Copyright 2004, TWI Ltd World Centre for Materials Joining Technology

TWI
CSWIP 3.0
WIS 1
WELDING INSPECTION

TERMS & DEFINITIONS


Copyright 2004, TWI Ltd World Centre for Materials Joining Technology
Terminology
Butt Joints
Single Sided Butt
Double Sided Butt
Square Edged
Closed Open
Vee Bevel
Vee
Bevel
Copyright 2004, TWI Ltd World Centre for Materials Joining Technology
Terminology
Fillet Joints
Lap
Corner
Tee
Copyright 2004, TWI Ltd World Centre for Materials Joining Technology
Terminology
0-2 mm
2-4 mm
60-70
0
Included Angle
Root Gap
Root Face
Copyright 2004, TWI Ltd World Centre for Materials Joining Technology
Terminology
Butt Weld Features
1
2
3
4
5
6
7
8
9
10
Copyright 2004, TWI Ltd World Centre for Materials Joining Technology
Terminology
Fillet Weld Features
1
3
5
6
7
8
10
2
9
4
Copyright 2004, TWI Ltd World Centre for Materials Joining Technology
Joint Design
Butt Weld
Corner
Joint
Lap Joint
Tee Joint
Edge Weld
Copyright 2004, TWI Ltd World Centre for Materials Joining Technology
Zones in Fusion Welds
Parent Material or Base Metal
Heat Affected Zone
Fusion Zone


Copyright 2004, TWI Ltd World Centre for Materials Joining Technology
When do I carry out inspections?
How do I carry out inspections?
What do I look for?
What equipment do I need?
How do I interpret the code or standard
requirements?
What is the nature of the product?
What operating conditions will be present?
What is the quality of welding required?
Is there a code or standard available to
inspect the welds against

Visual Inspection Procedures
Important things to consider
Copyright 2004, TWI Ltd World Centre for Materials Joining Technology
Welding Checklist
Documentation
Materials
Weld preparations
Fit up for welding
Welding equipment
Before Welding Commences
Copyright 2004, TWI Ltd World Centre for Materials Joining Technology
Welding Checklist
Correct parameters
WPS at the work place
Inter run cleanliness and quality
Interpass temperature
Consumable control
Maintenance of preheat
Process control NDE regime
Weld records and maintenance of weld maps
During Welding
Copyright 2004, TWI Ltd World Centre for Materials Joining Technology
Welding Checklist
Visual inspection and records
NDE
PWHT
Final testing
Cleaning, painting, preservation, packing
Final documentation
Welding Completion
Copyright 2004, TWI Ltd World Centre for Materials Joining Technology
Features to Consider
Butt welds - Size
Excess weld
metal height
Root
penetration
Root bead width
Weld cap width
Copyright 2004, TWI Ltd World Centre for Materials Joining Technology
Features to Consider
Fillet welds - Size
Minimum and
maximum leg
length size
Excess
weld
metal
Actual throat
thickness
Design throat
thickness
Copyright 2004, TWI Ltd World Centre for Materials Joining Technology
Features to Consider
Importance of Fillet weld leg length Size
4mm
6mm
8mm
4mm
What size is the Throat thickness of (a)
What size is the Throat thickness of (b)
(a)
(b)
Copyright 2004, TWI Ltd World Centre for Materials Joining Technology
Features to Consider
Importance of Fillet weld leg length Size
4mm
4mm
6mm
6mm
How much bigger is (b) in volume than (a)
(a)
(b)
Copyright 2004, TWI Ltd World Centre for Materials Joining Technology
Features to Consider
(a) volume =
4 x 4 = 8mm
2

2
(b) volume =
6 x 6 = 18mm
2

2
The volume of (b) is over double the volume of (a)
Without the extra reinforcement being added
4mm
4mm
6mm
6mm
(a) (b)
Copyright 2004, TWI Ltd World Centre for Materials Joining Technology
Features to Consider
Fillet welds - Size & Shape
Mitre
Concave
Convex
Copyright 2004, TWI Ltd World Centre for Materials Joining Technology
Features to Consider
Fillet welds - Toe Blend
Copyright 2004, TWI Ltd World Centre for Materials Joining Technology
Features to Consider
Copyright 2004, TWI Ltd World Centre for Materials Joining Technology
Features to Consider
Calculating fillet weld sizes

Leg length X 0.7 = Throat Thickness
Throat Thickness X 1.4 = Leg length

The Leg length is 14mm what is the Throat?
10mm
The Throat is 10mm what is the leg length?
14mm

Fillet welds connecting parts with fusion faces with
an angle more than 120
0
or less than 60
0
should not
use the above calculations


Copyright 2004, TWI Ltd World Centre for Materials Joining Technology
Features to Consider
120
0
60
0
Throat CSA is small Throat CSA is large
Copyright 2004, TWI Ltd World Centre for Materials Joining Technology
Features to Consider
The design throat thickness of a flat or convex fillet
weld connecting parts with the fusion faces which
form an angle between 60
0
and 120
0
may be
calculated by multiplying the leg length by the
appropriate factors as given below


Angle between fusion
faces in degrees
Factor
60 to 90
91 to 100
101 to 106
107 to 113
114 to 120
0.7
0.65
0.6
0.55
0.5
Copyright 2004, TWI Ltd World Centre for Materials Joining Technology
EFFECTIVE THROAT THICKNESS
s = Effective throat thickness

s

a

a = Nominal throat thickness

Deep throat fillet welds from FCAW & SAW etc
Features to Consider