Set 1 No.

1
OXY WELDING

72327 psi
145

499 N/mm2

Calulation for elongation

Original=50mm,Increased=62.5mm
Strain % =increased of gauge length x 100
Original gauge length
=12.5 mm x 100
50 mm
=25%

Acetylene is the only fuel gas

suitable for welding most metals including
CS,SS,Coper,AL.
The main area is on metal less than 5mm
Disadvantage is the slow speed of travel cause wide
HAZ area,possiblly undesireble metalugical changes
and distortion
Process Technique:
Forehand:
filler wire precedes the blow pipes along the seam to
be weld
general purpose work
Backhand:
vice versa forehand tech.(blow pipe precedes the filler
wire along the welded join)
used on thicker section,modification,position.
The oxy-acetylene flame:

Set 1 No.3a
STRESS
1.may be devided into two main categories:
Normal stress:
stress arising from a force applied perpedicular to
cross section area of material
Tensile stress :
normal stress resulting from tension
Compressive stress:
normal stress resulting from compression
2.Shear stress:stress arising from forces which parallel
to,lie in the plane of the cross sectional area
3.Residual stress:are self balancing internal forces and
not stress induced whilst applying an external load
4.Hoop stress:stress acting circumferentially around
pipe for internal pressure
Set 1 No.3b
DISTORTION

Oxidizing:
sharp inner cone deeoer in color in center
more o2
suitable for all brass,bronze,zn

Neutral:
fully luminous inner color
equally balance of o2 and acetylene
most frequently used
suitable for all CS,cast iron,low alloy steel and AL

Carburizing:
Feather of excess acetylene around inner cone
excess of acetylene
suitable for high carbon steel & hard surfacing
application
Set 1 No.2
CALCULATION UTS
max load=46000lbs,least cross section=1.015 x
0.627
UTS
=
max load applied
Least cross section area
=

46000lbs
1.015 x 0.627

factor which affect distortion:

a.material properties & condition
b.heat input
c.lack of restrain
d.thickness
method of reducing distortion
a.preheating
b.force restrain
c.use balancing technique(back skip/back step)
d.used different joint design to reduce amount of weld
deposition
e.reduce heat input(long heat input weling less
distortion)

Set 1 No.4
HICC

Should keep dry but never baked

Content of rutile:
titanium dioxide(rutile)slag former & secondry ionizer
clay-binding agent
Sodium silicate-main ionizer
Set 2 No.2
STEEL ELEMENT
Element
a.Carbon(C)

during welding process

above 200C
individual atoms of hydrogen are attracted toward
each other as the weld cools

b.Manganese(Mn)

c.silicon(Si)
d.aluminium(Al)
e.Molybdenum(Mo)
f.Chromium(Cr)

g.Nikel(Ni)
during cooling,grain boundary become closer
H2 molecus exits in large number
make a lot of pressure 60000 to 20000
lead of H2 cracking
B4 H2 cracking occurs the following criteria must exits:
H2
suspectable grain structure cracking
stress
temp < 200C
To reduce change of H2 cracking:
ensure joint prep clean
preheat the joint prep
use a low H2 welding process,or if using mma used
H2 controlled electrode
use multi pass technique
use H2 release PWHT
Factor necessary for HICC:
grain structure suspectable to cracking
H2 eg:from moisture or flux
stress eg:unequal expansion/contraction,poor
assembly
temp below 200C~the lower temp with this range,the
higer the H2 pressure will be
H2 cause general embritllement
Set 2 No.1
RUTILE
Purpose:
General purpose work(mild steel,fabrication,low
pressure pipework,support structure,brackets)
Give a fluid fast freezing slag
Suitable in all position but not often vertical
suitable & easy in all position but not often vertical
down
very popular in welding industry
Storage:

Properties
Key element
major influence
strength
loughness
ductility
hardness
primary desulphuriser
secondry deoxider
affect strenght & hardenbility
Primary deoxider
reduce thoughness
grain refiner
tertier deoxider
improves creep resistance
reduce temper embrittlement
improve hardness
resistance wear
add for corrosion resistance
in Stainless steel
improve ductility & toughness
improve corrosion resistance
acid in Stainless steel

