Distortion Case studies

Shrinkage during welding definitions

Shrinkage during welding definitions
Shrinkage during welding definitions
Shrinkage during welding definitions
Shrinkage during welding

The shrinkage is of three fundamental types

Longitudinal Shrinkage along the length of weld

Transverse shrinkage shrinkage across the length
of weld
Shrinkage across the thickness
 definitions
Shrinkage during welding

Longitudinal Shrinkage along the length

of weld -  l
Transverse shrinkage shrinkage across
the length of weld -  t
Shrinkage across the thickness -- s

t

l s
Types of distortion definitions

Longitudinal distortion

Angular distortion
Types of distortion definitions

Transverse distortion

N A
Types of distortion definitions

Typical Longitudinal distortion

Types of distortion Angular distortion
Types of distortion Buckling distortion
 Influence of Material

W 600

The width of the isotherm (W 600 ) depends upon the

thermal diffusivity [ k / c ] of the material for a given
level of heat input
Thermal conductivity ( k )
Specific heat ( c )
Density (  )
The Isotherm width indicates the extent of the base metal
regions heated during welding and in turn the shrinkage in
the base metal regions
Thermal Properties of Influence of Material
Engineering Materials

Co-efficient Vol. Thermal Distortion Thermal

Of thermal expansion Capacity factor diffusivity
Material c x10 –6
 x 10 –6
( C) / c (m3/J) k/ c (m2/s)
( J/ m3 C)
Aluminum 23-27 2.7 8.5-10 85-100
Ferritic steel 14 4.5 3.1 9.1
Aus. St. steel 17 4.7 3.6 4.7
Monel 400 16 4.4 3.7 8.0
Titanium 17 3.0 5.7 9.0
Distortion control methods

Prevention Control Correction

Optimum design Heat Input Hot correction

Fixtures Sequencing Stress Relieving
Elastic pre-bending Clamping Cold correction
Plastic pre-bending Heat Sink
Selection of Process
Distortion Prevention

Minimize Number of weld

joints

Replace fabricated sections

by extruded / rolled sections
Distortion Prevention

Locate welds near the

neutral axis

Use the appropriate Edge

preparation that gives the
required penetration with
minimum weld deposit
Distortion Prevention Selection of Process

5
Heat Input kJ/ mm

4
3
GW

2
SMAW

GTAW
SAW

1
CO2 PAW
EBW
1 2 3 4 5 6 7
Distortion Prevention Effect of Edge Preparation

Strong back
10

Free
Distortion

h1: h2 - 7:3
5 h1
h1: h2 - 6:4 h2

h1: h2 - 1:1
h1: h2 - 4:6

0 1/2 1 1 1/2 2 2 1/2

Plate thickness in
inches
Effect of Number of weld passes on Distortion

11
11
10 10
9 9
8 8
7 7
6 5
6
5 
4 4
3 3
2 2 
1 1
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10
Weld Pass Weld Pass
 Effect of Weld Cross Section on Transverse
shrinkage

11
transverse shrinkage in mm

4
9 10
3
8
5,6 7
2
3 4
11 1 2

100 200 300

Cross section area of weld mm 2
Effect of number of Passes on Transverse Shrinkage
6
5

2
Transverse Shrinkage
4
3

1
2
1

0 4 8 12 16 20 24
Pass Number
 Distortion Control
Minimize Over Welding by

Reducing the Root gap during fit up

Right gap Excessive gap Buttering / buildup

Minimize Reinforcement Optimization of fillet size

Normal Higher fillet

size
Increases
distortion
Excessive
 Distortion Control

1 2 3 4

Back Step Welding

8 7 4 8
6 5 7 3

4 3 2 6
Intermittent Welding
2 1 5 1
Positioning welds
Distortion Control

Elastic Presetting
Distortion Control Back to Back Welding
Technique

Back to Back Welding

Back to Back with presetting

 Weld Sequencing

2 1
3 10

4 1 4 9

2 3 5 8

6 7

Combinations = !10 =3,628,800

 Analysis Procedure
Generation of Geometry (cross Section)
through CAD To scale using CAD commands
Convert the section into a extruded solid
using REGION command
LOAD & RUN the VB Program
Pick the weld in the order of sequence that
will yield minimum distortion
Submit the Heat input for each weld in
Cal /mm
 Inputs for the CAD Assisted Program
Section Properties
Area of Cross section,
Neutral axis,
Area Moment of
Inertia
Material Parameters
Thermal expansion co-efficient,
Specific heat & density
Yield strength

