CWI / Visual Testing (VT) LEVEL -II Training Course Prepared by Dr. Samir Saad General Manager Cutech Arabia LLCAA) About the Author Dr. Samir Saad General Manager Cutech Arabia LLC Experience: 17 Years (Oil and Gas) Skills & Expertise Welding and Welding Inspection + Non-Destructive Testing Material Technology In Service & On-stream Inspection * Corrosion and Management Asset Integrity Management DrSamir Saad Education Certification M.S. and Ph.D. degrees in Welding Engineering Technology. Bachelor of Mechanical Engineering Professional Certification ASME Authorized Inspector (Al), Soller and Pressure Vessel ‘ASNT NDT LEVEL I In 14 methods, ASNT 10: 190902 Visual and Optical Testing (VT), 7. Magnetic ux leakage Testing (MFL), 1 2 Radiographic Testing (RT), 8. inferred thermal testing (IR), 3. Uttasonie Testing (UT), 8. Leak Testing (LT, 4. Liguid Penetrant Testing (PT), 10, Acoustic Emission Testing (AE) 5. Magnetic Testing (MT), 11, Neutron Radiography (NR) 8. Electromagnetic Testing ET), ‘AWS-CWEng. - Certified Welding Engineer, ID NO. 17010046, ‘AWS-CWE - Gertied Welding Educator, ID NO. 1902001 E. ‘AWS-CWI- Certified Welding inspector, ID NO. 19021321 ‘AWS-CWS - Cerfied Welding Supervisor, ID NO. 20020008, 'AWS-CWSR - Certfed Welding Sales Representative, ID NO. 2003000R CSWIP 3.2.2 - Senior Welding inspector Personal, ID NO.74305, BGAS-CSWIP-Painting Inspector Grade 2-BGAS, 10:589730. [APL 510- Pressure Vessel Inspector ID NO. 35376. [API 570. Process Piping Inspector ID NO. 38328, ‘API 853. aboveground storage tank inspector ID NO. 36171, [APL RP 580 -Risk-Based inspection professional ID NO. 52784 [APP 871- Corrosion and Materials Professional ID NO. 58359 ‘API 896 - Refractory Personnel, ID NO. 94784 [API S77 - Welding Inspection and Metallurgy, ID NO. 94785, [API SIFE-Source Inspector Fixed Equipment, ID NO. 95780 ‘Lead aualtor according to 180 9001:2015 from IRCChapter Qualification and Certification we Requirements . Y Dr.Samir Saadi£The following documents outline personnel qualification and certification requirements: 1. ASNT Recommended Practice No. SNT-TC-1A. 2. ANSI/ASNT CP-189: Standard for Qualification and Certification of Nondestructive Personnel. 3. ACCP: ASNT Central Certification Program. 4. NAS 410, National Aerospace Standard Certification and Qualification of Nondestructive Testing Personnel. DrSamir SaadSX Training and Qualification Process: % % 1. Certification of NDT personnel is the responsibility of the employer A person who is in the process of training and qualification is considered a trainee. Three Basic Levels of Qualification LEVEL | — is qualified to perform specific calibrations, specific tests, and specific evaluations. The NDT Level | should receive the necessary instruction and supervision from a certified NDT Level Il or MW individual. LEVEL II — is qualified to set up and calibrate equipment and to interpret and evaluate results with respect to codes, standards and specifications, LEVEL Ill — must be capable and responsible for establishing techniques, interpreting codes, and designating the test method and technique to be used. The NDT Level Il in the methods in which certified, should be capable of training and examining NDT Level | and II personnel for certification in those methods. DrSamir SaadLt Qualification Requirements: 1. Organized training (required class hours). Required testing (general, specific, practical). Education (depends on written practice). Experience (documented hours). Physical attributes to perform examinations (vision acuity and color contrast test performed annually). XX Certification ‘% Certification is a written testimony that an individual has met all the qualifications of a company’s written practice. DrSamir SaadChapter pas Introduction to NDT Woe Ww . Y Dr.Samir SaadXf Nondestructive testing methods are used for the following reasons: . To ensure product integrity and reliability. . To avoid test object failure, prevent accidents and save lives. . To make user profits. . To ensure customer satisfaction. . To