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Wis5 stress and distortion 15
1.
Faisal Yusof TE Copyright ©
2003 TWI Ltd Welding Inspection Residual Stress and Distortion Course Reference WIS 5
2.
Faisal Yusof TE Copyright ©
2003 TWI Ltd Normal Stress Stress arising from a force perpendicular to the cross sectional area Compression Tension StressesStresses
3.
Faisal Yusof TE Copyright ©
2003 TWI Ltd Shear Stress Stress arising from forces which are parallel to, and lie in the plane of the cross sectional area. Shear Stress StressesStresses
4.
Faisal Yusof TE Copyright ©
2003 TWI Ltd Hoop Stress Stress acting circumferentially around a pipe due to internal pressure. Hoop Stress StressesStresses
5.
Faisal Yusof TE Copyright ©
2003 TWI Ltd Metal contract during solidification and subsequent cooling. If this contraction is prevented or inhibited residual stress will develop. The tendency to develop residual stresses increases when the heating and cooling is localised. Welding is very localised heating and the presence of liquid and solid metal in contact can be expected to induce very high levels of residual stresses. Residual StressResidual Stress
6.
Faisal Yusof TE Copyright ©
2003 TWI Ltd Residual stresses are very difficult to measure with any real accuracy. Residual stresses are self balancing internal forces and not stresses induced whilst applying external load Stresses are more concentrated at the surface of the component. The removal of residual stresses is termed stress relieving. Residual StressResidual Stress
7.
Faisal Yusof TE Copyright ©
2003 TWI Ltd Residual StressResidual Stress Longitudinal Along the weld – longitudinal residual stresses Transverse Across the weld – transverse residual stresses Short Transverse Through the weld – short transverse residual stresses Residual stresses occur in welds in the following directions
8.
Faisal Yusof TE Copyright ©
2003 TWI Ltd Material properties and condition Heat input The amount of restraint The amount of weld metal deposited DistortionDistortion Factors which affect distortion
9.
Faisal Yusof TE Copyright ©
2003 TWI Ltd DistortionDistortion Distortion will occur in all welded joints if the material are free to move i.e. not restrained Restrained materials result in low distortion but high residual stress More than one type of distortion may occur at one time Highly restrained joints also have a higher crack tendency to joints of a low restraint The action of residual in welded joints is to cause distortion
10.
Faisal Yusof TE Copyright ©
2003 TWI Ltd DistortionDistortion Distortion is a very complex matter more than 20 factors influence its magnitude and for this reason it is very difficult to predict its exact amount of distortion that may occur
11.
Faisal Yusof TE Copyright ©
2003 TWI Ltd DistortionDistortion Fit-up is very important to minimise distortion, fit-up must be even and uniform to ensure constant shrinkage along the joint
12.
Faisal Yusof TE Copyright ©
2003 TWI Ltd DistortionDistortion A mechanised welding process is preferable to a manual process because its consistent operation allows for better distortion control. The required volume of weld metal should be deposited in the shortest time to minimise heat input
13.
Faisal Yusof TE Copyright ©
2003 TWI Ltd DistortionDistortion The shorter the welding time the less heat is transmitted in to the material and less distortion will occur. Keep welding times down by carefully selecting the welding process, electrode type and size, welding current and travel speed
14.
Faisal Yusof TE Copyright ©
2003 TWI Ltd DistortionDistortion Longitudinal shrinkage/distortion
15.
Faisal Yusof TE Copyright ©
2003 TWI Ltd DistortionDistortion Transverse shrinkage/distortion
16.
Faisal Yusof TE Copyright ©
2003 TWI Ltd DistortionDistortion Angular distortion: weld metal contraction transverse
17.
Faisal Yusof TE Copyright ©
2003 TWI Ltd DistortionDistortion Angular distortion: weld metal contraction transverse
18.
Faisal Yusof TE Copyright ©
2003 TWI Ltd DistortionDistortion Longitudinal bowing: weld metal contraction longitudinal
19.
Faisal Yusof TE Copyright ©
2003 TWI Ltd Angular distortion: weld metal contraction transverse DistortionDistortion Longitudinal bowing: weld metal contraction longitudinal Longitudinal shrinkage/distortion Transverse shrinkage/distortion
20.
