Professional Documents
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Weld Inspection
Level 1
Introduction to Welding
Definition
Introduction to Welding
Welding Terminology
Physics of Welding
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Definition
Welding: A group of processes used to join metallic and
nonmetallic materials. Often done using heat but maybe
done using pressure or a combination of heat and pressure.
A filler material may or may not be used.
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Introduction to Welding
Joint between the materials is melted
Intermixing occurs
Arc Welding
Intense heat to melt metal is produced by electric arc
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The Arc
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Mechanism of transfer:
Molten metal drop touches and transfers by
surface tension
Magnetic pinch effect
Gravity (flat welding)
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Electrical Supply
AC
DC, electrode positive
DC, electrode negative
Properties of Metals
Physical
Chemical
Mechanical
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Physical Properties
Colour
Melting Temperature
Chemical Properties
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Mechanical Properties
Strength (ability to resist load without failing)
Effects of Welding
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Preheat parts
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Heat Treating
Pre heating
Heat Treating
Interpass heating
Reduce stress
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Heat Treating
Annealing
Slow cooled
Heat Treating
Stress Relieving
Air cooled
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Electrical Principles
Voltage
Force that causes electrons to flow in a circuit
Similar to pressure
Measured in volts
Electrical Principles
Resistance
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Electrical Principles
Current
Units of Measure
Kilo [ K] = 1,000
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Terminology
Welding Technology Fundamentals
Page 441
Page 16.1-1
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Butt Joints
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Corner Joint
T - Joint
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Edge Joint
Fillet Welds
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Engineering Drawings
Isometric Projection
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Orthographic Projection
Orthographic Projection
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Orthographic Projection
Orthographic Projection
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Orthographic Projection
View Selection
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Drawing Lines
Dimensioning
S = size
P = position
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Dimensioning
Angles Chamfers
Tapers
Auxiliary Views
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Sectional Views
Sectional Views
Mating parts
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Thread Illustrations
Team Project 2
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e = member thickness
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g = root gap
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Used in SAW
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Welding Symbols
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Welding Symbols
F
A
R
S (E) L-P
T
F
A
R
S (E) L-P
T
Weld-all around
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F Field Weld
A
R
S (E) L-P
T
F
A
R
S (E) L-P
T
Reference Line
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F
A
R
S (E) L-P
T
Tail
(Tail omitted when references not used)
F
A
R
S (E) L-P
T
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F
A
R
S (E) L-P
T
N
Depth of penetration, size or strength
F
A
R
S (E) L-P
T
N
Groove weld size
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F
A
R
S (E) L-P
T
N
Basic weld symbols
Finish symbol
F
A
R
S (E) L-P
T
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F Finish contour
A
R
S (E) L-P
T
F Groove angle
A
R
S (E) L-P
T
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F
A Root opening
R
S (E) L-P
T
F
A
R
S (E) L-P
T
N
Number of spot, stud or projection welds
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Square
Single V
Single bevel
Double J
Double flare
Fillet
Plug
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J Groove
Flare
Fillet
Arrow Significance
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WeldingSpecification,
process process or other reference
Welding procedure
“Typical” representative of all welds on the drawing
Field Weld
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Melt-thru Symbol
Extent of Welding
If length is not specified
length is between abrupt changes in direction
Weld-all around
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Finishing of Weld
C Chipping
G Grinding
M Machining
R Rolling
H Hammering
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Break in Arrow
Arrow points to member to be chamfered
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Complete Penetration
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Groove Welds
Key parameters:
Depth of penetration
Bevel angle
Root opening
Θ1 = Bevel angle
Θ2 = Groove angle
Θ3 = Angle at root
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F
A
R
S (E) L-P
T
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Practice
Single Groove
Partial Penetration
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Practice
Single Groove
Partial Penetration
Practice
Single Groove
Partial Penetration
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Practice
Single Groove
Partial Penetration
Practice
Double Groove
Partial Penetration
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Practice
Double Groove
Partial Penetration
Practice
Double Groove
Partial Penetration
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Practice
Double Groove
Partial Penetration
Practice
Double Groove
Full Penetration
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Practice
Double Groove
Full Penetration
Practice
Double Groove
Full Penetration
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Practice
Square Groove
Square Groove
