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Significance of defects
Incomplete fusion can influence brittle fracture in either static or dynamic loads. The effect of lack of fusion is almost same as Lack of penetration Arc strikes consist of un annealed martensite and contains a number of small fissures. These small fissures can lead to brittle fracture when remaining load bearing material has been sufficiently reduced in cross section.
A Defect is Rejactable discontinuity A defect is a discontinuity but a discontinuity need not be a defect. Acceptance of a discontinuity is based on different factors. Few examples are as follows: Stresses to which the parts will be subjected during service Type of Material Used The environment Consequence of failure
Acceptance Standards Dictate the type of Inspection and testing. The weld defects can be broadly classified into two types. Planer defects / two dimensional defects (Crack, Lack of Fusion, Lack of Penetration, Severe Undercut These are not acceptable defects) Volumetric Defects / Three Dimensional defects.(Slag inclusion, cavities, Porosities are acceptable to certain extent)
Lack of Know-how Welding Process Characteristics Base metal Composition Defective welding filler metal Joint design Welding Environment (Wind, fit-up, Temperature etc.)
Due to improper manipulation of electrode Incorrect position of electrode Low welding current Too rapid arc advance Improper joint fit-up
INCOMPLETE PENETRATION Incorrect Joint design Improper welding parameters specifically current Incorrect electrode size Incorrect polarity where DC is used Un fused root can cause stress concentration that could lead to brittle failure
Inclusions
Slag Inclusion Because of the string action of the arc slag may be forced down to the molten metal and the high viscosity of weld metal, rapid solidification at a low temperature leads to entrapment. Preheating the base metal to control the rate of solidification will ensure release of slag from molten metal
Oxide Films In MIG welding oxides in the form of Globules are found in weld metal. The presence of such films seriously impairs the ductility of weld metal. This defect is rarely detectable except with the aid of a microscope
Tungsten Inclusions These are particles deposition in the weld metal from a tungsten electrode in TIG welding These inclusions are not generally considered harmful unless their size and number become excessive. Superimposed high frequency current for arc starting tends to minimize these inclusions
Geometric Defects Undercuts represents a depression into the base metal adjacent to the toe of the weld and it form a notch. A small amount of undercut under pulsating stress often acts as a starting point for fatigue cracks. Correct choice of current range and good manipulation of electrode during welding will avoid undercut
Burn through or excess penetration Occurs because of very high current and low travel speed. It is also called as icicles and are found at the root of the weld. Consumable inserts may be used to avoid excess penetration
Improper weld profile This occurs more in the case of fillet joints Excessive concave or convex beads are examples of this. These are caused because of improper weld parameters, electrode size & weaving. Visual examination is sufficient to decide these defects.
METALLURGICAL DEFECTS
CRACKS Hot cracking Caused because of restraint on the joint and the presence of higher carbon and sulfur. Segregation of weld metal due to bead shape also is a reason for these defects. MPI or LPI are used to detect surface defects while UT is suitable for internal cracks.
Cold cracking Cold cracking starts in the HAZ of the parent metal It is associated with combined effects of hydrogen, restraint and martensite formation Low hydrogen electrode and preheating minimizes cold cracking.
Crater cracks Cracks formed from a circular surface with a depression either in the weld or at the end of a weld. It is caused by a volume concentration of molten metal during solidification usually the result of abrupt interruption of the welding arc in the root run.
Gas porosity
Porosity is the presence of gas pockets of voids caused by the entrapment of gases evolved during weld metal solidification Porosity is caused due to improper shielding, rust on the weld face, too much generation of gas in the weld pool. Porosity is considered to be the least dangerous defect but is often an indication of damp electrodes having been used.
Arc Strikes
Localized heat affected zone caused by an arc is known as arc strikes Arc strikes produce hardening particularly in high carbon steels and alloy steels.
Embrittlement
The carbon and alloy steels containing 0.18% carbon tends to form brittle martensite structure in HAZ. This is avoided by controlled cooling rate.
Quality Of Welding
Welding Defects (Root Cause Analysis)
Incomplete Fusions
Lack of supervision Incompetent welder / operator Poor performance of welding equipment In-proper handling / use of welding tools In-proper handling / use of welding consumables Poor joints fit-ups & etc
Incomplete Penetration
Lack of supervision Incompetent welder / operator. Poor joints fit-ups Welding current too low Wrongly use of electrode size (too big) Arc length too long Melting filler rod instead of welding Insufficient gas shielding (GTAW SUS)
Cracks
Lack of supervision Incompetent welder / operator. In-proper use of welding consumables. Weather condition. Quality & characteristic of base metal. In-proper control of preheating & post heating process & etc
Areas Of Concern
Quality Is Client Driven, Company Has Not Set Clear Quality Goals & Targets And Communicate To Shop Floor Ineffectiveness Of Implementation Of QMS Expectations And Deliverables Are Not Clearly Defined At Supervisors, QA Personnel And QC Personnel Levels Quality Is A QA/QC Function, Supervisors are more Concern In Timely Delivery Of Projects Subcontractors Management Has No Commitment Toward Quality Goals
WELDING EQIPMENT
Frequent pow er tripping Not using HF units for GTAW w elding
Using of rusted plates Using of contaminated electrodes/fluxes Using of cold w elding consumables
Welding of pitting corroded plates Welding of old and already used materials in the process
Poor eye sight, over fatigue and personal reasons Not using w ind protectors.
