Example Slide of User Functions

Time guide the slide should be finished by A fillet welded Lap joint*

A spot welded Lap joint* Indicates a click is required to progress to the next element Relevant course text section:page/pages if applicable Text Page Ref 1:9/10

A Weld:*

A union between materials caused by heat, and or pressure

A Joint:*

A configuration of members

Text Page Ref 1:1

Butt welds:*

Fillet welds:* Spot/Seam welds:* Plug/Slot welds:* Edge welds:*

Butt joints: * T joints: * Lap joints: *

Corner joints:*

Closed corner

Open corner*

Remember, the purposes of a weld preparation is to allow access for the welding process, penetration and fusion through the area of the joint and its faces* The basic rule is this: The more you take out, then the more you must put back in* This has major effects on economics and distortion control etc The root face, root gap and angle of bevel values, the choice of single, or double sided preparations, are dictated only by the type of welding process, the position and accessibility of the joint*

Angle of bevel* Root face*

Included angle* Root gap*

Root radius*

Root landing*

Single bevel Single V Single J

Single U*

Double bevel

Double V

Double J

Double U*

A butt welded butt joint*

A fillet welded butt joint*

A compound welded butt joint*

A fillet welded T joint*

A butt welded T joint*

A compound welded T joint*

A fillet welded Lap joint*

A spot welded Lap joint*

A compound welded Lap joint*

A fillet welded Closed Corner joint*

A butt welded Closed Corner joint*

A compound welded Closed Corner joint*

An inside fillet welded Open Corner joint* C

An outside fillet welded Open Corner joint*

A double fillet welded Open Corner joint*

Actual Throat Thickness* 1.2.3.4. Weld Toes*

1
A

Weld Face* Weld Width* Design Throat Thickness*

2

HAZ* Weld Root*

Fusion Boundary* Fusion Zone*

A + B = Excess Weld Metal**

Vertical Leg Length* Weld face*

Horizontal Leg Length* Excess weld metal ** Design throat* Actual throat*

a = Nominal throat thickness s = Effective throat thickness

Deep throat fillet welds from FCAW & SAW etc*

6 mm 80 Very Poor Weld Toe Blend Angle 3 mm* 20 Improved Weld Toe Blend Angle

It is also possible that the height of excess weld metal is within the accepted limit of an applied standard, but the toe blend is unacceptable, as shown below* unacceptable

90

3 mm

Extremely poor toe blend, but excess weld metal is within limits*

Weld: Joint: Weld Preparation: Types of Weld: Types of Joint: Types of Preparation: Preparation Terms: Weldment Terms: Weld Sizing (Butts): Weld Sizing (Fillets):

A Union of materials A Configuration of members Preparing a joint to allow access and fusion. Butt. Fillet. Spot. Seam Plug. Slot. Edge. Butt. T. Lap. Corner (Open & Closed) Bevels. Vs. Js. Us. Single & Double Sided. Bevel/included angle. Root face/gap. Land/Radius Weld face & root. Fusion zone & boundary. HAZ. Weld toes.Weld width DTT. ATT. Excess weld metal. DTT. ATT. Excess weld metal. Leg length *

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

Describe your duties to your code of practise. CSWIP Exam*

Discuss the following Before Welding:

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* Activities & Imperfections* Activities & Imperfections*

To Record

To Compare

Some attributes/skills of an effective Welding Inspector:*

Honest Literate Respected Dedicated Impartial Observant Decisive Analytical*

Knowledgeable Experienced Record keeping skills Communication skills Safety conscious Inquisitive Responsible Diplomatic skills*

A Welding Inspectors toolbox should contain* A welding gauge (Cambridge style, or high low gauges etc) A tape measure and scale A wire brush A magnifying glass A torch and mirror A specification, pen and report, or note paper Any other aids to visual inspection*

Inspection may utilise the following specialised equipment:* Boroscopes (For assessing root runs in small pipes) Flow-meter (For measuring gas flow rates in MIG/MAG/TIG) Simple NDT equipment (Penetrants and MPI) Complex NDT equipment (Radiography or Ultrasonics) Note: Both simple and complex NDT methods requires the specialised skills of qualified operators/technicians*

Welding imperfections can be categorized into groups: 1) 2) 3) 4) 5) 6) 7) Cracks Gas Pores & Porosity Solid Inclusions Lack of fusion Profile & Lack of Filling Mechanical or Surface damage Misalignment*

