TWI CSWIP 3.1 Welding Inspector

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PT SURVEYOR INDONESIA

THE WELDING INSTITUTE U.K

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WELDING INSPECTION - STEELS

. COURSE REF: WIS.5

The Welding Institute Training Services Group Abington Hall, Abington Cambridge CB1 6AL

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CS\VIP vVELDING INSPECTOR

THEORY A - 30 QUESTION MULTICHOICE - 30 MlNUTES

THEORY B -l\1ANDA. TORY QUESTION

"DUTIES OF:.A \VELDING lNSPECTOR" TO YOUR CHOICE OF CODE

(NO MORE THAN 30 MINUTES ON THIS QUESTION) APPROK. 300\VORDS, ~

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4 FROM 6 TECHNOLOGY QUESTIONS 1 HR 15 1\1INUTES

PRACTICAL A:

INSPECTION AND SENTENCING OF A PIPE TO YOUR CODE 1 HR45 MINUTES

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INSPECTION OF A PLATE TO CSWIP ACCEPTANCE LEVELS 1 HR 15 MJNUTES

PRACTICAL B:

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} BEND & MACROS (3 OFF) 45 MINUTES

ORAL:

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10 QUESTIONS ON YOUR CODE RE APPLICATION 10-201v.!INUTES

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COURSE REF: WIS5

CONTENTS

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TERMINOLOGY

THE DUTIES OF A WELDING INSPECTOR CODES AND STANDARDS

WELD PROCEDURES & PROCEDURE & WELDER APPROVAL MECHANICAL TESTING

SYMBOLS

MATERIALS

CONSUMABLES

THE FOUR FACTORS FOR ESTABLISHING A WELD MANUAL METAL ARC WELDING

TUNGSTEN INERT GAS WELDING

DEFECTS WHICH MAY BE DETECTED BY SURFACE INSPECTION METAL INERT GAS WELDING

SUBMERGED ARC WELDING

CALIBRATION OF EOUIPMENT

RESIDUAL STRESS AND DISTORTION

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WELDABILITY

HEAT TREATMENTS

NON OESTRUCTIVE,TESTING REPAIR BY WELDING

GAS WELDING, GUTTING & GOUGING ARC CUTTING

OTHER WELDING SYSTEMS

INTERNAL DEFECTS & THEIR INTERPRETATION

APPENDIX.

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TrlE \VELDING INSTITUll:

SECTION

1 2 3 4 5 6 7 8 9

- 10

11 12 13 14 15 16 17 18 19 20 21 22 23 24

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COURSE DETAIL

ALL COURSE MEMBERS PLEASE READ CAREFULLY

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1.

The general working programme is attached.

2.

Any alterations will be announced by the course tutor.

3.

The lectures and tutorials etc are supported by the course text. please read as appropriate.

4.

Question papers will be used to reinforce most sessions please attempt the QuestIons. these will be discussed or marked at the discretion of the lecturer/tutor.

5.

The end of course assessments are marked and the results recorded.

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Standards reproduced with the permission of British Standards Institute.

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TIlE \VELD!NG INSTITUTE

KEY KNOWLEDGE FOR WELDING INSPECTION PERSONNEL

The information contained in this course text supplements the lectures given in the course WIS 5.

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Terminoloqy given in the test is that recommended in BS 499 Pt 1: 1983; Weld Symbols to BS 499 Pt 2 : 1980. To supplement this further, however, an indication of both International (ISO) and American standards is given.

The sections are written in general. terms and do not include all of the conditions that may apply to a specific fabrication or product.

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SECTION 1

TIrE WEillING L'<STIT1lTE

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THE WELDING iNSTrnTfE

TERMINOLOGY

Use of the correct terminology is important. This course uses BS 499.

GENERAL TERMINOLOGY

WELDS and JOINTS

t Frequently the terms 'weld' and 'joint' are used incorrectly. Exact definitions are given in BS 499 Welding terms and symbols'.

TYPES OF WELD

BUTT WELD

FILLET WELD

J EDGE WELb

Sr.JJ{( hdMt~flons .1 ~.at v~ld

SPOT WELD

Illustration depicts resistance weld. Spot welds can be made with

MIG or TIG processes. '

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WELDING TECHNOLOGY Issue 0191

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TIlE WELDING [NSTITUTE

TYPES OF JOINT

The four basic welds can be used to join various types of joints.

The following are some typical joints

TYPE OF JOINT

EXAMPLES

BUTT

TEE

CORNER

LAP

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TI-fE \VELD IN G INSTITlfIl::

PLATE EDGE PREPARATION FOR BUTT WELDS

The illustrations show standard terminology for the various features of plate edge preparations.

Single - V f ~(.; 1
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Double - V X J Single bevel

Single - U

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FEATURES OF COMPLETED WELD

A butt weld in a plate, made by welding from both sides, h2S WO weld faces, tour toes. In a fuff penetration weld made from one side, the protruding weld onthe underside is the penetration bead.


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THE WELDING INSTITUTI::

If a weld is sectioned, polished and etched, the fusion boundary can be established. t.1etaJ lying between the two fusion boundaries is weld metal, a mixture of deposited metal and plate material that has been melted. Adjacent to the fusion boundary is the heat affected zone (HAZ), in which the plate material has 2 metallurgical structure modified by the hear of welding.

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Fillet welds also have

Toes

A weld face

A root

A fusion boundary

A heat affected zone

Hut ~ffltcftd zon«

The shape of a fillet weld in cross-section is described by three terms

Mitre fillet, - ---II()2))))\

Convex fillet

Concave fillet

Excess weld metal, as illustrated, is often referred to as 'weld reinforcement'. This does not necessarily mean it strengthens a joint.

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SIZE OF WELDS

T.o-fE WELDING l},'STfJ1JTE

For full penetration butt welds, the general rule is: design throat thickness, t, ;::: thickness of the thinner pari joined,

Partial penetration butt welds

The term partial penetration strictly. implies butt welds that are designed to have less than full penetration. Failure to achieve full penetration when it is wanted should be listed as the defect INCOMPLETE PENETRA1~ION.

The throat thickness of a partial penetration weld made from both sides is 1z + 1z, and the design throat thickness t, + t., Note that the degree of penetration must be known.

Fillet weld sizes are calculated by reference 10 allowable shear stress on the throat area, i.e. throat area » design throat thickness x length of weld. The size required is specified on drawings in terms of leg length ( I).

For fillet welds with equal leg lengths:

where t, is as defined for mitre and convex fillets.


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ruE \VELD[",G INSTrnrrE

If an asymmetrical fillet weld is required, both leg lengths are specified and t, is taken as the minimum throat dimension.

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Deep penetration fillet weld

With high current density processes, e.g. submerged arc and MIG (spray). penetration along the joint line can be produced.

This gives an increase in throat thickness with no change in leg length .

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wELDING POSITfONS CBS 499:"1991/1S0 6947)

PF Vertical up

PC Vertical down

PD Horizontal overhead

PC

Hor-Lzonca".

Horizontal vertical

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SECTlO>1IX _;_ PAR I QW. \l,'ELDl:-':G

Q\\,~4{j1 Positions (Cont'd) .

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QW~61.3 GROOVE WElDS IN PLATE - TEST PO-S!TIONS

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QW41.4 GROOVE WELDS IN PIPE - TEST POSmONS

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QW41.5 fiLLET WELDS IN PLATE - TEST fDSmONS

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QUESTIONS

TERMINOLOGY

Q1. Sketch a single vee butt [olnt and a single bevel butt joint

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Q2. Sketch a tee joint and indicate for fillet welds:

a) leg length

b) throat thickness

c) root

d) toes

03. Complete the necessarv features of the sketch:

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SECTION 2

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THE \VELDI!>"G INSTITUTE

THE DUTIES OF THE WELDING INSPECTOR

VISUAL INSPECTION

At any point in the course of welding, i.e, tacking, root pass, filler pass or capping pass, but particularly for the root and cap, a detailed inspection may be required. British Standard 5289 : 1976 gives guidance on tools and responsibilities together with sketches of typical defects .• }

The inspector at this pointmust -

a) observe, identify and perhaps record the features of the weld.

b) decide whether the weld is acceptable in terms of the particular levels which are permitted; defect levels may be 'in-house' or National Codes of Practice.

