V.W.I - 3.0 Theory & Practical

CSWIP Visual Welding Inspection
Welcome
Course reference WIS 1
Sharul Rohaizad
World Centre for Materials Joining Technology Copyright 2006, TWI Ltd
The Course
The Visual Welding Inspector course provides
an introduction to welding inspection topics
Whats in it ?
A mixture of welding inspection and
quality related topics
Sharul Rohaizad
Course Topics
Roles and duties of a Visual Welding
Inspector
Welding gauges
Inspection reporting
Welding defects
Joint types
An introduction of welding processes
Codes and standards
Sharul Rohaizad
Course Assessment
Exam after the course No continuous
is completed assessment
Sharul Rohaizad
CSWIP Certificate Scheme
Certificate Scheme for Welding & Inspection
Personnel
10,000 certificate holders

Sharul Rohaizad
CSWIP Certificate Scheme
Level 1: 3.0 Visual Welding Inspector
Level 2: 3.1 Welding Inspector
Level 3: 3.2 Senior Welding Inspector
For further examination

information please see website
www.cswip.com
Sharul Rohaizad
CSWIP 3.0 Examination
Closed book exam
Any standards required on for the examination will be

provided during on the examination day
Sharul Rohaizad
CSWIP 3.0 Examination
Before attempting the examination, you must provide the
following
1. Two passport size photographs, with your name and
signature on reverse side.
2. Eye test certificate, the certificate must show near vision and
colour tests.
3. Completed examination From, you can print from the
website www.twisea.com.
4. Your current CV / Resume, your CV must be emailed or
faxed to the following for evaluation by the examination
manager.
E-mail: shajprem@twisea.com
Fax: +60 3 61572378
Sharul Rohaizad
CSWIP 3.0Examination
Practical A2: The inspection of a plate butt weld

sample code provided
1 Hour 30 mins
Practical part B2: The inspection of a T-Fillet

weld code ISO 5817
1 Hour 15 mins
Total examination time 2 hours 45 minutes
Sharul Rohaizad
Notification of Examination
Results
70% pass
mark
For every section to be

awarded the certificate
2 copies of certificates and an identity card sent to

delegates sponsor Sharul Rohaizad
CSWIP Examination Renewals
5 years 10 years
CV assessment Renewal examination
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Certification Scheme for
Welding & Inspection Personnel
recognised worldwide
Sharul Rohaizad
TWI Headquarters
CSWIP Secretariat Tel: + 44 (0) 1223 891162

TWI Certification Ltd Fax: + 44 (0) 1223 894219
Granta Park E-mail: twicertification@twi.co.uk
Great Abington
Cambridge CB1 6AL, UK Sharul Rohaizad
CSWIP Visual Welding Inspection
Course Reference WIS 1

Sharul Rohaizad
How Do I Carry out a Visual Inspection?
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 against
Sharul Rohaizad
Main Responsibilities
Code compliance
Workmanship control
Documentation control
Sharul Rohaizad
Personal Attributes
Honesty
Integrity
Knowledgeable
Good communicator
Physically fit.
Sharul Rohaizad
Duties of a Visual Welding Inspector
Duties Before Welding
Duties During Welding
Duties After Welding
Sharul Rohaizad
Visual Welding Inspectors Check List
Before Welding Commences
Familiarization to the relevant code and specification
Check welding equipment and calibration certificates
Material identification,size,type and condition
Consumables type,size,condition,storage and handling
Review/witness WPS and PQR test and record
Joint preparation( check)
Welder qualification test( Review/witness)
Welding process involved
Check pre-heating before welding ( if required)
Sharul Rohaizad
During Welding
Check weather condition
Check clearance for welding/welder
Check welder identification for weld
Check consumables as per WPS used
Check welding parameters as per WPS used
Check distortion control
Check interpass cleaning
Check run out length ( travel speed)
Check interpass temperature
Check usage of line up clamps
Maintain daily log book Sharul Rohaizad
After Welding Completion
Perform visual inspection

