Post on 04-Apr-2015
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WELCOMEWELCOME
ESAB Welding InstituteESAB Welding Institute
ChennaiChennai
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Weld
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Institu
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hennai
Weld Defects
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Weld
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Institu
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hennai
Weld Defects
REJECTABILITY
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Weld
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Institu
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Weld Defects
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Institu
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Weld Defects
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Institu
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Weld Defects
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Weld Defects
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Weld DefectsFormation of Pores
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Weld Defects
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Weld Defects
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Weld Defects
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Weld Defects
Uniformly distributed porosity
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Institu
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Weld Defects
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Weld Defects
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Weld Defects
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Weld Defects
Surface porosity in a ‘T’ joint on a primed plate
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Weld Defects
Porosities in the weld bead
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Institu
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Weld Defects
• Elongated pores or worm holes
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Institu
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Weld Defects
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Weld Defects» Principal gases causing porosity and recommended
cleaning methods
• Material Gas Cleaning• C Mn steel Hydrogen, Nitrogen Grind to remove
and Oxygen scale coatings• Stainless steel Hydrogen Degrease + wire
brush • Aluminium and alloys Hydrogen Chemical clean +
wire brush + degrease + scrape
• Copper and alloys Hydrogen, Nitrogen Degrease + wire brush + degrease
• Nickel and alloys Nitrogen Degrease + wire brush + degrease
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Weld
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Institu
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Weld Defects
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Institu
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Weld Defects
Incomplete Fusion of Side Wall
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Institu
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Weld Defects
Incomplete inter-run fusion
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Weld Defects
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Institu
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Weld Defects
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Weld Defects
Insufficient Penetration• Root Face too thick
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Weld Defects
Insufficient Penetration• Root Face too Narrow
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Weld Defects
Insufficient Penetration• Misplaced Welds
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Institu
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Weld Defects
Insufficient Penetration• Power Input too Low
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Institu
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Weld Defects
Insufficient Penetration• Arc (heat) input too low
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Institu
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Weld Defects
Effect of electrode size on root fusion• Too large a diameter
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Institu
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Weld Defects
Effect of electrode size on root fusion
• Too small a diameter
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Weld Defects
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Weld Defects
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Weld Defects
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Weld Defects
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Weld Defects
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Weld Defects
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Weld Defects
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Weld Defects
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Weld Defects
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Weld Defects
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Weld Defects
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Weld Defects
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Institu
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Weld Defects
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Institu
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Weld Defects
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Weld Defects
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Weld Defects
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Weld Defects
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Weld Defects
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Weld Defects
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Weld Defects
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Weld Defects
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Weld Defects
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Weld Defects
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Weld Defects
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Weld Defects
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Weld Defects
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Weld DefectsPotential and actual Hydrogen levels in Weld
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Weld DefectsHydrogen crack examples
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Weld Defects• Crack in coarse grained HAZ due to
Hydrogen embrittlement
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Weld DefectsPreheating to avoid HIC
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Weld Defects
Guide to Preheat Temperature
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Weld Defects
• Micrograph of a crack in coarse grained Weld
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Weld Defects
Intergranullar morphology of a reheat crack
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Weld Defects
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Weld Defects
Solidification Crack
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Weld Defects
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Weld Defects
Weld bead penetration too small
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Institu
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hennai
Weld Defects
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Weld Defects
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Weld Defects
• Brittle fracture in CrMoV Steel Pressure Vessel - Combination of Hydrogen Induced Cracking
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Weld Defects
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Weld Defects
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Weld Defects
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Weld Defects
Slag inclusion due to a poor bead - Convex
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Weld Defects
Smooth Bead profile allows easy slag removal
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Weld Defects
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Weld Defects
Radiograph of Slag Inclusions
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Weld Defects
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Weld Defects
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Weld Defects
Grinding out Slag Inclusions
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Weld Defects
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Weld Defects
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Weld Defects
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Weld Defects
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Weld Defects
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Weld Defects
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Weld Defects
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Weld Defects
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Weld Defects
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Weld Defects
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Weld Defects
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Weld Defects
Thickness measurements
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Weld Defects
• Measurement of Combined Thickness
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Weld Defects
Lamellar Tearing
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Weld Defects
Fracture face of Lamellar Tearing
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Weld DefectsSuggested configuration to avoid Lamellar Tearing
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Weld Defects
Suggested configuration to avoid lamellar Tearing
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Weld Defects
Suggested configuration to avoid lamellar Tearing
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Weld Defects
• Buttering to avoid Lamellar Tearing
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Weld Defects
In-situ buttering to avoid Lamellar Tearing
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Weld Defects
• Arc Deflection By Magnetic Forces
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Weld Defects
• Bead Deflection in dc SMAW
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Weld Defects
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Weld Defects
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Weld Defects
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Weld Defects
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Institu
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Weld Defects
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Weld Defects
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Weld Defects
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Institu
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Weld Defects
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Weld Defects
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Institu
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Weld Defects
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Institu
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Weld Defects
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Institu
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hennai
Weld Defects
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Institu
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hennai
Weld Defects
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Weld
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Institu
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hennai
Weld Defects
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Weld
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Institu
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hennai
Weld Defects
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Weld
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Institu
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hennai
Weld Defects
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Institu
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hennai
Weld Defects
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Institu
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Weld Defects