Welding of Piping

Presented by
RANENDRA CHAKRABORTY
WELDING
Definition as per AWS / ASME:

A localized coalescence of metals or non-metals produced either by heati

ng the materials to the welding temperature with or without the applicatio
n of pressure alone, and with or without the application of filler material.
SELECTION OF WELDING PROCESS DEPENDS ON

Thickness & Size of part to be welded

Location and position of weld joints
Joint design
Welding equipment availability
Process and operation requirement
Production cost

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 MAJOR WELDING PROCESSES

 Shielded Metal Arc Welding

 Gas Metal Arc Welding
 Gas Tungsten Arc Welding
 Submerged Arc Welding
 Flux Cored Arc Welding
 Thermit Welding

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SHIELDED METAL ARC WELDING

SMAW process defined as an arc welding process

which produces coalescence of metals by heating the
metal with an arc between a covered metal electrode
and the work-piece.

Shielding is obtained from decomposition of the elect

rode covering.

Pressure is not used and filler metal is obtained from

the electrode.

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Shielded Metal Arc Welding -- Polarity

SMAW - DC Polarity

Straight Polarity Reverse Polarity

(–) (+)

(+) (–)
Shallow penetration Deeper weld penetration
(thin metal)

AC - Gives pulsing arc

- used for welding thick sections

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OVERALL ADVANTAGES
Low Equipment Cost
Usage possible with restricted access.

OVERALL LIMITATIONS
Skilled operator is required for good quality welds.
Slow, mainly because flux must be chipped away.

SAFETY
Arc emits visible and ultraviolet radiation.
High open circuit voltage present while electrode is fitted to h
older.
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 GAS METAL ARC WELDING

GMAW is defined as an arc welding process which produces

coalescence of metals by heating them with an arc between a
continuous filler metal (consumable) electrode and the work
piece.

Shielding is obtained entirely from an externally supplied gas

or gas mixture.

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OVERALL ADVANTAGES
Continuous process
Reduced finishing operations
Thin sheets can be welded in all positions by dip transf
er mode.

OVERALL LIMITATIONS
No independent control of filler addition.

Range of action limited by wire feed.

SAFETY
Arc emits visible and ultraviolet radiation.
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 GAS TUNGSTEN ARC WELDING
GTAW is defined as an arc welding process which produces coa
lescence of metals by heating them with an arc between a tungste
n (non- consumable) electrode and the work piece.

Gas Tungsten Arc Welding (GTAW) uses a non consumable tun

gsten electrode which must be shielded with an inert gas.
The arc is initiated between the tip of the electrode and work to
melt the metal being welded, as well as the filler metal, when used
A gas shield protects the electrode and molten weld pool, and pr
ovides the required arc characteristics.

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GAS TUNGSTEN ARC WELDING(Contd.)

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GAS TUNGSTEN ARC WELDING(Contd.)

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GAS TUNGSTEN ARC WELDING(Contd.)
OVERALL ADVANTAGES
Superior quality welds
 Welds can be made with or without filler metal
 Precise control of welding variables (heat)
 Free of spatter
 Slag free
 Low distortion

OVERALL LIMITATIONS
 Requires greater welder dexterity than MIG or stick welding
 Lower deposition rates
 More costly for welding thick sections

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 SUBMERGED ARC WELDING

SAW is defined as an arc welding process which

produces coalescence of metals by heating them w
ith an arc or arcs between a bare metal electrode o
r electrodes and the work piece.
Pressure is not used and filler metal is obtained fr
om the electrode and sometimes from a supplemen
tary welding rod.

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SUBMERGED ARC WELDING(Contd.)

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SUBMERGED ARC WELDING(Contd.)

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 SUBMERGED ARC WELDING(Contd.)
OVERALL ADVANTAGES
High weld metal Quality
Smooth and uniform weld bead with no spatters.
Extremely high deposition rate and welding speed.
High Arc time can be achieved through automation.
Minimum operator fatigue.

OVERALL LIMITATIONS
High initial cost
Limited welding positions.
Requirement of special jigs and fixtures.
Difficulty in welding low thickness metals.
Full penetration weld joints not possible from single side.

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COMPARISON

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COMPARISON(Contd.)

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 Flux Cored Arc Welding

Flux Cored Arc Welding (FCAW) is frequently referred to as flux

cored welding. Flux cored welding is a commonly used high de
position rate welding process that adds the benefits of flux to th
e welding simplicity of MIG welding. As in MIG welding wire is
continuously fed from a spool. Flux cored welding is therefore r
eferred to as a semiautomatic welding process.

Self shielding flux cored arc welding wires are available or gas
shielded welding wires may be used. Flux cored welding is ge
nerally more forgiving than MIG welding. Flux cored welding pr
oduces a flux that must be removed. Flux cored welding has g
ood weld appearance (smooth, uniform welds having good cont
our).

