I Single-Bevel Groove Welds Welded from III Single-U Groove Welds Welded from

One Side with Backing One or Both Sides

1/16 to 3/16
X X 1/4R X 1/4R
X X 1/16 to 3/16

45° 1
Min. /4R
3/16 Max.
3/16 1/16
*3/32 Max. to 3/16 1/8 Max.
R R R Min. 3/16 Max.
*3/32 Max. 5°–10°
*3/32 Max.
Angle X Dim. R Positions *R
Angle X Positions
45° Min. 1/4 Min. All *1/8 Min. 45° Min. All Joint Recommended for
35° Min. 3/8 Min. All *1/4 Min. 20° Min. F, V, O Horizontal Position.
12° Min. F
25° Min. 3/8 Min. F, V, O *1/4 Min.
IV Double-U Groove Welds Welded from Both Sides
X
R X 1/4R 1/16 to 3/16
X 1/16 to 3/16
1/4R

45° Min.

R 3/16 Max.
3/16 Max.
Angle X Dim. R Positions *R *3/32 Max.
5°–10° *3/32 Max.
45° Min. 1/4 Min. All *1/8 Min.
35° Min. 3/8 Min. All *1/4 Min. Angle X Positions Joint Recommended for
45° Min. All Horizontal Position.
20° Min. F, V, O

II Double-Bevel Groove Welds Welded from Both Sides V Single-J Groove Welds Welded from One or Both Sides
1/16 to 1/8 X
45° Min. 45° Min.
X 1/2R
45° Min. 1/8 to 1/4 1/2R 1/16 to 3/16 X 1/2R
*1/8 Max.

3/16 Max.
1/16 to 1/8
3/16 Max.
*3/32 Max.
1/16 Max. *3/32 Max.
1/8 1/16 Max. 3/16 Max.
1/16 Max. to 1/4 1/16 to 1/8 X 1/2R
1/8 to 1/4
*1/8 Max. Angle X Positions *3/32 Max.
*1/8 Max. 35° Min. All
25° Min. F, V, O
3/16 Max.

*3/32 Max.

Fig. 28-24  Recommended dimensions of grooves for shielded metal arc welding, gas metal arc welding, and gas
welding (except pressure gas welding). Note: Dimensions marked * are exceptions that apply specifically to designs for MIG
welding.

also specified. Following a particular procedure ensures
uniform results. Tests that certify welders for codework
may be known as welder qualification tests or perfor-
mance qualification tests. They are given to find out
whether or not the welder has the knowledge and the
skill to follow and apply a procedure of welding as devel-
oped for the class of work at hand. Testing may be with
handheld welding equipment (the stick-electrode holder,
the gas welding torch, or the semiautomatic welding gun)
or with fully automatic welding equipment. Every effort
has been made to simplify these tests so that they can be
administered at low cost and still establish the soundness
of the weld.
Reliability of welding is based on the use of appro-
priate inspection controls. The methods of testing that
determine the quality of a weld are divided into three
very broad classifications: (1) nondestructive testing,
(2) destructive testing, and (3) visual inspection.
A nondestructive test, as the name implies, is any
test that does not damage the weld or the finished prod-
uct. Modern inspection equipment and techniques have
made nondestructive testing an effective inspection tool.

900   Chapter 28   Joint Design, Testing, and Inspection

 I Double-J Groove Welds Welded from Both Sides
1/2R 1/16
X to 3/16 X 1/2R

1/16 to 3/16

35° 1
/2R

3/16 1/16 to 3/16

Max.
3/16Max. 35°
*3/32 Max.
*3/32 Max. 3/16Max.
Angle X Positions *3/32 Max.
35° Min. All
25° Min. F, V, O

II Joint for Plug Weld V Joint for Slot Weld W/2R

45°
W
T
10T Max.
Dia.
T
Dim. T Dia.
Under 1/8 1/4 Min.
Dim. T Dim. W
1/8 to 1/2 2T Min. Under 1/4 2T Min.
Over 1/2 T + 1/2 1/4 and Over 11/2T Min.

