Welding Inspection. heory (Mu ice) Paper WI - 2 Date: eee 1A product defect eaused during steel manufacture » A hot crack mechanism associated with joint fit up crack mechanism which occurs in the parent material due to welding siresses acting in the short transverse direction of the parent material \ type of crack associated with welds. which are subjected to cyclic loading \ hat are the four criteria necessary to produce HICC? 1 Hydrogen, moisture, martensite, heat bh. Hydrogen, poor weld profile, temperature above 200°C and slow cooling .) Hydrogen, a grain structure susceptible to cracking, stress and a temperature below 200°C |. Hydrogen, weld defects, pearlite and a high heat input What is a typical carbon equivalent in carbon manganese steels ? Which of the following alloys is non-magnetic ? 4% Chromium molybdenum ». 12% Chromium ©) Austenitic stainless steels | 9% Nickel steel Paper eg WI-26 sorsWhich of the following statements is true regarding hydrogen cracking? a. Itisa type of hot crack b. It is most commonly found in ductile materials -c. Itonly occurs in the HAZ (@)_Itis the most common type of crack encountered in steel weldmerts What is the Heat Affected Zone ? a, It is the melted part of the plate material by) [tis the area immediately adjacent to the weld metal which has undergone a micro structural change ©. Itis the weld area plus the parent material which has undergone a micro structural change Its the area in the weld zone with the lowest tensile strength the heat input during a fusion welding process: 2. Does not affect the grain structure of the material unless it is very high h. Must be as high as possible to avoid lack of fusion ©) Affects the width and metallurgy of the HAZ d.— Must be very low to avoid grain growth : Why is pre-heat sometimes carried out on steels? 8, To remove moisture from the weld preparation b. To retard the cooling rate of the weld ¢, To aid fusion between weld metal and parent material (d) All of the above ‘hen calculating pre-heat requirements what factors need to be considered? 8, Heat input, material thickness and rate of cooling bb, Travel speed, heat input and carbon equivalent. (& Heat input, carbon equivalent and material thickr d. Travel speed, rate of cooling and welding position Which of the following is not a type of crack? a. Fissure i) Fish eye ©, Lamellar tear a. Hot tear per eat11 What is meant by the term minimum interpass temperature? 4. Minimum post weld heat treatment temperature b. Minimum stress relief temperature “The lowest temperature allowed during welding and between weld passes d. The lowest temperature to be used during pre heat Ina martensitic grain structure which of the following mechanical properties would tbe more likely to increase? a. Ductility bn) Hardness c¢. Toughness d.— Allof the above Pre-heat prior to welding: a, Must always be carried out on steels b. Need not be carried out if PWHT is to follow welding ¢. Must always be carried out using gas flames d None of the above | amellar tearing has occurred in a steel fabrication. Before welding could it have been detected by a. Radiography b. Dye penetrant inspection ®_ Itwould not have been found by any inspection method d. Ultrasonic testing rhe steel composition in a structural steel is changed from 0.15% carbon 0.6% manganese to 0.2% carbon 1.2% manganese. What might this influence? a. Decrease in tensile strength b. Increase in ductility c, Decrease in hardness (@ Cracking in the weld area The throat thickness of a mite fillet weld with 20mm equal leg lengths will be: a, 235mm. b. 17mm @ 14mm dd, It cannot be determined from the information given Paper eu Wl 26 3 it‘A large grain structure in steels could produce Low ductility values a ()) _Low fracture toughness values c. High fracture toughness values d. High tensile strength Hydrogen cracking is most likely to occur when welding: a Carbon manganese steels b, Stainless steels een crn (c) High strength low alloy steels hops COM Low carbon steels The presence of iron sulphide in weld metal is most likely to produce which of the following crack mechanisms as the weld contracts after welding: Hydrogen cracking ( Solidification cracking © Lamellar tearing d. Reheat cracking Stray arcing may be considered to be a serious defect because: a. Itmay reduce the thickness of the component b. Tt may cause liquation cracking c. _ It may cause hard areas @)— Allof the above Welding a single V butt weld with laminations in the side wall may cause: a. Lamellar tearing @&) Solidification cracking c. Martensite d. Undercut Pre-heating prior to welding on high tensile strength material applies to which of the following ? 4 Only on joints over 25mm thickness }) _ Production welding and tack welding ©. Production welding only d Pre-heat is not required if PWHT is to be carried out Paper et W126 sotoWhich of the following is the correct heat input for a MAG weld if the values recorded were; 280 Amps, 26 volts, travel speed 310mm/min.(Thermal efficiency for MAG welding = 0.8) a. 14ks/mm b)1.12ks/mm cc UkS/mm d 1.12J/mm Which of the following mechanical test(s) gives @ quantitative measurement of ductility? Fat Tensile test b. Bend test ©. Charpy test Nick break test Which ofthe following are correct dimensions for the vee notch ina charpy specimen? a. Depth 2.5mm, included angle 40°, root radius 0.25mm Ey Depth 2mm, included angle 45°, root radius 9 2$mm eee th 2mm, included angle 22.5°, rt radius 0°50 « aeeth 2 5mm, included angle 22.5°, root radius 0.20mm Which of the following mechanical properties of a weld made on C-Mn steel is most ith of weld is excessively high: affected, if the heat input per unit leng a, Tensile strength () Toughness cc — Ductility 4. Elongation When visually inspecting the root ofa single V but weld with the external excess weld metal removed, root concavity of 0.5mm depth is identified ‘The application standard contains the following statement vided that the density of the radiographic Poot concavity shall be acceptable pro’ ial” image does not exceed that of the pars Which of the following would be correct ? a. The weld must be radiographed & Sentencing of the radiograph could only be carried out by a qualified radiographic interpreter. ae weld is acceptable, there is no radiograph fo vie ‘The weld should be rejected Paper oul -20Shrinkage that takes place in line (parallel)to the weld line of the joint is termed? a Transverse * b. Hoop ics Longitudinal d Bowing Which of the following best describes the elastic limit? : The resistance ty fractions tuner impact loading , The maximum stess a material can be subjected to without permanent deformation ‘ The point at which the material fails a The ability of a material to streteh and become permanently deformed without breaking or cracking When considering lamellar tearing what is a butering runt? a ‘A weld deposit used to increase the throat thickness size of a fillet weld {.) A weld deposit which may be used to take up contraction Emer stresses c ‘A weld deposit used to increase the UTS value of the parent material d ‘A weld deposit used to locally heat treat preceding weld runs vllntractions, Using a PEN ph Welding Inspection. eral Theory (Multi-choice) Paper WI - 3 Name wt lHAL EQ. UYESLEN Date circle the letter next to your chosen answer. When hydrogen control is specilied for MMA welding, what type of electrode ssoutld normally be used ?: Cellulosic i Rutile Acidic de Basie \ cellulosic. MMA electrode could be identified from the: Colour of the flux covering 1h. Length of the electrode «Trade name of the electrode dy AWS/BSEN classification In UK practice, BS EN 22553 specifies that the minimum drawing dimension for a fillet weld is the: wi Leg Length: h. Actual throat thickness Weld width J. Depth of penetration \ thus for SAW is described as sharp or glassy in appearance. What type of flux coul’! a Basie Fused Acidic Alkaline Paper e130 torsWhat would be a typical diameter range for basic electrodes for all positional MMA welding? 1 2.$-8mm b. 0.8~ 1.2mm 6) 254mm a. Size doe not matter (Which of the following MMA electrode types would be associated with the stove welding teehnique 7 = : 1) Cellulosic bh. Rutile ©. Agglomerated d. Basic \n electrode identified as E 6013 would be classified to which of the following standards? 1 BSEN 499 bh AWS AS.5 © BSEN 440 ds AWS ASI S RSEN 15614 refers to what? 1. Welder approval testing b. Welding equipment validation ‘ey Welding procedure qualification d. Weld symbols on fabrication drawings ©. What is the maximum allowable HI/LO for 8mm thick material if the following is applied: Linear misalignment is permissible if the maximum dimension does not exceed 10% oft ry tea maximum of 2mm “a 0.8mm, b. 2mm c. 8.8mm dd. It can not be sentenced as an incorrect term has been used 1 to BSEN 22553 a weld on the other side is shown by the symbol a) On the dashed identification line b. Below the reference line c. On the solid line d. Above the reference line Paper ed WEE dato11. Manual metal arc electrodes can be grouped into three main types. What are they? Fused, cellulosic & basics Neutral, cellulosic & basic Agglomerated, cellulosic & rutile Rutile, basic & cellolosic exe According to BSEN 22553 the letter @ preceding the symbol for a fillet weld would indicate what ? a Leg length b. Nominal depth of penetration ec) Design throat thickness d. All of the above ed to BSEN 499 as E 42 3 B, the figure 3 would represent: Is Onan electrode clas a, Strength & elongation properties b! Impact properties Chemical composition «Weld metal recovery and type of current : |} ‘The main causes of solidification cracking are? a. Phosphor, joint geometry and tensile stress B) Sulphur, joint geometry and tensile stress Hydrogen, joint geometry and tensile stress d. Laminations, poor through thickness ductility and tensile stress . \ welder qualification test is used to verify: a. The compatibility between consumable and materials b) The skill of the welder c. The manufacturing process d. The NDT procedures " The leg length of a mitre fillet weld with an 8mm throat thickness will be: 11.Smm 10mm 2mm 10.5mm Paper ediWl -3¢The BS EN code for welder approval a BSEN4872,— sy b. BS EN 499 fe. BS EN 287 d. BS EN 719 Incomplete root penetration in a butt weld could be caused by: a Excessive root face width bh. Excessive root gap size c. Low current setting td. Both A & C Incomplete root fusion could certainly be caused by: a. Linear misalignment b. Incorrect electrode tilt angle c Differing root face widths > Alllof the above Which of the following would relate to the term planar defect: a A lamination (A serious defect which could lead to failure of the product c._ Anelongated slag inclusion a. Both A & C Which of the following hardness tests would be used by a test house to assess hardness for procedure approval in the UK a. Brinell b, Rockwell © Vickers d. — Ecotip An alteration of an essential variable on a WPQR may: a, Change the properties of the weld b, Affect visual acceptance c. —_ Require re-approval 2) All of the above Paper ed W-30 totoWhich of the following type of bend test would best show lack of inter run fusion on 25mm thick carbon steel butt weld? a Root bend a b. Face bend tc. Side bend d 5D bend Which of the following abbreviations is the odd one out? a GTAW ‘MMA c SMAW GMAW In which of the following positions would you expect to find the highest heat input ona pipe butt weld made in the horizontal vertical position? anal b PB re PF d PG Defects out side the limits specified by the standard should always be: a. Reported to a senior person b. Repaired as soon as possible ©. _ Radiographed when practicable d.