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Preheat
Presentation
Overview
• Preheat
– Why
preheat
prior
to
welding
– What
represents
preheat
for
different
weldments
• Torch
heating
• Electric
resistance
heating
• Interpass
temperature
+ -‐ + -‐
H H
-‐
Oxygen Oxygen -‐ Metal
+ -‐ H + -‐
H Surface
-‐
-‐
°°
Surface
Hydration
• Water
molecules
form
several
layers
of
metal
surface
• The
attraction
force
between
a
water
molecule
and
a
metal
surface
is
greater
than
the
attraction
between
two
water
molecules
• Heat
of
vaporization
of
water
from
water
at
100°C
is
about
2,250
kJ/kg
• Heat
of
vaporization
of
water
from
metal
surfaces
ranges
from
about
2,750
to
3,000
kJ/kg
• As
a
result,
more
heat
is
required
to
separate
water
from
a
metal
surface
than
to
boil
water
Invisible
Moisture
• Hydrated
water
on
a
metal
surface
is
not
visible
to
the
human
eye
• Water
present
on
a
metal
surface
can
be
measured
by
weight
change
of
metal
upon
heating
90
Weight
Loss
80
70 100°C
200°C
grams/m²
loss
60
300°C
50
40
30
20
10
0
0
1
2
3
4
5
6 7
8
9
Hours
The
removal
of
water
from
a
metal
surface
is
a
function
of
time
and
temperature
Surface
Cleanliness
• The
amount
of
water
hydrated
on
a
metal
surface
is
also
a
function
of
surface
cleanliness
• Oxide
covered
surfaces
can
hold
4
to
6
times
more
moisture
than
clean
metal
surfaces
• At
arc
temperatures,
water
molecules
convert
to
atomic
hydrogen
and
atomic
oxygen
ions
• Both
hydrogen
and
oxygen
ions
are
soluble
in
molten
filler
metal
– this
leads
to
porosity
and
hydrogen
embrittlement
• Hydrocarbon
contamination
on
metal
surfaces
will
lead
to
migration
of
hydrogen
and
carbon
into
weld
metal
• It
is
also
important
to
clean
the
interior
surface
of
pipes
Recommended
Preheat
Practices
• It
is
best
to
preheat
first
to
a
high
temperature
(>300
°C)
for
at
least
one
hour
to
drive
moisture
from
metal
surfaces
• Then
reduce
preheat
temperature
to
that
specified
by
the
weld
procedure
• Filler
metal
and
fluxes
will
also
hydrate
– use
of
rod
ovens
is
encouraged
• Just
as
it
takes
time
for
metal
surfaces
to
dehydrate,
it
also
takes
time
for
metal
surfaces
to
rehydrate
• Maintaining
metal
surfaces
at
least
25
°C
above
ambient
dew
point
will
minimize
rehydration
rate
Preheat
Methods
• Torch,
radiant
element,
resistance
elements
and
induction
are
all
useful
methods
to
apply
preheat
• Uniform
application
of
heat
to
a
work
piece
will
not
provide
uniform
work
piece
temperatures
• Local
temperature
is
a
function
of
both
the
rate
of
heat
input
and
the
rate
of
heat
loss
• Convection
current
will
tend
to
generate
a
higher
rate
of
heat
loss
from
the
bottom
of
a
work
piece
– as
a
result
the
top
temperatures
will
be
higher
than
bottom
temperatures
• Joints
between
metal
sections
of
different
thickness
will
require
more
heat
input
to
the
heavy
side
of
the
joint
Insulation
• Insulation
plays
a
critical
role
in
minimizing
heat
loss
from
a
work
piece
• It
is
advisable
to
take
measures
to
limit
thermal
convection
a
pipe
• Where
it
is
not
possible
to
limit
thermal
convection
currents
in
a
pipe,
application
of
additional
heat
to
the
bottom
of
the
pipe
will
mitigate
the
effect
of
convection
losses
• For
a
joint
on
a
vertical
pipe,
applying
heat
to
twice
the
area
below
the
weld
centerline
will
generally
result
in
a
uniform
preheat
temperature
Enough,
Not
Too
Much
• Excessive
preheat
temperatures
can
be
detrimental
to
a
sound
weld
• It
is
critical
to
control
preheat
temperature
as
specified
by
the
weld
procedure
• Preheat
temperature
can
be
monitored
by
crayons,
thermal
guns
or
capacitor
discharged
welded
thermocouples
• Preheat
methods
regulated
by
the
temperature
measuring
means
provide
greater
control
• Controlled
preheat
application
methods
can
also
serve
to
regulate
interpass
temperature
control
Questions?