Visual Welding Inspector: Course Reference D 73

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TWI

Visual Welding Inspector


Part 1

Course Reference D 73
TWI

CSWIP Examination Requirements

# Butt Weld Inspection


Code reference : CSWIP PH6/WI/00
Time Given : 1 Hour 30 minutes
# Fillet Weld Inspection
Code reference : ISO 5817 ( Level D)
Time Given : 1 Hour 15 minutes
Butt Joints
Terminology
• Square Edged, Open and Closed

• Single Vee, Butt and Bevel

• Double Vee, Butt and Bevel


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Terminology Joint Types

Edge Corner Lap

Tee
Cruciform
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Terminology Joint Welds

Compound Fillet Butt

Edge Spot Plug


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Types of Joint Preparation
Included angle 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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Types of Joint Preparation

Angle of Angle of
bevel bevel

Root
Radius

Root Face Root Gap Root Face


Root Gap Land

Single Bevel Butt Single J Butt


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Weld Zone Terminology
Weld zone

Weld metal Heat affected


zone

Fusion zone Root Weld Junction


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Butt Weld Features

Weld cap width


Excess weld metal

Excess root penetration Root bead width


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Fillet Weld Features

W
Vertical leg length

el
d
fa
ce
Design throat
thickness

Horizontal leg length


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Fillet Weld Features

a = Design/ Nominal throat thickness

b = Actual throat thickness


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Fillet Weld Profiles

Mitre fillet Convex fillet

Concave fillet
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Welding Positions
Flat position

UK (USA) 1G rotated UK (USA): 1G


ISO/EN PA ISO/EN: PA

vertical
position

UK (USA) 2G Fixed UK (USA): 2G


ISO/EN PC ISO/EN: PC
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Welding Positions
Vertical Vertical
up down
UK (USA) 3G UK (USA) 3G
ISO/EN PF ISO/EN PG

Vertical Position
Overhead Position Pipe fixed Horizontal
UK (USA) 4G UK (USA) 5G
ISO/EN PE ISO/EN PF, PG
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Welding Positions

45o 45o

Inclined position fixed Inclined position Rotated


UK (USA) 6G UK (USA) 1FR
EN/ISO H-LO45 EN/ISO L 45/PA
Terminology
Butt Weld Features
10

7 8
9
2
1

5 3 4

6
Terminology
Fillet Weld Features

10
4
9
7
2 5

3 8
1

6
Visual Inspection Procedures
• 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 to?
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Main Responsibilities

Code compliance

Workmanship control

Documentation control
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Personal Attributes
Honesty

Integrity

Knowledgeable

Good communicator

Physically fit.
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Duties of a Welding Inspector

Before Welding.
before assembly.
after assembly.

During welding.

After welding.
Welding Checklist
Before Welding Commences

• Familirization to the relevant code and specification


• Check welding equipment and calibration certificates
• Material identification,size,type and condition
• Consumables type,size,condition,storage and handling
• Review/witness WPS and PQR test and record
• Joint preparation( check)
• Welder qualification test( Review/witness)
• Welding process involved
• Check pre-heating before welding ( if required)
Welding Checklist
During Welding
• Check weather condition
• Check clearance for welding/welder
• Check welder identification for weld
• Check consumables as per WPS used
• Check welding parameters as per WPS used
• Check distortion control
• Check interpass cleaning
• Check run out length ( travel speed)
• Check interpass temperature
• Check usage of line up clamps
• Maintain daily log book
Welding Checklist
Welding Completion
• Perform visual inspection
• Weld and welder identification ( check)
• Post weld heat treatment ( if required)
• Non-destructive Testing ( witness)
• Acceptance standards of NDT
• Repairs (if any)
• Dimensional check ( as per drawing)
• Document control - welding reports etc
Welding Checklist
In the event of repair
• Authorization for repair
• Removal and preparation for repair
• Testing of repair - visual and NDT
How Do I Carry Out a Visual
Inspection?
• 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
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 design
Minimum and throat thickness
maximum leg
length size
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
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Weld Defects
Defects which may be detected by visual
inspection can be grouped under five headings
Cracks

Surface irregularities

Contour defects

Root defects

Miscellaneous
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Weld Defects
Other associated defects

Cavities

Solid inclusions

Set up irregularities

Parent material defects


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Cracks
The four essential crack mechanisms

Hydrogen (HICC)

Solidification (Hot tears)

Reheat cracks

Lamellar tearing
Welding Defects
Cracks
Classified by Shape Classified by Position
• Longitudinal • HAZ
• Transverse • Centreline
• Branched • Crater
• Chevron • Fusion zone
• Parent metal
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Cracks

Longitudinal parent metal crack Transverse weld metal crack

Longitudinal weld metal crack 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
Welding Defects
Cracks
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
Welding Defects
Cracks
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
Welding Defects
Cracks
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
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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

 Slow travel speed

 Incorrect welding
technique
 Current too high
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Crater Pipe
Depression at the end of a weld that has a insufficient
cross section.

 Too fast a cooling rate

 Deoxidization
reactions and liquid to
solid volume change
Crater crack
 Contamination
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Contour Defects

Incomplete filled groove Poor cap profile

Incomplete filled groove Excessive cap height


+ Lack of sidewall fusion
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Root Defects
 Low Amps/volts
 Large Root face

Incomplete root fusion


 Small Root Gap
 Fast Travel Speed
 Incorrect Electrode
Angle
Incomplete root penetration  Contamination
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Root Defects
A shallow groove, which may occur in the root of a butt weld

 Root faces too large


 Root gap too large
 Excessive back purge
pressure during TIG welding
Concave root
 Excessive root bead grinding
before the application of the
second pass
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Root Defects
A shallow groove caused by contraction in the weld
metal along each side of the penetration bead

 Insufficient weld metal


deposited in the root
pass
 Too fast a cooling rate
during the application of
Shrinkage groove the root bead pass
 Poor welding technique
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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

 Poor return lead


Arc strike clamping
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Miscellaneous Defects
 Excessive current

 Damp electrodes

 Contamination

 Incorrect wire feed


speed when welding
with the MAG welding
Spatter process
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Gas Cavities
Gas pore Cluster porosity  Loss of gas shield
 Damp electrodes
 Contamination
Blow hole  Arc length too large
Herringbone porosity
 Damaged electrode flux
 Moisture on parent
material
 Welding current to low
Root piping
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Solid Inclusions
Slag inclusions are defined as a non-metallic inclusion
caused by some welding process
 Slag originates from welding
flux
 MAG and TIG welding
process produce silica
Slag inclusions Lack of sidewall inclusions
fusion with
associated slag  Slag is caused by
inadequate cleaning
 Other inclusions include
tungsten and copper
inclusions from the TIG and
Parallel slag lines MAG welding process
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Set-up Irregularities

Linear Misalignment
(Hi-Lo)

Poor fit-up

Angular Misalignment
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Parent Material Defects


A welding inspector should also inspect the parent
material for any visible defects

Mechanical damage Lap

Lamination

Segregation line

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