—Alllof the above Which of the following defects would not normally be detected by radiography? a, 2mm by 4mm long centreline crack in the weld root 6b 200mm long lamination c. 10mm deep lack of side wall fusion d. 1.5mm dia gas pore forces is termed? Movement of the are by magn Are deviation b Are eye c Are strike d Are blow Paper ed/WI- 30 sors‘9. Ultrasonic testing is of advantage in detecting which of the following weld Imperfections over other NDT methods: a, Lack of side wall fusion b. Surface undercut c. Incomplete filled groove d. Cold lap |The presence of iron sulphide in the weld metal is most likely to produce which of the following crack mechanisms, as the weld contracts? a Hydrogen Induced Cold Cracking b Re-heat cracking a Lammellar tearing d Solidification cracking Paper ewW1-37 ore vtWelding Inspection. | Theory (Multi-choice) Paper WI - 4 instrictions, Using a PEN please circle the letter next to your chosen answer. |. When monitoring welding current using a tongue test ammeter itis essential that it Js placed around the welding cable. a. As close as practical to the are Ata position that depends on the welding process « Asclose as practical to the power source MIG/MAG welding using Dip Transfer mode is susceptible to: 1 Solidification cracking b, Slag inclusions c. Lack of side wall fusion ud. Hydrogen cracking & \ metallurgical problem most associated with submerged arc welding is: a. Hydrogen cracking in the HAZ h) Solidification cracking in the weld metal c. Lamellar tearing in the weld metal d. Hydrogen cracking in the weld metal &. \ common gas/gas mixture used for MIG welding nickel alloys to combine good levels of penetration with good arc stability would be: a. 100% Cor fb) 100% Argon ¢. 80% Argon + 20% Co2 d. 98% Argon + 2%O2 b. SMAW welding equipment requires what type of output characteristic? a. Constant voltage n ©. Constant current d. Constant polarity Paper eaWl 46What would be a typical welding defect associated with the TIG welding process? a. Slag inclusions {b) Tungsten inclusions * ©, Hydrogen cracking «Solidification cracking When MIG welding aluminium alloys in the overhead position which current type would normally be used? a AC. b. D.C. negative ‘c) D.C. positive d. Drooping An inverter a, Changes ac to de b> Changes de to ac at a higher frequency c. Changes mains ac to ac suitable for welding Changes welding polarity The term hack step welding refers to what? Welding position b. Welding schedule c. Welding run sequence d. Welding deposition rate <_ During TIG welding the are voltage is controlled by: a. The welder The flat output characteristic of the power source c. The polarity of the electrode d. The constant voltage control c In arc welding processes. excess weld metal profile is most affected by: la Arc Length b. Open circuit voltage c. Amperage d. Root gap Paper ed Wt -36 Born m17 Autogenous welding means: a. Fully automated b, Fusion welding with filler wire c. Fully mechanised - Sop od Fusion welding without filler wire Gy $ Which of the following radioactive terms is not associated with NDT? a Gamma jb Cobalt 60 c Thorium Iridium 192 ' Which submerged are welding flux may be described as powdery or ball like ? a. Basic b. Fused. ¢ Agglomerated d Acidic Which of the following parameters presents the greatest difficulty when monitoring MMA welding: a Current b. Travel speed © Arc length 4 Interpass temperature Which of the following would be a typical are energy for a single pass MAG weld? A 1.2j/mm bo 0.12kJ/mm a 12kJ/mm a} 1.2kJ/mm. Which of the following welding processes uses a constant voltage output characteristic: a. Sub-are<1000amps, MMA, electroslag b. TIG, sub-arc>1000amps, electroslag © Sub-arc<1000amps, MIG/MAG, electroslag d. MIG/MAG, sub-arc>1000amps, electroslag Paper WIA sofThe main reason for using a back purge when welding 18-8 stainless steel with the TIG welding process is to a. Control root pendtration b, Prevent root bead porosity ¢. Improve positional welding d. Prevent oxidation of the weld root Which of the following would act as de-oxidisers in a terti MAG welding wire ? ry de-oxidised 1. Manganese. silicon, copper b. Silicon, nickel, aluminium €) Manganese, silicon, aluminium d, — Manganese, molybdenum, nickel What is meant by the term specification ? a. A document that prescribes the requirements with which the product or service has to conform b. A set of guidelines recommending practices and procedures c. A general term given to all normative documents d. A written description of the exact steps to be followed i manufacturing a product Which of the following best describes a semi-automatic welding process? a. The welder is responsible for the are gap and travel speed 1b) The welder is responsible for travel speed only ©. The power source controls both are gap and travel speed but under constant supervision The power source controls both travel speed and arc gap Vor a given voltage and current setting on a constant current output power source, when the arc length is shortened: a The current will decrease the voltage will increase b, The travel speed will increase the current will decrease The current will increase the voltage will decrease Gd — The current will increase the travel speed will decrease Which of the following butt welds would be considered the aiost difficult to weld? a Double V butt welded both sides b Single V butt © Single U butt with backing d Assymetrical double V butt welded both sides Paper eh 2. When welding low carbon steels with the GMAW process on dip transfer, one purpose of the inductance control is to reduce: tenes Spatter * Lack of fusion Porosity Cold lap Which of the following would be considered to be the duty of a welding inspector? a b a. Supervision of welders” Writing procedures Witness welder qualification tests All of the above Paper ew/Wl 46 bot viWelding Inspection. Gene Theory (Multi-choicc) Paper WI - EOC SSE jons. Using a PEN please circle the letter next to your chosen answer. ‘gc your answer put an X Uwrough the original answer, add your initials a the side and rele your new answer. Answer all questions. According to AWS AS.1 which of the following MMA/SMAW electrodes would be classified as rutile ? a. E6010 2 7018 gran “ E90IL A fillet weld has a design throat thickness of mm, What is the minimum Teg length required? 4.2mm ® 8.5mm 8.2mm {Ibis impossible to determine the size from the information given © According to BS EN 22553 the number 111 at the end of the dual weld symbol reference line would indicate ? a, The welding procedure number The welding process is manual metal arc welding © The welding process is TIG d_ The type of welding elevirode 1 Onan electrode classified to BS EN 499 as E42 3 B the 42 would indicate 7 ® 420 Nimm? min yield strength F i 42 Joules @ -30°C - ©. AZ ksi tensile strength Sf. fh 42 Nimnvé max tensile strengthA Constant Voltage output characteristic would be required for which of the following, welding processes? a MMA/SMAW TIG / GTAW 8 MIG / MAG / GMAW . ad TAGS (What could Carbon Equivalent Values (CEV) be used for? a Assess the risk of lamellar tearing b Estimate the need for PWHT ec, Calculate HAZ toughness. €@)_ Determine the proheat to be used A typical are energy value for a MAGS weld run would be ? (SY 12 kum Fo 12k © 1.2/mm a 120ks/mn 4 When referring to fully austenitic stainless steels which one of the following statements would be correct? 4 Itis magnetic under certain conditions b_Ithas poor toughness at low temperatures «.Tthas a low coefficient of thermal expansion and a high coefficient of thermal conductivity Tt has a high coefficient of thermal expansion and a low coefficient of thermal conductivity © ‘The area of joining between parent metal and weld metal is termed a The fusion zone 1 The HAZ “©The weld zone d_— The parent material A submerged arc flux described as flaky or sharp would be classed as? a Agglomerated Fused TF Basic Acidicae x 1) Which of the following welding processes would give the highest heat input when using typical parameters? 2 Manual metal arc welding b, Shielded metal arc welding » - @ __—_ Submerged are welding , d ‘Tungsten inert gas welding 1> According to BS EN 22553, what would an elongated Z through the dual reference line on the right hand side of the fillet weld symbols indicate ? a throat thickness b The weld toes must be dressed Leg length 7 @ Intermittent welds that are staggered 1} For cross-country pipelines, which type of MMA electrode would require the deposition of a hot pass technique to reduce the tisk of cracking in the root bead? @ Basic ' v Iron powder 7 iX c | Cellulose 7 ( d Rutile - 14 The use of a degreasing solvent, for cleaning the joint prior to welding, may be classed as an unsafe practice because, Stef The welds may contain porosity © ( OD b Harmful fumes may be given off 7 « ‘Traces from the solvent may cause irregular arcing “We __Itsuse could lead to cracking in the HAZ |S Which of the following may increase the risk of HAZ cracking when welding thick section carbon manganese steels? 