Welding

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7 2560
 Contents

1 Introduction

2 Join and Arc welding

3 Welding Process

4 Welding Defect

5 Residual Stress and Distortion

6 Welding Engineering

7 Safety and Health

8 Application Welding
1. Introduction
 Ship Offshore New Products

New Welding Process High Efficiency Welding

PAW Laser Process

MIG

50t

Application of Welding Simulation of Welding

Machine Distortion
Special Ship
Importance of welding
2. Join and Arc Welding
 Type of Join
Mechanical

Screwing

Riveting
Chemical

Bonding
Metallurgical

Soldering/Brazing

Welding
 Mechanism of Welding

Welding: Join by melting

Heating Cooling
Solid Liquid Solid
Melting Solidification
 Arc Welding

Arc Ignition
Dissociation
Dissociation Ionization
Ionization Plasma
Plasma Arc
ArcIgnition
Ignition
ofofmolecule
molecule ofofAtom
Atom

Contact between electrode and

base metal: an electric spark

Torch

electrode

Base Metal
Contact between
Initial state electrode and Arc ignition Stable arc
base metal
 Arc Welding

Three elements of Welding

Material
Base metal
Consumables

Welding Machine
Power source
Welding torch
Carriage / Gantry / Robot

Protect
Shield gas
Flux
 Arc Welding

Polarity
 Arc Welding

Effect of shielding gas

Ar Ar-He He CO2
 Arc Welding

Heat Input and Welding Condition

1. Heat Input

Amperage X Voltage X 60
KJ/cm = X 1000
Speed(cm/min)

2. Welding Condition
Base Material, Thickness, Groove Design, Tack Welding,
Temperature, Humidity, Cleanliness,
Kind and Diameter of welding consumable,
Amperage, Voltage, Speed, Welding sequence,
Welding Process
 Arc Welding

Consideration for welding

Base metal Deformation

/ Defect

welding Weld metal

Welding

Me rope

y
om
P
ch rti
an es

on
ica

Ec
l
Heat Affected Zone
Weldability
3. Welding Process
 Classification of Welding Process

Welding Arc Welding SMAW

GTAW

GMAW

SAW

FCAW
Resistance
EGW
Gas Welding
Self-Shield FCAW

High Energy Stud Welding

Beam Welding

Thermit Welding SMAW Shielded Metal Arc Welding

GMAW Gas Metal Arc Welding
GTAW Gas Tungsten Arc Welding
FCAW Flux Cored Arc Welding
SAW Submerged Arc Welding
EGW Electro-Gas Welding
 Welding Process

SMAW(Shielded Metal Arc Welding)

Characteristic
* Strip : Low carbon / Rimmed Steel
* Flux Covering
: Shield Atmosphere
: Addition of alloying elements
: Arc convergence
* Types of current : AC, DCSP, DCRP
 Welding Process

GMAW(Gas Metal Arc Welding)

Characteristic
* Semi-automatic process
* Good Feedability (Solid wire electrode )
* Shielding Gas
Steels : CO2(CO2 Welding)
Ar +2 to 5% O2
Ar +5 to 25% CO2
Non-ferrous : Ar / He
* Types of current :
: Constant Voltage Characteristic, DCRP
 Welding Process

FCAW(Flux Cored Arc Welding)

Characteristic
* Semi-automatic process
* Electrode : Flux cored wire
Metal Cored wire
* Shielding Gas
CO2(CO2 Welding)
Ar +2 to 5% O2
Ar +5 to 25% CO2
* Types of current :
: Constant Voltage Characteristic, DCRP
 Welding Process
SAW(Submerged Arc Welding)
Characteristic

* Shielding : Granular Flux

* Flux + Wire
: Addition of alloying elements
* Type of current
: Constant Current / Voltage Characteristic
: AC, DCSP, DCRP
 Welding Process

GTAW(Gas Tungsten Arc Welding)

Characteristic
* Electrode : Tungsten(W)
Tungsten Alloy(2% thoriated)
* Shielding Gas : Ar, He
* Consumable Feeding : Manual/Automatic
* Type of Current
: Constant Current Characteristic
: AC, DCSP, DCRP
 Welding Process
EGW(Electro Gas Welding)
A : Electrode Guide Tube

Backing B : Electrode Free Roll

Material
Torch
C : Flux Cored Electrode
Wire
Tip D : Water Connection

Arc E1 : Workpiece 1
Shielding gas
Molten E2 : Workpiece 2
Slag Copper Shoe
F : Water Circulation
Molten
Weld Metal
Cooling Water G : Solidified Weld Metal
Solidified
Metal
H : Molten Metal Pool

I : Molten Slag Base

J : Shield Gas

* Electrode : Solid wire, Flux cored wire

* Shielding Gas : CO2, Ar+CO2
* Electrode Feeding : Automatic
* 1Pass Vertical-Up Welding

