failures in stainless steel welds examples and causes

  • 5 Types of Resistance Welding Defects to Look Out for in ...

    Resistance welding is an excellent way to join two pieces of stainless steel wire to create a strong, durable bond without relying on a separate welding material. When done right, resistance welding can join small pieces of metal, such as those used in stainless steel wire .

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  • Weld Failure Analysis: A Case Study

    study provides an example of a failure analysis conducted for a customer in the steel fabrication industry. Case Study After a 439 stainless steel (SS) oil tank was heated to a high temperature in service, a through-thickness crack was found in a circumferential weld between a carbon-steel pipe fitting and the 439 stainless steel (SS) tank panel.

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  • How to Solve 10 Common TIG Welding Problems [Guide]

    Apr 03, 2020· 8. Sugaring on stainless steel. Figure 8 shows sugaring on the backside of a stainless steel weld. Sugaring (oxidation) occurs around the weld when it is exposed to oxygen in the air. The best way to prevent sugaring is to back purge the weld with argon shielding gas or reduce welding amperage.

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  • Rust On Stainless Steel - Sperko Engineering

    so it corrodes to protect the stainless steel, just like zinc corrodes to protect carbon steel when zinc is used as galvanizing. A second means of forming a rust film on stainless steel occurs during welding when using a process that depends on flux for shielding, such as SAW and GMAW using flux-cored wire.

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  • How to Spot A Good Weld vs Bad Weld - Valley Box

    The resulting heat causes the metals to melt and join. Materials: Thinner sheet metals and alloys such as mild steel, stainless steel as well as aluminum. Signs of a bad weld include: Lack of uniformity, cracks down the middle of the bead, too thin, and/or a lack of discoloration of the parent metal (which should be about 1/8 of an inch).

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  • Recent Experience in Dissimilar Metal Weld Failures

    is primarily a function of the weld metal composition, which is either an iron-based austenitic stainless steel or a nickel-based filler metal. Each of the two compositions can be character- ized by a distinct DMW failure mechanism. However, the performance is also influenced by

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  • Factors Affecting Inservice Cracking of Weld Zone in ...

    Inspect weld HAZs for cracks by a suitable NDE method if hard HAZs are suspected. Field repair welds are likely to have hard HAZs unless proper preheat or PWHT is applied. Small welds on thick members and arc strikes are examples of conditions resulting in .

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  • MIG Welding Troubleshooting - Common Problems And ...

    Cause: Simple chemistry of the base metal can also lead to weld porosity. For example, the base metal can have a high content of sulfur and phosphorous. Solution: The only solution for this MIG welding issue is to switch to a base metal that has a different composition or a slag-generating welding process.

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  • Fusion weld stregenth w/ stainless - Miller Welding ...

    The welds on some of the lighter fabrications are fusion welds and even on some pretty thick plate the weld beads are very small like pin head size. When I weld stainless my welds are allways larger maybee 1/4 in beads. I really seem to have trouble developing a very small puddle, but do use .035 or .045 filler material.

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  • Failure Modes and Effects Analysis (FMEA) of Welded ...

    Dec 17, 2013· This report documents a failure modes and effects analysis (FMEA) of the welded stainless steel canisters used to confine spent nuclear fuel in most dry cask storage systems. This document specifically considers the stainless steel canisters in dry cask storage systems licensed in the U.S., and focuses on designs currently in use.

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  • Failures Related to Welding | Failure Analysis and ...

    This article briefly reviews the general causes of weldment failures, which may arise from rejection after inspection or failure to pass mechanical testing as well as loss of function in service. It focuses on the general discontinuities observed in welds, and shows how some imperfections may be tolerable and how the other may be root-cause ...

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  • 5 Things That Will Corrode Stainless Steel

    Although stainless steel is widely known for resisting corrosion, it isn't completely impervious to corrosion. Under the right (or is that wrong) circumstances, stainless steel alloys can become corroded. Many a manufacturer has ordered a stainless steel part or basket, only to find that their "stainless" steel has started to show signs of rust and/or other problems within a few days or ...

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  • Different Types of Corrosion: Weld Decay - Causes and ...

    Different Types of Corrosion: Weld Decay and Intergranular Corrosion -causes and prevention. All Different Forms of Corrosion are explained by NACE certified Corrosion Specialist (#5047). WebCorr provides corrosion consultancy services, corrosion expert witness and corrosion short courses for in-house training, online and distance learning.

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  • The seizing of Stainless Steel fasteners | Fabory

    When applying stainless steel or aluminum fasteners, 'cold welding' (also known as seizing, galling or fretting) may occur during assembly. In this case, the threading sticks together until no further movement is possible, which may lead to the fracturing of screws during tightening.

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  • Investigation of fatigue-induced socket-welded joint ...

    Nuclear power plants typically experience two or three high-cycle fatigue failures of stainless steel socketwelded connections in small bore piping during each plant-year of operation. This paper discusses fatigue-induced failure in socket-welded joints and the strategy Texas Utilities Electric Company (TU Electric) has implemented in response to these failures.

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  • Avoid Common Stud Welding Failures | PFSNO

    Jan 06, 2016· Conduct visual and physical inspection of finished welds to assure satisfactory weld quality. Secure a relationship with reliable stud weld supplies in New Orleans. Production Fastening Systems New Orleans supplies superior quality weld studs manufactured from AISI 1006-1020 low-carbon steel, 300 series stainless steel, and 5000 series aluminum.

