T & D Powerpoint

TECHNOLOGY
A Weld:*
A union between materials caused by heat,

and or pressure
A Joint:*
A configuration of members
Copyright 2002 TWI Ltd
TECHNOLOGY
Butt welds:*
Fillet welds:*
Spot/Seam welds:*
Plug/Slot welds:*
Edge welds:*
TECHNOLOGY
Butt joints: *
T joints: *
Lap joints: *
Corner joints:*
Closed
corner
Open
corner*
3
TECHNOLOGY
Angle of bevel*
Root face*
Included angle*
Root radius*
Root gap*
Root landing*
TECHNOLOGY
Single bevel
Single V
Single J
Single U*
TECHNOLOGY
Double bevel
Double V
Double J
Double U*
TECHNOLOGY
Remember, the purposes of a weld preparation is to allow access

for the welding process, penetration and fusion through the area
of the joint and its faces*
The basic rule is this:
The more you take out, then the more you must put back in*
This has major effects on economics and distortion control etc
The root face, root gap and angle of bevel values, the choice of
single, or double sided preparations, are dictated only by the
type of welding process, the position and accessibility of the
joint*
7
TECHNOLOGY
A butt welded butt joint*
A fillet welded butt joint*
A compound welded butt joint*
TECHNOLOGY
A fillet welded T joint*
A butt welded T joint*
A compound welded T joint*
TECHNOLOGY
A fillet welded Lap joint*
A spot welded Lap joint*
A compound welded Lap joint*

10
TECHNOLOGY
A fillet welded Closed Corner joint*
A butt welded Closed Corner joint*
A compound welded Closed Corner joint*
11
TECHNOLOGY
An inside fillet welded Open Co

C rner joint*
An outside fillet welded Open Corner joint*
A double fillet welded Open Corner joint*
12
TECHNOLOGY
Actual Throat Thickness
Weld Face
Weld Width
1.2.3.4. Weld Toes
Design Throat Thickness
Fusion Boundary
HAZ
Weld Root
Fusion Zone
A + B = Excess Weld Metal

13
TECHNOLOGY
Vertical Leg Length*

Weld face*
Horizontal Leg Length*

Excess weld metal *
Design throat*
Actual throat*
14
TECHNOLOGY
a = Nominal throat thickness s = Effective throat thickness
Deep throat fillet welds from FCAW & SAW etc*

15
TECHNOLOGY
*
16
TECHNOLOGY
6 mm
80
Very Poor Weld Toe Blend Angle
3 mm*
20
Improved Weld Toe Blend Angle
17
TECHNOLOGY
It is also possible that the height of excess weld metal is within

the accepted limit of an applied standard, but the toe blend is
unacceptable,
unacceptable as shown below*
90
3 mm
Extremely poor toe blend, but excess weld metal is within limits*
18
TECHNOLOGY
Weld:
A Union of materials
Joint:
A Configuration of members
Weld Preparation:
Preparing a joint to allow access and fusion.
Types of Weld:
Butt. Fillet. Spot. Seam Plug. Slot. Edge.
Types of Joint:
Butt. T. Lap. Corner (Open & Closed)
Types of Preparation:
Preparation Terms:
Bevels. Vs. Js. Us. Single & Double.

Bevel/included angle. Root face/gap. Land/Radius
Weldment Terms:
Weld face & root. Fusion zone & boundary. HAZ.

Weld toes.Weld width
Weld Sizing (Butts):
DTT. ATT. Excess weld metal.
Weld Sizing (Fillets):
DTT. ATT. Excess weld metal. Leg length *
19
TECHNOLOGY
Welding imperfections can be categorized into groups:
1)
2)
3)
Cracks
Gas Pores & Porosity
Solid Inclusions
4)
Lack of fusion
5)
Profile & Lack of Filling
6)
7)
Mechanical or Surface damage

Misalignment*
20
TECHNOLOGY
A HAZ hydrogen crack, initiated at the weld toe

Most cracks are initiated from stress concentrations *
21
TECHNOLOGY
Surface breaking porosity

