RTFI Q&E (CTMS 308196) PARTICIPANT INFORMATION INTERPRETATION (CONT’D) Film Density Film density shall be measured with a calibrated densitometer or a film strip of known densities. SAEP-1143 par. 8.3 specifies that the film density throughout the area of interest and the body of the IQI shall be between 2.0 and 4.0 for gamma radiography and between 1.8 and 4.0 for x-ray radiography. Furthermore, there shall not be a density variation throughout the area of interest of -15% and +30% from the density measured at the IQI. If the density variation exceeds the limits, additional IQIs shall be used for each area of varying densities. Backscatter if_an image of the lead letter ‘B’ appears on the radiogre it a the radiograph has excessive backscatter a1 dark image of the letter ‘B’ is not cause for rejecting the radiograph. Film Physical Quality All radiographs shall be free of any mechanical, chemical or other blemishes that are in the area of interest and could mask a discontinuity. These include but are not limited to processing defects, scratches, crimps, light leaks, static marks and manufacturer film artifacts. 2RTFI Q&E (CTMS 308196) PARTICIPANT INFORMATION DISCONTINUITY INDICATIONS A film interpreter shall be able to recognize the different types of discontinuities on a radiograph. He shall be able to differentiate between types of discontinuities, as one type of discontinuity may be acceptable to the acceptance criteria whereas the other type could be rejected. He may request for the surface to be prepared (ie, grinding) when a rough weld surface profile could mask discontinuities due to changes in film contrast. Sometimes it can be beneficial to visually verify indications that could possibly be on the weld surface. The two major types of discontinuities covered in this module can be divided into two groups - welding and casting. Welding Discontinuities The various discontinuities found in welds and their appearance on a radiograph are sometimes similar in appearance. In order to recognize the different types of weld discontinuities, it is important for the film interpreter to know how the weld was made. By knowing the weld joint configuration, he can determine which areas of the weld are susceptible to certain types of discontinuities. By knowing the welding process, he can determine which discontinuities are most associated with that particular welding process. By knowing the welding position (ie,, flat, vertical, horizontal and overhead), he can determine the type and location of certain discontinuities due to the effect of gravity on the molten weld pool. BRTFI Q&E (CTMS 308196) PARTICIPANT INFORMATION DISCONTINUITY INDICATIONS (CONT'D) Welding Discontinuities (Cont'd) Porosity Porosity is caused by trapped gas in the weld before it solidifies. In general, porosity is not considered a critical discontinuity unless it is present in large quantities, contains sharp tails or is aligned in significant numbers. Porosity usually appears as dark round indications and can occur anywhere in the weld, Porosity can be subdivided into different types: © An individual pore is porosity that is one single pore. If there are no other pores in the area, itis classified as an isolated pore. 9 Clustered porosityis a concentrated area of porosity that is in groups of pores — Random porosity is porosity that is evenly distributed throughout the weld. ° — Hollow beadis linear porosity that is found in the root pass. It is a gas pocket that tunnels down the center of the root pass. It is differentiated from other root pass discontinuities, as full reinforcement of the root pass is evident on the radiograph. Slag Inclusions Slag inclusions occur from trapped slag and oxides in the weld metal. Slag appears as a dark image on a radiograph. Trapped slag is not usually found in the root pass of a weld. Slag can be classified as an isolated inclusion or as slag lines. It is found in welds that were made by a welding process that uses flux as a shield from the atmosphere. Tungsten Inclusions Tungsten inclusions occur on welds made with the gas tungsten arc welding (GTAW) process. They occur when pieces of the tungsten electrode have broken off into the weld and may appear anywhere in the weld. They appear as light images on a radiograph due the high material density of tungsten.RTFI Q&E (CTMS 308196) PARTICIPANT INFORMATION DISCONTINUITY INDICATIONS (CONT'D) Welding Discontinuities (Cont'd) Incomplete Penetration Incomplete penetration occurs in the root of the weld and is a condition where one or both root faces have not been melted. If only one root face has not been melted, it appears as a dark straight line. If both root faces have not been melted, it appears as two dark straight lines. Incomplete Fusion Incomplete fusion is the failure of a weld pass to melt into the base metal or an adjacent weld pass, and can occur anywhere in the weld. It appears as a dark straight line Internal Concavity Internal concavity (suckback) is a concave condition in the root pass and appears as a dark image on a radiograph. Concavity causes dimensional changes in the thickness of the weld, which can cause the weld thickness to be less than the base metal thickness. Undercut Undercut is a groove melted in the base metal at the edge or toe of a weld. It can be external on the edge of the weld crown or internal at the edge of the weld root It appears as a dark straight image sometimes with jagged edges. Underfill Underfil is the insufficient filling of the weld crown. It can be detected by visual inspection. Underfll will appear as a high film density area on a radiograph. Excessive Internal Reinforcement Excessive internal reinforcement is excess weld metal built up at the weld root. It appears as a light image the full width of the weld root.RTFI Q&E (CTMS 308196) PARTICIPANT INFORMATION DISCONTINUITY INDICATIONS (CONT’D) Welding Discontinuities (Cont’d) Burn Through Burn through is a hole burned through at the root pass of a weld. It sometimes occurs adjacent to an area that has excessive internal reinforcement It appears on a radiograph as a dark round image. Excess External Reinforcement Excess external reinforcement is excess weld metal built up on the weld crown. It can be detected by visual inspection. It appears on the radiograph as a light image the full width of the weld crown, Cracks Cracks are the most serious of all the weld discontinuities. Cracks are caused by rupture of the weld metal or base metal due to internal stresses. Cracks appear as dark lines which can be either straight or jagged. Cracks can be further classified as: © Transverse cracks which are perpendicular to the long axis of the weld. © Longitudinal cracks which are oriented parallel to the long axis of the weld. — Root cracks which are longitudinal cracks located in or along the weld root. Crater cracks which occur in a crater at the end of a weld bead and are star-shaped. © Underbead cracks which occur in a weld bead and propagate into the heat-affected zone in the base metal.