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Welding Inspection

Presenter
Steve Cave
Senior P & EW Instructor

WELDING PRESENTATION
By
Steve Cave
The Certified Welding Inspector (CWI) plays an important
role during any welded construction activities ensuring the
required specifications and standards are followed. Due to
the numerous materials and processes associated with
metal joining (welding) THIS PRESENTATION SHALL
SHOW ONLY THE BASIC WELDING PROCESSES AND
EXAMINATION METHODS (NDE). National and
International Codes and Specifications along with measuring
devices are the Inspectors tools. Hopefully the following
presentation shall give an insight into basic welding
inspection.

How To Prevent Weld


Failure

Weld Failures

Today welding is the most common method used for joining


steel fabrications largely because of the speed at which joints
can be made and the reliability of these joints in service.
However because most welding operations are now relatively
simple to perform it is all too easy to forget the complexity of
the chemical and metallurgical actions that are taking place

Overload

Before applying the various design formulas, the problem itself


must be analyzed and clearly stated. This is not always
obvious, and trying to solve the wrong problem can quickly
lead to insufficient design stresses. When a load is placed on a
member, stress and strain result. Stress is the internal
resistance to the applied force. Strain is the amount of "give or

Overload
For example of this is a lifting lug on a pressure vessel. If the
vessel is lifted by a spreader beam the loading condition on
the lug consists of a simple vertical force putting the
attachment welds either in tension or shear. However if the
vessel is lifted with a rope sling the loading condition
becomes more complex because there is now a horizontal
component of the force to consider as well a the vertical one,
which effectively increases the loading on the welds.

Joint Design

A welded joint should be designed such that the welder can


easily manipulate the electrode to ensure good fusion,
particularly in the root of the joint. The profile of each run
should be roughly as wide as it is deep; wide shallow weld
beads and particularly deep narrow beads are both ideal
candidates for hot cracking.

Hot Cracking
This type of cracking occurs when the weld is starting to
solidify, in the pasty state, as it posses very little strength and
therefore any residual loading is likely to cause it to break
before it has fully solidified. The problem can be
compounded by impurities that are forced out of the
solidifying weld, becoming trapped in the center of the weld
during final solidification. Hot cracking can occur where their
is a high degree of restraint in the structure of the fabrication
or where the structure moves slightly as the weld solidifies.

Hot Cracking
A good example of this type of failure is on the weld used to
secure the small plug in the mandrill hole of a spun dished
head on a pressure vessel, a weld that many people do not
take seriously because of its size. As the weld cools it
contracts causing the plug to move , if the weld at the other
side of the plug is still solidifying it could easily fail. This is
because of the very high contraction stresses generated by
the plug as the weld starts to solidify.

Bad Welding Methods


It is very important when carrying out any welding to ensure
that it is done correctly. Consideration has to be given to all
aspects of the process and also the environment. Often
welding has to be carried out under site conditions, the
welding is often carried out in situation so that small general
purpose electrodes are used resulting in low weld heat input
which when combined with no preheat gives very rapid heat
dissipation Which can create a hard micro structure
particularly in the location of the heat affected zone.

Bad Welding Methods


This along with high levels of residual stress will create the
ideal condition for hydrogen induced cracking, which although
normally associated with high strength steels can occur in low
carbon steels if the conditions are right. The resulting crack
may not occur immediately the weld cools down but some time
afterward, therefore if this type of failure is expected non
destructive examination should be delayed by at least 48 hours
after welding.

Metallurgical failure
Materials that are to be welded have to tolerate severe
thermal transients created by the welding process without
suffering deterioration of their mechanical properties or
adverse phase changes. The metallurgical composition or
temper conditions of certain types of metal may make them
unsuitable to weld or may require special controls to be
imposed during the welding operation. For example some
steels that are easy to machine may contain high levels of
sulphur that may result in cracking of any attaching weld.
Therefore this type of material should not be used on load
bearing fabricated items such as the eye bolts that are often
found holding down man way covers on pressure vessels.

Weld Defects
They can usually be attributed to the welders inability to set up
and manipulate the welding equipment; although bad joint
design and faulty welding equipment can also be responsible.
The most significant defects are cracks and those that
resemble cracks such as lack of fusion, cold overlap etc. This
is because of the risk that the crack may become unstable and
propagate when loaded causing a dramatic failure often by
brittle fracture

Weld Defects
Porosity seldom causes weld failure in multi-run welds
however it is a sign that something has gone wrong with
welding operation and can often be caused by other defects
that may not have been detected such as lack of side wall
fusion. Weld profile can also cause failure, if the weld size is
too small because the joint is underfilled with weld then its
load carrying capability will be reduced, if the joint contains
excessive weld metal this can create a notch effect which
can lead to failure by fatigue if the loading condition
fluctuates.