* Type of Current
: Constant Voltage Characteristic
: DCRP
 Comparison of welding process

SMAW GMAW FCAW

Metal Transfer Globular Globular Spray

Arc Stability Good Good Excellent

Bead Appearance poor Good Excellent

Spatter Quantity Medium Much Few

Penetration Normal Deep Normal

Welding Fume Much Low Low

Deposition Rate Poor Good Excellent

Deposition
Efficiency
Poor Excellent Good

Soundness Good Excellent Excellent

4. Welding Defect
 Kind of welding defect

Underbead crack

Cold crack Toe crack

Hot Crack Root crack

Distortion Crack Micro fissure

Crack lamellar tear

reheat crack)

Stress Corrosion Crack

Hydrogen Induced Crack

Porosity

Incomplete Penetration

Slag Inclusion, Lack of fusion

Undercut

Overlap
 Kind of welding defect

Cold crack
Crack

Causes
- Hydrogen present in the Microstructure
- High residual stress and restraint
- Low preheating temperature

Prevention
Crack
- Preheating
- Post Welding Heat Treatment
- Extra low hydrogen welding consumable
Kind of welding defect
 Kind of welding defect

Hot crack
Characteristic
- Crack type : Solidification cracking Crack

- Location : Weld centerline

- Steel type : High sulphur & phosphor concentration

Prevention
- Use of high manganese and low carbon content fillers
- Minimize the amount of stress / restraint acting on the joint during welding
- Joint design selection depth to width ratios
- Use of high quality parent materials
- Clean joint preparations contaminants
Kind of welding defect
 Kind of welding defect

Porosity
Causes
- Excessive moisture in flux or preparation
- Contaminated preparation
- Low welding current
- Excessively long or short arc length
- Removal of gas shield

Prevention
- Clean and degrease the workpiece surface
- Dry the electrode and flux
- Check the purity of shielding gas
- Dry out the base metal
- Suitable welding current
 Kind of welding defect

Incomplete Penetration / Slag Inclusion / Lack of Fusion

Incomplete Penetration Slag Inclusion Lack of Fusion

- Too small root gap - Insufficient cleaning between - Contaminated weld preparation
- Incorrect electrode angle passes - Amperage too low
- Welding over irregular profile
- Too fast welding speed
 Kind of welding defect

Undercut / Overlap

Undercut Overlap

- High amperage - Improper welding technique

- Incorrect electrode angle - High amperage and low speed
- Long arc length
 Kind of welding defect

Weld Metal Toe crack)

Undercut

Porosity

Underbead crack
Slag Inclusion
Root Crack
Undercut

Sulfur Crack Overlap

Overlap

Incomplete Penetration Lack of Fusion

Sulfur band Root Crack

Longitudinal Crack
Micro-Fissure or Micro Crack)

Hot Crack

Crater Crack Transverse Crack

5. Residual Stress and
Distortion
 Residual stress

Residual stress in weld

- Heat flows from the weld area and causing the joint area to expand
- Thermal expansion and contraction due to welding can leave behind
permanent stress and distortion
- Higher heat input welds are more prone to residual stress and distortion
- Increased restraint can decrease distortion but can result in higher residual stress
Distortion
 Distortion and Prevention

Prevention of distortion

1. Forming and rolled or extruded the plate 2. Consider weld placement

3. Reduce weld metal volume 4. Use of balanced welding

 Distortion and Prevention

Prevention of distortion

5. Pre-setting 6. Clamping, Jigging and strong back

7. Line heating
6. Welding Engineering

MATERIAL DESIGN
- Strength
- Base metal
ex) Tensile, Impact
- Consumables
fatigue

WELDING

FABRICATION PROCESS
- Qualification
- Equipment
- Mechanical Test
- method
- NDT
I. Welding Design
Welding Design
Defect Deformation
Defect
Crack / Porosity
Deformation
&
Crack
Slag / Porosity
inclusion &
Residual
Slag inclusion Residual
Stress
Stress

Accessibility
Accessibility
Easy to work
Easyposition)
(welding to work
(welding position)

Design
Material
Material
Heat capacity
Heatdirection
Rolling capacity
Rolling direction

Fatigue
Fatigue Hardenability
Hardenability
Crack initiation and Brittleness in HAZ
Crack initiation and
propagation Brittleness in HAZ
propagation
II. Welding Construction
Welding symbol
 Welding position
Butt Joint
Plate

1G 2G 3G 4G
Flat Horizontal Vertical Overhead

Pipe V 45
deg.

