Distortion

1) Any unwanted physical change in the dimensions in a fabricated structure or component as a

consequence of welding is distortion. Distortion are introduced in the joint due to uneven
strain distribution during weld solidification. Normally there are four types of distortions are
encountered in the welding: -
a. Transverse shrinkage perpendicular to weld line,
b. Longitudinal shrinkage parallel to the weld line,
c. Angular distortion (rotation around the weld line),
d. Rotational distortion of unwelded region.

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2) Main causes of Distortion: -
a. Non-uniform shrinkage and contraction,
b. Internal stress.

In a butt joint an angular distortion will be experienced when the top face of the weld shrinks
more than root.

A transverse bending will result in the plate. In addition to that, angular distortion, transverse
and longitudinal shrinkage will also take place in the butt joint.

The distortion problems can be approached in three angles: -

→Welding process and fabrication methods can be developed which will

minimise the distortion.
→Even after the (1) if distortion persists, then proper technique can be
developed to remove distortion from the joint.
→If above two methods fails to remove distortion then, establish a rational
standards for acceptable distortion limits.

Factors influencing Distortion: -

1) Welding process,
2) Welding parameters,
3) Yield strength of material
4) Thermal conductivity,
5) Interpass temperature and heat treatment,
6) Edge preparation and fit-up

Controlling distortion: -

1) Reduce effective shrinkage force,

a. Keep minimum angle of weld joint,
b. Do not do over welding,
c. Do not keep root gap more than required.
 2) Balance shrinkage forces with other forces,
a. Do sequence welding,
b. Back-step welding,
c. Skip welding,
3) Proper tack welding,
4) Increased travel speed,
5) Use external constraints such as fixtures and jigs.

NOTE: Distortion is more when weld is applied to a region which contains compressive residual
stress and conversely reduced if it contains tensile residual stress. A proper heat treatment may
reduce residual stress and consequent distortion in welding.

Distortion expectancy of some typical materials: -

(1) SS vs MS
a. YS are nearly same,
b. Moduli are almost same,
c. Thermal conductivity of SS is 1/3rd of MS,
d. This Inc. shrinkage effect in SS,
e. Therefore, SS show more distortion than mild steel under the same condition.
(2) Al vs Steel
a. Coeff of expansion of Al is twice then steel, which increase shrinkage effect.
b. Heat flow faster in Al than steel, resulting lower chances of temperature differential ,
which decrease distortion.