CSWIP 3.0 - Visual Welding Inspector - 181-261

CSWIP 3.
0 Training Questions for fillet Weld T12
1 In regards to the maximum vertical leg length, which of the answers best matches
your assessment and would you accept or reject your findings to the given
acceptance levels?
a 6-7mm.
b 11-12mm.
c 4-5mm.
d 9-10mm.
e Accept.
f Reject.
2 In regards to the minimum vertical leg length, which of the answers best matches
acceptance levels?
a 3-4mm.
b 5-6mm.
c 7-8mm.
d 9-10mm.
e Accept.
f Reject
3 In regards to the maximum horizontal leg length, which of the answers best
matches your assessment and would you accept or reject your findings to the given
acceptance levels?
a 6-7mm.
b 7.5-8.5mm.
c 9-10mm.
d 12-13mm.
e Accept.
f Reject.
4 In regards to the minimum horizontal leg length, which of the answers best
acceptance levels?
a 3-4mm.
b 5-6mm.
c 7-8mm.
d 9-10mm.
e Accept.
f Reject.
5 In regards to the maximum actual throat thickness, which of the answers best
acceptance levels?
a 10-11mm.
b 5-6mm.
c 3-4mm.
d 8-9mm.
e Accept.
f Reject.
WIS1-40215
Appendix 3 A3-4 Copyright © TWI Ltd 2015
6 In regards to the minimum actual throat thickness, which of the answers best
acceptance levels?
a 3-4mm.
b 8-9mm.
c 4.5-5.5mm.
d 6-7mm.
e Accept.
f Reject.
7 With reference to lack of fusion, which of the following answers best matches your
assessment of the total accumulative length and would you accept or reject your
findings to the given acceptance levels?
a 10-15 accumulative total.

b 20-30mm accumulative total.
c None observed.
d 1-9mm accumulative total.
e Accept.
f Reject.
8 With reference to arc strikes, which of the following answers best matches your
assessment of the total number and would you accept or reject your findings to the
given acceptance levels?
a 3 total.
b 4 total.
c None observed.
d 1 total.
e Accept.
f Reject.
9 With reference to mechanical damage (Excluding Hard Stamping and pop marks),
which of the following answers best matches your assessment of the total number
and would you accept or reject your findings to the given acceptance levels?
a 4 Areas.
b 1 Area.
c None observed.
d 3 Areas.
e Accept.
f Reject.
10 With reference to undercut, which of the following answers best matches your
assessment of the maximum value and would you accept or reject your findings to
the given acceptance levels?
a 1-2mm depth.
b 0.1-0.5mm depth.
c None observed.
d 3-4mm depth.
e Accept.
f Reject.
WIS1-40215
11 With reference to the accumulative length of undercut, which of the following
answers best matches your assessment of the maximum value and would you
accept or reject your findings to the given acceptance levels?
a 50-70mm in length.
b 10-16mm in length.
c None.
d 20-25mm in length.
e Accept.
f Reject.
12 With reference to cluster porosity, which of the following answers best matches
your assessment of the square area and would you accept or reject your findings to
a 10-14mm2.
b 20-60mm2.
c None observed.
d 61-87mm2.
e Accept.
f Reject.
13 With reference to cracks, which of the following answers best matches your
assessment of the accumulative total and would you accept or reject your findings
to the given acceptance levels?
a 28-35mm total length.

b 22-27mm total length.
c None observed.
d 5-10mm total length.
e Accept.
f Reject.
14 With reference to slag inclusions which of the answers best matches your

c None observed.
e Accept.
f Reject.
WIS1-40215
CSWIP 3.0 Training Questions for fillet Weld T13
acceptance levels?
a 10-11mm.
b 7-8mm.
c 4-5mm.
d 12-13mm.
e Accept.
f Reject.
acceptance levels?
a 3-4mm.
b 5-6mm.
c 7-8mm.
d 9-10mm.
e Accept.
f Reject.
acceptance levels?
a 6-7mm.
b 8-9mm.
c 4-5mm.
d 11-12mm.
e Accept.
f Reject.
acceptance levels?
a 3-4mm.
b 5-6mm.
c 7-8mm.
d 9-10mm.
e Accept.
f Reject.
acceptance levels?
a 4.5-5.5mm.
b 6.5-7.5mm.
c 3-4mm.
d 8-9.5mm.
e Accept.
f Reject.
WIS1-40215
acceptance levels?
a 1-2mm.
b 8-9mm.
c 3-4mm.
d 6-7mm.
e Accept.
f Reject.
a 10-15 accumulative total.

c None observed.
e Accept.
f Reject.
a 3 total.
b 4 total.
c None observed.
d 1 total.
e Accept.
f Reject.
a 2 Areas.
b 1 Area.
c None observed.
d 3 Areas.
e Accept.
f Reject.
a 1-2mm depth.
b 0-0.5mm depth.
c None observed.
d 3-4mm depth.
e Accept.
f Reject.
WIS1-40215
11 With reference to the total accumulative length of undercut, which of the following
c None.
e Accept.
f Reject.
12 With reference to porosity, which of the following answers best matches your
assessment of the largest pore and would you accept or reject your findings to the
a 2-2.5mm diameter.
b 0.5mm diameter.
c None observed.
d 1-1.5mm diameter.
e Accept.
f Reject.

