Critical To Quality – Welding

Importance & their impact

Duties of Supervisor

KG,PANDITHAN IWE
ADVISER-RIBO
 Heating Protection

To make a sound
weld we need to

Properties
Cleaning
Critical Points to Quality
Initial & Inter pass Cleaning
◼ The area to be welded shall be cleaned
25 mm on either side of Base metal free
of oil, dirt, grease and rust.
◼ To prevent the contamination in the weld
metal and avoid weld defects like
Hydrogen cracking, Porosity.
◼ Before depositing successive pass, each
pass shall be cleaned, free of slag so as
to prevent the slag inclusion. Especially
when using E xx15 because the slag
formed in this electrodes are very hard
and less slag detachability. Hence
grinding is preferred before depositing
next pass.
◼ In case of Gr.91 materials, only SS wire
brush, Wire Wheel to be used to avoid
contamination.
 Earthing
What happens in proper Earthing ?
◼ We are allowing the current to flow in the correct path of least
resistance through cables and finally reach the job through
clamp.
What Happens in Earthing Without Clamp by using strips ?
 Power loss due to High Resistance in the strips.
 Set Power does not reach the Welding.
 Cannot manipulate the Welding Current
What Happens in Earthing in the Rollers and not in the job ?
 During rotation of Job on the rollers, due to discontinuous
contact, Arc Strikes is produced in the Job.
 Not Continuous flow of Current
Arc Strike ?
◼ Since Small amount of Metal is he ated to a
very Hig h Temperature and cooled sud denly
(Three Dimensional Cooling), there is a
Change in the micro Structure in the local
sp ot wit h hig h restraint wh en comp are d to
the other Base Metal.
◼ The Micro Structure Forme d – martensite
with restraint has more chance for Cracking
◼ Arc Strike is very severe for Gr.91 materials
 W hat happens if the Electrode are not kept in
the oven maintained at 120°C ?

◼ The Electrodes what we are using are Low

Hydrogen type Electrodes except E 6013.
◼ Low Hydrogen Type Electrodes – Electrodes
having Hydrogen content less than 15 ml /
100 gms of Electrode
◼ These Electrodes have the tendency to
absorb the moisture (Water Vapour particles
suspended in the air) when exposed to
atmosphere
◼ At temp more than 80°C only Hydrogen gets
diffused out
◼ For this reason only our electrodes are
maintained above this Temperature.
◼ During Electrode transferring from the oven,
there may be temperature gradient so only
we have set the temperature as 120°C
 What will happen if the Hydrogen Absorbed
Electrodes are used in Welding ?
( a) During Welding, the Hydrogen
(H2 ) accumulated in the
Electrode coating dissociates in
to nascent or atomic Hydrogen
[H] and enters the molten
Wel d pool.

(b) Hydrogen occupies the

vaccant space in the metal.

(C) Hydrogen atoms join

together to form molecule
 What will happen if the Hydrogen Absorbed
Electrodes are used in Welding ?
(d) Build a pressure and

(e) finally burst leading to Crack.

This crack may occur immediately or 48 hours or •

month later.
This Crack is said to be Hydrogen I nduced Cracking •
or Delayed Cracking or Fish Eye Opening.
The same mechanism occurs if the flux is not •
properly baked.
 What is Preheat ?
Heating the metal to a certain
temperature just before
Welding. It is always expressed
as minimum.

It is carried out by Gas Burner,

Induction Heating or Resistance.

It is measured at a distance of 3”
from the area to be welded.

Measured using Thermo chalk or

Pyrometer or IR Thermo meter.
 What is the purpose of Preheat ?

◼ Reduces the build up of Residual Stress in the

weld joint.
◼ Drives away the moisture from the joint (Parent
metals), dirt, oil, grease, rust, etc.,
 Compensate for high heat losses.
 It slows down the cooling rate in the weld an
d
base metal, producing more ductile metallurgical
structure.
 What will happen if Preheat is not
done properly ?

 More Susceptibility to Hydrogen

Induced Cracking.
 Retards the Mechani cal Properties and
Build up of Resi dual Stress due to
rapi d cool ing
What is inter pass and its effect ?

In a multi pass weld, the

temperature of the weld
metal before the next pass
is started. It is normally
expressed as a maximum.
- Reduces the risk of coarse
grain formation.
- Improves toughness
What is post heating and its effect ?
The minimum temperature in the weld zone which
shall be maintained with defined time period
immediately after the completion of welding or if
welding is interrupted.
Usually, the temperature shall be the preheat
temperature or slightly higher.
It is done to diffuse out the hydrogen in the Weld
ment and to reduce the susceptibility to cracking.
Post Weld Heat Treatment
Purpose is to release the internal
elastic stress that has developed
in the weldment as a result of
high heat input during Welding.

