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• 2. Porosity
Porosity, often not visible without the use of advanced
nondestructive testing methods, is a serious concern because it can
potentially weaken the weld.
Arc Welding Defects
• 3. Poor fusion
Another defect affecting the strength of the weld is poor
fusion, though it is often easily visible. It is caused by low
current, contaminated joint surfaces, or the use ofan
improper electrode.
• 4. Shallow penetration
Shallow penetration, another detriment to weld strength, can be
addressed by decreasing welding speed, increasing the
current or using a smaller electrode.
• 5. Cracking.
Any of these weld-strength-related defects can make the weld
prone to cracking, but other factors are involved as well. High
carbon, alloy or sulfur content in the base material can lead to
cracking, especially if low-hydrogen electrodes and
preheatingare not employed. Furthermore, the workpieces
should not be excessively restrained, as this introduces residual
stresses into the weld and can cause cracking as the weld cools
and contracts.
Advantages of arc welding
• 1. Simple welding equipment
• 2. Portable
• 3. Inexpensive power source
• 4. Relatively inexpensive equipment
• 5. Welders use standard domestic current.
• 6. Process is fast and reliable
• 7. Short learning curve
• 8. Equipment can be used for multiple functions
• 9. Electric arc is about 5,000 oC
• 10. Used for maintenance, repair, and fieldconstruction
Disadvantages
• Not clean enough for reactive metals suchas
aluminium and titanium.
• The deposition rate is limited because the
electrode covering tends to overheat andfall off.
• The electrode length is ~ 35 mm and requires
electrode changing lower the overall production
rate.
Arc Welding
Arc Welding
ASME SEC IX WELDING CODES FOR PLATES
1 FLAT WELDING 1G
2 HORIZONTAL WELDING 2G
3 VERTICAL WELDING 3G
4 OVERHEAD WELDING 4G
ASME SEC IX WELDING CODES FOR PIPES
2) Corner Joint
3) T-Joint
4) Lap Joint
5) Edge Joint
Factors
Plate/Pipe
Current
Root Gap
Arc Voltage
Weld Joints Design (V , U , Double V , Double U)
Materials (Steel Types)
Post Weld Heat Treatment (PWHT) (Yes/No)
Angle
Electrode Diameter (3.2mm,4mm,5mm)
Electrode Pre-Heat (Yes/No)
Welding Position (Flat , Horizontal , Vertical , Overhead)
Response
Variables
Hardness
Impact Strength
Tensile Strength
Micro-Structure
Fatigue
Bend
Minimizing defects ( Cracks, Pin Holes, Under Cut, Slag
Intrusions)
Weld Bead (Width/Height)