High-low misalignment

Physical-Chemical Mechanism of Action

An edge misalignment causes an uneven load distribution at the joint during welding. The higher side is loaded more and can cause stresses that extend beyond the material.

Metallurgical Relevance & Risks during Welding

An edge misalignment increases the likelihood of cracks and bending stresses in the weld. The uneven load can cause localized stress concentrations that may overload the material and cause hot cracks or fractures.

Workshop Practice & Instructions

To minimize edge misalignment, the components should be aligned accurately. A maximum tolerance of 0.1 mm is common. For larger edge misalignments, pretreatment such as grinding or smoothing may be necessary to compensate for the height difference.