3. Personal Attributes 1.1
Important qualities that good Inspectors are expected to have
are:
•Honesty
•Integrity
•Knowledge
•Good communicator
•Physical fitness
•Good eyesight
4/23/2007 3 of 691
4. Standard for Visual Inspection 1.1
Basic Requirements
4/23/2007 4 of 691
BS EN 970 - Non-destructive examination of fusion
welds - Visual examination
Welding Inspection Personnel should:
• be familiar with relevant standards, rules and specifications
applicable to the fabrication work to be undertaken
• be informed about the welding procedures to be used
• have good vision (which should be checked every 12
months)
5. Welding Inspection 1.2
4/23/2007 5 of 691
Conditions for Visual Inspection (to BS EN 970)
Illumination:
• 350 lux minimum required
• (recommends 500 lux - normal shop or office lighting)
Vision Access:
• eye should be within 600mm of the surface
• viewing angle (line from eye to surface) to be not less than
30°
30°
600mm
6. Welding Inspection 1.3
Aids to Visual Inspection (to BS EN 970)
When access is restricted may use:
• a mirrored boroscope
• a fibre optic viewing system
Other aids:
• welding gauges (for checking bevel angles, weld profile, fillet
sizing, undercut depth)
• dedicated weld-gap gauges and linear misalignment (high-low)
gauges
• straight edges and measuring tapes
• magnifying lens (if magnification lens used it should have
magnification between X2 to X5)
4/23/2007 6 of 691
usually by
agreement
}
10. Welding Inspection 1.3
4/23/2007 10 of 691
Stages of Visual Inspection (to BS EN 970)
Extent of examination and when required should be defined in
the application standard or by agreement between the
contracting parties
For high integrity fabrications inspection required throughout
the fabrication process:
Before welding
(Before assemble & After assembly)
During welding
After welding
11. Typical Duties of a Welding Inspector 1.5
4/23/2007 11 of 691
Before Welding
Preparation:
Familiarisation with relevant „documents‟…
• Application Standard/Code - for visual acceptance
requirements
• Drawings - item details and positions/tolerances etc
• Quality Control Procedures - for activities such as material
handling, documentation control, storage & issue of
welding consumables
• Quality Plan/Inspection & Test Plan/Inspection Checklist -
details of inspection requirements, inspection procedures
& records required
12. Typical Duties of a Welding Inspector 1.5
4/23/2007 12 of 691
Before Welding
Welding Procedures:
• are applicable to joints to be welded & approved
• are available to welders & inspectors
Welder Qualifications:
• list of available qualified welders related to WPS‟s
• certificates are valid and ‘in-date’
13. Typical Duties of a Welding Inspector 1.5
Before Welding
Equipment:
• all inspection equipment is in good condition & calibrated as
necessary
• all safety requirements are understood & necessary equipment
available
Materials:
• can be identified & related to test certificates, traceability !
• are of correct dimensions
• are in suitable condition (no damage/contamination)
4/23/2007 13 of 691
14. Typical Duties of a Welding Inspector 1.5
Before Welding
Consumables:
• in accordance with WPS’s
• are being controlled in accordance with Procedure
Weld Preparations:
• comply with WPS/drawing
• free from defects & contamination
Welding Equipment:
• in good order & calibrated as required by Procedure
4/23/2007 14 of 691
15. Typical Duties of a Welding Inspector 1.5
Before Welding
Fit-up
• complies with WPS
• Number / size of tack welds to Code / good
workmanship
Pre-heat
• if specified
• minimum temperature complies with WPS
4/23/2007 15 of 691
16. Typical Duties of a Welding Inspector 1.5
4/23/2007 16 of 691
During Welding
Weather conditions
• suitable if site / field welding
Welding Process(es)
• in accordance with WPS
Welder
• is approved to weld the joint
Pre-heat (if required)
• minimum temperature as specified by WPS
• maximum interpass temperature as WPS
17. Typical Duties of a Welding Inspector 1.6
During Welding
Welding consumables
• in accordance with WPS
• in suitable condition
• controlled issue and handling
Welding Parameters
• current, voltage & travel speed – as WPS
Root runs
• if possible, visually inspect root before single-sided welds are
filled up
4/23/2007 17 of 691
18. Typical Duties of a Welding Inspector 1.6
During Welding
Inter-run cleaning
in accordance with an approved method (& back gouging) to
good workmanship standard
Distortion control
• welding is balanced & over-welding is avoided
4/23/2007 18 of 691
19. Typical Duties of a Welding Inspector 1.6
4/23/2007 19 of 691
After Welding
Weld Identification
• identified/numbered as required
• is marked with welder‟s identity
Visual Inspection
• ensure weld is suitable for all NDT
• visually inspect & „sentence‟ to Code requirements
Dimensional Survey
• ensure dimensions comply with Code/drawing
Other NDT
• ensure all NDT is completed & reports available
20. Typical Duties of a Welding Inspector 1.6
After Welding
Repairs
• monitor repairs to ensure compliance with Procedure, ensure
NDT after repairs is completed
• PWHT
• monitor for compliance with Procedure
• check chart records confirm Procedure compliance
Pressure / Load Test
• ensure test equipment is suitably calibrated
• monitor to ensure compliance with Procedure
• ensure all records are available
4/23/2007 20 of 691
21. Typical Duties of a Welding Inspector 1.6
After Welding
Documentation
• ensure any modifications are on ‘as-built’ drawings
• ensure all required documents are available
• Collate / file documents for manufacturing records
• Sign all documentation and forward it to QC department.
4/23/2007 21 of 691
22. Summary of Duties
A Welding Inspector must:
• Observe
To observe all relevant actions related to weld quality throughout
production.
• Record
To record, or log all production inspection points relevant to quality,
including a final report showing all identified imperfections
• Compare
To compare all recorded information with the acceptance criteria
and any other relevant clauses in the applied application standard
4/23/2007 22 of 691
It is the duty of a Welding Inspector to ensure all the welding and
associated actions are carried out in accordance with the
specification and any applicable procedures.
24. Welding Terminology & Definitions 2.1
4/23/2007 24 of 691
What is a Weld?
• A localised coalescence of metals or non-metals produced
either by heating the materials to the welding temperature,
with or without the application of pressure, or by the
application of pressure alone (AWS)
• A permanent union between materials caused by heat, and
or pressure (BS499)
• An Autogenous weld:
A weld made with out the use of a filler material and can
only be made by TIG or Oxy-Gas Welding
25. Welding Terminology & Definitions 2.1
What is a Joint?
• The junction of members or the edges of members that are
to be joined or have been joined (AWS)
• A configuration of members (BS499)
4/23/2007 25 of 691
30. Butt Preparations – Sizes 2.4
4/23/2007 30 of 691
Full Penetration Butt Weld
Partial Penetration Butt Weld
Design Throat
Thickness
Design Throat
Thickness
Actual Throat
Thickness
Actual Throat
Thickness
31. 4/23/2007 31 of 691
Weld Zone Terminology 2.5
Weld
Boundary
C
A B
D
Heat
Affected
Zone
Root
Weld
metal
A, B, C & D = Weld Toes
Face
32. Weld Zone Terminology 2.5
4/23/2007 32 of 691
Excess Root
Penetration
Excess
Cap height
or Weld
Reinforcement
Weld cap width
Design
Throat
Thickness
Actual Throat
Thickness
33. Heat Affected Zone (HAZ) 2.5
4/23/2007 33 of 691
tempered zone
grain growth zone
recrystallised zone
partially transformed zone
Maximum
Temperature
solid-liquid Boundarysolid
weld
metal
unaffected base
material
34. Joint Preparation Terminology 2.7
4/23/2007 34 of 691
Included angle
Root Gap
Root Face
Angle of
bevel
Root Face
Root Gap
Included angle
Root
Radius
Single-V Butt Single-U Butt
35. Joint Preparation Terminology 2.8 & 2.9
4/23/2007 35 of 691
Root Gap
Root Face Root FaceRoot Gap
Root
Radius
Single Bevel Butt Single-J Butt
Angle of bevel Angle of bevel
Land
36. Single Sided Butt Preparations 2.10
4/23/2007 36 of 691
Single Bevel Single Vee
Single-J Single-U
Single sided preparations are normally made on thinner materials, or
when access form both sides is restricted
37. Double Sided Butt Preparations2.11
4/23/2007 37 of 691
Double sided preparations are normally made on thicker materials, or
when access form both sides is unrestricted
-VeeDouble-BevelDouble
- JDouble - UDouble
38. Weld Preparation
4/23/2007 38 of 691
Terminology & Typical Dimensions: V-Joints
bevel angle
root face
root gap
included angle
Typical Dimensions
bevel angle 30 to 35°
root face ~1.5 to ~2.5mm
root gap ~2 to ~4mm
39. Butt Weld - Toe Blend
4/23/2007 39 of 691
6 mm
80
Poor Weld Toe Blend Angle
Improved Weld Toe Blend
Angle
20
3 mm
•Most codes quote the weld
toes shall blend smoothly
•This statement is not
quantitative and therefore
open to individual
interpretation
•The higher the toe blend
angle the greater the
amount of stress
concentration
•The toe blend angle ideally
should be between 20o-30o
40. Fillet Weld Features 2.13
4/23/2007 40 of 691
Design
Throat
Vertical
Leg
Length
Horizontal leg
Length
Excess
Weld
Metal
41. Fillet Weld Throat Thickness 2.13
4/23/2007 41 of 691
b
a
b = Actual Throat Thickness
a = Design Throat Thickness
42. Deep Penetration Fillet Weld Features2.13
4/23/2007 42 of 691
b
a
b = Actual Throat Thickness
a = Design Throat Thickness
43. Fillet Weld Sizes 2.14
Calculating Throat Thickness from a known Leg Length:
Design Throat Thickness = Leg Length x 0.7
Question: The Leg length is 14mm.
What is the Design Throat?
Answer: 14mm x 0.7 = 10mm Throat Thickness
4/23/2007 43 of 691
44. Fillet Weld Sizes 2.14
Calculating Leg Length from a known Design Throat
Thickness:
Leg Length = Design Throat Thickness x 1.4
Question: The Design Throat is 10mm.
What is the Leg length?
