Welding Inspector Terms & Definitions Section 2

Year-2007 (Egypt)

Welding Terminology & Definitions

What is a Weld?

2.1

A localised coalescence of metals or non-metals produced either by heating the materials to the welding temperature, with or without the application of pressure, or by the application of pressure alone (AWS)
A permanent union between materials caused by heat, and or pressure (BS499) An Autogenous weld: A weld made with out the use of a filler material and can only be made by TIG or Oxy-Gas Welding

Year-2007 (Egypt)

Welding Terminology & Definitions

What is a Joint?

2.1

The junction of members or the edges of members that are to be joined or have been joined (AWS) A configuration of members (BS499)

Year-2007 (Egypt)

Joint Terminology 2.2

Edge

Open & Closed Corner

Lap

Cruciform

Tee
Year-2007 (Egypt)

Butt

Welded Butt Joints 2.2

Butt A_________Welded butt joint

Fillet A_________Welded butt joint

Compound A____________Welded butt joint

Year-2007 (Egypt)

Welded Tee Joints 2.2

Fillet A_________Welded T joint

Butt A_________Welded T joint

Compound A____________Welded T joint

Year-2007 (Egypt)

Weld Terminology 2.3

Butt weld

Fillet weld

Spot weld

Edge weld

Plug weld Compound weld

Year-2007 (Egypt)

Butt Preparations Sizes

2.4

Partial Penetration Butt Weld

Actual Throat Thickness Design Throat Thickness

Full Penetration Butt Weld

Actual Throat
Thickness

Design Throat Thickness

Year-2007 (Egypt)

Weld Zone Terminology 2.5

A
Face

Weld metal Heat Affected Zone

Weld Boundary

C
Root

A, B, C & D = Weld Toes

Year-2007 (Egypt)

Weld Zone Terminology 2.5

Weld cap width

Excess Cap height or Weld Reinforcement

Actual Throat Thickness

Design Throat Thickness

Excess Root Penetration

Year-2007 (Egypt)

Heat Affected Zone (HAZ) 2.5

solid-liquid Boundary grain growth zone recrystallised zone partially transformed zone tempered zone unaffected base material

Maximum Temperature

solid weld metal

Year-2007 (Egypt)

Joint Preparation Terminology 2.7

Included angle
Angle of bevel Root Radius

Included angle

Root Face Root Gap

Root Face

Root Gap

Single-V Butt
Year-2007 (Egypt)

Single-U Butt

Joint Preparation Terminology

Angle of bevel

2.8 & 2.9

Angle of bevel

Root Radius

Root Face Root Gap

Root Gap

Root Face

Land

Single Bevel Butt

Year-2007 (Egypt)

Single-J Butt

Single Sided Butt Preparations

2.10

Single sided preparations are normally made on thinner materials, or when access form both sides is restricted

Single Bevel

Single Vee

Single-J
Year-2007 (Egypt)

Single-U

Double Sided Butt Preparations

2.11

Double sided preparations are normally made on thicker materials, or when access form both sides is unrestricted

Double -Bevel

Double -Vee

Double - J
Year-2007 (Egypt)

Double - U

Weld Preparation
Terminology & Typical Dimensions:
bevel angle
included angle

V-Joints

root face root gap

Typical Dimensions bevel angle root face 30 to 35 ~1.5 to ~2.5mm

root gap

~2 to ~4mm
Year-2007 (Egypt)

Butt Weld - Toe Blend

6 mm

Most codes quote the weld toes shall blend smoothly

80

Poor Weld Toe Blend Angle

3 mm

This statement is not quantitative and therefore open to individual interpretation The higher the toe blend angle the greater the amount of stress concentration
The toe blend angle ideally should be between 20o-30o

20

Improved Weld Toe Blend Angle

Year-2007 (Egypt)

Fillet Weld Features

2.13

Excess Weld Metal Vertical Leg Length Design Throat

Horizontal leg Length

Year-2007 (Egypt)

Fillet Weld Throat Thickness

2.13

a
a = Design Throat Thickness b = Actual Throat Thickness
Year-2007 (Egypt)

Deep Penetration Fillet Weld Features 2.13

a
a = Design Throat Thickness b = Actual Throat Thickness
Year-2007 (Egypt)

Fillet Weld Sizes

2.14

Calculating Throat Thickness from a known Leg Length:

Design Throat Thickness = Leg Length x 0.7

Question: The Leg length is 14mm.

What is the Design Throat?

