Weld troubleshooting/ consulting services, providing repair solutions to manufacturing and field operating issues – keeping you compliant to ASME API, AWS and other relevant Engineering Codes.
Our services include weld testing, analysis and resolving weld (distortion/ cracking /corrosion/ fatigue/ failure) issues – as well as joint analysis and stress analysis. Examples include:
- Hydroelectric Shaft Exhibiting Flaws
- Cracked Tube-to-Tubesheet Welds on a Chemical Reactor
- Welding Procedures for P91 Heavy Wall Pipe
- Cracked 1,400 Ton Hydraulic Press
- Design/ Application of Weld Overlay on a Refinery Vessel
See Portfolio to read about additional projects.
Our services also include Certified Weld Inspection Services (CWI). From the inspection results, we provide engineering analysis and design weld repair solutions, often through the use of three-dimensional finite element analysis. FEA is used to quantify residual welding stresses, fatigue strength reduction due to lack of fusion, underpenetration, inclusions and other imperfections.
Using various AWS welding codes (as AWS D1.1, AWS D1.5) and other engineering codes – we resolve issues including:
- Weld Defects/ Porosity
- Distortion/ Cracking
- Weld Failures
- Fatigue of Welded Joints
Weld troubleshooting and subsequent redesign was performed on a heater that had a limited structural life. The heater was constructed of .025 inch thick stainless steel. The configuration includes an edge weld joint type, where two .025 sheets are placed side-by-side and the top surfaces are welded. When this is connected to the header, a three point T weld joint configuration is created. Many fatigue cracks initiated in this area.
To see more of our projects, see Portfolio.
Engineering Support – Resolving Weld Issues
Durable welding is what holds every plant together. Often, equipment design life is compromised through inadequate manufacturing processes such as welding, thermal/ transient conditions, and high temperature conditions. At elevated temperatures, creep, and component strains occur, especially in welded connections.
Defects often occur in welded, cast and forged parts. Parts with complex geometries often include crack starters such as metallurgical notch effects. Our services include Certified Weld Inspections (CWI) and Nondestructive Testing (NDT) – radiographic (RT) and ultrasonic (UT) to determine quality and serviceability. Read about the various types of NDT.
Often, local post-weld heat treatment (PWHT) operations are performed on welded assemblies and weld repairs to minimize weld residual stress and mitigate various damage mechanisms. Engineering support is required to minimize potential non-compliances. We provide such support (including FEA) to optimize PWHT arrangements and thermal gradients to prevent detrimental distortion, cracking, excessive residual stress effects or fatigue failure.
We are a team of multi-disciplined engineers providing clients with support across the spectrum of welding and joining challenges. This includes troubleshooting, code compliance, weld and joint inspection, mechanical testing, and evaluation of weld procedure specifications (WPS), procedure qualification records (PQR), and welder performance qualifications (WPQ).
Several of our senior engineers have developed patents, published technical reports, and have been active in Codes and Standards Committees including the American Society of Mechanical Engineers (ASME), the National Association for Corrosion Engineers (NACE), the American Nuclear Society (ANS) and the American Welding Society (AWS).
Read article “Weld Defects and Failures: Quantifying Fitness for Service” in Fugitive Emissions Journal. (PDF)
Give us a call to discuss your welding challenges.