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<\/p>\nWorkpieces are easily deformed during welding. Six practical prevention tips<\/p>\n
When doing welding work, what everyone is most afraid of is that the workpiece will warp and shrink after welding. If you wait until then to bend it hard to correct it, it will cause the weld seam to crack or even the base material to be scrapped. This is a waste of materials and labor, and you will lose money in the end. To be honest, 80% of the cause of the deformation problem has been determined before welding. Even if you try to correct it later, it is just a way to make up for it.<\/p>\n
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Before welding thin-walled pipe fittings and small workpieces, they must be locked with a pressure block or C-type clamp, or with a tool clamp. This locking operation is to fix them on the platform or V-shaped frame. The clamping position must avoid the groove and weld area. Never drive the clamp over the weld. If you do this, the root of the weld will crack directly. Especially thin-walled parts like heat exchanger tube sheets must be carefully used.<\/p>\n
After all the locking measures are implemented, the workpiece will not experience any form of vibration or positional movement during the entire operation, so that the deformation problem will be completely intercepted and eliminated at the source.<\/p>\n
Compared with the practice of using a sledgehammer to forcefully knock and correct the welding process after the welding process, adding about ten to fifteen minutes more time for firm fixation at this stage can save up to two hours of time in the subsequent process for turning the workpiece and finely adjusting the level. The difference in labor hours and costs calculated from this will be several times higher.<\/p>\n
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The flat plate butt and pipe fitting combination is a simple structure. The welder can slightly lift the two parts upward two to three degrees before aligning the weld. This can leave room for deformation. This way you\u2019ll know what to do, so there\u2019s no need to make it too complicated.<\/p>\n
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After the metal is cooled, the tension generated by its shrinkage can be offset by the angle mentioned, so that the surface of the molded workpiece is very smooth, and there will be absolutely no deviation during the molding process. The dimensions during assembly can also be accurately matched with the hole positions, thus eliminating the trouble of using the flame correction machine for secondary processing, avoiding delays in the delivery date due to the processing process, and there will be no nitpicking when customers inspect the goods.<\/p>\n
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When welding large frames and large plates, never weld from the head to the tail. You should choose the center position as the starting point, and then use the step-back welding method to both ends. Make sure that the welding operations on the left and right sides are strictly symmetrical, and the rhythm and length of the welding should be consistent. There should never be a situation where one side has been welded but the other side has not yet started.<\/p>\n
Since the heat is dispersed and no longer concentrated in one place, there will be no local high-temperature accumulation. Therefore, the overall bending amount of the workpiece is significantly reduced. There is no need to wait until the welding is completed to drag the workpiece to the correction platform and use a jack to press it back to restore its shape. This saves a process.<\/p>\n
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When using thin-walled parts, the current should be adjusted to a smaller level for operation. At the same time, the walking speed must be kept constant, and there must be no pauses. It is very taboo to perform fixed-point burning of the base material, because once it stops, the heat input will be too concentrated, which will cause the thin-walled material to be directly burned through and deformed, ultimately making the cost of repair several times higher.<\/p>\n
The heat input is reduced, the overall heating becomes lighter, the amount of shrinkage and deformation is directly reduced by a large amount, the welded wall thickness becomes uniform and will not become thinner, and the subsequent UT flaw detection inspection can be passed in one go, without the need for rework, which saves the quality department the trouble of finding faults.<\/p>\n
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The welding sequence must be fixed. Specifically, the short welds and intermittent welds must be welded first. After the short seams have cooled and been shaped, and the overall size has been locked, the long main welds can be processed. Especially when dealing with these welds at the intersection of the tube bundles, do not complete the welding from beginning to end in one go.<\/p>\n
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The force will be uniform in succession, so the workpiece will not be pulled back and forth and deformed, the nozzle will not shrink, and the flange surface will not become elliptical. This will make subsequent assembly and docking much easier without having to use a grinder or other tools to repair the opening on site.<\/p>\n
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After the stainless steel pipe bundle is welded, it is strictly prohibited to pour cold water on it for rapid cooling, because the rapid cooling operation will cause the internal residual stress to become very large at once. It must be kept at normal temperature and allowed to cool down naturally and slowly. If conditions permit, you can also cover it with asbestos cloth or an insulation blanket and let it slowly cool down until it returns to normal temperature before moving it.<\/p>\n
For large objects made of ordinary carbon steel, you only need to take appropriate heat insulation and cooling measures according to the actual situation. You should never use cold water for pouring in the pursuit of speed.<\/p>\n
If this results in cracks in the weld or heat-affected zone, the entire tube bundle will become unusable and scrapped. The loss of this result will far exceed the benefits of the saved cooling time, and ultimately it is not worth the gain.<\/p>\n
Dear friends who work in the workshop, do you have other methods to prevent deformation and clever correction techniques? Please share your experience in the comment area. If you think this information is useful, please like the content and recommend it to your work partners so that they can also check out the content.<\/p>","protected":false},"excerpt":{"rendered":"
The heat input of thin-walled parts should be as small as possible to reduce the overall heating load and shrinkage deformation. 5\ufe0f\u20e3Follow the correct welding sequence: weld short welds and intermittent welds first, and then weld the long main welds after the short seams have cooled and finalized to avoid pulling and deforming the workpiece due to uneven stress.<\/p>","protected":false},"author":1,"featured_media":2656,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"footnotes":""},"categories":[28],"tags":[2318,2317,1197,2319,2320],"class_list":["post-2655","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-machining","tag-anti-deformation-skills","tag-practical-welder-operation","tag-welding-deformation","tag-welding-pit-avoidance","tag-workshop-experience"],"_links":{"self":[{"href":"https:\/\/endlfh.com\/de\/wp-json\/wp\/v2\/posts\/2655","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/endlfh.com\/de\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/endlfh.com\/de\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/endlfh.com\/de\/wp-json\/wp\/v2\/users\/1"}],"replies":[{"embeddable":true,"href":"https:\/\/endlfh.com\/de\/wp-json\/wp\/v2\/comments?post=2655"}],"version-history":[{"count":0,"href":"https:\/\/endlfh.com\/de\/wp-json\/wp\/v2\/posts\/2655\/revisions"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/endlfh.com\/de\/wp-json\/wp\/v2\/media\/2656"}],"wp:attachment":[{"href":"https:\/\/endlfh.com\/de\/wp-json\/wp\/v2\/media?parent=2655"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/endlfh.com\/de\/wp-json\/wp\/v2\/categories?post=2655"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/endlfh.com\/de\/wp-json\/wp\/v2\/tags?post=2655"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}