FABRICATION, WELDING AND INSPECTION BASICS FOR MAINTENANCE ENGINEER

Systematic Approach to Maintenance and Repair welding

By Mr. Nilendu Desai; Certified AWS Welding Inspector, Industrial Quality Concepts

Maintenance Welding:
Maintenance and Repair are distinct and separate operations but have common
attributes. Both require individuals possessing a broad knowledge of welding and
materials.
Maintenance is accomplished during scheduled outages or down time. Good preventive
maintenance performance requires ability to keep equipment in service without a major
shut down.
Repair work or corrective maintenance involves the salvage of parts that are broken or
worn and typically inoperable for continuous use.
Planning is essential before performing any welding repair or preventive maintenance
operation.
Welding Repair Planning Check List:
Equipment or Component Analysis:
Is the equipment or component a welded fabrication,
Defect location and type: Visual Examination,
Non destructive Examination,
Destructive Examination
Defect repair and service conditions : Should it be repaired,
Potential for future failure, Cost v/s Replacement Design Flaws,
What are the base Metals :
Document source to this information

FABRICATION, WELDING AND INSPECTION BASICS FOR MAINTENANCE ENGINEER

Operating and Maintenance Manuals

Physical methods to determine the base materials

Heat Treated conditions of the base metals
Are the Base Metals Weldable :
When they are and when they are not
Dissimilar weld metals
Distortion and Shrinkage:
Structural Restraints and Process Restraints
Standards and Codes:
Applicable welding Codes,
Preparation of the defect or worn parts:
Is the job accessible to the welder
Methods of material removal
Clean and safe working environment
Ensuring defect removal.
Development of Repair Procedure:
Selection of welding process,
Size and position of Repair
Type of Filler Metal
Service conditions
Physical and Metallurgical nature of base Metal

FABRICATION, WELDING AND INSPECTION BASICS FOR MAINTENANCE ENGINEER

Welding parameters

Dissimilar filler metal applications

Cleaning before and during the welding repair
Material categories
Tests to determine weldability
Techniques to deal with distortion
How to minimize Shrinkage
Material Removal
Filler Metals:
Corrosion Resistance
Match base material Chemistry
Match Mechanical properties
Preheating : If required
Post weld heating
Re inspection after completion of the repair
Types and size of defects
Commonly used NDT methods
Service life of the equipment.

Determine the Nature of Defect:

FABRICATION, WELDING AND INSPECTION BASICS FOR MAINTENANCE ENGINEER

Inspection of the worn or fractured surfaces first by Visual inspection and other NDE
methods helps in determine the nature and extent of the failure.
NDE methods include PT, MT, RT, UT,ET. And Hardness test.

Determine the base metal weldability

Most materials are readily weldable. It is important to know the material chemistry and
hardness in order to prepare a successful welding procedure. This information
sometimes may be found in parts manuals or by checking with manufacturers service
department. If necessary have the suspect material analyzed for its chemical
composition.
Determine Matching Filler Metal:
Electrode Chemistry and mechanical properties must be determined next in the planning
of sound maintenance and repair procedures. The cause of a fracture can have an
influence on the type of electrode selected for repair. A good rule is to use an electrode
with the same corrosion resistance and tensile strength as the parent material.
Shrinkage and Distortion:
Welding shrinkage commonly means the decrease in volume that occurs when molten
weld metal solidifies. Welding in flat or horizontal position with resultant higher travel
speeds tends to reduce the net shrinkage. Preheating to reduce the net shrinkage.
Preheating helps to reduce heating and cooling temperature gradient. Although
preheating depends upon the thickness and carbon equivalent.
Determine Welding Standards :
Welding repair procedures should be in accordance with applicable Codes, Standards,
Specifications, Recommended practices, Classifications and Methods.

Establishing Repair Procedure:

The purpose of welding repair procedure is to identify all of the variables necessary to
complete the repair. The repair procedure consists of the technical details usually
specified in welding procedures plus other ancillary details involving setup, fit-up,
welding positions, size of fillet welds, thickness of metal for groove welds, electrode size
and classification, preheating, post weld heating, amperage, voltage and sequence of
weld bead passes and travel speed.
Preparation of Defect Area:

FABRICATION, WELDING AND INSPECTION BASICS FOR MAINTENANCE ENGINEER

One of the most important considerations of a welding repair procedure is to clean the
fracture area or the worn part of all grease, paints, moisture, dirt, rust, spalled material,
or any other condition that may be detrimental.

