Tominnmome | [2 _ The CSWIP 3.2 Exam. ce repertory fir CSUIP 82 eam. wisto.51 Tony Whitaker rnc! tne Tongan goat sonar Tany Wier nae ! Terms & Definitions. | f! _ Types of Welds varvais (OF se rari SpotiSeam wells: —cS—— Abit: Aconfigortion of meters Plug/Slot welds: c by wns Tony Whiter Psp ase ipsa Gat 9 swetans Tony Whither rss emer ops, ~Types_of Joints. Weld Preparations... mui ag toe SGP ‘Comer joints: 7 OF pen bas Tony Whitaler Pap tecare 7 sate Be _+ 15 10. Tony Whitaker piu ieee rf pate Eneuseroa | K ‘Single bevel Single ¥ Double V x soos [1S ates FX sogeu [LS Dowie U KK] wis 19291 Tony Whitaker ping! tenes uae wis rons Toy Whitaker rip acre 1 apts Beet 0 . Welded _Joints_. BUR DotA er RS A ure weed bat joint A fillet weed but jot ‘Acompound welded butt joint wast tty Tony Whitaker resin cts somite Ee 6 Ml Welded Joints... Thoms Alle wetted T Jott eel i A cumpound welded join Ee =) wis re 251 Tony Whitaker ringpl acne rapide Bxer 1 Welded. Joints... (ap Joits biennial SF ear - Whitakiorericpat Lace 717 psa at_ ‘Aspat welded Lp Jat ede Lap joint . Welded. Joints. (Cosed Gamer Lotits a Afillet weld Closed Corner jist A at weed Closed Corner int ‘Accompound welded Closed Cerwer joint TT w1s ny Tony Whitaker rnin tee 7 fete owe[e _ Welded Joints... (pen Garner Loti An inside illt welded Open Comer joint (=e ‘An ounidefiler welded Open Comer joint (=ES 91s 1051 Tony Whitaker rnc Lace 11 94d Boe 9 Butt Welded. Butt Joint. Woldtoerxat Wel Facet “Actual toat| SG ieknes » Fusion Boundary, cor Weld mation Weldzoot * Fusion Zone * sa b= Excess Weld Metal _wistonas Tony Whitaker fein Leis 7 ome, _Sizing of Fillet Welds. sis t01y Tony Whitaker rincpd Lecter opaae oer {heat thickness ‘Deep throat fillet welds from FCAW & SAW ete ss rnp Tony Whitaker Pen! cnn ote Bae Fact of Poot Tos Blend Angie High stress concentration [* Fillet Weld Profiles. wis 10 vay Tony Whitaher rcpt techrersToyate East na 93 cot: (rea = RE zesdipied stress erm putin outs eee to iu a ‘ws10 is 1Tony Whitaker fecal Lecwe7:1onsite ome~. Welding Positions. ‘The BS EN System vf w tA t-.045| HL048 Y ‘ ba By ‘wis1000s1 Tony Whitaker isp cme 17 0p Bear 1 Terns Associated with QA/QC. What enna? natty ‘seperation echnguss an activi Ginack: wea tal got har nast be dane it order nies vot ds wanted vis 10nsy + Tony Whitaker pial acne 1 dt Be 2 seston seis 1005 Tony Whitaker Pisin Lt 77 aie nae 2 3 Terms Associated with QA/OC Terms Associated with QA/QC. Nex=Compincs sien ita ews Coenen ge dei et tamer feet Adame contain er Minor defect: Aces bal unlikely ease flu of the product eaak achat sti Mojordefect: Likely to cause failure, but small risk of Toss of Te ere ele ltetelelte tal Fclatalel eetalclanldaltacshdalaleke wis res Tony Whit Ker Pri Lest 7 onset 32 Duties.of.a Senior Inspector, 1) Plan ‘An agresdpr-tetemined ad suctured pathway, ht meets speci aim 2) Organize Tomakeallnecesay srengements ‘eid toca oor Bll plan Soe eienntpen ection 3) Suporvine Tost and consol he work of stat {nares for which you are response 9 Aust “To cay ot 3 pride and sstematic “heel on epcem/proceas to ens that ‘thas hee cael outa apeifed 915 01%) Tany Whitaker tine Leste tte ae 22 Organisation ___. (resem ispetion plantas heen mete ongstion ofthe plan Sond then begin ‘hie may invelv the flowing lamest: 1) Any teninng & cerifatonrequiced 2) Suffiagthe pha 3) Procsrenent of equipments 4) Tranpor tel site, and atte 5) Accommodation snd mesing 15) Any geal node (Religious te) 7) Lenweyslescte 11510 boy1 Tony Whitaker cpa Lecue Tonite Some 2F sibntes of an Efoctive Supervise Attribute kil ofa ffetive Senior Welding Inspector “Honosty “Knowledgeable Planning shila “Experience Organisational skills +Leadership skills ‘Responsible *Communication skills “Delegation skils “Recon! keeping skis ‘Motivation skills Impartial & fair Devisiveness «Problem