Temp Soak

Heat Cool

Time

Temp. depends upon the material

and is always lower than AC1.

Time depends on the thickness,

generally (2.5 mins/mm)
 Shielding gas profiles &
effect on weld length

weld length
1.2 m weld length
1.15 m weld length
1m

Ar-CO2-O2 Ar-CO2 CO2

 Gas Purging
◼ All the root passes welding
with more than 3 % Cr
Shall be purged with Argon
gas to avoid oxidation of
the weldment at the root .
Purging dams and fixtures
shall be used withstand the
temperature up to 300°C
 Fit Up
◼ Fit up of components shall be done by
using suitable clamping / fixtures or Bridge
piece or Tack Weld
◼ Bridge Piece – same material, same
procedure – Preheat, Electrode. Not be
used for Gr.91
◼ Tack Weld : Tack weld shall be performed
by qualified welder & approved WPS
 Techniques
◼ For SMAW, the Weaving width shall not
exceed 3 x core dia. Of Electrode.
◼ For GMAW & GTAW, the Weaving Width
shall be maximum 10 mm
◼ In case of SMAW, the current shall be set
approx. 1 mm = 40 A
◼ In case of Impact requirements, the Heat
Input shall be controlled
◼ If SMAW electrode coating is found, loose &
feathery, check for current or shall be taken
with Consumable Supplier
 Welding Symbols
Most weld symbols contain 5 elements, which are:

1) The arrow line* a. 7 b. 10 5 x 100 (100)

111*

2) The reference line*

3) The symbol*

4) The dimensions*

5) The supplementary information*

Representation of welds done from both sides of
the joint intersection, touched by the arrow head

Fillet weld Double bevel Double J*

Double V Double U
 Supplementary Weld Symbols
Toes to be ground
smoothly. (BSEn only)
Site Weld

Ground flush

Concave or Convex
111
Weld all round Welding process.
Numerical BS En & BS
Further supplementary information, such as WPS
number, or NDT may be placed in the fish tail*
“a” = Nominal throat thickness “s” = Effective throat thickness

a s

Deep throat fillet welds from FCAW & SAW etc*

It is also possible that the height of excess weld metal is within
the accepted limit of an applied standard, but the toe blend is
unacceptable, as shown below*

90° 3 mm

Extremely poor toe blend, but excess weld metal is within limits*
It is the duty of all supervisor to ensure that welding
operations are carried out in accordance with written, or
agreed practices or specifications

Before
During
After
 Spatter generated

1 metre of weld at 260 amps

using 1.2mm dia.
Savings with Argon / CO2 / O2 gas mixtures

Process
Savings in wire DIP SPRAY
----------------------
• From reduced spatter 5% 10 - 15 %

• From flatter weld 10 - 20 % 10 - 15 %

Total Savings 15 - 25 % 20 - 30 %

Savings in arcing time 15 - 25 % 20 - 40 %

-----------------------------------
• Savings in power Equivalent to Equivalent to
arcing time arcing time

• Savings in gas volume Equivalent to Equivalent to

assuming flow rate same as CO2 arcing time arcing time

Savings in weldshop productivity

------------------------------------------------
• From improved welder productivity 5 - 10 % 5 - 10 %

• From reduced spatter cleaning and upto 50 % upto 75 %

weld dressing time
 Discuss the following
Before Welding:
1) Safety:
Legislation and safe working practices
2) Documentation:
Spec. Drawings. Procedures. Welder approvals. Certificates. Mill sheets

3) Welding Process and ancillaries:

Equipment. Cables. Regulators. Ovens. Quivers etc

4) Incoming Consumables:
Materials/welding consumables (Size. Condition. Specification. Storage)
5) Marking out preparation & set up:
Method. Angles/Root face/gap values. Distortion control. Pre-heat prior to
tack welding if applicable
 During Welding:

1) Pre-Heating. (Method and control)

2) In process distortion control (Balance or sequence welding)
3) Consumable control. (Correct baking and storage prior to use)
4) Welding process (Related parameters i.e. volts/amps. gas flow rate)
5) Welding run sequence and inter-pass cleaning
6) Minimum/maximum Inter-pass temperatures
7) Full compliance with all elements given on the WPS
 After Welding:

1) Visual Inspection
2) Types of Non Destructive testing to be subjected to Weldment
3) Repair
4) Repair procedures (NDT/Excavation/Welding/Welder approval)
5) PWHT
THANK YOU