how to control distortion in welding?

how to control distortion in welding?

Controlling distortion is very important to achieve proper geometry of parts, So here we are providing tips on how to control distortion in welding. These tips are applicable for all welding industries and materials like Aluminium, steel, etc.

Some advanced welding companies like Fronius offers advanced welding technologies that can be used to reduce heat input in welding so that will control distortion in welding also saves time and gives high-quality welding and Better return on investment.

So if you are welding thick and V butt joints that need hours of preparation then go for Fronius ArcTig will provide you required penetration in Square butt preparation so avoiding excess heat and giving better penetration.

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If you are welding very thin sheets and facing issues like warpage, distortion, burn through, HAZ issues in welding then the most advanced MIG/MAG welding process i.e. CMT(Cold metal transfer) is best solution for thin sheets can weld from 0.6mm thin material easily and with faster speed and best thing gives spatter less welding. Know more about CMT Technology.

If you are an Indian customer and want Fronius Trials then comment on your mail address we will assist you to prove application and select the right welding process without any fees. We will also assist you in your Welding automation Projects.

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Top 10 Ways to control Distortion in welding.

1-Do not over-weld

Generally, the most common cause of weld distortion is over welding. So avoid over welding. we need to design the weldment to carry the welding only required for fulfilling service requirements. over welding will not give any benefit instead it will increase cost, distortion, and chances of defect.
for controlling this we need to provide fillet gauges to welder so they can check their weld fillets.

How to control distortion in welding?
How to control distortion in welding?

how to control/avoid distortion in welding.

2-Use Intermittent welding

To avoid amount of weld metal.use intermittent welding.It will saves weld metal by 75%  yet provides needed strenth. It also saves cost of welding and reduces weight of job.

continous welding vs intermittent welding.
how to control/avoid distortion in welding.

3-Use less no's of weld passes

Try to use fewer no of weld passes by welding with thicker rod or By increasing wire speed/feed.
shrinkage in each pass increases which will cause more shrinkage.Shrinkage accumulates from each weld pass.

how to control/avoid distortion in welding.

4-Place the welds near neutral axis

Place the weld near the neutral axis.Neutral axis is center of gravity of job to be welded.
This reduces distortion by providing the smaller leverage for shrinkage(contraction) forces to pull the plates 
place welds near neutral axis to control welding distortion

how to control/avoid distortion in welding.

5-Balance the weld near neutral axis

this will balance one shrinkage force with another.welding sequence and design can be used effectively to control distortion in welding.
avoid weld distortion

how to control/avoid distortion in welding.

6-Use backstep welding technique

with this welding technique,weld bead increments are deposited in the direction opposite to the progression of welding.

welding distortion control backstep welding technique.

how to control/avoid distortion in welding.

7-Presetting the parts

  • In this method shrinkage can help you to avoid distortion.In this method The job is made like that it will take desired/designed position after welding.
  • This will be made possible by taking few trials studying results and then presetting the job according to previous experience..

presetting welding distortion control

how to control/avoid distortion in welding.

8-welding sequence

  • Weld sequencing means planning weld at different points in a Job.
  • It is also most used method for distortion control.It is done by welding seams of weld alternatively instead of continuously. It will reduce heat input there by reduce distortion.Also it reduces Overheating of job which is main cause of distortion.
  • The weld metal is placed at different points about the structure so that as it shrinks at one place it will counteract the shrinkage forces of the weld already made.
  • Always weld outward from central point.
how to control/avoid distortion in welding.

9-reducing distortion by opposing forces (Clamping)
welding distortion reduction by clamping.

  • the opposing forces may be
  1. other shrinkage forces
  2. restraining forces created by clamps, jigs and fixtures.
  3. Arrangement of members in assembly.
  4. Due to force of gravity.
  • Clamps, jigs and fixtures that locks parts in desired positions  and hold them until welding is finished, are probably the mostly used weld distortion controlling method.
  • A common practice to balance shrinkage force is  to position identical weldments back to back and clamp them  tightly together.the welds are completed at both assemblies and allowed to cool before clamps are released.
how to control/avoid distortion in welding.

10-Peening (removal of shrinkage forces during or after welding.)

  • peening means stretching weld bead to relieve residual stresses
  • stress relief by controlled heating is used in special cases this heating of weldment at elevated temperature followed by controlled cooling is another way to remove contraction forces.

11-Weld as fast as possible - Last distortion control in welding technique.

  • Increased welding speed also decreases distortion so to avoid distortion complete welds as fast as possible.Use high welding speeds.

how to control/avoid distortion in welding.

  • Use of cooling jigs

    aluminium distortion control cooling jigs

  • Using strong-backs
it is an also effective method which reduces shrinkage's, mismatches and overlaps in welding
weld distortion control strongback

how to control/avoid distortion in welding.

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