When the defect size is in excess of the permitted level then either a concession must be applied for (from a competent person) or the weld rejected.

CODE OF PRACTICE FOR VISUAL INSPECTION

A code of practice for an inspection department could take the form outlined below. It is appreciated that full implementation of the code would be extremely costly and therefore it may be necessary to reduce the amount of inspection to less than is theoretically required.

AIDS OF VISUAL INSPECTION

Illumlnatlorn Inspection lenses:

Goad lighting is essential

The magnification should not exceed 2-2% diameters. If higher magnification is required use a binocular microscope.

Optical viewing devices area progressive development from the use of a hand torch and mirror, frequently with the addition of a magnifier and light source.

In order to achieve accessibility probe units are available down to a diameter, properties for which are:

1. 2. 3.

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l2;ge field of vision.

Freedom from distortion of image. Accurate preservations of colour values.

Arjequacy._oLillumina1i.0n~_~. .


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VISUAL INSPECTION PRACTICE

The inspector should be famiHar with the following:

1. All applicable documents.

2. Workmanship standards.

3. All phases of good workshop practice.

4. Tools and measuring devices.

INSPECTION BEFORE WELDING

Before assembly:

Check:

1. Application standard

2. Welding procedure sheets

3. Drawings

4. Welder qualifications

5. Material composition

6. Condition of material

7. Type of edge preparation, method and finish

8. Consumables, i.e. type of electrodes, filler wires, fluxes, shielding and backing gases (composition) and special drying requirements for electrodes

9. Welding process.processes

After assembly:

Check:

1. 2. , 3. 4.

Clearance dimensions, tolerances, type of backing (if any) Alignment, tack welds, bridging pieces, etc.

Cleanliness

Preheat (if any)

Note: Good inspection prior to welding could eliminate conditions that lead to the formation of defects.

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TIlE WELDING INSTITUTE

INSPECTION DURING WELDING

Check:

1. Welding process

2. Preheat and interpass temperatures

3. Inter-run cleaning

4. Joint preparation

5. Filler metals

6. Control of distortion )

7. Root and subsequent runs

8. Welding current and voltage

9. Chipping, grinding, gouging

10. Fluxes and shielding gases

11. Compliance with weld procedure sheet and application standard

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AFTER WELDING

Check:

1. Dimensional accuracy

2. Conformity of drawings and standard requirements

3. Acceptability of welds regarding appearance

4. Post-heat treatment (if any)

5. Repairs

REPAIRS

1. 2.

Mark out area positively and clearly.

Use a method established and understood by alr inspection and repair personnel.

Check when partially removed (visual and NOT). Check when fully removed (visual and NOn. Check rewelding.

Reinspect.

3. 4. 5. 6.


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TIlE WELDING INsrfTUTE

QUESTIONS

RESPONSIBILITIES AND DUTIES OF A WELDING INSPECTOR

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Q1. Give three (3) main responsibilities of a welding inspector

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Q3. What documents or records should be referred to -by the welding inspector?

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Q4. VYhat are the duties of the welding inspector?

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05. Should the most up to date code or specification be used?

N l) Nor N,{C,-e.SIV-:)l.-,) 6..1£,1\)]> 5PEC". To c; o~·

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SECTION 3

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TIIE \VELDING [N STfIllTE

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CODES AND STANDARDS

CLASS OF WORK

There are many types of work which require engineerj,lg materials to be joined by welding, for example:

pressure vessels bridges

oil rigs

earth moving equipment aero-engines

ventilation systems storage tanks

heavy vehicle chassis car bodies

food processing plant

The quality requirements of the joints in these fabrications depend on their fitness-far-purpose and differ significantly from one application to the next.

Pressure vessels require welds which can withstand the stresses and high temperatures experienced in operation.

Bridges must take into account the effect of differing vehicle loads and wind loading.

Oil rigs are designed to withstand the effect of wave formation and wind loads.

Earth moving equipment has to accommodate differences in terrain and earth conditions and is subject to fatigue loading.

Welds in food processing plants must withstand corrosion by hot acidic liquors.

On the next page some typical Codes of practice and Standards which cover various types of constructions being fabricated by welding are listed.

Note: Throughout this text, the term Code is used to cover Code of Practice, Standard and Specification.


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THE watrxxo INSTITUTE

Code
BS 5500
ASME VIII
BS 2633
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BS 5950
AWSD1.1
BS 5400
as 6235
API 1104 Class of Work

Unfired fusion welded pressure vessels

American boiler and pressure vessel code

Class 1 Arc welding of ferritic steel pipework for carrying

.

fluids

Process of welding steel pipelines on land and offshore

Structural use in steelwork in building

Structural welding code (American)

Steel concrete and composite bridges

Code of Practice for fixed offshore structure

Standard for welding pipelines and related facilities

These documents can also provide a useful source of data for applications where Codes do not exist. It should be remembered, however, that the principal criterion in the Codes listed is the quality of the joint in relation to the service conditions. There are other applications where success is judged by different criteria, such as dimensional accuracy.

Another important consideration is controJling the cost of welding. Variations in weld times 'and quantities of consumables can readily result if the method of making a weld is left to the welder to decide.

The continuous and satisfactory performance af weldments made to various Codes requires that specific guidelines are laid down to cover materials, design of 'joints, welding processes, welding consumables, acceptance criteria and inspection techniques.

These guidelines are usually grouped under the general heading of a Weld Procedure.

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1l-E WELD ING [NSTITlJTE

THE WELDING PROCEDURE

The task of collecting the data and drafting the documentation is often referred to as writing a weld procedure. In many ways this is an unfortunate term as the writing of documents is the last in a sequence of tasks.

Producing a weld procedure involves:

• planning the tasks

• collecting the data

• writing a procedure for use or for trial

• making test welds

• evaluating the results of the tests

• approving the procedure of the relevant Code

• preparing the documentation

In each Code reference is made to how the procedures are to be devised and whether approval of these procedures is required. In most Codes approval is mandatory and tests to confirm the skill of the welder are specified. Details are also given of acceptance criteria for the finished joint.

The approach used depends on the Code, for example:

8S 2633 : (Class 1 arc welding of ferritic steel pipework for carrying fluids) provides general comments on various aspects of a suitable weld procedure.

AWS 0.1.1 (Structural welding code - steel) favours more specific instructions for different joints and processes which are, in effect, pre-

qualifi~Q procedures. I

Other Codes do not deal specifically with the details of the weld procedure but refer to published documentation, e.g. BS 5135 'process of arc welding carbon and carbon manganese steels'.

WELDING TECHNOLOGY ISsue 0191

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THE WELDING INSTITUTE

COMPONENTS OF A WELD PROCEDURE

Items to be included in the procedure can be some of the following:

1. Parent metal 1.1 1.2 1.3 1.4

Type .

Thickness (for pipe this includes outside diameter)

Surface condition ~

Identifying marks

2. Welding process

2.1 Type of process (MMA. TIG, MAG etc) 2.2 Equipment

2.3 Make, brand. type of welding consumables

2.4 When appropriate the temperature and time adopted for drying and baking of electrode/consumables

3. Joint design 3.1 3.2 3.3 3.4 3.5 3.6

Welding position Edge preparation

Method of cleaning. degreasing etc Fit up of joint

Jigging or tacking procedure Type of backing

4. Welding position

4.1 Whether shop or site welding

4.2 . Arrangement of runs and weld sequence

4.3 Filler material, composition and size (diameter) 4.4 Welding variables - voltage, current travel sp.eed 4.5 Weld size

4.6 Back gouging

4.7 Any specific features, e.g. heat input control. run-out length

5. -Therrna: treatment

5.1 Preheat and interpass temperatures including method and control

5.2 Post weld treatment including method and control

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TI-fE WELDING INSTrn.n-c:

APPROVING THE PROCEDURE

When the data has been collected, the procedure must be validated by producing and testing a trial weld.

