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Design & Const 13 Stresses and Distortion
Design & Const 13 Stresses and Distortion
Welding stresses
Repair Welding
Introduction
Welding has been extensively developed as a method of joining materials. The
weld joints have substantial advantage over other types of joints.
Stresses and distortion developed during welding have adverse influence on
the quality of welded structure.
The theory of welding stresses and strains is one of the complex aspects of
welding science
It unites problems of thermal conductivity, elasticity, plasticity and creep of
metals over wide range rapidly changing temperature
The residual stresses and distortions can be controlled or reduced by applying
various measures , quality and reliability of the fabricated components can be
ensured.
Hence study of Residual stresses and Distortion is an important topic for
welding engineers.
Failure of a
Bridge ???
4.3.1. Residual Stresses
As long as theses stresses are above the yield point of the metal at the prevailing
temperature, they continue to produce permanent deformation, but in so doing they are
relieved and fall to yield - stress level. Then they cease to cause further distortion.
But, if at this point we could release the weld from plate by cutting along the joint line , it
would shrink further because , even when distortion has stopped , the weld still contain an
elastic strain equivalent to yield stress. The stresses left in the joint after welding are
referred to as residual stresses.
Residual stress
Without Fixed
ends
Residual stress
distribution on load
micro stresses.
They can be further classified into three
kind
4.3.5.Residual stresses 1st kind
+py
p3
p2
p1
P1 : macro stresses
P2 : micro stresses
-py P3 : submicro stresses
Factors influencing residual stresses
Material properties:
1) The temperature distributions in weldment characterized by thermal
conductivity and diffusivity.
diffusivity
2) The thermal expansion
3) Mechanical properties at elevated temperature
Welding processes: As the heat input varies , the selection of process influence
residual stresses
Welding sequence: Along the weld the effect of welding sequence is minor. Block
welding sequence produce less shrinkage than multilayer sequences
Basic effects of residual
stresses
1) The effect of welding stresses on the performance of welded
structures is significant on phenomena which occur under low applied
stress , such as brittle fracture and stress corrosion cracking .
Start with your part. These are the residual stresses that you
would like to measure
Experimentally cut the part in two. The part
will deform from the release of the stresses
Then experimentally measure the contour,
or shape, of the newly created surface
Now analytically
force the cut surface back flat. This gives the
original residual stresses normal to the cut
plane!
Typical distortion
of a plate
Reasons for distortion
Why distortion occurs ?
The bar of steel shown in fig (2) is uniformly heated it expands in all directions
and after cooling returns to original dimensions ( Unrestrained)
If restrained, as shown in (b) during heating, it can expand only in vertical direction
(deformed vertically)
On cooling it contracts uniformly as shown in (c) deformed permanently
The same process occurs during welding the heated metal restrains surrounding cooler
metal and results in distortion
Fig 2
F
i
g
Distortion from Welding Processes
Non-uniform shrinkage of weld bead
Difficult to maintain alignments
Solution: Rigid fixtures, pre-compensate for warping, loose
tolerances
Kalpakjian
Six main types of distortion
Longitudinal shrinkage
Transverse shrinkage
Angular distortion
produced by non-uniform
contraction
Bowing and dishing weld
center does not coincide with
the neutral axis
Buckling due to
compressive stresses
Twisting occurs in box-
sections caused by unequal
longitudinal thermal expansion
Types of distortion
Six types of distortion
Five factors affecting distortion
increases
Thermal conductivity decreases
Welding process
Welding procedure
Speed of travel
Joint design
sections
Design should use
intermittent welds, by
attaching stiffening plates
Where possible avail use of
neutral axis
Balancing of welds
Good
Poor
Poor
Good Good
As each bead segment is placed the heated edges expands and separates
Plates at B , but the heat moves out across the plate to C , thereby
brings the plates together.
ASSEMBLY TECHNIQUES
2. RESTRAINING
3. WELD SEQUENCES
This method of distortion control sets an expansion force from the weld being
deposited, against the contraction forces of a weld which has just been deposited
and is cooling down.
