Welding Problems, Solutions & Practices

In every work of genius we recognize our own rejected thoughts.

— Ralph Waldo Emerson

Introduction

There are few genuine welding secrets, but there are many valuable and little known techniques, methods, and procedures that can make any welding job go smoother. Called know-how, they can save time, money, and aggravation. Sometimes they can make the difference between success and failure, profit or loss. Many are based on science, others on experience. This chapter is a collection of this know-how.

Section I – Common Welding Problems & Their Solutions has information to help you solve common welding problems. Section II – Good Design Practices Checklist presents a systematic review of key considerations when designing a weldment. Section III – Controlling Distortion reviews the cause and practical remedies of weld-induced distortion. Section IV – Other Design Issues discusses the sizing of fillet welds and how to avoid fatigue failures. Section V – Simple Design Ideas provides insight into common welding applications. Section VI – Advanced Design Concepts discusses elastic matching and weld placement. Section VII – Structural Steel looks at common materials and practices in that specialty. Section VIII – Oxyfuel and Lance Cutting offers problem-solving tips and discusses the applications and capabilities of lances and burning bars. Section IX – Industrial Fasteners introduces nuts and bolts you will not find in the local hardware store and how they are used.

Advanced Design Concepts

Elastic Matching

The roller in Figure 6–79 deflects under load, causing misalignment and severe wear in its bearings. How can this problem be eliminated without putting the bearing on a swivel?

The solution is to design a welded steel bearing support that deflects the same angle under the same load that the shaft does, making the shaft and bearing stay in alignment. This technique is called elastic matching, Figure 6–79.

Figure 6–79. Elastic matching.