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Principles of Welding
Principles of Welding
663
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STEEL CONSTRUCTION:
FABRICATION AND ERECTION
1. INTRODUCTION
Welding offers a means of making continuous, load bearing, metallic joints between the
components of a structure.
In structural work, a variety of welded joints are used; these can all be made up from the
basic configurations shown in Figure 1, which are classified as follows:
butt joints.
tee joints.
lap joints.
corner joints.
As illustrated in Figure 2, a welded joint is made by fusing (melting) the steel plates or
sections (the parent metal) along the line of the joint. The metal melted from each
member at the joint
unites in a pool of molten metal which bridges the interface. As the pool cools, molten
metal at the fusion boundary solidifies, forming a solid bond with the parent metal, see
Figure 3. When the solidification is complete, there is continuity of metal through the
joint.
Disperse hyrodgen from the weld pool and HAZ. Hydrogen in the HAZ increases
the risk of cracking if hardening has occurred. The hydrogen comes principally
from the flux. An appropriate electrode, correctly stored, will reduce the risk of
hydrogen pick-up.
Remove surface moisture in high humidity conditions or on site.
Bring the steel up to 'normal' ambient conditions (20C).
The first run to be deposited in the bottom of the groove is called the root run. The root
faces must be melted to ensure good penetration, but at the same time the weld pool must
be controlled to avoid collapse, as seen in Figure 11. This task requires considerable skill.
The difficulties can be eased by using a backing strip.
type of process.
position of welding (Figure 12).
access for arc and electrode.
volume of deposited weld metal which should be kept to a minimum.
cost of preparing edges.
shrinkage and distortion (Figure 13).
5. WELDING PROCEDURES
The term welding procedure is used to describe the complete process involved in making a
weld. It covers choice of electrode, edge preparation, preheat, welding parameters
(voltage, current and travel speed), welding position, number of weld runs to fill the
groove, and post-weld treatments, e.g. grinding or heat treatment. Welding procedures
may be devised to meet various needs, e.g. to minimise costs, control distortion, avoid
defects or achieve good impact properties. Specific aspects of the weld procedure are
worth detailed comment.
5.1 Current
The current controls heat input. The minimum value is fixed by the need to fuse the plate
and to keep the arc stable; the specified minimum, however, may be higher to avoid HAZ
cracks. The maximum current depends on operating conditions. Usually, as high a current
as possible is used to achieve faster welding, and hence lower costs. The use of maximum
current may be restricted by position; in the overhead position, for example, currents
above 160 amps cannot be used. High currents usually give low impact properties. Note
that the current used is chosen to match the electrode diameter.
5.3 Environment
If on site welding is necessary the following points must be considered:
6. SHRINKAGE
During cooling, the hot metal in the weld zone contracts, causing the joint to shrink. The
contraction is restrained by the cold metal surrounding the joint; stresses are set up which,
being in excess of the yield stress, produce plastic deformation. This can lead to the
distortion or buckling shown in Figure 13. Distortion can be reduced by choice of edge
preparation and weld procedure; examples are shown in Figure 14.
When the plastic deformation has ceased, the joint is left with the residual stress pattern of
Figure 15 with tension in the weld metal and HAZ, and compression in the surrounding
steel. The significance of these residual stresses is discussed in other lectures.
7. CONCLUDING SUMMARY
A welded joint is made by fusing parent metal from both components being joined,
usually with added weld metal.
The properties of both the weld metal, which has melted and solidified, and the
surrounding heat affected zone may differ from those of the parent metal.
Welding procedures should be properly specified to give a satisfactory welded
joint. The major parameters are: welding position, electrode type, edge preparation,
preheat, voltage, current, travel speed, number of runs and post-weld heat
treatments.
Hot metal in the weld zone contracts during cooling causing residual stresses.
Distortion will occur if appropriate control is not exercised.
8. ADDITIONAL READING
1. Hicks, J. "Welding Design", Granada.
details of joints and welds.
strength of welded joints.