c None observed.
e Accept.
f Reject.
assessment to the accumulative total and would you accept or reject your findings

b 18-22mm total length
c None observed.
e Accept.
f Reject.
WIS1-40215
CSWIP 3.0 Training Questions for fillet Weld T15
acceptance levels?
a 6-7mm.
b 10-11mm.
c 4-5mm.
d 8-9mm.
e Accept.
f Reject.
acceptance levels?
a 3-4mm.
b 6-7mm.
c 1-2mm.
d 9-10mm.
e Accept.
f Reject.
acceptance levels?
a 9.5-10mm.
b 4-5mm.
c 10-11.5mm.
d 12-12.5mm.
e Accept.
f Reject.
acceptance levels?
a 4-5mm.
b 6-7mm.
c 2-3mm.
d 9-10mm.
e Accept.
f Reject.
acceptance levels?
a 1-2mm.
b 5-6mm.
c 3-4mm.
d 8-9mm.
e Accept.
f Reject.
WIS1-40215
acceptance levels?
a 1-2mm.
b 8-9mm.
c 3-4mm.
d 6-7mm.
e Accept.
f Reject.
a 10-15mm accumulative total.

c None observed.
e Accept.
f Reject.
a 3 total.
b 4 total.
c None observed.
d 1 total.
e Accept.
f Reject.
a 4 Areas.
b 1 Area.
c None observed.
d 3 Areas.
e Accept.
f Reject.
a 0.5-1mm depth.
b 0-0.5mm depth.
c None observed.
d 2-3mm depth.
e Accept.
f Reject.
WIS1-40215
11 With reference to the total accumulative length of undercut, which of the following
c None.
e Accept.
f Reject.
12 With reference to porosity, which of the following answers best matches your
assessment of the largest pore and would you accept or reject your findings to the
a 2-2.5mm diameter.
b 0.5mm diameter.
c None observed.
d 1-1.5mm diameter.
e Accept.
f Reject.

c None observed.
e Accept.
f Reject.
assessment to the accumulative total and would you accept or reject your findings

c None observed.
e Accept.
f Reject.
WIS1-40215
CSWIP 3.0 Training Questions for Plate Butt Weld 1
Answers to be indicated on the Candidate Answer Sheet under the heading of Plate
Butt Weld The Weld Face.
Weld Face
1 Maximum excess weld metal height (The highest individual point measured): Which
answer best matches your assessment and would you accept or reject your
a Equal to or less than 0mm.

b 1-4mm.
c 5-6mm.
d 7-8mm.
e Accept.
f Reject.
2 Incomplete fill: Which answer best matches your assessment of the total
accumulative length and would you accept or reject your findings to the given
acceptance levels?
a None observed.
b 50-70mm.
c 10-30mm.
d 80-110mm.
e Accept.
f Reject.
3 Slag inclusions: Which answer best matches your assessment of the total
acceptance levels?
a 50-65mm.
b 22-35mm.
c None observed.
d 8-18mm.
e Accept.
f Reject.
4 Undercut: Which answer best matches your assessment of the imperfection and
would you accept or reject your findings to the given acceptance levels?
a Smooth intermittent.
b Sharp but less than 1mm deep.
c None observed.
d Sharp but more than 1mm deep.
e Accept.
f Reject.
WIS1-40215
5 Cluster porosity in the weld: Which of the following answers best matches your
assessment of the weld and would you accept or reject your findings to the given
acceptance levels?
a The area is between 10-15mm2.

b The area is between 100-150mm2.
c None observed.
d The area is between 16-70mm2.
e Accept.
f Reject.
6 Cracks: Which answer best matches your assessment of the total accumulative
length and would you accept or reject your findings to the given acceptance levels?
a 2-3mm transverse crack.

b 15mm longitudinal crack.
c None observed.
d 9-14mm longitudinal crack.
e Accept.
f Reject.
7 Lack of fusion: Which answer best matches your assessment of the total
acceptance levels?

c None observed.
e Accept.
f Reject.
8 Arc strikes: Which answer best matches your assessment of the total number and
a 3 total.
b 4 total.
c None observed.
d 1 total.
e Accept.
f Reject.
9 Sharp indications of mechanical damage (excluding hard stamping and pop

marks): Which answer best matches your assessment of the total number and
a 4 areas.
b 1 area.
c None observed.
d 3 areas.
e Accept.
f Reject.
WIS1-40215
Weld Root
10 Misalignment: Which answer best matches your assessment of the maximum value
a 1-2mm.
b 3-4mm.
c None observed.
d Greater than 5mm.
e Accept.
f Reject.
11 Root penetration height (highest individual point measured): Which answer best
acceptance levels?
a 3-5mm.
b 1-2mm.
c None.
d Greater than 5mm.
e Accept.
f Reject.
12 Lack of root penetration: Which answer best matches your assessment of the
accumulative total and would you accept or reject your findings to the given
acceptance levels?

c None observed.
e Accept.
f Reject.
13 Lack of root fusion: Which answer best matches your assessment of the
acceptance levels?

c None observed.
d 15-23mm.
e Accept.
f Reject.
14 Root concavity: Which answer best matches your assessment to the accumulative
total and would you accept or reject your findings to the given acceptance levels?

c None observed.
e Accept.
f Reject.
WIS1-40215
15 Root undercut: Which answer best matches your assessment of the accumulative

c None observed.
e Accept.
f Reject.
16 Cracks in the root: Which answer best matches your assessment of the
acceptance levels?