Answer: 10mm x 1.4 = 14mm Leg Length
4/23/2007 44 of 691
45. Features to Consider 2 2.14
Importance of Fillet Weld Leg Length Size
4/23/2007 45 of 691
Approximately the same weld volume in both Fillet
Welds, but the effective throat thickness has been
altered, reducing considerably the strength of weld B
2mm
(b)
4mm
8mm
(a)
4mm
46. Fillet Weld Sizes 2.14
Importance of Fillet weld leg length Size
4/23/2007 46 of 691
Area = 4 x 4 =
8mm2
2
Area = 6 x 6 =
18mm2
2
The c.s.a. of (b) is over double the area of (a) without the extra
excess weld metal being added
4mm 6mm
(a) (b)
4mm 6mm
(a) (b)
Excess
Excess
47. 4/23/2007 47 of 691
Fillet Weld Profiles 2.15
Mitre Fillet Convex Fillet
Concave Fillet
A concave profile
is preferred for
joints subjected to
fatigue loading
Fillet welds - Shape
48. EFFECTIVE THROAT THICKNESS
4/23/2007 48 of 691
“s” = Effective throat thickness
sa
“a” = Nominal throat thickness
Deep penetration fillet welds from high heat
input welding process MAG, FCAW & SAW etc
Fillet Features to Consider 2.15
51. Welding position designation2.17
Butt welds in plate (see ISO 6947)
4/23/2007 51 of 691
Flat - PA Overhead - PE
Vertical
up - PF
Vertical
down - PG
Horizontal - PC
52. Welding position designation 2.17
Butt welds in pipe (see ISO 6947)
4/23/2007 52 of 691
Flat - PA
axis: horizontal
pipe: rotated
H-L045
axis: inclined at 45°
pipe: fixed
Horizontal - PC
axis: vertical
pipe: fixed
Vertical up - PF
axis: horizontal
pipe: fixed
Vertical down - PG
axis: horizontal
pipe: fixed
J-L045
axis: inclined at 45°
pipe: fixed
53. Welding position designation2.17
Fillet welds on plate (see ISO 6947)
4/23/2007 53 of 691
Flat - PA Overhead - PD
Vertical up - PF Vertical down - PG
Horizontal - PB
54. Welding position designation 2.17
Fillet welds on pipe (see ISO 6947)
4/23/2007 54 of 691
Flat - PA
axis: inclined at 45°
pipe: rotated
Overhead - PD
axis: vertical
pipe: fixed
Vertical up - PF
axis: horizontal
pipe: fixed
Vertical down - PG
axis: horizontal
pipe: fixed
Horizontal - PB
axis: vertical
pipe: fixed
Horizontal - PB
axis: horizontal
pipe: rotated
55. 4/23/2007 55 of 691
Plate/Fillet Weld Positions2.17
PA / 1G
PA / 1F
PC / 2G
PB / 2F
PD / 4F
PE / 4G PG / 3G
PF / 3G
57. Travel Speed Measurement2.18
4/23/2007 57 of 691
Definition: the rate of weld progression
measured in case of mechanised and automatic
welding processes
in case of MMA can be determined using ROL and arc
time
59. Welding Imperfections 3.1
4/23/2007 59 of 691
All welds have imperfections
• Imperfections are classed as defects when they are of a
type, or size, not allowed by the Acceptance Standard
A defect is an unacceptable imperfection
• A weld imperfection may be allowed by one Acceptance
Standard but be classed as a defect by another Standard
and require removal/rectification
60. Welding Imperfections 3.1
4/23/2007 60 of 691
Standards for Welding Imperfections
BS EN ISO 6520-1(1998) Welding and allied processes –
Classification of geometric
imperfections in metallic materials -
Part 1: Fusion welding
Imperfections are classified into 6 groups, namely:
1 Cracks
2 Cavities
3 Solid inclusions
4 Lack of fusion and penetration
5 Imperfect shape and dimensions
6 Miscellaneous imperfections
61. Welding Imperfections 3.1
4/23/2007 61 of 691
Standards for Welding Imperfections
EN ISO 5817 (2003) Welding - Fusion-welded joints in steel,
nickel, titanium and their alloys (beam
welding excluded) - Quality levels for
imperfections
This main imperfections given in EN ISO 6520-1 are listed in
EN ISO 5817 with acceptance criteria at 3 levels, namely
Level B (highest)
Level C (intermediate)
Level D (general)
This Standard is „directly applicable to visual testing of welds‟
...(weld surfaces & macro examination)
63. Cracks 3.1
Cracks that may occur in welded materials are
caused generally by many factors and may be
classified by shape and position.
Note: Cracks are classed as Planar Defects.
4/23/2007 63 of 691
Classified by Shape
•Longitudinal
•Transverse
•Chevron
•Lamellar Tear
Classified by Position
•HAZ
•Centerline
•Crater
•Fusion zone
•Parent metal
64. Cracks 3.1
4/23/2007 64 of 691
Longitudinal parent metal
Longitudinal weld metal
Lamellar tearing
Transverse weld metal
67. Cracks 3.2
Solidification Cracking
• Occurs during weld solidification process
• Steels with high sulphur impurities content (low ductility
at elevated temperature)
• Requires high tensile stress
• Occur longitudinally down centre of weld
4/23/2007 67 of 691
68. Cracks 3.3
Hydrogen Induced Cold Cracking
• Requires susceptible hard grain structure, stress, low
temperature and hydrogen
• Hydrogen enters weld via welding arc mainly as result of
contaminated electrode or preparation
• Hydrogen diffuses out into parent metal on cooling
• Cracking developing most likely in HAZ
4/23/2007 68 of 691
69. Lamellar Tearing3.5
• Location: Parent metal
• Steel Type: Any steel type possible
• Susceptible Microstructure: Poor through thickness ductility
• Lamellar tearing has a step like appearance due to the solid
inclusions in the parent material (e.g. sulphides and
silicates) linking up under the influence of welding stresses
• Low ductile materials in the short transverse direction
containing high levels of impurities are very susceptible to
lamellar tearing
• It forms when the welding stresses act in the short
transverse direction of the material (through thickness
direction)
4/23/2007 69 of 691
70. Gas Cavities 3.6
4/23/2007 70 of 691
Root piping
Cluster porosityGas pore
Blow hole
Herringbone porosity
Gas pore <1.5mm
Blow hole.>1.6mm
Causes:
•Loss of gas shield
•Damp electrodes
•Contamination
•Arc length too large
•Damaged electrode flux
•Moisture on parent material
•Welding current too low
74. 4/23/2007 74 of 691
Crater pipe is a shrinkage defect and not a gas defect, it has
the appearance of a gas pore in the weld crater
Causes:
• Too fast a cooling
rate
• Deoxidization
reactions and
liquid to solid
volume change
• Contamination
Crater cracks
(Star cracks)
Crater pipe
Crater Pipe 3.9
75. Solid Inclusions3.10
Slag inclusions are defined as a non-metallic inclusion caused
by some welding process
4/23/2007 75 of 691
Causes:
•Slag originates from
welding flux
•MAG and TIG welding
process produce silica
inclusions
•Slag is caused by
inadequate cleaning
•Other inclusions include
tungsten and copper
inclusions from the TIG
and MAG welding process
Slag inclusions
Parallel slag lines
Lack of sidewall
fusion with
associated slag
Lack of interun
fusion + slag
77. Welding Imperfections 3.13
4/23/2007 77 of 691
Typical Causes of Lack of Fusion:
• welding current too low
• bevel angle too steep
• root face too large (single-sided weld)
• root gap too small (single-sided weld)
• incorrect electrode angle
• linear misalignment
• welding speed too high
• welding process related – particularly dip-transfer GMAW
• flooding the joint with too much weld metal (blocking Out)
83. Surface and Profile 3.19
4/23/2007 83 of 691
Incomplete filled groove Poor cap profile
Excessive cap height
Poor cap profiles and
excessive cap reinforcements
may lead to stress
concentration points at the
weld toes and will also
contribute to overall poor toe
blend
84. Surface and Profile 3.19
4/23/2007 84 of 691
Incomplete filled grooveExcess cap reinforcement
86. Overlap 3.21
4/23/2007 86 of 691
An imperfection at the toe or root of a weld caused by metal
flowing on to the surface of the parent metal without fusing to it
Causes:
•Contamination
•Slow travel speed
•Incorrect welding
technique
•Current too low
88. Set-Up Irregularities 3.22
4/23/2007 88 of 691
Plate/pipe Linear Misalignment
(Hi-Lo)
Angular Misalignment
Linear misalignment is
measured from the lowest
plate to the highest point.
Angular misalignment is
measured in degrees
91. 4/23/2007 91 of 691
Lack of sidewall fusion + incomplete filled groove
Incomplete Groove3.23
92. 4/23/2007 92 of 691
Concave Root
Causes:
• Excessive back purge
pressure during TIG welding
Excessive root bead grinding
before the application of the
second pass
welding current too high for
2nd pass overhead welding
root gap too large - excessive
„weaving‟
A shallow groove, which may occur in the root of a butt weld
Weld Root Imperfections3.24
95. 4/23/2007 95 of 691
Causes:
• High Amps/volts
• Small Root face
• Large Root Gap
• Slow Travel
SpeedBurn through
A localized collapse of the weld pool due to excessive
penetration resulting in a hole in the root run
Weld Root Imperfections 3.25
97. 4/23/2007 97 of 691
Causes:
• Loss or insufficient
back purging gas (TIG)
• Most commonly occurs
when welding stainless
steels
• Purging gases include
argon, helium and
occasionally nitrogen
Oxidized Root (Root Coking)
98. 4/23/2007 98 of 691
Miscellaneous Imperfections 3.26
Arc strike
Causes:
• Accidental striking of the
arc onto the parent
material
• Faulty electrode holder
• Poor cable insulation
• Poor return lead
clamping
99. Miscellaneous Imperfections3.27
4/23/2007 99 of 691
Causes:
• Excessive current
• Damp electrodes
• Contamination
• Incorrect wire feed
speed when welding
with the MAG welding
process
• Arc blowSpatter
100. Mechanical Damage3.28
Mechanical damage can be defined as any surface material
damage cause during the manufacturing process.