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  • Weld Failure Analysis: A Case Study

    study provides an example of a failure analysis conducted for a customer in the steel fabrication industry. Case Study After a 439 stainless steel (SS) oil tank was heated to a high temperature in service, a through-thickness crack was found in a circumferential weld between a carbon-steel pipe fitting and the 439 stainless steel (SS) tank panel.

    Get price
  • Creep and Creep Failures

    Steam reacts with steel to form iron oxide along the ID surface of the tube. The microstructures themselves will show the grain-boundary sliding and the resultant creep cracks or voids. For stainless steels, the microstructures are similar in that the failure is by grain-boundary-sliding and crack formation.

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  • Weld Defects and Practical Advice for Stainless Steel Welding

    May 12, 2014· Weld spatter can also cause pitting. ... Note that failure to use sufficient shielding gas during pipe welding may result in oxidation of the root side. ... Stress-relief annealing of a non-stabilized stainless steel at temperatures within the range 550 .

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  • Why does stainless steel rust after welding? - Cougartron

    Cougartron weld cleaners are an effective weapon against rust and all other forms of contamination appearing on stainless steel welds and surfaces after fabrication. Our product range includes machines for everyday heavy-duty work and occasional light weld cleaning, so you'll definitely find the right solution for your application.

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  • Weld Defects and Practical Advice for Stainless Steel Welding

    May 12, 2014· Weld spatter can also cause pitting. ... Note that failure to use sufficient shielding gas during pipe welding may result in oxidation of the root side. ... Stress-relief annealing of a non-stabilized stainless steel at temperatures within the range 550 .

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  • Welding guide — Materials Technology

    For dissimilar joint welding (example; Stainless Steel to Carbon Steel) Consideration: Failure can occur as a result of low alloy mixtures if the incorrect filler metal is selected, or if dilution rates are too high. The most common failure mode is cracking but weld embrittlement is also possible.

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  • Why Passivate Stainless Steel and What Happens If You Don't

    Welding stainless steel is one of the primary reasons for passivating. The metal surface is altered and free ... where metal failure is directly related to chloride contamination. Few if any failures could be linked solely to ... In the proposed multiple step reaction the presence of chlorine causes the dissolution of the chromium oxide film ...

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  • Avoiding defects in stainles steel welding

    May 13, 2015· The weld pool can be shifted off-center, causing a missed joint, as shown in Fig. 10 for an autogenous or- bital tube gas tungsten arc weld made on 316L stainless steel tubing. The weld pool is shifted toward the low-sulfur compo- nent, as illustrated schematically in Fig. 11.

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  • 5 Types of Resistance Welding Defects to Look Out for in ...

    Resistance welding is an excellent way to join two pieces of stainless steel wire to create a strong, durable bond without relying on a separate welding material. When done right, resistance welding can join small pieces of metal, such as those used in stainless steel wire .

    Get price
  • Failure Modes: A Closer Look at Ductile and Brittle ...

    Failure of high strength plate at low temperature High strength plate was substituted for mild steel in a conveyor transfer point. This was done because the mild steel plate was bent by repeated impact of large material pieces hitting it. As winter approached and the temperature dropped, the high strength plate began to fracture.

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  • Recent Experience in Dissimilar Metal Weld Failures

    is primarily a function of the weld metal composition, which is either an iron-based austenitic stainless steel or a nickel-based filler metal. Each of the two compositions can be character- ized by a distinct DMW failure mechanism. However, the performance is also influenced by

    Get price
  • 3 types of mechanical failures in shell and tube heat ...

    Apr 03, 2018· In one failure analysis published in Case Studies in Engineering Failure Analysis, engineers determined that a faulty weld joint where the tube met the tubesheet was the catalyst that resulted in failure. After careful review, the team identified a small welding defect, just 0.4 millimeters long, which was the first crack that would eventually ...

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  • Fatigue in Welded-Steel Structures | Machine Design

    A few examples include intermittent fillet welds, welds at the ends of partial-length beam cover plates, longer attachments (more than 4 in.), and connections with a sharp transition radius (less ...

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  • Journal of Failure Analysis and Prevention

    Alloy 430 stainless steel tube-to-header welds failed in a heat recovery steam generator (HRSG) within one year of commissioning. The HRSG was in a combined cycle, gas-fired, combustion turbine ...

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  • What is Welding Defects – Types, Causes and Remedies ...

    External Welding Defects. The various types of external defects with their causes and remedies are listed below: 1. Weld Crack. This is the most unwanted defect of all the other welding defects. Welding cracks can be present at the surface, inside of the weld material or at the heat affected zones. Crack can also appear at different temperatures:

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  • Stainless Steels Welding Guide - Lincoln Electric

    post weld heat treatment to soften and toughen the weld. 3.3 AUSTENITIC STAINLESS STEEL The austenitic stainless steels contain 16-26% Cr, 8-24% Ni + Mn, up to 0.40% C and small amounts of a few other elements such as Mo, Ti, Nb (Cb) and Ta. The balance between the Cr and Ni + Mn is normally adjusted to provide a microstructure of 90- ...

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  • Factors Affecting Inservice Cracking of Weld Zone in ...

    Inspect weld HAZs for cracks by a suitable NDE method if hard HAZs are suspected. Field repair welds are likely to have hard HAZs unless proper preheat or PWHT is applied. Small welds on thick members and arc strikes are examples of conditions resulting in .

    Get price