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If the procedure is to be used on a fabrication which hasbeen designed to meet the requirements of a Code, the test weld is done under the supervision of an independent witness. The detailed arrangements }for the test are subject to agreement between the contracting parties .

A number of British Standards make cross reference to another Standard which covers approval testing.

Other Codes of practice include their own weld procedure/welder approval information.

In general they include a standard format which can be used to report the results of an approval test.


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MANUFACTURER'S WELDING PROCEDURE SPECIFlCATION (WPS) (sa(! EN 288-21

Lo=lIon: •...... TWI TRAINING WORKSHO? .

M~nuf~cturtr's Wlldln" ProeMuro: pWPS OOI/A .

R eter ence No: .4 19'20 ..

WPAA No: 0223 ..

M~nuj~cturur: FRED BLOGGS INDUSTRIES .

Ex:zmlnlr or 10$1 body: 8.D.f Lm ..

DEGREASE {,

Method 01 Prep~r~lfon .:.nd Cla.:.nlnC': ...... MACHINE ... PUlln! M.:.lorllll SpKlflc.;lIon: .. 316L ST'AJNLESS STEEL C ,03% Cr 17% Mn 1.5% Me 2.5%

Weldor',; N:zme: .A N OTHER............................................................................ Ni 11% Si O.S% + F\es.icuals

Welding Precess: 14I(T1G AOOn/lll(MMA FILL 6. CAP)................... M.;teri:d Thickness (mm): 15mm

Joint Type: SINGLE VEE BUTT......................................................... Outside OJamliUr (mm): 15Smm .

Welding PO$IUon: HLD45 · .

Weld Prepar;;t1on ~tallsJJolnt Design (Sketch)'

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WeldIng !illquencu

Walding Details

Aun Process Slzt 01 Currant Voltag' Typ9 01 Wlr.FHd Tr:z .... 1 Hut
FlUer Meul A V currenV Sp6ed S~· Input"
polarity
I 141 AlITOGENEOUS 60-70 10-12 DCEN - 4Drnm'mn I.OKj/mm
2-4 III 3.2mm 110-120 20-22 DCEP - l40mm AOL I.OK)lmm
'. 5-10 III 3.2mm 95-110 20-22 DCEP - 130mm ROL I.OK)lmm
10 to III 2.Smm 70-90 20-22 DCEP - l00mm ROL I.OK)lmm
completion 2.5mm I 70-90 20-22 OCEP - 100mm ROL 1.0000mm
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- - - , - - - - - - Filler ~etal ClotS3ll1calfon Ind Inldl n .. m'; SOUDOMETAL SU?ERCROM 316L 10 ISO 3$81-EI9:12:3:l..R23 .

AllY Sp<)cl;f B.lkfng or Drying: DRY AT IDYC FOR 2 HOURS OUIVER AT 7S·C _- ..

C, SlFlulI;: shielding: .A.1'!GON - COMMERCIAL PURITY Other lntorrnatlon'; ..

. b.:ocl<lng : ~GON - COMMERCIAL PURITY _ g. weaving (mulmum wfdth 01 run): 2 x ¢ ..

C, s Flow R;ato - ShlaldJIIQ': 8 UTRESlMINlITE Oscltlatton: arnplltude, f"'qulncy, dWIII tim.: 43 requilod

B;acldng: 4 UTRESIMINlITE........................................... Puln weldIng deUJls: NOT REOUIRED .

Tungsten EI9<:trod. T~/Slz': 2% THORIUM 2.S ¢ Stand oN dlslanc.: NOT REOUIRED .

DeL'lis of ~~'B .. c.i:lng: RETNN UNTIL RUN 5 ONWARD.. Plasma welding oeulfs: NOT REOUIRED .

Pr'ahoa! Temper2turo: ••.•.. NONE........................................................................ Torch ~n[lle: .TILT SO· SLOPE 70· .

Interpau Tempe,aturo: IS0·C MAXIMUM .

Post-WOld He,l Tr e atrne nt and/or Ageing: NDNE ..

Tima, Ternp eratur e, M'Hhcx1: NOT REOUfRED .

H~'t1ng and Cooflng R:ttu': .AS PROCEDURE ..

Ex:tmlner or last body c.\din.r

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WELDING TECHNOLOGY

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WELDING PROCEDURE APPROVAL RECORD FORM (WPAR) TO EN 288

WELDING PROCEDURE APPROVAL - TEST CERTIFICATE

Manul;c:lurer's Welding Procadura

Rererence No 4 1 92(l/001fA ..

Ex~mlner or lest body BOI lTD ..

Rererence No .. SDI 71000125 .

Manur;clurar: FRED 8LOGGS INDUSTRIES ..

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Address 375 LONDON ROAD. C--\-'>-!8RIDGE UK ~ · f ·· .

CodefTestlng Slandlll"ct EN 2B8 .

Dale or Welding: 00-00-199- ..

EXTENT OF APPROVAL

WeldlngProcess: gl TIGROOT 111 MMAF1LL&CAP .

Joint Type: .ANY BUTT JOINT IN PIPE OR PLAT8FIUET WELDS IN PIPEIPLATE &. T BUTT WELDS •...• _ : ..

Parent metal(s): .AUSTENITIC STNNLESS STEELS.................................... Conditions of tempere-d: .NOT APPUCABLE .

M eta I thlcknass (rnrn): _ 12mm - 16.5mm _ __ ..

OutsIde DI;metsr (mml: 7Bmm - 310mm ..

Filler Metal type: 316L SOUDOMETAL SUPERCROM TO ISO E19:12:3:L R 2:3 ONLY .

Shielding Gas.lflux: .ARGON .

Type 01 Welding Current DIRECT CURRENT 141 OCEN 111 DCEP : .

-, , WeldIng Posltlons: .<J..L POSITIONS EXCEPT P.G. (VERTICAL OOWN) ..

Preheat NOT REOt..~RED ..

Post-Weld He at Tr e atrne nt and/or ragelng: NOT REOUJRED .

I

Oth ar Inlorm.tlon: TACK WELDING NOT PERMlnED UNE UP CLAMPS ONLY ..

.•.• 4··.,· U._ •.. __ + •••••••••••• uu •••• __ ••• u •••• __ •••••••• H.U •.•••..• u ~ ••••••• _ •• _ •••••• u •• _ ••••••••••••••••••••• _.H ••• h ..• _._ .

Certified th~t lest w~c!$ prepued. weld&<! and tested s atis tactorlly In accord a nce with the raqulrements 01 Ihe coda/te~tlng ~Und;trd

Indic .. ted above. •

Loc<ltlon .

O;ta 01 Issue .00-00-199- Exarnlner or test body

Name ... B.6:J! f!.m·,.. I.C.ITCANBE

. :..... ".:,:,. -",

D;te.: .. _?O-OO-I99- .~ . ..,,~ J

.._ \C'_.I~

S IgrutlJre . : ~:: ~ .: _ _ _ •. __ ..

- .'

PlIgo 1 of J

~ ------- -- _-_. - --------


4.5

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TWI VOl


DETAILS OF WELD TEST

Locatlon: SHOP - T'vV1 TRAINING WORKSHOP .

Ex.mlner or test body: .... B.DJ. l TO ......

Manut.;cturer" Welding Procad'Jr1!

Reference No.: ••.... 41920 " .

WPAR No: ....•• WPAR 00l/A......................................................................... Method at Prep;r;!Ion ;nd Cle~nlng; .. M/C &. DEGREASE

Parent Materi~1 Specltlcatlon: .. 316L STJlJNLESS STEEL

Manufacturer. •..... FRED BLOGGS INDUSTRIES ..

