IOSR Journal of Engineering (IOSR JEN) www.iosrjen.

org
ISSN (e): 2250-3021, ISSN (p): 2278-8719,
|| Special Issue || June-2019, || PP 41-45 ||

Failure Mode and Effect Analysis on Welding Aseembly

Process
G.S.Sawadadkar1, H.K.Dhage2, R.R.Thorat3, D.B.Rankhambe4
1 (Professor Department of Mechanical Engineering, JSPM Narhe Technical Campus, Pune, Maharashtra,
India)
2,3,4 (BE Student Department of Mechanical Engineering, JSPM Narhe Technical Campus, Pune,
Maharashtra, India)

Abstract: Failure Modes and Effects Analysis (FMEA) is methodology for analyzing potential reliability
problems early in the development cycle where it is easier to take actions to overcome these issues, thereby
enhancing reliability through design. FMEA is precisely an analytical methodology used to ensure that potential
problems have been considered and addressed throughout the product and process development cycle. A
process or a design should be analyzed first before it is implemented and also before operating a machine the
failure modes and effect must be analyzed critically. In this work, process failure mode and effect analysis is
done on general welding process
Keywords: FMEA-Failure mode effect analysis, effective weld, risk priority numbers.

I. Introduction
The purpose of FMEA is to analyze the design characteristics relative to the planned
manufacturingprocesstoensurethattheresultantproductmeetscustomerneedsandexpectations. When modes of
failure are identified, improvement can be done by reducing the chances for occurrence by taking some
correctactions. FMEA provides an organized analysis of failure modes of the system being defined and
identifies related causes. Corrective action considerations. Used in both the design and manufacturing processes,
they substantially reduce costs by identifying product and process improvements early in the develop process
when changes are relatively easy and inexpensive to make. The result obtained found robust, as the need for
post corrective action and problems are reduced completely. This project discuses and implementation of
Process Failure mode and effect analysis for improvement in all sub-processes involved till the completion of
welding process.

II. Fmea Procedure

1. For each process input(start with high value inputs),determine the ways in which the input can go wrong
(failure mode).
2. For each failure mode, determine effects.
 Select a severity level for each effect.
3. Identify potential causes of each failure mode.
 Select an occurrence level for each cause.
4. List current controls for each cause.
 Select a detection level for each cause.
5. Calculate the Risk Priority Number (RPN).
6. Develop recommended actions, assign responsible persons, and take actions.
 Give priority to high RPNs.

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 Failure Mode and Effect Analysis on Welding Aseembly Process

2.1 Fish Bone/ Cause and effect diagram of welding defects

III. Welding Defects modes

The weld defects such as Lack of Penetration, Porosity, Slag Inclusion, Burn Through, Oxide
Inclusion, Lack of Fusion, Crack, Cluster Porosity, Internal Concavity, Offset, Tungsten Inclusion etc.,
deteriorate the mechanical properties of the welded structures thereby increasing the risks of fatigue, failure and
disaster. Lack of Penetration is one of the weld defects that occur as a result incomplete penetration of the weld
defect through a joint. This is one of the most unpleasant weld defects because this acts as a cause for Natural
stress. When this defect is pressurized, it may result in the failure of the entire weld metal. So this should be
avoided to the maximum possible extent. It usually appears as a dark straight line of medium width. Internal
Concavity defect arises due to the contraction of the weld metal as it cools. This defect resembles Lack of
Penetration but has irregular edges and is broader in the middle.
Cluster porosity and Porosity weld defect occur due to the presence of moisture, which turns into gas
that will be further trapped in the weld when heated. Lack of fusion weld defect occurs when the filler metal
doesn’t fuse correctly with the base metal. In a radiographic image these defects appear as straight lines between
the seam of the metal and they orient themselves in only one direction, along the weld seam in the metal. Oxide
Inclusion occurs as irregularities dark in color since they are less intense than the adjoining materials.

Fig: Porosity & Weld Bed

IV. Fmea Procedure & Chart

Step 1: Occurrence
In this step it is necessary to look at the cause of a failure mode and the number of times it occurs. This
can be done by looking at similar products or processes and the failure modes that have been documented for
them in the past. A failure cause is looked upon as a design weakness. All the potential causes for a failure mode
should be identified and documented. Again this should be in technical terms. A failure mode is given an
occurrence ranking (O), again 1–10. Actions need to be determined if the occurrence is high (meaning > 4 for
non-safety failure modes and > 1 when the severity-number from step 1 is 1 or 0). This step is called the detailed
development section of the FMEA process. Occurrence also can be defined as %. If a non-safety issue happened
less than 1%, we can give 1 to it. It is based on product and customer specification.

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 Failure Mode and Effect Analysis on Welding Aseembly Process

Step 2: Severity
Determining all failure modes based on the functional requirements and their effects. Examples of
failure modes are: Electrical short-circuiting, corrosion or deformation.A failure mode in one component can
lead to a failure mode in another component, therefore each failure mode should be listed in technical terms and
for function. Hereafter the ultimate effect of each failure mode needs to be considered. A failure effect is
defined as the result of a failure mode on the function of the system as perceived by the user. In this way it is
convenient to write these effects down in terms of what the user might see or experience. Examples of failure
effects are: degraded performance, noise or even injury to a user. Each effect is given a severity number (S)
from 1 (no danger) to 10 (critical). These numbers help an engineer to prioritize the failure modes and their
effects. If the sensitivity of an effect has a number 9 or 10, actions are considered to change the design by
eliminating the failure mode, if possible, or protecting the user from the effect. A severity rating of 9 or 10 is
generally reserved for
Step 3: Detection
When appropriate actions are determined, it is necessary to test their efficiency. In addition, design
verification is needed. The proper inspection methods need to be chosen. First, we should look at the current
controls of the system, that prevent failure modes from occurring or which detect the failure before it reaches the
customer. Hereafter one should identify testing, analysis, monitoring and other techniques that can be or have
been used on similar systems to detect failures. From these controls an engineer can learn how likely it is for a
failure to be identified or detected. Each combination from the previous 2 steps receives a detection number
(D).This ranks the ability of planned tests and inspections to remove defects or detect failure modes in time. The
assigned detection number measures the risk that the failure will escape detection. A high detection number
indicates that the chances are high that the failure will escape detection, or in other words, that the chances of
detection are low.

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 Failure Mode and Effect Analysis on Welding Aseembly Process

V. Conclusion And Results

 Proper early failure detection methods and potential failure prediction or detection is fundamental for
effective maintenance management. This reduces the probability of failure which leads to plant shut down
and thus improving OEE. To reduce the adverse effects of breakdown and to increase the equipment
availability at a low cost, FMEA Is a key reliability analysis tool that needs to be instituted in industrial set-
ups.

The FMEA benefits:

 prevention planning,
 identifies change requirements,
 cost reduction,
 decreased waste and warranty costs,
 reduce non-value added operations,
 systematic procedure,
 acknowledged procedure,
 knowledge transfer through departments,
 risk management instead of crisis management,
 Determination of failure modes.

Reference
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