Ho Chi Minh City University of Technology – VNU HCMC

Faculty Of Chemical Engineering

Fabrication, Inspection and

Testing
Instructor: Assoc. Prof. Nguyen Huu Hieu, Ph.D

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Contents
Fabrication

Inspection

Testing

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Machine manufacturing stages

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Fabrication 1
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Fabrication

Heat
Forging Welding
Treament

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Forging

Shaped the workpiece by compressive forces applied

through various dies and tooling
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 Heat treatment

Annealing: heating a material

above its recrystallization
temperature, maintaining a
suitable temperature for a suitable
amount of time, and then cooling.

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Heat treatment

Normalizing: balance the

structural irregularities and
makes the material soft for
further working

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Welding
Following this procedure

1 Determining types of welding

Depending on material, geometry, available
facilities

2 Types of joint
Butt joint, corner joint, T joint, lap joint, edge
joint

3 Preparation of joint

4 Completing the joint

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1. Fusion Welding

• Melting together and coalescing

materials by means of heat.
• Based on the heat source, fusion
welding could be classified as
follow:
o Oxyfuel-gas Welding
o Arc-welding
o Electro-beam welding
o Lazer beam welding

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1.1 Oxyfuel-gas Welding (OFM)
• Uses a fuel gas combined with
oxygen to produce a flame.
• Most ferrous and nonferrous
metals
• Most common gas: Acetylene

C2H2 + O2
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1.1 Oxyfuel-gas Welding (OFM)

Adjust the gas ratio to get the desired temperature

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 1.2. Arc Welding
An electric arc from an AC or DC power supply creates an intense heat of
around 30,000°C which melts the metal at the join between two work pieces.

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1.2. Arc Welding Nonconsumable Electrode

Gas Tungsten-arc Welding

• Shield gas usually argon

• Used for thin sections of Al, Mg, Ti.
• With or without filler metal

o Current I (200 A DC)

(500 A AC)
o Power ≈ 8-20 kW

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1.2. Arc Welding Consumable Electrode

Shielded Metal-arc Welding

 Thicknesses: 0.03m – 0.08m
 Current I (50 - 300 amps)
 Voltage V (15 - 45 volts)
 Power = 10 kW

About 50% of all industrial and maintenance welding currently is performed

by this process (2009)
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1.2. Arc Welding Consumable Electrode
Shielded Metal-arc Welding

 The SMAW process commonly is used

in general construction, shipbuilding,
pipelines, and maintenance work

 SMAW is best suited for workpiece

thicknesses of 3 to 19 mm

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1.2. Arc Welding Consumable Electrode

Shielded Metal-arc Welding

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1.2. Arc Welding Consumable Electrode
Submerged-arc Welding

The weld arc is shielded by a granular flux consisting of lime, silica,

manganese oxide, calcium fluoride, and other compounds
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1.2. Arc Welding Consumable Electrode
Submerged-arc Welding

 The quality of the Weld is very

high-with good toughness,
ductility, and uniformity of
properties.
 SAW process is limited largely
to welds in a flat or horizontal
position having a backup piece

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1.2. Arc Welding Consumable Electrode

Submerged-arc Welding

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1.3. Electro-beam welding

Heat is generated by high velocity

narrow-beam electrons.
Making high-quality welds that
are almost parallel sided
Distortion and shrinkage in the
weld area are minimal.

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 1.4. Lazer beam welding

Utilizes a high-power laser

beam as the source of heat to
produce a fusion weld.

𝐷𝑒𝑝𝑡h
≈ 4 − 10
𝑊𝑖𝑑𝑡h

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1.4. Lazer beam welding
Welding speeds range from 2.5 m/min to as
high as 80 m/min for thin metals.

Typical metals and alloys welded include

aluminum, titanium, ferrous metals, copper,
superalloys, and the refractory metals.

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COMPARISIONS OF FUSION WELDING
PROCESSES
Process Opertion
Skill level
Material
Welding Typical cost of
required position equiment
Oxyfuel-gas Most ferrous and
Manual High All Low
Welding (OFM) nonferrous metals
Gas Tungsten-arc Manual Thin sections of Al, All
Low to high medium
Welding Or Automatic Mg, Ti
Shielded Metal- Manual thicknesses from 3 All
High Low
arc Welding to 19 mm
carbon and alloy
Submerged-arc Automatic Low to medium steel, stainless- Flat & medium
Welding steel sheets or horizontal
plates
Electro-beam
welding Semiautomatic aluminum,
All
or Automatic Medium to high titanium, ferrous high
Lazer beam metals, superalloys
welding

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3. Welding Joints

Types of Welding Joints

• Butt joint
• Lap joint
• Corner joint
• T joint
• Edge Joint

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3. Welding Joints Butt Joint

