residualstresses,distortionwelddefects-iricen.docVIP

UNIT 12 RESIDUAL STRESSES, DISTORTION WELD DEFECTS Structure Introduction Objectives Residual Stresses and Distortion Factors Affecting Distortion 12.4 Controlling Distortion 12.4.1 Control the Heat Input 12.4.2 Preheat the Metal 12.4.3 Allow for Distortion 12.4.4 Use of Restraint 12.5 Corrective Techniques Mechanical Techniques Thermal Techniques? 12.6 Other Welding Defects Porosity Cracks Slag Inclusions/Entrapment Incomplete Fusion and Penetration Undercutting Suck Back and Drop Through Summary Key Words Answers to SAQs 12.1 INTRODUCTION In the previous unit we have studied various methods of welding. In all the mentioned methods one thing is common that is the requirement of heat source. It is also known that when a piece of metal is heated, the metal expands. Upon cooling, the metal contracts and tries to resume its original shape. These expansion and contraction forces act on the weld metal and base metal of a welded joint; however, when two pieces of metal are welded together, expansion and contraction may not be uniform throughout all parts of the metal. This is due to the difference in the temperature from the actual weld joint out to the edges of the joint. This difference in temperature leads to internal stresses, distortion, and warpage. All metals, when exposed to heat build-up during welding, expand in the direction of least resistance. Conversely, when the metal cools, it contracts by the same amount; therefore, if you want to prevent or reduce the distortion of the weldment, you have to use some method to overcome the effects of heating and cooling. In this unit, we are going to study the various reasons for these stresses and distortion. We will also go through the factors affecting distortion and the methods to control it. Distortion is one of the major defects while welding but there are other important defects, which should be studied as they occur very often while welding. The causes of defects and their remedies are discussed bri