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Tremsport] axstomo it Mee] Pb se nkea> sce) Labs problino Aetna be chen be eyeid w We butter er mere experiented Sahmder Me relae —_puyppliey * Aenlise. eskimnle of D deiseo Fee Reve ap availa le plan PemeS Mainkenance NE ee Breen ower * Fraction Praluss LT Skt du netic Of the defets thet yr considur de have cowl the fatlure What [hire 43 the winstabon pein precple mods of failure — Detisibe Hh Accondary medu ob rrilare (roy) — Auppert eadr amber with o Alecteb, D) Beatie facle > © malerical Ahinsing 4S Shoo Lip * gy Ge Artace prpile J—— Pedicksen fren D tern perfas Sua b) Hs? "Shear Lens a ie gmeoth D Bitte frective Felix ain Hsem * Verte (Arye A Skf tebe ab Sy Bxtt fread ‘Shreve Lerten fyabion Freep bela dhe brandibion Temp “FB Teamsilson bem PIM timperatin ab utich 1 metals cheng ee PTR Mperalin abutich ductile metals of yoo ae Me bette mode PP plied. Frank Ahew Lower than the Yael Shon (wo plerbe Sign) CR BisBemy oe Swrfacs cr flak det rou Coitee Piscts f valigg ) Bre SL Cin oanBUH fecchire D herons mares pointing Leivamsts pink @ sinitialiern Paks, frackine Fetes affakey * Shen va > HnlBti Jelaw yee Alven HOB Yd op age Prati purte Cte te shreo diveckion Inikabieo ponk ala Stvew fonuntration rechae surfau: Srmocté ee Smee, Sa ecg bee abwe geil poine dluctoe oF fail vin bE FREE SHEED Fenn ee Fedigec 5 Brite —S date Fab gens aes Fabgee > ducke rm meh nae noted eeetis Fede bye. ath, erate feck Surfer, @\ na eal % [abi Specimen chouiblsen’ Ltr a bee joirk | fillet weld Specimen. The Weld Alop (Steet poict Location ARB cw naar dhe Weld Unbre Failce tnibabren: ee tees Q fitet weld Thy prong msde B fale in Pabyur treatin, HH evitine g Amecte Aurtu. 8 heath mart> edt caboas | 9° Eeectony Jedle mad, The Frevetine prgrenck wr aductl ede With evidente form & Bbrus appre. ak Jeraker 3a,uA The Brot mode % fail 29 én a duetel manwr at beth He emu ¢ poser, sith the avidenue Jp Shear dips ak s treldng duals tive Ne Charged mag affee thy All Vequiremtnt ob ath, oelelurMethanical Wt method ee D Genk Letty Syren nee Ge joint for Sodhewalt & Ertermin furion NX Woe aR taet Sem — ACja bends Diameter Ya bers = Oxt ether lng — (6E DAU weld metl fenbile fore » De gore Lae: A tticaben Stendang deeds deat Lipp + sruxyy rep ui remnte weld " Sy mpelsF termd [og Petals: Bra the Grin Sigher th fouginess Of Mskoibe Stels denct unr ou, tel / avttte peers forenedion Duplin: * 2Phaw > Se) ferit +607. Avsknite * mesjnat very geek yeristenu fo Cher Coneiion racing Buk Sober duct bitte Kantprmatin. — Thyghar dave feonly wn Shee hak rpur yegiad ihre the Phere beac hutieun fe f Dusterite Conbumalles: * BSEN HAG i compulsory park E ab & 8 L oi peta I Bevbrode. Coverie Aborfom’ —_aeegpeet 3 ester. Bari all Crd: Gab Rotic ~ Alken (Gam ) mineral Areca mrinvak @l- max 2h 35 Bo Phan fm aybaen fedeSpecimens B-2 Pesrmun d208 phen, ToS probally aT jent, fillet weld fractin Toikabon CO ES TTR Fraaltive fasnio Hak amb rough (and ows tae) vd ceies Fail diy brittle There ane Flow dines en the Freackiu fare Hal run From a Small aren ck Ke bee hie ucla (ecg 1) thet are apprarvana ofa be Crakk. trun dhe frectaar dirtration point “The lark CPPearanu Of thes > ey E, Madi cates that the: Coe Bi ees chee ee Setond. failure « LLY Redes failune : Thee Un no Accordory mode D fetta Sere imu: p_ CARGO By CLeemen doesfon: —— “This ude Aoulle Aided Luttucla with the Ameot& x v £ s pre Surta pwil. an ueld bead Abra wndicating dn pS hei prue ASS dncabens Se Tae pp The frastion fous plat arn rough, With numer. Chu nine markings theta chereuknshe ofa peak runing brite freatiuThe thwrend Peink back ok ihe tnibation The fea tie, Pesibon | HOD wre pone WRichuis act Skew on Tho piece Hane ond dart eric) re erp op pe Characknshe a Sct Lifediin Creu. That net @ reece rrrtreePehek eb renee have deen . alr ie “sj dhe Ghibals & ep point further ROAGY Failure mode: The cr pe Aewerd0r) moda wef feslure ars (f , & eaten ote. : Specioun howd phe Thins @ butk -weldul fom beth $dir a weld Paws striata nul ocd foe blind have @ Bmootk pobl ant go failure Tnibabion! 4 ER CORES The primey meds of failure uo dy Fodiges Cree Fmt inihabon — Fodict® dye Amentt eppearane of regret and ule devel Freak CRs ate crete. “The crest has dinilecte fem One Arde only anh p per eck through the full cecen over almest the full engin ofthe SPecienen ELAS Fesleor mede Lee ee Ae ee chy clutch tearing form Lect end> of Me Fobyen rett., Shewn by fe Rbwur appearanu of regions 2K % Final Sepohabon thus ceuned win a dust Mannur -Shewe Ay ke Smeote Shear hep ak veyron som Le a boner degree ce ob giv s D Seecama a" Epeumundoceiblien Ta frastin ud home fractal Oo Yeund bay that Shows ne edinu ofa weld y J ct & Failure Epihations eae tee Failine started by Fabgus (rave inibabeo fem apoink Ob Ha Supa. in dicated Aj $R Smee Hy The falbyue crack appears tt have tome fern a ve “mrewkecben(h) ab He Aurfas and HE Crease than celeste he the OPPSE Aide OF ba Suvfeu ot region | su) Sma Preguened. Seseery_ mode Feslioe mea paar Feel Separabon Otareh by duck Feenes ay phew by he Fiore ePpearang, of raten a anh he Hu Small and Soom Frad aye Pheer Lp Shown wa ve, ae Fe BLA Parks Pat FenInede of faslye Tnibabien from facts wold? Cov he Shits) on Gu rte cf the platy Prgreved hiya fabgur medeon 3 front wn Avea 2 te Pesthen-% Pubsguc mode dancrah hey the Smreett fractiire hurts Retin Hun chengeat Le dvb. mode, area —4 demete Lage Oslin Ap puarane of tke Surf nally failure etek bey duct Teady ancas antlara & hole poh hte (rack ab axa-bamtlrermand of faticot}h, Peplica : "Yano fee | Dw | j Lee be a Y Sniraben goin 2 f Teche aby horn © Plaonardipect>s DM rove of feta “The Arinalion . Practise Aurfe Ao rgh Kehuror pointy bmwuls cheoth “Mae are Sema ¢ Seno i we Seoetth hater Lin — flag jon 230AS cherasheosBe Came het, NY 274 beak wy erates en dilnnt Meus Aport contig: Cras. uivils ation ak point 4- Berovbe wratthe as Fribek fuiluw mode +4 Co 2 @_| © va Ae wibabon point ow raOrea 2) Fobgen Proatiu 3D bk from 4) plat Laminar mede cE facta Cree State ak