Visual Welding Inspector

Part 1

Course Reference D 73
TWI
CSWIP Examination Requirements
TWI
# 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
Terminology Joint Types
Edge
Corner Lap
Tee
Cruciform
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Terminology Joint Welds
Compound Fillet Butt
Edge
Spot
Plug
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Types of Joint Preparation
Included angle
Root Gap
Root Face
Angle of
bevel
Root Face
Root Gap
Included angle
Root
Radius
Single -V Butt
Single - U Butt
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Types of Joint Preparation
Root Gap
Root Face
Root Face
Root Gap
Root
Radius
Single Bevel Butt
Single J Butt
Angle of
bevel
Angle of
bevel
Land
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Weld Zone Terminology
Weld zone
Weld metal
Heat affected
zone
Root
Fusion 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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Fillet Weld Features
Horizontal leg length
V
e
r
t
i
c
a
l

l
e
g

l
e
n
g
t
h

Design throat
thickness
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Fillet Weld Features
a = Design/ Nominal throat thickness
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a
b
b = Actual throat thickness
Fillet Weld Profiles
Mitre fillet
Concave fillet
Convex fillet
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Welding Positions
Flat position
UK (USA) 1G rotated
ISO/EN PA
UK (USA): 1G
ISO/EN: PA
UK (USA) 2G Fixed
ISO/EN PC
UK (USA): 2G
ISO/EN: PC
Horizontal
position
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Welding Positions
Vertical
down
UK (USA) 3G
ISO/EN PG
UK (USA) 3G
ISO/EN PF
Vertical
up
UK (USA) 4G
ISO/EN PE
Overhead Position
UK (USA) 5G
ISO/EN PF, PG
Vertical Position
Pipe fixed Horizontal
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Welding Positions
45
o

Inclined position fixed
UK (USA) 6G
EN/ISO H-LO45
Inclined position Rotated
UK (USA) 1FR
EN/ISO L 45/PA
45
o

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Terminology
Butt Weld Features
1
2
3
4 5
6
7
8
9
10
Terminology
Fillet Weld Features
1
3
5
6
7
8
10
2
9
4
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?
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.
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Welding Checklist
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)
Before Welding Commences
Welding Checklist
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

During Welding
Welding Checklist
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 Completion
Welding Checklist
Authorization for repair
Removal and preparation for repair
Testing of repair - visual and NDT
In the event of repair
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
Excess weld
metal height
Root penetration
Root bead width
Weld cap 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
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
Hydrogen (HICC)
Solidification (Hot tears)
Reheat cracks
Lamellar tearing
The four essential crack mechanisms
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Welding Defects
Classified by Shape
Longitudinal
Transverse
Branched
Chevron
Cracks
Classified by Position
HAZ
Centreline
Crater
Fusion zone
Parent metal
Cracks
Longitudinal parent metal crack
Transverse weld metal crack
Longitudinal weld metal crack Lamellar tearing
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Welding Defects
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
Cracks
Surface irregularities
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
Contamination
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Crater crack
Contour Defects
Incomplete filled groove Poor cap profile
Excessive cap height
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Incomplete filled groove
+ Lack of sidewall fusion
Root Defects
Incomplete root fusion
Incomplete root penetration
Low Amps/volts
Large Root face
Small Root Gap
Fast Travel Speed
Incorrect Electrode
Angle
Contamination
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Concave root
Root Defects
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Root faces too large
Root gap too large
Excessive back purge
pressure during TIG welding
Excessive root bead grinding
before the application of the
second pass
A shallow groove, which may occur in the root of a butt weld
Shrinkage groove
Root Defects
TWI
Insufficient weld metal
deposited in the root
pass
Too fast a cooling rate
during the application of
the root bead pass
Poor welding technique
A shallow groove caused by contraction in the weld
metal along each side of the penetration bead
Root Defects
Burn through
High Amps/volts
Small Root face
Large Root Gap
Slow Travel Speed
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A localized collapse of the weld pool due to excessive
penetration resulting in a hole in the root run
Miscellaneous Defects
Arc strike
Accidental striking of
the arc onto the parent
material
Faulty electrode holder
Poor cable insulation
Poor return lead
clamping
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Spatter
Excessive current
Damp electrodes
Contamination
Incorrect wire feed
speed when welding
with the MAG welding
process
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Miscellaneous Defects
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Gas Cavities
Cluster porosity Gas pore
Blow hole
Herringbone porosity
Root piping
Loss of gas shield
Damp electrodes
Contamination
Arc length too large
Damaged electrode flux
Moisture on parent
material
Welding current to low
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Solid Inclusions
Slag originates from welding
flux
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
Lack of sidewall
fusion with
associated slag
Slag inclusions
Parallel slag lines
Slag inclusions are defined as a non-metallic inclusion
caused by some 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
Lamination
Mechanical damage
Lap
Segregation line