A spot welded Lap joint*

A fillet welded Lap joint*

Text Page Ref 1:9/10
Example Slide of User Functions
Relevant course text section:page/pages if applicable
Time guide the slide
should be finished by
Indicates a click is required to progress to the next element
A Joint:* A configuration of members
A Weld:*
A union between materials caused by heat,
and or pressure
Text Page Ref 1:1
Butt welds:*
Fillet welds:*
Spot/Seam welds:*
Plug/Slot welds:*
Edge welds:*
Closed
corner
Open
corner*
T joints: *
Lap joints: *
Corner joints:*
Butt joints: *
This has major effects on economics and distortion control etc
The root face, root gap and angle of bevel values, the choice of
single, or double sided preparations, are dictated only by the type
of welding process, the position and accessibility of the joint*
The basic rule is this:
The more you take out, then the more you must put back in*
Remember, the purposes of a weld preparation is to allow access
for the welding process, penetration and fusion through the area
of the joint and its faces*
Angle of bevel*
Included angle*
Root gap*
Root face*
Root radius*
Root landing*
Single V
Single bevel
Single J
Single U*
Double bevel
Double V
Double J
Double U*
A butt welded butt joint*
A fillet welded butt joint*
A compound welded butt joint*
A butt welded T joint*
A fillet welded T joint*
A compound welded T joint*
A compound welded Lap joint*
A spot welded Lap joint*
A fillet welded Lap joint*
A butt welded Closed Corner joint*
A fillet welded Closed Corner joint*
A compound welded Closed Corner joint*
An outside fillet welded Open Corner joint*
An inside fillet welded Open Corner joint*
A double fillet welded Open Corner joint*
1 2
4 3
A
B
A + B = Excess Weld Metal**
Weld Face*
Weld Width*
Design Throat Thickness* 1.2.3.4. Weld Toes*
Fusion Boundary*
Fusion Zone*
Weld Root*
HAZ*
Actual Throat Thickness*


Weld face*
Vertical Leg Length*
Horizontal Leg Length*
Design throat*
Actual throat*
Excess weld metal **


s = Effective throat thickness

s

a

a = Nominal throat thickness

Deep throat fillet welds from FCAW & SAW etc*
*
80
20
6 mm
3 mm*
Very Poor Weld Toe Blend Angle
Improved Weld Toe Blend Angle
Extremely poor toe blend, but excess weld metal is within limits*
It is also possible that the height of excess weld metal is within
the accepted limit of an applied standard, but the toe blend is
unacceptable, as shown below*
3 mm
90
Weld Sizing (Fillets): DTT. ATT. Excess weld metal. Leg length *
Weld Sizing (Butts): DTT. ATT. Excess weld metal.
Weldment Terms: Weld face & root. Fusion zone & boundary. HAZ.
Weld toes.Weld width
Preparation Terms: Bevel/included angle. Root face/gap. Land/Radius
Types of Preparation: Bevels. Vs. Js. Us. Single & Double Sided.
Types of Joint: Butt. T. Lap. Corner (Open & Closed)
Types of Weld: Butt. Fillet. Spot. Seam Plug. Slot. Edge.
Weld Preparation: Preparing a joint to allow access and fusion.
Joint: A Configuration of members
Weld: A Union of materials
Describe your duties to your code of practise. CSWIP Exam*
It is the duty of all welding inspectors:
To ensure that welding operations are carried out in
accordance with written, or agreed practices or
specifications
Before
During
After
*
Discuss the following
1) Safety:
Legislation and safe working practices
2) Documentation:
Spec. Drawings. Procedures. Welder approvals. Certificates. Mill sheets
3) Welding Process and ancillaries: Equipment.
Cables. Regulators. Ovens. Quivers etc
4) Incoming Consumables:
Materials/welding consumables (Size. Condition. Specification. Storage)
5) Marking out preparation & set up:
Method. Angles/Root face/gap values. Distortion control. Pre-heat prior to
tack welding if applicable*

Before Welding:
During Welding:
1) Pre-Heating. (Method and control)
2) In process distortion control (Balance or sequence welding)
3) Consumable control. (Correct baking and storage prior to use)
4) Welding process (Related parameters i.e. volts/amps. gas flow rate)
5) Welding run sequence and inter-pass cleaning
6) Minimum/maximum Inter-pass temperatures
7) Full compliance with all elements given on the WPS*

After Welding:
1) Visual Inspection
2) Non Destructive testing
3) Repairs*
4) Repair procedures (NDT/Excavation/Welding/Welder approval)
5) PWHT
6) Hydro-static testing
7) Submission of all inspection reports to QC departments*


