Joining Processes

Joining
Process
Weld
Metalrgy
Weldabili
ty
Brazing
Weldg 1
Brazing
Weldg 2
Filler
HAZ
Dilution
Ratio
Fusion
Nonfusio
TMAZ
FSW
HAZ
PMZ
HAZ PMZ
Steel
HAZ PMZ
Cast Iron
Welding
Defect
PMZ
Crack

Joining
Process
Weld
Metalrgy
Weldabili
ty
Brazing
Weldg 1
Brazing
Weldg 2
Filler
HAZ
Dilution
Ratio
Fusion
Nonfusio
TMAZ
FSW
HAZ
PMZ
HAZ PMZ
Steel
HAZ PMZ
Cast Iron
Welding
Defect
PMZ
Crack

Weldability

Joining
Process
Weld
Metalrgy
Weldabili
ty
Brazing
Weldg 1
Brazing
Weldg 2
Filler
HAZ
Dilution
Ratio
Fusion
Nonfusio
TMAZ
FSW
HAZ
PMZ
HAZ PMZ
Steel
HAZ PMZ
Cast Iron
Welding
Defect
PMZ
Crack

Brazing Welding 1

Joining
Process
Weld
Metalrgy
Weldabili
ty
Brazing
Weldg 1
Brazing
Weldg 2
Filler
HAZ
Dilution
Ratio
Fusion
Nonfusio
TMAZ
FSW
HAZ
PMZ
HAZ PMZ
Steel
HAZ PMZ
Cast Iron
Welding
Defect
PMZ
Crack

Brazing Welding 2

Joining
Process
Weld
Metalrgy
Weldabili
ty
Brazing
Weldg 1
Brazing
Weldg 2
Filler
HAZ
Dilution
Ratio
Fusion
Nonfusio
TMAZ
FSW
HAZ
PMZ
HAZ PMZ
Steel
HAZ PMZ
Cast Iron
Welding
Defect
PMZ
Crack

Filler - HAZ - Base Metal

Joining
Process
Weld
Metalrgy
Weldabili
ty
Brazing
Weldg 1
Brazing
Weldg 2
Filler
HAZ
Dilution
Ratio
Fusion
Nonfusio
TMAZ
FSW
HAZ
PMZ
HAZ PMZ
Steel
HAZ PMZ
Cast Iron
Welding
Defect
PMZ
Crack

Dilution ratio
=
Am/(Am + Ar)

Deposition Rate - Dilution Ratio

Joining
Process
Weld
Metalrgy
Weldabili
ty
Brazing
Weldg 1
Brazing
Weldg 2
Filler
HAZ
Dilution
Ratio
Fusion
Nonfusio
TMAZ
FSW
HAZ
PMZ
HAZ PMZ
Steel
HAZ PMZ
Cast Iron
Welding
Defect
PMZ
Crack

Welding Fusion - Nonfusion

Joining
Process
Weld
Metalrgy
Weldabili
ty
Brazing
Weldg 1
Brazing
Weldg 2
Filler
HAZ
Dilution
Ratio
Fusion
Nonfusio
TMAZ
FSW
HAZ
PMZ
HAZ PMZ
Steel
HAZ PMZ
Cast Iron
Welding
Defect
PMZ
Crack

TMAZ - HAZ FSW

Joining
Process
Weld
Metalrgy
Weldabili
ty
Brazing
Weldg 1
Brazing
Weldg 2
Filler
HAZ
Dilution
Ratio
Fusion
Nonfusio
TMAZ
FSW
HAZ
PMZ
HAZ PMZ
Steel
HAZ PMZ
Cast Iron
Welding
Defect
PMZ
Crack

PMZ - HAZ

Joining
Process
Weld
Metalrgy
Weldabili
ty
Brazing
Weldg 1
Brazing
Weldg 2
Filler
HAZ
Dilution
Ratio
Fusion
Nonfusio
TMAZ
FSW
HAZ
PMZ
HAZ PMZ
Steel
HAZ PMZ
Cast Iron
Welding
Defect
PMZ
Crack

HAZ in Steel

Joining
Process
Weld
Metalrgy
Weldabili
ty
Brazing
Weldg 1
Brazing
Weldg 2
Filler
HAZ
Dilution
Ratio
Fusion
Nonfusio
TMAZ
FSW
HAZ
PMZ
HAZ PMZ
Steel
HAZ PMZ
Cast Iron
Welding
Defect
PMZ
Crack

HAZ in Cast Iron

Joining
Process
Weld
Metalrgy
Weldabili
ty
Brazing
Weldg 1
Brazing
Weldg 2
Filler
HAZ
Dilution
Ratio
Fusion
Nonfusio
TMAZ
FSW
HAZ
PMZ
HAZ PMZ
Steel
HAZ PMZ
Cast Iron
Welding
Defect
PMZ
Crack

Weld Defects

Joining
Process
Weld
Metalrgy
Weldabili
ty
Brazing
Weldg 1
Brazing
Weldg 2
Filler
HAZ
Dilution
Ratio
Fusion
Nonfusio
TMAZ
FSW
HAZ
PMZ
HAZ PMZ
Steel
HAZ PMZ
Cast Iron
Welding
Defect
PMZ
Crack

Hot Crack in PMZ

Joining
Process
Weld
Metalrgy
Weldabili
ty
Brazing
Weldg 1
Brazing
Weldg 2
Filler
HAZ
Dilution
Ratio
Fusion
Nonfusio
TMAZ
FSW
HAZ
PMZ
HAZ PMZ
Steel
HAZ PMZ
Cast Iron
Welding
Defect
PMZ
Crack