solving skills ‘Analytical “Diplomacy ete sis 10y4 Tony Whitaker rsp Lene 717 9s eat 38 —_ Auditing. Anais To cay ot period and eytematic chee en ‘ystemipocer fo on tha iar Boen card outs pesfiod + Stal + Equipment + Documentation (Le. NDT reports) + Health & Safety + Ete 11s 1001 Tony Whitaler ring! Vectra Boe _ Responsibilities ofa Senior Inspector For a supervisor the principles are: Pet pt) vom: ert. tay imple men 8 swisonisy Tony Whitaker pesca Letw tt onate gee 2 Non Desimuctive Testing [ ic se Non Destructive Tesng (NDT) when we wk to « ry ofa recta ihoatderoyng it "The {af he comnon types of NDT used when ssening wsldcnnt re wis 101uy Tony Whitaker Pins! Lecare 1 an Antages an Disadvantages. of Pentti, Disndraninges Advaniages acd Disadvantages of MPL Testing, ([fivonage Disadvantage [ize operator sat ovat) [3) gh surface preparation 3) Now magestic materials | [2)Surhace Mavs ony (Sas ers ws oa tere] ow cost method] [S) Nol for porous materi Relatively ow cst [SiGe ee re reer] [a)Relativey simple (4) No permanent record i very portable ] [Svtiserous chemin wis 10093 Tony Whitaker Pins! tere ona Goer > [Simple caine (3) No permanent record [) Used through thin coatings | [5) Teal i? dretions (0°) | Wen using th stright eurent prod telnique wis tay Tony Whitaker riscpt tere rte Boar _ 9Fat Date fk oi eing [Hewmariao_ meopa a] [iets] tinge) (3) No safety requirements _|(3) Requi ([WpPertattetasant reais | [Lower tz or Cu. yS/See_| Atle an Disaatage of Raflogapie Ts (is) (Garena md Natta ital [aeebar 3) Detects internal favs Senn [Dpiveet image of tows [igh heath hazard [S)Can mensure teloneas_|[) Restricted tojob geomet, ‘wisn 1 Tony Whitaker pins! tae 17 onde goat 3 (SiFTeomscopy et tne imag [5 High epiel cat suis 190.1 Tony Whitaker Peat Leu 7 dts Ease 2 Terence Classification of Steels AlL Stools are alloys that must contain the elements Iron & Carbon _Plain Carbon Steels: 1) Low.Carbon Steel 0.01 — 0.3% Carbon: |2) Medium Carbon Steel 0.3 — 0.6% Carbon [3) High Carbon Stee! 0.6 — 1.4% Carbon’ ~____ Alloy Steels: |Low Alloy Steel < 7% extra alloying elements: [High Alloy Steel> 7% extra alloying elements wis 10971 Tony Whitaker rnc tcte 7:7 aa Goes 2 ws 10 nay Tony Whitaker rnp tect Tiana Bot 3 Basie Atomic Structure of Steels Thefellowingslides 38 $0 area bast foundation n mctallurs| (and donot form any pert af the CSWTP examination ssabus Armor imperon neti a the mtauay of eels isthe bility of on to dso carton insolation “Thecarion ate very much smaller than the rn atom end xno ol replete sto structure, but is ewcen it al Be ele ‘This ype of slid solution istered as being Inerstiiel sv1s 00 2 Tony Whitaler Pini eco 7 pte one F* Basie Afonmic Structure of Stes Or [JO] Por rn ram (Fe) o--O GEE tn ities “Ape Pare of SS ‘(Present below <723 °C in Plain Carbon Steel) sea br elmer at ean it ner pet ‘hice galing bees Thiciea crtcalfentre of ron tick enable varon best veestets Lenonmising,stncting,hanening el lobe cared cal wis 10. Tony Whiter tinct eu 1 te Gate 2Basic Atomic Structure of Steels. [Attomporsturs Below Aci 1, (LCT) ion exes ie his @ Alpha iron This suture occurs below 723 °C aad is body centred or BCC in stretare ean aly dissolve up to 0.02% Carbon ‘Also known as Ferrite or BCC iron GBR cone rutin ape tis ors. Tony Ula npn peo FA Basie Atomic Structure of Steals, wis 10bs52 Tony Whitaker Prin acer maa feat 2 Attemperatures above the Aeir3, (UCT) iron exis ike this @ Y Gamma iron “THissmctar oun sone he UCT ia ean dials ap 206% Carbon ‘Ale called Austenite oF FCC iron BB compact rss spe hie \wis1aas2 Tony Whitaker rnp lence 1 ate Ente 2 Plan Carbon Steels and is FCC in strate. [fate seat and then cooled sly in sitio, then ‘euctrevere stom changes takeplsce satel hat conains> 0.3% Caton is cooled quietly then the ‘sathon doesnot have time to efae out of