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MACRO-SECTION.

TWI
CSWIP 3.1

WELDING INSPECTION
MACRO-SECTION.
PRACTICAL
Section 25.
World Centre for Materials Joining Technology
Copyright © 2005, TWI Ltd

MACRO SECTIONS
1. ASSESS THE MACRO PHOTOGRAPH FOR WELD
DEFECTS.
2. RECORD THE MAJOR DEFECTS ON THE
REPORT SHEET.
3. SENTENCE THE DEFECTS RECORDED TO THE
ACCEPTANCE CRITERIA GIVEN.

4. FOLLOW THE INSTRUCTIONS.
PLEASE DO NOT MARK THE PHOTOGRAPHS.
World Centre for Materials Joining Technology
Copyright © 2005, TWI Ltd

MACRO INSTRUCTIONS.

World Centre for Materials Joining Technology
Copyright © 2005, TWI Ltd

MACRO DEFECTS. 50mm 3mm ANGULAR DISTORTION = 3mm in 50mm World Centre for Materials Joining Technology Copyright © 2005. TWI Ltd .

5mm MISALIGNMENT World Centre for Materials Joining Technology Copyright © 2005. TWI Ltd .MACRO DEFECTS. INCOMPLETLEY FILLED GROOVE 1.

TWI Ltd COLD LAP & POOR TOE BLEND . COLD LAP & POOR TOE BLEND EXCESSIVE WELD METAL GAS PORE / BLOW HOLE World Centre for Materials Joining Technology Copyright © 2005.MACRO DEFECTS.

TWI Ltd .Macro defects INCOMPLETELY FILLED GROOVE World Centre for Materials Joining Technology Copyright © 2005.

MACRO DEFECTS. TWI Ltd . LACK OF SIDE WALL FUSIO N LACK OF SIDE WALL FUSION & SLAG LACK OF SIDE WALL FUSION / INCOMPELTELY FILLED GROOVE World Centre for Materials Joining Technology Copyright © 2005.

MACRO DEFECTS. TWI Ltd . COLD LAP LACK OF SIDEWALL FUSION / INCOMPLETELY FILLED GROOVE GAS PORES LACK OF ROOT FUSION World Centre for Materials Joining Technology Copyright © 2005.

TWI Ltd . INCOMPETELY FILLED GOOVE SLAG INCLUSION GAS PORE LACK OF ROOT FUSION World Centre for Materials Joining Technology Copyright © 2005.MACRO DEFECTS.

MACRO DEFECTS. LACK OF SIDEWALL FUSION LACK OF SIDEWALL FUSION & SLAG LACK OF SIDEWALL FUSION LACK OF ROOT PENETRATION World Centre for Materials Joining Technology Copyright © 2005. TWI Ltd LACK OF SIDEWALL FUSION .

MACRO SECTIONS QUESTIONS. TWI Ltd . World Centre for Materials Joining Technology Copyright © 2005.

LACK OF SIDEWALL FUSION CLUSTER / WORMHOLE POROSITY LAMINATIONS LACK OF INTER-RUN FUSION & SLAG LACK OF SIDEWALL FUSION & SLAG LACK OF INTER-RUN FUSION GAS PORES ROOT UNDERCUT World Centre for Materials Joining Technology Copyright © 2005.MACRO DEFECTS. TWI Ltd .

TWI Ltd 2 LACK OF SIDEWALL FUSION & GAS / SILICA .MACRO SAMPLE. WELDING PROCESS : MAG 1 COLD LAP 5 LACK OF SIDEWALL FUSION 4 LACK OF INTERRUN FUSION 3 COLD LAP World Centre for Materials Joining Technology Copyright © 2005.

MACRO NOTE: PHOTOGRAPH IS AT X10 MAGNIFICATION MATERIAL: LOW CARBON STEEL WELDING PROCESS: [MAG/GMAW] 8 9 7 6 # 1 2 3 4 5 6 7 8 9 10 DEFECT POOR TOE BLEND OVERLAP + 2 SMALL PORES LAMINATIONS/INCLUSIONS LACK OF SIDE WALL FUSION AS ABOVE +PORES OVERLAP LACK OF INTERRUN FUSION GAS PORE/PIPE LACK OF SIDE WALL FUSION + SILICA ANGULAR MISALIGNMENT 11 EXCESS WELD METAL 12 EXCESS PENETRATION 1 SIZE World Centre for Materials Joining Technology Copyright © 2005. TWI Ltd 5 3 2 4 ACCEPT/REJECT Assess To Specification .

