3 factors causing distortion in welding?

Question

any help anyone pls ?

Answer 1

There are many factors which cause distortion in the welding process:

Review - the principle elements of the process
Method
Materials
Workmanship

Then consider specific elements; i.e.
Heat input - see internal stresses
Section thickness - thinner sections are more prone to distortion
Cooling rate - see internal stresses
Set up or plating of parts to be welded
Restraint stress of asseembly to be welded
Internal stresses generated by the welding process

and more

Answer 2

Mostly this is the result of the contraction of the metal as it changes back t solid from a liquid phase.

Having said that, if you can keep you puddle down to as small a volume as possible, or if you can "stagger" the shrinkage ob y the sequencing of your welds, you will have the most luck.

We regularly hold structural weldments made of tubing (1/8" to 3/8" wall square and round) to .030" over 8 feet x 8 feet x 2 feet thick over all size. We do this principally by the sequencing of finish welds, but also by heat control (wire feed settings) and by "tweaking" a tacked structure in certain spots to allow the shrinkage (which is predictable) to pull the assembly back to square and flat.

Answer 3

Another very important argument is geometry of object to be welded: if you place your molten metal in the right place many structures could avoid deformations when the welding alloy cools and retires. If the system is correctly designed (if possible) and the welding sequence is respected you can get very good results. Materials and ability are obviously important.

Answer 4

Incorrect heat settings, wrong filler/rod, wrong welding speed. Thin metal needs to be stitch welded. Oops, that's four.

Answer 5

- location of the weld
- lack of pre-heating
- part cools too rapidly

Answer 6

excessive heat
insufficient space between parts being welded
maybe i will think of a third one later

Answer 7

internal stress