Cold laps are defined as micro-lack of fusion defects at the weld toe more or less parallel to the surface of the parent plate. These defects are known to negatively influence the fatigue properties of weldments. Previous studies suggest that cold lap formation can not be avoided completely in Gas Metal Arc Welding (GMAW). Therefore, a better understanding of formation mechanisms is imperative to be able to minimize the number and size of these defects. The main objective of this work has been to provide a more comprehensive understanding of cold laps, including categorising, characterisation and defining the most significant factors for formation. GMAW was used to produce welds that were investigated by metallographic methods using light optical microscopy, scanning electron microscopy and energy dispersive spectrometry. A novel classification of cold laps was introduced and three types of cold laps were identified: spatter cold laps, overlap cold laps and spatter-overlap cold laps. It was shown that cold laps are partially or fully filled by oxides. The most common oxides are manganese silicon oxides which were concluded to be formed primarily by oxidation of droplets. The presence of oxides was found to significantly increase the tendency to form spatter cold laps as well as overlap cold laps. Particularly for overlap cold laps, it was found that the depth (in transverse direction of weld) is reduced when welding in a non-oxidising environment. Welding on blasted surfaces increased the cold lap formation by entrapment of gas. The droplet and base metal temperatures were also found to be significant factors in cold lap formation. For overlap cold laps the occurrence frequency decreased with increased preheating temperature of the base metal. Mechanisms of overflowing resulting in overlap cold laps were discussed based on an extensive literature review. Several phenomena are believed to contribute to overflow including Rayleigh instability, the balance of forces, transfer of lateral momentum by droplets and an outward Marangoni fluid flow of the weld pool. The present studies suggest that cold lap formation can be suppressed by ensuring that the welding process (arc) is as stable as possible and by welding on a preheated work piece in a non-oxidising environment.

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<p>I både kvalitets- och kontrollarbete finns det behov att kunskapsmässigt komma så nära verkligheten som möjligt vid fastställande av defektparametrar för oförstörande provning (OFP). Orsaken är att olika acceptanskrav och bedömningsgränser är svåra att klarlägga när man inte kan förlita sig på att uppgifter är realistiska. I projektet har olika erfarenheter använts för att få en bättre helhetsbild i området för defektparametrar och oförstörande provning.</p><p>Denna rapport redovisar den inledande delen av forskning och utvecklingsprojektet PLANT 2, där olika defektparametrar kartlagts och en teoretisk bedömning utförts med avseende på hur signalsvaret påverkas för OFP-metoderna virvelström (ET) och ultraljudsprovning (UT) i form av puls-eko (PE) och ”time-of-flight-diffraction” (TOFD).</p><p>Definitionen av redovisade defektparametrar följer i stort SKI-rapport 95:70 [1]. Defektparametrar i denna rapport redovisas i bilaga 1.</p><p>Vid bedömningen av defektparametrarnas inverkan på OFP-tekniker, har drift¬inducerande defekter och tillverkningsdefekter hanterats separat. För de driftinducerande defekterna delades bedömningen upp i en generell och en specifik bedömning. De defektparametrar som bedöms specifikt och klassats att påverka signalsvaret betydligt bör vara av mest intresse i nästkommande etapp. Följande defektparametrar bedömdes påverka signalsvaret betydligt:</p><p>• Form i ytan, antal sprickor och avstånd i gatstensmönster</p><p>(vid termisk ut¬mattning)</p><p>• Form i djupled</p><p>• Sprickbredd vid sprickspets och sprickspetsradie</p><p>För tillverkningsdefekter bedömdes defektparametrarnas form i djupled och geometri påverka signalsvaret betydligt för defekttyperna slagg och bindfel.</p><p>Vid utvärdering av UT-PE och UT-TOFD teknikerna överensstämde resultatet helt med den teoretiska bedömningen. För ET-tekniken stämde endast en av tre defektparametrar överens med den teoretiska bedömningen.</p> / <p>In quality control of defect parameters for Non-Destructive Testing (NDT) it’s essential to have good knowledge about the defects. The reason is that different acceptance criteria and assessments must be based on defects that correspond to real defects. In this project different experience has been analyzed to get a better overview between defect parameters and non-destructive testing.</p><p>This report shows the beginning of the research & development project PLANT 2. There are different flaw parameters that have been mapped and a theoretical assessment has been performed with regard to how the signal response is influenced by the NDT techniques eddy current, ultrasonic pulse echo and ultrasonic time-of-flight-diffraction.</p><p>The definition of the reported flaw parameters does in general follow the one presented in SKI-report 95:70 [1]. The actual flaw parameters in this report are presented in appendix 1.