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Welding
Welding is a fabrication or sculptural process that joins materials (usually metals) by causing coalescence. This is often done by melting the work pieces and adding a filler material to form a pool of molten material (the weld pool) that cools to become a strong joint, with pressure sometimes used in conjunction with heat, or by itself, to produce the weld.
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Welding Processes
Types of Welding
Fusion Welding
Oxyacetylene Gas Welding Shielded Metal Arc (SMAW) Metal Inert Gas (MIG) Tungsten Inert Gas (TIG) Submerged Arc Welding (SAW)
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Functions of Flux :
Provide a protective coating around the arc to keep away oxygen, nitrogen etc. Facilitates arc striking and for arc stability. Forms a protective slag on molten pool and prevents oxidation. Gives better penetration. Varies the fluidity of slags for different purposes (for example: slag of reduced fluidity is desirable in overhead position welding) For controlling composition of weld metal.
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Correct Current :
If current is too high, the electrode melts too fast and the molten pool is large and irregular. If too low, there is not enough heat to melt the base metal.
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Coalescence is produced by heating with an electric arc set up between a bare metal electrode and the work piece. The arc end of the electrode and the weld pool remains completely hidden being submerged under a blanket of granular flux material. Continuously fed electrode melts and welding is progressively done. Used for very thick sections. C and Cr addition is to be done to the filler to avoid C and Cr depletion from the weld. SAW welds have better toughness and ductility compared to welds made by TIG.
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Wear dry, hole-free insulating gloves and body protection. Do not touch electrode with bare hand. Do not wear wet or damaged gloves. Do not touch live electrical parts.
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Do not weld near flammable material. Welding sparks can cause fires. Have a fire extinguisher nearby
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Use welding helmet with correct shade of filter. Wear welders cap and safety glasses with side shields. Wear complete body protection.
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Weldability
Weldability, as defined by AWS, is the capacity of a metal or combination of metals to be welded under fabrication conditions into a specific, suitably designed structure, and to perform satisfactorily in the intended service. The better the weldability, the greater is the ease with which these requirements are met.
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Weldability
Common Name Carbon Content (%) 0.03 max 0.15 max 0.15-0.3 0.3-0.6 0.6-2.0 Weldability Ingot Iron Low Carbon Steel Mild Steel Med. Carbon Steel High Carbon Steel Excellent Excellent Good Fair Poor (Difficult to Weld)
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Welding Positions
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Welding Electrode
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Welding Electrode
An electrode is a piece of wire or rod (of metal or alloy) with or without flux covering which carries current and also acts as filler material for welding.
At one end it is gripped in a holder and arc is generated at the other end.
Different types of electrodes are available in the market for different welding processes.
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Selection of Electrodes
Selection of right kind of electrode for a given application is very important to achieve desired properties of welding joints. The choice depends on following factors: Chemical composition of base metal. Thickness of work piece. Electrode coating. Welding position. Power source (AC / DC). Weld quality. Mechanical and other properties. Cost effectiveness.
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SMAW
GTAW
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Sl. No. 1 2 3 4 5 6 7 8 9 10 11
MATERIALS Carbon Steel Carbon Moly 1-1/4 Chrome Moly 2-1/4 Chrome Moly 5 Chrome Moly 9 Chrome Moly 12 Chrome 3-1/2 Nickel 18 Chrome 8 Nickel (308, 308L) 18 Cr 10 Ni Cb (347) 18 Cr 10 Ni Mo (316 316L) 25 Cr 12 Ni (309) Inconel Inconel Monel Nickel 25 Cr 20 Ni (310)
ASME SF A 5, 1 SF A 5, 5 SF A 5, 5 SF A 5, 5 SF A 5, 4 SF A 5, 4 SF A 5, 4 SF A 5, 5 SF A 5, 4 SF A 5, 4 SF A 5, 4 CLASSIFICATION E610, E7018 E7010 A1, E7018 A1 E8016 B2, E8018 B2 E9016 B3, E9018 B3 E502 16 or 15 E505 16 or 15 E410 16 or 15 E8016 C2, E8018 C2 E308 16 or 15 E308l 16 or 15 E347 16 or 15 E316 16 or 15 E316l 16 or 15
12
13 14 15 16
SF A 5, 4 SFA 5, 11
SF A 5, 11 SF A 5, 11 SF A 5, 11 SF A 5, 4
E309 16 or 15 ENi Cr Fe 3
ENi Cr Fe 3 ENi Cu 7 ENI 1 E310 16 or 15
SF A 5, 9 SF A 5, 14
SF A 5, 14 SF A 5, 4 SF A 5, 4 SF A 5, 9
ER 309 ER Ni Cr 3
ER Ni Cr 3 ER Ni Cu 7 ER Ni 1 ER 310
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Welding Electrode
Low Alloy Steel Electrodes (AWS A5.5):
Suffixes and Approximate alloy Content in Weld Deposit for Low Alloy Steel Electrodes for SMAW
SUFFIX
-A1 -B1 -B2
-B3
-B4 -B5 -C1 -C2 -C3 -D1 -G
2.25 Cr 1 Mo
2 Cr 0.5 Mo 00.5 Cr 1 Mo 2.5 Ni 3.25 Ni 1 Ni, 0.35 Mo, 0.15 Cr 0.25 0.45 Mo, 1.25 1.75 Mn 0.5 Min Ni, 0.3 Min Cr, 0.2 Min Mo, 0.1 Min V, 1 Min Mn (only one element required)
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Welding Electrode
Welding Electrodes for Alloy & Stainless Steel:
Sl. No.
