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8/17/2019 Welding Technology & Inspection Method.ppt
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FUNDAMENTAL OF WELDINGFUNDAMENTAL OF WELDING
WELDING : Welding is a joining process in whichmetals are heated, melted and mixed to produce a
joint with properties similar to those of thematerials being joined
!D"!N#!GE : $ortable, permanent, stronger than theparent materials with a %ller metal, the mosteconomical method to join in terms of material usageand fabrication costs
DI&!D"!N#!GE : Expensi'e manual Labor, highenerg( and dangerous, di)icult to disassemble andremo'e the defects
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APPLICATIONS APPLICATIONS
*onstructions, $iping, pressure 'essels
+oilers and storage tans, &hipbuilding, !erospace
!utomobile and -ailwa(s
!utomation . /achine, !utomatic and-obotic welding
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WELDING PROCESS WELDING PROCESS
*0//0NL1 2&ED WELDING $-0*E&&E& !-E:
&3IELDED /E#!L !-*WELDING4&/!W5
G!& /E#!L !-* WELDING4G/!W5 G!& #2NGEN !-* WELDING4G#!W5 &2+/E-GED !-* WELDING4&!W5 061!*E#1LENE WELDING40!W5
7L26 *0-ED !-* WELDING47*!W5 ELE*#-0&L!G WELDING D WELDING -E&I!N*E WELDING4-W5
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SMAW SMAW
&/!W 4&hielded /etal !rc Welding5 is
also nown as:&tic welding
/anual /etal !rc Welding4//!W5
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SMAW SMAW When an arc is struc between the metal rod 4electrode5 and the
wor piece, both the rod and wor piece surface melt to form aweld pool
&imultaneous melting of the 8ux coating on the rod will form gas
and slag which protects the weld pool from the surrounding
atmosphere
#he slag will solidif( and cool /ust be chipped o) the weld bead once the weld run is complete
or before the next weld pass is deposited
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Measurement ofundercut dept !"t #WAC $a$e%Underc
ut
SMAW SMAW
http://en.wikipedia.org/wiki/Image:Arc_welding_electrodes_and_electrode_holder.triddle.jpg
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SMAW SMAW
#he electrode coating is the feature which classi%es the
'arious t(pes of electrodes It actuall( ser'es thefollowing 7i'e separate function
&3IELDING: *oating decomposes to form a gaseousshield
DE.06ID!#I0N : *oating pro'ides a 8uxing action toremo'e the 09 other atmospheric gases
!LL01ING : *oating pro'ides additional allo(ingelements for the weld deposit
I0NI;ING : *oating impro'es electrical
characteristics to increase arc stabilit( IN&2L!#ING : #he solidi%ed slag pro'ides insulatingblanet to slow down the weld metal cooling rate
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SMAW SMAW
ELE*#-0DE IDEN#I7I*!#I0N &1E/
E < = > ? @ELE*#-0DE
#EN&ILE -ENG#3 4si5
$0&I#I0N
#1$E 07*0!#ING
*2--EN#
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WELDING POSITIONS WELDING POSITIONS
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GUESS T&E WELD POSITIONGUESS T&E WELD POSITION
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SMAW SMAW
&IGNI7I*!N*E 07 #3I-D DIGI# 07 &/!W
IDEN#I7I*!#I0N'() < INDI*!#E& &2I#!+LE 70- 2&E IN !N1$0&I#I0N
'*) < /E!N& #3!# /0L#EN /E#!L I& &0 7L2ID#3!# ELE*#-0DE *!N 0NL1 +E 2&ED IN 7L!#0- 30-I;0N#!L 7ILLE# $0&I#I0N
'+) < ELE*#-0DE I& &2I#!+LE 70- WELDING IND0WN3ILL $-0G-E&&I0N
',) < 3!& N0 &IGNI7I*!N*E
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&IGNI7I*!N*E 07 L! DIGI# 07 &/!W
IDEN#I7I*!#I0N
SMAW SMAW
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SMAW SMAW
CURRENT CONDITIONS
ELECTRODE SIZE(mm) AMPS.(CURRENT)
2.50 70 – 100
3.15 100 – 140
3.20 100 – 140
4.00 140 – 180
5.00 180 – 240
6.30 240 – 280
GENERAL T&UM-.RULE FOR CALCULATIGCURRENT/
0 DIA OF ELECTRODE 1 +2 3 45. *20 DIA OF ELECTRODE 1 +2 3 45. *2
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SMAW SMAW
LOW &6DROGEN ELECTRODES:
#hose Electrode ending with#hose Electrode ending with AA7)8)9) OR ':)7)8)9) OR ':) are classi%ed as BL0W 31D-0GENC #(pesare classi%ed as BL0W 31D-0GENC #(pes