Weider's N;ma: .A N OTHER .

Welding Pro~$.S: 141 [TIGI II! (MMA)............................................. M;terfal Thlekness (mm): 15mm .

Joint Type: •...•• SINGLE VEE BvrT.......................................................... Outside Diameter (mm)': .••• 155mm .

Weld Preparallon DeUlis (Sketch)"': NO AOOT FACE...................... Welding PosJUon: .. h~045 ..

~

~' lr- ~---Jo_r-n_t_~--s_lg_n---- __ -- __ -- __ -------+----~~-- __ -------w-e_1_d_ln~g~S_eq~u_tn_Cl ~1

} ----:t\!=====s. ~1.0mm S

Welding Details

Run Process Size of Current Vortage TYIJiI of currenV Wire Fe-W Travel Heat Input<
Aller Metal A V Polarity Spee-d SpsOO· KVmm
1 141 AUTOGENEOUS 65 11 OCEN - 45mm 0.95
2-4 111 32.mm 115 21 OCEP - 150mm 0.96
5-10 111 3.2mm lOS 21 OCEP - IS0mm 0.88
10 to 111 3.2mm 80 21 OCEP - 110mm 0.96
.~ I
" completion 3.2mm 80 21 OCEP - llOmm 0.00 Fl1Ier Metd Cia s.s HIc:rtI on and lrzde name: SOUDOMETAL SUPERCROM 316L ..

Any S~I.;j B4!klng Of Orylng: D~IED AT IOO·C - 2 HRS _ y .

Ga:!/Flux: Ullerdlng: BOC AAGON....................................... Other IntormaUon·:

b.;Jeklng: BOe ARGON....................................... e.g. wO;Ivlng (M;ulmum width of run): .. NONE.

G.s Flow R;ltll - Sh~ldlng: 6 UTRESIMIN...................................... Oscfllatton: .. mplUuda.lrequancy. dwell time

BoIckrng: ...•.. 4 UTRESlMIN............................................ Pulse walding details: NONE ..

Tungsten Electrode TypelSlz .. : ...••. 2% THORIUM 2.Smm.................... Stand oN dlst.:lnca: NONE .

DetaUs of Backing: RETAlNED UNTIL RUN 6................................... Plasm. welding details: NONE .

Prohe. t tamperature; NONE APPUEO............................................ Torch ~ngle: AS REOUIREO .

lnterp a sa Temperature:-: MAXIMUM 130·C .

Post-Weld HO;l( T~ent andlor Agalng: NONE .

Time. Temperature. Method: NONE .

He.tlng lind Cooling R.t8~": NONE ..

MANUFACTURER

Namo: FREDERICK BLOG~ ~ ..

D.le: 00-00-199- . - .. ..

Slgn~turo: _.. •

------- .---

. ._o __

Date: .

Slgn~ture: .

Page 2 01 J

WF{ rnut; TECHNOlnGY

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TIrE WELDING LNSTlTUTE

DOCUMENTATION

The objectives of a procedure or welder approval test are:

a) to prove the procedure meets the necessary requirements with reference to feasibility, mechanical strength etc

c

b) to prove the welders are competent to work in a particular job t

If a customer queries it, evidence can and would be supplied to prove validity, even though the approval tests might have been some considerable time ago.

Approval Test Specifications caJJ for a paper record which can be know as either:

procedure/welder approval certificate procedure/welder approval record procedure/welder approval report

The following records should also be kept:

a) NOT reports

b) records of visual examination or mechanical testing

c) test pieces from destructive testing

Other records which are equally important are:

a) PROOF of regular employment on a job

b) for scheduling re-tests

c} to avoid duplication on procedure approval

TEST CERTIFICATE

Should state clearly that it is a welder approval; and not a PROCEDURE approval, and, depending on the particular Standard, should contain the foll_owing:

a) welder's name and identity number - could be his/her clock or payroll

number, or possibly a photograph

b) date of the test

c) Standard of Code in fuJi, i.e. BRITISH STANDARD 4372 PT 1 : 1982

d) testpiece details including material specification

e) equlprnent and consumable details: welding equipment, type of filler etc

f) extent of approval

g) sketch of run sequence, preparation and dimer.sions


4.7

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VOI~--~--~~-----

THE WELD[~G L'..ISTffilTE

h) other factors, operating parameters etc

i) the test results (visual, NOT, OT etc)

j) remarks

k) witnessed by

J) test supervisor m) location

Most Standards give an example of the test certificate .• ' t

SIGNATURES ON CERTIFICATES MUST BE ENDORSED WITH COMPANY STAMP.

STORAGE AND RETRIEVAL

Most companies prefer to store the records in a conventional filing system. With larger companies it may be useful to use a computer filing system or register which could automatically give an indication of re-approval.

.. -._ •... - - .. --.--~.---~

4.8


TWI WELDER APPROVAL TEST CERTIFICATE

~LJ.7Ar~.~~maPR~$mm=lm&_jj==~mm*=eQ~"~~~$~$~ .... !~I~L1~ ..... ~ ..... ~ .. --=---'"

,.unuta.:::trll("~ Wala!rq P'=Xtc-.:1 Soectacaaco. ~ ,C20 ._.m _ .

Rtlarerce No.{lt 3.pplrc...:l:ll.~_. __ ._ =.223 •....•.••. ···.H .. ..•• __ ...... H .•..•.•••••...•..

W.gldBr.s Na.t1'lQ~ ? COC"\ _._~_. .•. u ••• •• • __ ••• _ •• __ •••• .,. h.

ICJsnll:!loe3~¢n: •. __ •••• _ $..tJ2~ .•••• _~.r. __ . HH •••• _ ••• _ _ •• _ •••••••••••••••••

Malhod 01 Id'tnUrcaUon: __ .• PASSPORT •.... --.· ..•. _ h ••••••• _ •• _ .

Oan a,""w::l DLa..::1 or bl,.l,"1: u_...2S :J::'CEM:S~ 1~:5.2 .• n __ •.. .

Empl~y.r. FFlED 6LCGGS :",:x,JSTf\IES •••.••• _ ....•.•••. _ _.

C:xJ.fT'$tlr<; Sta""""c: . __ =..., 251 _. __ ..........• ..

THE WELDIl\"G LJ-..lSTITUTE

':;~I&rGnc. Nc+ _ ••.. .:Z1J ._ ._ ..

WI$d 11S1 CleL:urJ } l".An;. or aporo"",
W,'C1r"9 ~~.U lH mOl III 1M MAl :.1 TIG/ll' MMA
{ P1.ala or C'OI PIPE "IPE & PLATE
_.
Jolm 1)1:)" SINGl~ VEE BUTT A.'lY WIT OR FILLET WELD
Paro", "",IS groupl' I WI! HJl/WO~fWJlll
Filler metal t)'p.e..otslgn.cCt'l ISO l~1 El0:12:J:lI'.23 ..aOVE APPROVAL USING SPECIFIED FILLER
SlvOI:lI"9 9"'0' ARGO'i AAGON
Au;rIUa,r1u ARGON BACKING MOON
To .. "tac. :n~kt\O.5.$ l"..,:j 15ITm ~ 1'1'.'0 GREATER
PLiPt 0IJt.SI(l, c;tlam-aur Ir.tTl! 1~5ITm • GR.EA TER ~ 0.3 •
W.~""SI"'n HLO<~ .oJ..L POSITlONS EXCEPT VERTICAL OOVVN
Gov9<~ NOr REOUlAEO "EOUlAEO ON DDulLE PREPS c

