Visual Welding Inspector: Course Reference D 73
Visual Welding Inspector: Course Reference D 73
Visual Welding Inspector: Course Reference D 73
Course Reference D 73
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Tee
Cruciform
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Terminology Joint Welds
Angle of
bevel
Root
Radius
Angle of Angle of
bevel bevel
Root
Radius
W
Vertical leg length
el
d
fa
ce
Design throat
thickness
Concave fillet
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Welding Positions
Flat position
vertical
position
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
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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Before Welding.
before assembly.
after assembly.
During welding.
After welding.
Welding Checklist
Before Welding Commences
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
Hydrogen (HICC)
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
Excessive weaving
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.
Deoxidization
reactions and liquid to
solid volume change
Crater crack
Contamination
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Contour Defects
Root Defects
A shallow groove caused by contraction in the weld
metal along each side of the penetration bead
Root Defects
A localized collapse of the weld pool due to excessive
penetration resulting in a hole in the root run
High Amps/volts
Miscellaneous Defects
Accidental striking of
the arc onto the parent
material
Faulty electrode holder
Miscellaneous Defects
Excessive current
Damp electrodes
Contamination
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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Lamination
Segregation line