sketch Plate
1.5 2.3 3.2 4.5 6 8 9 10 12 14 16 19 22 25 28 32 36 40 45 50 55 65 70 80 90 100 112 125 Chipping
Groove Drawing Thickness
Single-V
Groove Required
Double-V b
7 8 9 11 12 13 15 17 18 22 23 27 30 33 37 42
Groove
Required
a
11 12 13 15 16 17 19 21 22 26 27 31 34 37 41 46
Double-U b
18 22 23 27 30 33 37 42
Groove
Required
c
22 26 27 31 34 37 41 46
Single-
Bevel Required
Groove
9-13
SECTION 9 REPAIR WELDING
Double-V groove type weld joints are often employed in
welding repair work of construction machines to avoid
incomplete fusion and/or growth of notches leading to stress
concentration.
If backing weld is difficult like a box section structure, only
front side welding is applied by the single-V groove weld joint
with backing plates.
If the root gap of the butt weld joint should be prepared
beyond specification, causes of weld flaw, large weld
deformation, and residual stress may result. Accodingly, if the
root gap is 5 mm (3/16 in) or more, attach backing plates, and
modify the groove size by overlaying to specifications. Then,
after performing the regular welding, remove the backing V-shaped Groove by using Backing Plate
plates. RW-09-08-007
If the root gap should be too wide to modify, replaced the
base metal with a correct one.
Overlaying Finish the surface
(Cladding by welding) with a grinder
5-16 mm
(3/16-5/8”)
Base Base
metal metal
16 mm (5/8”)<G<25 mm (1”)
Remove all backing Remove all backing
plates after welding plates after welding
and finish the surface
with a grinder. TDC-23
9-14
SECTION 9 REPAIR WELDING
When installing the backing plate for covering the access Completely
RIGHT WRONG
remove
hole by tack welding, weld the backing plate at the weld Base metal
the tack
Outside
groove, as illustrated in the figure to the right. Then, remove welding
the tack welding beads one by one just before a regular beads using
a grinder
weld is performed on it. just before
When using a flat-bar-type-backing plate, avoid performing the regular
tack welding in the range approx. 40 to 50 mm (1-1/2 to 2 welding.
Backing plate
in) from the end-edge corner of the backing plate.
TDC-25
RIGHT WRONG
End
Maintain Backing plate
40 to 50 mm distance
(1-1/2 to 2”) TDC-26
9-15
SECTION 9 REPAIR WELDING
4. Root gap RIGHT WRONG
9-16
SECTION 9 REPAIR WELDING
TDC-28
If thick plates or high tensile strength steels are welded, weld
flaws such as excessive hardened areas or weld cracks are
liable to appear in the base metals. Even when supplementary
parts are temporarily welded to thick plates or to high tensile
strength steels, preheat the base metals sufficiently, and
perform welding with the appropriate electrode with extra
care. In addition, similarly in tack welding, the minimum
length of weld should be 40 to 50 mm (1-1/2 to 2 in).
Small Notch
If undercuts or spots of arc strikes remain, they will form Removal by Grinding
notches on the surface, causing cracks. Therefore, remove
them sufficiently using a grinder. The spot of arc strike is locally Large Notch Removing by Finishing by
hardened, potentially causing cracks at the bended corner of grinderCladdinggrinder
the plate even if finished by a grinder. Consequently, be sure
to avoid welding temporarily welded parts to the bent corner TDC-18
40 to 50 mm (1-1/2 to 2”)
of plates. High Tensile Strength steel
9-17
SECTION 9 REPAIR WELDING
RW-09-11-002
9-18
SECTION 9 REPAIR WELDING
Ruler
Before welding the restraint fixtures, make certain of the
original dimensions between the brackets.
TDC-31
Bead Build-up Sequence
Avoid preparing grooves that are too large. Prepare grooves TDC-32
Horizontal Downward
uniformly.
TDC-33
Avoid extending weld bead leg length unnecessarily.
TDC-34
9-19
SECTION 9 REPAIR WELDING
2. Preventive measures against distortions
There are many kinds of welding methods and procedures
to reduce weld distortions.
