WIS5 Imperfections 2006 PDF

Copyright 2006, TWI Ltd
World Centre for Materials Joining Technology

CSWIP 3.1 Welding Inspection CSWIP 3.1 Welding Inspection
TWI Training & Examination TWI Training & Examination
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Welding & Welding & Materials Materials
Imperfections Imperfections
Course Reference WIS 5 Course Reference WIS 5
Course notes section reference 3, 6 & 16 Course notes section reference 3, 6 & 16
Welding Imperfections Welding Imperfections
All welds have imperfections All welds have imperfections
Imperfections are classed as Imperfections are classed as defects defects when they are of a when they are of a
type, or size, not allowed by the Acceptance Standard type, or size, not allowed by the Acceptance Standard
A defect is an unacceptable imperfection A defect is an unacceptable imperfection
A weld imperfection may be allowed by one Acceptance A weld imperfection may be allowed by one Acceptance
Standard but be classed as a defect by another Standard Standard but be classed as a defect by another Standard
and require removal/rectification and require removal/rectification
Standards for Welding Imperfections Standards for Welding Imperfections
BS BS EN ISO 6520 EN ISO 6520- -1 1(1998) (1998) Welding and allied processes Welding and allied processes
Classification of geometric Classification of geometric
imperfections in metallic materials imperfections in metallic materials - -
Part 1: Fusion welding Part 1: Fusion welding
Imperfections are classified into 6 groups, namely: Imperfections are classified into 6 groups, namely:
1 Cracks 1 Cracks
2 Cavities 2 Cavities
3 Solid inclusions 3 Solid inclusions
4 Lack of fusion and penetration 4 Lack of fusion and penetration
5 Imperfect shape and dimensions 5 Imperfect shape and dimensions
6 Miscellaneous imperfections 6 Miscellaneous imperfections
Standards for Welding Imperfections Standards for Welding Imperfections
EN ISO 5817 EN ISO 5817 (2003) (2003) Welding Welding - - Fusion Fusion- -welded joints in steel, welded joints in steel,
nickel, titanium and their alloys (beam nickel, titanium and their alloys (beam
welding excluded) welding excluded) - - Quality levels for Quality levels for
imperfections imperfections
This main imperfections given in EN ISO 6520 This main imperfections given in EN ISO 6520- -1 are listed in 1 are listed in
EN ISO 5817 with acceptance criteria at 3 levels, namely EN ISO 5817 with acceptance criteria at 3 levels, namely
Level B (highest) Level B (highest)
Level C (intermediate) Level C (intermediate)
Level D (general) Level D (general)
This Standard is directly applicable to This Standard is directly applicable to visual visual testing of welds testing of welds
... ...(weld surfaces & macro examination) (weld surfaces & macro examination)
Welding imperfections Welding imperfections
classification classification
Cracks Cracks
Cracks Cracks
Cracks that may occur in welded materials are Cracks that may occur in welded materials are
caused generally by many factors and may be caused generally by many factors and may be
classified by shape and position. classified by shape and position.
Note: Note: Cracks are classed as Planar Defects. Cracks are classed as Planar Defects.
