‘THE NORTHERN ALBERTA INSTITUTE OF TECHNOLOGY SECOND PAPER METALLURGY and MATERIALS Student Study GuideTable of Contents SECOND PAPER OUTLINE OVERVIEW. PRE-TEST INFORMATION PRE-REQUISITES. RESOURCES..... OBJECTIVE 1: DESCRIBE SIGNIFICANT MILESTONES IN THE HISTORY OF WELDING OsyEcTIVE 2: DESCRIBE WELDING METALLURGY. OBsECTIVE 3: DESCRIBE HEAT TREATMENT PROCESSES. OBJECTIVE 4: DESCRIBE THE CRYSTALLINE STRUCTURE OF METALS.. MODULE 2... OBJECTIVE 1: DESCRIBE THE GENERAL CATEGORIES OF IRON AND STEEL, OBJECTIVE 2: DESCRIBE THE STEEL MAKING PROCESS. OpJECTIVE 3: DESCRIBE FOUNDRY STEEL MILL OPERATIONS. MODULE DESCRIBE THE SOLIDIFICATION OF WELD METAL.. OBJECTIVE 2: DESCRIBE THE WELD ZONE.This publication ©The Northen Alberta Institute of Technology (2003). All rights are reserved. No part of this publication may be reproduced, or transmitted in any form or by any means, or stored in a database and retrieval system, without the prior written permission of the copyright holder. Address all inquiries to: ‘THE NORTHERN ALBERTA INSTITUTE OF TECHNOLOGY 11762 - 106 Street Edmonton, Alberta Canada TSG 2R1‘Second Paper Metallurgy and Materials Second Paper Outline Module 1. Milestones in the history of welding 2. Welding Metallurgy 3, Heat Treatment 4, Crystalline structure of metals i, exystal growth from the melt ii. formation of dendrites iii, formation of grains iv. shape of grains ‘The properties of metal 1. mechanical properties 2, yield strength 3, breaking strength 4, tensile strength 5. ductility 6. hardness 7. toughness 8. thermal conductivity Alloying elements © effects of alloying elements © residual elements + iron - iron carbide diagram + analysis of Fe-Fe3c diagram Student Study guide THE STRUCTURE OF METALS (weighting 20%) Page 2Second Paper Metallurgy and Materials Module 2: TYPES OF STEEL AND THEIR MANUFACTURE _ (weighting 35%) General categories of iron and steel + pigiron + castiron + wrought iron carbon steel alloy steel high alloy steel Steel making process blast furnace » Bessemer furnace + Basic oxygen steelmaking + Electric arc furnace + Ladle refining + Electric induction + Foundry steel mills operation ‘+ Continuous casting of steel ‘+ Hot working operation + Forging + Rolling + Heat treatment ‘Student Study guide Page 3Second Paper Module 3: WELDING METALLURGY Solidification of weld metal 1, the weld zone i. unmixed zone ii, partially melted zone iii, heat affected zone iv. unaffected base metal Microstructural changes in iron and steel i. phase changes ii. ferrite ii. austenite iv. pearlite . martensite ii. importance of critical cooling rates role of grain size in weld metal ii, iii iv. v. vi. cementite vii viii. ix. . influence of'non-metallic inclusions Metallurgy and Materials (weighting 35%) 2. carbon and alloy steels commonly used in welded construction » . characteristics of steel important to welding 4, factors affecting weldability of steels i. chemistry ii, mechanical properties iii, metallurgical structure iv. internal soundness v. cleanliness Student Study guide Page 4Second Peper Temperature i, peak temperatures ii, cooling rates iii. time at temperature iv. workpiece pre-weld temperature -. instantaneous cooling rate vi. cooling end points vii. ctitical cooling rates Module Standards and specifications for steel i. unified numbering system ASTM standards iii, ASME material specifications REFERENCE MATERIAL + Welding Metallurgy (Linnert, Volume 1 fourth edition) « ASME Section Il- Part A Student Study guide Ally Metallurgy and Materials MATERIAL SPECIFICATIONS _ (weighting 10%) Page 5‘Second Paper Metallurgy and Materials Overview ‘The Alberta Boiler and Safety Association has been authorized by the Government of Alberta with the administration of the Welding Examiner Certificate of Competency Examination. This is the second in a series of four papers, which have been prepared by NAIT to assist candidates to undertake the required examination. ‘This Second Paper will introduce the candidate to the structure of metals, their properties, types of steel and their manufacture and welding metallurgy. Pre-test Information If you feel you know the information that is covered by the objectives in this module, contact the Alberta Boiler Safety Association (ABSA) to write the second paper of the Welding Examiners Certificate of Competency examination. Student Study guide Page 6Second Paper Metallurgy and Materials Pre-requisites This General Information is intended to assist candidates studying for the Welding Examiner Certificate of Competency Examination. To qualify to take this examination, a candidate must satisfy at least one of the following eligibility requirements CERTIFICATIONS/DESIGNATIONS + PEng. with a B.Sc. in Metallurgy, Welding, or Mechanidal Engineering + First Class Power Engineers, Certificate of Competency + CET with a Diploma in Materials or Mechanical Engineering Technology + Diploma in Welding Engineering Technology * Grade"A" or "B" Pressure Welder (see note 1) + CSA WI78.2 Welding Inspector Level I + Safety Codes Officer - Boiler Discipline + Designated Welder Testing Personnel (see note 2) * Other equivalent Qualifications (see note 3) NOTES Note 1 Candidates who have successfully completed papers 1 and 2 of the Grade "A" Pressure Welders examination may be granted credit for these same papers on the Welding Examiners Certificate of Competency Examination. Noté2 Designated welder testing personnel who were authorized under a testing organization's quality control program to conduct performance qualification tests as of October 1, 2002 are eligible to write the Welding Examiner Certificate of Competency Examination Note 3 Other qualifications will be considered under the provisions, which will allow the Administrator to accept equivalencies. The candidate must have relevant experience, which would include involvement in the pressure equipment industry related to fabrication, inspection, repair, welding design, quality control or operation. The candidate would also have suitable academic qualifications in recognized courses in welding, materials, ASME Codes, and NRE. Student Study guide ffl, Page 7Second Paper Metallurgy and Materials Resources ‘The following resources are required for the Second Paper. + Welding Metallurgy (Linnert, Volume I fourth edition) Student Study guide Page 8‘Second Paper Metallurgy and Materials Module1 : The Structure of Metals Student Study guide Page 9‘Second Paper ‘Metallurgy and Materials Learning Outcome and Objectives Learning Outcome Upon completion of this module the student will be able to describe the structure of metals. Learning Objectives 1. Describe significant milestones in the history of welding 2. Describe welding metallurgy. 3. Describe the heat treatment process. 4, Describe the crystalline structure of metals. Introduction Metallurgy is defined as the science and technology of metals. Both process and physical metallurgy are involved in welding. The study of migtallurgy will enable the candidate to understand the structure of metals, their properties, different types of steel and material specifications. This knowledge will help the candidate to challenge the Welder Examiner Certificate of Competency administered by The Alberta Boiler Safety Association. Resources The following resources are required in this module. + Welding Metallurgy (Linnert, Volume I, fourth edition) Student Study guide _ Alita‘Second Paper Metallurgy and Materials Module 1: Learning Activities and Practice Exercises Objective 1: Describe significant milestones in the history of welding Activity #1 : In the Welding Metallurgy (Linnert, Volume 1 fourth edition) book read pages 1 to 9 Practice Exercises 1. Give a brief description of the history of welding. 2. What is welding metallurgy? 3, What is the purpose of postweld heat treatment? Student Study guide Alle Page 11Second Paper Metallurgy and Materials Practice Exercises Answers Refer to the following pages in the Welding Metallurgy (Linnert, Volume 1 fourth edition) book to check your answers to the practice exercises. Lpl 2.p.6 3.p.9 Page 12 ‘Student Study guide‘Second Paper Metallurgy and Materials Objective 2: Describe welding metallurgy. Activity #1 In Welding Metallurgy (Linnert, Volume 1 fourth edition) read pages 61 to 72. a ‘ Practice Exercises 1. What is meant by the crystalline structure of metals? 