Symmetrical method
Start welding from the center of the weld line and weld
outwards within a certain length of the range in the Bead Build-up Sequence
Skip method
Weld within a certain length of the range skipping one or
Weld Progress Direction
two ranges in the numerical order, as shown in figure (c).
(b) Backstep Method Sequence (e) Restraining
Predistortion method Bead Build-up Sequence
Anticipate distortions caused by welding beforehand. Then,
provide predistortions before welding, as shown in figure
(d).
Weld Progress Direction
Peening
Tap welded beads with a peening hammer. Residual
stresses and distortion are reduced by plastically working
weld metals.
Peening method is widely employed since it is easy to apply
and have great practical results.
9-20
SECTION 9 REPAIR WELDING
3. Prevention of warp on weld metal surface RIGHT
Rear Front Front Rear
To prevent the base metal from warping, when welding
both front and rear sides of the base metal, be sure to weld
both sides in the same direction, as illustrated.
WRONG
Rear Front Front Rear
TDC-35
RIGHT
WRONG
RW-09-12-002
9-21
SECTION 9 REPAIR WELDING
(2) Incomplete fusion (7) Blowhole (12) Slender slag included between
base metal and weld metal.
Pit
(3) Crack (8) Blowhole
(13) Slag included in weld metal
(17) Dangling
(16) Dripping
(18) Undercut
(19) Overlap
Throat
9-22
SECTION 9 REPAIR WELDING
RW-09-14-002
Intercept
Plate RW-09-14-003
Cracks 1. High contents of carbon and other alloying element in the base
metal.
Bead Cracks Traverse Longitudinal
Crack Crack
RW-09-14-004
2. Restraint is too tight.
Crack in Heat-Affected Zone
Under
bead Crack
3. Small groove angle.
Toe
Crack
RW-09-14-005
Crater Crack
Star-shaped Crack 4. Incomplete amendment of crater.
Longitudinal Crack
Traverse Crack
RW-09-14-006
9-23
SECTION 9 REPAIR WELDING
2. External Defects
RW-09-14-010
RW-09-14-012
9-24
SECTION 9 REPAIR WELDING
9-25
SECTION 9 REPAIR WELDING
Undercut
Blowholes on Bead Surface
Allowable limit numbers: Four (4) per bead length of 500
mm (20 in). However, the diameter of a blowhole should not TDC-37
exceed 2 mm (80/1 000 in). If one blowhole has the larger
diameter than 2 mm (80/1 000 in), this weld should be
rejected.
Extent of concentration: 2
Extent of concentration means the total numbers of the
blowholes in the area of 10 mm × 50 mm (3/8”×2”) where
intensive blowholes exist. Overlap
Overlap
No overlap should be found. TDC-38
Weld Crack
Any kinds of weld cracks should be rejected.
Crater
Crater section should be refilled as flatly as possible. Thickness of
Bead Overlay
Allowable depth of the hollowness: less than 1 mm (40/1
000 in)
TDC-39
9-26
SECTION 9 REPAIR WELDING
Deviation in bead width (A1-A2):
4 mm (5/32 in) or less per 50 mm (2 in) bead length
A1
A2
L
50 mm (2 in)
TDC-40
Finish by
grinder
TDC-41
9-27
SECTION 9 REPAIR WELDING
Reinspection
(b) (c)
Examples of Repairing Weld Defects RW-09-17-001
Traverse crack Drills stop holes Gouge crack and make grooves
RW-09-17-002
9-28
SECTION 9 REPAIR WELDING
1/2 t TDC-43
9-29
SECTION 9 REPAIR WELDING
2. Inspection
Refer to the section 05 under the title of “Inspection of
Cracks” for the inspection methods of the weld defects after Examples of Photos
weld repair work.
It is recommended to take a photo of the weld repair work
after it is completed to put it on record. When taking a
photo of the rewelded section, be sure to take a photo
of a ruler placed close to the rewelded section together Ruler
to enable the dimensions of the rewelded section to be
checked later. TDC-44
If report of crack reparing is required for warranty claim
application and other reasons, use “Repair Welding Report
Form” in the section 12 “Appendix”.
