Welding Inspector

Terms & Definitions

 Terms and definitions
What is Welding?
A welding is the science by which we can join 2 or more
materials by the help of pressure or heat or both of them in
such a way that there is continuity in the nature of the metal
between these parts.
 Ways to Perform welding
• Autogenous Welding
• Homogeneous Welding
• Heterogenous Welding
• An Autogenous weld:
A weld made without the use of a filler material and can
only be made by TIG or Oxy-Gas Welding.
such as Plasma Arc Welding (PAW), Laser Beam Welding (LBW),
Electron Beam Welding (EBW), etc.
Ways to Perform Welding
Homogeneous Welding

In homogeneous welding, filler material having composition

same with that of the base metal is applied.
Ways to Perform welding
Heterogenous Welding

If filler material is applied during joining and the

metallurgical composition of filler is different from that of the
base metal, then it is termed as heterogeneous welding.
Welding Terminology & Definitions

What is a Joint?

 A connection where the individual

components, suitably prepared and
assembled, are joined by welding or brazing.

 Configuration of members.
Types of Joints

Edge Open & Closed Corner Lap

Tee Butt
Cruciform
https://blogpuneet.wordpress.com/
2013/09/17/welding-joints-and-symbols/
Welding Terminology & Definitions
What is a Weld?
• A permanent union of materials made by
heat and or by pressure.
Types of Weld
1 ) From Configuration point of view

• Butt Weld
• Fillet Weld
• Spot Weld
• Slot & Plug Weld
• Edge Weld
• Compound Weld
Weld Terminology

Butt weld Spot weld

Fillet weld

Edge weld Plug & Slot weld

Compound weld
Quiz- Name below weld types
Welded Butt Joints

Butt Welded butt joint

A_________

Fillet Welded butt joint

A_________

Compound Welded butt joint

A____________
Welded Tee Joints

Fillet Welded T joint

A_________

Butt Welded T joint

A_________

Compound Welded T joint

A____________
Types of Weld
2 ) From Penetration point of view
 Butt Preparations
Single sided preparations are normally made on thinner materials, or
when access form both sides is restricted

Single Bevel Single V

Double Bevel Double V

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

Single-U Single-J

Double-U Double-J
Joint Preparation Terminology
Single-J Butt Single Bevel Butt

Angle of bevel Angle of bevel

Root
Radius

Root Gap Root Face Root Face

Land Root Gap
Joint Preparation Terminology
Single V Butt Single U Butt

Included angle Included angle

Angle of
bevel

Root
Radius

Root Face Root Face

Root Gap Root Gap
Joint Preparation Terminology
 Features of completed weld
BUTT Weld

Weld Zone Parent Metal

Parent Metal
Weld Face
Toe

Excess weld
metal

Excess weld
metal
HAZ

Fusion Line
Weld Metal
Root
Weld Zone Terminology

Toe
Weld Zone Terminology
Weld cap width

Excess
Cap height Actual Throat Design
or Weld Thickness Throat
Reinforcement Thickness

Excess Root
Penetration
Toe Blend- Butt Weld
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
20° amount of stress
concentration

Improved Weld Toe Blend •The toe blend angle ideally

Angle should be between 20o-30o
In CSWIP 3.1 Book and certification

Remember Following Legends:

a: design throat thickness

s: Actual throat thickness
z: leg length
EWM: excess weld metal
 Sizes Butt Preparations
Partial Penetration Butt Weld
Actual Throat
Design Throat
Thickness
Thickness

Full Penetration Butt Weld

Design Throat Actual Throat

Thickness Thickness
 Features of completed weld
Fillet Weld Toe
Weld
Face
Parent
Metal

We
ld
Weld
Metal

Zo
ne
Root Leg Length

Excess weld
metal
Parent Throat Thickness
HAZ
Metal
 Fillet Weld Profiles
Fillet welds - Shapes

Mitre Fillet Convex Fillet

?
?
Concave Fillet

?
 Throat Thickness Features to Consider

Importance of Fillet Weld Leg Length Size

(a) (b)

8mm
4mm

4mm 2mm
Question : in above pictures which one has having bigger size weld? (b)
Question : in above pictures which one has having more strength? (a)

Approximately the same weld volume in both Fillet Welds,

but the effective throat thickness is small in one of welds.
 Fillet Weld Sizes
Importance of Fillet weld leg length Size

(a) (b) Excess

Excess

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

Area = 8mm2 Area = 18 mm2

(b) is over double the area of (a) without the extra

excess weld metal being added
Mitre
Fillet Weld-Formula

a = z x 0.707
Design Throat
Thickness = Leg Length x 0.707

z = a x 1.41
Leg Length = Design Throat Thickness x 1.41
PRACTICE SESSION
Calculating Throat Thickness from a known Leg
Length:
Question: The Leg length is 14mm.
What is the Design Throat?

Answer:
a = z x 0.707
a=14 x 0.707
a = 9.89 mm
PRACTICE SESSION
Calculating Leg Length from a known Design Throat
Thickness:

Z = a x 1.41
a= z x 0.707 Or Z= a ÷ 0.707

Question: The Design Throat is 10mm.

What is the Leg length?

Answer: 10mm x 1.41 = 14mm

PRACTICE SESSION
A fillet weld has an actual throat thickness
of 8mm and a leg length of 7mm. What is
the excess weld metal?
a. 2.1 mm
b. 1.8 mm
c. 3.1 mm
d. 1.4 mm

Answer: EWM= ??? , s=8 mm , z=7 mm

Formula: S= a+EWM
EWM= S- a = S- (zx0.707) =8- (7x0.707) = 3.06 Ans.
Throat Thickness Features to Consider

Fillet welds connecting part with fusion faces with an angle more
than 120o or less than 60o should not use the previous calculations

Assume the angle would be between 60o to 90o for exam.

Welding Positions
BRITISH AMERICAN

PA 1G / 1F Flat / Downhand

PB 2F Horizontal-Vertical

PC 2G Horizontal
PD 4F Horizontal-Vertical (Overhead)

PE 4G Overhead

PF 3G / 5G Vertical-Up

PG 3G / 5G Vertical-Down

H-L045 6G Inclined Pipe (Upwards)

J-L045 6G Inclined Pipe (Downwards)

Welding Positions