Professional Documents
Culture Documents
Visual Inspection of Weld
Visual Inspection of Weld
CSWIP
Tee Lap
Corner
Terminology
Included Angle
60-700
0-2 mm
2-4 mm
8
7 9
1 2
4
5
3
6
Terminology
Fillet Weld Features
10
9
4
7
2
5
3 8
1
6
Joint Design
Butt Weld
Lap Joint
Corner
Joint
Tee Joint
Edge Weld
Zones in Fusion Welds
• Documentation
• Materials
• Weld preparations
• Fit up for welding
• Welding equipment
Welding Checklist
During Welding
• Correct parameters
• WPS at the work place
• Inter run cleanliness and quality
• Interpass temperature
• Consumable control
• Maintenance of preheat
• Process control NDE regime
• Weld records and maintenance of weld maps
Welding Checklist
Welding Completion
• Visual inspection and records
• NDE
• PWHT
• Final testing
• Cleaning, painting, preservation, packing
• Final documentation
Features to Consider
Butt welds - Size
Root
penetration
(a) (b)
4mm 8mm
6mm 4mm
(a) (b)
4mm 6mm
4mm 6mm
4mm 6mm
4mm 6mm
Convex
Mitre
Concave
Features to Consider
Fillet welds - Toe Blend
Features to Consider
EFFECTIVE THROAT THICKNESS
“a” = Nominal throat thickness “s” = Effective throat thickness
a s
x
x x
Features to Consider
Butt welds - Toe Blend
x
x x
Features to Consider
Butt welds - Weld Width
A Weld : Definitions
BS 499 NASA
• A union between • A continuous defect
pieces of metal at surrounded by
faces rendered parent material
plastic or liquid by
heat,pressure or
both.
Welds
An ideal weld must give a strong bond
between materials with the interfaces
disappearing
To achieve this
• Smooth,flat or matching surfaces
• Surfaces shall be free from contaminants
• Metals shall be free from impurities
• Metals shall have identical crystalline structures
Electric Arc Welding
Electrode
Power
supply
Work piece
Clamp(Earth)
Electric Arc Welding
• Electric discharge produced between cathode
and anode by a potential difference (40 to 60
volts)
Power control
panel Power source.
Transformer/
Rectifier
Electrode oven
Heated quiver
Electrodes
Inverter
Power return power source
cable
Electrode
holder
Safety visor
(With dark lens) Power cable
*
Manual Metal Arc (MMA)
Tungsten Inert Gas (TIG)
Power Transformer/
control Rectifier
panel
Power return Inverter
cable power source
Torch Power
assemblies control panel
Power cable
Tungsten
electrodes
Flow-meter
Tungsten Inert Gas (TIG)
POWER SOURCE
RETURN LEAD Note that current actually flows from this lead
INERT GAS SUPPLY Correct type for application.(ar, he, ar/he mixture)
(Cylinder & regulator) Argon/hydrogen for austenitic stainless steel
FLOWMETER To deliver correct gas flow (velocity) depending on
(graduated in ltr/min) welding position and joint configuration.
Tungsten Inert Gas (TIG)
GAS
TORCH WELDING LEAD + SUPPLY
METERS
GAS SUPPLY (OPTIONAL)
VARIABLE
NORMALLY CURRENT I
ARC DC-VE CONTROLLER N
E
THE POWER I V R
SOURCE T
_ G
OUTPUT AC/DC
80 OCV A
MAX + CONSTANT S
CURRENT
RETURN ARC
EARTH* LEAD STRIKING
*CHECK WITH HSE GUIDANCE NOTE DEVICE
Tungsten Inert Gas (TIG)
Tungsten Tungsten
housing electrodes
Internal wire
feed system Power cable &
hose assembly
Power control
panel
Liner for wire
15kg wire spool
In order to avoid
solidification cracking,
reduce penetration and
increase bead width
(depth to width ratio
0,5:1)
Welding Defects
Cracks
Hydrogen Induced
• Requires susceptible grain structure, stress and
hydrogen
• Hydrogen enters via welding arc
• Hydrogen source - atmosphere or contamination of
preparation or electrode
• Moisture diffuses out into parent metal on cooling
• Most likely in HAZ
Welding Defects
Hydrogen Cracking
Welding Defects
Hydrogen Cracking
Welding Defects
Cracks
Lamellar Tearing
• Step like appearance
• Occurs in parent material or HAZ
• Only in rolled direction of the parent material
• Associated with restrained joints subjected to
through thickness stresses on corners, tees and
fillets
• Requires high sulphur or non-metallic inclusions
Welding Defects
Lamellar Tearing
Welding Defects
Lamellar Tearing
Restraint
High
contractional
stress
Lamellar tear
Welding Defects
Lamellar Tearing
Grind and infill with
ductile weld metal Re-design weld
Control
restraint
Causes
• Too small a root gap
• Arc too long
• Wrong polarity
• Electrode too large for joint
preparation
• Incorrect electrode angle
• Too fast a speed of travel for
current
Welding Defects
a) Excessively thick root face
c) Misplaced welds
Smaller (correct)
