Example Slide of User

Functions Time guide the slide

Lap Joints should be finished
by
A fillet welded Lap joint*

A spot welded Lap joint*

Indicates a click is required to progress to the next

element
Relevant course text section:page/pages if applicable

Text Page Ref 1:9/10

 Terms & Definitions

A Weld:* A union between materials caused by heat,

and or pressure

A Joint:* A configuration of members

Text Page Ref 1:1

 Types of Welds
Butt welds:*

Fillet welds:*

Spot/Seam welds:
*
Plug/Slot welds:
*
Edge welds:*
 Types of Joints
Butt joints: *

T joints: *

Lap joints: *

Corner joints:* Closed Open

corner corner
*
 Weld Preparations

Remember, the purposes of a weld preparation is to allow

access for the welding process, penetration and fusion
through the area of the joint and its faces*

The basic rule is this:

The more you take out, then the more you must put back
in*
This has major effects on economics and distortion
control etc
The root face, root gap and angle of bevel values, the
choice of single, or double sided preparations, are dictated
only by the type of welding process, the position and
accessibility of the joint*
Weld Preparations
Angle of bevel*
Root face*

Included angle*

Root radius* Root gap*

Root landing*
Types of Single Butt Preparation

Single bevel

Single V

Single J

Single U*
Types of Double Butt Preparation

Double bevel

Double V

Double J

Double U*
 Welded Joints
Butt Joints

A butt welded butt joint*

A fillet welded butt joint*

A compound welded butt

joint*
 Welded Joints
T Joints

A fillet welded T joint*

A butt welded T joint*

A compound welded T joint*

 Welded Joints

Lap Joints

A fillet welded Lap joint*

A spot welded Lap joint*

A compound welded Lap joint*

 Welded Joints
Closed Corner Joints
A fillet welded Closed Corner joint*

A butt welded Closed Corner joint*

A compound welded Closed Corner

joint*
 Welded Joints
Open Corner Joints
An inside fillet welded Open Corner
C rner joint*

An outside fillet welded Open Corner joint*

A double fillet welded Open Corner joint*

A Butt Welded Butt Joint
Weld Face*
Actual Throat Thickness*
Weld Width*
1.2.3.4. Weld Design Throat
Toes* Thickness*
1 2
A

B 3 4

HAZ* Fusion
Weld Root* Boundary*
Fusion Zone*
A + B = Excess Weld
Metal**
 Sizing of Fillet Welds
Vertical Leg Length*

Weld face*

Horizontal Leg
Length* Excess weld metal **
Design throat*
Actual throat*
Nominal & Effective Throat Thickness

“a” = Nominal throat “s” = Effective throat

thickness thickness

 
a s

Deep throat fillet welds from FCAW & SAW etc*

Fillet Weld Profiles

Convex Concave Mitre

*
Concave is preferred for joints subject to fatigue loading
Effect of a Poor Toe Blend Angle

6 mm

80°
Very Poor Weld Toe Blend Angle

3 mm*

20°
Improved Weld Toe Blend Angle
 Effect of a Poor Toe Blend Angle
It is also possible that the height of excess weld metal is
within the accepted limit of an applied standard, but the toe
blend is unacceptable,
unacceptable as shown below*

90° 3 mm

Extremely poor toe blend, but excess weld metal is within

limits*
 Summary of Terms
Weld: A Union of materials
Joint: A Configuration of members
Weld Preparation: Preparing a joint to allow access and fusion.
Types of Weld: Butt. Fillet. Spot. Seam Plug. Slot. Edge.
Types of Joint: Butt. T. Lap. Corner (Open & Closed)
Types of Preparation: Bevel’s. V’s. J’s. U’s. Single & Double Sided.
Preparation Terms: Bevel/included angle. Root face/gap. Land/Radius
Weldment Terms: Weld face & root. Fusion zone & boundary. HAZ.
Weld toes.Weld width
Weld Sizing (Butts): DTT. ATT. Excess weld metal.
Weld Sizing (Fillets): DTT. ATT. Excess weld metal. Leg length *
 Duties of a Welding Inspector
It is the duty of all welding inspectors:
To ensure that welding operations are carried out in
accordance with written, or agreed practices or
specifications

Before
*
During
After
All Welding Operations
Describe your duties to your code of practise. “CSWIP
Exam”*
 Duties of a Welding Inspector
Discuss the following
Before Welding:
1) Safety:
Legislation and safe working practices
2) Documentation: Spec
Drawings. Procedures. Welder approvals. Certificates. Mill sheets

