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MACRO-SECTION.

TWI
CSWIP 3.1
WELDING INSPECTION
MACRO-SECTION.
PRACTICAL
Section 25.
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MACRO SECTIONS
1. ASSESS THE MACRO PHOTOGRAPH FOR WELD
DEFECTS.
2. RECORD THE MAJOR DEFECTS ON
THE
REPORT SHEET.
3. SENTENCE THE DEFECTS RECORDED TO THE
ACCEPTANCE CRITERIA GIVEN.
4. FOLLOW THE INSTRUCTIONS.
PLEASE DO NOT MARK THE
PHOTOGRAPHS.

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MACRO INSTRUCTIONS.

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MACRO DEFECTS.
50m
m

3mm
ANGULAR DISTORTION = 3mm in
50mm
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MACRO DEFECTS.
INCOMPLETLEY FILLED
GROOVE

1.5mm
MISALIGNMENT

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MACRO DEFECTS.
COLD LAP

GAS
POOR
PORE /
TOE
BLOW
BLEND
HOLE

EXCESSIVE WELD
METAL

&

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COLD
LAP &
POOR
TOE
BLEND

Macro defects
INCOMPLETELY FILLED
GROOVE

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MACRO DEFECTS.
LACK
OF
SIDE
WALL
FUSIO
N
LACK OF
SIDE
WALL
FUSION
& SLAG

LACK OF SIDE WALL


FUSION / INCOMPELTELY
FILLED GROOVE

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MACRO DEFECTS.
COLD LAP

LACK OF SIDEWALL
FUSION / INCOMPLETELY
FILLED GROOVE

GAS
PORES

LACK OF ROOT FUSION


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MACRO DEFECTS.
INCOMPETELY FILLED GOOVE

SLAG
INCLUSIO
N
GAS
PORE

LACK OF ROOT FUSION


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MACRO DEFECTS.
LACK OF
SIDEWALL
FUSION
LACK OF
SIDEWALL
FUSION &
SLAG
LACK OF
SIDEWALL
FUSION
LACK OF ROOT PENETRATION
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LACK OF
SIDEWALL
FUSION

MACRO SECTIONS

QUESTIONS.

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MACRO DEFECTS.
LACK OF
SIDEWALL FUSION

CLUSTER / WORMHOLE
POROSITY
LAMINATIONS

LACK OF INTER-RUN
FUSION & SLAG
LACK OF
SIDEWALL FUSION
& SLAG

LACK OF INTER-RUN
FUSION
GAS PORES

ROOT UNDERCUT
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MACRO SAMPLE.
WELDING PROCESS : MAG
1 COLD LAP

5 LACK OF SIDEWALL
FUSION

4 LACK OF INTERRUN FUSION

3 COLD LAP

2 LACK OF SIDEWALL
FUSION & GAS / SILICA

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Copyright 2005, TWI Ltd

MACRO
NOTE: PHOTOGRAPH IS AT X10 MAGNIFICATION
MATERIAL: LOW CARBON STEEL WELDING PROCESS: [MAG/GMAW]

8
#
1
2
3
4
5
6
7
8
9
10

9
7
6

DEFECT
POOR TOE BLEND
OVERLAP + 2 SMALL PORES
LAMINATIONS/INCLUSIONS
LACK OF SIDE WALL FUSION
AS ABOVE +PORES
OVERLAP
LACK OF INTERRUN FUSION
GAS PORE/PIPE
LACK OF SIDE WALL FUSION +
SILICA
ANGULAR MISALIGNMENT

SIZE

11

EXCESS WELD METAL

12

EXCESS PENETRATION

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1
2
4

ACCEPT/REJECT

Assess
To
Specification

MACRO ACCEPTANCE.