c None observed.
e Accept.
f Reject.
17 With reference to mechanical damage in the root area weld and parent material
(excluding hard stamping): Which of the answers best matches your assessment of
the accumulative total and would you accept or reject your findings to the given
acceptance levels?
a 2 items observed.
b 1 item observed.
c None observed.
d 3 or more items observed.
e Accept.
f Reject.
18 Cluster porosity in the weld root area: Which of the following answers best matches
your assessment of the accumulative total area and would you accept or reject
your findings to the given acceptance levels?

c None observed.
e Accept.
f Reject.
19 With reference to burn through in the root area: Which of the following answers
best matches your assessment of the accumulative total and would you accept or
reject your findings to the given acceptance levels?
a 1 area.
b 2 areas.
c None observed.
d 3 areas.
e Accept.
f Reject.
WIS1-40215
20 With reference to angular distortion: Which of the following answers best matches
acceptance levels? (measure from the weld centreline to the plate edge)
a 3-5mm.
b 6-8mm.
c None observed.
d 1-2mm.
e Accept.
f Reject.
WIS1-40215
Visual Inspection Plate Report – Weld Face
Appendix 4
Name [Block capitals) Signature Test piece identification
WIS1-40215
Code/Specification used Welding process SMAW Joint type Single V
Welding position PA Length and thickness of plate Date
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Notes: Excess weld metal = Linear misalignment = Toe blend = Weld width =
Copyright © TWI Ltd 2015

Visual Plate Report
Weld Root
Appendix 4
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Note: Excess weld metal = Toe blend = Weld width=

Weld Face
1 Maximum excess weld metal height (highest individual point measured): Which

b 1-4mm.
c 5-6mm.
d 7-8mm.
e Accept.
f Reject.
acceptance levels?
a None observed.
b 45-80mm.
c 1-40mm.
d 100-120mm.
e Accept.
f Reject.
acceptance levels?
a 60-70mm.
b 15-24mm.
c None observed.
d 5-10mm.
e Accept.
f Reject.
a 60mm in length.
c None observed.
e Accept.
f Reject.
WIS1-40215
5 Cluster porosity in the weld: Which answer best matches your assessment of the
total accumulative area and would you accept or reject your findings to the given
acceptance levels?

b The area is greater than 100mm2.
c None observed.
e Accept.
f Reject.

c None observed.
e Accept.
f Reject.
acceptance levels?

c None observed.
e Accept.
f Reject.
a 3 total.
b 4 total.
c None observed.
d 1 total.
e Accept.
f Reject.
9 Mechanical damage (excluding hard stamping and pop marks): Which answer best
matches your assessment of the total number and would you accept or reject your
a 4 areas.
b 1 area.
c None observed.
d 3 areas.
e Accept.
f Reject.
WIS1-40215
Weld Root
a 1.5-2mm.
b 3-4mm.
c 0-1mm.
d Greater than 5mm.
e Accept.
f Reject.
acceptance levels?
a 4-5mm.
b 2-3mm.
c None.
d Greater than 5mm.
e Accept.
f Reject.
acceptance levels?

c None observed.
e Accept.
f Reject.
acceptance levels?

c None observed.
e Accept.
f Reject.
14 Root concavity: Which answer best matches your assessment of the accumulative
total and would you accept or reject your findings to the given acceptance levels.

c None observed.
e Accept.
f Reject.
WIS1-40215

c None observed.
e Accept.
f Reject.
acceptance levels?

c None observed.
e Accept.
f Reject.
17 Mechanical damage in the root area weld and parent material (excluding hard
stamping): Which answer best matches your assessment of the accumulative total
a 3 or more items observed.

b 1 item observed.
c None observed.
d 2 items observed.
e Accept.
f Reject.
18 Cluster porosity in the weld root area: Which answer best matches your
assessment of the accumulative total area and would you accept or reject your

c None observed.
e Accept.
f Reject.
19 Burn-through in the root area: Which answer best matches your assessment of the
acceptance levels?
a 1 area.
b 2 areas.
c None observed.
d 3 areas.
e Accept.
f Reject.
WIS1-40215
20 Angular distortion: Which answer best matches your assessment and would you
accept or reject your findings to the given acceptance levels? (Measure from the
weld centreline to the plate edge.)
a 3-5mm.
b 6-8mm.
c None observed.
d 1-2mm.
e Accept.
f Reject.
WIS1-40215
Appendix 4
WIS1-40215
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Visual Plate Report
Weld Root
Appendix 4
WIS1-40215
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Weld Face
1 Maximum excess weld metal height (highest individual point measured): Which

b 1-4mm.
c 5-6mm.
d 7-8mm.
e Accept.
f Reject.
acceptance levels?
a None observed.
b 45-65mm.
c 1-30mm.
d 75-100mm.
e Accept.
f Reject.
acceptance levels?
a 60-70mm.
b 24-39mm.
c None observed.
d 5-23mm.
e Accept.
f Reject.
a 50mm in length.
c None observed.
e Accept.
f Reject.
WIS1-40215
5 Cluster porosity in the weld: Which answer best matches your assessment of the
total accumulative area and would you accept or reject your findings to the given
acceptance levels?

b The area is greater than 100mm2.
c None observed.
e Accept.
f Reject.

c None observed.
e Accept.
f Reject.
acceptance levels?

c None observed.
e Accept.
f Reject.
a 3 total.
b 4 total.
c None observed.
d 1 total.
e Accept.
f Reject.
9 Mechanical damage (excluding hard stamping and pop marks): Which answer best
matches your assessment of the total number and would you accept or reject your
a More than 2 areas.

