Chapter 4.

1. What is the purpose of designing welding sequences?

The purpose of welding sequence is to produce a welded construction without any technical
problems and to reach good economy

- Meminimalisir distorsi dan residual stress

- Mengurangi biaya untuk perbaikan dan koreksi
- Kemudahan akses pengelasan
- Mempersingkat waktu pengerjaan
- Sebagai pemenuhan persyaratan standar/code/aturan yang berlaku
- Assessment untuk pencegahan kegagalan akibat welding imperfection
- Instruksi kerja untuk welder yang belum jago

2. What is the welding stresses and distortion? Drawn and explain it!
Distorsi  perubahan bentuk melebihi dari yang diijinkan.
SLV = perbedaan bentuk komponen setalah adanya pemanasan (mencair) dan pendinginan
(solidifikasi) ke temperature ruangan

Residual stress  mempengaruhi karakterisitik komponen, kemampuan menahan beban dan

ketahanan korosi turun / tegangan di dalam Kristal, yang korosi lebih anodic jadi mudah
terkorosi
Residual stress = sisa tekanan pada struktur Kristal karena kimia, panas, dan proses mekanis.

Residual stress diujung paling tinggi karena diujung ga ada shringkage. Dianggap tengah ditahan
kedua sisi, kedua sisi sebagai fixture

Pada prinsipnya terjadi penyusutan dari fasa cair ke padat, saat penyusutan terjadi compresi
(saat pemanasan) dan tension (saat dingin)

3. Describe the welding stresses distribution during and after welding processes!
4. Mention and explain as much as you can for the method to reduce the distortion
To reduce distortion:
a. Minimize the number of welded joints and arrange their localitions with sufficient space
b. Change of joint location and geometry, the change of structure or adoption of shape to
restrict distortion
c. Minimize heat input
d. Use a welding process whose energy density is high (maksudnya macem EBW)
e. Select a symmetric-shape groove which enables the amount of deposited metal small
f. Select a proper deposition method and a proper welding sequence
g. Use presetting method like figure below in which the plates are preset to give a distortion in
the opposite direction to compensate the distortion made by welding
5. What is the main cause of welding distortion and mention the main controlling factor to be
considered by designer?
Main cause of welding distortion is heating and subsequent cooling localized only near the
welded joint. Changing from liquid to solid causing shrinkage (in weldment). The shrinkage
enticing the base metal
Main controlling factors:
a. Factor related to welding heat input such as welding method, welding parameters, type of
welding electrode, number of welding layer, method of building-up and initial metal
temperature
b. Factors related to material such as mechanical properties, including strength, coefficient of
linear thermal expansion, dynamic melting temperature and transformation expansion
c. Factor related to restraint of welded joint such as shape and dimensions of welded joint,
position of welding line and welding sequence

6. Describe and explain the type of welding distortion!

Type of welding distortion:
a. Transverse shrinkage  shrinkage in the direction normal to welding line.

b. Longitudinal shrinkage  shrinkage in the welding line direction. Largest shrinkage at the
center of welding line. several times as large as plate thickness away from welding line
c. Longitudinal bending distortion  bending distortion in the welding line direction

d. Angular distortion  out-of-plane bending in the cross section normal to welding line easy
to occur in butt welding of plates
 e. In-plane rotational distortion  distortion in which groove opens or close during welding

f. Buckling distortion  saddle shaped distortion of thin plate caused by welding

7. Mentioned the way to reduce the residual stress during or after welding process!
 Adjust heat input (select proper welding process and welding parameter, number of
welding layer, method of building up and initial metal temperature)
 Choose proper material (mechanical properties, coefficient of linear thermal expansion,
dynamic melting temperature, transformation temperature and transformation expansion
 Choose proper shape and dimention of welded joint, position of welding line and welding
sequence
8. On welding designing state, what item to be consider to prevent distortion?
 Reduce the number and length of welding joints by employing press-bending and
intermittent welding for example
 Reduce heat input and the amount of weld metal by employing narrow gap grooves,
reducing leg length, and designing the balance of the face and back side groove sizes
 Strengthen restraint by arranging stiffeners
  Arrange welding joints so as to minimize distortion
9. On welding fabrication stage, what actions to be consider to prevent distortion?
 Prevent distortion of components by carefully storing, transferring, and cutting
components
 Improve the dimensional accuracy of components and assemblies.
 Improve the dimensional accuracy of the welding groove particularly for the bevel angle
and fitting up
 Apply the presetting methods such as elastic pre-bending (presetting)
 Apply a welding process that has lower specific deposition heat.
 Restrain the work with jigs for preventing distortion
10. How to make correction of exceeded tolerances of distortion good?
There are two methods for correcting distortion
A. Mechanical correction method:
Method that localized area shrunken by welding (weld and its vicinity) is stretched by cold
plastic processing using rollers or presses. This method can only applied by relatively small
components and structures.
work and causes damage of the weld
B. Thermal correction method:
A particular area that is not shrunken but is relaxed or elongated by welding is heated locally
by using an oxy-fuel gas flame as the heat source to shrink it for correction. This method
require skilled and experienced worker to perform