2. How does a crystal grow from the melt? 3, Explain the formation of dendrites. 4, How do — form? 5. Explain why grains are shaped the way they are. 6. Explain how grains are shaped. ‘Student Study guide nll, Page 13‘Second Paper Metallurgy and Materials Practice Exercises Answers Refer to the following pages in Welding Metallurgy (Linnert, Volume 1 fourth edition) to check your answers to the practice exercises. Lp.61 2. p. 64 3. p. 66 4. p. 68 5.p.71 6p.71 Student Study guide lie. Page 14Second Paper Metallurgy and Materials Objective 3: Describe heat treatment processes. Activity #1 In Welding Metallurgy (Linnert, Volume 1 fourth edition) read pages 133 to 155 and pages 261 to 263, m3 ! Practice Exercises 1, What does the phrase “properties of metals” mean? 2. Explain mechanical properties. 3. Define the following terms: i. yield strength ii. breaking strength iii, tensile strength iv. ductility v. hardness (Brinell hardness, Vickers hardness, Rockwell hardness) vi. toughness 4. Describe the effect of temperature on mechanical properties. Student Study guide Alli. Page 15Second Paper Metallurgy and Materials Practice Exercises Answers Refer to the following pages in Welding Metallurgy (Linnert, Volume 1 fourth edition) to check your answers to the practice exercises. 1p. 133, 2. p. 136 3. p. 143 to p. 154 4.p. 164 4 Student Study guide _ itl Page 16Second Paper Metallurgy and Materials Objective 4: Describe the crystalline structure of metals. Activity #1 In Welding Metallurgy (Linnert, Volume 1 fourth edition) read pages 295, 330 to 334 and pages 358 and 359. Et | t Practice Exercises 1. What is meant by the term “alloying”? 2. What are some of the effects of alloying elements to iron? 3. Explain what is meant by residual elements. es 4, Draw and label the iron- iron carbide diagram from 0 to 0.83% carbon. 5. Give an analysis of the iron- iron carbide diagram from 0 to 0.83% carbon. ‘Student Study guide iy, Page 17Second Paper Metallurgy and Materials Practice Exercises Answers Refer to the following pages in Welding Metallurgy (Linnert, Volume 1 fourth edition) to check your answers to the practice exercises. 1. p.295 2. p. 326 3. p. 358 4. p. 330 5.p.331 Student Study guide fl, Page 18‘Second Paper Metallurgy and Materials Module2 : Types of Steel and Their _ Manufacturing Process ‘Student Study guide Page 19Second Paper Metallurgy and Materials Learning Outcome and Objectives Learning Outcome At the end of this module you will demonstrate knowledge of types of steel and their manufacturing processes. Learning Objectives 1. Describe the general categories of iron and steel. ! 2. Describe steel making processes. 3. Describe foundry steel mills operations. Introduction A Imowledge of the manufacturing processes used to produce iron and steel is very helpful in understanding the behaviour of various steel products employed to construct weldments. The study of steel categories, the steel making process and welding metallurgy will enable the candidate to challenge the Welding Examiner Certificate of Competency ‘Examination administered by the Alberta Boiler Safety Association. Resources ‘The following resources are used in this module. + Welding Metallurgy (Linnert, Volume I, fourth edition) b Student Study guide eal, Page 20‘Second Paper Metallurgy and Materials Module 2: Lear s and Practice Exercises ig Aci Objective 1: Describe the general categories of iron and steel. Activity #1 In Welding Metallurgy (Linnert, Volume 1 fourth edition) read pages 361 to 367, and pages 410 to 413 Practice Exercises 1. Describe the following general categories of iron and steel. i. pig iron i. cast iron iii, wrought iron iv. carbon sitel vy. alloy steel vi. high alloy steel Student Study guide Ai. Page 21Second Paper Metallurgy and Materials. Practice Exercises Answers Refer to the following pages in Welding Metallurgy (Linnert, Volume 1 fourth edition) to check your answers to the practice exercises. i. p. 362 ii. p. 366 iii, p. 367 t iv. p. 410 v. p. 411 vi. p. 413 Student Study guide Page 22Second Paper Metallurgy and Materials Objective 2: Describe the steel making process. Activity #1 In Welding Metallurgy (Linnert, Volume 1 fourth edition) read pages 362 to 389. Practice Exercises 1. Describe the following steel making processes: i. blast furnace ii, bessemer converter iii. basic oxygen steel making iv. electric are furnace v. ladle refining vi. electric induction ‘Student Study guide _ Ala Page 23,‘Second Paper Metallurgy and Materials Practice Exercises Answers Refer to the following pages in Welding Metallurgy (Linnert, Volume 1 fourth edition) to check your answers to the practice exercises. ip. 362 ii. p. 369 iii, p. 380 t iv. p. 389 p.385 vi. p. 389 Student Study guide fl. Page 24‘Second Paper Metallurgy and Materials Objective 3: Describe foundry steel mill operations. Activity #1 In Welding Metallurgy (Linnert, Volume | fourth edition) read pages 400 to 408. my ‘ Practice Exercises 1. Describe the continuous casting of steel. 2. What are hot working operations? 3. Explain the following terms. i, Hot working ii, Cold finishing iii, Heat treatment ‘Student Study guide _ Alt, Page 25Second Paper Metallurgy and Materials Practice Exercises Answers Refer to the following pages in Welding Metallurgy (Linnert, Volume 1 fourth edition) to check your answers to the practice exercises. 1.p.400 2. p. 404 3. p.404, 407. 408 t Student Study guide A. Page 26Second Paper Metallurgy and Materials Module3 : Welding Metallurgy Student Study guide Page 27Second Paper Metallurgy and Materials Learning Outcome and Objectives Module Outcome Upon completion of this module students will demonstrate knowledge of welding metallurgy. Learning Objectives 1. Describe the solidification of weld metal. t 2. Describe the weld zone. 3. Describe carbon alloy steel used in welded construction. 4. Describe the characteristics of steel important to welding. 5. Describe factors affecting the weldability of steels. Introduction ‘Welding can be compared to a series of metallurgical operations that are involved in steel making. A molten metal (melt) is formed (cast) within the confines of a solid base metal (mold). A. study of welding metallurgy is important to challenge the Welding Examiner Certificate of Competency Examination administered by the Alberta Boiler Safety Association, Resources ‘The following resources are used in this module, + Welding Metallurgy (Linnert, Volume I, fourth edition) ‘Student Study guide Page 28Second Paper Metallurgy and Materials, Module 3: Learning Activities and Practice Exercises Objective 1: Describe the solidification of weld metal. Activity #1 In Welding Metaliurgy (Linnert, Volume 1 fourth edition) read pages 664, 674, 681, 683, 696, and 834. i Practice Exercises 1. Explain the term “peak temperature” as it applies to welding. 2. What is meant by time at temperature and how does it affect the micro-structure of the HAZ? = 3. Does the workpiece pre-weld temperature have an effect on the HAZ micro- structure? If yes, explain how? 4, Explain the effects of controlling the cooling end point in a weld? Student Study guide Page 29Second Paper Metallurgy and Materials Practice Exercises Answers Refer to the following pages in Welding Metallurgy (Linnert, Volume 1 fourth edition) to check your answers to the practice exercises. 1p. 664 2p. 614 3. p.681 4. p. 696 t ‘Student Study guide AGgit, Page 30‘Second Paper Objective 2: Describe the weld zone. Activity #1 In Welding Metallurgy (Linnert, Volume 1 fourth edition) read pages 788 to 802. Practice Exercises 1. Explain what happens when a weld solidifies. 2. Explain the following terms: i. weld zone unmixed zone iii, partially melted zone iv. heat affegted zone v. unaffected base metal Student Study guide it Metallurgy and Materials Page 31Second Paper Metallurgy and Materials Practice Exercises Answers Refer to the following pages in Welding Metallurgy (Linnert, Volume 1 fourth edition) to check your answers to the practice exercises. 