b 1 Area.
c None observed.
d 2 Areas.
e Accept.
f Reject.
WIS1-40215
Weld Root
a 2-3mm.
b 4-5mm.
c 0-1mm.
d Greater than 5mm.
e Accept.
f Reject.
acceptance levels?
a 2-3mm.
b 1-1.5mm.
c None.
d Greater than 5mm.
e Accept.
f Reject.
acceptance levels?

c None observed.
e Accept.
f Reject.
acceptance levels?

c None observed.
d 16-29mm.
e Accept.
f Reject.
14 Root concavity: Which answer best matches your assessment of the accumulative
total and would you accept or reject your findings to the given acceptance levels.

c None observed.
e Accept.
f Reject.
WIS1-40215

c None observed.
e Accept.
f Reject.
acceptance levels?

c None observed.
e Accept.
f Reject.
17 Mechanical damage in the root area weld and parent material (excluding hard
stamping): Which answer best matches your assessment of the accumulative total
a 2 items observed.
b 1 item observed.
c None observed.
d 3 or more items observed.
e Accept.
f Reject.
18 Cluster porosity in the weld root area: Which answer best matches your
assessment of the accumulative total area and would you accept or reject your

c None observed.
e Accept.
f Reject.
19 Burn-through in the root area: Which answer best matches your assessment of the
acceptance levels?
a 1 area.
b 2 areas.
c None observed.
d 3 areas.
e Accept.
f Reject.
WIS1-40215
20 Pore dimensions: Which answer best matches your assessment and would you
a 3-4mm.
b 5-6mm.
c None observed.
d 1-2mm.
e Accept.
f Reject.
WIS1-40215
Appendix 4
WIS1-40215
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Visual Plate Report
Weld Root
Appendix 4
WIS1-40215
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INVIGILATOR NAME: Mr Examiner INVIGILATOR SIGNATURE: Mr Examiner
WELD INSPECTION 3.0 Answer grid EXAM DATE: EXAMINATION NUMBER: 1 2 3 4 5 6 7 VERSION: 1 2 3 4 5 6 7
(training) CANDIDATE NAME:
I agree with the terms and Tick Date of Birth

conditions of this examination Box D D M M Y Y
PLATE 0 1 2 3 4 5 6 7 8 9
_
CANDIDATE SIGNATURE: O O O O O O O O O O
A B C D E F _
_
O O O O O O O O O O
YOUR SIGNATURE MUST BE _
O O O O O O O O O O
1 O O O O O O O O O O
FULLY CONTAINED IN THE BOX _
_
O O O O O O O O O O
3 FOR OFFICE USE ONLY
4
FILLET
5
CHECK
6 A B C D E F
ON THE DAY, SAMPLES
7 1
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YOU SHOULD HAVE PER
9 3 EXAM
10 4 EXAM 1 VERSION 1
11 5 EXAM 1 PLATE
12 6 FILLET E3
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15 9 EXAM 2 PLATE
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12 6 FILLET E3
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12 6 FILLET E3
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12 6 FILLET E3
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9 3 EXAM
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17 11
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CSWIP 3.0 Visual Welding Inspector
CSWIP 3.0 Visual Welding Inspector Introduction

Level 1
WIS1
Copyright © TWI Ltd 2015 Rev 3 October 2014 Copyright © TWI Ltd 2015
WIS1-40215
Course Objectives Course Objectives
 To identify various weld imperfections (defects).  To carry out inspection of parent materials and
 To understand the relevant welding technology consumables.
related to visual inspection.  To carry out visual inspection of welds, report
 To understand the need for documentation in on them and assess their compliance with
welding. specified acceptance criteria.
 To be aware of codes and standards related to  To pass the CSWIP 3.0 Visual Welding Inspector
inspection requirements. qualification.
Copyright © TWI Ltd 2015 Copyright © TWI Ltd 2015
Welcome Health and Safety
Getting the most out of the course Evacuation in the event of fire
 Leave by the nearest exit.
Please  Do not stop to pick up your possessions.
 Switch off mobile phones.  Go directly to the fire assembly point.
 Do not smoke in the building.
 Ask questions.

The Course The Course
The Visual Welding Inspector course provides an The main objective of the course is to prepare
introduction to practical inspection practices and for the CSWIP Visual Welding Inspection
procedures. examination.
CSWIP Certificate Scheme CSWIP Certificate Scheme
Certificate Scheme for Personnel The reference document

for the CSWIP scheme is:
Document No.
CSWIP-WI-6-92
(12th Edition May 2012).
CSWIP Certificate Scheme CSWIP Certificate Scheme
Document No. CSWIP-WI-6-92  Level 1: 3.0 Visual Welding Inspector.

 Provides terms of reference for the three
levels of Inspector grade.  Level 2: 3.1 Welding Inspector.
 Provides guidance on the knowledge required
for each level of Inspector grade.  Level 3: 3.2 Senior Welding Inspector.
 Sets out the examination format and provides
guidance on questions.

CSWIP 3.0 Examination Requirements The CSWIP 3.0 Examination
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 form, you can Practical Examination Only
print from the website www.twi.co.uk
The CSWIP 3.0 Examination The CSWIP 3.0 Examination
Practical part A1 Practical plate examination

Inspection of a plate butt weld to a code provided  There will be twenty multi choice questions, ie
by the Test Centre. identify the defect, size etc and also an accept
or reject to the acceptance criteria.
 In addition, a plan will be required detailing
where the defects are, their type and size.
1 Hour
30 Minutes
The CSWIP 3.0 Examination Notification of Examination Results
Practical fillet weld examination

 There will be fourteen multi choice questions,
the maximum and minimum weld leg lengths 70%
and throat thicknesses, identify other defects,
Pass mark
their size etc and accept or reject in
accordance with the acceptance criteria.
For every section to be

awarded the certificate
2 copies of certificates and an identity card sent
to delegates’ sponsor.

