TWI it ‘THE WELDING INSTITUTE CERTIFICATE IN VISUAL INSPECTION OF WELDS Course Ref. D73 OBJECTIVES OF COURSE Course Members, on completion of the course should: Be able to visually inspect a weld and sentence. Be able to identify and assess defect types, shapes and sizes. Use appropriate technical terms. Assess: Materials for compliance Consumables for compliance ‘Welding process for compliance Appreciate welding variables for a specific process. Be aware of typical documentation in welding END OF COURSE ASSESSMENT On successful completion of the course, each candidate may attempt an End of Course Assessment for the TWI Certificate of Competence in Visual Inspection © TWI 1994TW. ee CONTENTS: Section 1: Section 2: Section 3; Section 4: Section 5: Section 6: Section 7: Section 8: Section 9: Section 10: Section 11; Terminology Visual Inspection Procedures How do | carry out a visual inspection? Materials: Inspection points Welding Process Profile Sheets Consumables: Inspection points Defects which may be detectable by Visual Inspection Typical Documents Found in Welding Acceptance Levels Visual Inspection Report Sheets AppendixTWI Ua SECTION 1 TERMINOLOGY ‘THE WELDING INSTITUTTWI La ‘THE WELDING INSTITUTE SECTION ONE: TERMINOLOGY The Welding industry has its own special language and, like any other language, it is used for communication. It is important that everyone involved in welding uses this language, in order that personnel can interpret and understand specific tasks and requirements. Below are some examples of JOINTS and WELDS, BUTT JOINTS Cor 3 LE) Eh Square edge closed butt ‘Square edge open butt Single vea butt Single bevel byt PX} ft) Double yee butt Double bevel butt FILLET JOINTS Welding Technology © 1994 TEE LAP. CORNER 1TWI | Cm ‘THE WELDING INSTITUTE EXERCISE 1 To the single sided bevel and vee joints on the previous page, add the welds to the sketches to make both joints, WELDS. ij BUTT WELDS If you compare the results of the exercise with the person next to you, you may find variation in some of the weld features. This is because we all have different } ideas and views of how a weld should look visually. This will of course be addressed during the course. | BUTT WELD FEATURES Welding Technology © 1994TWI Li ‘THE WELDING INSTITUTE EXERCISE 2 Insert the appropriate terms it a= B= 42 9 b= 10= FILLET WELD FEATURES Welding Technology 3 © 1994TWI La ‘THE WELDING INSTITUTE EXERCISE 3 Insert the appropriate terms t= 6= a= T= ae a= aoe 9= co 5= ba Welding Technology © 1994TWI cla ‘THE WELDING INSTITUT SECTION 2 VISUAL INSPECTION PROCEDURESTWI La ‘THE WELDING INSTITUTE SECTION 2 - VISUAL INSPECTION PROCEDURES Before carrying out any form of inspection, it is essential that the inspector asks the following: What is the nature of the product? What operating conditions will be present? What is the quality of welding required? Is there a code or standard available to inspect the welds to? Asking these, and perhaps other questions, the Inspector will have a good idea of the requirements and can subsequently determine which points of inspection require the most emphasis. Overleaf is a summary of a ‘Welding Inspector's’ duties and responsibi Welding Technology 5 © 1994TWI a ‘THE WELDING INSTITUTE ! THE WELDING INSPECTOR ‘ RESPONSIBILITIES exgune: "ensure ENSURE COMPLIANCE WORKMANSHIP WELDING TO STANDARD OR CODE CAMERA By *POLICINGY WORK & BOCUMENTATICN: + armitures —— 1 HONESTY UTERACY FITNESS INTEGRITY —o_, PHYSICAL Eveslant ee OBSERVE MEASURE IDENTIFY BEFORE ‘DURING ARFER veo weipea wept MATERIAL VOLTAGE pwWar CONSUMABLES AMPERAGE VISUAL. WELDING PROCESSES ‘TRAVEL SPEED ASSESSMENT Jor Frrup INTERPASS TEMPERATURE NOT ASSESSMENT PREHEAT INTERPASS CLEANING. ‘TACKWELDINGICLAMPING. ALIGNMENT. CALIBRATION ‘SAFETY ‘ACCEPT ReJecT REPAIR COLLECT & COLLATE 7 ALL DOCUMENTS: LD. AREA { MARK OUT ‘CONCESSION WHICH MAY INCLUDE: REMOVE CODE OF STANDARD RE-WELD MATERIAL CERTIFICATES RE-INSPECT CONSUMABLE CERTIFICATES | GALIBRATION CERTIFICATES ORAWINGS(S) WELDING PROCEDURE APPROVAL CERTIFICATES. INSPECTION RECORDS PW HT RECORDS OTHER TEST RECORDS CONCESSIONS COMPLIANCE CERTIFICATES ‘ACCEPTANGE OF THE PRODUCT INSPECTOR PASSES THE DOCUMENT PACKAGE TO A HIGHER ‘AUTHORITY FOR FINAL APPROVAL Welding Technology © 1994TWI UL 2) documentation = | b) materials: parent ~ ©) weld preparations ~ | tp eweing- | e) welding equipment — | Welding Technology @ 1994 consumables ~ ‘THE WELDING INSTITUTE WELDING CHECKLIST 1. BEFORE WELDING COMMENCES. welding procedure approvals) welder approvals ) to code: weld map or drawing, Le. where the welds are, sizes etc. weld identification inspection procedures NDE procedures pre/post weld heat treatment procedures ~ methods, temperatures, times etc. correct specification correct storage and baking controlled issue and return batch identification correct specification identification - transference of cast marks forming activity procedures - rolling, pressing correct for the job machined or flame cut - note grinding sheared ~ thin plate - work hardened accurate and within tolerance forming activity procedures ‘accuracy of fit up ~ misalignment tack welding ~ incorporated in weld? safely ~ preheat manipulators etc, Iso, procedure approval, welder qualification, preheat and its maintenance/monitering maintenance and calibration condition correct consumables (wire, flux, gas) flux recirculation system (SAW)TWI Vit ‘THE WELDING INSTITUTE 2. DURING WELDING a) b) eo 4d) e) 9 9 A) a) ») a 4 C) Correct parameters and monitoring equipment WPS at the work-place Inter-run cleanliness inter run quality interpass temperature consumable contro! maintenance of preheat? process control NDE regime welding records and maintenance of weld maps WELDING COMPLETION visual inspection and recorés NDE: = working to procedure calibrated equipment records PWHT if required: . furnace or local (temp gradients) compliance with code recording of times and temperatures thermocouple positions Final testing: hydraulic test procedure leak test procedure proofjioad test procedure functional test procedure NDE Cleaning, painting, preservation, packing Final documentation package: WPS, WPAR. wa Consumable certs Material certs Inspection reports NDE reportsitest reports Heat treatment records Welding records Certificate of campliance/ authorised signatures Welding Technology © 1994TWI ASG THE WELDING INSTITUTE SECTION 3 HOW DO | CARRY OUT VISUAL INSPECTION?TWI La ‘THE WELDING INSTITUT! SECTION 3: HOW DO! CARRY OUT VISUAL INSPECTION The answer to this question is somewhat complex, in as much as it largely depends on the answers to the questions given on page one of Section 2 (Visual Inspection Procedures). For example, if a product is under vibration or cyclic loadirig thén the main problem to address could be toe biending or *sharp" toe defects. Equally, if a pipeline is carrying fluids it may be the degree of root penetration and resulting bore restriction which may be the most significant factor, therefore find out as much as possible about: The product Welding Technology © 1994 9TWI La ‘THE WELDING INSTITUTE The materials, welding process and consumable Welding Technology 10 © 1994TWI ci ‘THE WELDING INSTITUTE The allowable defects (Reference to the applicable code or standard) and, of course, the types of Joints being welded. a Welding Technology © 1994 nTWI i ‘THE WELDING INSTITUTE Features of a weld to be considered on visual examination SIZE For butt welded joints consider i | i > Excess weld metal height : foe Weld cap width oer Welding Technology 12 © 1994La SIZE For fillet welds consider: J I 7 SHAPE For butt welds consider: profile ‘THE WELDING INSTITUTE a) Minimum (and maximum) leg length size b) Minimum design throat thickness on ONO TF on rvs OR "Tet OR OR a Welding Technology © 1994 SES 1314 TWI La ‘THE WELDING INSTITUT ideally (a) is the most desirable but very often it may be difficult to achieve. Because of this one should assess both the excess weld height in conjunction with the weld profile and other factors previously stated. For fillet welds consider: OR () OR \ OR. © = } @ = j hy or = © = } ® (eee) In normal practice (a) is the most desirable but again in many instances it is difficult to achieve. OR Ly Welding Technology © 1994TWI La ‘THE WELDING INSTITUTE TOE BLEND Depending on the service conditions of the product the toe blend may be of greater importance then the size and shape of the weld. A poor toe blend may reduce service life by a considerable margin if the product is under a cyclic loading. For butt welds consider: c OR d e OR f For fillet welds