#o /aintain the low h(drogen moisture#o /aintain the low h(drogen moisture
content, the( must be stored in their originalcontent, the( must be stored in their original
factor( sealed container or an acceptable storagefactor( sealed container or an acceptable storage
o'eno'en
0'en should be heated electricall( ha'e0'en should be heated electricall( ha'e
temperature control capabilit( in the range oftemperature control capabilit( in the range of
?>?>>> to >to >>> **
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SMAW SMAW
AD#ANTAGES/EFuipment is relati'el( simple, inexpensi'e EFuipment is relati'el( simple, inexpensi'e
portableportableNumerous t(pes of electrodes < #he processNumerous t(pes of electrodes < #he process
considered as Fuite 'ersatileconsidered as Fuite 'ersatile
LIMITATIONS/&$EED < Welder periodicall( stop welding &$EED < Welder periodicall( stop welding
replace consumed electrode with new onereplace consumed electrode with new one#here is a la(er of solidi%ed slag which must be#here is a la(er of solidi%ed slag which must be
remo'ed which a)ects the producti'it(remo'ed which a)ects the producti'it(70- L0W 31D-0GEN ELE*#-0DE 2&ED :.70- L0W 31D-0GEN ELE*#-0DE 2&ED :.
#he( reFuire to store in an appropriate#he( reFuire to store in an appropriate
electrode baing o'en which will help toelectrode baing o'en which will help to
maintain their low moisture le'elsmaintain their low moisture le'els
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GMAW GMAW
Meta; Inert Gas We;d"n$ 0MIG3 / 0nl( inert gases
or gas mixtures are used for the shielding gas when/IG welding #(pical inert gases used for /IGwelding are argon and helium #hese gases areusuall( used for /IG welding of aluminum and other
non.ferrous metals
Meta; Act"
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GMAW GMAW General !rrangement
WI-E *0N#-0L WI-E 7EED /0#0- $0WE- &02-*E !rJ*09 G!& *1LINDE-
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GMAW GMAW
Ad
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GTAW GTAW
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GTAW GTAW
#he G#!W welding process uses a non.consumable
tungsten electrode to pro'ide an arc
7iller metal, when reFuired, is fed from a separate%ller rod
! shielding gas, eg argon, is fed through thewelding gun to the weld area and pro'ides a gasshield to pre'ent contamination b( the atmosphericgases
No 8uxes are used with the processWhen the arc onl( is used to produce the weld,without the addition of separatel( fed %ller wire,the process is nown as !utogenous G#!W
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SAW SAW
&!W is de%ned as an arc welding process which produces
coalescence of metals b( heating them with an arc or arcsbetween a bare metal electrode or electrodes and the wor piece$ressure is not used and %ller metal is obtained from theelectrode and sometimes from a supplementar( welding rod
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SAW SAW
AD#ANTAGES
3igh weld metal Kualit(
&mooth and uniform weld bead with no spatters
Extremel( high deposition rate and welding speed
3igh !rc time can be achie'ed through automation
/inimum operator fatigue
LIMITATIONS
3igh initial cost
Limited welding positions
-eFuirement of special jigs and %xtures
Di)icult( in welding low thicness metals
7ull penetration weld joints not possible from single side
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O16 ACET6LENE WELDINGO16 ACET6LENE WELDING
Tere are tree d"st"nct =ame used "n t"s metod
Te neutra; =ame EFual Fuantities of ox(gen and acet(lene Distinct inner white cone with a rounded tip &uitable for all carbon steel, cast irons, low allo( steels andaluminum
Te car>ur"?"n$ 0car>on"?"n$3 =ame &light excess of acet(lene 7eather around the inner white cone 2sed for welding of high carbon steels and for hard surfacing
Te o@"d"?"n$ =ame 3as an excess of ox(gen Inner white cone is shorter and sharper than the neutralcone #his 8ame is suitable for brass, brone, inc applications,
2sed for brone welding and braing
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OX!"AS #ELDIN" (C$%&'.)