Set 2 No.4
STRESS STRAIL RELATION

Set 2 No.5
STRESS RELIEVING
used to relax welding stress without any significant
affect on the components metalugical structure
because austenic no produce

archive by heating to 550-650

1 hrs/25mm thickness than cooling down in air
Annealing
Full-anneal:
produce very soft,low hardenss metal
Very slow cooling910
Very slow cooldown700
Colddown in air680
Sub-critical annealing(spherodizing):
Cheaper than full anneal
Not over 700(680-700)
Normalizing:
Used to maintan & improved mechnanical
properties(making more uniform)
Archive heating steel until fully austenic(same temp to
full anneal)
Set 3 No.1
HAZ

HAZ=The material immedietly adjancent to the weld

metal undergoes microstructural change which lies
between fusion boundary and uneffected parent metal.
Change in microstructure affect by:
material compositon,specialy Carbon content
Heat input hinger,hider HAZ
ARC ENERGY(Kj/mm)
=voltx amps
Travel of speed x 1000
Cooling rate-faster cooling rate-Harder HAZ.Espicialy
CEQ% steel high
Set 3 No.2
BEND TEST
to determind the soundness of the weld zone also to
measure ductility
Type of bend test
1.Root bend test puts the root in tension:
to open up & enlarge surface breaking discontinuities
2.Face band test put the face in tension
to open up & enlarge surface breaking discontinuities
3.Side bend test put the side of the weld in tension
to open up & enlarge surface breaking discontinuities
Set 3 No.3
CELLULOSIC
Purpose:
rapid burn off rate
fast freezing weld pool
thin slag
suitable for vertical down and overhead work
very forceful deeply penetratic arc
Main use:
Stovepipi welding of high strength large diameter
pipelines and storage tank
Good quality penetration bead can produced
Storage:
Must kept dry but never baked
cellulose flux are hygroscopic(potential to absorbed
moisture and are desing to hold between 4-7 moisture)
Content:

1.Cellulose-gas former.High in H2 which increase arc

voltage & overall power of the arc.May be dentrimental
for some steel
2.Tatanium Dioxide-slag former.A minor addition onlynot enough to affect ionization
3.Sodium silicate-main ionizer.Usualy permits welding
with dc + (potassium silicate)
Set 4 No.1
DUTY OF WI DURING WQT
1.Nessasary to present during WQT to ensure that the
weldong is being carried out according with the approve
procedure & specification
2.May stop the test if the welder obvious
fail:eg:excessive amount of LOP
3.Only one test weld allowed.Retest allowed if the
failure due to faulty welding set that is beyond the
welder control.
4.defect acceptance tollerance may be more strict than
production welding,however it still depend on
specification
5.Request for visual inspection & NDT(usually RT)
6.For more stringent specification,destructive may
nessary to asses the general soundness of the weld.
Set 4 No.2
LACK OF FUSION
Btw WM & PM
Btw PM & PM
Btw WM&WM
Cause
contaminated weld preparation-prevent the melting of
material beneath
amp too low
amp to high-may cause welder increase the travel of
speed resulting in a lack of melting on the underlying
metal
excessive inductance in MIG/MAG dip transfer welding
Set 4 No.3
BASIC PRINCIPLE OF FUSION WELDING
1.Heat source from arc/flame
temp:steel = 1400-1500
molten weld = 2500-3000
average arc = 6000
2.Removal of surface oxide by flux
3.Elimination of atmosphere,sheiling by flux
4.Weld must have acceptable mechanical & metalugical
properties
Set 5 No.1
CONSUMABLE BASIC
Purpose:
Reduce the posibility of hydrogen induce crack in
weld/HAZ
Ability to weld low alloy,high and medium tensile steels
& steels with a high sulphur content without any real
danger of solidification crack
Required higher operator skill
Conventional or vertical up technique must be used
Storage:
Prior to use the many be baked at temperature up to
50
Heated storage areas,sealed containers,pre-issue
ovens
Content:
1.Lime stone (calsium carbonate) gas former(mainly
co2)& secondary ionizer
2.Flourspar slag former.Similar to titanium dioxide but
higer quality
3.Sodium silicate or potassium silicate-main ionizer

4.H content 15ml/100g of weld metal deposited with

proper control below 5ml/100g o0f weld metal
deposited.

