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Welding Distortion Control: RKS, HZW
Welding Distortion Control: RKS, HZW
Distortion
Control
RKS,HZW
What is distortion ?
Before distortion
Undesirable change in
original shape is called
DISTORTION
After distortion
Distortion occurs due to heat input
and mechanical forces.
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Experiment No 1:
DURING HEATED CONDITION
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Experiment No 2 :
CLAMPING CLAMPING
JAWS JAWS
Distortion
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Heat input
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Distortion in case of spot heating?
HEAT SOURCE
HEATING
Heated area expands
Expansion restrained by surrounding solid area
Compressive stresses are developed
Further compressive stress leads to plastic
deformation
Material bulges at the spot towards heat sourceRKS,HZW
side
Distortion in case of spot heating?
COOLING
Resulting distortion
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Longitudinal distortion
WELD BEAD
ORIGINAL POSITION
WELD
BEAD
LONGITUDINAL
AFTER WELDING
DISTORTION
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Distortion in Butt welds
Longitudinal Distortion
LS = 3. I .L / 100,000 t
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LONGITUDINAL SHRINKAGE
• (B) FILLET WELD
LS = 25 Aw/ Ap
Aw = Weld X-sectional area
Ap = Resisting X-sectional area
Ap
Aw
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EXAMPLE OF LS IN FILLET
WELD
6
All dimensions in mm
75
8x8
6
100
LS = 1.52 mm
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Distortion in Butt welds
Transverse Distortion
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Transverse distortion
WELD BEAD
ORIGINAL POSITION
Where
S = Transverse Shrinkage (mm)
Aw = Cross sectional Area of Weld (mm2)
t = Thickness of Plates (mm)
d = Root Opening (mm)
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TRANSVERSE SHRINKAGE
DURING MULTIPASS WELDING
TS = TS0 + b (log w - log w0)
Where
TS = Total Transverse Shrinkage
TS0 = Transverse Shrinkage after first pass
w = Total weight of weld metal
w0 = weight of first pass weld metal
b = a coefficient
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Effect of Various Procedures on
Transverse Shrinkage of Butt Welds
Procedures Effect on TS
Root Gap TS increases with increase in RG
Joint design Single Vee produces more TS than
double V
Electrode dia. TS decreases with increase in electrode
dia.
Degree of constraint TS decreases with Degree of constraint
Peening TS decreases by peening
Gouging & repairs TS increases by these operations.
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TRANSVERSE SHRINKAGE
IN FILLET JOINTS
1. For T joints with two continuous fillets.
TS = Leg of fillet Weld (l) x 1.02
Bottom Plate thickness (tb)
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TRANSVERSE SHRINKAGE
IN FILLET JOINTS
2. For intermittent fillet welds , a correcting
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TRANSVERSE SHRINKAGE
IN FILLET JOINTS
l
t
t
l
(3) For fillet welds in a lap joints between
plates of equal thickness (two welds)
AFTER WELDING
ORIGINAL POSITION
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Distortion in Butt welds
Angular Distortion
t1 g = 3 mm
t t3
t2 t3 = 2 mm
t1 + 1/2 t3
= 0.6
t RKS,HZW
Angular Distortion in Fillet Welds
W W
t
AD
AD
t
l
AD = 0.0076 . W . l1.3
t2
Where
AD= Angular Distortion, mm
W=flange width, mm
l = weld leg length, mm
t = flange thickness, mm RKS,HZW
Example of Angular Distortion
in Fillet Welds
Find the angular distortion in a double fillet
weld of a T-joint between a flange 1000 mm
wide and a vertical member when the thickness
of both the members is 6 mm and the weld leg
length = 8 mm
Solution.
0.0076 x 1000 x (8)1.3
AD = = 3.15 mm.
(6)2
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Multiple Restrained Fillet Welds
Ø AD
L
AD x 2
1 1 Ø
= Ø
L 4 L 2
Solution.
By putting L = 1000 mm, Ø = 90 = 0.1571 rad.
x = L/2 - 400 = 100 mm in the Formula,
AD = 14.164 mm.
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Distortion in ‘T’-joints
Angular distortion
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Distortion in ‘T’-joints
Longitudinal distortion
(a) pulling effect towards neutral axis
Section A - A A
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Distortion in ‘T’-Stiffener
Longitudinal distortion
(b) pulling effect of welds above neutral axis.
