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Arc stray flash may cause many problems including several type of
cracks depends on type of steel, Arc strike can cause a depression bringing below the
design throat thickness. Grind and remove. DPI or MPI after filling re inspection DPI or
MPI.
2) Planner defects:
1. Cracks, 2. Lack of fusion
5) Mechanical Testing:
Charpy impact test
Brillness hardness
kJ/ F
BHN
6) Lack of Fusion:
Lack of fusion imperfection are defined as a lack of union between two
adjacent areas presence of
Slag, oxides, scale.
Lack of welder skill.
Poor manipulation of the welding process.
Magnetic arc blow. Poor Inter run cleaning.
7) Lack of Penetration:
Lack of penetration can caused by a small root gap which is not melted due to
insufficient current, big electrode size, poor welding technique.
9) Burn Through:
Burn through defined as local collapse of the weld puddle causing a hole. Depression
in the final weld root bead large root gap. Small face, High current.
Cracks:
Hydrogen Induced Crack HAZ
Hydrogen Induced crack Weld metal
Solidification cracks.
Lamellar tearing.
Intercrystaline corrosion.
Hydrogen crack HAZ:
Hydrogen induced crack may occur on the weld metal or HAZ. Depends on type of
steel welded. Hydrogen absorbs electric from water, oil, and moisture. Breaking
shielding gas Hydrogen can dissolve Weld molten metal and remains in solution on
solidification austenite cool transform to ferrite. Hydrogen has less solubility and wants
to diffuse increasing the temperature diffusion increases.
1. To preheat the weldment and ret ravels the rate of cooling
Reduce the Carbon percentage
2. Low Hydrogen consumable used.
Weld metal:
In a steel having 0.83% carbon will increase the tensile strength of plain carbon
steel, matching the weld metal to base metal results in a high hardenable. This may
results the cracking in the weld metal.
Solidification Crack or Hot Cracking:
This type of crack may occur during solidification of welds in steels having high
sulphur content.
During welding sulphur on the plate may remelt and will join with the iron to form
iron sulphides. Iron sulphides low melting point impurities at the grain boundaries
(e.g.) sulphur, phosphorous.
To check mill sheet sulphur content.
To add manganese via Electrode consumables
Lamellar Tear:
Lamellar Tear can cause the internal stress or contract ional through the thickness of the
weld. The metal having Lack of ductility. Check the sulphur 0.05 analysis and for
Lamination with ut, pt on plate edges, a gap can lift between horizontal members
And vertical member
Type of volumetric Defects?
Porosity, slag inclusion, Burn through
Porosity; internal gas filled in the weld metal
Causes; scale, grease, rust on the surface of the plate, moister content in the electrode,
temporary shielding gas.
Remedies, the plate should clean without any contamination, Electrode storage, electrode
baking 350 c, avoid damp condition
Slag; slag entrapped in the weld metal during welding
Improper cleaning between weld beads, improper technique used
Which ndt method detect crack?
Ultrasonic testing, radiographic testing
RT
Permanent record
Fluoroscopy can give real
Time imaging
Most materials can be tested
Detect internal flaws
UT
No permanent record unless automated
Difficult to interpret
MPI
It will detect sub surface (6mm)
Magnetization may require
(Ferromagnetic materials)
Simple equipment
Precleaning not as critical as with
Mpi
DPI
Open to the surface only
Applicable to non-ferromagnetic materials
require calibration
High operator skill required
Quantive test
hardness test
Charpy impact test
Tensile test
Root Bend;
Root bend test is the test carried out root area under tension, face in compression to detect
soundness, ductility of the materials
Face Bend test; face bend test is the face side is under tension, and root side is
compression to detect any imperfection on the surface and near surface also ductility of
the metal
Side bend test; side bend is carried out one side is tension and other side is compression
To detect a side wall, lof&HAZ and also ductility of the material
B- BASIC
R-RUTILE
AR-ACID RUTILE
O-OXIDISING
C-CELLULOSE
RR-RUTILE HEAVY COATED
E-51 33 B 160 2 0 H
51 -Tensile strength
33 -Impact value (toughness)
B -electrode coating
160 -Electrode efficiency
2 - Position
0 -electrical parameters
H -Low hydrogen
MICRO
With Aid (seeing magnifying glass
Microscope)
MACRO
With out Aid (Normal light view)
Preheat:
The purpose of preheat is to control structure of the weld metal and haz
It controls expansion and contraction
To control the formation of H2 cracks
Distortion;
Distortion is the movement of material in one area caused by contraction and expansion
Witch misshapes the component, to control the distortion use clamps, jigs bridging
Tack welds severely restrict any movement of materials.