9-30
SECTION 9 REPAIR WELDING
Curtains RW-09-20-001
Curtains RW-09-20-002
9-31
SECTION 9 REPAIR WELDING
MEMO
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9-32
SECTION 10
REINFORCEMENT
– CONTENTS –
10-1. Precaution for Reinforcement.................................. 10-1
10-2. Preparation for Reinforcement................................ 10-2
10-3. Precautions for Installation of
Reinforcing Plate................................................................ 10-4
10-4. Examples of Reinforcement...................................... 10-6
(Blank)
SECTION 10 REINFORCEMENT
10-1
SECTION 10 REINFORCEMENT
RF-002
RF-003
10-2
SECTION 10 REINFORCEMENT
Remove rust, paint and oil from the weld groove surface.
TDC-14
10-3
SECTION 10 REINFORCEMENT
Wedge
Crowbar
RIGHT
RF-009
Reinforcing Plates
10-4
SECTION 10 REINFORCEMENT
3. Plug Welding not Recommended RIGHT
Plug welding is often used to attach an abrasive-resistant
material onto the bucket. Moreover, this plug welding is not
effective for reinforcement and increases the chances of
causing new cracks. Anti-Wear
Plate
RW-03-03-002
WRONG
Reinforcing Plate
RW-03-03-003
WRONG
5. Adding Ribs for Reinforcement not Recommended
Adding ribs inevitably induces stress concentration in other
sections. Accordingly, do NOT add ribs unless instructed in
the repair drawing.
RF-013
10-5
SECTION 10 REINFORCEMENT
Crack Gouging
RF-014
Gouging RF-015
Reinforcing
Crack Plate
Crack
RF-016
RF-017
10-6
SECTION 10 REINFORCEMENT
Welding Two Reinforcing Plates of Different Thickness
Stress will be concentrated in the place where thickness
changes. Therefore, the joint section must be finished so
that the thickness changes smoothly.
t1
×(3 to 5)=L
t Finishing by Grinding
RF-018
10-7
SECTION 10 REINFORCEMENT
MEMO
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10-8
SECTION 11
FINISHING
– CONTENTS –
11-1. Importance of Finishing............................................. 11-1
11-2. Kinds of Grinders........................................................... 11-2
11-3. Proper Use of Grinder.................................................. 11-5
11-4. Direction of Grinding................................................... 11-6
11-5. Finishing Joint of New Bead with Old Bead........ 11-7
11-6. Use of R-Gauge.............................................................. 11-8
(Blank)
SECTION 11 FINISHING
11-1
SECTION 11 FINISHING
FN-002
11-2
SECTION 11 FINISHING
1. Air Grinder
Comparing with an electric grinder, an air grinder is lighter
in weight, reducing the physical burden to a worker when a
grinding work is performed for a long time.
Pencil Grinder
A small and light grinder. This grinder is used to slightly
finish the fringe of the base metal, inner or end surface of
a small diameter bore, and weld bead surfaces located at
a corner.
Pencil Grinder
RW-11-02-001
Straight Grinder
Suitable for finishing a wide-range of curved surfaces
or a corner surface of cladding. Two types of grinding
stones are available. One is used to medium speed such
as a max. 2000 m/min circumferential speed, and the
other is used to high speed such as a max. 3000 m/min
high circumferential speed. Select the grinding stones to
match the application speed.
Straight Grinder
RW-11-02-003
11-3
SECTION 11 FINISHING
Angle Grinder
An offset-type grinding stone is installed. With the
circumference and one side surfaces of the grinding
stone, a flat surface is ground. This grinder can be used at
high speed, and has a greater grinding ability.
11-4
SECTION 11 FINISHING
Corner Section:
Kind of Grinder : Pencil Grinder
Tungsten Carbide Cutter
Grain Size of Grinding Stone:
#24 or 36 for rough cutting
#60 or 80 for finishing
Grinding Direction : Arrow direction shown in the
figure to the right.
