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OBJECTIVE/SCOPE
To present an overall view of the implications of making joints by welding.
SUMMARY
This lecture describes the basic principles involved in making a welded joint.
It discusses the structure and properties of both the weld metal and the heat
affected zone. It explains the necessity for edge preparations when butt
welding, and gives examples of the types used. It outlines how the welding
procedure can be varied to meet the needs of the particular joint being made.
ABBREVIATIONS
MAG Metal Active Gas Welding (sometimes referred to as MIG Metal
Inert Gas Welding)
MMA Manual Metal Arc Welding
SAW Submerged Arc Welding
HAZ Heat Affected Zone
1. INTRODUCTION
Welding offers a means of making continuous, load bearing, metallic
joints between the components of a structure.
In structural work, a variety of welded joints are used; these can all be
made up from the basic configurations shown in Figure 1, which are
classified as follows:
butt joints.
tee joints.
lap joints.
corner joints.
of molten metal which bridges the interface. As the pool cools, molten
metal at the fusion boundary solidifies, forming a solid bond with the
parent metal, see Figure 3. When the solidification is complete, there
is continuity of metal through the joint.
The molten steel in the pool will readily absorb oxygen and nitrogen
from the air, which could lead to porosity in the solidified weld and
possibly to metallurgical problems. Figure 6 shows how this is avoided
by covering the pool with a molten flux, as in Manual Metal Arc (MMA)
and Submerged Arc Welding (SAW), or by replacing the air around the
arc by a non-reactive gas, as in Metal Active Gas (MAG) Welding or
cored wire welding.
metal and steel melted from the electrode. In structural work the
composition of the electrode is usually chosen so that the resultant
weld metal is stronger than the connected elements. Occasionally,
specific conditions may override this chocie. For example, when joining
stainless steel to carbon-manganese steel, a highly alloyed electrode
must be used to avoid cracking in the weld metal.
When the weld pool is cooling and solidifying, the majority of the heat
flows through the parent metal alongside the joint. The steel is thus
subjected to heating and cooling cycles similar to those experienced in
heat treatment practice. As shown in Figure 7, the structure of the
steel will be changed in this region (called the heat affected zone,
HAZ). This must be taken into account in the design in terms of notch
toughness (Charpy value), etc.
The first run to be deposited in the bottom of the groove is called the
root run. The root faces must be melted to ensure good penetration,
but at the same time the weld pool must be controlled to avoid
collapse, as seen in Figure 11. This task requires considerable skill.
The difficulties can be eased by using a backing strip.
5. WELDING PROCEDURES
The term welding procedure is used to describe the complete process
involved in making a weld. It covers choice of electrode, edge
preparation, preheat, welding parameters (voltage, current and travel
speed), welding position, number of weld runs to fill the groove, and
post-weld treatments, e.g. grinding or heat treatment. Welding
procedures may be devised to meet various needs, e.g. to minimise
costs, control distortion, avoid defects or achieve good impact
properties. Specific aspects of the weld procedure are worth detailed
comment.
5.1 Current
The current controls heat input. The minimum value is fixed by the
need to fuse the plate and to keep the arc stable; the specified
minimum, however, may be higher to avoid HAZ cracks. The
maximum current depends on operating conditions. Usually, as high a
current as possible is used to achieve faster welding, and hence lower
costs. The use of maximum current may be restricted by position; in
the overhead position, for example, currents above 160 amps cannot
be used. High currents usually give low impact properties. Note that
the current used is chosen to match the electrode diameter.
5.3 Environment
If on site welding is necessary the following points must be
considered:
6. SHRINKAGE
During cooling, the hot metal in the weld zone contracts, causing the
joint to shrink. The contraction is restrained by the cold metal
surrounding the joint; stresses are set up which, being in excess of the
yield stress, produce plastic deformation. This can lead to the
distortion or buckling shown in Figure 13. Distortion can be reduced by
choice of edge preparation and weld procedure; examples are shown
in Figure 14.
When the plastic deformation has ceased, the joint is left with the
residual stress pattern of Figure 15 with tension in the weld metal and
HAZ, and compression in the surrounding steel. The significance of
these residual stresses is discussed in other lectures.
7. CONCLUDING SUMMARY
A welded joint is made by fusing parent metal from both components
being joined, usually with added weld metal.
The properties of both the weld metal, which has melted and solidified,
and the surrounding heat affected zone may differ from those of the
parent metal.
Welding procedures should be properly specified to give a satisfactory
welded joint. The major parameters are: welding position, electrode
type, edge preparation, preheat, voltage, current, travel speed,
number of runs and post-weld heat treatments.
Hot metal in the weld zone contracts during cooling causing residual
stresses. Distortion will occur if appropriate control is not exercised.
8. ADDITIONAL READING
Hicks, J. "Welding Design", Granada.
details of joints and welds.
strength of welded joints.
effects of welding on metallurgical structures, heat affected
zones, HAZ cracking.
edge preparation.
welding positions - definitions and comments.
Gourd, L. M. "Principles of Welding Technology", Edward Arnold, 1980.
formation of a weld.
types of heat source.
strength of welded joints.
effects of welding on metallurgical structure, heat affected
zones, HAZ cracking.
edge preparation.
comments on residual stresses.
control of distortion.
Milner, D.R. and Apps, R. L. "Introduction to Welding and Brazing",
Pergamon.
effects of welding on metallurgical structure, heat affected
zones, HAZ cracking.
control of distortion.
Pratt, J. L. "Introduction to the Welding of Structural Steelwork",
Steel Construction Institute - Publication No 014.
British Standard BS 5135: 1986, "Metal Arc Welding of Carbon and
Carbon Maganese Steels", British Standards Institution, London.