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Square Groove
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Flare Weld
Flare Weld
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Surface Finish
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Sequence of Preparation
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Sequence of Preparation
CSA W59
Fillet Welds
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Fillet Welds
Equal-legged
Fillets
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Fillet Size
Fillet Size
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Fillet Size
Some countries specify the size of fillet by throat
rather than leg
Fillet Size
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or
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Fillet
All-around
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Fillets Welds
With Terminal Ends
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Fillets Welds
Surface Finish & Contour
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Plug Welds
Key Parameters:
Diameter of hole
Angle of countersink
Depth of filling
Spacing of welds
Contour and surface finish
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Complete fill
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Safety Considerations
Pressurized Gases
High temperatures and hot surfaces
Electrical hazards
Fume generation
Non-ionizing radiation
Ionizing radiation
Molten droplets of metal
Explosive hazards
Oxy-Fuel Cutting
Torch tip selection
Oxygen pressure
Acetylene pressure
Cutting Speed
Tip alignment
Torch Position
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Tip Alignment
Torch Position
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Torch Position
Torch Position
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Cutting Conditions
Good Cut
Cutting Conditions
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Cutting Conditions
Cutting Conditions
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Cutting Conditions
Cutting Conditions
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Cutting Conditions
Cutting Conditions
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Cutting Conditions
Cut lost
Not properly restarted
Bad gouges at restart point
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Acronyms:
AC Alternating Current
DC Direct Current
CC Constant Current
CV Constant Voltage
DCEN Direct Current Electrode Negative
DCEP Direct Current Electrode Positive
OCV Open Circuit Voltage
DCEN DCEP
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Welding Machines
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Welding Machines
Current Type (AC, DC, or AC/DC)
Duty Cycle
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Duty Cycle
How long a welding machine can be used at maximum
current
Based on a ten minute cycle
Duty Cycle
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Welding Leads
Electrode lead
Work lead
Voltage and current are affected when leads are too small
in diameter
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Welding Leads
Welding Technology Fundamentals
Page 58
Wire Diameter
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SMAW Electrodes
Specified by:
AWS
A5.1 carbon steel
A5.3 aluminum and aluminum alloys
A5.4 corrosion resistant steels
A5.5 low alloy steels
A5.6 copper and copper alloys
A5.11 nickel and nickel alloys
A5.15 gray and ductile cast iron
CSA W 48-01
carbon steel covered electrodes
chromium and chromium-nickel covered electrodes
low alloy steel covered electrodes
Electrode Coverings
1. Add filler metal
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Electrode Size
CSA W47-01
Electrode Size
AWS
Lengths: 9, 12, 14, and 18 inches
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Freezing Characteristics
Electrodes manufactured to melt rapidly are called
fast-fill electrodes
Electrode Designations
AWS
Minimum tensile strength in thousand psi
Electrode
Welding position
E 6010
Utilization
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Welding Position
1 All position
2 Flat and horizontal fillets only
3 Flat position only
4 Flat, horizontal, overhead and vertical down
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Team Assignment 5
Assignment
*5, 6 & 8
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E 7018
E4918 (CSA W48-01)
Low hydrogen
Fill-freeze
All position
70,000 psi, 490 Mpa
Moderately heavy slag easy to remove
Smooth quiet arc, very low spatter, medium penetration
AC or DCEP
Iron powder addition
Electrodes
Assignment: Prepare a similar description for E7015,
E7016, E7028, E8018, E6010, E6019
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Electrode Storage
Low Alloy
Steel
Electrodes
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Electrode Designations
AWS
Minimum tensile strength in thousand psi
Electrode
Welding position
E 10016-D2
Alloy addition
Utilization
Alloy Additions
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E 316L-16
Use-ability
15 all position DC only
16 all position AC/DC, (DC if available)
25 flat or horizontal position only, DC
26 flat or horizontal position AC/DC (DC if available)
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Arc Blow
Stringer Bead
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Weaving Bead
Travel Angle
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Work Angle
Good bead
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Constant current
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Cleaning Action
Shielding Gases
Argon Helium
Easier to start and maintain arc Hotter arc
Lower flow rates Deeper penetration
Less expensive Faster welding speeds
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Electrodes
Current Selection
R2 p9.4-2
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Current Selection
Current Selection
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Pulsed GTAW
Arc Starting
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Laying A Bead
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GTAW Variations
Autogenous
Automatic
Hot Wire
Multi-Electrode
Team Assignment 7
Prepare a welding procedure including all the details your
team is capable of to perform a full penetration Butt weld
to join two 3-1/2” schedule 40, 316L pipe for use in a
pressure chemical application.