4. Low moisture content in the electrode covering : by, Slow cooling after welding - Use of a low heat input Use of a steel with a low Ceq% Jo. Which of the following radioactive isotopes is most commonly used for the garni radiography of welds? Thorium 90 ! Cobalt 60 E Iridium 192 d Yrterbium 16917 Autogenous welding refers to what ? a ‘A mechanised welding process b ‘An automated welding process 7 ‘A means of welding withaut a filler wire ‘d A manual welding process 18. The back step method of welding could be used to control; a Weld profile b Penetration y Undercut Distortion 19 ‘The directions of shrinkage in a welded joint are, Transverse, short transverse and linear Longitudinal, transverse and short transverse Angular, diagonal and transgranular 4 Transverse, diagonal and torsional 1) MMA clectrodes that show a light coating of rust on the core wire, should, Be re-baked according to the manufacturer's instructions aes Be cleaned with solvent £4 \> © Have all rust removed by abrasives beforeuse +, xi ier’ y d+ Be quarantined for further inspection + yo ension of 7mm be indicate to 21 How would a fillet weld with a leg length BS EN 225537 @ 77 b a7 . © st d 7 22. Which of the following would not be classed as a weld with backing? a A single-V weld with a removable backing strip ( loc b A single-V weld witit a back purge } yes . © A single-V weld with a permanent backing strip 7° " ~ ‘A double-V weld with a back gouged root The term Transition Temperature is associated with, a Tensile testing b Fillet fracture testing @ Impact toughness testing The electrical characteristic of a power source24 Which of the following statements regarding carbon stecls is false? High heat input results in high hardness. cH bh High heat may result in large grains ad +, Loss of toughness may result from weaving Toughness may be restored by normalising 25 Which welding process would not be suitable for welding carbon steel? a. MMA MIG z ~ | «SAW a 1G 26. In order to calculate arc energy, it is necessary to know what? 4 Amperage and voltage b. Current, voltage and weave width @ Amperage, voltage and travel speed Wire feed speed, voltage and burn off rate 17 A short transverse tensile test (STRA test) will give what? The stress/strain characteristics of the joint hb The tensile strength of the weld ‘An indication of susceptibility to hydrogen cracking ‘An indication of the materials susceptibility to lamellar tearing 28 Which of the following standards gives guidance for the production of a WPQT? a BS EN 22553 bh BS EN 499 © BS EN 15614 BS EN 287 F 29 According to AWS 2.4 a weld symbol shown below the reference line would indicate, ® ‘Aweld made on the other side of the joint (\) a ‘A weld made on the root side of the joint 5 SY #1, Aweld made on the arsow side of the joint < “1 | None of the above; the symbol should be shown on the dashed line 30 ‘The output characteristic for a TIG/MMA power source would be? Qe Constant current Constant polarity Fl © Constant voltage 4d Constant pulsingWELDING INSPECTION STEELS. COURSE REF. WIS 5 END OF COURSE MULTIPLE CHOICE QUESTION PAPER (MCQ.005) Generally the most suitable method of detecting lack of side wall fusion would b: A Ultrasonics 8 MPL ©. Radiography. 0. — Penetrants Hot shortness is a term used to indicate: Lamellar tearing i Solidification cracking Hydrogen cracking. 1D. None of the above. ‘The use of cobalt as an isotope would generally be used on A. Thin material 6. Tee joints. C. Plate thicknesses greater tnan 25mm 1) None of the above: In welding procedure terms, a change in essential variable means: ‘A. Re-qualification of the weld procedure. 8. Possible changes in the weld's microstructure, Possible changes in the mechanical properties. D. — Allof the above Weld symbols placed on a dotted line in accordance with ISO requirements means Weld on “arrow’ side. = Weld on “other’ side. Weld on site. Full penetration required. oam> welding inspector's main attribute includes: Literacy. Honesty and integrity. 0. Allof the above, A A. Knowledge and experience. 8 Cc.( a. 40. 14 42. 13. on Which of the following weld processes uses a resistive heating system to aid weld metal deposition . ‘A Manual metal are welding RB. — Submerged are welding. ©. Llectroslag welding. 1. Resistance spot welding Whicl of the following units would a Charpy V notch energy be measured ity A Pounds per squate inch Joules: a Newtons per square millimeter. D. None of the above, Technically a code of practice is: A standard B. A“set of rules” for the manufacture of a product. > Related to welder and weld procedure approval. * 1) Allof about the above. The correct term for ap height” is: A. Reinforcement B Cap profile height, C Excess weld melal. 1D. Allof the above. ‘A tensile test will assess: A. Impact values. B Stress. Cc Strain. BD. Both Band ©. The important point of high temperature steels is that: fy be A. They can withstand creep failure B They may suffer re-heat cracking problems. C, They may suffer loss of toughness, 0. Allof the above An austenitic stainless steel may suffer A. Weld decay. ‘ Bb Sensitisation. > Solidification cracking c D Allof the above.16. iz. 18 20. Carbon equivalent values are useful to determine A. Weldability aspects 8. Crack sensitivily aspects ©. Typical mechanical properties, 1D. Allof the above, A basic electrode would normally: A. Have superior mechanical properties. R. Require baking before use. ©. Nol be used on low carbon steels, D Both A and B. ‘ When refering to TIG welding, the shielding gas could be. A Aigon-« Hydrogen 1. Argon + Helium 5 Argon + Nitrogen. 0D Allof the above. When teferiing to MIG welding, the shielding gas could be: A. Argon BR Argon * 1% Oxygen. © Argon + 20% Cor, 1 Allof the above. Submerged arc utilises: Deep, penetration characteristics. Nigh deposition rates on DC# © Flat (P.A.) welding only. 0 None of the above. Ultrasonics would be preferred over radiography due to: A. Ability to find niast detects 8 Lower skill requirements c Ability to detect laminations PD Both A and c The most serious defect types are: A Planar 8 Cracks. © Lack of fusion D. Allof the above.ig A 20-~ DLS- COURSE REF. WIS 5 WELDING INSPECTION STI MULTIPLE CHOICE QUESTION PAPER (MCQ.003) 4, The Lritish code for Visual Inspection Requirement is: BS 4872 BBS 499. n BS 4870 1D None of the above de of Practice for Visual Inspection should cover the following: ; Gofore, during and after .velding. i Before welding activities only i After welding activities only. ) None of the above 3. Ih cnplete root penetration in a butt joint could be caused by: Excessive root face width. 1 Excessive root gap size Low current setting, : Both A and C. 4. Incomplete root fusion would certainly be caused by: Linear misalignment t Incorrect tilt angle. ‘ Differing root face widths All the above. 5. When visually inspecting a completed single vee butt weld cap you would ontainly ass . Cap height 1 Toe blend. Wold with {ties boy 6. -Yeurnotice a very “veed" ripple shape. This is most likely caused by: Poor consumable choice 1 Welding position. (Excessive travel speed. i) Allof the above.A n 24. 25 27. Cracks in weld may be due to: ‘Hydrogen problems. B Solidification problems. i Excessive stresses . 1 Allof the above A ‘weave technique” may give rise to: A. Better profile fi. Improved toe blending. ©. Improved ripple shape. 1D Allof the above With reference to a root penetration bead, you should certainly assess: A. Root fusion and penetration &. Root concavity. ©. Burnthrough D. — Allof the above. A fatgue failure is characteristic by the appearance of the fracture surface. It would be: . A Rough and torn & “Cheveron" like. C. Smooth. 1 None of the above " Stray arcing" may be regarded as a serious defect. This is because: ‘A. It may reduce the thickness dimension of a component. 6. It may cause liquation cracks. C.__ Itmay cause hard zones. D. Allof the above. Overlap in welds could be influenced by’ ‘A. Poor welding technique. B. Welding process ©. Welding position. 1D. Allof the above Flame cut preparations may, during welding, increase the likelihood of: A Cracking. 8. Misalignment problems. >. Inclusions. D. Allof the above.28. 29, 30. Macrosopic examination requires any specimen to be inspected A. Once, after etching L. — Twice, before and after etching. C. Using a microscope . D. None of the above. Which of the following may be classed as a "more serious defect": A Slag inclusion B. Fusion defects (interun) © Fusion defects (surface). dD Porosity. A cade of practice ‘A Astandard for workmanship only. 2B. Aset of rules for manufacturing a specific product. © Levels of acceptability of a weldment. D. None of the above.ANS. ANSWER SHEET FOR MCQ.003 DATEL ON] ANSWER | ~ TIPIINololg | | 1 L t wobecWiss WELDING INSPEC LION SIEELS- COURSE f MULTIPLE CHOICE QUESTION PAPER (MCQ.004) Movement of the arc by magnetic forces in MMA welding is termed: A Arc deviation. B Arc misalignment . C.— Are blow. D. Arceye. ‘A metallurgical problem most associated with submerged arc welding is A. Hydrogen cracking in the HAZ B Solidification cracking in the weid metal. C. Hydrogen cracking in the weld metal. 1D. Lamellar tearing in the weld metal Oxy pressure and nozzle size would influence what in flame cutting The temperature required for cut initiation. The ability to cut stainless steel The depth of cut obtainable. None of the above. com> The main usage of are cutting/gouging processes is in The cutting of single bevel preparations. The removal of deposited welds The cutting of single U-type preparations. The cutting/gouging of non-ferrous materials only. Som> Which of the foliowing processes joins metals plastically A. Friction welding B. Resistance welding C. Plasma welding D. _ Allof the above. ication would be relevant to AWS AS.1-81: Which electrode cl A E6013, 8 E5133, ic E 7018-G D. Fleetweld 5.10. 12. 13. Which of the following coatings is associated with "Stove" weling A Ruble 8 Celluloste Cc Basic, 0. Oxidizing ‘A common gas/mixture in MIG welding nickel alloys to combine good levels of penetration with good arc stability would be: A. 100% Cor 100% argon. ©. 80% argon 20% Co2 98% argon 2% oxygen. Ihe type of SAW flux, more resistant to moisture absorption is: A Fused 8. Agglomerated. © Basic D. All of about the same resistance. The flame temperature of oxy/acetylene mixture gas is given as; A. 3200°C. B 2200°C c 5000°C D. None of the above: A large grain structure in steels is said to produce: A. Low duetility values. B. Low fracture toughness values C. High fracture toughness values. D. High tensile strength. D The likelihood of brittle fracture in steels will increase with: ‘A. Alarge grain formation A reduction of in-service temperature to sub zero levels C. _ Fertitic rather than austenitic steels. 1D. Allof the above, Repair welding is often more difficult than production due to: ‘A. The material being ingrained with in-service contaminates. B. Restricted access within the repair area. ©. The possible position of the weld repair. 1 Any of the above all14. 46. 18. 