Shrinkage cavity*
Fine cluster porosity
Hollow root bead
Coarse cluster porosity

Blow hole > 1.6 mm
An isolated internal pore
22
TECHNOLOGY
Surface breaking solid inclusion

Internal solid inclusion causing
a lack of inter-run fusion*
Internal solid inclusion
Internal solid inclusion causing

a lack of sidewall fusion
Solid inclusions caused by

undercut in the previous weld run
23
TECHNOLOGY
Lack of sidewall fusion &

incompletely filled groove*
Overlap
Lack of inter-run fusion
Lack of sidewall fusion

Lack of root fusion
24
TECHNOLOGY
Spatter
An Incompletely filled groove
Lack of root fusion

Bulbous, or irregular contour
Arc Strikes
Poor toe blend
Incomplete root penetration

*
25
TECHNOLOGY
Shrinkage grooves
Crater pipe
Root concavity
*
Excess penetration, and burn through
Root oxidation in Stainless Steel
26
TECHNOLOGY
Root Run or Hot pass undercut
Parent metal, surface undercut
Weld metal, surface undercut*
27
TECHNOLOGY
Weld metal, surface undercut
Parent metal, top toe undercut*
28
TECHNOLOGY
Any surface damage caused by:

Grinding
Hammering/chisel marks
Slag chipping hammer marks
Torn cleats (Hammered off attachments)
Arc strikes
All of the above may cause serious weakness to the weld area*
29
TECHNOLOGY
Linear
Excess weld metal height
Lowest plate to highest point
Linear misalignment measured in mm
3 mm
Angular
15
Angular misalignment measured in degrees*
30

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TECHNOLOGY

A union between materials caused by heat,

Copyright 2002 TWI Ltd

Remember, the purposes of a weld preparation is to allow access

A butt welded butt joint*

A fillet welded butt joint*

A compound welded butt joint*

Copyright 2002 TWI Ltd

A fillet welded T joint*

A butt welded T joint*

A compound welded T joint*

Copyright 2002 TWI Ltd

A fillet welded Lap joint*

A spot welded Lap joint*

A compound welded Lap joint*

A fillet welded Closed Corner joint*

A butt welded Closed Corner joint*

A compound welded Closed Corner joint*

Copyright 2002 TWI Ltd

An inside fillet welded Open Co

An outside fillet welded Open Corner joint*

A double fillet welded Open Corner joint*

Copyright 2002 TWI Ltd

Actual Throat Thickness

1.2.3.4. Weld Toes

Design Throat Thickness

A + B = Excess Weld Metal

Vertical Leg Length*

Horizontal Leg Length*

a = Nominal throat thickness s = Effective throat thickness

Deep throat fillet welds from FCAW & SAW etc*

It is also possible that the height of excess weld metal is within

Preparing a joint to allow access and fusion.

Butt. Fillet. Spot. Seam Plug. Slot. Edge.

Butt. T. Lap. Corner (Open & Closed)

Bevels. Vs. Js. Us. Single & Double.

Weld face & root. Fusion zone & boundary. HAZ.

Weld Sizing (Butts):

DTT. ATT. Excess weld metal.

Weld Sizing (Fillets):

DTT. ATT. Excess weld metal. Leg length *

Copyright 2002 TWI Ltd

Welding imperfections can be categorized into groups:

Copyright 2002 TWI Ltd

Profile & Lack of Filling

Mechanical or Surface damage

A HAZ hydrogen crack, initiated at the weld toe

Copyright 2002 TWI Ltd

Surface breaking porosity

Hollow root bead

Copyright 2002 TWI Ltd

Coarse cluster porosity

An isolated internal pore

Surface breaking solid inclusion

Internal solid inclusion

Copyright 2002 TWI Ltd

Internal solid inclusion causing

Solid inclusions caused by

Lack of sidewall fusion &

Lack of inter-run fusion

Lack of sidewall fusion

Copyright 2002 TWI Ltd

An Incompletely filled groove