Certification Scheme for
Personnel
Recognised Worldwide

TWI Visual Welding Inspection TWI Visual
CSWIP 3.0 Welding Inspection
Visual Welding Inspector
CSWIP 3.0 Visual Welding Inspector Terminology: Types of joints and welds
Level 1
WIS1

WIS1-40215
Terminology Terminology
A joint A weld
A configuration of members. A union between materials caused by heat, and
or pressure.
Types of Joint Butt Joints
T Edge Cruciform Square edged

Closed Open
Single sided butt

V Bevel
Double sided butt

V Bevel
Butt Lap Corner

Types of Joint Types of Joint
Single V and Single U Single Bevel and Single J
Included angle Included angle Angle of bevel Angle of bevel
Angle Angle
of bevel of bevel
Land Root
(optional) radius
Root Root face Root face

radius
Root face Root face Root gap Root gap
Root gap Root gap Land
Single V butt Single U butt Single bevel butt Single J butt
Types of Weld Types of Weld
Two commonly used welds types Fillet weld Edge weld Compound weld
Butt weld
Fillet weld
Butt weld Plug weld Spot weld
CSWIP 3.0 Visual Welding Inspector Weld Toes
The toes of the weld can be defined as the

junction of the weld face and the base metal.
Can be a serious stress raiser.

Terminology: Features of the weld

Weld Toes Excess Weld Metal
Weld metal lying

A B outside the plane
joining the toes.
BS499 -1
Also known as weld

reinforcement,
overfill, crown.
C D
Toe Blend Toe Blend

a Stress Concentration Stress Reduced
80° 6mm 20° 3mm
Excessive height = acute angle Excess height = lower angle

Acute angle = stress concentration Lower angle = reduced stress concentration
Excessive height + acute angle = Poor toe blend Excess height + lower angle = Good toe blend
Importance of Toe Blend Features of the Weld
The higher the toe blend angle the greater the Weld zone
concentration of stress.
Weld face
Excess weld metal height of 3mm max will give Weld

metal Fusion
a toe blend angle of 20°-30° approximately. boundary/line
Heat
Affected
Zone
(HAZ)
Root

Terminology
Plate Butt Weld Features
Features of the Weld
Parent metal Toe Weld face Features of a Fillet weld on plate
Toe
Toe
Parent
metal
Face
Weld
Weld
Root HAZ Root HAZ
CSWIP 3.0 Visual Welding Inspector Fillet Welds
Fillet welds
 Cheapest form of arc welded joint.
 Used extensively in many types of structure.
 The external shape and size can be measured.
Terminology: Types of weld  The internal quality is dependant on joint fit-up
and the use of a qualified WPS.
Fillet Weld Dimensions

Fillet Weld Profiles
Leg Length
Mitre fillet The leg length of a fillet weld is the distance from
the root to the toe of the fillet weld.
Also called the fusion face.
Concave fillet
Vertical leg length
Convex fillet
Horizontal leg length

Fillet Weld Dimensions Fillet Weld Dimensions
Throat Thickness Throat Thickness
The throat thickness of a fillet weld is the The throat thickness can be expressed in
perpendicular distance from the root to the face terms of either:
centre of the fillet weld.  Design throat thickness.
 Actual throat thickness.
Throat thickness
Throat Thickness Throat Thickness

Convex Fillet Weld Concave Fillet Weld
Actual throat Actual throat Design throat =

Actual throat
Design throat Design throat
Throat and Leg Terminology

The Ratio Types of Weld
Based on the right
angled triangle
Leg length
LL TT a = Horizontal leg length.
6
b b = Vertical leg length.
1.414 1
1 0.707
?
6 x 0.707 = 4.242 or 4.2mm a

Terminology Terminology
Types of Weld Types of Weld
Butt welds Partial Penetration Butt welds
t2 t2
t2
t1 t1
t1
t2 t1
t1
t’2
t’1
t1 – Design throat t2 – Actual throat t1 t’1= Design throat thickness
thickness thickness t 2 t’2= Actual throat thickness
Welding Inspector Duties
Any questions?

TWI Visual Welding Inspection CSWIP 3.0 Visual Welding Inspection
CSWIP 3.0 Visual Welding Inspection Inspection Equipment

Level 1
WIS1

WIS1-40215
Why Measure? Inspection Considerations
The purposes  When to carry out inspections?

of measuring  How to carry out inspections?
 What equipment will be required?
Demonstration Welding process
 What is the quality of welding required?
of conformance control
to specified  How to interpret the code or standard
requirements requirements?
 Welding current  Shielding gas flow rate

arc voltage preheat/inter-pass
travel speed temperature, humidity
Three Monitoring Stages Inspection Equipment
1. Before welding.  Steel rule.  Contour gauge.

 Flexible tape measure.  Torch or other light
2. During welding.  Bevel angle gauge. source.
 Root gap gauge.  Mirror.
3. After welding.  Misalignment gauge.  Magnifying glass - 5x
 Fillet gauge. magnification.
 Height/depth gauge.  Paint stick/marking
crayon.
 Voltmeter.
 Pea shooter type flow
 Ammeter. meter.
 Temp indicating  Stop watch.
crayons/pyrometer.