Classified by Shape Classified by Shape
Longitudinal Longitudinal
Transverse Transverse
Chevron Chevron
Lamellar Tear Lamellar Tear
Classified by Position Classified by Position
HAZ HAZ
Centerline Centerline
Crater Crater
Fusion zone Fusion zone
Parent metal Parent metal
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Longitudinal parent metal Longitudinal parent metal
Longitudinal weld metal Longitudinal weld metal
Lamellar tearing Lamellar tearing
Transverse weld metal Transverse weld metal
Cracks Cracks
Transverse crack Transverse crack Longitudinal crack Longitudinal crack
Cracks Cracks
Main Crack Types Main Crack Types
Solidification Cracks Solidification Cracks
Hydrogen Induced Cracks Hydrogen Induced Cracks
Lamellar Tearing Lamellar Tearing
Reheat cracks Reheat cracks
Cracks Cracks
Solidification Cracking Solidification Cracking
Occurs during weld solidification process Occurs during weld solidification process
Steels with high sulphur impurities content (low ductility at Steels with high sulphur impurities content (low ductility at
elevated temperature) elevated temperature)
Requires high tensile stress Requires high tensile stress
Occur longitudinally down centre of weld Occur longitudinally down centre of weld
Cracks Cracks
Cracks Cracks
Hydrogen Induced Cold Cracking Hydrogen Induced Cold Cracking
Requires susceptible hard grain structure, stress, low Requires susceptible hard grain structure, stress, low
temperature and hydrogen temperature and hydrogen
Hydrogen enters weld via welding arc mainly as result of Hydrogen enters weld via welding arc mainly as result of
contaminated electrode or preparation contaminated electrode or preparation
Hydrogen diffuses out into parent metal on cooling Hydrogen diffuses out into parent metal on cooling
Cracking developing most likely in HAZ Cracking developing most likely in HAZ
Cracks Cracks
Lamellar Tearing Lamellar Tearing
Step like appearance Step like appearance
Occurs in parent material or HAZ Occurs in parent material or HAZ
Only in rolled direction of the parent material Only in rolled direction of the parent material
Associated with restrained joints subjected to through Associated with restrained joints subjected to through
thickness stresses on corners, tees and fillets thickness stresses on corners, tees and fillets
Requires high sulphur or non Requires high sulphur or non- -metallic inclusions metallic inclusions
Cracks Cracks
Re Re- -Heat Cracking Heat Cracking
Occurs mainly in HAZ of low alloy steels during post weld Occurs mainly in HAZ of low alloy steels during post weld
heat treatment or service at elevated temperatures heat treatment or service at elevated temperatures
Occurs in areas of high stress and existing defects Occurs in areas of high stress and existing defects
Prevented by toe grinding, elimination of poor profile Prevented by toe grinding, elimination of poor profile
material selection and controlled post weld heat treatment material selection and controlled post weld heat treatment
Welding Imperfections Classification Welding Imperfections Classification
Cavities Cavities
Gas Cavities Gas Cavities
Root piping Root piping
Cluster porosity Cluster porosity Gas pore Gas pore
Blow hole Blow hole
Herringbone porosity Herringbone porosity
Gas pore <1.5mm Gas pore <1.5mm
Blow hole.>1.6mm Blow hole.>1.6mm
Causes: Causes:
Loss of gas shield Loss of gas shield
Damp electrodes Damp electrodes
Contamination Contamination
Arc length too large Arc length too large
Damaged electrode flux Damaged electrode flux
Moisture on parent material Moisture on parent material
Welding current too low Welding current too low
Root piping Root piping
Porosity Porosity
Cluster porosity Cluster porosity
Herringbone porosity Herringbone porosity
Crater pipe Crater pipe
Weld crater Weld crater
Crater Pipe Crater Pipe
Crater pipe is a shrinkage defect and not a gas defect, it has Crater pipe is a shrinkage defect and not a gas defect, it has
the appearance of a gas pore in the weld crater the appearance of a gas pore in the weld crater
Causes: Causes:
Too fast a cooling Too fast a cooling
rate rate
Deoxidization Deoxidization
reactions and liquid reactions and liquid
to solid volume to solid volume
change change
Crater cracks Crater cracks
(Star cracks) (Star cracks)
Crater pipe Crater pipe
Crater Pipe Crater Pipe
Solid Inclusions Solid Inclusions
Slag inclusions are defined as a non Slag inclusions are defined as a non- -metallic inclusion caused metallic inclusion caused
by some welding process by some welding process
Causes: Causes:
Slag originates from Slag originates from
welding flux welding flux
MAG and TIG welding MAG and TIG welding
process produce silica process produce silica
inclusions inclusions
