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ROLL NO:7
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A Weld:* A union between materials caused by heat,
and or pressure
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STRENGTH OF WELD
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Types of Common Welded Joints
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Types of Common Welded Joints (Contd.)
Butt Joint
Fillet Joint
Lap Joint
Open Corner Joint
Closed Corner Joint
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Types of Fillet Welds
Mitre Fillet
Convex Fillet
Concave Fillet
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Remember, the purposes of a weld preparation is to allow access
for the welding process, penetration and fusion through the area
of the joint and its faces*
Included angle*
Root landing*
Single bevel
Single V
Single J
Single U*
Double bevel
Double V
Double J
Double U*
A butt welded butt joint*
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A
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Face
Leg length
Reinforcement
Designed throat
Actual Throat
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JOINT DESIGN
Use larger sections to reduce the number of weld joints.
Select joint design requiring the least amount of weld or
filler metal
Make use of deep penetrating arc welding electrode or
process
Ensure minimum root opening and groove angle to reduce
the weld metal deposit
Use double V or double U groove weld design on heavier
sections if accessible to weld from both side
Avoid excessive weld deposit and convexity in butt and
fillet weld joints
Design weld joints for easy accessibility for welding
Utilize down hand welding, if possible
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Welding Symbols
Most weld symbols contain 5 elements, which are:
3) The symbol*
4) The dimensions*
*
2) Convention of The reference line:
BS 499 (UK) & AWS A 2.4 (US)
a) Shall touch the arrow line
b) Shall be parallel to the bottom of the drawing*
*
Symbols: BS 499 (UK) & AWS A2.4 (US)
a) Welds this side of joint, go underneath the reference line
b) Welds the other side of the joint, go on top of the reference line
c) Symbols with a vertical line component must be drawn with the
vertical line to the left side of the symbol
d) All CSA dimensions are shown to the left of the symbol
10 4 x 50 (50)*
Representation of welds done from both sides of
the joint intersection, touched by the arrow head
Double V Double U
Supplementary Weld Symbols
Toes to be ground
smoothly. (BSEn only)
Site Weld
Ground flush
Concave or Convex
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Weld all round Welding process.
Numerical BS En & BS
Further supplementary information, such as WPS
number, or NDT may be placed in the fish tail*
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CLASSIFICATION OF DEFECTS
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TYPES OF DEFECTS
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III. GEOMETRIC DEFECTS
UNDERCUT
EXECESSIVE REINFORCEMENT
BURN THROUGH OR EXECESSIVE PENETRATION
DISTORTION
IMPROPER WELD PROFILE.
IV. METALLURGICAL DEFECTS
CRACKS
GAS POROSITY
ARC STRIKES
EMBRITTLEMENT
STRUCTURAL NOTCHES
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WELD PROFILES
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Contd.
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Slide 4 of 81
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COMMON WELDING DEFECTS
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As per ISO 6520-1987 Welding discontinuities
are divided in following six groups
Group Designated Defect
1 Cracks
2 Cavities
3 Solid Inclusions
4 Lack of Fusion &
penetration
5 Imperfect Shape
6 1 Miscellaneous defects
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COMMONLY OBSERVED DISCONTINUITIES
IN FUSION WELDING
TYPE EXISTS REMARKS
Seams & laps Pm Base metal surface, often at all times longitudinal.
Lamellar tears Pm Invariably near the HAZ in flange plate of T-butt joint.
Cracks Pm, Wm Restraint, Hot, Brittle & Under bead cold cracks; which may be
Wm/Pm either in longitudinal or transvers direction.
Crater cracks Wm Usually with multi axial cracks at the point of termination.
Fissures Wm Micro cracks generally in fully austenitic stainless steel & less
ductile metal.
Stray flash Pm Appears away from the weld seam as a trail of arc spots with
micro fissures, excesively brittle & hard character.
Spatters Pm Globular weld particles ejected out of an arc zone & scattered
shabbily around over the base metal.
Pm = Parent metal; Wm = Weld metal; Pm/Wm = Junction of weld & base metal
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Continued...
Pm = Parent metal; Wm = Weld metal; Pm/Wm = Junction of weld & base metal
Weld decay & Pm Precipitation of chromium carbide in austenitic stainless steels &
stress corros- severely degrading the corrosion resistance property in HAZ; which
ion cracks may also be associated with the stress corrosion cracks.
Oxidation Wm Inadequacy in gas shield or gas purge from the root side causes a
heavy black scale or an extremely rough crinkled appearance.
Craters Wm An unfilled concave crater causes a point of stress raiser.
Underfill Wm Inadequate weld metal filling and causing weakness.
Undercut Wm/Pm Groove made by the arc force & left unfilled, causes severe stress
concentration.
Overlap Wm/Pm Accumulation of weld, without fusion, causes an extremely voilent
point of sstress raiser.
Lack of fusion Wm, Lack of union between the two weld beads or weld & base metal
Wm/Pm causes stress concentration.
Lack of Pm Inadequacy of through thickness fusion depth.
penetration
Solid particle Wm Trapped slag particle, tungsten or oxide (Al2O3) in weld.
inclusion
Gas inclusion Wm Gas voids contained within the weld causes: Blow hole, Gas pore,
Piping, Worm holes, Linear, Clustered or Scattered porasity.
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- due to segregation
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Lamellar Tearing:
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Cracks is detected in a radiograph, only when it produces a
change in thickness that is parallel to the x-ray beam. It appears
often zig-jagged with faint irregular line. Cracks can also appear
sometime as "tail" to an inclusion or porosity.
