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DESIGN PART 4
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Design - Part 4 - TWI Page 2 of 7
Part 1
Part 2
Part 3
Part 5
The previous article looked briefly at butt weld design where mention was made of
the increased risk of producing defects as the bevel angle or the root gap is
reduced. Bevelling the plate edges allows access to all parts of the joint, enabling
good fusion throughout the weld to be achieved. The bevel can be on one or both
edges of the items to be joined. What is important is the included angle which is
dictated by the need both to achieve the correct torch/electrode angle and to
maintain the required arc length and wire stick-out. as shown in Fig.1. The angle
double bevel V-joint if access problems are not to be encountered. Experience has
shown that a weld preparation angle of 45° on a single bevel joint is usually
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Fig.1. Effect >
of a narrow weld preparation angle
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A similar effect is produced by too narrow a root gap where, as above, there is
insufficient access to permit a correct arc length to be achieved and the arc cannot
be placed in the correct position. Conversely, too wide a root gap on an unbacked
weld will require a large, wide weld pool to bridge the gap, resulting in melt
through, a loss of control of the pool and the formation of localised excess weld
As may be guessed from the above, the most problematic region in a weld is that
of the root pass. Single sided joints require dimensionally accurate weld
preparations and fit-up and skilled welders to ensure full penetration welds with
an acceptable root contour. The best root pass appearance using conventional arc
welding processes will be achieved using the TIG process but acceptable root
conditions can also be achieved with MMA, MIG/MAG and FCAW welding.
When welding, it is obviously easier for the welder when there is a sound base on
which to deposit the weld metal; hence the need for a very skilled welder when
illustrated in Fig.3 of Connect article no. 92. However, note that this type of joint is
Where access to the reverse side of a partial penetration weld is available, then the
fabricator has the option of depositing a sealing pass. Remember, however, that
most welding processes have only limited penetration and there is a real risk that
not all of the unfused land will be melted away. To be certain of removing the
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unfused land, 'back gouging' the root and filling the groove with sound weld metal
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is generally carried out. Backgouging, or removal of the unfused land, can be done
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by any of the conventional metal removal techniques; machining, arc air gouging,
chipping, grinding etc (Fig.2). Of these methods, arc air gouging is probably the
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Design - Part 4 - TWI Page 4 of 7
most cost effective and can produce a smooth contoured U-shaped groove with an
The back gouging must be sufficiently deep that any lack of penetration is
removed. To confirm that this has been done it is good practice to perform
is to use a backing strip which will provide support for a fully penetrated root pass.
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In addition to providing support for the root pass, a further major advantage of
the backing strip weld is that fit-up tolerances may be relaxed as the strip acts as a
locating feature. This is particularly so when pipe butt welding where the strip
forms a spigot on which to centre the joining pipe. In addition root gap may be
varied, the only real limitations being those of cost; the wider the root gap the
The strip must be compatible with the filler metal and the parent base metal. It
must be correctly fitted, in close contact with both edges of the weld preparation
and welded into position using intermittent tack welds. Any gap between the
backing strip and the plate edges is a site for slag entrapment and results in a poor
root profile. To ensure full fusion in the root of the weld it is advisable to use a
feather edge and to direct the welding arc at the plate/pipe edges.
When a permanent backing strip cannot be used, then a temporary backing bar
temporary backing as a 'bar'). As the name suggests this is a backing that is easily
removed at the end of the welding operation; it has not become fused to the root
pass.
steel and nickel based alloys to prevent contamination. Austenitic stainless steel
has also been used. The metal backing bars may be water cooled to aid heat loss
and may be grooved to provide a mould for the molten weld metal. Welding
conditions and fit-up must be carefully controlled to prevent the welding arc from
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Ceramic backing bars can be obtained in a variety of sizes with shaped grooves to
form a weld pool mould. They may be rigid bars of ceramic or articulated such that
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they can be wrapped around the inside diameter of a pipe or tube. Ceramic tapes
These tapes have wide strips of adhesive either side of the ceramic tile to enable
the tape to be held in place during welding and peeled off on completion. As with
the permanent backing strip, care needs to be taken to ensure that the ceramic tile
is in close contact with the metal surfaces otherwise slag and/or weld metal will
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