I Por1otmod r<1
Typ. ef IISI 2O::'P~ NoII~td
...,""" I V
R.a.::J'O;1!aany I V
~I"I.IH:: pa.ru: •• I v"
Oy. c.otlr.V1t I V
M.>e"" I ! V
fr,dCu. I ...........
e."", I v
",l6:::ItJOlUJ T.su· I v Pro~rx;atlOl\ ior apPr;}..-a.':y lu~r« len boa'( lor in. Io'c~ 2 Y''''' n'" Ie 'O~)

Posu:lon or nnf

WELDING TECHNOLOGY

00-<>:) .. 1>9-

'/C~

N.amo ....... or>d .. 9""..... I C IrCN.'SE

601 LTD

oo-oo-,Q-iI-

OO-oo,,'Q-iI-

PrO\:lr.;mCfl fer .i!pprv"'"3J by .l'T'Plo~rk::::vorojNto( 1:( rna IoIIO'WT"IJ 15 I'TOnN It.r.r 10 t02)

OaU S<;f"Iu'. Po.3mon. or uu.
I 4.9

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VOI~~------~~~

THE \VEillING IN STITUTE

QUESTIONS

WELD PROCEDURE & WELDER APPROVAL

Q2. State the meaning of 'extent of approval' and give five (5) examples -

n,\\ s g ~ c..A"ilK. -tQ tN"Su>l!IZ.. A'f' pn.S:::,v"...1..i) 'N ec...D "' ... \~ f'~..,~

"Z) ,.."...., ~ u:_::, pas ( '1'\ 0 r--!

.3) "'T\-\" OC-tV ~ . ~p.'t.to; Eo

'0 P\ Ar..I\E..oM.fC. r( AN'i E. ~ .

.S) Res-noe..\C'TIgtoolS Lo.J\1ICH ~o(AI,..D E"l.C\AAOE r<.o~T W(c..pl""~ foll\ U$\fIt\P\.6

