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Transverse Crack in Welding: Causes and Prevention in Steel Pipes

Date:2025-07-01

In welded steel pipe production, various defects can occur, with cracks being one of the most common and severe issues. These cracks are typically categorized into transverse cracks and longitudinal cracks based on their orientation. This article focuses on the transverse crack in welding, exploring its causes and effective prevention methods.


What Causes a Transverse Crack in Welding?

Extensive metallurgical analysis reveals that transverse cracks typically originate during the critical phase of weld metal solidification. Three primary mechanisms contribute to their formation:

1. Thermal Stress-Induced Cracking

As the molten weld pool cools and transitions from liquid to solid state, it undergoes significant volumetric contraction. When this shrinkage is restrained by the surrounding base metal, intense tensile stresses develop. If these stresses exceed the material's fracture toughness, a transverse crack in welding will initiate and propagate.


2. Hydrogen Embrittlement

The presence of diffusible hydrogen (often from moist electrodes or humid environments) combines with residual stresses to create an especially brittle zone in the heat-affected area. This hydrogen-assisted cracking phenomenon frequently manifests as transverse cracks within hours or days after welding completion.


3. Microstructural Weaknesses

Certain alloy compositions and improper cooling rates can lead to the formation of brittle phases in the weld metal. For example, excessive carbon equivalent in the material promotes hard martensite structures that are highly susceptible to transverse cracking.

 

Industry experts note that these mechanisms often combine synergistically - for instance, hydrogen accumulation at grain boundaries can reduce the stress threshold required for crack initiation by up to 60%. Understanding these interactions is crucial for developing effective prevention strategies.


4 Effective Ways to Prevent Transverse Cracks in Welding

1. Use High-Quality Welding Materials

Selecting superior welding materials can significantly reduce harmful elements in the weld, lowering the risk of transverse crack in welding. Proper material choice ensures better structural integrity and minimizes defects.


2. Optimize Welding Process Parameters

Adjusting the welding technique can help reduce stress concentration. For instance, maintaining proper penetration depth while reducing the inner weld groove can minimize crack formation.


3. Improve Pipe Alignment (Precision Adjustment)

Accurate alignment reduces residual stress between welds, decreasing the likelihood of transverse cracks in welding. Proper machine calibration ensures uniform stress distribution.


4. Control the Weld Formation Coefficient

A well-controlled weld formation coefficient (preferably above 1) enhances weld quality and reduces crack susceptibility. Proper shaping prevents excessive stress buildup.


Additional Factor: Metallurgical Impurities (Copper Contamination)

In spiral-welded pipes, low-melting-point impurities like copper (from anti-rust coatings on welding wires) can enter the weld pool, leading to transverse cracks in welding. Ensuring clean welding materials and proper wire feeding mechanisms can mitigate this issue.


Conclusion

transverse crack in welding can severely impact steel pipe quality, but with the right materials, optimized processes, and precise adjustments, manufacturers can minimize this defect. Implementing these preventive measures ensures stronger, more reliable welded pipes.

By understanding and addressing the root causes of transverse cracks in welding, production efficiency and product durability can be significantly improved.

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