Teuctd U2, 304 Pregrered wnibally dy fe P69, which joinuk upat 8 Final feu we hey lustet Teatey +9, 10 eral matevind fess my bh yeu, clenoted ey ER Smelt frevliz,Stns dreuniey rovbiy ~ Seu binise. dhe drawings ard produce a rack fetch of numbered j0ink ways | Sect. Clee Fide Alutch govt your veka pctation. of tie usetd Agenbet invetved. = Fath Pymbot mut be oeperted Separately — temment if any dataiis uo 270 proach predus ver Dri TY 1) Exexcijeg 3 - Pour tae] A) JT. Sumbd od actarpur Bsew 22563 D deuble cial fillet weld 2) Frve “the Symbll arvows Side amd our we dey Gide tome by Side a not Char. ola Side pane dag imo Dashed din $v hmesidfoter Srdhe net chee ™ Symbef for ma tick veld Tocowet Te eta Aymbd Lutes Me veferene tine POO phacedh ne Ma Straight Line rin Vou FFM Pitck yocld Sreuld olwveyh ap The Att Side D The SD temo ey mak be om Bervab th. Feary D tetas Ni crtobe inj [row Ma weld sepuiral in Speier, dunk it Aw f be menbenuil TM tedlenly | Ans Sok prc parben Fen attide. setae Seats tee TPM pret DT Har Side Showry a back weld, which ur Seema bbe (pul conmthol OF possible, because diameter Op Pines Soommenly —_/ Seabrymnai ‘) Deis a Seg U weld ibe neldut fom arneside 8) Reciegrapihy preaduc 225 wate be wu V) Sine che a Pek joink zr dd remem de weld aU amund ) lot allarountr Symnet ua ave pent mit SD WPS2 othe wed QTL othr Side dette nk aor BS au 22552 ule missing D) A Siege S'pctd uke Be made froma armed Side 9) Then Filler eld fp be made inky amew Bde 0 aoe he Alict Sie menbened or chy, ity wv hawt ies Uy ex full (20 - Guk weld ®) Gre ound Plahen ottaSide ee dy proeoo i) ak be gle bWntwakd be ‘) thoes: “y Wwelduh from 0 Her Side, Ho vin \ ew ) het wha & e wurent, Nee prachol: / pers ine te peesshee , Sine pipe cba mater or ently corm Trea X flue fer Donde | 8) Dees debe nelded um feld aie K | ay bo be weak Be urldirs pee on e) ) The telling Symbe fo ct ape lorceck . Factithet rote BD PAZ Sem are sbeerat cere ee wold, chee a The flee weld i Si ee en erat clier abate : etn tog Length Pe tReiak tovenue te steggeredk Syahid “Ze OC) ab ma haggard aie lens hen filet weld tebe Peds both on ar Side and ofter Side ii) The song th Up Cath fillet ia b3mm usin Spaciny 6BeO ot sloaker the matt on argide om eltunice » nm The Agmoet s Ae de wewey beeen Oe fh feitasieg ease | 1) Drab devel on th brent pipes WE peissbe Da Billet utd ate 2m He efter Side Oy Me join Cannct An done i) tee date Line mony Sy mireticnt mla en Loy Sede he vemos Since aI) ndorentionk biet ued on beth Bue i) 5 Avagth, gach bamm eng each Acparcatah Lay &3 0? tub Side (imo) tomm fillet Brvide tine fillet i) Evert D Rillee dimunsion® by) Hoot It jndicatk *) epee Te Farge ivouda alles tarege ne xf » Syer A Complete asin finer Syrbnt 2 a 8) Bree Bevel pull Ney Butt veel 11) fom Ferooat concave pro & Charnde. 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Wei di be qrett WY dy Su smm de bewredin 3 pleas ¢ FMS Dark 1) Deatul Acne moving a) XA] 1) Bilt dela © cried Siake BY ten bom a) aan Simm uptsdirsis como kbediaa gM dom im 2 phew. 1) Semm Je, SF Filet weld Pt poitibds, becaure ee MY omm aide 9) pose dearyn igi: BYP, ConflccboinD | 4 oA . eve D) Single bewel win bras wot fax well form cena D) ne dew din D) Z : ¥) pureh aber yaere net Penetoben Fromm veq wack eae / 1) perapin cnr) ow, hoe BP mmm 38 —Renewik MT BA procedure tehe fellmut ae op Symha \ ») {Wi Sigkbin ) Fillef weld de be dene #1 ene Sole. DB) tebe weld seme all orveund BY dag Asve bron Foor: Dbmm dag Aire net pais be» k ee ) Ses Hebel writs des Simm b be dene. w Te be reldak all aroun Lnwr iu Symbet Len flehy wih Symbet H Breer cise! HER ) i 2) B.filletwela bo he clone om amos Sicke al oy gw? BS iii Prk chee +4 ag ov Hoe R) WOH Weld pur [35 bebe sect. Sree Te Sire uy bet weld mentioned ent Chur ica latiters| or Froat 2) ome’ lela bei nla bbecden f fab Twi +) prepenetin 1) Potten tome pain dep segue L tie eee M) weld abbecend Je be dene alt arround | °) prow dt » weldieg pram mt the und | ii) wvetdack REL corre Sees, ) Fasiae Cet py ae plete Homm Hike ~ > Pe tre be pal Po agtetien le wih pst pl only lomm SeshSide \» Aid? Doub beret parhal pen Busted — i Depi Oe pen-bmm Ubersite bated Aged Pight but cath wep fae Zo D) Doult- breelferr bevel weld te bedens em both $i dua | 1h) Weld penebaber Oh bmn Yequia | | | j om Prusie 5. dud “5 preparation Pe Brctr pen. putt ucla ) pereeben deprh gimme Ere ee Should Lua| ii) pled Pete thicener’ aly jem & Could only be Sem ) Doubs a Joint de be dent on bolt em belt sda), Fh Sse mene “) Pence Bann weqerweh cleath eye preparation xy iat] a FA Free lak wrly omen , Ban dep 7 ee TT NEI Preparebom 0 bom cide act perohle Pronk | fA Diubee Sia, S ] | Alret weld, } Znlermittene= 1S pres Abe Seyyernd Length Sach boom Lond Tntevms ent Aeggevel me 64. 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Single bevel ~ preparation depte,s2n Peter de Proubar| Joume A ino v) Singh avel weld requimdon eHrbile.! |) Sjmbef por parhel pn ii) Becet preparation 112 depth « op yoweduie ‘p) fe he “eel Te ye) fey wr Siege. borst wreey Sym str Rak em Sage $evefoe peat for preperntin chpth I Somes om flick he, at rs q Mrs, owt Sidi filet weld Scimka Sree: py © 2S epee aoe 2) RitePitet Fillek weld dy he Pdea onLen Aare & cthurds) my = equine dew te. Sickes Net ice dects sueende» a D) Siege Pred fillet tel A, | 1D & posts oe dor: ive Beg ea i) Fillet weld te be den on the arms | VW) re be dea ak 4 decahon? / Grom Bilek Ge at prodidaak‘hat cs Eransibion joint ® Tepper ta Coc D Trangibon Seink- behwcen 2 ifferent thicnrers (Butt weld 2) Boink bebween 2 different ™ ate Sips % Trans ben joint betwen 6-5 pesmbe prelema ) lonbrtling the weld mate lempetihen te groue that Ik ianct Pur cpt be be Cracking , became Emurrive alubon Need te Acted a higher eclley filler mefet than the Seino — Stee ee Af. To Allow for clilutien fom both materials 2 > fombet We dhintertion » we AS Coetheent of thermal excpanticn { t Feet [3i6L > So¥. higher kan c- Cheat Cet cent thermal concluctivi | 4y Belgien D507 Lower Than Steck D Mgt Ler dual Shenes doe Aiely ap