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Distortion
Control
What is distortion ?
Before distortion
Undesirable change in
original shape is called
DISTORTION
After distortion
Distortion occurs due to heat input
and mechanical forces.
Experiment No 1:
DURING HEATED CONDITION
CLAMPING CLAMPING
JAWS JAWS
Distortion
Heat input
HEAT SOURCE
HEATING
Heated area expands
Expansion restrained by surrounding solid area
Compressive stresses are developed
Further compressive stress leads to plastic
deformation
Material bulges at the spot towards heat source side
Distortion in case of spot heating?
COOLING
Resulting distortion
Longitudinal distortion
WELD BEAD
ORIGINAL POSITION
WELD
BEAD
LONGITUDINAL
AFTER WELDING
DISTORTION
LONGITUDINAL SHRINKAGE
• (A) BUTT WELDS IN CS/LAS
LS = 3. I .L / 100,000 t
weld
EXAMPLE (LS IN BUTT WELDS)
• Calculate LS for 6mm thick CS plate
welded by SMAW using 200 A current.
LS = 25 Aw/ Ap
Aw = Weld X-sectional area
Ap = Resisting X-sectional area
Ap
Aw
EXAMPLE OF LS IN FILLET
WELD
All dimensions in mm
75
8x8
6
100
LS = 1.52 mm
Distortion in Butt welds
Transverse Distortion
Where
S = Transverse Shrinkage (mm)
Aw = Cross sectional Area of Weld (mm2)
t = Thickness of Plates (mm)
d = Root Opening (mm)
TRANSVERSE SHRINKAGE
DURING MULTIPASS WELDING
TS = TS0 + b (log w - log w0)
Where
TS = Total Transverse Shrinkage
TS0 = Transverse Shrinkage after first
pass
w = Total weight of weld metal
w0 = weight of first pass weld metal
Effect of Various Procedures on
Transverse Shrinkage of Butt
Welds
Procedures Effect on TS
Root Gap TS increases with increase in RG
Joint design Single Vee produces more TS than
double V
TS decreases with increase in electrode
Electrode dia.
dia.
TS decreases with Degree of constraint
Degree of constraint
Peening TS decreases by peening
Gouging & repairs TS increases by these operations.
TRANSVERSE SHRINKAGE IN
FILLET JOINTS
1. For T joints with two continuous
fillets.
TS = Leg of fillet Weld (l) x 1.02
AFTER WELDING
ORIGINAL POSITION
Distortion in Butt welds
Angular Distortion
t1 + 1/2 t3
= 0.6
t
Angular Distortion in Fillet Welds
W W
t
AD
AD
t
l
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 RKS,HZW
Example of Angular
Distortion in Fillet Welds
Find the angular distortion in a double fillet
weld of a T-joint between a flange 1000 mm
wide and a vertical member when the
thickness of both the members is 6 mm and
the weld leg length = 8 mm
Solution.
0.0076 x 1000 x
(8)1.3
AD = = 3.15 mm.
(6)2
Multiple Restrained Fillet Welds
Ø AD
L
AD 1 x 1 2Ø
= Ø
L 4 L 2
AD = Angular distortion,
x = distance from weld to
mm.
the point where distortion is
L = span length, mm.
to be determined, mm.
Ø = angular change, radians RKS,HZW
Example of AD in Multiple
Restrained Fillet Welds
Solution.
By putting L = 1000 mm, Ø = 90 = 0.1571
rad.
x = L/2 - 400 = 100 mm in the Formula,
Distortion in ‘T’-joints
Angular distortion
Section A - A A
Distortion in ‘T’-Stiffener
Longitudinal distortion
(b) pulling effect of welds above neutral axis.
Section A - A A
To prevent distortion :-
(A)
Reduce the effective
shrinkage force.
Reduce effective shrinkage force
(A-1) Keep the angle of weld joint to the
barest minimum.
50 deg. +/- 5 deg.
19 mm +3/-1
N. A.
To prevent distortion :-
(B)
Make shrinkage work
for us
Make shrinkage work for us
WEDGE
(C)
Balance shrinkage
force with other
forces
Balance shrinkage forces
with other forces.
6
2 5
5
(C-1) 4
4 3
Do Sequence welding 3
6 1 1
4
1
2
3
Balance shrinkage forces
with other forces
(C-2) Back step welding
1 2 3 4
Welding progresion
Balance shrinkage forces
with other forces
PART -II
Two identical parts should be tacked back to back
together before welding as shown
Back to back welding of saddles
SADDLE-
I
D/4
3200
JOINT DETAIL WELD SEQUENCE
600
OUTSIDE 2
SAW
2/
3T T 1 SMAW
3 BACK
1/ GOUGING SAW
3T 3
INSIDE
600 0.2mm GAP
Distortion of shell long seams
LOCATION
STAGE
1 2 3
1 SET-UP STAGE 4+ 2+ 2+
2 AFTER SEAL RUN 6+ 4+ 5+
3 AFTE R O/S WELDING 8+ 6+ 8+
4 AFTER BACK GOUGING 6+ 5+ 5+
5 AFTER I/S WELDING 4+ 2.5 + 4+
Distortion of circumferential seams in shell
FOR CHECKING
D C B A
PRE-TILT OF T-STIFFENER = A - C
C
SAGGING OF T-STIFFENER = A - B
Distortion in flange to pipe welding
FLANGE WARPS
TEMP. SUPPORTS FLANGE
FLANGE FLANGE
PIPE
AFTER BEFORE
WELDING WELDING
PIPE PIPE
STRIP
TORCH I
STRIP
DIRECTION OF MOVEMENT
FOR TORCHES
SCRAP 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
Controlling distortion during
oxy - acetylene cutting
PLATE
STRIPS
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
Controlling distortion during
oxy - acetylene cutting
30 mm
12 mm THK
PLATE
R250 mm
30 mm 50 mm
PIERCE
START
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
Reduction in distortion
• Less weld edge preparation.
• Less welding current as per WPS.
• Higher base metal thickness.
• Lesser welding passes
• Do not over weld
• More distortion in stainless steel then
carbon steel.
• Less offset-Lesser welding-Lower
distortion
Reduction in distortion
• Provide intermittent welding
• Place weld near the neutral axis
• Balancing weld around neutral axis
• Back-step welding
• Sequence welding
• Pre bending OR Pre cambering
• Back to back clamping
• Double operator welding technique