c

~~~~-------~---~-----~. _ .... _._ ..

TWI

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SECTION 5

.------~--- ..

THE WELDING lNSTITLiTE

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ThE WELDING lNSTI1l.JTE

DESTRUCTIVE TESTING

Destructive tests on welded [olnts are usually made as part of the approval of a welding procedure or a welder.

The test pieces are cut from the test weld and their location is often specified in the standard.

~

British Standards for Testing of Welds . BS 709: 1983 Methods of testing fusion welded joints and weld metal in steel

Commonly used destructive tests are:

Bend

Tensile

Charpy

Fracture tests

Macro section

Discard

T est weld along ntre 0 f plate

Removal of t es t=piec es for destructive Jesting

T en~;le Bend Discard


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THE VlELDING lJ"lSTITUTE

BEND TESTS (transverse and longitudinal)

Object

To determine the soundness of weld metal, heat affected zone and weld zone.

This side in tension tor face bend

t \

These tests may also be used to give some measure of the ductility of the weld zone. It is not usual to use longitudinal and transverse bend tests for the same application.

tension for root bend

Test-piece for lace or root bend

Method

Sur tece in cont ect vith former is ground flat

The specimen is bent by the movement of a former of prescribed diameter, the relevant side of the specimen to be placed in tension. Angle of bend and diameter of former should be as specified in the appropriate application standard.

Force

~

Reporting Results

[al Face bend

1.

Thickness of specimen

I Force

2. Direction of bend (root or face)

3. Angle of bend

4. Diameter of former

[ht Root hend

5. Appearance of joint after bending, e.g. type and location of flaws.

R ~ Roller support

F • Former

01 spr:dfied ("dius

Irl ilf end

- -------_------_--

5.2


-Twr----

VOI~~~~~~~--

SIDE BEND TEST

Object

r>

- \-_j

To determine the soundness of a welded joint in a cross section.

This may be preferred to the transverse bend test on thick materials. _

Method

The. testing method is the same as that used for transverse bends.

Reporting Results

1. Width and thickness of specimen

2. Angle of bend

3. Diameter of former

4.

Appearance of joint after bending e.g. type and location of flaws


TIrE WELDING lNSTrIVI"E

plate

tension for side bend

Fest-piece for side bend

Force

(e) Side bend

R = Roller support F .. Former

of specified radius

Irl at end

5.3

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Vul~~~~~~~~

THE WELDING INSTfTUTE

TRANSVERSE TENSILE TEST

Object

Used to measure the transverse tensile strength under static loading of a butt joint employing butt welds.

The test is not designed to give the tensile strength of the weld metal.

Method

The testpiece is clamped at each end and a load is applied by a hydraulic or screw mechanism. The load is increased until fracture occurs.

Reporting Results

1. Type of specimen (e.g. reduced section)

2. Whether excess weld metal is removed or not

3. Tensile strength in N/mm2, is calculated from maximum load and original cross sectional areas. When excess weld metal is not removed the cross sectional area shall be the product of the parent metal thickness and the width of the specimen.

4.

Location of fracture, whether in parent metal, heat affected zone or weld metal. If the fracture is in the parent metal, the distance from the weld zone shall be stated.

5. Location and type of any flaws present on the fracture slJrfaces.

---------.-----.~~ ~-----

5A


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VOI~~.~~eNl_w~w~=ye~' ~~N~ __

---~-_-_---- __ -_---

CHARPY V NOTCH IMPACT TEST

Object

To determine the amount of energy absorbed in fracturing. a standardised testpiece at a specified temperature.

Method

A machined, notched specimen is broken by one blow from a pendulum. Because scatter occurs in the results, at least three specimens are used to assess the joint represented.

Testing is carried out at a temperature specified in the appropriate application standard in accordance with BS 131: Pt 2: 1972.

Reporting Results

1. Location and orientation of the notch

2.

Testing temperature

,

3. Energy absorbed

4.

Description of fracture appearance

5. Location of any defects


THE WELD[NG r:NSTrnrTE

Root radius

O_25mm I

'" __ 1

2mm

/~.

I

Hammer

\ Test-piece Ctierov impsct machine

Test-piece Hammer

blow

E ner9Y ;'bsorbed during

Test-piece in nOS,I,On lr acture is proportional

.on anvil 10 IA -8)

5.5

TWI

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FILLET WELD FRACTURE TEST

Object

To break the joint through the weld to permit examination of the fracture surfaces.

Method

The specimen is cut to length and a saw cut, normaJly 2mm deep, is made along the centre of the weld face. The specimen is fractured by bending or by hammer blows.

Reporting Results

1 . Thickness of parent metal

2. Throat thickness and leg length

3. Location of fracture

4. Appearance of joint after fracture

5. Depth of penetration/lack of penetration or fusion

- - __ ----------

WELDING TECHNOLOGY

, I

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TWI

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'NICK' BREAK TEST

Object

As for fillet weld fracture

Method

The specimen is cut transversely to the weld, and a saw cut is applied along the centre of the weld face. The specimen is fractured by bending or by hammer blows.

Reporting Results

1. Thickness of material

2. Width of specimen

3. Location of fracture

4. Appearance of joint after fracture

. 1


5.7

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TIIE WELDrl"G INSTITUTE

QUESTIONS

MECHANICAL TESTING OF WELDMENTS

Q1 From a tensile test the following items were proqressively recorded

t

C'

.

a) load

b) extension

If the original length is also known, state what can be assessed. EloNGATlpeJY9 CD\)vt'IL.I.-0

Q2

:",-.·o_

-IJ/...)

o -roO fpDMO'ft N-e.c.I(..INt. PrF T1~e AtZsto.. o~ IN'rf.!2E;&.l" tJ'i Dt..Oet2 QI>TA.u~ "DA.'-"_ 0,.;. ~A.1" ~P.IZ""IC.""I..A.&<.. S&c..1"IQ~ (Wl:.l.£J Me{))(\.,)

03 What is the purpose of a Charpy test?

T6 "D-"fSt2.M IN 6' Ttl G JoJo 1"C,... "TQU>~ '" ~e~ Df' A AJ\A.Te.t2\~ ..... A..-r ,... SpEc../FII! D nt.l\pE.ltATuYtl;.

05 What is the purpose of the 'nick' in a nick bend test?

1'0 f->~6A.K, Tlol Ii:- :r", N ,.. THltov. crH THE Wt"i) T<, r;;~AM'I"'" r; TI-\B AZ..A.c:."Uc'i~SORl'A"f (rtp-1- 1100

ass

0. '

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TWI

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r> ". __ ./

SECTION 6

TWI

VOI--~~~~~--~

THE WEWING [NSTITlJT""E

WELD SPECIFICATIONS

c

Welds must be specified by clear instructions and all staff includi[lg production personnel must understand the weld symbols specified.

It may only be necessary to specify the weld size and electrode to be used.

Or, the full details of a weld procedure may be needed.'· t

Three methods are commonly used to specify a weld:

Written statement

'Weld AZ321 is to be a single V butt welded from the outside of the vessel. The surface of the weld is to be ground flush. The root is to be sealed with a weld run deposited from inside the vessel. The completed weld is to be radiographed. '

Symbols on a drawing

------

WELDING TECHNOLOGY

fC:<:::flP niO"1

Pi 1

1,

I

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TWI

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STANDARDS FOR WELD SYMBOLS

Although the main features of weld symbols are inrerr.etional. variations in detail occur from country to country. Symbols are sp:::ciiied by National Standards.

UK BSEN 22553

USA AWS2.4

In this text, symbols are in accordance with BSEN 22553 which supercedes 8S499 and is identical to those in ISO 2553.

Indicating Joint Position

The position of the joint is indicated by an arrow.

Other side

The arrow points to one side of the joint.

This is called the ARROW SIDE.

Arrok' side

Th e side remote from the arrow is the OTHER SIDE.

6.2


TWI·

VOI~~~~~~--~~

WELD DETAILS

Information about the weld is given on a re.erence line attached to

the arrow. The reference line is always horizontal.

c

Details of the weld on the arrow side of the joint are given on the solid line.

Other side information is on the dotted line, and can be

shown above or below the

solid line.

A fillet weld is indicated by a triangle placed on the reference fine.

A triangle on the reference line specifies a fillet weld on the arrow side of the! joint.

A triangle on the dotted line

A triangle above the line calls for a fillet -weld on the other side of the joint.


T& \VELDING INSTITUTI:

,

...... :::.eferenr:e line

0.""0"" side informsfi:!" - -o~e;:-side info'-ma:i~:,;

-

-

-

-

6.3

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TWI

VOI~~~~~~~~

THE WELDING INSTfTVTE

TYPES OF BUTT WELD

The common types of edge preparation associated with a butt weld are indicated as follows:

Square edge preparation

'---.Jj....__1 ---..J

Single V preparation

Double V preparation
~ X ~

Single U preparation -:":
i \) f

U
Double U preparation rn-
~
~ X ~ Using symbols it is not necessary to draw the shape of the edge preparation. The joint is shown as 2 single line.

~_r' __ ••• __ ._~ • __ ~. __ .~~.

. ..

6.4


TWI

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ASYMMETRICAL PREPARATIONS

In some joints, only one component is prepared, e.q. sing::? bevel butt or single

J butt. .

,
~
, - )
- D/ I ~ 1 - /
- \
C 0
.. A s: Arro v side

o " Otller side

In these cases the arrow points at the edge which is to be prepared.

SURFACE PROFILE

The surface profile can be indicated by an extra symbol placed on the top of the weld symbol.

Single V butt weld with a flat surface. (Flushed after welding. Usually by grinding).

-

-

?

Convex fillet weld.

Concave fillet weld. (May be achieved by welding alone or by subsequent grinding).


6.5

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VOI_M~ii~i6 ~~~~~W~~WO~~

TIlE WELDING INSTITUTE

SEALING RUN

If the root of a butt weld is to be sealed the symbol is placed on the reference line, opposite the weld symbol.

-~--

//\

I

-

-

DIMENSIONING FILLET WELDS

The leg length of a fillet weld is located in front of the weld symbol (triangle). (The dimension is in millirnetres) preceded with the letter Z

-

-

10mm leg length fillet veta

Throat thickness is indicated in the same way but is preceded by the letter 'a'.

-

-

fillet veld .... ith 7mm design ttir o s t thickness

For deep penetration

fillet welds the dimensions are indicated for example:

SSa.b

z "0<

/

Intermittent fillet welds are dimensioned by giving:

~ number of weld elements (n).

~ length of weld element (I).

- distance between weld elements (e).

n x I {l I

6.6


TWI

VUI~n~M~#@~fftN~i_~IW#~*~~N~~mr~MR_W~~¥W=&"~,@~M4~

THE WELDING INSTfTIITE

SUPPLEMENTARY SYMBOLS

Three supplementary symbols 2re in ge.leraJ use:

Weld all round the component

(

Inspect by NOT, Weld, Paint, etc. the reference document can

be included in the box.

/~----<1wPSl

Weld this joint on site

----

WELDING TECHNOLOGY

Issue 0191

6.7

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TWI ~ _ ..

VOl JllP&Wi!!¥#3\!!¥*f h&iiUV* k W· II ?;Z"'fC,ggp Vb

QUESTIONS

..~------.--- ..... --.

SYMBOLS FOR WELDING SPECIFICATION

Q1

Sketch/describe the weld shown below

c

Q2 Sketdv'describe the weld shown below

. ' ..

• ~ I

• • ,-' .'.. • • ~::' ~ ._. • • <

:·:·:g3:·.··':.::S~t~~cify the \~eld sh~wn· belo~·by· mea:n~··of symbols

... "

: ..

.. ,' '"; :\'

t •. ' :

'., .

10

r-:yJ:=

,/

. Q4 Specify the weld shown below by means of symbols

J

05 Describe the following:

-.------.~---------~~-~

OSG

___________ o-i

0,

TWI --rllOlwf€

JJ¥ iSdllwMd"A@ !"t&!I!.!:tttn!tSQflM'" 5 W" -f4U1l!WVW #il!lifd§iikia9 " 1HE \VELDING INSITIlJTE

QUESTIONS

SYMBOLS FOR WELDING SPECIFICATION

Q1 Sketch/describe the weld shown below

b

Q2 Sketch/describe the weld shown below

. "'. ~"':;''-'.

. . '~.

~ .. "{.- .

.' ," ... :: ', ",;-:; ..

_'".,' ;' .....

. - .~ ~ -,'

", . . . . .-~ \:-~ :~ .

. . \. " ::,;::,,; ', ~.;;:~~':'""" "', . .: . . .... -. .

Q3 -----$e~cify theweld shown below by means of symbols

10

- -

Q4 Specify the weld shown below by means of symbols

.-

-,

05 Describe the following:

---------------~----~~---

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SECTION 7

