25 Macro Micro Examination

Welding Inspector
Macro/Micro Examination
Section 25
4/23/2007
Macro Preparation
Purpose
To examine the weld cross-section to give assurance that: -
• The weld has been made in accordance with the WPS
• The weld is free from defects
Specimen Preparation
• Full thickness slice taken from the weld (typically ~10mm thick)
• Width of slice sufficient to show all the weld and HAZ on both sides
plus some unaffected base material
• One face ground to a progressively fine finish (grit sizes 120 to ~ 400)
• Prepared face heavily etched to show all weld runs & all HAZ
• Prepared face examined at up to x10 (& usually photographed for records)
• Prepared face may also be used for a hardness survey
4/23/2007
Micro Preparation
Purpose
To examine a particular region of the weld or HAZ in order to:-
• To examine the microstructure
• Identify the nature of a crack or other imperfection
Specimen Preparation
• A small piece is cut from the region of interest
(typically up to ~ 20mm x 20mm)
• The piece is mounted in plastic mould and the surface of interest
prepared by progressive grinding (to grit size 600 or 800)
• Surface polished on diamond impregnated cloths to a mirror finish
• Prepared face may be examined in as-polished condition & then lightly
etched
• Prepared face examined under the microscope at up to ~ x 600
4/23/2007
Macro / Micro Examination
Object:
• Macro / microscopic examinations are used to give a visual
evaluation of a cross-section of a welded joint
• Carried out on full thickness specimens
• The width of the specimen should include HAZ, weld and

parent plate
• They maybe cut from a stop/start area on a welders
approval test
4/23/2007
Macro / Micro Examination
Will Reveal:
• Weld soundness
• Distribution of inclusions
• Number of weld passes
• Metallurgical structure of weld, fusion zone and HAZ
• Location and depth of penetration of weld
• Fillet weld leg and throat dimensions
4/23/2007
Macro Micro
• Visual examination for • Visual examination for
defects defects & grain structure
• Cut transverse from the • Cut transverse from a
weld weld
• Ground & polished P400 • Ground & polished P1200
grit paper grit paper, 1µm paste
• Acid etch using 5-10% • Acid etch using 1-5%
nitric acid solution nitric acid solution
• Wash and dry • Wash and dry
• Visual evaluation under 5x • Visual evaluation under
magnification 100-1000x magnification
• Report on results • Report on results
4/23/2007
Metallographic Examination
Macro examination Micro examination
4/23/2007
A Brief synopsis of:
Terms & Definitions
Duties & Responsibilities
Welding Imperfections
Mechanical Testing
Welding Procedures & Approval
Welder Approval
Any Questions ?*
4/23/2007
1) Use a pencil only for the arrow line, but make all
writing in ink
2) Report everything that you can observe
3) Do not forget to compare and sentence your report to

the code provided
4) Do not forget to date & sign your report
5) Make any observations, such as recommendations for

further investigation for crack-like imperfections*
4/23/2007
Using the macro photographs and report sheets given to
you, prepare your reports using the sheets given
(20 min’s/macro)
Identify indications, then draw a line on the report sheet
smaller macro photograph and number it. Using the boxes
below, identify the number and indicate what you have
identified
Place the size of the indication in the next box on the right,
remembering to divide the dimension from photograph by 10
Use the following slides as guidance!
4/23/2007
Macro Inspection Points
1) Use a pencil for the arrow lines, but make all
writing in ink only
2) Do not forget to print your name
3) Do not forget to put the date
4) Do not forget to SIGN the report
5) Make any comments such as recommendations for
further investigation for crack-like imperfections*
4/23/2007
09.20
Example Macro Photo
Macro Photo x 10*

4/23/2007
NOTE: PHOTOGRAPH IS AT X10 MAGNIFICATION
MATERIAL: LOW CARBON STEEL
8 WELDING PROCESS: [MAG/GMAW]
9
7 1
11 All dimensions in mm
6 2 3
4
10 5 12
# DEFECT SIZE ACCEPT/REJECT
1 Overlap
+ 2 pores
0.5 Ø max *
2 Laminations/inclusions*

3 Lack
of side wall fusion*
4 Overlap*

Linear
misalignment

Assess
5 0.4*
6 Lack
of inter-run fusion + silica*
7 Gas
pore/pipe ? Check penetrant 2.2 Ø * To
8 Lack of side wall fusion + silica*

9 Poor
toe blend Sharp
75° *
10
Angular misalignment
5°* Specification*

11 EXCESS WELD METAL

4.7*
12 EXCESS PENETRATION 1.4
Sharp*
4/23/2007
Continue with Practical Macro Inspection.
(Or as directed by your lecturer/presenter)*
4/23/2007

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Welding Inspector

• The width of the specimen should include HAZ, weld and

• Number of weld passes

• Metallurgical structure of weld, fusion zone and HAZ

• Location and depth of penetration of weld

• Fillet weld leg and throat dimensions

Macro examination Micro examination

3) Do not forget to compare and sentence your report to

5) Make any observations, such as recommendations for

Example Macro Photo

Macro Photo x 10*

11 EXCESS WELD METAL

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