A HAZ hydrogen crack, initiated at the weld toe Most cracks are initiated from stress concentrations *

Surface breaking porosity Shrinkage cavity* Coarse cluster porosity Fine cluster porosity Blow hole > 1.6 mm

Hollow root bead

An isolated internal porosity

Surface breaking solid inclusion Internal solid inclusion causing a lack of inter-run fusion* Internal solid inclusion causing a lack of sidewall fusion

Internal solid inclusion

Solid inclusions caused by undercut in the previous weld run

Lack of sidewall fusion & incompletely filled grove* Overlap (Causing cold laps)

Lack of inter-run fusion

Lack of sidewall fusion Lack of root fusion

Spatter

An Incompletely filled groove

Lack of root fusion Arc Strikes Bulbous, or irregular contour Poor toe blend

Incomplete root penetration

Shrinkage grooves

Crater pipe

Root concavity

*
Excess penetration, and burn through Root oxidation in Stainless Steel

Root Run or Hot pass undercut

Parent metal, surface undercut

Weld metal, surface undercut*

Weld metal, surface undercut

Parent metal, top toe undercut*

Any surface damage caused by:

Grinding Hammering/chisel marks Slag chipping hammer marks Torn cleats (Hammered off attachments) Arc strikes All of the above may cause serious weakness to the weld area*

Linear
Excess weld metal height Lowest plate to highest point

Linear misalignment measured in mm

3 mm

Angular
15 Angular misalignment measured in degrees*

Why ?*

To establish the level of mechanical properties* properties

Which properties ?* 1) 2) 3) 4) Hardness* Toughness* Tensile strength* Ductility*

Mechanical:* Properties:*

Describes the actions of force & motion Something that makes one material useful for a job. These include the properties of: The ability of a material to resist indentation The ability of a material to absorb impact energy The ability to resist the action of a pulling force The ability to deform plastically under tension*

Hardness:* Toughness:* Tensile strength:* Ductility:*

We test welds to establish minimum levels of mechanical properties, and soundness of the welded joint* We divide tests into Quantitative & Qualitative methods:* 1) Quantitative tests: 1) Quantitative tests: (Have units)* (Have units)*

2) Qualitative tests: 2) Qualitative tests:

(Have no units)* (Have no units)*

Types of tests include: 1) Quantitative tests: 1) Quantitative tests: Hardness tests Hardness tests Toughness tests Toughness tests Tensile strength tests* Tensile strength tests* 2) Qualitative tests: 2) Qualitative tests: Macro tests Macro tests Bend tests Bend tests Fracture tests* Fracture tests*

The test weld is usually cut into sections as follows: The location of specimens will depend upon the standard Charpy V test Bend test*

Tensile test

Start/ Stop

Macro/Hardness test

The specimen below has been polished and is ready to be hardness tested = Hardness Survey

Thickness

Base metal

HAZ Fusion boundary Weld metal

Further hardness surveys may be taken as the thickness of the specimen increases*

Generally we use a diamond or steel ball to form an indentation

We measure the width of the indentation to gauge the hardness*

1) 2)

Vickers Diamond Pyramid: Always uses a diamond* Brinell hardness test: Always uses a steel ball*

3)

Rockwell hardness test:

Uses a ball, or diamond depending on the scale*

Machined notch

10 x 10 mm

The specimen may be tested from different areas of the weld.* Graduated scale of absorbed energy in Joules* Pendulum Hammer

Location of specimen

1) 2) 3)

Charpy V test: 10 x 10 (Specimen horizontal) Joules* Izod test: CTOD test: 10 x 10 (Specimen vertical) Ft.lbs* Specimen used is actual design size. Detailed fracture report. mm*

Mn < 1.6 % increases toughness in steels* Transition Zone

Joules absorbed Ductile Fracture

47 Joules

Three specimens are normally tested at each temperature. 28 Joules Transition Temperature Range Brittle Fracture -40 -30 -20 -10 0 +10 +20 +30 + 40 Testing temperature

A Section of weld is cut, or machined out across the test piece and tested in tension to failure. The units are usually in N/mm

Transverse reduced test piece*

Radius (For radius reduced test specimens only) Weld Test gripping area HAZ

Direction of test Plate material Reduced Section

Used to assess the tensile strength of the weld metal

BS 709 / BS En 10002 All Weld Metal Tensile Testing

Direction of the test *

Tensile test piece cut along weld specimen.