Weld and welder identification ( check)
Post weld heat treatment ( if required)
Non-destructive Testing ( witness)
Acceptance standards of NDT
Repairs (if any)
Dimensional check ( as per drawing)
Document control - welding reports etc
Sharul Rohaizad
Summary of Duties
It is the duty of a Visual Welding Inspector to ensure all the
welding and associated actions are carried out in accordance
with the specification and any applicable procedures.
A Welding Inspector must:
Observe
To observe all relevant actions related to weld quality
throughout production.
Record
To record, or log all production inspection points
relevant to quality, including a final report showing all
identified imperfections
Compare
To compare all recorded information with the
acceptance criteria and any other relevant clauses in the
applied application standard Sharul Rohaizad
Visual Welding Inspectors Equipment
Measuring device e.g flexible tape, steel rule

Temperature indicating crayons
Welding gauges e.g. TWI multi-purpose gauge
Voltmeter
Ammeter
Magnifying glass
Torch/flash light
Sharul Rohaizad
Any Questions
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Welding Terms
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Joint Terminology
Edge Open & Closed Corner Lap
Tee Butt
Cruciform Sharul Rohaizad
Welded Joint Terminology
Compound Fillet Butt
Edge Spot Plug

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Types of Joint Preparation
Included angle Included angle
Angle of
bevel
Root
Radius
Root Face Root Face

Root Gap Root Gap
Single -V Butt Single - U Butt

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Types of Joint Preparation
Angle of Angle of
bevel bevel
Root
Radius
Root Face Root Face

Root Gap
Root Gap Land
Single Bevel Butt Single J Butt
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Single Sided Joint Preparation
Single sided preparations are normally made on thinner
materials, or when access form both sides is restricted
Single Bevel Single Vee
Single J Single U
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Double Sided Joint Preparation
Double sided preparations are normally made on thicker
materials, or when access form both sides is unrestricted
Double Bevel Double Vee
Double J Double U
Sharul Rohaizad
Weld Zone Terms
Weld zone
Face
A B
Weld
metal Fusion
zone
Heat
Affected
Zone Weld
Junction
C D
Root
A, B, C & D = Weld Toes
Sharul Rohaizad
Butt Weld Features
Weld cap width
Excess
Cap height
or Weld
Reinforcement
Excess Root
Penetration Root bead width
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Toe Blend Angle
6 mm
Most codes quote the weld
80 toes shall blend smoothly
This statement is not
quantitative and therefore open
Poor Weld Toe Blend Angle to individual interpretation
The higher the toe blend angle
3 mm the greater the amount of
stress concentration
20
The toe blend angle should be
between 20o-30o
Improved Weld Toe Blend
Angle Sharul Rohaizad
Butt Weld Exercise
Butt Weld Features
Identify the butt weld features shown
10
7 8
9
2
1
5 3 4
6 Sharul Rohaizad
Butt Weld Exercise Answers
Butt Weld Features
1.Cap height
2. Weld toes
3. Fusion junction
10
4. HAZ
5. Plate thickness 8
7 9
2
1
5 3 4
6 Sharul Rohaizad
Butt Weld Exercise Answers
Butt Weld Features
6. Plate width
7. Plate & weld length
8. Weld width
9. Cap contour 10
10. Convex cap profile

