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WELCOME

ESAB Welding Institute


Chennai

ESAB Welding Institute

1/29/03
Chennai
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Weld Defects
ESAB Welding Institute
Chennai
Weld Defects

REJECTABILITY
ESAB Welding Institute
Chennai
Weld Defects
ESAB Welding Institute
Chennai
Weld Defects
ESAB Welding Institute
Chennai
Weld Defects
ESAB Welding Institute
Chennai
Weld Defects
ESAB Welding Institute
Chennai
Weld Defects
Formation of Pores
ESAB Welding Institute
Chennai
Weld Defects
ESAB Welding Institute
Chennai
Weld Defects
ESAB Welding Institute
Chennai
Weld Defects
ESAB Welding Institute
Chennai
Weld Defects
Uniformly distributed porosity
ESAB Welding Institute
Chennai
Weld Defects
ESAB Welding Institute
Chennai
Weld Defects
ESAB Welding Institute
Chennai
Weld Defects
ESAB Welding Institute
Chennai
Weld Defects
Surface porosity in a ‘T’ joint on a primed
plate
ESAB Welding Institute
Chennai
Weld Defects
Porosities in the weld bead
ESAB Welding Institute
Chennai
Weld Defects
• Elongated pores or worm holes
ESAB Welding Institute
Chennai
Weld Defects
ESAB Welding Institute
Chennai
Weld Defects
» Principal gases causing porosity and recommended
cleaning methods
• Material Gas Cleaning
• C Mn steel Hydrogen, Nitrogen Grind to remove and
Oxygen scale coatings
• Stainless steel Hydrogen Degrease + wire brush
• Aluminium and alloys Hydrogen Chemical clean + wire brush +
degrease + scrape
ESAB Welding Institute

• Copper and alloys Hydrogen, Nitrogen Degrease + wire brush +


degrease
• Nickel and alloys Nitrogen Degrease + wire brush + degrease
Chennai
Weld Defects
ESAB Welding Institute
Chennai
Weld Defects
Incomplete Fusion of Side Wall
ESAB Welding Institute
Chennai
Weld Defects
Incomplete inter-run fusion
ESAB Welding Institute
Chennai
Weld Defects
ESAB Welding Institute
Chennai
Weld Defects
ESAB Welding Institute
Chennai
Weld Defects
Insufficient Penetration
• Root Face too thick
ESAB Welding Institute
Chennai
Weld Defects
Insufficient Penetration
• Root Face too Narrow
ESAB Welding Institute
Chennai
Weld Defects

Insufficient Penetration
• Misplaced Welds
ESAB Welding Institute
Chennai
Weld Defects

Insufficient Penetration
• Power Input too Low
ESAB Welding Institute
Chennai
Weld Defects

