Thermal Energy

The most important manufacturing process in the energy industry is welding. The generation of thermal energy in welding happens through friction between the workpiece, plastic deformation of the workpieces, and the welding tool.

Most of the thermal plants are large industrial installations useful for generating electricity on a vast scale. These thermal power plants use a wide range of fuels to process heating liquid and convert them to steam. The steam generator or a boiler is the most integral part of a thermal plant. It burns the fuel to generate heat, which upon transferring to water converts to steam, which is boiling.

In power generation, from both existing as well as new plants, materials play a vital role. Coal, nuclear, and oil/ gas are energy supplies. The designing of high-efficiency power plants presently requires materials with an improved mechanical property and should be corrosion resistant even under elevated temperature, aggressive gaseous environment, and stress—most of these materials need welding during their initial fabrication and plant maintenance stage. Again, the severe strain and thermal cycles associated with welding can produce large gradients, usually associated with some detrimental changes to material properties.

Industrial Welding
Thermal Energy

Some common weld defects in thermal power plants

The following are some of the common welding defects usually found during welding processes in thermal power plants –


  • Slag inclusions
  • Porosity
  • Excess penetration
  • Undercuts
  • Incomplete fusion
  • Cracks
  • Inadequate joint penetration
  • Welding debris

These welding defects can be removed using innovative welding technology is useful by way of weld monitor or weld data monitoring. Various welding control equipment such as weld monitor current sensor timer, sensory arc timer, and welding arc timer help achieve the perfect weld every time, thereby reducing risks.