7 8
9
2
1
5 3 4
6 Sharul Rohaizad
Fillet Weld Profiles
Mitre fillet Convex fillet
A concave profile is
preferred for joints
subjected to fatigue loading
Concave fillet
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Fillet Weld Leg Lengths
a. = Vertical leg length

b. = Horizontal leg length
Sharul Rohaizad
Fillet Weld Throat Thickness
b
a. = Design Throat Thickness
b. = Actual Throat Thickness
Sharul Rohaizad
Deep Penetration Fillet Weld Features
a
b
a. = Design Throat Thickness

b. = Depth of Penetration
Sharul Rohaizad
Fillet Weld Dimensions
a = Design / Theoretical
throat thickness
s = Effective design throat
b = Horizontal leg length

c
c = Vertical leg length
e.g
Leg length = 6mm
Design Throat = 6mm x 0.7
a Design Throat = 4.2mm
b s
The leg length should be approximately equal to the
material thickness
The design throat thickness is 0.7 of the leg length
Sharul Rohaizad
Fillet Weld Exercise
Fillet Weld Features
Identify the fillet weld features shown
10
4
9
7
2 5
3 8
1
6 Sharul Rohaizad
Fillet Weld Exercise Answers
1.Horizontal leg length
2. Vertical leg length
3. Plate thickness 10
4. Weld width
4
5. Plate/weld length 9
7
2 5
3 8
1
6 Sharul Rohaizad
Fillet Weld Exercise Answers
6. Plate width
7. Plate height
8. Root 10
9. HAZ
4
10. Weld toe 9
7
2 5
3 8
1
6 Sharul Rohaizad
Welding Positions
Flat: PA / 1G:
Flat PA / 1F
Vertical upwards
PF / 3G
Horizontal vertical:
PB / 2F: Horizontal vertical:
PC / 2G:
Overhead Vertical downwards

Horizontal overhead PE / 4G PG / 3G
PD / 4F Sharul Rohaizad
Welding Positions
PF / 5G PG / 5G
PA / 1G
Weld: Flat Weld: Vertical upwards Weld: Vertical
Pipe: rotated Pipe: Fixed downwards
Axis: Horizontal Axis: Horizontal Pipe: Fixed
Axis: Horizontal
PC / 2G H-LO 45 / 6G
Weld: Horizontal vertical Weld: Upwards
Pipe: Fixed Pipe: Fixed
Axis: Vertical Axis: Inclined
Sharul Rohaizad
Any Questions
Sharul Rohaizad
Weld Defects
Sharul Rohaizad
World
Copyright Centre
2004 for Materials Joining Technology
TWI Ltd Copyright 2006,M.S.Rogers
TWI Ltd
Fusion Weld Defects
Defects which may be detected by visual inspection can

be grouped under five headings
Root Defects
Contour Defects
Surface irregularities
Surface cracks
Miscellaneous
Sharul Rohaizad
Weld Root Defects
Sharul Rohaizad
Weld Root Defects
Low Amps/volts
Large Root face
Small Root Gap

Lack of root fusion
Fast Travel Speed
Incorrect Electrode Angle
Contamination
Lack of root penetration
Sharul Rohaizad
Weld Root Defects
Lack of root fusion Lack of root Penetration
Sharul Rohaizad
Weld Root Defects
A shallow groove, which may occur in the root of a butt weld
Root faces too large
Root gap too large
Excessive back purge pressure

during TIG welding
Excessive root bead grinding before

Root Concavity the application of the second pass
Sharul Rohaizad
Weld Root Defects
Root Concavity
Sharul Rohaizad
Weld Root Defects
Root penetration bead in excess in accordance with the

relevant specification being used
Root faces too small
Root gap too large
Excessive amps/volts
Slow travel speed

Excessive root penetration
Sharul Rohaizad
Weld Root Defects
Excessive root
penetration
Sharul Rohaizad
Weld Root Defects
A shallow groove caused by contraction in the weld

metal along each side of the penetration bead
Insufficient weld metal deposited

in the root pass
Too fast a cooling rate during the

application of the root bead pass
Poor welding technique
Shrinkage groove
Sharul Rohaizad
Weld Root Defects
A localized collapse of the weld pool due to excessive

penetration resulting in a hole in the root run
High Amps/volts
Small Root face
Large Root Gap
Slow Travel Speed
Burn through
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Weld Root Defects
Burn Through
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Weld Root Defects
Root Coking/Oxidized Root
Loss or insufficient back
purging gas
Most commonly occurs when

welding stainless steels
Purging gases include argon,

helium and occasionally
nitrogen
Sharul Rohaizad
Contour Defects
Sharul Rohaizad
Weld Contour Defects
Poor Toe Blend Excessive Weld Metal
Poor Cap Profile & Poor Toe Blend Sharul Rohaizad
Incomplete filled groove Incomplete filled groove +

