CH 7 Weld Processes

TECHNOLOGY
WELDING PROCESSES
CSWIP training presentation Steve Brooks
TECHNOLOGY
WELDING PROCESSES
There are a very large number of fusion

processes currently used in industry
(approximately 35). The underwater inspector
needs only to have an appreciation of three of
these fusion processes, these are as follows:
TECHNOLOGY
Welding Processes contd
1. Flux Shielded Arc Welding techniques

2. Gas Shielded Arc Welding techniques
3. Friction welding
TECHNOLOGY
Flux shielded ARC welding Techniques
1. Manual Metal Arc (MMA).

2. Automatic Metal Arc.
3. Submerged Arc.
TECHNOLOGY
Manual Metal Arc (MMA)
Welding torch
Flux coated filler rod
Gas shield
Slag coating on
the weld metal
Weld metal
TECHNOLOGY
Automatic Metal Arc
Spiral wound electrical pickup wires,

wound outside the flux coating
Electrical pickup slides
Slag coating
Weld metal
TECHNOLOGY
Submerged Arc
Filler rod
submerged in the
Slag coating
on the weld
flux and fed into

the weld pool
automatically
Powder flux dropped down

tube
Powder flux
Electrical pickup
TECHNOLOGY
Gas Shielded ARC Welding Techniques
1. Metal Inert Gas (MIG) or Metal Active Gas (MAG).

2. Tungsten Inert Gas (TIG).
TECHNOLOGY
Metal Inert Gas or Metal Active Gas
Reel of filler
wire
Trigger
Inert or active shielding gas
Electrical pickup
slides
Gas shield
Weld metal with no slag coating

TECHNOLOGY
Tungsten Inert Gas
Inert gas for shielding

weld pool
Electrical
connection
Trigger
Filler rod fed in

to the weld pool
from the side
Tungsten
electrode
Weld metal with no slag coating
10
TECHNOLOGY
Friction Welding
Stub rotated to produce friction

Parent plate
Axial pressure
Applied
Heat build-up
produces weld
11
TECHNOLOGY
Types of welded joint
There are approximately 110 different welded

joint variations, most of which are not widely
used in the construction of offshore
structures. The underwater inspection
personnel need to have a knowledge of only
five main types of joint which are:
12
TECHNOLOGY
Butt Joint
Two parent plates fitted together at an angle

of between 135 and 180. This will be used
offshore for circumferential and seam welds.
13
TECHNOLOGY
"T" Joint
The two parent plates are fitted together at an

angle of between 5 to 90. This means the
end of one piece and the face of the other
piece will come into contact, such as the joint
between two tubular members as in a node.
14
TECHNOLOGY
Lap Joint
The two parent plates are fitted one on top of

the other the angle will be 0 to 5.
15
TECHNOLOGY
Corner Joint
The two parent plates make a connection at

the edges to make a joint at an angle of
between 30 to 135.
16
TECHNOLOGY
Cruciform Joint
A joint at which two flat plates or two bars are

welded to another flat plate at right angles
and on the same axis.
17
TECHNOLOGY
TYPES OF WELD
There are two types of weld most often

referred to during inspection, they are "butt"
and "fillet" welds.
18
TECHNOLOGY
A Butt weld is:
"A tension resisting weld in which the bulk of the weld

metal is contained within the planes or thickness of the
joined parent metals".
19
TECHNOLOGY
A Fillet Weld:
"The bulk of a fillet weld is contained outside the

parent metal planes or thickness. Therefore fillet welds
tend to have less strength".
Fillet Welded Butt Joint
20
TECHNOLOGY
BRITISH STANDARD WELDING TERMS & DEFINITIONS
(BS499 [BS EN ISO 3059.2001])
1. Parent plate
The metals which are to be joined by the weld.
2. Filler rod
Filler metal in the form of a rod. Sometimes the filler
rods will be laid into the weld in layers, these will be
termed Filler Beads
3. Run or pass
Weld metal deposited in a single movement.
21
TECHNOLOGY
Weld definitions contd

4. Heat affected zone
The part of the parent plate which has been affected by
heat but which has not melted.
5. Weld zone
The area containing the weld and both heat affected
zones.
6. Cap, Face of the weld
This is the exposed surface of a weld usually single, multibeaded or weaved. Weave refers to the welder weaving
from side to side during the fabrication of the weld, this will
produce a weld which has one single woven lay of weld in
the cap.
22
TECHNOLOGY

7. Excess weld metal
Weld metal lying outside the plane joining the weld toes or
in excess of the specified weld size.
8. Toe of the weld
The junction between the face of the weld and the parent
metal.
9. Root
The point at which the back of the weld intersects the
parent metal.
10. Root bead, run
Weld bead protruding beyond the plane of the back-wall of
the parent plates.
23
TECHNOLOGY

