Problem-solving model

Determine
Identify
root cause

Standardize

Develop
corrective
actions
Validate
and verify
corrective
actions
 Failur Mode

Operation:
Maintenance: - Overload
- Lack of lubrication - Incorrect usage
- Loose connection - etc
- etc
Fabricatian:
- Weld defects
- Wrong heat treament
Failur Mode - etc

Design:
- Material selection
Other - Configuration
- etc
Discontinuities and Defects in Fusion Welds
Cracks in Welded Joints
 Factors affecting incomplete fusion in weld metal
Oversized Insufficient
electrode backgouging

Misalignment of Excessive root Wrong included Incomplete

second side weld face angle slag removal

Wrong Low heat input Insufficient Improper bead Dirty surface Wrong welding
electrode angle gap shape technique

Wrong work Heat of arc does not Improper joint Heat of arc does not High travel
position melt underlying geometry reach underlying metal speed

Causes
Incomplete fusion
Cures
Better Heat of arc melts Proper joint Heat of arch reaches Proper welding
alignment underluing metal geometry underlying metal technique

Improved High heat Sufficient Optimal Proper Clean Low travel

wor position input gap included angle backgouging surface speed

Proper bead Optimal Optimal Complete Better electrode

shape root face electrode size slag removal angle
 Factors affecting incomplete penetration in weld metal
Oversized Insufficient
electrode backgouging

Wrong electrode Excessive root Tight root Incomplete

angle face opening slag removal

incorect
Unstable arc Low heat input Insufficient Improper bead Dirty surface welding
root opening shape technique

High travel Heat of arc does not Improper joint Heat of arc does not Long stickout
speed melt underlying geometry reach underlying metal

Causes
Incomplete penetration
Cures
Heat of arc melts Better electrode Proper joint Heat of arch reaches Stabilized arc
underluing metal angle geometry underlying metal

High heat Low travel Sufficient Optimal Proper Clean Proper welding
input speed root opening included angle backgouging surface technique

Optimal Proper bead Optimal Complete Short stickout

root face shape electrode size slag removal
 Factors affecting porosity in weld metal

High travel
speed Electrode
coverings Rapid
dissociate at cooling,
Moisture oil, Sulfur > 0,05%
high hydrogen
paint, rust in base metal
Current too temperature present from Insufficing
and grease welding
low shielding

Long arc Trapped gas C + O CO S + O2 SO2 Hydrogen Poor fit-up

legth S + H2 H2S bubbles

Causes

Porosity
Cures
Lower travel Use short arc Improve fit-up
Decrease surface Manganese or
speed tension and silikon; remove
viscosity of melt
oxygen before
SO2 or CO can
Eliminate Low sulfur steel, Clean metal
form
moisture < 0,05%

Use low hydrogen

electrodes
 Factors affecting slag inclusion in weld metal

Slag not
V shaped removed from
Electrode too junction of bead
recess or
large to and base metal
convex weld
Low High energy reach bottom
bead shape;
temperature welding of groove
low heat at
bottom

Oxygen or
High viscosity Stirring High Slag falls to
nitrogen +
temperature bottom of V
manganese or
Slag not silicon, and
removed aluminium (in
between Slag cannot Slag forced back into Bond line or large amounts)
passes rise to surface melt or remelting root slag

Causes
Slag inclusions
Cures
Use proper Remove all slag Use proper size
energy input between passes electrodes Avoid excessive
amounts of
oxygen,
Slower cooling Improve joint Improved flux nitrogen,
rate abd bead shape composition manganese,
silicon, and
aluminium
Remove bond line
slag
 Factors affecting hot cracking in weld metal

Low weld Poor joint

current preparation

Small weld No or low

preheat Poor weld
Mainly sulfur (also profile
oxygen and
High thermal selenium) froms
High Poor fit-up
stress iron sulfur at grain
restraint
boundries
Excessive
travel speed Unbalanced
Reduced grain Poor
heat input electrode
boundary cohesion
Small manipulation
electrode Causes
Hot cracking of weld metal
Cures
Decrease Increased hot
travel speed ductility
Low sulfur High preheat
steel
Large
electrode Manganese froms with
Eliminate or Balanced heat sulfur, oygen, and
decrease restraint input selenium into globular
Inproved joint inclusions before iron
design, fit-up, and can react (hinger
tecnique Excess manganese temperature reaction)
Increase weld
present
current
 Factors affecting hot cracking in base metal

