Materials & Welding: Re: [MW:35254] Overlay welding defects

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

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

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.

On Thu, Sep 12, 2024 at 6:15 PM sridhar cn <sridharcn305@gmail.com> wrote:

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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On Wed, 11 Sept 2024 at 14:04, Karthick Flow Controls <kfccovaigm@gmail.com> wrote:
Dear sir,
Photo attached.

Regards,
R.Gowtham.

On Wed, Sep 11, 2024 at 1:48 PM Karthick Flow Controls <kfccovaigm@gmail.com> wrote:
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 <kfccovaigm@gmail.com> wrote:

Sir,

The above photo is one sample.

Regards,
R.Gowtham.

On Tue, Sep 10, 2024 at 4:17 PM sridhar cn <sridharcn305@gmail.com> wrote:
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.

On Tue, 10 Sept 2024 at 11:39, Karthick Flow Controls <kfccovaigm@gmail.com> wrote:
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.

On Mon, Sep 9, 2024 at 5:44 PM sridhar cn <sridharcn305@gmail.com> wrote:
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.
--------------------------------------------------------------------------------------------------------

properly according to your WPS.

On Mon, 9 Sept 2024 at 10:57, Karthick Flow Controls <kfccovaigm@gmail.com> wrote:
Dear sir,
Welding Valve body & Adapter,(Ball Valve,Triple offset Butterfly,Trunnion mounted Ball Valve & Top Entry Ball Valve.

Regards,
R.Gowtham.

On Fri, Sep 6, 2024 at 11:21 AM Mohd Siraj <mohd52100@gmail.com> wrote:
WCB/LCB fitting elbow or tee components, pl follow,
weld with CS filler wire first then start overlay.

On Thursday, September 5, 2024 at 11:07:20 AM UTC+3 Karthick Flow Controls wrote:

Inconel 625 & 316L -GMAW
Shielding Gas - Argon
Position -1G

Regards,
R.Gowtham.

On Wed, Sep 4, 2024 at 4:08 PM 'J Prinsen' via Materials & Welding <material...@googlegroups.com> wrote:
First questions: which process, which shielding gas, which welding position, which welding parameters

Regards

Jurgen Prinsen IWE
Weld-Tech BV
Welding Engineering and Consultancy

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

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.

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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

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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

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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

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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

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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

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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

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