1. p. 788 2. p. 798 to 802 Student Study guide lis, Page 32Second Paper Metallurgy and Materials Objective 3: Describe carbon alloy steel used in welded construction. Activity #1 In Welding Metallurgy (Linnert, Volume 1 fourth edition) read pages 802 to 872. Practice Exercises 1. Explain the following terms. i. phase changes ferrite iii. austenite iv. pearlite v. martensite vi. cementite 2. Explain the importance of the critical cooling rate, 3. What are the implications of martensite in welding? 4, What is the importance of weld metal composition? 5. What is the role of grain size in weld metal? 6. What is the potential influence of non-metallic inclusions? ‘Student Study guide lit Page 33‘Second Paper Metallurgy and Materials Practice Exercises Answers Refer to the following pages in Welding Metallurgy (Linnert, Volume 1 fourth edition) to check your answers to the practice exercises. 1. p. 803 to 809 2. p. 834 3. p. 836 4. p.870 t 5.p.872 6. p.872 ‘Student Study guide Page 34‘Second Paper Metallurgy and Materials Module 4 : Material Specifications Student Study guide Page 35‘Second Paper Metallurgy and Materials Learning Outcome and Objectives Module Outcome Upon completion of this module you will be able to demonstrate knowledge of standards and specifications of steel. Learning Objectives Describe the standards and specifications for steel. t Introduction ‘There are many different ways that steel is identified and specified. There are more than 150 major “standards” organizations in the US and each has its own way of identifying their product, The study of the different classification systems and standards and a knowledge of the information will help you challenge the Welding Examiner Certificate of Competency Examination administered by the Alberta Boiler and Safety Association, Resources ‘The following resources are used in this module. + ASME Code,Section Il, Part A © Welding Metallurgy (Linnert, Volume I fourth edition) ‘Student Study guide A. Page 36Second Paper Metallurgy and Materials Module 4: Learning Act ies and Practice Exercises Objective 1: Describe the standards and specifications for steel. Activity #1 f In Welding Metallurgy (Linnert, Volume | fourth edition) read pages 416 to 430, Practice Exercises 1. Explain the following terms: i. unified numbering system ii, AISI-SAE system of standards ASTM standards iv. API specifications vy. ASME material specification 2. Give a brief description of carbon and low alloy steel used in welded construction. 3, What are some of the qualities of steels that make them important to welding? 4, Explain the following factors and their effect on the weldability of steels. i. chemistry ii, mechanical properties . metallurgical structure iv. intemal soundness ‘Student Study guide _ Ali Page 37‘Second Paper Metallurgy and Materials vy. cleanliness Practice Exercises Answers Refer to the following pages in Welding Metallurgy (Linnert, Volume 1 fourth edition) to check your answers to the practice exercises. 1. p.416 to p. 426 2. p. 430 3.p.431 t 4, p. 432 to p. 436 a Page 38 Student Study guideSecond Paper Metallurgy and Materials Activity #2 In ASME Section IL, Part A read the information on the steel specification SA-106. Practice Exercises 1, Whatis the scope of SA-106? 1 2. What is the steel making process for SA-106? 3, Does SA-106 require heat treating? 4, Whatiis the frequency of product analysis? 5, What tests ~ required for SA-106? 6, What are the variation limits for the weight, diameter, thickness, and length? 7. How many different grades are there of SA-106? What makes each grade different? 8. What elements are required to be reported? Student Study guide Page 39‘Second Paper Metallurgy and Materials Practice Exercises Answers Refer to the following pages in ASME Code Section II part A to check your answers to the practice exercises. 1.p.210 2.p.210 3.p.210 4. p. 210 S.p. 211 6.p. 212 7p. 216 8. p. 216 Student Study guide eran, pecan,Second Paper Metallurgy and Materials Activity #3 In ASME Section II part A read the steel specification SA-516, Practice Exercises 1, What is the scope of SA-516? 2. What are the Grades of strength levels for SA-516? 3. Under what specification would you look for the general requirements for SA 516? 4, From what steel making practice do you obtain SA-516 specification? 5, What heat treatment is required with SA-516? 6. What elements are required to be reported with SA-516 specification? 7. What are the mechanical requirements SA-516-70? student Study guide fl Page‘Second Paper Metallurgy and Materials Practice Exercises Answers Refer to the following pages in ASME Code Section II part A to check your answers to the practice exercises. 1. p.931 2. p. 931 3. p.931 4. p.932 5. p. 932 6. p.932 7. p.932 Student Study guide Page 42‘Second Paper Metallurgy and Materials Activity #4 In ASME Section I part A read the steel specification SA-333. Practice Exercises 1. What is the scope of SA-333? 2. How shall the pipe be made? 3. Explain some of the heat treatments that may be applied to SA-333. 4, What elements are required to be reported? 5. At the request of the purchaser how is a product analysis obtained? 6. What mechanical testing is required for SA-333? 7. What is a surface defect and how may it be dispositioned? 8, Is rejected pipe allowed to be reused? Student Study guide Aim Page 43‘Second Paper Metallurgy and Materials, Practice Exercises Answers Refer to the following pages in ASME Code Section II part A to check your answers to the practice exercises. 1. p.531 2. p.532 3.p.532 4. p. 533 5. p.533 6. p.533 7. p.533 8. p.537 : Student Study guide Page 44‘Second Paper Metallurgy and Materials Activity #5 In ASME Section II part A read the steel specification SA-387. ma Practice Exercises 1, What is the scope of SA-387? 2. What steelmaking practice is used for SA-387? Is heat treating of SA-387 specification required? 4, What are the chemical requirements for SA-387? 5. When are supplementary requirements needed? ‘Student Study guide eesease, Page 45Second Paper Metallurgy and Materials Practice Exercises Answers Refer to the following pages in ASME Code Section II part A to check your answers to the practice exercises. 1p. 704 2. p. 70S 3. p. 705 4, p. 705 5. p. 708 Student Study guide nafpee, Page 46Second Paper Metallurgy and Materials Activity #6 In ASME Section II part A read the steel specification SA-312. Practice Exercises 1. What is the scope of SA-312? t 2, How shall this pipe be manufactured? 3. Does SA-312 specification require heat treatment? 4, What elements are required to be reported? 5. What stn tests are required of SA-312? 6. What non-destructive examination is required? 7, What are the requirements for the workmanship, finish, and appearance SA-312? 8. Can weld repairs to the product be performed to bring it into compliance to specification SA-312? Student Study guide ieee Page 47‘Second Paper Metallurgy and Materials: Practice Exercises Answers Refer to the following pages in ASME Code Section II part A to check your answers to the practice exercises. 1. p. 494 2. p.495 3. p.495 4. p.496 5. p.496 6. p.496 7. p.499 8. p.499 Student Study guide eal, Page 48Second Paper Metallurgy and Materials Second Paper Summary In this Second Paper you have learned about steel from its atomic structure through to what happens when welded, The last section of the paper dealt with different specifications for steel as called for by several important standards organizations. As a ‘Welding Examiner you will be expected to know what the different types of steel are that are called up by standards organizations, how to weld them, where they are used and how they were manufactured. t Student Study guide feat Page 49All rights reserved. No part of this manual may be reproduced in any form, traded, rented or resold ‘without written permission from The Northern Alberta Institute of Technology, except by a reviewer who wishes to quote brief excerpts. ‘THE NORTHERN ALBERTA INSTITUTE OF TECHNOLOGY 11762 - 106 Street Edmonton, Alberta (Canada TSG 2R1 cp2at2 2412 Printed January 28, 2003‘THE NORTHERN ALBERTA INSTITUTE OF TECHNOLOGY THIRD PAPER Student Study GuideThis publication © The Northern Alberta Institute of Technology (2000). All rights are reserved. No part of this publication may be reproduced, or transmitted in any form or by any means, or stored in a database and retrieval system, without the prior written permission of the copyright holder Address all inquiries to ‘THE NORTHERN ALBERTA INSTITUTE OF TECHNOLOGY 11762 ~ 106 Street Edmonton, Alberta Canada TSG 2R1Table of Contents Ai Pre-requisites.. Module 1: Quality Control... 