T** D+,&+%-& /m*
O16 ACET6LENE WELDINGO16 ACET6LENE WELDING
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App;"cat"on/
Low.carbon steel, low.allo( steel, cast steel, and wrought iron areeasil( welded b( the ox(.gas process ! 8ux is not necessar( withthese metals because their oxides melt at a lower temperaturethan the base metal During the welding process, (ou shouldenclose the molten puddle with the 8ame en'elope to ensure the
molten metal does not contact the air If the metal is exposed tothe air, it will oxidie rapidl( 1ou also should a'oid o'erheatingthe metal
!s the carbon content of a steel increases, welding becomes moredi)icult &teels whose carbon content is within the >.percent to
>.percent range are welded with a slightl( carburiing 8ame
O16 ACET6LENE WELDINGO16 ACET6LENE WELDING
#he melting is slow compared with arc processes,limiting the speed of wor #he weld pool is shieldedfrom atmospheric contamination b( the burnt gasmixture which can be made mildl( oxidiing or
reducing
L"m"tat"on/
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T6PE OF OINTS B WELDST6PE OF OINTS B WELDS
Tpes of o"nts Tpes of We;ds-utt o"nt F";;et !e;d
Corner o"nt Groo
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-UTT OINT
! joint between two members alignedapproximatel( in the same plane
Di)erent Edge &hapes and &(mbols for some+utt.Moints
T6PE OF OINTS B WELDST6PE OF OINTS B WELDS
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CORNER OINT
! joint between two members located at rightangles to each other
Di)erent Edge &hapes and&(mbols for some *orner. Moints
T6PE OF OINTS B WELDST6PE OF OINTS B WELDS
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T OINT
! joint between two members locatedapproximatel( at right angles to eachother in the form of a #
D"erent Ed$e Sapesand Sm>o;s for someT.o"nts
T6PE OF OINTS B WELDST6PE OF OINTS B WELDS
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LAP OINT
! joint between two o'erlappingmembers
D"erent Ed$e Sapes andSm>o;s for some Lap.
o"nts
T6PE OF OINTS B WELDST6PE OF OINTS B WELDS
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EDGE OINT
! joint between the edges of two or more parallel or nearl(
parallel members
D"erent Ed$e Sapesand Sm>o;s for someed$e.o"nts
T6PE OF OINTS B WELDST6PE OF OINTS B WELDS
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T6PE OF OINTS B WELDST6PE OF OINTS B WELDSFILLET WELD
#hese welds are roughl( triangular in cross sectionand between two surfaces not in the same planeand the weld metal is substantiall( placedalongside the components being joined Depositedweld metal is external to the pro%le of the weldedelements
We;dSm>o;
MITRE
CON#E
1
CONCA# E
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GROO#E WELD
#he weld metal is substantiall( placed inside thecomponents being joined Deposited weld metal is internalto the pro%le of the welded elements
T6PE OF OINTS B WELDST6PE OF OINTS B WELDS
T6PE OF OINTS B WELDST6PE OF OINTS B WELDS
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T6PE OF OINTS B WELDST6PE OF OINTS B WELDS
G-00"E WELD #1$E&
T6PE OF OINTS B WELDST6PE OF OINTS B WELDS
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$L2G !ND &L0# WELD&
2sed withpreparedholes
Weld&(mbol
T6PE OF OINTS B WELDST6PE OF OINTS B WELDS
T6PE OF OINTS B WELDST6PE OF OINTS B WELDS
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&$0# 0- $-0ME*#I0N WELD
Weld at theinterface of themember 2sed without
prepared holes 2se !rc or-esistance We;d
Sm>o;
T6PE OF OINTS B WELDST6PE OF OINTS B WELDS
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GUESS T6PE OF OINTGUESS T6PE OF OINT
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WELDING S6M-OLWELDING S6M-OL
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-eference Line !rrow
#ail omitted whenreference notused
Arro! connectsreference ;"ne to arro!s"de mem>er of o"ntor arro! s"de of o"nt
#ail
-eference Line must alwa(s be horiontal, !rrow
points to the line or lines on drawing which clearl(identif( the proposed joint or weld area
