Weld defects welding stresses

Although not commonly listed as a weld defect, high-welding stress nevertheless provides an essential ingredient to stress-corrosion cracking and other failures. It differs in an important respect from other types of weld defects in that stresses cannot be visually identified or revealed by conventional nondestructive testing techniques. 

The immediate technical cause of the collapse of Sea Gem was the breaking of tie bars. Many of the factors needed to induce brittle fracture were present, stress concentrations, weld defects, residual stresses, vibrations and low temperatures. The operational problem in December 1965 was the final trigger that caused the actual collapse. 

Defects produced during manufacture — welding defects —machining defects —heat treating defects —residual stress cracking... 

Nondestmctive testing (qv) can iaclude any test that does not damage the plastic piece beyond its iatended use, such as visual and, ia some cases, mechanical tests. However, the term is normally used to describe x-ray, auclear source, ultrasonics, atomic emission, as well as some optical and infrared techniques for polymers. Nondestmctive testing is used to determine cracks, voids, inclusions, delamination, contamination, lack of cure, anisotropy, residual stresses, and defective bonds or welds in materials. 

Weld attack. Welds are often more susceptible to corrosion than other areas (see Chap. 15, Welds Defects ). Welds may contain porosity, crevices, high residual stresses, and other imperfections that favor attack. Carbon steel welds are usually ditched by acid attack (Fig. 7.10). 

Most defects can be detected using one or more appropriate nondestructive testing techniques. However, in the absence of routine nondestructive testing inspections, identification of defects in installed equipment is generally limited to those that can be observed visually. Defects such as high residual stresses, microstructural defects such as sensitized welds in stainless steel, and laminations will normally remain undetected. Defects that can be detected visually have the following features ... 

General description. Incomplete penetration describes the condition in which the weld fails to reach the bottom of the weld joint, resulting in a notch located at the root of the weld (Fig. 15.12). This critical defect can substantially reduce the intrinsic mechanical strength of the joint and can combine with environmental factors to produce corrosion fatigue (Chap. 10), stress-corrosion cracking (Chap. 9), or crevice corrosion (Chap. 2). 

Figure 15.18 Examples of crack patterns due to stress-corrosion cracking and corrosion fatigue in butt welds. (Reprinted with permission from Helmut Thielsch, Defects and Failures in Pressure Vessels and Piping, New York, Van Nostrand Reinhold, 1965.)...

These weld defects not only substantially reduced the mechanical strength of the weld, the pores also formed stress-concentrating notches. Consequently, when the door frame was inadvertently struck during the scrap charging operation, a fracture initiated at the deficient weld and propagated rapidly through the %-in. (1.9-cm) plate, as revealed by the brittle appearance of the plate fracture and the directional chevron markings. 

Moulded plastics will also have crack initiation sites created by moulding defects such as weld lines, gates, etc and by filler particles such as pigments, stabilisers, etc. And, of course, stress concentrations caused by sharp geometrical discontinuities will be a major source of fatigue cracks. Fig. 2.72 shows a typical fatigue fracture in which the crack has propagated from a surface flaw. 

Other factors which can affect impact behaviour are fabrication defects such as internal voids, inclusions and additives such as pigments, all of which can cause stress concentrations within the material. In addition, internal welds caused by the fusion of partially cooled melt fronts usually turn out to be areas of weakness. The environment may also affect impact behaviour. Plastics exposed to sunlight and weathering for prolonged periods tend to become embrittled due to degradation. Alternatively if the plastic is in the vicinity of a fluid which attacks it, then the crack initiation energy may be reduced. Some plastics are affected by very simple fluids e.g. domestic heating oils act as plasticisers for polyethylene. The effect which water can have on the impact behaviour of nylon is also spectacular as illustrated in Fig. 2.80. 

In the case of the ASME codes for nuclear pressurised components, the questions of fatigue design and of flaw evaluation are dealt with separately in ASME Section III and Section XI Appendix A, respectively. The design S-A curve for machined butt welds typical of thick section pressurised components is set at a factor of two on stress range or twenty on cyclic life, whichever is more conservative, below the mean of S-N data developed on smooth cylindrical specimens in air. (A somewhat similar design curve obtained by a different method from experimental S-A data for machined butt welds is given in British Standard 5500.) These safety factors are intended to encompass any adverse influence of minor weld defects, size effects, data scatter and environment. As far as environmental effects are... 

Repair or Removal of Defective Welds in Piping Intended to Operate at Hoop Stress Levels of 20% or More of the Specified Minimum Yield... 

In summary, therefore, processing, and in particular injection moulding, can introduce limited chemical degradation, local polymer orientation, orientation of short fibre reinforcements, internal stresses, warpage, shrinkage and defects such as weld lines and voids. 

Defects can also occur when two melt streams join together in a mould, forming a not properly welded interface sharp internal angles may give rise to stress concentrations, etc. 

Risk evaluation programmes exist, for pressure vessels, which take into account European Directives [12] the risk factor - related to material brittleness and embrittlement, corrosion effects and localised stresses - is elevated and requires the adoption of rigorous safety measures. The manufacture and control procedures - including welding parameters and structural solutions - should be, in this case, more accurate and devoted to avoid the described defects. 

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