Practical information for welders and others involved in welding and ils allied processes One + WELDING WORKBOOK patadhest No Dida Dealing with Distortion ‘The nonuniform expansion and contraction of weld metal and adjacent base motal during the heating and ccooiing cycles of the welding process causes disloriion. ‘The knowledge of effects of shrinkage on various types of welds is helpful In planning fabrication ana minimizing distortion, A groove weld in 2 butt joint ean shrink transversely, changing the actual width of the assembly. The shrinkage may also produce angular distortion in the base metal joined by a groove or fillet weld. The heating and cooling cycies of welding cannot be avoided, but there are some practical steps that can be taken to minimize distorion caused by shrinkage. 1) Use only the amount of weld metal required by the service condition of the joint. Using more weld metal than required increases the shrinkage forces, With a filet weld, the effective throat determines the strength, thatefore, a highly convex bead will not ads strength, bul will increase the possibilty of distortion. With @ butt joint, edge preparation, fiiup and reinforcement all contribute to the amount of weld metal needed. Decrease the bevel angio if possible. Minimize the foot opening. Using a J- or U-groove on thick plate will help reduce the root opening. A double V-groove will requite loss weld metal than a single V. 2) the application allows i, use intermittent welds 2) Use as few weld passes as possible. The shrinkage from each pass tends to be cumulative, 4) Weld as close to the neutral avis as possible, ‘There is less leverage for tho shrinkage forces to pull the plates. '5) Backstep when possible. 6) Make shrinkage work to your advantage. Use shrinkage during welding to pull cistoried parts back into alignment. 7) Prebending or prespringing the part before welding will help counteract the shrinkage forces. 8) Use opposing forces to balance the shrinkage forces. Restraining forces can be imposed with clamps, Jigs oF fixtures, or by the arrangement of other members In the assembly, A countertorce can be producad by the ‘ravily action of 2 sagging member. 9) Plan a welding sequence whereby welds are placed at different points on the structure with the intent (of counteracting the shrinkage forces of welds already made. 10) Weld as quickly as possible and limit heat input to only what is needed. The less teal trensmitted to the ‘base metal, the less chance for cistotion. Types of Distortion Co Lousiruoeat shmmeace ‘OF WELD -Jl. : i | PULUnG erreeTs FRED CENTER OF GEA oe. {o)PuLUNG errect oF weLo ‘ABOVE NEUTRAL AXIS Excorptod trom Jotlerson's Welding Eneylapecke 18th Esltion aie CenreR EE sev Ly crontitee wan x] Si Rael ty em euLuns ereecr oF welo BELOW NEUTRAL RI WELDING JOURNAL | 65e Ways to Minimize Distortion EXCESSIVE WELD METAL use oouste v" INCREASES DISTORTION PREPARATION A Bin ad 4 Ww a © (A) Do NOT OVERWeELD. 00 ANAK fa REOUGE BEVEL ANGLES WITH LARGE FOOT OPENINGS 602 AM, ee eee (©) ReTERMETTENT WELDING vad esa ce. Se (6) CORRECT EDGE PREPARATION AND GOOD FITUP WRONG FIGHT € (0) MINIMUM NUMBER OF PASSES J ° . Fl GA 1234 a l i A 7 Ly => Tess c 7 i oistormIon ue FEE eet (E) WELD NEAR THE DISTORTION ee a (F) BALANCE WELDS AROUND i l CENTER OF GRAVITY moa ce (H) PRESET PARTS. (oPREBENONG i Ci abl (Eh. +B Bs] 18h, 26B:| | 7A Bs co (QwELD Posmion. aN 'Gh TECHNICAL NOTES ABLHINICAL NOTES DISTORTION IN ARC WELDED FABRICATION — SUMMARY A checklist to Minimize Distortion In summary, follow the checklist below in order to minimize distortion in the design and fabrication of weldments. © Do not overweld © Control fit up Use intermittent welds where possible that are consistent with design requirements. Use the smallest leg size permissible when filleFwelding For groove welds, use joints that will minimize the volume of weld metal. Consider double-sided joints instead of single-sided joints. © Weld alternately on either side of the joint when possible with multiple-pass welds, Use a minima! number of weld passes Use low heat-input procedures. This generally means high deposition Tates and higher travel speeds. ee * ¢ z = 2 & 2 3 = 5 s 2 = a 5 B & & 5 a 8 5 5 e g Position welding. The flat position permits the use of large-diameter electrodes and high-dep osition-rate welding procedures, * Distribute welding heat as evenly as possible through « planned Welding sequence and weldment positioning, Weld toward the unrestrained part of the member, Use clamps, fixtures, and strongbacks to maintain fit up and alignment. ¢ Prebend members or preset joints to let shrinkage pull both back into alignment, © Sequence subassemblies and final assemblies so the welds being made will continually belance each other around the neutral axis of the Section. Following these techniques will help minimize the effects of distortion aud residual stresses, Reference: Welding Journal ~ Oct. 2001) DS. HONAVAR