Beruflich Dokumente
Kultur Dokumente
BY
SURENDRA SINGH
Discussion P i t Di i Points
Classification of metals Effect of alloying elements Weld Defects
Classification of Metals
Metals M l Ferrous metals Steels Plain carbon steels Low carbon steels Medium carbon steels High carbon steels Low alloy steels
High alloy steels Stainless & T l steels St i l Tool t l
Non-ferrous metals Cast Irons Grey Iron y White Iron Malleable & Ductile Irons
Cast Iron
Alloy of iron and carbon content 2 4% 2-4%. Higher strength and hardness but ductility is low. Cannot be rolled in the from plate or sheet. Can be made ductile by addition of element Mg. Higher fluidity
Graphite Nodules
Ferrite
Tampered Nodules
Ferrite
Classification of Steel
Steel: An alloy of the metal iron with carbon. 0.01 1.4% C is considered as the general range for steels Steels are classified into 1. 1 Low Carbon Steel 0 01 0 3% Carbon 0.01 0.3% 2. Medium Carbon Steel 0.3 0.6% Carbon 3. High Carbon Steel 0.6 1.4% Carbon Plain carbon steels contain only iron & carbon as main alloying elements, traces of Mn, Si, Al, S & P may also be present
Stainless Steel
Types
Austenitic Stainless Steel Ferritic Stainless Steel Duplex Stainless Steel Martensitic Stainless Steel Precipitation Hardened Stainless Steel
ASTM No. 7
HCl+Picric Acid+Ethanol
100X
Aluminum
Alloyed to steel mainly as grain refiner. Also act as de-oxidised agent upto some extent.
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Chromium
Sharply increases corrosion resistance at high concentrations (> 12%). Improves hardenability, strength and wear resistance upto some extent (<5%). (<5%)
Titanium
Carbide stabilisation to form titanium carbide, more resistant to IGC. Added upto 0 23 to 0 60 in SS 321. 0.23 0.60 321
Molybdenum
Improves resistance to pitting corrosion (2-3%) Provides high temperature strength, hardness and creep resistant. resistant
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Nickel
Increases s e g , impact s e g a d toughness a low c eases strength, pac strength and oug ess at o and high temperature, it also act as grain refiner(>8%). Provide ductility, formability as well as weldability in small concentration. t ti
Manganese g
Improves the depth of hardness, toughness and wear resistance. (<1.6%). Control solidification cracking. Substitute for Ni.
Sulphur
It improve the machinability but high concentration cause brittleness or solidification cracking (<0 030%) (<0.030%).
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Silicon
Act as deoxidizer agent (<0.8%) and provide machinability. Increases strength but excessive amount reduce ductility
Phosphorus
Added with sulphur to improve machinability (<0.045%). It greatly reduce ductility and toughness
Vanadium
Used as a de-oxidant
Tungsten
Mainly alloyed to high speed tool steels for providing wear resistance at high temperature temperature.
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Weldability W ld bilit
Weldability can be defined as the ability of a material to be welded by most of the common welding processes, Poor weldability generally results in the occurrence of some sort of cracking problem CEN = C + Mn + Cr + Mo + V + Cu + Ni
6 5 15
Weld: A union b t i between materials caused b h t and or pressure t i l d by heat, d Joint: A configuration of members fi ti f b
Welding Defects f
Weld Defects
Defects detected by visual inspection
Cracks Solid inclusions Surface and profiles g (setMisalignment ( up irregularities) Gas pores and porosity
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Cracks
Cracks that may occur in welded materials are caused generally b many f t ll by factors and may b classified b shape d be l ifi d by h and position, cracks are classed as planar defect.
Cracks
HIC Macrostructure
Prevention of HIC y g g process Use low hydrogen welding p Bake or heat the welding electrode before welding Preheat the metal to remove moisture Reduce stress by heat treatment
Solidification Cracking
Occurs during weld solidification process Steels with high sulphur impurities content (low strength at elevated temperature) Requires tensile stress Occur longitudinally down the centre of weld
Lamellar Tearing
M i l occur i rolled Mainly in ll d steel plate Higher concentration of impurities or inclusion such as sulphides or silicates Reduction in through thickness ductility y
Intercrystalline cracking
Occur mainly in austenitic stainless steels, due to the formation of chromium carbide along the grain boundary
Line of sensitization
Loss of gas shield g Damp electrodes Contamination Arc length too large Damaged electrode flux Moisture on parent material
Gas Cavities
Entrapment of slag between passes p Slag is caused by inadequate cleaning q g Other inclusions include tungsten and copper g pp inclusions from the TIG and MAG welding process
Lack of Fusion
Poor welder skill Incorrect welding current/voltage or low t/ lt l heat input. High travel speed Incorrect inter-run inter run cleaning
Root Defect
Profile Defects
Poor cap profiles and excessive cap reinforcements may lead to stress concentration points at p the weld toes.
Undercut Underc t
An irregular g g groove at the toe of a weld run in the parent metal
Excessive amps/volts Excessive travel speed d Excessive weaving g Electrode dia too large
Root faces too small Root gap too large Excessive amps/volts Slow travel speed Lack f L k of welder skill ld kill Use of unsuited electrode in welding position
High Amps/volts Small S ll root f t face Large root gap Slow Travel Speed Lack of welder skill
Root Defects
Crater Pipe
Crater pipe is a shrinkage defect and not a gas defect
Crater Pipe
Linear Misalignment
Exercise 1
Exercise 2
Exercise 3 E i
Thank You