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VIJAYANMG
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Weldingvcasting
Weldmustadheretomouldwall Heatisaddedcontinuallytowelds
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Hightemperaturegradient
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Fusionweldstructure
Fusionline Weldpreparation Base metal Weldmetal
HAZ
HAZ
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ThermalgradientsinHAZ
Temperature Fusionline Fusionline+2mm Fusionline+5mm
HAZstructure
Highpeaktemperature Hightemperaturegradient
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SuperimposedHAZsinmultipasswelds Weldingstressesaffecttransformation
Variablecoolingrate
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Multipassfusionweld
Lastweldrun Previousweldrun
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Weldproperties
Weldmetalhasdifferentcomposition& thermalhistorytobasemetal Weldingheatmodifiesadjacentbasemetal (HAZ) Variationinstrength,ductility&corrosion resistanceacrosswelds
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Weldingprocedure
Selectionofprocessconditions& consumablesforaweld Designedtomatchbasematerialproperties ascloselyaspossible&avoidwelddefects Needstoconsiderserviceconditionsofthe weld
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Definitionofweldability
Thecapacityofamaterialtobewelded undertheimposedfabricationconditions intoaspecific,suitablydesignedstructure& toperformsatisfactorilyinintendedservice.
(ANSI/AWSA3.0)
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Factorsaffectingweldability
Weldabilityisoftenconsideredtobea materialproperty,howevertheeffectofother variablesshouldnotbeignored. Designofweldment Itsserviceconditions Choiceofweldingprocess
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Materialproperties
Melting&vaporisationtemperatures Electrical&thermalproperties
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AffinityofweldmetalforO,N&H
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Presenceofasurfacefilmonbasemetal
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Serviceenvironment
Extremeenvironments
q q q q
Themoreextremetheenvironment
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WeldingDefects
Cracks
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Porosity
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InweldmetalorHAZ Gasbubblesentrappedinweldmetal
Incompletefusion(interrunoratpreparationedge) Inclusions
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Defectiveprofile
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Slagorothermatterentrappedinweld
Underweld,overweld,lackofpenetration,overlap, undercut
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Causesofwelddefects
Poordesignofweldment
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Mistakesbywelder
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Poorweldingprocedure
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Welddefects
Slag inclusion
Overlap
Solidificationcracking
Contractionstrains causeruptureofthe weldatthepointwhere thelastmaterial solidifies.
q q
Solidificationrange Weldpoolsize&shape
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Residualstress&distortion
Unevenheatingleadstoconstrainedthermal expansion Atcompletionoftheweldthermalcyclethe weldmenteitherdistortsorifrestrainedwill containresidualstress Residualstressfieldsarecomplex,but stressesashighasyieldoftenoccur Stressesmayneedtoberemovedbyastress reliefheattreatment
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Residualstressinabuttweld
sy X sx X
Compression y 0
sx
Tension
Tension
X
Compression
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Welddetailing
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Weldpositionsplate
Flat (1G)
Horizontal (2G)
Overhead (4G)
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Weldingpositionspipe
Axisvertical 2G
Axishorizontal 5G
Axisinclined45 6G
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Welddetails
JointsArrangementsofmembersbeing joined
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WeldsGeometryofwelddetailselectedto makethejoint
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Butt,tee,lap,corner,flare
Butt,fillet,plug&slot
Jointtypes
Butt
Tee
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Weldtypes
Buttweld
q q q
Filletweld
q q
Plug&slotwelds
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Filletwelds
Simple&cheaptoassemble&weld Stressconcentrationsattoes&root Notchatroot(fatigue,toughness) Criticaldimensionisthroatthickness Rootgapaffectsthroatthickness Radiography&ultrasonictestingisof limiteduse Largefilletsusealotofweldmetal& thereforeareuneconomic
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Filletweldterms
Toe Weldface
Root
Toe Gap
Throat thickness
Apparentleglength
Buttwelds
Types:
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Buttweldtypes
Singlebevel
Doublevee
Backedbutt(permanentortemporary)
Buttweldterms
Fusionface Includedangle Bevelangle
Rootrun
Weldpreparationdimensions
Compromise
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Weldcrosssectionalarea
Standardpreparations
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Cost Easeofwelding(riskofdefects)
Fabricatorsrisk
AS1554,AWSD1.1,ANSIB31.3
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Singleweldedbuttjoints
Accesstoonesideonly
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Pipe&hollowsectionbuttjoints
Rootmaybecontaminated Insideisdifficulttoinspect
Specialwelderqualification
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J&UPreparations
Upreparation
Rootradius Land
AS1101.2drawingsymbols
OTHERSIDE Tail ARROWSIDE Referenceline Arrowpointstoweld location
Weldtypesymbol
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TypicalAS1101.2symbols
6 6mm CJP
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