3 4 5s Module Outcome. 6 Module Objectives, 6 Introduction 6 Module 1: Learning Activities and Practice Exercises 7 Objective 1: Describe the goals, purpose, scope and concepts of a Quality system for Performance Qualification Testing, ‘Objective 2: Describe the system for preparing, revising and controlling the distribution of ‘the Quality System for Performance Qualification Testing manual ‘Objective 3: Describe the roles responsibilities, procedures, and duties of personnel who ‘conduct and supervise performance qualification testing Objective 4: Describe the activities, procedure and requirements for performance qualification testing of Welders/Machine Welding Operators Objective 5: Describe the radiographic examination that may be used to qualify Welders/Machine Operators Objective 6: Describe the system for identifying, documenting and resolving non conformities Module 2: Non-Destructive Examination Module Outcome. ‘Module Objectives Introduction Resources Module 2: Learning Activities and Practice Exercises Objective 1: Describe and explain Visual examination Objective 2: Describe the details for Radiographic Examination Objective 3: Describe the details for Radiographic Examination, Objective 3: Describe the details for ultrasonic examination,Objective 4: Describe the details for Liquid Penetrant Inspection 4 Objective 5: Describe the details for Magnetic Particle Testing 2 Module 3: Weld Examination. Module Outcome. . 60 Module Objectives 6 Introduction. 60 Resources. 60 Module 3: Learning Activities and Practice Exercises 61 Objective 1: Examine the SMAW coupons for acceptability to various referencing codes 6 Objective 2: Examine the GTAW coupons for acceptability to various referencing codes 6 Objective 3: Examine the GMAW coupons for acceptability to various codes. 0 Objective 4: Examine the bend coupons for acceptability to ASME Section X. n ‘Third Paper SummaiThird Paper Quality Control, Non-destructive Testing, and Weld Examination Third Paper Outline Module 1: Quality Control (weighting 30%) A quality system for the performance qualification testing of pressure welders and machine operators in accordance with ASME Section IX and the Alberta Safety Codes Act and Regulations, i. Concepts, Goals, Purpose, and Scope ii, Roles Responsibilities and Duties of Personnel iii, Elements of a Quality Control Manual for Performance Qualification Testing, iv. Relationship between Codes and Regulations v. Accredited organizations vi, Testing Standards and Procedures Module 2: Non-destructive Examination (weighting 35%) The applications, examination processes, requirements, uses, benefits, limitations, personnel qualifications, physical weld defects and acceptance criteria of the following NDE methods i, Visual Examination ii, Radiographic Examination iii, Ultrasonic Examination iv. Liquid Penetrant Examination v. Magnetic Particle Examination Module Weld Examination (weighting 35%) Candidates will examine and assess representations of coupons for weld defects and acceptability standards referenced in ASME Section I, Section VIII Div. I,X and B31.1, B31.3 (normal) and B31.3 (severe) me L Student Study guide Page 1Third Paper Quality Control, Nondestructive Testing, and Weld Examination REFERENCE MATERIAL ABSA sample Quality Control Manual for the Performance Qualification Testing of Pressure Welders and Machine Operators ASME Section I + ASME Section V + ASME Section VII Div. 1 &~ + ASME Section IX 4 44 + ASME B31.1 ao 7 + ASME B313 ~ (i Student Study guide Page 2} ‘Third Paper Quality Control, Nondestructive Tes 9, and Weld Examination Overview The Alberta Boiler and Safety Association (ABSA) has been charged by the Government of Alberta with the administration of the Welding Examiner Certificate of Competency Examination. This is the third in a series of four papers which have been prepared by NAIT to assist candidates to prepare for the required examinations. This third paper will introduce the candidate to the concepts of a quality system for the performance qualification testing of welders and welding operators as well as the fundaments of various non-destructive testing methods. In addition, the paper will close with illustrations of weld samples which will be evaluated for defects and acceptability standards, Pre-test Information If you know the information that is covered in this module, contact the Alberta Boiler Safety Association (ABSA) to write third paper of the Welding Examiners Certificate of Competency examination Student Study guide Page 3Third Paper Quality Control, Nondestructive Testing, and Weld Examination Pre-requisites This General Information is intended to assist candidates studying for the Welding Examiner Certificate of Competency Examination. To qualify to take thi eligi examination, a candidate must satisfy at least one of the following ity requirements CERTIFICATIONS/DESIGNATIONS + PEng. with a B.Sc. in Metallurgy, Welding, or Mechanical Engineering + First Class Power Engineers, Certificate of Competency + CET with a Diploma in Materials or Mechanical Engineering Technology + Diploma in Welding Engineering Technology + Grade "A" or "B" Pressure Welder (see note 1) + CSA WI78.2 Welding Inspector Level III + Safety Codes Officer - Boiler Discipline + Designated Welder Testing Personnel (see note 2) + Other equivalent Qualifications (see note 3) NOTES Note 1 Candidates who have successfully completed papers 1 and 2 of the Grade "A" Pressure Welders examination may be granted credit for these same papers on the Welding Examiners Certificate of Competency Examination. Note 2 Designated welder testing personnel who were authorized under a testing organization's quality control program to conduct performance qualification tests as of October 1, 2002 are eligible to write the Welding Examiner Certificate of Competency Examination Note 3 Other qualifications will be considered under the provisions which will allow the Administrator to accept equivalencies. The candidate must have relevant experience, which would include involvement in the pressure equipment industry related to fabrication, inspection, repair, welding design, quality control or operation. The candidate would also have suitable academic qualifications in recognized courses in welding, materials, ASME Codes, and NDE Stucent Study guide le Page 4Third Paper ‘Quality Control, Non-destructive Testing, and Weld Examination Module 1 Quality Control Student Study guide Page §Third Paper Quality Control, Nondestructive Testing, and Weld Examination Module Outcome ‘Upon completion of this module the candidate will be able to describe the concepts, goals, and the required elements needed in a Quality System Manual for Performance Qualification Testing Module Objectives 1. Describe the goals and purpose of a Quality System Manual for Performance Qualification Testing. 2, Describe the system for preparing, revising and controlling the distribution of the Quality System manual 3. Describe the roles, responsibilities, and duties of personnel who conduct and supervise performance qualification testing 4, Describe the activities, procedures and requirements for performance qualification testing 5. Describe the radiographic examination that may be used to qualify Welders! Machine Operators 6. Describe the system for identifying, documenting and resolving non conformities Introduction All persons wishing to undertake pressure welding in the province of Alberta must pass the performance qualification test required by the Administrator and conducted by an accredited organization. A Welding Examiner should be familiar with a Quality System Manual for Performance Qualification Testing and the functions of an Examiner as defined in the manual, ‘Student Study guide Page 6\ } Third Paper Quality Control, Nondestructive Testing, and Weld Examination Module 1: Learning Activities and Practice Exercises Objective 1: Describe the goals, purpose, scope and concepts of a Quality system for Performance Qualification Testing. Activity #4 In the ABSA sample Quality System Manual for the Performance Qualification Testing of Welders and Welding Operators read sections "A", "D", and "E" Practice Exercises 1. What is the purpose of the Quality System manual? n ‘At what locations is the Quality System manual valid? 