aid in better product design. . To lower manufacturers’ costs. . To maintain uniform quality levels. DrSamir Saad! | Surface Surface/sub-surface and Volumetric 1Visual Testing(VT) 1.Radiography Testing(RT) 2.Magnetic Particle Testing (MT) 2.Ultrasonic Testing(UT) ( surface and near surface , applied on only ferromagnetic material) 3. Penetrant Testing (PT) (any defects open to surface) 4, Eddy Current (ET) ( surface and near surface) DrSamir SaadVI % > isthe most extensively used NDE method for welds. > The oldest and most widely used inspection techniques > — The eyes of inspector are the only ‘equipment’ used for the inspection > Applicable to virtually any material > — \Tis commonly performed on castings, forgings, and welds and it is performed after machining processes as. well. » Itincludes either the direct or indirect observation of the exposed surfaces of the weld and base metal. DrSamir SaadXf Direct visual examination > is conducted when access is sufficient toplace the eye within 6 in. through 24 in. (150 mm through 600 mm) of the surface to be examined and at an angle not less than 30 degrees to ‘the surface as illustrated in Figure. Mirrors may be used to improve the oe angle of vision. DrSamir SaadVI * Codes and specifications may list compliance with these requirements as. mandatory. * a) A written procedure is required for examinations. * b) The minimum amount of information that is to be included in the written procedure. - * c) Demonstration of the adequacy of the inspection procedure. lists a ene ee ean ee ecener a eT i Jaeger-type eye vision test, FECUIFEMENES — - «)direcevisual examination requires access to permit the aye tobe within 6 in. through 24 in. (150 mm through 600 mm) of the surface, at for visual fan angle not less than 20 degrees, * f) The minimum required illumination of the part under examination. EXAMINATION. —-#) rcirectvisual examination permits the use of remote examination and devices be employed. * h) Evaluation of indications in terms of the acceptance standards of the referencing code. DrSamir Saad«READING CARD (Metric) ‘quagmire and in dey weather the dust wan scaive Tanw with ‘aintheinbabtantesrading nud whic purchatingtheirprovinons ‘tacOptical Aids Optical aids used in visual inspection {Adequate Illumination: include the following. Ambient Light Meters Lighting the inspection surface illumination is of extreme importance. Adequate ilumination levels should be established in order to ensure and effective visual inspection. a Illumination meters for the Standards such as ASME Section V Article 9 measurement of ambient specify lighting levels of 100 foot-candles (white) light in foot-candles (1000 lux) at the examination surface. cor lux. Dr Samir SeadQ Effective program of visual inspection It has been proven that EFFECTIVE program of visual inspection will discover vast majority of the defects which would be found later using expensive NDE methods + This only possible when the VT is accomplished: > BEFORE, DURING and AFTER welding. > Bya trained and qualified inspector (that’s why AWS developed the CWI program) > PropertoolsQ Why VT is very cost effective: Relative simplicity It is least expensive inspection method Minimal amount of equipment required Minimize the repair time and cost; » Itallows for detection and correction of many discontinuities before weld completion Application of VT % Before welding “ During welding % After weldingDuring Welding After Welding. — Chemical analysis — Mechanical properties Base Metal Conditions — Freedom from internal and surface discontinuities — Flatness, straightness, dimensional accuracy Joint Condition — Edge Shape Dimensional accuracy — Cleanliness — Root opening — Alignment - Backing, — Tack welds Special Assembly/Fabrication Practice — Adequacy and accuracy of jigging, bracing, or ‘fixturing — Application and accuracy of pre-stressing or precambering Preheat and interpass temperatures, — Controls — Measurement methods Filler Metal — Identification — Control — Handling Root Pass — Contour — Soundness Root preparation prior to welding second side + Cleaning between passes Appearance or passes (sometimes in comparison with workmanship standard) In-process NDE as required or specified ‘Conformance to approved welding procedure Postheat treatment requirements ‘Acceptance inspection Method of cleaning for inspection Nondestructive examination — Visual examination — Surface contour and finish of welds — Conformity of welds with drawings — Magnetic particle — Liquid penetrant examination — Radiographic examination — Ultrasonic examination — Proof testing — Other suitable methods Destructive testing —Chemical — Mechanical — Metallographic Marking for acceptance or rejection Repairs Inspection after repairXf Optical Aids » — Optical aids used in visual inspection include the following. b) Mirrors valuable to the inspector allowing them to look inside piping, threaded and bored holes, inside castings and around corners if necessary. DrSamir Saad WsXf Optical Aids > — Optical aids used in visual inspection include the following. Cc) Magnifiers ¥ helpful in bringing out small details and defects. Y._ DrSamir SaadVisual Inspection Tools Optical aids used in visual inspection include the following. widely used for examining tubes, a deep hole, long bores, and pipe bends, having internal surfaces not accessible to direct viewing metal. DrSamir SaadWeld Examination Devices > — Typical inspection tools for weld inspection include the following. a) a) Inspector's kit + contains some of the basic tools needed to perform an adequate visual examination of a weld during all stages of welding {Before welding ,During welding and After welding} It includes as the following:- 6 inch Ruler 1 inch Micrometer Metric Dial Caliper Palmgren Gage Underout Gage Fillet Weld Gages DrSamirSaadSt Weld Examination Devices > — Typical inspection tools for weld inspection include the following. b) Bridge cam gauge “can be used to determine the weld preparation angle prior to welding. oeneut ICES WELD METAL LET Les LENOTH This tool can also be used to measure excess weld metal (reinforcement), depth of undercut or pitting, fillet weld throat size or weld leg length and misalignment (high-low). ELLETWELDTIROAT. —ANGLEOFPREPARATIN —MSALLNEYT DrSamir Saad¢ Weld Examination Devices Typical inspection tools for weld inspection include the following. Bridge Fillet weld gauge-The types of fillet weld gauges include. 1) Adjustable fillet weld gauge —measures weld sizes for fit-ups with 45 degree members and welds with unequal weld leg lengths. The weld fillet gauge —a quiok go/no-go gauge used to measure the fillet weld leg length, Gauges normally come in sets with weld leg sizes from 1/8 in, (3 mm) to 4 in (25.4 mm). a weld filet gauge being used to determine i the crown has acceptable concavity or convexity. DrSamir Saad£ Weld Examination Devices > Typical inspection tools for weld inspection include the following. ¢) —_Hi-lo welding gauge. Eliminates rejects, 41) Italso measures internal mismatch, weld crown height and root weld spacing eae DrSamir Saad3% Weld Examination Devices > Typical inspection tools for weld inspection include the following ¢) Digital pyrometer or temperature sensitive crayons “+ measures preheat and interpass temperatures. DrSamir SaadQ Penetrant examination is a sensitive method of detecting and locating discontinuities, provided the discontinuities are clear and open to the surface. Q Method * The method employs a penetrating liquid dye which is applied to the properly cleaned surface to be examined and which enters the discontinuity. * After a suitable dwell time, the excess penetrant is removed from the surface and the part is dried * A developer is then applied which acts as a blotter, drawing the penetrant out of the discontinuity. * The penetrant, drawn from an opening on the surface, indicates the presence and location ofa discontinuityApply Penetrant Clean then apply Developer Result Drsami SandO basic classifications of the penetrant method There are two basic classifications of the