Slag is caused by Slag is caused by
inadequate cleaning inadequate cleaning
Other inclusions include Other inclusions include
tungsten and copper tungsten and copper
inclusions from the TIG inclusions from the TIG
and MAG welding process and MAG welding process
Slag inclusions Slag inclusions
Parallel slag lines Parallel slag lines
Lack of sidewall Lack of sidewall
fusion with fusion with
associated slag associated slag
Lack of interun Lack of interun
fusion + slag fusion + slag
Elongated slag lines Elongated slag lines Interpass slag inclusions Interpass slag inclusions
Lack of Fusion Lack of Fusion
Typical Causes of Lack of Fusion: Typical Causes of Lack of Fusion:
welding current too low
bevel angle too steep
root face too large (single-sided weld)
root gap too small (single-sided weld)
incorrect electrode angle
linear misalignment
welding speed too high
welding process related particularly dip-transfer GMAW
flooding the joint with too much weld metal (blocking Out)
Incomplete filled groove + Incomplete filled groove +
Lack of sidewall fusion Lack of sidewall fusion
1 1
2 2
1. 1. Lack of sidewall fusion Lack of sidewall fusion
2. 2. Lack of inter Lack of inter- -run fusion run fusion
Causes: Causes:
Poor welder skill Poor welder skill
Incorrect electrode Incorrect electrode
manipulation manipulation
Arc blow Arc blow
Incorrect welding Incorrect welding
current/voltage current/voltage
Incorrect travel speed Incorrect travel speed
Incorrect inter Incorrect inter- -run cleaning run cleaning
Lack of sidewall fusion + incomplete filled groove Lack of sidewall fusion + incomplete filled groove
Overlap Overlap
Overlap Overlap
An imperfection at the toe or root of a weld caused by metal 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 flowing on to the surface of the parent metal without fusing to it
Causes: Causes:
Slow travel speed Slow travel speed
technique technique
Current too low Current too low
Overlap Overlap
Toe Overlap Toe Overlap
Toe Overlap Toe Overlap
Weld Root Imperfections Weld Root Imperfections
Incomplete root fusion Incomplete root fusion
Incomplete root penetration Incomplete root penetration
Causes: Causes:
Low Amps/volts Low Amps/volts
Large Root face Large Root face
Small Root Gap Small Root Gap
Fast Travel Speed Fast Travel Speed
Incorrect Electrode Incorrect Electrode
Angle Angle
Arc blow Arc blow
Lack of root penetration Lack of root penetration Lack of root fusion Lack of root fusion
Lack of Root Fusion Lack of Root Fusion
Lack of Root Penetration Lack of Root Penetration
Shrinkage groove Shrinkage groove
Causes: Causes:
Insufficient weld metal Insufficient weld metal
deposited in the root pass deposited in the root pass
Too fast a cooling rate Too fast a cooling rate
during the application of during the application of
the root bead pass the root bead pass
Poor welding technique Poor welding technique
A shallow groove caused by contraction in the weld metal A shallow groove caused by contraction in the weld metal
along each side of the penetration bead along each side of the penetration bead
Concave Root Concave Root
Causes: Causes:
Excessive back purge pressure Excessive back purge pressure
during TIG welding during TIG welding
Excessive root bead grinding Excessive root bead grinding
before the application of the before the application of the
second pass second pass
welding current too high for 2nd welding current too high for 2nd
pass pass overhead welding overhead welding
root gap too large root gap too large - - excessive excessive
weaving weaving
A shallow groove, which may occur in the root of a butt weld A shallow groove, which may occur in the root of a butt weld
Concave Root Concave Root
Excessive root penetration Excessive root penetration
Causes: Causes:
Root faces too small Root faces too small
Root gap too large Root gap too large
Excessive amps/volts Excessive amps/volts
Slow travel speed Slow travel speed
Root penetration bead in excess in accordance with the Root penetration bead in excess in accordance with the
relevant specification being used relevant specification being used
Excessive root Excessive root
penetration penetration
Concave root Concave root Excess root penetration Excess root penetration
Causes: Causes:
High Amps/volts High Amps/volts
Small Root face Small Root face
Large Root Gap Large Root Gap
Slow Travel Speed Slow Travel Speed
Burn through Burn through
A localized collapse of the weld pool due to excessive A localized collapse of the weld pool due to excessive
penetration resulting in a hole in the root run penetration resulting in a hole in the root run
Burn Through Burn Through
Causes: Causes:
Loss or insufficient back Loss or insufficient back
purging gas purging gas
Most commonly occurs Most commonly occurs