branion ents* Dilubon + edt Pershakior bees Garrent will minimise Penchetion ark Hur fore dilution — Petawily Pv. = hover Peretrabor —Aawer dilution — Pulsed mis /ose, oy Pull Th helprte minimize cliluben ae Bulterieg degen of 30g9L-min 3g dager th? ve mmechine he edge and weld MIB SS Bee Bey whee % tbecion, a 2 Rese woul Gu te peek He Lonmin in 65-56 joint occu. + pietup: Ae PIES’ Slemnente from bare mectorel Beng “picked ep’ dilataa sinks ht Diluben? The yatie C Golde Aller de bare rrotericd mettertXr mmr) what th cliluton of the Kiler muted foro bare mokerial would be Wypicad To dere aml mia vange taren Os5-3s% Shw upto soz, Tih teuld ke soy » hew dilaton pres Dip harsfer bento % Sleebe Hey ship Claddies Emly ni ley dilukon OK thet list for aking bransibion Joints hebween Carbon am Atainlos Steet ~ Comet filler wire “— mederial uot Fox (Both material) = cleemee of igh alley material Cave eokeminaion) TONY pre heat vequeinel — Comet treletiny Fechnsque CFS wes) THe of Lome curremk + MOB tomet plait © Bek equim + + Trevek pce — welden Quclifesden SE CL ulebson hey heat Po pak- Heat Soe Veh Ba es Tarts pudh Yoo Tree! Saad = Burn gd thm% Cartily Tn de of foe Ralic of Baris minrals ch atid minerals Tal -aeans (SP 10) ar 3B.) 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Mor paver — Sreater Strin tage weld, A Sctidi Feation LAG’ Love mretelimetting point material prodant ina Weld bead forme & Week region — net abi te verse the veriduol_ Strona That Ateotte build Op asthe weld mbal Actidifies an& Mots te cot Game ker seed Reg Bemis de crastey: composition meant Lie th Actidifies over a wide femperatiine vange— normed dehaviour ali Chemical Compesi bon 24 BLT wi Shel, Mby 825, pq), A lepper Contaminabion Sengibve! (u-an Abel Meflen bln ek dow te wneve Atel Sclidipes O tyeo-igese. F Satphun beveto Fron pal hide mcd biry Allecte Manganese Comdecse> With Ane phur de from mangree audjirades ee Hemp aman bere aes ue: Fretesney we weld metas Progen 4s bapped sin He weld mufetl Weld mefal Frans formaben fom high kemyp Phase autlenite te femite, oceurs Atewa then his Gransformotion umn HAZRearond 1) weld metal camposiion May be different Kan the Shel 24. porrent Shek micro ably. 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D Coron Shel, atlasie) enue BF may degrada. veld dd me. hughes ey s D mry etfet dhe bans firme micsshuctin ye perbo cen (weld mubed leaner (set £3s0mex) SF theejore machaniced DD) Abacdlor Afeal MAY votlue Corroigim vemivfene jrmay couse Sens b saben. By snax ie. bas Dates pve 3 Faker pew Feaps The Aeinpevalinn We math par weld on ddjurcen Parenk — raberie wmmdiately prior be the appticaber CF fa next yun, HF hue the wey, te be meres? Phe me measured. othe weld Mak oy The wim mactictely aAdjwont parent mefat a &Repair procedure 6 Maret re gut otek yee Dierersiond Cpetsbona) * Frecavation muthed + Shon 4, excevation. 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Be meterieolPaes Ot D tro Shengch sn tis Les D> tbh siicane h Ca D Boe sah ng prosuck *) FN ye lormyyty matron he D Fm DY at psebige ss enhifoke : ae Premier try aw fre 8-6 bles win Say me i) Jowett best Prkowaber 49 abiepaty « 5) Spi pr acat Lhe SFP Fromm by Pear Speci fr cab om wwnenyly ben meh STM WA romh. : wou ee Hille &. 3 Dy & ce 4 be Boo oS ty ° 9. CL eo Jeane BR pv 7 Dw ob Web 12, O/ Bo yeWELDED JOINTS - SYMBOLIC REPRESENTATION ON DRAWINGS (to BS EN 22553) TWI 1, Elementary Symbols Ea The symbols shown below are some of the symbols given in the Standard f Designation # Illustration Symbol | t T 1 | equare but weld w ll : | | single-V butt weld wv | | single-bevel butt weld single-bevel butt weld with broad root face yy ‘single-V butt weld with broad root face | 7 vr v single-U butt weld singled butt weld (EGE ao ieee backing run (USA - back or backing weld) | ev fillet weld h plug weld (USA - slot or plug weld) a Oo; 174 tit iS / ~30mm). Nate: this type of cracking és not associated with plate laminations - itis not delamination 2, Mechanism & Crack Appearance * Cracks form just outside the HAZ and they are ‘stepped? or “terraced” * They lie parallel to the plate surface and are located just outside the HAZ. Cracking occurs because inclusion ‘stringers’ (mainly sulphide inclusions) in the plate are ‘weak? points that are ‘opened up’ when large stresses occur in the “through-thickness" direction. Large residual stresses, from welding, occur in this direction when large welds are made in T, L, K & Y- Joint configurations, When the inclusions are opened up, the crack extends by tearing of the ‘ligaments’ between the inclusion stringers so that they join up into a ‘stepped’ crack - under the weld (Fig. 1) 3. Influencing Factors Lamellar tearing occurs when there are 2 factors operating at the same time, namely: - 1. High stress acting in the through-thickness direction of the plate - such as occurs when T, K, L, & Y-joints are made. 2. A susceptible material is used, namely a rolled plate that has verv low ductility in its? through-thickness direction - known as the short-transverse direction or Z-direction, AVOIDING LAMELLAR TEARING Lamellar tearing can be avoided by removing, or reducing, the influence of one of the 2 factors. * If the plate is susceptible it is essential to reduce the influence of the through-thickness stress * Ideally (and the modern practice) lamellar tearing is avoided by ensuring that plate is not susceptible to tearing because it has good through thickness ductility (particularly when large welds in T, K, L, & Y-joints are made) Reducing through-thickness stress - when the plate is susceptible to tearing + reduce the size of welds - use fillets instcad of butt welds (Fig. 2) * re-design the joint so that susceptible plate so stress is not through its thickness (Fig. 3) ‘butter’ the plate - usually with at least 2 layers of weld metal so that the highest stress is in the ‘butter’ layer rather than the plate (Fig. 4) Ensuring that plate is not susceptible to tearing * use forgings or castings - sulphide inclusions are only ‘elongated’ during plate rolling * ensure that plate has good through-thickness ductility by STRA* testing (f the %R of A is above ~25 - 30% then lamellar tearing should not occur even for very large welds in highly restrained T, K, L & ¥-joints under any circumstances) = use stecl plate with low Sulphur content (ideally <~ 0.010%) (if there is very little § then there will be very few sulphide inclusions and no'weak" regions) * STRA = Short Transverse Reduction of Area STRA tests are small tensile test pieces, taken in the through-thickness direction of the plate, that are taken just to measure the % Reduction of Area at fracture (Fig. 5) Supplementary Notes on Weldability 1 (CJM Rev. 4)WELDING INSPECTION LAMELLAR TEARING thickness residual crack extension by tearing of the between the inclusions through thickness resid stesss from weling cause these inclusions “open up > y sulphide inclusions ~ flattened out during plate rolling T-Joint showing how the weld produces residual stress in the through-thickness direction that causes lamellar tearing in a susceptible plate Figure 1 Figure 3 Avoid lamellar tearing by changing the joint reducing the through thickness stress on the design - in this case using a cruciform shaped extrusion susceptible plate by redueing the size of the weld af the joint intersect 2 layers of weld ‘ t tensile test ‘cal "battering ( [piece with ate surfaces ielesede 7 plate the throug! thickness direction Figure 4 Avoid lamellar tearing by reducing Figure 5 Schematic showing how a STRA test the through 3s stress on the piece is taken from a plate to measure the susceptible plate by putting 2 layers of weld Reduction of Area when tensile tested to ‘metal (‘buttering’). The highest residual failure. High values of R of A indicate good stress is then in the buttering layer. resistance to lamellar tearing, Supplementary Notes on Weldability (CIM Rev. 4)WELDABILITY SOLIDIFICATION CRACKING OCCURRENCE "occurs in weld metal and typically runs down centre of a weld run -usually breaks the surface ‘sometimes also called weld metal centre-line cracking or hot cracking or the weld is said to show ‘hot shortness’ (crater cracking is a form of solidification cracking & weld metal that gives crater cracking could be susceptible to centreline cracking - if larger weld runs are made) cracks form at high temperatures - when weld metal is solidifying (for steels >1000°C) 2._CRAC! Solidification cracking occurs when the weld metal solidifies over a wide temperature range so that the centre region of a weld bead is still liquid when the residual stresses from contraction of the hot weld zone start to build up It is transverse residual stresses (acting across the weld bead) that cause the weld to crack. These stresses can casily ‘open up" the weak central area of a weld bead when there is still liquid present. Solidification cracks are generally quite wide and can be seen on visual examination as soon as the weld bead has been deposited/deslagged. Centreline solidification cracking tends to occur most often in SAW welds because such weld beads tend to be quite large and may not have a ‘favourable shape’ (see schematics). 3. 2 FACTORS For cracking to occur 2 factors need to be operating at the same time 1, The weld metal has some susceptibility to solidification cracking 2, There is a high tensile stress acting across the weld (a transverse stress) 4. AVOIDING SOLIDIFICATION CRACKING Cracking can be avoided by reducing, or removing, one or both of the 2 factors. A Susceptible Weld Metal has the following characteristies:~ * achemical composition that solidifies over a wide temperature range so that low melting point liquid is present when most of the weld bead has solidified * the low melting point liquid may be caused by the presence of elements like sulphur (e.g., iron sulphides in steel or nickel sulphides in Ni-based weld metal) or the weld metal may just be particularly sensitive (those with wide solidification ranges - e.g., some Al alloys, Ni alloys & higher C steels) Actions to reduce the cracking susceptibility of a weld metal + minimise pick up of any elements/compounds that have low melting points, (particularly S - perhaps from oils and greases and minimise the pick up of any Carbon) "avoid contamination from low melting point materials such as Copper or Lead (ensure joints are clean and free from external contamination) * avoid welding parameters (and joint designs) that give deep and narrow weld beads (see schematics) ‘Supplementary Notes on Solidification Cracking 1 (CIM Rev.3)WELDABILITY Transverse Stress TWI ‘Transverse stress results from the residual welding stress - shrinkage of weld metal Se across a restrained joint. Once the material thickness and joint design has been decided it may be difficult to control‘reduce the residual stresses that will occur during welding. As material thickness increases, parent material strength increases and joint restraint increases - tacks, strong backs, clamps ete. - then the tranverse residual stresses will increase. Although control of residual stress is difficult, its’ effects may possibly be reduced by ensuring that welding is balanced and a welding sequence is used that allows residual stresses to build up gradually o ape wel rope inating sliieaton Figure! (Schematic af tanever ‘ator with (0) Fas view ofthe wld bea dpe) beng he tides teardrop sbaped wel poo ed how they pine a w Figure?) Sema (Man sew of he meld Bend peed (2) hung heaton ude pro rm ede ancl shaped meld poo! a how hy Therein pit ‘Supplementary Notes on Solidification Cracking, 2 (CIM Rev.3)WELDABILITY TWI WELD DECAY 1 Occurrence weld decay is a service failure problem - caused by corrosion - may occur after a long time in service it is associated with welding but is not a fabrication problem like H cracking * appearance itis called weld decay because narrow zone in the HAZ is severely corroded (for example, through the wall of a pipe wall) but surrounding areas (weld and parent metal) are usually completely unaffected + materials only affects certain alloys - particularly