Discontinuities and Defects in

Fusion Welds

Weld
Defect
Weld
Crack
Residual
Stress 1
Residual
Stress 2
Internal
Stress
Shrinkag
Metals
Distorsi
1
Distorsi
2
Welding
Symbol
Welded
Joint
Welding
Design
Welding
Positin 1
Welding
positn 2

Cracks in Welded Joints

Weld
Defect
Weld
Crack
Residual
Stress 1
Residual
Stress 2
Internal
Stress
Shrinkag
Metals
Distorsi
1
Distorsi
2
Welding
Symbol
Welded
Joint
Welding
Design
Welding
Positin 1
Welding
positn 2

Residual Stresses and Distortion

Weld
Defect
Weld
Crack
Residual
Stress 1
Residual
Stress 2
Internal
Stress
Shrinkag
Metals
Distorsi
1
Distorsi
2
Welding
Symbol
Welded
Joint
Welding
Design
Welding
Positin 1
Welding
positn 2

Residual Stresses and Distortion

Weld
Defect
Weld
Crack
Residual
Stress 1
Residual
Stress 2
Internal
Stress
Shrinkag
Metals
Distorsi
1
Distorsi
2
Welding
Symbol
Welded
Joint
Welding
Design
Welding
Positin 1
Welding
positn 2

Internal Stress

Weld
Defect
Weld
Crack
Residual
Stress 1
Residual
Stress 2
Internal
Stress
Shrinkag
Metals
Distorsi
1
Distorsi
2
Welding
Symbol
Welded
Joint
Welding
Design
Welding
Positin 1
Welding
positn 2

Transverse Shrinkage

Weld
Defect
Weld
Crack
Residual
Stress 1
Residual
Stress 2
Internal
Stress
Shrinkag
Metals
Distorsi
1
Distorsi
2
Welding
Symbol
Welded
Joint
Welding
Design
Welding
Positin 1
Welding
positn 2

Distorsi - 1

Weld
Defect
Weld
Crack
Residual
Stress 1
Residual
Stress 2
Internal
Stress
Shrinkag
Metals
Distorsi
1
Distorsi
2
Welding
Symbol
Welded
Joint
Welding
Design
Welding
Positin 1
Welding
positn 2

Distorsi - 2

Weld
Defect
Weld
Crack
Residual
Stress 1
Residual
Stress 2
Internal
Stress
Shrinkag
Metals
Distorsi
1
Distorsi
2
Welding
Symbol
Welded
Joint
Welding
Design
Welding
Positin 1
Welding
positn 2

Weld Symbols

Weld
Defect
Weld
Crack
Residual
Stress 1
Residual
Stress 2
Internal
Stress
Shrinkag
Metals
Distorsi
1
Distorsi
2
Welding
Symbol
Welded
Joint
Welding
Design
Welding
Positin 1
Welding
positn 2

Welded Joints

Weld
Defect
Weld
Crack
Residual
Stress 1
Residual
Stress 2
Internal
Stress
Shrinkag
Metals
Distorsi
1
Distorsi
2
Welding
Symbol
Welded
Joint
Welding
Design
Welding
Positin 1
Welding
positn 2

Weld Design

Weld
Defect
Weld
Crack
Residual
Stress 1
Residual
Stress 2
Internal
Stress
Shrinkag
Metals
Distorsi
1
Distorsi
2
Welding
Symbol
Welded
Joint
Welding
Design
Welding
Positin 1
Welding
positn 2

Welding position 1

Weld
Defect
Weld
Crack
Residual
Stress 1
Residual
Stress 2
Internal
Stress
Shrinkag
Metals
Distorsi
1
Distorsi
2
Welding
Symbol
Welded
Joint
Welding
Design
Welding
Positin 1
Welding
positn 2

Welding Position 2
FLAT POSITION
1F

HORIZONTAL
POSITION
2F

VERTICAL POSITION
3F

OVERHEAD POSITION
4F

Weld
Defect
Weld
Crack
Residual
Stress 1
Residual
Stress 2
Internal
Stress

Axis of Weld
Horizontal

FLAT POSITION
1G

Axis of Weld
Horizontal

HORIZONTAL POSITION
2G

Axis of Weld
Vertical

Axis of Weld
Horizontal

VERTICAL POSITION
3G

OVERHEAD POSITION
4G

Shrinkag
Metals
Distorsi
1
Distorsi
2
Welding
Symbol

Plate Horizontal
FLAT 1G

Plate Vertical
HORIZONTAL
2G

Plate Vertical

Plate Horizontal

5G POSITION

6G POSITION
V

Welded
Joint
Welding
Design
Welding
Positin 1
Welding
positn 2

Pipe Shall Not Be

Turned or Rolled
While Welding
Axis of Pipe Horizontal

Axis of
Pipe Vertical

Pipe Shall Not Be

Turned or Rolled
While Welding
Axis of Pipe Horizontal

H
Inclined Axis with
Pipe Stationary

Effect of Energy Input 1

Variation of heat input to the work piece with power density of the heat
source.