5G H
1G 2G
Horizontal 6G
Flat / Rotated Horizontal
Fixed Inclination Fixed
 Welding position
Fillet Joint
Plate

1F 2F 3F 4F
Flat Horizontal Vertical Overhead
Pipe

2FR 5F
1F 2F Horizontal 4F Horizontal
Flat / Rotated Horizontal / Rotated Overhead Fixed
Backing Material
 Welding consumable

SMAW consumable standard

Expression
Expressionof
ofElectrode
Electrode - - - AWS A5.1 and A5.5

E XX X X A1
Chemical composition of deposited metal
Usability(Type coating / welding current)
Welding position (1 : All Positions, 2: Horizontal fillet and Flat position only
3 : Vertical with downward progression)

Min. tensile strength (XX Kpsi, 60 means 60,000psi)

Electrode

Ex: E 6010-A1
 Welding consumable

Strip
FCAW consumable standard

Expression
Expressionof
ofElectrode
Electrode - - - AWS A5.20
Flux

E XXT-X
Chemical composition, operating
characteristics
Tubular wire
Welding position (0 : flat or horizontal fillet position , 1: any position )
Min. tensile strength (Kpsi)
Electrode

Ex: E 71T-1
 Welding consumable
SAW consumable standard
Expression
Expressionof
ofFlux
Flux&&Electrode
Electrode - - - AWS A5.17
F XXA
A: As-welded, P: With post-heat treatment
Lowest temperature (at which the impact strength of weld metal will equal

or exceed 20ft-lb; Z: No impact requirement, 0: at 0 degree, 2: -20, 4: -40, 6: -60)

Min. tensile strength (x 10 Kpsi)
Initial of Flux
E L8 K
Tubular wire
Wamount of carbon(8: 0.10%)
Level of manganese(L: low, M: midium, H: high)
Initial of Electrode

Example: F6A2-EL8K
 Welding terminology

Joint Detail

Groove Angle

Root face

Root Gap

< Butt Joint >

< Fillet Joint >

 Welding terminology

Joint Detail

CJP
PJP

CJP : Complete Joint Penetration

PJP : Partial Joint Penetration

Fillet

 Welding Procedure Specification (WPS)

Selection of welding
Owner/class requirement Investigate range of approval
- Project spec. consumable
- Welding Process to be used
- Code - Owner/class
- Contracts - Material types used in the project requirement
- Pipe or plate applications - Design requirement
Design requirements - Weld Productivity
- T.S./Y.S. - Weld joint type
- Toughness - Cost saving
- Welding positions encountered
- Hardness, Corrosion - Weld Quality

Establishment of Welding Proposal Procedure

Discussion to related Department(Design/Production/QC)

Performance WPQT(welding, VE, NDE, Mechanical Test)

Procedure Qualification Records

Distribution of the WPSs Approved by Owner and Class

III. Evaluation Weldment
 Weldment Test

Tensile
Strength
Destructive Hardness
Impact
Bending

Weldment
Tests
Visual inspection
Radiographic test(RT)
Ultrasonic test(UT)
Non-destructive
Magnetic particle (MT)
Penetrant test (PT)
Electromagnetic test
 Destructive Test

Tensile test
 Destructive Test

Bend test
 Destructive Test

Analysis Microstructure Micro(X200)

Macro

Hardness

A //
/
//
/

B //
/
//
/

C //
/
//
/

 Destructive Test

Impact Test
 Destructive Test

CTOD(Crack Tip Opening Displacement) TEST

A=0.45W ~ 0.55W
B
2B;
W=
 Non-Destructive Test

Visual Inspection

Undercut Reinforcement

Length of Leg Thickness of throat

Bevel Angle Discrepancy

Typical Guages
(a) Multipurpose guage (B) Fillet weld size guage
Measuring Examples of a gauge
 Non-Destructive Test

RT : Radiographic Test
Dark region
Slag inclusions
Pores
Incomplete fusion
Incomplete penetratn
Under cut
Cracks

Light region
Spatter
Reinforcement

Employs X-rays or gamma rays to penetrate an object

 Non-Destructive Test

UT : Ultrasonic Test
Employs high-frequency
sound waves
Ultrasonic search unit
Is mounted on a surface

Detects: Discontinuities
Slag inclusions
Pores
Incomplete fusion
Incomplete penetratn
Cracks
 Non-Destructive Test

MT : Magnetic particle Test

Magnetic particles applied on a surface, distorted by a distinct

change in continuity of material
7. Safety and Health
Harmful Factor of Welding
Protective Kit
8. Application Welding
Application Welding

<FCAW + SAW>

<SAW>

<EGW>

<FCAW : Manual>

<FCAW : Robot> <FCAW : Robot>

 Application Welding

SAW

SAW both side welding (single or

Tandem)
Joint Design 1st Welding 2nd Welding

T 25mm
Turn over

T 30mm

T> 30mm
 Application Welding
FCAW

Grand assembly Sub assembly

Lug welding Over head lug welding

 Application Welding

FCAW

Welding process : FCAW

Welding Speed : max.1,500mm/min
 Application Welding
EGW 18,000TEU Container

80mm 80mm

Applicable Thickness : Max.

80mm
EGW
1pass

80m
FCAW : m
26pass

FCAW 56pass EGW+FCAW EGW