solution, rapping the tbo nthe Term of rn. This now disor the cabot an Ineguacor tetragonal bape “Tis saperstursted solution istered as Martensite and is the Merdeststractrethet can be erm: produced insects »-2Tony Whitaker Pop acne 717 dla oes _ F2 Basis Atomic Structure of Steels some sees ae cooled quicly their structure Fock i this Martemite can be defined Asupersaturated solution of carbon ia [BCTiron (Body Centre Tetagena!) Wis the hardest structure that canbe ‘tenmally produced in sels Compressed representation could appear like this wis 199.2 Toay Whitahior Priaspl oore 1 anaefner_o Ty ‘The Lert Pots of See Micvoatrutes Solbity of Cerbon in HCC & FCC phases of teks ere: ©. Ly carbon salable, Ninuin (3% Awstnite: 7 High carbon elubilty, Mason 2.06% (Martemite: The bent boy rapid coo wie 1013 2'Tony Whitaker Pincpt eens 08 apie[ Hardenability in Steele ‘This erm sa to deeb the silty of astel wo harden rough its cross seton, or depth of hardening. We naw undentand (te mechasiam of hardening and is cline on the ate of cooling fom above the UCT ofthe sect “Thellardonsblity ofa tel ie lsd by the faflaence of the alleying element i delaying the traneoreation ternperaars ofa tel Eschallaying element bat 2 dient seveity oo this est ‘se from has as bors te fllsing fomnule: Coq or Cov %6C+ M+ Crt MOY +N CU 6 3 15 ys t0iy2 Tony Whitaker Pipl Lect 17 ie Een 2 Tine Temperature Transformation ‘eC opr dap ie owe we ge arco eciien etnona alge ne oo ncntcen cing Thondeman ervey of sel mig SeinsTad ecules dopa tts oe cet een toll deleted taletate telat hata etd petal Teta Sobene vw cheat eta earn asas Renae taaseiityed Eee tebe wis 19nay2 Tony Whitaker riaips eco! onset Bot ny 7 my a Medium Carbon Sted Tre 1) Austenite to PearlitefFerrite transformation begin 1) Austenite to Peselite(Ferrte uansformation begin. penn reer mtn nt 2) Parittransformation lo Peatlite! Fete ver | vcr Ten Suatesr Tap art aerate c a a Tew og tO isin Tory Whitaker negate rnayuae te «| Losses Tony Whither ines esrnanege_ ry ‘TIT.Carve for a Low Carbon Steel _. Effect of Hardenability iiss mj ef 0 he wlio es seetetstaeae teat aie? hn ef the neces ar Peart a Pin Carbon Lew Aly ie deere teas meee bation Potter rol tesean (eee been rife a Basrcr A tach noo a Atego th UCT ad gc ling ty 0 wis ren? Tony Whitaker rcp Leese it onyate Eat © ‘sestioned and ardnes tse sere the rea wis 19 o9y2 Tony Whitaker rast este opyete Entvis 0pny2 Tony Whitaker rings tectee 217 9te Ee 0 Suramary_of Hardensbility (On analysing this experiment it ea be determined thatthe only Afirenze between Use wo spacieas is tei composition [By eebtatng the value inthe Cag formas we canes sk te ardeesbilty of specimens ae flame: Ayas%C= Coys Dyas C+ 026+ 045 +005 co 0.76 IWcan be detninod fem this experiment tat bell: chemial ton snl material hickmess have 2 major ellen the ardenabiltyol seals Alii of hardenabiltina too is temed it relngscsine wis 100212 Tony Whitalir tres tectre onde Bao ‘Lasting Fest ‘Soliianeracinaln Astenlesttee eels Inter granalorcrosnn Stile Sel Studied of 3 loved wis 1092 Tony Whitaker rcp! Lacie 717 pale Game 9 ~" Hydrogen Induced Cracking wisi 2Tony Whitaker Pincinl tess iv opgateEnet_3 Hydrogen Induced Cracking Crack ype: TEHAZ,& weld metal cracking Location: sTIAZ (Longitinal) ed Cracking B, Weld metal (Tanene) hydrogen aa siling psa yop seabed in Stel pee Allhardenabl tet inctaing: lang orenctable are ‘HSLA telex Low Aloy steels & 7 fom \ fea ‘Quench & Tempered sees ee Betoor ore Hydrogen erack Micromet: Marensite M \ / (Occur when: = F Minas 15 108 gm weld et andres aNPN Siess Pusat the yiel sess Xx Teuperare We Mertenste rms my a gies toyia HAZ wis sop Tony Whitaker Pines ce 17 mae Set wis wy Tony Whitaker fincpst Lacie 7 pu Bae[™ eyogen Ince Cre in HSL.A Sele SLAor Misr Alloyed Stes are high teagth sees tat Aerveheirhigh abength