9
TLE-IA-SMAW
REPAIR WELD
What I Need to Know
Learning Objectives:
At the end of the lesson; you should be able to:
Identify the different types of welding defects, problems and remedies.
Perform procedures in locating weld defects.
Determine location of weld defects.
Mark weld defects for repair in accordance with job requirements.
What I Know
Direction: Read the statement carefully and identify what is being described
or defined. Choose your answer from the choices below.
1. Below are the causes of porosity except:
A. Insufficient pudding time C. Impurities on base metal
B. Too short Arc D. Current too high
2. Below are causes of poor penetration and incomplete fusion except:
A. Inform weave motion C. Too low Arc
B. Improper electrode size and type D. Too fast Travel
3. Below are causes of slag inclusion except:
A. Extremely short Arc C. Improper electrode manipulation
B. Too fast travel speed D. None of the above
4. Below are the causes of undercutting except:
A. Too low current C. Faulty electrode manipulation
B. Improper electrode size D. Too high Current
5. Below are causes of poor weld appearance except:
A. Long Arc C. Improper travel speed
B. Overheating D. Uniform Weave
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What’s In
Directions: Enumerate the problems and remedies of the following defect.
Defect/s Problem/s Remedies
Slag Inclusion
Porosity
Incomplete
Fusion
Undercut
Poor Penetration
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What’s New
Introduction:
This module contains information and suggested learning activities on
repairing weld. It includes instructions and procedure on how to repair weld.
Completion of this module will help you develop your welding skill in
preparation to performing repair of welded materials.
This module consist of four (4) learning outcomes. Each learning
outcome contains learning activities supported by instruction sheets. Before
you perform the instruction, read the information sheets and answer the self-
check and activities provided. Your Teacher will assess whatever knowledge
and skills you have acquired for a particular learning outcome.
Upon completing this module, report to your competence teacher for
assessment to check your achievement of knowledge and skills required of
this module. If you pass the assessment, you will be given a certificate of
completion.
WELDING DEFECTS
It is important for a beginner to know the defferent weld defects producced
during the welding process caused by incorrect welding procedure, wrong
selection of materials or improper preparation of base metal. If no
precausionary measures or remedies will be done, welding defects will result
which can lessen the strenght or durability of your output.
DIFFERENT TYPES OF WELDING DEFECTS
Porosity – Is the result of gas being
entrapped in solidifying weld material
and has a diameter of less than 1.5
mm.
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a. Uniformity Scattered Porosity – May be distributed throughout single
pass welds of throughout several passes of multiple pass welds.
b. Cluster Porosity – Is a localized grouping of pores that may result from
improper initiation or termination of the welding arc.
c. Linear Porosity may be aligned along
1. A weld interface;
2. Root of the weld; and
3. A boundary between weld beads.
d. Elongated Porosity – Piping porosity is a term for elongated gas pores.
- Piping porosity in fillet welds normally extends from the root of the weld
toward the face.
Slag inclusion – This a non-metallic
material trapped in the weld metal or
at the weld metal interface.
- Generally, it results from faulty
welding technique and improper
access to the joint for welding.
Incomplete Fusion – Means incorrect
welding technique, improper
preparation of the materials for welding
or wrong joint design.
Poor Penetration – This condition may
result from insufficient welding heat
improper joint design, incorrect bevel
angle or poor control of welding arc.
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Undercut – Visible undercut is
generally associated with improper
welding techniques or excessive
welding current.
- It is usually located parallel to
the junction of weld metal and
base metal at the toe or root of
the weld.
Under Fill – This results simply from
the failure of the welder or welding
operator to fill the joint with weld
metal.
Overlap – This is usually/caused by
incorrect welding procedure, wrong
selection of welding materials or
improper preparation of the base metal
prior to welding.
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Crack of Weld – This occurs in weld
metal and base metal when localized
stresses exceed the ultimate strength
of the metal. Cracks can be classified
as either hot or cold types.
Identification of Cracks according to location in weld base metal.
1. Crater crack in the weld
metal.
2. Transverse crack in the weld
metal.
3. Transverse crack in heat-
affected zone.
4. Longitudinal crack in
weld metal.
5. The crack in base metal.
6. Under bead crack in base
metal.
7. Fusion line crack.
8. Root crack in weld metal.
9. Hot crack in weld metal.
10 Welding defects, causes and
remedies.
Spatter - Small Pieces of Metal
Scattered Over Weld Surface and Base
Metal.
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Cold Laps - is a type of weld defect
which occurs when molten metal does
not completely fuse with the cold plate
surface. This produces a crack like
defect, often very small, which is
parallel to the plate.
