APPENDIX K
SECTIONING OF WELDED JOINTS
ETCH TESTS
K-1
(a) Carbon and Low Alloy Steels. Etching solutions
suitable for carbon and low alloy steels, together with
directions for their use, are suggested as follows.
(1) Hydrochloric Acid. Hydrochloric (muriatic)
acid and water equal parts by volume. The solution
should be kept at or near the boiling temperature during
the etching process. The specimens are to be immersed
in the solution for a sufficient period of time to reveal
all lack of soundness that might exist at their cross-
sectional surfaces.
(2) Ammonium Persulfate. One part of ammonium
persulfate to nine parts of water by weight. The solution
should be used at room temperature and should be
applied by vigorously rubbing the surface to be etched
with a piece of cotton saturated with the solution. The
etching process should be continued until there is a
clear definition of the structure in the weld.
(3) Iodine and Potassium Iodide. One part of
powdered iodine (solid form), two parts of powdered
potassium iodide, and ten parts of water, all by weight.
The solution should be used at room temperature and
brushed on the surface to be etched until there is a
clear definition of outline of the weld.
(4) Nitric Acid. One part of nitric acid and three
parts of water by volume.
CAUTION: Always pour the acid into the water. Nitric acid causes
bad stains and severe burns.
The solution may be used at room temperature and
applied to the surface to be etched with a glass stirring
rod. The specimens may also be placed in a boiling
solution of the acid but the work should be done in
a well-ventilated room. The etching process should be
continued for a sufficient period of time to reveal all
lack of soundness that might exist at the cross-sectional
surfaces of the weld.
(b) The appearance of the etched specimens may be
preserved by washing them in clear water after etching,
removing the excess water, immersing them in ethyl
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alcohol, and then drying them. The etched surface may
then be preserved by coating it with a thin clear lacquer.
(c) Aluminum Alloy. The following etching solution
is suggested for revealing the macrostructure of welded
aluminum alloy specimens:
Hydrochloric Acid (conc.) 15 ml
Hydrofluoric Acid (48%) 10 ml
Water 85 ml
This solution is used at room temperature and etching
is accomplished by either swabbing or immersion of
the specimen. The surface to be etched should be
smoothed by filing or machining or by grinding on
No. 180 Aloxite paper. With different alloys and tempers
the etching period will vary from 15 sec to several
minutes and should be continued until the desired
contrast is obtained.
CLOSURE OF OPENINGS
RESULTING FROM SECTIONING
K-2
(a) Holes in welded joints left by the removal of
trepanned plug specimens may be closed by any welding
method approved by the authorized inspector. Some
suggested methods for closing round plug openings by
welding are as follows.
(1) Insert and weld in special plugs of which some
acceptable types are shown in Fig. K-2. Type (a) is
adapted to welding from both sides and should be used
wherever that method is practicable, and Types (b) and
(c) when access is possible only from one side. The
diameter of the filler plug shall be such as to make a
snug fit in the hole to be filled. Each layer of weld
metal as deposited shall be thoroughly peened to reduce
residual stresses. The 1⁄4 in. (6 mm) hole in the center
of the plugs shown in Fig. K-2 may afterwards be
closed by any reasonable method. Plain plugs without
a hole may be used.
(2) For joints where the thickness of the thinner
plate at the joint is not greater than one-third of the
 K-2 APPENDIX K — NONMANDATORY
FIG. K-2 SOME ACCEPTABLE TYPES OF FILLER
PLUGS
diameter of the hole, place a backing plate on the
inside of the shell over the opening and fill the hole
completely with weld metal applied from the outside
of the shell. Rebuild fillet welds where cut.
(3) For joints where the thickness of the thinner
plate at the joint is not less than one-third, nor greater
than two-thirds the diameter of the hole, fill the hole
completely with weld metal applied from both sides
of the shell. Rebuild fillet welds where cut.
(4) For butt joints where the thickness of the
thinner plate at the joint does not exceed 7⁄8 in. (22 mm),
chip a groove on one side of the plate each way along
the seam from the hole. The groove at the opening
shall have sufficient width to provide a taper to the
bottom of the hole, and the length of the groove on
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K-3
each side of the opening is to have a slope of approxi-
mately one to three. Use a backing plate on the side
opposite that on which the chipping is done or a thin
disk [not over 1⁄8 in. (3.2 mm) thick] at the bottom
of the hole and fill the groove and the hole with weld
metal.
(5) For butt joints, and for plates of any thickness,
chip a groove on both sides of the plate each way
along the seam from the hole. The groove at the
opening shall have sufficient width to provide a taper
to the middle of the plate, and the length of the groove
on each side of the opening is to have a slope of
approximately one to three. Place a thin disk [not over
1
⁄8 in. (3.2 mm) thick] in the hole at the middle of
the plate and fill the grooves and the hole on both
sides with weld metal.
(b) The following is a suggested method for closing
openings cut with a spherical saw: For butt welded
joints place a backing plate, where necessary, on the
inside of the vessel shell over the opening. For lap-
welded joints, a part of the parent plate remaining
opposite the removed weld will usually serve as a
backing plate. Fill the opening completely with the
weld metal. Rebuild fillet welds where cut.
K-3
Where gas welding is employed, the area surrounding
the plugs shall be preheated prior to welding.