Unstable current
POROSITY
Wrong selection of w elding process Using of SMAW w here more appropriate GTAW process Using of GMAW w here FCAW can be used Using of SMAW w here more appropriate SAW process Lack of understanding on application of process
Poor in keeping of w elders records and repair rates Lack of job / WPS know ledge
Engaging of unqualified w elders Poor control and guiding w elders Lack of responsibility and commitment tow ards quality
Using of unqualified w elder for tack w elding Gas cutting notches on edge preoeration
WELDING ENVIRONMENT
JOINT FITUPS
SUPERVISOR ROLE
WELDING PROCESS
WELDING EQIPMENT
Not using HF units for GTAW welding
Unstable current
Using of too narraow groove Using of tack welds in the groove for single side joints
Poor in keeping of welders records and repair rates Lack of job / WPS knowledge Poor organizing of tools Poor monitoring
Using of unqualified welder for tack welding Using defective tools Non availability of proper tools Gas cutting notches on edge preoeration Not using proper run and run off plates
Lack of responsibility and commitment towards quality Lack of Quality awareness/ targets
WELDING TOOLS
JOINT FITUPS
SUPERVISOR ROLE
WELDING PROCESS
WELDING EQIPMENT
Frequent power tripping Improper aligning of rotators Not using HF units for GTAW welding
Using of poor quality shielding / purging gasses Using of damaged contaminated electrodes fluxes / filler metals
Unstable current Exocentric or over loading on rotators. Non uniform welding travel speed
LACK OF FUSION
Using of SMAW where more appropriate GTAW process Using of SMAW where more appropriate SAW process Using of GMAW where FCAW can used Lack of understanding on application of process using
Using of unqualified welder for tack welding Welding at windy environment Inadquate bevel angle
Using of tack welds in the groove for single side joints Poor accessibility for welding
Using of square butt joints. Not using proper run and run off plates
Not grinding rusted /mill scales and gouged surfaces Not keeping joint for easy welding position
WELDING ENVIRONMENT
JOINT FITUPS
SUPERVISOR ROLE
WELDING PROCESS
Lack of commitment towards quality Using of wrong welding parameters Using of low or high flow gasses
Unstable current
Using of tack welds in the groove for single side joints Using of unqualified welder for tack welding Not keeping joint for easy welding position Not using proper run and run off plates Using of too narrow groove
Poor in keeping of welders records and repair rates Lack of job / WPS knowledge
INCOMPLETE PENETRATION
Poor control and guiding welders Using of SMAW where more appropriate GTAW process Lack of understanding on application of process using Using of GMAW where FCAW can used Wrong selection of welding process
Lack of responsibility and commitment towards quality Poor planning and co ordination with fitting group Engaging of unqualified welders
JOINT FITUPS
SUPERVISOR ROLE
WELDING PROCESS
WELDING EQIPMENT
Non uniform travel speed Unstable arc voltage Unstable current No calibration of equipment Using of damaged gas hoses Non uniform rotation of welding rotators
Lack of commitment towards quality Using of wrong welding parameters Using of too high travel speed
Using of cold welding consumables Using of poor quality shielding / purging gasses
Using of high Ceq. materials Using of unkilled & high impurities content steels
Using of improper bead laying sequence Using of wrong size and cold electrodes
Not maintaining preheat, interpass temp. and not covering joints with fire blankets Poor in keeping of welders records and repair rates Lack of job / WPS knowledge Poor organizing of site protection from wind
Poor eye sight, over fatigue and personal reasons Engaging of unqualified welders Poor control and guiding welders
CRACKS
Wrong selection of welding process Using of high hydrogen inducing process ( for Ex. using SMAW instead of GTAW process)
Poor house keeping Welding at dusty environment Not using of weather protectors Not removing gouged surfaces by grinding Not using proper run and run off plates Large gaps Using of unskilled gas cutters, Gougers and grinders Using of square butt joints for high Sulphour & Phosphorus steels Not keeping joint for easy welding position
Lack of responsibility and commitment towards quality Lack of Quality awareness/ targets Poor planning and coordination with fitting group Using of poor preheating methods and not arranging fire blankets
WELDING ENVIRONMENT
JOINT FITUPS
SUPERVISOR ROLE
WELDING PROCESS
WELDING EQIPMENT
Frequent power tripping Not using HF units for GTAW welding
Unstable current
Using of too narrow groove or large groove Using of unqualified welder for tack welding
Poor in keeping of welders records and repair rates Lack of job / WPS knowledge
Engaging of unqualified welders Poor control and guiding welders Using of GMAW where FCAW can used
Poor accessibility for welding Inadquate bevel angle Not keeping joint for easy welding position
Lack of responsibility and commitment towards quality Lack of Quality awareness/ targets Poor planning and coordination with fitting group
JOINT FITUPS
SUPERVISOR ROLE
WELDING PROCESS