Professional Documents
Culture Documents
Number 2 Inaserles @
Complledas a ueefultool tor on-the-lobweldingpersonnelby the AWSProductDevelopment Commlttee
@2004by AmericanWelding Society.All rights reserved hinted in the United Statesof America
v \ - - 7 v
Tableof Contents
BasicSafety hecautions...........................................4
Notes ...... visuallnspection Discontinuity Types: ........... Cracks . . . . . .1 .0 Inclusions Fusion..........,,,.,,,,,...........,,,,,,,.,,...,,,12 Incomplete ............................. 14 Incomplete Joint Penetration OverIap...............................................................16 .........18 Polosity......................... tn Undercut,.....................
Weld hofi les......,.-......
FilletWeldMeasurement.
..........25
30
BasicSafetyPrecautions
Burn Protection. Molten metal, sparks,slag, and hot work surfaces are producedby welding, cutting, and allied processes. These can cause bums if precautionarymeasuresare not used. Workers should wear protectiveclothing made of fire-resistant material.Pant cuffs, openpockets, or other places on clothing that can catch and retain molten metal or sparksshould not be worn. High-top shoes or leather leggings and fire-resistantgloves should be wom. Pant legs should be wom over the outside of highlop shoes. Helmetsor handshieldsthat provide protection for the face, neck, and ears, and a head covering to protect the head should be used.In addition, appropriateeye protection should be useq. Electrical Hazards. Electric shock can kill. However, it can be avoided.Live electdcalparts should not be touched. The manufacturer's instuctions and recommendedsafe practices should be read and understood. Faulty installation, improper grounding, and inconect opemtion and maintenanceof electdcal eouiDment are all sources of danger. All elect cal equipment and the workpiece should be grounded. The workpiece lead is rlot a ground lead. It is used only to complete the welding circuit. A sepamteconnection is rcquired to ground the workpiece. The workpiece should not be mistaken for a ground connection.
Fumes and Gases. Many welding, cuttmg' producefumes and gases and allied processes to health Avoid breathharmful which mav be ing lhe ai; in lhe fumeplumedirectlyabovethe ari. Do not weld in a confined area without a ventilation system.Use point-of-welding fume removal whin welding galvanized steel, zinc' or brass' manganese' chromium. cadmium. lead, contalners or piping bronze. Do not weld on that have held hazardousmaterials unless the have beeninertedproperly' containers
Compressed Gas Cylinders' Keepcapson cvlinderswhen not in use.Make surethat gas ut" chained to a wall or other struc"ylind"tt $ral support. Radiation. Arc welding may produce ultraviolet, infrarcd, or light radiation Always wear protecliveclothing and ele protectionlo proiect the skin and eyes from radiation Shield others from light rtdiation from your welding oDeratron.
''Ar-cWelding Safely"' "Fire Safetyin Welding and Cuta personalcopy of AWS alsorecommends Cutting'and AIlredProcesses ting". and"safety in Welding.
-.
Notes VisualInspection
Visual lnspection is a very effective inspection method, and it should be the primary method includedin any effective Quality Control Program.It has been shown repeatedlythat, "Visual inspection, conducted by properly trained inspectors, results in the discovery of the yast majority of those defects which would only be discovered later by some more expensivenondestructive test method." While visual inspection is limited to materials' surface-onlyexamination, it often detects the most damaging defects. Visual inspection labbreviated "YT" by the American Society for Nondeshuctive Testing (ASNT)I of welded components requires inspectorsto have a broad knowledge ol many technologie\.including welding. nondestructive testing. destructive testing, and metallurgy, as well as the correctterminoloevfor each. It is importantto distinguishbetweenthe words 'discontinuity' and 'defect'. Discontinuity refe6 to "An interruption of the typical structure of a material, such as a lack of homogeneity in its mechanical, metallurgical, or physical characteristics; a dis. continuity is not necessarily a defect." A defect refers to "A condition. or conditions. that render a part unable to meet applicable minimum acceptance standards or specifrcations." All defects are discontinuities, but not all discontinuitiesare defects. A defectcan be considered a 'rejectable discontinuity'. This pocket handbookprovides a convenientsource for the most comrnon base"metal and weld metal discontinuitiesfound by effective VT. The handbook is arranged by discontinuity type, including applicable VT detection methods,and likely causesand remediesin addition to suggested repair methods.
