Socket weld leaks at overlap/crater
Socket weld leaks at overlap/crater
(OP)
Hi All, I'm trying to decrease frequency of weld leaks in an automated GMAW-P socket weld process.
It is a weld between a "cap" and a tube which are pressed together, then welded in an automated rotating fixture.
It is SAE 1010 steel, and the cap has wall thickness .080" and the tube is .049"
The weld only ever leaks at the overlap pass, at the crater and its always on the tube side of the weld.
Any suggestions for crater options or burnback etc. ?
see picture for clarity of the part.
Thanks
It is a weld between a "cap" and a tube which are pressed together, then welded in an automated rotating fixture.
It is SAE 1010 steel, and the cap has wall thickness .080" and the tube is .049"
The weld only ever leaks at the overlap pass, at the crater and its always on the tube side of the weld.
Any suggestions for crater options or burnback etc. ?
see picture for clarity of the part.
Thanks





RE: Socket weld leaks at overlap/crater
Regards
Stonecold
RE: Socket weld leaks at overlap/crater
RE: Socket weld leaks at overlap/crater
A competent, manual welder would readily compensate. Essentially, you need to mimic what he would do wiyh your automatic process.
RE: Socket weld leaks at overlap/crater
The ramp at the start acts as a pre-heat on this metal so that when you come around and weld over it you get good fusion with less gas evolution.
= = = = = = = = = = = = = = = = = = = =
Plymouth Tube
RE: Socket weld leaks at overlap/crater
RE: Socket weld leaks at overlap/crater
Also possible that the porosity is from gas evolution from lack-of-cleanliness. GMAW, being fluxless, has almost zero tolerance for oil, etc.
RE: Socket weld leaks at overlap/crater
What is causing the weld to leak?
Are you blowing thru the .049" tube wall or not fusing?
I agree with stanweld, your parameters need to be modified, however the condition causing the leak will depend on how you modify. Another parameter to consider is the diameter of the wire.
If you are blowing thru you could decrease the overlap to avoid excessive heat input.
RE: Socket weld leaks at overlap/crater
WBH:
The weld leaks always on the tube side of the weld, see the attached pic for clarity. It seems to be lack of fusion on the thin wall and creates a pinhole leak path.
RE: Socket weld leaks at overlap/crater
RE: Socket weld leaks at overlap/crater
Were you able to remedy this issue? If so how did you accomplish?
RE: Socket weld leaks at overlap/crater
RE: Socket weld leaks at overlap/crater
Suggest dye penetrate testing these areas.