Butt joint Symbol

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3. Welding Joints Butt Joint

Advantages Disadvantages Applications

 Universally accepted  Chances of porosity in  Pipes
method butt welds  Valves
 Easiest welding method  Edge preparation is  Flanges
 Very cheap method required while  Fittings
working with thick
metal pieces

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3. Welding Joints

S 8mm S 8mm
Root gap depend on thickness of equipment:
Thickness, ≤ 𝟖 10 - 12 14 - 18 20 - 30 30 - 40 40 - 50
mm
Root gap 0-1 1-2 2-3 3-4 4-5 5-6
(l) ,mm
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3. Welding Joints Lap Joint

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3. Welding Joints Lap Joint
Advantages Disadvantages Applications
 Satisfactory lap weld is  Sheets  Lap weld joint is most commonly
obtained easily , not difficult bearing used in resistance spot welding, gas
technique heavy loads tungsten arc weld & gas metal arc
 No risk of blowing through can’t bear welding
the weld joint because the one-sided lap  Lap joints are also applicable in
second sheet is present on weld plastic & wood.
the other side of joint  Lap welds are commonly used in
 Lap joints are quicker & automation involving processes.
simple to be made  Tabling
 Stronger welded joints are  Temporary framing
obtained if a double-sided  Frame assembly in cabinet
weld is made making

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3. Welding Joints Corner Joint

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3. Welding Joints Corner Joint
Advantages Disadvantages Applications
 Strong welds can be  In a corner joint, there is a  Attach pieces together for
produced chance of Increased Wear creating different shapes.
 The most popular & Tear  For welding light sheets of
technique to join metal metal where strength is
sheets not necessary a close
corner joint may be used.
 For heavier metal sheets
welding is done on one
side of the heavy metal to
form a half corner joint.

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3. Welding Joints Tee Joint

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3. Welding Joints Tee Joint

𝐾 ≤ 1,2 𝑠 𝑚𝑖𝑛
𝐿 ≤ 50𝐾 (𝐿 : length of butt)

Thickness, 𝒔 (mm) ≤ 𝟒 𝟒- 𝟖 𝟗- 𝟏𝟓 𝟏𝟔- 𝟐𝟓 𝟐𝟓

Butt width, 𝐾𝑚𝑛𝑖 (mm) 𝟑 𝟒 𝟔 𝟖 𝟏𝟎

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3. Welding Joints Tee Joint

Advantages Disadvantages Applications

 No  Extra care is necessary to  T welded joints are used
preparation ensure effective penetration on when a metal piece is
needed in weld roof attached to some sort of a
case of plain  Corrosion fatigue is common in base
TEE joint T welded joints  A single beveled joint is used
 Due to geometry generated by in thin plates which can be
T joints, they may contain welded from one side, usually
increased cracking, moisture used for joining thin plates
entrapment, excess porosity,  A double beveled joint is used
corrosion in heavy plates which can be
welded from both sides

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3. Welding Joints Edge Joint

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3. Welding Joints Edge Joint

Advantages Disadvantages Applications

 Useful for sheets less  Weld doesn’t penetrate  Edges of sheets are
than 3mm thicker completely at the joint adjacent & are
 No preparation is thickness approximately parallel
required for this weld  This welding joint type planes at the welding
joint can’t be used in stress & point.
 The filler material is not pressure applications  Most commonly used for
required to fuse the  Very rarely used joints parts of metals that have
sheets together technique flanging up edges
 Sheets’ thickness are less
than 3mm .

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3. Welding Joints

The welding position should easy to weld

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3. Welding Joints

False Right
𝑎 ≥ 3s or 𝑎 ≥ 40𝑚 𝑚
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3. Welding Joints

Right False

Reduce weld length by combining bending and stamping methods

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2 Inspection

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Inspection

 Examining the materials

 Examining the pressure retaining parts to
conform to the prescribed shape and meet
the thickness requirements
 Examining the nozzles, manhole frames,
nozzle reinforcement
 Examining all welds and lining

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Non-destructive Testing (NDT)

Visual testing

Liquid penetrant testing

Magnetic particle testing

Eddy Current Testing

Ultrasonic Testing

Radiography Testing
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NDT - Visual Testing
 Normally performed by using naked eyes.
 The aid of special tools: Fiberscopes, borescopes, magnifying glasses and
mirrors.

FIBERSCOPE
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NDT - Visual Testing

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NDT - Visual Testing
• Advantages:
 Cheapest NDT method
 Applicable at all stages of construction or manufacturing
 Do not require extensive training
 Capable of giving instantaneous results
• Limitations:
o Limited to only surface inspection
o Require good lighting
o Require good eyesight

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 NDT - Liquid penetrant testing

• Utilizes the principle of capillary action.

