Iso 5817 Practice: L.Srinivasan Cms/Awti

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ISO 5817 PRACTICE

L.SRINIVASAN CMS/AWTI
WELDING INSPECTION METHODS

Visual Destructive Mechanical,


Chemical,
inspection Testing

Ultrasonic
Testing
NDT
D P Testing
MPT,ECT,X-RAY,
Light, LEAK,

Sound
What are the main welding
requirements covered in ISO 3834?
 Equipment
 Production and testing equipment; Suitability of
equipment; Equipment maintenance
 Welding and related activities
 Production planning; Welding procedure
specifications (WPS); Process Qualification of the
welding (WPQR); Work instructions;
 Welding Consumables
 Batch testing; Storage and handling
 Storage of parent materials
 Avoidence of damage and mixup

 Post-weld heat treatment


Inspection
WELD QUALITY
DISCONTINUITY:
• An interruption of the typical structure of a material,
such as a lack of homogeneity in its mechanical,
metallurgical, or physical characteristics.
• A discontinuity is not necessarily a defect but all
defects are discontinuities.
• Certain discontinuity acceptable in one type of product
need not be of acceptable nature in another product.
DEFECT
• A defect is a reject able discontinuity, which occurs in
an amount great enough to render a particular object
or structure unsuitable for its intended service based
on criteria in the applicable code.
What is the difference between an
imperfection & defect?
• Imperfection is deviation from ideality

• Defect is an imperfection above acceptance


level resulting in impaired use in service
condition.
Acceptance or rejection of flaws depend on
different factors and to mention a vital few are:
 Stress to which the parts will be subjected during
service
 Type of material used
 The temperature and pressure to which parts will be
stressed
 Its thickness
 The environment ( Corrosive or non-corrosive)
 Safety
 Consequences of failure
 Cost and accessibility for repair
CHARACTERISTICS OF DEFECTS AND
DISCONTINUITIES

 Size
 Acuity or sharpness or notch effect
 Orientation with respect to principal
working stress and residual stress
 Location with respect to weld. The
exterior surfaces of the joint and the
critical sections of the weld.
Classification of Defects
• PLANAR DEFECTS / Two dimensional defects -- E.g.
cracks, lack of fusion, lack of penetration, are critical in
nature and are not tolerated to any extent.
• VOLUMINAR DEFECTS / Three dimensional defects --
E.g. slag inclusion, Tungsten inclusions, cavities,
porosities, etc are tolerated to a certain extent depending
on the product class and applicable code.
• GEOMETRIC DEFECTS-- E.g., Misalignment, undercut,
Concavity & convexity, Excessive reinforcement, improper
reinforcement, excess reinforcement, underfill, root
suckback Overlap, burn through, Incomplete penetration,
Lack of fusion, Shrinkage, Surface irregularity & distortion
are also permitted to a certain extent.
• OTHERS:-Arc strike, Oxide films, Spatter, Arc craters
CLASSIFICATION OF DEFECTS IN WELD JOINT

Metallurgical
 Cracks or fissures
Cold, Hot or Reheat cracks, Lamellar tears
 Porosity
Spherical, Elongated worm holes
 Heat affected zone, micro structural alteration
 Weld metal and HAZ segregation
 Base plate lamination

Design Related
 Changes in section and other concentrations
 Weld joint type
WELD MEASUREMENT
AIDS TO VISUAL INSPECTION
Where access is restricted for direct visual inspection,
The use of a mirrored boroscope, or a fibre optic viewing system, are
options that may be used - usually by agreement between the contracting
parties.
 It may also be necessary to provide auxiliary lighting to give suitable
contrast and relief effect between surface imperfections and the
background.
Temperature Indicators , temperature measuring devices are necessary
to ensure the pre heat and post heat temperatures
Other items of equipment that may be appropriate, to facilitate visual
examination, are:
welding gauges (for checking bevel angles and weld profile, fillet sizing,
measuring undercut depth)
Dedicated weld-gap gauges and linear misalignment (high-low) gauges
Straight edges and measuring tapes
Magnifying lens
ACOUSTICS TESTING

 Striking with a
rounded object

 Ringing tone if no
defect

 Tone changes when


object is cracked
Magnifying Glass

Used to read small scales


Flashlight
Used to cast shadows to find porosity, undercut and overlap.
BORESCOPE
DIGITAL CAMERA SYSTEM
TEMPERATUR INDICATORS
• Temperature indicators can be in the form of sticks, pellets,
liquids. It is used in large heavy pieces for prolonged
heating where stick or lacqer marks will fade with time.
• For temperatures below 340 degree C ,Indicator marks can
be removed by water or alcohol. .But for temperature
above 340 degree C water is preferred
• Temperature indicators are used in
• (a)Preheating ,heat treatment, SR work,
Hot spots in insulations and engines
railway bearing breakdown in inboard journal
boxes verifying oven temperature
process control applications
TEMPERATUR INDICATORS
MEASURING DEVICES
Measuring instruments
• Measuring tape – 1mm or finer

• Vernier calipers

• Feeler gauge – 0.1mm to 3mm

• Radius gauge
Measuring instruments –
weld gauges

• Simple weld gauge

• Set of welding gauges

• Weld gauge with vernier


Measuring instruments –
weld gauges

• Self made weld gauge

• Three scale weld gauge

• Gauge for checking profile of


fillet welds
Measuring instruments –
weld gauges

• Multipurpose gauge

• Universal weld gauge

• Gap gauge

• Hook gauge for misalignment.