Weld Parameters
Weld co-ordinates
Weld sequence,
Heat input for each
Typical generation of Geometry for Channel Box
section through TEMPLATE
Software for prediction
of welding distortion
Typical output Of CADIST
 Generated Geometry for Channel Box Section
+Z
+Y

-X +X

-Z -Y
CADISP–02 Computer Assisted distortion Prediction
The Program works with VB as the front
end and AutoCAD for graphics related
computations
Highly user friendly and interactive type
Applicable for both single and Multi-pass
welds
Validated in long beam type Buck Stay
beams
Distortion Control Projects Completed

Distortion control
in 500 MW Wind
Box Assembly

Distortion control
Ceiling girder
beams for NLC
Project

Weld sequencing
to minimize twist
distortion in box
section columns
 Applications

Box Section columns

Diagonal distortion within

+/- 3 mm
Width – 1.5 Ms, Breadth –1.5 Ms
Length– 6,9,12 Ms,
Weight – 8-16 Tons
Unrestrained assembly Procedure
with Weld Sequencing Technique
Applications
Box Section Column Assy.

3
4
2
5
1
Weld 1 & 2 plate to diaphragm
Weld 3- 5 plate to T-stiffeners
Applications
Box Section Column Assy.

6
8

Weld 6 to 9 Side plate to diaphragm

Applications
Box Section Column Assy.

10 Chamber 2
11
Chamber 1

Chamber 3
Applications
Box Section Column Assy.

The T-stiffeners have not been shown

Welds between stiffener to top plate and
top plate to diaphragm are done
Applications
Box Section Column Assy.

After completing the

outside corner
welding the corner
B2 welds on the opposite
A1 side is completed by
B1 FCAW process.
A2
Distortion Control
Effect of Number of
Passes

8
Angular Strain  deg

Pass 1 to 5
Pass 6 to 34

6
Pass 3-6 Pass 13-33
4
GW

Pass 7-12 Pass 1&2

Pass 34-40
2

CO2

Welding Passes
8 16 24 32 40
Distortion Control Effect of Layer Sequence
Pass 10-34
Pass 1-9

Sequence -I

Pass 13-17 Pass 18-34

Pass 14-18 Pass 19-34

Pass 1-3 Pass 4-12

Pass 1-4 Pass 5-13

Sequence -II Sequence -III

Distortion Control Effect of Layer Sequence
10

8
6
Sequence -I
Angular Distortion in mm

4
Sequence -III
2 Sequence -II

-2

-4 Pass Number
4 9 14 19 24 29 34
 Applications Plus section columns

Long. distortion within +/- 10 mm

Width–1.2 Ms,Breadth–1.2Ms,Length–21Ms,Weight–16 Tons
Unrestrained assembly Procedure & Weld Layer Sequence
Technique
 Applications
Ceiling Girder
beam of Boiler

Gap between the flanges within +/- 1 mm

Width – 1.5 Ms, Height –3.5 Ms
Length – 21 Ms, Weight – 40 Tons
Unrestrained assembly Procedure with
Weld Sequencing Technique
 Applications Railway Bogie frame

Top Flange
11 7 5 10
Diaphragm
Plate
1 2

8 4 3 6 9

20 mm
 Applications

Residual stress Measurement in

Welded Railway bogie Frame
 Applications Studies on control of
Angular distortion in
Pass 10-34
Pass 1-9 Full Penetration
Side A T - Joints

Sequence -I

Pass 14-18 Pass 19-34

Pass 13-17 Pass 18-34

Pass 1-3 Pass 4-12 Pass 1-4 Pass 5-13

Sequence -II Sequence -III

 Applications Studies on control of Angular distortion in
Full Penetration T -Joints

Distortion controlled within

0.8 mm
Transducer
10

8
6
Angular Distortion in

Sequence -
4 I
Sequence -II
2 Sequence
-III
0
mm

-2

-4
4 9 14 19 24 29 34
Distortion control in
Ship Structures
Waviness in Plate Panel construction
Angular distortion due to Double Fillet Weld
Angular distortion due to Double Fillet Weld

The distortion pattern follows rotation theory

Angular distortion behaviour in T-joints
with fillet welds

Rotation effect due to

Single Fillet Weld

Resultant distortion
after both Fillet Welds
Angular Distortion Behavior in Panels with
T-sections