Answer: 14mm x 0.7 = 10mm Throat Thickness

Year-2007 (Egypt)

Fillet Weld Sizes

2.14

Calculating Leg Length from a known Design Throat Thickness:

Leg Length = Design Throat Thickness x 1.4

Question: The Design Throat is 10mm.

What is the Leg length?

Answer: 10mm x 1.4 = 14mm Leg Length

Year-2007 (Egypt)

Features to Consider 2

2.14

Importance of Fillet Weld Leg Length Size

(a) (b)

4mm 4mm

8mm 2mm

Approximately the same weld volume in both Fillet Welds, but the effective throat thickness has been altered, reducing considerably the strength of weld B
Year-2007 (Egypt)

Fillet Weld Sizes

(a)
Excess

2.14

Importance of Fillet weld leg length Size

(b)
Excess

4mm
(a) 4mm

6mm
(b) 6mm

Area = 4 x 4 = 8mm2 2

Area = 6 x 6 = 18mm2 2

The c.s.a. of (b) is over double the area of (a) without the extra excess weld metal being added Year-2007 (Egypt)

Fillet Weld Profiles

2.15

Fillet welds - Shape

Mitre Fillet

Convex Fillet
A concave profile is preferred for joints subjected to fatigue loading

Concave Fillet
Year-2007 (Egypt)

Fillet Features to Consider

EFFECTIVE THROAT THICKNESS
a = Nominal throat thickness

2.15

s = Effective throat thickness

Deep penetration fillet welds from high heat input welding process MAG, FCAW & SAW etc
Year-2007 (Egypt)

Welding Positions
PA PB PC PD 1G / 1F 2F 2G 4F

2.17

Flat / Downhand Horizontal-Vertical Horizontal Horizontal-Vertical (Overhead)

PE
PF PG H-L045 J-L045

4G
3G / 5G 3G / 5G 6G 6G

Overhead
Vertical-Up Vertical-Down Inclined Pipe (Upwards) Inclined Pipe (Downwards)
Year-2007 (Egypt)

Welding Positions

2.17

ISO

Year-2007 (Egypt)

Welding position designation 2.17

Butt welds in plate (see ISO 6947)

Flat - PA Vertical up - PF

Overhead - PE

Vertical down - PG Year-2007 (Egypt)

Horizontal - PC

Welding position designation 2.17

Butt welds in pipe (see ISO 6947)

Flat - PA
axis: horizontal pipe: rotated

Vertical up - PF Vertical down - PG

axis: horizontal pipe: fixed
axis: horizontal pipe: fixed

H-L045

J-L045

Horizontal - PC

axis: inclined at 45 axis: inclined at 45 axis: vertical pipe: fixed pipe:Year-2007 fixed(Egypt) pipe: fixed

Welding position designation 2.17

Fillet welds on plate (see ISO 6947)

Flat - PA

Horizontal - PB

Overhead - PD

Vertical up - PF

Year-2007 (Egypt)

Vertical down - PG

Welding position designation 2.17

Fillet welds on pipe (see ISO 6947)

Flat - PA
axis: inclined at 45 pipe: rotated

Horizontal - PB
axis: vertical pipe: fixed

Overhead - PD
axis: vertical pipe: fixed

Horizontal - PB Vertical up - PF Vertical down - PG

axis: horizontal pipe: rotated axis: horizontal Year-2007 (Egypt) pipe: fixed axis: horizontal pipe: fixed

Plate/Fillet Weld Positions

2.17

PA / 1G

PA / 1F
PF / 3G

PB / 2F

PC / 2G

PD / 4F

PE / 4G
Year-2007 (Egypt)

PG / 3G

Pipe Welding Positions

2.17

PA / 1G
Weld: Flat Pipe: rotated Axis: Horizontal

PF / 5G
Weld: Vertical upwards Pipe: Fixed Axis: Horizontal 45o

PG / 5G
Weld: Vertical Downwards Pipe: Fixed Axis: Horizontal

45o

PC / 2G
Weld: Horizontal Pipe: Fixed Axis: Vertical

H-LO 45 / 6G
Weld: Upwards Pipe: Fixed Axis: Inclined

J-LO 45 / 6G
Weld: Downwards Pipe: Fixed Axis: Inclined

Year-2007 (Egypt)

Travel Speed Measurement

2.18

Definition: the rate of weld progression measured in case of mechanised and automatic welding processes in case of MMA can be determined using ROL and arc time

Year-2007 (Egypt)