HAZ AND WELDING

DEFECTS
Cross section of a typical fusion-welded joint:

(a) principal zones in the joint and (b) typical grain structure.
 A typical fusion-weld joint inwhich filler metal has
been added consists of several zones:
(1) fusion zone, (2) weld interface, (3) heat-
affected zone, and (4) unaffected base metal
zone.
The fusion zone consists of a mixture of filler
metal and base metal that have completely
melted.
This zone is characterized by a high degree of
homogeneity among the component metals that
have been melted during welding.
 The second zone in the weld joint is the weld
interface, a narrow boundary that separates the
fusion zone from the heat-affected zone.
The interface consists of a thin band of base
metal that was melted or partially melted
(localized melting within the grains) during
the welding process but then immediately
solidified before any mixing with the metal in the
fusion zone.
Its chemical composition is therefore identical to
that of the base metal.
 The third zone in the typical fusion weld is the heat-affected zone
(HAZ).
The metal in this zone has experienced temperatures that are below
its melting point, yet high enough to cause microstructural changes
in the solid metal.
The chemical composition in the heat-affected zone is the same as
the base metal, but this region has been heat treated due to the
welding temperatures so that its properties and structure have been
altered.
The amount of metallurgical damage in the HAZ depends on factors
such as the amount of heat input and peak temperatures reached,
distance from the fusion zone, length of time the metal has been
subjected to the high temperatures, cooling rate, and the metals
thermal properties.
The effect on mechanical properties in the heat-affected zone is
usually negative, and it is in this region of the weld joint that welding
failures often occur.
 As the distance from the fusion zone increases,
the unaffected base metal zone is
finally reached, in which no metallurgical change
has occurred. Nevertheless, the base
metal surrounding the HAZ is likely to be in a
state of high residual stress, the result of
shrinkage in the fusion zone.
Welding defects: causes and remedies

1) Cracks
2) Cavities
3) Solid inclusions
4) Incomplete fusion
5) Imperfect shape or
Unacceptable
contour
6) Miscellaneous
defects
 Destructive testing of welds
These tests are used to quantify welding procedures and
welders.
Very expensive to carry out because
involve preparation of material
actual making of welds
the cutting and machining of weld test specimens
testing

Common Methods
1) Tensile tests
2) Impact tests
3) Hardness tests
4) Bend tests
5) Fatigue tests
6) Creep tests
Root bend FACE BEND
CHARPY IZOD
 Spot Weld Testing

Test methods for spot welds: (a) tension-shear test, (b) cross-tension
test, (c) twist test, (d) peel test.
 Non-Destructive Testing (NDT)
Methods
Visual inspection
Liquid-penetrant testing
Magnetic particle testing
Eddy current testing
X-Ray testing
Ultrasonic testing
The use of noninvasive techniques to
determine the integrity of a material,
component or structure
or
quantitatively measure some characteristic of
an object.

i.e. Inspect or measure without doing harm.

 Visual Inspection

Most basic and common inspection method.

Tools include fiberscopes, borescopes,

magnifying glasses and mirrors.
 Liquid Penetrant Inspection
A liquid with high surface wetting characteristics is
applied to the surface of the part and allowed time to
seep into surface breaking defects.
The excess liquid is removed from the surface of the
part.
A developer (powder) is applied to pull the trapped
penetrant out the defect and spread it on the surface
where it can be seen.
Visual inspection is the final step in the process. The
penetrant used is often loaded with a fluorescent dye
and the inspection is done under UV light to increase
test sensitivity.
 Eddy Current Testing

Coil's
Coil magnetic field

Eddy current's
magnetic field
Eddy
currents

Conductive
material
 Magnetic Particle Inspection

The part is magnetized. Finely milled iron particles coated

with a dye pigment are then applied to the specimen.
These particles are attracted to magnetic flux leakage
fields and will cluster to form an indication directly over the
discontinuity. This indication can be visually detected
under proper lighting conditions.
 Film Radiography
The part is placed between the
radiation source and a piece of film.
The part will stop some of the
radiation. Thicker and more dense
area will stop more of the radiation.
The film darkness
(density) will vary with
the amount of radiation
X-ray film reaching the film
through the test object.
= less exposure
= more exposure
Top view of developed film
 Ultrasonic Inspection (Pulse-Echo)
High frequency sound waves are introduced into a
material and they are reflected back from surfaces or
flaws.
Reflected sound energy is displayed versus time, and
inspector can visualize a cross section of the specimen
f
showing the depth of features that reflect sound.

initial
pulse

back surface
echo
crack
echo

crack

0 2 4 6 8 10 plate

Oscilloscope, or flaw
detector screen