Product Technology

NDT Training & Certification

BSS Non Destructive Testing
Pvt.Ltd.
Product Technology
Welding

BSS Non Destructive Testing

Pvt.Ltd.
 A Weld : Definitions

 A union between  A continuous defect

pieces of metal at surrounded by
faces rendered parent material
plastic or liquid by NASA
heat,pressure or
both.
BS 499

BSS Non Destructive Testing

Pvt.Ltd.
 Deposition Rate:

The term used to describe the mass of metal deposited per

unit of time

Weld Sequence:

The order and direction in which joints, welds or weld runs are
made

Tack Weld

Weld used to assist assembly or to maintain misalignment of edge

BSS Non Destructive Testing
Pvt.Ltd.
 Welds
 An ideal weld must give a strong bond
between materials with the interfaces
disappearing

To achieve this
• Smooth,flat or matching surfaces
• Surfaces shall be free from contaminants
• Metals shall be free from impurities
• Metals shall have identical crystalline structures

BSS Non Destructive Testing

Pvt.Ltd.
 Welding
 A union between pieces of metal at faces
rendered plastic or liquid by heat,pressure or
both.
BS 499
Possible energy sources
 Ultrasonics
 Electron beam
 Friction
 Electric resistance
 Electric arc BSS Non Destructive Testing
Pvt.Ltd.
 Electric Arc Welding

Electrode

Power
supply

Work piece

Clamp(Earth)
BSS Non Destructive Testing
Pvt.Ltd.
 Electric Arc Welding
Arc Welding Processes
 Manual metal arc (mma / smaw / stick)
 Tungsten Inert Gas (TIG / TAG)
 Metal Inert Gas (MIG / MAG / GMAW)
 Submerged Arc (SAW)

Differences between them

 Methods of shielding the arc
 Consumable or Non-consumable electrode
 Degree of automation

BSS Non Destructive Testing

Pvt.Ltd.
 Joint Design
Fillet
Single V

Single Bevel

Corner
Single V
Partial pen.

Double V BSS Non Destructive Testing

Pvt.Ltd.
 Joint Design
Lap Joint

Corner fillet weld

Cruci-form

Edge Weld
BSS Non Destructive Testing
Pvt.Ltd.
 Weld Prepareration / Joint Design

BEFORE WELDING C
L
Included angle
60°
Parent metal/
Base metal Angle of bevel
30°

Root Face
2-3mm
Fusion face/ Root Gap
Sidewall or bevel 2-3mm
BSS Non Destructive Testing Single -V Butt
Pvt.Ltd.
 A FINISH WELD

AFTER WELDING

Weld width Weld reinforcement

Weld cap
Capping
Crown Surface

Toes

Fill pass
HAZ Hot Pass Weld Layer
Root run
Penetration
BSS Non Destructive TestingRoot bead
Weld bead Pvt.Ltd.
Root reinforcement
 MMA

Manual Metal Arc Process (MMA)

(USA: SMAW)
Definition
Electrode Uses an arc to produce weld metal in
core wire between a consumable electrode and
parent metal
Electrode
covering Type of process
Manual
Electric Arc
Gas shield Solidified slag

Molten weld pool Build up of weld metal

Penetration
Parent
BSSmaterial
Non Destructive Testing
Pvt.Ltd.
 TIG
Tungsten Inert Gas (TIG)
Definition
Uses an arc to produce weld metal in (USA: GTAW)
between a non consumable electrode and
parent metal Cap Switch
power
Type of process cable
Switch
Manual / fully auto Handle

Filler wire Tungsten

Shielding gas
Deposited Gas
weld metal inlet

BSS Non Destructive Testing

Pvt.Ltd.
Tungsten Inert Gas (TIG)

BSS Non Destructive Testing

Pvt.Ltd.
 TIG
Helium Argon mixes
Argon (Ar) Inert

 Suitable for welding carbon  Suitable for welding carbon

steel, stainless steel, steel, stainless steel, copper,
aluminium and magnesium. aluminium and magnesium

 Lower cost, lower flow  High cost, high flow rates.

rates.
 More suitable for thicker
materials and materials of
 More suitable for thinner
high thermal conductivity.
materials and positional
welding.
BSS Non Destructive Testing
Pvt.Ltd.
 TIG
Advantages & Disadvantages TIG Welding:

Advantages Disadvantages

 High quality  High skill factor required

 Good control  Small consumable range
 All positions  High protection required
 Low hydrogen  Low productivity
 Minimal cleaning  High ozone levels

BSS Non Destructive Testing

Pvt.Ltd.
 Metal Active Gas / Metal Inert Gas (MAG / MIG) - USA: GMAW

The gas metal-arc welding process (GMAW), often

called MIG, has revolutionized arc welding. In this
process:-
Wire electrode
A consumable electrode (in the form of wire) is fed
from a spool through the torch (welding gun) at a
preset controlled speed. As the wire passes through the
contact tube of the gun, it picks up the welding
Shielding gas in
current. - Semi Auto / fully auto
Contact tip and
electrode wire guide
Electric Arc
Gas shield
Molten weld pool Build up of weld metal
Penetration

BSS Parent material

Non Destructive Testing
Pvt.Ltd.
CHAPTER 4 WELDING PROCESSES, ACCESSORIES & CONSUMABLES

Advantages & Disadvantages of MIG / MAG Process

Advantages Disadvantages

 High productivity  Lack of fusion (dip)

