TWI

Visual Welding Inspector

Part 1

Course Reference D 73

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CSWIP Examination Requirements

# Butt Weld Inspection
Code reference : CSWIP PH6/WI/00
Time Given
: 1 Hour 30 minutes
# Fillet Weld Inspection
Code reference : ISO 5817 ( Level D)
Time Given
: 1 Hour 15 minutes

Terminology

Butt Joints
Square Edged, Open and Closed

Single Vee, Butt and Bevel

Double Vee, Butt and Bevel

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Terminology Joint Types

Edge

Lap

Corner

Tee
Cruciform

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Terminology Joint Welds

Compound

Edge

Fillet

Spot

Butt

Plug

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Types of Joint Preparation

Included angle

Included angle
Angle of
bevel

Root
Radius

Root Face

Root Face

Root Gap

Root Gap

Single -V Butt

Single - U Butt

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Types of Joint Preparation

Angle of
bevel

Angle of
bevel
Root
Radius

Root Face
Root Gap

Single Bevel Butt

Root Gap

Root Face

Land

Single J Butt

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Weld Zone Terminology

Weld zone
Weld metal

Fusion zone

Root

Heat affected
zone

Weld Junction

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Butt Weld Features

Weld cap width
Excess weld metal

Excess root penetration

Root bead width

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d
el
W
ce
fa

Vertical leg length

Fillet Weld Features

Design throat
thickness

Horizontal leg length

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Fillet Weld Features

a
b
a = Design/ Nominal throat thickness
b = Actual throat thickness

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Fillet Weld Profiles

Mitre fillet

Convex fillet

Concave fillet

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Welding Positions
Flat position
UK (USA): 1G
ISO/EN: PA

UK (USA) 1G rotated
ISO/EN PA

Horizontal
position

UK (USA) 2G Fixed
ISO/EN PC

UK (USA): 2G
ISO/EN: PC

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Welding Positions
Vertical
up
UK (USA) 3G
ISO/EN PF

Overhead Position
UK (USA) 4G
ISO/EN PE

Vertical
down
UK (USA) 3G
ISO/EN PG

Vertical Position
Pipe fixed Horizontal
UK (USA) 5G
ISO/EN PF, PG

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Welding Positions

45o
Inclined position fixed
UK (USA) 6G
EN/ISO H-LO45

45o
Inclined position Rotated
UK (USA) 1FR
EN/ISO L 45/PA

Terminology
Butt Weld Features
10

8
2

1
5

Terminology
Fillet Weld Features

10
4
9

7
2
3

1
6

Visual Inspection Procedures

What is the nature of the product?
What operating conditions will be
present?
What is the quality of welding required?
Is there a code or standard available to
inspect the welds to?

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Main Responsibilities
Code compliance
Workmanship control
Documentation control

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Personal Attributes
Honesty
Integrity
Knowledgeable
Good communicator
Physically fit.

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Duties of a Welding Inspector

Before Welding.
before assembly.
after assembly.

During welding.
After welding.

Welding Checklist
Before Welding Commences

Familirization to the relevant code and specification

Check welding equipment and calibration certificates
Material identification,size,type and condition
Consumables type,size,condition,storage and handling
Review/witness WPS and PQR test and record
Joint preparation( check)
Welder qualification test( Review/witness)
Welding process involved
Check pre-heating before welding ( if required)

Welding Checklist
During Welding

Check weather condition

Check clearance for welding/welder
Check welder identification for weld
Check consumables as per WPS used
Check welding parameters as per WPS used
Check distortion control
Check interpass cleaning
Check run out length ( travel speed)
Check interpass temperature
Check usage of line up clamps
Maintain daily log book

Welding Checklist
Welding Completion

Perform visual inspection

Weld and welder identification ( check)
Post weld heat treatment ( if required)
Non-destructive Testing ( witness)
Acceptance standards of NDT
Repairs (if any)
Dimensional check ( as per drawing)
Document control - welding reports etc

Welding Checklist
In the event of repair
Authorization for repair
Removal and preparation for repair
Testing of repair - visual and NDT

How Do I Carry Out a Visual

Inspection?
What is the nature of the product?
What operating conditions will be
present?
What is the quality of welding required?
Is there a code or standard available to
inspect the welds against

Features to Consider
Butt welds - Size
Weld cap width
Excess weld
metal height
Root penetration
Root bead width

Features to Consider
Fillet welds - Size

Minimum and
maximum leg
length size

Minimum design
throat thickness

Features to Consider
Butt welds - Profile

Features to Consider
Fillet welds - Size

Features to Consider
Butt welds - Toe Blend

Features to Consider
Fillet welds - Toe Blend

Features to Consider
Butt welds - Weld Width

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Weld Defects

Defects which may be detected by visual

inspection can be grouped under five headings

Cracks

Surface irregularities
Contour defects
Root defects
Miscellaneous

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Weld Defects
Other associated defects