3, Which Codes does the Quality System manual apply to? 4, What is the scope of the Quality System manual? 5, Who can be tested and can it be an initial test? 17> 6. Who has the ultimate responsibility for the quality system? 7. Who has the responsibility of resolving any conflicts and what must they not compromise? Student Study guide Page 7Third Paper Quality Control, Nondestructive Testing, and Weld Examination Practice Exercises Answers Refer to the following sections in the ABSA Quality System for Performance Qualification Testing manual to check your answers to the practice exercises, 1, Section "A" 2. Section "A" 3, Section "A" 4, Section "D" 5. Section "D" 6. Section 7. Section Student Study guide Page 8Third Paper Quality Control, Nondestructive Testing, and Weld Examination Objective Activity #1 In the ABSA sample Quality System Manual for Performance Qualification Testing read Section 5 Describe the system for preparing, revising and controlling the distribution of the Quality System for Performance Qualification Testing manual. Practice Exercises 1, Who is responsible for implementing the Quality system? 2. Explain how revision to the Quality System manual is implemented. 3. How does the system assure that all copies of the manual are revised? Student Study guide aliia Page ®Third Paper ‘Quality Control, Non-destructive Testing, and Weld Examination Practice Exercises Answers Refer to the following sections in the ABSA Sample Manual for Performance Qualification Testing to check your answers to the practice exercises 1, Section 5.1 2. Section 5.1 Qu, £1 © 3.Sections.2 4, Student Study guide 06 Page 10Third Paper Quality Control, Nondestructive Testing, and Weld Examination Weloine Expmine es Objective 3: Describe the roles responsibilities, procedures, and duties of personnel who conduct and supervise performance qualification testing Activity #4 In the ABSA sample Quality System Manual for Performance Qualification Testing read Section 6 Practice Exercises 1, What are the duties of the Quality Control Manager when appointing the Welding Examiner? 2. What qualifications should the Welding Examiner have? 3. Who shall conduct supervise a performance qualification test? Sp pores Student Study guide Page 11‘Third Paper Quality Control, Non-destructive Testing, and Weld Examination Practice Exercises Answers Refer to the following sections in the ABSA sample Quality System Manual for Performance Qualification Testing to check your answers to the practice exercises 1. Section 6.1 2. Section 6.2 3. Sectionsa~ 4+! Student Study guide Page 12‘Third Paper Quality Control, Nondestructive Testing, and Weld Examination Objective 4: Describe the activities, procedure and requirements for performance qualification testing of Welders/Machine Welding Operators Activity #4 In the ABSA sample Quality System Manual for Performance Qualification Testing read Section 9 Practice Exercises 1. Can an Examiner issue a Performance Qualification card to himself/herself or to the immediate Supervisor? ~ 2. What are the Welding Examiners duties prior to the test? 3. What are the Welding Examiners duties during the test? 4, What are the Welding Examiners duties after the test? 5. State the additional duties of a commercial testing facility 6. What instructions should be provided to a Welder/Machine Operator performing a 2 test? fess OS Student Study guide Page 13Third Paper Quality Control, Nondestructive Testing, and Weld Examination Practice Exercises Answers Refer to the following sections in the ABSA sample Quality System Manual for Performance Qualification Testing to check your answers to the practice exercises 1. Section ge G1 pmnmnpatere Sexe eeu rsee 2 2. Section 91-~ Ft 3.Sectiong2 4. > 4. Seaionss~” 2-1 5. Sectionga~ 7° 6. Exhibit 9.1 Student Study guide _ Pete Page 14Third Paper Quality Control, Nondestructive Testing, and Weld Examination Objective 5: Describe the radiographic examination that may be used to qualify Welders/Machine Operators Activity #1 In the ABSA sample Quality System Manual for Performance Qualification Testing read Section 10 Practice Exercises b 1, What Code Section must a welder be for renewal of qualifications by radiography? SHAN DOG OS SPE: Fis Al SIE taal A 2. What qualifications must the radiographer be certified to? . sat Te -1A CGS 3. What are the duties of a Welding Examiner in regards to the NDE subcontractor? LiASr ont with MDE Preswvee 4, What level of certification must an NDE examiner have to interpret a radiograph? hevte /t o¢ hevee Mh Student Study guide Gis Poge 15Third Paper Quality Control, Nondestructive Testing, and Weld Examination Practice Exercises Answers Refer to the following sections in the ABSA sample Quality System manual for Performance Qualification Testing to check your answers to the practice exercises 1. Section 10,0 2. Section 10.1 3. Section 10.2 ard, ¢/4,€, 4. Section 10.1 (d) Student Study guide Page 18Third Paper ‘Quality Control, Non-destructive Testing, and Weld Examination Objective 6: Describe the system for identifying, documenting and resolving non conformities Activity #1 In the ABSA sample Quality System Manual for Performance Qualification Testing read Section 11 Practice Exercises 1. Who shall be notified of a non conformance? ben 2. How must a non conformance be identified? TAGGING pa HOD 3. When can a non conforming item be released? or 2 Can Pekan ne? APTHC IT [ons Pee) Boe a a? 4, Where should the report be filed? DW Firth Student Study guide Reh Page 17Third Paper Control, Non-destructive Testing, and Weld Examination Practice Exercises Answers Refer to the following sections in the ABSA sample Quality System manual for Performance Qualification Testing to check your answers to the practice exercises, 1. Section 11.1 2. Section 1L.2~ //, | 3. Section 11.3 4, Section 11.4 Student Study guide Page 18Third Paper Quality Control, Non-destructive Testing, and Weld Examination Module 2 Non-Destructive Examination Student Study guide Beat Page 19Third Paper Quality Control, Non-destructive Testing, and Weld Examination Module Outcome ‘Upon completion of this module the candidate will be able to describe the uses, requirements, benefits, limitations, personnel qualifications and acceptance criteria of various inspection methods. Module Objectives 1. Describe the details for Visual Examination 2. Describe the details for Radiographic Examination 3. Describe the details for Ultrasonic Examination 4. Describe the details for Liquid Penetrant Examination 5. Describe the details for Magnetic Particle Examination Introduction In today's complex and competitive fabrication and maintenance industry, the use of non destructive examination is a must to ensure maximum reliability. The study of these methods will help personnel to ascertain that the proper test technique is used to assure the quality of the finished product. ‘The study of non destructive testing will enable the Candidate to further his knowledge so that they may attempt to challenge the Welding Examiner Certificate of Competency administered by the Alberta Boiler and Safety Association, ‘Student Study guideThird Paper Quality Control, Nondestructive Testing, and Weld Examination Resources ‘The following resources are used in this module. If you feel that you are not familiar with the four methods of non-destructive testing we recommend the following additional resource materials that you can obtain in the following books. alt i u s “~ //\ i. Radiographic Testing ae id edition fe y ii, Ultrasonic Testing AH Cre edition gb | iii, Liquid Penetrant #e 1 Acta ion \ iv. Magnetic Particle #z’~"" " CT-6-3/second edition V ViSute Testine MENA [F Student Study guide Rea Page 21Third Paper ‘Quality Control, Nondestructive Testing, and Weld Examination Module 2: Learning Acti ities and Practice Exercises Objective 1: Describe and explain Visual examination Activity #4 In ASME Section V read Article 9 Practice Exercises 1, What is the scope of Article 9? Does Visual Examination require a written procedure? 