Learning Objectives

Upon completion of this course you will be able to:

 Use recognized welding inspection terminology

 Interpret Welding and Nondestructive Examination Symbols
 Recognize welding quality control elements before, during, and after welding
 Identify welding discontinuities and their causes
 Communicate welding procedure and performance qualifications requirements
 Identify advantages and limitations of destructive and nondestructive testing methods

1. The Welding Inspector: who is the welding inspector?; qualifications; code of ethics;
communications; responsibilities
2. Metric Systems, Welding Terms and Symbols: SI International system of units; basic metric
units; welding terms and definitions; welding positions; elements of and construction of
welding symbols
3. Welding Metallurgy: iron carbon system; iron-iron carbide diagram; diffusion; effect of
cooling rates and alloy addition on transformation
4. Weld Joint Preparation and Temperature Control: checks prior to weld joint preparation;
joint preparation check; preheating and interpass heating; post weld heating; heating processes;
insulation of heated joints
5. Welding and Cutting Processes I: choosing the welding process; imperfections and
discontinuities; oxyacetylene welding; brazing; arc-welding processes, SMAW, GMAW,
FCAW, GTAW, SAW, stud welding, thermal and mechanical cutting
6. Welding and Cutting Processes II: electrogas welding; plasma arc welding; resistance
welding; flash; upset; adhesive bonding; percussion; solid state electron and laser beam;
thermal; welding of plastics; soldering
7. Welding Procedure and Welding Operator Qualifications: welding procedure
specifications; joint designs; welding positions; heat input; preheat and interpass temperatures;
removal of weld section for repair; post heat treatment
8. Codes Governing Welding Inspection: structural welding code; ASME boiler and pressure
vessel code; spot examination of welded joints; duties of the inspector; ASTM standards; API
standards
9. Weldment Imperfections and Discontinuities: classification of discontinuities; base metal
discontinuities; methods of testing; glossary of weld imperfections
10. Chemical, Metallurgical and Mechanical Testing of Welds: comparison of destructive and
nondestructive tests; chemical tests; forms of corrosion; testing for corrosion resistance;
metallographic test
11. Visual and Liquid Penetrant Inspection: selection of NDT method; relationship of welding
processes; discontinuities and inspection methods; visual inspection prior to, during and after
welding
12. Magnetic Particle and Radiographic Inspection: magnetic particle inspection; type of
magnetizing current; demagnetization; interpretation of patterns; nonrelevant indications;
radiographic sources; detectable discontinuities
13. Ultrasonic Inspection: advantages; limitations; criteria for successful inspection; test
equipment; techniques
14. Eddy Current Inspection, Acoustic Emissions, Proof Tests and Leak Tests: eddy current
inspection; fundamentals; inspecting welding pipe and tubing; applications; acoustic emissions;
types of emissions; inspection of pressure vessels

The following tools and methods will be used in class on engineered and actual welded connections:

 Hi/Lo gauge- for examination of joint fit up.

 Convex Fillet Weld Gauges- for determining size of convex fillet welds.
 Concave Fillet Weld Gauges- for determining size of concave fillet welds.
 Undercut gauge (V-WAC)- checking depth of undercut or pitting or height of reinforcement.
 Bridgecam Gauge- is a unique, versatile tool applied to the inspection of welded surfaces and
joints.
 Extension mirror
 Flashlight
 Magnifying glass

When using the above methods to assess quality, participants will be instructed on determining
acceptance according to the following common industry standards:

 CSA Standard W59 Welded Steel Construction

 AWS D1.1 Structural Welding Code – Steel
 ASME B31.1 Power Piping
 ASME B31.3 Process Piping

TOPICS INCLUDE:
1. Design

i. Drawings and
symbols
ii. Design concepts
iii. Codes specifications
and standards
 2. Materials

i. Base metals
ii. Welding consumables
iii. Welding metallurgy

3. Production

i. Preparation for
welding
ii. Production methods
iii. Health and safety
iv. Elements of
supervision

4. Welding

i. Processes
ii. Welding equipment
iii. Welding consumables
iv. Distortion and stress

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.

This page contains visual inspection tips. The following pages contain inspection
methods for GMAW and physical weld testing.

These tests reveal weak or defective sections that can be corrected before the
materiel is released for use in the field. The tests also determine the proper
welding design for ordnance equipment and forestall injury and inconvenience to
personnel.
NDT refers to nondestructive testing. It is an approach to testing that involves
evaluating the weld without causing damage. It saves time and money including
the use of remote visual inspection (RVI), x-rays, ultrasonic testing and liquid
penetration testing.