austenitic stainless steels that are not L Grades, for example 304 & 316 Grades = it requires 2 Factors to operate at the same time, namely 1. The HAZ has been ‘sensitised’ to corrosion during welding 2. A corrosive liquid that is in contact with the ‘sensitised’ HAZ (in service) Avoiding Weld Deca} Weld decay can be avoided by ensuring that the HAZ. is not ‘sensitised! during welding. Sensitisation of the HAZ when stainless steels that are not low carbon grades (L grades) ¢.g., 304 & 316 are welded, Chromium carbides form at grain boundaries in HAZ and this reduces the corrosion resistance of these zones thicker sections that require many weld runs are more likely to become sensitised because there are more 'thermal cycles' to cause Chromium carbide formation Actions to Avoid Sensitisation of HAZ the use low C grades of austenitic stainless steel (304L & 316L) has become the standard practice - the so called 'weldable grades’ - much less carbon means much less chromium carbide formation (and it also occurs more slowly in L- Grades) use ‘stabilised’ grades of stainless steel such as Grades 321 & 347 (Grade 321 has Titanium in it to from Titanium carbides (in preference to Chromium carbides) and 347 Grade has Niobium to from Niobium carbides; this leaves all the Chromium to provide corrasion resistance) if higher carbon Grades have to be used then low heat input welding é& the fewest weld runs possible should be used to minimise the time when Chromium carbides can form it is possible to remove the sensitised HAZ by giving the welded component a full n heat treatment - typically at ~1050 to 110°C - but this may not be practical Supplementary Notes on Weld Decay 1 (CIM Rev.3)TRAINING EXAMPLES (Paper #1) Radiographic Interpretation Questions [WIS10 (CSWIP 3.2)] 1. How is backscatter prevented from reaching the film? By paring Load Socom at the back tp Ha bho 2. Static marké are caused by? frcbion, Trpeue georalics 3. Water spots on drying films are ‘caused by? bethreeers; Lenic ve propu webline agen ae 4. Lead foil screens intensity primary radiation more than scatter? Trie/ False 5. ATLD measures? Peckiation POSE del 6. The difference in densities on a radiograph is called? Radusprnphee, Lenhart 7. Who designates that the employee is a classified worker? Le REO -Feaplayer a 8. When using gamma radiography, the monitors should be: a) Onalll the time during exposure ~ b) Only when winding in/out the source 9. __ Instant readout of radiation dose is given by? tok DeSireakei- — Gua ve cleehas cepe 10. To find out the safe distance from an unshielded source what procedure is used Fen babe Cheetos rater 11, Before taking a gamma source to site or the first time, how much notice is required? 12. what types of wamings are used on X ray enclosures Daegey fecip” WireryRonedh y 13. Wheat is the Purpose ofa densitometer? 14, Whatis the purpose ofan lal se cheat Tes SE Indica the quelihy yy ~wediographAy Oe eyat 15. _Whatis the HALF-LIFE of the following gamma sources? Cobalt 60 = <2 lridium 192 ~ esc, Yiterbium 169 — 16. What liquide are used to develop a film? 17. What does increasing the film speed do? Thestiateten otras? Pe 18. [Ql's should be placed where? 19. What are inensitying screens? h allt © eid Ae = 20. For a given thickness, which of the following will give the greatest protection against ionising radiation: Concrete Steel Lead” Brickwork_TRAINING EXAMPLES (Paper #1) Radiographic Interpretation Questions [WIS10 (CSWIP 3.2)] 21, What isthe purpose of a FILM BADGE? se aeqats Kpercrarnt reading ey dosage 22. Inwhich part ofthe body can the effec of over-exposure to radiation be frst detected? . Sein pretedechn orgasim Blo 23. What faults may be present on a radiographic film, which are not from the specimen being radiographed? 24. In general, does X-rays give more, or less, sharp images than Gamma rays? 25. What are the three common techniques applied to the radiography of plates and pipes? 26. A section of fim that receives more radiation than the surrounding area will be? 27. _ Radiation exposure will be detected firstly in which part of the body? 28. When do intensifying screens do their work? 29. Film badges ose fore ova of exposure by using? 30. The ability a dotect small flaws is called 31. What ie cracks look like on a radiographic film? 32. Sensitivity in radiography depends on three factors, what are they? 33. Scatored aation fomwals and fooiiscansar EEE 34, How do lead screens work? 35. Whyare lead letters used for identification when using radiography? becanse th be fighter c umier, f abterk, be 36. Which three liquids are essential for processing radiographic film 37. Pressure marks on the film before exposure are lighter or darker than the surrounding area after development? 38. What Is reticulation? 39. A permanent dose record is maintained by using which type of dosemeter? 40. What are the main steps of Xs ray film processing?DRAWING SYMBOLS to BS EN 22553 EXERCISE #1 (Rev. 3) ion Draw andor describe the following welds 4. Plug Weld dio MW a ucla tebe mode cocthe fey D Wweldieg process i dv fo be wreck 5. Fillet Weld gpack Bape Rok wer ber cave filet cela with Sy" fem pice we PO Mes veld bo 6. Butt Joint do COW Batt je 2 “a beDRAWING SYMBOLS to BS EN 22553 EXERCISE #1 (Rev. 3) wea Draw the appropriate weld symbol for the following weld joints 1. Structural T- joint blend both toes concave profile ale Set-on nozzle-to-shell weld nozzle shell a 3. Butt weld (closure weld) finished weld to be ground flush permanent backing stripX-X wons9g, soorid p ut 00st saowid Zul NS . (L-aoy) [# astouaxg Suraceac *BuyUTeLL, OT STAL USED weedore a y WNaTA ONG nu MATA NVTSaa 7. SO WNaLy SO TTE WRT Maen aATT SWIAES SL asiov 9x7PES bow ar Ob b o1eos suopuention sjoquig [ cssez vasa as as youeig pabuelt P wzWELD TEST REPORT: ULTRASONICS NAME AND ADDRESS OF INSPECTING COMPANY: CAMBRIDGE NDT SERVICES ABINGTON HALL, CAMBS, WORK LOCATION: ABINGTON DATE OF TEST: 10.08.91 REPORT REFERENCE NO: 3214-2 SHEET 1 OF 1 SHEETS WELD IDENTIFICATION: 3324-1 MATERIAL: LOW CARBON STEEL WALL THICKNESS: 