Effect
Heat 1
Efeect
heat 2
Effect
Heat 3
Weld
pool 1
Weld
pool 2
Weld
pool 3
Solidifct
1
Solidifct
2
Solidifct
3
Solidifct
4
Solidifct
5
Solidifct
Mode 1
Solidifct
Mode 2

Effect of Energy Input 2

Effect
Heat 1
Efeect
heat 2
Effect
Heat 3
Weld
pool 1
Weld
pool 2
Weld
pool 3
Solidifct
1
Solidifct
2
Solidifct
3
Solidifct
4
Solidifct
5
Solidifct
Mode 1
Solidifct
Mode 2

Effect of Energy Input 3

Effect of heat input per unit length of weld

Effect
Heat 1
Efeect
heat 2
Effect
Heat 3
Weld
pool 1
Weld
pool 2
Weld
pool 3
Solidifct
1
Solidifct
2
Solidifct
3
Solidifct
4
Solidifct
5
Solidifct
Mode 1
Solidifct
Mode 2

Weld pool convection 1

Effect
Heat 1
Efeect
heat 2
Effect
Heat 3
Weld
pool 1
Weld
pool 2
Weld
pool 3
Solidifct
1
Solidifct
2
Solidifct
3
Solidifct
4
Solidifct
5
Solidifct
Mode 1
Solidifct
Mode 2

Weld pool convection 2

Effect
Heat 1
Efeect
heat 2
Effect
Heat 3
Weld
pool 1
Weld
pool 2
Weld
pool 3
Solidifct
1
Solidifct
2
Solidifct
3
Solidifct
4
Solidifct
5
Solidifct
Mode 1
Solidifct
Mode 2

Weld pool convection 3

Effect
Heat 1
Efeect
heat 2
Effect
Heat 3
Weld
pool 1
Weld
pool 2
Weld
pool 3
Solidifct
1
Solidifct
2
Solidifct
3
Solidifct
4
Solidifct
5
Solidifct
Mode 1
Solidifct
Mode 2

Solidification 1
Chill-Columnar- Central zone

Effect
Heat 1
Efeect
heat 2
Effect
Heat 3
Weld
pool 1
Weld
pool 2
Weld
pool 3
Solidifct
1
Solidifct
2
Solidifct
3
Solidifct
4
Solidifct
5
Solidifct
Mode 1
Solidifct
Mode 2

Solidification 2
Effect of welding speed on columnar-grain structure in weld metal

Effect
Heat 1
Efeect
heat 2
Effect
Heat 3
Weld
pool 1
Weld
pool 2
Weld
pool 3
Solidifct
1
Solidifct
2
Solidifct
3
Solidifct
4
Solidifct
5
Solidifct
Mode 1
Solidifct
Mode 2

Solidification 3
Microstructure around the weld pool boundary

Effect
Heat 1
Efeect
heat 2
Effect
Heat 3
Weld
pool 1
Weld
pool 2
Weld
pool 3
Solidifct
1
Solidifct
2
Solidifct
3
Solidifct
4
Solidifct
5
Solidifct
Mode 1
Solidifct
Mode 2

Solidification 4
Variation in dendrite arm spacing across fusion zone

Effect
Heat 1
Efeect
heat 2
Effect
Heat 3
Weld
pool 1
Weld
pool 2
Weld
pool 3
Solidifct
1
Solidifct
2
Solidifct
3
Solidifct
4
Solidifct
5
Solidifct
Mode 1
Solidifct
Mode 2

Solidification 5
Nucleation mechanisms during welding

Effect
Heat 1
Efeect
heat 2
Effect
Heat 3
Weld
pool 1
Weld
pool 2
Weld
pool 3
Solidifct
1
Solidifct
2
Solidifct
3
Solidifct
4
Solidifct
5
Solidifct
Mode 1
Solidifct
Mode 2

Solidification Mode 1

Effect
Heat 1
Efeect
heat 2
Effect
Heat 3
Weld
pool 1
Weld
pool 2
Weld
pool 3
Solidifct
1
Solidifct
2
Solidifct
3
Solidifct
4
Solidifct
5
Solidifct
Mode 1
Solidifct
Mode 2

Solidification Mode 2

Effect
Heat 1
Efeect
heat 2
Effect
Heat 3
Weld
pool 1
Weld
pool 2
Weld
pool 3
Solidifct
1
Solidifct
2
Solidifct
3
Solidifct
4
Solidifct
5
Solidifct
Mode 1
Solidifct
Mode 2

Solidification Mode 3

Solidifct
Mode 3
Solidifct
Mode 4
Solidifct
Mode 5
Solidifct
Mode 6
Weld
Defect 1
Weld
Defect 2
Electrod
Angle 1
Electrod
Angle 2
Electrod
Angle 3

Solidification Mode 4

Solidifct
Mode 3
Solidifct
Mode 4
Solidifct
Mode 5
Solidifct
Mode 6
Weld
Defect 1
Weld
Defect 2
Electrod
Angle 1
Electrod
Angle 2
Electrod
Angle 3

Solidification Mode 5
Effect of welding parameters on heterogeneous nucleation

Solidifct
Mode 3
Solidifct
Mode 4
Solidifct
Mode 5
Solidifct
Mode 6
Weld
Defect 1
Weld
Defect 2
Electrod
Angle 1
Electrod
Angle 2
Electrod
Angle 3

Solidification Mode 6

Solidifct
Mode 3
Solidifct
Mode 4
Solidifct
Mode 5
Solidifct
Mode 6
Weld
Defect 1
Weld
Defect 2
Electrod
Angle 1
Electrod
Angle 2
Electrod
Angle 3

Weld Defects 1

Solidifct
Mode 3
Solidifct
Mode 4
Solidifct
Mode 5
Solidifct
Mode 6
Weld
Defect 1
Weld
Defect 2
Electrod
Angle 1
Electrod
Angle 2
Electrod
Angle 3

Weld Defect 2
Effect of weld depthwidth ratio on centerline cracking

Solidifct
Mode 3
Solidifct
Mode 4
Solidifct
Mode 5
Solidifct
Mode 6
Weld
Defect 1
Weld
Defect 2
Electrod
Angle 1
Electrod
Angle 2
Electrod
Angle 3