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Copyright 2005, TWI Ltd

MACRO
EXCERCISES.AM1030
TRAINING SAMPLE ONLY
MACRO INSTRUCTION/REPORT SHEET [I.D: AM1030]
CHECK PHOTOGRAPH I.D MATCHES THIS REPORT I.D
ALL DEFECTS TO BE REPORTED [AND SIZED IF REQUIRED]
THEN SENTENCED TO ISO 5817 LEVEL B [STRINGENT]
NOTE: PHOTOGRAPH IS AT X10 MAGNIFICATION
MATERIAL: LOW CARBON STEEL
WELDING PROCESS: [MMA/SMAW]

8
7
4

6
5

1
2

3
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Copyright 2005, TWI Ltd

MACRO EXCERCISES. AM
1030
#
1
2
3
4
5
6
7
8
9
10
11
12

DEFECT
Lack of side wall fusion and
slag
Misalignment
Lack of root penetration
Angular distortion
Lack of side wall
fusion
Lack of inter run fusion and slag
Lack of side wall
fusion
Excess weld metal

SIZE

ACCEPT/REJECT

8.6
0.2
N/A
0.5
2.5
4.2
2.5
3.2

COMMENTS:

SIGNATURE:

DATE:

PRINT FULL NAME:

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Copyright 2005, TWI Ltd

Reject
Accept
Reject
Accept
Reject
Reject
Reject
Reject

MACRO EXCERCISES. AM
1031
TRAINING SAMPLE ONLY
MACRO INSTRUCTION/REPORT SHEET [I.D: AM1031]
CHECK PHOTOGRAPH I.D MATCHES THIS REPORT I.D
ALL DEFECTS TO BE REPORTED [AND SIZED IF REQUIRED]
THEN SENTENCED TO ISO 5817 LEVEL B [STRINGENT]
NOTE: PHOTOGRAPH IS AT X10 MAGNIFICATION
MATERIAL: LOW CARBON STEEL
WELDING PROCESS: [MMA/SMAW]

1
2

6
5

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Copyright 2005, TWI Ltd

MACRO EXCERCISES. AM
1031
#
1
2
3
4
5
6
7
8
9
10
11
12

DEFECT
Lack of side wall fusion/ underfill
Lack of side wall fusion and slag
Cold lap
Misalignment
Excess penetration
Cold lap
Slag inclusion
Cold lap
Excess weld metal

SIZE

ACCEPT/REJECT

0.7
7.5
0.5
1.8
3.3
0.3
0.7
0.5
3.5

COMMENTS:

SIGNATURE:

DATE:

PRINT FULL NAME:

World Centre for Materials Joining Technology


Copyright 2005, TWI Ltd

Reject
Reject
Reject
Reject
Reject
Reject
Accept
Reject
Reject

MACRO EXCERCISES. AM
1032
MACRO INSTRUCTION/REPORT SHEET [I.D: AM1032]
CHECK PHOTOGRAPH I.D MATCHES THIS REPORT I.D
ALL DEFECTS TO BE REPORTED [AND SIZED IF REQUIRED]
THEN SENTENCED TO ISO 5817 LEVEL B [STRINGENT]
NOTE: PHOTOGRAPH IS AT X10 MAGNIFICATION
MATERIAL: LOW CARBON STEEL
WELDING PROCESS: [MMA/SMAW]

8
1
3

4
5
7 6

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MACRO EXCERCISES. AM
1032
#
1
2
3
4
5
6
7
8
9
10
11
12

DEFECT

Lack of side wall fusion/underfill


Lack of sidewall fusion & Slag
Lack of side wall fusion & slag
Slag inclusion
Cold lap
Misalignment
Excess penetration
Excess weld metal

COMMENTS:

Plate laminations
noted

SIGNATURE:

SIZE

ACCEPT/REJECT

0.5
2.8
4.5
1.5
0.3
1.8
2.0
3.3

DATE:

PRINT FULL NAME:

