Analysis of Common Weld Quality Defects and Detection of Grids
Welding quality defects are common in construction and can significantly impact the structural integrity of a joint. One of the most frequent issues is an incorrect weld height—either too high or too low. A well-executed weld should have a smooth transition from the base material, with a consistent and aesthetically pleasing appearance. If the weld is too high, it can cause stress concentration, while if it's too low, it may lead to insufficient strength and potential failure under load. These issues can be identified using a weld inspection ruler, which helps assess the overall quality of the weld.
In automated gas-shielded welding, improper alignment between the wire and the groove can result in incomplete fusion on one side of the weld. This defect often occurs when the wire doesn't oscillate properly, leading to a lack of penetration. Compared to undercut, this issue is more severe because it reduces the cross-sectional area of the weld, weakening its load-bearing capacity. Another serious problem is false soldering, where the base material isn’t melted, and molten metal simply flows from one side to the other without proper fusion. In tension members, this can lead to catastrophic failure when the joint is pulled apart.
Other common defects include porosity, slag inclusions, crater cracks, and undercuts. While minor undercuts may be allowed within certain limits, all other defects must be repaired before the structure is deemed acceptable. These internal flaws—such as incomplete fusion or cracks—are typically detected using ultrasonic testing. However, due to the small diameter and thin walls of grid members, performing such tests can be technically challenging.
Once the grid structure is completed, it’s important to check the height difference between adjacent supports, ensuring that it remains within allowable limits. If measurements cannot be taken directly due to closed or hard-to-reach supports, data from the construction process can be used for analysis instead.
Grid deflection and dimensional accuracy are key indicators of overall quality, including manufacturing precision, installation accuracy, and design performance. Measuring vertical and horizontal dimensions and deflection values is essential. For existing grids, especially those in use, traditional steel tapes may not be practical. Laser measurement tools offer a faster, more accurate, and efficient alternative.
To detect bolt screwing depth in ball joints, the ray vertical projection method is often used. This technique captures an image of the sleeve part, clearly showing the number of threads on the bolt. Since the length, thread count, and pitch of bolts of the same specification are standardized, the actual engagement length can be calculated. The presence or absence of a gap between the bolt head and the cone sealing plate in the image indicates whether the screwing depth is sufficient. To ensure accuracy, the error calculation principle focuses on minimizing negative deviations in readings, thereby guaranteeing a positive deviation in the final screwing depth calculation.
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