Bead Profile Defects
Weld Defects: Causes and Remedies
Why What to do
Porous Welds
1. Hold longer arc
1. Short arc with exception of 2. Allow sufficient pudding time
low hydrogen and stainless. for gases to escape. (Use
2. Insufficient pudding time. proper current)
3. Impaired base metal. 3. Check impurities of the base
4. Poor electrode. metal.
5. Improper shield coverage. 4. Use proper electrode for the
job.
5. Weave your weld to eliminate
pin holes.
Poor Penetration
1. Use enough current to obtain
1. Too fast speed. desired penetration and weld
2. Too large electrode. slowly.
3. Too low current. 2. Select electrode according to
4. Faulty preparation. welding groove size.
3. Leave proper gap at the
bottom of weld.
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Warping
1. Peen joint edges before
1. Shrinkage of weld metal. welding.
2. Faulty clamping of parts. 2. Weld more rapidly.
3. Faulty preparation. 3. Avoid excessive space
4. Overheating at joint. between parts.
4. Use proper sequence.
5. Clamp or tack parts properly
back up tool.
6. Adopt a proper welding
procedure.
Undercutting
1. Use a uniform weave in butt
welding.
2. Use proper electrode
1. Faulty electrode and gun animeter.
manipulation. 3. Avoid excessive weaving.
2. Faulty electrode usage. 4. Use moderate current, weld
3. Too high current. slowly.
5. Hold electrode at safe
distance from the vertical
plane in making horizontal
fillet weld.
Crack welds
1. Design structure to eliminate
rigid joints
2. Heat parts before welding
(Preheating).
1. Wrong electrode 3. Avoid welding in string beads.
2. Unbalanced weld parts size. 4. Keep ends free to move
3. Faulty weld. as long as possible.
4. Faulty preparation. 5. Make sound weld of good
5. Rigid joints. fusion.
6. Adjust welding size to parts
size
7. Allow joints to fit in properly
in uniform gaps.
8. Work with amperage as low as
possible.
Poor amperage
1. Use proper welding
1. Faulty electrode. techniques.
2. Overhang. 2. Avoid overheating.
3. Improper use of electrode. 3. Use uniform weave.
4. Wrong arc voltage and current 4. Avoid overly high current
design.
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Poor fusion
1. Adjust electrode to match the
joint.
1. Wrong speed. 2. Weave must be sufficient to
2. Improperly adjusted current. melt side joint.
3. Faulty preparation. 3. Select proper current and
4. Improper electrode size. voltage.
4. Keep welding metal from
flowing away from plates.
Brittle welds
1. Preheat at 30 degrees F, if
welding on medium carbon
1. Wrong electrode steel or certain alloy steels.
2. Faulty preheating 2. Make a multiple layer weld.
3. Metal hardened by air. 3. Relieve stress after welding.
4. Use low hydrogen processes
for increased weld ductility.
Spatter
1. Arc blow. 1. Clean parts in welding area.
2. Too high current. 2. Adjust current properly.
3. Too long arc. 3. Adjust voltage.
4. Faulty electrode. 4. Pick suitable electrode.
Magnetic blow
1. Use steel block to alter
magnetic path around the
arc.
1. Magnetic fields cause the arc 2. Divide the ground into parts.
to deviate from its intended 3. Weld in same directions of the
course. arc blow.
4. Use the short arc length.
5. Locate the ground properly on
the work.
6. Use AC welding.
Weld stresses
1. Allow parts to move freely as
long and as practical as
possible.
1. Faulty weld 2. Make as few passes as
2. Faulty sequence practically possible.
3. Rigid joints 3. Peen the deposit.
4. Relieve stress according to
thickness of weld.
5. Move parts slightly when
welding the rigid joint to
reduce stresses.
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What is It
Repair Weld
Repair weld - are minor welds applied to structures in order to fix areas of
areas of minor damage. Unfortunately, structural failures are often initiated
at the site of a repair weld. Sometimes those repair welds are field repairs,
but many times they occur during original fabrication and are unknown to
the purchaser.
Successful repair welding also involves following a logical sequence to make
sure that all factors are considered and adequately provided.
Welding procedure -The welding procedure must be available for the use of
the welders. It must include the process to be used, the specific filler metals,
the pre-heat required, and any other specific information concerning the
welding joint technique.
Welding equipment - Sufficient welding equipment should be available so
that there will be no delays. Standby equipment might also be required. This
not only includes welding equipment but includes sufficient electrode holders,
grinders, wire feeders if required, cables, etc.