This weld sequence may be used to bring the whole of the joint to a fairly
even temperature by depositing welds in a planned sequence.
This results in more equal expansion of the work during welding and equal
contraction during cooling.
4. CHILLS
Chills are thick blocks of metal which help to conduct heat away from the joint,
they also stop the welding heat from spreading into the base metal.
It would not be practical to use metal chills for this type of job.
5. PREHEATING
This means heating the work before carrying out the welding operation.
Preheating as a means of distortion control has little use when welding thin
sheet, but can be of advantage when welding thicker sections, as it offsets heat
losses by conduction.
Preheating allows smaller nozzle sizes when gas welding and lower current
settings when arc welding. Welding speeds may be increase and it is easier
to obtain good penetration and fusion.
Post heating
The greater the included angle of a vee preparation, the greater the amount of
angular distortion of the completed weld.
Pressing
Distortion Correction
Techniques Thermal technique by
localised
Heating
Strong back
Clip and wedge assembly forces the plate
edges into alignment during welding
Distortion control after welding
Peening
Peening is the mechanical working of metals by means of hammer blows or by
blasting with shot (shot peening). Peening is a cold work process. It tends to
expand the surface of the cold metal, thereby relieving tensile stresses and/or
inducing compressive stresses. Peening also encourages strain hardening of the
surface metal.
Peening the bead stretches it and makes it thinner, thus relieving (by plastic
deormation) the stresses induced by contraction as the metal cools.
However this method is done with care. The root bead and final beads are not
permitted to undergo peening because of the possibility of concealing a crack or
causing one and undesirable work-hardening effect. The utility of this technique is
limited.
For this reason peening is not normally accepted by the majority of codes,
standards or specifications (ex. ASME B31.3 para 328.5.1 (d)). Any peening that
is carried out on a weld should have been carried out on the weld procedure
qualification test piece
POST WELD HEAT TREATMENT:
.
Post weld heat treatment (PWHT) includes any heat treatment after
welding. The process involves controlled heating of weldments to an
elevated temperature, followed by controlled cooling The objectives of
PWHT of carbon steel and low-alloy steel weldments are to relieve welding
residual stresses, decrease hardness of the heat affected zone, improve
ductility and notch toughness, and release diffusible hydrogen. Among
these objectives, stress relieving is the main purpose.
Repair
Welding
4.9.1. Repair Of Welds
1. Under cut
2. Root defects
3. Spatter
4. Irregular weld bead
5. Surface cracks
6. Surface porosity
7. Unfilled craters
4.9.4. Visual Inspection
Following equipment may be used
in visual inspection process :
1. Magnifying glass
2. Dye penetrants
3. Telescope
4. Gauges
5. Optical comparator.
4.9.5. Internal Defects
Internal defects can be
detected by the following
methods :
1. Ultra sonic tests
2. Magna-flux testing
3. Radiographic testing.
4. Micro-hardness testing
4.9.6.Removal Of The Defective
Part Of Weld
Defective part of the weld can be
removed
by :
1. Flame cutting
2. Arc gouging
3. Chipping
4. Grinding
5. Machining
4.9.7. Cleaning And
Preparation Of Joint
The joint must be thoroughly
cleaned and dried to remove :
Dirt and dust
Carbonaceous particles
Moisture
Inserts/spacers
Pre-heat if required
required
Inspect the weld
inspection
4.4.9.Procedural Qualifications
It is imperative that to carry out
either welding or repair of welds
procedural qualifications are to be
used. The A.S.M.E. Section IX
specifies use of :
Welding procedure specification
Distortion :
Influencing factors Material properties-Joint design-restraint- welding procedure
Control measures: Minimize heat input, control on weld size, follow weld sequence
Weld fixtures Mechanical & Thermal methods Peening & Controlled heating
Residual stresses:
Types of stresses Stress distribution in Longitudinal , transverse and through
thickness direction
Effect of residual stresses on mechanical properties- geometry corrosion resistance
Methods of control / reduction Mechanical and thermal methods Vibration / PWHT
Measurement methods Physical & Mechanical X-ray & Deep hole drilling technique
Thank You