Welder Handbook – PT McDermott Indonesia

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Welder Handbook – PT McDermott Indonesia
1. SMAW Trouble shooting
(Shielded Metal Arc Welding)
WELD SPATTER
Correction Action:
➢ Lower Current
➢ Be sure the polarity is correct
➢ Try a shorter arc length
➢ Change the electrode angle, if molten
metal is running in the front of the arc.
➢ Watch for the arc blow
➢ Be sure the electrode is not
contaminated
UNDERCUT
Corrective Action:
➢ Reduce current, travel speed, electrode
size.
➢ Change the electrode angle
➢ Use uniform travel speed
➢ Avoid excessive weaving
POROSITY
Corrective Action:
➢ Remove foreign matter (scale, rust,
paint, moisture or dirt) from the joint
➢ Use short arc length
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SLAG INCLUSION
Corrective Action:
➢ Use proper inter-pass cleaning
➢ Use proper welding technique
INCOMPLETE ROOT PENETRATION
Corrective Action:
➢ Use higher currents (see WPS)
➢ Use correct arc length
➢ Use correct size electrode diameter
to reach into deep, narrow grooves
HOT CRACKING
Corrective Action:
➢ Crater crack can be minimized
through the use of a run-off tab.
➢ By cleaning the joints to remove
surface contaminants.
COLD CRACKING
Corrective Action:
➢ Pre-heating to reduce the amount of
hydrogen in the weld and HAZ
➢ Filler metal, fluxes and shielding gas
are properly stored, handled and
utilized to prevent moisture pick-up
and contaminants.
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2. SAW Trouble shooting

(Submerge Arc Welding) POROSITY
Corrective Action:
LOW PENETRATION ➢ Increase voltage
Corrective Action: ➢ Lower current
➢ Increase Welding Current ➢ Clean joint completely
➢ Use electrode positive (DCEP) ➢ Decrease speed
➢ Lower voltage
➢ Use shorter stick out POOR BEAD SHAPE
➢ Decrease arc speed Corrective Action:
➢ Increase voltage to get wider flatter
DIFFICULTY IN SLAG REMOVAL bead
Corrective Action: ➢ Decrease current to get flatter bead
➢ Decrease voltage ➢ Decrease speed to get flatter bead on
➢ Decrease current fillets
➢ Clean mill scale, rust & oil off plate

UNDERCUTTING
Corrective Action:
➢ Use electrode negative (DCEN)
➢ Decrease voltage
➢ Decrease current
➢ Decrease speed

CRACKING
Corrective Action:
➢ Use electrode negative (DCEN)
➢ Lower voltage
➢ Decrease travel
➢ Preheat
➢ Make sure that back gauging is not
narrow and deep
➢ Check for copper pick-up
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3. FCAW Trouble shooting

ELECTRODE FEEDING
(Flux Core Arc Welding)
Corrective Action:
POROSITY ➢ Reduce drive roll pressure
Corrective Action: ➢ Reduce voltage
➢ Clean weld joint faces ➢ Replace worn liner
➢ Shield weld zone from draft/wind ➢ Change conduit liner
➢ Regular gas flow
➢ Check for leaks in hoses and fittings
➢ Clean oil from rollers
➢ Avoid shop dirt
➢ Follow correct electrical parameters
➢ Reset stick out

INCOMPLETE FUSION OR Underfill

PENETRATION
Corrective Action:
➢ Direct electrode to the joint root
➢ Increase current
➢ Decrease stick out
➢ Reduce wire size
➢ Increase root opening
➢ Decrease root face

CRACKING
Corrective Action:
➢ Reduce restraint
➢ Preheat
➢ Use more ductile weld metal
➢ Use peening if allowed
➢ Use correct filler wire
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4. GTAW Trouble shooting

➢ Keep gas flowing after stopping arc for
(Gas Tungsten Arc Welding)
at least 10-15 seconds.
TUNGSTEN INCUSION
Corrective Action:
➢ Avoid contact of the electrode tip with
the molten weld pool and filler wire
➢ Ensure electrode tip is clean
➢ Use correct electrical parameters
➢ Tighten holding collet or electrode chuck
➢ Ensure adequate shielding

POROSITY
Corrective Action:
➢ Blow out air from all lines before striking
arc.
➢ Remove condense moisture from line
➢ Use welding grade (99.99%) inert gas
➢ Check hoses and connection for leaks
➢ Clean base metal with chemical cleaner
and allow to dry prior to welding

