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Assignment One

The document outlines ten common welding defects, their explanations, and causes, such as porosity, cracks, and distortion. It also identifies types of welding distortion, including longitudinal, transverse, and angular distortion, along with methods to control distortion before, during, and after welding. Additionally, it describes mechanical and chemical cleaning methods, as well as surface preparation techniques used before repairing worn-out components.

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tawandachakauya96
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16 views

Assignment One

The document outlines ten common welding defects, their explanations, and causes, such as porosity, cracks, and distortion. It also identifies types of welding distortion, including longitudinal, transverse, and angular distortion, along with methods to control distortion before, during, and after welding. Additionally, it describes mechanical and chemical cleaning methods, as well as surface preparation techniques used before repairing worn-out components.

Uploaded by

tawandachakauya96
Copyright
© © All Rights Reserved
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
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Assignment One

1.) Ten weld defects and their causes


Welding defect explanation causes
a.) Porosity Small gas pockects or spaces Contaminated base or filler
within the weld metal material or moisture on the
welding surface
b.) cracks Fractures in the weld metal Rapid cooling, high residual
or on the heat affected Zones stress or improper welding
technique.
c.) Undercut A groove melted into the base Excessive welding current or
metal adjacent to the weld toe incorrect electrode angle
d.) Incomplete The weld metal does not Insufficient heat input or
penetration extend through the joint improper joint preparation
thickness
e.) Lack of fusion The weld metal fails to join Low welding current or
with the base metal. contaminated welding surface
f.) Slag inclusion Non-metallic solid material Contaminated filler material
trapped in the weld metal or welding on dirty surface.
g.) Overlap Excess weld metal rolls over Low welding speed or
the base metal without fusing excessive welding current
h.) Spatter Small droplets of molten High welding current or
metal expelled from the weld incorrect arc length
and adhering to the base
metal.
i.) Burn through The weld metal penetrates Excessive heat input or thin
completely through the base base metal
metal, creating a hole.
j.) Distortion Warping or deformation of Uneven heating and cooling,
the welded assembly excessive heat input, or
improper welding sequence.

2.) Identify the welding distortion

i.) Longitudinal distortion: Angular distortion occurs when there is a change in the
angle between the welded parts. It results in the welded components being
misaligned or tilted. Longitudinal distortion is caused by uneven expansion an
contraction of the weld metal along the weld’s length. The heat from welding
causes the metal to expand and as it cools it contracts leading to distortion
ii.) Transverse Distortion: It is the distortion that occurs across the width of the weld.
The welded component then as a result become wider or narrower.
Transverse Distortion is caused by uneven expansion and contraction of the weld
metal across the weld’s length. The heat from welding causes the metal to expand
and as it cools it contracts leading to distortion

iii.) Angular distortion: Angular distortion occurs when there is a change in the angle
between the welded parts. It results in the welded components being misaligned
or tilted.
Angular distortion is caused by non-uniform heating and cooling through the
thickness of the weld. When one side of the weld metal cools, it contracts more
than the others creating bending moments.

3.) Explain the ways of controlling distortion before, during and after welding
Before welding
Use of fixtures and clamps: secure the weld components in order to hold them in
place.Use strongbacks or jigs to maintain alignment and prevent movement
Pre-bending or Pre-setting: pre set or pre bend the weld components in the opposite
direction were you anticipate distortion to occur. If you anticipate the part will bend
upwards, pre-bend it slightly downwards.
During welding
Intermittent Welding: Use intermittent welds instead of continuous welds to reduce
heat input. Use stitch welds were possible
Backstep Welding Technique: Weld in small sections in the opposite direction of the
overall welding direction. If welding from right to left, start a small section on the left
and move right.
Balanced Welding: Weld on both sides of the weld component to balance the heat input .
Weld a small section on one side, then a corresponding section on the opposite side.

After welding:
Peening: Lightly hammer the weld bead to relieve residual stresses. Use a peening hammer.
Mechanical Straightening: Use mechanical methods to correct the distortion that may have
occurred. Apply controlled force to bend or press the distorted part back into shape.
Post-Weld Heat Treatment (PWHT): Apply controlled heating and cooling to relieve residual
stresses

4.) Explain the mechanical and chemical cleaning methods and surface preparation methods
used before repairing worn out components
Mechanical methods
Abrasive blasting: uses high pressure air to propel abrasive particles like sand or steel grit.
Remove rust, paint and other contaminants to prepare surface for repairing eg sand blasting
Grinding: Use a rotating abrasive wheel to remove material from the surface. We can use a
grinder to grind seams thus preparing a uniform surface.
Wire brushing: use a wire brush to scrub the surface of a component to be repaired. Removes
loose rust, paint, and debris.

Chemical Cleaning Methods

Acid pickiling: This uses acidic solutions to remove rust and scale from the surface of metals.
For example using hydrochloric acid to clean steel before galvanizing
Solvent Cleaning: use chemical solvents to dissolve and remove contaminants on metals. Using
acetone to clean a metal surface before painting.

Surface Preparation Methods


Etching: Uses chemical or mechanical means to create a rough surface usually done before
applying adhesives or coatings.

Degreasing: Remove grease and oil from the surfaces using detergents or solvents

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