World Centre for Materials Joining Technology


Copyright 2005, TWI Ltd

Reject
Reject
Reject
Reject
Reject
Reject
Accept
Reject

MACRO EXCERCISES. AM
1033
TRAINING SAMPLE ONLY
MACRO INSTRUCTION/REPORT SHEET [I.D: AM1033]
CHECK PHOTOGRAPH I.D MATCHES THIS REPORT I.D
ALL DEFECTS TO BE REPORTED [AND SIZED IF REQUIRED]
THEN SENTENCED TO ISO 5817 LEVEL B [STRINGENT]
NOTE: PHOTOGRAPH IS AT X10 MAGNIFICATION
MATERIAL: LOW CARBON STEEL
WELDING PROCESS: [MAG/GMAW]

1
6

5
4
3

7
2

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Copyright 2005, TWI Ltd

MACRO EXCERCISES. AM
1033
#
1
2
3
4
5
6
7
8
9
10
11
12

DEFECT

Cold Lap/ Overlap


Lack of sidewall fusion & gas
Cold lap / Overlap
Misalignment
Lack of interrun fusion & gas
Lack of sidewall fusion
Blow hole
Excess weld metal

COMMENTS:

SIZE

ACCEPT/REJECT

2.8
8.0
0.3
0.6
2.0
2.6
1.5
5.0

Plate laminations
noted

Poor toe blend


SIGNATURE:

DATE:

PRINT FULL NAME:

World Centre for Materials Joining Technology


Copyright 2005, TWI Ltd

Reject
Reject
Reject
Accept
Reject
Reject
Reject
Reject

MACRO EXCERCISES. AM
1034
TRAINING SAMPLE ONLY
MACRO INSTRUCTION/REPORT SHEET [I.D: AM1034]
CHECK PHOTOGRAPH I.D MATCHES THIS REPORT I.D
ALL DEFECTS TO BE REPORTED [AND SIZED IF REQUIRED]
THEN SENTENCED TO ISO 5817 LEVEL B [STRINGENT]
NOTE: PHOTOGRAPH IS AT X10 MAGNIFICATION
MATERIAL: LOW CARBON STEEL
WELDING PROCESS: [MMA/SMAW]

10
1
2

8
7

3
6 5

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Copyright 2005, TWI Ltd

MACRO EXCERCISES. AM
1034
#
1
2
3
4
5
6
7
8
9
10
11
12

DEFECT

Lack of sidewall fusion & slag


Lack of sidewall fusion
Lack of inter-run fusion & slag
Angular distortion
Misalignment
Excess penetration
Lack of inter-run fusion & slag
Lack of side wall fusion
Spatter
Excess weld metal

COMMENTS:

SIZE

ACCEPT/REJECT

2.8
1.0
2.0
6in13
0.5
0.1
5.5
5.0
0.1
3.6

Plate laminations
noted

Poor toe blend


SIGNATURE:

DATE:

PRINT FULL NAME:

World Centre for Materials Joining Technology


Copyright 2005, TWI Ltd

Reject
Reject
Reject
Accept
Reject
Reject
Reject
Reject
Accept
Reject

Macro defects

World Centre for Materials Joining Technology


Copyright 2005, TWI Ltd

Macro defects

World Centre for Materials Joining Technology


Copyright 2005, TWI Ltd

Macro defects

World Centre for Materials Joining Technology


Copyright 2005, TWI Ltd

Macro defects

World Centre for Materials Joining Technology


Copyright 2005, TWI Ltd

Macro defects

World Centre for Materials Joining Technology


Copyright 2005, TWI Ltd

Macro defects

World Centre for Materials Joining Technology


Copyright 2005, TWI Ltd

Macro defects

World Centre for Materials Joining Technology


Copyright 2005, TWI Ltd

Macro defects

World Centre for Materials Joining Technology


Copyright 2005, TWI Ltd

Macro defects

World Centre for Materials Joining Technology


Copyright 2005, TWI Ltd

Macro defects

World Centre for Materials Joining Technology


Copyright 2005, TWI Ltd