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Undercut is an erosion of the base metal next to the toe of the weld
face. It appears in radiograph as a dark irregular line on outer edge
of the weld.
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Root undercut is an erosion of the base metal next to the root of the
weld. It appears in radiographic images as a dark irregular line offset
from the centerline of the weldment. Undercutting is not as straight
edged as LOP because it does not follow the straight edge
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Root concavity or suck back is a condition where the weld metal
has contracted as it cools down & has been drawn up into the root of
the weld. On a film it appears similar to the lack of root penetration
but the line has irregular wide edges and placed in the middle.
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Cold lap is a condition where the weld metal does not fuse with the
base metal or the previous weld bead (interpass cold lap). The arc
does not melt the base metal and causes the molten puddle to flow
into the base metl without the proper bonding.
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Incomplete fusion is a condition where the weld metal does not
fuse with the base metal. Appearance on radiograph is usually a
darker line or lines oriented in the direction of the weld seam along
the weld joining area.
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Whiskers are the short lengths of electrode wire, visible on
the top or bottom surfaces of the weld or contained within the
weld. On radiograph they appear as light, "wire like" indications.
Burn through (icicles) results when too much heat causes weld to
pierce through. Lumps of weld metal sag through the seam creating
a thick globular condition on the root face. On a radiograph, burn
through appears as dark spots surrounded by light globular areas.
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Lack of penetration occurs when the weld metal fails to penetrate
through the joint. Allows a linear stress riser like discontinuity from
which a crack may initiate. The appearance on a radiograph is a dark
well-defined straight edges that follows the land or root face down the
center of a joint.
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Gas inclusion
Gas pore _ singular.
Blowhole _ singular.
Scattered Porosity.
Fine Severe
Cluster Porosity.
Linear Porosity.
Piping.
Worm holes.
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Porosity appears often as dark round irregular spots in clusters or
rows. Sometimes it is elongated and may have an appearance of a
tail. This is the result of gas attempting to escape while the metal is
still in a liquid state & is called wormhole porosity. All porosity is
indeed a void will have a darker density than the surrounding.
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Cluster porosity is caused when electrodes are contaminated with
moisture or hydrocarbon. It appears like regular porosity in a film
but the indications will be grouped close together.
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Oxide inclusion/ Puckering
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Slag inclusions are the nonmetallic solid materials trapped in weld
or between the weld and base metal. In a radiograph, dark, jagged
asymmetrical shapes within the weld or along the weld joint areas
are indicative of slag inclusions.
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Tungsten inclusions. Tungsten is a brittle and dense material used
as an electrode in tungsten inert gas welding. If an incorrect welding
procedures & skill is performed, then only the tungsten gets trapped.
Radiographically, tungsten is more dense than aluminum or steel;
therefore, it shows as a lighter area with a distinct outline on the
radiograph
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The radiographic image is a noticeable difference in density between
the two mismatched pieces. The difference in density is caused by the
difference in material thickness. The dark, straight line is caused by
failure of the weld metal to fuse with the land area.
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Excessive reinforcement is an area of a weld added in excess of
that specified by the drawings and codes. The appearance on a rad-
iograph is a localized & less darker area. A visual examination will
easily determine if the weld reinforcement is in excess.
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Underfilling is an area where the deposited weld metal is less than
the required thickness. It is easy to determine by RT films, because
the image density in the area of inadequacy will be darker than the
surrounding image density.
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Mechanical Testing
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Mechanical Testing
In mechanical Testing representative test samples produced under
similar conditions to the in service components are normally used
and comparison is made
Which properties ?*
1) Hardness*
2) Toughness*
3) Tensile strength*
4) Ductility*
We test welds to establish minimum levels of mechanical
properties, and soundness of the welded joint*
1) Quantitative tests:
Hardness tests
Toughness tests
Tensile strength tests*
2) Qualitative tests:
Macro tests
Bend tests
Fracture tests*
The test weld is usually cut into sections as follows:
The location of specimens will depend upon the standard
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Tensile Test
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Tensile Test
The reduction in the cross sectional area indicates the ductile fracture
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A Section of weld is cut, or machined out across the test piece
and tested in tension to failure. The units are usually in N/mm
Weld
Test gripping area HAZ
Direction of test
50 mm
During the test, Yield point & Tensile strength are measured
The specimen is put together and the marks are re-measured
75 mm
The specimen are usually bent through 90o,120o , 135o and , 180o 90o,
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Bend Test
The diameter of the Firmer is typically four times the specimen thickness
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Bend tests are used to establish fusion in the area under test
Guide A Guided root bend test*
Lack of root fusion shown here*
Former
Test Piece
Force
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Impact Test
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Machined notch 10 x 10 mm
Location of specimen
Hardness Test
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Harness Test
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Generally we use a diamond or steel ball to form an indentation
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Saw Cuts Hammer blow
A
Fracture line
Two nicks are cut each on either side of the of the weld
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Saw cut 1 2 3
Hammer blow
X Line of fusion
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Fracture line
Full fracture
X
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Y Any strait line indicates a
Inspect both surfaces
Lack of root fusion*
Fillet Weld Fracture Test
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CTOD(Crack Tip opening Displacement)
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1) Excess Weld Metal Height 8) Poor Toe Blend*
7) Laminations
6)Porosity
A probe is then applied with the correct angle for the weld
preparation and sound waves are transmitted*
CRT display
Signal rebounded
from Lack of fusion
Advantages Disadvantages