1 2

1 2
Effect of welding Sequence on Angular Distortion
Behavior of welded Panels

1 2

1 3 4 2

1 2

3 1 2 4
Effect of welding Sequence on Angular Distortion
Behavior of welded Panels

1 2

1 4 3 2

1 6 4 3 5 2

1 8 6 5 7 2
4 3
Effect of welding Sequence on Angular Distortion
Behavior of welded Panels

1 8 6 4 3 5 7 2

7 5 3 1 3 4 6 8

7 1 3 5 6 4 2 8

7 1 5 3 4 6 2 8
welding Sequence To control waviness in deck plate panel

10 8 5 6 7 4 9
13 14 12 1 3 2 11

Lower Deck of Section II --Stage I

11 2 9 4 7 6 5 8 3 10 1 12

Lower Deck of Section II --Stage II

 Lower Deck of Section II --Stage I

16
12 1 10 3 8 5 6 7 4 9 2 11
15

12 1 10 3 8 5 6 7 4 9 2 11
14
13

13 14 12 1 10 3 8 5 6 7 4 9 2 11

Weld sequence for bulb-bar welding transverse to long axis

 Lower Deck of Section II of Hull for SBC Vizag

13 14 12 1 10 3 8 5 6 7 4 9 2 11

Weld sequence for bulb-bar welding transverse to long axis

Mobile Launch Pad (MLP)
 BOGIE
MLP
MBG

m
TBG

m
MBG

0
CAS

0
TBG

2
TBG

19,
MBG
MBG TBG

7250 mm

19,200 mm
 Overall assembly of the Mobile Launch Pad
structure [Bogie & CAS structure ]
Central Annular
Space (CAS)

Main Girder Interconnecting

Girder (Bogie)

Tie Girder Bogie

Cylindrical
Annular Main Girder of
space Bogie
(CAS)
View of the Main and inter-connecting girders of
Bogie of MLP

Interconnecting
Bogie girders

Main girders
Assembly of the main Girder & Tie Girders with CAS

Tie Girder

Main Girder
Cylindrical
Annular
space
(CAS)
Cross section of the Main box girder
and TIE girder

00
 Details of Assembly welds of MLP
Type of
Sl.No Weld details Weld length in meters Remarks
Edge. Prep

Horizontal – I.0 and 4.2 ms 4 welds in

TIE-girder to MBG Single
1 on top and 1.0 & 4.2 ms on Each girder
14 to 32 mm VEE
Bot. 4 welds in each girder -4 girders

DBF-in CAS 4 welds in

TIE girder to MBG Vertical welds of 3.78 ms
2 Side & SV at Each girder
14 to 32 mm -six nos in each girder
tie girder end -4 girders

Stiffener to MBG Vertical welds of 3.78 ms

3 DF-8 mm
14 to 32 mm -six nos in each girder

16 DH
CAS to MBG Four welds of 750 mm Welds of
20 to 32(20), 32 in (two top & two bot.) in Each 750
4 MBG is tapered to DV each girder four vertical and 16
20 to suit the CAS Welds of 2 meters Vertical
structure Each in each girder Welds of
2mts
 Preparatory steps taken before welding
The MBG & TBG’s were properly supported by steel structure
after maintaining water level
The fit up was done with care to minimize the root gap within
2 mm. The gaps were minimized by buildup wherever
necessary.
The joint edges were kept clamped on either sides by special
cleats till the inside root welding is completed.
Preheating was done when the thickness was greater than 32
mm and post heating was done after welding by resistance
heating pads to take care of high humidity conditions at site.
The WPS established at TISCO works was meticulously
followed for site welding
Support structure provided before welding

MBG MBG

TBG

SUPPORTS
WELDING SEQUENCE
FOR
BOGIE ASSEMBLY
 SEQUENCE FOR WELDING THE BOGIE

2 3

4 1

Vertical weld followed by horizontal and overhead position

Outer side- one pass, Inner side- two passes, outer side-two
passes, Inner side –one pass.
 SEQUENCE FOR WELDING THE BOGIE

6 8

7 5

Vertical weld followed by horizontal and overhead position

Outer side- one pass, Inner side- two passes, outer side-two
passes, Inner side –one pass.
 SEQUENCE FOR WELDING THE BOGIE

13 1
2
1 9
1

Vertical weld followed by horizontal and overhead position

Outer side- one pass, Inner side- two passes, outer side-two
passes, Inner side –one pass.
View of one
of the bogies
with cross
girder,
intermediate
girders and
wheels
 SEQUENCE FOR WELDING THE BOGIE