diameter electrode
Lack of sidewall
fusion due to arc
deflection
Welding Defects
Incomplete root Fusion
Causes
• Too small a root gap
• Arc too long
• Wrong polarity
• Electrode too large for
joint preparation
• Incorrect electrode angle
• Too fast a speed of travel
for current
Welding Defects
Root concavity
Causes
• Root gap too large
• Insufficient arc energy
• Excessive back purge TIG
Welding Defects
Excess Root Penetration
Causes
• Excessive amperage during
welding of root
• Excessive root gap
• Poor fit up
• Excessive root grinding
• Improper welding
technique
Welding Defects
Root undercut
Causes
• Root gap too large
• Excessive arc energy
• Small or no root face
Welding Defects
Cap Undercut
Causes
• Excessive welding current
• Welding speed too high
• Incorrect electrode angle
• Excessive weave
• Electrode too large
Welding Defects
Overlap
Excess weld
metal
Welding Defects
Lack of fusion
Causes
• Contaminated weld preparation
• Amperage too low
• Amperage too high (welder increases speed of
travel)
Welding Defects
Incompletely Filled Groove
& Lack of Side wall Fusion
• Causes
• Insufficient weld metal deposited
• Improper welding technique
Welding Defects
Inter run Incompletely Filled Groove
Causes
• Insufficient weld metal deposited
• Improper welding technique
Welding Defects
Gas pores / Porosity
Causes
• Excessive moisture in flux or preparation
• Contaminated preparation
• Low welding current
• Arc length too long
• Damaged electrode flux
• Removal of gas shield
Welding Defects
Gas pores / Porosity
Welding Defects
Inclusions - Slag
Causes
• Insufficient cleaning between passes
• Contaminated weld preparation
• Welding over irregular profile
• Incorrect welding speed
• Arc length too long
Welding Defects
Inclusions - Slag
Causes
• Insufficient cleaning between passes
• Contaminated weld preparation
• Welding over irregular profile
• Incorrect welding speed
• Arc length too long
Welding Defects
Causes
• Contamination of weld Caused by tungsten touching
weld metal or parent metal during welding using the
TIG welding process
Welding Defects
Burn Through
Causes
• Excessive amperage during welding of root
• Excessive root grinding
• Improper welding technique
Welding Defects
Spatter
Causes
• Excessive arc energy
• Excessive arc length
• Damp electrodes
• Arc blow
Welding Defects
Arc Strikes
Causes
Chisel
Chisel Marks
Marks Pitting Corrosion Grinding Marks
Welding Defects
Non-alignment of
two abutting edges
Page 1 of 3 EXAMPLE PLATE REPORT
Name: [Block capitals] Mr. I C Plenty Signature: I C Plenty Test piece ident: 001
Code/Specification used: TWI 09-09-03 Welding process: MMA/SMAW Joint type: Single V Butt
Welding position: Flat /PA Length & thickness of plate: 300mm x 10 mm Date 22/08/2003
MEASURE
WELD FACE
A B C
Lack of
sidewall fusion Gas pore Undercut smooth
1.5 Ø 1.5 max
FROM
87 236
22 230
30
THIS
51 8 153 40
Arc Strike
Slag
Centreline 241
inclusion
DATUM
crack
NOTES: Cap height : 4mm.
Weld width: 12-14mm
Toe blend: Poor
Misalignment: 2mm
EDGE
WELD ROOT
A B C
Root concavity
2 deep LACK OF ROOT
FUSION
FROM
23 247
10 20
THIS
128 50
Incomplete root
penetration
DATUM
This *pipe/plate has been examined to the requirements of code/specification TWI 09-09-03
.........................................
and is accepted/rejected accordingly.
Comments:
* Request MPI testing to confirm crack and length.
** Large amount of spatter on weld face. Recommend this is removed and re inspected.
*** Recommend arc strikes are ground flush prior to MPI testing for crack detection.
I C Plenty
Signature.........................................................
22nd August 2003
Date................................................. ....................................
*Delete which is not applicable. Use the other side for any comments.
Inspection Practice Specification
Number TWI 09-09-03
All dimensions are given in mm
No Imperfection Comments Allowance
1 Cracks Confirm with penetrant testing Not permitted
INSPECTION OF
FILLET WELDS
Fillet Weld Inspection
CSWIP 3.0 Fillet Welded T Joint
F 123
VERTICAL LEG LENGTH (Max & Min) = Max 8mm Min 7mm
HORIZONTAL LEG LENGTH (Max & Min) = Max 10mm Min 5mm
DESIGN THROAT THICKNESS (Max & Min) = Max 8mm Min 4.5mm
Fillet Weld Inspection
2) Sentence the fillet weld dimensions using the following design criteria:
Signature: I C Plenty
Name: I C Plenty
Date: 01-01-04