consider: re a ‘ OR b rm © a OR d e c OR f -t Welding Technology © 1994 15TWI Vit ‘THE WELDING INSTITUT: Weld Width For butt welds consider: \ ' a OR b p_—____| epee rons i i e OR d = ej] J |_ —_—_~_— \ e OR f Srreenneeeneree ca sresterter ree ea pee] | pt j {stances aeaeUeee) One area that has not been looked at in this section is defects. These will be j considered in a future section but before determining specific defects assess the features of the weld. The main point to consider of all the previously mentioned factors is: CONSISTENCY. Welding Technology ie © 1994TWI VLE ‘THE WELDING INSTITUT the better Other factors may be of equal importance, but the more you know... A simple inspection procedure can be implemented. This may then ensure that the Inspector follows the same method each time, The Quality Control department may implement such 2 procedure for you to follow, depending on the nature of the product (and company). Welding Technology © 1994 17TWI Ua ‘THE WELDING INSTITUTE VISUAL INSPECTION ASSESSMENT FORM Visual Inspection of the Complete Weld Reference No. of weld ... [ v = Acceptable X = Non~Acceptable I Dimensions mm [ee eceaeeew t _Side 1 Side 2 Excess wm/Penetration bead = _ mm ___mm Weld Width ____mm —__mm Toe blend Weld Consistency Arc Strikes Spatter Grinding marks Mechanical damage Surface Colour mm Misalignment Angular Distortion Longitudinal Distortion Other comments: 18 mm in___mm mm: in___mm Welding Technology © 1994TWI Mat ‘THE WELDING INSTITUTE DEFECT ASSESSMENT FORM DEFECTS WELD FACE WELD ROOT MARK ‘A! FOR ACCEPTABLE MARK Rt FOR REJECTABLE CRACKS: INCOMPLETE SIDE FUSION INCOMPLETE INTERUN FUSION INCOMPLETE ROOT FUSION q TROONPLETE ROOT PENETRATION | - UNDERCUT DEPTH UNDERCUT BLEND UNDERCUT LENGTH EXCESS PENETRATION ROOT CONCAVITY OVERLAP Welding Technology © 1994 19TWI Ly ‘THE WELDING INSTITUTE WELD FACE WELD ROOT SOLID INCLUSIONS: SLAG SILICA, ] TUNGSTEN COPPER GAS INCLUSIONS: POROSITY WOAMHOLES | ISOLATED PORES| CRATER PIPES: OTHER: THE WELD, REFLNO. cen IS snsnecsneses TO THE STANDARD ... .. SIGNATURE .. DATE Welding Technology 20 © 1994TWI LL ‘THE WELDING INSTITUTE SECTION 4 MATERIALS: INSPECTION POINTSTWI VI ‘THE WELDING INSTITUTE SECTION 4: MATERIALS AND EDGE PREPARATIONS In order that the correct material grade or composition is used on the project, it is necessary for the Inspector to check 3 main areas: SIZE: The: Number of pieces (Number off) Thickness (abbreviated *) Length (abbreviated 't) Width (abbreviated ‘w') Diameter (abbreviated '¢' for pipes) TYPE: The : Composition of the material, e.g, : Grade of the material, e.g. : Tradename of the material, e.g. CONDITION: The surface condition: freedom from contaminants that may affect the welding or "in-service" operation 1. 10, Welding Technology © 1994 2tTWI Li ‘THE WELDING INSTITUTE ‘The heat treatment condition: has the material been correctly processed? These may present problems during the welding operation. 1. Welding Technology © 1994TWI Civ WIYHALVA 7 40 & AONVIda00"V 2 emavida00¥ earavidgoov a (erred } “SNOISTHONI BLO. SNOUWNINY] — .SCNVE Sd¥1_ "8 ALISOHOd TWIKBLYW | nee Meer een 33S TW, ‘103330 ASNIVeY eS3ONVESTOL wav.d300¥ ANaWLvauL TWOINVHOBW OMHSHL GauadWal = smu Hola INYd _ diviscuvu BHONAND —_SINIVd G3SMWAUON —asvauD UN ‘aaTvaNNy 0 NOUWOIsIINaOI { BIvos walanvid ANAVULVAWL IV3H ROvuNS Hai t $ ANaTvAINDa NOgEVS HINT TWOINYHOAW TOISAHd Bqvup SSANDOIHL t j ae | NowWaNoo aay azis 40 NOLLD3dSNI (S1431S SAOTIV MOT/NOHVO) NOLLOAdSNI STVINALLWW 23 Welding Technology © 1994TWI VLA ‘THE WELDING INSTITUT: Joint Preparations Many defects and/or imperfections may be caused by poor joint preparation. This can be attributed to the following: a. method of edge preparation b. finish of edge preparation c, details of edge preparation Method of Edge Preparation Thermal Cutting may cause hardness, oxidation, poor shape, distortion. ii) Machined edges may cause evolution of harmful gases during welding, poor shape, poor finish. iti) Sheared edges may cause evolution of harmful gases during welding, poor shape and work hardening, iv)” Grinding may cause poor shape, poor surface finish and inaccurate features, Joint features: For butt welds n, b. burnthrouigh; c.’shrinkage grooves, Gap size Too large: a. excess penetré d. gas entrapment. Too small: 1. incomplete penetration, 2, incomplete root fusion, 3, incomplete side walll fusion, 4. slag inclusions, 5. root concavity, ba\yf Jey 3feyy pS a Li} a Ea as A a ae Welding Technology © 1994 24TWI uae ‘THE WELDING INSTITUTE, Root Face Too large: (a) incomplete root penetration, (b) incomplete root fusion. Too small: 1, excessive penetration, 2. burnthrough, 3. root concavity, 4. root undercut. Taw) EN) MYA Lo oy Included angle Too large: a. excess penetration, b. incomplete filled groove Too small: . 