intellectual welding training

7/29/2019 Intellectual Welding Training

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I n t e l l e c t u a l d e s i g n & e n g i n e e r i n g

Training on

WELDING AND

INSPECTION

Presentation on

Welding

application ,

Symbol,Inspection


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Trainers background info

15Years in Welding Inspection by Visualand NDT

Heavy Equipment FabricationConstruction equipment

Trainer in Manufacturing Quality, QMS,

Six sigma Green Belt, TPM Facilitator,Quality Circle Team Leader, WeldingQuality, NDT Ultrasonic testing and

Quality concept.

I n t e l l e c t u a l

d e s i g n & e n g i n e e r i n g


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Welding is joining two pieces of materials. Solid+solid Welding = Solid state bonding

Liquid+Liquid welding=Fusion Welding

Solid+Liquid Welding=Braze Welding Oxy-Aceteline=Gas Welding

Thermit =

Atomic hydrogen=



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FCAW -Flux cored Arc Welding

CAW -Carbon arc Welding

SMAW -Shielded metal arc Welding GMAW -Gas metal arc Welding

GTAW -Gas Tungsten arc Welding

SW -Stud Welding

PAW -Plasma Arc Welding



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SMAW

CURRENT RANGE 75 - 300 A

THICKNESS RANGE 2MM

DEPOSITION RATE 1 - 6 Kg\ hr

JOINTS TYPES ALL

POSITION OF WELDI ALL

ELECTRODE DIA. 1.5 - 8 MM

FLUX COAT 1 - 5 MM

MATERIAL ferrous alloy only

APPLICATION structural,ship,repair,hardface

ADVANTAGE low cost m/c.

LIMITATION skill operator,slow flux chipping

SAFETY emits visible,UV ,hi open circt volt

EQUIPMENT AC or DC



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SAW


THICKNESS RANGE 5 MM

DEPOSITION RATE 7 - 30 Kg / hr

JOINTS TYPES butt & T- Joint

POSITION OF WELDING B/J,F,T,h,v

ELECTRODE DIA. 2 - 6 MM COIL

FLUX COAT Copper coat

MATERIAL CS, corrosion resist steel& some alloys

APPLICATION pr.vessel,cem plant,structural engg,ship

ADVANTAGE high dep.rate, surface finish, Xray weld,flux shieldarc

LIMITATION Regular weld line, fitup,low impact strength,less position

SAFETY minor problem with flux dust

EQUIPMENT DC, upto 2000A



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MIG


THICKNESS RANGE 0.5 MM

DEPOSITION RATE 1 - 10 Kg/hr

JOINTS TYPES ALL+SPOT

POSITION OF WELDING Dip ,pulsed arc

ELECTRODE DIA. 0.6 -1.6MMspool


MATERIAL steel,al alloys and other metal that can be wire form

APPLICATION light&heavy vehicle,high rate production

ADVANTAGE continuous process,less finall dressing

LIMITATION no independent filler addition control, action limited to wire feed

SAFETY

EQUIPMENT



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MIG



DEPOSITION RATE 1 - 10 Kg/hr

JOINTS TYPES ALL+SPOT

POSITION OF WELDING Dip ,pulsed arc

ELECTRODE DIA. 0.6 -1.6MMspool


MATERIAL steel,al alloys and other metal that can be wire form

APPLICATION light&heavy vehicle,high rate production

ADVANTAGE continuous process,less finall dressing

LIMITATION no independent filler addition control, action limited to wire feed

SAFETY

EQUIPMENT



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BRAZE

CURRENT RANGE


DEPOSITION RATE Upto 2 Kg/hr

JOINTS TYPES lap,fillet,butt

POSITION OF WELDING flat,verticle

ELECTRODE DIA. 1.6 - 6 MM,

FLUX COAT

MATERIAL

APPLICATION Steel,CI, Copper

ADVANTAGE ventilation,cast iron repair

LIMITATION Slow,corrosion,limited material

SAFETY poisenous flux

EQUIPMENTI n t e l l e c t u a l d e s i g n & e n g i n e e r i n g


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Spot Welding.

Seam Welding.

Projection welding.

Flash butt Welding.

Electro slag Welding.

Stud Welding.



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Induction Pressure Welding.

Induction Brazing.



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Friction Welding.

Ultrasonic Welding, High freq sound waves.

Explosive Welding.



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Electron Beam Welding.

Laser Welding .



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Absorption or loss Moisture

Cracking & descaling covering

Contamination

Oxidation of the cored wire

Formation of deposits on the surface



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Porosity in weld metal.

Excessive Projection.

Spattering arc instability.

Visual worsening of seam surface.

Scouring / Blistering in cellulose coating.

Difficulty in removing slag.

Cracking caused by hydrogen.



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Absorption or loss Moisture.

Cracking & descaling covering.

Contamination.

Oxidation of the cored wire.



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ROLE OF WELDING

OPERATOR.

ENSURING GOOD WELDING QUALITY ALL

TIMES



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Crack. Bead shift.

Burn through.

Porosity.

Pin holes.

Waviness.

Under cut.

Weld appearance.


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Weldments - Symbols and Drawing Practices


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Primary Reference -

ISO 2553:1992

Secondary References -

AWS A2.4:1998



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Contour Symbols are not used much in the

past.


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Reference lines andweld symbol detailsremain the sameregardless of whichend the arrow is on.