EXCESSIVE ELECTRODE
CONSUMPTION
Corrective Action:
➢ Use larger electrode and change to
straight polarity
➢ Ensure proper collet contact
➢ Remove contaminated portion of
electrode
➢ Use proper gas shield
Welder Handbook – PT McDermott Indonesia
5. GMAW Trouble shooting
(Gas Metal Arc Welding)
UNDERCUTTING
Corrective Action:
➢ Reduce travel speed, voltage, and wire
feed speed
➢ Increase dwell time of electrode and
edge of molten weld pool.
➢ Change gun angle so arc force can aid
in metal placement
POROSITY
Corrective Action:
➢ Optimize gas flow and eliminate air
drafts
➢ Use welding grade shielding gas
➢ Use only clean and dry electrodes
➢ Clean weld surfaces
➢ Reduce voltage and electrical stick out
INCOMPLETE FUSION
Corrective Action:
➢ Clean all weld surfaces
➢ Increase wire feed speed and voltage
but reduce electrode extension
➢ Increase travel speed and minimize
excessive weaving
➢ While welding, dwell momentarily on the
side walls of the groove
➢ Use correct groove angle
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EXCESSIVE MELT-THROUGH
Corrective Action:
➢ Reduce wire feed speed and voltage
➢ Increase travel speed
➢ Reduce root opening
➢ Increase root face dimension
WELD METAL CRACKS
Corrective Action:
➢ Maintain proper groove dimensions
➢ Decrease travel speed to increase
cross section of the weld deposit
➢ Reduce current and voltage
➢ Increase travel speed
➢ Use preheat
➢ Eliminate craters by back-stepping
techniques.
HEAT AFFECTED ZONE CRACKS
Corrective Action:
➢ Preheat
➢ Use stress relieving
➢ Use clean electrodes and dry
shielding gas
➢ Clean base metal
Welder Handbook – PT McDermott Indonesia 29
Figure 6.a. Dye Penetrant Testing
6. INTRODUCTION TO
BASIC NON
DESTRUCTIVE TEST
(NDT)
A. LIQUID PENETRANT TEST (Dye
Penetrant Testing)
Figure 6.b. Magnetic Particle Testing
NDT method for finding discontinuities that
is open to the surface. Being used to
inspect all types of materials provided they
are open to the surface.
B. MAGNETIC PARTICLE TESTING (MPI)
Being used for finding surface or near
surface defects in magnetic material such
as carbon steel. Able to detect:
➢ Surface crack in Weld and HAZ
➢ Lamination on Base Metal
➢ Incomplete fusion and undercut
Limited to ferromagnetic materials only.

C. RADIOGRAPHY (RT)
NDT that can produce a visible image of
weld defects, either surface or sub surface
such as slag, porosity, lack of fusion and
excess pen.
RT cannot find very narrow discontinuities
such as cracks, laminations, and laps that
are not aligned with the radiation beam.
Radiation hazard during operation.
Welder Handbook – PT McDermott Indonesia 30

D. ULTRASONIC INSPECTION (UT) Figure 6.d. Ultrasonic Inspection (UT)

Very common method of NDT primarily for

detection of internal defects.
Determines the position of the defect,
estimating their size, orientation, depth,
shape and type of defect.
Requires clean surface free of spatters,
clean surface of base materials to have an
effective inspection.

Figure 6.c. Radiography Testing (RT)

Welder Handbook – PT McDermott Indonesia 31

7. TYPES OF DEFECTS & DESIRABLE FILLET WELD PROFILES

DISCONTINUITIES

ACCEPTABLE FILLET WELD PROFILES

UNACCEPTABLE FILLET WELD

PROFILES
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ACCEPTABLE BUTT WELD PROFILES

UNACCEPTABLE BUTT WELD PROFILES

Welder Handbook – PT McDermott Indonesia 33

INCOMPLETE FUSION
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Welder Handbook – PT McDermott Indonesia 35

Crack In Weld
Transverse Cracks In weld,
Propagated in to
HAZ and BM
Longitudinal In weld or BM HAZ
Cracks adjacent to weld
fusion boundary
Crater cracks In weld, pointed at
where arc is
terminated
Toe Cracks Junction between
face of weld & BM
Root Cracks In weld metal, root

SPATERS
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8. WELDING SYMBOLS