World Centre for Materials Joining Technology Copyright © 2005.MACRO ACCEPTANCE. TWI Ltd .

D: AM1030] CHECK PHOTOGRAPH I.D MATCHES THIS REPORT I.MACRO EXCERCISES. TWI Ltd .AM1030 TRAINING SAMPLE ONLY MACRO INSTRUCTION/REPORT SHEET [I.D ALL DEFECTS TO BE REPORTED [AND SIZED IF REQUIRED] THEN SENTENCED TO ISO 5817 LEVEL B [STRINGENT] NOTE: PHOTOGRAPH IS AT X10 MAGNIFICATION MATERIAL: LOW CARBON STEEL WELDING PROCESS: [MMA/SMAW] 8 7 4 6 5 1 2 3 World Centre for Materials Joining Technology Copyright © 2005.

TWI Ltd ACCEPT/REJECT Reject .2 N/A Reject Accept 0.6 0. AM 1030 # 1 2 3 4 5 6 7 8 9 10 11 12 DEFECT Lack of side wall fusion and slag Misalignment Lack of root penetration Angular distortion Lack of side wall fusion Lack of inter run fusion and slag Lack of side wall fusion Excess weld metal SIZE 8.2 2.5 3.MACRO EXCERCISES.2 Accept Reject Reject Reject Reject COMMENTS: SIGNATURE: DATE: PRINT FULL NAME: World Centre for Materials Joining Technology Copyright © 2005.5 2.5 4.

D ALL DEFECTS TO BE REPORTED [AND SIZED IF REQUIRED] THEN SENTENCED TO ISO 5817 LEVEL B [STRINGENT] NOTE: PHOTOGRAPH IS AT X10 MAGNIFICATION MATERIAL: LOW CARBON STEEL WELDING PROCESS: [MMA/SMAW] 8 9 1 2 7 3 6 5 World Centre for Materials Joining Technology Copyright © 2005. TWI Ltd 4 .D: AM1031] CHECK PHOTOGRAPH I. AM 1031 TRAINING SAMPLE ONLY MACRO INSTRUCTION/REPORT SHEET [I.MACRO EXCERCISES.D MATCHES THIS REPORT I.

TWI Ltd ACCEPT/REJECT Reject Reject Reject Reject Reject Reject Accept Reject Reject .3 0.5 3. AM 1031 # 1 2 3 4 5 6 7 8 9 10 11 12 DEFECT Lack of side wall fusion/ underfill Lack of side wall fusion and slag Cold lap Misalignment Excess penetration Cold lap Slag inclusion Cold lap Excess weld metal SIZE 0.7 0.5 0.7 7.5 COMMENTS: SIGNATURE: DATE: PRINT FULL NAME: World Centre for Materials Joining Technology Copyright © 2005.5 1.8 3.3 0.MACRO EXCERCISES.

D MATCHES THIS REPORT I.D ALL DEFECTS TO BE REPORTED [AND SIZED IF REQUIRED] THEN SENTENCED TO ISO 5817 LEVEL B [STRINGENT] NOTE: PHOTOGRAPH IS AT X10 MAGNIFICATION MATERIAL: LOW CARBON STEEL WELDING PROCESS: [MMA/SMAW] 8 1 3 4 5 7 6 2 World Centre for Materials Joining Technology Copyright © 2005. TWI Ltd .D: AM1032] CHECK PHOTOGRAPH I.MACRO EXCERCISES. AM 1032 MACRO INSTRUCTION/REPORT SHEET [I.

