Influence of lack-of-fusion defects on load capacity of MAG welded joints

Pressure vessels operating at elevated temperatures and pressures are made of creep resisting plate and welded from individual components using the MAG welding process. The paper proposed focuses on the occurrence of lack-of-fusion defects in MAG welded plate components of pressure vessels. Lack of fusion, which is a planar defect and is, therefore, difficult to detect by common NDT methods, can result in catastrophic consequences since the latter do not only damage a pressure vessel but also jeopardize the environment and workers' health. The present paper deals with a research on the influence of a welding speed in welding of plate components made of S235JR steel of 8 mm in thickness, special care being taken to deliberately produce lack-of-fusion defects and possibly other weld defects. Test pieces prepared so as to contain various lack-of-fusion defects were subjected to destructive tensile testing. The force required for a weld failure was compared to actual weld defects. In the test pieces produced with lower welding speeds, a failure occurred in the welded joint and along a lack-of-fusion defect. In the test pieces produced with higher welding speeds, however, a fracture occurred outside a weld, although lack of fusion was present in the weld. Parallel to the tensile tests, radiographic examinations of lack-of-fusion defects were conducted and relevant micro sections were analysed. The aim of the study conducted was to elaborate a guideline for quality welding of plate components of pressure vessels.