(Underfill) Lack of sidewall fusion
Incomplete filled groove + Lack of sidewall fusion

Sharul Rohaizad
(Underfill)
Poor stop/starts
Sharul Rohaizad
Fillet Weld Unequal Leg Lengths
A variation of leg lengths on a fillet weld
Note: Unequal leg lengths on a fillet weld may be specified

as part of the design, in which case it will not be
considered as a defect.
Sharul Rohaizad
Surface Irregularities
Sharul Rohaizad
Cap & Root Undercut
An irregular groove at the toe of a weld run in the
parent metal
Excessive amps/volts
Excessive travel speed
Incorrect electrode angle
Excessive weaving
Incorrect welding technique
Electrode too large
Sharul Rohaizad
Cap Undercut
Intermittent Cap Undercut

Sharul Rohaizad
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
Contamination
Slow travel speed
Incorrect welding technique
Current too low
Sharul Rohaizad
Weld Overlap
Toe Overlap
Butt weld
Toe Overlap
Fillet weld
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Crater Pipe
Weld crater
Crater pipe
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Crater Pipe
Crater pipe is a shrinkage defect and not a gas defect, it

has the appearance of a gas pore in the weld crater
Crater cracks Too fast a cooling rate

(Star cracks)
Deoxidization reactions
and liquid to solid
volume change
Contamination
Crater pipe
Sharul Rohaizad
Cracks
Classified by Shape Classified by Position
HAZ
Longitudinal
Centerline
Transverse
Crater
Branched Fusion zone
Chevron Parent metal
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Cracks
Longitudinal parent metal crack Transverse weld metal crack
Longitudinal weld metal crack Lamellar tearing

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Miscellaneous Defects
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Accidental striking of the arc
onto the parent material
Faulty electrode holder
Poor cable insulation
Poor return lead clamping
Arc strike
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Spatter
Excessive current
Damp electrodes
Contamination
Incorrect wire feed speed when

welding with the MAG welding
process
Sharul Rohaizad
Other Associated Weld Defects
Cavities
Solid inclusions
Set up irregularities
Parent material defects
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Inclusions
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Gas Cavities
Gas pore
Cluster porosity Loss of gas shield
(Porosity)
Damp electrodes
Contamination
Arc length too large

Blow hole
Damaged electrode flux

Herringbone porosity
Moisture on parent material
Welding current too low
Root piping
Sharul Rohaizad
Gas Cavities
Porosity
Root piping
Sharul Rohaizad
Solid Inclusions
Slag inclusions are defined as a non-metallic inclusion
caused by some welding process
Slag originates from welding
flux
MAG and TIG welding process
produce silica inclusions
Slag is caused by inadequate
Slag inclusions Lack of sidewall
fusion with cleaning
associated slag
Other inclusions include
tungsten and copper inclusions
from the TIG and MAG welding
process
Parallel slag lines Sharul Rohaizad
Set-up Irregularities
Plate/pipe Linear Misalignment

(Hi-Lo)
Poor fit-up
Angular Misalignment
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Linear Misalignment
Linear Misalignment
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Mechanical Damage
Chipping Marks
Mechanical Damage/Grinding Mark