3) Welding Process and ancillaries:

Equipment. Cables. Regulators. Ovens. Quivers etc
4) Incoming Consumables:
Materials/welding consumables (Size. Condition. Specification. Storag
5) Marking out preparation & set up:
Method. Angles/Root face/gap values. Distortion control. Pre-heat
prior to tack welding if applicable*
Duties of a Welding Inspector
During Welding:

1) Pre-Heating. (Method and control)

2) In process distortion control (Balance or sequence welding)
3) Consumable control. (Correct baking and storage prior to use)
4) Welding process (Related parameters i.e. volts/amps. gas flow
rate)
5) Welding run sequence and inter-pass cleaning
6) Minimum/maximum Inter-pass temperatures
7) Full compliance with all elements given on the WPS*
Duties of a Welding Inspector
After Welding:

1) Visual Inspection
2) Non Destructive testing
3) Repairs*
4) Repair procedures (NDT/Excavation/Welding/Welder approval)
5) PWHT
6) Hydro-static testing
7) Submission of all inspection reports to QC departments*
Responsibilities of a Welding Inspector

To Observe Activities &

Imperfections*

To Record Activities &

Imperfections
*
Activities &
To Compare
Imperfections
*
 Attributes of an effective Welding Inspector
Some attributes/skills of an effective Welding Inspector:*

•Honest •Knowledgeable
•Literate •Experienced
•Respected •Record keeping skills
•Dedicated •Communication skills
•Impartial •Safety conscious
•Observant •Inquisitive
•Decisive •Responsible
•Analytical* •Diplomatic skills*
A Welding Inspectors Toolbox
A Welding Inspectors toolbox should contain*
A welding gauge (Cambridge style, or high low gauges
etc)
A tape measure and scale
A wire brush
A magnifying glass
A torch and mirror
A specification, pen and report, or note paper
Any other aids to visual inspection*
Specialised Aids for Inspection
Inspection may utilise the following specialised
equipment:*
Boroscopes (For assessing root runs in small Ø pipes)
Flow-meter (For measuring gas flow rates in MIG/MAG/
TIG)
Simple NDT equipment (Penetrants and MPI)
Complex NDT equipment (Radiography or Ultrasonics)
Note: Both simple and complex NDT methods requires
the specialised skills of qualified operators/technicians*
Imperfections in Welded Joints

Welding imperfections can be categorized into

groups:
1) Cracks
2) Gas Pores & Porosity
3) Solid Inclusions
4) Lack of fusion
5) Profile & Lack of Filling
6) Mechanical or Surface damage
7) Misalignment*
 Cracks
A HAZ hydrogen crack, initiated at the weld
toe
Most cracks are initiated from stress
concentrations *
Gas pores and Porosity

Surface breaking porosity

Shrinkage cavity*
  Coarse cluster porosity
Fine cluster porosity
Blow hole > 1.6 mm Ø

Hollow root bead An isolated internal porosity

 
 Solid Inclusions

Surface breaking solid inclusion

Internal solid inclusion causing
a lack of inter-run fusion* Internal solid inclusion causing
a lack of sidewall fusion

Internal solid inclusion Solid inclusions caused by

undercut in the previous weld
run
 Lack of Fusion

Lack of sidewall fusion &

incompletely filled grove*
Overlap (Causing cold laps)

Lack of inter-run fusion Lack of sidewall fusion

Lack of root fusion

 Profile Imperfections
Spatter An Incompletely filled groove

Lack of root fusion

Bulbous, or irregular contour
Arc Strikes
Poor toe blend

Incomplete root
penetration *
 Profile Imperfections
Shrinkage grooves

Crater pipe Root concavity

 

*
Root oxidation in Stainless
Excess penetration, and burn through Steel
Undercut in Butt Welds
Root Run or “Hot pass” undercut

Parent metal, surface undercut

 

Weld metal, surface undercut*

 
Undercut in Fillet Welds

Weld metal, surface undercut Parent metal, “top toe” undercut*

 Mechanical and Surface Damage

Any surface damage caused

by:
Grinding
Hammering/chisel marks
Slag chipping hammer marks
Torn cleats (Hammered off attachments)
Arc strikes

All of the above may cause serious weakness to the weld

area*
 Misalignment
Linear
Excess weld metal height
Lowest plate to highest point