Weld Defects
Bad fit up excessive root penetration on single sided welds
can create defects in the root of the weld such as wormholes
and even cracking. Distortion of welded joints can cause
failure by buckling if the welded member is subjected to
compressive loads.

Conclusion
To minimize these problems the following points should be
considered
1
. Design of the weld based on the loading condition(s) the joint will carry
2
. Accessibility to enable ease of welding
3
. Control of distortion
4
. Careful consideration of the welding environment
5
. Matching welding process with materials
6 A factor of safety applied to the design stress of the weld which should be based on the
. consequence of weld failure and the level of non destructive testing that is to be carried out.

Welding Inspection
Duties of a Welding
Inspector

Duties Prior to Welding

Obtain all relevant


documentation
Relevant specifications.
Relevant procedures.
Copies of welders test test
certificates.
Copies of drawings.

Duties Prior to Welding

Obtain all relevant documentation


Ensure welder qualification.
Correct material type condition etc.
Correct equipment with certificates.
Correct consumables type
condition, size.
Correct pre heat.

Duties Prior to Welding

Assess / measure fit up


Root face.
Bevel angle.
Root gap.
Alignment.
Joint cleanliness.
Ensure no undue stress is applied to
the joint.

Duties During welding

Check amperage, voltage, polarity.


Ensure correct welding technique.
Ensure correct welding direction.
Check welding time.
Ensure adequate cleaning between
passes.
Correct interpass temperature.

Duties During welding

Check root internally.


Check all back gouged welds.

Duties After welding

Ensure welds are post cleaned.


Visual inspection of welds for defects.
Visually check for arc strikes.
Check weld contour and weld width.
Ensure joint is covered to retard
cooling rate.
Ensure monitor post weld heat
treatment.

Duties After welding

Report on weld.
Check NDT reports where needed.

Welding Processes

Shielded Metal Arc


Welding

Gas Metal Arc Welding

Tungsten Arc Welding

Submerged Arc Welding

Problems Associated With


Incorrect Weld Joint Fit Up

Root Problems
Gap size too large:
b) burnthrough
a) excess penetration

c) shrinkage grooves

d) gas entrapment

Root Problems
Gap size too small:
1) incomplete penetration

2) incomplete root fusion

4) slag inclusions

3) incomplete side wall fusion

5) root concavity

Root Problems
Root face too large:

a) incomplete root penetration

b) incomplete root fusion

Root Problems
Root face too small:
1) excessive
penetration

3) root concavity

2) burnthrough

4) root undercut

Included Angle Too large

a) excess penetration

b) incomplete filled groove

Fillet Welds
Gap size too large:

1) reduced root penetration

2) slag inclusions

3) gas inclusions
4) reduced vertical
leg length size

5) cracking

Included Angle Too Small


1) incomplete root
penetration

3) incomplete root fusion

5) excessive cap

2) incomplete interun fusion

4) incomplete sidewall fusion

6) poor toe blend

7) slag
inclusions

Visual Inspection of Welds

Butt Weld Size


a) excess weld metal height

b) root penetration

c) weld width

d) root bead width

Fillet welds (size)


Consider:

a) z minimum (and maximum) leg


length size

b) a minimum design
throat thickness

Shape (Butt Welds)


Consider:
Ideally, (a) is the most desirable
but very often it may be difficult
to achieve. Because of this, one
should assess the excess weld
height in conjunction with the
weld profile and perhaps the
toe blending.

Shape (Fillet Welds)


Consider:

In normal practice, (a) is the most


desirable but, again, in many instances
it is difficult to achieve. Acceptance
levels, therefore, allow tolerances on
weld shape.

Toe Blend (Butt Welds)


For butt welds,
consider:

In normal practice, (a) is the


most desirable but, again, in
many instances it is difficult to
achieve. Acceptance levels,
therefore, allow tolerances on
weld shape.
Depending on the service
conditions of the product, the
toe blend may be of greater
importance than the size and
shape of the weld. A poor toe
blend may reduce service life by
a considerable margin if the
product is under a cyclic load.

Toe Blend (Fillet Welds)


For fillet welds,
consider:

In normal practice, (a) is the


most desirable but, again, in
many instances it is difficult
to achieve. Acceptance levels,
therefore, allow tolerances on
weld shape.

