Fdocuments - in Wis5 Stress and Distortion 15

TECHNOLOGY
Welding Inspection
Residual Stress and Distortion
Course Reference WIS 5
Copyright © 2003 TWI Ltd Faisal Yusof
TECHNOLOGY Stresses
 Normal Stress
Stress arising from a force perpendicular to the
cross sectional area
Compression
Tension

TECHNOLOGY Stresses
 Shear Stress
Stress arising from forces which are parallel to, and lie
in the plane of the cross sectional area.
Shear Stress

Stresses
 Hoop Stress
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Stress acting circumferentially around a pipe due to

internal pressure.
Hoop Stress

Residual Stress
 Metal contract during solidification and subsequent
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cooling.
 If this contraction is prevented or inhibited
 residual stress will develop.
 The tendency to develop residual stresses increases
when the heating and cooling is localised.
 Welding is very localised heating and the presence of
liquid and solid metal in contact can be expected to
induce very high levels of residual stresses.

Residual Stress
 Residual stresses are very difficult to measure with
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any real accuracy.

 Residual stresses are self balancing internal forces
and not stresses induced whilst applying external
load
 Stresses are more concentrated at the surface of the
component.
 The removal of residual stresses is termed stress
relieving.

Residual Stress
Residual stresses occur in welds in the following directions
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 Along the weld – longitudinal residual stresses

 Across the weld – transverse residual stresses
 Through the weld – short transverse residual stresses
Longitudinal
Transverse
Short Transverse
TECHNOLOGY Distortion
Factors which affect distortion
 Material properties and condition
 Heat input
 The amount of restraint
 The amount of weld metal deposited

 Distortion will occur in all welded joints if the material
are free to move i.e. not restrained
 Restrained materials result in low distortion but high
residual stress
 More than one type of distortion may occur at one time
 Highly restrained joints also have a higher crack
tendency to joints of a low restraint
 The action of residual in welded joints is to cause
distortion

Distortion
Distortion is a very complex matter more than 20 factors
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influence its magnitude and for this reason it is very difficult

to predict its exact amount of distortion that may occur

Distortion
Fit-up is very important to minimise distortion, fit-up must be
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even and uniform to ensure constant shrinkage along the

joint

Distortion
A mechanised welding process is preferable to a manual
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process because its consistent operation allows for better
distortion control. The required volume of weld metal should
be deposited in the shortest time to minimise heat input

Distortion
The shorter the welding time the less heat is transmitted in to
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the material and less distortion will occur. Keep welding
times down by carefully selecting the welding process,
electrode type and size, welding current and travel speed

Longitudinal shrinkage/distortion

Transverse shrinkage/distortion

Angular distortion: weld metal contraction transverse


Longitudinal bowing: weld metal contraction longitudinal

Distortion
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Distortion
TECHNOLOGY

Distortion
TECHNOLOGY

Distortion
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Angular Distortion Transverse Distortion
Bowing Distortion Longitudinal Distortion

Distortion
Control of distortion my be achieved in on of the
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following way
The used of a different joint design

Distortion
The volume of weld metal in a joint will affect the amount
TECHNOLOGY
of local expansion and contraction, hence the more weld

deposited the higher amount of distortion
Preparation angle 60o

Distortion
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following way
Offsetting the joints to be welded – so that the

metal distorts into the required position.

Distortion
Offsetting:
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The amount of offsetting required is generally a function of

trail and error

Distortion
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following way
Offsetting the joints to be welded – so that the

The use of a balanced welding technique

Back-step welding technique
1. 2. 3. 4.
Back-skip welding technique

1. 3. 2. 4.

Distortion
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following way
Presetting the joints to be welded – so that the

The use of a balanced welding technique
The use of clamps, jigs and fixtures.

Distortion
Clamping and jigging:
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The materials to be welded are prevented from moving by

the clamp or jig the main advantage of using a jig is that the
elements in a fabrication can be precisely located in the
position to be welded. Main disadvantage of jigging and
high restraint is the high levels of residual stresses.

