Scribd Logo
Upload

Welcome to Scribd!

  • 35 views

    Properties of Fusion Welds: EF420 Lecture 4 John Taylor

    Uploaded by

    Bakheit Layli
    This document discusses properties of fusion welds. It explains that welds solidify much faster than castings and have a constant surface shape. There is strong mixing in the weld pool. The heat affected zone (HAZ) experiences high peak temperatures and thermal gradients during welding, resulting in variable microstructures. Multipass welds can have overlapping HAZs. Weld metal composition and properties differ from the base metal due to the welding thermal cycle. Defects like cracks, porosity, and incomplete fusion can occur due to material properties, welding procedure flaws, or welder mistakes. Residual stresses are also introduced during welding.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPT, PDF, TXT or read online from Scribd

    Properties of Fusion Welds: EF420 Lecture 4 John Taylor

    Uploaded by

    Bakheit Layli
    35 views34 pages
    This document discusses properties of fusion welds. It explains that welds solidify much faster than castings and have a constant surface shape. There is strong mixing in the weld pool. The heat affected zone (HAZ) experiences high peak temperatures and thermal gradients during welding, resulting in variable microstructures. Multipass welds can have overlapping HAZs. Weld metal composition and properties differ from the base metal due to the welding thermal cycle. Defects like cracks, porosity, and incomplete fusion can occur due to material properties, welding procedure flaws, or welder mistakes. Residual stresses are also introduced during welding.

    Original Description:

    Original Title

    04 Weld Met

    Copyright

    © Attribution Non-Commercial (BY-NC)

    Available Formats

    PPT, PDF, TXT or read online from Scribd

    Did you find this document useful?

    Is this content inappropriate?

    This document discusses properties of fusion welds. It explains that welds solidify much faster than castings and have a constant surface shape. There is strong mixing in the weld pool. The heat affected zone (HAZ) experiences high peak temperatures and thermal gradients during welding, resulting in variable microstructures. Multipass welds can have overlapping HAZs. Weld metal composition and properties differ from the base metal due to the welding thermal cycle. Defects like cracks, porosity, and incomplete fusion can occur due to material properties, welding procedure flaws, or welder mistakes. Residual stresses are also introduced during welding.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    35 views34 pages

    Properties of Fusion Welds: EF420 Lecture 4 John Taylor

    Uploaded by

    Bakheit Layli
    This document discusses properties of fusion welds. It explains that welds solidify much faster than castings and have a constant surface shape. There is strong mixing in the weld pool. The heat affected zone (HAZ) experiences high peak temperatures and thermal gradients during welding, resulting in variable microstructures. Multipass welds can have overlapping HAZs. Weld metal composition and properties differ from the base metal due to the welding thermal cycle. Defects like cracks, porosity, and incomplete fusion can occur due to material properties, welding procedure flaws, or welder mistakes. Residual stresses are also introduced during welding.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    of 34

    Properties of fusion welds

    EF420 Lecture 4 John Taylor

    Welding v casting
    Weld must adhere to mould wall Heat is added continually to welds

    High temperature gradient

    Welds solidify much faster than castings In welds, the surface shape is constant There is strong mixing of weld pools

    Fusion weld structure


    Fusion line

    Weld preparation

    Base metal

    Weld metal

    HAZ

    HAZ

    Thermal gradients in HAZ


    Temperature

    Fusion line Fusion line + 2mm Fusion line + 5 mm

    Time
    4

    HAZ structure
    High peak temperature High temperature gradient

    Variable cooling rate

    Superimposed HAZs in multipass welds Welding stresses affect transformation

    Multipass fusion weld

    Last weld run

    Previous weld run

    Weld properties
    Weld metal has different composition & thermal history to base metal Welding heat modifies adjacent base metal (HAZ) Variation in strength, ductility & corrosion resistance across welds

    Welding procedure
    Selection of process conditions & consumables for a weld Designed to match base material properties as closely as possible & avoid weld defects Needs to consider service conditions of the weld

    Definition of weldability
    The capacity of a material to be welded under the imposed fabrication conditions into a specific, suitably designed structure & to perform satisfactorily in intended service.
    (ANSI / AWS A3.0)

    Factors affecting weldability


    Weldability is often considered to be a material property, however the effect of other variables should not be ignored. Design of weldment Its service conditions Choice of welding process