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Metal Transfer
Short Circuit
Globular Transfer
Spray Transfer
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Short Circuit
Thin material
Out of position
Low heat transfer
Globular Transfer
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Spray Transfer
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Power Supply
Constant Potential
Inductance
Slope Adjustment
No current adjustment
Wire Feeder
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Shielding Gas
Type of transfer
Speed of Welding
Shielding Gas
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Shielding Gas
Argon: aluminum, nickel, copper magnesium
excellent arc stability
good penetration and bead profile
finger like penetration
CO2 steel
reactive gas
will not support spray transfer
greater spatter and fumes
good fusion and penetration
Shielding Gas
Argon-Oxygen 1 to 8% Oxygen
Stainless steel
increases droplet rate
more fluid puddle
reduces undercut
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Electrode Wire
Rod
Solid
Electrode
ER49S-B2
Alloy
Tensile Strength
[MPa]
Electrode Wire
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Torch Position
Torch Position
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Team Assignment 8
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2. Self Shielded
3. Metal Cored
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Electrode Designations
Tensile Strength Welding Position
1= all, 2 = F groove and F&H fillet
Electrode
Tubular or C = metal cored
EXXXT-1
Power Supply
Constant Potential
Inductance
Slope Adjustment
No current adjustment
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Electrodes
Typical wire size: 1/16, 5/64, 3/32”
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Fluxes
Manufacturing: Fused (mixed, melted, fused, crushed,
screened & packaged)
Alloy Content
of Weld: Active (Controlled amounts of Mn & or Si
to improve resistance to porosity
and cracking)
Power Supplies
DCEN, DCEP, AC
DCEP recommended for deep penetration
DCEN recommended for: fillets (clean plate)
hard facing
hard to weld steels
greater build-up
AC recommended for: tandem arc
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Joint Preparation
Joint Preparation
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Joint Preparation
Backing Required
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Team Assignment 9
Make a short presentation (7 to 10 minutes) to act as a
review for your class mates on one of the welding methods.
SMAW
GTAW
GMAW
FCAW
SAW
Heating
Preheating: Just prior to welding
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Preheating
Why?