III Fillet-Welded Joints VI Double-Fillet Welded Corner Joint

Root Opening T
A = 3/16 Max.
T/2 Min.
1/8
Max.
Root Opening
S = Required Fillet
Size Plus A

IV Three-Piece Joints VII Three-Piece Joints

3/8 Min.

3/32 Min.

3/8 to 1/2 Over 1/2

Fig. 28-25  Recommended dimensions of grooves for shielded metal arc welding,
gas metal arc welding, and gas welding (except pressure gas welding). Note: Dimensions
marked * are exceptions that apply specifically to gas metal arc welding.

Nondestructive testing is usually done by specialists who
have been trained in the use of the equipment and the in-
terpretation of test results. Although the original cost of
the equipment may be high, nondestructive testing can be
the fastest and least expensive of the inspection methods.
Destructive testing, also called mechanical testing, usu-
ally requires that a test specimen be taken from the fab-
rication or that sample plates be welded from which the
test specimens are cut. The weld is damaged beyond use.
Destructive testing is normally used to determine the me-
chanical and metallurgical qualities of a proposed welding
procedure and to determine the ability of a welder before
the actual production work is started.
In visual inspection, which should be the first inspection
method used, the surface of the weld and the base metal are
observed for visual imperfections. Certain inspection tools
and gauges may be used with the observation procedure. Vi-
sual inspection is the testing method most commonly used

Joint Design, Testing, and Inspection   Chapter 28    901

 I Grooved Corner Joint Welded III Modified Square Groove
from Both Sides
1/8 Max.
60° Min.

1.0 Max.

1/16 Max.
Thermal Gouge before
Depositing Second Weld

IV Modified Single-V Groove

45° Min.
45°
1/8
Min.
to 1/4
*1/16 Max.

II U-V Groove Joint

1/8 Max.
Dims. from
Fig. 28-24 III 1/8 Thermal Gouge before
Max. – S. M. A.
Depositing Second Weld
3/32 Max. – G. M. A.

1/4 Min. – S. A. V Single-V Groove for Reduced

Metal Deposit

10° to 20°
3/32 Max. S. M. A.
Dims. from Fig. 28-23 IV and G. M. A.
3/16 Max. Shielded Metal Arc (S. M. A.) 50°
3/16 Min. S. A.
3/32 Max. Gas Metal Arc (G. M. A.) 75°
3/4

1/32 Max. Submerged Arc (S. A.)

3/16 Max. Shielded Metal Arc (S. M. A.)

3/32 Max. Gas Metal Arc (G. M. A.)

1/32 Max. Submerged Arc (S. A.)

Fig. 28-26  Recommended dimensions of mixed grooves for arc welding.

by welders themselves as well as by the welding inspector
and welding supervisor.
This method is highly effective when applied before,
during, and after the welding operation by properly
trained and skilled welders and inspectors. See Table 28-2,
page 904 for an example of a well laid out inspection
program. The American Welding Society has a certifica-
tion program QC-1 to certify welding inspectors at three
different levels. This certification is for visual inspection
only, but additional add-ons are available for other nonde-
structive and destructive methods.
Nondestructive Testing (NDT)
Magnetic Particle Testing
Magnetic particle testing is one of the most easily used
nondestructive tests. It is used to inspect plate edges before
welding for surface imperfections. It tests welds for such
defects as surface cracks, lack of fusion, porosity, under-
cut, incomplete root penetration, and slag inclusions. This
method is limited to magnetic materials such as steels and
cast iron. It cannot be used with such nonmagnetic mate-
rials as the stainless steels, aluminum, and copper. Very
often the method is referred to as the Magnaflux® method.
Magnaflux® is the name of a particular brand of testing
equipment, Fig. 28-29 (p. 905).
Magnetic particle testing, Fig. 28-30, page 905, detects
the presence of internal and surface cracks too fine to be
seen by the naked eye. Defects can be detected to a depth
of 1⁄4 to 3⁄8 inch below the surface of the weld. Defects much
deeper than this are not likely to be found.
The part to be examined must be smooth, clean, dry,
and free from oil, water, and excess slag from the weld-
ing operation. Wire brushing or sandblasting is usually
satisfactory preparation for most welds. The part is mag-
netized by using an electric current to set up a magnetic

