3/28/2012

Defect of Welding

Ir.Soeweify, M.Eng
Head of Strength and Structure Groups
Department of Shipbuilding Engineering
Surabaya Institute of Technology
Welding Engineer 1980 Hiroshima University
Welding Inspector 1984 Hamburg University
Fracture mechanic sertificate 1990 Bandung Institute of
Technology

Welding defect
Metallurgical defect
Melting process
Incomplete fusion and incomplete penetration

Alloying process
Slag inclusion and porousity

Cristalization process
Cold crack and hot crack

Dimensional defect
Tranversal shrinkage
Angular distortion

Longitudinal shrinkage
Longitudinal distortion

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Weld defect

Crack
Incomplete fusion
Incompl. penetration
Slag inclusion
Porosity
Under cut
Underfill
Over lap

Covexity
Weld reinforcement
Arc strike
Tungten Inclusion
Spatter
Delamination
Lamelar tear
Seams/lap
Dimensional

Defect of Welding
Metallurgical defect

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Crack of welding
Hot crack, Cold crack
Longitudinal crack,
Transversal crack
Base metal ,Weld metal
,HAZ crack
Throat, root, toe, under
bead, crater crack
Lamelar tearing

Hot Crack

Just start for cristalization

Segregeration between cristal
Weld metal crack
Crack of the first layer
Creater crack
Micro crack
Transversal and logitudinal crack

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The influence of hot cracking

Name of
crack

Form of crack

Crack on
the first
layer
Dendrite
crack

Crater crack

Influence factor for cold

cracking
Wcond Chem Rs
Bform
VVV VV VV
VV

VVV VV

VV

VVV

VVV VV
V

Hot Crack
Welding condition
Chemical composition
Shrinking load of weld
point
Form of bead

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Crater crack
Crater crack is one of dangerous hot crack
Crater crack occour in the
end of weld couse of wrong
welding electrode
manipulation, Filler metal
have flow characteristiecs
with produce concave profile
when solidification
Hot crack start from crater
crack of fillet weld in pipe
welding, E 308 -16, E 30916, E 316 -16, The welder
must take care the end of
welding to full fill the crater

Preventive Methode of the Hot cracking for each material

Sensitivity
Kind of
Material

Crack of Weld Metal

Crack
In
the
HAZ

Preventive Methods
For
For
For
Material Prose
De
dur
sign

First Layer
Crack

Dendrit
Crack

Micro
Crack
HAZ

Other
Crack

Midle
sensitive
necc to care

Midle
sensitive
necc to
care

Low
sensitive
No
Problem

Midle
sensitive
necc to
care

Midle
sensitive
necc
care

Midle
sensitive
necc
Care

Low
sensitive
No
Problem

Midle
sensitive
necc
care

Low
sensitive
Reduce of
No
P.S
Problem
Increase
of Mn
Low
examine
sensitive
of the
No
elememt
Problem

60
S Kg/mm2
T
E
E 70
L Kg/mm2

Midle
sensitive
necc
care

Midle
sensitive
necc
Care

Low
sensitive
No
Problem

Midle
sensitive
necc
care

Low
sensitive
No
Problem

Midle
sensitive
necc to care

80
Kg/mm2

Midle
sensitive
necc
care

Midle
sensitive
necc to
care
Midle
sensitive
necc
care

Low
sensitive
No
Problem
Low
sensitive
No
Problem

Midle
sensitive
necc to
care
Midle
sensitive
necc
care

Midle
sensitive
necc to
care
Midle
sensitive
necc to
care

40
Kg/mm2
C
A
R 50
B Kg/mm2
O
N

Examine
weld
conditio
n
examine
format
weld
bead.

Low
Shrink
age
Pre
vent
Stress

3/28/2012

Preventive Methode of the Hot cracking for each material

Cr Mo

Midle
sensitive
necc
care

Midle
sensitive
necc to
care

Low
sensitive
No
Problem

Midle
sensitive
necc to
care

Low
sensitive
No
Problem

1Cr
Mo

Midle
sensitive
necc to care

Midle
sensitive
necc
Care

Low
sensitive
No
Problem

Midle
sensitive
necc
care

Low
sensitive
No
Problem

Midle
sensitive
necc
care

Midle
sensitive
necc
Care

Low
sensitive
No
Problem

Midle
sensitive
necc
care

Midle
sensitive
necc
care

Midle
sensitive
necc to
care

Low
sensitive
No
Problem

Midle
sensitive
necc to
care

Reduc of
P.S
Low
sensitive Increase
of
No
Mn
Problem
Examined
of the
Low
sensitive elememt
No
Problem

Midle
sensitive
necc to care

Midle
sensitive
necc
Care

Low
sensitive
No
Problem

Midle
sensitive
necc
care

Low
sensitive
No
Problem

Midle
sensitive
necc
care
Midle
sensitive
necc
care

Midle
sensitive
necc to
care
Midle
sensitive
necc
care

Low
sensitive
No
Problem
Low
sensitive
No
Problem

Midle
sensitive
necc to
care
Midle
sensitive
necc
care

Low
sensitive
No
Problem
Low
sensitive
No
Problem

L
O 1 Cr
W Mo
A
L
L 2 Cr
O Mo
Y
S 3 Cr
T Mo
E
E
L
5 9 Cr
Mo
Mn - Mo

Examine
weld
codition
Examine
format
weld
bead.
Clean
Keep
enough
Slag

Low
Shrink
age
Pre
vent
SC

Preventive Methode of the Hot cracking for each material

Austenit

Midle sensitive Midle

necc to care
sensitive

necc
S
care
T
A Martensit Midle sensitive Midle
necc
sensitive
I
care
necc to
N
care
L Ferrit
Midle sensitive Midle
E
necc
sensitive
care
necc
E
care
S

