Lesson 1Distortion prevention: stitch welds, backstep technique, clamping, low heat input processes, balanced welding sequence, and pre-bending allowanceDis part go explain how to stop bend with stitch weld, backstep way, clamp, low heat process, balance weld order, and pre-bend allow for join shape and material thick.
Stitch welding and skip sequence planningBackstep technique for shrinkage controlUse of clamps, strongbacks, and fixturesLow heat input processes and passesPre-bending and presetting componentsLesson 2How to prevent hot cracking: filler selection, heat input control, bead sequencing, and use of stabilized/low-carbon fillersDis part go explain way to stop hot cracking, looking at filler pick, heat put-in control, bead order, and use of stable or low-carbon filler to handle solidify way and stress wey no go away.
Selecting fillers for proper ferrite balanceUsing stabilized and low-carbon filler gradesHeat input limits and interpass temperatureBead sequencing to spread shrinkagePreheat and cooling control for crack resistanceLesson 3Repair/mitigation of distortion: mechanical straightening, local heating, re-welding strategy, acceptance criteria and rework planningDis part go talk repair and cut bend, covering mechanical straight, control local heat, plan re-weld, and check against okay rule to pick fix, re-do, or let go.
Measuring distortion and recording baselinesMechanical jacking, pressing, and peeningLocal heat straightening proceduresRe-welding strategies to counter shrinkageAcceptance criteria and repair documentationLesson 4Distortion and warping mechanisms in circumferential shells and brackets: longitudinal and transverse shrinkage, uneven heat distributionDis part go look into bend and warp way in round shell and bracket, looking at long and cross shrink, uneven heat spread, and how join lay and weld order dey affect final shape.
Longitudinal shrinkage around circumferencesTransverse shrinkage and ovality in shellsBracket-induced local bending and twistHeat input distribution around the jointPredicting distortion from weld size and pathLesson 5Three-pronged prevention methods for fusion/penetration defects: joint prep, parameter control, and techniqueDis part go detail how join ready, setting pick, and welder skill dey work together to stop no-fusion and no-deep enter bad ting, stressing steady set-up, check step, and paper of good way.
Joint design, bevel angle, and root face selectionRoot opening, land, and fit-up tolerancesCurrent, voltage, and travel speed windowsArc length, electrode angle, and manipulationVerification of fusion with visual and NDT checksLesson 6Repair and post-weld remediation of porosity: grinding, re-weld, vacuum backing if needed, and re-inspectionDis part go detail after-weld fix for hole, including grind out bad area, control re-weld, optional backing or vacuum hold, and final re-check to see follow quality rule.
Identifying porosity extent with NDTGrinding and blending porous regionsRe-welding techniques to avoid repeat poresUse of backing bars or vacuum assistanceFinal inspection, records, and traceabilityLesson 7Hot cracking (solidification cracking/intergranular cracking): root causes in stainless (composition, high sulfur/phosphorus, restraint, heat input)Dis part go check hot cracking way in stainless weld, linking make-up, dirt level, join hold, and heat put-in to solidify and grain-between cracking, stressing see risk in work.
Solidification cracking in austenitic stainless weldsIntergranular hot cracking along grain boundariesEffects of sulfur and phosphorus impuritiesInfluence of joint restraint and fit-upHeat input, cooling rate, and crack susceptibilityLesson 8Repair strategies for hot cracking: stop-drill and gouge, re-weld with controlled heat input, post-weld cleaning and inspectionDis part go cover plan repair for hot cracking, including stop-drill, gouge or grind, control re-weld, and full after-weld cleaning and check to make sure crack go full and no come back.
Crack mapping, marking, and extent assessmentStop-drill techniques to arrest crack growthGouging and grinding to sound metalControlled re-weld with adjusted heat inputPost-weld cleaning, NDT, and documentationLesson 9Lack of fusion and lack of penetration: how they occur on circumferential butt joints and filletsDis part go clear how no-fusion and no-deep enter dey happen in round butt join and fillet weld, linking join shape, reach, place, and skill to normal bad place and check focus.
Root fusion problems in pipe butt weldsSidewall fusion loss in narrow groovesLack of penetration in double-sided weldsFillet weld throat and leg size issuesInspection focus zones on circumferential weldsLesson 10Prevention strategies for porosity: cleaning, gas control, travel technique, purge integrity, and weld pool manipulationDis part go show real way to stop hole, stressing cleaning way, gas pick and flow control, travel skill, purge good check, and weld pool work to let gas go before hard.
Pre-weld cleaning and degreasing proceduresShielding gas composition and flow settingsTorch angle and travel speed for gas escapePurge dams, venting, and leak testingStringer versus weave beads for porosity controlLesson 11Repair methods for lack of fusion/penetration: grind-out, re-weld procedures, preheat/interpass controls, and NDT acceptance limitsDis part go list repair way for no-fusion and no-deep, including bad take-off by grind, good re-weld way, pre-heat and between-pass control, and use NDT okay limit before final okay.
Locating fusion defects with UT and radiographyGrinding and carbon arc gouging techniquesRe-weld parameters for full penetrationPreheat and interpass temperature controlApplying code NDT acceptance limitsLesson 12Porosity causes in stainless welds: contamination, inadequate shielding, purge failures, and entrapment of gasesDis part go check hole start in stainless weld, relating dirt, no-good shielding, purge fail, and gas trap to hole shape, and show how join design and place dey affect gas go path.
Surface contaminants and moisture sourcesShielding gas flow, turbulence, and draftsBack purging failures in root passesGas entrapment in deep or narrow groovesRecognizing porosity patterns in radiography