4/23/2007 100 of 691
• Grinding
• Hammering
• Chiselling
• Chipping
• Breaking off welded attachments
(torn surfaces)
• Using needle guns to compress
weld capping runs
103. Qualitative and Quantitative Tests4.1
The following mechanical tests have units and are termed
quantitative tests to measure Mechanical Properties
• Tensile tests (Transverse Welded Joint, All Weld Metal)
• Toughness testing (Charpy, Izod, CTOD)
• Hardness tests (Brinell, Rockwell, Vickers)
The following mechanical tests have no units and are termed
qualitative tests for assessing joint quality
• Macro testing
• Bend testing
• Fillet weld fracture testing
• Butt weld nick-break testing
4/23/2007 104 of 691
104. Mechanical Test Samples 4.1
4/23/2007 105 of 691
Tensile Specimens
Fracture Fillet
Specimen
CTOD Specimen
Charpy Specimen
Bend Test
Specimen
105. Destructive Testing4.1
4/23/2007 106 of 691
Typical Positions for Test
Pieces
Specimen Type Position
•Macro + Hardness 5
•Transverse Tensile 2, 4
•Bend Tests 2, 4
•Charpy Impact Tests 3
•Additional Tests 3
WELDING PROCEDURE QUALIFICATION TESTING
2
3
4
5
top of fixed pipe
106. Definitions
4/23/2007 107 of 691
• Malleability
• Ductility
• Toughness
• Hardness
• Tensile Strength
Ability of a material to
withstand deformation
under static compressive
loading without rupture
Mechanical Properties of metals are related to the amount of
deformation which metals can withstand under different
circumstances of force application.
107. Definitions
4/23/2007 108 of 691
• Malleability
• Ductility
• Toughness
• Hardness
• Tensile Strength
Ability of a material
undergo plastic
deformation under static
tensile loading without
rupture. Measurable
elongation and reduction
in cross section area
Mechanical Properties of metals are related to the amount of
deformation which metals can withstand under different
circumstances of force application.
108. Definitions
4/23/2007 109 of 691
• Malleability
• Ductility
• Toughness
• Hardness
• Tensile Strength
Ability of a material to
withstand bending or the
application of shear
stresses by impact loading
without fracture.
Mechanical Properties of metals are related to the amount of
deformation which metals can withstand under different
circumstances of force application.
109. Definitions
4/23/2007 110 of 691
• Malleability
• Ductility
• Toughness
• Hardness
• Tensile Strength
Measurement of a
materials surface
resistance to indentation
from another material by
static load
Mechanical Properties of metals are related to the amount of
deformation which metals can withstand under different
circumstances of force application.
110. Definitions
4/23/2007 111 of 691
• Malleability
• Ductility
• Toughness
• Hardness
• Tensile Strength
Measurement of the
maximum force required to
fracture a materials bar of
unit cross-sectional area in
tension
Mechanical Properties of metals are related to the amount of
deformation which metals can withstand under different
circumstances of force application.
111. Transverse Joint Tensile Test4.2
Weld on plate
4/23/2007 112 of 691
Multiple cross joint
specimensWeld on pipe
115. Charpy V-Notch Impact Test4.5
4/23/2007 116 of 691
Objectives:
• measuring impact strength in different weld joint areas
• assessing resistance toward brittle fracture
Information to be supplied on the test report:
• Material type
• Notch type
• Specimen size
• Test temperature
• Notch location
• Impact Strength Value
116. Ductile / Brittle Transition Curve4.6
4/23/2007 117 of 691
- 50 0- 20 - 10- 40 - 30
Ductile fracture
Ductile/Brittle
transition
point
47 Joules
28 Joules
Testing temperature - Degrees Centigrade
Temperature range
Transition range
Brittle fracture
Three specimens are normally tested at each temperature
Energy absorbed
117. Comparison Charpy Impact Test Results4.6
4/23/2007 118 of 691
Impact Energy Joules
Room Temperature -20oC Temperature
1. 197 Joules
2. 191 Joules
3. 186 Joules
1. 49 Joules
2. 53 Joules
3. 51 Joules
Average = 191 Joules Average = 51 Joules
The test results show the specimens carried out at room
temperature absorb more energy than the specimens carried
out at -20oC
118. Charpy V-notch impact test specimen4.7
4/23/2007 119 of 691
Specimen dimensions according ASTM E23
ASTM: American Society of Testing Materials
119. Charpy V-Notch Impact Test 4.8
4/23/2007 120 of 691
Specime
n
Pendulu
m
(striker)
Anvil (support)
121. Hardness Testing4.10
4/23/2007 122 of 691
Definition
Measurement of resistance of a material against
penetration of an indenter under a constant load
There is a direct correlation between UTS and
hardness
Hardness tests:
Brinell
Vickers
Rockwell
122. Hardness Testing 4.10
4/23/2007 123 of 691
Objectives:
• measuring hardness in different areas of a welded joint
• assessing resistance toward brittle fracture, cold cracking
and corrosion sensitivity within a H2S (Hydrogen Sulphide)
environment.
Information to be supplied on the test report:
• material type
• location of indentation
• type of hardness test and load applied on the indenter
• hardness value
123. Vickers Hardness Test 4.11
4/23/2007 124 of 691
Vickers hardness tests:
indentation body is a square based diamond pyramid
(136º included angle)
the average diagonal (d) of the impression is
converted to a hardness number from a table
it is measured in HV5, HV10 or HV025
Adjustable
shuttersIndentationDiamond
indentor
125. Brinell Hardness Test 4.11
4/23/2007 126 of 691
• Hardened steel ball of given diameter is subjected for
a given time to a given load
• Load divided by area of indentation gives Brinell
hardness in kg/mm2
• More suitable for on site hardness testing
30KN
Ø=10mm
steel ball
127. Hardness Testing 4.12
4/23/2007 128 of 691
Hardness Test Methods Typical Designations
Vickers 240 HV10
Rockwell Rc 22
Brinell 200 BHN-W
usually the hardest region
1.5 to 3mm
HAZ
fusion line
or
fusion
boundary
Hardness specimens can also be used for CTOD samples
128. Crack Tip Opening Displacement testing 4.12
• Test is for fracture toughness
• Square bar machined with a notch placed in
the centre.
• Tested below ambient temperature at a
specified temperature.
• Load is applied at either end of the test
specimen in an attempt to open a crack at the
bottom of the notch
• Normally 3 samples
4/23/2007 129 of 691
129. Fatigue Fracture4.13
4/23/2007 130 of 691
Location: Any stress concentration area
Steel Type: All steel types
Susceptible Microstructure: All grain structures
Test for Fracture Toughness is CTOD
(Crack Tip Opening Displacement)
130. Fatigue Fracture4.13
4/23/2007 131 of 691
• Fatigue cracks occur under cyclic stress conditions
• Fracture normally occurs at a change in section, notch
and weld defects i.e stress concentration area
• All materials are susceptible to fatigue cracking
• Fatigue cracking starts at a specific point referred to as
a initiation point
• The fracture surface is smooth in appearance
sometimes displaying beach markings
• The final mode of failure may be brittle or ductile or a
combination of both
131. Fatigue Fracture
4/23/2007 132 of 691
• Toe grinding, profile grinding.
• The elimination of poor profiles
• The elimination of partial penetration welds and weld
defects
• Operating conditions under the materials endurance limits
• The elimination of notch effects e.g. mechanical damage
cap/root undercut
• The selection of the correct material for the service
conditions of the component
Precautions against Fatigue Cracks
132. Fatigue Fracture
Fatigue fracture occurs in structures subject to repeated
application of tensile stress.
Crack growth is slow (in same cases, crack may grow into an
area of low stress and stop without failure).
4/23/2007 133 of 691
133. Fatigue Fracture
4/23/2007 134 of 691
Initiation points / weld defects
Fatigue fracture surface
smooth in appearance
Secondary mode of failure
ductile fracture rough fibrous
appearance
134. Fatigue Fracture
• Crack growth is slow
• It initiate from stress concentration points
• load is considerably below the design or yield stress level
• The surface is smooth
• The surface is bounded by a curve
• Bands may sometimes be seen on the smooth surface –”beachmarks”.
They show the progress of the crack front from the point of origin
• The surface is 90° to the load
• Final fracture will usually take the form of gross yielding (as the
maximum stress in the remaining ligament increase!)
• Fatigue crack need initiation + propagation periods
4/23/2007 135 of 691
Fatigue fracture distinguish features:
135. Bend Tests 4.15
4/23/2007 136 of 691
Object of test:
• To determine the soundness of the weld zone. Bend
testing can also be used to give an assessment of
weld zone ductility.
• There are three ways to perform a bend test:
Root bend
Face bend
Side bend
Side bend tests are normally carried out on welds over 12mm in thickness
136. Bending test4.16
Types of bend test for welds (acc. BS EN 910):
4/23/2007 137 of 691
Thickness of material - “t”
“t” up to 12 mm
“t” over 12 mm
Root / face
bend
Side bend
137. Fillet Weld Fracture Tests 4.17
Object of test:
• To break open the joint through the weld to permit
examination of the fracture surfaces
• Specimens are cut to the required length
• A saw cut approximately 2mm in depth is applied along
the fillet welds length
• Fracture is usually made by striking the specimen with a
single hammer blow
• Visual inspection for defects
4/23/2007 138 of 691
138. Fillet Weld Fracture Tests4.17
4/23/2007 139 of 691
Fracture should break weld saw cut to root
2mm
Notch
Hammer
139. Fillet Weld Fracture Tests 4.17
4/23/2007 140 of 691
This fracture indicates
lack of fusion
This fracture has
occurred saw cut to root
Lack of Penetration
140. Nick-Break Test4.18
Object of test:
• To permit evaluation of any weld defects across the
fracture surface of a butt weld.
•Specimens are cut transverse to the weld
•A saw cut approximately 2mm in depth is applied along the
welds root and cap
•Fracture is usually made by striking the specimen with a
single hammer blow
•Visual inspection for defects
4/23/2007 141 of 691
141. Nick-Break Test4.18
4/23/2007 142 of 691
Approximately 230 mm
19 mm
2 mm
2 mm
Notch cut by hacksaw
Weld reinforcement
may or may not be
removed
142. Nick Break Test 4.18
4/23/2007 143 of 691
Inclusions on fracture
line
Lack of root penetration
or fusion
Alternative nick-break test
specimen, notch applied all
way around the specimen
143. 4/23/2007 144 of 691
We test welds to establish minimum levels of mechanical
properties, and soundness of the welded joint
We divide tests into Qualitative & Quantitative methods:
Qualitative: (Have no units/numbers)
For assessing joint quality
Macro tests
Bend tests
Fillet weld fracture tests
Butt Nick break tests
Quantitative: (Have units/numbers)
To measure mechanical properties
Hardness (VPN & BHN)
Toughness (Joules & ft.lbs)
Strength (N/mm2 & PSI, MPa)
Ductility / Elongation (E%)
Summary of Mechanical Testing4.19
145. 4/23/2007 146 of 691
Welding Procedure Qualification5.1
Question:
What is the main reason for carrying out a Welding Procedure
Qualification Test ?
(What is the test trying to show ?)