3, Who may perform visual examinations? 4. What are the essential and non essential variables of visual examination? What needs to be done when an essential variable is changed in a visual examination procedure? 6 What equipment might be used in a visual examination? uv 7. What information should a written procedure contain? “/ (f 4 é ‘8. What are the physical requirements of personnel? pl 9, What is visual examination used for? 10, What are the requirements for direct visual examination?" Student Study guide Page 22‘Third Paper Quality Control, Nondestructive Testing, and Weld Examination 11. How would you perform remote visual examination? 7 12, What is meant by translucent visual examination? yore pee 13. What are the acceptance standards of an evaluation? 14, What documentation is required for visual inspection? aa Student Study guide Page 23Third Paper ly Control, Non-destructive Testing, and Weld Examination Practice Exercises Answers Refer to the following sections in ASME Section V Article 9 to check your answers to the practice exercises. 1. T-910 2, T-921 3, T-922 4, T-923 5, T-923.2 6. T-930 7.79412 8, T-942 9. 7-951 10. T-952 11, T-953 12. T-954 13. T-980 14 T-991 Student Study guide 06th Page 24Seo ws T 9 WHEY Spegikite By A Cone Seerrew Wor (Artepacraried Wed ha de® tl Ths Vive SoMa ~Depelerim Tau Ps pericde | 7998. Uhlan Phocuouer Ki duiatn ~ fuailacrr€ 72 Asp. Be Oe Mt Mgpe Sutter D1 hp ~ Tiel Fol Suttrte peip Ditict ok Line lt Co Liga. -72ls - caspeen ade GG pekucwe - /@ “SABUMATAQO DATA = CIT Foti ot Ctaitndag STIR Aaa F-92122 ChuetHe Fob T9224 FE wa Lue 72 lene Photaruce. “T3922 Cobparges Data Aw? E@ipriga A tid oT Ke tearite Kellasypjazim - JT. FYO ~ ViSKAe UeSlo St DETER TIE FUR eA Condi tcon 6K PAT ARIGU DEAT, Staple, Léth & Mse usin Te ~Tanslactiut LArawett FUbSiul Poe TEY4 = bits? BE well 4 By (Wat LESS Titmd Fo? Pt-g sé 1b eho pa mea Charen LAS erg hh (VER D paapwimlety (85 FE G ewe Bn % She Fk Sopg{ ane atlas AWRUAL YOSuhe Ex Sravored JS - SaegecThird Paper Quality Control, Non-destructive Testing, and Weld Examination Objective Activity #1 In ASME Section V read Article 2 Describe the details for Radiographic Examination Practice Exercises 1, What is the scope of Article 2? 2. Radiographic examination shall be performed in accordance with a written procedure. What information shall be included? 3. What would constitute a procedure demonstration? 4, Why must the surface of a material being radiographed be prepared?_ 7 5. In what condition must a weld be on both surfaces before radiography? 6. What is the purpose of the letter “B” attached to the back of the film? A system of identification shall be used on a radiograph, What information shall be 4 included on the radiograph? aa we 8, What is a densitometer used for? a 40 9. How much of a weld must be examined? 10, What type of image quality indicator can be used? Student Study guide Page 25Third Paper Quality Control, Non-destructive Testing, and Weld Examination 11. What size of hole-type and wire type IQI designation would be used on 1” thick ie . 7 material? az 6 7293" a 12, What shall the facilities for viewing radiographs provide? a \ 13, How often and by what method shall a densitometer be calibrated?” |" age PME 14, When shall a step wedge, comparison film be verified? 2 te u 15. What is single-wall exposure technique? oy v we & L » 16, What is double-wall exposure technique? “1 — EA 17. What is single-wall and double-wall viewing? 18. What is a location marker and how are they used? 19. What material shall an 1QI be made of? 20. On what thickness of the material is the selection of the [QI based? 21. Where is the hole type IQI placed for welds? 22, Where is the wire type IQI placed for welds? 23, Where a series of exposures are used to examine a weld, how many IQI are required? Student Study guideThird Paper Quality Control, Nondestructive Testing, and Weld Examination 24, When shims are used, what should be the dimensions? 25. What blemishes should not be on a radiograph? au 26. What are the minimum and maximum densities of a radiograph alloyed? Ay \ ar 27. What is the required sensitivity ofa radiograph? «= 7 V Qu 4 28. What are the manufacturers responsibility for evaluation of a radiograph? “! v 29. What information is required on the radiographic documentation? 30. What information shall a radiographic review form have? 4 Student Study guide Page 27Third Paper Quality Control, Nondestructive Testing, and Weld Examination Practice Exercises Answers Refer to the following paragraphs in ASME Section V to check your answers to the practice exercises, 1. 7-210 2.72211 3. T2212 47-221 - 5.1-222.2 6. 1-223 7.1204 8. 7-225 9. 7-226 &- CHG 10, T-233 11. Table T-233.1 & T-233.2 (27 13, T-262.1 34 fear sree Kok Weg 14, T-262.2 15, T-271.1 16, T-271.2 17. T-271.2 (a) & (0) 18. T-275 19.7-276.1 <= 20, T-276.2 21, T-277.1 (c) 22, T-277.1 (d) Student Study guide Page 28Third Paper Quality Control, Non-destructive Testing, and Weld Examination 23, 7-277.2 24.17.2773 @ 28. 7-281 26, T-282.1 27. T-283.1 28. 7-286 << 29, T-291 30, T-292 Student Study guide Page 29)) Cts 7070 ¢ fferrile? 4 2 Lad sypz pp 2 - DESIA7G ARLE (OER ARPT E TER. = Com) ong @ Wh kwess Qi fSorepe oc peltage CO Seutet -Fitry DsTineg CC seacee Se a Pilea BROUD — Des gnarion @ scesrus (0177 v9 Yet prsk Dicertjau Fa ves Tew F Dewy ExCKKD [EMRE AT ape Qussr7m bo = Le7The & x 4° Back Seaton Qvsspirt 7 Prtmangus Mtaft fitariox QD PATS. Soy 3/8 Wer To OBscute tht pti 16 FMEE RL beksTiem Y= DEMS Pek PIs Ee ek WEPGE dea Daass ry on Q Woesr7+ fnes7ire fo Ute ype eh Wie Fy pC Vo = OR ee oe MlrwsT1 i 2 Yaya Beh hiner Sones - DeBary BackGegews. 9 eer (2 = BEG RIrIg 1K Enel SHAE oe BITRE Shos (a BK CMa gh OT MP Eeatitees FE ~ lo 2G a betsrten cy = C2 beenftir 5luk 17. ~ GrGght Dewks, suk pepe = VEE ag heel Aire HCE a OF AADC Ghee GlekstIO NG = BE ye Wekipa 5, pemine SINGLE Wt? Dehli ChcES7tr> 25. < PEEP ROO tular fe £n6%h tr wero GRVEST IW 2% ~ OA TD Ate RT GokTO™ 26 ~ She» DioiteStory 07 LEST 3 Slog, LLTIIONAS = DE Het C4 0 OED CAL ot hex BAL i175 HES. Be tsren ble 112 Arras “Ray Ri 07H CWman a Comye. 7) Bere PI10R G2 Bews7ipn 17 = Hae PEMETIERIDE TI, [Pr OG. SPECS RE Ade - OF2 DESIG A aPED lee Quccrrows 2B Buc 29 g- K- GOaS7? oA PO - Com yk awe ith Fag Coem Beeren\Third Paper Quality Control, Nondestructive Testing, and Weld Examination it 25° ou 8 ee oe j08 246 - gen 4, i, 38 Activity #2 i q S ei Tn ASME Section V read Article 22 Standard Guide for Radiographic Testing 9 Practice Exercises 231 5 1. What is the scope of Article 22” — 22 2. What information does this guide cover? 3. What is the quality level required for radiography? 4, What is a filter? 5, Where are filters usually placed? 6, What is masking or blocking? 7, How can the effects of back-scatter radiation be reduced? 8, How would you determine the adequacy of protection from backscatter? \Y 9, What is the purpose of lead screens? 10. When should lead screens be used? LL. When should fluorescent scréens be used? 12, What is geometric unsharpness? Student Study guide Page 30Third Paper Quality Control, Nondestructive Testing, and Weld Examination 13. Final acceptance of a radiograph is based on the ability to see what? 14, How should radiographs be identified? 15, What is the suggested method of identifying repairs? 16. Where should location markers be placed? 17. What is another use of location markers in relation to repairs? 18. How should unexposed film be stored? 19. Describe the proper cleanliness and film handling practices? 20. What is automatic processing? 21, Describe manual processing? 22. When viewing radiographs what must the illuminator provide? 23, Describe the characteristics ofa viewing room — 2 24, How should radiographs be stored? 