14 1
6
1 1
5 3

Vertical weld followed by horizontal and overhead position

Outer side- one pass, Inner side- two passes, outer side-two
passes, Inner side –one pass.
WELDING SEQUENCE FOLLOWED FOR
CAS, MBG & TIE GIRDERS ASSEMBLY

STAGE I
Root welding of CAS to MBG inside
Flatness check at 8 axes
Welding of stiffeners inside MBG to Tie girder
Welding of Tie girder flange to MBG inside
Flatness check at 8 axes
 Sequence for
13 12 Root pass Welds
bet MBG and
CAS

11 10

12 09

13 16

16 09 14 15
 Flatness of top
surface of CAS –
critical dimension

CAS STRUCTURE
Pre& Post
CAS to MBG joint
heating Pads

MBG
CAS to MBG welding
 13 Sequence for
12 Root pass
Welds
11 (vertical)bet
14 MBG and CAS

Top

3 1 4

15 10 5 6
10

7 8
16 09 9 2 10
09, 13, 16, &12 in DH position simultaneously
Bot
10,14,11 & 15 in OH position simultaneously
 Welding stiffener of Tie girder with MBG
Two welders used inside each Tie girder. Two opposite
Tie girders are welded simultaneously

2 1

11 12
3 4
9 10
5 6

7 8
 Sequence for root welding (inside) Tie girder with MBG

In each tie girder vertical welds nearer to CAS is carried out inside
followed by vertical welds at the outer ends. Two welders used inside
each Tie girder. Welds are carried out in two opposite Tie girders
simultaneously
 Sequence for root welding Tie girder with MBG
In each tie girder root welds are carried out in overhead position at top
and inside the MBG at bottom in DH position simultaneously by two
welders. Two opposite Tie girders are welded simultaneously

bot

top

1 9 2

3 4

5 6

7 10 8
FLATNESS
MEASUREMENT
in CAS WERE
MADE by
THEODOLITE
INSTRUMENT
+
after WATER -
LEVELING THE
SAME on the
TOP SURFACE
of MBG
FLATNESS MEASUREMENT IN CAS
WELDING SEQUENCE FOLLOWED FOR
CAS, MBG & TIE GIRDERS ASSEMBLY
Before full welding, Back chipping,grinding and LPI
was carried out to ensure full penetration

STAGE II
Welding of Tie girder to MBG outside (Vertical welds)
Flatness check of the CAS at 8 axes
Welding of Tie girder to MBG outside (top & bot welds)
Flatness check of the CAS at 8 axes

Filler pass welding of CAS to MBG outside

Flatness check of the CAS at 8 axes
 Flatness of top
surface of CAS –
critical dimension

CAS to MBG joint

Sequence for welding Tie girder with MBG [outside]
In each tie girder vertical welds nearer to CAS is carried out followed by
vertical welds at the outer ends. Two welders used inside each Tie girder.
Welds are carried out in two opposite Tie girders simultaneously
Close up view of the TIE girder

TIE BOX GIRDER

Sequence for filler pass welding Tie girder with MBG
[outside]
In each tie girder filler pass welds in overhead position is carried out on
outside bottom followed by filler pass welding outside in DH position.
Two welders used inside each Tie girder. Two opposite Tie girders are
welded simultaneously

1 9 2

3 4

5 6

7 10 8
 Sequence
for filler
13 12 pass Welds
bet MBG
and CAS

16 09
 Sequence for
13 12 filler pass
Welds bet
MBG and
14 11 CAS

15 10

16 09
Flatness readings at various stages
Measured
Sl.No Stage
Deviation

After fit up of the MBGs and TIE girders with CAS

1 0.20 mm
( after provision of pops ups and supports)

2 After completion of root welds 0.50 mm

After completion of all welds except top four welds

3
connecting MBG with CAS
0.60 mm

After completion of all welds prior to removal of

4
supporting structure
0.46 mm

After completion of all welds after removal of

5 supporting structure 0.28 mm

After completion of all welds after removal of

6 0.28 mm
supporting structure
Oxy-acetylene Flame Correction
What is the principle of Flame Correction?
Expansion and contraction during Heating

Expansion during Heating

Shrinkage After Cooling

 What are the basic steps of hot correction?