19. Hydrogen cracking in the weld metal is likely when welding ‘A Carbon manganese steels. B. Stainless steels. ©. Micro alloyed steels (HSLA) 1D Low carbon steels N standard 288 would refer to which of the following: A. Welder approval testing. B Welding equipment. C. Welding procedure approval Consumables for submerged arc welding Porosity is caused by ‘A. Entrapped slag in the solidifying weld. 3 Entrapped gas in the solidifying weld 5. Entrapped metallic inclusions in the solidifying weld. ) None of the above. Ina bend test, the face of the specimen is in tension and the root is in compression; the type of test being carried out would be: /\ Aroot bend test 8 Aside bend test, © Aface bend test 1) None of the above. Ultrasonic testing is an advantage in detecting which of the following weld imperfections over other NDT methods: A. Lack of side wall fusion B. Surface undercut. ©. Incompletely filled groove. D. Overlap. The process of tempering is often carried out to regain toughness after which of the following processes: A. Annealing B._Normalising CG. Hardening. D. Stress relieving26. The presence of iron sulphide in the weld metal is most likely to produce whit the following upon contraction of the weld ‘\ Soliditication cracking I Hydrogen cracking Intergranular corrosion 5 corrosion cracking~~ STANT GLOSSARY OF TERMS. | DUCTILETY:- The ability of a material to stretch and become permanently | deformed without breaking or cracking. | ELASTICITY:- The ability of a material to return to its original shape after a tensile load has been applied PLASTICITY:- Permanent deformation of a material due to the slipping of the | ervstal lattice structure, The material will remain permanently deformed if the load is removed, KLONGATION:- The total extension produced in a tensile test, expressed as a percentage of the original test length. Strain % = Increase of gauge length x 100 Original gauge length | The elongation percentage provides a measurement of ductility. . BRITTLENESS:- The tendency of a material to fail suddenly by breaking without Plastic. permanent, deformation of the material before failure. HARDNESS:- The ability of a material to resist indentation, abrasion or scratching. - The ability of a material to resist cracking IMPACT TOUGHNESS:- The resistance to fracture under impact loading. | PLASTIC LIMIT: The maximum stress to which a material ean be subjected t0 without permanent deformation or failure by breaking | TENSILE STRENGTH:- The resistance of a material to a force which is acting to pull it apart ULTIMATE TENSILE STRENCTH:- The maximum pulling force to which a material can be subjected to without failure. uts id Applied ‘tional Area imum, Least Cross S exert_ ee GLOSSARY OF TERMS. The production of a crack through repeated loading which FATIGUE FAILURI is critical for failure. FATIGUE LIFE:- The number of stress cycles sustained before failure. FATIGUE LIMIT:- The stress range below which crack growth will not occur. LOAD:- ‘The amount of dynamic or static force applied to a material or structure. YIELD POINT:- The amount of stress at which point the material will continue to elongate without an increase in the force applied. YIELD STRENGTH:- The stress point at which permanent deformation results. BEACH MARKS:- Dark acylic banding on a fracture surface indicating the position of the crack front at that time, and indicating crack initiation sites. Indicative of fatigue failure. .NUMBER: TITLE i amendgtions for welding of metallic materials, eral guidance for arc weldin; lain rinless i [ding of aluminium and aluminium alloys z on welds in metallic materials. 7 amination of welds - Radiographic examination of welded and classification of gr harpy impact tests on metallic materials, fetallic products - Types af inspection documents J, brazed and soldered joints - Symbolic representation on Welding, brazing , soldering and braze welding of metal nclature of processes and reference numbers for symbolic RS EN 25817 BS EN 26870 BS FN 26848 .presentation on drawing ‘Arc welded joints in steel. Guidance on quality levels for imperfect Classification of imperfections in metallic fusion welds, with explanations, ‘Specification for tungsten electrodes for inert gas shielded arc welding and for plasma cutting and welding, iso woMnER ISO 897-1 180.6947 18019606 2 1S0y 15607 ISO 15608 150 15609 - 1 180 15610 180 15611 1s 15613 | isotsett Part 1 pants Pare Pans Part 6 Pan? 1 bans: Part Part 1: } part t1 Part Pin TITLE, Welding and allied processes - Vocabulary - Part I - Metal welding processes Welds - Working positions - Definitions of angles of slope and rotation ‘Qualification test of welders ~ Fusion welding, Part 2 Aluminium & aluminium Alloys. Specification and qualification of welding procedures for metallic materials General rules. Welding - Guidelines for a metallic material grouping system. Specification and qualification of welding procedures for metallic materials Welding procedure specification - Part |: Arc welding Specification and qualification of welding procedures for metallic materials- Qualification based on tested welding consumables. Specification and qualification of welding procedures for metallic materials- Qualification based on previous welding experience. Specification and qualification of welding procedures for metalic materials Qualification based on pre - production welding test. Specification and qualification of welding procedures for metalic materials Welding procedure test ‘Are and gas welding of steels and arc welding of nickel and nickel alloys ‘Arc welding of aluminium and its alloys* ‘Welding procedure tests forthe arc welding of cast irons* Finishing welding of aluminium castings® ‘Arc welding of titanium, zirconium and their alloys Copper and copper alloys* Not used Welding of tubes to tube-plat joints Underwater hyperbaric wet welding* Hypertaric dry welding* Electron and laser beam welding Spot, seam and projection welding,* Resistance butt and flash welding*J 85.499. Part | hs 709 Bs tit Bs nass WS 1821 bs 20 BS 2633 is 2e0 [as cost S901: Part 3 | ps 2926 bs 2971 [ns 3605 pS ass 8S 4570 WS 4677 Ws 4872 art | part 2 JS 6323 1S 6693 hs 6990 Lis Tr9t 1S EN 287 | part SEN 440 WS BN 499 Ls EN 719 | para [nS EN 756 | [ns EN 700 BS EN 970 ing. Terms. iethods of destructive testing fusion welded joins and weld metal ir steel Specifiation for design and manufacture of water - tube steam generating plant. Specification for filler materials for gas welding Specifcation for class Toxy acetylene welding of feritic ste! pipework for carrying fluids. Low alloy steel electrodes for MMA welding, Speeaction for class tare welding of Ferric ses pipework for carying is anccitcation for elass I oxy ~ acetylene welding of earbon ste! pipewerk for carrying fluids Specification for manufacture of vertical stel welded non «refrigerated tors “Tanks with butt welded shells for the petroleum industry. Filler rods and wires for copper and copper alloys. ‘Specification for chromium éechromium -nicke stel electrodes for MMA. Specification for class Il arc welding of carbon steel pipework Fr earring Fluids. TIG welding sei rites and tubes for pressure purposes ert alloy see with specified Slevated temperature properties for pressure purposes ‘Specification for seamless tubes. Specification for welding of steel pipeines on land and offshore Specification for fusion welding of steel castings Specification for arc welding of austenitic stainless ster! pipework for er fluids. ‘Approval testing of welders when procedure approval is not required Fusion welding of ste! TIG or MIG welding of aluminium and its alloys. Specification for seamless and welded steel tubes fr atomic mechanical ‘and general engineering purposes. Mtcthed for determination of diffusible hydrogen in weld metal creer practice for welding on steel pipes containing process ds cir residues. Specification for weldable structural steels for fixed offshore struct Code of practice for validation of arc welding equipment. TITLE Qualification test of welders - Fusion weld Steels eels ectrodes and deposits for gas shielded metal arc weld = alloy and fine grain steels cae aMcctrodes for manual metal arc welding of ron alloy an: \/ = S218 steels. Welding co ordination - Tasks and responsibilities Quality requirements for welding. Fusion welding of metalic male Guidelines for selection and use. Comprehensive quality requirements. Standard quality requirements Elementary quality requirements Flea ey and Tux wire combinations for submerged are wel" of 107 alloy and fine grain steels. Fluxes for submerged arc welding. Nondestructive examination of fusion welds - visual examination Cut2oEN 10204: METALLIC MATERIALS, LYPES OF INSPECTION DOCUMENTS SUMMARY. T snspection document type 2.1 Fdanahon of complance wath the order FL atcny at al compliance with the order dhs manufacturer iy quvettic inspection may be idard or the order + spection certificate type 3.1 J Saatemen! of compliance wath the order, wily Prakeation of results of specific inspection dates by the manufacturer's authorised | cayapar tings esiernsentative independent of the » Quality management syst Pipestone Era in aa NON - SPECIFIC INSPECTION * _|— foi. —— Je ene torre Inspection document type 2.2 Test report Statement of compliance with the order, with indication of results of non-specific inspection. Validated by the manufacturer replaced by specific inspection if specified Inspection certificate type 3.2 Statement of compliance with the order, with indication of results of specific inspection Validated by the manufacturer's authorised inspection representative independent of the manufacturing department and either the purchaser's authorised inspection representative or the inspector designated by the official regulations tem of the material manufacturer certified by 2 aoa body established within the Community and having undergone @ scific assessment for materials eoTW Tee 101006a , WELDING PROCEDURE SPECIFICATIONS AND WELDER QUALIFICATION. Introduction. . Before starting production welding, detailed written welding procedure specifications must be submitted by the contractor to the client for content approval. Alternatively, welding procedure specifications may be provided by the client for the contractor to work to. I here are essentially three documents that the inspector may be required to review: 3 Jer Approval Test Certificate (WAT.C) BS EN 287 -1 Welder Qualification Test (W.Q.T.) ASME IX Article I Welding Procedure Specification (W.P.S.). The Welding Procedure Specification (W.P.S.) is a company produced document \which details the variables required to ensure repeatability of a specific application. The WPS would include for example; material type, thickness, consumable type. joint ucometry, welding parameters, run sequence, etc. \ Preliminary Welding Procedure Specification (pWPS) is a tentative welding procedure specification that is assumed to be adequate by the manufacturer but has not heen approved, \ welding procedure test involves the production and testing of a welded joint in onder to prove the feasibility of a welding prncedure: Different phases