25am TYPE OF JOINT: SINGLE VEE BUTT PLATE WELD PROCESS: MMA FILL/TIG ROOT WELD PREPARATION: 60° INCLUDED ANGLE, EXCESS WELD METAL: AS WELDED 2nm ROOT FACE 2mm ROOT GAP ULTRASONIC TEST INFORMATION ULTRASONIC FLAW DETECTOR: KRAUTKRAMER USM 2 - Serial No KO21 PROBES TYPE SIZE FREQUENCY ANGLE SCANNING PROCEDURE ‘Twin comp 10mm dia. 5MHz o* Single shear 10am dia. 5Mtiz 45° In accordance with code or specification Single shear 10ma dia. 5Mitz 60° Single shear 10mm dia. 5MHz Jo" SENSITIVITY SETTING: TWIN COMPRESSION SCAN - SECOND BACK WALL ECHO AT F SH SINGLE SHEAR SCAN ANGLE - ECHO FROM 1.5M DIA, HOLE AT MAXIMUM RANGE SET ‘TO FULL SCREEN HEIGHT PLUS 2-4dBs TRANSFER LOSS CALIBRATION PROCEDURE: TINE BASE CALIBRATED TO 100mm RANGE ON V2CAL BLOCK SPECIFICATION OR CODE: REPORT ACCEPTABLE TO SPECIFICATION NAME ..A N OTHER, srvarine 1 pate 20. BOR. Welding Technology Issue 0191WELD TEST REPORT: ULTRASONICS NAME AND ADDRESS OF INSPECTING COMPANY: CAMBRIDGE NDT SERVICES WORK LOCATION: ABINGTON REPORT REFERENCE NO: WELD IDENTIFICATION: WALL THICKNESS: 25mm WELD PROCESS: MMA FILL/TIG ROOT EXCESS WELD METAL: AS WELDED 3214-1 3324-2 ABINGTON HALL, CAMBS. DATE OF TEST: SHEET 1 OF 1 MATERIAL: MILD STEEL TYPE OF JOINT: SINGLE VEE BUTT PLATE WELD PREPARATION: 60° INCLUDED ANGLE 2mm ROOT GAP ‘2mm ROOT FACE SHEETS ULTRASONIC TEST INFORMATION ULTRASONIC FLAW DETECTOR: KRAUTKRAMER USM 2 - Serial No KO21 PROBES TYPE SIZE FREQUENCY ANGLE SCANNING PROCEDURE Twin comp 10mm dia. 5MHz ot Single shear 10mm dia. 5Mitz 45° In accordance with code or specification Single shear 10mm dia. 5NHz 60° Single shear 10mm dia. Miz 70" SENSITIVITY SETTING: ‘TWIN COMPRESSION SCAN - SINGLE SHEAR SCAN ANGLE - 2-3mm OF GRASS AT MAXIMUM TESTING RANGE CALIBRATION PROCEDURE: TIME BASE CALIBRATED TO 100mm RANGE ON V2,CAL BLOCK SPECIFICATION OR CODE: ‘WI CODE 438 REPORT ACCEPTABLE TO SPECIFICATION Welding Technology Issue 0191QO WELD TEST REPORT: ULTRASONICS NAME AND ADDRESS OF INSPECTING COMPANY: CAMBRIDGE NDT SERVICES ABINGTON HALL, CAMBS. WORK LOCATION: ABINGTON DATE OF TEST: 10.08.91 REPORT REFERENCE NO: 3214-3 SHEET 1 OF 1 SHEETS WELD IDENTIFICATION: 3324-3 MATERIAL: MILD STEEL WALL THICKNESS: 25am TYPE OF JOINT: SINGLE VEE BUTT PLATE WELD PROCESS: MMA FILL/TIG ROOT WELD PREPARATION: 60° INCLUDED ANGLE EXCESS WELD METAL: AS WELDED 2am ROOT GAP 2mm ROOT FACE ULTRASONIC TEST INFORMATION ULTRASONIC FLAW DETECTOR: KRAUTKRAMER USM 2 - Serial No KO21 PROBES TYPE SIZE FREQUENCY ANGLE: ‘SCANNING PROCEDURE ‘Twin comp 10mm dia. ‘SMHz o Single shear 10mm dia. ‘MHz 45° In accordance with code or specification Single shear 10mm dia. ‘SMHz 60° Single shear 10mm dia. SMHz 70° SENSITIVITY SETTING: ‘TWIN COMPRESSION SCAN - IN ACCORDANCE WITH ASME V ARTICLE 4, APP. B DAC plus 2dB SINGLE SHEAR SCAN ANGLE - CALIBRATION PROCEDURE: IN ACCORDANCE WITH ASME V ARTICLE 4, APP. B SPECIFICATION OR CODE: TWI CODE 438 RECORDING THRESHOLD LEVEL EVALUATE SIGNALS ABOVE 20% DAC REPORT ACCEPTABLE TO SPECIFICATION Welding Technology issue 0191WELD TEST REPORT: PENETRANT TESTING NAME AND ADDRESS OF INSPECTING COMPANY: CAMBRIDGE NDT SERVICES WORK LOCATION: ABINGTON REPORT REFERENCE NO: WELD IDENTIFICATION: WALL THICKNESS: 12mm WELD PROCESS: TIG EXCESS WELD METAL: AS WELDED 3422-3 TH ABINGTON HALL, CAMBS. DATE OF TEST: 10.08.91 SHEET 1 OF 1 MATERIAL: ALUMINIUM TYPE OF JOINT: FULL PEN TEE BUIT WELD PREPARATION: FULL PEN TEE BUTT ‘SHEETS TEST INFORMATION MAGNETIC PARTICLE TEST MAGNETISING APPARATUS: DETECTING MEDIUM: ACCESSORIES: N/A FIELD STRENGTH: MAG DIRECTION : VIEWING CONDITIONS: TYPE OF JOINT: T-JOINT PENETRANT TEST PENETRANT: COLOUR CONTRAST SOLVENT REMOVABLE REMOVER: SOLVENT REMOVER DEVELOPER: DRY POWDER ACCESSORIES: CONTACT TIME: 5 MINS DEVELOPMENT TIME: 10 mins SPECIFICATION OR PROCEDURE: ‘TWI CODE MAG/PEN 876 REPORT NO VISIBLE INDICATIONS Welding Technology Issue 0191tise WELD TEST REPORT: MAGNETIC PARTICLE INSPECTION NAMB AND ADDRESS OF INSPECTING COMPANY: CAMBRIDGE NDT SERVICES ABINGTON HALL, CAMBS. WORK LOCATION: ABINGTON DATE OF TEST: 10.08.91 REPORT REFERENCE NO: 3422-2 SHEET 1 OF 1 SHEETS WELD IDENTIFICATION: 734-2 MATERIAL: MILD STEEL WALL THICKNESS: 12m ‘TYPE OF JOINT: FULL PEN TEE BUTT WELD PROCESS: TIG WELD PREPARATION: FULL PEN TEE BUTT EXCESS WELD METAL: AS WELDED ‘TYPE OF JOINT: ‘T-JOINT ‘TEST INFORMATION MAGNETIC PARTICLE TEST PENETRANT TEST MAGNETISING APPARATUS: ELECTROMAGNETIC PENETRANT = & YoKE (AC) DETECTING MEDIUM: FLUORESCENT INK REMOVER : ACCESSORIES: BURMAH CASTRO FLUX DEVELOPER : INDICATOR (TYPE 1) UVA LIGHT ACCESSORIES : N/A FIELD STRENGTH: 3 CLEAR INDICATIONS CONTACT TIME : ON FLUX INDICATOR DEVELOPMENT TIME : DIAGONAL TO LONGITUDINAL MAG DIRECTION : AXIS OF WELD VIEWING CONDITIONS: 10 LUX OR LESS SPECIFICATION OR PROCEDURE: TWI CODE MAG/PEN 876 Ls REPORT NO SIGNIFICANT DEFECTS NAME. 8 ay stavaruné ¢ loan pate . AON as Welding Technology Issue 0191-6- WELD TEST REPORT: MAGNETIC PARTICLE INSPECTION NAME. AND ADDRESS OF INSPECTING COMPANY: CAMBRIDGE NDT SERVICES ABINGTON HALL, CAMBS. WORK LOCATION: ABINGTON DATE OF TEST: 10.08.91 REPORT REFERENCE NO: 3422-1 SHEET 1 OF 2 SHEETS WELD IDENTIFICATION: 734-3 MATERIAL: ALUMINIUM WALL THICKNESS: 12mm TYPE OF JOINT: FULL PEN TEE BUTT WELD PROCESS: TIG WELD PREPARATION: FULL PEN TEE BUTT EXCESS WELD METAL: AS WELDED ‘TYPE OF JOINT: 1-JOINT ‘TEST INFORMATION MAGNETIC PARTICLE TEST PENETRANT TEST MAGNETISING APPARATUS: PRODS PENETRANT + DETECTING MEDIUM: BLACK INK WITH WHITE CONTRAST PAINT REMOVER : ACCESSORIES: DEVELOPER : FIELD STRENGTH: 5.3 AMPS AC rms per ACCESSORIES : a PROD SEPARATION CONTACT TIME + MAG DIRECTION : DIAGONAL TO LONGITUDINAL AXIS OF WELD VIEWING CONDITIONS: DEVELOPMENT TIME : SPECIFICATION OR PROCEDURE: ‘TWI CODE MAG/PEN 876 REPORT ACCEPTABLE TO SPECIFICATION Welding Technology Issue 0191WELD TEST REPORT: RADIOGRAPHY NAME, AND ADDRESS OF INSPECTING COMPANY: CAMBRIDGE NDT SERVICES ABINGTON HALL, CAMBS. WORK LOCATION: ABINGTON DATE OF TEST: 10.08.91 REPORT REFERENCE NO: 3116-3 SHEET 1 OF 1 SHEETS WELD IDENTIFICATION: 442-3 MATERIAL: MILD STEEL WALL THICKNESS: 8mm TYPE