Overlay welding defects

[Karthick Flow Controls]

Dear Experts,

Welding Overlay, After Machining the Pin holes and blow holes noticed in Overlapping Joint area, After attend the defects, It will open some other places, The defects noticed Uniform inline.   ( Overlay Material ,316L ,Inconel 625 ,St6 & ST21,Base Material WCB/LCB),

How to prevent the defects?

Regards,

R.Gowtham.

[J Prinsen]

First questions: which process, which shielding gas, which welding position, which welding parameters

Regards

Jurgen Prinsen IWE

Weld-Tech BV

Welding Engineering and Consultancy

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Van: "Karthick Flow Controls" <kfcco...@gmail.com>
Aan: "Materials & Welding" <material...@googlegroups.com>
Verzonden: Woensdag 4 september 2024 07:26:39
Onderwerp: [MW:35217] Overlay welding defects

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[Karthick Flow Controls]

Inconel 625 & 316L -GMAW

Shielding Gas - Argon 

Position -1G

Regards,

R.Gowtham.

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Thanks & Regards,

R.GOWTHAM.

KARTHICK FLOW CONTROLS, 

1/575 SNMV College Road, 

Mallumichampatti,

Coimbatore - 641 050.

Website: http://www.karthickflow.com

[Mohd Siraj]

WCB/LCB fitting elbow or tee components, pl follow,

weld with CS filler wire first then start overlay.

[Karthick Flow Controls]

Dear sir,

Welding Valve body & Adapter,(Ball Valve,Triple offset Butterfly,Trunnion mounted Ball Valve & Top Entry Ball Valve.

Regards,

R.Gowtham.

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[sridhar cn]

Mr. Gowtham,

These sorts of problems are common in overly welding. 

Please make sure that jobs are preheated properly (not with Oxy-fuel gas; it may create pinholes) 

using LPG, according to your WPS.

Make sure that the Argon gas is procured from a reputed brand and not from a local manufacturer

as it may not be pure even though certified for a 99.99% purity level.

The overlay should not be done in an open area where air circulation is more and should be well-protected 

from fan breeze, etc.

If required, use UHP Argon (99.999% pure), but it will be very costly.

GTAW and plasma arc welding could be more appropriate for the overlay technique.

If you are using the GMAW process, make sure to keep a lower stick out and the correct amount of shielding 

gas flow rate. A very low/high gas flow rate or welding without a flow meter may also induce porosity. 

Make sure not to open the Argon cylinder fully, as it may increase gas flow velocity and may induce pinholes.

Hope the above information will be of help to you.

C Sridhar.

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properly according to your WPS.

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[Karthick Flow Controls]

Dear sir,

Thank you for your feedback sir.

We use LPG Cylinder for Preheat dia above 1000mm,We use Furnace for Small sizes.

Argon Gas Used Praxair ( Linde).

The below points,We will check in the Process.

If you are using the GMAW process, make sure to keep a lower stick out and the correct amount of shielding 

gas flow rate. A very low/high gas flow rate or welding without a flow meter may also induce porosity. 

Make sure not to open the Argon cylinder fully, as it may increase gas flow velocity and may induce pinholes.

Mainly the defect is noticed in the Bore bottom Radius Area ,Second one Continuous dotted line in the Overlapping.

Regards,

R.Gowtham.

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[Macario Jr. Palola]

To prevent defects such as pinholes and blow holes in welding overlay, especially in overlapping joints, consider the following approaches:

1. Pre-Welding Preparation

- Material Cleanliness: Ensure that both overlay and base materials are clean and free from contaminants like oil, grease, and rust.
- Edge Preparation: Properly prepare the edges to be welded, ensuring appropriate fit-up to minimize gaps.

2. Welding Parameters

- Heat Input Control: Adjust the heat input to avoid overheating, which can lead to excessive dilution and defects.
- Travel Speed: Optimize travel speed to ensure adequate fusion without excessive heat.
- Electrode Type: Use suitable electrodes or filler materials that match the base and overlay material properties.

3. Shielding Gas

- Gas Composition: Use appropriate shielding gas to protect the molten weld pool from contamination.
- Flow Rate: Ensure proper gas flow rates to avoid turbulence that can trap gas in the weld pool.

4. Post-Weld Treatment

- Heat Treatment: Consider post-weld heat treatment to relieve residual stresses and improve mechanical properties.
- Inspection: Conduct thorough inspection (e.g., NDT methods) after welding to identify and address any defects early.

5. Welding Technique

- Weaving Pattern: Utilize appropriate weaving techniques to ensure uniform deposition and minimize defects.
- Control of Interpass Temperature: Monitor interpass temperatures to prevent overheating and promote proper solidification.