in welding procedure qualification (EN ISO 15607 : 2003) Activity Result Party involved [Development oF pWPS ‘Manufacturer j procedure E ‘Qualification by any WPQR including the range of validity based on the relevant standard of qualification Manufacturer and. if applicable examiner / examining body | Finalisation ofthe provedute WPS based on this WPQR Manufacturer | Retease the production Copy of WPS or work instruction ManufacturerFlow diagram for the development and qualification of a WPS (EN ISO 15607 : 2003) ‘An applicable WPS available Jopment of a pWPS ¥ ———— Qualification based ona welding procedure test based on tested consumables Applicable part of prEN or EN 15614, EN ISO 14555, EN ISO 15620 applicable, by the examiner/examining bodyThe ASME system follows the above definitions but includes a third term, supplemental essential variable. Supplemental essential variabl This refers to a change in a wel cof the weld. Examples of supplemental essential variable are: welding , heat input, preheat etc. 1g condition which will affect the impact properties , direction of elding proce {he specification, or the client, will determine whether a new welding procedure would need to be made, this will depend on whether the proposed change is considered to be either an essential or non-essential variable. A fabricator or contractor would be required to submit a new written welding procedure prior to any welding variables being changed for production. Example | A welding procedure specification for manual metal are (MMA) welding has been approved for using basic electrodes. During production the fabricator decides to use rutile electrodes as an alternative, Would this be permissible? No. this change would not be permitted as changing the type of flux coating would be 1 change to an essential variable, A new WPS supported by a new WPQR would be required ; Example 2 A welding procedure specification for a large diameter pipeline has been approved for manual metal arc (MMA) welding using two root bead welders. During construction the contractor wants to raise the number of root bead welders to four. Would this he permissible? Yes. this change would be acceptable as increasing the number of root bead welders would be considered as a change in a non-essential variable, and would not necessitate the submission of a new WPQR, providing that the contractor has submitted a written WPS which has been approved. Approval, without a new procedure being made. could not be given if the contractor wanted to reduce the number of root bead welders. Procedure qualification welds should be made under conditions which siraalate production. although this is not always practicable.Welder Approval Test Certificate (W.A-T.C.). involves the production and testing ofa welded joint in order to assess the capability of the welder. or most applications this single document will include details of the weld test parameters, the test results and the range ofepproval Na general rule this document relates to degree of difficulty Fy aGiable changes and the new variable is considered more difficult to use, then a sew qualification test would normally be required. Summary. | he Welding Procedure Specification is the controling document which is used by ai vieual / welding inspector and other interested parties to ensure compliance and repeatability. The WPS or WPS’s must be supported by an approved Welding Procedure Qualification Record. The Welding Inspector would normally be required to be present throughout the welding procedute qualification test to ensure that the written specification is being complied with. tye welding procedure qualification test also sets a standard with which welders must comply with. A main duty of the welding inspector is to ensure that this isso. |\ welding procedure test proves the compatibility of the base material and © consumable as a welded joint. ‘A welder qualification test proves the welder’s ability to weld in accordance with the approved procedure.WELDING POSITION. Vertical upward: PFI3G Vertical downwe PG/ 3G. Horizontal overhead PD / 4FWELDING POSITION. Weld: Vertical downward Weld Flat Weld: Vertical upwards Pipe: Fixed Pipe rotated Pipe: Fixed ‘Axis: Horizontal Axis Horizontal Axis: Horizontal - as Weld: Hotizontal vertical ‘Weld: Upwards Pipe: Fixed Pipe: Fixed Axis Vertical Axis: InclinedWELDING POSITION. General. {wo systems cover welding position; * ASME/AWS: Until recently widely used in the UK. 1S 6947: Now widely used in the UK and Europe. ASME/AWS: shoes numbers and letters to identify degree of difficulty and type of joint 1 = Flat to 5 = Horizontal vertical / Vertical / Overhead / Vertical up / Vertical down (~ Inclined position fixed at 45° G > Groove ¥ © Fillet ISO 6947: {ees letters to express the orientation of the weld in terms of working position. slope and weld rotation. PA = Flat position PC/PE/PG/PE = Horizontal vertical/ Vertical up/ Vertical down/ Overhead 11-1045 = Inclined position fixed at 45°TRAINING. INSTRUCTIONS FOR PLATE AND PIPE PRACTICAL EXERCISES. SKETCH. Sheets 1 & 2 1 Carry out inspection of both the face and root of the PLATE / PIPE samples. bor the PLATE, plot the position of, identify and dimension any defects found from the left hand edge (datum end A). Vor the PIPE, defect location shall be made from the nearest left hand datum Section A-B measurement from datum A. Section B-C measurement from ‘um B and so on. All dimensions to be in millimetres. Also record any weld features and dimensions. e.g. cap height 4mm. Toe blend poor / acceptable, cap width, 1 1 of 3 for the weld cap face examination and sheet 2 of 3 for the weld root examination 6 Hise she REPORT. Sheet 3. he report should be completed as follows; Column 1. Pipe / Plate Section. This section refers to where the defect is located on the plate A to C. or the pipe A to B, B to C ete Column 2. Accumulative Total. Record the accumulated total length of the defect. Defects such as excess ‘einforcement / excess penetration should also have the height measurement recorded. Depth measurement for undercut should also be recorded. I there is no defect found, write the word NONE in this column (2). Puta line through columns 3 & 4 and write ACCEPT in column 5. Column 3. Maximum Allowance. Record the defect allowance permitted by the code / specification. Column 4. Seetion / Table No. The section / table number from the code / specification relating to the type of defect, Column 5. Accept / Reject. Accept / Reject as applicable. Notes: The sketch can be in pencil the report must be in ink. Do not use abbreviations e.g. LORP for lack of root penetration. De not use suckback for root concavity. missed edge for lack of root fusion, poor pick up for poor restart, Hi/Lo for misalingment. Do not use colour coding or indexes. Do not leave any blank spaces on the report. Ed wis $0800 1 igiArc Energy / Heat Input. ‘Arc energy is the amount of heat generated in the welding arc per unit length of weld, “and is usually expressed in kilojoules per millimetre length of the weld (k3/mm). Ac energy can be shown as the formula; ‘Are energy (ki/mm re voltage x welding current ‘welding speed (mm/s) x 1000 Hou inpue is the energy supplied by the welding arc to the work piece and is nie energy x thermal efficiency factor. sxpressed in terms of Hicrmal eficiemey ts the ratio uf heat energy introduced into the weld to the electrical energs saved by the are ‘Heat mpua values to the weld for various processes ean be calculated from the arc energy by innltiplying by the following thermal efficiency factors: Submerged are welding ( wire electrode) 10 MMA ( covered electrode) 08 MIG ’ MAG welding os Pus cored wire metal are welding ( with or without gas shield) 08 1G welding, 06. Plasma welding 06 ‘sample. ‘A weld is made using the MAG welding process. The following conditions were recorded; Volts 24 Amps 240, Travel speed 300mm / minute Are energy (ki/mm) = are voltage x welding current welding speed (mm / sec) x 1000 - 24x240 (300 / 60 )x 1000 5260 5000 Are Pnergy 1.182 of L.2ks/mm Meas mput + 0.8 = 0.96ki/mmKEY POINTS FOR A.W.S. A2 8 [he use of three reference lines 2, 10 show sequence of operations. ® Staggered intermittent fillet welds welded both sides are shown by the symbol about the reference line. ——1 ® Fillet weld distances are measured snire fo centre. © ‘definite break in the arrow line whea . only one side is prepared. © [dimensions may be shown in imperial.“paloBSeys 99 0} spjom “WUQp Pari Yous uaemjoq aoURISIP at pue WU QZ Pjam you Jo Bud] ap ‘sIPBua] 39} WW OT MM spjom 19] TOHTULIONT OM], :apIs 19490 PapjaA4 "WU Og Pjam Yee Ud9MI9q aoueISIp ain pue ww cz pjam yoea Jo wus} amp ‘sipBuay 39} WU g YIM Slam JI] JANTLLOIUT samy], :apIs MOE PIPPAAL “paraddejs aq 0} Spjam “WwLICZ pjam Yyors usamiaq aoue)SIp atp pure URLS pjom Yoeo yPBud| ay) ‘syPBudy Ba] WNW g splom 19]]y JeNTULAIUT SaTYL :apIs 19yI0 Pappa “UMLIQE PJaat Yea UaaMraq, QOURISIP a] WUT Op PJam yoRS Jo IPSug] ap ‘syrSuay Ba] UW Q] YIM Spjom JOU] TUSHIWOIU! SONY], :Opls MOLE POPPA * 2ounasip aip pue wlu CZ plam yoeo Jo yPSua} ayp “sypBua] Bo] UY 9 IDEN spjon rely Wan RUTaIUT 9am4.] :sapis IOG PapIaA, aiIn verter Systems secant: Lf mene Lf ee Jee A enter FS § he tueeas in Freaneney alo aoe 4 A Stab : Welding Plant = Transformer Changes mains supply voltage to a voltage suitable for welding. ‘las no moving parts and is often termed static plant. = Rectifier: janges ac to d.c., can be mechanically or statically achieved. i (Generator | Produces welding current, The generator consists of an) armature rotating in a magnetic field, the armature must|be tolated at a constant speed either by a motor unit or, inthe sence of electrical power, by an internal combustion engine changes dc. to a.c. at a higher frequency.Welding Inspection: Multi-Choice Questions Paper 2 (Rev.2) I eturn this paper unmarke: | Deflection of the are by magnetic forces, that ca make welding difficult to control, is commonly known as A arcinitiation Bare misalignment © arcblow D ——arcconstriction 2 Which of the following electrodes is classified to BS EN 499 ? A EMIR 8 ool “ ETO. G DESH AS 1 Which oftype of electrode is used for ‘stove-pipe’ welding for overland pipelines construction 7 A tatile Be eellulosic © high recovery rutile DB —allofthe above The three main types of MMA electrodes used for welding C & C-Mn steels are A basic, cellulosic and rutile B neutral, cellulosic and rutile © basic, cellulosic and neutral D__utile, low hydrogen and basic 5 A.WPS may specify a maximum width for individual weld beads (the 'weave! width) when welding C-Mn steels the width is exceeded it may cause lack of inter-run fusion a reduction in HAZ toughness lack of sidewall fusion all