penetrant method, both using a similar principle. * One uses a visible dye and the other uses a fluorescent dye which is only visible with exposure to ultraviolet light. Visible penetrant is usually red in color to provide a contrast against the white developer background. Normal white light is usually sufficient to view the discontinuities. Fluorescent penetrants provide a greenish yellow indication against a dark background when viewed in a darkened area under a black (ultraviolet) light source. The fluorescent method is more sensitive due to the fact that the human eye can more easily discem a fluorescent.indication.Ovisible dye OFluorescent dye OThree removal systems: > Solvent > Water > Emulsifiable Solvent removal , Visible dye typeQ These Are the Medias by Which They Can Keep Permanent Records. % Sketches “% Photographs Lift off tapesQ Advantages and Disadvantages Advantages Disadvantages 1) Low operator skill level 1) Highly clean metal 2) All materials (Non Porous) 2) Open Surface flaws only 3) Low cost method 3) Somewhat slow 4) Simple equipmentQ Application = Magnetic particle inspection may be applied to detect surface and near surface defects in ferromagnetic materials only . QO Method Clean area to be tested Apply contrast paint Apply magnetism to the component Apply ferromagnetic ink to the component during magnetising Interpret the test area Post clean and demagnetise (if required) Drsami SandO Method Contrast paint Magnet & Ink ResultQ Magnetic Field Orientation and Flaw Detectability » Ifthe magnetic field is parallel to the defect, the field will see little disruption and no flux leakage field will be produced. —_— ' > An orientation of 45 to 90 degrees between the magnetic field and the defect is necessary to form an indication.Q Circumferential Magnetization » Circular magnetic fields are produced by a 1) passing current through the part 2) A headshot on a wet horizontal test unit an 3) Prods 4)Central conductorsQ longitudinal Magnetization > alongitudinal magnetic fields are produced by, 1) Permanent magnets and Electromagnetic yokes 2) Coils & Solenoids lMacnenc FretQuestion » ? From the previous slide regarding the optimum test sensitivity, which kinds of defect are easilv found in the images below? ELECTRIC Cracks at 90° to line force will show Cracks at parallel to line force will notQuestion » ?~ From the previous slide regarding the optimum test sensitivity, which kinds of defect are easily found in the CURRENT G) (ae GA DoS MAGNETIC LINES SPP OacE Longitudinal (along the axis)Question From the previous slide regarding the optimum test sensitivity, which kinds of defect are easily found in the images below? CURRENT an he Panne _ Sab Longitudinal (along the axis) Transverse (perpendicular the axis)O Magnetic Particles OMT Equipment + ferromagnetic iron oxides “AC / DC bench units “Dry or wet *AC yokes Types “AC / DC yokes “Color dyed “AC / DC prods “Fluorescent AC / DC coilsQ These Are the Medias by Which They Can Keep Permanent Records. % Sketches “% Photographs Lift off tapesO Magnetic Particles Advantages Disadvantages 1) Low operator skill level 1) Fe Magnetic metal only 2) Rapid 2) De-magnetize may be required 3) Relatively cheap 3) Can cause are strikes # 4) Portable 4) Poor with thick coatings # When using the straight current prod techniqueQ Overview of Radiographic Testing X or Gamma radiation is imposed upon a test object Radiation is transmitted to varying degrees dependent upon the density of the material through which it is travelling Thinner areas and low density materials show as darker areas on the radiograph Thicker areas and High density materials show as lighter areas on a radiograph Applicable to metals, non-metals and composites(Magnetic particle testing.) Load film Exposure to Radiation Interpret Graph e Developed Graph Radioactive source Iai : Rca ‘tent image on the filmDARKEST 2 Areas of high radiation transmission, or low absorption, appear as dark areas on the developed film, 2 Areas of low radiation transmission, or high absorption, appear