In most welds, quality is tested based on the function for which it is intended. If
you are fixing a part on a machine, if the machine functions properly, then the
weld is often considered correct. There are a few ways to tell if a weld is correct :

 Distribution: Weld material is distributed equally between the two

materials that were joined.
 Waste: The weld is free of waste materials such as slag. The slag after
cooling should peel away from the project. It should be removed easily. In
Mig welding, any residue from the shielding gas should also be removed
with little problem. Tig, being the cleanest process, should also be waste
free. In Tig, if you see waste, it usually means that the material being
welded was not cleaned thoroughly.
 Porosity: The weld surface should not have any irregularities or any
porous holes (called porosity). Holes contribute to weakness. If you see
holes it usually indicates that the base metal was dirty or had an oxide
coating. If you are using Mig or Tig, porosity indicates that more shielding
gas is needed when welding. Porosity in aluminum welds is a key
indicator of not using enough gas.
 Tightness: If the joint is not tight, this indicates a weld problem. In
oxyacetylene welding, if using autogenous welding, where there is no filler
material, the weld must be tight. Same for Tig autogenous welding. The
gap is not as critical in other types of welds since any gap is filled in by the
filler material. That said, gaps, in general, indicate a potential quality
problem.
 Leak-Proof: If you are repairing an item that contains liquid, a leak is a
sure-fire way (and obvious way) to see that there is a problem. Same for
something that will contain a gas. One testing method is to use soap
bubbles to check for problems (can be easily applied with a squirt bottle.
 Strength: Most welds need to demonstrate the required strength. One way
to ensure proper strength is to start with a filler metal and electrode rating
that is higher than your strength requirement.
Other checks using visual methods include checks before (root face, gap, bevel
angle, joint fit), during (electrode consumption rate, metal flow, arc sound and
light), and after welding (undercut, root fusion issue, pinholes, excessive spatter,
weld dimensions) as described below.

Common Weld Faults

Incomplete Penetration
This term is used to describe the failure of the filler and base metal to fuse
together at the root of the joint. Bridging occurs in groove welds when the
deposited metal and base metal are not fused at the root of the joint. The
frequent cause of incomplete penetration is a joint design which is not suitable for
the welding process or the conditions of construction. When the groove is welded
from one side only, incomplete penetration is likely to result under the following
conditions.

1. The root face dimension is too big even though the root opening is
adequate.
2. The root opening is too small.
3. The included angle of a V-groove is too small.
4. The electrode is too large.
5. The rate of travel is too high.
6. The welding current is too low.
Lack of Fusion
Lack of fusion is the failure of a welding process to fuse together layers of weld
metal or weld metal and base metal. The weld metal just rolls over the plate
surfaces. This is generally referred to as overlap. Lack of fusion is caused by the
following conditions:

1. Failure to raise to the melting point the temperature of the base metal or
the previously deposited weld metal.
2. Improper fluxing, which fails to dissolve the oxide and other foreign
material from the surfaces to which the deposited metal must fuse.
3. Dirty plate surfaces.
4. Improper electrode size or type.
5. Wrong current adjustment.
Undercutting

Undercutting is the burning away of the base metal at the toe of the weld.
Undercutting may be caused by the following conditions:
 1. Current adjustment that is too high.
2. Arc gap that is too long.
3. Failure to fill up the crater completely with weld metal.
Slag Inclusions
Slag inclusions are elongated or globular pockets of metallic oxides and other
solids compounds. They produce porosity in the weld metal. In arc welding, slag
inclusions are generally made up of electrode coating materials or fluxes. In
multilayer welding operations, failure to remove the slag between the layers
causes slag inclusions. Most slag inclusion can be prevented by:

1. Preparing the groove and weld properly before each bead is deposited.
2. Removing all slag.
3. Making sure that the slag rises to the surface of the weld pool.
4. Taking care to avoid leaving any contours which will be difficult to
penetrate fully with the arc.
Porosity
Porosity is the presence of pockets that do not contain any solid material. They
differ from slag inclusions in that the pockets contain gas rather than a solid.

