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Visual Welding Inspection

Visual Welding Inspection

Welding Quality & Inspection Welding Quality & Inspection

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Quality Fundamentals Quality Fundamentals

• What is quality?
• Is there a universally accepted definition of
quality?
• The perception of quality varies around the
world.
• How do you define quality?
• Quality is a moving target!
• Common Quality Themes
– Quality involves meeting or exceeding the
customers expectations
– Quality applies to products, services, people,
processes and environments
– Quality is always changing – what is considered
acceptable today may not be acceptable
tomorrow!

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Quality Fundamentals Welding Quality Fundamentals

Define: a good weld
• Quality = Conformance to requirements
(1) Does it perform it's intended function
• Quality = Reliability
(2) Does it meet the acceptance criteria for the applicable specification
• Quality = Value
• Quality = Safety
• Quality = Maintainability
• Quality = Fitness for Use
• Quality = Customer Satisfaction

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Welding Quality Fundamentals Welding Quality Fundamentals

• Can a weld ever be too good?

Welds can be considered "too

good" if additional efforts, time
or expense are used improving
weld quality beyond that
required by it's application or
applicable specification

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Quality Fundamentals Quality Fundamentals

Quality has been defined as:
• W. Edwards Demming defined quality as:
• “Right the first time – every time – at an acceptable cost”
– “Quality means the effective production of the
quality that the market expects, it does not mean • “Conformance to requirements”
achieving perfection.”

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Quality Fundamentals Root Cause Analysis

• The key to resolving quality problems (in welding or other
aspects of industry), is to discover the ‘Root Cause’ of the
problem and to implement a countermeasure
100% inspection is only ~80% effective!
• There are many techniques in use, however one of the
simplest and easiest to use is the “5 - Why’s”
• This strategy involves looking at any problem and asking:
"Why?" and "What caused this problem?"
(find the ‘r’s) • Most often the answer will lead to further questions and you
must go through the process several times to reach the Root
Cause.

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5-Why’s Example 5-Why’s Example

1. The FCAW welds have porosity…Why? 1. The FCAW welds have porosity…Why?
2. The electrode wire is rusty…Why?

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5-Why’s Example 5-Why’s Example

1. The FCAW welds have porosity…Why?
1. The FCAW welds have porosity…Why?
2. The electrode wire is rusty…Why?
2. The electrode wire is rusty…Why?
3. The wire rusted because its been sitting exposed in
3. The wire rusted because its been sitting exposed in
the back corner of the shop for months…Why
the back corner of the shop for months…Why
wasn’t it properly stored?
wasn’t it properly stored?
4. We didn’t know that it mattered…Why?

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5-Why’s Example Quality Control vs. Quality Assurance

1. The FCAW welds have porosity…Why?
2. The electrode wire is rusty…Why? Quality Control
3. The wire rusted because its been sitting exposed in –Detection method
the back corner of the shop for months…Why
wasn’t it properly stored? –Non value added activity
4. We didn’t know that it mattered…Why?
5. The company doesn’t have procedures for electrode
wire storage and hasn’t trained its staff on why it is
important…Root Cause.

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Quality Control vs. Quality Assurance Quality Control vs. Quality Assurance
• Quality Control is expensive.
Quality Assurance • Many companies believe that poor quality
can be overcome by increased inspection.
–Prevention method • Control check points don’t always address
–Value added activity the root cause.
• Improvements are neglected because
everyone is busy putting out fires rather
than improving the process!
• Non-value added activity.

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Quality Control vs. Quality Assurance
• Quality Assurance ensures that the process
is designed to prevent problems from
occurring.
• Quality is assured by activities that prevent
the problem.
• Every department within the company is
works to prevent problems.
• Value added activity.
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Quality Control vs. Quality Assurance
Quality
Assurance
System
Structure
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Quality Control vs. Quality Assurance
 Quality Control (QC) would have
checks in place (like inspection) to
detect defective welding from Look for
things like defective electrodes or Defects
bad welding procedures
 Quality Assurance (QA) would
have the checks in place to
prevent defective electrodes or
unqualified procedures are never
used in fabrication
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Welding Procedures & Work Instructions
• Successful cooking requires a ‘recipe’ and a skilled chef
• These recipes can be considered a ‘work instruction’
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Welding Procedures & Work Instructions Welding Procedures & Work Instructions
• Successful welding requires a ‘recipe’ and a skilled welder • To help assure weld quality,
detailed work instructions
are provided to welders in
many shops

• These instructions (WPS -

Welding Procedure
Specifications or WPDS -
Welding Procedure Data
Sheets) provide a ‘recipe’ for
successful welding

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Welding Acceptance Criteria Welding Acceptance Criteria

Weld Evaluation – Conformance to Requirements
• Clear and agreed upon welding standards are critical
to determining “conformance to requirements”
• Welding is not an exact fabrication process
• Most operations rely on the skill of the individual or
operator – human error and inexperience can create
conflict with inspection processes
• Applicable Specification is the code, standard or
other contractual document that specifies welding
requirements for a project including:
– Inspection Required
– "Weld Acceptance Criteria"
– Welder Qualification
• The specification applicable depends on the nature
of the work, governing legislation, customer
requirements, etc.