3 mm
Linear misalignment measured in mm

Angular

15

Angular misalignment measured in degrees*

 Mechanical Testing

Why ?* To establish the level of mechanical

properties*
properties
Which properties ?*
1) Hardness*
2) Toughness*
3) Tensile strength*
4) Ductility*
 What are Mechanical Properties?
Mechanical:* Describes the actions of “force & motion”

Properties:* Something that makes one material useful

for a job. These include the properties of:

Hardness:* The ability of a material to resist indentation

Toughness:* The ability of a material to absorb impact

energy
Tensile strength:* The ability to resist the action of a pulling
force
Ductility:* The ability to deform plastically under
tension*
Introduction to Mechanical Testing
We test welds to establish minimum levels of
mechanical properties, and soundness of the welded
joint*
We divide tests into Quantitative & Qualitative methods:
*

1) Quantitative tests: (Have units)*

2) Qualitative tests: (Have no units)*

Introduction to Mechanical Testing
Types of tests include:
1) Quantitative tests:
Hardness tests
Toughness tests
Tensile strength tests*

2) Qualitative tests:
Macro tests
Bend tests
Fracture tests*
 Testing the Weldment
The test weld is usually cut into sections as follows:
The location of specimens will depend upon the
standard
Charpy V Bend
test test*

Tensile test Start/ Macro/Hardness

Stop test
Hardness Testing
The specimen below has been polished
and is ready to be hardness tested

= Hardness
Survey

Thickness

Base HAZ Fusion boundaryWeld metal

metal
Further hardness surveys may be taken as the
thickness of the specimen increases*
 Hardness Testing

Generally we use a diamond or steel ball to form an

indentation

We measure the width of the indentation to gauge the

hardness*
 Hardness Testing

1) Vickers Diamond Pyramid: Always uses a

diamond*
2) Brinell hardness test: Always uses a steel
ball*

3) Rockwell hardness test: Uses a ball, or

diamond depending
on the scale*
 Charpy V Testing
Machined 10 x 10
notch mm

The specimen may be tested from different areas of the

weld.*
Graduated Pendulum
scale of Hammer
absorbed
energy in
Joules* Location of
specimen
Toughness Testing

1) Charpy V test: 10 x 10 (Specimen horizontal)

Joules*

2) Izod test: 10 x 10 (Specimen vertical) Ft.lbs*

3) CTOD test: Specimen used is actual design

size. Detailed fracture report.
mm*
 Charpy V Testing
Mn < 1.6 % increases
Joules
toughness in steels*
absorbed

Transition 47 Ductile Fracture

Zone Joules
Three specimens are
normally tested at each
temperature.
28
Joules
Transition Temperature
Brittle Fracture Range
-40 -30 -20 -10 0 +10 +20 +30 +
40 Testing temperature
 Transverse Tensile Test

A Section of weld is cut, or machined out across the test

piece and tested in tension to failure. The units are
usually in N/mm²

Transverse reduced test

piece*
 Radius Reduced Transverse Tensile Test

Radius
(For radius reduced test specimens only)
 
Weld
Test gripping area   HAZ
   
Direction of test
  Plate material Reduced Section
   

Used to assess the tensile strength of the weld

metal
 All Weld Metal Tensile Test

BS 709 / BS En 10002
All Weld Metal Tensile Testing

Direction of the test *

Tensile test piece

cut along weld
specimen.
 Ductility Elongation %
Firstly, before the tensile test 2 marks are made 50mm
apart
50 mm

During the test, Yield point & Tensile strength are

measured
The specimen is put together and the marks are re-
measured
75 mm

A new measurement of 75mm will indicate Elongation

E50 %*
 Macro Inspection

1) Excess Weld Metal 8) Poor Toe Blend*

Height 7) Laminations

6)Porosity

2) Lack of Sidewall
Fusion 5) Root
3) Lack of Root Fusion Penetration

4) Slag inclusion & Lack of inter-run

fusion
 Bend Tests
Bend tests are used to establish fusion in the area under
test
Guide A Guided root bend test*
Lack of root fusion shown
here*

Former
Test
Piece Force

Further tests include face, side and longitudinal bend

tests*
For material over 12 mm thickness, side bend test may be
used*
 Bend Tests

Specimen prior to test* Specimen after test*

 Fillet Weld Fracture Tests
Saw cut 1 2 3
Hammer
X Line of fusion
blow
1 3

Fracture line

Full fracture
X
2 3

1 2
Y Any strait line indicates
Inspect both
a “Lack of root fusion”*
surfaces
 Butt Nick Break Tests
Saw Cuts Hammer blow