1. incomplete root penetration, 2. incomplete interun fusion, 3. incomplete root fusion, 4. incomplete sidewall fusion, 5. excessive-cap, 6. poor toe blend, 7. slag inclusions. CY By Bd eS Welding Technology © 1994 25TWI La ‘THE WELDING INSTITUTE For fillet welds Gap size Too large: 1. reduced root penetration, 2, slag inclusions, 3. gas inclusions, 4. reduced vertical leg length size, 5. cracking. o a [7 2 i) 3 i be Poor fitup and joint preparations very often account for a large proportion of welding imperfections. The tips given here are for guidance only but one should always remember there is no such thing as the" perfect weld". Welding Technology 26 © 1994TWI La ‘THE WELDING INSTITUTE SECTION 5 WELDING PROCESS PROFILE SHEETSTWI LL TUNGSTEN INERT GAS (TIG) Completed Type of Operation Usually manual, but can be mechanised. Mode of Operation An arc is maintained between the end of a tungsten electrode and the work. The electrode is not consumed and the current is controlled by the power source setting. The operator must control the arc length and also add filler metal if needed to obtain the correct weld: consequently, 2 high degree of skill is needed for best results. The arc is unstable at low currents. Special provision is made for starting (h-f, or surge injection) and for welding thin materials (pulse TIG). In all cases the electrode and weld poo! are shielded by a stream of inert gas. Filler rod is fed into the weld pool in some cases. Welding Technology © 1994 ‘THE WELDING INSTITUTE. Tungsten arc gas shielded; Argon arc; Gas tungsten arc welding; GTAW (USA) Typical detects associated with this process: Tungsten inclusions. Lack of fusion. Incomplete penetr Undercut. Porosity. Burnthrough. Excess penetration. Oxide inclusions. Unequal leg length. 27TWI Za ‘THE WELDING INSTITU : TUNGSTEN INERT GAS ‘ALSO KNOWN AS ‘ GTAW. wie a ARG HELI ARC | GAS TUNGSTEN WOLFRAM UK TRADENAME U.S. TRADE ARG WELDING) = INERT NAME GAS ‘ NORMALLY AC, ‘Ar or Ho Shieiding Gas { DCEN. ARMg alloys FOR ALL MATERIALS (CATHODIC { EXCEPT Al & Mg. CLEANING) t WELDING VARIABLES i AMPERAGE VOLTAGE TRAVEL, GAS FLOW ELECTRODE 1 tole RATE rel CONTROLS CONTROLS DEPTH PROTECTS AFFECTS | OF WELD PENETRATION | musion'& ARC LENGTH PENETRATION FROM PENETRATION ATMOSPHERE TYPICAL DEFECTS TUNGSTEN ROOT POROSITY LACK OF : INCLUSIONS — CONCAVITY FUSION : ‘APPLICATIONS AEROSPACE — CRITICAL GENERAL MECHANISED MATERIALS ROOT RUNS UGHT APPLICATIONS IN PIPES FABRICATIONS, Welding Technology 28 © 1994TWI ae MANUAL METAL-ARC (MMA) Core view Flux coathg Solktted stag. Are ‘Type of Operation Manual, Mode of Operation Arc melts parent plate and electrode to form a'weld pool which is protected by flux cover: Operator adjusts electrode feed rate, ie. hand movement, to keep arc length constant. Slag. must be removed after depositing each bead. Normally. a small degree af penetration, requiring plate edge Preparation. Butt welds in thick plate or large fillets are deposited in a number of passes. The process can also be used to deposit metal to form a surface with alternative properties. Welding Technology © 1994 ‘THE WELDING INSTITUTE Shielded metal-are (US); Stick; Electric arc welding Typical defects associated with this process: Overiap. Porosity. Slag inclusions. Excessive spatter. Stray flash. Incomplete penetration. Excess penetration, Undercut. Crater cracks. Lack of fusion. 29TWI a ‘THE WELDING INSTITUTE MANUAL METAL ARC smick SMAW, WELDING us) (SLANG) : De. Ac, SITESHOP eT DCE. DGEN. ‘SHOP APPLICATIONS | | DEEP PENETRATION SHALLOW PENETRATION SIMILAR TO | | DOEPDCEN FILLET WELDS & ‘OPEN ROOT FILL & CAP PASSES BUTTS WELDING VARIABLES vouTs AMPS RUN OUT ELECTRODE LENGTH "ANGLES eed CONTROLS ‘SLOPE TT HEAT INPUT. 