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Course Reference D 73
TWI
Terminology
Butt Joints
Square Edged, Open and Closed
TWI
Edge
Lap
Corner
Tee
Cruciform
TWI
Compound
Edge
Fillet
Spot
Butt
Plug
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Included angle
Angle of
bevel
Root
Radius
Root Face
Root Face
Root Gap
Root Gap
Single -V Butt
Single - U Butt
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Angle of
bevel
Root
Radius
Root Face
Root Gap
Root Gap
Root Face
Land
Single J Butt
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Fusion zone
Root
Heat affected
zone
Weld Junction
TWI
TWI
d
el
W
ce
fa
Design throat
thickness
TWI
a
b
a = Design/ Nominal throat thickness
b = Actual throat thickness
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Mitre fillet
Convex fillet
Concave fillet
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Welding Positions
Flat position
UK (USA): 1G
ISO/EN: PA
UK (USA) 1G rotated
ISO/EN PA
Horizontal
position
UK (USA) 2G Fixed
ISO/EN PC
UK (USA): 2G
ISO/EN: PC
TWI
Welding Positions
Vertical
up
UK (USA) 3G
ISO/EN PF
Overhead Position
UK (USA) 4G
ISO/EN PE
Vertical
down
UK (USA) 3G
ISO/EN PG
Vertical Position
Pipe fixed Horizontal
UK (USA) 5G
ISO/EN PF, PG
TWI
Welding Positions
45o
Inclined position fixed
UK (USA) 6G
EN/ISO H-LO45
45o
Inclined position Rotated
UK (USA) 1FR
EN/ISO L 45/PA
Terminology
Butt Weld Features
10
8
2
1
5
Terminology
Fillet Weld Features
10
4
9
7
2
3
1
6
TWI
Main Responsibilities
Code compliance
Workmanship control
Documentation control
TWI
Personal Attributes
Honesty
Integrity
Knowledgeable
Good communicator
Physically fit.
TWI
During welding.
After welding.
Welding Checklist
Before Welding Commences
Welding Checklist
During Welding
Welding Checklist
Welding Completion
Welding Checklist
In the event of repair
Authorization for repair
Removal and preparation for repair
Testing of repair - visual and NDT
Features to Consider
Butt welds - Size
Weld cap width
Excess weld
metal height
Root penetration
Root bead width
Features to Consider
Fillet welds - Size
Minimum and
maximum leg
length size
Minimum design
throat thickness
Features to Consider
Butt welds - Profile
Features to Consider
Fillet welds - Size
Features to Consider
Butt welds - Toe Blend
Features to Consider
Fillet welds - Toe Blend
Features to Consider
Butt welds - Weld Width
TWI
Weld Defects
Cracks
Surface irregularities
Contour defects
Root defects
Miscellaneous
TWI
Weld Defects
Other associated defects
Cavities
Solid inclusions
Set up irregularities
Parent material defects
TWI
Cracks
The four essential crack mechanisms
Hydrogen (HICC)
Solidification (Hot tears)
Reheat cracks
Lamellar tearing
Welding Defects
Cracks
Classified by Shape
Longitudinal
Transverse
Branched
Chevron
Classified by Position
HAZ
Centreline
Crater
Fusion zone
Parent metal
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Cracks
Lamellar tearing
Welding Defects
Cracks
Solidification
Occurs during weld solidification process
Steels with high sulphur content (low
ductility at elevated temperature)
Requires high tensile stress
Occur longitudinally down centre of weld
eg Crater cracking
Cracks
Welding Defects
Hydrogen Induced
Requires susceptible grain structure, stress and
hydrogen
Hydrogen enters via welding arc
Hydrogen source - atmosphere or contamination of
preparation or electrode
Moisture diffuses out into parent metal on cooling
Most likely in HAZ
Cracks
Welding Defects
Lamellar Tearing
Step like appearance
Occurs in parent material or HAZ
Only in rolled direction of the parent material
Associated with restrained joints subjected to
through thickness stresses on corners, tees and
fillets
Requires high sulphur or non-metallic inclusions
Cracks
Welding Defects
Re-Heat Cracking
Occurs mainly in HAZ of low alloy steels during
post weld heat treatment or service at elevated
temperatures
Occurs in areas of high stress and existing defects
Prevented by toe grinding, elimination of poor
profile material selection and controlled post weld
heat treatment
Surface irregularities
TWI
Undercut
An irregular groove at the toe of a weld run in
the parent metal
Excessive amps/volts
Excessive travel speed
Incorrect electrode angle
Excessive weaving
Incorrect welding technique
Electrode too large
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Overlap
An imperfection at the toe or root of a weld caused by
metal flowing on to the surface of the parent metal
without fusing to it
Contamination
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Crater Pipe
Depression at the end of a weld that has a insufficient
cross section.
Contamination
TWI
Contour Defects
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Root Defects
Low Amps/volts
Large Root face
Incomplete root fusion
Contamination
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Root Defects
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Root Defects
A shallow groove caused by contraction in the weld
metal along each side of the penetration bead
Shrinkage groove
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Root Defects
A localized collapse of the weld pool due to excessive
penetration resulting in a hole in the root run
High Amps/volts
Small Root face
Large Root Gap
Slow Travel Speed
Burn through
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Miscellaneous Defects
Accidental striking of
the arc onto the parent
material
Faulty electrode holder
Poor cable insulation
Arc strike
TWI
Miscellaneous Defects
Excessive current
Damp electrodes
Contamination
Spatter
TWI
Gas Cavities
Gas pore
Cluster porosity
Blow hole
Herringbone porosity
Root piping
TWI
Solid Inclusions
Slag inclusions are defined as a non-metallic inclusion
caused by some welding process
Slag originates from welding
flux
Slag inclusions
Lack of sidewall
fusion with
associated slag
TWI
Set-up Irregularities
Linear Misalignment
(Hi-Lo)
Poor fit-up
Angular Misalignment
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Lap
Lamination
Segregation line