25. How should radiographic records be kept? Student Study guide Page 31Third Paper Quality Control, Non-destructive Testing, and Weld Examination Practice Exercises Answers Refer to the following pages in the General Dynamics Radiographic Testing handbook to check your answers to the practice exercises a — ye anit 212 3.5.18 4.9.1 5.93 6.10.1 9.12.11 10, 12.1.2 11, 12.3 12, 14.2 & 143 13, 14.4 14, 18.1.1 15, 18.1.2 16. 18.2.1 17. 18.2.2 18. 19.1 Student Study guide Page 32Third Paper Quality Control, Nondestructive Testing, and Weld Examination 23.27 24, 28 oe Student Study guide hit ioe Page 33Third Paper Quality Control, Non-destructive Testing, and Weld Examination Objective 3: Describe the details for ultrasonic examination Activity #1 a? In the ASME Section V read ArticleS U7 + (JR! Practice Exercises 1, What is the scope of Article 5? 2, What are the procedure requirements of ultrasonic examination? TS22 3. What is the range of frequency that should be used with ultrasonics? Jingo ~ S0ite 753) 4. How is checking and calibration of equipment accomplished? 1 S34 5. What product forms may be examined with the ultrasonic method? F554.) ~ 3 6. What is the scope of paragraph 1-542? senue ” Cal Cae ri ew , Leck 5A -UeF eee 7. Describe a basic calibration block that would be used to evaluate welds described in 542 : = co 8. Of what material must the calibration block be? -T-3. 3u er ————————————_—_L Student Study guide Page 43Third Paper Quality Control, Nondestructive Testing, and Weld Examination Practice Exercises Answers (/7™ Refer to the following pages in ASME Section V Article 5 to check your answers to the practice exercises, a 1. T-510 2. 7-522 3.1-531 47-534 5. T-S41.1, T-541.2, T-S413, T-S41.4, T-541.5 6. T-542, 7. T-542.2.1 8. T-542.2.1,1 ‘Student Study guide Page 44Third Paper ‘Quality Control, Non-destructive Testing, and Weld Examination Activity #2 ur Bitany wer tsa bf Wel as In the ASME Section V Article 5 read 7542.7 2 aa Practice Exercises 1, What surface preparation to the b: metal is required prior to weld examination? 2. What surface preparation to the weld metal is required prior to examination? 3. To what Code Section are indications evaluated to? [Wort AaTte) IW ERCESS 26 JOY DAT EEE} MING Copn Sects, Student Study guide Page 45Third Paper Quality Control, Nondestructive Testing, and Weld Examination Practice Exercises Answers Refer to the following pages in the General Dynamics Ultrasonic Testing handbook to check your answers to the practice exercises. 1, 542.711 2, T-542.7.1.2 he wh 3, T-542.7.2.5 2 WAI) MATE ee. vein a yee oto) 5 , 7 CWFee marion 106 ) TSEI2 beans Se Recess CP AS (EE EKEO MDG CODK SECT Student Study guide 56th, Page 46Third Paper Quality Control, Nondestructive Testing, and Weld Examination Objective 4: Describe the details for Liquid Penetrant Inspection Activity #1 In the ASME Section V read Article 6 Practice Exercises 1, What is the scope of Article 6? 2. Liquid penetrant examination shall be performed in accordance to a written procedure. List the information required 3. The user shall obtain a certificate of contaminant content for all liquid penetrant ‘materials. What contaminants are harmful? 4, What condition should the surface to be examined be when examining the surface? 5. How is cleaning and drying of the surface accomplished? 6. What temperature range would a standard test be conducted at? 7. Describe each step of the examination process. 8. How long after application of the developer can an interpretation be performed? © Explain the difference between a color contrast and fluorescent penetrant 10. What Code Section should all indications be evaluated to? Student Study guide Page 47Third Paper Quality Control, Non-destructive Testing, and Weld Examination Practice Exercises Answers ao Refer to the following pages in the General Dynamics Ultrasonic Testing handbook to check your answers to the practice exercises. _ Pi r0 17-60 = L/luro Priereant Eten here’ 2, T-621.1 3. T-641 (b) 4, T-642 5, T-643 6. T-652 7. T-611, 7-672, T-673, T-674, T-675 8, T-676.1 9. T-676.3, T-676.4 10, T-680 Student Study guide Page 48‘Third Paper Quality Control, Nondestructive Testing, and Weld Examination Sb -129 Sb- BOX B go tes Sf-270 Activity #2 Acricli nth gE ILO9 In ASME Section V read Standard Test Method for Liquid F a 35) oo Practice Exercises 1. What is the scope of the standard for liquid penetrant examination? 2. How would indications be evaluated? 3. Give a summary of the test method for liquid penetrant examination, 4, What is the significance and use of liquid penetrant examination? Explain the difference between fluorescent and visible penetrant examination 6. What materials are required to perform liquid penetrant examination. 7. Describe the three types of penetrants. 8, Describe two different types of emulsifiers. 9, What is the function of a developer? 10, Deseribe the various types of developers. 11, Give a detailed explanation of a general processing procedure Student Study guide bite Page 49‘Third Paper Quality Control, Non-destructive Testing, and Weld Examination 12. On stainless steel, titanium, nickel-base, and other high temperature alloys there is a need to restrict impurities. What are these impurities and what is their effect on these metals? 13, Are personnel performing this method required to be qualified? se (68 CMs 1 By We * a he un ROE Student Study guide . Page 50Third Paper Quality Control, Non-destructive Testing, and Weld Examination Practice Exercises Answers Refer to the following pages in the General Dynamics Ultrasonic Testing handbook to check your answers to the practice exercises. ———— Lu 2.13 3.4 45 5.6.18 6.2 67 9.74 10. 7.5.1, 7.5.2, 7.5.3, 7.5.4 1.8 12.9 13, 10.1 Student Study guide Page 51Third Paper Quality Control, Non-destructive Testing, and Weld Examination Objective 5: Describe the details for Magnetic Particle Testing Activity #1 In ASME Section V read Article 7 Practice Exercises 1. What is the scope of Article 72. 1" 0 2. Give a general description of the principle of magnetic particle inspection. ~7-"7 2.0 3. What are the requirements for the particles used for inspection? 7~73/ 4, How should the surface be prepared prior to examination? 170 5. What are the requirements for a written magnetic particle examination? “7752 6 Does the current need to remain on while magnetization occurs? 775 / 7. What are the five magnetization techniques that may be used during examination? “T 752 8. How often should the equipment be calibrated? 10. How many examinations shall be performed on each area and what should the coverage be? 791 x Student Study guide Page 52Third Paper Quality Control, Nondestructive Testing, and Weld Examination 11, For the prod technique explain the following 3 7 i. Magnetizing procedure T7734 ii, Magnetizing current iii, Prod spacing 12, Describe the longitudinal magnetization technique. 7 774 13, Describe the circular magnetization technique. TIS CEUPE BL Lye Doc 14, Describe the yoke technique. T7776 2 FEMA Ce 15, Describe multidirectional magnetizing technique. —~ 77 16. Describe the method of interpretation using nonfluorescent and fluorescent particles. 77 7. 3 17. Describe the evaluation of indications, Student Study guide Page 53Third Paper Quality Control, Non-destructive Testing, and Weld Examination Practice Exercises Answers Refer to the following pages in the General Dynamics Handbook Magnetic Particle to check your answers to the practice exercises 1.T-710 2. 7-720 3. 1-731 4. 7-740 5. T-750 6. T-751 7, 1-152 8. T-761(a) 9, 1-762 10, T-771 & T-772 11. T-773.1, 1773.2, T-773.3 12, T-774 13. T-775 14, T-776 15, T-777 16. T-778 Student Study guide Page 54Third Paper Quality Control, Non-destructive Testing, and Weld Examination Activity #2 In ASME Section V page 493 read Article 25 Standard Guide For Magnetic Particle Examination, w, Practical Exercises 1. What is the scope of Article 25? 2, What Magnetic Particle Method techniques does this guide describe? 3. What qualifications does the personnel that perform Magnetic Particle Method technique require? 