1 I 1 AFFECTS: BISECTS FOR EFFECTS SIMILAR PENETRATION ANGLE OF TO MIG/SA WELDING SOINT ‘CONSUMABLES (PRINCIPALLY) Basic RUTILE ‘CELLULOSIC TRON | mom Low Ht FOR GENERAL HIGH IN POTENTIAL PURPOSE NON- Hy HIGH (GAKING) CRITICAL APPLICATIONS | DEPOSITION ‘VERTICAL, IN FLAT “CRICAL* DOWN &HY, WELDS "STOVE PIPE" 1 WELDING TOUGHNESS MAY SUFFER TYPICAL DEFECTS SLAG LACK OF FUSION PROFILE, HP CRACKING INCLUSIONS PENETRATION DEFECTS APPLICATIONS PIPELINES. NOZZLES! MEDIUMIHEAVY STE NODES FABRICATIONS, APPLICATIONS Welding Technology 30 © 1994TWI La METAL INERT GAS (MIG) Copper contact tube ‘connected 79 the power supply unit } Gun nozzle Gas shletd are Completed veld ‘Type of Operation Manual, mechanised or automatic. Mode of Operation An arc is maintained between the end of the bare wire electrode and the work. The wire is fed at a constant speed, selected to give the required current, and the are length is controlled by the power source. The operator is not therefore concerned with controlling the arc length and can concentrate on depositing the weld metal in the correct manner. The process can be operated at high currents (250-500A) when metal transfer is in the form of a ‘spray’, but, except for aluminium, this technique is confined to weiding in the flat and horizontal positions. For vertical and overhead welding special low-current techniques must be used, i.e. ‘dip’ transfer or pulsed are, The arc and weld pool are shielded by a stream of gas. The electrode can be solid or flux cored. Welding Technology © 1994 THE WELDING INSTITUT Metal Active Gas (MAG); CO,; Metal-arc gas shielded; GMAW (US) Typical defects associated with this process: Incomplete penetration, Excessive penetration. Undercut. Excessive spatter. Cracking, Porosity. Lack of fusion. Stray flash. 31TWI Ww ‘THE WELDING INSTITUTE MIGMAG METAL INERTGAS — FLUXCORE = CO, GMAW. METAL ACTIVE GAS. wus) ALL DIRECT CURRENT (NORMALLY POSITIVE) (DIP TRANSFER ea TRANSFER SPRAY TRANSFER PULSE TRANSFER I LOW VOLTS MED VOLTS HIGH VOLTS: HIGH & LOW. vowawes” ” MED AMS HIGH AMPS VOLTS & AMPS THIN SHEET, FILLING PASSES THICK PLATE ee ROOT RUNS IN * USED MAINLY FLAT & HV. THICKNESS | BUTTS-ALL ©. WITH FLUX POSITIONS > 6mm POSITIONS —' CORED WIRES ONLY ~ ALL POSITIONS. WITH AL, WELDING VARIABLES euprone: INDUCTANGE WIRE FEED TRAVEL SPEED "GAS FLOW VOLTS 32 SPEED RATE, | (AMPs) | ‘AFFECTS : CONTROLS PROTECTS CONTROLS. AMPS, *“SMOOTHS' CONTROLS DEPTH OF WELD ARG ARC FUSION & PENETRATION FROM _ LENGTH CHARACTERISTIC PENETRATION ATMOSPHERE TYPICAL DEFECTS ALLLLAGK OF ‘SOLIDIFICATION POROSITY SILICA FUSION TYPES CRACKS/PIPES INCLUSION (SPRAY) (Fe ONLY) ee i APPLICATIONS ‘SOME OFFSHORE STRUCTURAL ALUMINIUM STAINLESS (FLUX CORE ONLY) STEEL SECTIONS ‘STEEL & NI ALLOYS SSS ay SEMI-AUTOMATIC OR MECHANISED OR AUTOMATED (ROBOTICS) Welding Technology © 1994TWI Lia SUBMERGED-ARC (SA) Wie electrode Granutar flux Type of Operation Mechanised, automatic or semi-automatic. Mode of Operation An arc is maintained between the end of a bare wire electrode and the work. As the electrode is melted, it is fed into the arc by a set of rolls, driven by a governed motor. Wire feed speed is automatically controlled to equal the rate at which the electrode is melted, thus arc length is constant. The arc operates under a layer of granular flux {hence ‘submerged’ arc). Some of the flux melts to provide a protective blanket over the Weld padl; the remainder of the flux is unaffected'and can be recovered and re-used provided it is dry and not contaminated. A semi-automatic version is available in which the operator has control of a welding gun which carries a small quantity of flux in a hopper. Welding Technology © 1994 ‘THE WELDING INSTITUTE Typical defects associated with this process: Porosity. Cracking. Slag inclusions. Incomplete penetration. Excessive penetration. Weld profile defects. Undercut. Lack of fusion. 