Cambridge Inspection Gage

Material Thickness
Cambridge Inspection Gage

Bevel Angle
Cambridge Inspection Gage

External Misalignment
Cambridge Inspection Gage

pit or undercut
Cambridge Inspection Gage
Cambridge Inspection Gage
FILLET WELD GAGE

Fillet Weld Leg Size


FILLET WELD GAGE
FILLET WELD GAGE

Reinforcement of Butt Welds


Undercut Guage
G.A.L. Hi Lo Gage

Misalignment/Thickness
G.A.L. Hi Lo Gage

Fillet Weld Leg Measurement


INCORRECT TOE ANGLE
EXCESS THROAT THICKNESS
UNEQUAL LEG
UNEQUAL LEG
INSUFFICIENT THROAT
INCORRECT ROOT GAP OF FILLET
LACK OF CORNER PENETRATION
LACK OF SIDEWALL FUISON
EXCERCISE1
EXCERCISE -2
EXCERCISE-3
EXCERCISE -5
• EVALUATE THE SAMPLES AS PER ISO 5817
VISUALLY
QUALITY LEVELS OF ACCEPTANCE
CHARACTERISTICS QUALITY LEVEL
excess weld metal, LEVEL C
excessive convexity LEVEL C
excessive throat thickness LEVEL C
incorrect weld toe LEVEL C
undercut LEVEL C
excessive penetration LEVEL C
All other parameters LEVEL B
IMPERFECTIONS IDENTIFICATION BY
VISUAL EXAMINATION
Sl.No Imperfection designation - Linear defects Quality level B
1 Crack & crater crack Not permitted
2 Lack of fusion (butt) Not permitted
3 Incomplete penetration (Butt) Not permitted
4 Shrinkage groove (t upto 3mm) Not permitted
5 Overlap Not permitted
6 Incompletely filled groove (t upto 3mm) Not permitted
7 Burn through Not permitted
8 Root concavity (t upto 3mm) Not permitted
9 Root porosity Not permitted
10 Poor restart Not permitted
11 Insufficient throat thickness Not permitted
12 Stray arc Not permitted
13 Undercut (t upto 3mm) Not permitted
IMPERFECTIONS IDENTIFICATION BY
VISUAL EXAMINATION
Sl.No Imperfection designation - Rounded Quality level B
1 Surface pore/cavity
2 Crater pipe
IMPERFECTIONS IDENTIFICATION BY
VISUAL EXAMINATION
Sl.No Imperfection designation Quality level B
1 Undercut (continuous/intermit) h ≤ 0.0.5t, 0.5mm max
2 Shrinkage groove h ≤ 0.05t, 0.5mm max
3 Excess weld metal (Butt) h ≤ 1mm + 0.1 b max 5 mm
4 Excess convexity (Fillet) h ≤ 1mm + 0.15 b max 3 mm
5 Excess penetration Upto 3mm h ≤ 1mm + 0.1 b
more than 3mm h ≤ 1mm + 0.2b max 3 mm
INTERNAL IMPERFECTIONS
Sl.No Imperfection designation Quality level B
1 Cracks / micro cracks Not permitted
2 Porosity (isolated, linear, clustered)
3 Shrinkage cavity Not permitted
4 Crater pipe Not permitted
5 Solid, slag, oxide and flux inclusions
6 Metallic inclusions other than copper
7 Copper inclusions other than copper Not permitted
8 Incomplete fusion, lack of side wall fusion, lack Not permitted
of inter run fusion, lack of root fusion, lack of
penetration
EVALUATION BY MACRO ETCH TEST
Sl.No Imperfection designation Quality level B
1 Excessive asymmetry of fillet weld h ≤ 1.5mm+0.15a
2 Excessive throat thickness h ≤ 1mm+0.15a
3 Incorrect weld toe Α ≥ 150◦
INSTRUMENTS REQUIRED
• Vernier caliper of accuracy 0.01mm
• Digital pit guage of accuracy 0.01 mm
• Digital throat guage of accuracy 0.01mm
• Digital protractor of accuracy 0.1o
DIGITAL CALIPER
DIGITAL PIT GUAGE
DIGITAL PROTRACTOR
Thank you

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