    10

    Material properties
    Melting & vaporisation temperatures Electrical & thermal properties

    Conductivity, expansion coefficient, thermal capacity, latent heat Susceptibility to porosity, embrittlement or wetting problems Oxide, paint or metallic surface coating
    11

    Affinity of weld metal for O, N & H

    Presence of a surface film on base metal

    Service environment
    Extreme environments

    Corrosive Low temperature (brittle failure) High temperature (oxidation, creep, embrittlement) Others (wear, fatigue, nuclear) The more difficult it is to find suitable materials The more restricted the welding procedure becomes to avoid service failure

    The more extreme the environment


    12

    Welding Defects
    Cracks

    In weld metal or HAZ Gas bubbles entrapped in weld metal

    Porosity

    Incomplete fusion (interrun or at preparation edge) Inclusions

    Slag or other matter entrapped in weld Under-weld, over-weld, lack of penetration, overlap, undercut
    13

    Defective profile

    Causes of weld defects


    Poor design of weldment

    Lack of access to make weld

    Mistakes by welder

    Lack of skill Poor placement of weld metal Inadequate cleaning

    Poor welding procedure

    14

    Weld defects

    Slag inclusion

    Wormhole porosity Incomplete fusion

    Overlap

    Solidification cracking
    Contraction strains cause rupture of the weld at the point where the last material solidifies.

    Solidification range Weld pool size & shape

    16

    Residual stress & distortion


    Uneven heating leads to constrained thermal expansion At completion of the weld thermal cycle the weldment either distorts or if restrained will contain residual stress Residual stress fields are complex, but stresses as high as yield often occur Stresses may need to be removed by a stress relief heat treatment
    17

    Residual stress in a butt weld


    sy s
    X sx s X
    Compression
    sy

    sx s
    0 Tension

    Tension

    X
    Compression

    18

    Weld detailing

    19

    Weld positions - plate

    Flat (1G)

    Horizontal (2G)

    Vertical (3G) Up or Down

    Overhead (4G)
    20

    Welding positions - pipe

    Axis vertical 2G

    Axis horizontal 5G

    Axis inclined 45 6G

    21

    Weld details
    Joints - Arrangements of members being joined

    Butt, tee, lap, corner, flare

    Welds - Geometry of weld detail selected to make the joint

    Butt, fillet, plug & slot

    Joint types

    Butt

    Tee

    Edge Lap Corner

    23

    Weld types
    Butt weld

    Between mating members Best quality High weld preparation cost Easy preparation Asymmetric loads, lower design loads Modified fillet welds in lap joints, using holes through one member
    24

    Fillet weld

    Plug & slot welds

    Fillet welds
    Simple & cheap to assemble & weld Stress concentrations at toes & root Notch at root (fatigue, toughness) Critical dimension is throat thickness Root gap affects throat thickness Radiography & ultrasonic testing is of limited use Large fillets use a lot of weld metal & therefore are uneconomic

    25

    Fillet weld terms


    Toe

    Weld face

    Toe

    Root
    Gap

    Throat thickness

    Apparent leg length

    Butt welds
    Types:

    Double welded butt Permanent or temporary backing Single welded butt

    Lower stress concentration Easier ultrasonic testing or radiography Expensive preparation

    27

    Butt weld types

    Single vee can be single or double welded

    Single bevel

    Double vee

    Backed butt (permanent or temporary)

    Butt weld terms


    Fusion face
    Included angle Bevel angle

    Reinforcement
    Toe Root face Root gap

    Root run

    Toe

    Weld preparation dimensions


    Compromise

    Weld cross sectional area


    Cost Ease of welding (risk of defects)

    Standard preparations

    AS1554, AWS D1.1, ANSI B31.3

    Fabricators risk

    30

    Single welded butt joints


    Access to one side only

    Pipe & hollow section butt joints

    Root run forms inside surface High fit-up tolerances required High skill required

    Special welder qualification

    Root may be contaminated Inside is difficult to inspect

    31

    J & U Preparations

    U preparation

    Root radius
    Land

    Double U butt
    32

    AS1101.2 drawing symbols


    OTHER SIDE
    Tail ARROW SIDE Arrow points to weld location Reference line

    Weld type symbol

    33

    Typical AS1101.2 symbols


    6mm 6 CJP

    34

    You might also like