frm Bile alloying ‘Typically the leveof eying it inthe region wf 0.0336and clement och a vanaf myblenarn and acum. are ‘lI would be impose to mat ths mcr alloying ix Ueeletre di a eet of Tass acrns an electri ar= ‘Liehowever importat to atch the strength ofthe weld tothe strength of he plat, snd saa sap way of matching weld strength rut Be found sod lied ‘alind a siple method wo woud ned a look atthe eect of Increasing carbon content onthe propa aren sis 10 p2y2 Tony Whitaker pal tone 17 ype goat 2 Adkins of exibon (up 00.8386 or Eutectoid composition) will, ‘nero the tests of psa carbon tel. Over alloying te ‘weld metal with Ce Mx ho. Vice wl vente wel metal sheng, bu both wil ls insease erdenabiy in the Weld (0.83% Cash testa) wis 19252 Toay Whitalie rial Lanse TTandte Bat 1 H.Ceocking in ein Carbon and HSLA Sels "Frannene Waid Grads IN HISLA Steels Low duetity weld metal 7 THAT Cracks i Alloy stcts, Longtadiol contractional stria sw1s10nyy2 Tony Whitaker Pineal tsi apsate unt 2 H2 Cracking in QT Steels ‘Quench and empeved sts ae high alloyed secs to predse ‘teste structure an colin (> 9096) ove in uf tne nf eal i Carton 2H Manganese L 0%. Chrominm GS% —— Malyilenum 839% nino (A 2 gran fins tains Coq 78 thestcelicremes, tell fer the slower cooling or mass elec, "Tin eto intone he "Hardens or ruling section wis 1012 Tony Whitaker Pinca! cues 1 an H2 Cracking in QTS ‘Quench & Tempered, er QU tela eo steclthat are produced specifically with high hadenailiy to rece» fine martensitic (prinstrecture doring manufacture. Those tel then Iinorr tht hae tess en fden thought theichenie! composion changes athe plate thickness Inereses, This sto maintain thei seen of he plats o in cer wort, tines the harden of te stct “Thereulatweldailityis xtreme low and gest cae must be {aken avoid 1 crackin Weld & HAZ. Carel consideration ‘ste ive o Keeping anv st concentration at weld toes andthe cole inthe eld a ow as posse vs 10 p.y2Tony Whitaker tind Leste 1 gate Gane Prevention of Hydrogen Induced Cracking 1) Masia calelted peas and ever alow het _pss temperature to go below the pre-besl value Fa) Ure Lew Hydrogen procimes withthe ars sie consumables ar comet baked & sored a8 resin! 3) fusing s cellulosic EGDIO for he root en inset Ue “Hot as” 2 son as posible. Belore HAZ < 300°C) [Remove an pain el or moisture from the plate pps 3) Camy out any apc PWHT at roo 24 pose (6) Avoid any rerain, and te high duetliv weld meal wig 19 by Tony Whitaker risopa acter 10[solidification Cracking Fe Steels | [Solidification Cracking Fe Steals ack ype: Losatoa: Stel yes: Mierotctie: wiss0n2 Tony Whitaker Ped Lee 717 ade oat wis tonss2 Tony Whitaker rinpal ci TU pte Ent “eatcieal arin wis02y2 Tony Whitaker piaipl ecuce i:s0yfaae gosto ‘Conelinanain Jw1s 10 nay Tony Whitaker pros! ects Tz onite Eto Control. of Solidification, Cracking [™ Liquation Cracking Re Steals 1) The it sep in elvan this problem would beim hoon low dilution races, and change tei design crack ype: Liguston eracing “Location: HAZ (ongitoinal) Sic ype igh spr & pusphars sets Fld gana tc dsodsto ora head Na Microstuctue: Areas eubiining high S eanent ih rm tec gin an nan pin cose (Occurs whew: ys caon nseatn the Mv rato roid increser espanentily and ia mor fete Carbon coal! oa mininiaed by careful cont! in elecrode nd dilation 53) Liat the het input, hence Yow contacto, 8 nimise eatin. cxiper ental iti Sino f2AZ wil gus sil fom aroun ‘wis 10 py Tony Whitaker rea tenes i7anfate Exe © wis 100091 Tony Whitaker rascal ecu 7:1 0pyate Eee 6(Opposing contraction in HAZ, Weld metal swiss0nay2"Tomy Whiter tic Lesnew 157i oes z [2) Minimise heat input — swis1002¢2 Tony Whitaker piecil sence Dandie fae Lamellar Tearing. swiston2 Tony Whitaker rscipl Late 7 ae Bowe __Lamellar Tearing. rsktype: Lameltrtesring Lecation: Blow web HAZ Stel ype: igh sugtur & phosphorous