Cracks
_ characterized ' discontinuitv LJPEurJlv fracturetvpe A' rracrurc as"A as defined A crack is dellneo ls P{ A crack i 113":11-1ll':"::il":*'"::i::.t:l} :vere discontinuity because of usuall] are " cracks uni t"ioiitto op""ingdisplacement of ::1tJi:l'^1i1,'^j:t'::1,";, r^^,tion seometrv. rime rerminolosv for AwS crack *' rig"'ebelow ;";#f ::'#:;:'.3 "',g;i"'i' CFACK 7 BOOT SURFACE LEGEND:
CRACK 1O TBANSVERSE CRACK 11 UNDEBBEAD CFACK 12 WELD NTEBFACE 13 WELD META! CRACK
(B)
b:
Types of cracksoften include the following prefixes:basemetal,cold, crater,delayed,face, heaFaffected zone, hot, hydrogen,intergranular, lamellar tear, longitudinal, quench,root, serviceinduced,stresscorrosion,throat, toe, transgranular, tmnsverse, underbead, weld metal, and others. Crack deteciioncan be achievedvisually ifthe crack is presenton the surfaceand is of sufficient size to be visible to the eye. Smooth,clean surfaces, oblique angle lighting, and a 10x power magnifier are extremely helpful during visual inspectionfor surfacecracking.If the surfacecracking cannot be found visually, the next step is the use of the PenetrantTest method (PT). Magnetic Particle Testing (MT) can also be used,but is limited to testingmagneticbasematerials.UltrasonicTesting (UT), Eddy Cunent Testing (ET), and RadiographicTesting (RT) are requhed for the detection of subsurface cracking. Ref'er to the AWS Welding Inspection Technology materialsfor more detailsregardingPT, MT, UT, ET, and RT. Cracking can be causedby a multitude of conditions,but the more common causesare: embrittlementof the baseor weld metal causedby too rapid cooling and the formation of brittle martensite, weld shrinkagestresses, insufficientroot beadsize,poorjoint design,nonmatchingfiller metals,and corrosiveenvironment.Seefbllow ing chart for specificcauses remedies. and recommended Repairsto cracksinclude the following generalrequirementsl l. Locate crack extentand orientation. 2. Grind to remove completely;confirm withNDT. Do not weld over (on top ofl crucks. 3. Weld using proper procedure,including preheatif required,use small diameterelechodesand stringerbead Progression. 1. NDT finished \ eld and ba5e meral. Noter The aboveprocedures may not result in a suitablerepair of stresscorosion cracking, which may require replacement of the affectedpart or parts.
craterTa6re;xtEuEhhg
lnclusions
Inclusions are defined as 'Tntrapped foreign solid material, srrch as slag, flux, tungsten, or oxide." The inclusions may be found as single particles,aligned particles, or clusteredparticles. Slag inclusions are frequently found on the weld surfaces, or along the toes of the weld due to improper cleaning techniques. Tungsten inclusionsare usually subsudace. Examplesof inclusions are shown below. Inclusions on the surfacecan be detectedby VT; subsurface inclusionsrequireUT or RT.
10
Remedies
Clean suface and Previousweld bead Power wire brush the Previous weld bead Avoid contact btween the electrode and the work; use larger electrode Increasegroove angleofjoint
of reftactoryoxides Entrapment
Tungsten in the weld metal ImFoperjoi design
Oxide inclusions Slag flooding ahead of the welding arc Poor electrode manipulative technique Entrapped pieces of electrode covenng
Providepropergasshielding
Reposition work to prevent loss of slag control Charge electrode or flux to imProve slag control
Fusion Incomplete
Incomplete fusion is defined as "A weld discontinuity in which fusion did not occur between weld melal and fusion faces or adjoining weld beads." IncompleteFusion (IF) can occur on both groove welds and fillet welds. The term specifically appliesto fillet welds where the weld doesnot extendto thejoint root. Seethe figures below.