Root Defects
Incomplete root penetration
Failure of weld metal to extend into the root of a

Lack of root fusion


Lack of union at the root of a joint
Excess penetration bead
Excess weld metal protruding through the
root of a fusion weld made from one side
only

Root Defects
Root concavity
(suck-back; underwashing - non-standard
terms)
A shallow groove which may occur in the root
of a butt weld, but full fusion is evident

Shrinkage groove
A shallow groove caused by contraction in the
metal along each side of a penetration bead o
along the weld centreline
Burnthrough
(melt through)
A localised collapse of the molten pool
due to excessive penetration, resulting in
a hole in the weld run

Contour Defects

Incompletely filled groove


A continuous or intermittent
channel in the surface of a
weld, running along its length,
due to insufficient weld metal.
The channel may be along the
centre or along one or both
edges of the weld

Bulbous Contour

Bulbous contour
A non-standard term used to
describe poor appearance

Unequal Legs
Unequal legs
(non standard term)
Variation of leg length on a fillet weld
Note: Unequal leg lengths may be
specified as part of the design - in
which case they are not imperfections

Undercut
Undercut
An irregular groove at a toe of a run
in the parent metal or in previously
deposited weld metal
The inspector must determine if the
undercut is continuous or
intermittent, or sharp or smooth

Overlap

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

Gas Pore
Gas pore
A cavity, generally under
1.5mm in diameter,
formed by trapped gas
during the solidification of
molten metal
Porosity
A group of gas pores

Crater Pipe

Crater pipe
A depression due to shrinkage at the end
of a run where the source of heat was
removed. Crater pipes may also lead to
micro-cracking

Surface Cracks
Crack
A linear discontinuity produced by fracture
Cracks may be ...
a) ... longitudinal, in the weld metal, i.e. centreline

b) ... longitudinal, in the parent metal or heat affected

c) ... transverse

d) Crater crack
(star cracking)

Arc Strike
Stray flash/arc burn/arc strike
(stray arcing)
1. The damage on the parent material
resulting from the accidental striking
of an arc away from the weld
2. The accidental striking of an arc
away from the weld
Note that the same term is used for
both the action and the result

Weld Width
Weld width and consistency of weld
width

For butt welds and fillet


welds, consider:

Weld Defects

Lack of Side Wall Fusion

Lack of Inter Run Fusion

Porosity

Slag Inclusions

Incomplete Root Fusion


/Penetration

Solidification Cracking

Overlap

Excess Weld Metal

Excess Penetration

Root Concavity

Slag Inclusion

Surface Breaking Porosity

Cracking

Arc Strikes

Crater Pipe

Using Welding Inspection


Tools

Weld Profile Gauge


Scale in
inches or
mm

Measurin
g
Fillet
Welds

Measuring Cap
Reinforcement/
Misalignment

Measuring
Bevel
Angle

Hi Lo Gage

Measures Hi Lo
Pipe Thickness
Bevel Angle

Using the tools

Throat Thickness (WPG)


Fillet Weld

Cap Reinforcement (WPG)

Measurin
g the
height of
the cap

Bevel Angle (WPG)


Readout
Measurin
g the
pipe
bevel
angle

Misalignment (WPG)
Shown
on scale

Misalignment (Hi Lo)


Pipe
Misalignment

Non Destructive Testing

Visual Inspection
Visual inspection is the one NDT
method used extensively to evaluate
the condition or the quality of a weld or
component. It is easily carried out,
inexpensive and Visual inspection is the
one NDT method used extensively to
evaluate the condition or the quality of
a weld or component. It is easily carried
out, inexpensive and usually doesn't
require special equipment.

Radiography
X-rays are produced by high voltage x
ray machines whereas gamma rays
are produced from radioactive
isotopes such as Iridium 192 The xray or gamma rays are placed close
to the material to bc inspected and
they pass through the material and
are then captured on film This film is
then processed and the image is
obtained as a series of gray shades
between black and white.

Magnetic Particle
Inspection
Magnetic particle inspection is a method that
can be used to find surface and near surface
flaws in ferromagnetic materials such as steel
and iron.
The technique uses the principle that
magnetic lines of force {flux) will be distorted
by the presence of a flaw in a manner that
will reveal it's presence. the flaw (for
example, a crack) is located from the "flux
leakage", following the application of fine iron
particles, to the area under examination.
There are variations in the way the magnetic

Penetrant Testing
Inspection
Liquid penetration inspection is a method that
is used to reveal surface breaking flaws by
bleed out of a colored or fluorescent dye from
the flaw.

Ultrasonic Testing
Ultrasonic inspection uses sound waves of
short wavelength and high frequency to
detect flaws or measure material thickness.
It is used on aircraft, the power stations
generating plant, or welds in pressure
vessels at an oil refinery or paper mill.

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