Inspection Equipment Multi Purpose Inspection Gauge
Inspection of welds
using the Cambridge
multi purpose welding
gauge.
Temperature Indicating Crayons Digital Thermometers
Temperature sensitive  Are temperature-sensitive

materials resistors whose resistance
varies inversely with
 Crayons, paints and temperature.
pills.  Used when high sensitivity
 Cheap and convenient, is required.
easy to use.  Gives the actual
temperature.
Doesn’t measure the  Need calibration.
actual temperature!
Contactless Temperature
Inspection Equipment
Measurement
 IR radiation and optical
pyrometer.
 Measure the radiant
energy emitted by the
hot body.
Any questions?
 Contactless method,
can be used for remote
measurements.
 Very complex.
 For measuring high
temperatures.

CSWIP 3.0 Welding Inspection
CSWIP 3.0 Visual Welding Inspector Welding Imperfections and

Level 1 Materials Inspection
WIS1

WIS1-40215
Features to Consider Features to Consider
Butt welds - Size Butt welds - Profile
x
Weld cap width
Excess weld
metal height
Root bead width

Root penetration x x
Features to Consider Features to Consider
Butt welds - Toe blend Butt welds - Weld width
x
x x
Welding Defects Welding Defects
Incomplete root penetration a. Excessively thick

root face.
Causes
b. Too small a root
 Too small a root gap.
gap.
 Arc too long.
 Wrong polarity. c. Misplaced welds.
 Electrode too large for joint
preparation. d. Lack of cross
 Incorrect electrode angle. penetration.
 Too fast a speed of travel for
current.
Incomplete root fusion Root concavity
Causes
 Too small a root gap. Causes
 Arc too long.  Root gap too large.
 Wrong polarity.  Excessive grinding.
 Excessive back purge TIG.
 Electrode too large for joint
preparation.
 Incorrect electrode angle.
 Too fast a speed of travel for
current.
 Linear misalignment.
Excess root penetration Root undercut
Causes Causes
 Excessive amperage  Root gap too large.
during welding of root.  Excessive current/arc
 Excessive root gap. energy.
 Insufficient root face.  Small or no root face.
 Poor fit up.
 Excessive root grinding.
 Improper welding
technique.

Cap undercut
Overlap
Causes
 Excessive welding current.
 Welding speed too high. Excess weld metal
 Incorrect electrode angle.
 Excessive weave.
 Electrode too large.
Lack of fusion Incompletely filled groove

and lack of side wall fusion
Causes
 Contaminated weld
preparation.
 Amperage too low.
 Amperage too high
(welder increases
speed of travel). Causes
 Dip transfer MIG/MAG.  Insufficient weld metal deposited.
 Improper welding technique.
Inter run Incompletely Filled Groove/ Incompletely filled groove

Lack on inter-run fusion
Causes
 Insufficient weld
metal deposited.
 Improper welding
technique.

Gas pores/porosity Gas pores/porosity
Causes
 Excessive moisture in
flux or preparation.
 Contaminated preparation.
 Low welding current.
 Arc length too long.
 Damaged electrode flux.
 Loss of gas shield.
Inclusions - Slag Inclusions - Slag
Causes Causes
 Insufficient cleaning  Insufficient cleaning
between passes. between passes.
 Contaminated weld preparation.  Contaminated weld
 Welding over irregular profile. preparation.
 Incorrect welding speed.  Welding over irregular profile.
 Arc length too long.  Incorrect welding speed.
 Arc length too long.
Inclusions - Tungsten Burn through
Causes
 Excessive amperage
Causes
during welding of
 Contamination of weld Caused by tungsten
root.
touching weld metal or parent metal during
 Excessive root grinding.
welding using the TIG welding process.
 Improper welding technique.
 Excessive current.

Spatter Arc strikes

Causes
 Electrode straying onto
parent metal.
Causes  Electrode holder with
 Excessive arc energy/ poor insulation.
current.  Poor contact of earth
 Excessive arc length. clamp.
 Damp electrodes.  Striking outside the
 Arc blow. joint preparation.

Linear
Mechanical damage Excess weld metal height
Lowest plate to highest point
Chisel
Chisel
Chisel Marks
Marks
Marks Pitting Corrosion Grinding Marks
3mm
Excess penetration
Lowest plate to highest point
Linear misalignment measured in mm.
Angular
3mm
Angular misalignment measured in mm.
Non-alignment of two abutting edges
50mm
3mm
Angular distortion.
Measure the distance to the edge of the plate (50mm).
Use a straight edge (rule) to find the amount of distortion then
2mm measure the space (3mm).
This reported as Angular distortion 3mm in 50mm.
Also known as: Hi low, mismatch or misalignment.

Welding Imperfections and
Materials Inspection
Any questions?

TWI Welding Inspection
CSWIP 3.0 Visual Welding Inspector Introduction to Welding Processes

Level 1
WIS1

WIS1-40215
Welding Processes Factors for Fusion Welding
Fusion welding Welding with pressure  A high intensity heat source.

 Protection from the atmosphere.
Resistance Solid state  Protection from surface contaminants.
welding welding
 Adequate properties – physical, metallurgical
and mechanical.
Arc Oxy fuel Electroslag Thermit Power
welding welding welding welding beam
welding
MMA TIG MIG/MAG/ SAW PAW

FCAW EBW LBW
Heat Source Atmosphere
 Local application of heat in order for fusion to Protection from oxygen and nitrogen
occur.
 ARC – a low voltage high energy spark across Fluxes - MMA/SAW.
an air gap. Gases - TIG, MIG/MAG, FCAW.
 Typical temperature range for steels Vacuum - Lasers, electron beam.
approximately 1400-1500°C.
 Average temperature in the arc approximately
6000°C.

