How To Use Custom Welding Systems To Limit Weld Cracks
Welding is a skill that takes a lot of time and practice to master. Regardless of how well you handle a blowpipe by hand, the odds are that custom welding systems are better than you are at preventing defects. Learning how to use custom welding systems to limit weld cracks should give you the reasoning and motivation to invest in this technology. First, let’s find out about the types of cracks that can appear during a weld.
Centerline Cracks
A centerline crack can happen from three separate incidents: segregation-induced cracking, bead shape-induced crack, or surface profile-induced cracking. It can be challenging to distinguish one crack from another, especially since the three phenomena appear in a centerline crack. Knowing why one of these cracks come about aids in correcting and preventing it in the future. Plus, more than one of the events can contribute to creating a centerline crack.
Segregation-Induced Cracking
A segregation-induced crack may combine a low melting point in the admixture during solidification. Any time you deal with a low melting point, you must worry about centerline cracks because the center is the last thing to solidify.
To prevent these cracks from rearing their ugly head, you’ll need to limit penetrating the material. A welder can accomplish this by reducing welding currents. Shielded metal arc welding successfully alters the risk of contamination.
Bead Shape-Induced Cracking
This type of crack is a result of deeper penetration. Some careful welding counteracts this mishap from happening. The main issue is guaranteeing that the weld beads have as much width as depth. Typically, the goal is a 1:1 width-to-depth ratio, but some prefer 1.4:1 to play it safe. Therefore, if a bead shape-induced crack occurs, correct the width. Other tips for controlling penetration include lowering amperages and using larger electrodes.
Surface Profile Cracking
Surface profile cracks happen due to high voltage. Thus, lessening the voltage will correct the weld bead, thus eradicating cracking issues. Increased travel speeds may also be the culprit of surface profile cracks. Vertical-up welding is the process you want to use to fight against these types of cracks.
Crater Cracks
Crater cracks are frustrating because they develop slowly, with some taking as long as a year before appearing. Crater cracks develop toward the ends of welds from quickly ending a welding process. Generally, weld ends tend to contract during the cooling process, becoming a vulnerable point within the weld. Although, if a crater develops at the end of the weld, it makes it even more feeble. Consequently, crater cracks occur from not tolerating the pressures from shrinking.
Root Cracks
A strong current or proper filling material will create a root crack. You can avoid these flaws by beginning with a higher current and utilizing the appropriate filler material. Additionally, preheating and suitable joint formation can overcome these defects.
Transverse Cracks
Also referred to as cross cracking, a transverse crack in the weld is perpendicular to the direction of travel. Of all the imperfections, this is the least likely to occur. Usually, transverse cracks happen when the weld metal is stronger than the base material. Higher hydrogen levels are likely the cause of these cracks. Hence, reducing hydrogen, using another filler metal, managing the heat levels, and using weaker consumables will ward off transverse cracks.
How Automated Welding Limit Cracks
Manual welding can be problematic because human beings aren’t robots, and fatigue is a common occurrence while working. Mistakes like cracks lead to an abundance of scrap metal, resulting in a loss of profit. Automated welding ensures the accuracy of the part, and the following factors help explain why.
Precise Positioning
Automated welding systems narrow down the precise point you want. Also, an automated welding system will continue to attack that point repeatedly. Doing so counters any asymmetrical weld marks that may develop from welding by hand. Having pieces that have exact cuts make customers happy, and you’ll be able to correct any issue with minor adjustments.
Consistency
Have you ever had a repetitive task you do for an extended period? Even something as mundane as sealing envelopes, packing boxes, or stickering merchandise will have a hiccup along the way. After all, the phrase “I’m only human” implies that mistakes are inevitable.
Automated welding systems don’t have to worry about the margin of error that humans have since they are always consistent. Automated welding is the way to go with the various cracks that develop from erratic manual welding.
Controllable Current
As stated above, most defects are a result of improper tactics. Inaccurate electrodes have a negative effect on the quality of the weld. Manual welders have to set this themselves, creating a greater possibility for an error. Automated welding systems circumvent this concern because they offer precise control.
Versatility
Automated welding has a wide range of applications. It works with numerous metals and is better for fragile metals because of the limited heat-affected zone and low temperatures. Automated welding systems have minimal problems with thick material because of the added versatility. Because of the reduced heat, this approach can even fuse metals that are impossible to weld manually, such as unique metals prone to cracking.
Safety
Using automated welding systems is safer than manual welding. However, that doesn’t mean the workers operating these devices can sit back and relax. Operators must remain diligent with safety precautions, even though automation completes the job. Nevertheless, automation eliminates the risks that make people susceptible to injuries.
As you can see, manual welding opens the door to an abundance of complications. As a result, learning how to use custom welding systems to limit weld cracks shows the value of investing in these equipment pieces. At SEC Industrial, we have orbital welding equipment to improve the quality of your welds and minimize any errors that occur in manual welding. We carry the highest quality tools and machines to meet our customers’ needs. Whether buying or renting our equipment, we are here to please you, so don’t hesitate to contact us today, and our team will be more than happy to help!
