CSWIP 3.

1 Welding Inspection

Welding Terminology and Definitions

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Course Reference WIS 5
Course notes section reference 2.0
 Welding Terminology & Definitions

What is a Weld?
• A localised coalescence(ket tinh) of metals or non-metals
produced either by heating the materials to the welding
temperature, with or without the application of pressure, or
by the application of pressure alone (AWS)

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• A permanent union between materials caused by heat, and ©

or pressure (BS499)

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 Welding Terminology & Definitions

What is a Joint?

• The junction of members or the edges of members that are to be

joined or have been joined (AWS)

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• A configuration(hinh dang) of members (BS499) ©

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 Joint Terminology

Edge Open & Closed Corner Lap

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Tee Butt
Cruciform
 Butt Preparations

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Square Edge Square Edge
Closed Butt Open Butt
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 Single Sided Butt Preparations
Single sided preparations are normally made on thinner materials, or
when access form both sides is restricted

Single Bevel Single Vee

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Single-J Single-U
 Double Sided Butt Preparations
Double sided preparations are normally made on thicker materials, or
when access form both sides is unrestricted

Double -Bevel Double -Vee

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Double - J Double - U
 Joint Preparation Terminology

Included angle Included angle

Angle of
bevel

Root
Radius

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Root Face Root Face

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Root Gap Root Gap
Single-V Butt Single-U Butt
 Joint Preparation Terminology
Angle of bevel Angle of bevel

Root
Radius

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Root Face Root Face
Root Gap
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Root Gap

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Land
Single Bevel Butt Single-J Butt
 Weld Terminology

Butt weld Spot weld

Fillet weld

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Edge weld Plug weld
Compound weld
Welded Butt Joints

Butt Welded butt joint

A_________

Fillet Welded butt joint

A_________

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Compound Welded butt joint
A____________
Welded Tee Joints

Fillet Welded T joint

A_________

Butt Welded T joint

A_________

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Compound Welded T joint
A____________
Welded Lap Joints

Fillet Welded lap joint

A_________

Spot Welded lap joint

A_________

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Compound Welded lap joint
A____________
Welded Closed Corner Joints

Fillet Welded closed corner joint

A_________

Butt Welded closed corner joint

A_________

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Compound Welded closed corner joint
A____________
 Joint Types - Weld Types

Summary

Joint Weld Types

Types
BUTT FILLET PLUG SPOT EDGE
BUTT X X
TEE X X

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CORNER X X ©

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LAP X X X
EDGE X
 Weld Zone Terminology

Face B
A

Weld
metal

Heat

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Affected Weld
Zone Boundary ©

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C D A, B, C & D = Weld Toes
Root
 Weld Zone Terminology
Excess
Cap height
or Weld
Reinforcement

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Excess Root
Penetration
 Weld Zone Terminology

Weld Width

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 Heat Affected Zone (HAZ)

Maximum solid solid-liquid Boundary

Temperature weld
grain growth zone
metal
recrystallised zone
partially transformed zone
tempered zone
unaffected base

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material
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 Toe Blend
6 mm
•Most codes quote the weld
toes shall blend smoothly
80° •This statement is not
quantitative and therefore
open to individual
Poor Weld Toe Blend Angle
interpretation
3 mm •The higher the toe blend
angle the greater the

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20° amount of stress ©

concentration

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Improved Weld Toe Blend •The toe blend angle ideally
Angle should be between 20o-30o
Features to Consider
Fillet welds - Toe Blend

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 Fillet Weld Profiles
Fillet welds - Shape

Mitre Fillet Convex Fillet

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A concave profile

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is preferred for
joints subjected to
Concave Fillet fatigue loading
 Fillet Weld Leg Length

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a. = Vertical leg length ©

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b. = Horizontal leg length
Note: The leg length should be approximately equal to the
material thickness
Fillet Weld Features

Excess
Weld
Vertical Metal
Leg
Length
Design

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Throat
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Horizontal leg
Length
Fillet Weld Throat Thickness

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a = Design Throat Thickness
Fillet Weld Throat Thickness

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b = Actual Throat Thickness
Deep Penetration Fillet Weld Features

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a = Design Throat Thickness b
b = Actual Throat Thickness
 Fillet Weld Sizes

Calculating Throat Thickness from a known Leg Length:

Design Throat Thickness = Leg Length x 0.7

Question: The Leg length is 14mm.