902   Chapter 28   Joint Design, Testing, and Inspection

 Consumable Insert Parts Preparation for Aluminum
I IV IX X
30° to 37.5° 30° 30°
10° 1/8 Up
3/8 Max.

1/16R
25°–37°
3/4
.133 1/16– 3/32
.040–.070 1/8
.406
3/16 1/32 Max.
.030–.090
1/16 – 1/8
1/16– 5/32
II
20°–30°
1/8R–1/4R 3/8 Min. Joint Preparation for Critical Applications Using Flat or
1/4 – 5/16 3/32
0–1/32 Taper Machined Backing Rings
XI Taper Ring XII Flat Ring
V T
10° 10°
3/4 Max. 3/4
.032–.065 Max.
D=T= 37.5° 37.5°
.060–.090 .060–.090
III 3/16 3/16
3/8 Min.
3/16R–1/4R 1/16 – 3/16
VI 1 /8 and Greater C C
70°–80°
1/2 Min. 30°
10°
7/32 Min. 1/16 ± 1/32 Bevel
1/8R Min. 1/16 ± 1/32
1/16 – 3/32 0–1/32 1/64– 1/32
3/32 D. Rod
1/16 – 1/8
To Suit Note: C = Outside Dia. – .041 in.–1.75 t
(t = Nominal Wall Thickness)
Prepared Root Joints
VII 20° VIII 20°
3/4 Min. 3/32R 1/16
3/16 Min.

75°

3/32 ± 1/32 3/32 5/32

1/16 ± 1/32 45°
3/32 –1/8

Fig. 28-27  Recommended dimensions of grooves for gas tungsten arc welding processes to obtain controlled and complete
penetration. Note: Dimensions are for steel except as noted.

field within the material or by putting the piece in an “flux leakage.” These poles have a stronger attraction
electric coil. The magnetized surface is covered with a for the magnetic particles than the surrounding surface
thin layer of magnetic powder such as blast resin or red of the material.
iron oxide, Fig. 28-31 (p. 905). Another method uses a Figure 28-32 (p. 906) gives a simple explanation of
fluorescent powder that glows in black light. These pow- the principles of magnetic particle testing. As shown in
ders can be applied dry or they may flow over the sur- Part  1, an open magnet has two poles: north and south.
face if they are in a suspension of oil, water, or any other The magnetic field between the two poles attracts and
low viscosity liquid. The layer of powder can be blown holds a nail. If the magnet is bent until the poles almost
off the surface when there are no defects. If there is a touch, the magnetic field between the two poles attracts
defect, the powder is held to the surface at the defect be- iron powder (Part 2). If the magnet is completely closed
cause the powerful magnetic field in the workpiece sets as in Part 3, it will not attract or hold iron powder because
up a north magnetic pole at one end of the defect and a the magnetic field is in a circle inside the ring and there
south magnetic pole at the other. This is referred to as can be no polarity. This is the reason that the powder can

Joint Design, Testing, and Inspection   Chapter 28    903

 Before After Welding Tube
Before
Cover Pass Welding Sheet Welded
Tube Welding

Root
Pass

Weld Metal Plug Drill Sub-

Before Welded Before sequently
Welded Welding Welding

Annulus

Tube Sheet Drill Tube Sheet

Weld
Before Extrusion After Extrusion Tube

Fig. 28-28  Recommended dimensions of grooves for the welding of tubes to tube sheets.

