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Overview
To ensure the satisfactory performance of a welded structure, the quality of the welds
must be determined by adequate testing procedures. Therefore, they are proof tested
under conditions that are the same or more severe than those encountered by the
welded structures in the field. These tests reveal weak or defective sections that can be
corrected before the materiel is released for use in the field.
This chapter is designed to give you an understanding of what to look for and how to
test the finished weld using nondestructive and destructive methods. The weld should
be inspected for undercut, overlap, surface checks, cracks, or other defects. Also, the
degree of penetration and side wall fusion, extent of reinforcement, and size and
position of the welds are important factors in the determination as to whether a welding
job should be accepted or rejected, because they all reflect the quality of the weld.
Always refer to the American Welding Society for guidance.
Objectives
When you have completed this chapter, you will be able to do the following:
1. Describe nondestructive testing.
2. Describe destructive testing.
Prerequisites
None
This course map shows all of the chapters in Steelworker Basic. The suggested training
order begins at the bottom and proceeds up. Skill levels increase as you advance on
the course map.
Gas Cutting
Introduction to Welding
During fabrication, visual examination of a weld bead and the end crater may reveal
problems such as cracks, inadequate penetration, and gas or slag inclusions. Among
the weld detects that can be recognized visually are cracking, surface slag in inclusions,
surface porosity, and undercut.
NAVEDTRA 14250A 12-4
On simple welds, inspecting at the beginning of each operation and periodically as work
progresses may be adequate. Where more than one layer of filler metal is being
deposited, however, it may be desirable to inspect each layer before depositing the
next. The root pass of a multipass weld is the most critical to weld soundness. It is
especially susceptible to cracking, and because it solidifies quickly, it may trap gas and
slag. On subsequent passes, conditions caused by the shape of the weld bead or
changes in the joint configuration can cause further cracking, as well as undercut and
slag trapping. Repair costs can be minimized if visual inspection detects these flaws
before welding progresses.
Visual inspection at an early stage of production can also prevent underwelding and
overwelding. Welds that are smaller than called for in the specifications cannot be
tolerated. Beads that are too large increase costs unnecessarily and can cause
distortion through added shrinkage stress.
After welding, visual inspection can detect a variety of surface flaws, including cracks,
porosity and unfilled craters, regardless of subsequent inspection procedures.
Dimensional variances, warpage, and appearance flaws, as well as weld size
characteristics, can be evaluated.
Before checking for surface flaws, welds must be cleaned of slag. Shot blasting should
not be done before examination because the peening action may seal fine cracks and
make them invisible. The AWS Structural Welding Code, for example, does not allow
peening "on the root or surface layer of the weld or the base metal at the edges of the
weld."
Visual inspection can only locate defects in the weld surface. Specifications or
applicable codes may require that the internal portion of the weld and adjoining metal
zones be examined. Nondestructive examinations may be used to determine the
presence of a flaw, but they cannot measure its influence on the serviceability of the
product unless they are based on a correlation between the flaw and some
characteristic that affects service. Otherwise, destructive tests are the only sure way to
determine weld serviceability.
With the scribed lines on the outside and the piece placed so all the bending occurs in
the weld, bend the test piece by using a hydraulic press or similar machine. When the
proper precautions are taken, a blacksmith’s forging press or hammer can be used to
complete the bending operation. If a crack more than 1/16 inch develops during the test,
stop the bending because the weld has failed; otherwise, bend the specimen flat. After
completing the test, measure the distance between the scribed lines and call that
measurement (y). The percentage of elongation is then determined by the formula:
The test specimen is placed across the supports of the die. A plunger, operated from
above by hydraulic pressure, forces the
specimen into the die. To fulfill the
requirements of this test, bend the
specimen 180 degrees—the capacity of the
jig. No cracks should appear on the surface
greater than 1/8 inch. The facebend tests
are made in this jig with the face of the weld
in tension (outside), as shown in Figure 12-
7. The root-bend tests are made with the
root of the weld in tension (outside), as
shown in Figure 12-7
Figure 12-8 shows a machine used for
making the guided-bend test. It is used in
many welding schools and testing
laboratories for the daily testing of
specimens. Simple in construction and easy
to use, it works by hydraulic pressure and
can apply a direct load up to 40,000 Figure 12-7 — Guided-bend test
pounds, and even more on small specimens.
specimens. To test the specimen, place it in
the machine as previously stated and start
to pump the actuator. Keep your eye on the large gauge and watch the load increase.
You will know the actual load under which the test piece bends by the position of an
Summary
This chapter has introduced you to welding quality control. You should now have an
understanding of what to look for and how to test the finished weld using nondestructive
and destructive methods. The weld should be inspected for undercut, overlap, surface
checks, cracks, or other defects. Also, the degree of penetration and side wall fusion,
extent of reinforcement, and size and position of the welds are important factors in the
determination as to whether a welding job should be accepted or rejected because they
all reflect the quality of the weld. The chapter finished up with a description of possible
weld defects and how to identify for them using multiple methods of nondestructive and
destructive tests and inspections. As always, use the manufacturer’s operator manuals
for the specific setup and safety procedures of the welder you will be using.
NAVEDTRA 14250A 12-19
Review Questions (Select the Correct Response)
1. How do you know which tests to use on a weld?
A. Experience
B. Code
C. Type of metal
D. Welding method
A. Ultrasonic
B. Etching
C. Magnetic particle
D. Liquid penetrant
A. ANSE
B. ASTM
C. AWS
D. NRTC
A. Ultrasonic
B. Liquid penetrant
C. Tensile strength
D. Visual
5. Prior to the first welding arc being struck, what visual checks should be made to
the material being welded?
6. Prior to checking a work piece for surface defects, what cleaning method is NOT
authorized?
A. X-rays
B. Liquid penetrant
C. Ultrasonic
D. Magnetic particle
8. What is the visual indication that a flaw exists when using magnetic particle
testing?
9. How do you check the entire surface of the weld using magnetic particle testing?
10. What factors help interpret the test results of a magnetic particle test?
11. How do you check for the presence of a magnetic field in the work piece?
12. How many steps are needed to complete the liquid penetration process?
A. 3
B. 4
C. 5
D. 6
A. 4
B. 3
C. 2
D. 1
A. Dipping
B. Spraying
C. Rolling
D. Immersing
15. What is the normal temperature range for using liquid penetrant?
A. 32° F to 400°F
B. 0 to° F 250°F
C. 40° F to 125°F
D. 98° F to 300°F
16. How many minutes should the developer stay on a work piece?
A. 5
B. 10
C. 15
D. 30
18. How are the vibrations from an ultrasonic transducer imparted to the base metal
being tested?
19. Which of the following tests can be used in the field without elaborate
equipment?
A. Fillet-welded joint
B. Etching
C. Impact
D. Free-bend
A. 1/32
B. 1/16
C. 1/8
D. 1/4
22. When performing a nick-break test, how many inches deep should the end cuts
be on the weld?
A. 1/4
B. 1/2
C. 1
D. No more than half the thickness of the weld
A. Charpy
B. Nike
C. Izod
D. Franklin
24. Which destructive test method does NOT use the actual welded material when
testing?
A. Etching
B. Tensile strength
C. Fillet-welded joint
D. Impact
Description
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(Optional) Correction
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