(c)
t2
of incomplete fusion usil -' Detection obrique angrerish,,n, *o,o*,"urlr;o"tul-ol #*-r*tl'""""i:i,,n,fi11:;,;;:'J'j;Jl i:ijJffi: UT or RT methods. Repairs of incompletefusion rcquire removal of the discontinuity by gouging or grinding, followed by weld repair and final insDection.
Remedies
follow correct welding procedurespecificalion
Maintain proper electrodeposihon Reposition work, lower current, or increase weld travel speed
ffi
INCOMPLETE JOINTPENETRATION
Incompletejoint penetrationcan easily be found by VT if the root of the groove weld is visible; oblique angle lighting assists in its detection.For groove welds with the root not visible, UT or RT are requiredfor detection. Repairsfor IJP, when access to the root of the groove weld is possible: permitting access 1. Gougeor grind root to an oval, open shape, to root. 2. Weld, followed by appropdateNDT method. Repairsfor IJP, where access to the root is not possible: 1. Couge or ground from the weld face to remove entire weld down to joint root. 2. Weld, followed by appropriate I\rDT method. tl
Bridging or rootopening
------
Overlap
Overlapis definedas"Ihe protrusion of weld metal beyondthe weld toe or weld root." Examples areshown belowfor fillet andsoove welds.
OVERLAP OVERLAP
t6
v v v
Detectionof overlapis usuallyfoundby VT if the sudaces arevisible to the eye;obliquelighting and tox magnification arehelpful.PI andMT may be requiredto inspectquestionable arcas. Repai$ includeremovalof overlapby gougingor grinding asa minimum,andmay requireweld repais to the gouged or groundareas, followed by reinspection usingappropriate NDT method.
Remedies
Addirionalweldertrainilg Additionalweldertraining
t7
Porosity
Porosityis definedas "Cavity-type discontinuities formed by gasetrtrapment during solidilication or in a thermalspraydeposit." maybe sudace or subsurface, a single Thepolosity cavity,aligned, or clustercd, andis represented by the following figues.
Repaks of porosity by gouging consist of removal of theaffected area or gdnding, weldrepair, followed by reinspection by the appropriate NDT method. 18
Remedies
Use low-hydmgen welding process:filler metalshigh in deoxidizers;increase shieldinggas flow Use preheat or increase heat input Clean joint faces and adjacent surfaces Use speciallycleanedand packagedfiller wire, and store it in cleanarea Changewelding conditionsand techniques Use copper-silicon filler metal; reduce heat input Remove zinc prior to welding Use 86010 electrodes and manipulate the arc heat to volatilize the zinc ahead of the molten weld pool
Undercut
Undercutis defioedas"A groovemelted into the basemetal a4iacent to the weld toe or weld face and left areshownin the followirg figues. unfilled by weld metal." Exarnples UNDEBCUT
'Catching a thumbnail' in the underDetection of surface undercut is easily found by VT using oblique lighting. cut groove is also helpful in its detection. Measuement of undercut calr be accurately determined using an undercut gauge showo in the following figure. Intemal undercut on groove welds \there accessto the root is not possible requires UT or RT methods. 20
Set bottom of gage on base material. Set poiot on boF tom of undercut. Read depth on scale at pointer. Locking screw can be tightened to hold reading for future reference.
Repahs to ufldercut usually require light g nding and additional welding to replace the base metal removed during the undercutting and repair grinding
Remedies
Weld Profiles
Visual inspection is very useful in determiniflg the adequacy of weld profiles; the actual welds are compared with code or specification requirements rcgarding convexity or concavity for fillet welds, and face and root rei[forcement for groove welds. The following profiles arc found in AWS D1.1, Structural Welding Code. Additionally, fillet weld sizescan be determinedusing fillet weld gages;theil use is shown on page25.
EM
NOTE: CONVEXtry C, OFA WELD ORINDIV|DUAL SURFACE BEAD WITHD|MENS|ON W SHALL NOT EXCEED THEVALUE OFTHEFOLLOWING TABLE: 22
MAXIMUM CONVEXITY OF FILLETWELDS WIDTHOF WELDFACEOR INDIVIDUAL SURFACE BEAD,W W< Vl6 in.(8 mm) W > 5/16 in. TO W < I in. (2Smm) W> 1 in.