Set 5 No.2
HYDROGEN CONTENT
Hydrogen content in weld depend on a variety of
factors:
degree of contamination on weld preparation
arc length used
cooling rate
1.TIG
< 1ml possible
2.MIG/MAG < 2ml possible
3.Electroslag > 3ml likely
4.MMA electrode < 5ml possible for high temperature
baked basic but could be as much as 70ml for certain
selulose
5.Submerge ard > 5ml depend on flux type and heat
treatement of flux
6.Flux core MAG >10ml is likely
FACTOR WHICH AFFECT WELDABILITY
Defination:
a metallic nmaterial is considered to be weld,to a
certain degree,by given process and purpose
1.Design
access
restrain
2.Metalugical properties
structur & properties of weld
structur & properties of HAZ
3.Physical properties
termal resistant
coefficient of therma expansion
elestic modulus
viscosity of molten material
4.Chemical properties
oxidation resistance
surface films
impurities

Specimen thickness is dependent on specification and

depand on wall thickness
Impact testing asseses notch toughness by measuring
the energy absorbed by each test speciment during
impact
Toughness is the ability of material to withslad
cracking which is essential the opposite to brittleness

Set 5 No.4
TUNGSTEN INERT GAS

Develop for high alloy(AL&MG)

Expensive compare to other MMZ
Only use on c-steel for hi-metalugical & mechanical
properties on hig deposition root runs om pipe
Use back purge to prevent oxidizing(coking)on
stainlnes steel
Slick out tungsten.
Current Type

Set 5 No.3
TEST PROCEDURE FOR CHARPY & IZOD

Set 5 No.5
GAS SHIELD
1.Protect the weld pool from atmospheric contamination
2.Suitable ionizer atmosphere for the electric arc
3.Excess gas pressure will rippling,coarse finish
Argon
cost effective
for all metal
produce a
smooth quiet
arc
with low voltage
for light gage
material or
positional
welding
improved
cleaning action

Helium
lighter than
argon
reguired
higher rate
to provide the
same shielding
higher arc
voltage
more
expensive than
argon

Nitrogen
room
temperature
combine with 02
at a room temp &
become action
suitable for most
metal

Set 6 No.1
PRE-HEAT ADVANTAGES
1.slow down the cooling rate
reduce the risk of herdening
allow absorbed hydrogen
reduce change of cracking
to counteract the adverse metalugical effect produce
by welding on the material
2.Remove any moisture in the region of preparation
3.Improves the overall of fusion characteristic during
welding
4.Ensure more expansion & contraction & lowers the
stress btw the weld and PM
Set 6 No.2
BS EN 499:1995
Covered electrode for MMA welding of non-alloy & fine
grain steels,classified electrode designate a flux
covering code
Example: E 46 3 1Ni B 5 4 H5
Esymbol 4 product/process.flux coated for MMA
46symbol 4 strength & elongation of all weld.46
relates to tensile strength 530-680
3symbol 4 impact properties of all weld metal
1Nisymbol of chemical composition
Bsymbol of type of electode
A-asid covering
C-cellulose covering
R-rutile covering
RR-rutile thick covering
RC-rutile cellulose covering
RA-rutile asid covering
RB-rutile basic covering
B-basic covering
5symbol 4 weld metal recovery & current type
4symbol 4 welding position
H5symbol 4 hydrogen content
Set 6 No.3
ESSENTIAL VARIABLE
Any variable which if change have an adverse effect on
mechanical & metallugical properties of the weld
A welding procedure thest for MMA welding using
basic electrode has been qualified.During production
the contractor wishes to use rutlie electrode instead
Contractor would almost certainly to resubmit & requalify a new procedure even if the specification
permited to used basic electrode on
production.Changing type of flux coating is changing an
essenstial variable.