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What is distortion ?
Before distortion
Undesirable change in
Experiment No 1:
DURING HEATED CONDITION
X X + 9X
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Experiment No 2 :
CLAMPING JAWS CLAMPING JAWS
Distortion
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Heat input
Gas cutting/heating
welding
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HEATING
Heated area expands Expansion restrained by surrounding solid area Compressive stresses are developed Further compressive stress leads to plastic
deformation
Resulting distortion
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Longitudinal distortion
WELD BEAD ORIGINAL POSITION
WELD BEAD
LONGITUDINAL DISTORTION
at the weld
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LONGITUDINAL SHRINKAGE
(A) BUTT WELDS IN CS/LAS
LS = 3. I .L / 100,000 t LS = longitudinal shrinkage (mm) I = welding current(amp) L = length of weld (mm) t = plate thickness (mm)
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LONGITUDINAL SHRINKAGE
(B) FILLET WELD LS = 25 Aw/ Ap Aw = Weld X-sectional area Ap = Resisting X-sectional area
Ap Aw
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75
8x8 6 100 LS = 1.52 mm
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It is not uniform along the length of the plate It is lesser at that end of plate where bead is started.
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Transverse distortion
WELD BEAD ORIGINAL POSITION
TRANSVERSE DISTORTION
lxl
tb
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(3) For fillet welds in a lap joints between plates of equal thickness (two welds) TS = Leg of fillet Weld (l) Plate thickness (t) x 1.52
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Angular distortion
AFTER WELDING
ORIGINAL POSITION
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Due to It is the bending transverse to the weld. non-uniform heating and cooling along the thickness of plate.
This is the main source of mismatch and dimensional inaccuracy in large welded structures
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g = 3 mm t3 = 2 mm
t1 + 1/2 t3 t
= 0.6
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W
AD
AD = 0.0076 . W . l1.3 t2 Where AD= Angular Distortion, mm W=flange width, mm l = weld leg length, mm t = flange thickness, mm
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AD L =
1 4
x
L
1 2
AD = Angular distortion, mm. x = distance from weld to the L = span length, mm. point where distortion is to be = angular change, radians determined, mm.
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Distortion in T-joints
Angular distortion
Before welding
After welding
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Distortion in T-joints
Longitudinal distortion (a) pulling effect towards neutral axis
Section A - A
A
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Distortion in T-Stiffener
Longitudinal distortion
(b) pulling effect of welds above neutral axis.
Section A - A
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To prevent distortion :-
MINIMUM ANGLE, LESS WELDING , LESS HEAT INPUT Hence less distortion
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KEEP REINFORCEMENT UP TO 19 MM
(A-2) Do not keep root gap more than required (A-3) Do not do over- welding.
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7 mm +3/-1
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MORE NO OF PASSES
LESS NO OF PASSES
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N. A.
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To prevent distortion :-
WEDGE
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To prevent distortion :-
5
5
(C-1)
4 3
4 3 2
Do Sequence welding
1
4
1 2 3
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Welding progresion
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PART -II
Two identical parts should be tacked back to back together before welding as shown
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WELDING TACKS
SADDLE-II
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TUBE SHEET BULGES DURING SHELL TO TUBE SHEET WELDING Welding of shell to tube sheet
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D/4
D 3200
JOINT DETAIL 600 WELD SEQUENCE
OUTSIDE
2/ 3T
2 SAW
1/
3T
BACK GOUGING
1
3
SMAW SAW
INSIDE
600
0.2mm GAP
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STAGE 1 2 3 4 5 SET-UP STAGE AFTER SEAL RUN AFTE R O/S WELDING AFTER BACK GOUGING AFTER I/S WELDING
1 4+ 6+ 8+ 6+ 4+
LOCATION 2 2+ 4+ 6+ 5+ 2.5 +
3 2+ 5+ 8+ 5+ 4+
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Reduction in shell length Controlled by Provide compression spiders on both sides of C/S Design weld joint to have minimum weld metal deposit Use restricted heat input ( minimum no. of passes )
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CIRCSEAM JIINT
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B PRE-TILT OF T-STIFFENER = A - C
SAGGING OF T-STIFFENER = A - B
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FLANGE
FLANGE
FLANGE
PIPE
PIPE
Heavy fillet weld on flange to pipe joint leads to warping of flange Causing no machining allowance on flange face thickness CONTROL : back to back welding Temporary set up two flanges back to back as shown RKS,HZW
STRIP
the metal
During cutting when hot, the bow is more on cooling & the bow diminishes slightly Finally the strip never returns to its intended shape
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STRIP
10 mm
TORCH II
METHOD I Two Torches Technique Mark strip of required width leaving 10 mm distance Move two torches simultaneously carrying out cutting operation
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KERF
HOLE
Method II Mark the strips with kerf allowance on the plate Drill small hole in kerf allowance at distance 20 mm away from the edge Start cut from drilled hole in kerf to the end such that the strip is attached to main plate Cut the balance strip attached to the plate
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R250 mm
30 mm
PIERCE START
50 mm
Aim : To get undistorted segment from the plate of size as shown Specific Steps Mark leaving 30mm Dist. from edge Start with pierce cut as shown instead of starting from the edge Follow the path as shown
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Reduction in distortion
Less weld edge preparation.
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Reduction in distortion
Provide intermittent welding
Back-step welding
Sequence welding Pre bending OR Pre cambering Back to back clamping Double operator welding technique RKS,HZW