#he tail of the welding s(mbol is used to indicatethe welding or cutting processes, as well as thewelding speci%cation, procedures, or the
supplementar( information to be used in maing
WELDING S6M-OLWELDING S6M-OL
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WELDING S6M-OLWELDING S6M-OL
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FILLET WELD EHUAL LEGFILLET WELD EHUAL LEG
WELDING S6M-OLWELDING S6M-OL
WELDING S6M-OLWELDING S6M-OL
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FILLET WELD. LENGT&FILLET WELD. LENGT&
WELDING S6M-OLWELDING S6M-OL
WELDING S6M-OLWELDING S6M-OL
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FILLET WELD. STITC&FILLET WELD. STITC&
WELDING S6M-OLWELDING S6M-OL
WELDING S6M-OLWELDING S6M-OL
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FILLET WELD. UNEHUAL LEGFILLET WELD. UNEHUAL LEG
WELDING S6M-OLWELDING S6M-OL
WELDING S6M-OLWELDING S6M-OL
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GROO#E WELD. -E#ELGROO#E WELD. -E#EL
WELDING S6M-OLWELDING S6M-OL
WELDING S6M-OLWELDING S6M-OL
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GROO#E WELD . # GROO#E WELD . #
WELDING S6M-OLWELDING S6M-OL
WELDING S6M-OLWELDING S6M-OL
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GROO#E WELD. # GROO#E WELD. #
WELDING S6M-OLWELDING S6M-OL
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GUESS T&E WELDING S6M-OLGUESS T&E WELDING S6M-OL
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WELDING INSPECTION WELDING INSPECTION
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WELDING INSPECTION WELDING INSPECTION
WELDING DEFECTSWELDING DEFECTS
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T6PE OF DEFECTST6PE OF DEFECTS
Defects can >e c;ass"ed as/ Defects "n
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T6PE OF DEFECTST6PE OF DEFECTS
Geometr"c defects2ndercutExcessi'e reinforcement+urn through or excessi'e
penetrationDistortion Improper weld pro%le
Meta;;ur$"ca; defects
*racsGas porosit( !rc stries&tructural notches
WELDING DEFECTSWELDING DEFECTS
WELDING DEFECTSWELDING DEFECTS
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REASONS FOR DEFECTSREASONS FOR DEFECTS
Lac of now.how and experience ofwelderJoperator
Welding process and characteristics +ase metal composition
Defecti'e welding %ller metals Moint design Welding en'ironment 4wind, %t.up,
temperature5
WELDING DEFECTSWELDING DEFECTS
WELDING DEFECTSWELDING DEFECTS
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LACK OF FUSIONLACK OF FUSION
It in'ol'e incomplete melting and fusion of someportion of weld metals in joints It ma( occureither between parent metal and weld metal orbetween two la(ers of weld metals #hesebasicall( occur in fusion and pressure welding
REASONS/ Improper manipulation of electrodes Incorrect position of electrodes Low welding current
#oo rapid arc ad'ance $oor edge preparationDISAD#ANTAGES/ Lower strength of joints &tress concentration will occur
WELDING DEFECTSWELDING DEFECTS
WELDING DEFECTSWELDING DEFECTS
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LACK OF FUSIONLACK OF FUSION
WELDING DEFECTSWELDING DEFECTS
WELDING DEFECTSWELDING DEFECTS
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INCOMPLETE PENETRATIONINCOMPLETE PENETRATION
#his is lac of penetration of the weldsthrough the thicness of the joints #hisusuall( occur at the root of the weld orbetween deposits made from both sides
REASONS/
Incorrect joint design Improper welding parameters particularl(
currents Incorrect electrode sie
DISAD#ANTAGES/ It ad'ersel( a)ects the joints which aresubjected to either tensile or bendingstresses
It can initiate brittle fracture under static or
d(namic loads
WELDING DEFECTSWELDING DEFECTS
WELDING DEFECTSWELDING DEFECTS
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INCOMPLETE PENETRATIONINCOMPLETE PENETRATION
WELDING DEFECTSWELDING DEFECTS
WELDING DEFECTSWELDING DEFECTS
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FOREIGN INCLUSIONFOREIGN INCLUSIONSLAG INCUSION/ #his is formed due to entrapment of oxides