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TIIE WELDING INSTITUTE

REVIEW OF STEELS AND MATERIAL DEFECTS

The term 'steel' is used to describe many different metals, they ar-e all a/loys based on iron, but the alloying addltions, such as carbon, manganese, silicon and chromium, etc., singly or in combination produce a range of metals with widely differing physical and mechanical properties as well as quite different weJdabiJity.

IRON Fe ,
.: CARBON C
-_-" MANGANESE Mn
SILICON Si
ALUMINIUM AI
CHROMIUM Cr
MOLYBDENUM Mo
TITANIUM Ti
NIOBIUM Nb
VANADIUM V
SULPHUR S
NICKEL Ni
COPPER Cu
RIMMING STEEL
Composition O.09%C
O.9%Mn
+ residuals Weldability

The weld pool will require to have added deoxidant via a filler rod,

LOW CARBON STEEL

Composition

O.2%C O,9%Mn

+ residuals

We/dability The general weldabillty is good but the level of residuals

(S) may cause weld metal/heat affected zone cracking.

MEDIUM CARBON STEEL

Composition

0.45%C O.90%Mn + residuals

Weldability

The high carbon content induces hydrogen cracking in the

HAZ as the section size increases. .

.... --~- •. - •. ~---~---

I/'/ELDING TECHNOLOGY Issue 0191

7.1

TWI

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Composition

HIGH CARBON STEEL

Weldability

O.8%C O.9%Mn

+ residuals

The weld pool is subject to solidification type cracking and the HAZ suffers hydrogen cracking.

C:

"

Composition

CARBON-MANGANESE STEEL

Weldability

O.2%C 1.S%Mn

+ residuals

may also contain Tl, Nb and V.,.

These high Mn steels have good toughness, particularly the Ti, Nb and V grades, and the main weldability problem is to maintain these.

Composition

QUENCHED AND TEMPERED STEEL

Weldability

O.4%C 1.0%Mn O.8%Cr O.3%Mo

.+ Tl or Al + residuals

These steels are difficult to weld, and defect free welds with good mechanical properties are only attained by using the greatest care.

Composition'

HIGH TEMP. STEEL

LOW TEMP. STEEL

Composition

Weldability

O.2S-9%Cr O.2S-3%Mo etc.

The weldability of the low Cr is difficult.

3.S-9%Ni etc.

The higher Ni are subject to solidification cracking.

~ _ -.-~--.-.-----~-----~- -_ _ _. _ .. __ . -- ~ .'-- .-.- -.-- .. ----~- -_ -.--~-~---- .. ---.- .. ,. -- -- - -.--.-.--- -.~.-- .. -~--.--,--'j,

---- .. --.-- .. -- .. ---.-- .. -. I

I

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WELDING TECHNOLOGY I

7.2 Issue 0191 I

TWI

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MICRO ALLOYED STEEL (HSLA)

Composition O.2S%C

1.5%Mn O.002%V ) O.005%Nb ) min. O.003%Ti)

WeldabiJity

-

These steels may suffer hydrogen crlicking in the weld metal.

STAINLESS STEELS 1. MARTENSITIC SS

Composition

11%Cr O.08%C

+ residuals

Weldability

Poor due to hydrogen cracking.

2. FERRITIC SS Composition

12-27%Cr O.08%C

+ residuals

Weldability

Poor due to cracking, brittleness and temper embrittlement.

3. AUSTENITIC S5 (NB NON-MAGNETIC)

Composition 18-27%Cr

8-22%Ni O.08%C

+ residuals

Weldability

Problems with solidification cracking and weld decay.


7.3

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A great variety of materials may require to be inspected with a view to satisfactory welding.

Inspection points are:

Specification/supplier - to mill sheet or reference number.

Quantity:

Size Distortion Condition Defects Storage

length, breadth, thickness, diameter

flatness/ovality -

rust/paint, heat treatment

laps, bands, laminations

SPECIFICATION

It is not, in general, safe for the inspector to identify materials by composition from mill sheet, since very small variations or additions to the metal may give rise to significant changes in properties and weldability. However, limited selectivity is permissible, such as % carbon maximum, etc.

The procedure is for the mill sheet to be submitted for approval and then the inspector records and transfers the reference number.

SUPPLIER

This can be found on the Goods Inwards documents or the receipt documents, or occasionally on packaging or even marked on the metal.

aUANTITY\

The quantity being inspected should always be noted as well as the sample size, if 100% inspection is not being employed.

SIZE

Sizes must be checked for secondary identification as well as conformance. The inspector will, as appropriate, be given tolerances on size which are permissible.

7.4


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DISTORTION

A check is often required on the degree of distortion, i.e.

Flatness squareness straightness ovality

consistent wall thickness

CONDITION

Rust, paint and grease on the surface of the metal are all harmful to welding and must usually be removed at least near to the actual weld. Guidance is normally given to the inspector regarding acceptable levels or the treatment which is required. An inspector should be alert to gradual changes, such as increased corrosion. Carefully maintained specimens showing acceptable conditions are often the best method. Heat treatment condition, annealed, normalised etc.

DEFECTS

In wrought products the most common defects are laps and laminations. Both these wi!! normally be subsurface so unless NDE Is being employed only, the edges of plate, and particularly cut edges, can be inspected. The lap/lamination will appear as a narrow black line parallel" to the surface .

. STORAGE

After inspection and approval for use it is essential that the metal is stored in such a way as to maintain its good condition. Protect from corrosion and mechanical. damage.

"_

Questions to be asked:

1. Do the markings or, the material match those On the procedure sheet or drawing?

2_ Are the dimensions correct?

3. Is the surface condition satisfactory for welding?

WEColNG TECHNOLOGY" -_. Issue 0191

~--.---.----

7_5

.~

TWI

Vul~--~--~~~~-

TIIE WELDING IN'STIT1.JTE

QUESTIONS:

REVIEW OF STEELS AND MATERIAL DEFECTS

01 / Name two (2) wrought plate defects.

L;p>,ops

:; lA",Mrto.,l-,b.. • .-n cn'l ~ v" S:ecH~e<:'A.-no~

c

02

Give examples of composition

A rimming steel "0.099/9 e~ o.9°joMYI; ~'e."i0710\}1>.l--5 A low carbon steel D ~'2... '10 c. ~ 0 .. 9 0}4 M t'\ : Res lD o,t:..'--<

A tool steel D. q10 C; 0.,91) b ,'M Y) ~ R..(<; \ DUk-S

/a)

b) c)

03 Give an example by composition of a stainless steel

AUSTEN. ITI C ..5:''TAlt4 L.5S ~nr..L$.! 1 g-'-2.. 71Q 6v

I / "8" 2-2.J<;) N I

V c» .o~% c....

-+ R E.S I DIAIlI.-':J

Q4 " What'is the purpose of the increased Mn content of a " carbon-manganese steel

) N-cfi. {;:M liD 1£:>1.A (j' H NY-. s

I / _ - iN ~ S;;V S"...,-n.s 1.J<j11-l

tv' H A.l2p eN Af:>1 L.J1'(

S Gco....p IV1 0 1;" .0)(".1 D KB :DB-Su J.... P J.! l .. q:~l5 r..,<

05

State the features/defects which should be noted when inspecting

wrought plate L..I\P5 A,1\l"D LAM)~A.l)o* Wl-l.lcH A..P1'fj>.«._.

J f\ c:; 'O~It.K I.-,\l'\G) -AT T" E E':V<;'S> D-F -rn.e; y?t_A."'"'R: llel r',u;

<J)lP,e.r1i:91"} Of'"""fl.IG M f't Yl"'" "L:! ~"-n'" C' 1\0":"

}-1; ..... ~ ILl(." "to » Ul<.y1\C.IQ,/

~ .1....., ~r f & <!41'iJD If'Pri

as?

c

--~---- ---.

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CONSUMABLES

Welding consumables are the:

Electrodes

Wire (lengths or rolls) Fluxes

Gases.

Each consumable is critical in respect to -

Specification/supplier Condition

Treatment (it any)

Take as an example a common MMA covered electrode. This will be to a specified type but an additional requirement may be that only one or MO suppliers/manufacturers are acceptable. The electrode must be in good condition with regard to corrosion and mechanical damage and so storage and mechanical handling are important. If the electrode requires heat treatment for low hydrogen potential then the temperature, time and oven condition require attention. The issue of electrodes to the welder for use and the procedures for recycling and scrap must often be dealt with care.

There are many codes in existence which cover the various consumables. The only reasonable rule is to keep to what is specified unless (and only unless) a written order for variation is received.

Covered Electrodes

BS 639 AWS AS 1 ISO 2560 BS 2493 BS 2926

Gas-shielded wires

BS 2901, Part 1-5

Gases

BS 4365 BS 4105


8_1

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Identification of covered electrodes

In the BS system for carbon and carbon manganese steels the electrode may be partially or completely specified by a Jetter/number.

The summary sheet gives details.

FIRST GROUP COVERING EFFICIENCY (HI
Electrode Tensile Minimum yield a basic % recovery to Indicates
designation strength. stress. Nlmm' aa higi'l efficiency nearest 10% hydrogen
Nlmm' C cellulosic (;. 110) controlled
E43 430.550 330 0 oxidising (" 151\11/1009)
E51 510-650 380 R rutile (medium coated)
RA rutile (heavy coated)
5 other types SECOND GROUP
First Temperature for
digit impact value of
28J. ·C
0 Not specified
1 +20
2 0
3 -20
4 -30
5 -40
Second Temperature lor
digit impact value of
47J .... C
0 Not specified
1 +20
2 0
3 -20
.: -30
5 -40
6 -50
7 -60
B -70 POSITION DIGIT

all positions

all positions except vertical down

Ila t and. for fillet welos. hor,zontal vertical lIat

flat, vertical down and, for fillet welds. horizontal vertical

1 2 J 4 5

9 any position or cornbinatioc 01 positions not cia ssifted above

o

1

ELECTRICAL DIGIT

Code Direct current

I Recommended electrode polarity

Polarity as
recommended
by manufac·
0 tur er
1 I + Or-
2
3 +
~ I -+- or-
5
6 +
7 I + or-
8 I
9 + I ........... ,~ n-rn-.t

Alternating current

Minimum opencircuit voltage. V

Not suitable lot use on AC

50 50 50

70 70 70

80 80 80

WELDING TECHNOLOGY

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BRITISH STANDARD 639 1986

MANUAL METAL ARC WELDING CONSUMABLES FOR C.C/Mn STEELS

E 51

•

33 8 1 so 2

COVERED ELECTRODE ----

STRENGTH------------------~

TOUGHNESS ---------------.;1

COVERING ----~-------'---------

',;_""

r EFFICIENCY (%)-------------------

POSITIONAL CAPABILITY ---------------------

ELECTRICAL CAPABILITY -JI

o

(H)

LOW HYDROGEN POTENTIAL --------------------'-----

WELDING TECHNOLOGY lseu» n1Q1

TWI

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AMERICAN WELDING SOCIETY A5. 1-81 MANUAL METAL ARC WELDING CONSUMABLES FOR

C. C/Mn STEELS

E

70

WELDING POSITION _- ..-..J

1 = ALL POSITIONAL 2 = FLAT & HV FILLETS

).

1

8

G

FLUX COVERING CURRENT TYPE AND POLARITY ----~

AS.5-81 LOW ALLOY STEEL (ALLOY CONTENT) ---

R4

WELDING TECHNOLOGY

T·WI

VUI __ ~@~~H~NIci_R@~~~~4 __

THE WELDING INSTfI1JTE

QUESTIONS:

THE BRITISH STANDARD CLASSIFICATION OF MMA ELECTRODES

03. State the meaning of the following:
a) B = basic
b) R = Rut, I-e.. CM.Q. cR.l \nlI\ Co~&)
.I. c) AR = A (,.\' cl (tu..t(I~
/ d) 0 = D~l.JCv~
e) C = G..-l.A.N-lo ~L c
f)' RR = Rv:h.\«. (hs..(M.~ eoo.lacO) Q4. When an electrode specification terminates with an (H), what is

-; usually required in order to give the specified results?

\ / {.\~.J.,...~~ ~+f?:r ~ MR.--t~ ~ ~~~ 15 ~.Qf lO~ V ~~lh~ .. (,'l'6J~:-J MCAfA~~ ~(_o~)o'\~~

05. / Wh~t'iPthe meaning ";f

V "S" fJ.?'~..... "T'1tft.... MC" G'RN.P.1:r'.~

......... _- .-.=.....:.::.:======

ass

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SECTJON 9

THE WELDING LNSTf11ITC

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THE FOUR ESSENTIAL FACTORS FOR ESTABLISHlNG A WELD

Welding is usually regarded as a joining process in which the work pieces are in atomic contact often with a filler metal of broadly similar properties .

.

Hence soldering and brazing are excluded but both solidLstate and fusion welding are included.

Solid state processes include:

Forge welding Friction welding

Fusion welding processes Include:

Oxy-acetylene

Manual metal arc (MMA)

Metal inert/active gas (MIG/MAG) Submerged arc welding (SAW) Electro-slag welding (ES'N)

Fusion welding factors

1. Fusion (melting)

The metal must be melted which requires a high intensity heat source.

2. The process must remove 211y oxide and other contamination from the joint I

faces. .'

3. Contamination by the atmosphere must be avoided.

4 .. The welded joint must possess adequate properties.


a 1

TWI

Vul~~~~~~~--

THE WELD ING lNSTITlITE

QUESTIONS:

FOUR FACTORS IN WELDING

01. State the four (4) factors which must be satisfiBd for good welds.

/1) Fu'1 Ot(\." ( W\...t_.\ \. ~ _

v-D I<..~~ %- oi.\~ a- c9 ~ c.o-r. --t- cw....1.-v\~\ 6h. ~) Avo\cJ.c.\N\~ '% ~o~f'hsw-~c ec;j-~ ~ .... ~ v4-)~ ~ ~ ~ ~ rv~e>.,

02. What ar the mechanical tests which are usually used to ensure

compliance with adequate mechanical properties. v--- -1 J'ef\.S t \-Q.

