What is Weld Distortion? 

Weld Distortion is the deformation or misalignment of metal components caused by the expansion and contraction of the weld metal and base metal during welding process. This occurs accidentally, and there are many techniques to avoid distorting the metal throughout the welding process. Weld Distortion occurs when an incorrect amount of heat is applied to the metal during welding, causing it to expand, changing its shape and dimensions. Distortion can be problematic due to resulting in misalignment of parts, poor fit-up, and compromised structural integrity. It is crucial that welds are perfect, every time to ensure the accuracy we promise, and the strength and durability that we guarantee.

What Causes Weld Distortion?

There are multiple factors that could lead to weld distortion.

• Heat input: The heat that is generated during the welding process may cause the metal to expand unevenly, resulting in distortion
• Welding Technique: the speed, voltage, and current all have an impact on the amount of heat input, and degree of distortion.
• Incompatible base metal and weld metal:
• Material properties: Different materials have different thermal expansion coefficients, which may result in unequal expansion and contraction rates throughout the welding process, also resulting in distortion. It is crucial to have a great understanding of various materials to yield the perfect weld, each and every time.
• Joint Design: A joint design that does not distribute heat evenly can cause stress within the metal’s joints. Proper preparation is key to avoiding joint issues during the welding.
• Rapid Welding: Welding too quickly can result in distortion. A slow and stable welding procedure is key to
• Incomplete Fusion: This happens when the welder is not able to melt the parent metal with the base metal. The metals pre-solidify, resulting in gaps in the weld.

How do you avoid weld distortion? 

First, ensure that you are choosing the correct metal to weld to your material, having an understanding of how they interact with each other will help immensely. Knowing the correct speed, current, and electrode size are three major variables in a successful weld, while many other smaller factors all have effects on the final product, as well. Practicing correct welding procedures is a simple way to avoid any issues. This includes making sure the part is secure before beginning to weld, the proper torch angle, speed of the part’s rotation, and bead position.

Proper preparation is also key. Having a design that will allow the welds to form properly is another crucial step in the process. A design that does not have areas of high stress is ideal for a durable and long-lasting weld.

Testing and evaluating the weld’s strength is another way to ensure the highest quality part. The most common procedures would be visual inspecting, pressure testing, liquid penetrants, eddy currents, magnetic particles, acoustics, radiography, or other options.