stots ‘Microsiucnre: —Laminatlan & Sopregatian Occur when: igh contol is ace inthe shot tome dition fur conan in he hans eta esliyiathe boss etal suis 10592 Tony Whither rindpl acne} die Bae) 7 * Lamellar Tearing ‘ig contraetional strains wis sein Tony Whitaker ried ves 7 pau fase 7 Testing for Lamellar Tearing _ ‘UrTeampresion wave svey ting O° Probe fr nations ‘Machined tele specimens. ‘With fietion welded ends Penetrantie fertaminations 118193 Tony Whitaker racial Leda 717 9p oweFock for Lane eaing Selby Accezmmentofsancepiity to Lamellar Tearing: + Cany’ out thoogh thickness fee rest + Cony aut ten sonie ts + Cay at ponetrant testing of pte egos + Cary’ aut fat chal analysis (804576) wist0012 Tomy Whitaker rial Laie 17 ade 2nt_2 Control, of Lamellar, Tearing Redesioinvweld, LP L onl (Grind a i Auetileweld metal Fer ital wore ange “Triese my bewsed wis won? Tony Whitaker rip core 1 pede Bat F2 Control of Lauaellar Tearing. feel ste ree =r (5) Usea forged T picce (Crile Applications) —) wis 1092 Tony Whitaker Pics Lace 17 gate Ene _3 crcktype: Selciteaton cracking Location ‘Weld centre Gangitedial) Steeltyp ‘Aste tanks Seals. Misrosinate: Colum In diction of eoliifiaton Ocean: sy metas pi impsitis Fer aren th 1915 100512'Tony Whitaker teil tee onsite Bnet > F™ sattcalion Cracking Aus, Stik ‘Low mting point impertce ifcationcrack, Large susesite grits & tay gain bosndry area rs r a, Risiaive ‘Solidification Crashing Austeaiti Stainless Lo ming ningun Santer Del epi vig seco pet bossy aes nines oan soak cau tnputs ate dee a Shon ese ad sinning Na between the grains — \ A ee — ie sone jee sworn Wer catering + | Losunos say Witness ga =Contzol of Solidification Cracking in SIS, (2)As daha lritehae mosh enoler grin zeit ofl wed [to inerease the gain bouncy sta daring the welding oF 5) Lint the hat inp hance low conteon, Smininive | resent ws 109052 Tomy Whitaker rl cere 770 Intergranular Corrosion, rack type: Intergranular corrosion LLecaion: ‘Weld HAZ. (ongteinaty Steltypes: ‘Stans steels Microstuctre: Sensitsed grain boundaries cea when: An aren in he HAZ hs hen sete by the fostion of ‘oii cris, Ths ae ein the Fea ofa ne aig paralc}too don both ids ofthe Weld. Ts depletion of ‘hromian wl Tenet ‘shih shat prd shocks He mtrestd isin and fr ll Be rape sms 1a12 Tony Whitaker fed sneer anes Gaet_ By Tosig: Daring the welling of eases tc, s small rin ares the HAZ, pall othe wel wil fm chromium carbides the ginboundcres. Tis depletes this grain ofthe eomosian ‘essing erome exide ‘Westy thatthe sta has become “Seasifzed” or har become selive to corrosion sisiop.y2 Tony Whitaker tis Lee 1110040 owe ot “Control of Intergranular Corrosion. 1) Use Stabilized Stine Stele 2) Use Low Con Stites Stes (Below 0596) 3) Seuvity in lanl Stel may be reverse by Bel Aesbeve 1100" where the Chrome cade this temperate to sop re-sseition i107 Tony Whitaker rescoat acura angate Evert » 7 Re-Heat. Cracking. Het racking Conse ted HAZ & vel Lama eey ret Hel nbd sews wsuyy Toy Whitaker nupstawervonuasgoe «| [_ynstonesTony Wither iste sonia gato 4Dabsication goes for PWVIFT Stree lit = Reheat Cracking during PWRTS0-550°C. ‘Crvep Resistant Stet ‘yistaps92Tony Whitaker Pep ewe 770s Ent * Tye gully Crogh Uh cepibe Tonparture ange ier pce \enpotise, ad ie we of PWHTT uring hostages of weding Lege ations, rede ie risks verhatcacing uring inal resale [) Dressing of let weld oor and rezeleallacmenta welds, ex completion ofthe Wed before loons to reduce tess a) Ticuse of weld mein wih high dasiy wl abo edace (Gers of hes emcking wis 10913 Tony Whitalier pit team Tape Boe = Surumary of Weldability of Steels au exiles met insininlow eels wis 10952 Tony Whi Ke Poin Leer 07 gl Eve _ © Health, &. Ctasvevening work: ‘An direted by the course presenter, prepare sheath nd ‘ey ant check lit for the flaming indus ares: fety Audit, 1) Working ina doe pit rea. 2) Workings height 3) Wodkiag with esicmotras i, Cala castings. 