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8 views6 pages

PDF Document

JW

Uploaded by

Ramirez1911Dr
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Lesson Plan

WLDG 1428

Unit #3

(Student Outline)

Lesson Title: Weld Bead Imperfections and Their Cures

Date: 19 Aug 08

Student Performance Objectives:


By the end of this lesson, students will be able to:

1. Define and identify the following weld bead imperfections:


a. porosity
b. undercut
c. crack
d. overlap
e. excess weld bead convexity
f. improper weld bead starts and stops
g. improper weld bead tie-ins between adjacent beads
h. crater under-fill
i. improper bead width
j. arc strike
k. overall uniformity
2. Specify two common recommendations for eliminating each of the imperfections
above.
3. Evaluate a weld in terms of the Weld Evaluation Form.

Materials and Equipment:

LapTop

Page 1 of 6
Teaching Aids:

1 Handout per Student

References:

1. New Lessons in Arc Welding.

Lesson Outline:

A goal of the Welding Programs is to make sure that before you graduate and go to
work, you are an expert at visually inspecting welds and making recommendations as to
how to improve bead quality and eliminate welding defects. One tool that we use is the
Weld Evaluation Form which will allow you to put a numeric score on any given weld –
this unit will introduce you to that form. In later quarters while at TSTC, you will become
familiar with the weld evaluation systems found in various welding codes. The industry
can’t get enough welders and inspectors who can properly identify what is wrong with a
weld and make effective suggestions as to how to prevent problems in the future.

1. WELD IMPERFECTIONS include the following:

a. _________________: Cavity type discontinuities formed by


__________________________ during the weld metal cooling period.

b. ____________________: A __________________ into the base metal next


to the weld toe or weld root and left unfilled by weld metal. Each 1/16” length
of undercut is a 3 point deduction.
______________________________________________________________
______________________________________________________________
_____ levels are four common remedies for undercut.

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c. ________________: A ____________________________ which has a sharp
tip and a high ratio of length and width to opening displacement. These are
usually not visible without special test methods such as dye penetrant and are
not part of our first quarter weld evaluation system.
_________________________ and filling craters properly are two common
methods for preventing cracks. As we will see later,
_________________________________________ are also important.

ARC strikes _______________________________________. A


d. _______________:
clean, clear lens and careful body positioning and hood dropping prior to
striking the arc are most often helpful. You may want to draw a soapstone
line in the line of bead travel. Too low an amperage setting or too short an
arc length can cause the electrode to stick and the wild motion of trying to
free the electrode will cause an arc strike. If the electrode sticks, open your
electrode holder and let the electrode cool before trying to free it.

Over uniformity Is a category which makes allowances for


e. ________________________:
variations inside acceptable limits but still very noticeable – such as bead
width, straightness and amount of weld spatter.
______________________________________________________________
__________________________________________________ probably have
the greatest bearing on overall uniformity.

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Crater underfill Each weld bead with an ending crater below
f. ________________________:
base metal surface level will entail a 5 point deduction.
Pulling out to fast
______________________________________________________________
__________________________________________________. As the end
of the weld bead is approached, the electrode angle can be slowly changed to
where it becomes perpendicular by the time crater filling is taking place.

g. ____________________: Each instance of bead width


______________________________________________________ is a 3
point deduction. Such beads are referred to as “stringer” beads as opposed
to beads made wide on purpose which are called “weave” beads. Having
________________________________________ will cause an excessively
wide bead. Traveling too fast or having too long an arc length will cause the
bead to be too narrow.

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Weld bead restart Either a gap at the restart or excess
h. _________________________:
convexity at the restart. If the gap or height exceeds 1/8”, a 3 point deduction
is made. Restarts in adjacent weld beads must be
__________________________________________ or a 3 point deduction
will be made. Making sure your clear lens is clean, use a slightly longer arc
length to light the way to the crater as you restart your bead. Use a slightly
faster travel speed with either slight bead oscillation or a looping motion to
spread the restart out to the bead, as you locate the start at mid-crater.

i. _____________________________: Where the _________________ and


“valley” depth exceeds 1/16”, each 1/8” length of valley will be a 3 point
deduction. Proper ____________________________________ will help
ensure good tie-ins between beads. A slight side-to-side oscillation (not
weave) is often helpful. ______________________ will cause a valley to
form – even when all else is correct.
Overlap Bead roll
j. _________________: The protrusion (_____________________) of weld
metal is a 5 point deduction. ____________________________ are two
common methods of preventing overlap. Also proper bead location can be
very important, as well as maintaining proper electrode angles.

Increasing
k. __________________________: _______________________ above the
base metal more than a set limit. Each instance of bead height (convexity)
greater than 1/8” is a 5 point deduction. _______________ and guarding
To low pressure of an amperage
against ________________________________ are two common
preventative measures.

Start and stops Either starting inside of the edge of the


l. __________________________:
A (___________________)
base metal late startor starting so slowly on the edge that
weld metal ______________________. Each 1/16” of a late start is a 3 point
Hangs over Page 5 of 6
the edge
deduction. Starting fast (with a slightly oscillated bead action) to spread the
bead out is a good way to prevent overhang. Make sure you have a clean,
clear lens and use a slightly longer arc length when you strike your arc to spot
the edge of the plate for an accurate start on the edge.

Evaluation: Student to be tested on Welding Program WLDG 1428 Test #2.

Summary: As a welding technician, you are to be an expert at visually inspecting welds


and making recommendations as to how to improve bead quality and eliminate welding
defects. The industry can not get enough welders and inspectors who can properly
identify what is wrong with a weld and make effective suggestions as to how to prevent
problems. Knowing how to eliminate and negotiate yourself through welding defects will
be one of your primary duties as a welding technician, here at TSTC welding you will
encounter these defects and be able to find solutions to the same.

Page 6 of 6

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