Reduce local shrinkage stresses
Plate thickness
Restraint
Rigidity of members
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W59-03 Appendix P
W59-03 Appendix P
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W59-03 Appendix P
W59-03 Appendix P
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W59-03 Appendix P
Methods of Preheating
Production of small parts maybe best in a furnace
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Measuring Preheat
Temperature
With the exception of Q&T steels temperatures
can be exceeded by 40º C
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Interpass Temperatures
Annealing
Normalizing
Stress Relief
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Full Annealing
Purpose:
Make steel soft and ductile
Reduce stresses
Normalizing
Purpose:
Reduce stresses, usually after welding
Greater hardness & tensile strength than
full annealing
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Stress Relief
Purpose:
Provides dimensional stability
Softens martensitic areas
Improves fracture resistance
Slowly cool
Welding Procedures
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Procedure Qualification
CWB Approval
Qualify Welders
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No pre-approved joints
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Welding Procedure
Specification
Scope
Welding Procedure
Base Metal
Base Metal Thickness
Preparation of Base Material
Filler Material
Shielding Gas
Position
Minimum Preheat and Interpass Temperatures
Electrical Characteristics
Welding Technique
Treatment of Underside of Groove
Weld Metal Cleaning
Quality of Welds
Storage of Electrodes
Data Sheet
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Data Sheet
Process
Mode of Application
Position
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Classification
S With backing
T Without backing
FW = fillet & tack welds, ASW = arc spot weld, WT = tack welds
Process
SMAW SAW
FCAW ESW
GMAW EGW
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Mode of Application
Manual
Semi-automatic
Machine Welding
Automatic
Position
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Electrode Designations
Team Assignment 10
Review a weld procedure and present your teams
understanding to your class
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Verification Functions
Procurement Verification
Vendor approval
Quantity & Dimensions
Material Specification
Special Requirements
Heat treatment
Inspection
Nondestructive Testing
QA Requirements
Documentation Requirements
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Receiving Inspections
Quantity Inspections
Dimensions
Identification
Mill test reports or other required documentation
Manufacturing defects
Weather or transportation damage
Documentation Verification
Certificates of Compliance
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Workmanship
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Tack Welds
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Backing
Distortion Control
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Dimensional Tolerances
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Sweep
Camber
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Misalignment
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Undercut
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Weld Discontinuities
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Incomplete Penetration
Lack of Fusion
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Porosity
Slag
Inclusions
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Solidification
Crack
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Lamellar Tearing
Arc Strikes
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Excess Convexity
Excessive Concavity
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Excessive Reinforcement
Insufficient Reinforcement
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Undercut
Discontinuities Related to
Specific Welding Methods
SMAW
SAW
GTAW
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SMAW
SMAW
Undercut Reduce current
Reduce travel speed
Reduce electrode size
Change electrode angle
Avoid excessive weaving
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SMAW
SMAW
Porosity Remove scale rust and moisture
Use low hydrogen electrodes
Use shorter arc length
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SMAW
Lack of Fusion Increase current
Stringer bead technique
Ensure joint is clean
Check joint fit-up and design
Over Lap
SMAW
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SMAW
SMAW
Cracking Hot Cracking
Proper fit-up
Proper electrode selection
Ensure root pass is of sufficient size
Check rigidity of joint
Check Distortion control techniques
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SMAW
Cracking Solidification Cracking
If originating in crater use back
step technique
If centre bead decrease travel speed
SAW
Cracking Fillet Welds
If members 25 mm or greater ensure
gap of 1 to 1.5 mm to help with
shrinkage
Check polarity, usually DCEP but
DCEN sometimes used to
reduce penetration to help
deal with cracking
Check wire size, larger wire often used
when cracking is a problem
Check condition of root pass and fit-up
Check bead shape (1-1/4 to 1)
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SAW
Cracking Fillet Welds & T Welds
Groove angles should be at least 60º
SAW
Cracking Butt Welds
If bead is hat shaped , check voltage
and travel speed, may need to be
reduced
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Slag
Check for slag removal between passes
GTAW
Porosity Check shielding gas flow rates, leaks etc.
Check arc length (too long cannot be protected)
Tungsten Inclusions
Check for touching the electrode into the puddle
Check for current being to high
Check the size and type of electrode
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Team Assignment 11
Record results
Mechanical Testing
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Bend Tests
Bend Tests
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Bend Tests
Bend Tests
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Hardness Tests
Three groups:
Elastic hardness
Resistance to penetration
Resistance to Penetration
Brinell Hardness Test
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Resistance to Penetration
Rockwell Hardness Method
Measures the net increase in depth of the
impression after a minor load is applied
and after the major load is applied
14 different scales
Resistance to Penetration
Vickers Hardness Test
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Resistance to Penetration
Tukon Hardness Method
Resistance to Penetration
Knoop Hardness Method
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Impact Tests
Measures the decrease in
fracture resistance caused by
sudden loading in the
presence of a notch
Methods:
Charpy
Izod
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Transition Temperature
Impact test results must include temperature
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