FN-005
11-5
SECTION 11 FINISHING
Grinding Notch
Crack Grinder
SA-006A
11-6
SECTION 11 FINISHING
11-7
SECTION 11 FINISHING
FN-008
11-8
SECTION 12
APPENDIX
– CONTENTS –
12-1. Nominal Stress and Stress Concentration............ 12-1
12-2. Crack at Weld Joint....................................................... 12-2
12-3. Fatigue Strength and Importance of
Grinding Finish.................................................................... 12-3
12-4. Mechanical Properties of Welding Steel............... 12-4
12-5. Specifications of Shield Arc Electrodes for
Mild Steel............................................................................... 12-5
12-6. Specifications of Shield Arc Electrodes for
High Tensile Strength Steel............................................. 12-6
12-7. Estimation Formula of Preheat Temperature...... 12-7
12-8. Crack Report................................................................... 12-8
12-9. Weld Terms....................................................................12-14
(Blank)
SECTION 12 APPENDIX
AP-001
12-1
SECTION 12 APPENDIX
Whether a crack develops or not from the toe of fillet weld (1) (3)
bead greatly depends on the smoothness of the bead form. A
Thus, the toe of weld bead should be smoothly finished by a
grinder after removing undercut or overlap of bead, if any, as
they will cause the reduction of material strength. When weld A
joint with backing plate or one-side-weld joint is employed, a
crack is liable to start from the gap between the base metals
and backing plate or the incomplete fusion area of one- (2)
side-weld joint, as they constitute weld defects. The stress Gap
concentration factor at the toe of fillet weld bead is approx. 3 (4)
when the bead is left as welded. After finishing the toe of the Backing Plate
bead smoothly by molding or grinding the bead, the stress
Types of Cracks Developed at Weld Joints AP-005
concentration factor can be reduced to 1.6 to 1.8.
12-2
SECTION 12 APPENDIX
12-3
12-4. Mechanical Properties of Welding Steel
Kind of Steel Chemical compositions % Yield points or Proof stress Tensile Impact
kgf/mm2 (N/mm2) strength value
Plate thickness mm kgf/mm2 kg-m/cm2
(N/mm2) (J/cm2)
C Si Mn P S Ni Cr Mo T 16 16<T 40 T>40
12-4
High tensile
60-72 4.8 (47)
steel 60 kgf/mm2 0.13 0.15-0.55 0.90-1.50 0.03 0.03 0.60 0.03 0.03 46 (451) (588-706) @ -5 °C
(85000 psi) Class
High tensile
80-95 3.6 (35)
SECTION 12 APPENDIX
steel 80 kgf/mm2 0.16 0.15-0.55 1.60 0.03 0.03 0.60-1.20 0.30-0.18 70 (686) (784-931) @ -15 °C
(115000 psi) Class
S35C (JIS) 0.32-0.38 0.15-0.35 0.60-0.90 0.03 0.035 0.20 0.20 40 (392) 58 (568)
1035 (AISI) 0.32-0.38 - 0.60-0.90 0.03 0.050 - -
SECTION 12 APPENDIX
Mechanical properties
Type of Welding Tensile Yield point Elongation Temperature Impact
JIS AWS Electric power strength N/mm2 % °C value
coating flux position
N/mm2 (kgf/mm2) (°F) J
(kgf/mm2) (kgf·m)
E4303 E6013 Lime-titania F, V, O, H AC or DC (±) 0 27
20 ( 2.8)
E4311 E6011 High cellulose F, V, O, H AC or DC (+) -30
E4312 E6012
High titania F, V, O, H AC or DC (±) 16 - -
E4313 E6013
27
E4316H15
( 2.8)
E7016 Low hydrogen F, V, O, H AC or DC (+) 16 -30
47
E4316UH15
( 4.8)
27
E4319
430 330 ( 2.8)
E7016 ilmenite F, V, O, H AC or DC (±) 20 -20
( 44) ( 34) 47
E4319U
( 4.8)
Iron powder
E4324 E7024 F, H AC or DC (±) 16 - -
titania
27
E4327 E6027 Iron powder F, H AC or DC (-) 20 -30
( 2.8)
Iron powder-
E4328 E7028 F, H AC or DC (±) - - -
Low hydrogen
F, V, O, H, or 27
E4340 E7024 Special AC or DC (±) 20 0
any posture ( 2.8)
fNOTE: 1. The alphabet in the column ” Position of weld” stands for the followings.
F: Downward Position V: Vertical Position O: Overhead Position
H: Horizontal Position or Horizontal fillet welding
The position of weld shown above is applied when the electrode diameter is smaller than 5 mm (0.2 in).
