Weld failure ....... what to do?

[Solutions-Hunter]

I produce a Stainless product using 304 stainless steel. I have the parts welded outside. I have had a few failures at the weld since the product takes a lot of stress.

Was anything done wrong (that can be seen in the photo) ? How to solve this problem? A better way to weld in the future?

Thanks in advance.

 

[Shox Dr]

Very hard to say from the limited information and photo.

 

[Tiggy_dorset]

I have the parts welded outside.

Welded outside? or welded by outside contractor?

From what I can make out in the pic, the weld seems to have been ground back (probably for neatness) but maybe ground back too much leaving it weak. If it hasnt been ground back, has it just been fused rather than welded?

 

[awemawson]

You say the part takes a lot of stress - is this vibration? Is it being Tig'd with no added filler rod - perhaps it needs a bit more meat in the weld and the vibratiuons damping out?

 

[brightspark]

the weld looks awfully thin for the thickness of the material it looks as if its being ground back as said above

 

[Solutions-Hunter]

outside contractor

Welded outside? or welded by outside contractor?

From what I can make out in the pic, the weld seems to have been ground back (probably for neatness) but maybe ground back too much leaving it weak. If it hasnt been ground back, has it just been fused rather than welded?

I had it welded by a contractor.

The part was not ground after welding.

I don't know if they added material or melted the part together...???

So if rod was applied and built up it would have been stronger?

Chuck

 

[malcolm]

Looks like the weld has been worn away so it's not there any more. Can't really blame the weld for failing when it's not there. There are witness marks on the black bit suggesting heavy wear too.

Do you know what has caused the wear? I'd guess some sort of redesign to protect against it might be sensible.

Any photos of the same area on a new part?

 

[Solutions-Hunter]

Type of stress?

You say the part takes a lot of stress - is this vibration? Is it being Tig'd with no added filler rod - perhaps it needs a bit more meat in the weld and the vibratiuons damping out?

The part is a shovel and is pushed and pulled back and forth for hours.

The weld was not ground.

Chuck

 

[Wozzaaah]

Can you post a couple of better photos of the failure? Preferably including at least one close-up.

 

[Solutions-Hunter]

better picture?

Can you post a couple of better photos of the failure? Preferably including at least one close-up.

That picture is from a customer .................

I have some others that I will look up

Thanks

 

[Hitch]

Very possibly an autogeneous weld, nice and easy for the contractor. (Welded without filler rod)
Not much throat thickness the to be able to take any kind of abrasion, i gather that might be a bit of an issue in the way that bar at the top has worn....?

What is the product?

 

[Wozzaaah]

I've just zoomed in on the photo and it really does look like the weld is simply worn away!
Looking at the damage I'd say a design issue rather than a manufacturing one.

 

[Tino]

Weld it on the inside

 

[Solutions-Hunter]

More pictures

Can you post a couple of better photos of the failure? Preferably including at least one close-up.

I have examined my inventory. Some of the welds seem to go from sharp edge to sharp edge. The others have more of a crown but still within the edges of the two sheet metal parts. By the way, the metal is .074" thick 14 gage 304 stainless

I am amazed how many responses I have received........ Thanks

Chuck

 

[Luke]

What environment does the device operate in?

As previously posted, it looks like the weld has been worn away.

Is there any reason it can't be welded on the inside?

 

[Solutions-Hunter]

Weld in the inside?

Weld it on the inside

I did have them hit 3 places for a little added strength. It seems to me it would be difficult to do. Right?

See my picture

Frankly it is kind of a joke how much they did.

Chuck

 

[the snooper]

some close up's of the broken parts just like your last 2 would be perfect

 

[Shox Dr]

It looks like it's been welded autogenously, and if that's the case the fit up is wrong. ie it hasn't achieved full pen. If that's the way you want it to look re-enforce it with weld on the inside.


OK so you've added another pic, looks to have full pen

 

[Solutions-Hunter]

Saltwater

What environment does the device operate in?

As previously posted, it looks like the weld has been worn away.

Is there any reason it can't be welded on the inside?

It is used in saltwater digging in sand. The weld is not worn away.
Chuck

 

[Paul.]

Just lately I seem to spend more and more time repairing poorly made joints like this, as others have said a fillet on the inside, even if only for an inch or so at the point will make a big difference. but if its a common failure point then some joint re design may be required, a simple folded angle on the inside, plug welded through the perforations would most likely be enough, and get who ever is welding them to do it properly, aiming to get a full penetration into the joint and with adequate reinforcement, that will mean using a filler rod and not just fusing the edges together.