MOTOVOLT Engineering Standard

INSPECTION METHOD ES No.: 002

OF WELDED PARTS Sheet No.: 1 of 9
Motovolt Mobility Pvt Ltd
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1 1–9 0 Initial release 05.03.2020

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 MOTOVOLT Engineering Standard
INSPECTION METHOD ES No.: 002
OF WELDED PARTS Sheet No.: 2 of 9
Motovolt Mobility Pvt Ltd

1.0 Scope:
This document is the property of MV. It shall not be communicated to

This standard specifies the method of checking the weld quality requirements and
inspection method for welded parts other than spot welding.

2.0 Responsibility:
or copied by anyone without the written approval of MV

QAD, R&D

3.0 Test Facility:

Stereo microscope,UTM, Brinellscope.

4.0 Definitions:

# Terms Definition
1 Under cutting Undercutting is a defect that appears
as a groove in the parent metal directly
along the edges of the weld. Due to
Weld bead
high arc travel speed the weld bead
will be drawn into the base metal and
base metal will be drawn out. So the
weld bead will deposit in the base
metal groove. The undercut groove is
where melted base material has been
drawn into the weld and not allowed to Parent metal
wet back properly because of the rapid
solidification.
2 Second bead This is the defect when weld bead is
deposition deposited on an already existing weld
bead.
Layered weld
bead deposit

3 Weld cracks Cracks can appear on the weld bead

during cooling from liquid state to solid
state. This is termed as solidification Weld
cracks. Sometime at the end where cracks
weld ends very small cracks can be
observed. Its due to abrupt ending of
the weld arc at the end. These are
called cold cracks.

4 Gas porosities Gas porosity and blow holes on the

and blow holes weld bead appear due to atmosphere
contamination, excessively oxidized
work piece surfaces, inadequate Porosity
deoxidizing alloys in the wire and the
presence of foreign matter.
Atmospheric contamination can be
caused by:
 MOTOVOLT Engineering Standard
INSPECTION METHOD ES No.: 002
OF WELDED PARTS Sheet No.: 3 of 9
Motovolt Mobility Pvt Ltd
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1) Inadequate shielding gas flow.

2) Excessive shielding gas flow.
This can cause aspiration of
air into the gas stream
3) Severely clogged gas nozzle
or copied by anyone without the written approval of MV

or damaged gas supply

system (leaking hoses, fittings,
etc.)
5 Spatter This is the solidified droplets of weld
which is found around the weld bead. Spatter
This occurs mainly due to very low arc
speed and high voltage.

6 Fusion This is the extent to which weld Pictures of improper fusion are shown in
characteristics material is fused with parent material. appendix A.
7 Burn through A localized collapse of the molten pool
due to excessive penetration, resulting
in a hole in the weld run Hole

8 Slag inclusion It is principally a deoxidation product

from the reaction between the flux, air
and surface oxide. The slag becomes
trapped in the weld when two adjacent
weld beads are deposited with Inclusion
inadequate overlap and a void is
formed. When the next layer is
deposited, the entrapped slag is not
melted out. Slag is normally seen as
elongated lines either continuous or
discontinuous along the length of the
weld.
 MOTOVOLT Engineering Standard
INSPECTION METHOD ES No.: 002
OF WELDED PARTS Sheet No.: 4 of 9
Motovolt Mobility Pvt Ltd
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5.0 Check Items

Check Items Test Equpiment to be used

or copied by anyone without the written approval of MV

Class A characteristics (Nondestructive testing)

Gap between Visual inspection -
components welded
Under cutting Visual inspection -
Second bead deposition Visual inspection -
Burn through Visual inspection -
Weld cracks Visual inspection / -
Magnetic Particle
examination / Liquid
Penetrant Inspection
Gas porosities and blow Visual inspection -
holes
Spatter Visual inspection -
Punctured parent Visual inspection -
material around weld
Class B characteristics (Destructive testing)
Gas porosities and Visual inspection Stereo microscope
internal blow holes
Fusion characteristics Visual inspection Stereo microscope
Slag inclusion Visual inspection Stereo microscope
Weld penetration Penetration Brinell-scope
inspection

6.0 Test Method

6.1 Inspection of Class A characteristics:

All the Class A characteristics shall be checked as given below
6.1.1 Part shall be identified with the drawing
6.1.2 Visually check for presence of rust preventive oil on the parts, free from
dust or external matter
6.1.3 Clean the oil using a piece of cloth.
6.1.4 Inspect under microscope at a magnification of 40 X for all parameter as
mentioned in the relevant quality parameter for that particular part in
drawing.