Answer:
To show that the welded joint has the properties* that satisfy
the design requirements (fit for purpose)
* properties
•mechanical properties are the main interest - always strength but
toughness & hardness may be important for some applications
•test also demonstrates that the weld can be made without defects
146. Welding Procedures5.1
4/23/2007 147 of 691
Producing a welding procedure involves:
• Planning the tasks
• Collecting the data
• Writing a procedure for use of for trial
• Making a test welds
• Evaluating the results
• Approving the procedure
• Preparing the documentation
147. Welding Procedures 5.2
4/23/2007 148 of 691
In most codes reference is made to how the procedure are to
be devised and whether approval of these procedures is
required.
The approach used for procedure approval depends on the
code:
Example codes:
• AWS D.1.1: Structural Steel Welding Code
• BS 2633: Class 1 welding of Steel Pipe Work
• API 1104: Welding of Pipelines
• BS 4515: Welding of Pipelines over 7 Bar
Other codes may not specifically deal with the requirement of
a procedure but may contain information that may be used in
writing a weld procedure
• EN 1011Process of Arc Welding Steels
148. 4/23/2007 149 of 691
The welding engineer writes qualified Welding Procedure
Specifications (WPS) for production welding
Welding Procedure Qualification 5.3
Production welding conditions must remain within the range of
qualification allowed by the WPQR
(according to EN ISO 15614)
149. 4/23/2007 150 of 691
Welding Procedure Qualification5.3
(according to EN Standards)
welding conditions are called welding variables
welding variables are classified by the EN ISO Standard as:
•Essential variables
•Non-essential variables
•Additional variables
Note: additional variables = ASME supplementary essential
The range of qualification for production welding is based on
the limits that the EN ISO Standard specifies for essential
variables*
(* and when applicable - the additional variables)
150. 4/23/2007 151 of 691
Welding Procedure Qualification5.3
(according to EN Standards)
WELDING ESSENTIAL VARIABLES
Question:
Why are some welding variables classified as essential ?
Answer:
A variable, that if changed beyond certain limits (specified by
the Welding Standard) may have a significant effect on the
properties* of the joint
* particularly joint strength and ductility
151. 4/23/2007 152 of 691
Welding Procedure Qualification5.3
(according to EN Standards)
SOME TYPICAL ESSENTIAL VARIABLES
• Welding Process
• Post Weld Heat Treatment (PWHT)
• Material Type
• Electrode Type, Filler Wire Type (Classification)
• Material Thickness
• Polarity (AC, DC+ve / DC-ve)
• Pre-Heat Temperature
• Heat Input
• Welding Position
152. Welding Procedures5.3
Components of a welding procedure
Parent material
• Type (Grouping)
• Thickness
• Diameter (Pipes)
• Surface condition)
Welding process
• Type of process (MMA, MAG, TIG, SAW etc)
• Equipment parameters
• Amps, Volts, Travel speed
Welding Consumables
• Type of consumable/diameter of consumable
• Brand/classification
• Heat treatments/ storage
4/23/2007 153 of 691
153. Welding Procedures5.3
Components of a welding procedure
Joint design
•Edge preparation
•Root gap, root face
•Jigging and tacking
•Type of baking
Welding Position
•Location, shop or site
•Welding position e.g. 1G, 2G, 3G etc
•Any weather precaution
Thermal heat treatments
•Preheat, temps
•Post weld heat treatments e.g. stress relieving
4/23/2007 154 of 691
154. Welding Procedures5.3
4/23/2007 155 of 691
Object of a welding procedure test
To give maximum confidence that the welds mechanical
and metallurgical properties meet the requirements of the
applicable code/specification.
Each welding procedure will show a range to which the
procedure is approved (extent of approval)
If a customer queries the approval evidence can be
supplied to prove its validity
156. 4/23/2007 157 of 691
Example:
Welding
Procedure
Specification
(WPS)
157. Welder Qualification5.4
4/23/2007 158 of 691
Numerous codes and standards deal with welder qualification,
e.g. BS EN 287.
• Once the content of the procedure is approved the next
stage is to approve the welders to the approved procedure.
• A welders test know as a Welders Qualification Test (WQT).
Object of a welding qualification test:
• To give maximum confidence that the welder meets the
quality requirements of the approved procedure (WPS).
• The test weld should be carried out on the same material and
same conditions as for the production welds.
158. 4/23/2007 159 of 691
Welder Qualification 5.4 & 5.5
(according to EN Standards)
Question:
What is the main reason for qualifying a welder ?
Answer:
To show that he has the skill to be able to make production
welds that are free from defects
Note: when welding in accordance with a Qualified WPS
159. 4/23/2007 160 of 691
The welder is allowed to make production welds within the
range of qualification shown on the Certificate
The range of qualification allowed for production welding is
based on the limits that the EN Standard specifies for the
welder qualification essential variables
Welder Qualification 5.5
(according to EN 287 )
A Certificate may be withdrawn by the Employer if there is
reason to doubt the ability of the welder, for example
• a high repair rate
• not working in accordance with a qualified WPS
The qualification shall remain valid for 2 years provided there is certified
confirmation of welding to the WPS in that time.
A Welder‟s Qualification Certificate automatically expires if the welder has not
used the welding process for 6 months or longer.
160. 4/23/2007 161 of 691
Welding Engineer writes a preliminary Welding Procedure
Specification (pWPS) for each test weld to be made
• A welder makes a test weld in accordance with the pWPS
• A welding inspector records all the welding conditions used
for the test weld (referred to as the „as-run‟ conditions)
An Independent Examiner/ Examining Body/ Third Party
inspector may be requested to monitor the qualification
process
Welding Procedure Qualification5.7
(according to EN ISO 15614)
The finished test weld is subjected to NDT in accordance with
the methods specified by the EN ISO Standard - Visual, MT or
PT & RT or UT
161. 4/23/2007 162 of 691
Welding Procedure Qualification 5.7
Test weld is subjected to destructive testing (tensile, bend,
macro)
The Application Standard, or Client, may require additional
tests such as impact tests, hardness tests (and for some
materials - corrosion tests)
(according to EN ISO 15614)
A Welding Procedure Qualification Record (WPQR) is prepared
giving details of: -
• The welding conditions used for the test weld
• Results of the NDT
• Results of the destructive tests
• The welding conditions that the test weld allows for
production welding
The Third Party may be requested to sign the WPQR as a true
record
162. Welder Qualification5.9
4/23/2007 163 of 691
(according to EN 287 )
An approved WPS should be available covering the range of
qualification required for the welder approval.
• The welder qualifies in accordance with an approved WPS
• A welding inspector monitors the welding to make sure that the
welder uses the conditions specified by the WPS
EN Welding Standard states that an Independent Examiner,
Examining Body or Third Party Inspector may be required to
monitor the qualification process
163. 4/23/2007 164 of 691
The finished test weld is subjected to NDT by the methods
specified by the EN Standard - Visual, MT or PT & RT or UT
The test weld may need to be destructively tested - for certain
materials and/or welding processes specified by the EN
Standard or the Client Specification
Welder Qualification5.9
(according to EN 287 )
• A Welder‟s Qualification Certificate is prepared showing the
conditions used for the test weld and the range of qualification
allowed by the EN Standard for production welding
• The Qualification Certificate is usually endorsed by a Third
Party Inspector as a true record of the test
164. Welder Qualification5.10
4/23/2007 165 of 691
Information that should be included on a welders test certificate are,
which the welder should have or have access to a copy of !
• Welders name and identification number
• Date of test and expiry date of certificate
• Standard/code e.g. BS EN 287
• Test piece details
• Welding process.
• Welding parameters, amps, volts
• Consumables, flux type and filler classification details
• Sketch of run sequence
• Welding positions
• Joint configuration details
• Material type qualified, pipe diameter etc
• Test results, remarks
• Test location and witnessed by
• Extent (range) of approval
166. Material Inspection
One of the most important items to consider is Traceability.
The materials are of little use if we can not, by use of an effective QA
system trace them from specification and purchase order to final
documentation package handed over to the Client.
All materials arriving on site should be inspected for:
• Size / dimensions
• Condition
• Type / specification
In addition other elements may need to be considered depending on
the materials form or shape
4/23/2007 168 of 691
167. Pipe Inspection
4/23/2007 169 of 691
We inspect the condition
(Corrosion, Damage, Wall thickness Ovality, Laminations & Seam)
Specification
Welded
seam
Size
LP5
Other checks may need to be made such as: distortion tolerance,
number of plates and storage.
168. Plate Inspection
4/23/2007 170 of 691
Size
We inspect the condition
(Corrosion, Mechanical damage, Laps, Bands &
Laminations)
5L
Specification
Other checks may need to be made such as: distortion
tolerance, number of plates and storage.
169. 4/23/2007 171 of 691
Parent Material Imperfections
Lamination
Mechanical damage Lap
Segregation line
Laminations are caused in the parent plate by the steel making
process, originating from ingot casting defects.
Segregation bands occur in the centre of the plate and are low
melting point impurities such as sulphur and phosphorous.
Laps are caused during rolling when overlapping metal does not
fuse to the base material.
174. Codes & Standards
4/23/2007 176 of 691
The 3 agencies generally identified in a code or standard:
The customer, or client
The manufacturer, or contractor
The 3rd party inspection, or clients representative
Codes often do not contain all relevant data, but may
refer to other standards
177. Weld symbols on drawings
Advantages of symbolic representation:
• simple and quick plotting on the drawing
• does not over-burden the drawing
• no need for additional view
• gives all necessary indications regarding the specific joint to
be obtained
Disadvantages of symbolic representation:
• used only for usual joints
• requires training for properly understanding of symbols
4/23/2007 179 of 691
178. Weld symbols on drawings
The symbolic representation includes:
• an arrow line
• a reference line
• an elementary symbol
The elementary symbol may be completed by:
• a supplementary symbol
• a means of showing dimensions
• some complementary indications
4/23/2007 180 of 691
179. Dimensions
4/23/2007 181 of 691
In most standards the cross sectional dimensions are given to
the left side of the symbol, and all linear dimensions are give on
the right side
Convention of dimensions
a = Design throat thickness
s = Depth of Penetration, Throat thickness
z = Leg length (min material thickness)
BS EN ISO 22553
AWS A2.4
•In a fillet weld, the size of the weld is the leg length
•In a butt weld, the size of the weld is based on the depth of the
joint preparation
180. 4/23/2007 182 of 691
A method of transferring information from the
design office to the workshop is:
The above information does not tell us much about the wishes
of the designer. We obviously need some sort of code which
would be understood by everyone.
Most countries have their own standards for symbols.
