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Defects 01

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17 views74 pages

Defects 01

Uploaded by

865900707
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Weld Discontinuities

Causes & Remedies


Weld Discontinuities
Causes & Remedies

 Definition
 Influence
 Types
 Causes
 Remedies
Discontinuity & Defect

Discontinuity refers to any interruption or


in-homogeneity in the material that is
otherwise homogenous
Defect refers to an interruption having
dimensions /features beyond acceptable
limits.
Defects are otherwise called as Flaw or
Imperfections that are to be repaired so that
the material is made more homogeneous as
assumed in the design
Weld joint - a Discontinuity
HAZ

WM
PM

The Microstructure is different in the different


regions of weld zones of weld joint.
So the mechanical properties also vary from
zone to zone causing heterogeneity
Discontinuity & Strength

Strength of the weld joint is influenced by


 Filler metal strength
 The extent of penetration
 Presence of discontinuities in the weld
 Presence of stresses in the weld joint

t t
Weld Strength
Lack of penetration

Presence of Fusion related discontinuities


Weld Strength
Weld strength equal to parent metal is obtained when

 The weld is carried out on both sides


 Back gouging is done after welding the first side
 LPI or MPT is carried out after Back gouging
 100% RT / UT is carried out after second side
welding
Weld Strength
The Electrode or the filler wire should be selected
such that it
 Matches with the strength of the base material
 Has fairly low carbon & controlled impurities to
avoid cracking
 Moisture level is controlled and is of low H 2 type
 Is usable in all positions
Influence of discontinuities

 Act as stress raisers


 Reduces the cross sectional area and
thereby increase the stress
concentration around them
 Provide a leak path
 They are potential sites of crack
initiation
 They act as potential sites of corrosion
and erosion
Types/classification of discontinuities
 Metallurgical discontinuity
 Fusion type discontinuity
 Geometrical discontinuity

 Surface discontinuity
 Internal discontinuity

Voluminar discontinuity
 Planar discontinuity
Common surface Discontinuities

 Un-equal weld size


 Under sized weld
 Oversized weld
 Weld offset (from seam)
 Non-uniform weld size (along
the length)
Common surface
Discontinuities
 Excess Penetration
 Excess Convexity
 Root concavity
 Excess Reinforcement
 Overlap
 Undercut
 Misalignment
Common Surface
Discontinuities
 Spatter
 Wire sticking
 Surface Porosity
 Crater pin hole
 Lack of Penetration
 Crater crack
 Surface cracks
Gas cut surfaces
Excess Penetration

P
Excess Penetration

Proper Penetration
Excess Penetration
Root Concavity
Weld Size & Reinforcement

R = max 3 mm
Shallow Obtuse
angle > 100 

Obtuse angle > 90

High level of SC
Acute angle > 90
Weld Size & Reinforcement

L T –Throat Size
T R
T L – Leg size
R- Reinforcement

L L
Weld bead Profile Definitions

Fillet Weld with


straight bead

Fillet Weld with


Convex bead

Fillet Weld with


Concave bead
Weld Bead Profile

Straight bead without Convex bead with re-


re-enforcement enforcement

L2

L1
Concave bead with Convex bead with un-
under sized weld equal sized weld
Undercut &
Bead Off-set
Undercut -causes
Mis-alignment
Surface Porosity & Slag
Porosity Common Internal
Discontinuities
Blow Holes / Aligned / distributed /
Cluster / worm hole Porosities
Lack of fusion/ Lack of Penetration
Lack of side wall fusion / Inter run
fusion / lack of fusion at root
Cracking
Under-bead cracking / delayed
cracking / Delayed cracking
/Hydrogen induced cracking
Hot cracking, shrinkage cracks,
Fatigue cracking
Porosity - Cause /Source
Cavities / voids formed due to entrapment of gases when the
molten metal solidifies from liquid state when more gases get
dissolved into molten metal

Moisture in Inadequate Gas shielding


due to
Plate edges
Improper setting of gas
Non-baked/dried flow rates
Electrodes Improper Torch angles
Filler wire Improper setting of
welding Parameters
Wet / Non-dried flux
Pneumatic fixture
In the atmosphere
1-Excessive Penetration
2-slag Inclusion