6.2 Inspection of Class B characteristics:

Visual inspection of Class B characteristics shall be checked as given below

6.2.1 Take the welded section for inspection.

6.2.2 In stereo microscope check for spattering mark, undercut etc.
6.2.3 Select critical welded section for weld penetration inspection.
 MOTOVOLT Engineering Standard
INSPECTION METHOD ES No.: 002
OF WELDED PARTS Sheet No.: 5 of 9
Motovolt Mobility Pvt Ltd

6.2.4 Take cross sectional cut from the selected area and make a mould of it.
This document is the property of MV. It shall not be communicated to

Polish the sample with emery papers and etch it with 2% nital solution.
6.2.5 Under stereo microscope check the etched component for slag inclusion
and fusion characteristics.
6.2.6 For measuring weld penetration, measure the length (A) of the weld melt
or copied by anyone without the written approval of MV

under the base metal. Calculate

the total thickness of the base metal (B) on which welding has been done
(ref Pic 1).
6.2.7 Calculate the weld penetration (A/B).

Pic 1

6.3 Magnetic Particle Examination:

As per ASTM E 709

7.0 Acceptance Criteria:

# Check item
1 Gap between components
welded
2 Under cutting
3 Second bead deposition
4 Weld cracks
5 Gas porosities and blow
Acceptance criteria
Min. of ( 75% of weld wire dia. Or 40% of min.
component thickness)
Parent material thickness less than 2.5 mm shall
have no undercutting.undercutting shall not be
permitted within 10 mm of each end of the weld.
Undercutting exceeding a depth of 0.5 mm, upto a
maximum of 0.2T (T = T1 or T2 whichever is
minimum,refer appendix A) for a cumulative length
of no longer than L/8, where L is total weld
length,shall be permitted on material over 2.5 mm.
Not allowed. In case tack weld is used , it is
prefferable to cover with main weld. In such case
weld on tack may be allowed depending on the
application.
Not allowed
Not allowed
 MOTOVOLT Engineering Standard
INSPECTION METHOD ES No.: 002
OF WELDED PARTS Sheet No.: 6 of 9
Motovolt Mobility Pvt Ltd

holes
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6 Spatter Not allowed in A class area,Not more than 2 spot

around a particular weld in B and C class area.
7 Punctured base material Not allowed
around weld (burn through)
or copied by anyone without the written approval of MV

8 Gas porosities and internal Not allowed

blow holes
9 Improper fusion Not allowed (see appendix B)
9 Weld penetration 15%~ 45 % of min. thickness of the parent
material. Pictures have been given in appendix A.
10 Slag inclusion Not allowed
11 Weld Strength As given in the drawing

NOTE: For all other details refer drawing / JIS welding Handbook. / MDS 001 / IS 812 / IS
813.

Appendix A

Various type of weld joints and their respective weld penetration:

Wp – 15% to 45 % of (T1 or T2 whichever is minimum)

 MOTOVOLT Engineering Standard
INSPECTION METHOD ES No.: 002
OF WELDED PARTS Sheet No.: 7 of 9
Motovolt Mobility Pvt Ltd
This document is the property of MV. It shall not be communicated to
or copied by anyone without the written approval of MV

Wp – 15% to 45 % of (T1 or T2 whichever is

Wp – 15% to 45 % of (T1 or T2 whichever is minimum)
minimum)

Wp – 15% to 45 % of (T1 or T2 whichever is minimum)

 MOTOVOLT Engineering Standard
INSPECTION METHOD ES No.: 002
OF WELDED PARTS Sheet No.: 8 of 9
Motovolt Mobility Pvt Ltd
This document is the property of MV. It shall not be communicated to
or copied by anyone without the written approval of MV

Wp – 15% to 45 % of (T1 or T2 whichever is

minimum)
 MOTOVOLT Engineering Standard
INSPECTION METHOD ES No.: 002
OF WELDED PARTS Sheet No.: 9 of 9
Motovolt Mobility Pvt Ltd
This document is the property of MV. It shall not be communicated to

Appendix B:

Various improper weld fusion:

or copied by anyone without the written approval of MV

Misplaced welds

Excessively thick
root face

Too narrow root

face

Excess penetration /
puncture