Table 28-2  Welding Inspection Program

Phase 1 Initial review 1. Review purchase order, all codes, and drawings.
2. Develop all necessary inspection plans.
3. Check welding procedures.
4. Check welder status (determine whether they qualified for the work to be done).
5. Establish inspection documentation system.
6. Publish nonconforming product identification system.
7. Create a corrective action program.
Phase 2 Prewelding checks 1. Check suitability and condition of welding equipment.
2. Check conformance of base and filler materials.
3. Check the positioning of weldments and specific joints.
4. Check joint preparation, fitup, cleanliness.
5. Check fixturing for adequacy of alignment maintenance.
6. Check preheat (or initial) temperature.
Phase 3 During welding inspection 1. Check compliance with the WPS provisions.
2. Check quality and placement of key weld passes.
3. Check weld bead sequencing and placement.
4. Check interpass temperature and cleaning.
5. Check adequacy of back-gouging.
6. Monitor any specified in-process nondestructive examination.
Phase 4 Postwelding activities 1. Check finished weld appearance and soundness.
2. Check weld sizes and dimensions.
3. Check dimensional accuracy of weldment.
4. Carry out or monitor and evaluate specified nondestructive examination.
5. Monitor any PWHT or other postweld work.
6. Finalize and collate inspection documentation.