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Parent Material Defects
A welding inspector should also inspect the parent

material for any visible defects
Mechanical damage Lap
Lamination
Segregation line
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Plate Lamination
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Any Questions
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An Introduction to Welding Processes
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World
Copyright Centre
TWI Ltd
Welding Processes
Welding is regarded as a joining process in

which the work pieces are in atomic contact
Common Fusion welding processes

Oxy-acetylene
MMA (SMAW)
MIG/MAG (GMAW)
TIG/TAG (GTAW)
Sub-arc (SAW)
Sharul Rohaizad
Manual Metal Arc Processes (MMA)
The MMA welding Process was first developed in the late 19th
century using bare wire consumables.
MMA is a simple process in terms of equipment

The process can by used in AC, DC+ or DC-
The process is a manual process and demands a high skill
from the welder.
Electrode
core wire The process is widely used throughout the
Electrode weldingindustry both for shop and site
covering
working conditions
Electric Arc
Gas shield Solidified slag
Molten weld pool Build up of weld metal

Penetration USA: SMAW
Parent material Sharul Rohaizad
Manual Metal Arc (MMA)
The three main electrode covering types
used in MMA welding
Rutile - general purpose
Basic - low hydrogen
Cellulose - deep penetration/fusion
Sharul Rohaizad
Checks when MMA Welding
The welding equipment
A visual check should be made on the equipment to ensure it
is in good working order
The electrodes
Checks should be made to ensure that the correct
specification of electrode is being used, the electrode is the
correct diameter and in good condition. In the case of basic
fluxed electrodes ensure the correct heat treatment is being
carried out before use
e.g Baked at 350oC, holding 150oC, quiver temps 70oC
Cellulose and rutile electrodes do not require pre-baking but
should be stored in a dry condition. Sharul Rohaizad
Advantages & Disadvantages
Advantages Disadvantages
Field or shop use High welder skill required
Range of consumables Low operating factor*
All positions High levels of fume
Portable Hydrogen control (flux)
Simple equipment Stop/start problems
* Comparatively uneconomic when compared with

some other processes i.e MAG, SAW and FCAW
Sharul Rohaizad
Arc Blow / Wander
Arc blow is the deviation of
the arc due to magnetic
influences.
Arc blow occurs using DC Electrode
current only Magnetic

flux
The occurrence of arc blow
may cause the following
problems
Poor penetration/fusion
Poor cap profiles
High spatter
Welding
General manipulation arc
problems Sharul Rohaizad
Precautions Against Arc Blow
If the procedure allows Change the electrodes
change welding current from angle, opposite to the arc
d.c. to a.c. blows direction.
Hold as short an arc as If possible weld towards
possible. heavy tack welds or
Reduce welding current previously deposited welds.
(within the procedures range) Wrap ground cables (return
leads) around the work
piece .
De-magnetise component
being welded
Sharul Rohaizad
Manual Metal Arc Basic Equipment
Control panel Power source

(amps, volts)
Electrode Holding oven

oven
Electrodes Inverter power
source
Return lead
Electrode holder
Welding
visor/filter Power cables
glass
Sharul Rohaizad
Tungsten Inert Gas Welding (TIG)
The TIG welding process was first developed in the USA during
the 2nd world war for the welding of aluminum alloys
The process uses a non-consumable tungsten electrode
The arc may be initiated by a high frequency to avoid scratch
stating, which could cause contamination of the tungsten and weld
The process produces very high quality

welds. Welding Torch
The TIG process is considered as a slow Current Conductor
process compared to other arc welding

processes Shielding gas
Ceramic Contact Tube
The process requires a high Nozzle
Gas Shield
level of welder skill Tungsten
Arc
Electrode
Filler Wire Weld Pool
USA: GTAW
Sharul Rohaizad
TIG Torch Assembly
Tungsten Tungsten
housing electrode
Fitted ceramic Ceramic

