We perform a spectrum of weld consulting services – from weld testing and analysis, to weld overlay design and joint analysis, to procedure development and qualification, to (corrosion/ fatigue/ failure) troubleshooting and repair of non-conformance, distortion/cracking, and other Code compliant issues.
- Weld Troubleshooting & Repair of a Heater with Limited Fatigue Life
- Weld Consulting on a Hydroelectric Shaft Exhibiting Flaws
- Failure Analysis on Cracked Tube to Tubesheet Welds on Chemical Reactor
- Welding Procedures Used to Attach Appendages to P91 Heavy Wall Pipe
- Structural Analysis & Redesign on a Cracked 1,400 Ton Hydraulic Press
- Design/ Application of Weld Overlay on a Refinery Vessel
To see a more comprehensive list of equipment we have worked on, see Industries Served.
Our services also include Certified Weld Inspection Services (CWI) as well as engineering analysis – presenting effective repair solutions to challenging weld issues, often through the use of three-dimensional finite element analysis to quantify residual welding stresses, fatigue strength reduction due to lack of fusion, underpenetration, inclusions and other imperfections.
Our experience covers AWS D1.1, AWS D1.5 and the numerous ASME codes, resolving issues including:
- Weld Defects/ Porosity
- Weld Distortions
- Weld Cracking
- Fatigue of Welded Joints
We investigated the cause of a fractured axle bracket. Shown here is a high magnification where a small portion of the weld metal adhered to the bracket. Slag is observed under the initial weld pass and the frame surface, indicative of lack of fusion.
To see more of our projects, see Portfolio.
Durable welding is what holds every plant together. Often, equipment design life is often 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. We provide Certified Weld Inspections (CWI) and Nondestructive Testing (NDT) including radiographic (RT) and ultrasonic (UT) to determine quality and serviceability. Read about the various types of NDT.
A few examples include:
- Oil/ Gas
- Power Generation
We are experienced, multi-disciplined engineers, providing clients with support across the spectrum of welding and joining challenges – including troubleshooting, code compliance, weld and joint inspection, mechanical testing, and evaluation of welding 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 our article about managing risk specific to weld failures in Fugitive Emissions Journal. (PDF)
Learn from the experience of others. Especially when one such “other” is Dr. William O’Donnell, PhD, PE, Founder and President of O’Donnell Consulting Engineers, Inc., and ASME “Engineer of the Year” – his 50 years of experience in analysis of components including fatigue and fracture safety evaluations and failure analyses are now comprised in this volume.
If you are interested learning more in Engineering Design, Manufacturing and Construction, as well as Failure Analysis, then this book is a must have!
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