4) Working in an explosive area, Petrochemical 15) Working insides vessel dat has cared toxilexplsive Sus wis 18 pay? Tamy Whitaker Pincow Lecure tangent Evening. Work _ 1) Comtinge with he suit checks “Signing off product” 2) Prepares general Health & Safety ui list to cover ll ‘neal hava within a welding eevironment 3) Explain th enn ardenabiins thon dace te mechan and coral of Fy eracking is QUT steels 4) Review th days werk andthe elvan sections ofthe ‘WIS Iecure tet ond sraver tho tet quostons 5) Prepay quetons that you may bve to preset tothe ‘otal during the ned cour reson wis 10 oy Tony Whitaker rnin Use 77 ange Enee_ © __Mechanical Testing. Why? Toestbish the fvel of mechnieat properties Which properties ? 1) Hardness 2) Toughness 3) Tensile strength 4) Duetility ‘wis 0 foes Tony Whitaker rnc ects 7 nga fue 0 15What ore Mechanical Doctetieactnataf yore man” ACharcerietht monet wel Tees of ae ret inn Ometelard=Set Thea ofa mata skagen? “Teutestengthy Theatres te aon of pig fe OpgostetStone= Wek Decay: ———Theaby dpa under tee swis1900y3 Tony Whitaker repel Lee 17 pate ae A] Destructive, “Types of tests include: Testing, fay Quatiauve tests: Mascots Bend tests Fractwetets wis ion 3 Tony Whitaker rascal ashe rit onsute feet Hardness..Testing. 1) Vickers Dlsmond Pyramids Always wes a damon 115 427 Vickers Hanns Test 2) Pirnelt hardness text> Alaye anes soo ball, » ‘Uses bl oF darn Alepending on theca a ‘Measures resilience wis10ay3 Tony Whitaker ping etre angie eet 2 Toughness_Testing. 1) Charpy Vies: 10x 10(Speeimen hortzont! Joules BSS eeplvet by BS EN 10a 2) Wadst: 10510 (Specimen vertical) Fibs 3) CTODtest: Specimen used is actus design ste Detaled fracture report. mm" wis 10 by sTany Whitakor ria! acne Tpdte Go 7 mga Machin matt J——105 10m Graduted sale ofabaotbed nergy in Toules** Pendulum Hamner 5 Hesston of specimen rs wis tobays Tony Whitaler meget Levine onyate Suet Fa Charpy VY. Testing. Ma 1.66 insane, toughacs grate “ules sbvorbed 16‘fet of vars and fine grain srteres 00 toughness energy vi casio of eat i rr Ta ale Hires fives meh Doped tones simoreeeray absorbed by te specimen! visto poy Tony Whitaker Psclteire D7 opie Bat CTrOD Testing. crown Fatigues ‘Displacement values re converte to eack tip value vis 1903 Tony Whitaker rel ecw it pide Gem Transverse Tensile Test. [A Sesion of wel ie ctor machined out aerae the test pioce tested in esion to Glare. Te anit nelly in Nin? Temes Gace ot pes wis ro1s3 Tony Whitaker rinse 7 onsae oat 2 All Weld Metal Tensile Test ‘BS 709/28 EN 10002 AN Wl Metal Tense Testing [state piece cut slong veld specie. Jus ray Tony Whitaker rept cure 7 anate Bee _Duetility Elongation A%_ "Tho now dinensin is taken a 2 onerosseinexcass (of 30 aa (ach ze ‘ct sa (ccasionlly Duciity is measured as 46 oF educa CSA, particulary in specimens that ae shorter thon 50 mun wis toy Tony Whitaker rnd rte 1 nga me _Dustility Elongation A%.. Occasionally dctitys meanved a 2% of Redution in (CSA, pacar in specimens that are shecter ha 50 mm AN@uvm bar (x51 rahe paste © "YaRestacti i Atea = 19% wis 10093 Tony Whitaker rinipt cae te Caen‘Tearlle Characteristics and Unite Yield Stress Re( or) ets Uperor Laver Sem) ‘Tensile Sires: (ate nae ee) Proof Stes: py OF a) (Canter Ost 2% 07 Cee Leng) longetin: AMG (acai lucas ef eng ag Sto) sta: (Stent Tannen son in rea > ri 2 Phe) ‘wise Tony Whitaker ecps acte!11 pds Geer ry _. Welding Procedures... 