TWI “im ‘THE WELDING INSTITUTE INTERNAL DEFECTS & THEIR INTERPRETATION During interpretation it is necessary to identify associated defects, e.g. example 1. Report 1: Incomplete root penetration and root fusion In the above sketch incomplete root penetration can be seen but, because of the loss of penetration, incomplete root fusion is also present. Planar defects such as incomplete sidewall, incomplete inter-run and incomplete root fusion are very often associated with the presence of a non ‘metallic inclusion, typically slag for MMA and SA and deoxidiser residue for MIG and TIG (ferritic steels). e.g. example 2. Process MAG In this example incomplete sidewalll fusion is present. Because the defect also has width it can largely be associated with a ‘silica’ Inclusion, Report 1: Incomplete sidewall fusion with associated silica dioxide inclusion (and dimension). WELDING TECHNOLOGY Issue 0191 244Twi NN! THE WELDING INSTITUTE ‘The sketch below shows a root penetration/fusion defect caused because of either insufficient root gap or no back gouging; on examination incomplete sidewall fusion has resulted because of poor access, e.g. example 3. Process MMA CS Report: 1) Incomplete root penetration and root fusion 2) _ Incomplete sidewall fusion* 3) Incomplete sidewall fusion* *Your judgement will be necessary in order to determine any associated inclusion. ‘As previously mentioned, slag and silica inclusions are associated with specific processes. With regard to interpretation the Inspector must confirm the welding process in order to make an accurate assessment. This may be by reference to the welding procedure or by assessment of the weld face. Slag inclusions will be clearly volumetric against silica inclusions which will have length and limited width, e.g. example 4.. Slag inclusions or silica inclusions? 3 Ww Report: 1) _ Slag Inclusion 2) Silica Inclusion (Incomplete Interpass fusion may also be present) In general terms, slag inclusions are non uniform in their shape, also very often the slag is still visible. WELDING TECHNOLOGY 24.2 Issue 0191TWI ma ‘THE WELDING INSTITUTE Gas inclusions, on the other hand, are generally uniform in their shape and are of a metallic appearance, e.g. example 5. Gas inclusions (pores), porosity or solid inclusions? Report: 1) Slag inclusion } 2) Elongated gas cavity } dimensions required 3) Gas pore } The inspector should report any parent metal defects (laps, laminations and segregation bands) e.g. example 6, Parent metal defects N23 Meneenneatatoaatana 3) Report: 1) Laminations (straight and narrow) 2) Lap {near surface of material) 3) Segregation band (similar to lamination but lacks definite edges (hazy)). “Above are examples for reference, greater detail will be provided during the course. WELDING TECHNOLOGY Issue 0191 24.3