Potential of error for arc welding processes: Where can i make mistakes and how they affect the component?

For example in vehicle or crane production and in the steel construction area - in many areas the weight reduction has a decisive influence on the development of new products. So modern, temperature-sensitive high-performance materials replace more and more unalloyed structural steels. The processing window by welding these materials is much smaller, so that the exact determination and compliance of the t8/5-value (cooling rate) is important. This is why the welding parameters and the exact determination of specific parameters have a great impact on the calculation and determination of the t8/5-value as well on the resulting mechanical and technological characteristics. Depending on the welding process, a variety of welding parameters, welding seam geometry, the welding position and the layer structure changes the heat input into the component. On the one hand, the efficiency is changed and on the other hand they affect the cooling behavior by more than 60%. Various welding processes and parameters are analyzed as well different error potentials discussed and following their impact will be illustrated. The summation of the possible errors shows that the compliance with the mechanical and technological characteristics, as well as the theoretical determination of these values, and the calculation and simulation of the resulting sizes like arrears, microstructure or internal stresses is practically insufficiently possible. Knowing the sources of error and the use of this knowledge gained at the TU Chemnitz has a large contribution to improve the quality of welded joints. At the end recommendations of necessary adaptions of actual standards are visualised.