as light areas on the developed film.Radiographic Testing High dense discontinuity Low dense discontinuity Film Darker region ‘on radiographLIGHTEST. Metal Densities Grams/cubic centimeter Aluminum — 2.70 Steel 7.87 Copper 8.96 Lead 11.34 Tungsten 19.30Radiographic Testing Flaw Orientation a° 10° 20°Radiographic Techniques Single Wall Single Image (SWSI) (AM S. yw ms )) IQI’s should be placed source sideRadiographic Techniques Single Wall Single Image Panoramic IQI’s are placed on the film side Source inside film outside (single exposure)Radiographic Techniques Double Wall Single Image (DWSI) IQI’s are placed on the film side Source outside film outside (multiple exposure) This technique is intended for pipe diameters over 100mmRadiographic Techniques Double Wall Double Image (DWDI!) IQ's are placed on the source or film side Source outside film outside (multiple exposure) A minimum of two exposures This technique is intended for pipe diameters less than 100mmRadiographic Techniques Double Wall Double Image (DWD!) Elliptical RadiographRadiographic Testing Radiographic Sensitivity (2% thickness test object) QO Image Quality Indicators (IQIs) (Penetrameters Hole type IQI Wire type IQIRadiographic Sensitivity OPlacement of IQI Hole Type IQI Wire Type IQIAdvantages Disadvantages 1) A permanent record 1) High operator skill 2) Most materials 2) Difficult interpretation 3) Little surface preparation 3) Requires access to both sides 4) Flaw orientation 5) Safety requirements*Apply Couplant — Sound wave Result* CRT display I Signal rebounded from Lack of fusionPulse echo signals A scan Display Compression probe checking the material ThicknessThicknessO Longitudinal (straight beam)-Compression Probe “Thickness measurement ‘ta defect Back wall initial pulse echo echo “Lamination check Compression Probe CRT DisplayQ Shear (angle beam) Probe Weld check initial pulse- defect echo % Skip CRT Display initial pul Full Skip.UT Advantages UT Limitations Atrue volumetric test One side access * Highly skilled operator * Smooth surfaces * Groove welds > 1/4” thick Very accurate Deep penetration - 200” Critical flaws found Equipment fully portableEddy Current Testing “Based on the principle of eddy currents being formed in conductive materials in the presence of an AC coil and changes in those eddy currents by material changes.” Induced Eddy CurrentsET application = Flaw detection Metal thickness Coating thickness Metal hardness Heat treatmentET Advantages ET Limitations No contact required with part Highly skilled operator No couplant required “Too sensitive” Readily Automated Shallow penetration - 3/16” Applicable to all metals Calibration standards required Requires surface cleanliness Magnetic materials more difficultChapter.3_ Metal Properties and Destructive ~ Testing ; . Y Dr.Samir SaadQ Destructive Testing “ destroying, a part, or a portion thereof, to determine its properties Q Nondestructive Testing Does not affect the serviceability of the part after testing is completedQ Mechanical Properties of Metals The important mechanical properties of metals Strength Ductility Toughness Fatigue Strength Soundness TestingIntroduction Mechanical Test Samples Tensile Specimens CTOD Specimen “Ss Bend Test Specimen Charpy Specimen Fracture Fillet SpecimenQ Strength * The property of metals that describes their ability to carry a load Q Two common methods of ane Streteh, in. 0 expression: “ Ultimate tensile strength (UTS) * Yield strength (or yield point 0.002 0.004 0.005 Elongation (n.)Tensile Testing Q Tensile TestingQ Metal Behavior Under Load Elastic - No permanent deformation Plastic - Permanent deformation.uuu Tensile Testing) Q Offset Method “+ Used for Deterring Yield Point Yield Point * Usually Offset at 0.2% (0.002 IN/IN) * Line Parallel to Elastic Limit Intersection With Curve Is Y. P Unit tess, plo a)QO The result of the tensile test include + Ultimate Tensile Strength Yield Strength “+ Percent Elongation “+ Percent Reduction of AreaQ Ultimate Tensile Strength Maximum load applied = 22000 