Professional Documents
Culture Documents
AWS Qualification Program: Dr. Eng. Hamed A. Nagy
AWS Qualification Program: Dr. Eng. Hamed A. Nagy
Module 6 :
Metal Properties and Destructive
Testing
Module 7 :
Metric Practice for Welding
Inspection
Module 8 :
Welding Metallurgy for the
Welding Inspector
Module 9 :
Weld and Base Metal
Discontinuities
Module 10 :
Visual Inspection and Other NDE
Methods
Hamed A. Nagy, Ph.D.
Who is the
Welding Inspector ?
Who is the
Welding Inspector ?
Overseer
Specialist
Combination Overseer Specialist
Important Qualities
1-Professional attitude:
Determines the degree of respect and cooperation received
from others during the performance of inspection duties.
Ability of the welding inspector to make decisions based on
facts so that inspectors are fair, impartial and consistent.
Familiarity with the job requirements so that decisions are
neither too critical nor too lax.
Inspectors will often find themselves being tested by other
personnel on the job, especially when newly assigned to some
task. Maintaining a professional attitude helps overcome
obstacles to successful job performance.
Hamed A. Nagy, Ph.D.
Important Qualities
2- Physical condition:
Should have good vision, whether natural or
corrected. The AWS CWI program requires a
minimum 20/40 visual acuity, natural or corrected,
and the completion of a color perception test.
Should be in good enough physical condition to go to
any location where the welder has been. This does
not imply that inspectors must violate safety
regulations just to do their duties.
Hamed A. Nagy, Ph.D.
Important Qualities
3- Knowledge:
To understand and apply the various documents describing weld
requirements. These can include drawings, codes, standards and
specifications.
Documents provide most of the information regarding what, when,
where and how the inspection is to be done.
It is important that these documents are reviewed before the start of
any work or production, because the welding inspector must be aware
of the job requirements.
Often this pre-job review will reveal required hold points for
inspections, procedure and welder qualification requirements.
Requirements should be memorized. These are reference documents
and should be readily available for detailed information any time in the
fabrication process.
Important Qualities
4. Experience:
Better ways of thinking and working will develop with
time.
Experience will also help the inspector develop the
proper attitude and point of view regarding the job.
We often see a novice inspector paired with an
experienced one so the proper techniques can be
passed along.
5. Safe work habits:
Hamed A. Nagy, Ph.D.
Important Qualities
Records:
All records developed should be understandable to anyone
familiar with the work. Reports that can only be deciphered by
the welding inspector are useless when he or she is absent.
Therefore, neatness is important as well.
The welding inspector should look at these reports as his or her
permanent records should a question arise later.
When reports are generated, they should contain information
regarding how the inspection was done so it can be duplicated
later by someone else with similar results.
Important Qualities
Ethical Requirements
Ethical Requirements
The
WI as a Communicator
WI as a Communicator
WI as a Communicator
CERTIFICATION
CERTIFICATION
Experience:
Candidates with a high school education, either by diploma or
state or military equivalency, must have at least 5 years
experience.
With supporting documentation (e.g., copies of transcripts,
reference letters, credited hours of training, quarter hours or
semester hours) up to two years of work experience may be
substituted for post high school educational experience.
Substituted educational experience includes as Associate or
higher degree in engineering, physics or physical science and
welding technology.
Trade and vocational courses can be applied to work experience
substitution for completed courses related to welding (up to one
year maximum).
CERTIFICATION
CERTIFICATION
Part A Fundamentals.
The Fundamental examination is a closed book test
consisting of 150 multiple choice questions.
The topics covered in this portion of the exam
include reports and records, destructive tests,
welding performance, duties and responsibilities,
weld examination, definitions and terminology,
safety, welding and nondestructive examination
symbols, nondestructive examination methods
welding processes, heat control, metallurgy,
mathematical conversions and calculations.
Hamed A. Nagy, Ph.D.
CERTIFICATION
Part B Practical.
The Practical examination consists of 46 questions.
It requires measurement of weld replicas with provided
measuring tools, and evaluation in accordance with a supplied
Book of Specifications.
Not all questions require the use of the Book of Specifications;
they do require the individual to answer from practical
knowledge.
The Practical Test covers welding procedures, welder
qualification, mechanical tests and properties, welding
inspection and flaws, and nondestructive test. Test candidates
should be familiar with fillet and butt weld gages, micrometer,
dial calipers, and machinists scale.
Hamed A. Nagy, Ph.D.