General Concepts of welding Consumables:

In General

The prefix E designates Arc Welding Electrode

The first two digits of four digit numbers and the first three digits of
five digit number indicates minimum tensile strength.
E-60xx- 60000 psi Minimum tensile strength
E-70xx-70000 psi Minimum tensile strength
The next to last digits indicates position
E-xx1x All positions
E-xx2x-Flat position and horizontal fillets
The last two digits indicate the types of electrode covering, current and polarity. All low
hydrogen type covering (those ending in EXX-15, Exx-16, Exx-18) must be kept in an
oven at 250Deg. C minimum before use.
The suffix e.g. EXXX-A1 indicates the approximate alloy composition in the weld
deposits.
A1-0.5% Mo
C2 3.5%Ni
B1-0.5% Cr, 0.5%Mo,
B2-1.25% Cr, 0.5% Mo

C3- 1% Ni, 0.3% Mo, 0.15% Cr

D1,D2- 0.25 to 0.45% Mo, 1.75%mn

B3-2.25% Cr, 1% Mo
B4-2% Cr, 0.5% Mo

D3-0.4 to 0.65% Mo, 1.5% Mn

C1-2.5% Ni Coated type :

Coated Electrodes : Used in SMAW process (Shielded Metal Arc Welding).
e.g. E 6013 : E Electrode

FABRICATION, WELDING AND INSPECTION BASICS FOR MAINTENANCE ENGINEER

60- stands for deposited weld metal strength 60000 psi

1-stands for all position welding electrode.

13-stands for coating characteristic- Type of Current DC electrode Negative.
Coated type :
Coated Electrodes : Used in SMAW process (Shielded Metal Arc Welding).
e.g. E 6013 : E Electrode
60- stands for deposited weld metal strength 60000 psi
1-stands for all position welding electrode.
13-stands for coating characteristic- Type of Current DC electrode Negative.

E7018 E-electrode
70-deposited weld metal strength 70000 psi
1-stands for all position
18 stands for Type of Current DC Electrode positive.

Coding and
Classification

Typical weld Metal

Properties

Current and Packing Data

Size Length Current Pieces per

FABRICATION, WELDING AND INSPECTION BASICS FOR MAINTENANCE ENGINEER

% Chemical

AWS 5.1 E 7018

Physical

C-0.06
YS 470 N/mm
Mn-1.25 UTS-550N/mm
Si-0.42

Stainless Steel Electrode :

AWS A 5.4 E 316-16
C-0.05

mm

Amps

Carton

2.50
3.15

350
450

60-100
100-140

100
75

E-28%
4.00
CVN at 30Deg.C 5.00

450
450

150-200
200-240

50
30

70Joules

6.00

450

270-360
20
AC. DC+ve

2.50

300

50-70

3.15
4.00

350
350

70-100
100-140

5.00

350

140-180
30
AC, DC+ve

UTS 590 N/mm

Mn-1.5 E-40%
Si- 0.50 FN-6
Cr-19

mm

100
60
50

Selection of Electrode for welding when base metal is knownSelection of electrode is dependant mainly on the chemical and mechanical properties of
the base metal.
a) Find the chemical composition of the base metal, Find the Ultimate tensile strength of
the base metal.
b) Select the welding process which is most suitable for the repair job.
c) Select the appropriate the electrode which is matching the nearest chemical and
mechanical properties of the base metal.
d) Select appropriate diameter of the electrode and appropriate current for the same.

FABRICATION, WELDING AND INSPECTION BASICS FOR MAINTENANCE ENGINEER

F Numbers :
Grouping of Electrodes and Welding Rods have been suggested in ASME Section IX.
Is based essentially on their usability characteristics which fundamentally determine the
ability of welders to make satisfactory welds.
e.g.
F No.

ASME Specification

SFA 5.1

SFA 5.4 Austenitic and

Duplex

AWS Classifications
EXX18
EXXX-16

A Numbers :
Identification of weld metal chemical composition designated on the WPS and PQR.
It is meant for Ferrous metals only.
Selection of the proper detection method for defects.
Inspection of the worn out surfaces first by visual inspection and other NDE methods
helps in determine the nature and extent of the failure. Visual Inspection may be
supplemented with remote visual videos using computer enhancement and macrographic
examinations.
NDE methods include : Liquid Penetrant examination : LPT
Magnetic particle examination : MPT

FABRICATION, WELDING AND INSPECTION BASICS FOR MAINTENANCE ENGINEER

Radiography examination : RT

Ultrasonic examination : UT
Eddy Current examination : ET
All this methods have their own limitations and shall be appropriately used.

Interpretation Criterion:
The personnel conducting NDE shall be fully conversant with the method and preferably
shall be qualified to a level-II structure so that he can perform the NDE in the correct
manner and interpret the defects.
Inspectors perspective of the difficulties and problems encountered during welding of
various metals:
Carbon and low alloy Steels can be welded by arc , oxyfuel, laser beam, electron beam
and other welding processes.
Filler Metals. : Suitable welding filler metals are available for all groups of carbon and
low alloy steels. Filler metals should be selected to provide the mechanical properties
that are required for the intended service conditions. Chemical composition, Corrosion
resistance , and heat treatment are other important considerations in choosing a filler
metal. The diffusible weld metal hydrogen level of welding electrodes and filler metals is
particularly important when welding carbon and low alloy steels.