904   Chapter 28   Joint Design, Testing, and Inspection

Fig. 28-29  A portable magnetic particle testing unit. This
method speeds inspection of welds and stressed areas during
fabrication and repair. The unit can be used both in shop and field. 
© Magnaflux
Fig. 28-30  Remote control used with a magnetic particle test
unit. Welds can be inspected for incomplete penetration and fusion,
slag inclusions, crater cracks, and porosity.  © Magnaflux
Fig. 28-31  A portable magnetic particle test unit checking
critical welds during the construction of a Detroit bank build-
ing. Note the use of magnetic powder as the unit is applied.
© American Welding Society. B1.10M/B1.10:2009, Figure 17, p. 19
be blown off the surface of a weld without defects. If there
is a crack in the weld, a flux leakage will occur at the
crack which will hold the powder (Part 4).
Cracks must be at an angle to the magnetic lines of
force in order to show. The method illustrated by Fig. 28-
32, page 906 (Part 3) applies electrical current directly
to both ends of the piece being inspected. This is often
referred to as a “Headshot.” A magnetic field is produced
at right angles to the flow of current, which may be rep-
resented by circular lines of force within the workpiece
(Part 3). When these lines of force encounter a longitu-
dinal (lengthwise) crack, they leak through and become
points of surface attraction for the magnetic powder
dusted on the surface (Part 4). A transverse (crosswise)
crack would not show because the lines of force would
be parallel with the crack, Fig. 28-33, page 906. This
is known as circular magnetism. Another method is to
magnetize a workpiece by putting it inside a coil. In this
method, the magnetic lines of force are longitudinal and
parallel with the workpiece so that transverse cracks show
up, Fig. 28-34, page 906. This is known as longitudinal
magnetism.
Joint Design, Testing, and Inspection   Chapter 28    905
 Circular Magnetization
1. Open Magnet
N S
2. Partially Closed Magnet
N S
3. Completely Closed Magnet
4. Cracked Magnet
Flux
N S Leakage
Fig. 28-32  Circular mag-
netization produces the lines
of force shown in Parts 3 and
4. Compare these patterns
with those evident in the com-
mon horseshoe and closed
magnets.
Longitudinal Cracks
Will Not Show
Current
Transverse and
45° Cracks Show
Magnetic Lines of Force
Fig. 28-34  Longitudinal
magnetism is when the mag-
netic field is produced with
a coil, the lines of force are
parallel and longitudinal. A
longitudinal crack will not
show, but a crack angled
against the lines of force is
indicated.
906   Chapter 28   Joint Design, Testing, and Inspection
Transverse Crack
Will Not Show
Longitudinal
Crack Will
Show Current
Crack at 45°
Will Show
Magnetic Lines
of Force
Fig. 28-33  Circular
magnetism is when a current
is passed through the work-
piece, the magnetic lines of
force are at right angles to
the current, and discontinui-
ties that are angled against
the lines of force will create
the flux leakage needed
to produce magnetic poles
on the surface. Under the
illustrated arrangement, a
transverse crack would not
give an indication, but by
changing the position of the
probes 90°, it would be at
right angles to the lines of
force and would show.
A direct magnetization
method is normally used
with direct current, half wave
direct current, or full wave
direct current, Fig. 28-35.
These types of currents have
penetrating abilities that gen-
erally allow slight subsurface
discontinuities to be detected.
Direct magnetization may
also be used with alternat-
ing current, which is limited
to the detection of surface
discontinuities only. An in-
direct magnetization method
may also be used, Fig. 28-36.
This method uses an electri-
cally supplied coil wrapped
around a soft iron core to
produce an electromagnet.
Lines of Magnetic Force
Prod
Prod
Electric
Current
(–) Cracks at 90° (+)
to Lines of Force
Will Show
Cracks Parallel to
Lines of Force Will
Not Show
Fig. 28-35  Direct magnetization using d.c. prods.
American Welding Society (AWS) B1.10M/B1.10:2009, Guide for
Nondestructive Examinations of Welds, Fig 13, p. 15
(–)
Current (+)
Yoke
Weld
Test
Article
Magnetic Lines
of Force
Fig. 28-36  Indirect magnetization using a yoke.  American Welding
Society (AWS) B1.10M/B1.10:2009, Guide for Nondestructive Examinations
of Welds, Fig 14, p. 15
In some cases where portability is an issue and no source
of electric power is readily available, permanent bottle
magnets can be used.
The volume and variety of products tested by the mag-
netic particle method is enormous. In addition to weld-
ments of all types, finished steel products, castings, pipe
and tubing, racing cars, aircraft, and missiles can be
checked for structural defects.
Radiographic Inspection
Radiography is a nondestructive test method that shows
the presence and type of microscopic defects in the
 Table 28-3  Gamma Ray Sources, Strength, and Usage
Gamma Half Energy Strength
Source Life Level
Cobalt-60 5.3 years 1.33 and 1.17
(Co-60) MeV
Iridium-192 74 days 0.31, 0.47, and
(Ir-192) 0.60 MeV
Thulium-170 130 days 52 and 84 keV
(Tm-170)
Note: eV = electron volt, Ci = curie.
interior of welds. The method utilizes either the X-ray
or gamma ray. The source of X-rays is the X-ray tube.
Gamma rays are similar to X-rays except for their shorter
wavelengths. They are produced by the atomic disintegra-
tion of radium or one of the several commercially avail-
able radioisotopes. While gamma rays, because of their
short wavelengths, can penetrate a considerable thickness
of material, exposure time is much longer than for X-rays.
The film produced by X-rays or gamma rays are referred
to as radiographs.
The size of X-ray equipment is rated on the basis of
its electric energy which in turn determines the intensity
of the X-ray produced. The voltage across the tube con-
trols the X-ray wavelength and penetrating power. Voltage
is measured in kilovolts: 1 kilovolt equals 1,000  volts.
Generally, industrial applications run from 50 kilovolts
(50,000 volts), which is used for microradiography, to
2,000 kilovolts (2,000,000 volts) which can penetrate
9-inch thick steel. These thickness limits increase with
softer metals. One hundred fifty kilovolts (150,000 volts)
have a thickness limit of 1 inch in steel and 41⁄2 inches in
aluminum. Special units have a capacity of 24,000 kilo-
volts (24,000,000 volts).
Gamma rays can also be used as a source of radiation.
These types of sources are typically used for field radio-
graphic inspection. See Table 28-3. These radioisotopes
are constantly emitting radiation and are typically pro-
vided in small cylinders. They must be properly stored
and exposure requires special equipment.
In radiographic testing, a photograph is taken of the
internal condition of the weld metal. The photographic
film is placed on the side opposite the source of radiation,
Fig. 28-37, page 908. The distance between the film and
the surface of the workpiece must not be greater than 1
inch. The radiation rays penetrate the metal and produce
(Ci) Usage
20 For examination of thicker sections, typically 4–8 in. thick and of
medium density such as steel or copper. This source requires heavy
shielding, the weight of which makes for difficult transportation and
setup.
50 For examining steels up to 3 in. thick. It is used extensively for weld
inspection. Its relative low activity makes for easy shielding, and thus
simplifies handling.
— Produces a soft disintegration of the gamma rays. Has an energy
level similar to that of a 110-kV X-ray machine. The best application
is on 3⁄8- to ½-in. thick metal.
an image on the film. Different materials absorb radiation
at different rates. Since slag absorbs less radiation than
steel, the presence of slag permits more radiation to reach
the film. Thus, the area of the slag inclusion shows up
darker than the steel on the film, and this indicates a dis-
continuity in the weld metal. A radiograph can establish
the presence of a variety of defects and record their size,
shape, and relative location. As can be seen in Fig. 28-38,
page 908, the orientation of the discontinuity with the
source may or may not make it detectable.
Figure 28-39 (p. 909) shows common defects as they
appear in radiographs. Porosity, which is caused by gas
being entrapped in the weld deposit, shows up as small
dark spots (Fig. 28-39A). A nonmetallic inclusion,
such as slag, usually shows up as an irregular shape
(Fig. 28-39B). These images may be fine or coarse,
and they may be widely scattered or closely grouped.
Cracks show up as a line darker than the film back-
ground (Fig. 28-39C). Both longitudinal and transverse
cracks are detectable. Incomplete fusion gives dark
shadows (Fig. 28-39D). Incomplete root penetration is
indicated as a straight dark line (Fig. 28-39E). Under-
cutting shows up as a dark, linear shadow at the edge of
the weld (Fig. 28-39F).
Penetrant Inspection
Penetrant inspection is a nondestructive method for locat-
ing defects open to the surface. Like radiographs, it can
be used on nonmagnetic materials such as stainless steel,
aluminum, magnesium, tungsten, and plastics. The pen-
etrant method cannot detect interior defects.
Red Dye Penetrant  The surface to be inspected must be
clean and free of grease, oil, and other foreign materials.
It is sprayed with the dye penetrant, which penetrates into
Joint Design, Testing, and Inspection   Chapter 28    907
 B A