Pure
Nikkel

High sensitive
Must care

Inconnel

High sensitive
Must care

N
I Hactelloy High sensitive
Must care

B
A
S Monel
E

High sensitive
Must care

Midle
sensitive
necc
care
High
sensitive
Must care
Midle
sensitive
necc
care
High
sensitive
Must care

High
Midle
sensitive sensitive
Must care necc
care
Midle
Midle
sensitive sensitive
necc to
necc to
care
care
Midle
High
sensitive Sensitive
not care
Must care

Midle
sensitive
necc to
care
Midle
sensitive
necc to
care
Midle
sensitive
necc to
care

High
High
Midle
sensitive sensitive
sensitive
Must care Must care necc to
care
High
High
High
sensitive sensitive
sensitive
Must care Must care Must care
Midle
High
Midle
sensitive sensitive
sensitive
necc
Must care necc to
care
care
High
High
Midle
sensitive sensitive
sensitive
Must care Must care necc to
care

Reduc of
P.S
Increase
of Mn
Examin of
the
element
Reduced
Harmful
element
Pb,B,O
Keep delts
ferrite

Examine
weld
codition
Take of
crater
Examine
format
weld
bead.
Clean
Keep
enough
Slag

Reduce
PS
Increase
Mn
Reduce
Harmful
elemen,
Pb,B,O
Add little
element
Ti,Nb.Al,Ni
Examine
element
comp

Examine
weld
codition
Examine
format
weld
bead.
Clean
Keep
enough
Slag
Apply
peening

Low
Shrink
age
Prevent
Stress
Concent

Low
Shrink
age
Prevent
Stress

3/28/2012

Cold crack
Process of crack

Finish cristalization
Hydrogen diffusible
Stress at the weld metal
HAZ and base metal
crack
Root crack
Toe crack
Under bead crack

Caused of crack

Chemical composition
Welding heat input
Hydrogen diffusible
Restraint of joint
Residual stress
Diforation anggle

The influence of cold cracking

Name
of
crack

Form of crack

Influence factor for cold

cracking

Wh Hdiff Pcm
VV VV VV
V
V

Root
crack

VV VV VV
V

Rs

VV VV
V
V

VV
V

3/28/2012

The influence of cold cracking

Name
of
crack

Form of crack

Toe
crack

Influence factor for cold

cracking
Wh Hd Pcm
R
A Rs
VV VV VV
V
V

VV
V

VV VV
V

The influence of cold cracking

Name
of
crack
Under
bead
crack
Lame
lar
tear
ing

Form of crack

Influence factor for cold

cracking
Wh Hd Pcm
R
A Rs
VV VV
V

VV

VV

VV VV
V

VV VV
V
V

3/28/2012

Longitudinal and transversal crack

Longitudinal
crack start from
the weld toe in
the HAZ

Transvers crack
start from the
stop and run of
weld

Longitudinal and transversal crack

3/28/2012

Under bead crack

Under bead crack
Some kind of cold
crack
Start from the toe of
weld in HAZ
Mainly caused by
Hydrogen diffusible

Effect of pre heating on root craking

Experimental results

10

3/28/2012

Couse and Prevention Cracks on the HAZ

Couse

Preventive

Base metal have high

hardenability
High C ek and P cm
C, Mn,Cr conten to high
Hidrogen diffusible
Hidrogen Embrittlemen
High restrain joint

Chose the lower Cek

and Pcm
Elec. Low hydrogen
Dry Filler metal
Clean edge preparation
Moderate high restrain
Good weather
Pre heating and post
heating

Lamelar tearing
Thick material only
Delamination first
High Stress through the
thickness
Fillet weld only
Degree of constraint
High inclusion of base
metal
Low transverse ductility
High residual stress

11

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Lamellar tearing

Lamellar tearing

12

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Lamellar tearing

Lamelar tearing

13

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Lamelar tearing
Lamelar tearing

Lamellar tearing

Incomplete fusion

Low heat input

Travel speed to high
Amperage to low
Wrong electrode
position
Weld metal to weld
metal
Weld metal to base
metal

14

3/28/2012

Incomplete fusion

Typical side wall incomplete

fusion

Incomplete penetration

Couse of Incomlete penetration

Diameter electrode to big
Groove angle to small
Amperage to low
Wrong electrode not deep penetration
Weld metal does not extend entirely

15

3/28/2012

Incomplete penetration

Incomplete penetration
on radiography

Incomplete penetration
in root of weld

Slag inclusion
Incorrect welding
parameter
Difficult to clean slack
Molten slack to thick
Oxidation and deoxidation
process
Unadequate weld
preparation
Iregular visual in X Ray
Black vision on DT

16

3/28/2012

Porosity
Gas entrapment during
solidification
The least dangerous
H2S, CO, NO2
Uniformly scattered
Clustered porosity
Piping porosity
Linear porosit
Dirty base metal

Under cut
Under Cut
Amperage to high
The wrong welding
technique
Angle of electrode
during welding
Initial crack start from
this defect
Maximum 0.5 mm

17

3/28/2012

Under fill

Over lap
Over lap
Protrusion of weld metal
beyond the
weld toe
Wrong electrode
position
Burn torch

18