OF JOINT: SINGLE VEE BUTT PLATE WELD PROCESS: MMA FILL/TIG ROOT WELD PREPARATION: 60° INCLUDED ANGLE EXCESS WELD METAL: WELD GROUND FLUSH ‘2nm ROOT GAP WITH PARENT MATERIAL, 2mm ROOT FACE RADIOGRAPHIC INFORMATION : KV or Isotope : IRIDIUM 192 (Focal spot or source size : 2mm x Imm Focus or source to film distance + 500mm Exposure time : 15¢ci mins (555 G.Bq.mins) Film: KODAK Industrex CX 10mm x 40mm Screens : Pb ~ 0.12am FRONT AND BACK Development : STANDARD, TIME/TEMPERATURE PROCESSING Technique : SWSI Number of exposures : 1 Image Quality Indicator : BS 3971 9 Fe 15 Sensitivity: 3% Density + WELD : 2.5 PLATE: 3.0 Specification or Code of Practice : TWI Code R/312 REPORT ACCEPTABLE TO SPECIFICATION Welding Technology issue 0191WELD TEST REPORT: RADIOGRAPHY NAME AND ADDRESS OF INSPECTING COMPANY: WORK LOCATION: ABINGTON REPORT REFERENCE NO: WELD IDENTIFICATION: WALL THICKNESS: 12mm WELD PROCESS: MMA FILL/TIG ROOT EXCESS WELD METAL: AS WELDED WITH PARENT MATERIAL 42-2 CAMBRIDGE NDT SERVICES ABINGTON HALL, CAMBS. DATE OF TEST: 10.08.91 SHEET 1 OF 1 MATERIAL: MILD STEEL TYPE OF JOINT: SINGLE VEE BUTT PLATE WELD PREPARATION: 60° INCLUDED ANGLE 2mm ROOT GAP 2mm ROOT FACE SHEETS RADIOGRAPHIC INFORMATION : 270 KV Focal spot or source size KV or Isotope : Focus or source to film distance : 25aAn Exposure tine Film : KODAK INDUSTREX CX 10mm x Screens : Pb - 0.12am FRONT AND REAR Development : Technique : D WS I Number of exposures : 1 3am x 3am 94am 40am STANDARD, TINE/TEMPERATURE PROCESSING Image Quality Indicator : BS 3971 9AL15 Sensitivity : 2a Density : WELD : 25 PLATE: 3.0 Specification or Code of Practice : TWI Code R/312 REPORT ACCEPTABLE TO SPECIFICATION NAME .. A ‘SIGNATURE! ae hice pare ..4 2% Welding Technology Issue 0191WELD TEST REPORT: RADIOGRAPHY NAME AND ADDRESS OF INSPECTING COMPANY: CAMBRIDGE NDT SERVICES ABINGTON HALL, CAMBS. WORK LOCATION: ABINGTON DATE OF TEST: 10.08.91 REPORT REFERENCE NO: 3116-1 SHEET 1 OF 1 SHEETS WELD IDENTIFICATION: 442-1 MATERIAL: MILD STEEL WALL THICKNESS: 25mm TYPE OF JOINT: SINGLE VEE BUIT PLATE WELD PROCESS: MMA WELD PREPARATION: 60° INCLUDED ANGLE EXCESS WELD METAL: AS WELDED ‘2mm ROOT GAP 2mm ROOT FACE RADIOGRAPHIC INFORMATION = @ KV or Isotope : IRIDIUM 192 Focal spot or source size: 2mm x Imm Focus or source to film distance : 500mm Exposure time: 40mAm Film : KODAK INDUSTREX CX 10mm x 40mm Screens : Pb - 0.12mm FRONT AND REAR Development : STANDARD TIME/TEMPERATURE PROCESSING Technique : SWSI Number of exposures : 1 Image Quality Indicator : BS 3971 9Fe 15 Sensitivity: 2% Density : WELD : 25 PLATE: 3.0 Specification or Code of Practice : TWI Code R/312 REPORT ACCEPTABLE TO SPECIFICATION Welaing Technology dssue 0191-1A- WELD TEST REPORT: ULTRASONICS NAME AND ADDRESS OF INSPECTING COMPANY: CAMBRIDGE NDT SERVICES ABINGTON HALL, CAMBS. WORK LOCATION: ABINGTON DATE OF TEST: 10.08.91 REPORT REFERENCE NO: 3214-2 SHEET 1 OF 1 SHEETS WELD IDENTIFICATION: 3324-1 MATERIAL: LOW CARBON STEEL WALL THICKNESS: 25am ‘TYPE OF JOINT: SINGLE VEE BUTT PLATE WELD PROCESS: MMA FILL/TIG ROOT WELD PREPARATION: [60° INCLUDED ANGLE] EXCESS WELD METAL: AS WELDED [ema ROOT FACE] [2aa ROOT GAP ULTRASONIC TEST INFORMATION ULTRASONIC FLAW DETECTOR: KRAUTKRAMER USM 2 - Serial No KO21 PROBES TYPE SIZE FREQUENCY ANGLE SCANNING PROCEDURE [COUPLANT| Twin comp 10mm dia. 5MHz or Single shear 10mm dia. 5MH2 45* In accordance with code or specification Single shear 10mm dia. 5MHz 60" Single shear 10mm dia. 5MHiz Jo" SENSITIVITY SETTING: ‘TWIN COMPRESSION SCAN - SECOND BACK WALL ECHO AT FS H SINGLE SHEAR SCAN ANGLE - ECHO FROM 1.5MM DIA. HOLE AT MAXIMUM RANGE SET ‘TO FULL SCREEN HEIGHT PLUS 2-4dBs TRANSFER LOSS CALIBRATION PROCEDURE: TIME BASE CALIBRATED TO 100mm RANGE ON V2 CAL BLOCK SPECIFICATION OR CODE: [No SPEC. OR CODE] REPORT ACCEPTABLE TO SPECIFICATION NAME ae yi peat crowns Le, Ohare ! Welding Technology Issue 0191-2A- WELD TEST REPORT: ULTRASONICS NAME AND ADDRESS OF INSPECTING COMPANY: CAMBRIDGE NDT SERVICES ABINGTON HALL, CAMBS. WORK LOCATION: ABINGTON DATE OF TEST: NO DATE REPORT REFERENCE NO: 3214-1 SHEET 1 OF 1 SHEETS WELD IDENTIFICATION: 3324-2 MATERIAL: MILD STEEL WALL THICKNESS: 25mm TYPE OF JOINT: SINGLE VEE BUTT PLATE WELD PROCESS: MMA FILL/TIG ROOT WELD PREPARATION: EXCESS WELD METAL: AS WELDED ULTRASONIC TEST INFORMATION ULTRASONIC FLAW DETECTOR: KRAUTKRAMER USM 2 ~ Serial No KO21 (© proses ‘TYPE SIZE FREQUENCY ANGLE SCANNING PROCEDURE [COUPLANT] Twin comp 10mn dia. 5Mitz o Single shear 10mm dia. SMiz 45° In accordance with code or specification Single shear 10um dia. Siz 60" Single shear 10m dia. SMiiz 70° SENSITIVITY SETTING: ‘TWIN COMPRESSION SCAN - 2nd B TO F. SINGLE SHEAR SCAN ANGLE - 2-3mm OF GRASS AT MAXIMUM TESTING RANGE CALIBRATION PROCEDURE: TIME BASE CALIBRATED TO 100mm RANGE ON V2 CAL BLOCK SPECIFICATION OR CODE: TWI CODE 436 REPORT ACCEPTABLE TO SPECIFICATION Welding Technology issue 0191WELD TEST REPORT: ULTRASONICS NAME AND ADDRESS OF INSPECTING COMPANY: CAMBRIDGE NDT SERVICES ABINGTON HALL, CAMBS, WORK LOCATION: ABINGTON DATE OF TEST: 10.08.91 REPORT REFERENCE NO: 3214-3 SHEET 1 OF 1 SHEETS WELD IDENTIFICATION: 3324-3 MATERIAL: MILD STEEL WALL THICKNESS: 25am ‘TYPE OF JOINT: SINGLE VEE BUTT PLATE WELD PROCESS: MMA FILL/TIG ROOT WELD PREPARATION: EXCESS WELD METAL: AS WELDED 3-Sma ROOT GAP] 2mm ROOT FACE ULTRASONIC TEST INFORMATION ULTRASONIC FLAW DETECTOR: KRAUTKRAMER USM 2 - Serial No KO2i PROBES TYPE SIZE FREQUENCY ANGLE SCANNING PROCEDURE [COUPLAN; Twin comp 10mm dia, — 5Milz o Single shear 10mm die. — 5Miiz 45* In accordance with code or specification Single shear 10mm dia. 5Miz 60° Single shear 10mm dia. 5MHz 70" SENSITIVITY SETTING: ‘TWIN COMPRESSION SCAN - IN ACCORDANCE WITH ASME V ARTICLE 4, APP. B DAC plus 24B (648, SINGLE SHEAR SCAN ANGLE - [As above + 6dB CALIBRATION PROCEDURE: IN ACCORDANCE WITH ASME V ARTICLE 4, APP. B - SPECIFICATION OR CODE: TWI CODE 438 RECORDING THRESHOLD LEVEL EVALUATE SIGNALS ABOVE 20% DAC REPORT ACCEPTABLE TO SPECIFICATION EEsiigy, NAME .. ASN OTHER ©).. SIGNA’ ; pare . 