Effect Electrode Angle

Effect of weld depthwidth ratio

Solidifct
Mode 3
Solidifct
Mode 4
Solidifct
Mode 5
Solidifct
Mode 6
Weld
Defect 1
Weld
Defect 2
Electrod
Angle 1
Electrod
Angle 2
Electrod
Angle 3

Effect Electrode Angle

Effect of weld depthwidth ratio

Solidifct
Mode 3
Solidifct
Mode 4
Solidifct
Mode 5
Solidifct
Mode 6
Weld
Defect 1
Weld
Defect 2
Electrod
Angle 1
Electrod
Angle 2
Electrod
Angle 3

Effect Electrode Angle

Effect of weld depthwidth ratio

Solidifct
Mode 3
Solidifct
Mode 4
Solidifct
Mode 5
Solidifct
Mode 6
Weld
Defect 1
Weld
Defect 2
Electrod
Angle 1
Electrod
Angle 2
Electrod
Angle 3

Heat affected zone - HAZ 1

effect of welding parameter

HAZ 1
Weld pr
HAZ 2
Hnet
H cycle 1
tickness
H cycle 2
SMAW
H cycle 3
SMAW
Welded
Cu -Ni
Cold wrk
Anneal
Recrystal
G.growth
Cold wrk
T.recrytl
H input
WM-HAZ
Welded
C. Steel
HAZ 1
C. Steel
HAZ 2
C, Steel

Heat affected zone - HAZ 2

effect of heat intensity

HAZ 1
Weld pr
HAZ 2
Hnet
H cycle 1
tickness
H cycle 2
SMAW
H cycle 3
SMAW
Welded
Cu -Ni
Cold wrk
Anneal
Recrystal
G.growth
Cold wrk
T.recrytl
H input
WM-HAZ
Welded
C. Steel
HAZ 1
C. Steel
HAZ 2
C, Steel

Typical heat cycles 1

effect of plate thickness

HAZ 1
Weld pr
HAZ 2
Hnet
H cycle 1
tickness
H cycle 2
SMAW
H cycle 3
SMAW
Welded
Cu -Ni
Cold wrk
Anneal
Recrystal
G.growth
Cold wrk
T.recrytl
H input
WM-HAZ
Welded
C. Steel
HAZ 1
C. Steel
HAZ 2
C, Steel

Typical heat cycles 2

in shielded metal arc welding - SMAW

HAZ 1
Weld pr
HAZ 2
Hnet
H cycle 1
tickness
H cycle 2
SMAW
H cycle 3
SMAW
Welded
Cu -Ni
Cold wrk
Anneal
Recrystal
G.growth
Cold wrk
T.recrytl
H input
WM-HAZ
Welded
C. Steel
HAZ 1
C. Steel
HAZ 2
C, Steel

Typical heat cycles 3

in shielded metal arc welding - SMAW

HAZ 1
Weld pr
HAZ 2
Hnet
H cycle 1
tickness
H cycle 2
SMAW
H cycle 3
SMAW
Welded
Cu -Ni
Cold wrk
Anneal
Recrystal
G.growth
Cold wrk
T.recrytl
H input
WM-HAZ
Welded
C. Steel
HAZ 1
C. Steel
HAZ 2
C, Steel

Characteristics of welded
joints in pure metals Cu - Ni

HAZ 1
Weld pr
HAZ 2
Hnet
H cycle 1
tickness
H cycle 2
SMAW
H cycle 3
SMAW
Welded
Cu -Ni
Cold wrk
Anneal
Recrystal
G.growth
Cold wrk
T.recrytl
H input
WM-HAZ
Welded
C. Steel
HAZ 1
C. Steel
HAZ 2
C, Steel

Cold Work Anneal Cycle

HAZ 1
Weld pr
HAZ 2
Hnet
H cycle 1
tickness
H cycle 2
SMAW
H cycle 3
SMAW
Welded
Cu -Ni
Cold wrk
Anneal
Recrystal
G.growth
Cold wrk
T.recrytl
H input
WM-HAZ
Welded
C. Steel
HAZ 1
C. Steel
HAZ 2
C, Steel

Recrystallization
grain growth

HAZ 1
Weld pr
HAZ 2
Hnet
H cycle 1
tickness
H cycle 2
SMAW
H cycle 3
SMAW
Welded
Cu -Ni
Cold wrk
Anneal
Recrystal
G.growth
Cold wrk
T.recrytl
H input
WM-HAZ
Welded
C. Steel
HAZ 1
C. Steel
HAZ 2
C, Steel

Cold
Work Effect
Temperature Recrystallization

HAZ 1
Weld pr
HAZ 2
Hnet
H cycle 1
tickness
H cycle 2
SMAW
H cycle 3
SMAW
Welded
Cu -Ni
Cold wrk
Anneal
Recrystal
G.growth
Cold wrk
T.recrytl
H input
WM-HAZ
Welded
C. Steel
HAZ 1
C. Steel
HAZ 2
C, Steel

Effect of Energy Input

Effect of heat input per unit length of weld - HAZ

HAZ 1
Weld pr
HAZ 2
Hnet
H cycle 1
tickness
H cycle 2
SMAW
H cycle 3
SMAW
Welded
Cu -Ni
Cold wrk
Anneal
Recrystal
G.growth
Cold wrk
T.recrytl
H input
WM-HAZ
Welded
C. Steel
HAZ 1
C. Steel
HAZ 2
C, Steel