</p><p>In the assessment of the influences on the NDT techniques with regard to flaw parameters, service-induced flaws and manufactured flaws have been separated in to two categories. The service-induced flaws have further on been separated in a general and a specific assessment. Those flaw parameters that have been assessed to be specific and classified to influence the signal response considerably should be the ones of most interest in future studies. The following flaw parameters were assessed to affect the signal response considerably:</p><p>• Macroscopic shape in the surface direction, number of cracks</p><p>and cobblestone stone pattern distance (for thermal fatigue)</p><p>• Macroscopic shape in the through thickness direction</p><p>• Crack width at the crack tip and the crack tip radius</p><p>For flaws caused by the manufacturing process, type slag and lack of fusion, the flaw parameters “Macroscopic shape in the through thickness direction” and “the geometry” were influenced by the signal response considerably.</p><p>In the evaluation of signal response with the UT pulse echo and UT TOFD techniques, the result corresponded to the theoretical assessment. For the eddy current technique only one of three flaw parameters corresponded to the theoretical assessment.</p>

I både kvalitets- och kontrollarbete finns det behov att kunskapsmässigt komma så nära verkligheten som möjligt vid fastställande av defektparametrar för oförstörande provning (OFP). Orsaken är att olika acceptanskrav och bedömningsgränser är svåra att klarlägga när man inte kan förlita sig på att uppgifter är realistiska. I projektet har olika erfarenheter använts för att få en bättre helhetsbild i området för defektparametrar och oförstörande provning. Denna rapport redovisar den inledande delen av forskning och utvecklingsprojektet PLANT 2, där olika defektparametrar kartlagts och en teoretisk bedömning utförts med avseende på hur signalsvaret påverkas för OFP-metoderna virvelström (ET) och ultraljudsprovning (UT) i form av puls-eko (PE) och ”time-of-flight-diffraction” (TOFD). Definitionen av redovisade defektparametrar följer i stort SKI-rapport 95:70 [1]. Defektparametrar i denna rapport redovisas i bilaga 1. Vid bedömningen av defektparametrarnas inverkan på OFP-tekniker, har drift¬inducerande defekter och tillverkningsdefekter hanterats separat. För de driftinducerande defekterna delades bedömningen upp i en generell och en specifik bedömning. De defektparametrar som bedöms specifikt och klassats att påverka signalsvaret betydligt bör vara av mest intresse i nästkommande etapp. Följande defektparametrar bedömdes påverka signalsvaret betydligt: • Form i ytan, antal sprickor och avstånd i gatstensmönster (vid termisk ut¬mattning) • Form i djupled • Sprickbredd vid sprickspets och sprickspetsradie För tillverkningsdefekter bedömdes defektparametrarnas form i djupled och geometri påverka signalsvaret betydligt för defekttyperna slagg och bindfel. Vid utvärdering av UT-PE och UT-TOFD teknikerna överensstämde resultatet helt med den teoretiska bedömningen. För ET-tekniken stämde endast en av tre defektparametrar överens med den teoretiska bedömningen. / In quality control of defect parameters for Non-Destructive Testing (NDT) it’s essential to have good knowledge about the defects. The reason is that different acceptance criteria and assessments must be based on defects that correspond to real defects. In this project different experience has been analyzed to get a better overview between defect parameters and non-destructive testing. This report shows the beginning of the research &amp; development project PLANT 2. There are different flaw parameters that have been mapped and a theoretical assessment has been performed with regard to how the signal response is influenced by the NDT techniques eddy current, ultrasonic pulse echo and ultrasonic time-of-flight-diffraction. The definition of the reported flaw parameters does in general follow the one presented in SKI-report 95:70 [1]. The actual flaw parameters in this report are presented in appendix 1. In the assessment of the influences on the NDT techniques with regard to flaw parameters, service-induced flaws and manufactured flaws have been separated in to two categories. The service-induced flaws have further on been separated in a general and a specific assessment. Those flaw parameters that have been assessed to be specific and classified to influence the signal response considerably should be the ones of most interest in future studies. The following flaw parameters were assessed to affect the signal response considerably: • Macroscopic shape in the surface direction, number of cracks and cobblestone stone pattern distance (for thermal fatigue) • Macroscopic shape in the through thickness direction • Crack width at the crack tip and the crack tip radius For flaws caused by the manufacturing process, type slag and lack of fusion, the flaw parameters “Macroscopic shape in the through thickness direction” and “the geometry” were influenced by the signal response considerably. In the evaluation of signal response with the UT pulse echo and UT TOFD techniques, the result corresponded to the theoretical assessment. For the eddy current technique only one of three flaw parameters corresponded to the theoretical assessment.