Welding Inspection Level-1

Presented By:
M.Ilyas
 Section-I
Welding Technology
Introduction:
• Welding is the process of joining together pieces of metal or metallic parts by bringing
them into intimate proximity and heating the places of contact to a state of fusion or
plasticity. This leads to Inter-penetration of atoms of metals in the weld zone and a strong
inseparable joint is formed, after the metals have cooled.

• Welding has been known to man, since he started using metals. Forge welding was
perhaps the basic type of welding, in which two pieces of metals were heated to red-hot
and forge welded by a hammer.

• Historically, arc welding, one of the most commonly used welding processes was
visualized with the invention of the electric arc, by Sir Humphrey Davy in 1801. Although
the arc welding was used even in the later part of the nineteenth century, it got a
tremendous boost with the invention of covered electrode by a Swedish engineer, Oskar
Keilberg during first decade of 20th century. During the two world wars, welding engineering
took a new turn on way to the modem day developments.

• During our every day life we come across the products, almost every thing of which is
either directly produced by welding or is made on the machines fabricated by welding.
 Section-I

Welding Technology
• Welding encompasses more than 100 specific welding processes divided into seven
families.

• Experts estimate that 50 % of the GNP (Gross National Product), in most industrial
countries, is produced by welding. Welding is important as well as complex. In our country
it is one of the branches of applied science and engineering which has been badly ignored.
It is thought to be the most simple art or craft. This thinking prevails not only in common
man, but amongst an over whelming majority in our colleges, universities and industries as
well.
.
 Section-I

Welding Technology

Need of Welding Technology:

• In the field of engineering, whenever a quality job is planned to be carried out, every
major activity is prepared in written form e.g. First of all process layout is drawn, type
and number of equipment is shown in the layout. Process parameters are laid down,
conceptual design of the equipment is made, approval of the end user is got and
detailed design is prepared. In almost all of the developed and even developing
countries, a detailed quality assurance programme for the manufacture of a particular
equipment is prepared and got approved from the customer. The welding technology
is usually part of the whole Q/A programme.
• In, our country, as already described, welding has been considered as an art and not
as a science and engineering. This is why, any sort of written document has either
been considered un-necessary or has been limited to welders qualification
certificates. However when a multinational company or consultants are involved from
the customer’s side, as a third party inspector, some kind of welding technology is
available, again as a part of the file and in most cases is not implemented on the
shop floor as an important manufacturing document.
• For promotion of welding as science and engineering, in our industry, this idea of
welding technology as an important document need to be made popular.
 Section-I

Welding Technology
Welding Technology Procedure:

• Contract Analysis
• Drawing study
• Selection of welding processes
• Filler Metal (consumable) selection
• Selection of edge preparation
• Pre and post weld heat treatment.
• Selection of auxiliary equipment.
• Type, scope and stages of inspection
• Sequence of operations
• Review of the technology
• Preparation of technology documents
 Section-II
Section-II
Welding Terminology
1: Welding:
Welding may be described as a metal working process in which metals are joined by
heating to the melting point and allowing the molten portions to fuse or flow together!.

2: Weldability
The capacity of a metal to be welded under the fabrication conditions imposed into a
specific, suitably designed structure and to perform satisfactorily in the intended service.

3: ARC
A comparatively low voltage electrical discharge through a gas, between spaced
electrodes.
Basically there are three kinds of Arc
1) Arc due to direct current
2) Arc due to alternating current
3) Arc due to pulse current
Direct current is further divided into DCSP and DCRP.
 Section-II

Welding Terminology
4: DCRP:
In this case electrode is negative and base metal is positive.
2/3 heat is produced at the base metal and 1/3 at the electrode.

5: DCSP:
In this case electrode is positive and work piece is negative.
2/3 heat is produced at the electrode and 1/3 at the base metal.

6: ARC Welding:
A group of welding processes which produce coalescence of metals by heating with Arc or
Arcs, with or without the application of pressure and with or without the use of filler.

7: Gouging & Air Carbon Arc Cutting

An arc cutting process that melts base metal by the heat of a carbon arc and removes the
molten metal by a blast of air.
 Section-II

Welding Terminology
8: Arc Blow:
An electric current flowing through the electrode sets up magnetic field in a continuous
series of circles in a plane perpendicular to the axis of the rod. Similarly magnetic lines are
also formed around the work piece and ground cables. When the fields around the work
piece or around the electrode are unbalanced, the arc bends away from the greater
concentration of the magnetic fields. This deflection of the arc from its intended path is
called arc blow. Arc blow is encountered particularly when using direct current, because
the magnetic field is in a constant direction. This occurs to a minor degree alternating
current welding.
Forward Blow, when the Arc gets deflected in the direction of travel and the backward
blow, the Arc is deflected in a direction opposite to welding direction.

9: Arc Force:
The axial force developed by an Arc plasma.

10: Electrode Force:

The force between the electrodes in making spot, seams, or projection welds by resistance
welds.
 Section-II

Welding Terminology
11: Deposition Rate:
Deposition rate is the weight of metal deposited in a given period of time, usually
expressed in kg/hr.