Characteristics of welded
joints in carbon steel Fe Fe3C

HAZ 1
Weld pr
HAZ 2
Hnet
H cycle 1
tickness
H cycle 2
SMAW
H cycle 3
SMAW
Welded
Cu -Ni
Cold wrk
Anneal
Recrystal
G.growth
Cold wrk
T.recrytl
H input
WM-HAZ
Welded
C. Steel
HAZ 1
C. Steel
HAZ 2
C, Steel

Heat affected zone - HAZ 1

effect of cold work

HAZ 1
Weld pr
HAZ 2
Hnet
H cycle 1
tickness
H cycle 2
SMAW
H cycle 3
SMAW
Welded
Cu -Ni
Cold wrk
Anneal
Recrystal
G.growth
Cold wrk
T.recrytl
H input
WM-HAZ
Welded
C. Steel
HAZ 1
C. Steel
HAZ 2
C, Steel

Heat affected zone - HAZ 2

effect of heating - cooling

HAZ 1
Weld pr
HAZ 2
Hnet
H cycle 1
tickness
H cycle 2
SMAW
H cycle 3
SMAW
Welded
Cu -Ni
Cold wrk
Anneal
Recrystal
G.growth
Cold wrk
T.recrytl
H input
WM-HAZ
Welded
C. Steel
HAZ 1
C. Steel
HAZ 2
C, Steel

Heat affected zone - HAZ 3

effect of heating - cooling

HAZ 3
C. Steel
H.Cycle 1
t 8/5
H.Cycle 2
t 8/5
H.Input
Preheat
H.Cycle 3
t 8/5
H.Cycle 4
t 8/5
Alloy
Cold crk
T.Regn 1
%C
T.Regn 2
Thicknes
Hydrogn
Cold crk
T.Regn 3
T,Ceq,Pc
T.Regn 4
T.Ceq,Pc
H.Cycle 5
Mlt.Layer

Typicalheatcycles1
t8/5 (Temperatur800o 500o/300o C)

HAZ 3
C. Steel
H.Cycle 1
t 8/5
H.Cycle 2
t 8/5
H.Input
Preheat
H.Cycle 3
t 8/5
H.Cycle 4
t 8/5
Alloy
Cold crk
T.Regn 1
%C
T.Regn 2
Thicknes
Hydrogn
Cold crk
T.Regn 3
T,Ceq,Pc
T.Regn 4
T.Ceq,Pc
H.Cycle 5
Mlt.Layer

Typicalheatcycles2
t8/5 (Temperatur800o 500o/300o C)

HAZ 3
C. Steel
H.Cycle 1
t 8/5
H.Cycle 2
t 8/5
H.Input
Preheat
H.Cycle 3
t 8/5
H.Cycle 4
t 8/5
Alloy
Cold crk
T.Regn 1
%C
T.Regn 2
Thicknes
Hydrogn
Cold crk
T.Regn 3
T,Ceq,Pc
T.Regn 4
T.Ceq,Pc
H.Cycle 5
Mlt.Layer

Heat input - Preheat

Stress Relieving Hydrogen

HAZ 3
C. Steel
H.Cycle 1
t 8/5
H.Cycle 2
t 8/5
H.Input
Preheat
H.Cycle 3
t 8/5
H.Cycle 4
t 8/5
Alloy
Cold crk
T.Regn 1
%C
T.Regn 2
Thicknes
Hydrogn
Cold crk
T.Regn 3
T,Ceq,Pc
T.Regn 4
T.Ceq,Pc
H.Cycle 5
Mlt.Layer

Typicalheatcycles3
t8/5 (Temperatur800o 500o/300o C)

HAZ 3
C. Steel
H.Cycle 1
t 8/5
H.Cycle 2
t 8/5
H.Input
Preheat
H.Cycle 3
t 8/5
H.Cycle 4
t 8/5
Alloy
Cold crk
T.Regn 1
%C
T.Regn 2
Thicknes
Hydrogn
Cold crk
T.Regn 3
T,Ceq,Pc
T.Regn 4
T.Ceq,Pc
H.Cycle 5
Mlt.Layer

Typicalheatcycles4
t8/5 (Temperatur800o 500o/300o C)

HAZ 3
C. Steel
H.Cycle 1
t 8/5
H.Cycle 2
t 8/5
H.Input
Preheat
H.Cycle 3
t 8/5
H.Cycle 4
t 8/5
Alloy
Cold crk
T.Regn 1
%C
T.Regn 2
Thicknes
Hydrogn
Cold crk
T.Regn 3
T,Ceq,Pc
T.Regn 4
T.Ceq,Pc
H.Cycle 5
Mlt.Layer

Cold Crack
CCT diagram Cooling Rate Welding CRW

HAZ 3
C. Steel
H.Cycle 1
t 8/5
H.Cycle 2
t 8/5
H.Input
Preheat
H.Cycle 3
t 8/5
H.Cycle 4
t 8/5
Alloy
Cold crk
T.Regn 1
%C
T.Regn 2
Thicknes
Hydrogn
Cold crk
T.Regn 3
T,Ceq,Pc
T.Regn 4
T.Ceq,Pc
H.Cycle 5
Mlt.Layer

Temperature Region 1
preheat in carbon steel Fe Fe3C

HAZ 3
C. Steel
H.Cycle 1
t 8/5
H.Cycle 2
t 8/5
H.Input
Preheat
H.Cycle 3
t 8/5
H.Cycle 4
t 8/5
Alloy
Cold crk
T.Regn 1
%C
T.Regn 2
Thicknes
Hydrogn
Cold crk
T.Regn 3
T,Ceq,Pc
T.Regn 4
T.Ceq,Pc
H.Cycle 5
Mlt.Layer