Gas Pores
Internal Porosity

10 mm
Types of Porosity – Cluster & distributed
Types of Porosity – Aligned
Aligned Porosity

20 mm
Pin-hole Porosity

Start Stop Porosity


10 mm
Worm-Hole Porosity

10 mm
Slag Inclusion
Slag Inclusion
1-Incomplete fusion
2-Linear slag Inclusion
3-Crack

Mis-alignment
Lack of fusion
Lack of Penetration
Incomplete Fusion - Causes
LOP
1-Lack of penetration
between runs
2-LOP at side wall
Cold Cracking (Under bead cracking)

HAZ
0.5 mm

0.2 mm
Lamellar
Tearing
Weld Metal
cracking
10 mm
Hot Cracking

10 mm
Discontinuities commonly associated with
welding Processes
Incomplete Incomplete
Weld Process Porosity slag fusion Penetration
undercut cracks

SMAW X X X X X X

GMAW X X X X X X
SAW X X X X X X

GTAW X X X X
RES. spot X X
Solid State X X
EBW O X X X
LW X X X
ESW X X X X X X
Applicable Inspection Methods for weld Joints

Joints RT UT PT MT VT ET

Butt A A A A A A
Corner O A A A A O
Tee O A A A A O
Lap O O A A A O

A – Applicable Method
O – Marginal applicability depending upon factors such as material
thickness, discontinuity size orientation and location
RT – Radiographic testing, UT – Ultrasonic testing
PT – Penetrant testing, MT – Magnetic particle testing,
VT – Visual testing, ET – Eddy current testing
Applicable Inspection Methods Vs Discontinuities

Discontinuities RT UT PT MT VT ET

Porosity A O A O A O
Slag Inclusion A A U O U O
Incomplete fusion O A U O U O
Incomplete Penetration A A U O U O
Undercut A O O O A O
Overlap U O A A O O
Cracks O A A A A A
Laminations U A A A A U

A – Applicable Method
O – Marginal applicability depending upon factors such as material
thickness, discontinuity size orientation and location
RT – Radiographic testing, UT – Ultrasonic testing, PT – Penetrant testing, MT – Magnetic
particle testing, VT – Visual testing, ET – Eddy current testing
Causes of Discontinuities

Discontinuities Opr Cons Par Matl Tech Des others

Porosity X X -- XX X XXX
Slag Inclusion XXX X X X X
Incomplete fusion X XX XX X X X
Incomplete Penetration XX O X X XXX
Undercut XXX X XX
Overlap XXX X
Cracks --- XXX XX XX -- -- X
Laminations -- -- -- XX -- -- XX

Opr– Operator, Cons– consumable, Par – Parameters, Matl- Material,


Tech – technique, Des – Design parameters,
XXX – High influence, XX – Moderate influence, X- low influence
Characterization of defects

 Discontinuity Size & Number

 Location of discontinuity

 Distribution of the discontinuities

 Orientation of the discontinuity

 Shape / asperity / morphology

Significance
Characterization of defects
 Discontinuity Size & Number
Diameter, length, width etc
 Location of the Discontinuity
Weld, HAZ, Toe region, Root, Face of weld
Surface / sub-surface / Interior of weld

 Distribution of the Discontinuity


Random, Aligned, clustered /grouped
Close proximity, distantly located
Significance
Characterization of defects

 Orientation of the discontinuity


Parallel to the loading direction
Perpendicular to the loading direction
longitudinal / transverse to the weld
 Shape / asperity / morphology
Voluminar / Planar
Rounded / Elongated / linear

Significance
Modes of failures

 Overloading / Plastic collapse


 Buckling collapse
 leakage and bursting
 Overheating / burning
 Fatigue
 Creep
 Corrosion & Erosion
 Brittle fracture
 Combinations Significance
Load / Stress field
 Primary stress
 Secondary stress
 Primary stress [ Applied stress ]
Static / Dynamic
Tensile, compressive, bending /shear
stress, Torsional stress and combination
 Secondary stress
Deflection caused stress, Residual stress,
Peak stress caused by the presence of
discontinuities, localized finishing operations &
stress raisers
Significance
Stress distribution

Membrane Bending Residual Peak Peak stress


Total
Stress Stress Stress Stress due to
Stress
misalignment
Stress distribution

Hot Spot Region

n b r s p
+ +
+- + -
+
+ +

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