To Record
To Compare
To Observe Activities &
Imperfections*
Activities &
Imperfections*
Activities &
Imperfections*
Honest
Literate
Respected
Dedicated
Impartial
Observant
Decisive
Analytical*
Knowledgeable
Experienced
Record keeping skills
Communication skills
Safety conscious
Inquisitive
Responsible
Diplomatic skills*
Some attributes/skills of an effective Welding Inspector:*
A Welding Inspectors toolbox should contain*
A welding gauge (Cambridge style, or high low gauges etc)
A tape measure and scale
A wire brush
A magnifying glass
A torch and mirror
A specification, pen and report, or note paper
Any other aids to visual inspection*
Inspection may utilise the following specialised equipment:*
Boroscopes (For assessing root runs in small pipes)
Flow-meter (For measuring gas flow rates in MIG/MAG/TIG)
Simple NDT equipment (Penetrants and MPI)
Complex NDT equipment (Radiography or Ultrasonics)
Note: Both simple and complex NDT methods requires the
specialised skills of qualified operators/technicians*

Welding imperfections can be categorized into groups:
3) Solid Inclusions
4) Lack of fusion
1) Cracks
6) Mechanical or Surface damage
5) Profile & Lack of Filling
2) Gas Pores & Porosity
7) Misalignment*
A HAZ hydrogen crack, initiated at the weld toe
Most cracks are initiated from stress concentrations *
Surface breaking porosity

Fine cluster porosity

Blow hole > 1.6 mm

Hollow root bead


An isolated internal porosity

Coarse cluster porosity
Shrinkage cavity*


Internal solid inclusion causing
a lack of sidewall fusion
Surface breaking solid inclusion

Internal solid inclusion causing
a lack of inter-run fusion*

Solid inclusions caused by
undercut in the previous weld run
Internal solid inclusion
Lack of root fusion

Overlap (Causing cold laps)

Lack of inter-run fusion

Lack of sidewall fusion

Lack of sidewall fusion &
incompletely filled grove*

An Incompletely filled groove

Lack of root fusion

Spatter

A

Poor toe blend

Bulbous, or irregular contour
Arc Strikes

Incomplete root penetration

B

*
Root concavity


Excess penetration, and burn through

Root oxidation in Stainless Steel

Crater pipe
Shrinkage grooves

*
Root Run or Hot pass undercut
Parent metal, surface undercut


Weld metal, surface undercut*


Weld metal, surface undercut

Parent metal, top toe undercut*

Any surface damage caused by:
Grinding
Hammering/chisel marks
Slag chipping hammer marks
Torn cleats (Hammered off attachments)
Arc strikes
All of the above may cause serious weakness to the weld area*
Linear misalignment measured in mm

3 mm

Angular misalignment measured in degrees*

15

Excess weld metal height
Lowest plate to highest point
Linear
Angular
Why ?* To establish the level of mechanical properties*
Which properties ?*
4) Ductility*
3) Tensile strength*
2) Toughness*
1) Hardness*
Hardness:*
Toughness:* The ability of a material to absorb impact energy
Tensile strength:* The ability to resist the action of a pulling force
Ductility:* The ability to deform plastically under tension*
Mechanical:*
Describes the actions of force & motion
Properties:* Something that makes one material useful for a
job. These include the properties of:
The ability of a material to resist indentation
We test welds to establish minimum levels of mechanical
properties, and soundness of the welded joint*
We divide tests into Quantitative & Qualitative methods:*
1) Quantitative tests: (Have units)*
2) Qualitative tests: (Have no units)*
Types of tests include:
1) Quantitative tests:
Hardness tests
Toughness tests
Tensile strength tests*
2) Qualitative tests:
Macro tests
Bend tests
Fracture tests*
The test weld is usually cut into sections as follows:
The location of specimens will depend upon the standard
Tensile test
Charpy V test Bend test*
Macro/Hardness test
Start/ Stop
The specimen below has been polished and is
ready to be hardness tested
= Hardness Survey
Further hardness surveys may be taken as the thickness
of the specimen increases*

Thickness
Base metal HAZ Fusion boundary Weld metal
Generally we use a diamond or steel ball to form an indentation
We measure the width of the indentation to gauge the hardness*
1) Vickers Diamond Pyramid: Always uses a diamond*
2) Brinell hardness test: Always uses a steel ball*
3) Rockwell hardness test:
Uses a ball, or diamond
depending on the scale*
10 x 10 mm Machined notch
Pendulum Hammer
Location of specimen
The specimen may be tested from different areas of the weld.*
Graduated scale
of absorbed
energy in Joules*
1) Charpy V test: 10 x 10 (Specimen horizontal) Joules*
2) Izod test: 10 x 10 (Specimen vertical) Ft.lbs*
3) CTOD test:
Specimen used is actual design size.
Detailed fracture report. mm*
Testing temperature
Joules absorbed
Ductile Fracture
47 Joules
28 Joules
Transition
Zone
Transition Temperature Range
Mn < 1.6 % increases
toughness in steels*
Brittle Fracture
Three specimens are normally
tested at each temperature.
-40 -30 -20 -10 0 +10 +20 +30 + 40
Transverse reduced test piece*
A Section of weld is cut, or machined out across the test piece
and tested in tension to failure. The units are usually in N/mm
Weld


HAZ


Plate material


Test gripping area


Radius
(For radius reduced test specimens only)