11. Root gap
Separation between the parent plates to be joined.
12. Root face
The un-bevelled portion of the parent plate adjacent to the
root gap.
13. Throat thickness
The total thickness of the weld metal.
14. Effective throat thickness
(design throat thickness) - Weld thickness for design
purposes, usually a line between both toes or maybe
slightly raised.
24
TECHNOLOGY

15. Weld width
The shortest distance between the outer toes of the weld.
16. Leg of a fillet weld
The distance from the root of the weld to the toe of the
weld.
17. Toe Blend
The transition between the weld material and the parent
plate.
18. Prepared face
The bevelled portion of the parent plate prior to welding.
25
TECHNOLOGY

19. Single V butt weld
A butt weld in which the prepared faces will form a V in
section, welded from one side only.
20. Double V butt weld
A butt weld in which the prepared faces will form two
opposing V's in section, welded from both sides.
21. Prepared angle, weld prep
The angle of bevel between the prepared face and the
perpendicular line.
26
TECHNOLOGY

22. Included angle of a butt weld
The angle between the prepared faces.
23. Included angle of a fillet weld
The angle between the parent plates.
23. Weld-ment
This is sometimes the term used to describe the total weld
zone.
24. Fusion Zone
Point at which parent plate melts and mixes with weld
metal
27
TECHNOLOGY
Plate Edge Preparation
Root face
28
TECHNOLOGY
Plate edge preparation contd
Prepared face
Root face
29
TECHNOLOGY
Prepared
angle
Prepared
face
Root
face
30
TECHNOLOGY
Included
angle
Prepared angle
Prepared face
Root face
31
TECHNOLOGY
Included
angle
Prepared angle
Prepared angle
& Included angle
Prepared face
Root face
Single Bevel Butt
Weld
32
TECHNOLOGY
Included
angle
Prepared angle
Prepared angle
& Included angle
Prepared face
Root face
Root Gap
Single Bevel Butt

Weld
33
TECHNOLOGY
Double V Butt weld (Welded from both sides)
34
TECHNOLOGY
Butt Weld Terminology
Cap of the weld
35
TECHNOLOGY
Butt Weld terminology contd
Excess weld
metal
Cap of the weld
36
TECHNOLOGY
Excess weld
metal
Cap of the weld
Filler beads,
weld beads
making up the
bulk of the weld
37
TECHNOLOGY
Excess weld
metal
Cap of the weld
Filler beads,
weld beads
making up the
bulk of the weld
Effective throat
thickness
38
TECHNOLOGY
Excess weld
metal
Cap of the weld
Filler beads,
weld beads
making up the
bulk of the weld
Root bead or
penetration bead
Effective throat
thickness
39
TECHNOLOGY
Excess weld
metal
Filler beads,
weld beads
making up the
bulk of the weld
Cap of the weld
Heat affected
zone (HAZ)
Root bead or
penetration bead
Effective throat
thickness
40
TECHNOLOGY
Excess weld
metal
Filler beads,
weld beads
making up the
bulk of the weld
Cap of the weld

Toe of the weld
Heat Affected
Zone HAZ
Root bead or
penetration bead
Effective throat
thickness
41
TECHNOLOGY
Excess weld
metal
Cap of the weld
Throat thickness
Toe of the weld
Filler beads,
weld beads
making up the
bulk of the weld
Root bead or
penetration bead
Effective throat
thickness
42
TECHNOLOGY
Weld zone
Excess weld
metal
Filler beads,
weld beads
making up the
bulk of the weld
Cap of the weld
Throat thickness
Toe of the weld
Heat Affected
Zone HAZ
Root bead or
penetration bead
Effective throat
thickness
43
TECHNOLOGY
Fillet weld terminology
Toe of the weld
44
TECHNOLOGY
Fillet weld terminology contd
Toe of the weld

Included angle
45
TECHNOLOGY
Toe of the weld

Included angle
Throat
thickness
46
TECHNOLOGY
Toe of the weld

Included angle
Toe of the weld

Throat
thickness
47
TECHNOLOGY
Toe of the weld

Included angle
Effective throat
thickness
Toe of the weld
Throat
thickness
48
TECHNOLOGY
Toe of the weld