A
Fracture line

B
Inspect both surfaces

Lack of root penetration Inclusions on fracture line*

or fusion
 Summary of Mechanical Testing
We test welds to establish minimum levels of
mechanical properties, and soundness of the welded
joint
We divide tests into Qualitative & Quantitative
methods:*
Quantitative: (Have units) Qualitative: (Have no units)
Hardness (VPN & BHN) Macro tests
Toughness (Joules & ft.lbs) Bend tests
Strength (N/mm2 & PSI) Fillet weld fracture tests
Ductility/Elongation (E%) Butt Nick break tests*
Macro Inspection
The main difference between Macro & Micro is that
Micro is the study of the micro-structure at much higher
magnification
The limit of Macro inspection is magnification < X 10
The specimen is usually cut from a stop/start in the test
piece
The cut specimen is polished to a fine finish (400 grit)

The specimen must be inspected, before etching*

Macro Inspection
Remember! The process of inspection is to first:
Observe, then Report, then Compare!*

Use the TWI macro sheets provided to observe and

then make a report on a separate sheet of what you
observe*

When you have finished reporting, turn the macro

sheet over and compare your observations with those
given on the back of the sheet* (1 hour)
 Welding Procedures

A definition of the term “Procedure”?*

A systematic method of producing an aim*

Therefore, a “Welding procedure” is?

*
A systematic method of producing a sound
weld*
 Welding Procedures
What do “you” think about the following
statements?*
• Do all welding procedures need to be written?*
• Most production welding procedure are formatted on written
documents or computer spreadsheets, but they need not be written
and may be a product of experience

• Do all welding procedures need to be approved?*

• Most procedures are approved, but not all? An approved
welding procedure is one that has been tested to ensure that the
procedure as carried out, produces a weld that satisfies a minimum
level of quality for the mechanical, physical or chemical properties
desired. If these are not required, then “procedural approval is
unnecessary”*
 Welding Procedures
A Welding Procedure is a recipe of variable parameters,
which will produce the same results of certain quality &
properties if carried out in the same way each time*

To evaluate a Provisional Welding Procedure we need to

check if all the parameters set will work together to
produce the desired results*

.*
 Welding Procedures
Once the weld has been completed it is usually visually
inspected, then Radiography or Ultrasonic testing is
usually applied*
Finally, and most importantly, Mechanically tested to
ensure that the desired level of mechanical properties
have been met*
If all the desired properties have been met, then a
procedure qualification record (WPQR or WPAR) is
completed with all the test results, and the procedure
then becomes qualified*
From this data, a workable document for production
welding is prepared and called a Welding Procedure
Specification. (WPS)*
A CSWIP 3.2 Senior Welding Inspector is normally responsible for
the testing and approval of welding procedures*
 Welding Procedures
Examples of “Extents of Approval” include:*

a) Diameter of pipe, or thickness of plate

b) Welding position, amperage range, or number of runs
c) Process (On multi process procedures only)
d) Certain material groups
e) Change of consumable to one of the same
classification Only if the class is given in the original
procedure
f) Heat input range (kJ/mm)*
 Welder Approval
Once the procedure has been approved it is then
important to test each welder, to ensure that he has the
skill to reach the minimum level of quality in the weld, as
laid down in the application standard*

There is no need to carry out the mechanical tests of the

procedure, although bend tests are often used to ensure
good side wall fusion
Normally; visual, x ray, bends, fractures and macro’s are
used in welder approval tests*
 Welder Approval
When supervising a welder test the welding inspector should:
*
 
1)    Check the welding process, condition of equipment and test area for
suitability.
2)    Check that extraction systems, goggles and all safety equipment are
available.
3)    Check grinders, chipping hammers, wire brush and all hand tools are
available.
4)    Check materials to be welded are correct and stamped correctly for the test.
5)    Check welding consumables specification, diameter, and treatment with
WPS.
6)    Check the welder’s name and stamp details are correct.
7)    Check that the joint has been correctly prepared and tacked, or jigged.
8)    Check that the joint and seam is in the correct position for the test.
9)    Explain the nature of the test and check that the welder understands the
WPS.
A CSWIP 3.1 Welding Inspector is normally responsible for the
10)  Check that the welder carries out the root run, fill and cap as per the WPS.
supervision
11)  Ensure and testing
welders identityof
andwelder location*are clearly marked.
approvals
stop start
12)  Supervise or carry out the required tests and submit results to Q/C
department.*