ofthe above one> (You notice that MMA electrodes, withthe flux covering removed, are being used as filler rods for TIG welding This should not be allowed because iis wasteful a> z eter be too large the tal composition may be wrong the rod is too short or TIG welding, what benefit does a current slope-out device have ? A itreduces Tungsten spatter 1B —_itreduces the risk of crater cracking © itreduces the risk of are strikes D —__itreduces the interpass temperature Which type of power source characteristic is normally used for manual wel A constant voltage B Mlat characteristic © constant current D—— amotor generator HWE North, Middlesbrough 'Welding Inspection: Multi-Choice Questions Paper 2 (Rev. 2) Please return this paper unmarked 1 In MMA welding, penetration i principally controlled by A arcvoltage B welding speed G ferro-silicon in the electrode coating D current 10 Pipe bores of some materials must be purged with Argon before and during TIG welding in order to ‘A prevent linear porosity B prevent bum-through r prevent oxidation of the root bead 1D elminate morsture pick-up in the root bead |The chemical composition of the weld metal deposited by a C-Mn steel MMA electrode is usually controlled by ‘A the core wire composition 1B additions in the flux coating © iron powder inthe lux coating dilution from the base material 2 Silicon is added to steel, and the covering of MMA electrodes, in order to give . A deoxidation B improve strength C improve toughness D more resistance to hydrogen cracking 1A fusible insert for TIG welding helps to A reduce porosity give controlled root penetration © avoids the need for a back purge D —allofthe above 14 According to AWS 2.4 a weld symbol for the ‘other side is placed ‘A above the dashed line B_ below the dashed line © above the solid tine D_ below the solid line 1s When low hydrogen MMA electrodes are specified for what type of covering will they have? A cellulosic Btutile © acid D baste A hydrogen controled MMA electrode can always be recognised by the EN code letter (or AWS code number) Belectrode length rade Name D colour af the covering, EWE North, MiddlesbroughWelding Inspection: Multi-Choice Questions Paper 2 (ev. 2) Please return this paper unmarked +A quultfied Welding Procedure Specification is used to ‘A give instruction to the welder B__give information to the welding inspector C give confidence that welds will have the specified properties D —_allof the above 24 Anare strike (stray flash) on a steel component is regarded by some codes as unacceptable because ‘A twill cause copper contamination 1 itmay cause had spots © itmay give enching bof bah BAC 25. Ina transverse tensile test, brittleness would be indicated if ‘A there is a reduction in cross-section atthe position of fracture B the fracture surface is flat and featureless but has a rough surface © fracture occurred in the weld metal the fracture face shows beach marks 26 The surface of a fatigue crack will : ‘Abe rough and torn B__have sharp chevron markings © be smooth D have shear lips 27, What does the number 141 refer to on this drawing symbol ? A the WPS Number B the welding process © afiller material D_ the acceptance standard vat 28 The polarity used for TIG welding of all materials, except aluminium and magnesium, is A DC negative BDC positive CAC Dany polarity ean be used 29 Atypical temperature range for baking low hydrogen electrodes is A 15010 200°C B 20010 250°C C 30010 350°C D400 450°C 10 If welding travel speed is doubled, but the current and voltage remain the same, the heat input will ‘Abe reduced by 50% B_ be increased by a factor of two © beabout the same be reduced by approximately 25% TWH North, Middlesbrough 4Student Name. Date. Answers Sheet for Paper 2 Rev 2 OONVAHRWNA3) Toughness tests: Used to check the fracture toughness of the weld zone. Types of toughness test are. a) Charpy V. b) Izod c) CTOD or Crack tip opening displacement testing Ihnere are many factors that affect the toughness of the weldment and weld metal, One of the most major is the effect of temperature. in the Charpy V and Izod test, the fracture toughness is assessed by the cunt of impact'enery absorbed by a small specimen of 10 mm? during a een ay Yor thw Reif le transition cereve fora ferritie steel } Ductile tracture v-fature range . ransition range Ductile/Brittle transition point rs Energy absort (in Joules) Brit i | | | | i 50 40, 30, 20 -10 oO 10 20 30 40 50 Degrees Centigrade The curve can be shifted to the left or right by a number of factors: a) Alloying The curve can be shifted to the left by additions of manganese of up to_1.6 %. Additions over this value have a negative effect on the low temperature joughness Nickel has a positive effect on low temperature toughness, and a 9% nickel steel has good toughness at very low temperatures. - rully austenitic stainless steels are tough down to -270 °C or a few degrees above absolute zero.TR. MACRO INSTRUCTION/REPOR’ (CHECK PHOTOGRAPH LD MATCHES THIS REPORT LD ALL. DE TO BE REPORTED [AND SIZED IF REQUIRED] PEN SENTENCED TO ISO. 5817 LEVEL B [STRINGENT] NOTE: PHOTOGRAPH IS AT X10 MAGNIFICATION MATERIAL: LOW CARBON STEEL WELDING PROCESS: [MMA/SMAW] OMMENTS SIGNATURE:MACRO INSTRUCTION/REPOE CHECK PHOTOGRAPH LD MATCHES 5 Ki ALL DE S TO BE REPORTED [AND SIZED IF REQUIRED] } HEN SENTENCED TO ISO 5817 LEVEL B [STRINGENT] NOT : PHOTOGRAPH IS AT X10 MAGNIFICATION MATERIAL: LOW CARBON STEEL. WELDING PROCESS: |MMA/SMAW] FOMMENTS. SIGNATURELRAINING SANIT Leo MACRO INSTRUCT ION/REPORT SHEET 1D: AM1031 CHECK PHOTOGRAPH LD MATCHES THIS REPORT LD (CTS TO BE REPORTED [AND SIZED IF REQUIRED] ENCED TO ISO 5817 LEVEL B [STRINGENT] PHOTOGRAPH IS AT X10 MAGNIFICATION MATERIAL: LOW CARBON STEEL WELDING PROCESS: [MMA/SMAW] DEFECT SIZK | ACCEPTREJECT | fajed COMMENTS SIGNATURE: PRINT FULL NAME:t 4 a iy 3 =‘ Heat - affected zo 5 = g g a ol | HAZ __ columnar bam 4 wo | @ o [ees he wold ee ae | (1) Overheated sub-cone. Grain growth. (2) Kegningsub-zone, Complete vecrystalli (3) Transition sub-cone, Partial reerytallic (4) Wafected porent metal. Original grain structure, ——parent metal J ie SCHEAATIC HACKOSIRUCTURE OF A WELOGD JOHKT INTHE ASWELDED CONDITION () Weld metal, columnar exystal formation g Ouerheated zone, grain growth. Refining cone, complete reer (2) Transition cone, partial reerystallization (5) Parent metal, anafeeted annealed structure (o) Hahing ene, empl relia (8) Transition gone, (©) Parent metal, sje i 12)Mechanical casting of wallds g by @B Whitaker Sue Gag. Sie OM WL Sunt, LCS. SWS. Mechanical testing is carried out to ensure that certain levels of mechanical properties have been maintained. When metals have been welded, the mechanical properties of the plates may have changed in the HAZ due to the thermal effects of the welding process. Wiis also necessary to establish that the weld metal itself reaches the nunimum specified values are 2 number of mechanical tests available to test for specific mechanical properties, the most common of which are’ |. end tests Used to check weld ductility & fusion in the area under stress. bes of band test ¢ We 4) Face bend b) Root bend ©) Side bend. (10 mm t> plate and MIG welded joints) d) Longitudinal bend [ Face bend t Ductility, good face fusion, and freedom: from surface, or near surface welding imperfectionsue & acsclhrg Tusived ler Iiis Soho clone Renmuwe that all Perations Concer § weldliny] CVE Cars cut sh icheccerefance with written, oragrecel prauctice ser speci Ficalvew The welelins inspectar vrecels sence numerous stipelard peasvins Tools Fé Wl Ver ients potentSur tee TE 4 Lrepectr wel esrsetres [hell Bay 1119Pe he carr Hee? Tran wich will be rrecelecd we war aaron & lhis Sev MW irrchacte reper tig of HELIS Crime ber of ortre Fire fet et v0 0 Preperalienrs ~ AT the be yu oh Anes Giteee TV, asereligy iaspectler should ensure Awt AW hocusnen tS releTes fe Gort ret eve reviewes! bebor fhe start elo oe tcdien beceuse. 13 Pleveles vores of the tithe enc ierr Pete tn Whe” Wher, where & rich bows The inspecTien Te be. chlorite. TIP cok. fa vtnrenS cre werk 2 See trons (Year prerrston) per cevyen$ Lolling iq) clechecte sterege ; ooltumesil Ce Atal ete) heeTion Shtrularcl ( for waual exeminrd precacturess Cay, oreTerialtros Tous wccepTamee ervlerve) erunsytchers é hee k Wats ~The. cade Ah Crstectiers | Vay» (Serres Mewesien Fer assenr by /fitesyrelelatts pelmerste'«y: “ 2 ArPravect weleling prececture spreciQiesWins nel wellers List _Calibrelion Certificates ( weteling eg uiPrrents erate baspecTecn by Tee is | pletler reds caclcensuct bles Cert Pic Tieens» wi Befer weielira rene het His in cccerclance chaswrny [PS tel. can be Pracec! Te relent? cH ficeTes aie cle Pe (eel js in suitable dmrelttic veetef avilable Te oelders (inspectors) we gfltahle 7s the JowwXs Ne we cselded. jscalibratecdand checle ell relele Jarrediaries( Cle ovens, regululers, e7E)>) Hardness tests: Used to check the level of hardness across the weld. Types of hardness test are . a) Rockwell scale Diamond or steel ball) ( b) Vickers pyramid. 2X (Diamond) c) Brinnel (5 or 10 mm steel! ball) d) Shore schleroscope. (Measures resilience) Weldment hardness survey Jardness suiveys are generally carried out across the weld as shown above. in some applications il may also be required to takes hardness readings at the eld junction sometimes maximum limits are placed upon HAZ hardness values, and so if these are exceeded then post weld heat treatments may need to be specified \r attention may need to be given to adjusting any preheat values. \ shore schleroscope measures hardness by dropping a weight from a height snto the surface of a metal and measuring the height of the rebound. Ine harder the material the higher the rebound. Early equipment was umbersome, but more portable than other hardness testing methods. jay equipment is available which works on the resilience principle, but is the size of a ball point pen. his equipment is generally scaled to give hardness values in all of the above scaleswe in tecercturce: with WPS drowsy) 74 ese that i Fice from luraindtians pany surface. ote fects, ) wow on dnetpplaval. list for the Joiw® Mey wsithuseltel aecl apple Certificites cure valid i. oteite EVE iraccerclance WA WPS, being Sferealf Aavediect we accerlance with prececkires = eins aetarclance WI WPS Jelracsing, {for $ilelevandT hevelay preot face, Heof gor, reel Vdd us, Migyrareel, Tack wells tre | devel werk mon Ship pYandlardendalss Hine UF cle? S + Pe per ctecerefumce WARS IW requrivedl aacleheek al! leva Needs is fiiatcees elace WPS (corre, volts, Po lowihy, ete) culel be vereicde befor Wellin % a a aE 4 APY Cre 44 uring wedding _ site [freiel Welelia — emsur weather conrhilions Conrply 02'th Cocle ct lOc Use Corepies