shielding cup shield cup
On/Off switch Gas lens
Split collet
Gas diffuser
Torch body
Spare ceramic
shielding cup
Sharul Rohaizad
Variable Parameters
Tungsten electrodes
The electrode diameter, type and vertex angle are all critical
factors considered as essential variables. The vertex angle is
as shown
DC -ve AC
Vertex angle
Note: too fine an angle will promote Note: when welding aluminium with
melting of the electrodes tip AC current, the tungsten end is
chamfered and forms a ball end
when welding
Sharul Rohaizad
Tungsten Electrodes
Old types
Thoriated: DC -ve electrode - steels and most
metals
Zirconiated: AC - aluminum alloys and magnesium
New types
Cerium: DC -ve elctrode - steels and most metals
Lanthanum: DC -ve electrode - steels and most metals
Sharul Rohaizad
Variable Parameters
Gas type and flow rate
Generally two types of gases are used in TIG welding, argon and helium,
though nitrogen may be considered for welding copper and hydrogen
may be added for the welding of austenitic stainless steels. The gas flow
rate is also an important
Argon (Ar) Inert Helium Argon mixes
Suitable for welding carbon Suitable for welding carbon
steel,stainless steel, aluminium steel, stainless steel,
and magnesium copper, aluminium and
magnesium
Lower cost, lower flow rates
High cost, high flow rates
More suitable for thinner
More suitable for thicker
materials and positional
materials and materials of
welding high thermal conductivity. Sharul Rohaizad
High quality High skill factor required
Good control Small consumable range
All positions High protection required
Low hydrogen Low productivity
Minimal cleaning High ozone levels
Sharul Rohaizad
TIG Welding Basic Equipment
Power source
Power control
panel Inverter power
source
Return lead Source control

panel
Torch
assembly Power cable hose
Tungsten Flow-meter
electrodes
Sharul Rohaizad
Metal Active Gas Welding (MAG)
The MIG/MAG welding process was initially developed in the USA in
the late 1940s for the welding of aluminum alloys
The process uses a continuously fed wire electrode
The weld pool is protected by a separately supplied shielding gas
The process is classified as a semi-

Gas automatic welding process but may be fully
Nozzle
automated
Wire Electrode Contact Tip The wire electrode can be either

Electrode bare/solid wire or flux cored/hollow
Extension
Nozzle to Work wire
Arc Length
USA: GMAW
Weld Pool
Sharul Rohaizad
Metal Transfer Modes for MAG/MIG
Dip Transfer: Voltage < 22 Amperage < 200
Thin materials positional welding
Globular Transfer: Between Dip & Spray Transfer
Limited commercial, Used only in some mechanised MAG process
using CO2 shielding gas
Spray Transfer: Voltage > 27 Amperage > 220
Thicker materials, limited to flat welding positions, high deposition
Pulse Transfer: Both spray and dip transfer in
one mode of operation, frequency range 50-300 pulses/second
Positional welding and root runs
Sharul Rohaizad
Variable Parameters
Wire feed speed
Increasing the wire feed speed automatically increases the
current in the wire
Voltage
The voltage is the most important setting in the spray
transfer mode, as it controls the arc length. In dip transfer it
controls the rise in current
Current
The current is automatically increased as the wire feed is
increased. Current mainly affects penetration
Sharul Rohaizad
Variable Parameters
Gasses
The gasses used in MIG/MAG welding can be either 100%
CO2 or Argon + CO2 mixes.
100% CO2: Can not sustain true spray transfer, but gives
very good penetration. The arc is unstable which produces
a lot of spatter and a coarse weld profile.
Argon + CO2 mixes: Argon can sustain spray transfer
above 24 volts, and gives a very stable arc with a reduction
in spatter. Argon being a cooler gas produces less
penetration than CO2. Argon in normally mixed with CO2 at
a mixture of between 5-20%
Sharul Rohaizad
Checks when MIG/MAG Welding
Wire liner
Check that the liner is the correct type and size for the wire
being used. Steel liners for steel and Teflon liners for
aluminium.
Contact tips
Check the tip is the correct size for the wire being used and
check the amount of wear. Excessive wear will affect wire
speed and electrical current pick-up
Gas and gas flow-rates
Type of gas and the flow rate need to be checked to ensure
they comply with the WPS
Other welding variables
Check WFS, amps, volts and travel speed Sharul Rohaizad
Variable Parameters
Inductance
Applicable to MIG/MAG process in dip transfer mode.
The electrode is fed slowly through the arc until it touches
the weld pool, at this point the output from the power supply
is short circuited and a very high current flows through the
electrode. If this was allowed to continue, the wire would melt
and eject excessive amounts of spatter.
The inclusion of the choke in the welding circuit controls the
rate at which the current rises so that the electrode tip is
melted uniformly without excessive spatter
Sharul Rohaizad
Checks when MIG/MAG Welding
The welding equipment
A visual check should be made on the equipment to ensure it
is in good working order
The electrodes
The diameter, specification and the quality of the wire are
essential for inspection. The level of deoxidisation in the
wire, single, double or triple de-oxidised. The quality of the
wire winding and the copper coating should also be
inspected to minimize wire feed problems.
Sharul Rohaizad
High productivity Lack of fusion (dip)
Easily automated Small range of
All positional (dip &
consumables
pulse)
Material thickness Protection on site
range Complex equipment
Continuous electrode Not so portable
Sharul Rohaizad
MAG Welding Basic Equipment
External wire External wire