Some of them are AWS A2.4 & BS EN 22553 (ISO 2553)
Please weld
here
Weld symbols on drawings
181. 4/23/2007 183 of 691
Joints in drawings may be indicated:
•by detailed sketches, showing every dimension
•by symbolic representation
Weld symbols on drawings
182. Elementary Welding Symbols
(BS EN ISO 22553 & AWS A2.4)
Convention of the elementary symbols:
Various categories of joints are characterised by an elementary symbol.
The vertical line in the symbols for a fillet weld, single/double bevel butts
and a J-butt welds must always be on the left side.
4/23/2007 184 of 691
Square edge
butt weld
Weld type Sketch Symbol
Single-v
butt weld
183. Elementary Welding Symbols
4/23/2007 185 of 691
Single-V butt
weld with broad
root face
Weld type Sketch Symbol
Single
bevel butt
weld
Single bevel
butt weld with
broad root
face
Backing run
185. ISO 2553 / BS EN 22553
4/23/2007 187 of 691
Plug weld
Resistance spot weld
Resistance seam weld
Square Butt weld
Steep flanked
Single-V Butt
Surfacing
186. 4/23/2007 188 of 691
Arrow Line
(BS EN ISO 22553 & AWS A2.4):
Convention of the arrow line:
• Shall touch the joint intersection
• Shall not be parallel to the drawing
• Shall point towards a single plate preparation (when only
one plate has preparation)
187. 4/23/2007 189 of 691
(AWS A2.4)
Convention of the reference line:
Shall touch the arrow line
Shall be parallel to the bottom of the drawing
Reference Line
188. 4/23/2007 190 of 691
or
Reference Line
(BS EN ISO 22553)
Convention of the reference line:
• Shall touch the arrow line
• Shall be parallel to the bottom of the drawing
• There shall be a further broken identification line above or
beneath the reference line (Not necessary where the weld
is symmetrical!)
189. 4/23/2007 191 of 691
(BS EN ISO 22553 & AWS A2.4)
Convention of the double side weld symbols:
Representation of welds done from both sides of the joint
intersection, touched by the arrow head
Fillet weld
Double V
Double bevel
Double U
Double J
Double side weld symbols
190. ISO 2553 / BS EN 22553
4/23/2007 192 of 691
Arrow line
Reference lines
Arrow side
Other side Arrow side
Other side
191. ISO 2553 / BS EN 22553
4/23/2007 193 of 691
Single-V Butt flush cap Single-U Butt with sealing run
Single-V Butt with
permanent backing strip
M
Single-U Butt with
removable backing strip
M R
192. ISO 2553 / BS EN 22553
4/23/2007 194 of 691
Single-bevel butt Double-bevel butt
Single-bevel butt Single-J butt
193. ISO 2553 / BS EN 22553
4/23/2007 195 of 691
Partial penetration single-V butt
„S‟ indicates the depth of penetration
s10
10
15
194. ISO 2553 / BS EN 22553
4/23/2007 196 of 691
a = Design throat thickness
s = Depth of Penetration, Throat
thickness
z = Leg length(min material thickness)
a = (0.7 x z)
a 4
4mm Design throat
z 6
6mm leg
a
z s
s 6
6mm Actual throat
195. ISO 2553 / BS EN 22553
4/23/2007 197 of 691
Arrow side
Arrow side
196. ISO 2553 / BS EN 22553
4/23/2007 198 of 691
Other side
Other side
s6
s6
6mm fillet weld
197. ISO 2553 / BS EN 22553
4/23/2007 199 of 691
n = number of weld elements
l = length of each weld element
(e) = distance between each weld element
n x l (e)
Welds to be
staggered
Process
2 x 40 (50)
3 x 40 (50)
111
198. ISO 2553 / BS EN 22553
4/23/2007 200 of 691
80 80 80
909090
6
6
5
5
z5
z6
3 x 80 (90)
3 x 80 (90)
All dimensions in mm
199. ISO 2553 / BS EN 22553
4/23/2007 201 of 691
All dimensions in mm
8
8
6
6
80 80 80
909090
z8
z6
3 x 80 (90)
3 x 80 (90)
200. 4/23/2007 202 of 691
Supplementary symbols
Concave or Convex
Toes to be ground smoothly
(BS EN only)
Site Weld
Weld all round
(BS EN ISO 22553 & AWS A2.4)
Convention of supplementary symbols
Supplementary information such as welding process, weld
profile, NDT and any special instructions
201. 4/23/2007 203 of 691
Supplementary symbols
Further supplementary information, such as WPS number, or
NDT may be placed in the fish tail
Ground flush
111
Welding process
numerical BS EN
MR
Removable
backing strip
Permanent
backing strip
M
(BS EN ISO 22553 & AWS A2.4)
Convention of supplementary symbols
Supplementary information such as welding process, weld profile,
NDT and any special instructions
202. ISO 2553 / BS EN 22553
4/23/2007 204 of 691
ba
dc
203. ISO 2553 / BS EN 22553
4/23/2007 205 of 691
ConvexMitre
Toes
shall be
blended
Concave
204. ISO 2553 / BS EN 22553
4/23/2007 206 of 691
a = Design throat thickness
s = Depth of Penetration, Throat
thickness
z = Leg length(min material thickness)
a = (0.7 x z)
a 4
4mm Design throat
z 6
6mm leg
a
z s
s 6
6mm Actual throat
205. ISO 2553 / BS EN 22553
Complimentary Symbols
4/23/2007 207 of 691
Field weld (site weld)
The component requires
NDT inspection
WPS
Additional information,
the reference document
is included in the box
Welding to be carried out
all round component
(peripheral weld)
NDT
206. ISO 2553 / BS EN 22553
4/23/2007 208 of 691
Numerical Values for Welding Processes:
111: MMA welding with covered electrode
121: Sub-arc welding with wire electrode
131: MIG welding with inert gas shield
135: MAG welding with non-inert gas shield
136: Flux core arc welding
141: TIG welding
311: Oxy-acetylene welding
72: Electro-slag welding
15: Plasma arc welding
215. Welding Processes
4/23/2007 222 of 691
Welding is regarded as a joining process in which the work
pieces are in atomic contact
Pressure welding
• Forge welding
• Friction welding
• Resistance Welding
Fusion welding
• Oxy-acetylene
• MMA (SMAW)
• MIG/MAG (GMAW)
• TIG (GTAW)
• Sub-arc (SAW)
• Electro-slag (ESW)
• Laser Beam (LBW)
• Electron-Beam (EBW)
216. 4/23/2007 225 of 691
20 8040 60 130 140120100 180160 200
10
60
50
40
30
20
80
70
90
100
Normal Operating
Voltage Range
Large voltage variation, e.g. +
10v (due to changes in arc
length)
Small amperage change
resulting in virtually constant
current e.g. + 5A.
Voltage
Amperage
Required for: MMA, TIG, Plasma
arc and SAW > 1000 AMPS
O.C.V. Striking voltage (typical) for
arc initiation
Constant Current Power Source
(Drooping Characteristic)
217. Monitoring Heat Input
• Heat Input:
The amount of heat generated in the
welding arc per unit length of weld.
Expressed in kilo Joules per millimetre
length of weld (kJ/mm).
Heat Input (kJ/mm)= Volts x Amps
Travel speed(mm/s) x 1000
4/23/2007 227 of 691
220. Monitoring Heat Input
• Monitoring Heat Input As Required by
• BS EN ISO 15614-1:2004
• In accordance with EN 1011-1:1998
4/23/2007 230 of 691
When impact requirements and/or hardness requirements are
specified, impact test shall be taken from the weld in the highest
heat input position and hardness tests shall be taken from the
weld in the lowest heat input position in order to qualify for all
positions
223. MMA welding
Main features:
• Shielding provided by decomposition of flux covering
• Electrode consumable
• Manual process
Welder controls:
• Arc length
• Angle of electrode
• Speed of travel
• Amperage settings
4/23/2007 234 of 691
224. Manual Metal Arc Basic Equipment
4/23/2007 235 of 691
Power source
Holding oven
Inverter power
source
Electrode holder
Power cables
Welding visor
filter glass
Return lead
Electrodes
Electrode
oven
Control panel
(amps, volts)
225. MMA Welding Plant
4/23/2007 236 of 691
Transformer:
• Changes mains supply voltage to a voltage suitable for welding.
Has no moving parts and is often termed static plant.
Rectifier:
• Changes a.c. to d.c., can be mechanically or statically achieved.
Generator:
• Produces welding current. The generator consists of an armature
rotating in a magnetic field, the armature must be rotated at a
constant speed either by a motor unit or, in the absence of
electrical power, by an internal combustion engine.
Inverter:
• An inverter changes d.c. to a.c. at a higher frequency.
226. MMA Welding Variables
4/23/2007 237 of 691
Voltage
• The arc voltage in the MMA process is measured as close to
the arc as possible. It is variable with a change in arc length
O.C.V.
• The open circuit voltage is the voltage required to initiate, or
re-ignite the electrical arc and will change with the type of
electrode being used e.g 70-90 volts
Current
• The current used will be determined by the choice of
electrode, electrode diameter and material type and
thickness. Current has the most effect on penetration.
Polarity
• Polarity is generally determined by operation and electrode
type e.g DC +ve, DC –ve or AC
227. 4/23/2007 239 of 691
20 8040 60 130 140120100 180160 200
10
60
50
40
30
20
80
70
90
100
Normal Operating
Voltage Range
Large voltage variation, e.g. +
10v (due to changes in arc
length)
Small amperage change
resulting in virtually constant
current e.g. + 5A.