2) Matera types and fr to be welded? Taw Al Steet Pipe BB ¥) Welding Posi? isi Neri! Pipe hinted er & ©) Welding Process & Consumables + eat apt? MMISUSMGG- 325 ated 380°C, a: 125m Bh soa design? {Gr Single But lle bs joint _ ©) Hest treatments? Pre hos 380 C+ PAVE Sires Rane 80°C wis 190 1 Tony Whitaker rnc Lectse 7 apts Batt pWPS Preininary Welding Procedure Spesfcton WPAR (WPQR) Wing Procedure Approve fr Glen) Ree wes ‘Welding Procadere Speciation wis 101s 3 Tony Whitaker rnp tcbre rttangaae Goes __Welder. Approval. ‘Once te proce hs ben approved tis the pnt ta {esteach welder, loenrere tat he hs the all trol he sslamane level of quay lathe weld, said down inthe ‘rplicationstadard ‘Therein no need to cay out the mectanical tea of the ‘roceduse, hough bend tet ae aflen ase to ensue apo fide wal fasion ‘Nonmaly; vss xy, bens, ctr and mac's aused in welder approval tests AcSWIPs. Wale lepecorie army repute te ‘apreisonandtesaget er areal ws 1905.9 Tony Whi Ker Pia ena 1 AR Sere i Weld Symbols on Drawings ‘Mos weld pmol convention entsn 5 element, whi are: [4 Weld Symbols on Drawings ‘Woling Processes: Pasion, Said Phos, Surice Hom! Welding [BSEN 4065: Nomenclature of processes and reference members: 1 Ave Welding oan Welding 1) The arm fine Postal set, a 2) Reshtance Welding 7) Other Weng Processes 2) Theewerence tne y 3) Gan Welding 8) Thera Cutting’ Gouging 3) Thesgmbt 4) Vhedinensians 4) Prosare Wel Deady Sadsing Fi cenlslay thrall 1) Indicator main process group (ie reeling As above : 11) Indicates sub welding procos group (idont sel 111) tadicatasepaifie welding proces (Maneal Metal Ie) ister Tony Whitaker rincinlLecre apse eet sys 1» Tony Whitakor ring te 11 ont Gem 18“ Heat Treatments. Heat. Treatments. “Tilia restaneis applied to mca ae eles af clement Heine [2) Soaking Temp Time swist0ay4 Tomy Whitalir Psp Lanes 77s Suet ‘Anvcaling: -|[Usaite make metas sot and duce erate, be canponati narataboe es UEoe LSet nate Heer Posies sce orto ‘Norman |[Useu to make seo tna steering bt reg oa J \, erases east or noes se Wh pe es wis sony ‘Tony Whitaker rindpt Lxace pate fame 00 Heat Treatments 1 eat Treats 8 PIVHT Wor Tampering: Fis pire meson 2m—7a-c Te ay JERS RETA oi healt seen wong es Paahenas pint anhnnscvcrio ae wis rapa Tony Whitaker ipl teste 7 apse Geo sis 10 by ¢Tony Whitaker rip ste 795i Ge af Heat Treatments. Toad aly on oss to and th coking Protesting: rate of hardens tet and roo the seeing elfot (Martens Soretinn) sion oF Lgdrogen is a sed a se form ate serio, th Fatigue Faihures_ Fatigue tacts sents ike al facture, fom areas whee ‘Mestre ar hipe an alee ares. We ell hes aeae Sites ‘Conssatrtions 280 they ecur a points whore thre ian abrupt thangein CSA sucha the toes of welds, or an are ike Fatigue fuluesaser dt ci lang and at res ve ‘well blow the materials UTS So that weld devine ean have safe Hats to were within, SN ‘papi hve been praduce to give facto af ait tobe applied ‘wih specie welded joint desiens ‘Wheres Fig Limit ietbliahed tis importa to remeber wis 1854 Tony Whitaker pracpa tecre7}790§ateGaee_10 hat th tl be race athe preseace ofa evens me as toy (Tony Whitaber rip tcure 77 aygute foot o 19“" Obvervations of Fatigue Fractures Fatigue fractures sented rom ss concentrations andthe progres slowly Urough the setion in dutiematrials nl the Fnitsuiciet CSA to support the applied Toa Areas of changes in coins i. Iosdnglorerion ee are ‘harclesed by ash wars obvered onthe facie srfce Theenientre af the rad Lines of major pai (Beach nats) at cn hej sway points tate crac stat Fractured rotating shaft svi 1900yTony Whitaker posit Lees 7a Best pa Suenmary,of Fatigue Failures 1) Fatigue lars are lays insted fon rose 2) The Gna Gactred eurice ie charecternod by area of late thse areknown 28 acts marker 3) The epicentenf thera te ‘stare 9) Thefacturegenecly conus to wove wail fi ‘Siig avalablete cay the creased evel of es 5) Fatiguowil ot bode final ds fen the fet, (ation pia the sista Tony Whitaker rnc terete Eee facta, bts very F* _Brittle Fracture Failures Brit incurs are rapid flues of metals structures tat occur ‘wher stl has became rile and in he presence of me Kind ‘ft and