~~~~

V-£)H~~

03. Name three (3) methods of protecting the molten metal from contamination.

~0 ~~ SkL~

;0Fl~

V' j) Vo-..c.~

I

Q4. Describe the metal cleaning requirements required when making high

/ class stainless steel welds.

• 5~ lV...ta\-r ~ l,.~~

VL 0 Bvl.).') h~ ")

~ .. Sl~ J$~(..~ r~ tyOlV\ ~ ~J ~

05. Name two methods of protecting the arc from contamination.

V· GCa.J) ~k ... ~J.~ V· Ver...c\A.\nVl

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SECTION 10

W39!H1M THE WELDING INSTrnrr-E:

c

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Vfll ._:IIrn."I2l!!I\!!!9I¥SlDliII!ZII:IS!iIISiIIII!lEi!lIIl!tnmll5lmaEllllli_~_;aaIlil!m:E:!!l=--II::IIIIl"III1I!"'1IIl TIlE WELD ING INSTITlITE

EQUIPMENT

Welding inspection necessarily involves checking that the correct. welding/cutting process is being used, that the equipment is in workable condition and that the welding parameters of amperes and volts are being adhered to. The following paqes outline the constant current process and list the types of defects which are associated with them.

You will notice that the arc processes are divided into tvlo (2) types ('drooping' and '~at'). This refers to their volt-amp output characteristics.

! .

The conventional machine is known as the constant current machine (drooping characteristic) and has for many years been used for manual metal arc and tungsten inert gas welding. By using drooping an alteration in arc length gives a very small change in current.

J


10.1

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VUI~~~4~~-~4_~P~--ti----

TIE WELDING INSTITUTE

A 'DROOPING ARC' PROCESS (CONSTANT CURRENT)

MANUAL METAL-ARC (MMA)

.

Shielded metal-arc (US); Stick; Electric

arc welding

Typical defects associated with this process:

Overlap.

Sol/dfflld sl;'9 Art:

\ Va IIcld pool

w(((mWJ\~-,_,

• Porosity.

• Slag inclusions.

• Excessive spatter.

Type of Operation Manual.

Stray flash.

Incomplete penetration.

Mode of Operation

Arc melts parent plate and electrode to Excess penetration.

form a weld pool which is protected by

flux cover. • Undercut.

Operator adjusts electrode feed rate, i.e. Crater cracks.

hand movement, to keep arc length

constant. Slag must be removed after Lack of fusion.

depositing each bead. Normally a small

degree of penetration, requiring plate edge

preparation. Butt welds in thick plate or

large fiifets are deposited in a number of

passes. The process can also be used to

deposit metal to form a surface with

aJtpr~-' ~ properties.


TWI CSWIP 3.1 Welding Inspector

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