33\ TWI VL ‘THE WELDING INSTITUT ‘SUBMERGED ARC ‘TRACTOR TYPE BEAM BOOM MULTI-HEAD TYPE TYPE TYPES Dec. AG. DCEP CEN USED ON ! t MULTI-HEAD DEEP SHALLOW SYSTEMS TO PENETRATION PENETRATION REDUCE 'ARC BLOW EFFECTS WELDING ‘SURFACING/ 1 ‘SOME WELDING SQ WAVE Ac, APPLICATIONS SIMILAR TO) DCEN & DCEP WELDING VARIABLES vouTs WIRE FEED =» TIPTOWORK = TRAVEL FLUX | SFEED (AMPS) DISTANCE ta i oepTH CONTROLS CONTROLS CONTROLS CONTROLS DEPTH PROPERTIES ARC LENGTH FUSION & ELECTRODE OF PENETRATION g PENETRATION EXT(NOT VISIBLE) PoRosmry. Flux CONSUMPTION WELD METAL PROPERTIES FLUXES: {—————________ AGGLOMERATED : FuseD uaer IN COLOUR TYPICAL DEFECTS. : DaRicwGotoun ae ‘AS FOR MIG WELDING sare ud Lol A POSSIBLE (BAKING) —_(@Cept silca inclusions) GOOD SURFACE | PRORLE) BEST PROPERTIES PROPERTIES REASONABLE APPLICATIONS. SHIP HEAVY CIRCUMEERENTIAL LONGITUDINAL CLADDING BUILDING FABRICATION WELDS (ROTATED ‘SEAMS. APPLICATIONS, VESSELS PIPELINES ‘SEMI AUTOMATIC/MECHANISED Welding Technology 1994 34TWI VI GAS WELDING Slovpbe oxygen Mode of Operation A fuel gas (usually acetylene) and an oxidant gas (oxygen) are mixed and burnt, The operator must manipulate the blowpipe to give the correct weld poo! size, and also add filler metal as required. The meiting is slow compared with arc processes, limiting the speed of work. The weld pool is shielded from atmospheric contamination by the burnt gas mixture which can be made mildly oxidising-or reducing. Welding Technology © 1994 ‘THE WELDING INSTITU Oxyacetylene (OA) Typical detects associated with this process: Unequal leg length fillet. Too concave butt weld profile, Too convex butt weld profile. Undesirable weld profile (lap, fillet). Excessive penetration. Excessive fusion of root edges. Burnthrough. Undercut along vertical member of fillet weided T joint. Root run too large with undercut in butt joint. Undercut both sides-of weld fate in butt joint. i * . Oxidised weld face. Overheated weld. incomplete root penetration in butt joints {single V or double V), Incomplete root penetration in close square T joint.TWI TL A ‘THE WELDING INSTITUT OXVIACETYLENE (FLAME TEMP. 3200°C) BLACK AVOID OL & AVOID Cu. MARCON CYLINDER "GREASE CONTACT ‘CONTACT “—— cyLINDER (3000 pei) (225 ps (228g (isan REGULATORS TO REGULATORS TO ‘yp 200 psi (Cuting) ‘yp 25 psi Sp 0 pl ewe) Mex pressure ¥p 7p FLASHBACK ARAESTOR FLASHBACK ARRESTOR i NON RETURN VALVE NON RETURN VALVE 1 1 HOSE (RED) ose Wwe FITTINGS AH, THREAD FITTINGS LH. THREAD BLOWPIPE & NOZZLES ~ 1,2:35,7,10,13,18.25, Refers 10 gas consumption (FT) [SMALL NOZZLES TO 10 = LEFTWARD TECHNIQUE LARGE NOZZLES 10.25 ~ RIGHTWARD TECHNIQUE RIGHTWARD leerano {HIN SHEET 4 PIPE BUTT WeLDS aoe Jp 80" NGLUDED ANGLE NO ROOT FACE SEOR ro = INGLUBED Aste awe TYPES Feeney 1 pagal xisinG hes eas NOZZLE TO GAS VELOCITY WORK DISTANCE | sa OF Or LACK OF FUSION PENETRATION 36 Gansurisinis FOR HARDFACING. WELDING BRASS (og. STELUTE) & BRONZE 4 BRAZING STEELS ) WELDING STEELS PROCESS VARIABLES TRAVEL SPEED NOZZLE SIZE TECHNIQUE FUSION & QUANTITY OF QUANTITY OF PENETRATION EAT HEAT TYPICAL DEFECTS OVERHEATED OVERLAP’ —OXIDISED WELD WELD Welding Technology © 1994TWI Via ‘THE WELDING INSTITUTE SECTION 6 CONSUMABLES: INSPECTION POINTSTWI Vit ‘THE WELDING INSTITUTE SECTION 6: CONSUMABLES ‘As the mechanical properties of the welded joint are greatly affected by the consumables used to make the weld, it is essential that the Inspector confirms the correct: ‘ ELECTRODE (MMA) WIRE (MIG/MAG & SUB-ARC) ROD (TIG & GAS WELDING) FLUX (SUB-ARC & GAS WELDING) SHIELDING GAS (TIG & MIG WELDING) Similar to materials, inspection of 3 main areas apply. These are: | SIZE: For ELECTRODES the diameter and length | For WIRES the diameter and weight “| For RODS the diameter and weight For FLUX in Submerged Arc the diameter/size of the particle For SHIELDING GAS the cylinder size and pressure. TYPE: ELECTRODES: Tradename, brand name, specification:and grade flux coverings: GASES/FLUXES/RODS & WIRES: Tradename, brand name, specification and grade.in many instances, it may also be necessary to check the BATCH NUMBERS. 1 CONDITION: It is essential that any consumable is in a first class condition. In order that this can be achieved (and maintained), the following may be necessary: Good Storage: Considerations should be made of: Humidity, Temperature : stacking, issue and return, date of purchase and perhaps some others. Packaging: The inspector should ensure good “housekeeping procedures", therefore unused consumables must be returned to their original packaging. Baking and Drying. In order that MMA electrodes and, for submerged are welding, fluxes are low in moisture content, it may be necessary to heat treat the consumable in order to avoid cracking in the weld, Welding Technology © 1994 37TWI La ‘THE WELDING INSTITUTE Consumable manufacturers also have to meet stringent “approvals”. Below are some of the organisations which give such approvals. @ RECOGNITION CERTIFICATE Welding Technology © 1994TWI CL ‘THE WELDING INSTITU SECTION 7 DEFECTS WHICH MAY BE DETECTABLE BY VISUAL INSPECTIONTWI La ‘THE WELDING INSTITUTE SECTION 7: DEFECTS WHICH MAY BE DETECTED BY VISUAL INSPECTION It should not be forgotten that visual assessment of a weld is, in many circumstances, one small part of the total inspection process. On many products, non-destructive testing (NDT) is applied, perhaps confirming "visual uncertainties". Also, very often it may be employed to locate defects that cannot be seen with "naked eye" (although in some instances the use of low power magnification may be used, typically 2-2% diameters). ‘Therefore, if NDT is not being employed, it may be necessary to carry out more extensive visual inspection which may involve longer inspection times. However, visual inspection normally requires assessment of the consistency of the weld features (Refer Section 1) and of the defects that are present. FOOTNOTE: Most codes and standards use the term ‘DEFECT’ but this word implies unacceptable, e.g. it is DEFECTIVE. Therefore a more appropriate term is IMPERFECTION. This is because many weld "defects" may prove to be acceptable to acceptance levels quoted in some International codes and standards. Welding Technology 39 © 1994TWI La ‘THE WELDING INSTITUI BS 5289 lists the defects which can be identified by visual inspection after welding. In addition there are a number of defects which are not specifically mentioned in BS 5289, but which may be cause for rejection. Defects which can be detected by visual inspection can be grouped under five headings: 1. Root defects Ta Se Area to be 2. Contour defects inspected ly 3. Surface irregularities 4. Surface cracks 5, Miscellaneous Standard Terminology for Defects The terminology relating to defects in fusion welds has been standardised in BS 499, In this Standard the defect is described briefly and is given an identification number. Definitions of defects which can be found by visual examination are given on the following pages. Those mentioned specifically in BS 5289 are indicated by an asterisk after the BS 499 code number. Welding Technology © 1994TWI Lat ‘THE WELDING INSTITUT) Group 1 Root Defects 60 022* Incomplete root penetration Failure of weld metal to extend into the root of a joint. 60020 Lack of root fusion Lack of union at the root of a joint. 60001* Excess penetration bead Excess weld metal protruding through the root of a fusion weld made from one side only. 60.002* Root concavity (suck-back; tinderwashing) A shallow groove which may occu in the root of 4 butt weld. 60 004* Shrinkage groove Ashallow groove caused by contraction in the metal along each side of a penetration bead. 60039 Burnthrough Mesied tue 8 CBT D A localised collapse of the molten pool due to excessive penetration, resulting in 2 hole OZ, in the weld run. Welding Technology © 1994 4TWI VL Group 2 Contour Defects 60 003 00 000* | 00 000* 42 incompletely filled groove A continuous or intermittent channel in the surface of a weld, running along its length, due to insufficient weld metal. The channel may be along the centre or along one or both edges of the weld. Bulbous contour {not BS 489 term) Unequal legs {not BS 499 term) Variation of leg length on a fillet weid. N.B. Unequal leg lengths may be specified as part of the design — in which case they are not defects. ‘THE WELDING INSTITUT. Cw} WH (CO te ap a cf, Welding Technology © 1994TWI Law ‘THE WELDING INSTITUT Group 3 Surface Irregularities 60 006" Undercut An irregular groove at 2 toe of a tun in the parent metal or in previously deposited weld metal. (The inspector must determine if the undercut is continuous or intermittent.) 60007" Overlap An imperfection at the toe or root of a weld caused by metal flowing on to the surface of the parent metal without fusing to it. 60029. Gas pore A cavity, generally under 1.5mm. in diameter formed by trapped gas during the solidification of molten metal, 60 031 Porosity A group of gas pores. 