Distortion

The undesirable dimension change of a

DBT 204 fabrication.
Technology of Metal Welding I
Due to shrinkage of weld metal & base metal
during cooling.
Distortion Control
Residual stress causes part to move  part is
forced out of alignment

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Azmi Kamardin
2015-2016 S01

Weld Metal Shrinkage Weld Metal Shrinkage

Occur during cooling, produce distortion in weld
Transverse shrinkage:

As metal solidifies, it will contracts in volume but Perpendicular to weld axis
adjacent base metal restrains it from doing so. Depends on the volume of

Stress build up & might exceed the yield weld metal & the amount of
strength of the metal  stretch, thinning out & root opening
adjusted to the new volume.
Longitudinal shrinkage

Locked-in tensile stress Parallel to weld axis

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Weld Metal Shrinkage: Groove Welds

Residual stresses caused
by multiple passes in
groove welds cause
transverse & longitudinal
distortion.

Longitudinal shrinkage is
less of a problem than
transverse shrinkage.
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Distortion Control

Distortion causes poor fit-up.

Distortion control:
Fit-up & edge preparation
Pre-heat
Welding process & travel speed
Weld metal deposited
Weld passes
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Base Metal Shrinkage

During welding, the HAZ is heated close to its
melting point.

The intense heat causes expansion of HAZ.

The cooler base metal restrains the expansion
of HAZ  build up stress in HAZ  distortion
Fit-up & Edge Preparation

Ensure correct amount of
weld metals is used.

Too wide  slower speed
 excessive contraction

Root opening increased,
groove angle reduced

J-groove to reduce the
amount of weld metal

Double-V = single-V
Pre-heat Welding Process & Travel Speed

Lower the temp gradient in the metal around the
weld.

Reduce the tendency for cracking in HAZ or
weld metal of steel.

Automatic & semi-auto welding: higher speed &
deposition rate  less distortion than manual
welding.

Manual welding: Distortion in PAW < GMAW <
GTAW

Oxyfuel welding: slower heating  higher
distortion than arc welding.

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Welding Techniques Welding Techniques

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Mechanical Restraint Methods Mechanical Restraint Methods

A device used to restrict movement and

counteract shrinkage stresses that occur during
welding.

The restraint holds the part in the desired
position until welding is completed.
Strongbacks
Back-to-Back Positioning
Pre-bending

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Heat Shaping

The application of localized heating to restore

the dimension of a distorted part.

Oxyacetylene flame.

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