Ib. Least cross sectional area = 0.5 in2 UTS = Maximum load applied cross sectional area UTS = 22000 0.5 UTS = 44000 psi= 44 ksiQ Percent Elongation Original gage length = 2.0 in. Final gage length = 2.6 in. %Elongation = final length - original length x 100 original length “Elongation = 2.6- 2.0 x 100 = 30% 0.2Q Percent Reduction of Area Original area = 0.2 in.? Final area =0.1 in. 2 %Reduction of area (%RA) = ? %RA = original area - final area x 100 original area %RA = 0.2 -0.1 x 100 = 50% 0.2Stress-Strain Diagram High and Medium Strength Steels High Strength Steel 1 High Carbon Spring Steel High Carbon Spring Steel ~~ Structural Steel Medium Strength SteelQ Hardness % Ability to resist indentation Q hardness tests * Brinell “ Rockwell “+ Hardness Tests Microhardness » Vickers » KnoopQ Indenters, and Shapes of Indentation Tost Indenter Shape of Indentation 10 mm sphere of steel = (> Brinell or tungsten carbide wo Diamond Viewers pyrami -] Knoop Diamond microhardness pyramid ——— Rockw vec a Diamond 4/16 in Diameter } Steel Sphere 1/8 in Diameter steel sphereHardness and Hardness Testing Q Brinell “ can use it DT or NDT Approximate Tensile Strength = BHN X 500QO Rockwell “% uses both minor and major loadQ Microhardness + Two Major Types v Vickers v KnoopQ Temperature Effects < As metal temperatures increase: » Strength decreases > Hardness decreases » Ductility increasesQ Toughness % “The ability to absorb energy” “ The common notch toughness or impact tests include > Charpy V notch > crack tip opening displacement (CTOD).Q Charpy Test Results Energy absorption - Ft. Ibs. “+ Lateral expansion - MilsQ Ductility % The ability of a metal to deform without breaking Q Brittle vs Ductile Failure Ductile Brittle ¥ Percent elongation Y Percent reduction of areaQ Transition Temperature “+ The temperature at which a metal fracture mode changes from ductile to brittle Transition Temperature t z 2 z fa 2 = aoQ Fatigue Strength * The strength of a metal when exposed to repeated reversals of cyclic stresses Q Endurance Limit “ ‘The maximum stress at which no failure will occur, regardless of cycles” Y_ Only Ferrous alloys and titanium alloys have Endurance Limit v Other structural metals such as. aluminium and copper, do not have 1047 Stee 201616 Alumioum wow ot Number of cytes Typical S-N CurvesQ Soundness * “Freedom from discontinuities” Q Soundness Testing + Bend testing “+ Nick-break Fillet breakBend testing Wrap-around Bendfest Jig Guided Bend Test JigTransverse Weld Bend Specimens a Root / face Tupi 2mm “Thickness of material - "t Ter tai Side bend GSend testing Bend Test Samples Transverse Weld Bend SpecimensSend testing Bend Test Samples Longitudinal Weld Bend Specimens( Bend testing ) Defect indication Acceptance for Generally this minor ruptures on specimen would be tension surface unacceptable depends upon code requirementsFillet Break - Sample FractureNick Break Test Samples earn rarer SOURCE: ANSVAWS 640-02| Nick Break. Tes ) Evaluation of Nick-Break TestQ Metallographic Testing Macroscopic — specimens examined at magnification of 10x or lower * Microscopic - specimens examined at use magnifications greater than 10X, usually 100X or higher.Q Photomacrograph Macroscopic - 10x or lower Macro specimen “for determining such as depth of fusion depth of penetration ,effective throat, weld soundness, degree of fusion, presence of weld discontinuities, weld configuration, number of passes”{ Metallographic Testing ) Q Photomicrograph usually 100X or higher100X 1 “used to determine various features as well included are microstructure constituents, presence of inclusions, presence of microscopic defects, and nature of cracking”Metallographic Testing Q Photomicrograph a) Base metal (BM).Chapter Metal Joining, & ae Cutting Processes Y Dr.Samir SaadQ) 3 Basic ‘Process’ Groups Welding * Brazing CuttingQ Shielded Metal Arc Welding > isan arc welding process wherein coalescence is produced by heating with an electric arc between a covered metal electrode and the work. > Sometimes called “Stick” >_ Manual process “The SMAW process is almost totally WELDER dependent” ELECTRODE COVERING SHIELDING ATMOSPHERE WELD PooL. METAL AND SLAG SOLIDIFIED SLAG Z DROPLETS LLL Op DIRECTION OF WELDINGQO The electrode coating, It Provides: 4. Shielding > some of the coating decomposes to form a gaseous shield for the molten metal. 