• Involved the following sequence:
o Pre-cleaning
o Penetrant application
o Removal of excess penetrant

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NDT - Liquid penetrant testing
• Advantages:
 Simple to perform.
 Inexpensive.
 Applicable to materials with complex geometry.
• Limitations:
o Limited to detection of surface breaking discontinuity.
o Not applicable to porous material.
o Require access for pre- and post-cleaning.
o Irregular surface may cause the presence of non-relevant
indication.
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NDT - Magnetic particle testing
Firstly, material is magnetized. Then, a magnetic field is
established in the vicinity of the material.

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NDT - Magnetic particle testing
• Advantages:
 Inexpensive
 Equipment are portable, easy to operate
 Provide instantaneous results
• Limitations:
o Applicable only to ferromagnetic materials
o Insensitive to internal defects
o Require power supply for magnetization
o Material may be burned

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 NDT - Eddy Current Testing

 Detecting surface cracks and used to make

electrical conductivity or coating thickness

measurements.

 A small surface probe is scanned over the

part surface in an attempt to detect a crack.

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NDT - Eddy Current Testing

• Advantages:
High testing speed, no blank surface needed, no danger to the
environment, painted surfaces have no influence, no
temperature influence, evaluation of crack depth.
• Limitations:
Only used for conductive materials, such as carbon steel,
stainless steel, duplex, alloy.

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NDT - Ultrasonic Testing

 Directing high frequency sound

waves through the base plate and
weld. They introduce into the
material and reflect back from
surface or flaw.
 Plotting signal strength or time-
of-flight using a computer-
controlled scanning system.

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NDT - Ultrasonic Testing

 Advantages:
 Can be used for thick plates, welds, castings, forgings.
 Can be used for welds which radiographic testing not practical.
 Limitations:
 Equipment must be constantly calibrated.

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 NDT - Radiography Testing

 The used radiation is a high energy

(short wavelength) electromagnetic
wave, can come from an X-ray
generator or a radioactive source.
 The part is placed between the
radiation source and a piece of film.
Thicker and more dense area will
stop more of the radiation.

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NDT - Radiography Testing

 Advantages:
 Produces permanent record.
 Detects small flaws.
 Most effective for butt welded joints.
 Limitations:
 Expensive, not practical for complex shapes.

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Testing 3
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 Why testing??
 To ensure the integrity of the
equipment
 To ensure the strength of the weld
joints and material
 To ensure the strength of the
nozzle flange joints.
 To relieve the stresses
 Ensurees safe and reliable
performance during the
operational life

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Standard hydrostatic test

DEFINITION

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Standard hydrostatic test
DEFINITION
A hydrostatic test is a way in
which pressure vessels, tanks can
be tested for strength and leaks.
The vessel or pipe system is filled
with a liquid, usually water, which
may be dyed to aid in visual leak
detection, and pressurization of
the vessel to the specified test
pressure

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Standard hydrostatic test
Water is often used because it almost doesn't

shrink under high pressure. On the other hand,

using safe water, it takes much less energy than

compressed air. Adding just one drop of water can

increase the pressure in the tank to 25 PSi while it

will take a large amount of gas to have the same

pressure change.

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Standard hydrostatic test

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Standard hydrostatic test

ASME CODE

Minimum Hydrostatic Test Pressure = 1.3 X MAWP x LSR

*Where LSR is the smallest ratio of the allowable stress at test temperature to the allowable
stress at design temperatures of materials used in the vessel construction. 

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Pneumatic Test

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 Pneumatic Test
DEFINITION
 A hydrostatic test is performed by using water as the test medium,
whereas a pneumatic test uses air, nitrogen, or any non-flammable and
nontoxic gas
 Pressure tests (both hydrostatic and pneumatic) must always be
performed under controlled conditions, following an approved test plan,
and documented in a test record.
 Recommended only for low pressure applications.

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Pneumatic Test

Pneumatic tests are potentially more dangerous than

hydrostatic. Pneumatic tests may be performed only when at
least one of the following conditions exits:
 when pressure systems are so designed that they cannot
be filled with water.
 when pressure systems are to be used in services where
traces of the testing medium cannot be tolerated.

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Purpose of Pneumatic Test

 To verify that a system may be safely subjected to its

maximum operating pressure by testing it beyond its
designed pressure limit.
 The pneumatic strength test uses air, or an inert gas medium
such as nitrogen, to pressurize the system to 110% of its
designed pressure limit.
 A holding period is then applied for a fixed amount of time
and the results monitored to determine the safety and
integrity of the system.
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Benefits of Pneumatic Test

 Accurate test results means

confidence in the integrity of
the system
 No need to dry or clean the
system after testing
 Will not lead to contamination
of pipelines or systems
 Certified test with full records
and charts provided.

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