onmast oosasons ain niger “Thin ste eam be static dynamic tess, er te final mode of (olla ssocated wil ueter fora of Eseure ‘The rctred secs is ameterised by ts Ml nd eres sppesranee ths generally at 2 co the plan of the sess “Thesueface is marked wilh ccerons (->>8<<<) whieh point inthe direction of # the acre iiation pint swist0 uy Tony Whitaker Prec tse 14 90dte Eee Observations of Brittle Fractures, Fracture Surface CChevrons point to the fracture initiation point sis 100.4 Tony Whitaker fineinl tease ate Bast Summary of Brittle Fractures 1) Brite factares fit om anes of high ress eanceareio 2) Mayalsobe the nfmedeoffrctre in fatigue fete 3) Bri aetues generally occur at O° othe applied fond ')—Beilefistnedsefivsn ae rsaline (Flor anus) 5) Arcasindiatng bile fncture may be observed in ‘oliersse ductile pines enusel by ° Pain Stata Fifer™ 6) Dus eile end 1 Become brite when exposed tosub ze temperatres(leaze DucilBreleTeaaiion) 11510 9+ Tony Whitaker Piel taste 1 pdt st F2 _ Duetile Fracture Failures Dect actus ae pencrly 2 final mode of fctre and sre smareeflen axcated wi fal flute of fala eels “The final nce is characterised bya distin lore a 5°10 {he ine of applied ies Thief accompanied by seat Tips am thefts Face ‘Duce ess ae often ead in beans wel before Hn ‘Brewresnd ae regulary monitored by NDT Doel tam can olen ser themlve in melalicactrcs svi2200 Tony Whitaker inl Leste 9 ee 1 20Bai Observations of Ductile Fractures Fillet Welded T Joint Fillet Welded Joint Side View Bront View inl dette fracture Dives of sees wis 100» ¢Tony Whitaker Pips Lets D1 nade vet Summary of Ductile Fractures 1) Daetilefintures ose from ares igh sess conecuraron 2) Rima ak be he fine! moda fester in figs este 3) Ductile etre gently scur at 15° othe applied lod 44) Ductile facture surices ae rough, and ofen show stew ps 5) Wixpowibe to findiniesions oF a3 nts meatoned ia this presentation shown onsale rasture ures C= wis 02 Tony Whitaker roa tem Tvansdte fet ‘Sunmary, of Brittle Fracture Analysis, seta tobe considered when investigating BritleFrctres itl Retrer ae ely occur seas hat exit good tugmens a renal ream trpertires afer they hve been exponad torr femporstures for any length of ine. (AL ‘erpertuesholw the tansion range) ‘The presence of sudden bnpact will caus the see toudergo Iwi nctre with characters muon Fire. This omest ‘enacconpanied by #wiarp and lua mabe Factor to be acetsined would include eyewitness accounts of these elements an rer vestigative wor to exablsh aker ‘possible consi fete, suchas the caring of eryogcaic Tid gen under pre wis tony + Tony Whitaker reid Lense TFs ewe Soummeary_of Fatigue Failure Analysis, Fao codec when ving Fate Freee Faget etl om are fg es toncntin oh sly ee ones ome Fie ns Taye abies esters Stn bere ees tte OTS In analysing Stic Bre, hs presen of cle tee na prime reqiresen inte ination and iter propagation of boas simple ar degre Anolis of to inte face and ienifeation of epceutcs of ‘he plants lipwil eadto the imovery ofthe ratarsiitaton point {1s 1000 +Tony Whitaker Pino! Lecter ide Boer Summary. of Ductile Failwe Analysis. act tobe considered when nventigatng Ductile Fnetres eile acter inate om areas of high sess concetaton ‘When analysing the lure pttem of dtl ile, the propagation rateof tie erck may have bam extremely hon, bt final Hata wil ‘berapid ithe component is onde Analg ofthe ast ries wil nitty she that ha cre ‘ccured 15° to the ond, andthe surfs snd may be accompanied Tysheor lips, arlarge aren uf plastic soncoint Daslie materiale may very allen show indications associated with Title iste eaused dang Gcture by the “Zin Senin Effeer wis 10D2y Tony Whiter rns tenes i nde ner 1). gee rer ae ole tae 2) Manse (Showing cnet 50a a 8) 3) enemas terrae 1 apn es) sui Re. tt. Observemts 09/03/09] ‘wis wins ‘Tony Whitaker Pincnt Lecue 17 apse 21