Tensile stress Presence of High alloy

sulfur content

Excessive weld Sulfur High carbon

segregation content

Causes
Hot cracking of base metal
Microcracking

Cures

Preheat Decrease Improved joint

strain design

Controlled Low sulfur High

heating and steel manganese to
cooling rates ratio, 50 to 1
or more
 Causes and cures of cold cracking in weld metal
Low amperage, Dirty, greasy, or Hydrogen
high speed contaminated surface electrodes

High TSN, high Low heat input No preheat Hydrogen contamination

plate thickness

Poor joint design Fast cooling of weld metal Hydrogen diffusion to

and fit-up weld metal

High stress Susceptible Hydrogen trapped in weld

microstruture metal

Causes
Cold cracking of weld metal
Microfissures, Microcracks, Weld metal cracks

Cures
Nonsusceptible Postheat stress Hydrogen free welding
microstructure relief

Slow cooling High heat input Clean, wire Use low

brush, and/or hydrogen
grind surface electrodes

Preheat Interpass High amperage,

temperature control low speed
 Causes and cures of cold cracking in base metal

Low amperage, Dirty, greasy, or Hydrogen

high speed contaminated surface electrodes

High TSN, high Low heat input No preheat Hydrogen contamination

plate thickness

Poor joint design Fast cooling of weld metal High carbon

Hydrogen diffusion to
and fit-up equivalent
base metal

High stress Hard, brittle Hydrogen trapped in

martensitic structure martensite lattice

Causes
Cold cracking of base metal
Underbead cracking, Heat affected zone cracking, Hydrogencracking, Delayed cracking

Cures
Ductile, non Postheat stress Hydrogen free welding
martensitic structur relief

Low carbon Slow cooling High weld heat Clean, wire Use low
equivalent hydrogen
brush, and/or
grind surface electrodes

Preheat Interpass High amperage,

temperature control low speed
 Welding
Parameters
(thermal cycle)

Size of Thermal
Mushy Strain
Zone Distribution

Alloy
Composition Weld Fixturing
(solidification (restraint intensity)
range) Mechanical
Response
 Welding

Material Stucture

When ? Where ? Why ? What ?

Welding Crack Consider Mechanical Thermal

location load load

Post weld Base Weldment Stress Allotrope

treatment metal Stress rate reaction

Servise HAZ Micro Strain Physical

condition structure Strain rate reaction

Life time Fusion Weld Lattice Displace Chemical

line metal ment composition

Transition Atom Ambient Residual

precipitation media stress

Distance to Super
fusion line position
Distorsi
 2003 Brooks/Cole, a division of Thomson Learning, Inc. Thomson Learning is a trademark used herein under
license.

Figure 8.8 (a) If the liquid is undercooled, a protuberance on

the solid-liquid interface can grow rapidly as a dendrite. The
latent heat of fusion is removed by raising the temperature of
the liquid back to the freezing temperature. (b) Scanning
electron micrograph of dendrites in steel (x 15)
Figure 8.9 (a) The secondary dendrite arm spacing
(SDAS). (b) Dendrites in an aluminum alloy (x 50).
(From ASM Handbook, Vol. 9, Metallography and
Microstructure (1985), ASM International, Materials
Park, OH 44073-0002.)
 2003 Brooks/Cole, a division of Thomson Learning, Inc. Thomson Learning is a trademark used
herein under license.

Figure 8.17 (a) Shrinkage can occur between the dendrite

arms. (b) Small secondary dendrite arm spacings result in
smaller, more evenly distributed shrinkage porosity. (c)
Short primary arms can help avoid shrinkage. (d)
Interdendritic shrinkage in an aluminum alloy is shown (x
80)
 Creep

Stress (logarithmic scale) versus rupture

lifetime (logarithmic scale) for a low
carbonnickel alloy at three temperatures.

Jurusan Teknik Mesin FTI -

Internal Stress
Internal Stress
Internal Stress
Internal Stress
 Longitudina
l residual
Internal Stress stresses in
a butt weld.
Area AI =
A2.
Schematic weld distortions
Internal Stress
Distorsi
Distorsi
Distorsi
Distorsi
Tensile Test
Tensile Test
Bend Test
Tensile Test