MAXCONVEXIry C
1/16in. (1.6rnm) 1/8in. (3 mm) 3/16 in. (5 mm)
1%WWMWM
INSUFFICIENT EXCESSIVE THROAT CONVEXITY EXCESSIVE UNDERCUT OVERLAP INSUFFICIENT INCOMPLETE LEG FUSION
M M-M
NOTE:REINFORCEMENT R SHALLNOT EXCEED1/8 in. (3 mm). (E) UNACCEPTABLE GROOVEWELD PROFILESIN BUTT JOINTS
rffiffiwrffi
EXCESSIVE REINFORCEI\,IENT INSUFFICIENT THROAT EXCESSIVE UNDERCUT How to Use Weld Fillet cage
OVERLAP
FilletWeldMeasurement
CONVEX WELDS
CONCAVE WELDS
FOBCONVEX WELDS: USEBLADE W|THSTNGLE ARCAT APPROPRIATE SIZE.FOBCONCAVE WELDS: USEBLADE WITHDOUBLE ARCATAPPROPRIATE SIZE. 25
Dimensional Considerations
An important aspectof VT is the measurements for size. geometry,and assemblyof welded structures.The manufactwing drawingswill show the requiredlengths,widths, thicknesses, diameters,elc., ofthe variouscomponents, as well as weld sizes. The inspectorshould determinethe dimensionaltolerances for each of the measuementsspecified,and considerthem dwing componentmeasurement for conformance.If the tolerancesare not stated,the inspectorshould ask for clarification. Often, 'minimums,"maximums,' or a dimensional thesetolerances are noted as mnge such as "1.500 1.750inches."The inspector should also be awarethat measurements can be given in the U.S. Customaryunits, or in the S.l. or metric units. Incorrct Joint Preparation L lncorrect joint penetration subject to visual inspection, generally before welding is started, includes out of lolerance welding bevel or groove dimensions,basemetal misalignment,and undesirable weldjoint fit up conditions. 2. Included in the requirementsfor weld joint preparationshall be inspectionfor removal of scale,paint. oil. etc., from lhe weldjoint. 3. Paaial pnetration weldjoint preparadons shall be visually inspected prior b weldirg to assureproper weld drcat dimensions. Incorreca Weld Size 1. Incorrectweld sizesubjectto visual inspectionincludesundersized fillet weld leg dimensionsand underfilledgroove weld throat dimensions. 2. Fillet weld size shall be determinedby meansof a fillet weld gage. Incorect Final Dimensions Inconect final dimensionssubject!o visual inspectioninclude all conditionsofdimensional inaccuracies, distortion, and lack of conformity to designrequirements.
Detects Dimensional
mm
o.194
1.588 2.381 3.175 3.969 4.'.763 5.556 6.350
tb/ft2 1.215 2.550 3.825 5.100 6.375 7.650 8.925 10.200 tt.475 t2.150 t4.025
Gage
Fraction Decimal
t1/32 9/t6 19/32 5/8 0.531 0.563 0.594
mm
t3.494 14.287 15.081 15.875 16.669 17 .463 18.256 19.050 t9.8M 21.431 22.225 23.Ot9 23.813 24.606
13
ll
o.625
0.656 0.688 0.'7 t9 0.750 0.?81 0.844 0.875 0.906
9 ,7 5
l
I
2r/32
l l/16 23/32 3/4
3/t6
7/32 t/4
0.r88
0.2\9 0.250
9/32
5/16
0.28t
't.t44
Not
r0.600
31.875 34.425 J5.700 36.975
0.3r3
0.344 0.375
0.406 0.438 0.469 0.500
25/32 1l/r6
21/32
0 . 8 r 3 20.638 3 3 . 1 5 0
|/32
Not