Temperature Region 2
combined thickness steel type

HAZ 3
C. Steel
H.Cycle 1
t 8/5
H.Cycle 2
t 8/5
H.Input
Preheat
H.Cycle 3
t 8/5
H.Cycle 4
t 8/5
Alloy
Cold crk
T.Regn 1
%C
T.Regn 2
Thicknes
Hydrogn
Cold crk
T.Regn 3
T,Ceq,Pc
T.Regn 4
T.Ceq,Pc
H.Cycle 5
Mlt.Layer

Pengaruh Kadar Hidrogen

Usaha Menghindari Retak - Cold crack

HAZ 3
C. Steel
H.Cycle 1
t 8/5
H.Cycle 2
t 8/5
H.Input
Preheat
H.Cycle 3
t 8/5
H.Cycle 4
t 8/5
Alloy
Cold crk
T.Regn 1
%C
T.Regn 2
Thicknes
Hydrogn
T.Regn
2
Cold crk
Thicknes
T.Regn 3
T,Ceq,Pc
T.Regn 4
T.Ceq,Pc
H.Cycle 5
Mlt.Layer

Temperature Region 3
combined thickness Ceq _Pcm

HAZ 3
C. Steel
H.Cycle 1
t 8/5
H.Cycle 2
t 8/5
H.Input
Preheat
H.Cycle 3
t 8/5
H.Cycle 4
t 8/5
Alloy
Cold crk
T.Regn 1
%C
T.Regn 2
Thicknes
Hydrogn
Cold crk
T.Regn 3
T,Ceq,Pc
T.Regn 4
T.Ceq,Pc
H.Cycle 5
Mlt.Layer

Temperature Region 4
combined thickness Ceq _Pcm

HAZ 3
C. Steel
H.Cycle 1
t 8/5
H.Cycle 2
t 8/5
H.Input
Preheat
H.Cycle 3
t 8/5
H.Cycle 4
t 8/5
Alloy
Cold crk
T.Regn 1
%C
T.Regn 2
Thicknes
Hydrogn
Cold crk
T.Regn 3
T,Ceq,Pc
T.Regn 4
T.Ceq,Pc
H.Cycle 5
Mlt.Layer

Typicalheatcycles5
t8/5 (Temperatur800o 500o/300o C)multilayer

HAZ 3
C. Steel
H.Cycle 1
t 8/5
H.Cycle 2
t 8/5
H.Input
Preheat
H.Cycle 3
t 8/5
H.Cycle 4
t 8/5
Alloy
Cold crk
T.Regn 1
%C
T.Regn 2
Thicknes
Hydrogn
Cold crk
T.Regn 3
T,Ceq,Pc
T.Regn 4
T.Ceq,Pc
H.Cycle 5
Mlt.Layer

Characteristics of welded
joints in stainless steel

Welded
SS
Precipt 1
corrosn
Precipt 2
Cr23C6
Carbon
Containt
Diagram
fasa
Weldabili
ty SS
Welded
Aluminm
Hardnes
6061
Hardne
Heat Inp
Precipt
T4 Al -Cu
Precipt
T6 Al -Cu
Al Cu
T6 Aging
Crack
Compost

Effectofprecipitation1
onisothermalprecipitation

Welded
SS
Precipt 1
corrosn
Precipt 2
Cr23C6
Carbon
Containt
Diagram
fasa
Weldabili
ty SS
Welded
Aluminm
Hardnes
6061
Hardne
Heat Inp
Precipt
T4 Al -Cu
Precipt
T6 Al -Cu
Al Cu
T6 Aging
Crack
Compost

Effectofprecipitation2
onisothermalprecipitationCr23C6

Welded
SS
Precipt 1
corrosn
Precipt 2
Cr23C6
Carbon
Containt
Diagram
fasa
Weldabili
ty SS
Welded
Aluminm
Hardnes
6061
Hardne
Heat Inp
Precipt
T4 Al -Cu
Precipt
T6 Al -Cu
Al Cu
T6 Aging
Crack
Compost

Effectofcarboncontent
onisothermalprecipitation

Welded
SS
Precipt 1
corrosn
Precipt 2
Cr23C6
Carbon
Containt
Diagram
fasa
Weldabili
ty SS
Welded
Aluminm
Hardnes
6061
Hardne
Heat Inp
Precipt
T4 Al -Cu
Precipt
T6 Al -Cu
Al Cu
T6 Aging
Crack
Compost

DiagramPhasa
onFeC,FeCrand70%FeNiCr

Welded
SS
Precipt 1
corrosn
Precipt 2
Cr23C6
Carbon
Containt
Diagram
fasa
Weldabili
ty SS
Welded
Aluminm
Hardnes
6061
Hardne
Heat Inp
Precipt
T4 Al -Cu
Precipt
T6 Al -Cu
Al Cu
T6 Aging
Crack
Compost

Schaeffler_DeLongDiagram
WeldabilityStainlessSteel

Welded
SS
Precipt 1
corrosn
Precipt 2
Cr23C6
Carbon
Containt
Diagram
fasa
Weldabili
ty SS
Welded
Aluminm
Hardnes
6061
Hardne
Heat Inp
Precipt
T4 Al -Cu
Precipt
T6 Al -Cu
Al Cu
T6 Aging
Crack
Compost

Characteristics of welded
joints in precipitation hardened alumunium alloy Al Cu

Welded
SS
Precipt 1
corrosn
Precipt 2
Cr23C6
Carbon
Containt
Diagram
fasa
Weldabili
ty SS
Welded
Aluminm
Hardnes
6061
Hardne
Heat Inp
Precipt
T4 Al -Cu
Precipt
T6 Al -Cu
Al Cu
T6 Aging
Crack
Compost

