Metal soude
Soude se yon pwosesis fabwikasyon k ap fonn metal debaz la pandan se tan yo ajoute yon filler nan jwenti a pou fòme yon pisin nan materyèl fonn ki refwadi pou fòme yon fizyon. Soude trè diferan de metal tanperati ki pi ba -jwenn tankou brase ak soude, ki pa fonn metal debaz la.
Pwosedi soude ak kalifikasyon soude
The welding procedure specification (WPS) is a required document for all code welding, and it describes all of the parameters required to perform a correct welding operation. It covers great details of welding process or processes used, the base materials used, the joint design and geometry, gases and flow rates, welding position and relevant variables.
Welder qualification indicates the WPS referenced during the qualification test, identifies the welder's name, and specifies qualified limits for the welder. In short, this qualification test demonstrates that the welder has the necessary skills to produce a satisfactory weld under the conditions specified in WPS. As a general rule, the test piece approves the welder not only for the conditions used in the test but also for all joints which are considered easier to weld.
Anvan WPS yo konplètman itilize kòm yon liy gid pou operasyon an soude, WPQR (kalifikasyon pwosedi soude) oblije apwouve li. Paramèt tès aktyèl yo anrejistre nan moman soude a pou asire yo te swiv WPS la. Anjeneral, tout dokiman sipò ki gen ladan espesifikasyon materyèl, espesifikasyon elektwòd ak espesifikasyon gaz pwoteksyon. Tout tès obligatwa yo, ki pa-destriktif ak destriktif, yo anrejistre tou. Tès NDT a anjeneral gen ladan egzamen X-Ray, egzamen ultrasons ak tès mayetik, ak tès destriktif yo enkli tès tansyon ak tès koube.
Estanda Pwosedi soude
√ Welding procedure test (BS EN ISO 15614)
√ Konsomasyon soude apwouve (BS EN ISO 15610)
√ Eksperyans soude anvan (BS EN ISO 15611)
√ Pwosedi soude estanda (BS EN ISO 15612)
√ Tès soude pre-pwodiksyon (BS EN ISO 15613)
Ki jan Fabmann fè enspeksyon soude?
Our welding engineers have over 15 years working experience in metal material and welding operation, and our quality team mostly use 100 percent visual inspection for each production batch, and we also use destructive test solution or NDT solution to verify welding quality based upon client's requirements. For all common welding defects, we have solid training cross the whole welding fabrication team and our QC team, so we can minimize the welding non-conformity to lowest level, and this practice also maximizes the possibility to have a sound metal surface treatment. Our visual inspection mainly focuses the following welding defects.
√ Porosite
√ Kratè
√ Spatters
√ Salop
√ Krak
√ Undercut
√ Pòv pénétration
√ Boule-atravè
√ Plis pase Lap
√ Distòsyon
√ Fizyon enkonplè
√ Arc Strike discontinuity
√ Ranfòsman twòp
√ Ranfòsman undercut
What are The Common Welding Defects, and What's the Cause and How to Solve Them?
Based upon Fabmann's welding fabrication experience, we have identified around fourteen different welding defects, and most of them are quite easy to solve, and it does require extremely high welding skills and knowledge.
1. Porosity, often caused by contamination, whether it is from the surrounding air at the weld site or the surface of the base metal, and contamination of metal includes dirt, debris, dust, grease, and rust. Therefore, it's critical that the operator needs to clean the base metal before starting the welding process, and contamination in the base metal can contribute to excess porosity and cracking in the metal. The second reason is that striking arc is too long, and the remedy is that the operator performs a quick strike or vertical strike.
2. Krak, li gen ladan fann cho, fann frèt, mikrofissure ak krak kratè, ki te koze pa anpil pwoblèm diferan soti nan refwadisman rapid nan kontaminasyon. Rezon fondamantal la se ke estrès entèn yo depase swa soude a, metal debaz la oswa toude. Resèt ki pi efikas yo se
√ Retire enpurte yo.
√ Debure bor plak yo pou yo anfòm ansanm.
√ Chofe tou de bò jwenti a espesyalman lè tanperati travay la pi ba pase tanperati chanm nòmal.
√ Kranpon oswa kole plak ansanm oswa itilize konsepsyon jwenti apwopriye.
√ Teste paramèt machin yo pou wè si bon kantite chalè a konpoze anvan soude kòmanse.
√ Bon refwadisman nan zòn nan soude
√ Sèvi ak metal apwopriye
√ Use proper welding speed and amperage current
√ Retire enpurte yo.
√ Debure bor plak yo pou yo anfòm ansanm.