2. Deoxidation » the coating provides a fluxing action to remove impurities and oxygen and other atmospheric gases. 3. Alloying > the coating provides additional alloying elements for the weld deposit. 4. lonizing > when the flux coating becomes molten it improves electrical characteristics to increase arc stability. 5. Insulating > the solidified slag provides an insulating blanket to slow down the weld metal cooling rate.Q AWS Shielded Metal Arc Covered Electrode Classification System = E-XXXX j E (OxX x a | | Minimum Tensile Strength in ksi. First Two Digits Of A Four Digit Or First Three Digits of a Five Digit Number Position 1 = All Positions 2 = Flat & Horizontal Fillet 4 = Vertical Down Usability, Type of Coating, Weld Current Type. & PolarityQ AWS Shielded Metal Arc Covered Electrode Classification System “ Example ELECTRODEQ Stainless Steel Electrodes E - 308 L 16 -—— seu 1 Position 2 Type of Current 15 DCEP 16 AC or DCEP Type of Stainless SteelQO Electrode Coating Classification F #: “ F-1 High Deposition Group > (Exx20, Exx24, Exx27, Exx28) “+ F-2 Mild Penetration Group > (Exx12, Exx13, Exxt4) “+ F-3 Deep Penetration Group > (Exx10, Exx11) Cellulosic electrode ‘+ F-4 Low Hydrogen Group > (Exx15, Exx16, Exx18)QO Low Hydrogen Electrodes. Types end in a ‘5’, ‘6, or ‘8° * Purchase in sealed, metal containers “Store after opening in heated, vented oven > Most codes require that low hydrogen electrodes be held at a minimum oven temperature of 250°F [120°C] after removal from their + Limit atmospheric exposure » alow moisture content(less than 0.2%),Q Stainless Steel Electrodes *» E308, E308L - Weld 304 and 304L “ E316, E316L - Weld 316 and 316L “* E309 - Weld Stainless to Carbon Steel) Welding Current Types 2 AC ‘* DCEN- DC Electrode Negative -— (Straight) Polarity DCEP DC Electrode Positive (Reverse) Polarity Drsami Sand) Arc length The distance between the tip of electrode and the weld surface | \ \ As arc length increases, voltage goes up; and ~ asarc length decreases, voltage goes down. Desai StdU) Traditional Welding Power Source “Constant Current Power Source ¥ Electrode moved closer, Arc V falls, Arc A rises Y Electrode moved away, Arc V rises, Arc A drops| Vv O “AA current directly related to heat input 4 jer controls heat input to workQO) Arc blow welding problems is the result of a distorted magnetic field that deflects the welding are Porosity can also result from the presence arc blow ( \ Direction of flux Direction of current Distorted __ Distorted Magnetic Fields at Ends of Welds | Fields at Ends of Welds Around Electric ConductorQ To reduce the effects of arc blow, several alternatives can be tried. They include: . Change from DC to AC. . Hold as short an arc as possible. . Reduce welding current . Use a back-step technique. . Wrap work cable around the workpiece and pass work current through it . Extend the end of the joint by attaching runoff plates.Q SMAW Advantages 4. Field or shop use Inexpensive power supply Very portable All positions Welds most alloys A, Q SMAW Limitations High welder skill required Rate deposition is very low Slag removal Electrode storage considerations Arc blow( Welding JGas Metal Arc Welding > An arc welding process that uses an arc between a continuous filler metal electrode and the weld pool the process is used with shielding from an externally supplied gas > Sometimes called “MIG” or MAG > Used as automatic or semiautomatic process ELECTRODE 8 CURRENT CONDUCTOR WIRE GUIDE AND CONTACT TUBE Gas NozzLE CONSUMABLE a ELECTRODE 2 SAseous ARG DasaraQ Process Principles > Heat source- electric arc between electrode (wire) and the work > Shielding- an external gas supply > Filler metal- fed automatically from a spool or ree! > Flux- not