4. Give a summary of Article 25 Standard Guide and mention the principle, method, magnetization, field direction, field strength, types of magnetic particles and their use, evaluation of indications, surface discontinuities, and near surface discontinuities 5. Define the following terms i. Types of equipment ii, Polarity iii, Yokes iv, Permanent magnets v. Prods vi, Remote control switch vii, Black light Student Study guide Page 56Third Paper 6. Explain the following terms i i iv, v. vi vii light intensity for examination visible light intensity field inspection black light intensity black light warm-up dark area eye adaptation housekeeping 7. Define the following terms i, ii, iti iv. vi vii viii xi xii xiii xiv, xv xvi xvii XViii xix, xx, xxi xxii Student Study guide particle types particle characteristics dry particles advantages and disadvantages of dry particles nonfluorescent colors fluorescent wet particle systems primary use where used color suspension vehicles petroleum distillates their advantages and disadvantages characteristics water vehicles with conditioning suspension characteristics foaming corrosiveness viscosity limit fluorescence nonreaetiveness water pH Quality Control, Non-destructive Testing, and Weld Examination Page 56Third Paper Quality Control, Non-destructive Testing, and Weld Examination xxiii, odor xxiv, concentration of wet magnetic particle suspension 8. Explain the general part preparation as well as when the part has a magnetic and nonmagnetic coating, 9, Explain the sequence of operation for both continuous and residual magnetization Student Study guide Page 57Third Paper Quality Control, Non-destructive Testing, and Weld Examination 9 Practice Exercises Answers Refer to the following pages in the General Dynamics Handbook Magnetic Particle to check your answers to the practice exercises Li 214 3.15 4.4.1,4.2, 43, 44,45, 46 5.6.1, 6.2, 63, 6.3.1, 6.4, 6.4.1, 6.5 6.7.1, 711, LAA, 71.2.1, 7.1.2.2, 7.13, 72 7.8.1, 82, 83, 83.1, 83.2, 83.3, 83.4, 84, 841, 8.42, 843, 844, 8441. 8.4.4.2(1),(2),3),(4),6).(6),(7).(8),(9), 8.4.4 8.9.1, 9.1.1, 9.1.2 9.10.1, 10.1.1, 10.1.1.2 Student Study guide Page 58Third Paper Quality Control, Nondestructive Testing, and Weld Examination Module 3 Weld Examination Student Study guide Page 59Third Paper Quality Control, Non-destructive Testing, and Weld Examination Module Outcome ‘Upon completion of this module students will be able to assess coupons for weld defects and acceptability to standards referenced in ASME Section IX and B31,3 Module Objectives 1, Examine the SMAW coupons for acceptability to various referencing Codes 2. Examine the GTAW coupons foe acceptability to various referencing Codes 3. Examine the GMAW coupons for acceptability to various Codes 4. Examine the bend coupons for acceptability to ASME Section X Introduction Each welder and welding operator who welds under the rules of the Code shall have passed the visual examination in QW-302.4. It is the Code users responsibility who must supervise the welding of the WPQ test coupons. The study and evaluation of these coupons will enable the Candidate to become familiar with weld defects and the acceptability of these in welder testing and construction standards, Resources The following resources are used in this module « ASME Section I ‘+ ASME B31.1 (severe cyclic condition) + ASME B31.3 (normal fluid service) + ASME Section VII Div. I « ASME Section IX Student Study guide Page 60Third Paper Quality Control, Nondestructive Testing, and Weld Examination Module 3: Learning Activities and Practice Exercises Objective 1: Examine the SMAW coupons for acceptability to various referencing codes Activity #1 Evaluate the following samples to the acceptance criteria of the referencing Code Practice Exercises The following welds were produced with the SMAW process on 0. 375" plate accept reject accept reject B31.1 ‘ B3L.1 a [B} B31.3 (normal fluid service) (_) oO B31.3 (normal) ag im B31.3 (severe cyclic cont'd) [] gO B31.3 (severe) ga oO ASME Section 1 fa) el ASME Section 1 QO QO ASME Sec VIII Div I oO oO ASME Sec VIII Div I [] oO Cause for rejection Cause for rejection (ifany) (ifany) Student Study guide Page 61Third Paper ‘Quality Control, Non-destructive Testing, and Weld Examination accept reject B3L1 B31.3 (normal fluid service) [] B31.3 (severe cyclic cont'd) [_] ASME Section 1 oO ASME See VIII Div I [el Cause for rejection (ifany) oooo0c B31.1 B31.3 (normal) B31.3 (severe) ASME Section 1 ASME Sec VIII Div 1 [] Cause for rejection (ifany) QO O oO Oo a O og fa] accept reject B3i.l Oo B31.3 (normal fluid service) [] Oo B31.3 (severe cyclic cont'd) (] Qo ASME Section 1 fe Oo ASME See VIII Div I ia) Oo Cause for rejection (ifany) Student Study guide B31.1 B31.3 (normal) B31.3 (severe) ASME Section 1 ASME Sec VIII Div | (J Cause for rejection (ifany) Page 62Third Paper Practice Exercises Answers 1 reje B3LI “— B31.3 (normal fluid service) [} B31,3 (severe cyclic cont'd) () ASME Section 1 o ASME Sec VIII Div I o BRIRREI Excessive reinforcement Cause for rejection (fany) 3 accept reject BBL.1 B31.3 (normal fluid service) B31.3 (severe cyclic cont'd) ASME Section 1 ASME Sec VIII Div I | accept reject RRR, Oo (a 0 0 Oo Cause for rejection (if any) 5 B31 B31.3 (normal fluid service) [] B31 3 (severe cyclic cont'd) [) ASME Section 1 Oo ASME Sec VIII Div 1 oO Cause for rejection [Incomplete (ifany) penetration Student Study guide q a Q zd ‘Quality Control, Non-destructive Testing, and Weld Examination 2 accept reject B3L1 ca i B31.3 (normal) oO & B31.3 (severe) oO ii} ASME Section 1 [a] & ASME See VIII Div I [) & Cause for rejection [Excessive (ifany) reinforcement 4 accept reject B31.1 & B31.3 (normal) o 8 B31.3 (severe) QO i] oO & Oo WwW Oo ASME Section 1 ASME See VIII Div I Cause for rejection [Tncomplete (ifany) penetration | 6 accept reject B31 a fis] B31.3 (normal) ei & B31.3 (severe) QO & ASME Section! [J] ASME Sec VIIDivIE] Cause for rejection (ifany) Low height of reinforcement Page 63‘Third Paper Quality Control, Non-destructive Testing, and Weld Examination Objective 2: Examine the GTAW coupons for acceptability to various referencing codes Activity #1 Examine the specimens for acceptability to the referencing Code ua, Practice Exercises The following samples were produced using the GTAW process on 0,250" plate accept reject accept reject B31.1 a QO B31.1 (a) B31.3 (normal fluid service) [] = B31.3 (normal) o oa B31.3 (severe cyclic cont'd) oO | B31.3 (severe) Qo oO ASME Section 1 gO a Q Oo ASME Sec VIII Div I oO QO ASME Sec VIII Div I 1] Oo Cause for rejection | Cause for rejection (ifany) re (ifany) Student Study guide Page 64Third Paper ‘Quality Control, Non-destructive Testing, and Weld Examination accept reject B31.1 B31.3 (normal fluid service) [] B31.3 (severe cyclic cont'd) [] ASME Section 1 o ASME Sec VIII Div I o Cause for rejection (fany) B31.1 B31.3 (normal) B31.3 (severe) ASME Section 1 ASME Sec VIII Div I Cause for rejection (if any) accept reject B311 a B31.3 (normal fluid service) [] B31.3 (severe cyclic cont'd) ] ASME Section 1 [a] ASME Sec VIII Div I Oo Cause for rejection (ifany) Student Study guide B311 B31,3 (normal) B31,3 (severe) ASME Section 1 ASME See VIII Div 1 Cause for rejection (ifany) accept reject Oo Oo oO oO oO Page 65Third Paper accept B3L.1 cP “i B31.3 (normal fluid service) ] fs B31.3 (severe cyclic cont'd) [) ga ASME Section 1 O Qa ASME See VIII Div I oOo QO Cause for rejection (ifany) accept reject B311 Oo QO B31.3 (normal fluid service) [J oO B31.3 (severe cyclic cont'd) [] go ASME Section 1 QO O ASME Sec VIII Div I Oo 0 Cause for rejection (ifany) Student Study guide Quality Control, Non-destructive Testing, and Weld Examination accept rej B3L1 c ia B31.3 (normal) im oO B31.3 (severe) Oo QO ASME Section! [J ASME Sec VIII Div 1 [] oO Cause for rejection (ifany) accept reject B31 GO Qa B31.3 (normal) ‘a oO B31.3 (severe) oO Oo ASME Section! =F] ASME Sec VIII Div I [] oO Cause for rejection : | (ifany) Page 66Third Paper ao rte B311 B31.3 (normal fluid service) B31.3 (severe cyclic cont'd) ASME Section I ASME Sec VIII Div I Cause for rejection (ifany) Student Study guide Quality Control, Non-destructive Testing, and Weld Examination Page 67