√ Chofe tou de bò jwenti a espesyalman lè tanperati travay la pi ba pase tanperati chanm nòmal.
√ Kranpon oswa kole plak ansanm oswa itilize konsepsyon jwenti apwopriye.
√ Teste paramèt machin yo pou wè si bon kantite chalè a konpoze anvan soude kòmanse.
√ Bon refwadisman nan zòn nan soude
√ Sèvi ak metal apwopriye
√ Use proper welding speed and amperage current
3. Inclusions, it will occur when slag and oxides are trapped between the base metal and the weld, and it can lead to the weakening of the weld. The most effective way of preventing inclusion is keeping the base metal clean, and the cleaning main focuses on:
√ Mill Scale
√ Rust
√ Corrosion
√ Preexisting slags from previous welds
4. Undercutting, caused by failure to get good tie-in with both toes of a weld which the base metal meets the face of the weld. It occurs when the digging arc of the electrode leaves a pit in the base metal that will not be fully filled with the appropriate filler material. The risk factors are:
√ An arc is too long
√ Incorrect weld angle, which will mislead the heat
√ Welding speed is too fast or too slow
√ Welding with too much current
Pou evite koupe, operatè a dwe sonje aspè sa yo:
√ Diminye longè ark la.
5. Poor penetration, it means that the groove of the metal is not filled completely, and consequently the weld metal doesn't fully extend through the joint thickness. The possible causes are:
√ Twòp espas ant pati metal yo
√ Vwayaje twò vit, pa pèmèt ase metal yo dwe depoze nan jwenti a.
√ Anviwònman ba amperaj, aktyèl la pa fò ase pou byen fonn metal la.
√ Gwo dyamèt elektwòd.
√ Move aliyman.
√ Move jwenti.
√ Twòp espas ant pati metal yo
√ Vwayaje twò vit, pa pèmèt ase metal yo dwe depoze nan jwenti a.
√ Anviwònman ba amperaj, aktyèl la pa fò ase pou byen fonn metal la.
√ Gwo dyamèt elektwòd.
√ Move aliyman.
√ Move jwenti.
Solisyon prevansyon yo se:
6. Boule-atravè, sitou ki te koze pa twòp-chofaj nan soude a, epi li souvan rive mens metal mwens pase 3mm epesè. Remèd yo se:
√ For vertical welding, it is recommended to start from the top of the weld site and work the way down, and it's particularly effective for welding thin materials with GMAW (MIG) welding solution.
√ Lowering both the voltage and the wire feed speed to avoid over-heating for welding thin metals. In particular, extra attention is required for welding aluminum as it is amongst the most vulnerable of metals when it comes to burn-through.
7. Sipèpoze, li se ekstrèm opoze a soti nan undercotting, epi li anjeneral ki te koze pa chalè ensifizan fonn metal debaz la, oswa move manipilasyon nan elektwòd la. Sipèpoze ka anpeche si operatè a kenbe baton an soude nan ang ki kòrèk la epi vwayaje nan yon vitès modere. Men, soude dousman ka lakòz tou sipèpoze.
8. Kratè, li se fen a plen nan soude a, epi souvan rive soude a nan aliminyòm. Si kratè a pa pran swen, Lè sa a, li pral mennen nan kreyasyon an nan pwen estrès ki pral evantyèlman lakòz fann rive nan soude a. Kratè yo anjeneral ki te koze pa sispann arc la twò bonè anvan ou ranpli fen soude a. Ki jan yo rezoud pwoblèm sa a, epi gen kèk solisyon:
√ Ranpli zòn ki genyen ant tach soude ak chaplèt soude a anvan ou sispann arc la.
√ Grind the crater area, and then fill in the crater after starting an arc strike from a point just beyond the crater and working back over the crater.
9. Spatters, defini kòm ti gout nan metal soude ki mete deyò nan pisin nan soude fonn, epi yo nòmalman rete sou kote yo nan pèl la soude ki lakòz pwoblèm ayestetik. Pwoblèm sa a ta ka lakòz pa kòrèk vitès fil, vòltaj segondè ak polarite kòrèk. Apwopriye prevansyon nan depase spè nan soude MIG (GMAW) se chwazi gaz pwoteksyon ki kòrèk la pou pwosesis la soude. Spatters yo se sètènman youn nan pi move domaj pou kouch poud oswa penti, ak Se poutèt sa yo bezwen yo dwe retire anvan plis tretman metal sifas yo. Zouti posib yo se mato, chisel, bwòs metal, dosye metal oswa moulen ang.