when welding stainless when welding stainless
steels steels
Purging gases include Purging gases include
argon, helium and argon, helium and
occasionally nitrogen occasionally nitrogen
Oxidized Root (Root Coking) Oxidized Root (Root Coking)
Imperfect Shape and Dimensions Imperfect Shape and Dimensions
Weld Imperfections Weld Imperfections
Typical Causes of Imperfect Shape (including poor toe blend) Typical Causes of Imperfect Shape (including poor toe blend)
Poor welding technique is the usual cause these Poor welding technique is the usual cause these
imperfections, such as: imperfections, such as:
electrode size for the cap passes is too large electrode size for the cap passes is too large
welding speed too slow welding speed too slow
welding current too low welding current too low
arc voltage too low (SAW and GMAW) arc voltage too low (SAW and GMAW)
poor manipulation of the electrode poor manipulation of the electrode
incorrect weld bead positioning / placement incorrect weld bead positioning / placement
Surface and Profile Surface and Profile
Incomplete filled groove Incomplete filled groove Poor cap profile Poor cap profile
Excessive cap height Excessive cap height
Poor cap profiles and Poor cap profiles and
excessive cap reinforcements excessive cap reinforcements
may lead to stress may lead to stress
concentration points at the concentration points at the
weld toes and will also weld toes and will also
contribute to overall poor toe contribute to overall poor toe
blend blend
Incomplete filled groove Incomplete filled groove Excess cap reinforcement Excess cap reinforcement
Poor Cap Profile & Poor Toe Blend Poor Cap Profile & Poor Toe Blend
Poor Poor
Stop / Starts Stop / Starts
Cap and Root Undercut Cap and Root Undercut
An irregular groove at the toe of a weld run in the parent metal An irregular groove at the toe of a weld run in the parent metal
Causes: Causes:
Excessive amps/volts Excessive amps/volts
Excessive travel speed Excessive travel speed
Incorrect electrode angle Incorrect electrode angle
Excessive weaving Excessive weaving
technique technique
Electrode too large Electrode too large
Arc length too high Arc length too high
Cap Undercut Cap Undercut
Intermittent Cap Undercut Intermittent Cap Undercut
Cap undercut Cap undercut Root undercut Root undercut
Undercut Undercut
Miscellaneous Imperfections Miscellaneous Imperfections
Arc strike or stray arc: Arc strike or stray arc:
accidental striking of an arc on to base material accidental striking of an arc on to base material
loss of welding cable insulation loss of welding cable insulation
poor connection of current return cable poor connection of current return cable
Spatter: Spatter:
excessive current or voltage excessive current or voltage
Grinding mark / mechanical damage: Grinding mark / mechanical damage:
Torn surface Torn surface
Causes: Causes:
Excessive current Excessive current
Damp electrodes Damp electrodes
Incorrect wire feed speed Incorrect wire feed speed
when welding with the when welding with the
MAG welding process MAG welding process
Arc blow Arc blow
Spatter Spatter
Arc strike Arc strike
Causes: Causes:
Accidental striking of the Accidental striking of the
arc onto the parent arc onto the parent
material material
Faulty electrode holder Faulty electrode holder
Poor cable insulation Poor cable insulation
Poor return lead Poor return lead
clamping clamping
Mechanical Damage Mechanical Damage
Mechanical damage can be defined as any surface material Mechanical damage can be defined as any surface material
damage cause during the manufacturing process. damage cause during the manufacturing process.
Grinding Grinding
Hammering Hammering
Chiselling Chiselling
Chipping Chipping
Breaking off welded attachments Breaking off welded attachments
(torn surfaces) (torn surfaces)
Using needle guns to compress Using needle guns to compress
weld capping runs weld capping runs
Mechanical Damage/Grinding Mark Mechanical Damage/Grinding Mark
Chipping Marks Chipping Marks
Set Set- -Up Irregularities Up Irregularities
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A variation of leg lengths on a fillet weld A variation of leg lengths on a fillet weld
Note: Note: Unequal leg lengths on a fillet weld may be specified as Unequal leg lengths on a fillet weld may be specified as
part of the design, in which case it will not be part of the design, in which case it will not be
considered as a defect. considered as a defect.
Unequal Leg Lengths Unequal Leg Lengths
Plate/pipe Linear Misalignment Plate/pipe Linear Misalignment
(Hi (Hi- -Lo) Lo)
Angular Misalignment Angular Misalignment
Linear misalignment Linear misalignment is is
measured from the lowest measured from the lowest
plate to the highest point. plate to the highest point.