Faisal Yusof TE Copyright ©
2003 TWI Ltd DistortionDistortion Angular distortion: weld metal contraction transverse Longitudinal bowing: weld metal contraction longitudinal Longitudinal shrinkage/distortion Transverse shrinkage/distortion
21.
Faisal Yusof TE Copyright ©
2003 TWI Ltd DistortionDistortion Angular distortion: weld metal contraction transverse Longitudinal bowing: weld metal contraction longitudinal Longitudinal shrinkage/distortion Transverse shrinkage/distortion
22.
Faisal Yusof TE Copyright ©
2003 TWI Ltd DistortionDistortion Angular distortion: weld metal contraction transverse Longitudinal bowing: weld metal contraction longitudinal Longitudinal shrinkage/distortion Transverse shrinkage/distortion
23.
Faisal Yusof TE Copyright ©
2003 TWI Ltd DistortionDistortion Angular Distortion Bowing Distortion Longitudinal Distortion Transverse Distortion
24.
Faisal Yusof TE Copyright ©
2003 TWI Ltd DistortionDistortion The used of a different joint design Control of distortion my be achieved in on of the following way
25.
Faisal Yusof TE Copyright ©
2003 TWI Ltd DistortionDistortion The volume of weld metal in a joint will affect the amount of local expansion and contraction, hence the more weld deposited the higher amount of distortion Preparation angle 60o Preparation angle 40o Preparation angle 0o
26.
Faisal Yusof TE Copyright ©
2003 TWI Ltd DistortionDistortion The used of a different joint design Offsetting the joints to be welded – so that the metal distorts into the required position. Control of distortion my be achieved in on of the following way
27.
Faisal Yusof TE Copyright ©
2003 TWI Ltd DistortionDistortion Offsetting: The amount of offsetting required is generally a function of trail and error
28.
Faisal Yusof TE Copyright ©
2003 TWI Ltd The used of a different joint design Offsetting the joints to be welded – so that the metal distorts into the required position. The use of a balanced welding technique Control of distortion my be achieved in on of the following way DistortionDistortion
29.
Faisal Yusof TE Copyright ©
2003 TWI Ltd Back-skip welding technique Back-step welding technique 1. 2. 3. 4. 1. 2. 4. DistortionDistortion 3.
30.
Faisal Yusof TE Copyright ©
2003 TWI Ltd The used of a different joint design Presetting the joints to be welded – so that the metal distorts into the required position. The use of a balanced welding technique The use of clamps, jigs and fixtures. Control of distortion my be achieved in on of the following way DistortionDistortion
31.
Faisal Yusof TE Copyright ©
2003 TWI Ltd DistortionDistortion Clamping and jigging: The materials to be welded are prevented from moving by the clamp or jig the main advantage of using a jig is that the elements in a fabrication can be precisely located in the position to be welded. Main disadvantage of jigging and high restraint is the high levels of residual stresses.
32.
Faisal Yusof TE Copyright ©
2003 TWI Ltd 1. Residual stresses are locked in elastic strain, which is caused by local expansion and contraction in the weld area. 2. Residual stresses should be removed from structures after welding. 3. The amount of contraction is controlled by, the volume of weld metal in the joint, the thickness, heat input, joint design and the materials properties 4. Offsetting may be used to finalise the position of the joint. 5. If plates or pipes are prevented from moving by tacking, clamping or jigging etc (restraint), then the amount of residual stresses that remain will be higher. Summary of Residual Stress & DistortionSummary of Residual Stress & Distortion
33.
Faisal Yusof TE Copyright ©
2003 TWI Ltd 6. The movement caused by welding related stresses is called distortion. 7. The directions of contractional stresses and distortion is very complex, as is the amount and type of final distortion, however we can say that there are three directions: a. Longitudinal b. Transverse c.Short transverse 8. A high percentage of residual stresses can be removed by heat treatments. 9. The peening of weld faces will only redistribute the residual stress, and place the weld face in compression. Summary of Residual Stress & DistortionSummary of Residual Stress & Distortion
34.
Faisal Yusof TE Copyright ©
2003 TWI Ltd Any Questions?Any Questions?
35.
Faisal Yusof TE Copyright ©
2003 TWI Ltd QU 1. What causes residual stress in welds? QU 2. State three directions which residual stresses form in a welded joint QU 3. Give four methods of controlling distortion. QU 4. Sketch a balanced welding techniques. QuestionsQuestions QU 5. State four factors which affect distortion.
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