10. Fizyon enkonplè, ki te koze pa mank de fizyon apwopriye ant metal la baz ak metal la soude, epi li ka parèt tou ant pèl soude vwazin. Rezon prensipal yo se
√ Filler metal la pa kapab fusion sifizameman nan yon kouch metal soude ki te deja depoze.
√ Metal la soude pa kapab byen fonde nan figi jwenti a.
√ For vertical welding, it is recommended to start from the top of the weld site and work the way down, and it's particularly effective for welding thin materials with GMAW (MIG) welding solution.
√ Lowering both the voltage and the wire feed speed to avoid over-heating for welding thin metals. In particular, extra attention is required for welding aluminum as it is amongst the most vulnerable of metals when it comes to burn-through.
11. Sipèpoze, li se ekstrèm opoze a soti nan undercotting, epi li anjeneral ki te koze pa chalè ensifizan fonn metal debaz la, oswa move manipilasyon nan elektwòd la. Sipèpoze ka anpeche si operatè a kenbe baton an soude nan ang ki kòrèk la epi vwayaje nan yon vitès modere. Men, soude dousman ka lakòz tou sipèpoze.
12. Kratè, li se fen a plen nan soude a, epi souvan rive soude a nan aliminyòm. Si kratè a pa pran swen, Lè sa a, li pral mennen nan kreyasyon an nan pwen estrès ki pral evantyèlman lakòz fann rive nan soude a. Kratè yo anjeneral ki te koze pa sispann arc la twò bonè anvan ou ranpli fen soude a. Ki jan yo rezoud pwoblèm sa a, epi gen kèk solisyon:
√ Ranpli zòn ki genyen ant tach soude ak chaplèt soude a anvan ou sispann arc la.
√ Grind the crater area, and then fill in the crater after starting an arc strike from a point just beyond the crater and working back over the crater.
13. Spatters, defini kòm ti gout nan metal soude ki mete deyò nan pisin nan soude fonn, epi yo nòmalman rete sou kote yo nan pèl la soude ki lakòz pwoblèm ayestetik. Pwoblèm sa a ta ka lakòz pa kòrèk vitès fil, vòltaj segondè ak polarite kòrèk. Apwopriye prevansyon nan depase spè nan soude MIG (GMAW) se chwazi gaz pwoteksyon ki kòrèk la pou pwosesis la soude. Spatters yo se sètènman youn nan pi move domaj pou kouch poud oswa penti, ak Se poutèt sa yo bezwen yo dwe retire anvan plis tretman metal sifas yo. Zouti posib yo se mato, chisel, bwòs metal, dosye metal oswa moulen ang.
14. Fizyon enkonplè, ki te koze pa mank de fizyon apwopriye ant metal la baz ak metal la soude, epi li ka parèt tou ant pèl soude vwazin. Rezon prensipal yo se
√ Filler metal la pa kapab fusion sifizameman nan yon kouch metal soude ki te deja depoze.
√ Metal la soude pa kapab byen fonde nan figi jwenti a.
√ Ranpli zòn ki genyen ant tach soude ak chaplèt soude a anvan ou sispann arc la.
√ Grind the crater area, and then fill in the crater after starting an arc strike from a point just beyond the crater and working back over the crater.
15. Spatters, defini kòm ti gout nan metal soude ki mete deyò nan pisin nan soude fonn, epi yo nòmalman rete sou kote yo nan pèl la soude ki lakòz pwoblèm ayestetik. Pwoblèm sa a ta ka lakòz pa kòrèk vitès fil, vòltaj segondè ak polarite kòrèk. Apwopriye prevansyon nan depase spè nan soude MIG (GMAW) se chwazi gaz pwoteksyon ki kòrèk la pou pwosesis la soude. Spatters yo se sètènman youn nan pi move domaj pou kouch poud oswa penti, ak Se poutèt sa yo bezwen yo dwe retire anvan plis tretman metal sifas yo. Zouti posib yo se mato, chisel, bwòs metal, dosye metal oswa moulen ang.
16. Fizyon enkonplè, ki te koze pa mank de fizyon apwopriye ant metal la baz ak metal la soude, epi li ka parèt tou ant pèl soude vwazin. Rezon prensipal yo se
√ Filler metal la pa kapab fusion sifizameman nan yon kouch metal soude ki te deja depoze.
√ Metal la soude pa kapab byen fonde nan figi jwenti a.
√ Filler metal la pa kapab fusion sifizameman nan yon kouch metal soude ki te deja depoze.
√ Metal la soude pa kapab byen fonde nan figi jwenti a.
Pou evite fizyon enkonplè sa a, operatè a toujou bezwen netwaye salop la apre yo fin fòme yon soude, epi li bezwen tou asire w ke vitès vwayaj la ak ang soude kòrèk.
