CSWIP 3.

1 Welding Inspection

Weld Repairs

TWI Training & Examination

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Services

Course Reference WIS 5

Course notes section reference 18
 Weld Repairs

A weld repair can be a relatively straight forward activity, but in

many instances it is quite complex, and various engineering
disciplines may need to be involved to ensure a successful
outcome.
• Analysis of the defect types may be carried out by the Q/C
department to discover the likely reason for their occurrence,

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(Material/Process or Skill related).

In general terms, a welding repair involves What!

 Weld Repairs

• Is welding the best method of repair?

• Is the repair really like earlier repairs?
• What is the composition and weldability of the base metal?
• What strength is required from the repair?
• Can preheat be tolerated?
• Can softening or hardening of the HAZ be tolerated?

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• Is PWHT necessary and practicable?
• Will the fatigue resistance of the repair be adequate?
• Will the repair resist its environment?
• Can the repair be inspected and tested?
 Weld repair related problems

• heat from welding may affect dimensional stability and/or

mechanical properties of repaired assembly
• due to heat from welding, YS goes down  danger of collapse
• filler materials used on dissimilar welds may lead to galvanic
corrosion
• local preheat may induce residual stresses

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• cost of weld metal deposited during a weld joint repair can reach
up to 10 times the original weld metal cost!
 Weld Repairs
• Cleaning the repair area, (removal of paint, grease, etc)
• A detailed assessment to find out the extremity of the defect. This
may involve the use of a surface or sub surface NDE method.
• Once established the excavation site must be clearly identified
and marked out.
• An excavation procedure may be required (method used i.e.
grinding, arc-air gouging, preheat requirements etc).
• NDE should be used to locate the defect and confirm its removal.

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• A welding repair procedure/method statement with the
appropriate* welding process, consumable, technique, controlled
heat input and interpass temperatures etc will need to be
approved.
 Weld Repairs

A weld repair may be used to improve weld profiles or extensive

metal removal:
• Repairs to fabrication defects are generally easier than repairs
to service failures because the repair procedure may be
followed
• The main problem with repairing a weld is the maintenance of
mechanical properties
• During the inspection of the removed area prior to welding the

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inspector must ensure that the defects have been totally
removed and the original joint profile has been maintained as
close as possible
 Weld Repairs

In the event of repair, it is required:

• Authorization and procedure for repair

• Removal of material and preparation for repair

• Monitoring of repair Weld

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• Testing of repair - visual and NDT
 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
• Filing

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• Oxy-Gas gouging
• Arc air gouging
 Weld Repairs

Weld repairs can be divided into 2 specific areas:

• Production repairs
• In service repairs

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 Production Weld Repairs

Production Repairs
• are usually identified during production inspection
• evaluation of the reports is usually carried out by the
Welding Inspector, or NDT operator

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 Production Weld Repairs

Before the repair can commence, a number of elements need

to be fulfilled:
If the defect is surface breaking and has occurred at the fusion
face the problem could be cracking or lack of sidewall fusion.
If the defect is found to be cracking the cause may be
associated with the material or the welding procedure
If the defect is lack of sidewall fusion this can be apportioned
to the lack of skill of the welder.

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In this particular case as the defect is open to the surface, MPI
or DYE-PEN may be used to gauge the length of the defect and
U/T inspection used to gauge the depth.
 In Service Weld Repairs

service repairs
• can be of a very complex nature, as the component is very likely
to be in a different welding position and condition than it was
during production
• It may also have been in contact with toxic, or combustible fluids
hence a permit to work will need to be sought prior to any work
being carried out
• The repair welding procedure may look very different to the

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original production procedure due to changes in these elements.
 In Service Weld Repairs

Other factors to be taken into consideration:

effect of heat on any surrounding areas of the component i.e.
electrical components, or materials that may become damaged by
the repair procedure.
This may also include difficulty in carrying out any required pre or
post welding heat treatments and a possible restriction of access
to the area to be repaired.
For large fabrications it is likely that the repair must also take place

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on site and without a shut down of operations, which may bring
other elements that need to be considered.
 Weld Repairs

There are a number of key factors that need to be considered

before undertaking any repair:
• The most important - is it financially worthwhile?
• Can structural integrity be achieved if the item is repaired?
• Are there any alternatives to welding?
• What caused the defect and is it likely to happen again?
• How is the defect to be removed and what welding process is to

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be used?
• What NDE is required to ensure complete removal of the defect?
• Will the welding procedures require approval/re-approval?
 Weld Repairs

• What will be the effect of welding distortion and residual stress?

• Will heat treatment be required?
• What NDE is required and how can acceptability of the repair be
demonstrated?

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• Will approval of the repair be required – if yes, how and by
whom?
 Weld Repairs

• Use of approved welders.

• Dressing the weld and final visual.
• A NDT procedure/technique prepared and carried out to ensure
that the defect has been successfully removed and repaired.
• Any post repair heat treatment requirements.
• Final NDT procedure/technique prepared and carried out after
heat treatment requirements.

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• Applying protective treatments (painting etc as required).
• (*Appropriate’ means suitable for the alloys being repaired and
may not apply in specific situations)
 Weld repair decision tree

Has nature of NDE +

the defect been NO Destructive
determined? tests

YES

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Is repair the Replace the
right decision? NO part

YES
 Weld repair decision tree
YES
Determine Choose the Determine
base metal welding the filler
weldability process material

Train the Qualify the

welder welder

NO

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Establish Determine
Is welder
repair welding
qualified?
procedure standards
YES
 Weld repair decision tree

YES
Perform
Prepare the
welding Inspection
defect area
repair

Procedure
Fix problem NO Has repair been
problem successful?

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Welder
problem
YES
Protect and return
to service
 Weld Repairs

Plan View of defect

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Production Weld Repairs

Side View of defect excavation

Side View of repair welding

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 Cost of Weld Repairs
Original weld Cost Repair weld Extra cost

Cut, prep, tack weld £ Inspector Repair report (NCR etc) ££

Welder time £ Inspector Identify repair area ££

Consumable & gas £ Inspector Mark out repair area ££

Visual inspection £ Welder Remove defect ££

NDT ££ Inspector Visual inspection of excavation ££

Documentation £ Inspector NDT area of excavation ££

Inspector Monitor repair welding ££

Welder time £

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Consumable & gas £

Inspector Visual inspection ££

NDT ££

Extra repair Documentation £

Penalty % NDT ££
 Defect Excavation
Arc-air gouging

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 Arc-air gouging features
• Operate ONLY on DCEP
• Special gouging copper
coated carbon electrode
• Can be used on carbon
and low alloy steels,
austenitic stainless steels
and non-ferrous materials
• Requires CLEAN/DRY
compressed air supply

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• Provides fast rate of metal removal
• Can remove complex shape defects
• After gouging, grinding of carbured layer is mandatory
• Gouging doesn’t require a qualified welder!