Documente Academic
Documente Profesional
Documente Cultură
• Presented to the
people in need
Course on
WELDING AND INSPECTION
Presentation on
“Welding fundamentals,application , Symbol,inspection
An Overview”
by
V UMASHANKAR
Info.umashankar@gmail.com
Chennai
Introduction
• Trainer’s background info …
• 15Years in Welding Inspection by Visual and
NDT
• Heavy Equipment Fabrication Construction
equipment
• Trainer in Manufacturing Quality, QMS,
• Six sigma Green Belt, TPM Facilitator, Quality
Circle Team Leader, Welding Quality, NDT
Ultrasonic testing and Quality concept.
WELDING THEORY
• “… Welding is joining two pieces of
materials.
• Solid+solid Welding = Solid state bonding
• Liquid+Liquid welding=Fusion Welding
• Solid+Liquid Welding=Braze Welding
• Oxy-Aceteline=Gas Welding
• Thermit =
• Atomic hydrogen=
ELECTRICAL ENERGY
WELDING
A) ELECTRICAL ARC
WELDING
• FCAW -Flux cored Arc Welding
• CAW -Carbon arc Welding
• SMAW -Shielded metal arc Welding
• GMAW -Gas metal arc Welding
• GTAW -Gas Tungsten arc Welding
• SW -Stud Welding
• PAW -Plasma Arc Welding
SHIELDED METAL ARC WELD
SUBMERGED ARC WELDING
Metal inert gas welding,MIG
TUNGSTEN INERT GAS WELDING
BRAZE WELDING
B) ELECTRICAL
RESISTANCE WELDING
• Spot Welding
• Seam Welding
• Projection welding
• Flash butt Welding
• Electro slag Welding
• Stud Welding
C) ELECTRICAL INDUCTION
WELDING
• Induction Presuure Welding
• Induction Brazing
MECHANICAL ENERGY
• Friction Welding
• Ultrasonic Welding,High freq sound waves
• Explosive Welding
SPECIAL SOURCE WELDING
• Electron Beam Welding
• Laser Welding
ELECTRODE DAMAGE &
INFLUANCE
• Absorbtion or loss Moisture
• Cracking & discaling covering
• Contamination
• Oxidation of the cored wire
• Formation of deposits on the surface
Absorbtion or loss Moisture
& INFLUANCE
• Porosity in weld metal
• Excessive Projection
• Spattering arc instability
• Visual worsening of seam suface
• Scouring / Blistering in cellulose coating
• Difficulty in removing slag
• Cracking caused by hydrogen
Formation of deposits on the
surface
• Absorbtion or loss Moisture
• Cracking & discaling covering
• Contamination
• Oxidation of the cored wire
Welding inspection
• Crack
• Bead shift
• Burn through
• Porosity
• Pin holes
• Waviness
• Under cut
• Weld appearance
Weldments - Symbols and Drawing Practices
DWGA130 Overview (Cont.)
Primary Reference -
• ISO 2553:1992
Secondary References -
• AWS A2.4:1998
Welding Symbol, Weld Symbol
• Required minimum
weld size dimension
(mm)
z = leg dimension
a = throat dimension
Butt/Groove Weld Size
• Required minimum
throat dimension
(mm)
• No direct
measurement -
requires destructive
test and evaluation
Intermittent Weld Dimensions
• ISO vs AWS (App 2)
• Size convention is the
same
• Number and length of
segments
• Spacing between
segments vs AWS ctr
to ctr method
Symmetric Intermittent Weld
• Same weld symbol
and dimensions
both sides
• Dashed line not
required
• Anchor welds at
each end
Staggered Intermittent Weld
• Usually specified to
avoid weld distortion
or interference
• Offset dimension
specified in detail vs
default
• Anchor welds - Z denotes staggered
standard shop practice intermittent weld
Intermittent Weld on Circular Part
Visual Destructive
Mechanical,
inspection Chemical,
Testing
Ultrasonic
Testing
DP
Testing ,
MPT,ECT,
X-RAY
AET,LEAK,
NRT,
Good welding Practice summary
Right Welding
parameter at any time
Setting
With
error
WELDING No
proof
interlock SOUNDNESS Adjustment
(Poka
yoke)
Monitering
For right welding at first
Time and any time
Continuous Improvement Model
Welding parameter entry
Trend Chart
GOAL
Check
TIME
REPAIR,
ACTION PLAN IDENTIFY 100%
PARETO
ANALYSIS
Action Name Date
PM Good Welding
CURRENT
Wire feed
VOLTAGE
WIRE
Alingment POSITION
Setting
Input DIFT
Quality,
Good
Fittment,
Job
TIME
position,
GOOD WELDING CONTRIBUTION
METHOD MACHIN
27% E
34%
OTHERS
9%
MATERI WELDER
AL 16%
14%
Flux baking
Check incoming component
FITUP GAP
Clean and remove rust,oil
Spool quality
Ensure proper welding.
Rollequality
RUST
CHECK POINTS
Torch setting
Key Decisions Made
Ensure proper welding
parameter
Set appropriate Time
Alingnment
Correct and monitor the process
Input material
Quality
Machine
truness
Requirement
Weld width
•Leading Consultants for 6σ
and Cycle time Reduction
•Clients:Citicorp, PwC, ICI,
3M, Telstra
Meet spec Penetration
Quantum Improvement in
terms of
Quality
Side wall
fusion Cost
Cycle time
Six Sigma’s definition of Defect
ll welds shall be inspected. A weld
subject to inspection shall be
Circumferentia acceptable if inspection shows:
NDE l Butt Weld
Inspection a) No surface cracks
c) No craters Repairable