60038 Crater pipe 5 A depression due to shrinkage at the end of a run where the source of heat was removed. CITOID Crater pipe Welding Technology © 1994 éTWI La ‘THE WELDING INSTITUTE Group 4 Surface Cracks 60015" Crack A linear discontinuity produced by fracture. Cracks may be longitudinal, in the weld metal, ie. centreline longitudinal, in the parent metal transverse crater (star cracking) Welding Technology © 1994TWI it Group 5 Miscellaneous 32 104 10 031 Stray flash (stray arcing) 1. The damage on the parent material resulting from the accidental striking of an are away from the weld. 2. The accidental striking of an arc away from the weld. Note that the same term is used for both the action and the result. Spatter Globules of metal expelled during welding on to the surface of parent metal or of a weld. Weiding Technology © 1994 ‘THE WELDING INSTITUTE °S Saaeseces e eTWI Li ‘THE WELDING INSTITUTE eeepc aera ae seramer aw ncunt 073/00! merece Tg S57 agp Meermena bean i ae eee eet ge Se es eases coremece o0/a0/ Smee Foe Seite (jlbne _visreueserecrs—t ESE eomehn aeeet rye Zon] PIPE Senet. SEG Noeene” heed Pame Kira "Siinbe — neceronede Sean Acicuneur ‘wor mere] EXERCISE 4 Above is an example of a typical visual inspection report which is required for the end of course assessment. Although the report is concise and well presented, unfortunately the Inspector has failed to SENTENCE the weldment to the applicable standard. WHAT IS YOUR OPINION, IS THE WELD ACCEPTABLE OR NON-ACCEPTABLE TO THE STANDARD? 46 Welding Technology © 1994TWI Lia ‘THE WELDING INSTITUTE SECTION 8 TYPICAL DOCUMENTS FOUND IN WELDINGTWI Lat ‘THE WELDING INSTITUTE DOCUMENTATION Many of us find the “paper work" to be an unnecessary evil. The fact is, that in today's quality conscious market, the paperwork is part and parcel of the manufacturing process. ‘These documents are useful in many different circumstances, it may tell the inspector, for instance, that the welder is not competent on this type of work; the welding amperage is inaccurate; the material may, when welded, crack. Therefore, it provides a useful source of information and helps with the inspection procedure as discussed in Section 3, Overleaf are specimen documents that you may find contact with. Do remember the inspector's responsibility of the documentation requirement which can be found on page 6 Section 2. Welding Technology L 47 © 1994‘THE WELDING INSTITUTE TWI a ro [ow [on % SIshjeuy [eaqEYD, sequin 3529 TUN ondunseg ronpoig TOY Suauicisng, ON sBeg seworsng ALVOWILYAD LsaL Iwiualvw © 1994 Welding TechnologyTWI La JOE BLOGGS CONSUMABLES SUPPLIES ‘Abington Hall, Abington, Cambridge CB1 6AL Telephone (0223) 891162 ' Telefax (0223) 891630 CONSUMABLE TEST CERTIFICATE CERTIFICATE OF CONFORMITY DATE ... ORDER NO. Prost 8 ‘Spectator BSS 501 Pat 19 Milos. Spamate 100A _ Six: 1.8m Troe 8 ‘oerng Corte ‘cabveacn na O7SS23138 Conary 3855040 We hereby certify that the above material, unless stated to the contrary, is covered by the Suppliers Certificate of Conformity/Test Certificate as detalled, and has been subjected to the Company's Quaity Control Procedures. Signed {for and on behalf of Joe Bloggs Consumable Supplies) Welding Technology © 1994 ‘THE WELDING INSTITUTE 49TWI ‘THE WELDING INSTITUTE MANUFACTURER'S WELDING PROCEDURE SPECIFICATION (WPS) [poe EN 25-2) Examine tat Bod BILD ‘ecnease 8 atnod of Prapaiion and Canin bACHINE Tamera Theenens n= 15r0% (utaaa Dlamevee me ase oai a eas |r eae eee vee | ome fre] eae [om fee feet | ee] tee | C[ a famemesa em _[ ea [ffi | serra cara go ear ee ae gs es oo ert sel a) Gp eco cet fae me gts ego meer | em pes fae | eee eae ‘Fit etal Classteaton aed rae nae SOUOCHETAL SUPERGFOM 316, 1 150 3581-81123 723.. ‘nv pec ating o Dyn ORY 102C FOR? HOURS QUIVER AT 75m SiReae ing SAGES COMMERODL PURITY onnece Ober bommlonh aa (cas Fow fata” Sng ‘ching’ 4 UTRESNUTEN “TungtenEtcrode Type 2 THORUM 28 kone Dail ot eck ceupoptacing -RETAM UNTIC AUN § ONWARD. Prenat Tampere MONE nn Ire Torperatne 6G WAHL ‘Stand ei tines NOY AEOURED Pama wading ta NOT REQURED {orem angesILT 90 SLOPE 7 Welding Technology © 1994TWI ‘THE WELDING INSTITUTE WELDER APPROVAL TEST CERTIFICATE Welding Technology © 1994 :i orl ech 7. OF st As | He I ao A oe bt i t Ned : V=¥ No NoLLDas Davey Hany aS Lb $9 !Soans aaam| vesocy ROrTusTa S538 , 30790, sae Bt e — = == = b H : 8 sa t | DOE © 1994 Welding Technology 52