Heat the convex side of the bend

Heat selected places up to 750 o C in carbon and low
alloy steels and 600°C in QT steels
Heat the surface rapidly with right type of pattern
Cool the heated surface with force if necessary

Apply Mechanical force to improve the effectiveness

Analyze the restraint conditions & provide the
necessary freedom for movement of material
Ensure that no metallurgical damage is left in the
material by surface NDT
 Types of shrinkages associated with
localized heating

Longitudinal
shrinkage Transverse
shrinkage Longitudinal
& Transverse Angular
shrinkage shrinkage
Shrinkage in Spot Heating
 What are the heat patterns used ?

Single spot

Multiple
spot

Large size
spot

Oval
spot
 What are the heat patterns used ?

Intermittent
line

Multiple
Line

Stripe Heat

Wedge/
V- Heat
What are the features of oxy–acetylene?

Inner Cone

Outer Cone

Outer Envelope
What are types of heating torches used?

95

55

15

The number indicates the flow rate

of O2 and C2H2 in cu.ft per min
What are the types of flames used ?

Neutral Flame

Reducing Flame

Oxidising Flame
What temperatures can be achieved with
Oxy-acetylene flame?

3. mm
3100 °C

2400 °C

1800 °C

1200°C
 How does one control the temperatures achieved?
The temperature is normally
checked by thermal chalks and by
the colour of the heated steel
surface. Hand held non-contact
pyrometers can also be used.

> 950 C

800-950 C

700-850 C

600-750 C

450-600 C

300-450 C

250-300 C
 What are the factors to be considered for selection
of pattern & dimension of heat?

Thickness of the section to be straightened

Extent of Bend to be straightened

The nature and type of bend

The number of flames available

Application of Mechanical force if any

Degree of constraints for the movement

What are the basic steps of hot correction?
How do we straighten distortion in T-section?

Line heating
How do we straighten distortion in T-section?

Line heating
How do we straighten distortion in T-section?

Line heating
How do we correct bulging in
sheet panel structures?
How do we straighten distortion in T-section?

Stripe Heating
How do we straighten angular distortion
in thick section?
How do we straighten angular distortion
in thick section?
How do we straighten angular distortion
in thick sections?

Line heating
How do we straighten angular distortion
in thin sections?
 How do we straighten gas cut plates?

Shrinkage varies along the depth

For straightening in-plane bends and

angular distortion
 How do plates distort during Gas cutting?

Gas cutting
During Gas After Gas
cutting cutting
How do we straighten distortion in thick plates?
How do we straighten distortion in thick plates?

3 1 2 4
5
How do we straighten T-sections ?

3
 How do we straighten thick plates?

A
w

B
How do we straighten real life welded structures?
How do we straighten local buckling distortion in thick
section?

Removal of Twist type of distortion

How do we straighten local buckling distortion in thick
section?
 How do we straighten local buckling distortion in thick section?

Application of Wedge
Type heating
What are the ways to increase the effect?

heating with addition of weight

What are the ways to increase the effect?

heating with self weight

 What are the ways to increase the effect?

heating with addition of mechanical forces

 What are the ways to increase the effect?

Mechanical methods to remove buckling in flanges

What are the ways to increase the effect?

heating with jacking

What type of distortion occurs in Tubular Panels ?
What type of distortion occurs in Tubular Panels ?

Side bend [Banana bend]

Face [Bowing]
How do we correct angular distortion in ceiling girder?

Application of stripe heating

 What are the precautions to be followed?
Do not heat already heated surface
Heating already plastically deformed surface
does not produce any shrinkage effect
Plan the location of heats
Plan such that some unheated regions are
available
Decide the number of heats based on trials
Application of few heats and observation of its
effectiveness would indicate the required number
of heats necessary
Check for the restraint condition of the heated plate
The restraint for the movement of metal during
correction is to be estimated and necessary
relief is to be provided
What type of flame setting is selected for different
materials?
Materials Neutral Oxidizing Carburizing
Structural Not
Suitable Advantageous
steels suitable
 What type of flame setting is selected for different
materials?
Notable Plastic condition Temperature Melting
Materials Strength redn at about °C Range in °C Point In °C

Structural steel
400-450 600 600 to 800 1540
St-37

Rail Steels 400-500 600 500 to 600 1520

Quenched and
400-450 500 500 to 590 1520
Tempered steels
What type of flame setting is selected for different
materials?

Materials Temperature Range in °C

Structural steel St-37 600 to 800

Rail Steels 500 to 600

Quenched and tempered
500 to 590
steels
Thank You