Voltage
Amperage
O.C.V. Striking voltage (typical) for arc
initiation
Constant Current Power Source
(Drooping Characteristic)
228. MMA welding parameters
Travel speed
4/23/2007 240 of 691
Travel
speed Too highToo low
•wide weld bead contour
•lack of penetration
•burn-through
•lack of root fusion
•incomplete root
penetration
•undercut
•poor bead profile,
difficult slag removal
229. MMA welding parameters
Type of current:
• voltage drop in welding cables is lower with AC
• inductive looses can appear with AC if cables are coiled
• cheaper power source for AC
• no problems with arc blow with AC
• DC provides a more stable and easy to strike arc, especially
with low current, better positional weld, thin sheet applications
• welding with a short arc length (low arc voltage) is easier with
DC, better mechanical properties
• DC provides a smoother metal transfer, less spatter
4/23/2007 241 of 691
230. MMA welding parameters
Welding current
4/23/2007 242 of 691
– approx. 35 A/mm of diameter
– governed by thickness, type of joint and welding
position
Welding
current Too highToo low
•poor starting
•slag inclusions
•weld bead contour too
high
•lack of
fusion/penetration
•spatter
•excess
penetration
•undercut
•burn-through
231. MMA welding parameters
Arc length = arc voltage
4/23/2007 243 of 691
Arc
voltage Too highToo low
•arc can be extinguished
•“stubbing”
•spatter
•porosity
•excess
penetration
•undercut
•burn-through
Polarity: DCEP generally gives deeper penetration
232. MMA - Troubleshooting
4/23/2007 244 of 691
MMA quality (left to right)
current, arc length and travel speed normal;
current too low;
current too high;
arc length too short;
arc length too long;
travel speed too slow;
travel speed too high
234. MMA Welding Consumables
4/23/2007 246 of 691
The three main electrode covering types used in MMA welding
• Cellulosic - deep penetration/fusion
• Rutile - general purpose
• Basic - low hydrogen
(Covered in more detail in Section 14)
MMA Covered Electrodes
235. 4/23/2007 247 of 691
Most welding defects in MMA are caused by a lack of welder
skill (not an easily controlled process), the incorrect settings
of the equipment, or the incorrect use, and treatment of
electrodes
Typical Welding Defects:
•Slag inclusions
•Arc strikes
•Porosity
•Undercut
•Shape defects (overlap, excessive root penetration, etc.)
MMA welding typical defects
236. Manual Metal Arc Welding (MMA)
4/23/2007 248 of 691
Advantages:
• Field or shop use
• Range of consumables
• All positions
• Portable
• Simple equipment
Disadvantages:
• High welder skill required
• High levels of fume
• Hydrogen control (flux)
• Stop/start problems
• Comparatively uneconomic when compared with some
other processes i.e MAG, SAW and FCAW
238. Tungsten Inert Gas Welding
4/23/2007 250 of 691
The TIG welding process was first developed in the USA
during the 2nd world war for the welding of aluminum alloys
• The process uses a non-consumable tungsten electrode
• The process requires a high level of welder skill
• The process produces very high quality welds.
• The TIG process is considered as a slow process compared
to other arc welding processes
• The arc may be initiated by a high frequency to avoid scratch
starting, which could cause contamination of the tungsten
and weld
240. TIG Welding Variables
4/23/2007 254 of 691
Voltage
The voltage of the TIG welding process is variable only by the
type of gas being used, and changes in the arc length
Current
The current is adjusted proportionally to the tungsten
electrodes diameter being used. The higher the current the
deeper the penetration and fusion
Polarity
The polarity used for steels is always DC –ve as most of the
heat is concentrated at the +ve pole, this is required to keep
the tungsten electrode at the cool end of the arc. When
welding aluminium and its alloys AC current is used
241. Types of current
• can be DCEN or DCEP
• DCEN gives deep penetration
• requires special power source
• low frequency - up to 20 pulses/sec
(thermal pulsing)
• better weld pool control
• weld pool partially solidifies
between pulses4/23/2007 256 of 691
Type of
welding
current
can be sine or square wave
requires a HF current (continuos
or periodical)
provide cleaning action
DC
AC
Pulsed
current
242. Choosing the proper electrode
Current type influence
4/23/2007 257 of 691
+
+
+
+
+
+
+
+
+
-
-
-
-
-
-
-
-
-
Electrode capacity
Current type & polarity
Heat balance
Oxide cleaning action
Penetration
DCEN DCEPAC (balanced)
70% at work
30% at electrode
50% at work
50% at electrode
35% at work
65% at electrode
Deep, narrow Medium Shallow, wide
No Yes - every half cycle Yes
Excellent
(e.g. 3,2 mm/400A)
Good
(e.g. 3,2 mm/225A)
Poor
(e.g. 6,4 mm/120A)
243. ARC CHARACTERISTICS
4/23/2007 258 of 691
Volts
Amps
OCV
Constant Current/Amperage Characteristic
Large change in voltage =
Smaller change in amperage
Welding Voltage
Large arc gap
Small arc
gap
244. TIG - arc initiation methods
• simple method
• tungsten electrode is in contact
with the workpiece!
• high initial arc current due to the
short circuit
• impractical to set arc length in
advance
• electrode should tap the
workpiece - no scratch!
• ineffective in case of AC
• used when a high quality is not
essential
4/23/2007 259 of 691
Arc initiation
method
Lift arc HF start
need a HF generator (spark-
gap oscillator) that generates a
high voltage AC output (radio
frequency) costly
reliable method required on
both DC (for start) and AC (to
re-ignite the arc)
can be used remotely
HF produce interference
requires superior insulation
245. Pulsed current
• usually peak current is 2-10 times
background current
• useful on metals sensitive to high heat
input
• reduced distortions
• in case of dissimilar thicknesses equal
penetration can be achieved
4/23/2007 260 of 691
Time
Current(A)
Pulse
time
Cycle
time
Peak
current
Background
current
Average current
one set of variables can be used in all positions
used for bridging gaps in open root joints
require special power source
246. Choosing the proper electrode
Polarity Influence – cathodic cleaning effect
4/23/2007 261 of 691
247. Tungsten Electrodes
4/23/2007 262 of 691
Old types: (Slightly Radioactive)
• Thoriated: DC electrode -ve - steels and most metals
• 1% thoriated + tungsten for higher current values
• 2% thoriated for lower current values
• Zirconiated: AC - aluminum alloys and magnesium
New types: (Not Radioactive)
• Cerium: DC electrode -ve - steels and most metals
• Lanthanum: AC - Aluminum alloys and magnesium
248. TIG torch set-up
• Electrode extension
4/23/2007 263 of 691
Electrode
extension
Stickout 2-3 times
electrode
diameter
Electrode
extension
Low electron
emission
Unstable arc
Too
small
Overheating
Tungsten
inclusions
Too
large
249. Choosing the correct electrode
Polarity Influence – cathodic cleaning effect
4/23/2007 264 of 691
250. Tungsten Electrodes
4/23/2007 265 of 691
Old types: (Slightly Radioactive)
• Thoriated: DC electrode -ve - steels and most metals
• 1% thoriated + tungsten for higher current values
• 2% thoriated for lower current values
• Zirconiated: AC - aluminum alloys and magnesium
New types: (Not Radioactive)
• Cerium: DC electrode -ve - steels and most metals
• Lanthanum: AC - Aluminum alloys and magnesium
251. Tungsten electrode types
4/23/2007 266 of 691
Pure tungsten electrodes:
colour code - green
no alloy additions
low current carrying capacity
maintains a clean balled end
can be used for AC welding of Al and Mg alloys
poor arc initiation and arc stability with AC compared
with other electrode types
used on less critical applications
low cost
252. Tungsten electrode types
4/23/2007 267 of 691
Thoriated tungsten electrodes:
colour code - yellow/red/violet
20% higher current carrying capacity compared to
pure tungsten electrodes
longer life - greater resistance to contamination
thermionic - easy arc initiation, more stable arc
maintain a sharpened tip
recommended for DCEN, seldom used on AC
(difficult to maintain a balled tip)
This slightly radioactive
253. Tungsten electrode types
4/23/2007 268 of 691
Ceriated tungsten electrodes:
colour code - grey (orange acc. AWS A-5.12)
operate successfully with AC or DC
Ce not radioactive - replacement for thoriated types
Lanthaniated tungsten electrodes:
colour code - black/gold/blue
operating characteristics similar with ceriated
electrode
254. Tungsten electrode types
4/23/2007 269 of 691
Zirconiated tungsten electrodes:
colour code - brown/white
operating characteristics fall between those of pure
and thoriated electrodes
retains a balled end during welding - good for AC
welding
high resistance to contamination
preferred for radiographic quality welds
255. Electrode tip for DCEN
4/23/2007 270 of 691
Electrode tip prepared for low
current welding
Electrode tip prepared for high
current welding
Vertex
angle
Penetration
increase
Increase
Bead width
increase
Decrease
2-2,5times
electrodediameter
256. Electrode tip for AC
4/23/2007 271 of 691
Electrode tip ground
Electrode tip ground and
then conditioned
DC -ve AC
257. TIG Welding Variables
4/23/2007 272 of 691
Tungsten electrodes
The electrode diameter, type and vertex angle are all critical
factors considered as essential variables. The vertex angle is
as shown
Vetex angle
Note: when welding
aluminium with AC
current, the tungsten end
is chamfered and forms a
ball end when welding
DC -ve
Note: too fine an angle will
promote melting of the
electrodes tip
AC
258. Choosing the proper electrode
4/23/2007 273 of 691
Unstable
arc
Tungsten
inclusions
Welding
current
Electrode tip
not properly
heated
Excessive
melting or
volatilisation
Too
low
Too
high
Factors to be considered:
Penetration
259. Shielding gas requirements
• Preflow and
postflow
4/23/2007 275 of 691
Preflow Postflow
Shielding gas flow
Welding current
Flow rate
too low
Flow rate
too high
260. Special shielding methods
4/23/2007 276 of 691
Pipe root run shielding – Back Purging to prevent
excessive oxidation during welding, normally argon.
261. TIG torch set-up
Electrode extension
4/23/2007 277 of 691
Electrode
extension
Stickout 2-3 times
electrode
diameter
Electrode
extension
Low electron
emission
Unstable arc
Too
small
Overheating
Tungsten
inclusions
Too
large
262. TIG Welding Consumables
Welding consumables for TIG:
•Filler wires, Shielding gases, tungsten electrodes (non-
consumable).
•Filler wires of different materials composition and variable
diameters available in standard lengths, with applicable
code stamped for identification
•Steel Filler wires of very high quality, with copper coating to
resist corrosion.
•shielding gases mainly Argon and Helium, usually of highest
purity (99.9%).
4/23/2007 278 of 691
263. Tungsten Inclusion
4/23/2007 279 of 691
A Tungsten Inclusion always shows up as
bright white on a radiograph
May be caused by Thermal Shock of
heating to fast and small fragments
break off and enter the weld pool, so a
“slope up” device is normally fitted to
prevent this could be caused by touch
down also.
Most TIG sets these days have slope-
up devices that brings the current to
the set level over a short period of
time so the tungsten is heated more
slowly and gently
264. 4/23/2007 280 of 691
Most welding defects with TIG are caused by a lack of welder
skill, or incorrect setting of the equipment. i.e. current, torch
manipulation, welding speed, gas flow rate, etc.