Contamination Properties
Mechanical cleaning The completed weld must have adequate

 eg MMA, TIG, MIG, MAG properties
 Material selection.
 Consumable selection and control.
Chemical cleaning  Control of heat input.
 eg TIG, MIG, MAG  Add alloying elements.
 Heat treatments.
Fluxes/slag
 eg SAW, MMA,FCAW
Four Factors Welding Variables
All welding processes must comply with these 1. Amperage

four factors in order to produce an acceptable  Flow of electrical current through a conductor.
weld.  Measured in Amperes (I).
 Controls burn off rate and depth of penetration.
 Electrical pressure required to cause current to flow
through a circuit.
2. Voltage
 Volt (E) is the unit of electrical pressure.
 Controls weld pool fluidity.
Welding Variables Constant Current Characteristic
3. Polarity Drooping characteristic

 Determines heat distribution at the arc.
 Direct current (DC), can be either DC+ or DC-.
 Alternating current (AC). OCV
Operating Work Point
 Current flow alternates between the positive
Volts
and negative poles.

 The rate of weld progression. Increase arc
gap
20
4. Travel speed
Decrease
 Affects heat input and affects metallurgical and arc gap
mechanical properties.
120 Amps

Constant Current Characteristic Summary
Flat characteristic Constant current Constant voltage

(drooping) characteristic (flat) characteristic
OCV
20
MMA MIG/MAG
Volts
TIG FCAW
SAW > 1000 AMPS ELECTROSLAG
SAW < 1000 AMPS

200 Amps
Welding Inspection Manual Metal Arc (MMA) Welding
Manual Metal Arc Welding

(MMA) Consumable electrode
Evolved gas shield Flux covering
Shielded Metal Arc Welding Weld Metal Core Wire
Slag Arc
(SMAW) Weld Pool
Parent metal
MMA – Principle of operation
Manual Metal Arc (MMA) Welding MMA
Power source.
Power control
Transformer/
Advantages: Disadvantages:
panel
Rectifier
Electrode oven  Field or shop use.  High skill factor.

Heated quiver
 Range of  Slag inclusions.
consumables.  Low operating factor.
Electrodes  All positional.  High level of fume.
Inverter power
Power return
source  Very portable.  Hydrogen control.
cable
Electrode
 Simple equipment.
holder
Safety visor
(with dark lens) Power cable

MMA Defects Welding Process
Typical defects Main features

1. Slag inclusions.  Shielding provided by decomposition of flux
2. Arc strikes. covering.
3. Porosity.  Electrode consumable.
4. Undercut.
 Manual process.
5. Shape defects (overlap, excessive root
penetration, etc). Welder controls
 Arc length.
Most welding defects in MMA are caused by a lack of  Angle of electrode.
welder skill (not an easily controlled process), the  Speed of travel.
incorrect settings of the equipment or the incorrect
use and treatment of electrodes.  Amperage settings.
WELDING PROCESS MIG/MAG Welding Process
Metal Inert Gas (MIG)-

Metal Active Gas (MAG) External wire
feed unit Transformer/
Rectifier
Internal wire
Gas Metal Arc Welding

feed system
(GMAW) Power control

panel
Power cable
and hose
assembly
15kg wire spool

Liner for wire
Power return
cable Welding gun
assembly
MIG/MAG Torch Assembly MIG/MAG Wire Drive System

Torch body
Internal wire drive system Plain top roller
On/Off switch
Torch head assembly
(less nozzle)
Hose
port
Nozzles or Spot welding

shrouds spacer
Contact tips Half grooved Wire guide

Gas diffuser bottom roller

MAG/GMAW MIG/MAG - Principle of Operation
MIG-Metal Inert Gas 100% Argon
Aluminium,
copper,
9% nickels
MIG/MAG - Principle of Operation MIG/MAG Principle of Operation
MAG - Metal Active Gas 100% CO2 Effect of shielding gas on weld bead shape
80% Argon + 20% CO2
Carbon steels,
low alloy steels
De oxidisers: Silicon,
100% CO2 80% ARGON/20% CO2
manganese and
aluminium Wire formulation EN 439:M21
MIG/MAG Variables MIG/MAG Metal Transfer
Three process variables MIG/MAG (GMAW) Transfer Modes

1. Wire stick out/extension.
Pulse Transfer
2. Arc voltage.
Volts
3. Wire feed speed.

Cold Metal Dip Transfer
Transfer
(CMT)
Surface Tension Transfer
(STT)
<20V
Dip Transfer
<200 A Amps

MIG/MAG Synergic Systems MIG/MAG Synergic Systems
Example: Synergic pulsed MIG/MAG welding

A form of pulsed welding using electronic control
logic to determine the value of the pulse
parameters and pulse frequency, according to the
selected value of wire feed speed.
MIG/MAG Pulsed Transfer Pulsed Transfer
Peak current - Spray Transfer
AMPS: 107–220
Amps
VOLTS: 22.8
WFS: 3.3m/min
Wire dia: 1.2mm
Background current - Dip Transfer
Time
MIG/MAG Pulsed Transfer MIG/MAG Digital systems
Peak Current =
Spray Transfer
Amps
Background Current =
Dip Transfer
Time