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 %*

1) Excess Weld Metal Height

8) Poor Toe Blend* 7) Laminations 6)Porosity

2) Lack of Sidewall Fusion 3) Lack of Root Fusion

5) Root Penetration

4) Slag inclusion & Lack of inter-run fusion

Bend tests are used to establish fusion in the area under test Guide A Guided root bend test* Lack of root fusion shown here*

Former Test Piece Force

Further tests include face, side and longitudinal bend tests* For material over 12 mm thickness, side bend test may be used*

Specimen prior to test*

Specimen after test*

Saw cut Hammer blow 1 Fracture line Full fracture X 2 1 2 3 3

1 X

3 Line of fusion

Y Inspect both surfaces

Any strait line indicates a Lack of root fusion*

Saw Cuts A

Hammer blow

Fracture line

Inspect both surfaces

Lack of root penetration or fusion

Inclusions on fracture line*

We test welds to establish minimum levels of mechanical properties, and soundness of the welded joint We divide tests into Qualitative & Quantitative methods:* Quantitative: (Have units) Quantitative: (Have units) Hardness (VPN & BHN) Hardness (VPN & BHN) Toughness (Joules & ft.lbs) Toughness (Joules & ft.lbs) Strength (N/mm2 & PSI) Strength (N/mm2 & PSI) Ductility/Elongation (E%) Ductility/Elongation (E%) Qualitative: (Have no units) Qualitative: (Have no units) Macro tests Macro tests Bend tests Bend tests Fillet weld fracture tests Fillet weld fracture tests Butt Nick break tests* Butt Nick break tests*

The main difference between Macro & Micro is that Micro is the study of the micro-structure at much higher magnification The limit of Macro inspection is magnification < X 10 The specimen is usually cut from a stop/start in the test piece The cut specimen is polished to a fine finish (400 grit) The specimen must be inspected, before etching*

Remember! The process of inspection is to first:

Observe, then Report, then Compare!*

Use the TWI macro sheets provided to observe and then make a report on a separate sheet of what you observe*

When you have finished reporting, turn the macro sheet over and compare your observations with those given on the back of the sheet* (1 hour)

A definition of the term Procedure?*

A systematic method of producing an aim*

Therefore, a Welding procedure is?*

A systematic method of producing a sound weld*

What do you think about the following statements?*

Do all welding procedures need to be written?*
Most production welding procedure are formatted on written documents or computer spreadsheets, but they need not be written and may be a product of experience

Do all welding procedures need to be approved?*

Most procedures are approved, but not all? An approved welding procedure is one that has been tested to ensure that the procedure as carried out, produces a weld that satisfies a minimum level of quality for the mechanical, physical or chemical properties desired. If these are not required, then procedural approval is unnecessary*

A Welding Procedure is a recipe of variable parameters, which will produce the same results of certain quality & properties if carried out in the same way each time* To evaluate a Provisional Welding Procedure we need to check if all the parameters set will work together to produce the desired results* .*

Once the weld has been completed it is usually visually inspected, then Radiography or Ultrasonic testing is usually applied* Finally, and most importantly, Mechanically tested to ensure that the desired level of mechanical properties have been met* If all the desired properties have been met, then a procedure qualification record (WPQR or WPAR) is completed with all the test results, and the procedure then becomes qualified* From this data, a workable document for production welding is prepared and called a Welding Procedure Specification. (WPS)*
A CSWIP 3.2 Senior Welding Inspector is normally responsible for the testing and approval of welding procedures*

Examples of Extents of Approval include:* a) Diameter of pipe, or thickness of plate b) Welding position, amperage range, or number of runs c) Process (On multi process procedures only) d) Certain material groups e) Change of consumable to one of the same classification Only if the class is given in the original procedure f) Heat input range (kJ/mm)*

Once the procedure has been approved it is then important to test each welder, to ensure that he has the skill to reach the minimum level of quality in the weld, as laid down in the application standard* There is no need to carry out the mechanical tests of the procedure, although bend tests are often used to ensure good side wall fusion Normally; visual, x ray, bends, fractures and macros are used in welder approval tests*

When supervising a welder test the welding inspector should:*

1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 11) 12)

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.*

A CSWIP 3.1 Welding Inspector is normally responsible for the supervision and testing of welder approvals *