Defect BWE

20 dB Beam profile

10%

When the main beam is on the defect the defect signal is at it maximum

If the probe is moved and the signal is observed until it is reduced to 10%
(20dB Drop), the edge of the beam is on the edge of the defect

Repeat the above at the other side of the defect

Using the pre‐constructed Beam profile and a plotting card, the defect
maybe sized
Product Technology
Welding
A Weld : Definitions
•  A union between •  A continuous defect
pieces of metal at faces surrounded by parent
rendered plastic or material
liquid by heat,pressure
or both. NASA
BS 499
 Welds
•  An ideal weld must give a strong bond between
materials with the interfaces disappearing

To achieve this

• Smooth,flat or matching surfaces

• Surfaces shall be free from contaminants
• Metals shall be free from impurities
• Metals shall have identical crystalline structures
 Welding
• A unio
union
n betw
betwee
eenn piec
pieces
es of
of meta
metall at face
faces
s
rendered plastic or liquid by heat,pressure or
both.
BS 499

Possible energy sources

• Ultrasonics
• Electron be
beam
• Friction
• Electric re
resistan
tance
• Electric arc
Electric Arc Welding

Electrode

Power
supply

Work piece

Clamp(Earth)
 Electric Arc Welding
•  Electric discharge produced between cathode and anode by
a potential difference (40 to 60 volts)

•  Discharge ionises air and produces ‐ve electrons and +ve

ions

•  Electrons impact upon anode, ions upon cathode

•  Impact of particles converts kinetic energy to heat (7000o C)

and light

•  Amperage controls number of ions and electrons, Voltage

controls their velocity
 Electric Arc Welding
Arc Welding Processes
•  Manual metal arc
•  Tungsten Inert Gas
•  Metal Inert Gas
•  Submerged Arc

Differences between them

• Meth
Method
ods
s of
of shi
shiel
eldi
ding
ng the
the arc
arc
• Cons
Consum
umab
able
le or
or Non-
Non-co
cons
nsum
umab
able
le ele
electr
ctrod
ode
e
• Degree of
of au
autom
tomation
Zones in Fusion Welds

•  Fusion Zone
Zones in Fusion Welds

•  Fusion Zone
•  Heat Affected Zone
Zones in Fusion Welds

•  Fusion Zone
•  Heat Affected Zone
•  Parent Material or Base Metal
Joint Design
Butt Weld

Corner Lap Joint

Joint

Edge Weld T Joint
Manual Metal Arc (MMA)
Consumable
electrode

Flux coating
Arc

Evolved gas
shield
Core wire
Slag

Weld metal
Parent metal
Manual Metal Arc Welding

•  Shielding provided by Welder controls

decomposition of flux •  Arc length
covering
•  Angle of electrode
•  Electrode consumable
•  Speed of travel
•  Manual process
•  Amperage settings