Insufficient Penetration
• Arc (heat) input too low
ESAB Welding Institute
Chennai
Weld Defects
Effect of electrode size on root fusion
• Too large a diameter
ESAB Welding Institute
Chennai
Weld Defects
Effect of electrode size on root fusion
• Too small a diameter
ESAB Welding Institute
Chennai
Weld Defects
ESAB Welding Institute
Chennai
Weld Defects
ESAB Welding Institute
Chennai
Weld Defects
ESAB Welding Institute
Chennai
Weld Defects
ESAB Welding Institute
Chennai
Weld Defects
ESAB Welding Institute
Chennai
Weld Defects
ESAB Welding Institute
Chennai
Weld Defects
ESAB Welding Institute
Chennai
Weld Defects
ESAB Welding Institute
Chennai
Weld Defects
ESAB Welding Institute
Chennai
Weld Defects
ESAB Welding Institute
Chennai
Weld Defects
ESAB Welding Institute
Chennai
Weld Defects
ESAB Welding Institute
Chennai
Weld Defects
ESAB Welding Institute
Chennai
Weld Defects
ESAB Welding Institute
Chennai
Weld Defects
ESAB Welding Institute
Chennai
Weld Defects
ESAB Welding Institute
Chennai
Weld Defects
ESAB Welding Institute
Chennai
Weld Defects
ESAB Welding Institute
Chennai
Weld Defects
ESAB Welding Institute
Chennai
Weld Defects
ESAB Welding Institute
Chennai
Weld Defects
ESAB Welding Institute
Chennai
Weld Defects
ESAB Welding Institute
Chennai
Weld Defects
ESAB Welding Institute
Chennai
Weld Defects
ESAB Welding Institute
Chennai
Weld Defects
ESAB Welding Institute
Chennai
Weld Defects
ESAB Welding Institute
Chennai
Weld Defects
Potential and actual Hydrogen levels in Weld
ESAB Welding Institute
Chennai
Weld Defects
Hydrogen crack examples
ESAB Welding Institute
Chennai
Weld Defects
• Crack in coarse grained HAZ due to
Hydrogen embrittlement
ESAB Welding Institute
Chennai
Weld Defects
Preheating to avoid HIC
ESAB Welding Institute
Chennai
Weld Defects
Guide to Preheat Temperature
ESAB Welding Institute
Chennai
Weld Defects
• Micrograph of a crack in coarse grained
Weld
ESAB Welding Institute
Chennai
Weld Defects
Intergranullar morphology of a reheat crack
ESAB Welding Institute
Chennai
Weld Defects
ESAB Welding Institute
Chennai
Weld Defects
Solidification Crack
ESAB Welding Institute
Chennai
Weld Defects
ESAB Welding Institute
Chennai
Weld Defects
Weld bead penetration too small
ESAB Welding Institute
Chennai
Weld Defects
ESAB Welding Institute
Chennai
Weld Defects
ESAB Welding Institute
Chennai
Weld Defects
• Brittle fracture in CrMoV Steel Pressure
Vessel - Combination of Hydrogen Induced
Cracking
ESAB Welding Institute
Chennai
Weld Defects
ESAB Welding Institute
Chennai
Weld Defects
ESAB Welding Institute
Chennai
Weld Defects
ESAB Welding Institute
Chennai
Weld Defects
Slag inclusion due to a poor bead - Convex
ESAB Welding Institute
Chennai
Weld Defects
Smooth Bead profile allows easy slag removal
ESAB Welding Institute
Chennai
Weld Defects
ESAB Welding Institute
Chennai
Weld Defects
Radiograph of Slag Inclusions
ESAB Welding Institute
Chennai
Weld Defects
ESAB Welding Institute
Chennai
Weld Defects
ESAB Welding Institute
Chennai
Weld Defects
Grinding out Slag Inclusions
ESAB Welding Institute
Chennai
Weld Defects
ESAB Welding Institute
Chennai
Weld Defects
ESAB Welding Institute
Chennai
Weld Defects
ESAB Welding Institute
Chennai
Weld Defects
ESAB Welding Institute
Chennai
Weld Defects
ESAB Welding Institute
Chennai
Weld Defects
ESAB Welding Institute
Chennai
Weld Defects
ESAB Welding Institute
Chennai
Weld Defects
ESAB Welding Institute
Chennai
Weld Defects
ESAB Welding Institute
Chennai
Weld Defects
ESAB Welding Institute
Chennai
Weld Defects
ESAB Welding Institute
Chennai
Weld Defects
Thickness measurements
ESAB Welding Institute
Chennai
Weld Defects
• Measurement of Combined Thickness
ESAB Welding Institute
Chennai
Weld Defects
Lamellar Tearing
ESAB Welding Institute
Chennai
Weld Defects
Fracture face of Lamellar Tearing
ESAB Welding Institute
Chennai
Weld Defects
Suggested configuration to avoid Lamellar Tearing
ESAB Welding Institute
Chennai
Weld Defects
Suggested configuration to avoid lamellar
Tearing
ESAB Welding Institute
Chennai
Weld Defects
Suggested configuration to avoid lamellar
Tearing
ESAB Welding Institute
Chennai
Weld Defects
• Buttering to avoid Lamellar Tearing
ESAB Welding Institute
Chennai
Weld Defects
In-situ buttering to avoid Lamellar Tearing
ESAB Welding Institute
Chennai
Weld Defects
• Arc Deflection By Magnetic Forces
ESAB Welding Institute
Chennai
Weld Defects
• Bead Deflection in dc SMAW
ESAB Welding Institute
Chennai
Weld Defects
ESAB Welding Institute
Chennai
Weld Defects
ESAB Welding Institute
Chennai
Weld Defects
ESAB Welding Institute
Chennai
Weld Defects
ESAB Welding Institute
Chennai
Weld Defects
ESAB Welding Institute
Chennai
Weld Defects
ESAB Welding Institute
Chennai
Weld Defects
ESAB Welding Institute
Chennai
Weld Defects
ESAB Welding Institute
Chennai
Weld Defects
ESAB Welding Institute
Chennai
Weld Defects
ESAB Welding Institute
Chennai
Weld Defects
ESAB Welding Institute
Chennai
Weld Defects
ESAB Welding Institute
Chennai
Weld Defects
ESAB Welding Institute
Chennai
Weld Defects
ESAB Welding Institute
Chennai
Weld Defects
ESAB Welding Institute
Chennai
Weld Defects
ESAB Welding Institute
Chennai
Weld Defects
ESAB Welding Institute
Chennai
Weld Defects
ESAB Welding Institute
Chennai