12: Deposition Efficiency:

Electrode deposition efficiency is defined as the ratio between deposited and melted
weight of the electrode.

13: Shielding Gas:

Protective gas used to prevent atmospheric contamination. Argon, Helium & Carbon
dioxide are commonly used as shielding gases. ‘.

14: Operation Factor:

It is defined as the proportion of the total welding time an operator is actually fusing
electrodes.
 Section-II

Welding Terminology

Deposition Rate Operation Factor

Process
% %

SMAW 60-75 20-30

GTAW 90-100 20-30

50 for Semi Auto m/c

GMAW 90-95
100 for Auto m/c

50 for Semi Auto m/c

FCAW 85-90
100 for Auto m/c

50 for Semi Auto m/c

SAW 95
100 for Auto m/c
 Section-II

Welding Terminology
15: Dilution:
When two metals are fusion welded, the final composition of the weld metal will depend on
the relative proportion of the base metal and electrode metal or filler melted in the process.
Thus the dilution is defined as a change in composition of a welding filler metal caused by
the admixture of the base metal or previously deposited weld metal in the deposited weld
bead.

16: Residual Stress:

Stress remaining in a structure or member as a result of thermal or mechanical treatment.
In fusion welding, stress arises because of the contraction of the metal during cooling from
the solidus temperature to room temperature.

17: Peening.
The mechanical working of metals by means of impact blows.

18: Pre-heating.
The application of heat to the base metal prior to a welding or cutting operation.

19: Post-heating:
The application of heat to a weldment after welding.
 Section-II

Welding Terminology
20: Inter-pass Temperature:
In a multiple-pass weld, the temperature minimum or maximum, (as specified) of the
deposited weld metal before the next pass is started.

21: Puddling:
If welding is done without filler rod, it is called puddling. Normally this is used for plates of
less than 3 mm thickness.

22: Forehand Welding

A welding technique in which the welding torch or gun is directed towards the progress of
The forehand welding technique adopted for thin sheets.

23: Backhand Welding

A welding technique in which the welding torch or gun is directed opposite to the progress
of welding. A backhand welding is used for the thickness greater than 3 mm.
 Section-II

Welding Terminology
24: Weaving.
A type of weld bead made with transverse oscillation, and consequently wider than the
stringer bead.

25: Stringer.
A type of weld bead made without appreciable transverse oscillation.

26:Duty Cycle.
Duty cycle Is defined as the percentage of a 10 minute period that an equipment can be
operated at a rated amperage without over heating or suffering other damage.

27: Buttering
A form of surfacing in which one or more layers of weld metal are deposited on the face of
a joint. The buttering provides a, metallurgically compatible transition weld deposit for
subsequent completion of the weld joint.

28: KERF.
The width of a cut produced during a cutting process.
 Section-II

Welding Terminology
29: Brazing And Soldering
Brazing and soldering are joining processes involving a filler metal with a melting
temperature below the solidus temperature of the base metal.
If the filler metal melts above 450 °C, the process is called brazing.
If the melting temperature is below 450 °C, it is called soldering.
Brazing Alloys -Aluminum silicon Alloy, Copper phosphorous alloy, Silver, Gold, Copper,
Copper - zinc alloy, Magnesium, Nickel.
Soldering Alloy - lead and tin

30: Open Circuit Voltage

It is the voltage at the output terminals of a welding power source, when it is energized but
has no current out put.
 Section-III
Duties of Welding Inspector

It is the duty of all welding inspectors to ensure that welding operations are carried out in
accordance with written, or agreed practices or specifications

Before
During
After
 Section-III

Duties of Welding Inspector

Before Welding:
• Safety:
Ensure that all operations are carried out in complete compliance with local, company,
or National safety legislation (i.e. permits to work are in place).
2) Documentation:
Check Specifications, Drawings, Procedures etc.
3) Welding Process and ancillaries:
Check equipment ,Cables, Regulators, Ovens etc.
4) Incoming Consumables:
Materials/welding consumables (Size. Condition. Specification. Storage)
5) Marking out preparation & set up:
Check Angles/Root face/gap values. Distortion control. Pre-heat prior to tack welding if
applicable.
 Section-III

Duties of Welding Inspector

During Welding:

1) Pre-Heating.

2) In process distortion control

3) Consumable control

4) Welding process

5) Welding run sequence and inter-pass cleaning

6) Minimum/maximum Inter-pass temperatures

7) Full compliance with all elements given on the WPS.