Summary of Residual Stress & Distortion
1. Residual stresses are locked in elastic strain, which is
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caused by local expansion and contraction in the weld

area.
2. Residual stresses should be removed from structures
after welding.
3. The amount of contraction is controlled by, the volume of
weld metal in the joint, the thickness, heat input, joint
design and the materials properties
4. Offsetting may be used to finalise the position of the joint.
5. If plates or pipes are prevented from moving by tacking,
clamping or jigging etc (restraint), then the amount of
residual stresses that remain will be higher.

Summary of Residual Stress & Distortion
6. The movement caused by welding related stresses is
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called distortion.
7. The directions of contractional stresses and distortion is
very complex, as is the amount and type of final distortion,
however we can say that there are three directions:
a. Longitudinal b. Transverse c.Short transverse
8. A high percentage of residual stresses can be removed by
heat treatments.
9. The peening of weld faces will only redistribute the
residual stress, and place the weld face in compression.

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Any
Any Questions?
Questions?

Questions
QU 1. What causes residual stress in welds?
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QU 2. State three directions which residual stresses form in a

welded joint
QU 3. Give four methods of controlling distortion.
QU 4. Sketch a balanced welding techniques.
QU 5. State four factors which affect distortion.

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TECHNOLOGY

Copyright © 2003 TWI Ltd Faisal Yusof

Copyright © 2003 TWI Ltd Faisal Yusof

Stress acting circumferentially around a pipe due to

Copyright © 2003 TWI Ltd Faisal Yusof

Copyright © 2003 TWI Ltd Faisal Yusof

any real accuracy.

Copyright © 2003 TWI Ltd Faisal Yusof

 Along the weld – longitudinal residual stresses

 Through the weld – short transverse residual stresses

Factors which affect distortion

 Material properties and condition

 The amount of restraint

 The amount of weld metal deposited

Copyright © 2003 TWI Ltd Faisal Yusof

Copyright © 2003 TWI Ltd Faisal Yusof

influence its magnitude and for this reason it is very difficult

Copyright © 2003 TWI Ltd Faisal Yusof

even and uniform to ensure constant shrinkage along the

Copyright © 2003 TWI Ltd Faisal Yusof

Copyright © 2003 TWI Ltd Faisal Yusof

Copyright © 2003 TWI Ltd Faisal Yusof

Copyright © 2003 TWI Ltd Faisal Yusof

Copyright © 2003 TWI Ltd Faisal Yusof

Copyright © 2003 TWI Ltd Faisal Yusof

Copyright © 2003 TWI Ltd Faisal Yusof

Copyright © 2003 TWI Ltd Faisal Yusof

Copyright © 2003 TWI Ltd Faisal Yusof

Copyright © 2003 TWI Ltd Faisal Yusof

Copyright © 2003 TWI Ltd Faisal Yusof

Copyright © 2003 TWI Ltd Faisal Yusof

Angular Distortion Transverse Distortion

Bowing Distortion Longitudinal Distortion

Copyright © 2003 TWI Ltd Faisal Yusof

of local expansion and contraction, hence the more weld

Preparation angle 40o

Copyright © 2003 TWI Ltd Faisal Yusof

Offsetting the joints to be welded – so that the

Copyright © 2003 TWI Ltd Faisal Yusof

The amount of offsetting required is generally a function of

Copyright © 2003 TWI Ltd Faisal Yusof

Offsetting the joints to be welded – so that the

Copyright © 2003 TWI Ltd Faisal Yusof

Back-skip welding technique

Copyright © 2003 TWI Ltd Faisal Yusof

Presetting the joints to be welded – so that the

Copyright © 2003 TWI Ltd Faisal Yusof

The materials to be welded are prevented from moving by

Copyright © 2003 TWI Ltd Faisal Yusof

caused by local expansion and contraction in the weld

Copyright © 2003 TWI Ltd Faisal Yusof

Copyright © 2003 TWI Ltd Faisal Yusof

Copyright © 2003 TWI Ltd Faisal Yusof

QU 2. State three directions which residual stresses form in a

QU 3. Give four methods of controlling distortion.

QU 4. Sketch a balanced welding techniques.

QU 5. State four factors which affect distortion.

Copyright © 2003 TWI Ltd Faisal Yusof

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