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Welding Acceptance Criteria Welding Acceptance Criteria

• If you look close enough, most welds will have some Which structure would most likely have the least tolerance
imperfections, very noticeable in some cases while subtle in to weld porosity in the acceptance criteria?
others
• When welds are assessed for acceptance, that should be
done by comparing actual weld quality to that allowed in the
applicable acceptance criteria

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Welding Acceptance Criteria Weld Discontinuities Classification

Considerations for Acceptance Criteria:
• How much weight or load will the weld be subjected to?
• What type of load is it, static (unchanging) or dynamic
(cyclic)?
• What is the consequence of failure if the weld breaks?
Does it need to be leak-proof?
• Will weld appearance be considered?
• Weld Discontinuities are also known as weld
faults or weld defects.
• The type and quantity of weld defects is
relative to the type of weld and its service
requirements.
• Welding related codes and standards define
acceptance standards for welded structures in
service.

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Welding Inspector Certification Functions of the Welding Inspector

Visual Welding Inspector Certification: The Welding Inspection Function includes
activities:
• CSA W178.1 – Inspection Companies
• Before Welding
• CSA W178.2 – Welding Inspectors
 Inspectors have 3 Levels (I, II, or III) • During Welding
 New inspectors must start at Level I and under the • After Welding
supervision of a Level II or III Inspector
 NDE Qualifications are separate methods from visual
inspection (VT) and require separate qualification
http://www.youtube.com/watch?v=UVWTnHXR2AY

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Functions of the Welding Inspector Three General Classes of Weld

Discontinuities
Qualified Welding Inspectors must be able to:
• Properly identify welding discontinuities (using 1. Dimensional
the appropriate technical terminology)
2. Defective properties
• Interpret the applicable ‘acceptance criteria’
• Evaluate the discontinuity against the
3. Structural discontinuities in the weld zone
applicable acceptance criteria
• Document findings

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Dimensional Discontinuities
Departure from specified dimensions in any way
is considered a dimensional defect. Weld faults
in this classification include:
– Poor or incorrect material preparation
– Poor or incorrect fit up
– Incorrect weld size and/or profile
– Distortion or warpage
– Undercut
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Defective Properties
• Specific mechanical and chemical properties are
often required of welds made on a given
fabrication.
• Mechanical properties that may be defective
include:
– Tensile Strength and Yield Strength
– Fracture Toughness (Impact Strength)
– Ductility
– Hardness
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Structural Discontinuities in the Weld Zone
• Generally caused by the welding operation itself.
Often internal and can be most serious.
• Weld faults in this classification include:
– Porosity
– Slag inclusions
– Cracking
– Lack of fusion
– Incomplete penetration
– Stray arc strikes
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Chemical Properties
• Incorrect weld metal composition causes too much dilution
between the weld metal and base metal, resulting in a loss of
corrosion resistance at the weld
– Example: using a mild steel electrode to weld stainless steel
• Incorrect welding procedure can lead to a serious
metallurgical condition known as intergranular carbide
precipitation. This leads to a loss of corrosion resistance in the
area adjacent to the weld.
– Example: GMAW on stainless steel with the wrong CO2/Argon mix
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Properties of the Base Metal Welding Discontinuities

• Some discontinuities can be caused by the • Defects:
base metal condition. “A discontinuity that may affect the intended
• Examples of the base metal conditions not service of a material or part and does not meet
being met are: the acceptance criteria of the applicable
specification.”
– Chemical composition
– Internal conditions (laminations)
– Surface Conditions (mill scale, paint, oil, paint) • Flaws or Faults:
– Mechanical properties and dimensions “A discontinuity that will not affect the intended
service of a material or part and is acceptable.”

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Welding Discontinuities Welding Discontinuities

The "porosity" in this weld are
discontinuities and are assessed in When defective welds are detected that are not acceptable, the
comparison with the applicable two processing options are:
acceptance criteria 1. Repair the defective weld
If it exceeds the discontinuities 2. Scrap the part with the defective welds
permitted by the acceptance
Discontinuity
criteria, it is considered a "defect"
and must be repaired or scrapped
Which of these two decisions is made involves consideration of:
Acceptance Criteria – Estimated time and cost of required repair welding
If it does not exceed the – Value or cost of part with rejected weld
acceptance criteria, it is considered
Reject Accept a "fault" and does not need repair

Scrap Repair

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Repair Welding Plan Repair Welding Plan

Defective weld removal methods….
• CAC is often preferred for
1. Grinding defect removal since it
2. Carbon Arc Cutting (Gouging) provides better visibility to
ensure defect removal and
faster metal removal than
grinding
– NOTE: in some cases it may be necessary to
follow gouging with a light grinding to
remove carbon pickup at the surface

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Repair Welding Plan

• Complete removal of welding discontinuities

such as cracks is necessary or else the crack can
start to grow again

Repair
CrackedWeld
Defect Excavation
Weld

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