6. Environmental Factors

- Welding Environment: Perform welding in controlled conditions to minimize the effects of moisture and contaminants.
- Drafts and Wind: Protect the welding area from drafts and wind that could affect the shielding gas coverage.

7. Training and Skill Development

- Welder Training: Ensure that welders are trained in techniques specific to the materials being used, especially for high-performance alloys like Inconel.

By following these guidelines, you can significantly reduce the occurrence of defects in welding overlays. Regular monitoring and adjustments based on specific conditions will also help in achieving better outcomes.

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[sridhar cn]

Mr. Gowtahm,

Using an LPG burner or furnace is fine. Argon gas supplier is OK. 

Please send a photo of your defects and setup if possible and weld parameters like ampere, 

voltage, stick-out, travel speed (not rotation time), torch angle if you are using an SPM, gas 

flow rate, oscillation width, and position of the contact tip in the nozzle (is it inside or 

outside—if so, how much, type/make of the welding equipment, nozzle opening, etc. to 

diagnose the issues. 

Sridhar.

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[Karthick Flow Controls]

Dear Sir,

The below is another type of defect,Mostly these two type of defects we faced.

Regards,

R.Gowtham.

On Wed, Sep 11, 2024 at 1:42 PM Karthick Flow Controls <kfcco...@gmail.com> wrote:

 Sir,

The above photo is one sample.

Regards,

R.Gowtham.

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Thanks & Regards,

R.GOWTHAM.

KARTHICK FLOW CONTROLS, 

1/575 SNMV College Road, 

Mallumichampatti,

Coimbatore - 641 050.

Website: http://www.karthickflow.com

[Karthick Flow Controls]

Dear sir,

Photo attached.

Regards,

R.Gowtham.

[Karthick Flow Controls]

 Sir,

The above photo is one sample.

Regards,

R.Gowtham.

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[james gerald]

What is your weld bead to bead overlap.

Thanks & Regards

J.Gerald Jayakumar

0091-8838619635

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[Karthick Flow Controls]

Dear sir,

Bead 8.0mm,Overlapping 5.0mm & Height 2.5mm.

Regards,

R.Gowtham.

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[sridhar cn]

The pores in the photos point to the shielding gas issue only. 

It could be due to: 

a contamination in the gas or the filler wire

an insufficient gas flow rate,

a higher flow rate creating turbulence drawing outside air into the welding area,

Gas line leaks or solenoid valve leaks thereby reducing the gas flow,

a higher stick out for the filler wire,

air draft disrupting the flow of shielding gas, 

a faster travel speed, 

a defective gun nozzle,

The weld nozzle held too far away from the well puddle,

a wider nozzle (use 14 or 16 mm nozzle) opening like 20 to 22 mm,

the gun being laid at an angle that sucks in air from the backside.

Please check the above points. 

You have not sent the stick-out used and other parameter details yet.

Sridhar.

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[Karthick Flow Controls]

Dear sir,

Thanks for your valued feedback.Details given below.

Stick out                     - 5 to 7.0mm

Gas flow Rate            - 15 to 20 lpm

Ams                            - 175 to 190 Ams

Voltage                       - 23-26V

Nozzle Gas cup size  - 14mm

Travel Speed             - 130 to 160

Oscillation Width       - 8mm

Regards,

R.Gowtham.

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[sridhar cn]

Mr. Gowtham,

The parameters mentioned by you are OK except for the stick out and will not cause porosity.

It should be 12 to 15 mm and can reach a maximum of 20 mm for your ampere and voltage selection. 

As mentioned earlier, the problem is shielding gas flow or its flow system, and please check.

Sridhar.

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[J Prinsen]

In the past I did a major 625 cladding project, we used same parameters but wit 70Ar/30He gas, torch 10 degrees in leading position, very limited defects due to good wetting properties

Wire 1.2 mm, Pulse 170 Amps. Beware of short lifecycle of contact-tips (20 minutes)

All the best

Jurgen Prinsen MSC/IWE

Welding Engineer

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Van: "Karthick Flow Controls" <kfcco...@gmail.com>

Aan: "materials-welding" <material...@googlegroups.com>
Verzonden: Vrijdag 13 september 2024 11:38:29
Onderwerp: Re: [MW:35251] Overlay welding defects

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[Karthick Flow Controls]

Dear sir,

Thank you for your Valuable Reply,

We check our Gas flow system and implement your Previous suggestions. 

Thanks a lot.

Regards,

R.Gowtham.

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[Karthick Flow Controls]

Dear Mr. Jurgen,

We look into the Mixture Gas .

Can we use the same Mixture Gas for 316L Cladding?.Pl.clarify.

Regards,

R.Gowtham.

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