Troubleshooting – WELDING ANSWERS

Could a tiny weld imperfection lead to a catastrophic failure? Our latest article reveals how a common fabrication defect, undercut, can become a hidden danger when combined with the stresses of a component in service. Discover how this seemingly minor flaw can act as a stress riser, initiating cracks that grow over time and culminate in sudden, brittle fracture with no warning. Don't let a small oversight lead to disaster – click to understand undercut, its dangers, and crucial prevention techniques.

Ever wondered why some welds fail while others endure? This article uncovers the critical differences between welding defects that occur during fabrication and those that emerge later in service. From mysterious "hot cracks" to the silent threat of corrosion fatigue, we break down the causes and consequences of these imperfections. Learn how understanding these defects is your first step towards prevention and ensuring the lasting integrity of your welded structures. Don't let weld imperfections compromise your projects – click to read more and build defect-free from the start.

This article challenges the common assumption that reducing amperage and electrode diameter lessens welding distortion. It explains that lowering amperage also decreases deposition rate, forcing slower travel speeds which can negate heat input reduction or even increase total heat input due to the inverse relationship between travel speed and heat input. The surprising solution often involves increasing amperage and travel speed to reduce overall heat input, though the most significant factor in minimizing distortion remains maintaining the smallest possible weld size.

ASTM A514 (T-1) is a high-strength, quenched and tempered steel known for its exceptional yield strength and use in heavy-duty structural applications like cranes and bridges. Its martensitic microstructure, while providing strength, makes it susceptible to cracking if not welded correctly, particularly in the heat-affected zone. Successful welding requires careful selection of high-strength, low-hydrogen electrodes, precise adherence to preheat and interpass temperature guidelines, and diligent control of hydrogen sources. Unlike many steels, AWS D1.1 requires qualification by testing for A514, emphasizing the need for rigorous procedures to achieve sound and reliable welds.

Austenitic stainless steels are highly prone to distortion during welding due to their high thermal expansion, low thermal conductivity, and reduced yield strength at elevated temperatures. These properties cause significant localized expansion and uneven contraction, leading to residual stresses and warpage. To minimize distortion, welders can employ techniques like controlling heat input, optimizing welding sequences, using rigid fixturing, and in some cases, post-weld heat treatment. A tailored approach combining these methods is crucial for achieving sound and dimensionally accurate stainless steel weldments.

Weld failures in the field often expose deeper systemic issues within a company's welding operations, leading to severe consequences like litigation and financial distress. Many companies mistakenly rely on past success as justification for lacking proper quality control, including welding procedure and welder performance qualifications, and robust inspection processes. When failures occur, the absence of crucial documentation complicates failure analysis and almost guarantees liability. This post emphasizes the critical need for proactive measures like developing welding quality standards, qualifying procedures and welders, and implementing stringent inspection processes to prevent catastrophic failures and ensure long-term structural integrity.

Rework in welding is a massive productivity killer—tripling labor, wasting material, and slowing down production. While there are many causes, three simple fixes can drastically reduce rework: stop overwelding, use properly qualified welding procedures, and maintain your equipment. In this post, we dive into how these small changes yield big results—lowering costs, improving quality, and increasing efficiency across the shop. If you're tired of grinding out the same welds twice, this is the post for you.