HardnessProfileOf6061Welds
onisothermalprecipitation

Welded
SS
Precipt 1
corrosn
Precipt 2
Cr23C6
Carbon
Containt
Diagram
fasa
Weldabili
ty SS
Welded
Aluminm
Hardnes
6061
Hardne
Heat Inp
Precipt
T4 Al -Cu
Precipt
T6 Al -Cu
Al Cu
T6 Aging
Crack
Compost

HardnessProfilesHeatInputOf6061
onisothermalprecipitation

Welded
SS
Precipt 1
corrosn
Precipt 2
Cr23C6
Carbon
Containt
Diagram
fasa
Weldabili
ty SS
Welded
Aluminm
Hardnes
6061
Hardne
Heat Inp
Precipt
T4 Al -Cu
Precipt
T6 Al -Cu
Al Cu
T6 Aging
Crack
Compost

EffectOfPrecipitation
onisothermalprecipitationT4

Welded
SS
Precipt 1
corrosn
Precipt 2
Cr23C6
Carbon
Containt
Diagram
fasa
Weldabili
ty SS
Welded
Aluminm
Hardnes
6061
Hardne
Heat Inp
Precipt
T4 Al -Cu
Precipt
T6 Al -Cu
Al Cu
T6 Aging
Crack
Compost

EffectOfPrecipitation
onisothermalprecipitationT6

Welded
SS
Precipt 1
corrosn
Precipt 2
Cr23C6
Carbon
Containt
Diagram
fasa
Weldabili
ty SS
Welded
Aluminm
Hardnes
6061
Hardne
Heat Inp
Precipt
T4 Al -Cu
Precipt
T6 Al -Cu
Al Cu
T6 Aging
Crack
Compost

DiagramfaseAlCu&T6
onisothermalprecipitation

Welded
SS
Precipt 1
corrosn
Precipt 2
Cr23C6
Carbon
Containt
Diagram
fasa
Weldabili
ty SS
Welded
Aluminm
Hardnes
6061
Hardne
Heat Inp
Precipt
T4 Al -Cu
Precipt
T6 Al -Cu
Al Cu
T6 Aging
Crack
Compost

CrackSensitivityCompositionofWeld
onisothermalprecipitation

Welded
SS
Precipt 1
corrosn
Precipt 2
Cr23C6
Carbon
Containt
Diagram
fasa
Weldabili
ty SS
Welded
Aluminm
Hardnes
6061
Hardne
Heat Inp
Precipt
T4 Al -Cu
Precipt
T6 Al -Cu
Al Cu
T6 Aging
Crack
Compost

DiagramfaseAlCu
onisothermalprecipitation

Welded
SS
Precipt 1
corrosn
Precipt 2
Cr23C6
Carbon
Containt
Diagram
fasa
Weldabili
ty SS
Welded
Aluminm
Hardnes
6061
Hardne
Heat Inp
Precipt
T4 Al -Cu
Precipt
T6 Al -Cu
Al Cu
T6 Aging
Crack
Al
Cu
Compost
Aging

Welded
SS
Precipt 1
corrosn
Precipt 2
Cr23C6
Carbon
Containt
Diagram
fasa
Weldabili
ty SS
Welded
Aluminm
Hardnes
6061
Hardne
Heat Inp
Precipt
T4 Al -Cu
Precipt
T6 Al -Cu
Al Cu
T6 Aging
Crack
Compost

Incomplete
fusion
Incomplete
penetration
Porosity
Slag
inclusion
Hot crack
(WM)
Hot crack
(HAZ)
Cold crack
(WM)
Cold crack
(HAZ)

Incomplete
fusion
Incomplete
penetration
Porosity
Slag
inclusion
Hot crack
(WM)
Hot crack
(HAZ)
Cold crack
(WM)
Cold crack
(HAZ)

High travel
speed

Heat of arc does not

melt underlying

Wrong work
position

Incomplete
fusion
Incomplete
penetration

Wrong welding
technique
Wrong
electrode angle

Low heat input

Misalignment of
second side weld
Improper joint
geometry
Heat of arc
does not reach
underlying
metal

Porosity

Insufficient
gap

Excessive
root face

Improper
bead shape

Wrong
included
angle

Dirty
surface
Insufficient
backgouging

Slag
inclusion
Low travel
speed

Hot crack
(WM)
Hot crack
(BM)
Cold crack
(WM)
Cold crack
(BM)

Sufficient
gap

Low sulfur
steel

Proper joint
geometry

Better
alignment

Proper welding
technique

Improved
work position
Better
electrode angle

Optimal
root face

Optimal
electrode size
Clean
surface

Heat of arc reaches

underlying metal
Heat of arc melts
underluing metal

Oversized
electrode

High heat
input

Incomplete
slag
removal

Proper
bead
shape
Optimal
included
angle
Proper
backgouging
Complete
slag
removal

Long
stickout

Heat of arc does not

melt underlying

Unstable
arc

Incomplete
fusion
Incomplete
penetration

High travel
speed
Wrong
electrode angle

Low heat input

Incorect welding
technique

Insufficient
root opening

Excessive
root face

Improper
bead shape

Tight
root
opening

Improper joint
geometry
Heat of arc
does not reach
underlying
metal

Porosity

Dirty
surface
Insufficient
backgouging

Slag
inclusion

Hot crack
(BM)
Cold crack
(WM)
Cold crack
(BM)