Section A - A A
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To prevent distortion :-
(A)
Reduce the effective
shrinkage force.
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Reduce effective shrinkage force
(A-1) Keep the angle of weld joint to the
barest minimum.
50 deg. +/- 5 deg.
KEEP REINFORCEMENT UP TO 19 MM
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7 mm +3/-1 keep fillet size 18 mm/6 mm
19 mm +3/-1
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Reduce effective shrinkage force
(A-4) Minimize no of passes larger size of
electrodes
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Reduce effective shrinkage force
N. A.
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To prevent distortion :-
(B)
Make shrinkage work
for us
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Make shrinkage work for us
(B.1) Pre cambering OR Pre bending in plate
WEDGE
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Make shrinkage work for us
(B-2) Keep over dimensions OR over
bend before welding
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To prevent distortion :-
(C)
Balance shrinkage
force with other
forces
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Balance shrinkage forces
with other forces.
6
2 5
5
(C-1) 4
4 3
Do Sequence welding 3
6 1 1
4
1
2
3 RKS,HZW
Balance shrinkage forces
with other forces
(C-2) Back step welding
1 2 3 4
Welding progresion
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Balance shrinkage forces
with other forces
(C-3) Back to back clamping for welding
PART -I
END PLATES
TACKED
PART -II
Two identical parts should be tacked back to back
together before welding as shown
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Back to back welding of saddles
SADDLE-
I
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Good working
methods for
welding distortion
in our routine work
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Bulging of tube sheet of heat
exchanger
TUBE SHEET
D/4
3200
JOINT DETAIL WELD SEQUENCE
600
OUTSIDE 2
SAW
2/
3T T 1 SMAW
3 BACK
1/ GOUGING SAW
3T 3
INSIDE
600 0.2mm GAP RKS,HZW
Distortion of shell long seams
LOCATION
STAGE
1 2 3
1 SET-UP STAGE 4+ 2+ 2+
2 AFTER SEAL RUN 6+ 4+ 5+
3 AFTE R O/S WELDING 8+ 6+ 8+
4 AFTER BACK GOUGING 6+ 5+ 5+
5 AFTER I/S WELDING 4+ 2.5 + 4+
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Distortion of circumferential seams in shell
D C B A
PRE-TILT OF T-STIFFENER = A - C
C
SAGGING OF T-STIFFENER = A - B
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Distortion in flange to pipe welding
FLANGE WARPS
TEMP. SUPPORTS FLANGE
FLANGE FLANGE
PIPE
AFTER BEFORE
WELDING WELDING
PIPE PIPE
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Distortion During Oxy-acetylene
Cutting
PLATE
STRIP
TORCH I
STRIP
DIRECTION OF MOVEMENT
FOR TORCHES
SCRAP 10 mm TORCH II
METHOD I
Two Torches Technique
• Mark strip of required width leaving 10 mm distance
• Move two torches simultaneously carrying out cutting operation
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Controlling distortion during
oxy - acetylene cutting
PLATE
STRIPS
KERF HOLE
Method II
• Mark the strips with kerf allowance on the plate
• Drill small hole in kerf allowance at distance 20 mm away from
the edge
• Start cut from drilled hole in kerf to the end such that the strip
is attached to main plate
• Cut the balance strip attached to the plate RKS,HZW
Controlling distortion during
oxy - acetylene cutting
30 mm
12 mm THK
PLATE
R250 mm
30 mm 50 mm
PIERCE
START
Aim : To get undistorted segment from the plate of size as
shown
Specific Steps
• Mark leaving 30mm Dist. from edge
• Start with pierce cut as shown instead of starting from the
edge
• Follow the path as shown
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Reduction in distortion
• Less weld edge preparation.
• Less welding current as per WPS.
• Higher base metal thickness.
• Lesser welding passes
• Do not over weld
• More distortion in stainless steel then
carbon steel.
• Less offset-Lesser welding-Lower
distortion RKS,HZW
Reduction in distortion
• Provide intermittent welding
• Place weld near the neutral axis
• Balancing weld around neutral axis
• Back-step welding
• Sequence welding
• Pre bending OR Pre cambering
• Back to back clamping
• Double operator welding techniqueRKS,HZW