2. Horizontal fillet welding is applied for JIS E4324, E4326 and equivalent.
3. The alphabet in the column ” Electric power” stands for the followings.
AC: Alternating current DC (±): Direct current, electrode (+) or (-)
DC (+): Direct current, electrode (+) DC (-): Direct current, electrode (-)
4. Even if yield point and tensile strength decrease 9.8 N/mm2 every 2% increase of elongation, it is allowable in JIS
E4327 or equivalent on condition that yield point is 320 N/mm2 or up and tensile strength is 400 N/mm2 or up.
12-5
SECTION 12 APPENDIX
12-6. Specifications of Shield Arc Electrodes for High Tensile Strength Steel
Mechanical properties
Tensile Yield point Elongation Temperature Impact
Type of Welding Electric
JIS AWS strength N/mm2 % °C value
coating flux position power
N/mm2 (kgf/mm2) (°F) J
(kgf/mm2) (kgf·m)
47
E4903 E6013 Lime-titania F, V, O, H AC or DC (±) 0
( 4.8)
27
E4916H15 E7016
( 2.8)
Low hydrogen F, V, O, H AC or DC (+) -30
490 400 47
E4916UH15 E7016 20
( 50) ( 41) ( 4.8)
27
E4919 E6019
( 2.8)
ilmenite F, V, O, H AC or DC (±) -20
47
E4919U E6019
( 4.8)
12-6
SECTION 12 APPENDIX
Mechanical properties
Tensile Yield point Elongation Temperature Impact
Type of Welding Electric
JIS AWS strength N/mm2 % °C value
coating flux position power
N/mm2 (kgf/mm2) (°F) J
(kgf/mm2) (kgf·m)
27
E4928H15 E7018
490 400 ( 2.8)
20 -30
( 50) ( 41) 47
E4928UH15 E7018
( 4.8)
27
E5728H10 -
Iron powder- ( 2.8)
F, H AC or DC (+)
Low hydrogen 47
E5728UH10 -
570 490 ( 4.8)
16 -20
( 58) ( 50) 27
E5728H10 -
( 2.8)
47
E5728UH10 -
( 4.8)
fNOTE: 1. The alphabet in the column ” Position of weld” stands for the followings.
F: Downward Position V: Vertical Position O: Overhead Position
H: Horizontal Position or Horizontal fillet welding
The position of weld shown above is applied when the electrode diameter is smaller than 5 mm (0.2 in).
2. The alphabet in the column ”Electric power” stands for the followings.
AC: Alternating current DC (±): Direct current, electrode (+) or (-)
DC (+): Direct current, electrode (+) DC (-): Direct current, electrode(-)
12-7
SECTION 12 APPENDIX
Where:
Pw: Weld-crack-sensitivity index shown in the following
formulas.
PCM=C+Si/30+Mn/20+Cu/20+Ni/60+Cr/20+Mo/15+V/10+5B (%)
.................................... [4]
12-8
SECTION 12 APPENDIX
12-9
SECTION 12 APPENDIX
Example of Crack Report for Excavators
RW-12-01-001E
12-10
SECTION 12 APPENDIX
Stamping Position of Serial Number for Excavators (1/2)
RW-12-01-002E
12-11
SECTION 12 APPENDIX
Stamping Position of Serial Number for Excavators (2/2)
RW-12-01-003E
12-12
SECTION 12 APPENDIX
Example of Crack Report for Dump Trucks
RW-12-01-004E
12-13
SECTION 12 APPENDIX
Stamping Position of Serial Number for Dump Trucks
RW-12-01-005E
12-14
SECTION 12 APPENDIX
Terms Definition
A
Actual throat Throat actually welded. The shortest distance from the root to the surface of a
(- of a fillet weld) section of the fillet weld.
Actual throat Theoretical throat
Theoretical
Actual throat
throat
Size Size
Leg Leg
RW-12-09-008
Arc air gouging Method of grooving on metal surface by continuously blowing metal melted with
arc heat with compressed air.
Arc strike To generate arc first or to generate arc instantaneously on base metal and then
immediately cut it in arc welding.
