The slag can be peeled off on the cooling of the project easily. MIG welding residue from shielding gas can be removed easily. TIG welding is known as clean welding and if waste is seen there, it means the welded material was not properly cleaned. We need the weld surface, regular, smooth, and without any porous holes.
These porous holes lead to weakness of the structure which indicates that the base metal was not cleaned properly or is having an oxide coating. In the case of the MIG or TIG welding process, this porosity is an indication of improper shielding utilization as this improper use may lead to porosity. Loose joint always indicates the weld problem. In oxyacetylene and TIG autogenous welding where filler material is not used, the weld must be tight.
The gap is not very troublesome in other types of welding as the gap is filled with filler material. The gap otherwise is a quality issue and weak weld. When repairing an article containing liquid, a leak in the vessel is an obvious way to detect the problem.
F or the vessel that contains gas, the testing is done by putting soap bubbles over the vessels to detect the leak as in a squirt bottle. This is required in most situations. The easy way to ensure the strength is to choose a filler metal and electrode the rating of those higher than your needed strength. The other visual weld inspection methods include before the weld as root face, angle of the bevel, gap, joint fit. During the weld electrode consumption rate, the flow of metal, arc sound, arc light.
After the weld undercut, pinholes, root fusion issue, excessive spatter, dimensions of the weld. We will be discussing these in the following pages. The incomplete penetration happens when filler matter and base metal do not fuse together at the root of the weld joint. The completion of the groove welding with deposited material and base metal had not joined completely at the root of the desired joint. The commonest cause of this incomplete penetration is unsuitable weld design not suitable for the welding process.
When we weld the groove from one side only, incomplete penetration is the possibility due to the following conditions. The failure of the welding process is due to a lack of joining and fusion between layers of weld and base metal. The weld metal rolls over plate surfaces and termed as overlap. The lack of joining and fusion is caused by the following conditions.
The globular and elongated pockets of metal oxide and other compounds are termed slag inclusions. They result in the porosity of the weld metal. In arc welding , slag inclusions consisted of electrode coatings, fluxes, and other materials.
Failure to remove the slag in multi-layer welding leads to slag inclusions. This slag inclusion can be prevented by the following:. Porosity is defined as pockets that do not have any solid material. The difference between a slag is that it contains gas rather than s a solid. The gas here derived from:. An open eye inspection or visual welding inspection is a non-destructive testing NDT where weld quality is judged with the help of the eyes for surface discontinuities.
This is the most common method to judge the weld quality. In the case of the butt joint, examine the backside of the weld to judge the complete penetration passing through the root of the joint. A tiny bead should form on the backside to judge the complete penetration through the root of the butt joints.
The fusion and root penetration of these laps and T-joints can be assessed by exerting pressure on the upper plate until it bent to double.
If the penetration is not completely through the root, then the plate will crack open at the joint on bending. In the situation of the break-in plate, judge the extent of the fusion and penetration as it lacks complete penetration and fusion. Nowadays such indicating gauge has a system of the visual display.
Combination Gauge is defined as the gauge which can take more than one dimension of the parts of the material consecutively. It is very useful as at a time more than one measurement of the parts can be taken. It consumes less time and produces more efficient results.
Workshop Gauge is defined as the gauge which is used to measure the parts of the material at the time of production. This gauge is used in the production time at the workshop so that this gauge is named as the Workshop Gauge. The Workshop gauge is designed like that, where the tolerance is in the center-line. So that Workshop Gauge is very useful in the plants or workshops rather than the others. Inspection Gauge is defined as the gauge which is used by the inspectors in the plants after finishing the manufacturing of the products to accept it.
As the acceptance or the rejection is depending on the gauge measurement so that tolerance of this Inspection Gauge is slightly more than the Workshop Gauge. If the tolerance of the material part is high then it is accepted otherwise the material should be rejected.
Master Gauge is defined as the gauge to check the other gauges. As the expenditure is involved, the measuring instruments, optimizers, comparators, slip gauges, etc. All the other gauges are checked by this gauge so that this gauge is called the Master Gauge. It is very useful because the efficiency of the other gauges depends on the master gauge. If the master gauge cannot check the other gauges or instruments properly then those gauges and instruments cannot give accurate results.
Dimension Measuring Gauge is defined as the gauge which measures very small parameters of the parts of the material with very high accuracy. These dimensions are depth, height, diameter, etc. This Gauge is used to get very specific and accurate dimensions. This Dimension Measuring Gauge is classified in the other three types. Those are as follows:. Inside Dimension Measuring Gauge is used to measure the inner or inside diameter, width, height, etc.
In an example, the inner diameter of a bolt can be measured by Plug Gauge. Inside Dimension Measuring Gauge is classified in different types. It is used to measure the diameter of a hole like things with accuracy. In order to measure the parts, it has to pass a Measurement and another one has not to pass the Measurement. That is called Go and Not-Go measurement. Pin Gauge generally works on the same working principle as the Plug Gauge, which is used to measure the diameter which is more than 75mm.
Measurement of the width of the slots or grooves is done by Pin Gauge. It is measured across cylinder bore and the gauge placed as lengthwise. Dimension Measuring Gauge is used to measure the outer or outside diameter, width, height, etc. As an example, the outer diameter of a bolt can be measured by Snap Gauge. Dimension Measuring Gauge is classified in different types. It has jaws by which it checks the accuracy and tolerance. Here Go is a high or maximum limit and the Not-Go is the low or minimum limit.
The Ring Gauge is the same as the snap gauge but it is separated the Go and Not-Go pass or in a single ring. Both Sides Dimension Measuring Gauge is used to measure the outer or outside and inner or the inside, both diameters, width, height, etc. In an example, the outer and inner both the diameters of a bolt can be measured by Calipers. Outside Dimension Measuring Gauge is classified in different types.
And those are. The Caliper Gauge is the gauge that is used to measure the distance of an object, between the two different sides. It is very useful as it can give more accurate results and very easy to use. Geometric measuring gauges are defined as a measuring device that can measure its concentricity, taper, and profile.
Mainly the geometric measuring gauge is used to measure the roughness or unevenness of the surface. There are several types of measuring and calculating procedures for roughness characterization through its concentricity, profile and so on. The concentricity gauge is used to measure runout by revolving the cylinder or the loaded round on two pairs of bearings that are captured in anodized aluminum blocks.
This gauge mainly measures the circle of the plane. The taper gauge is basically used to measure the internal tapers. This gauge looks like an internal gauge in the shape of a frustum of a cone.
The profile gauge or contour gauge is a tool that is used to draw the profile or copy it on to another surface. The single limit gauge has a jaw that is fixed that makes the gauge limited, But in the case of the double limit gauge, it has a movable jaw that can be doubled with the help of the adjustable jaws.
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