welding
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WeldingTRANSCRIPT
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Welding ProcessesWelding Processes
EN358 – Ship Structures
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A Brief History of WeldingA Brief History of Welding
• Late 19th Century• Scientists/engineers apply advances in electricity to heat
and/or join metals (Le Chatelier, Joule, etc.)• Early 20th Century
• Prior to WWI welding was not trusted as a method to join two metals due to crack issues
• 1930’s and 40’s• Industrial welding gains acceptance and is used extensively
in the war effort to build tanks, aircraft, ships, etc.• Modern Welding
• the nuclear/space age helps bring welding from an art to a science
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Types of WeldingTypes of Welding
Fusion Welding Pressure Welding
Homogeneous Heterogeneous
Brazing SolderingGas Welding
Electroslag
High Energy Beam
Electric Arc
MIG
TIG
Shielded Metal Arc – “Stick”
Friction Welding
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Weldability of a MetalWeldability of a Metal
• Metallurgical Capacity• Parent metal will join with the weld metal without
formation of deleterious constituents or alloys
• Mechanical Soundness• Joint will be free from discontinuities, gas porosity,
shrinkage, slag, or cracks
• Serviceability• Weld is able to perform under varying conditions
or service (e.g., extreme temperatures, corrosive environments, fatigue, high pressures, etc.)
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Fusion Welding PrinciplesFusion Welding Principles
• Base metal is melted
• Filler metal may be added
• Heat is supplied by various means• Oxyacetylene gas• Electric Arc• Plasma Arc• Laser
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Fusion WeldingFusion Welding
BASE METAL
WELD
SOLIDIFIED SLAG
ARC POOL
WELDING ATMOSPHERE
CORE WIRE
ELECTRODE COATING
ARC STREAM
PENETRATION DEPTH
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Weld Metal ProtectionWeld Metal Protection
• During fusion welding, the molten metal in the weld “puddle” is susceptible to oxidation
• Must protect weld puddle (arc pool) from the atmosphere
• Methods• Weld Fluxes• Inert Gases• Vacuum
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Weld FluxesWeld Fluxes
• Typical fluxes• SiO2, TiO2, FeO, MgO, Al2O3
• Produces a gaseous shield to prevent contamination
• Act as scavengers to reduce oxides• Add alloying elements to the weld• Influence shape of weld bead during
solidification
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Inert GasesInert Gases
• Argon, helium, nitrogen, and carbon dioxide
• Form a protective envelope around the weld area
• Used in• MIG• TIG• Shield Metal Arc
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Vacuum Vacuum
• Produce high-quality welds
• Used in electron beam welding
• Nuclear/special metal applications• Zr, Hf, Ti
• Reduces impurities by a factor of 20 versus other methods
• Expensive and time-consuming
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Types of Fusion WeldingTypes of Fusion Welding
• Oxyacetylene Cutting/Welding
• Shielded Metal Arc (“Stick”)
• Metal Inert Gas (MIG)
• Tungsten Inert Gas (TIG)
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Oxyacetylene WeldingOxyacetylene Welding
• Flame formed by burning a mix of acetylene (C2H2) and oxygen
• Fusion of metal is achieved by passing the inner cone of the flame over the metal
• Oxyacetylene can also be used for cutting metals
Inner Cone: 5000-6300 deg F Combustion Envelope 3800 deg F
2300 deg FTORCH TIP
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Shielded Metal Arc (Stick)Shielded Metal Arc (Stick)
• An electric arc is generated between a coated electrode and the parent metal
• The coated electrode carries the electric current to form the arc, produces a gas to control the atmosphere and provides filler metal for the weld bead
• Electric current may be AC or DC. If the current is DC, the polarity will affect the weld size and application
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Shielded Metal Arc (con’t)Shielded Metal Arc (con’t)
• Process:• Intense heat at the arc melts the tip of the
electrode• Tiny drops of metal enter the arc stream and are
deposited on the parent metal• As molten metal is deposited, a slag forms over
the bead which serves as an insulation against air contaminants during cooling
• After a weld ‘pass’ is allowed the cool, the oxide layer is removed by a chipping hammer and then cleaned with a wirebrush before the next pass.
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Inert Gas WeldingInert Gas Welding
• For materials such as Al or Ti which quickly form oxide layers, a method to place an inert atmosphere around the weld puddle had to be developed
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• Uses a consumable electrode (filler wire made of the base metal)
• Inert gas is typically Argon
Metal Inert Gas (MIG)Metal Inert Gas (MIG)
BASE METAL PUDDLE
POWER SOURCE
DRIVE WHEELSCONSUMABLE ELECTRODE
ARC COLUMNSHIELDING GAS
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• Tungsten electrode acts as a cathode• A plasma is produced between the tungsten cathode and the
base metal which heats the base metal to its melting point• Filler metal can be added to the weld pool
Tungsten Inert Gas (MIG)Tungsten Inert Gas (MIG)
BASE METAL PUDDLE
POWER SOURCE
ARC COLUMNSHIELDING GAS
TUNGSTEN ELECTRODE
+ +
BASE METAL (ANODE)
TUNGSTEN ELECTRODE
(CATHODE)
- - -
+ +
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Welding PositionsWelding Positions
FLATFLAT
HORIZONTALHORIZONTAL
VERTICALVERTICAL
OVERHEADOVERHEAD
INCREASING DIFFICULTY
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Weld DefectsWeld Defects
• Undercuts/Overlaps
• Grain Growth• A wide T will exist between base metal and HAZ.
Preheating and cooling methods will affect the brittleness of the metal in this region
• Blowholes• Are cavities caused by gas entrapment during the
solidification of the weld puddle. Prevented by proper weld technique (even temperature and speed)
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Weld DefectsWeld Defects
• Inclusions• Impurities or foreign substances which are forced into the weld
puddle during the welding process. Has the same effect as a crack. Prevented by proper technique/cleanliness.
• Segregation• Condition where some regions of the metal are enriched with an
alloy ingredient and others aren’t. Can be prevented by proper heat treatment and cooling.
• Porosity• The formation of tiny pinholes generated by atmospheric
contamination. Prevented by keeping a protective shield over the molten weld puddle.
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Residual StressesResidual Stresses
• Rapid heating and cooling results in thermal stresses detrimental to joint strength.
• Prevention• 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 removes 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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Joint DesignJoint Design
BUTT JOINTBUTT JOINT
STRAP JOINT
LAP JOINT
FILLET JOINT
CORNER JOINT
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Generalized Welding SymbolGeneralized Welding Symbol
FAR SIDE DETAILS
ARROW SIDE DETAILS
Field weld symbol
Weld all-around for pipes, etc.
L1-L2
L1-L2
D = Weld Depth (usually equal to plate thickness)
L1 = Weld Length
L2 = Distance between centers for stitched welds
The Field Weld Symbol is a guide for installation. Shipyardsnormally do not use it, except in modular construction.
ElectrodeMaterial
D
D
Weld Geometry
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Example Welding SymbolExample Welding Symbol
1/2” 1/2”
1/2
1/2
One-sided welds are max 80% efficientTwo sided are 100% efficient
Geometry symbol for V-groove
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Weld Symbols (Butt Joints)Weld Symbols (Butt Joints)
Backing
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Weld Symbol (Fillet Joints)Weld Symbol (Fillet Joints)
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Weld Symbol (Corner Joints)Weld Symbol (Corner Joints)