1
Base Metal
P. No.
P3
Classificatio n
E7018 A1
C-1/2 Mo
1.1/4 Cr1/2 Mo
P4
S.F.A.5.5
1500C Minimum
7200C, 1hr/in, with 2 hrs. min., none for thickness<1/2 or base metal T.S. 71Ksi
7200C, 1hr/in, with 2 hrs. min. None for thickness 1/2 and C 0.15%
2.1/4 Cr1 Mo
P5
S.F.A.5.5
1800C Minimum
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Welding Electrode
Sl. No. Base Metal P. No. Welding Electrodes A.S.M.E. A.W.S
S.F.A.5.4
Classificatio n
E505-16 or -15
E505-16 or -15 E410-16 or 15 E309-16 or -15 E309-16 or 15 ENi Cr Fe-3 E410-16 or 15
5 Cr1/2 Mo
9 Cr1 Mo 12 Cr Type 410
P5
1800C Minimum
P5
S.F.A.5.4
1800C Minimum
P6
S.F.A.5.4 S.F.A.5.4
12 Cr Type 405
P7
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Welding Electrode
Sl. No.
8
Base Metal
P. No.
P 9B
Classificatio n
E8016-C2 E8018-C2 E Ni Cr Fe-3 E308-16 or 15 E308L-16 or -15 E347-16 or 15
3.1/2 Ni
18 Cr-8Ni SS Type 304 SS Type 304L 18 Cr-8Ni Stabilised SS Type 347, 321 18 Cr-10NiMo SS Type 316 SS Type 316L
P8
100C min.
None
10
P8
S.F.A.5.4
100C min.
None
11
P8
S.F.A.5.4
E316-16 or 15 E316L-16 or 15
100C min.
None
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Welding Electrode
Sl. No. Base Metal P. No. Welding Electrodes A.S.M.E. A.W.S
12 25 Cr-12Ni Type 309 P8 S.F.A.5.4
Classificatio n
E309-16 or -15 100C min.
None
13
P8
S.F.A.5.4
E310-16 or -15
100C min.
None
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Inspection Of Welding
Inspection Before Welding:
Inspection Of Welding
Inspection During Welding:
Inspection Of Welding
Inspection After Welding: Destructive Tests (for mechanical properties / chemical analysis / spectro etc).
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FIG. 2 GROOVE WELD TEST ASSEMBLY FOR MECHANICAL PROPERTIES AND SOUNDNESS EXCEPT FOR E6022 AND E7018M ELECTRODES
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FIG. 4 TEST ASSEMBLY FOR TRANSVERSE TENSION AND LONGITUDINAL GUIDED BEND TESTS FOR WELDS MADE WITH E6022 ELECTRODES
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FIG. 5 GROOVE WELD TEST ASSEMBLY FOR MECHANICAL PROPERTIES AND SOUNDNESS OF WELD METAL MADE WITH E7018M ELECTRODES
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Welder Qualification
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Welder Qualification
This shall be done as per ASME Section IX The performance qualification is done in accordance with one of any of the qualified Welding Procedure Specifications (WPS). When performance qualification is done in accordance with a WPS that requires Post weld heat treatment (PWHT), this PWHT may be omitted. The welded test joints for qualification may be examined by mechanical tests or by radiography.
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Welder Qualification
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Welding Defects
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Welding Defects
Porosity Cracks Undercut Distortion Spatter Lack of Fusion Overlapping Lack of Penetration Magnetic Arc Blow Inclusion
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Welding Defects
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Welding Defects
Defect Porosity Causes Excessively long or short arc length. Welding current too high. Insufficient or damp shielding gases. Base metal surface covered with oil, grease, moisture, rust, mill scale etc. Wet, unclean or damaged electrode/filler wire. Remedies Maintain proper arc length. Use proper welding current. Increase gases flow rate & check gas purity. Reduce travel speed. Clean properly base metal prior to welding. Maintain and store electrode/filler wire properly.
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Welding Defects
Defect Crack Causes Insufficient weld size. Excessive joint restraint. Poor joint design and/or preparation. Filler metal does not match base metal. Rapid cooling rate. Base metal surface covered with oil, grease, moisture, rust, and dirt or mill scale. Remedies Adjust weld size to part thickness. Reduce joint restraint through proper design. Select the proper joint design. Use more ductile filler. Reduce cooling rate through preheat. Clean properly base metal prior to welding.
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Welding Defects
Defect Lack of penetration Causes Travel speed too fast. Welding current too low. Poor joint design and/or preparation. Electrode diameter too large. Wrong type of electrode. Excessively long arc length. Remedies Decrease travels speed. Increase welding current. Increase root opening or decrease root face. Use smaller electrode. Use electrode with deeper penetration characteristics. Reduce arc length.
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Welding Defects
Defect Inclusion Causes Incomplete slag removal between passes. Erratic travel speed. Too wide a weaving motion. Too large an electrode. Letting slag run ahead of arc. Tungsten spitting or sticking. Remedies Completely remove slag between passes. Use a uniform travel speed. Reduce width of weaving technique. Use a smaller electrode size for better access to joint. Increase travel speed or change electrodes angle or reduce arc length. Properly prepare tungsten and use proper current.
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Radiography Test
Principle :
RADIATION SOURCE DISCONTINUITY METAL
FILM
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Radiography Test
Sample Films :
Lack Of Penetration
Cluster Of Porosity
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Radiography Test
Sample Films :
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AUTOMATIC WELDING
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CASE STUDIES
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CASE STUDIES
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CASE STUDIES
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CASE STUDIES
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CASE STUDIES
Standard Joint
Crack
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THANK YOU
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