B
Back chipping To chip from the back the part of poor penetration at the bottom of groove or the
first layer in butt welding.
Backhand welding Welding in which the progressing direction of welding is opposite to the direction
of the torch of gun.
Backing plate Material to align the bottom of the groove from the back.
(backing metal)
Both side welding Welding performed from both sides; front and back.
(- of butt joint)
RW-12-09-020
Butt joint Weld joints in which the base metals lie nearly in the same plane.
Buttering To provide surfacing on the groove surface in order to prevent influence from
base metal in butt welding.
12-15
SECTION 12 APPENDIX
Terms Definition
C
Cladding by welding Process in which metal of required structure and dimensions is deposited on the
base metal surface, depending on the purpose, such as hardening, corrosion
resistance, repair, or regeneration.
CO2 gas shielded arc Automatic or semiautomatic welding performed in an atmosphere of mainly
welding carbon dioxide (CO2).
Cold crack Generic term for cracks caused after weld has been cooled near the ordinary
temperature after being welded. Under bead crack, toe crack, etc. are included in
this type of crack.
Complete joint penetration, Penetration over the entire area of the plate thickness of joint.
full penetration
D
Deposited metal Metal deposited on base metal from filler metal by the welding operation.
Deposition efficiency Ratio of mass of deposited metal to mass of consumed welding electrode,
provided that the unused part of the electrode should be restricted.
For a covered electrode, the mass of the cover is usually included, but excluded in
special cases.
Droplet Particles of molten metal transferring from the tip of welding electrode to base
metal.
F
Filler metal (material) Metal (material) to be melted and added in order to make a deposited metal.
Fillet weld Welding forming a triangular section to weld two faces intersecting nearly
orthogonally in lap joints, T joints, cross-shaped joints and corner joints, etc.
Fish eye Silver white defect like fish eye which appears on a fracture of the deposited
metal.
Flux cored wire Wire for welding in the form of a pipe, in which flux is filled for the purpose of arc
stabilization and deoxidation.
Forehand welding Welding in which the progressing direction of welding coincides with the
direction of the torch or gun.
12-16
SECTION 12 APPENDIX
Terms Definition
G
Gas cutting Cutting performed by utilizing the rapid chemical reaction between the metal
and the oxygen generated by heating with a gas flame. Generic term of oxygen-
acetylene cutting, oxygen-hydrogen cutting, oxygen-propane cutting and
oxygen-natural gas cutting, etc.
RW-12-09-003
d
Groove depth d in Figs. below.
RW-12-09-004
H
Hand welding, manual Welding where welding operation is performed by hand.
welding
Hardfacing Deposition of hard metal layer on base metal surface so that the base metal can
resist wear.
Heat-affected zone Unmelted zone whose base metal structure and mechanical properties have been
changed by the heat of welding and cutting.
Hot crack Cracks caused under elevated temperature, such as within the range of solidifying
temperature of the weld or immediately below it.
I
Intermittent fillet weld Fillet weld where the welded parts and unwelded parts alternately exist.
RW-12-09-010
12-17
SECTION 12 APPENDIX
Terms Definition
I
Interpass temperature, Lowest temperature of pass before the next pass starts in multipass welding.
(Interlayer temperature) Interpass temperature for one layer per one pass is called interlayer temperature.
L
Lack of fusion, incomplete Condition in which welding boundary faces are not sufficiently fused with each
fusion other.
Lack of fusion
RW-12-09-016
Lack of penetration, Causing the unpenetrated portion in full penetration weld joint.
incomplete penetration
RW-12-09-013
Leg Distance from root of joint to the toe of the fillet weld.
(- of a fillet weld) When used in design, the dimension of size is sometimes called by this name.
Leg
Leg
RW-12-09-006
Longitudinal crack Crack nearly parallel to the direction of bead caused on bead or its heat-affected
zone.
RW-12-09-009
M
Melting rate Speed at which the welding rod melts per unit time.
Mold welding Welding in final layer of cladding using the electrode which forms smoother
welding beads.
Molten pool Place where molten part appears like a pool due to heat of arc in welding.
N
Non-distructive testing Any testing method which does not involve damaging or destroying the test
sample; include use of X-rays, ultrasonics, magnetic flux, and so on.