 Easily automated  Small range of consumables
 All positional (dip & pulse)
 Expensive equipment
 Material thickness range
 Complex equipment
 Continuous electrode
 Not so portable

BSS Non Destructive Testing

Pvt.Ltd.
BSS Non Destructive Testing
Pvt.Ltd.
Low Hydrogen Welding Process

TIG
MIG
MAG

BSS Non Destructive Testing

Pvt.Ltd.
 Submerged Arc
Reel feed

Flux
retrieval Consumable
electrode

Flux feed

Slag

Weld metal
Parent metal

BSS Non Destructive Testing

Pvt.Ltd.
BSS Non Destructive Testing
Pvt.Ltd.
BSS Non Destructive Testing
Pvt.Ltd.
 Submerged Arc Welding

High Thickness steel plates – High Heat

input – Solidification cracking will take
place

Surface Breaking Porosity – Damp Flux

BSS Non Destructive Testing

Pvt.Ltd.
 Welding Defects
Cracks
4 Crack Types
 Solidification cracks
 Hydrogen induced cracks
 Lamellar tearing
 Reheat cracks

BSS Non Destructive Testing

Pvt.Ltd.
 Welding Defects
Cracks
Classified by Shape Classified by Position
 Longitudinal  HAZ
 Transverse  Centreline
 Branched  Crater
 Fusion zone
 Parent metal

BSS Non Destructive Testing

Pvt.Ltd.
 Welding Defects
Cracks
Solidification Crack
 Occurs during weld solidification process
 Steels with high sulphur content (low
ductility at elevated temperature)
 Requires high tensile stress
 Occur longitudinally at the weld centre
line
 eg Crater cracking
BSS Non Destructive Testing
Pvt.Ltd.
 Welding Defects
Cracks
Hydrogen Induced
 Requires susceptible grain structure, stress
and hydrogen
 Hydrogen enters via welding arc
 Hydrogen source - atmosphere or
contamination of preparation or electrode
 Moisture diffuses out into parent metal on
cooling
 Most likely in HAZ
BSS Non Destructive Testing
Pvt.Ltd.
 Welding Defects
Cracks
Lamellar Tearing
 Step like appearance -
 Occurs in parent material or HAZ
 Only in rolled direction of the parent material
 Associated with restrained joints subjected to
through thickness stresses on corners, tees
and fillets
 Requires high sulphur or non-metallic
inclusions BSS Non Destructive Testing
Pvt.Ltd.
 Welding Defects
Cracks
Re-Heat Cracking
 Occurs mainly in HAZ of low alloy steels
during post weld heat treatment or service at
elevated temperatures
 Occurs in areas of high stress and existing
defects
 Prevented by toe grinding, elimination of poor
profile material selection and controlled post
weld heat treatment
BSS Non Destructive Testing
Pvt.Ltd.
 Welding Defects
 Incomplete root penetration

Causes
 Too large or small a root gap
 Arc too long
 Wrong polarity
 Electrode too large for joint preparation
 Incorrect electrode angle
 Too fast a speedBSS
ofNon
travel
Pvt.Ltd. for current
Destructive Testing
 Welding Defects
 Root concavity or Suck Back

Causes Contraction & shrinkage

 Root gap too large
 Insufficient arc energy
 Excessive back purge (TIG)
of the molten pool at the
root of the weld, due to
incorrect weld preparation
or insufficient heat input

BSS Non Destructive Testing

Pvt.Ltd.
 Welding Defects
 Lack of fusion

Causes
 Contaminated weld preparation
 Amperage too low
 Amperage too high (welder increases speed of
travel) BSS Non Destructive Testing
Pvt.Ltd.
 Welding Defects
 Undercut

Causes
 Excessive welding current
 Welding speed too high
 Incorrect electrode angle
 Excessive weave
Electrode too large Pvt.Ltd.
BSS Non Destructive Testing

 Welding Defects
 Incompletely Filled Groove

Causes
 Insufficient weld metal deposited
 Improper welding technique

BSS Non Destructive Testing

Pvt.Ltd.
 Welding Defects
 Gas pores / Porosity

Causes
 Excessive moisture in flux or preparation
 Contaminated preparation
 Low welding current
 Arc length too long
 Damaged electrode flux
BSS Non Destructive Testing
 Removal of gas shield Pvt.Ltd.
 Welding Defects
 Inclusions - Slag

Causes
 Insufficient cleaning between passes or
poor cleaning between runs
 Contaminated weld preparation
 Welding over irregular profile
 Incorrect welding speed
 Arc length too long
BSS Non Destructive Testing
Pvt.Ltd.
 Welding Defects
 Inclusions - Tungsten

Causes
 Contamination of weld during TIG welding
process

BSS Non Destructive Testing

Pvt.Ltd.
 Welding Defects
 Burn Through

Causes
 Excessive amperage during welding of root
 Excessive root grinding
 Improper welding technique

BSS Non Destructive Testing

Pvt.Ltd.
 Welding Defects
 Arc Strikes -  Spatter

Causes Causes
 Electrode straying onto  Excessive arc energy
parent metal  Excessive arc length
 Electrode holder with  Damp electrodes
poor insulation  Arc blow
 Poor contact of earth
clamp
Weld defects can create
localized hard spots which
may contain cracks BSS Non Destructive Testing
Pvt.Ltd.