Weldability:
The heat of welding, thermal cutting causes changes in microstructure and mechanical
properties in region of the heated steel is referred as HAZ. The resulting microstructure
in
HAZ will depend upon the composition and the rate at which the steel is heated and
cooled..
With some steels the thermal cycle may result in the formation of martnsite in the weld
metal and HAZ. The amount of martensite formed and the hardness of the steel depend
upon the carbon equivalent of the steel. Martensitic transformation and the resulting
high hardness can lead to cracking in the weld or HAZ. Weldability and resistance to
hydrogen cracking generally decreases with increasing carbon or martensite in the weld
metal HAZ.
Hydrogen Cracking : It is also known as under bead cracking or delayed cracking. It can
occur when welding carbon and low alloy steels. The potential for hydrogen cracking in
weld metal or HAZ depends upon composition, hydrogen content, and stress level. It
generally occurs at a temperature level below 150Deg.c immediately upon cooling or
after a period of several hours.
Hydrogen cracking or cold cracking results when both hydrogen and tensile stresses are
present in a crack-susceptible microstructure of the weld metal or HAZ. Sometimes
cracking may occur in the weld metal particularly hen yield strength is over 90 ksi, in
general high alloy steels are more likely to crack in HAZ. Diffussion of hydrogen into HAZ
from the weld metal during welding contributes to cracking. Microstructure and tensile
stresses also contributes to the same.
To summarize hydrogen cracking in welded joints is associated with the combined
presence of four conditions namely :

FABRICATION, WELDING AND INSPECTION BASICS FOR MAINTENANCE ENGINEER

1) presence of diffusible hydrogen in the steel

2) A susceptible microstructure, generally accepted to be partly or wholly martensitic.

3) A tensile stress at sensitive location
4) A temperature below 150 Deg. C
Welding Process : Available hydrogen during welding can be limited by using a low
hydrogen process. Primary sources of hydrogen are cellulose, moisture or both in the
electrode covering with shielded metal arc welding. Other sources of hydrogen are
adsorbed moisture, rust or hydrocarbon contaminants(Oil, grease, etc.)
The use of low hydrogen welding electrodes is recommended for shielded metal arc
welding of steels that are susceptible to hydrogen cracking.

Welding Processes:
Shielded Metal Arc Welding : SMAW:
It is a constant current power supply. The decrease in arc voltage will result in increase
in arc current. The arc voltage is directly related to the arc length(distance from the
electrode to work piece.) i.e as the welder moves the electrode towards or away from
the work piece, the arc voltage is decreasing or increasing respectively.
These voltage changes correspond with the changes in the arc current or amount of heat
created by the welding arc. So as the welder draws the electrode away from the work
piece, the arc length increases which reduces the current and consequently reduces the
heat input in the weld. Porosity will occur when arc is too long.
One of the limitations is speed and affects productivity.
Arc Blow: There is a magnetic field whenever an electric current is passed through the
conductor. This magnetic field is developed in a direction perpendicular to the direction
of the electric current. Now when welding a magnetic material such as steel, the field
can become distorted when the arc approaches the edge of a plate, the end of a weld or
some abrupt change in contour of the part being welded. To reduce the effects of arc
blow, several alternatives can be tried.
1) Change from DC to AC.
2) Hold as short an arc as possible
3) Reduce the welding current
4) Angle the electrode in the direction opposite the arc blow.
5) Use heavy tack welds.
6) Use a back step technique.
In addition arc blow can also cause spatter, undercut, improper weld contour, and
decreased penetration.

FABRICATION, WELDING AND INSPECTION BASICS FOR MAINTENANCE ENGINEER

Gas Tungsten Arc Welding: (GTAW)

The most significant feature of GTAW is that the electrode used is not intended to be
consumed during the welding operation. It is made of alloyed tungsten which has the
ability to withstand very high temperatures. Here the arc is created between the
electrode and the work piece. When filler metal is required it is added externally, usually
manual or mechanical. The arc and metal shielding is achieved by the use of inert gas
which flows through the nozzle. The deposited weld metal has no slag.

GTAW can be performed using DCEP, DCEN or AC. Since no flux is used it produces
welds of high quality and good visual appearance.
Disadvantages :
It is the slowest welding process.

It has low tolerance for contamination.

Tungsten Inclusion.

Reasons for Tungsten Inclusion:

Contact of electrode tip with molten metal.

Contamination of the electrode tip by spatter.

Exceeding the current limit for a given electrode diameter or type.

Extension of electrodes beyond their normal distances from the collet resulting
in overheating of the tungsten electrode.

Defects such as spilts or cracks in the electrode.

Improper grinding of the electrode tip.