CERTIFICATION
CERTIFICATION
The passing score in each part for the CWI is 72 percent; the
passing for CAWI is 50 percent.
Part of the welding inspectors job is there view and
interpretation of various documents relating to the welded
fabrication.
This requires that the individual have a full understanding of the
proper terms and definitions that are used.
ANSI/AWS A3.0 was developed by the Committee on
Definitions and Symbols to aid in welding information
communication.
When non-standard terms are mentioned, they appear in
parentheses after the preferred words.
Hamed A. Nagy, Ph.D.
CERTIFICATION
While
WELDING PROCESSES
SMAW
SMAW
SMAW
Electrode
Covering
Core Wire
Shielding atmosphere
Metal & Slag
Droplets
Depth of Penetration
Direction of Welding
SMAW
Base or
Parent Metal
Slag
Weld Metal
SMAW
All carbon and low alloy steel electrodes use essentially the
same type of steel core wire, a low carbon, rimmed steel.
Any alloying is provided form the coating, since it is more
economical to achieve alloying in this way.
The electrode coating serves five separate functions:
Shielding.
Deoxidation.
Alloying.
Ionizing.
Insulating. (minor effect).
Hamed A. Nagy, Ph.D.
SMAW
Eletrode
Position
EXXXX
Strength
SMAW
SMAW
SMAW
SMAW
SMAW
Suffix Major
Alloy Elements(s)
A1
0.5% Molybdenum
B1
0.5% Molybdenum-0.5% Chromium
B2
0.5% Molybdenum-1.25% Chromium
B3
1.0% Molybdenum-2.25% Chromium
B4
0.5% Molybdenum-2.0% Chromium
C1
2.5% Nickel
C2
3.5% Nickel
C3
1.0% Nickel
D1
0.3% Molybdenum-1.5% Manganese
D2
0.3% Molybdenum-1.75% Manganese
G*
0.2% Molybdenum; 0.3% Chromium;
0.5% Nickel; 1.0% Manganese; 0.1%
Vanadium
* Need to have minimum content of one element only.
SMAW
SMAW
Voltage
Max. OCV
Min. OCV
Current, A
SMAW
Advantages:
equipment is relatively simple and inexpensive.
So, quite portable (Numerous gasoline or diesel
engine-driven types and also, some so small and
lightweight of the newer solid state power sources).
Availability of numerous types of electrodes, the
process is considered quite versatile.
Cheapness of alloying.
Hamed A. Nagy, Ph.D.
SMAW
Limitations:
1-
SMAW
Associated Discontinuities:
1- Porosity: Presence of moisture or contamination in the weld
region. It could be present in the electrode coating, on the
surface of the material, or come from the atmosphere
surrounding the welding operation + long arcing. + Arc blow.
There is a perpendicular magnetic field developed whenever an
electric current is passed through a conductor.
Magnetic Field can be visualized as a series of concentric
circles surrounding the conductor.
This magnetic field is strongest when contained entirely within
a magnetic material and resists having to travel through the air
outside this magnetic material.
Hamed A. Nagy, Ph.D.
SMAW
Forward Blow
Current
Direction
Back Blow
Travel
SMAW
Consequently,
SMAW
SMAW
Voltage
GMAW
Current, A
Electrode Rod
Solid Wire
ER X X S X
Strength
Chemical Composition
Electrode
Position
CC & OC
E X X X-X
Strength
Tubular
Electrode
Condition of HT
Electrode
F X X X-EXXX
Strength
For Impact
Flux
Contact Tube
Gas Nozzle
Electrode Consumable
Electrode Extension
Setback
Stickout
Arc Length
Standoff Distance
Travel
Contact Tube
Flux from
Hopper
Electrode Consumable
Slag
Solidified Metal
Weld
Pool
Travel
I. Transferred Arc
Tungsten Electrode
Constricting
Nozzle
Secondary
Shielding Gas
+
Filler Metal
Orifice Gas
Travel
Tungsten Electrode
Constricting
Nozzle
Secondary
Shielding Gas
Filler Metal
Orifice Gas
Back Cap
Shielding Gas In
Gas Nozzle
Collet Body
Nonconsumable Electrode
Filler Metal
Travel
I. Spray Mode
II. Globular
Mode
Electrode
Guide Tube
Molten
Metal
Solidified Metal
Molten Slag
Water Out
Water In
Water Cooled
Copper Shoes
Emitter (Cathode)
Grid (Cup)
Anode
Magnetic
Focusing Lens
Magnetic
Deflection Coil
Focal Range
Preforms in Brazing
Travel