Short
stickout
Stabilized
arc
Low travel
speed
Better
electrode angle

Proper joint
geometry
Proper welding
technique

Optimal
root face

Optimal
electrode size

Optimal
included
angle

Clean
surface

Heat of arc reaches

underlying metal
Heat of arc melts
underluing metal

Incomplete
slag
removal

Proper
bead
shape

Sufficient
root opening

Hot crack
(WM)

Oversized
electrode

High heat
input

Proper
backgouging
Complete
slag
removal

Long arc
legth
Insufficing
shielding
Poor fit-up
Incomplete
fusion

S + O2 SO2
S + H2 H2S

Sulfur > 0,05%

in base metal

Hydrogen
bubbles

Trapped gas
Current
too low

C + O CO
Incomplete
penetration

Moisture
oil, paint,
rust and
grease

Porosity

Rapid cooling,
hydrogen
present from
welding

High travel
speed

Electrode
coverings
dissociate at
high
temperature

Slag
inclusion
Hot crack
(WM)
Hot crack
(BM)
Cold crack
(WM)
Cold crack
(BM)

Use short
arc

Low sulfur
steel, < 0,05%

Low travel
speed

Use low hydrogen

electrodes

Eliminate
moisture
Clean metal

Improve fit-up

Decrease
surface
tension and
viscosity of
melt

Manganese or
silikon; remove
oxygen before
SO2 or CO can
form

Slag not
removed
between
passes

Incomplete
fusion
Incomplete
penetration

Oxygen or
nitrogen +
manganese or
silicon, and
aluminium (in
large amounts)

High
viscosity
Slag cannot
rise to surface

Bond line or
root slag

Slag forced
back into
melt or
remelting

Porosity
Slag
inclusion
Hot crack
(WM)
Hot crack
(BM)
Cold crack
(WM)
Cold crack
(BM)

Avoid excessive
amounts of
oxygen,
nitrogen,
manganese,
silicon, and
aluminium
Remove
all slag
between
passes

Low
temperature
Slag not
removed
from junction
of bead and
base metal
Slag falls to
bottom of V
Stirring
High
temperature

V shaped
recess or
convex weld
bead shape;
low heat at
bottom
Electrode
too large to
reach
bottom of
groove
High energy
welding

Use proper
energy input

Remove bond
line slag

Slower
cooling rate

Improved flux
composition

Improve joint
and bead shape

Use proper
size electrodes

Incomplete
fusion
Incomplete
penetration

Low weld
current

Excessive
travel speed

Poor joint
preparation

Small weld

Poor weld
profile

Poor fit-up

High
restraint

High thermal
stress

No or low
preheat

Small
electrode

Unbalanced
heat input

Poor
electrode
manipulation

Mainly sulfur
(also oxygen
and selenium)
froms iron
sulfur at grain
boundries

Reduced grain
boundary
cohesion

Porosity
Slag
inclusion
Hot crack
(WM)
Hot crack
(BM)
Cold crack
(WM)
Cold crack
(BM)

Decrease
travel speed
Large
electrode

High preheat

Increased
hot ductility

Balanced
heat input

Low sulfur
steel

Eliminate or
decrease restraint

Increase
weld current

Inproved joint design,

fit-up, and tecnique

Excess
manganese
present

Manganese froms with

sulfur, oxygen, and
selenium into globular
inclusions before iron
can react (hinger
temperature reaction)

Tensile
stress

Incomplete
fusion
Incomplete
penetration

Excessive
weld
High alloy
content
Small
electrode

High carbon
content

Presence of
sulfur

Sulfur
segregation

Porosity
Slag
inclusion
Hot crack
(WM)

Preheat

Hot crack
(BM)

Decrease
strain

Cold crack
(WM)

Low sulfur
steel

Cold crack
(BM)

Improved
joint design

Controlled
heating and
cooling rates

High
manganese
to ratio, 50 to
1 or more

High stress

Incomplete
fusion
Incomplete
penetration

Poor joint design

and fit-up

Susceptible
microstruture

Fast
cooling of
weld metal

High TSN, high

plate thickness

Low heat
input
No preheat

Hydrogen trapped
in weld metal

Hydrogen
diffusion to
weld metal

Hydrogen
contamination

Low amperage,
high speed

Dirty, greasy,
or
contaminated
surface

Hydrogen
electrodes

Porosity
Slag
inclusion
Hot crack
(WM)

Nonsusceptible
microstructure

Hot crack
(BM)
Cold crack
(WM)

Hydrogen free
welding

Cold crack
(BM)
Postheat
stress relief

Slow cooling

High heat
input

Clean, wire
brush, and/or
grind surface

Preheat

Use low
hydrogen
electrodes

Interpass
temperature
control

High
amperage,
low speed

High stress

Incomplete
fusion
Incomplete
penetration

Poor joint design

and fit-up

Susceptible
microstruture

Hydrogen trapped
in martensite
latttice

High TSN, high

plate thickness

Fast
cooling of
weld metal

Low heat
input

High carbon
equivalent

No preheat

Hydrogen
diffusion to
base metal

Hydrogen
contamination

Low amperage,
high speed

Dirty, greasy,
or
contaminated
surface

Hydrogen
electrodes

Porosity
Slag
inclusion
Hot crack
(WM)

Ductile, non
martensitic
structur

Hot crack
(BM)
Cold crack
(WM)

Slow cooling
Low carbon
equivalent

Hydrogen free
welding

Cold crack
(BM)
Postheat
stress relief

Clean, wire
brush, and/or
grind surface
Use low
hydrogen
electrodes

High heat
input

Preheat

Interpass
temperature
control

High
amperage,
low speed