MIG/MAG MIG/MAG Flux Cored Arc Welding
 Lower skill required.  Lack of sidewall FCAW
fusion. methods
 Easily automated.
 All positional dip and  Range of
 Thick/thin materials. consumables.
 Continuous  Loss of gas
electrode. shield/site.
With gas shielding Without gas With metal
 Complex equipment. - gas shielded shielding – self powder - Metal
 High ozone levels. shielded core
Gas Shielded – Principle of Operation Shielded - Principle of Operation
Gas nozzle Gas nozzle
Consumable flux/metal cored Consumable flux-cored wire

wire electrode electrode
Gas shield Contact Tube Evolved Gas shield Contact Tube
Weld Pool Arc Weld Metal Arc
Slag Slag Weld Pool
Parent Metal Weld Metal Parent Metal
Advantages/Disadvantages Tungsten Inert Gas (TIG)

 Field or shop use.  High skill factor. Gas Tungsten Arc Welding
 High productivity.  Slag inclusions. (GTAW)
 All positional.  Cored wire is
 Slag supports and expensive.
shapes the weld  High level of fume
bead.  (self shielded).
 No need for shielding  Limited to steels and
gas. nickel alloys.

TIG - Principle of Operation TIG Torch
Tungsten
Gas nozzle housing Tungsten
electrodes
Non-consumable tungsten
Fitted ceramic
electrode Ceramic
shielding cup
shield cup
Gas shield
Arc
Filler Rod
Weld Pool Gas lens
On/Off switch
Weld Metal
Parent Metal Split collet
Gas diffuser
Torch body
Spare ceramic
shielding cup
Manual TIG Automatic TIG
Advantage and Disadvantages
 High quality.  Very high skill factor.
 Good control.  Range of
 All positional. consumable.
 Lowest H2 arc  Loss of gas Submerged Arc Welding
process. shield/site.
 No slag.  Complex equipment.
 High ozone levels.
 Low output.

SAW SAW Fluxes
Fused
Contact tube Baked at high temperature, glossy, hard and
Flux recovery
black in colour, cannot add ferro-manganese,
Consumable
Weld Pool non moisture absorbent and tends to be of the
electrode Flux Feed
acidic type.
Weld Metal Arc Parent Metal
Slag Agglomerated
Baked at a lower temperature, dull, irregularly
shaped, friable, (easily crushed) can easily add
alloying elements, moisture absorbent and tend
to be of the basic type.
SAW Fluxes SAW Fluxes
Fused SAW flux Agglomerated SAW Flux
SAW Fluxes Introduction to Welding Processes
Fluxes for SAW may be classified as
Type of Flux Improving quality

Acid
general purpose
Any questions?
Fused
Neutral
Semi-basic
Basic
High basic
Maximum toughness Agglomerated

CSWIP 3.0 Visual Welding Inspection
CSWIP 3.0 Visual Welding Inspection Material Inspection

Level 1
WIS1

WIS1-40215
Material Inspection Pipe Inspection
All materials arriving on site should be Condition

inspected for: (Corrosion, damage, wall thickness ovality, laminations and seam)
 Size/dimensions.
 Condition.
 Type/specification.
Welded seam
 In addition other elements may need to be
considered depending on the materials form or
shape.
Specification
Other checks may need to be made such as:

Distortion tolerance, number of pipes and storage*.
Plate Inspection Rolling Imperfections
Condition
(Corrosion, mechanical damage, laps, bands and laminations)
Direction of rolling
Specification Laps*
Lamination Segregation
Other checks may need to be made such as:
Distortion tolerance, number of plates and storage.

Material Imperfections Lapping
Mechanical damage Lap
Lamination
Segregation line
Laminations are caused in the parent plate by the steel
making process, originating from ingot casting defects.
Segregation bands occur in the centre of the plate and
are low melting point impurities such as sulphur and
phosphorous.
Laps are caused during rolling when overlapping metal
does not fuse to the base material.
Lapping Lapping
Lamination Lamination
Plate lamination

Material Inspection
Any questions?

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CSWIP 3.

0 Training Questions for fillet Weld T12

a 10-15 accumulative total.

a 28-35mm total length.

a 14-17mm total length.

a 10-15 accumulative total.

a 28-35mm total length.

a 10-15mm total length.

a 10-15mm accumulative total.

a 28-35mm total length.

a 10-15mm total length.

a Equal to or less than 0mm.

a The area is between 10-15mm2.

a 2-3mm transverse crack.

a 70-90mm accumulative total.

9 Sharp indications of mechanical damage (excluding hard stamping and pop

a 35-40mm total length.

a 28-35mm total length.

a 31-39mm total length.

a 15-30mm total length.

a 10-17mm total length.

a The area is between 10-15mm2.

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Note: Excess weld metal = Toe blend = Weld width=

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a Equal to or less than 0mm.

a The area is between 10-15mm2.

a 2-3mm transverse crack.

a 35-45mm accumulative total.

a 35-40mm total length.

a 28-35mm total length.

a 31-39mm total length.

a 15-30mm total length.

a 10-17mm total length.

a 3 or more items observed.

a The area is between 1-5mm2.

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Note: Excess weld metal = Toe blend = Weld width=

Copyright © TWI Ltd 2015

a Equal to or less than 0mm.

a The area is between 15-25mm2.

a 2-3mm transverse crack.

a 70-90mm accumulative total.

a More than 2 areas.

a 40-55mm total length.

a 30-45mm total length.

a 31-39mm total length.

a 40-60mm total length.

a 10-17mm total length.

a The area is between 2-3mm2.

Copyright © TWI Ltd 2015

Note: Excess weld metal = Toe blend = Weld width=

Copyright © TWI Ltd 2015

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