and non metallic solids in the weld depositsor between the weld metals and base metals-apid solidi%cation at lower temperature ofweld metals pre'ent the release of suchentrapments
O1IDES FILMS/ ! thin %lm of oxides forms due to inadeFuate
shielding in case of /IG welding Ita)ects the ductilit( of weld metals
WELDING DEFECTSWELDING DEFECTS
WELDING DEFECTSWELDING DEFECTS
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FOREIGN INCLUSIONFOREIGN INCLUSION
TUNGSTEN INCLUSION/ In case of #IG welding some particle ma( get
deposits from tungsten electrodeREASONS/
Improper preparation of groo'e $reheating the base materials is not done
properl( Improper sie of electrode
InadeFuate shielding in case of oxides %lms
WELDING DEFECTSWELDING DEFECTS
WELDING DEFECTSWELDING DEFECTS
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FOREIGN INCLUSIONFOREIGN INCLUSION
TUNGSTEN INCLUSION/ In case of #IG welding some particle ma(
get deposits from tungsten electrodeREASONS/ Improper preparation of groo'e $reheating the base materials is not done
properl(
Improper sie of electrode InadeFuate shielding in case of oxides %lms
WELDING DEFECTSWELDING DEFECTS
WELDING DEFECTSWELDING DEFECTS
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GEOMETRIC DEFECTSGEOMETRIC DEFECTS
UNDERCUT/It represent a depression into the base
metal adjacent to the toe of the weldand if it forms a notch it is danger for
the welds
WELDING DEFECTSWELDING DEFECTS
WELDING DEFECTSWELDING DEFECTS
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REASONS/ In correct choice of current range
Improper tra'el speed
Improper design and poor %t.up
Not following the welding procedure
Improper electrode sie and wea'ing
GEOMETRIC DEFECTSGEOMETRIC DEFECTS
WELDING DEFECTSWELDING DEFECTS
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WELDING DEFECTSWELDING DEFECTS
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GEOMETRIC DEFECTSGEOMETRIC DEFECTSWELDING DEFECTSWELDING DEFECTS
WELDING DEFECTSWELDING DEFECTS
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DEFECTS 0UNDERFILL3DEFECTS 0UNDERFILL3WELDING DEFECTSWELDING DEFECTS
WELDING DEFECTSWELDING DEFECTS
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METALLURICAL DEFECTSMETALLURICAL DEFECTSCRACKS/ #hese are linear ruptures of the metals under
stress
CRATOR CRACKS/
*racs formed from a circular surface withdepression either in the welds or at the end of thewelds
POROSIT6/ $orosit( is the presence of the gas pocets of
'oids caused b( the entrapment of the gas
e'ol'ed during weld metal solidi%cation
WELDING DEFECTSWELDING DEFECTS
WELDING DEFECTSWELDING DEFECTS
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METALLURGICAL DEFECTSMETALLURGICAL DEFECTS WELD DEPOSITS/
&ometimes in a particular one excess weldsaccumulate due to high current which can causeformation of notches and ultimatel( a)ect fatiguestrength
REASONS/ 2ne'en heating and cooling rate Improper shielding, rust on the weld face, too much
generation of gas in weld pool, sudden cooling of slag
WELDING DEFECTSWELDING DEFECTS
WELDING DEFECTSWELDING DEFECTS
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METALLURGICAL DEFECTSMETALLURGICAL DEFECTS
WELDING DEFECTSWELDING DEFECTS
WELDING DEFECTSWELDING DEFECTS
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DEFECTSDEFECTS
0"E-L!$
-00#*0N*!"I#1
WELDING DEFECTSWELDING DEFECTS
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PAUSE FOR T&OUG&TSPAUSE FOR T&OUG&TS
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GUESS T6PE OF DEFECTSGUESS T6PE OF DEFECTS
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GUESS T6PE OF DEFECTSGUESS T6PE OF DEFECTS
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GUESS T6PE OF DEFECTSGUESS T6PE OF DEFECTS
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GUESS T6PE OF DEFECTSGUESS T6PE OF DEFECTS
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GUESS T6PE OF DEFECTSGUESS T6PE OF DEFECTS
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