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What is the Design Throat?
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Answer: 14mm x 0.7 = 10mm Throat Thickness
 Fillet Weld Sizes

Calculating Leg Length from a known Design Throat

Thickness:

Leg Length = Design Throat Thickness x 1.4

Question: The Design Throat is 10mm.

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What is the Leg length?
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Answer: 10mm x 1.4 = 14mm Leg Length
 Features to Consider

Throat Throat
Thickness Thickness
is larger is smaller

600 1200

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Fillet welds connecting parts with fusion faces with an
angle more than 1200 or less than 600 should not use
the previous calculations.
 Features to Consider
The design throat thickness of a flat or convex fillet weld connecting
parts with the fusion faces which form an angle between 600 and
1200 may be calculated by multiplying the leg length by the
appropriate factors as given below:

Angle between fusion Factor

faces in degrees
60 to 90 0.7

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91 to 100 0.65
101 to 106 0.6 ©

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107 to 113 0.55
114 to 120 0.5
 Features to Consider
Importance of Fillet Weld Leg Length Size

(a) (b)

8mm
4mm

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4mm 2mm ©

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Approximately the same weld volume in both Fillet Welds, but the
effective throat thickness has been altered, reducing considerably
the strength of weld B
 Fillet Weld Sizes
Importance of Fillet weld leg length Size

4mm 6mm
(a) (b)
4mm 6mm

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Cross Sectional Area
Question: How much larger is the c.s.a (b) comparable to (a)?
 Fillet Weld Sizes
Importance of Fillet weld leg length Size
(a) (b)

4mm 6mm
(a) (b)
4mm 6mm

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Area = 4 x 4 = 8mm2 Area = 6 x 6 = 18mm2 ©

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2 2
The c.s.a. of (b) is over double the area of (a)
without the extra excess weld metal being added
 Features to Consider
EFFECTIVE THROAT THICKNESS
“a” = Nominal throat thickness “s” = Effective throat thickness

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a s

Deep throat fillet welds from FCAW & SAW etc

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CSWIP 3.2 Welding Inspection

Joint Design & Weld Preparation

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 Joint Design & Weld Preparation

Bevel Angle

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Bevel angle must allow:
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• good access to the root

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• manipulation of electrode to ensure sidewall fusion
 Joint Design & Weld Preparation
Root Face

Root Face Size set to:

• allow controlled root fusion
• reduce the risk of burn-through

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Too small = burn-through Too large = lack of root penetration
 Joint Design & Weld Preparation
Root Gap

Root Gap set to:

• allow controlled root fusion
• reduce the risk of burn-through

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Too large = burn-through Too small = lack of root penetration
 Weld Preparation
Terminology & Typical Dimensions: V-Joints

bevel angle
included angle

root face
root gap

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Typical Dimensions ©

bevel angle 30 to 35°

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root face ~1.5 to ~2.5mm
root gap ~2 to ~4mm
 WELD PREPARATION

Joint Design / Weld Preparation to Reduce Weld Volumes

12 to 15°

35°

for MMA welding of pipe joints >

~20mm (compound bevel)
55°

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~5°
~6mm ©

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for mechanised GMAW of
for double-Vee joint for SAW of pipework
thicker sections
 Weld preparation
Welding process impacts upon weld preparation

Arc welding EBW

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X
 Weld preparation

Welding process impacts upon weld preparation

MMA MAG

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High heat input process allow a larger root face, less weld
metal required, less distortions, higher productivity.
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If the gap is too big risk of possible burn-through,
if gap is too small risk of lack of penetration
 Weld preparation

Preparation method impacts upon weld preparation

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Can be flame/plasma cut fast
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Requires machining slow and and cheap
expensive Large tolerance set-up can be
Tight tolerance easier set-up difficult
 Weld preparation

Preparation method impacts upon weld preparation

Variations in Variations in
cutting line cutting angle

Included angle too large

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heavy distortions, increase
Root face too large lack of
amount of filler metal required
penetration ©

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Included angle too small lack
Root face too small burn-
of penetration, lack of side
through
wall fusion
 Weld preparation

Preparation method impacts upon weld preparation -

corrective measures

No root face Backing strip (6 mm or

more, same material)

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Root face too large Recut groove preparation,
preparation increase
root gap and use backing strip.
 Weld preparation

Preparation method and impacts upon weld

preparation - corrective measures.

