Welding Engineering

R. Padmanabhan

30 September 2012

R. Padmanabhan

Welding Engineering

Weld thermal cycle

Fusion welding Severe thermal treatment strain cycle embrittlement with tensile strain

Nature and Effect Thermal Effect Weld Pool Heat Affected Zone Base Metal Grain Growth Mechanical Effect Distortion Lamellar Tearing

30 September 2012

R. Padmanabhan

Welding Engineering

Weld Bead Configuration

30 September 2012

R. Padmanabhan

Welding Engineering

Dilution
Base Metal Dilution = (a + c)/(a+b+c)

30 September 2012

R. Padmanabhan

Welding Engineering

Solidification
Factors controlling Solidification Temperature gradient Composition Rate of Solidification

30 September 2012

R. Padmanabhan

Welding Engineering

Solidification Epitaxial Growth

Undercooled liquid

Planar

Cellular

Columnar Dendritic

Cellular Dendritic
30 September 2012 R. Padmanabhan Welding Engineering

(a) Higher Welding Speed (b) Lower Welding Speed

30 September 2012

R. Padmanabhan

Welding Engineering

Metallurgical Reactions in the Solid State

Annealing and Recovery Grain Growth Precipitation Phase Transformation

30 September 2012

R. Padmanabhan

Welding Engineering

Transformation Temperature (A1)

30 September 2012

R. Padmanabhan

Welding Engineering

Reduce Stress and Distortion in Weld

Weld Procedure

Control Temperature
Preheat Inter-pass Heating

Post-weld heat treatment

Coefficient of thermal expansion Thermal conductivity

Yield strength
Modulus of elasticity
30 September 2012 R. Padmanabhan Welding Engineering

Pre-Weld Heat Treatment

Reduces the levels of thermal stress.
Provides compensation for high heat losses. Minimizes the rate of weld hardening.

Reduced porosity in the weld.

Reduced hydrogen cracking. Improved micro structure of heat affected zone (HAZ).

30 September 2012

R. Padmanabhan

Welding Engineering

Post-Weld Heat Treatment

Relaxes residual stress
Relaxes thermal stress Tempers the metal Phase Transformation Structural changes - effect of cooling rate Carbon content and alloying elements

Removes diffusible hydrogen Improves metallurgical structure Enhances strength and life of the material
Grain boundary sliding Removal of metallurgical defects like dislocations, vacancies and slip planes The micro-structure, tensile and impact strength are affected by the Stress relief treatment
30 September 2012 R. Padmanabhan Welding Engineering