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Reference lines and weld symbol details remain the

same regardless of which end the arrow is on.



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Appropriate weldsymbols above and

below referencelines.

Dashed line notrequired where the

weld joint isexactly symmetric.


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More thanone weld

type. Size

specifiedindividually

for each.


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Required minimum

weld size dimension(mm)

z = leg dimension

a = throat dimension


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Required minimumthroat dimension

(mm) No direct

measurement -requires destructive

test and evaluation


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ISO vs AWS (App 2)

Size convention is the

same Number and length

of segments

Spacing betweensegments vs AWS ctrto ctr method


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Same weld symboland dimensions

both sides Dashed line not

required

Anchor welds at

each end


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Usually specified toavoid weld distortion

or interference Offset dimension

specified in detail vsdefault

Anchor welds -standard shoppractice

Z denotes staggered

intermittent weld


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If necessary, start locationmust clearly be identified

Weld size

Number and length ofsegments

Spacing between segments(chord dimension)


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Simplified details

Exactly the same

joint conditions andwelds all the wayaround


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Testing methods

Destructive

Mechanical,

Chemical,

Testing

Ultrasonic

TestingD P

Testing ,

MPT,ECT,

X-RAY

AET,LEAK,

NRT,

Visual

inspection


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WELDINGSOUNDNESS

Right Welding parameter

at any time

No

Adjustment

Monitering

For right welding at first

Time and any time

Setting

With

error

proof

interlock

(Poka

yoke)


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Welding parameter entry

RESULT

EVALUATION

REPAIR,

IDENTIFYACTION PLANAction Name Date

TIME

Trend Chart

GOAL

Check

PARETOANALYSIS100%

Set alingment


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Setting

TIME

CURRENT

WIRE

POSITION

DIFT

Wire feed

Input

Quality,

Good

Fittment,

Job

position,

Alingment

VOLTAGE


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GOOD WELDING CONTRIBUTION

MACHIN

E

34%

WELDER

16%

MATERI

AL

14%

OTHERS

9%

METHOD

27%


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CHECK

POINTS

Rollequality

Spool

quality

Alingnment

Torch

setting

Flux baking

FITUP GAP

RUST

Input

material

QualityMachine

truness

Key Decisions Made

Ensure proper welding

parameter Set appropriate Time

Correct and monitor the

process

Check incoming component

Clean and remove rust,oil

Ensure proper welding.


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Meet spec

Weld width

Penetration

Side wall

fusion

Weld appearance

Weld cap angle

(Abtuse angle)

Uniform weld bead

Uniform reinforcement

TO ACHIVE

Quantum Improvement

in terms ofQuality

Cost

Cycle time

Leading Consultants for 6

and Cycle time Reduction

Clients:Citicorp, PwC, ICI,

3M, Telstra


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Six Sigmas definition of Defect


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SMAW SAW MIG TIG BRAZE

CURRENT RANGE 75 - 300 A 350 - 2000 A 60 - 500 A 10 - 400 A

THICKNESS RANGE 2MM ^ 5 MM ^ 0.5 MM ^ 0.1 MM ^ 0.5 MM ^

DEPOSITION RATE 1 - 6 Kg\ hr 7 - 30 Kg / hr 1 - 10 Kg/hr 0 - 2 Kg/hr Upto 2 Kg/hr

JOINTS TYPES ALL butt & T- Joint ALL+SPOT ALL+SPOT lap,f illet,butt

POSITION OF WELDING ALL B/J,F,T,h,v Dip ,pulsed arc ALL flat,verticle

ACCESS GOOD GOOD FAIR GOOD GOOD

PORTABILITY GOOD FAIR FAIR FAIR EXECLENT

ELECTRODE DIA. 1.5 - 8 MM 2 - 6 MM COIL 0.6 - 1.6 MM spool - 1.6 - 6 MM,

FLUX COAT 1 - 5 MM Copper coat Copper coat -

MATERIAL ferrous alloy only, corros on res s s ee

some alloyss ee ,a a oys an o er me athat c an be w ire f orm Most metal

APPLICATION

structural,ship,repair

,hardface

pr.vessel,cem

plant,structural engg,ship

light&heavy vehicle,high rate

production

SS-nuclear,Ni.alloy aircraft,Al.alloy

food indus. Steel,CI, Copper

ADVANTAGE low cost m/c.

finish, Xray weld,flux

shieldarc

continuous process,less f inall

dressing Wide range of material

ventilation,cast

iron repair

LIMITATION

skill operator,slow

flux chipping

Regular weld line, fitup,low

impact strength,less position

no independent filler additioncontrol, action limited to wire

feed skill operator,slow er than MIG.

Slow,corrosion,li

mited material

SAFETY

emits visible,UV ,hi

open circt volt minor problem w ith f lux dust emits visible & ultraviolet radiation.

poisenous

flux

EQUIPMENT AC or DC DC, upto 2000A


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NDECircumferentia

l Butt Weld

Inspection

All welds shall be inspected. A

weld subject to inspection shall be

acceptable if inspection shows:

(a) No surface cracks

(b) No Visible lack of fusion

between welds and base metal(c) No craters

(d) Uniform Weld profiles

(e) That frequency of visible

porosity in fillet welds does not

exceed one in each 100 mm of

length and the maximum diameter

does not exceed 2.4 mm That

groove welds have no visibleporosity.

(g) Undercut is not more than 0.5

mm deep.

Repairable


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