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Introduction
Welded joint Weldability Testing welding joint Weld design and process selection
Introduction
welded joint Kekuatan, keuletan,
ketangguhan
pada temperatur
Welded Joint
3 daerah yang berbeda
Base metal Heat affected zone (HAZ) Weld metal (logam las)
sangat bergantung pada jenis logam yang disambung, proses pengelasan, filler metal yang digunakan dan variable proses
metal
Fig : Characteristics of a typical fusion weld zone in oxyfuel gas and arc welding.
Grain Structure
(a)
(b)
Fig : Grain structure in (a) a deep weld (b) a shallow weld. Note that the grains in the solidified weld metal are perpendicular to the surface of the base metal. In a good weld, the solidification line at the center in the deep weld shown in (a) has grain migration, which develops uniform strength in the weld bead.
kolumnar yang mirip dengan proses pengecoran Butir relatif panjang dan membentuk paralel terhadap heat flow Struktur, ukuran butir dan sifat daerah las tergantung pada jenis paduan, komposisi dan siklus termal Logam las memiliki struktur pengecoran karena proses pendinginan yang lambat Pre-heating sangat penting untuk logam logam yang memiliki konduktivitas termal tinggi
Weld Beads
(a) (b)
Fig : (a) Weld bead (on a cold-rolled nickel strip) produced by a laser beam. (b) Microhardness profile across the weld bead. Note the lower hardness of the weld bead compared to the base metal.
dan temperatur yang dialami pada HAZ, ukuran butir asli, arah butir, degree of prior cold work
Kekuatan dan kekerasan tergantung pada kekuatan dan
menghasilkan proses rekristalisasi (apabila base metal telah mengalami pengerjaan dingin, maka elongated grains akan berubah)
Corrosion
Fig : Intergrannular corrosion of a 310-stainless-steel welded tube after exposure to a caustic solution. The weld line is at the center of the photograph. Scanning electron micrographs at 20X.
Weld Quality
Welding discontinuities can be caused by inadequate or
careless application The major discontinuities that affect weld quality are
Porosity Slag Inclusions Incomplete fusion and penetration Weld profile Cracks Lamellar tears Surface damage Residual stresses
Porosity
di daerah las tetapi terperangkap pada saat proses solidifikasi, reaksi kimia dan komtaminan
Proper selection of electrodes Improved welding techniques Proper cleaning and prevention of contaminants
Slag Inclusions
Yaitu : senyawa seperti oksida, fluxes, and electrode-coating materials yang terperangkan pada daerah las
Pencegahan dapat dilakukan dengan cara: Membersihkan permukaan yang akan dilas untuk setiap layer yang akan dilakukan Menggunakan gas pelindung
Redesigning the joint
electrode
Penetration:
Incomplete penetration occurs when the depth of the welded joint is
insufficient Penetration can be improved by the following practices : Increasing the heat Input Reducing the travel speed during the welding Changing the joint design Ensuring the surfaces to be joined fit properly
Weld Profile:
Under filling results when the joint is not filed
the base metal and consequent generation of a groove in the shape of a sharp recess or notch.
Overlap is a surface discontinuity usually
Cracks
Cracks occur in various directions and various locations
zone
Cracks
Fig : Types of cracks (in welded joints) caused by thermal stresses that develop during solidification and contraction of the weld bead and the surrounding structure. (a) Crater cracks (b) Various types of cracks in butt and T joints.
Cracks
Cracks are classified as Hot or Cold.
shrinkage during cooling Change the parameters, procedures, the sequence of welding process Preheat the components to be welded Avoid rapid cooling of the welded components
Fig : Crack in a weld bead, due to the fact that the two components were not allowed to contract after the weld was completed.
Lamellar tears :
Occurred due to the shrinkage of the restrained
members
adversely affect the properties of welded structure, particularly for notch sensitive metals.
Residual Stresses:
Caused because of localized heating and cooling during
welding, expansion and contraction of the weld area causes residual stresses in the work piece.
subsequently removed
Fig : Distortion of parts after welding : (a) butt joints; (b) fillet welds. Distortion is caused by differential thermal expansion and contraction of different parts of the welded assembly.
Weldability:
Capacity to be welded into a specific structure that has certain
Thorough knowledge of the phase diagram is essential Factors such as strength, toughness, ductility, notch sensitivity,
elastic modulus, specific heat, melting point, thermal expansion, surface tension characteristics of the molten metal, corrosion resistance.
Each technique has capabilities ,limitations and sensitivity reliability and requirement for special equipment and operator skill.
Destructive Techniques
Tension Test :
Longitudinal and transverse tension tests are performed Stress strain curves are obtained
Tension-Shear Test
Specifically prepared to simulate actual welded joints and procedures. Specimen subjected to tension and shear strength of the weld metal
Bend test :
Determines ductility and strength of welded joints.
welded joints
Destructive Techniques
Fig : Two types of specimens for tension-shear testing of welded joints.
Fig : (a) Wrap-around bend test method. (b) Three-point bending of welded specimens.
Fracture Toughness Test: Corrosion and creep tests Testing of spot welds Tension-Hear Cross-tension Twist Peel
Non-Destructive testing :
Often weld structures need to be tested Non-Destructively Non-Destructive testing are : Visual Radiographic Magnetic-particle Liquid-penetrant Ultrasonic
Fig : (a) Tension-shear test for spot welds. (b) Cross-Tension test. (c) Twist test. (d) Peel test
Methods used to manufacture the components Service requirements, Type of loading and stresses generated Location, accessibility and ease of welding Effects of distortion and discoloration Appearance Costs involved
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