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BENIFITS

All position capability

Good quality weld metal deposit
Higher deposition rates than SMAW
Low operator skill required
Metallurgical benefits that can be gained from a flux

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 THERMIT WELDING
Thermit Welding usually uses the exothermic reaction of a mixture of iron oxide and alu
minum powder or other similar mixtures to weld or repair large forgings and castings, an
d join pipes and railroad rails.
The parts are aligned and a ceramic or sand mold is built around the joint to be formed.
The thermitic mixture reaction is initiated with a special compound (an oxidizing agent) h
eating quickly to the desired temperature which melts the ends of the parts to be joined.
After the weld cools, excess material is removed by machining, grinding, or other cutting
methods
Heat source
chemical reaction between thermit mixture components
Iron oxide and aluminum powder
ignition fuse required

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THERMIT WELDING (Contd.)

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 THERMIT WELDING (Contd.)

Crucible loaded with Thermit mixture

On ignition the iron oxide is reduced to iron and the aluminium oxidizes.
·When reaction is complete the molten iron is tapped and cast into the mould
The alumina floats on the iron which is allowed to overflow to remove the slag
Risers allow free metal flow and must be cut off
Heat from the molten iron partially melts the joint faces
Mould faces and parent metal are preheated with oxy-acetylene flames to ensure fusio
n and reduce thermal stress

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Weld Metal Protection

• During fusion welding, the molten metal in the

weld “puddle” is susceptible to oxidation
• Must protect weld puddle (arc pool) from the at
mosphere
•Methods are:
• Weld Fluxes
• Inert Gases
• Vacuum

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Weld Fluxes
• Typical fluxes
•SiO2, TiO2, FeO, MgO, Al2O3
•Produces a gaseous shield to prevent contami
nation
•Act as scavengers to reduce oxides
•Add alloying elements to the weld
•Influence shape of weld bead during solidificati
on

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Inert Gases

•Argon, helium, nitrogen, and carbon dioxi

de
•Form a protective envelope around the
weld area
•Used in
•MIG
•TIG
•Shield Metal Arc

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 PREVENTION
• Rapid heating and cooling results in thermal stresses
detrimental to joint strength. Pre-caution to be followed
as below:

•Edge Preparation/Alignment – beveled edges and space between

components to allow movement
•Control of heat input – skip or intermittent weld technique
•Preheating – reduces expansion/contraction forces (alloys) and re
moves moisture from the surface
•Peening – help metal stretch as it cools by hitting with a hammer.
Use with care since it may work harden the metal
•Heat Treatment – “soak” the metal at a high temperature to relieve
stresses
•Jigs and Fixtures – prevent distortion by holding metal fixed
•Number of Passes – the fewer the better.

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 Welding
Techniques

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 Positions

• 1F
• 1G
• 2F
• 2G
• 2FR
• 5G
• 4F
• 6G
• 5F

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 1G Position

Pipe rotated, Electrode is always at the top

Either a split bead or weave technique may be used

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2G Position
Pipe Axis Vertical, Weld is Horizontal, Pipe is
considered in a “fixed” position.
Always use a split bead technique
Always work from the bottom up.

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 5G Position

Axis of the Pipe is Horizontal, The weld in vertical.

Progression may be up or down.
A weave bead is best used.

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6G Position
Pipe axis is fixed in position at a 45
degree incline. The position includes
flat, horizontal, vertical, and overhea
d welds.
A split bead technique is best used.

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1F Position
Pipe is rotated. The pipe axis is
at a 45 degree incline. Welding
is to occur at the top of the pipe
.
Split bead or weave technique
may be used.

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2F Position

Fixed Position
Best to use a split bead
technique

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 2FR Position

A split bead technique

is best used.
Rotated

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 4F Position

A split bead technique is best used

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5F Position

Not Rotated. Progression may

be up or down.
Split beads or weaves can be u
sed on 5F-up welds, split beads
are best used on 5F-down weld
s.

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Fill Pass Cover Pass
Root Pass Hot Pass

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 Joint Design

BUTT JOINT

STRAP JOINT
FILLET JOINT

CORNER JOINT
LAP JOINT 44
 Generalized Welding Symbol

FAR SIDE DETAILS

Field weld symbol
Weld Geometry
D L1-L2
Electrode Weld all-around
Material for pipes, etc.
D L1-L2

ARROW SIDE DETAILS D = Weld Depth (usually equal to plate thickness)

L1 = Weld Length
L2 = Distance between centers for stitched welds

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Example Welding Symbol

Geometry symbol for V-groove

One-sided welds are max 80% efficient

Two sided are 100% efficient

1/2

1/2

1/2” 1/2” 46
Weld Symbols (Butt Joints)

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Weld Symbol (Fillet Joints)

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Weld Symbol (Corner Joints)

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