THE IMPORTANCE OF WELDING QUALITY CONTROL

K.M. WONG & Scarlett YEUNG

A.E.S. Destructive & Non-Destructive Testing Ltd.
1 INTRODUCTION
Welding is an inevitable manufacturing process in steel fabrication. Design and
quality control in welding have important implications in the stability and robustness
of the final architecture. A comprehensive welding quality control program would
enhance the efficiency of welding projects and eliminate failure costs [1]. An
effective quality control program [2] consists of compliance check at every step of
fabrication. Test plan is required to be established in order to confirm the integrity of
items in the fabrication project and non-destructive tests are usually included in such
plan. Negligence of these quality control procedures would lead to considerable loss
as demonstrated by some typical failure examples given below.
2 NON-DESTRUCTIVE TEST
Some popular non-destructive testing techniques used in steel fabrication are
penetrant test, magnetic particle test, radiographic test, ultrasonic test and visual
examination. They are used, according to their different applications, as the
compliance check throughout the fabrication process.
2.1 Penetrant Test
Penetrant test locates and determines the severity of surface discontinuities in variety
of both metallic and non-metallic materials based on capillary action. Dwell time is
required for the penetrant to enter the discontinuities. Advantages of penetrant test
are its simplicity, portability, high sensitivity and applicability to all types of metallic
materials. Disadvantages of this type of test are slow in speed, limitation to surface
discontinuities and not suitable for dirty and rough surface.
2.2 Magnetic Particle Test
Magnetic particle test detects discontinuities in ferromagnetic materials by
establishing magnetic field in the materials. Minute poles are set up at the
discontinuities of the material in the path of magnetic flux since these poles have a
stronger attraction for the magnetic particles than the surrounding surface of the
material. Merits of this test are its rapidity, portability, high sensitivity and relative
low cost. Limitations of this test are its low accuracy with thick coating,
demagnetisation effort and applicable to magnetic materials only.
2.3 Radiograhic Test
Radiographic test, a well-established technique, uses X-ray or gamma-ray to produce
an image of an object on film. The technique is widely used to detect internal flaws in
weldments and castings. Advantages of this test are its capability of subsurface
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discontinuities detection, applicability on all types of materials and availability of
permanent record. Disadvantages of this test are requirement of access to both sides
of test material, limitation of flaw orientation and flaw types, radiation hazard and
dependence on the experiences of film reviewer.
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2.4 Ultrasonic Test
Ultrasonic test detects, locates and evaluates internal discontinuities in metals and
other materials by directing a high frequency sound beam into a test material on a
predictable path which, upon reflecting back from an interruption in material
continuity, produces a wave that is amplified and usually displayed as a vertical
displacement on a cathode ray tube. Ultrasonic test is a true volumetric test and
requires only one side to access a test material. Equipment is fully portable and
critical flaws can be found in a relatively safe way. The drawbacks of this test are
slow in speed, requirements of high operator skill and smooth test surface, limited
applicability on butt welds and test restriction on the geometrical shape of a test
material.
2.5 Visual Examination
Visual examination is the original non-destructive testing method. It is used as a
continuing basis in the fabrication sequence in order to make the quality control
program effective. Dimensional and weld joint preparation checks are examples of
visual examination. The main reason of continuing visual examination in the
fabrication is to rectify problems soon after any non-compliance is found. It
eliminates the chance of minor problem in early stage of fabrication developed into
major defect at the end of fabrication sequence.
3 TYPICAL FAILURE EXAMPLES
Failure of welded parts is usually due to welding problems and lack of quality control
procedure. Listed below are typical examples caused by incorrect welding practices
and non-compliances to quality control requirements.
3.1 Example I
A tower crane was suddenly collapsed during its daily operation resulting in the death
of the crane operator. The accident was due to the failure of the weld on the crane
foundation. A completed review showed that the root causes of failure were due to
poor welding quality, poor design and improper installation of the crane foundation.
Improvement could be made by modifying the crane foundation design and taking a
better method of installation. Maintenance practice could be adopted amongst
operating staff by arranging a simple daily check.
3.2 Example II
A 200 tons compression machine installed in an aluminium factory was broken down
after being put into service for only one and a half month. The failure was due to the
presence of a cold crack arising from a poor welding control and a loose quality plan.
The cold crack could be avoided under a stringent welding design and quality control
procedure.
3.3 Example III
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A huge lifting tool in an oil platform at the South China Sea was fractured after
undergoing a repair process. Welding was used as a means of repair and its purpose
was to refill worn-off area of the lifting tool with weld metal. The welded part was
fractured in a normal operation after the repair. The reason was due to the high
strength alloy of the lifting tool as it was not suitable for welding. Another important
point was the negligence of the quality plan as no preheat procedure was performed
prior to welding. The lifting tool cracked eventually because of the welding stress
imposed on the base materials causing the item to failure.
3.4 Example IV
A batch of handrail made of aluminium alloy was rifted before it was put into service.
The welded part of the handrail was found favourable to crack. The quality problems
were due to incorrect selection of welding process and poor quality welding control.
4 CONCLUSION
Comprehensive quality control together with a proper implementation of quality
control program would avoid or, at least, reduce the chance of loss and failure. There
are different types of tests used to verify correct implementation and compliance of
quality control program. The most popular test methods are magnetic particle test,
penetrant test, radiographic test, ultrasonic test and visual examination. A few typical
examples of failure relating to welding problems and absence of quality control
procedures were briefly reviewed.
REFERENCE
[1] BS EN ISO 9004-1: 1994. Quality Management and Quality System Elements
Guidelines.
[2] American Welding Society (1995). Welding Inspection Technology, 2
nd
Edition.