17. Arc strike discontinuities, it can be caused by starting the arc strike in an area other than the weld joint, and it can also be caused by improper grounding. The solution could be quite simple, and that is to make sure that attaching the ground clamp to clean and bare metal. Meanwhile also make sure that this job site is dry, and free of any clutter.
18. Excessive reinforcement, it usually caused by the deposition of too much filler material. According to the American Welding Society, the weld reinforcement must be at least the thickness of the base metal and can be 1/8" inch above the base metal at the thickest.
19. Undercut Reinforcement, it's opposite to excessive reinforcement, which means it's caused by deposition of too less filler material. The weld reinforcement is less than 1/32" inch above the base metal at the thickest.
For the last two defects, the solution is to control the feeding of filler, and make sure that the deposition of filler is at a reasonable level, and of course, welding angle and amperage setting are fine tuned by the operator.
20. Distòsyon, ki te koze pa ekspansyon ak kontraksyon metal la soude ak metal debaz adjasan pandan sik chofaj ak refwadisman nan pwosesis la soude. Gen anpil kalite deformation tankou kontraksyon longitudinal, shinkage transverse, deformation angilè, bese ak dishing, flambe ak trese. Gen rezon konplèks ki enplike nan distòsyon soude:
√ Pwopriyete materyèl paran yo
√ Kantite kontrent
√ Konsepsyon jwenti
√ Pati anfòm-anfòm
√ Pwosedi soude
Kòm yon prensip debaz, volim nan soude yo ta dwe kenbe nan yon nivo minimòm, epi tou, sekans nan soude ak teknik ta dwe vize balanse estrès yo pwovoke tèmik alantou aks net nan eleman an.
Sèvis fabrikasyon soude
In average, our welders have over 15-year experience, Fabmann has the expertise and modern equipment including welding robots to handle variety of material types and thickness. Our welding department mainly handles welding work like argon arc welding, spot welding, carbon dioxide protection welding, stainless steel sheet welding, aluminium sheet welding manual arc welding, and our welding engineers will make WPS prior to the welding task, which will minimize welding defect and lower down total manufacturing cost. For high quality welding tasks, our welding engineers will perform WPQR to make sure all welding seams are qualified before metal surface treatment starts.
Pou fè fas ak diferan kondisyon soude ak volim, Fabmann te devlope kat solisyon soude pou travay fabrikasyon soude.
√ Robotik soude ak wotasyon jig, li ka okipe volim mitan ak gwo ak kondisyon soude ti jan sofistike.
√ Full automation rotary welding machine for handling volume and full circular welding.
√ Manual welding for project tasks
Robotics Welding ak Jig Rotary
Oto Rotary Welding
Auto Rotation Welding for Post Support
Manyèl Spot Welding
Manyèl soude aliminyòm estrikti
To reach 100 percent welding repeatability for high volume product like pòs sipò, Fabmann uses full automation rotation welding solution, and our welding engineer will make welding strength test from each production batch. Circular welding generates precise welding effects with fixed horizontal positioned torch, and we can use this welding solution for cylindrical, rectangular, oval, triangular, and other complex forms.
Fabmann has developed interchanging fixture tools pneumatic clamping fixtures, thus we can ensure jigging time is within welding cycle. Meanwhile, we work closely with customers to design cost-effective weld fixtures to achieve precise alignment and maintain tight tolerances.
Pa analiz apwofondi solisyon soude ak pwosedi, Fabmann ka toujou fè soude bon jan kalite segondè nan yon pri konpetitif.
Materyèl metal pou soude
√ Steel, stainless steel, aluminum plates (max thickness 20mm)
√ Steel, stainless steel, aluminum tubes (max diameter 1200mm)
√ Steel, stainless steel, aluminum profile sections
√ Steel, stainless steel, aluminum angles (max 8mm)√ Steel, stainless steel, aluminum bar (max diameter 30mm)
Fabmann has a professional welding team, and we also have various welding facilities like robots and automized welding jig for volume projects. We are supplying a wide range of metal structure products for various industries:
√ Tretman dlo
√ Enfrastrikti
√ Pwosesis Manje
√ Enèji solèy
√ Konstriksyon kay ak kloti
√ Konstriksyon waf
√ Akwakilti
√ Telekominikasyon
Hot Tag: Steel Welding Fabrication, Metal Welding Fabrication, Aluminum Welding Fabrication, Custom Welding Fabrication, OEM Welding Fabriction, Stainless Steel Welding Fabrication, Welding Fabrication Service, Welding Service, Welding Specialist, Welding Company
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