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Example Slide of User Functions: Time Guide The Slide Should Be Finished by
Example Slide of User Functions: Time Guide The Slide Should Be Finished by
A Weld:*
A Joint:*
A configuration of members
Butt welds:*
Fillet welds:*
Spot/Seam welds:*
Plug/Slot welds:*
Edge welds:*
Butt joints: *
T joints: *
Lap joints: *
Corner joints:*
Closed
corner
Open
corner*
Angle of bevel*
Root face*
Included angle*
Root radius*
Root gap*
Root landing*
Single bevel
Single V
Single J
Single U*
Double bevel
Double V
Double J
Double U*
Weld Face*
Weld Width*
HAZ*
Weld Root*
Fusion Boundary*
Fusion Zone*
6 mm
80
Very Poor Weld Toe Blend Angle
3 mm*
20
Improved Weld Toe Blend Angle
3 mm
Extremely poor toe blend, but excess weld metal is within limits*
Weld:
A Union of materials
Joint:
A Configuration of members
Weld Preparation:
Types of Weld:
Types of Joint:
Types of Preparation:
Preparation Terms:
Weldment Terms:
Before
During
After
1) Safety:
Legislation and safe working practices
2) Documentation:
Spec. Drawings. Procedures. Welder approvals. Certificates. Mill sheets
3) Welding Process and ancillaries:
Equipment. Cables. Regulators. Ovens. Quivers etc
4) Incoming Consumables:
Materials/welding consumables (Size. Condition. Specification. Storage)
5) Marking out preparation & set up:
Method. Angles/Root face/gap values. Distortion control. Pre-heat prior to
tack welding if applicable*
During Welding:
1) Pre-Heating. (Method and control)
2) In process distortion control (Balance or sequence welding)
3) Consumable control. (Correct baking and storage prior to use)
4) Welding process (Related parameters i.e. volts/amps. gas flow rate)
5) Welding run sequence and inter-pass cleaning
6) Minimum/maximum Inter-pass temperatures
7) Full compliance with all elements given on the WPS*
After Welding:
1) Visual Inspection
2) Non Destructive testing
3) Repairs*
4) Repair procedures (NDT/Excavation/Welding/Welder approval)
5) PWHT
6) Hydro-static testing
7) Submission of all inspection reports to QC departments*
To Observe
Activities &
Imperfections*
To Record
Activities &
Imperfections*
To Compare
Activities &
Imperfections*
Honest
Literate
Respected
Dedicated
Impartial
Observant
Decisive
Analytical*
Knowledgeable
Experienced
Record keeping skills
Communication skills
Safety conscious
Inquisitive
Responsible
Diplomatic skills*
Cracks
Gas Pores & Porosity
Solid Inclusions
4)
Lack of fusion
5)
6)
7)
Spatter
Arc Strikes
Shrinkage grooves
Crater pipe
Root concavity
*
Excess penetration, and burn through
Linear
Excess weld metal height
Lowest plate to highest point
3 mm
Angular
15
Angular misalignment measured in degrees*
Why ?*
Which properties ?*
1)
2)
3)
4)
Hardness*
Toughness*
Tensile strength*
Ductility*
Mechanical:*
Properties:*
Hardness:*
Toughness:*
Tensile strength:*
Ductility:*
(Haveunits)*
units)*
(Have
2)Qualitative
Qualitativetests:
tests:
2)
(Haveno
nounits)*
units)*
(Have
Tensile test
Start/ Stop
Bend test*
Macro/Hardness test
Thickness
Base metal
1)
2)
3)
Machined notch
10 x 10 mm
Pendulum Hammer
Location of specimen
1)
2)
Izod test:
3)
CTOD test:
Joules absorbed
Transition
Zone
47 Joules
Ductile Fracture
Brittle Fracture
-40 -30 -20 -10 0 +10 +20 +30
Testing temperature
+ 40
Radius
(For radius reduced test specimens only)
Weld
Test gripping area
HAZ
Direction of test
Plate material
Reduced Section
BS 709 / BS En 10002
All Weld Metal Tensile
Testing
Direction of the test *
Firstly, before the tensile test 2 marks are made 50mm apart
50 mm
During the test, Yield point & Tensile strength are measured
The specimen is put together and the marks are re-measured
75 mm
A new measurement of 75mm will indicate Elongation E50 %*
5) Root Penetration
Bend tests are used to establish fusion in the area under test
Guide
Former
Test Piece
Force
Saw cut
Hammer blow
2
X
3
Line of fusion
Fracture line
Full fracture
2
1
3
2
Y
Inspect both surfaces
Saw Cuts
A
Hammer blow
Fracture line
C
Lack of root penetration
or fusion
Qualitative: (Have
(Have no
no units)
units)
Qualitative:
Hardness (VPN
(VPN &
& BHN)
BHN)
Hardness
Macrotests
tests
Macro
Toughness (Joules
(Joules &
& ft.lbs)
ft.lbs)
Toughness
Bend tests
tests
Bend
Strength (N/mm
(N/mm22 &
& PSI)
PSI)
Strength
Fillet weld
weld fracture
fracture tests
tests
Fillet
Ductility/Elongation (E%)
(E%)
Ductility/Elongation
Butt Nick
Nick break
break tests*
tests*
Butt
Check the welding process, condition of equipment and test area for suitability.
Check that extraction systems, goggles and all safety equipment are available.
Check grinders, chipping hammers, wire brush and all hand tools are available.
Check materials to be welded are correct and stamped correctly for the test.
Check welding consumables specification, diameter, and treatment with WPS.
Check the welders name and stamp details are correct.
Check that the joint has been correctly prepared and tacked, or jigged.
Check that the joint and seam is in the correct position for the test.
Explain the nature of the test and check that the welder understands the WPS.
Check that the welder carries out the root run, fill and cap as per the WPS.
Ensure welders identity and stop start location are clearly marked.
Supervise or carry out the required tests and submit results to Q/C department.*