 Section-III

Duties of Welding Inspector

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
 Section-IV
Welding Joints and Symbols

A Weld:
A union between materials caused by heat, and or pressure

A Joint:
A configuration of members
 Section-IV

Welding Joints and Symbols

Basics Types of Weld Joints:

Butt Joint

Tee Joint

Edge Joint

Corner Joint

Lap Joint
 Section-IV

Welding Joints and Symbols

Angular Limits of Different Joints:

Angular Limits
Type of Weld Joint
(Degree)

Lap Joint 0~5

Tee Joint 5(Excl.) ~ 90

Edge Joint 0 ~ 30

Corner Joint 30(Excl.) ~ 135

Butt Joint 135(Excl.) ~ 180

 Section-IV

Welding Joints and Symbols

Types of Welds:

1) Fillet weld,

2) Groove weld

3) Back or backing weld

4) Flange weld,

5) Plug or slot weld,

6) Spot or projection weld,

7) Seam weld,

8) Surfacing weld.
 Section-IV

Welding Joints and Symbols

Weld and Welding Symbols:
A weld symbol indicates the required type of weld while the welding symbol
includes the weld symbol and supplementary information.
 Section-IV

Welding Joints and Symbols

Weld and Welding Symbols:
 Section-IV

Welding Joints and Symbols

Weld and Welding Symbols:
 Section-IV

Welding Joints and Symbols

NDT Symbols:

NDT symbol will consists of the following elements:

1- Reference line (draw horizontally)
2- Arrow
3- Examination method letter designations

4- Dimensions, areas and number of examinations

5- Supplementary symbols
6- Tail
7- Specifications, code, or other references
 Section-V
Important Arc Welding Processes

The inspector should understand the basic arc welding processes most
frequently used in the fabrication and repair of refinery and chemical process
equipment. These processes include:
1) Shielded metal arc welding (SMAW)
2) Gas tungsten arc welding (GTAW)
3) Gas metal arc welding (GMAW)
4) Flux cored arc welding (FCAW)
5) Submerged arc welding (SAW)
 Section-V

Important Arc Welding Processes

1: SHIELDED METAL ARC WELDING (SMAW)

SMAW is the most widely used of the various arc welding

processes. SMAW uses an arc between a covered electrode
and the weld pool. It employs the heat of the arc, coming
from the tip of a consumable covered electrode, to melt the
base metal. Shielding is provided from the decomposition of
the electrode covering, without the application of pressure
and with filler metal from the electrode. Either alternating
current (ac) or direct current (dc) may be employed, depending
on the welding power supply and the electrode selected. Aconstant-
current (CC) power supply is preferred. SMAW is a
manual welding process. See Figures 1 and 2 for schematics
of the SMAW circuit and welding process.
 Section-V

Important Arc Welding Processes

 Section-V

Important Arc Welding Processes

Advantages of SMAW
Some commonly accepted advantages of the SMAW process
include:
a. Equipment is relatively simple, inexpensive, and portable.
b. Process can be used in areas of limited access.
c. Process is less sensitive to wind and draft than other welding
processes.
d. Process is suitable for most of the commonly used metals
and alloys.
5.2.3 Limitations of SMAW
Limitations associated with SMAW are:
a. Deposition rates are lower than for other processes such as
GMAW.
b. Slag usually must be removed at stops and starts, and
before depositing a weld bead adjacent to or onto a previously
deposited weld bead.
 Section-V

Important Arc Welding Processes

2: GAS TUNGSTEN ARC WELDING (GTAW)

GTAW is an arc welding process that uses an arc between

a non-consumable tungsten electrode and the weld pool.
The process is used with shielding gas and without the
application of pressure. GTAW can be used with or without
the addition of filler metal. The CC type power supply can
be used with either dc or ac, the choice depends largely on
the metal to be welded. Direct current welding is typically
performed with the electrode negative (DCEN) polarity.
DCEN welding offers the advantages of deeper penetration
and faster welding speeds. Alternating current provides a
cathodic cleaning (sputtering) that removes refractory
oxides from the surfaces of the weld joint, which is necessary
for welding aluminum and magnesium. The cleaning action occurs during
the portion of the ac wave, when the
electrode is positive with respect to the work piece.
 Section-V

Important Arc Welding Processes

 Section-V

Important Arc Welding Processes

Advantages of GTAW
Some commonly accepted advantages of the GTAW process
include:
a. Produces high purity welds, generally free from defects.
b. Little post-weld cleaning is required.
c. Allows for excellent control of root pass weld penetration.
d. Can be used with or without filler metal, dependent on the
application.
5.3.2 Limitations of GTAW
Limitations associated with GTAW process are:
a. Deposition rates are lower than the rates possible with
consumable electrode arc welding processes.
b. Has a low tolerance for contaminants on filler or base
metals.
c. Difficult to shield the weld zone properly in drafty
environments
 Section-V

Important Arc Welding Processes

Advantages of GTAW
Some commonly accepted advantages of the GTAW process
include:
a. Produces high purity welds, generally free from defects.
b. Little post-weld cleaning is required.
c. Allows for excellent control of root pass weld penetration.
d. Can be used with or without filler metal, dependent on the
application.
5.3.2 Limitations of GTAW
Limitations associated with GTAW process are:
a. Deposition rates are lower than the rates possible with
consumable electrode arc welding processes.
b. Has a low tolerance for contaminants on filler or base
metals.
c. Difficult to shield the weld zone properly in drafty
environments