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Africa Welding Notes

The document discusses various welding processes and defects. It describes Manual Metal Arc Welding (MMA or SMAW) as the most common and versatile process that uses a flux-covered electrode. Improper cleaning can lead to slag inclusion. Tungsten inert gas welding (TIG or GTAW) uses an inert gas for shielding and can result in porosity without proper gas coverage. Metal inert gas welding (MIG or MAG) uses a consumable electrode that is continuously fed, making it an efficient process for various materials. Submerged arc welding is mostly used for high thickness welding and can cause solidification cracking. Electroslag welding is for very thick welding over 40mm with little bevel preparation needed.

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58 views2 pages

Africa Welding Notes

The document discusses various welding processes and defects. It describes Manual Metal Arc Welding (MMA or SMAW) as the most common and versatile process that uses a flux-covered electrode. Improper cleaning can lead to slag inclusion. Tungsten inert gas welding (TIG or GTAW) uses an inert gas for shielding and can result in porosity without proper gas coverage. Metal inert gas welding (MIG or MAG) uses a consumable electrode that is continuously fed, making it an efficient process for various materials. Submerged arc welding is mostly used for high thickness welding and can cause solidification cracking. Electroslag welding is for very thick welding over 40mm with little bevel preparation needed.

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prabu
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© © All Rights Reserved
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Cracks- Because of high thermal gradient, uneven distribution of stress

Forging folds- Poor die design, buckling of part

Forging lap- Due to forging die mismatch

Forging Flakes- Presence of hydrogen molecules which opens up formed like fish eye

Forging burst- Low or incorrect forging temperature (either internal or external)

Manual Metal Arc Welding (MMA or SMAW)

 Most common and versatile welding process


 Frequently need to replace the electrode as it gets consumed
 Mostly used for repair welding process
 Utilizes flux covered electrode
 The purpose of flux is for shielding the molten metal from atmospheric air
 Improper cleaning between runs leads to slag inclusion
 Dampened flux, moisture condition, presence of oxide layers in the weld surface,
rusty surface leads to porosity

Tungsten inert gas welding: TIG or GTAW

 Non consumable electrode process commonly for low thickness material


 Inert gas (helium and argon) used for shielding purposes
 Lack of gas shielding leads to porosity
 High quality welding especially for root pass and nonferrous like aluminium and copper
 If electrode touches the weld pool, then sudden increase in current leads to tungsten
tip melted and leads to tungsten inclusion which can be identified in RT inspection
 Crater pipe or crater crack usually comes in poor start stop area due to wrong welding
practice (sudden withdrawal of electrode during welding)
 Crater crack otherwise called as star crack
 If electrode strikes over the parent metal, localised heating and sudden cooling takes place
leads to arc strike where that area becomes hard spot and may contain cracks

Metal Inert Gas-MIG / Metal active gas-MAG (Co2/N2)

 Consumable electrode process where electrode and filler material are same
 Electrode is continuously fed through the welding tube during the welding. only control is to
maintain the travel speed. Rate at which the electrode melts is called weld deposition rate
 Efficient welding process suitable to weld ferrous and non-ferrous material
 Most common defects occurs in MIG welding is porosity
Submerged Arc Welding –
 Mostly used for high thickness plate or vessel only in flat position
 Uses granules of flux that covers the arc. (Arc submerged in the flux)
 High heat input welding leads to solidification crack usually occurs at the weld centre line
 Weld distortion happens due to lack of restraint and contraction stresses

Electroslag Welding:

 Used to weld very high thick more than 40mm thick


 Usually there is no need to prepare bevel (least bevel preparation). Usually done by open
square butt
 Another name is guided tube welding and no arc method
 Discontinuity orients in vertical direction

Cracks

Lamellar Tear

 Usually comes in parent metal of T-Joint welds


 Due to poor through thickness ductility of plate or pipe
 Identified using compression probe

Hydrogen induced cold cracking (HICC)

 Another name is delayed crack


 Formed due to presence of hydrogen
 Usually occurs in HAZ
 High hydrogen process welding- SAW, SMAW, FCAW, ESW
 Low hydrogen process- MIG/TIG/PAW

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