The gases forming the voids are derived form:

1. Gas released by cooling weld because of its reduced solubility temperature

drops.
2. Gases formed by the chemical reactions in the weld.
Porosity is best prevented by avoiding:

1. Overheating and undercutting of the weld metal.

2. Too high a current setting.
3. Too long an arc.
Visual Inspection (VT)
Visual inspection is a non-destructive testing (NDT) weld quality testing
process where a weld is examined with the eye to determine surface
discontinuities. It is the most common method of weld quality testing.

Advantages of nondestructive weld quality testing:

 Inexpensive (usually only labor expense)

 Low cost equipment
 No power requirement
 Quick identification of defects and downstream repair costs due to issues
that weren’t caught early
Disadvantages:

 Inspector training necessary

 Good eyesight required or eyesight corrected to 20/40
 Can miss internal defects
 Report must be recorded by inspector
 Open to human error
Visual Weld Quality Testing Steps
1. Practice and develop procedures for consistent application of approach
2. Inspect materials before welding
3. Weld quality testing when welding
4. Inspection when weld is complete
5. Mark problems and repair the weld
Visual Weld Equipment
Fillet Weld Gauge
Fillet Weld Gauge is an essential weld quality testing tool. It is used to check fillet leg size,
checking fillet throat size
Shown: Estone 7 Piece Fillet Weld Set Gage Gauge Welding Inspection Test
Ulnar MM & inch MG11
Several pieces of equipment are required for visual weld quality testing:

 Weld handheld fillet gauge measures:

 flatness of the weld
 convexity (how the weld is welded outward)
 concavity (how the weld is rounded inward)
 Protective lenses with pocket viewer and shade lens for use when
observing the welding process
 A magnifying glass per the code in your area
 Flashlight
 Chisel and hammer for spatter and slag removal before the weld is
inspected
  Temperature device (Tempelstick, Pyrometer) to determine the
preheating, interpass and post-heating temperatures.
 Magnet to indicate the type of material being welded
 Tape measure
 Calipers

Visual Inspection Before Welding

 Check drawings
 Look at weld position and how ti corresponds to the specification. Watch
the vertical direction of travel
 Check fillet welding symbols
 Does procedure align with local codes and the weld specification
Weld Material Inspection

 Do the materials purchased match the specification for base metal size
and type? Check electrode size, gas selection and grade.
 Check materials for defects. Look for contaminants such as rust, scale,
mill, lamination etc.
 Are materials prepared for correct angles
Assembly Inspection

Follow these weld quality testing steps for assembly inspection:

 Check for fit

 Alignment of fixtures and jigs. Check cleanliness (look for spatter from
previous jobs)
  Check quality if tack welds are used. The tack weld must be made with the
same electrode as the main weld (s).
 Check use of pre heat to slow the cooling rate and to minimize distortion
Equipment Inspection
 Check for damage (cables, ground clamps, electrode holder).
 Check arc voltage
 Check amperage meter for range against specification
Visual Inspection During Welding
 Check electrodes for size, type and storage (low hydrogen electrodes are
kept in a stabilizing oven)
 Watch root pass for susceptibility to cracking
 Inspect each weld pass. Look for undercut and required contour. Ensure
the weld is cleaned properly between each pass.
 Check for craters that need to be filled
 Check weld sequence and size. Gauges are used to check size.
Inspection After Welding
 Check weld against code and standards
 Check size with gauges and prints
 Check finish and contour
 Check for cracks against standards
 Look for overlap
 Check undercut
 Determine if spatter is at acceptable levels
Gas Weld Testing
Inspection weld quality testing criteria for gas welds:

 The weld should be of consistent width throughout. The two edges should
form straight parallel lines.
 The face of the weld should be slightly convex with a reinforcement of not
more than 1/16 in. (1.6 mm) above the plate surface. The convexity should
be even along the entire length of the weld. It should not be high in one
place and low in another.
 The face of the weld should have fine, evenly spaced ripples. It should be
free of excessive spatter, scale, and pitting.
 The edges of the weld should be free of undercut or overlap.
 Starts and stops should blend together so that it is difficult where they have
taken place.
 The crater at the end of the weld should be filled and show no holes, or
cracks.
For Butt Joints:
If the joint is a butt joint, check the back side for complete penetration through the
root of the joint. A slight bead should form on the back side.

For Fusion of Lap and T-joint Testing:

The root penetration and fusion of lap and T-joints can be checked by putting
pressure on the upper plate until it is bent double. If the weld has not penetrated
through the root, the plate will crack open at the joint as it is being bent. If it
breaks, observe the extent of the penetration and fusion at the root. It will
probably be lacking in fusion and penetration.