the how [3 ir keeerelance OX WP ebistertion cortel (Seg uance Joelanceal we \horg) | Sin aceerelance With LPS ealgleSun Peres WES Yor BecificaTIen , Size char Conch tron for (Velie , JocoTon, methocl, ee Nrel ao eeheng sep yeical [realm cuts eet vo\S, Wave] Seek owe jen acanr han fe WO 73 Gecle. ue Carr Peelrent eb tack welds £15 visually ace~Tarce AT ife y Flow reFE. ancl toriTrol melhedl ate tr accerele ce ahi Fer feof Hun |hol poss. divvoles It S1y250g wen Tru is Toeatprevectwietlscl amelsrtlauble gresvie wetels, 2 cull caus iiie.. the. acta gaug ce! surface prerfewetd the. ccs! < 13 arirtion seed hy Us iiy aback slegplr ng. fechri jgvele reehce liste Trois of the ivelivickeed wetel 2155 + oe We Stee | Cheam I Catan Fe ernseare Lat Le ls BPC Clef. pettiffcedd VOLE A hte bes : ha the foie $$Aa AF fer weleliay - . ebb featlien. epee TheT etal s jrorkeed with wedler edi fiestier pumrber fetes epedd "19 Aecer Hae with eda) mentee Yo Per the eva/iteion ef we tol’s profile (Fee from sharz vet ctl avrosenT af cleslarTion heppercet, well seerfrce (Ve Vrms hsv erTint Prax: Cheanccl front ebjoes soley, Jirrally welel Shewil surtinje for tll MDE reperrwren TS. tat Lp an UE (7 ice elarce with keel fotrenwi) enseurce auny erect frceTigns ielaclecl bo (as-built records! Chit. won kall er ree vinnents Cirefaect, puctife caTion ef feretors, ch) we lall WOE eperitsens CenpheT@l atael Feforls We ees Table: a hey bat cheek wIps Keparr welders pif icoh snc 4 Yer hal Tein speot visually persue firal MOE we on jeleet. oie. Chee ball relevanleguipwrend Cali baled y fea Ze he beFel, hee ep, brelehinty Teste , Costing Boa vel Tonper Tart mreiiss? cine recoredirg obi oTrib aor. “toy Reeinspeet shoulel be carvieotadt tuith yrseted fer MOT Ah POUT iP reguirecl as Goele on pecificeTan s: we Nias avn Teal. |enserme ayy. festeguipmenT 63 cal biraled flevien. hycbalieat preceeteres afler tal brent lar 12578 Fe ensure, cen Plarce. ith precesture| Cache, CnSeve Negro Ts [records eve. wWailable- cleenéry the area has beer fected upter forse ps feet Mme CPSUNE. all recerels- tual taper Ts eve. aoyl eee are sutbytissler? SAeselEfet PS avwlealliehu clecuime 15 16 the O/C cteper onParont metal weld sone Weld metal me . tol wold) Ue . {Seta Leo tiergt eo tlengtm) Examples of toes, legs and weld widthsH Disc tibiae. = Th regure 5 Ahly hy level skied fp experience — Surface rust be fairly sireth _ ference otanolercls are requires " Beguires cobbrdtion " _ Me permenent” Becore. Wis brute por ederils Jess thers Jy Meds Difficalte Fa frlér ppeT~ conic Fru Le fonsimhle eich, soetdnetal / Buse rete direc Ter oh ae" diee Tan Sei w bare nee tal Vcrtohove Sthlerestofe ~ _ Measures herehvess by elopping dulei ght From specificed bight ate th: surface of metal ancl measuring the békgltot the rebound. _ The heigher the rebountof the weight, the harder 3 Va weiTerve/ — Tr seqirmentis generally scaled Fe yite harehress Values 1A allof fhe otha scalestt echusncdl FEsT#t ———— There owe Quatitative etme gualitetive mecleni cal 725 ting @. Quantitative - There cwe matraly usecdtin welding Pre ceckite approval ~ Whe Fy2 h Feist. tsced 5 measure Tensile strength (Wun) 4 Duchility (2% fSome of he peperhes that can be cdeTerminvecd as the. resiu/ti- _wtlhmale fensil strength field strength — Ducfiliy ~ PerEecrt clengdlion ~ Pertent Recluictionef Area AToug rte - Medulis of elasticity —Llostjc Lin’ _propertioral. Livwt é Tyres ef fénsile FéaI-- &# Prarsverse Tensile Test uscd te asvesthe strength of the weldorent elongifdchiral ~~ vv determine (UTS, pretest ebuyeTon pis tAsuceessful Pensil fest clone when Fails happens inthe base meTahy en weld if thapten above the. winimuna specified Pensile strengih- Ee bees Péwt ap evdyess isthe ability of ametal fe resisT, Penetration or tpiiherta fier 4 Tyres f harchess test + Etinet!. (BANS set 5 om herelened steel ball or t6 mm tangster carbice ball = Used (ee Zeee) ky loud wecereiugithe weatertal « wo Melebiny te feaed inthe reaTersdh Freee lo Fé Bo Seconds» ell pnedaodi~ peeks yp Use! fe chelermine the hardy ess ef thin metal gany tes f Eo _ usec! (ho 5e) Ky foacl — actersting 13 Phe ability ef rreterial. Medd vnuderitrs of several. Maneters{ chamend Brale ,or| Yip ro YzJomels ole _ found mary scales. B Forsefter ailey C ferhareler IYPE. A Kor ungnown Mey because (Teovering 7,6 scales. + Micro hurela ess. _ fis varyheneficial ithe eeinves7ig alien of rctal micro struclares becets canbe rer formed on single grair7s of metals = Tres Vickers and KN oe py = Lealhisecl Frem I~ Jeoo Jr Fhe muforily (loo- Soo) gras ted. , hee ue Moree Twn ne ahah he LELahm besviirce 3 el: se 4 Check the resistance te mmpacT hecuelior5 _ usectta lelapmine the amecvitef energy regaivedd Ie biTiale acvet € Land the someinsTop ackel banal exergy repuirecd For The crack 18 grou, PRyepyel a TYpes © f fest —CTOD | or creek TP opevsinny Displacement testing — (wut the frent” | Ft/bs) we (Ear ( Jevlee : -TZ0D specimen held verlealy Me arachise, noted Chany Vo ~ + herieosttaly ~~ a 4 Charpy V _ Shis the mest Comment Test us ecly Temp eritare 13 theimporlateffert inthe le.» — Uisec! char 135 mya borg devel bo mon by le mon Sy tare. _ Pie rele 5 2 rue Mee. , O25 ney Fool Pactiss fp pelch 45° O- ~The behasiref the meTal change From Muctile fe brittle by change Me temp Ma ep eI I EN GR willimproviny The Taughness- Bb). Qualitative ve muisaly Useelin welder Attrevals . — There ew LIB Fe BT sy. sec fe check welel ductility fasiow (seurseness) inthe area wuler shes of bend fest eve usually nam cel based on The orientalis —Thecl Nerent BP ob the weld with aspect Ze the bending «tien There wie #3 Types Ah Transverse weld benel $ dugitudinal berets There wie 3 bazpe Types ef bend fi§- Guided! ened roller ef wipped juiced bend wrere eienrel gue elecl Bend Day eetio: of the tect face is mace after the Est te check. the ize itn! huimhey of elefeet® which appear ot The fenstor supface~ Byer ow Toots # Mis Test juclyes the Seurdaess ofthe weld by fradaring the sp keine a cgutnaly of cltsy through heweld, 30 The Fracture Surface examine forthe pres: 4 Tre procfure /slecalized inthe weld zune. by The use of cow cuts aley Kiem cr thre ctr faces.4 Whe speciuren seer aly CLT OY PBK Sed Horaegh the weld faces Fe actey th statéet 17 The 3 Taindards LAM fw ehl Frichare. Io. — This teT judges She seuncdness of the weld by the bractariag The weld face. = This 13 reguitecd Fev the gualif ication of tackens in accordance With AWS DLL wight ne weuld indicdte aleck She prackire Surface is Ckaminecd did ary stra oh rect fusion au this sfficienT Fa fail The wedders cut by hacksas through the weld face Zo aeleplh Tie spicier 13 Hermrrally (l-2)iam sfateol iv the stanclare-: GG). Hig cacumnticn Fest used! te clelermine Stith Thingsr _ deplhel fusion acleyth of rerreTpatio = effective three R weld rcunchess ~ degree of Juste ~ Presence of welel eliscomfinity " Needls oly nyrough grein with ar BO grit Finish. ts reveal the structure. by acid solution (5- bt Wilreseid)in ale, efehiy cat from a step) stot position in the reefer helps _ Secmenss rermally _ Mecids pelishong by using Progressively finer grit Paperwe forests. TESTA) ®%- x Penctiant testing vevedls sur face elis continuities by the bleceleit of apenetrihy mecliuns aganist a contpasting Coferec! back ground # Tyres of pT Were ave Toes Privrary aps i which penetraitm aerials are freiper = by the Tyre oP inchedtion Pre claced 4 the rrethod » fexcess pertren it” rerreviul- « Tht Tipe of incation Proclucecd 1 Too Hes The visible elye ( usually veel) Prehuces avivid reel ireli cation aga mn, ph televeleper backsyrecurd When Vreweel ureler while ligt _ Tie fluorescent Perri? Prodtces agreensh Plearesce-ot iniclice Tory against al ght background when observer! uncles ultraviclet (black) bight: ta use of Fluorescent canresult in amore sensifive Jest: 4 The meth cl ofewcess Pentraritremoval | Bi (walker washable — SclvenPFemovable - Post emulsifiasle ) 4# Basic Procekayve.:- eS bce repr dient. Compeneetinust be throughly Cleaned 4 Free From oil, rushpairt, cfc K ctiady iT wp hcation i= penetra Tappliec! bf lpping or by 3, Prayin (brushing) a Te cctwell time (5- Se edinite) » we Frasihe nel alleroced Poccess yt qwithaclean jin three cloth, Finally wipe with asoflpyer J morte rect with Liguiel solvedt Rlphicircre af clove fey ere © Reafrel thal h os been dawn inte aereck by capillary ATiors will he drown outof the clefecT by reverse capilary achon — Age purticle dize @rel Thick Layers ef olereloper Will Fer Ste chee reise the sensIhily of fhe penetreait. # ope behing firclectienbe Fea li AR aA hylan tales Fe af qener Tiny anraqine tie pide ti) the fest piece, ONC disc wales are preset; these perTicles ve(t be alrectlect. eandletivess of pan particles andl avisual jich celTion ~ a Tires, of AlagneTiz. Piel duced. Pernsarreit rag ned elect magnet current blows A The. may eTizing current must be sufficient te Wf "V8 Ky” wet DC magnetization ¢ pkg? with Ac magnetrzctYen- *# Slethod » the contrast Pain? inthe Area Ts be exapar eel lex ust he applied while the pals rignchie netic partiiles misthe observed $i = Arphos a Magne He porte. - Any accunulation of ong vlaqea # OF a Pre clearing netas crifiealas with OPI -surlace fe fects. With defect surfoce and Some sub = Kafied feshing speed and Lew Cost. _ The method Can be wracdeé ce lremely Portable _ fessible te imopect Through thin doaThags. Ki: witewe + Must be applied 16 Ferremag nei priate ines ely. uirecd “specially tra AE “Method” (simvle eguiparesit —DemeypeTredTion pray be © ferts rust be cleaned befor anel af fer inspection io way mask refectable hacli aliens The very Shick CodTir§ of eyphcaTions 5 Mis pray Meni, (por leh FY oF hectic ty 13 reguirec! for 7103 We perrancrt Becorel. — Beginred Jo festivr 2 irecten. — Curren Fle Prods — ore sTrikes-st Lacliv. graphic testing ## oe # Kachographic. testing of weld ment or bratemen? emplys £-rajs or Comma rays 72 PeneWate an objectand cdetet any cliscoritoruily by fhe resulting Inage on arecordling or aviewing petecl ter 4 Areas of high rection Pransmission, or lows obserption (Thinnest Area} Procluce, darkest ovrthe. Filva anand with the highestclensity wmch absorfsthe most ractidlien will appear hight onthe filva- & Gammra vfs _ Bre the resulk eof the olecuy of ractio ative mdleriads such 43 Lridjuny i 72. Cesium ISF Cobalt £0 4 LA-TAYS-~ — They cue jrecktceed her clecTpons, travelling aT high peed, Colficle wilh cc ther- aul the tenversion of eleetPredl eneryy Ze z-ractiation 1's achiered in an evacuctécl (Vacuns) 7abe- KLQL pare trroneters . Inage suality jadicater ave usectts verify the resolitien sensitiv ly of the fest These are Z ty Pes (shin on wie) we lewal ltley » are used ta lelentihy The Test object & Adlvaritayes _ Permiunrent” yecorelif storeel Properly away from heated tight "Stcan cefect surbace ancl-sub surface. otis onlin ui Hes Shean be tested all common engincsring materials. _ St can asses Penetration in small cliameler or line PIPE ~ Sean ywe a ctirecT Innage of Flas. — Campa rejs 1S very Perlable- x Disadvantages .