• Tungsten inclusions (low skill or wrong vertex angle)
• Surface porosity (loss of gas shield mainly on site)
• Crater pipes (bad weld finish technique i.e. slope out)
• Oxidation of S/S weld bead, or root by poor gas cover
• Root concavity (excess purge pressure in pipe)
• Lack of penetration/fusion (widely on root runs)
TIG typical defects
265. Tungsten Inert Gas Welding
Advantages
• High quality
• Good control
• All positions
• Lowest H2 process
• Minimal cleaning
• Autogenous welding
(No filler material)
• Can be automated
Disadvantages
• High skill factor required
• Low deposition rate
• Small consumable range
• High protection required
• Complex equipment
• Low productivity
• High ozone levels +HF
4/23/2007 281 of 691
267. Gas Metal Arc Welding
4/23/2007 283 of 691
The MIG/MAG welding process was initially developed in the
USA in the late 1940s for the welding of aluminum alloys.
The latest EN Welding Standards now refer the process by the
American term GMAW (Gas Metal Arc Welding)
• The process uses a continuously fed wire electrode
• The weld pool is protected by a separately supplied
shielding gas
• The process is classified as a semi-automatic welding
process but may be fully automated
• The wire electrode can be either bare/solid wire or flux
cored hollow wire
269. MIG/MAG process variables
• Welding current
• Polarity
4/23/2007 286 of 691
•Increasing welding current
•Increase in depth and width
•Increase in deposition rate
270. MIG/MAG process variables
• Arc voltage
• Travel speed
4/23/2007 287 of 691
•Increasing travel speed
•Reduced penetration and width, undercut
•Increasing arc voltage
•Reduced penetration, increased width
•Excessive voltage can cause porosity,
spatter and undercut
271. Gas Metal Arc Welding
4/23/2007 289 of 691
Types of Shielding Gas
MIG (Metal Inert Gas)
• Inert Gas is required for all non-ferrous alloys (Al, Cu, Ni)
• Most common inert gas is Argon
• Argon + Helium used to give a „hotter‟ arc - better for thicker
joints and alloys with higher thermal conductivity
272. MIG/MAG – shielding gases
4/23/2007 290 of 691
Type of material Shielding gas
Carbon steel
Stainless steel
Aluminium
CO2 , Ar+(5-20)%CO2
Ar+2%O2
Ar
273. MIG/MAG shielding gases
Argon (Ar):
higher density than air; low thermal conductivity the arc
has a high energy inner cone; good wetting at the toes; low
ionisation potential
Helium (He):
lower density than air; high thermal conductivity uniformly
distributed arc energy; parabolic profile; high ionisation
potential
Carbon Dioxide (CO2):
cheap; deep penetration profile; cannot support spray
transfer; poor wetting; high spatter
4/23/2007 291 of 691
Ar Ar-He He CO2
274. MIG/MAG shielding gases
Gases for dip transfer:
• CO2: carbon steels only: deep penetration; fast welding
speed; high spatter levels
• Ar + up to 25% CO2: carbon and low alloy steels: minimum
spatter; good wetting and bead contour
• 90% He + 7.5% Ar + 2.5% CO2:stainless steels: minimises
undercut; small HAZ
• Ar: Al, Mg, Cu, Ni and their alloys on thin sections
• Ar + He mixtures: Al, Mg, Cu, Ni and their alloys on thicker
sections (over 3 mm)
4/23/2007 292 of 691
275. MIG/MAG shielding gases
Gases for spray transfer
• Ar + (5-18)% CO2: carbon steels: minimum spatter; good
wetting and bead contour
• Ar + 2% O2: low alloy steels: minimise undercut; provides
good toughness
• Ar + 2% O2 or CO2: stainless steels: improved arc stability;
provides good fusion
• Ar: Al, Mg, Cu, Ni, Ti and their alloys
• Ar + He mixtures: Al, Cu, Ni and their alloys: hotter arc than
pure Ar to offset heat dissipation
• Ar + (25-30)% N2: Cu alloys: greater heat input
4/23/2007 293 of 691
276. Gas Metal Arc Welding
Types of Shielding Gas
MAG (Metal Active Gas)
• Active gases used are Oxygen and Carbon Dioxide
• Argon with a small % of active gas is required for all steels
(including stainless steels) to ensure a stable arc & good
droplet wetting into the weld pool
• Typical active gases are
Ar + 20% CO2 for C-Mn & low alloy steels
Ar + 2% O2 for stainless steels
100% CO2 can be used for C - steels
4/23/2007 294 of 691
277. MIG/MAG Gas Metal Arc Welding
Electrode
orientation
4/23/2007 295 of 691
Penetration Deep Moderate Shallow
Excess weld metal Maximum Moderate Minimum
Undercut Severe Moderate Minimum
Electrode extension
•Increased extension
278. MIG / MAG - self-regulating arc
4/23/2007 296 of 691
Stable condition Sudden change in gun position
L 19 mm
25 mmL‟
Arc length L = 6,4 mm
Arc voltage = 24V
Welding current = 250A
WFS = 6,4 m/min
Melt off rate = 6,4 m/min
Arc length L‟ = 12,7 mm
Arc voltage = 29V
Welding current = 220A
WFS = 6,4 m/min
Melt off rate = 5,6
m/min
Current (A)
Voltage(V)
279. MIG/MAG - self-regulating arc
4/23/2007 297 of 691
Sudden change in gun position
25 mmL‟
Arc length L‟ = 12,7 mm
Arc voltage = 29V
Welding current = 220A
WFS = 6,4 m/min
Melt off rate = 5,6 m/min
Current (A)
Voltage(V)
Re-established stable condition
25 mm
L
Arc length L = 6,4 mm
Arc voltage = 24V
Welding current = 250A
WFS = 6,4 m/min
Melt off rate = 6,4 m/min
280. Terminating the arc
• Burnback time
4/23/2007 298 of 691
– delayed current cut-off to prevent wire freeze
in the weld end crater
– depends on WFS (set as short as possible!)
Contact tip
Workpiec
e
Burnback time 0.05 sec 0.10 sec 0.15 sec
14 mm
8 mm
3 mm
Current - 250A
Voltage - 27V
WFS - 7,8 m/min
Wire diam. - 1,2 mm
Shielding gas -
Ar+18%CO2
Insulatin
g slag
Crater fill
281. MIG/MAG - metal transfer modes
Set-up for dip transfer Set-up for spray transfer
4/23/2007 299 of 691
Electrode
extension
19-25 mm
Contact tip
recessed
(3-5 mm)
Contact tip
extension
(0-3,2 mm)
Electrode
extension
6-13 mm
282. MIG/MAG - metal transfer modes
Current/voltage conditions4/23/2007 301 of 691
Current
Voltage
Dip transfer
Spray
transfer
Globular
transfer
Electrode diameter = 1,2 mm
WFS = 3,2 m/min
Current = 145 A
Voltage = 18-20V
Electrode diameter = 1,2 mm
WFS = 8,3 m/min
Current = 295 A
Voltage = 28V
283. MIG/MAG-methods of metal transfer
4/23/2007 303 of 691
Dip transfer
Transfer occur due to short circuits
between wire and weld pool, high
level of spatter, need inductance
control to limit current raise
Can use pure CO2 or Ar- CO2
mixtures as shielding gas
Metal transfer occur when arc is
extinguished
Requires low welding current/arc
voltage, a low heat input process.
Resulting in low residual stress
and distortion
Used for thin materials and all
position welds
284. MIG/MAG-methods of metal transfer
4/23/2007 306 of 691
Spray transfer
Transfer occur due to pinch
effect NO contact between wire
and weld pool!
Requires argon-rich shielding
gas
Metal transfer occur in small
droplets, a large volume weld
pool
Requires high welding
current/arc voltage, a high heat
input process. Resulting in high
residual stress and distortion
Used for thick materials and
flat/horizontal position welds
285. MIG/MAG-methods of metal transfer
4/23/2007 307 of 691
Pulsed transfer
Controlled metal transfer, one droplet per pulse,
No transfer between droplet and weld pool!
Requires special power sources
Metal transfer occur in small droplets (diameter equal
to that of electrode)
Requires moderate welding current/arc voltage, a
reduced heat input . Resulting in smaller residual
stress and distortion compared to spray transfer
Pulse frequency controls the volume of weld pool,
used for root runs and out of position welds
286. MIG/MAG - metal transfer modes
Pulsed transfer
4/23/2007 308 of 691
Controlled metal transfer. one droplet
per pulse. NO transfer during
background current!
Requires special power sources
Metal transfer occur in small droplets
(diameter equal to that of electrode)
Requires moderate welding current/arc voltage, reduced
heat input‟ smaller residual stress and distortions
compared to spray transfer
Pulse frequency controls the volume of weld pool, used
for root runs and out of position welds
287. MIG/MAG-methods of metal transfer
4/23/2007 310 of 691
Globular transfer
Transfer occur due to gravity or
short circuits between drops and
weld pool
Requires CO2 shielding gas
Metal transfer occur in large drops
(diameter larger than that of
electrode) hence severe spatter
Requires high welding current/arc
voltage, a high heat input process.
Resulting in high residual stress
and distortion
Non desired mode of transfer!
288. 4/23/2007 315 of 691
O.C.V. Arc Voltage
Virtually no Change.
Voltage
Flat or Constant Voltage Characteristic Used With
MIG/MAG, ESW & SAW < 1000 amps
100 200 300
33
32
31
Large Current Change
Small Voltage
Change.
Amperage
Flat or Constant Voltage Characteristic
289. MIG/MAG welding gun assembly
4/23/2007 316 of 691
Contact
tip
Gas
diffuser
Handle
Gas
nozzle
Trigger WFS remote
control
potentiometer
Union nut
The Push-Pull gun
290. Gas Metal Arc Welding
4/23/2007 318 of 691
PROCESS CHARACTERISTICS
• Requires a constant voltage power source, gas supply, wire
feeder, welding torch/gun and „hose package‟
• Wire is fed continuously through the conduit and is burnt-off
at a rate that maintains a constant arc length/arc voltage
• Wire feed speed is directly related to burn-off rate
• Wire burn-off rate is directly related to current
• When the welder holds the welding gun the process is said
to be a semi-automatic process
• The process can be mechanised and also automated
• In Europe the process is usually called MIG or MAG
291. 4/23/2007 322 of 691
Most welding imperfections in MIG/MAG are caused by lack of
welder skill, or incorrect settings of the equipment
•Worn contact tips will cause poor power pick up, or transfer
•Bad power connections will cause a loss of voltage in the arc
•Silica inclusions (in Fe steels) due to poor inter-run cleaning
•Lack of fusion (primarily with dip transfer)
•Porosity (from loss of gas shield on site etc)
•Solidification problems (cracking, centerline pipes, crater
pipes) especially on deep narrow welds
MIG/MAG typical defects
293. Flux cored arc welding
4/23/2007 324 of 691
FCAW
methods
With gas
shielding -
“Outershield”
Without gas
shielding -
“Innershield”
With metal
powder -
“Metal core”
296. ARC CHARACTERISTICS
4/23/2007 327 of 691
Volts
Amps
OCV
Constant Voltage Characteristic
Small change in voltage =
large change in amperage
The self
adjusting arc.
