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Weld metal has a susceptible chemical composition (low melting point impurities)
Welding conditions used give an unfavourable bead shape
High level of restraint or tensile stresses present in the weld area
Contamination in weld joint
Unfavourable welding condition
Improper Width to depth ratio
Control measures
1. Control the low melting point impurities (sulphur/phosphorous)
2. Ensure the weld joints are thoroughly cleaned
3. Limit the heat input, hence minimising expansion and contraction
4. Increase the grain boundaries by adding delta ferritic
5. Minimise restraints
6. Use low dilution process
7. Weld joints are thoroughly cleaned immediately before welding
8. Maintain proper width to depth ratio
13. What is weld decay describe the causes and prevention measures?
Weld decay occurs in unstabilised austenitic stainless steel with 550C to 850C range of the HAZ. At
this temperature range carbon is absorbed by chromium and chromium carbide precipitated at the
grain boundaries as a metal cools down. This precipitation of chromium carbides consumed the
alloying element cause a local reduction in chromium content, which has the effect of lowering the
resistance to corrosive attack and allowing occurring.
Controlling measures
1. using of stabilised steels (with addition of Ni or Ti)
2. Use low carbon stainless steels i.e. 316L, 304L (carbon content below 0.03%)
3. Heating to about 1100C where chromium carbide will be dissolved. Then steel is normally
quenched from this temperature to stop re-association.
14. What is liquation cracking describe the causes and prevention measures?
Crack type
: Liquation crack
Location
: HAZ
Steel type
: Low quality sulphur content steels
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124. Give three reasons why pipe may form in the weld metal?
a. Premature freezing of the surface
b. Excessive depth of bead related to width
c. Bad bead shape
125. Give three reasons which contribute to premature freezing of the weld pool surface?
Premature of the surface due to
a. No slag covers i.e. the process
b. Gas not heated
c. Flow rate too high
126. Why ferritic material is usually added to austenitic electrodes?
To avoid centreline cracking
127. Why are austenitic electrodes used for welding carbon manganese steel?
To control the hydrogen level i.e. making the hydrogen level acceptable to avoid hydrogen cracking
128. When ferritic is added to electrodes what are two possible consequences?
It tends to avoid solidification cracking it does induce magnetism and makes the weld metal avoid so
reducing the corrosion resistance.
129. Why are small stringer beads usually recommended for SS weldments?
To reduce the level of heat input and avoid cracking
130. Describe the thermal conditions which give rise to weld decay in austenitic SS weldments
550 degree C for six seconds
131. State the special mechanical properties of 25%Cr in Fe alloys?
Ferritic SS is poor weldability due to cracking brittleness and temper embitterment. It is a single
phase alloy which is ferritic at all solid temperatures, so solidification cracking is a problem.
132. What is a specification?
Specification is a description of what to use in the making of a product i.e. type of material type of
process and type of consumables.
133. What is the extent of approval in a procedure?
Extent of approval is the range over which certain variables may alter without requiring new
procedure i.e. when there is a limitation in the welding qualification i.e.
a. The minimum and maximum diameter of the pipe that the test sample covers e.g. two inch
test piece would allow down 1 and upto 4
b. The test may only allow welding of consumables in the same grouping, any other
consumable would require retest
c. The use of set electrical characteristics would not allow change without retest
d. The direction of welding if changed may require retest
e. Change of material to be tested would require retesting
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144. Discuss the reasons for the existence of arc blow and state possible methods of minimising arc
blow.
145. Welder used cellulose electrode instead of low hydrogen electrode. Suggest corrective action
and your course of action in it?
a. Raise Non conformity report
b. Further investigation to be done to identify any other joints welded.
c. Analysis and identify the root cause for this incident
d. Check with approved drawing, product specification and welding procedures specifications.
If welding procedure specification available for this electrode and product design
requirement accept as it is provided a deviation request to be raised and approved.
e. If the specifications not allowed, the entire joints which is identified to be refabricated as per
approved specification.
f. The changes to be incorporated in the as built drawing.
g. Move welder for training and requalification
h. Issue a strong warning letter to Concern person involved.
i. Conduct meeting with all inspectors and make them awareness, such as things recur in future.
j. Document all the above and close the NCR
146. Name four commonly used NDT methods and list their advantages and disadvantages?
NDT METHOD
ADVANTAGES
DISADVANTAGES
Inexpensive Highly portable Immediate Surface discontinuities only Generally
Visual
results Minimum training Minimum
only large discontinuities
part preparation
Misinterpretation of scratches
Portability
Locates surface breaking defects only
Dye Penetrant
Inexpensive
Little indication of depths
Sensitive to very small discontinuities
Direct visual detection of results
Simple to use
required
Quick results
Penetrant may contaminate component
Can be used on any non-porous
Surface preparation critical
material
Post cleaning required
Low operator skill required
Potentially hazardous chemicals
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Eddy Current
Ultrasonic
Radiographic
Test
Can be portable
Low cost
Sensitive to small discontinuities
Immediate results
Moderate skill required
Detects surface and subsurface
discontinuities
Relatively fast
No harm to test piece
Portable
Detects surface and subsurface
discontinuities
Moderate speed
Immediate results
Sensitive to small discontinuities
Thickness sensitive
Accurate conductivity measurements
Can detect thorough several layers
Can be automated
Can detect thorough surface coatings
Little pre-clean required
Portable
Inexpensive
Sensitive to very small discontinuities
Immediate results
Little part preparation
Wide range of materials and thickness
can be inspected
Permanent record
Internal flaws
Can be used on most materials
Direct image of flaws
Real time imaging
Minimum part preparation
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