Too big/too small

included angle Crevice areas

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Warning! Backing strips give a built-in crevice ©

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•Susceptible to corrosion
•Give a lower fatigue life
 Weld preparations

Access impacts upon weld preparation

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 Weld preparations

Access impacts upon weld preparation

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 Weld preparations

Access impacts upon weld preparation

Pipe weld preparation - one side access only!

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for wall thickness up to 3 mm ©

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for wall thickness 3 to 20 mm

for wall thickness over 20 mm

 Weld preparations

Access impacts upon weld preparation

Pipe weld preparation - one side access only!

•self-adjusting items.
•no danger of burn-through
•susceptible to corrosion
•lower fatigue life

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To ensure minimum root
mismatch, the internal bore is
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sometimes machined with a
low angled bevel
 Weld preparations

Type of joint impacts upon weld preparation

Corner joints require offset

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offset
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Danger of burn-through Easy set-up.
difficult to set-up no burn-through.
 Weld preparations
Type of joint impacts upon weld preparation
Lap and square edge butt joints do not require preparation

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Bevel angle = 30º Included angle = Bevel
Included angle = 60º angle = 50º
 Weld preparations
Type of parent material impacts upon weld preparation

To reduce distortions on stainless steels welds, reduce

included angle and increase root face.
To avoid lack of side wall fusion problems aluminium
require larger included angles than steel.
60º 70-90º

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30º 35-45º
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Steel Aluminium
 Weld preparations
Thickness of parent material impacts upon weld
preparation
•A single bevel groove requires a volume of weld metal
proportional to the square of plate thickness
•Its lack of symmetry lead to distortions

Reduce shrinkage by:

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•reduce weld volume ©

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•use single pass welding
 Weld preparations

Thickness of parent material impacts upon weld

preparation.

Reduce weld volume by:

•Reduced included angle

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•Reduced root gap

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 Weld preparations

Thickness of parent material impacts upon weld

preparation.

Reduce weld volume by:

•Increase root face

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•Use double bevel weld prep

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 Weld preparations

Thickness of parent material impacts upon weld

preparation
Reduce weld volume by:
•Use U prep instead V prep

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U prep better than V prep

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V prep better than U prep
 Weld preparations

Thickness of parent material impacts upon weld

preparation
Reduce distortions by using an asymmetric V prep
instead of a symmetric V prep

t/3 t

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Weld first into the deeper side ©

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after welding to half of the depth, back gouge the
root. complete welding on the shallow
side first first.
 Weld preparation

Welding position impacts upon weld preparation

60º
60º
30º
15º

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PF symmetric PC asymmetric ©

preparation preparation

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If symmetric preparation is used in the PC position the
weld may spill out of the groove
 Weld preparation

Type of loading impacts upon weld preparation

Static loads - prohibited application of one sided fillet

weld

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 Weld preparation

Type of loading impacts upon weld preparation

Static loads - equal throat T joints

13 mm 13 mm

60º

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weld area = 160 mm2 weld area = 90 mm2

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•no preparation required •preparation required
•danger of lamellar tearing •reduced distortions
 Weld preparation
Type of loading impacts upon weld preparation
Static loads - equal throat T beams in bending

neutral
axis neutral
axis

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Deep penetration
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Normal fillet welds

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fillet welds
Lower neutral axis is more advantageous (also helps to
reduce residual distortions!)
 Weld preparation

Type of loading impacts upon weld preparation

Dynamic loads - full vs. partial penetration welds

cyclic load

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fillet welds double bevel weld
Lack of penetration promotes cracking!
 Welding Terminology

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