Reduced Section


Used to assess the tensile strength of the weld metal
Direction of test


Tensile test piece cut
along weld specimen.
Direction of the test *
BS 709 / BS En 10002
All Weld Metal Tensile Testing
Firstly, before the tensile test 2 marks are made 50mm apart
During the test, Yield point & Tensile strength are measured
The specimen is put together and the marks are re-measured
A new measurement of 75mm will indicate Elongation E50 %*
50 mm
75 mm
3) Lack of Root Fusion
1) Excess Weld Metal Height
8) Poor Toe Blend*
4) Slag inclusion & Lack of inter-run fusion
2) Lack of Sidewall Fusion
5) Root Penetration
6)Porosity
7) Laminations
Bend tests are used to establish fusion in the area under test
Former
Test Piece
Lack of root fusion shown here*
Further tests include face, side and longitudinal bend tests*
For material over 12 mm thickness, side bend test may be used*
Force
A Guided root bend test*
Guide
Specimen prior to test* Specimen after test*
Saw cut
Hammer blow
Full fracture
Any strait line indicates a
Lack of root fusion*
1
3
1
Fracture line
1
2
3
Inspect both surfaces
2
2 3

Line of fusion
X
Y
X
A
B
Inclusions on fracture line*
C
Lack of root penetration
or fusion
Hammer blow Saw Cuts
Fracture line
I nspect both surfaces
We test welds to establish minimum levels of mechanical
properties, and soundness of the welded joint
We divide tests into Qualitative & Quantitative methods:*
Qualitative: (Have no units)
Macro tests
Bend tests
Fillet weld fracture tests
Butt Nick break tests*
Quantitative: (Have units)
Hardness (VPN & BHN)
Toughness (Joules & ft.lbs)
Strength (N/mm
2
& PSI)
Ductility/Elongation (E%)
The main difference between Macro & Micro is that Micro is
the study of the micro-structure at much higher magnification
The limit of Macro inspection is magnification < X 10
The specimen is usually cut from a stop/start in the test piece
The cut specimen is polished to a fine finish (400 grit)
The specimen must be inspected, before etching*
Remember! The process of inspection is to first:
Observe, then Report, then Compare!*
Use the TWI macro sheets provided to observe and then
make a report on a separate sheet of what you observe*
When you have finished reporting, turn the macro sheet
over and compare your observations with those given on
the back of the sheet* (1 hour)
A definition of the term Procedure?*
A systematic method of producing an aim*
Therefore, a Welding procedure is?*
A systematic method of producing a sound weld*
Most procedures are approved, but not all?
An approved welding procedure is one that has been tested to
ensure that the procedure as carried out, produces a weld that
satisfies a minimum level of quality for the mechanical, physical
or chemical properties desired. If these are not required, then
procedural approval is unnecessary*
Do all welding procedures need to be approved?*
Most production welding procedure are formatted on written
documents or computer spreadsheets, but they need not be written
and may be a product of experience
Do all welding procedures need to be written?*
What do you think about the following statements?*
A Welding Procedure is a recipe of variable parameters, which
will produce the same results of certain quality & properties if
carried out in the same way each time*
To evaluate a Provisional Welding Procedure we need to
check if all the parameters set will work together to produce
the desired results*
.*
Once the weld has been completed it is usually visually
inspected, then Radiography or Ultrasonic testing is usually
applied*
If all the desired properties have been met, then a procedure
qualification record (WPQR or WPAR) is completed with all
the test results, and the procedure then becomes qualified*
Finally, and most importantly, Mechanically tested to ensure
that the desired level of mechanical properties have been met*
A CSWIP 3.2 Senior Welding Inspector is normally responsible for the
testing and approval of welding procedures*
From this data, a workable document for production welding is
prepared and called a Welding Procedure Specification. (WPS)*
a) Diameter of pipe, or thickness of plate
b) Welding position, amperage range, or number of runs
c) Process (On multi process procedures only)
d) Certain material groups
e) Change of consumable to one of the same classification
Only if the class is given in the original procedure
f) Heat input range (kJ/mm)*
Examples of Extents of Approval include:*
Once the procedure has been approved it is then important to
test each welder, to ensure that he has the skill to reach the
minimum level of quality in the weld, as laid down in the
application standard*
There is no need to carry out the mechanical tests of the
procedure, although bend tests are often used to ensure good
side wall fusion
Normally; visual, x ray, bends, fractures and macros are used
in welder approval tests*

1) Check the welding process, condition of equipment and test area for suitability.
2) Check that extraction systems, goggles and all safety equipment are available.
3) Check grinders, chipping hammers, wire brush and all hand tools are available.
4) Check materials to be welded are correct and stamped correctly for the test.
5) Check welding consumables specification, diameter, and treatment with WPS.
6) Check the welders name and stamp details are correct.
7) Check that the joint has been correctly prepared and tacked, or jigged.
8) Check that the joint and seam is in the correct position for the test.
9) Explain the nature of the test and check that the welder understands the WPS.
10) Check that the welder carries out the root run, fill and cap as per the WPS.
11) Ensure welders identity and stop start location are clearly marked.
12) Supervise or carry out the required tests and submit results to Q/C department.*
When supervising a welder test the welding inspector should:*
A CSWIP 3.1 Welding Inspector is normally responsible for the
supervision and testing of welder approvals *