Bevel
Angle

Radiation Source
Radiation Beam
B
A Film Location
During
Exposure
Fig. 28-37  Typical arrangements of the radiation source and film in weld radiography. The angleB ofProcess
exposure and the
geometry of the weld influence the interpretation of the negative. NoteA that multiple exposure may be necessary for pipe
welds.  American Welding Society (AWS) B1.10M/B1.10:2009, Guide for Nondestructive Examinations of Welds, Fig 17, p. 19

Test
Object

Radiation Source
Radiation Beam
Film Location C
During
Exposure
B Process
A Only Vertical Discontinuity (B) Exposed and
Results in a Discernible Developed Film
Radiographic Image
Test
Object

Only Vertical
Fig. 28-38 Discontinuity
Orientation(B)of discontinuities
Exposed andwith radiographic inspection.  American Welding Society
ResultsB1.10M/B1.10:2009,
(AWS) in a Discernible Guide for Nondestructive
Developed Film Examinations of Welds, Fig 13, p. 15
Radiographic Image

cracks and other irregularities. The excess penetrant is Evaporation of the liquid will leave the dry white pow-
wiped clean with a solvent. Then the part is sprayed with der which has a blotting paper action on the red dye left
a highly volatile liquid that contains a fine white powder. in the cracks, drawing it out by capillary action so that the
This is known as a developer. defects are marked clearly in red.

908   Chapter 28   Joint Design, Testing, and Inspection