Materials - Sufficient materials must also be available for the entire job.
This includes the filler metals stored properly for use on the repair. It also
includes materials such as insert pieces, reinforcing pieces, etc. Materials
also include fuel for maintaining preheat and interpass temperature,
shielding gases if used, and fuel for engine powered welding machines.
Alignment markers - Prior to making the weld alignment markers are
sometimes used. These can be nothing more than center punch marks made
across the joint in various locations.
Welding sequences - The welding sequence should be well described in the
welding procedure and can include block welding, back-step sequence
welding, wandering sequence welding, and peeling.
Safety - Finally, safety cannot be overlooked throughout the welding
operation. For example, ventilation must be provided when fuel gases are used
for preheating, etc.
Weld Quality - The quality of the weld should be continually checked. The
final weld should be smooth, there should be no notches, and reinforcing, if
used, should fair smoothly into the existing structure. If necessary, grinding
should be done to maintain smooth flowing contours.
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Post weld Operation
After the weld has been completed, it should be allowed to slow cool. It should
not be exposed to winds or drafts, nor should the machinery loads be placed
on the repaired part until the temperature has returned to the normal
ambient temperature.
Inspection. The finished weld should be inspected for smoothness and
quality. This can include nondestructive testing such as magnetic particle,
ultrasonic, or X-ray. The repair weld should be of high quality since it is
replacing original metal of high quality.
Clean up operation. This includes the removal of strong backs and the
smooth grinding of the points where they were attached. It also involves the
removal of other bracing and protective covers, etc. In addition, all weld
stubs, weld spatter, weld slag, and other residue should be removed from
the repair area to make it cleaner than it was originally. Grinding dust is
particularly troublesome and every effort should be made to remove it
entirely since it is abrasive and can get into working joints, bearings, etc.,
and create future problems.
Repainting - After the weld and adjacent repair area has been cleaned it
should be repainted and other areas should be re-greased in preparation for
the re-operation of the machinery.
Reassembly - After cleaning and painting, etc., the pieces of machinery that
were taken away are returned. This involves the reassembly of machinery.
What’s More
Multiple Choice.
Instruction: Read the questions carefully and choose the correct answer in
the choices below. Note: Use Intermediate paper only.
1. Cannot be overlooked throughout the welding operation. For example,
ventilation must be provided when fuel gases are used for preheating,
etc.
A. Safety C. Inspection
B. Weld quality D. Reassembly
2. After cleaning and painting, etc., the pieces of machinery that were
taken away are returned. This involves the reassembly of machinery.
A. Reassembly C. Repainting
B. Clean up operation D. Inspection
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3. Is a type of weld defect which occurs when molten metal does not
completely fuse with the cold plate surface.
A. Cold Lap C. Weld quality
B. Safety D. Porosity
4. Means incorrect welding technique, improper preparation of the
materials for welding or wrong joint design.
A. Long Arc C. High Current
B. Incomplete fusion D. Base Metal
5. The finished weld should be inspected for smoothness and quality.
A. Reassembly C. Current
B. Inspection D. Voltage
6. Small Pieces of Metal Scattered Over Weld Surface and Base Metal.
A. Cold Lap C. Weld quality
B. Spatter D. Porosity
7. This occurs in weld metal and base metal when localized stresses
exceed the ultimate strength of the metal.
A. Crack of weld C. Transverse crack
B. Weld defect D. Longitudinal crack
8. This is usually/caused by incorrect welding procedure, wrong
selection of welding materials or improper preparation of the base
metal prior to welding.
A. Overlap C. Porosity
B. Butt Weld D. Incomplete fusion
9. Must be available for the use of the welders. It must include the
process to be used, the specific filler metals, the pre-heat required,
and any other specific information concerning the welding joint
technique.
A. Welding Technique C. Welding Procedure
B. Tacking D. Safety
10. Prior to making the weld alignment markers are sometimes used. These
can be nothing more than center punch marks made across the joint in
various locations.
A. Alignment marker C. Welding procedure
B. Safety D. Welding Technique
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What I Have Learned
Fill in the Blanks
Successful repair also involves following a logical sequence to
make sure that all are considered and adequately provided. The
must be available for the use of the . It must include the process to be
used, the specific filler metals, the required, and any other specific
information concerning the welding joint .
What I Can Do
Instruction: Identification of welding defect/s, causes and remedies. Write your answer
in the table below. (Use separate sheet)
Weld Defect/s Why What to do
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Assessment
I have learned that
I have realized that
I will apply
Additional Activities
Identification:
Instruction: Identify what kind of weld cracks shown in the picture below.