Included angle
Cap or face of
the weld
Effective throat
thickness
Toe of the weld
Throat
thickness
49
TECHNOLOGY
Leg length
Toe of the weld
Cap or face of
the weld
Included angle
Effective throat
thickness
Toe of the weld
Throat
thickness
Root
50
TECHNOLOGY
DEFECTS IN WELDS
(BS 499 [BS EN ISO 3059.2001])
1.
Cracks
2.
Cavities
3.
Solid inclusions
4.
Lack of fusion and penetration
5.
Imperfect shape
6.
Miscellaneous
51
TECHNOLOGY
PLANAR DEFECTS
These will have large surface area but low

volume, so they are essentially two
dimensional defects such as laminations and
cracks. Fatigue cracking is a planar defect
and is the most dangerous form of in service
deterioration (fatigue cracks mainly occur in
the heat affected zone of the weld).
52
TECHNOLOGY
VOLUMETRIC DEFECTS
These will have a comparatively small surface

area but a large volume (3d), they include :
Undercut
lack of penetration
cavities and porosity amongst others.
Primarily, volumetric defects occur while the
weld is molten during the fabrication of the
weld and general cannot occur in service.
53
TECHNOLOGY
REPORTING OF DEFECTS
1. Type - Accurate assessment and description of
the defect using correct terminology.
2. Location - Give the relative location,
HAZ/CAP/TOE (giving which toe or haz i.e. chord
toe or brace toe etc), together with its start
position measured in millimetres from the 12
o/clock datum mark.
3. Dimensions - Overall length of the defect stating
whether it is intermittent or continuous, where
necessary, report depth and width in millimetres.
54
TECHNOLOGY
Reporting of defects contd
4. Orientation - For a crack like defect indicate the

orientation of the plane of the defect to the axis
of the weld i.e. Transverse or Longitudinal.
5. Branching - State if the defect is branching giving
the location, length and orientation of each
branch.
55
TECHNOLOGY
Defects according to BS 499 Cracks
Solidification
cracking
Crater crack
Toe crack
Longitudinal
centreline
Star
Transverse
Heat affected zone crack
Longitudinal
centreline
branching
crack
56
TECHNOLOGY
Defects according to BS 499 - Cavities

Porosity
Porosity
Gas pores
Elongated cavity
Crater
Crater pipe
57
TECHNOLOGY
Defects to BS 499 - Solid Inclusions
Solids trapped in the weld when the metal is

still molten, from a visual inspection point of
view, apart from slag inclusions these will not
normally be visible.
58
TECHNOLOGY
Lack of Fusion and Penetration
Lack of interun fusion
Lack of sidewall fusion
Lack of root fusion
Lack of penetration, or
concave root
Incompletely filled groove or

underflushing
59
TECHNOLOGY
Imperfect shape
Undercut
Overlap
Linear misalignment
Angular misalignment
60
TECHNOLOGY
Miscellaneous
Stray arcs
Spatter
Unequal leg
lengths
Torn surface
61
TECHNOLOGY
62

CH 7 Weld Processes

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TECHNOLOGY

CSWIP training presentation Steve Brooks

There are a very large number of fusion

CSWIP training presentation Steve Brooks

Welding Processes contd

1. Flux Shielded Arc Welding techniques

CSWIP training presentation Steve Brooks

Flux shielded ARC welding Techniques

1. Manual Metal Arc (MMA).

CSWIP training presentation Steve Brooks

Manual Metal Arc (MMA)

Flux coated filler rod

CSWIP training presentation Steve Brooks

Automatic Metal Arc

Spiral wound electrical pickup wires,

Electrical pickup slides

CSWIP training presentation Steve Brooks

flux and fed into

Powder flux dropped down

CSWIP training presentation Steve Brooks

Gas Shielded ARC Welding Techniques

1. Metal Inert Gas (MIG) or Metal Active Gas (MAG).

CSWIP training presentation Steve Brooks

Metal Inert Gas or Metal Active Gas

Inert or active shielding gas

Weld metal with no slag coating

Tungsten Inert Gas

Inert gas for shielding

Filler rod fed in

CSWIP training presentation Steve Brooks

Weld metal with no slag coating

Stub rotated to produce friction

Types of welded joint

There are approximately 110 different welded

CSWIP training presentation Steve Brooks

Two parent plates fitted together at an angle

CSWIP training presentation Steve Brooks

The two parent plates are fitted together at an

CSWIP training presentation Steve Brooks

The two parent plates are fitted one on top of

CSWIP training presentation Steve Brooks

The two parent plates make a connection at

CSWIP training presentation Steve Brooks

A joint at which two flat plates or two bars are

CSWIP training presentation Steve Brooks

There are two types of weld most often

CSWIP training presentation Steve Brooks

A Butt weld is:

"A tension resisting weld in which the bulk of the weld

CSWIP training presentation Steve Brooks

"The bulk of a fillet weld is contained outside the

Fillet Welded Butt Joint

CSWIP training presentation Steve Brooks

BRITISH STANDARD WELDING TERMS & DEFINITIONS

(BS499 [BS EN ISO 3059.2001])

CSWIP training presentation Steve Brooks

Weld definitions contd

Weld definitions contd

Weld definitions contd

Weld definitions contd

Weld definitions contd

CSWIP training presentation Steve Brooks