12-18
SECTION 12 APPENDIX
Terms Definition
O
One side welding Welding performed from only one side of butt joint.
(- of butt joint)
RW-12-09-005
Overlap Lapped portion of deposited metal without being fused with base metal at the
toe.
Overlap Overlap
RW-12-09-002
P
Partial joint penetration Penetration that is not prevailing on the entire area of the plate thickness of joint.
Partial joint
RW-12-09-015
Penetration Distance between the summit of molten part of base metal and the surface of the
plane to be welded. Penetration
Penetration
Penetration
Penetration
RW-12-09-012
Penetration bead Bead of regular waveform caused at opposite side (back) of the electrode in one
side welding.
Plug welding Welding in which holes are bored in one of the base metals to weld fully from the
surface of plate to the other base metal.
12-19
SECTION 12 APPENDIX
Terms Definition
P
Postheating Application of heat afterward to weld or gas cutting zone.
Preheating Application of heat to base metal prior to operation in welding or gas cutting.
Preset distortion Distortion given in inverse direction by predicting angular and other deformation
resulting from welding.
R
Reinforcement of weld Deposited metal piled out of surface more than required dimension in groove or
fillet weld. Reinforcement
Repair welding Welding to repair defects, and incorrect dimensions and shape. RW-12-09-019
S
Semi-automatic arc welding Arc welding performed by using equipment that automatically feeds wire while
operating the torch manually.
Slag inclusion Remaining of slag in deposited metal or fused zone with base metal.
Solid wire Wire, for welding, the section of which is solid and homogeneous.
Spatter Slag and metal particles scattering during welding in arc welding and gas
welding.
Surfacing Generic term for method in which metal is deposited on a base metal surface,
such as cladding by welding or thermal spraying.
T
Tack welding Intermittent positioning welding for holding base metal at a definite position
prior to regular welding.
Theoretical throat Throat used in design calculation. Height of triangular fillet determined by the
(- of a fillet weld) size of the fillet measured from the root of the joint.
(Refer to the figure in “actual throat”.)
12-20
SECTION 12 APPENDIX
Terms Definition
T
Toe Point at which base metal surface and welding bead surface intersect.
a b
c d e
RW-12-09-007
Torch, blowpipe Apparatus used to heat, weld, and cut metal and other material by using
gas flame, argon arc, plasma arc, etc. Called welding torch, cutting torch, etc.
depending on the application.
Transversal crack Cracks nearly perpendicular to the direction of bead caused on bead or its heat-
affected zone.
RW-12-09-018
U
Under-bead crack Internal cracks caused near the bead.
RW-12-09-014
Undercut A portion remaining as a gulf without being filled with deposited metal after base
metal has been sunk along the toe of the welding.
RW-12-09-001
V
Voltage reducing device Equipment to prevent electric stroke by lowering the secondary no-load voltage
of welding machine when arc is not generated in arc welding.
12-21
SECTION 12 APPENDIX
Terms Definition
W
Weld line Assumed line for expressing the bead and weld as a line.
Weld metal Metal melted and solidified during welding, a part of the weld.
Weld metal
RW-12-09-017
Welding current Current required to flow in order to give the required heat for welding.
Welding speed Speed of welding bead. Usually expressed by bead length per minute.
Wire extension Extending length of welding wire from the end of contact tube or tip.
Wire extension
Arc length
RW-12-09-011
12-22
Progress and Deliberation
Revision history
REV. Date of issue Page Remarks Consultation department and members
0 Jun. 1, 1994 All First edition issued -
1 Sep. 30, 2019 All Mainly changed the following contents. • Service Material Development Center:
• Review and enhancement of welding K. Naruse, J. Ishikawa
related standards. • Mining Development & Production Div.:
• Added description about post heat and M. Ebisawa
cast steel. • Structure Production Engineering Dept.:
• Delete BS standard. H. Sakamoto
• Added "Progress and Deliberation“. • Global Production & Procurement Strategy Office:
i. Aizawa, K. Koyanagi
• Tsuchiura Production Dept.:
H. Sumiya
• Global Quality Strategy Dept.:
O. Ootaki
• Mining Sales and Service Div.:
H. Tanaka, K. Uno