Angular misalignment Angular misalignment is is
measured in degrees measured in degrees
Linear Misalignment Linear Misalignment
Linear Misalignment Linear Misalignment
Any Questions Any Questions
Questions Questions
Weld Imperfections: Weld Imperfections:
QU 1. QU 1. Give two main causes for the occurrence of a burn Give two main causes for the occurrence of a burn- -through through
QU 2. QU 2. Give two main causes for the occurrence of excessive Give two main causes for the occurrence of excessive
root penetration on a single root penetration on a single- -V butt weld V butt weld
QU 3. QU 3. Give five defects, which may occur when welding carbon steel Give five defects, which may occur when welding carbon steel
using the MMA welding process with the current setting to low using the MMA welding process with the current setting to low
QU 4. QU 4. Give three possible causes for the occurrence of lack of side Give three possible causes for the occurrence of lack of side
wall fusion wall fusion
QU 5. QU 5. Sketch the following defects Sketch the following defects
a. a. Lack of root wall fusion Lack of root wall fusion b. b. Lack of root penetration Lack of root penetration
c. c. Incomplete filled groove Incomplete filled groove d. d. Concave root Concave root
Material Inspection Material Inspection
Parent Material Imperfections Parent Material Imperfections
Material Inspection Material Inspection
All materials arriving on site should be inspected for: All materials arriving on site should be inspected for:
Size / dimensions Size / dimensions
Condition Condition
Type / specification Type / specification
In addition other elements may need to be considered In addition other elements may need to be considered
depending on the materials form or shape depending on the materials form or shape
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Condition
(Corrosion, Damage, Wall thickness Ovality, Laminations & Seam)
Specification
Welded
seam
Size
LP5
Pipe Inspection Pipe Inspection Pipe Inspection Pipe Inspection
Other checks may need to be made such as: distortion
tolerance, number of plates and storage*
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Size
Condition
(Corrosion, Mechanical damage, Laps, Bands &
Laminations)
5L
Specification
Other checks may need to be made such as: distortion
tolerance, number of plates and storage*
Plate Inspection Plate Inspection Plate Inspection Plate Inspection
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Laminations
Segregation
Cold Laps*
Direction of rolling
Rolling Imperfections Rolling Imperfections
Parent Material Imperfections Parent Material Imperfections
Lamination Lamination
Mechanical damage Mechanical damage
Lap Lap
Segregation line Segregation line
Laminations Laminations are caused in the parent plate by the steel making are caused in the parent plate by the steel making
process, originating from ingot casting defects. process, originating from ingot casting defects.
Segregation bands Segregation bands occur in the centre of the plate and are low occur in the centre of the plate and are low
melting point impurities such as sulphur and phosphorous. melting point impurities such as sulphur and phosphorous.
Laps Laps are caused during rolling when overlapping metal does not are caused during rolling when overlapping metal does not
fuse to the base material. fuse to the base material.
Lapping Lapping Lapping Lapping
Lapping
Lapping Lapping Lapping Lapping
Lamination Lamination Lamination Lamination
Laminations Laminations
Plate Lamination Plate Lamination
Any Questions Any Questions
Material imperfections Material imperfections
Questions Questions
Weld Repairs: Weld Repairs:
QU 1. QU 1. State six points of importance of repair welding. State six points of importance of repair welding.
QU 2. QU 2. State two NDT methods that may be applied in a weld State two NDT methods that may be applied in a weld
repair repair
QU 3. QU 3. State three documents, which the inspector should State three documents, which the inspector should
refer to when carrying out repairs. refer to when carrying out repairs.
QU 4. QU 4. In some cases why might a specification not allow a In some cases why might a specification not allow a
crack to be repaired, regardless of size or orientation? crack to be repaired, regardless of size or orientation?
Elements Elements
Iron Iron Fe Fe
Carbon Carbon C C is for Strength is for Strength
Manganese Manganese Mn Mn is for Toughness is for Toughness
Silicon Silicon Si Si < 0.3% Deoxidiser < 0.3% Deoxidiser
Aluminium Aluminium Al Al Grain refiner, <0.008% Deoxidiser + Grain refiner, <0.008% Deoxidiser +
Toughness Toughness
Chromium Chromium Cr Cr Corrosion resistance Corrosion resistance
Molybdenum Molybdenum Mo Mo 1% is for Creep resistance 1% is for Creep resistance
Elements Elements
Vanadium Vanadium VV Strength Strength
Nickel Nickel Ni Ni Low temperature applications Low temperature applications
Copper Copper Cu Cu Used for weathering steels (Corten) Used for weathering steels (Corten)
Sulphur Sulphur SS Residual element (can cause hot Residual element (can cause hot
shortness) shortness)
Phosphorous Phosphorous PP Residual element Residual element
Titanium Titanium Ti Ti Grain refiner, Used a a micro alloying Grain refiner, Used a a micro alloying
element (S&T) element (S&T)
Niobium Niobium Nb Nb Grain refiner, Used a a micro alloying Grain refiner, Used a a micro alloying
element element (S&T) (S&T)
(S&T) = Strength & Toughness (S&T) = Strength & Toughness
Stainless Steel Stainless Steel

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