applicable Feed control Control system — Gas our. orkpiece Gun control “EeeWelding Current Types > DCEP- normal type of current used Q_ Shielding Gas > Inert- ( Argon )a gas that does not combine chemically with the base or filler material Carbon Dioxide- not inert, is the most common gas used on low carbon steel 75% Argon,25%CO2- is used to produce a smoother bead with less spatter, but will reduce penetration > Argon/Oxygen- this mixture with 5% Oxygen as maximum will produce a spray transfer with no spatterGMAW Modes of Transfer Spray > ARIO2 > High amperage and voltage » flat and horizontalQ GMAW Modes of Transfer “Pulsed Arc > various amperage levels > spray transfer > all positions » transition currentQ ~GMAW Modes of Transfer “Globular » C02 or AR/CO2 > higher amperage and voltage » — flat and horizontalL) GMAW Modes of Transfer Short-Circuiting » CO2 or AR/CO2 > low amperage and voltage > all positions > provides the lowest amount of heat to the workpiece and therefore is. prone to incomplete fusion > This type of transfer produces a small, fast-freezing weld pool that i generally suited for the joining of thin sections, out-of-position ee ee Drop touches weld puddle, , and filling of large root , poe a causing short circuitQ GMAW Modes of Transfer “Factors for Transfer Modes > Shielding gas » Current level > Voltage level >» Power supplyQ GMAW Electrode Identification System Chemical Strength Composition C1 S-X CI Electrode Rod Solid WireQ Low Alloy (Solid) Electrode Classification GMAW, GTAW, and PAWS ER 80 S - Ni3 Electrode or Rod —_Tensile’Strength Solid or Chemical Composition KsI Metal Cored ER70S-3 Solid ~ & Shielding GasQ Stainless Steel (Solid) Electrode Classification GMAW, GTAW, and PAWS ER - 308 LS JO ZA FN Electrode or Rod Type of Low Carbon Content High Stainless Steel .04 Maximum SiliconQ GMAW Power Source Types and Characteristics Constant Voltage- 100% duty cycle with flat volt/amp curve Is ‘self-regulating’ (maintains constant arc length) A (25V @ 100A) B (20V @ 200A) 8 ei S 100 150 200 CURRENT, AQ GMAW Advantages 1. Works faster as compared to SMAW due to Continuous filler metal feed . High deposition rates as compared to S.M.A.W. . produce welds with deeper penetration . No slag formation takes place . Clean process . Welds most alloysQ GMAW Limitations . Equipment is more complex . The equipment are Costly and less portable. . GMAW is not suitable for Filed since strong wind may below away the shield( Welding J Arc Welding S (FCAW)) Flux Cored Arc Welding > An arc welding process that uses an arc between a continuous filler metal electrode and the weld pool. > the process is uses with shielding gas from a flux contained within the tubular electrode with or without additional shielding from an externally supplied gas Self-shielded FCAW Flux-Cored€) Flux Cored Arc Welding(B) Self-ShieldedQ Welding Current Types ** DCEN or DCEP depending on type of wire Q_ Shielding Gas * Carbon dioxide (C02) is the most widely used for use in welding steel because ¥ C02 provides deep penetration and low cost Q Methods of Application Manual N/A ‘Semiautomatic Most Popular Mechanized widely used Automatic widely usedQ FCAW Electrode Identification System Strength Tubular E X X'T} X L_ L_] L_] Electrode Position Chemical/Operating CharacteristicsQ Low Alloy (tubular) Electrode Classification FCAW aan Electrode’ Tensile Strength Indicates Usability and X10 KSI Performance Capabilities Indicates Flux Cored Electrode Position O - flat and horizontal Tubular 1-all positionsQ Stainless Steel (tubular) Electrode Classification FCAW E316LT-3 Type of Soe Stainless Steel tered anererehnaae) External Shield -Q ~FCAW Power Source Types and Characteristics + Constant voltage with flat volt amp curve ++ Constant speed system with a constant current machine “+ The wire feeder is a variable speed system + 100% duty cycleQ FCAW Advantages 1. 2. 3. 4. 5. 6. High quality welds . High deposition rates . Deep penetration Relatively high travel speeds .. Suitable for field work . Easily mechanized