feed unit feed motor
control panel
Transformer/
Power Rectifier
control panel
Power cable &
15kg wire spool hose assembly
Power return Spare contact
cable tips
Welding gun Liner for wire
assembly
Sharul Rohaizad
MAG Welding Torch Assembly
Torch body
On/Off switch
Torch head assembly
(Less nozzle)
Hose port
Nozzles or Spot welding

shrouds spacer
Gas diffuser
Contact tips
Sharul Rohaizad
Flux Core Arc Welding (FCAW)
Flux core
Insulated extension nozzle
Current carrying guild tube

Wire joint
Flux cored hollow wire
Flux powder
Arc shield composed of
vaporized and slag forming
Flux core compounds
wires
Molten
weld Metal droplets covered
Solidified weld pool
with thin slag coating
metal and slag Sharul Rohaizad
Submerged Arc Welding Process (SAW)
Submerged arc welding was developed in the USA: SAW
Soviet Union during the 2nd world war for the
welding of thick sections Filler wire spool
Flux hopper
The process uses amps in the range Power
supply
of 100 to over 2000, which gives a
very high current density in the wire
producing deep penetration and high
dilution
- +
A flux is supplied separately via a
flux hopper in the form of either Slide rail
Wire electrode
fused or agglomerated
Flux
The arc is submerged beneath the flux
layer and no eye protection is required
The process is normally mechanised. Sharul Rohaizad
Submerged-arc (SAW)
Schematic diagram of SAW

Sharul Rohaizad
Sub-arc (SAW) Fluxes
Fused SAW Agglomerated SAW

Fluxes Fluxes
Sharul Rohaizad
Sub-arc Fluxes
Fused Flux Agglomerated Flux
Flaky appearance Granulated appearance
Lower weld quality High weld quality
Low moisture intake Addition of alloys
Low dust tendency Lower consumption
Good re-cycling Easy slag removal
Very smooth weld Smooth weld profile
profile
Sharul Rohaizad
Low weld-metal cost Restricted welding
Easily automated positions
Low levels of ozone Arc blow on DC current
High productivity Shrinkage defects
No visible arc light Difficult penetration
control
Limited joints
Sharul Rohaizad
SAW Basic Equipment
Transformer/
Rectifier
Power return
cable Welding carriage
Power control control unit
panel
Welding carriage
Granulated Electrode wire

