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Chapter 4

The document discusses weld inspection, weld testing, weld quality, common weld defects like lamellar tearing, welding distortion, and methods to control distortion. Weld inspection qualitatively examines welds for defects and dimensions while testing determines quantitative properties. Quality welding is free of defects and carries load as intended. Distortion occurs due to uneven heating and cooling during welding. Methods to control it include minimizing weld passes, pre-bending parts, and using fixtures during welding.

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Vandan Gundale
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95 views20 pages

Chapter 4

The document discusses weld inspection, weld testing, weld quality, common weld defects like lamellar tearing, welding distortion, and methods to control distortion. Weld inspection qualitatively examines welds for defects and dimensions while testing determines quantitative properties. Quality welding is free of defects and carries load as intended. Distortion occurs due to uneven heating and cooling during welding. Methods to control it include minimizing weld passes, pre-bending parts, and using fixtures during welding.

Uploaded by

Vandan Gundale
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
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Chapter 4

Inspection and Testing .


Weld Inspection & Weld Testing:
Difference between weld inspection & weld testing:
Weld Inspection:
Inspection includes observation of the processes & products of
weldments to ensure the presence of desired qualities.
Inspection is mostly qualitative & involve only visual observation of
correctness of operations or dimensions, examination of surface
defects of welded joints, etc.
Weld Inspection & Weld Testing:
Difference between weld inspection & weld testing:
Weld Testing:
Testing specifically includes the physical performance of operations
(tests) to determine the quantitative measure of certain properties
such as mechanical strengths etc.

Testing aims to determine quality, i.e. to discover facts regardless of


the implications of the results.
Whereas
Inspection intends to control quality through the application of
established criteria & involves the idea of rejection of substandard
products.
Weld Quality:
The quality of weldment can be defined as
the weld joint capable of carrying desired load
for the predetermined life span, with
uniformly filled weld metal in joint, which is
free from internal or external defect and being
capable of performing the desired task which
joint is designed.
Weld Defect- Lamellar Tearing:
Weld Defect- Lamellar Tearing:
Lamellar tearing is among those defects that deteriorates the
surface of metal joints.
The occurrence of this kind of defect makes it quite hard to gain the
quality of the welding. It appears generally in rolled steel plates. It
appears below the welding parts.
Weld Defect- Lamellar Tearing:
Causes:
• It occurs due to the accumulation of weld metal deposit on the
surface of the weld metal where there is optimal restraint.
• Development of strain.
• Improper weld orientation.
• Improper material selection.
Remedies:
• This can be prevented by using materials that are of the best quality
and conducting welding tests at the end.
• Proper weld orientation.
Weld Distortion
Welding Distortion:
The welding process requires highly concentrated heating of the joint
edges to merge the workpieces. Due to the expansion and contraction of
heated and cooled material, non-uniform stresses are formed.

Firstly, compressive stresses are produced when the weld pool is formed
in the surrounding cold parent metal due to the thermal expansion of the
hot metal (heat-affected zone) adjacent to the weld pool. During the
cooling, tensile stresses occur on weld metal and heat-affected zone. The
volume change in the welding area during solidification can show the
magnitude of the thermal stresses induced into the material.
Welding Distortion:
When the stresses produced by the thermal metal
expansion/contraction exceed the yield strength of the parent, plastic
deformation occurs. Plastic deformation causes a permanent reduction in
the dimensions of the workpieces and distorts the structure and shape.

The shape and rate of the distortion depend on several factors;


•material type,
•the geometry of the workpiece,
•weld design,
•heat input,
•welding procedure,
•part fit-up,
•amount of restraint
Effects of Thermal Distortion:
• Stresses in weldment
• De-shaped weldment
• Change in geometrical alignment
• Sometimes results in cracks
• Such weldment when machined, desired geometrical shape can not be
achieved
• Reduction in fatigue, creep strength
(Creep is a type of metal deformation that occurs at stresses below the
yield strength of a metal, generally at elevated temperatures. ... Creep is
unique in the fact that it is a phenomena that causes materials to
plastically strain even though yield stresses have not been reached.)
Types of Distortion:
Transverse Distortion:
It is the extraction of the weld metal that occurs in the
direction perpendicular to the welding seam caused by the
transverse stresses, during cooling. Since hot weld metal has
lower yield strength than cold plates, deformation firstly
occurs at welding. Nevertheless, deformation of the base
metal may also happen at the end of cooling. This deformation
causes a reduction in the width of the base metal.
Longitudinal Distortion:
Longitudinal distortion is shrinkage stress which results
in shortening along the length of the weld bead. Longitudinal
shrinkage is maximum along with the weld bead and
decreases away from the bead. 
Angular Distortion:
The angular distortion comprises the rotation of the
structure around the welding line. It is a special form of
transverse distortion, so when transverse shrinkage is not
uniform in the thickness direction, the angular distortion
occurs in a butt joint.
The major factors altering the development of angular
distortion are: material properties (thermal conductivity,
thermal expansion coefficient, specific heat), welding
procedures (welding current, arc voltage, welding speed,
shielding gas chemical composition, gas flow rate, welding gun
angle), weld groove geometry, (joint type).
Methods to Control Thermal Distortion:
Strategies to be used in the design & shop practices to overcome the
effect of the heating and cooling cycles.
1. Keep the contraction forces as low
Minimum amount of weld metal
• Use flat or slight convex bead
• Proper edge preparation
• Bevel not exceeding 30°
• “J” Or “U” preparation
• Use of double joint
• Intermittent welds
Methods to Control Thermal Distortion:

2. Use as few as weld passes as possible


• Fewer passes using large size electrode
• Selection of electrodes with high deposition rate
3. Try to place welds near neutral axis
4. Balance welds around neutral axis
5. Use backstep and/or skip welding method
Methods to Control Thermal Distortion:

6. Make shrinkage forces to work in desired direction


• Pre-bending or presetting the parts
• Several assemblies can be preset out of position before
welding, so that shrinkage forces will put the plates in
alignment
7. Balance shrinkage (contraction) forces with opposing forces that
is :
• Position identical weldment back to back and clamp them
tightly together. The welds are completed on both
assemblies and allowed to cool before clamps are released.
• Use of clamps, jigs & fixtures
Methods to Control Thermal Distortion:
8. Welding procedure
• Weld downhand wherever possible
• Weld outward from central point
• Restrict the HAZ by keeping the metal adjacent to joint as cool
as possible
9. Removal of shrinkage forces during or after welding
• Peening on weld (tapping with hammer)
• Stress relieving by controlled heating & cooling
10. Reduce welding time wherever possible
11. Breakdown large weldments in to sub-assemblies. Thus distortion
effect can be rectified on each sub-assembly before final erection.

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