2a Bs Welding Technology Issue 0191= 4a WELD TEST REPORT: PENETRANT TESTING NAME AND ADDRESS OF INSPECTING COMPANY: CAMBRIDGE NDT SERVICES ABINGTON HALL, CAMBS. WORK LOCATION: ABINGTON DATE OF TEST: 10.08.91 REPORT REFERENCE NO: 3422-3 SHEET 1 OF 1 SHEETS WELD IDENTIFICATION: 734-1 MATERIAL: ALUMINIUM WALL THICKNESS: [12m] ‘TPE OF JOINT: FULL PEN TEE BUTT weLD Process: [FIG WELD PREPARATION: FULL PEN TEE BUTT EXCESS WELD METAL: AS WELDED ‘TPE OF JOINT: ‘T-JOINT ‘TEST INFORMATION PENETRANT TEST MAGNETIC PARTICLE TEST PENETRANT: COLOUR CONTRAST SOLVENT MAGNETISING APPARATUS: REMOVABLE \ DETECTING MEDIUM: RENOVER: SOLVENT REMOVER|SOLVENT NON AQUEOUS| [wer DEVELOPER|_ ACCESSORIES: N/A DEVELOPER: DRY POWDER FIELD STRENGTH: ACCESSORIES: CONTACT TIME: § MINS 10-30 mins DEVELOPMENT TIME: |10 mins Approx(30 max] MAG DIRECTION VIEWING CONDITIONS: [MINIMUM 500 LUX-GOOD DAYLIGHT SPECIFICATION OR PROCEDURE: TWI CODE MAG/PEN 876 REPORT Xe NO APPARENT FLAWS Welding Technology Issue 0191-5A- WELD TEST REPORT: MAGNETIC PARTICLE INSPECTION NAME AND ADDRESS OF INSPECTING COMPANY: CAMBRIDGE NDT SERVICES ABINGTON HALL, CAMBS. WORK LOCATION: ABINGTON DATE OF TEST: 10.08.91 REPORT REFERENCE NO: 31122-2 SHEET 1 OF 1 SHEETS WELD IDENTIFICATION: 734-2 MATERIAL: MILD STEEL WALL THICKNESS: [12mm] TYPE OF JOINT: FULL PEN TEE BUTT weLD Process: [Fra] WELD PREPARATION: FULL PEN TEE BUTT EXCESS WELD METAL: AS WELDED ‘TYPE OF JOINT: ‘T-JOINT ‘TEST INFORMATION MAGNETIC PARTICLE TEST PENETRANT TEST MAGNETISING APPARATUS: ELECTROMAGNETIC PENETRANT + YOKE (AC) DETECTING MEDIUM: FLUORESCENT INK REMOVER : ACCESSORIES: FOIL TYPE BRASS FLUX DEVELOPER : INDICATOR (TYPE 1) UVA LIGHT ACCESSORIES : N/A FIELD STRENGTH: 3 CLEAR INDICATIONS CONTACT TIME : ON FLUX INDICATOR DEVELOPMENT TIME : DIAGONAL TO LONGITUDINAL MAG DIRECTION : 90° TO AXIS OF YOKE, VIEWING CONDITIONS: 10 LUX OR LESS BLACK LIGHT INTENSITY 0.8nk/cm? |AT WORK SURFACE SPECIFICATION OR PROCEDURE: TWI CODE MAG/PEN 876 REPORT. NO_APPARENT FLAWS| Welding Technology Issue 0191= 6A WELD TEST REPORT: MAGNETIC PARTICLE INSPECTION NAME AND ADDRESS OF INSPECTING COMPANY: CAMBRIDGE NDT SERVICES ABINGTON HALL, CAMBS. WORK LOCATION: ABINGTON DATE OF TEST: 10.08.91 REPORT REFERENCE NO: 3422-1 SHEET 1 OF 2 SHEETS WELD IDENTIFICATI( 734-3 MATERIAL: ALUMINIUN WALL THICKNESS: [12mm] ‘TYPE OF JOINT: FULL PEN TEE BUTT wei process: [ria] WELD PREPARATION: FULL PEN TEE BUTT EXCESS WELD METAL: AS WELDED ‘TYPE OF JOINT: ‘T-JOINT ‘TEST INFORMATION (wnonG Nor meTHoD] MAGNETIC PARTICLE TEST PENETRANT TEST _. MAGNETISING APPARATUS: PRODS PENETRANT {C) perecrina meprum: BLACK INK WITH WHITE CONTRAST PAINT REMOVER : ACCESSORIES: DEVELOPER FIELD STRENGTH: 5.3 AMPS AC rms per ACCESSORIES : mm PROD SEPARATION CONTACT TINE : DEVELOPMENT TIME : MAG DIRECTION : IN LINE WITH PRODUCTION CONTACTS VIEWING CONDITIONS: | MINIMUM 500 LUX - GOOD DAYLIGHT SPECIFICATION OR PROCEDURE: TWI CODE MAG/PEN 876 \" peporr ACCEPTABLE TO SPECIFICATION Welding Technology dssue 0191-7A- WELD TEST REPORT: RADIOGRAPHY NAME AND ADDRESS OF INSPECTING COMPANY: CAMBRIDGE NDT SERVICES ABINGTON HALL, CAMBS. WORK LOCATION: ABINGTON DATE OF TEST: 10.08.91 REPORT REFERENCE NO: 3116-3 SHEET 1 OF 1 SHEETS WELD IDENTIFICATION: 442-3 MATERIAL: MILD STEEL WALL THICKNESS: 8am ‘TYPE OF JOINT: SINGLE VEE BUTT PLATE WELD PROCESS: MMA FILL/TIG ROOT WELD PREPARATION: 60° INCLUDED ANGLE EXCESS WELD METAL: WELD GROUND FLUSH (3-Sem ROOT car} WITH PARENT MATERIAL 2nm ROOT FACE RADIOGRAPHIC INFORMATION : KV or Isotope : IRIDIUM 192 - RECOMMENDED MIN. THICKNESS 10am STEEL] Focal spot or source size : 2am x 1mm Focus or source to film distance : 500mm Exposure time : 15ci mins (555 G.8q.mins) Film: KODAK Industrex CX 10mm x 40mm Screens : Pb ~ 0.12mm FRONT AND BACK Development : STANDARD, TINE/TEMPERATURE PROCESSING Technique : SWSI Number of exposures : 1 Image Quality Indicator BS 3971 9 Fe 15 [(WRONG TOI eg. 4 Fe 10) Sensitivity : 3% [NORMALLY 27 oR ER] Density : WELD : 2.5 PLATE ; 3.0 Specification or Code of Practice : TWI Code R/312 REPORT ACCEPTABLE TO SPECIFICATION Welding Technology Issue 0191= BA = WELD TEST REPORT: RADIOGRAPHY NAME AND ADDRESS OF INSPECTING COMPANY: CAMBRIDGE NDT SERVICES ABINGTON HALL, CAMBS. WORK LOCATION: ABINGTON DATE OF TEST: 10.08.91 REPORT REFERENCE No:[NO NuMBER] SHEET 1 OF i SHEETS WELD IDENTIFICATION: 4412-2 MATERIAL: MILD STEEL WALL THICKNESS: 1200 ‘TYPE OF JOINT: SINGLE VEE BUTT PLATE WELD PROCESS: MMA FILL/TIG ROOT WELD PREPARATION: 60° INCLUDED ANGLE EXCESS WELD METAL: AS WELDED |3-5Sam ROOT GAP WITH PARENT MATERIAL ‘2mm ROOT FACE RADIOGRAPHIC INFORMATION : KV or Isotope : 270 Kv |(T00 HIGH FOR MATERIAL THICKNESS) Focal spot or source size : 3am x 3am Focus or source to film distance : 914mm Exposure time: 25mAm Film : KODAK INDUSTREX CX 10mm x 4Onm Screens : Pb ~ 0.12mm FRONT AND REAR Development = STANDARD, TIME/TEMPERATURE PROCESSING Technique : DWST (SwSI) Number of exposures: 1 Image Quality Indicator : BS 3971 9ALI5 (9 FE 15) Sensitivity : 2k Density : WELD : 2.5 PLATE : 3-0 Specification or Code of Practice : TWI Code R/312 REPORT ACCEPTABLE TO SPECIFICATION Welding Technology Issue 0191= 9A - WELD TEST REPORT: RADIOGRAPHY NAME AND ADDRESS OF INSPECTING COMPANY: CAMBRIDGE NDT SERVICES ABINGTON HALL, CAMBS. WORK LOCATION: ABINGTON DATE OF TEST: 10.08.91 REPORT REFERENCE NO: 3116-1 SHEET 1 OF 1 SHEETS WELD IDENTIFICATION: 442-1 MATERIAL: MILD STEEL WALL THICKNESS: 25mm ‘TYPE OF JOINT: SINGLE VEE BUTT PLATE WELD PROCESS: MMA WELD PREPARATION: 60° INCLUDED ANGLE EXCESS WELD METAL: AS WELDED RADIOGRAPHIC INFORMATION : KV or Isotope : IRIDIUM 192 Focal spot or source size ; 2om x iam Focus or source to film distance 500mm Exposure tise: Omha Film: KODAK INDUSTREX CX 10mm x 40mm Screens ; Pb ~ 0.12mm FRONT AND REAR Development : STANDARD TIME/TEMPERATURE PROCESSING Technique : SWSI Number of exposures : 1 a Image Quality Indicator : BS 3971 9Fe 15 Sensitivity: 2% Density : WELD : 2.5 PLATE: 3.0 Specification or Code of Practice : TWE Code R/312 He REPORT : ACCEPTABLE TO SPECIFICATION Welding Technology dssue 0191