8 2.5 1. AM 1032 # 1 2 3 4 5 6 7 8 9 10 11 12 DEFECT Lack of side wall fusion/underfill Lack of sidewall fusion & Slag Lack of side wall fusion & slag Slag inclusion Cold lap Misalignment Excess penetration Excess weld metal COMMENTS: SIZE 0. TWI Ltd ACCEPT/REJECT Reject Reject Reject Reject Reject Reject Accept Reject .8 4.MACRO EXCERCISES.0 3.5 0.3 Plate laminations noted SIGNATURE: DATE: PRINT FULL NAME: World Centre for Materials Joining Technology Copyright © 2005.3 1.5 2.

D MATCHES THIS REPORT I. AM 1033 TRAINING SAMPLE ONLY MACRO INSTRUCTION/REPORT SHEET [I.MACRO EXCERCISES. TWI Ltd .D ALL DEFECTS TO BE REPORTED [AND SIZED IF REQUIRED] THEN SENTENCED TO ISO 5817 LEVEL B [STRINGENT] NOTE: PHOTOGRAPH IS AT X10 MAGNIFICATION MATERIAL: LOW CARBON STEEL WELDING PROCESS: [MAG/GMAW] 8 1 6 5 4 3 7 2 World Centre for Materials Joining Technology Copyright © 2005.D: AM1033] CHECK PHOTOGRAPH I.

6 1.6 2.0 2.3 0.0 0. TWI Ltd ACCEPT/REJECT Reject Reject Reject Accept Reject Reject Reject Reject .0 Plate laminations noted Poor toe blend SIGNATURE: DATE: PRINT FULL NAME: World Centre for Materials Joining Technology Copyright © 2005.8 8.5 5. AM 1033 # 1 2 3 4 5 6 7 8 9 10 11 12 DEFECT Cold Lap/ Overlap Lack of sidewall fusion & gas Cold lap / Overlap Misalignment Lack of interrun fusion & gas Lack of sidewall fusion Blow hole Excess weld metal COMMENTS: SIZE 2.MACRO EXCERCISES.

TWI Ltd 4 . AM 1034 TRAINING SAMPLE ONLY MACRO INSTRUCTION/REPORT SHEET [I.D ALL DEFECTS TO BE REPORTED [AND SIZED IF REQUIRED] THEN SENTENCED TO ISO 5817 LEVEL B [STRINGENT] NOTE: PHOTOGRAPH IS AT X10 MAGNIFICATION MATERIAL: LOW CARBON STEEL WELDING PROCESS: [MMA/SMAW] 9 10 1 2 8 3 7 6 5 World Centre for Materials Joining Technology Copyright © 2005.D MATCHES THIS REPORT I.D: AM1034] CHECK PHOTOGRAPH I.MACRO EXCERCISES.

8 1.5 0.1 5. TWI Ltd ACCEPT/REJECT Reject Reject Reject Accept Reject Reject Reject Reject Accept Reject .6 Plate laminations noted Poor toe blend SIGNATURE: DATE: PRINT FULL NAME: World Centre for Materials Joining Technology Copyright © 2005.0 2.0 6in13 0. AM 1034 # 1 2 3 4 5 6 7 8 9 10 11 12 DEFECT Lack of sidewall fusion & slag Lack of sidewall fusion Lack of inter-run fusion & slag Angular distortion Misalignment Excess penetration Lack of inter-run fusion & slag Lack of side wall fusion Spatter Excess weld metal COMMENTS: SIZE 2.1 3.5 5.0 0.MACRO EXCERCISES.

Macro defects World Centre for Materials Joining Technology Copyright © 2005. TWI Ltd .

Macro defects World Centre for Materials Joining Technology Copyright © 2005. TWI Ltd .

Macro defects World Centre for Materials Joining Technology Copyright © 2005. TWI Ltd .

TWI Ltd .Macro defects World Centre for Materials Joining Technology Copyright © 2005.

Macro defects World Centre for Materials Joining Technology Copyright © 2005. TWI Ltd .

Macro defects World Centre for Materials Joining Technology Copyright © 2005. TWI Ltd .

TWI Ltd .Macro defects World Centre for Materials Joining Technology Copyright © 2005.

Macro defects World Centre for Materials Joining Technology Copyright © 2005. TWI Ltd .

TWI Ltd .Macro defects World Centre for Materials Joining Technology Copyright © 2005.

TWI Ltd .Macro defects World Centre for Materials Joining Technology Copyright © 2005.