Cavities
Solid inclusions
Set up irregularities
Parent material defects

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Cracks
The four essential crack mechanisms

Hydrogen (HICC)
Solidification (Hot tears)
Reheat cracks
Lamellar tearing

Welding Defects
Cracks
Classified by Shape
Longitudinal
Transverse
Branched
Chevron

Classified by Position
HAZ
Centreline
Crater
Fusion zone
Parent metal

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Cracks

Longitudinal parent metal crack

Longitudinal weld metal crack

Transverse weld metal crack

Lamellar tearing

Welding Defects
Cracks
Solidification
Occurs during weld solidification process
Steels with high sulphur content (low
ductility at elevated temperature)
Requires high tensile stress
Occur longitudinally down centre of weld
eg Crater cracking

Cracks

Welding Defects

Hydrogen Induced
Requires susceptible grain structure, stress and
hydrogen
Hydrogen enters via welding arc
Hydrogen source - atmosphere or contamination of
preparation or electrode
Moisture diffuses out into parent metal on cooling
Most likely in HAZ

Cracks

Welding Defects

Lamellar Tearing
Step like appearance
Occurs in parent material or HAZ
Only in rolled direction of the parent material
Associated with restrained joints subjected to
through thickness stresses on corners, tees and
fillets
Requires high sulphur or non-metallic inclusions

Cracks

Welding Defects

Re-Heat Cracking
Occurs mainly in HAZ of low alloy steels during
post weld heat treatment or service at elevated
temperatures
Occurs in areas of high stress and existing defects
Prevented by toe grinding, elimination of poor
profile material selection and controlled post weld
heat treatment

Surface irregularities

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Undercut
An irregular groove at the toe of a weld run in
the parent metal
Excessive amps/volts
Excessive travel speed
Incorrect electrode angle
Excessive weaving
Incorrect welding technique
Electrode too large

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Overlap
An imperfection at the toe or root of a weld caused by
metal flowing on to the surface of the parent metal
without fusing to it

Contamination

Slow travel speed

Incorrect welding
technique
Current too high

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Crater Pipe
Depression at the end of a weld that has a insufficient
cross section.

Too fast a cooling rate

Deoxidization
reactions and liquid to
solid volume change
Crater crack

Contamination

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Contour Defects

Incomplete filled groove

Poor cap profile

Incomplete filled groove

+ Lack of sidewall fusion

Excessive cap height

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Root Defects
Low Amps/volts
Large Root face
Incomplete root fusion

Small Root Gap

Fast Travel Speed
Incorrect Electrode
Angle

Incomplete root penetration

Contamination

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Root Defects

A shallow groove, which may occur in the root of a butt weld

Root faces too large

Root gap too large
Excessive back purge
pressure during TIG welding
Concave root

Excessive root bead grinding

before the application of the
second pass

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Root Defects
A shallow groove caused by contraction in the weld
metal along each side of the penetration bead

Insufficient weld metal

deposited in the root
pass

Shrinkage groove

Too fast a cooling rate

during the application of
the root bead pass
Poor welding technique

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Root Defects
A localized collapse of the weld pool due to excessive
penetration resulting in a hole in the root run

High Amps/volts
Small Root face
Large Root Gap
Slow Travel Speed
Burn through

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Miscellaneous Defects
Accidental striking of
the arc onto the parent
material
Faulty electrode holder
Poor cable insulation

Arc strike

Poor return lead

clamping

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Miscellaneous Defects
Excessive current
Damp electrodes
Contamination

Spatter

Incorrect wire feed

speed when welding
with the MAG welding
process

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Gas Cavities

Gas pore

Cluster porosity

Loss of gas shield

Damp electrodes
Contamination

Blow hole
Herringbone porosity

Arc length too large

Damaged electrode flux
Moisture on parent
material

Root piping

Welding current to low

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Solid Inclusions
Slag inclusions are defined as a non-metallic inclusion
caused by some welding process
Slag originates from welding
flux

Slag inclusions

Lack of sidewall
fusion with
associated slag

Parallel slag lines

MAG and TIG welding

process produce silica
inclusions
Slag is caused by
inadequate cleaning
Other inclusions include
tungsten and copper
inclusions from the TIG and
MAG welding process

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Set-up Irregularities

Linear Misalignment
(Hi-Lo)
Poor fit-up

Angular Misalignment

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Parent Material Defects

A welding inspector should also inspect the parent
material for any visible defects
Mechanical damage

Lap

Lamination

Segregation line