flux reel
Granulated
flux
Sharul Rohaizad
Any Questions
Sharul Rohaizad
Weld Repairs
Sharul Rohaizad
World
Copyright Centre
TWI Ltd
Weld Repairs
In the event of repair
Authorization for repair
Removal and preparation for repair
Testing of repair - visual and NDT
Sharul Rohaizad
Weld Repairs
The specification or procedure will govern how the defective
areas are to be removed. The method of removal may be
Grinding
Chipping
Machining
Filling
Oxy-Gas gouging
Arc air gouging
Sharul Rohaizad
Any Questions
Sharul Rohaizad
Electro-slag (ESW)
Consumable-Guide Non Consumable-Guide
Electrode
Feed Rolls Electrode Wire
Electrode Wire
Electrode
Guide Tube Feed Rolls
Drive Unit
Molten Slag
Bath Electrode
Guide
Copper
Shoe Copper Shoe
Solid Weld Solid Weld
Metal Metal
More suitable for short weld lengths and More suitable for longer weld lengths
mechanically simpler. Can also be used and mechanically more complicated.
in portable models.
Sharul Rohaizad
Electro-slag
Electro-slag welds are relatively defect free
More suited to the joining of thick materials
No costly joint edge preparations required, square
butt
Minimal distortion
Minimal pre-heat required
Low flux consumption
High deposition
Vertical up welding position only
Low toughness values, may require PWHT.
Timely Set-ups Sharul Rohaizad
Process Comparisons
Process Electrical characteristic Electrode current type
MMA Drooping / constant current DC+ve, DC-ve, AC
TIG Drooping / constant current DC-ve, AC
MIG/MAG Flat / constant voltage DC+ve,
MAG FCAW Flat / constant voltage DC+ve, DC-ve,
Drooping / constant current >500amp

Sub-arc DC+ve, DC-ve, AC
Flat / constant voltage <500amp
Electro-slag Flat / constant voltage DC+ve,
Sharul Rohaizad
Any
Any Questions?
Questions?
Sharul Rohaizad

V.W.I - 3.0 Theory &amp; Practical

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CSWIP Visual Welding Inspection

10,000 certificate holders

Level 2: 3.1 Welding Inspector

Level 3: 3.2 Senior Welding Inspector

For further examination

Closed book exam

Any standards required on for the examination will be

Practical A2: The inspection of a plate butt weld

Practical part B2: The inspection of a T-Fillet

Total examination time 2 hours 45 minutes

For every section to be

2 copies of certificates and an identity card sent to

CV assessment Renewal examination

CSWIP Secretariat Tel: + 44 (0) 1223 891162

Course Reference WIS 1

What is the nature of the product?

What operating conditions will be

What is the quality of welding required?

Is there a code or standard available to

inspect the welds against

Duties Before Welding

Duties During Welding

Duties After Welding

Perform visual inspection

Measuring device e.g flexible tape, steel rule

Edge Open & Closed Corner Lap

Compound Fillet Butt

Edge Spot Plug

Included angle Included angle

Root Face Root Face

Single -V Butt Single - U Butt

Root Face Root Face

Single Bevel Single Vee

Double Bevel Double Vee

7. Plate & weld length

10. Convex cap profile

Mitre fillet Convex fillet

a. = Vertical leg length

a. = Design Throat Thickness

b = Horizontal leg length

2. Vertical leg length

Overhead Vertical downwards

Defects which may be detected by visual inspection can

Large Root face

Small Root Gap

Incorrect Electrode Angle

Lack of root penetration

Lack of root fusion Lack of root Penetration

A shallow groove, which may occur in the root of a butt weld

Root faces too large

Root gap too large

Excessive back purge pressure

Excessive root bead grinding before

Root penetration bead in excess in accordance with the

Root faces too small

Root gap too large

Slow travel speed

A shallow groove caused by contraction in the weld

Insufficient weld metal deposited

Too fast a cooling rate during the

Poor welding technique

A localized collapse of the weld pool due to excessive

Small Root face

Large Root Gap

V.W.I - 3.0 Theory & Practical

V.W.I - 3.0 Theory & Practical