3/8 13/32
r5.300
16.5',75 17.850 19.125 20.400
t/8
29t32 15/16
't/t6
0.s38
0.969 1.000
t5/32 l/2
31t32
I
38.250 39.52s
40.800
25.4n
#'
Decimal
1.03t 1.063 1.094 1.125 1.156 1.188 1.219 1.250 1.281 1.344 t.375 1.406 1.438 t.469 1.500
t-1t32
l-1l8 | 5t32 1-3t16 l-'7t32 t-t/4 1-9/32 1,5/16 111/32
r-3/8
1-13t32 1',7t16 t-t5t32 1-1t2
mm 26.t94 26.988 2't.'781 28.575 29.369 30.163 30.956 31.750 32.544 33.338 34.131 34.925 35.719 36.513
tbftt2
42.075 43.350 44.625 45.900
Fraction t-t7ti2
1-9/t6 1.19/32 I 5/8
Decimal
1.531 t.563 1.594 1.625 1.656 1.688 |.1t9 1.750 1.781 t.813 |.844 1.875 1.906
mm
38.894 39.688 40.481 4t.2',75 42.069 42.863 41.656 44.450 45.244 46.038 46.831 4'7.625 48.4t9
66._r00
67.575 68.850 70.125 71.400 12.675 13.950 't5.225 76.500 17.',7',75 19.O50 80.325
47.n5
48.450 49.725 51.000 52.275 53.550 54.825 56.100 5',7.315 58.650 59.925 61.200 28
t-2v32
1-1t/16
r 23/32
| 3/4 1-25t32 l-r3/16 1-21t32 1 7/8 1 29t32
i -15/16
r.938
1.969
49.2r3
50.006 50.800
31.306
38.100
131/32 2
2.000
8r.600
Nominal Wall Thicknesses in inches for Sched. StanSched. Sched. xx xs3 Sched. 't60 dand2 40 80 120 Slronq 0.068 0.068 4.095 0.095 0.088 0.088 4.119 0 . 1 1 9 0.091 0.091 a.126 o.126 0.109 0.109 0.147 u.t4'7 0 . 1 8 8 o.294 0. 3 0 . 1 1 3 0.154 0.154 0 . 2 r 9 0.306 0 . 1 3 3 0 . 1 3 3 0.179 0.179 0.250 0.358 0.144 0.140 0.191 0.191 0.250 0.382 0.145 0.145 0.240 0.200 0.281 0.400 0.154 0 . 1 5 4 0.218 0.218 0.344 0.436 0.243 0.203 0.276 o.2'76 0.375 0.552 0.216 0.216 0.300 0.300 0.438 0.600 0.226 0.226 0.3l8 0.318 0.237 0.23',7 0.337 0.438 0 . 5 3 1 0.6'74 0.258 0.258 0.375 0.375 0.500 0.625 0.750 0.280 0.280 0.432 0.432 0.562 0.1t9 0.864
29
*..,
----------E
Iuletric Converslon Table (Commonly used conversions) Propsrty To Convsn From
inches': millimte$2 flow rate lidear feet3/hour irches2
To
millimete$2
Multiplyby
x t(P 6.452 1.550 x 103
literVmioute
inches millimeters inches feet mass (weight)
litervminute feeC/hour
millimeteIs inches centimetels inches
o.472
2.119 25.4 3.931x loa 2.54 o.3937 0.305
meters pounds
kiloglams Psr lfa psi MPa
feet kilogams
3.281
0.454 2.205 6.895 0.L45 x 10 3 6.895 1.450 x 1d
pouncls
kilopascal (kPa)
Prssure
tensile strength
psr
megapascal (MPa)
psr JO
TestingSymbols Nondestructive
The examination symbolconsists of thefollowing elements: l. 2, 3. 4, 5, 6. Reference line Arrow Examination methodletterdesignations Extentandnumberof examinations Supplementary symbols Tail (Sperifications, codes, or otherreferences)
FleldExaminatlon
Radiation Dlrection
Examination MethodLetterDesignations Nondesfuctive specified by use of theletter examination methods shall be designation shown below.
Examlnatlon Method
Electromagnetic Leak Magnelic pa$icle Neurron radiogaphic Penetmnt P{oof
Radiographic
UlEasonic
Visual
UT VT
T H E -H '
550 N.W. LJ6rre Roa4 Mimi, Flo{ide 33126