AYUDA offers:
- Welder and welding procedure evaluation and qualification testing, and direction at your location with your equipment.
- All necessary and required reports, written procedures and qualification records, customized to reflect your company’s identity.
- Fabrication/Erection inspection and verification and surveillance inspection, troubleshooting, and investigation of weld failures.
- We provide Welding Procedure Specifications (WPSs) for all your needs.
- We can qualify new procedures (PQRs) as well as implement pre-qualified ones.
- Ascertain compliance to codes and specifications
Experienced and familiar with a wide variety of codes and specifications including:
- ASME IX -Boiler and Pressure Vessel Code
- A.W.S. Structural Welding Codes for Steel
- Aluminum, Stainless Steel, Reinforcing Steel
- Rotating Elements
- Industrial and Mill Cranes
- Structural Sheet Steels
- …and others
Weld Process Optimization
AYUDA assists our clients by conducting a thorough on-site review of the welding process. The review usually leads to short-term and long-term recommendations. In the short-term, every attempt is made to bring the process in control either with minor modifications of the weld schedule or suitable changes to electrode materials, electrode design, or shielding gas. In the long-term, recommendations are submitted in a written report for suitable changes to part design, materials, equipment, or process.
We can help optimize your welding process variables and eliminate common welding problems and discontinuities such as those listed below.
GTAW or TIG Welding:
Gas Tungsten Arc Welding (GTAW) is frequently referred to as TIG welding. TIG welding is a commonly used high quality welding process. TIG welding has become a popular choice of welding processes when high quality, precision welding is required.
Common GTAW (TIG) Welding Concerns
Weld Discontinuities
- Undercutting
- Tungsten inclusions
- Porosity
- Weld metal cracks
- Heat affected zone cracks
TIG Welding Problems
- Erratic arc
- Excessive electrode consumption
- Oxidized weld deposit
- Arc wandering
- Porosity
- Difficult arc starting
GMAW or MIG Welding
Gas Metal Arc Welding (GMAW) is frequently referred to as MIG welding. MIG welding is a commonly used high deposition rate welding process. Wire is continuously fed from a spool. MIG welding is therefore referred to as a semiautomatic welding process.
Common MIG Welding Concerns
Weld Discontinuities
- Undercutting
- Excessive melt-through
- Incomplete fusion
- Incomplete joint penetration
- Porosity
- Weld metal cracks
- Heat affected zone cracks
MIG Welding Problems
- Heavily oxidized weld deposit
- Irregular wire feed
- Burnback
- Porosity
- Unstable arc
- Difficult arc starting
FCAW or Flux Cored Welding
Flux Cored Arc Welding (FCAW) is frequently referred to as flux cored welding. Flux cored welding is a commonly used high deposition rate welding process that adds the benefits of flux to the welding simplicity of MIG welding. As in MIG welding wire is continuously fed from a spool. Flux cored welding is therefore referred to as a semiautomatic welding process.
Weld Discontinuities
- Undercutting
- Excessive melt-through
- Incomplete fusion
- Incomplete joint penetration
- Porosity
- Cracks
- Slag inclusions
Flux Cored Welding Problems
- Melted contact tip
- Irregular wire feed
- Burnback
- Porosity
SMAW or Stick Welding
Shielded Metal Arc Welding (SMAW) is frequently referred to as stick or covered electrode welding. Stick welding is among the most widely used welding processes.
Common Stick Welding Concerns
Weld Discontinuities
- Undercut
- Incomplete fusion
- Porosity
- Slag Inclusions
- Cracks
Stick Welding Problems
- Arc Blow
- Arc Stability
- Excessive spatter
- Incorrect weld profile
- Rough surface
- Porosity
SAW or Submerged Arc Welding
Submerged arc welding (SAW) is a high quality, very high deposition rate welding process. Submerged arc welding is a high deposition rate welding process commonly used to join plate.
Common Submerged Arc Welding Concerns
Weld Discontinuities
- Cracks
- Porosity
- Slag
- Undercut
Submerged Arc Welding Problems
- Solidification Cracking
- Hydrogen Cracking
- Incomplete fusion
- Irregular wire feed
- Porosity
RSW or Resistance Welding
Resistance Spot Welding (RSW), Resistance Seam Welding (RSEW), and Projection Welding (PW) are commonly used resistance welding processes. Resistance welding uses the application of electric current and mechanical pressure to create a weld between two pieces of metal. Weld electrodes conduct the electric current to the two pieces of metal as they are forged together.
Common Resistance Welding Concerns
Resistance Welding Problems and Discontinuities
- Cracks
- Electrode deposit on work
- Porosity or cavities
- Pin holes
- Deep electrode indentation
- Improper weld penetration
- Surface appearance
- Weld size
- Irregular shaped welds
EBW or Electron Beam Welding
Electron Beam Welding (EBW) is a fusion joining process that produces a weld by impinging a beam of high energy electrons to heat the weld joint. Electrons are elementary atomic particles characterized by a negative charge and an extremely small mass. Raising electrons to a high energy state by accelerating them to roughly 30 to 70 percent of the speed of light provides the energy to heat the weld.
EBW Problems and Discontinuities
- Undercutting
- Porosity
- Cracking
- Underfill
- Lack of fusion
- Shrinkage voids
- Missed joints
Soldering and Brazing
Soldering and Brazing are joining processes where parts are joined without melting the base metals. Soldering filler metals melt below 840 °F. Brazing filler metals melt above 840 °F. Soldering is commonly used for electrical connection or mechanical joints, but brazing is only used for mechanical joints due to the high temperatures involved.
Soldering and Brazing Joining Problems
- No wetting
- Excessive wetting
- Flux entrapment
- Lack of fill (voids, porosity)
- Unsatisfactory surface appearance
- Base metal erosion
Meet Our Welding Specialist and AWS-CWI:
Tommy Richardson
Oil & Gas Industry Consultant, AWS Certified Welding Inspector # 616136
25+ years of experience in the Oil/Gas Industry from construction of drilling rigs to onsite drilling, production, tank batteries, pipelining, compressor stations and refinery to final delivery; several years experience at the management level in AR/AP, general accounting, construction projections, human resources, training and development, delivery and administration of risk management procedures.
Additionally, Tommy is also an experienced welder and holds a current American Welding Society Certified Welding Inspector (AWS-CWI) license. His welding/welding inspection experience includes a strong technical background in construction/repair of structural, vessel, and pipe welding. Holds current/previous welding certifications in SMAW,FCAW,GTAW,SAW, including CS,SS,DUPLEX SS, LTCS, Aluminum, Drisco (polyethylene) plastic pipe. Holds previous level II certifications in NDE (UT,RT,MT,PT).
Travels throughout the US and abroad.