Large arc gap
Small arc gap
297. 4/23/2007 328 of 691
Insulated extension nozzle
Current carrying guild tube
Flux cored hollow wire
Flux powder
Arc shield composed of
vaporized and slag forming
compounds
Metal droplets covered
with thin slag coating
Molten
weld
poolSolidified weld
metal and slag
Flux core
Wire joint
Flux core
wires
Flux Core Arc Welding (FCAW)
298. Flux cored arc welding
4/23/2007 329 of 691
FCAW
methods
With gas
shielding -
“Outershield”
Without gas
shielding -
“Innershield”
(114)
With metal
powder -
“Metal core”
With active
gas shielding
(136)
With inert gas
shielding (137)
299. FCAW - differences from MIG/MAG
• usually operates in DCEP
but some “Innershield”
wires operates in DCEN
• power sources need to be
more powerful due to the
higher currents
• doesn't work in deep
transfer mode
• require knurled feed rolls
4/23/2007 330 of 691
“Innershield” wires use
a different type of
welding gun
300. Backhand (“drag”) technique
Advantages
4/23/2007 331 of 691
preferred method for flat or horizontal position
slower progression of the weld
deeper penetration
weld stays hot longer, easy to remove dissolved
gasses
Disadvantages
produce a higher weld profile
difficult to follow the weld joint
can lead to burn-through on thin sheet plates
301. Forehand (“push”) technique
Advantages
4/23/2007 332 of 691
preferred method for vertical up or overhead
position
arc is directed towards the unwelded joint , preheat
effect
easy to follow the weld joint and control the
penetration
Disadvantages
produce a low weld profile, with coarser ripples
fast weld progression, shallower depth of penetration
the amount of spatter can increase
302. FCAW advantages
• less sensitive to lack of fusion
• requires smaller included angle compared to MMA
• high productivity
• all positional
• smooth bead surface, less danger of undercut
• basic types produce excellent toughness properties
• good control of the weld pool in positional welding especially
with rutile wires
• seamless wires have no torsional strain, twist free
• ease of varying the alloying constituents
• no need for shielding gas
4/23/2007 333 of 691
303. FCAW disadvantages
• limited to steels and Ni-base alloys
• slag covering must be removed
• FCAW wire is more expensive on a weight basis than solid
wires (exception: some high alloy steels)
• for gas shielded process, the gaseous shield may be
affected by winds and drafts
• more smoke and fumes are generated compared with
MIG/MAG
• in case of Innershield wires, it might be necessary to
break the wire for restart (due to the high amount of
insulating slag formed at the tip of the wire)
4/23/2007 334 of 691
304. 4/23/2007 335 of 691
Advantages:
1) Field or shop use
2) High productivity
3) All positional
4) Slag supports and
shapes the weld Bead
5) No need for shielding
gas
Disadvantages:
1) High skill factor
2) Slag inclusions
3) Cored wire is
Expensive
4) High level of fume
(Inner-shield)
5) Limited to steels and
nickel alloys
FCAW advantages/disadvantages
306. 4/23/2007 337 of 691
• Submerged arc welding was developed in the Soviet Union
during the 2nd world war for the welding of thick section steel.
• The process is normally mechanized.
• The process uses amps in the range of 100 to over 2000, which
gives a very high current density in the wire producing deep
penetration and high dilution welds.
• A flux is supplied separately via a flux hopper in the form of either
fused or agglomerated.
• The arc is not visible as it is submerged beneath the flux layer
and no eye protection is required.
Submerged Arc Welding Introduction
308. Principles of operation
4/23/2007 339 of 691
Factors that determine whether to use SAW chemical
composition and mechanical properties required for the weld
deposit
• thickness of base metal to be welded
• joint accessibility
• position in which the weld is to be made
• frequency or volume of welding to be performed
SAW methods
Semiautomatic Mechanised Automatic
310. SAW process variables
4/23/2007 341 of 691
• welding current
• current type and polarity
• welding voltage
• travel speed
• electrode size
• electrode extension
• width and depth of the layer of flux
311. SAW process variables
4/23/2007 342 of 691
Welding current
•controls depth of penetration and the amount of
base metal melted & dilution
312. SAW operating variables
4/23/2007 343 of 691
Current type and polarity
•Usually DCEP, deep
penetration, better
resistance to
porosity
•DCEN increase
deposition rate but
reduce penetration
(surfacing)
•AC used to avoid
arc blow; can give
unstable arc
313. SAW Consumables
(Covered in detail in Section 14)
4/23/2007 344 of 691
Fused fluxes advantages:
•good chemical homogeneity
•easy removal of fines without affecting flux
composition
•normally not hygroscopic & easy storage and handling
•readily recycled without significant change in particle
size or composition
Fused fluxes disadvantages:
•difficult to add deoxidizers and ferro-alloys (due to
segregation or extremely high loss)
•high temperatures needed to melt ingredients limit the
range of flux compositions
314. SAW Consumables
4/23/2007 345 of 691
Agglomerated fluxes advantages:
• easy addition of deoxidizers and alloying elements
• usable with thicker layer of flux when welding
• colour identification
Agglomerated fluxes disadvantages:
• tendency to absorb moisture
• possible gas evolution from the molten slag leading to
porosity
• possible change in flux composition due to segregation or
removal of fine mesh particles
315. SAW equipment
4/23/2007 346 of 691
Power sources can be:
• transformers for AC
• transformer-rectifiers for DC
Static characteristic can be:
• Constant Voltage (flat) - most of the power sources
• Constant Current (drooping)
316. SAW equipment
4/23/2007 347 of 691
Constant Voltage (Flat Characteristic) power sources:
• most commonly used supplies for SAW
• can be used for both semiautomatic and automatic welding
• self-regulating arc
• simple wire feed speed control
• wire feed speed controls the current and power supply
controls the voltage
• applications for DC are limited to 1000A due to severe arc
blow (also thin wires!)
317. ARC CHARACTERISTICS
4/23/2007 348 of 691
Volts
Amps
OCV
Constant Voltage Characteristic
Small change in voltage =
large change in amperage
The self
adjusting arc.
Large arc gap
Small arc gap
318. SAW equipment
4/23/2007 349 of 691
Constant Current (Drooping Characteristic) power sources:
• Over 1000A - very fast speed required - control of burn off
rate and stick out length
• can be used for both semiautomatic and automatic welding
• not self-regulating arc
• must be used with a voltage-sensing variable wire feed
speed control
• more expensive due to more complex wire feed speed
control
• arc voltage depends upon wire feed speed whilst the power
source controls the current
• cannot be used for high-speed welding of thin steel
319. SAW equipment
4/23/2007 350 of 691
Welding heads can be mounted on a:
Tractor type carriage
• provides travel along straight or
gently curved joints
• can ride on tracks set up along the
joint (with grooved wheels) or on
the workpiece itself
• can use guide wheels as tracking
device
• due to their portability, are used in
field welding or where the piece
cannot be moved
Courtesy of ESAB AB
Courtesy of ESAB AB
320. SAW operating variables
4/23/2007 351 of 691
Welding current
•too high current: excessive excess weld metal
(waste of electrode), increase weld shrinkage and
causes greater distortions
•excessively high current: digging arc, undercut,
burn through; also a high and narrow bead &
solidification cracking
•too low current: incomplete
fusion or inadequate penetration
•excessively low current:
unstable arc
321. SAW operating variables
4/23/2007 352 of 691
Welding voltage
•welding voltage controls arc
length
•an increased voltage can increase pick-up of alloying elements
from an alloy flux
•increase in voltage produce a
flatter and wider bead
•increase in voltage increase
flux consumption
•increase in voltage tend to
reduce porosity
•an increased voltage may
help bridging an excessive
root gap
322. SAW operating variables
4/23/2007 353 of 691
Welding voltage
•low voltage produce a
“stiffer” arc & improves
penetration in a deep
weld groove and resists
arc blow
•excessive low voltage
produce a high narrow
bead & difficult slag
removal
323. SAW operating variables
4/23/2007 354 of 691
Welding voltage
•excessively high voltage
produce a “hat-shaped” bead
& tendency to crack
•excessively high voltage
increase undercut & make slag
removal difficult in groove
welds
•excessively high voltage
produce a concave fillet weld
that is subject to cracking
324. SAW operating variables
4/23/2007 355 of 691
Travel speed
•increase in travel speed: decrease heat input & less
filler metal applied per unit of length, less excess
weld metal & weld bead becomes smaller
325. SAW operating variables
4/23/2007 356 of 691
Travel speed
•excessively high speed
lead to undercut, arc
blow and porosity
•excessively low speed
produce “hat-shaped” beads
danger of cracking
•excessively low speed produce rough beads and
lead to slag inclusions
326. SAW operating variables
4/23/2007 357 of 691
Electrode size
•at the same current, small electrodes have higher
current density & higher deposition rates
327. SAW operating variables
4/23/2007 358 of 691
Electrode extension
•increased electrode extension adds resistance in the
welding circuit I increase in deposition rate, decrease in
penetration and bead width
•to keep a proper weld shape, when electrode extension is
increased, voltage must also be increased
•when burn-through is a problem (e.g. thin gauge), increase
electrode extension
•excessive electrode extension: it is more difficult to
maintain the electrode tip in the correct position
328. SAW operating variables
4/23/2007 359 of 691
Depth of flux
•depth of flux layer influence the appearance of weld
•usually, depth of flux is 25-30 mm
•if flux layer is to deep the arc is too confined, result is
a rough ropelike appearing weld
•if flux layer is to deep the gases cannot escape & the
surface of molten weld metal becomes irregularly
distorted
•if flux layer is too shallow, flashing and spattering will
occur, give a poor appearance and porous weld
329. SAW technological variables
4/23/2007 363 of 691
Travel angle effect - Butt weld on plates
Penetration Deep Moderate Shallow
Excess weld metal Maximum Moderate Minimum
Tendency to undercut Severe Moderate Minimum
330. SAW technological variables
4/23/2007 364 of 691
Earth position +
-
Direction of
travel
•welding towards earth produces backward arc blow
•deep penetration
•convex weld profile
331. SAW technological variables
4/23/2007 365 of 691
Earth position
+
-
Direction of
travel
•welding away earth produces forward arc blow
•normal penetration depth
•smooth, even weld profile