~ © Be hazared Posect 76 humans by ezcessive ractioTien CLposure- _ Many hours of training ir racliéTien a fy oe required) hor BA personnels. _ The tes! perker rect aller the 727 area hasheen evacuated. _ We equipments are Very expendi Ve~ hith cost _ operators 4 inter ppefers needs high shills. Gis nee uteel for acces Je beth sicles.of the-test-objet- t+ Be eet ee hrc cre FInd Nge lUllfasciuc. Te Tai ee eee a tis any imspecTion meted Wack ases Wagh Frequency sound Waves, well above the Mga of human hearin jterreasure Jeon ancl Pi sica. Peper Tes fa rralerie ls Pea Ting U3ES eclectic encryy ta the Form of an applied voltage eis converTet bY aTruns ducer Je rrecharical eneryy vs enversion called Prezoeledirr. ef (ec Tie niaterials Ufa 01" avred This Volta Inthe fern ef souncl waves Th arte § boridm Ti tandtecl used as Pec prezoelee xA_Dveatag® wiaks Cue Verevad pes Tanke ty Cemepley deemidt arrheabie fo courall parts cpl ge Lew ater ty Lew epretoy SELL Leyele a dy oun tary © + appheable te Perous Surya poem timtve sword be chesy aad open te The serpae 4 te beds Tb yeheotl aurtace Prepare trace POU pe Pay manend vera d oe rt Yeccerede Union! yee Sage be Geeca apy Nee hva eh PEN SVE Cevipaunl myrck beca tien a6 detech wld be apphed wrthed Cover wat phelecl sub. svVad defects Cotas) feuick msted Mogae § iat feokew cenier dtiy poeeter) aha phe eayi pment pe falamively bow va SA Pay be 5 ed ww The dak Cus wad) vetle pa teyperd Mayeactis Tei Conte - Veyre waivielve wade cals only Acreas Py be A oebdees Gn the Yor weeel power 1 amy ok Take : a carbya ten ab Save P aed Vea garred Leh vay 2 dre Meng hee ed yaad Wade fier LEK ae Demetyre oa tter map be ry Ce ypead Pike wl pends Ave state | |UT Ady portable (we battery aneet boat fon Bowen o \ 7 ey gen etehyy Ue ‘ en a Gewed uw aay eGo Coy ctdewins \ ‘ A whe Paice uate ts we ? qmanenk Feeee dl Cyatess aukiviakel ) Wok bewel ek ape ater awale Te quire lt Pah rte a Suapens wh peqeard ayy kw Fant dhay Ube, Peder od we qand Vay te Peniio pare wet tae Ache at Ve Co Ae vewde Ret ae ees a dae, te Abad oy a Cyt ob Nite Cod Mees ws) ogee weg em bet Wenn’vecuydl food Vo Sas siat wow pdare hevedls | Fi ams am ag wate ake wack Tage 3f clog vets HP Ln ws a Pa aeln, mabe PPE oo ee ora th Gesense . Lewitt Wass saFe ty & Neat) . jeanne vA delecd acta’ ow ‘ ener planar Htetort je leer 5 Reces To bete “des cequu ed * aged vw Ker pretation yeu B Lcerepes hare hak te C cost) * Lae tet ye by oo bew : Iriqgh Capeval ces °MANAUL METAL ARC STICK S.M.A.W. WELDING (U.S) (SLANG) i D.C. (portable-safe on site, 50voc) A.C. (80v ocv) SITE/SHOP oclep D.C.E.N. SHOP APPLICATIONS DEEP PENETRATION SHALLOW SIMILAR TO DCEP/DCEN FILLET WELDS & OPEN ROOT” FILL & CAP PASSES BUTTS ~~ T WELDING VARIABLES VOLTS(arc length) AMPS(penetration) RUN OUT(travel speed) ELECTRODE | _(bead shape) | LENGTH ‘ANGLES CONTROLS SLOPE TH HEAT INPUT | AFFECTS BISECTS FOR EFFECTS SIMILAR PENETRATION ANGLE OF TO MIGISA WELDING JOINT CONSUMABLES (PRINCIPALLY) Co — 1 BASIC RUTILE CELLULOSIC \ 1 (no drying) LOW Hz FOR GENERAL HIGH IN Hz POTENTIAL PURPOSE NON- | (BAKING) CRITICAL APPLICATIONS VERTICAL | (dried not baked, good profile) DOWN “CRITICAL” (high strength “STOVE PIPE” wpLos welds) eee TYPICAL DEFECTS r SLAG LACK OF FUSION PROFILE POROSITY Hz CRACKING INCLUSIONS PENETRATION DEFECTS STOP/START ~ 7 ' APPLICATIONS r Sn En PIPELINES NOZZLES! MEDIUM/HEAVY SITE NODES FABRICATIONS APPLICATIONSTUNGSTEN INERT GAS ALSO KNOWN AS STAM. wiG ARGON ARC HELI ARC GAS TUNSTEN WOLFRAM UK TRADENAME US TRADENAME ARC WELDING INERT GAS Li ' ee | NORMALLY DC. TS ArorHe _ AC. | SHEILDING GAS C.E.N AL& Mg ALLOYS FOR ALL MATERIALS (CATHODIC EXCEPT Al & Mg CLEANING) THORIATED OR ZIRCONIATED CERIATED TUNGSTEN TUNGSTEN WELDING VARIABLES S 1 aeane T T AMPERAGE VOLTAGE TRAVEL GAS FLOW ELECTRODE SPEED RATE EXTENSION 1 1 I CONTROLS CONTROLS DEPTH OF PROTECTS AFFECTS I \ PENETARTION WELDFROM — PENETRAION FUSION & ARC LENGTH ATMOSPHERE 1 PENETRAION (CERAMIC @ L GAS LENS) eee | —— TYPICAL DEFECTS ' — TUNGSTEN ROOT POROSITY LACK OF INCLUSIONS CONCAVITY FUSION APPLICATIONS a AEROSPACE CRITICAL GENERAL MECHANISED MATERIALS ROOT RUNS LIGHT APPLICATIONS IN PIPES. FABRICATIONSMIG/MAG T CC T T 1 METAL INERT FLUX CORE CcO2 G.M.AW. METAL ACTIVE Gas : : ws) Gas = T ALL DIRECT CURRENT NORMALLY POSITIVE) ~~ (Synergic) DIP eenecen GLOBULAR TRANSFER eee nenener PULSE TRANSFER LOW VOLTAGE(16-18) MED VOLTS HIGH VOLTS (20) HIGH & LOW LOW AMPS(135.158) MED AMPS HIGH AMPS (300) VOLTS & AMPS [wow HEAT) THIN SHEET FILLING PASSES: THICK PLATE ALL POSITIONS ROOT RUNS IN. USING MAINLY FLAT & HV. THICKNESS BUTT-ALL WITH FLUX POSITIONS > 6mm POSITIONS: CORED WIRES WITH A} t (Unstable arc) WELD VARIABLES: ToL IT ELECTRODE INDUCTANCE WIRE TRAVEL GAS . VOLTS GAS EXTENSION FEED SPEED FLOW ‘TYPE AMPS RATE | | AFFECTS “SMOOTHS” CONTROLS CONTROLS PROTECTS CONTROLS AMPS ARC FUSION & DEPTHOF WELD ARC CHARACTERISTICS PENETRATION PENETRATIONFROM LENGTH | | ATMOSPHERE _ L TYPICAL DEFECTS t IT ALL LACK OF SOLIDIFICATION POROSITY ‘SILICA FUSION TYPES CRACKS/PIPES INCLUSION 1 (SPRAY) (Fe ONLY) APPLICATIONS SOME OFFSHORE STRUCTURAL ALUMINIUM STAINLESS (FLUX CORED ONLY) STEEL SECTIONS STEEL & Ni | ALLOYS ‘SEMI-AUTOMATIC OR MECHANISED OR AUTOMATIC (ROBOTS)SUBMERGED ARC | TRACTOR TYPE (1000 amps max due BEAMTYP! _BOOM-TYPE MULTI-HEAD TYPE mS Ac. a i DCEP, D.C.EN. USED ON I MULTI-HEAD DEEP SHALLOW SYSTEMS TO PENETRATION PENETRATION REDUCE “ARC BLOW” 1 EFFECTS WELDING SURFACING/ 1 SOME WELDING SQUARE WAVE A.C. APPLICATIONS: SIMILAR TO D.C.E.N. & D.C.E.P. a WEL DING VARIABLES. _ oo —7 VOLTS WIRE FEED TIP TO WORK TRAVEL FLUX SPEED (AMPS) DISTANCE SPEED DEPTH | I I 1 CONTROLS CONTROLS CONTROLS CONTROLS . PROPERTIES ARC LENGTH FUSION & ELECTRODE DEPTH OF & i PENETRATION EXT(NOT VISIBLE) PENETRATION POROSITY FLUX CONSUMPTION 1 WELD METAL PROPERTIES FLUXES = 1 AGGLOMERATED FUSED \ | LIGHT IN COLOUR TYPICAL DEFECTS DARK IN COLOUR “SPHERICAL” IN “PLAKEY IN SHAPE AS FOR MIG WELDING SHAPE 1 \ LOW H2 POSSIBLE (BAKING) (Except Silica Inclusions) GOOD SURFACE PROFILE 1 BEST PROPERTIES PROPERTIES | REASONABLE a APPLICATIONS SHIP HEAVY CIRCUMFERENTIAL LONGITUDINAL —_GLADDING BUILDING FABRICATION WELDS (ROTATED VESSELS) tL? d SEAMS PIPELINES SEMI-AUTOMATIC/MECHANISED APPLICATIONSTRAINING SAMPLES Acceptance Stand Macro Examination: (Ref. TWEN/WIS-ME-sentence-2002-rev 0) (el IMPERFECTION REMARKS MAXIMUM DESIGNATION ALLOWANCE 1_| Cracks _ —_ not permitted 2 | Porosity/gas pores/elongated | Maximum dimension of any | 1.5mm gas cavities [wormholes] __| individual 3_| Lack of fusion sidewall, inter-run, root ot permitted {4 | Incompietely filled groove not permitted C5 | Undereut smooth transition is required | Imm max. depth 6_[ Are strikes/stray flash = = [not permitted 7 | Excess weld metal * ‘smooth transition is required and | Imm + (0.1 x weld a ____|{ all runs shall blend smoothly _| width); max. 4mm | Solid inclusions (slag, silica, etc) | any inclusion except copper 1.5mm. ‘9 | Copper inclusions not permitted 10 | Overlap _ not permitted 11 | Lack of penetration not permitted 12 | Root concavity/shrinkage groove 7 Imm max. depth 13 | Excessive penetration * Imm + (0.3 x bead L - - width), max. 3.5mm 14 | Caps, laminations depends on application; 7 __ ___| make your own judgement 15 | Mechanical damage not permitted 16 | Angular misalignment = accept 17 [Linear Misalignment [high/low : 10% t up to max. 2mm * When linear misalignment is present, measure from the lower plate as shown ‘EXCESS weld metal excess penetration Nay”TRAIN SAMPLE ONLY MACRO INSTRUCTION/REPORT SHEET [1.D: AM1033} CHECK PHOTOGRAPH I.D MATCHES THIS REPORT LD 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] ewealneuln =k | SIGNATURE: : ~ DATE: | PRINT FULL NAME:MACRO INSTRUCTION/REPORT SHEET : AM1033) CHECK PHOTOGRAPH L.D MATCHES THIS REPORT 1.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]MACRO INSTRUCTION/REPORT SHEET [I.D: AM1034] CHECK PHOTOGRAPH LD MATCHES THIS REPORT LD ALL DI (CTS TO BE REPORTED [AND SIZED IF REQUIRED] NTENCED TO ISO 5817 LEVEL B [STRINGENT] NOTE: PHOTOGRAPH IS AT X10 MAGNIFICATION MATERIAL: LOW CARBON STEEL WELDING PROCESS: [MMA/SMAW] TACCI EPT/REJECT __|CHECK PHOTOGRAPH 1D MATCHES" ‘ PORTED [AND SIZE! 'O 1SO 5817 LEVEL B [STRINGENT] NOTE: PHOTOGRAPH IS AT X10 MAGNIFICATION MATERIAL: LOW CARBON STEEL ae WELDING PROCESS: [MMA/SMAW] N . iu 12 EXC COMMENTS: » dares on aft ee hay | SIGNATUR TDASAMPLE ONLY HEET |1.D: AM1030 TRAIN MACRO INSTRUC TION/REPORT CHECK PHOTOGRAPH L.D MATCHE: ALL DEFECTS TO BE REPORTED [AND SIZED IF REQUI THEN SENTENCED TO ISO 5817 LEVEL B [STRINGENT] PHOTOGRAPH IS AT X10 MAGNIFICATION MA |AL: LOW CARBON STEEL fe) epibos 3 alispan AD ACCEPT/REJECT _ aley vin Fra $0 an a slag Tcby Law k ok vert at fohin | | } | ' + as COMMENTS SIGNATURE: +f | SIGN Ef { PRINT hamed Elewiel KashaPage Lot? VISUAL INSPECTION PIPE REPORT Name [Block capitals] STEVE HUGHES Signature S¥_Hughes ___Pipe Ident Code/Specification used YOUR CODE Weldin Welding position___SG_ wr Outside @ & Thicknes Lid. 1g Process___ MMA _Joint type 168 x 12 mm Date_12 march 03, D FACE, Cap height Smay Cap avidihy 18-21 Tog blend! poor Cap height 3am Cap width 20-22 Toe blend! smoath HiLo 0.5mm Stray are A 0.5 deep smooth Incomplete B Sr] fel rl apa J deep smooth Poor restart 89 Mu i rm »| | 3 x Stray ares B +—— <1 deep sharp Cc ~ - 3 7 Cap width 18-24 ing leep shat - Toe blend poor Grinding | deep sharp ia Underent Underent Unudercat y 0.5 deep shor Underfilt sharp sharp smooth twas om weld “pele 2 Spel] SA» | | a. =e = wey Ae] 31 pen unten aL | intermittent 18 tnalerent 25 eee Stray are 0.8 deep 10 —> 26 noo Grinding Cap width 17-20 1.5 deep Grinding | Toe blend poor sharp deep smocth Hilo 15mm PTO IFoR ROOT!Honetration wich 7 ‘Toe blend poor Penetration height 3 Penetration width 6-8 Toc blend poor Hite ints Hille 0.5mm A Underout B—Unvereut Undereut ¢ 0.5 dep sharp 0.5 desp shorp 0.8 deep sharp 24 30 - | i SL “Undercut Underout { 0.5 deep sharp 0.5 decp shaxp ! \ { ngermittent Undercut Poétration height 3 Penetration width) 6-8 ‘Toe blend poor Hilo Lan D A——~ 1 deep (tas) sharp A Intermittent Hp (ae) sharp undercut | 0.5 decp a fi shuep i — if == t 6 jow | a Cie | oe a im = Unda 0.5 deep sharp concavity concavity 0.5 deep Tdoep 0.5 deep smooth Penetration height 1 Penetration width 6-% ‘Toe blend poor Hilo teamWELDANSPECTION REBORTSENLE Sheet 3 of | STEVEN HUGHE