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Figure 1: Crater cracks occur when the weld pool does not have enough volume after cooling to overcome shrinkage stresses. One of the primary objectives of any weld fabrication is to prevent weld defects, especially cracks.
Cracks are the most severe of all weld defects and are unacceptable in most circumstances. Rework robs the company of precious time and material (that is, money), so prevention is the primary concern. Cracks don’t always happen immediately after welding, and certain cracks, such as the underbead variety, may not be open to the weld surface.
Cracks can develop over time after the weld has been subjected to loads while in service. Tensile and fatigue loads; bending, twisting, or flexing; as well as hot and cold expansion and contraction all can occur long after welding, be it two days, two months, or even two years.
The major cause of a crack is when internal stresses exceed the strength of the weld metal, the base metal, or both. And once a focal point for these stresses—that is, a stress riser—develops and accumulates, a crack can propagate. Defect or Discontinuity? A discontinuity is a weld fault that may or may not be serious enough to cause a rejection. Whether or not it violates code specifications will depend on further examination by a competent person against code requirements or in-house quality assurance specifications.
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If the fault violates either of these two, it becomes a defect. Defects require repair, but discontinuities do not. Violations of customer requirements often fall under the discontinuity rule and the weld will have to be repaired. In short, defects always are discontinuities, but not all discontinuities are defects. The Buck Stops—Where? The responsibilities of both welder and supervisor affect weld quality. The welder is responsible for the defect when it is due to his or her skill level or weld deposition technique.
Weld characteristics like incomplete fusion, excessively concave or convex bead contours, and improper weld size all can come from poor welding technique, improper travel speed, poor electrode manipulation, incorrect weld parameter settings, as well as failure to notify supervision of a problem with the job at hand. Supervisors must ensure welders have the tools necessary to do an effective job. They must maintain a shop safety program in compliance with OSHA regulations. They also should, among other things, ensure welders are using the correct base and filler metal; have proper weld procedure testing; work with adequate and functional welding equipment; receive effective and meaningful welder training; and work with properly designed, accessible weld joints.
Responsibility often goes beyond the welder and supervisor, especially when design-for-manufacturability issues come into play. Buku pendidikan pancasila pdf to word online. For instance, joint accessibility has become more of a problem nowadays as many designers are not adequately familiar with the requirements of depositing a serviceable, defect-free weld. Can the welder get the gas metal arc welding gun, shielded metal arc welding electrode, or gas tungsten arc welding torch to the work area and still see the joint—or is he welding blind? Does the welder have enough room to manipulate the electrode at all the required angles to deposit a good weld, and still see the joint? If no design alternative exists, managers must plan for potential weld errors. If an unacceptable weld defect occurs, can a worker get a grinder into the joint to remove the bad weld? If so, how will the weld be repaired?