Professional Documents
Culture Documents
CSWIP 3.1 By
MR ANSAR BALOCH
Contents
Terms & Definition Types of Welds Types of Joints Weld Preparations Types of Single Butt Preparation Butt Welded Joint Fillet Weld Profile Effect of a Poor Toe Blend Angle Summary of Terms Duties of Welding Inspector Responsibilities of Welding Inspector Imperfections in Welded Joints Mechanical Testing Macro Inspection
A Weld:*
A Joint:*
A configuration of members
Butt welds:*
Fillet welds:*
Spot/Seam welds:*
Plug/Slot welds:* Edge welds:*
Corner joints:*
Closed corner
Open corner*
Included angle*
Root gap*
Root radius*
Root landing*
Single bevel
Single V
Single J
Single U*
Double bevel
Double V
Double J
Double U*
Weld face*
Horizontal Leg Length* Excess weld metal ** Design throat* Actual throat*
6 mm
80
20
Improved Weld Toe Blend Angle
90
3 mm
Extremely poor toe blend, but excess weld metal is within limits*
Weld: Joint: Weld Preparation: Types of Weld: Types of Joint: Types of Preparation: Preparation Terms: Weldment Terms: Weld Sizing (Butts):
A Union of materials A Configuration of members Preparing a joint to allow access and fusion. Butt. Fillet. Spot. Seam Plug. Slot. Edge. Butt. T. Lap. Corner (Open & Closed) Bevels. Vs. Js. Us. Single & Double Sided. Bevel/included angle. Root face/gap. Land/Radius Weld face & root. HAZ. Weld toes.Weld width DTT. ATT. Excess weld metal.
During Welding:
1) Pre-Heating (Min 15 C as per UW-30 ASME Section VIII Div-I)
2) In process distortion control (Balance or sequence welding) 3) Consumable control. (Correct baking for E-7018 260-425 C and storage 30-140 C prior to use)
After Welding:
1) Visual Inspection
2) Non Destructive testing 3) Repairs* 4) Repair procedures (NDT/Welding/Welder approval) 5) PWHT 6) Hydro-static testing 7) Submission of all inspection reports to QC departments*
To Observe
To Record
To Compare
A magnifying glass
A torch and mirror A specification, pen and report, or note paper
Welding imperfections can be categorized into groups: 1) 2) Cracks Gas Pores & Porosity
3)
4) 5)
Solid Inclusions
Lack of fusion Profile & Lack of Filling
6) 7)
A HAZ hydrogen crack, initiated at the weld toe Most cracks are initiated from stress concentrations *
Spatter
Linear
Excess weld metal height Lowest plate to highest point
Linear misalignment measured in mm (over 13mm to 19mm as per UW 33 of ASME Sec VIII Div-I)
3 mm
Angular
15 Angular misalignment measured in degrees*
Why ?*
We test welds to establish minimum levels of mechanical properties, and soundness of the welded joint* We divide tests into Quantitative & Qualitative methods:*
1) Quantitative tests:
(Have units)*
2) Qualitative tests:
(Have no units)*
Types of tests include: 1) Quantitative tests: Hardness tests Toughness tests Tensile strength tests* 2) Qualitative tests: Macro tests
Bend tests
Fracture tests*
The specimen below has been polished and is ready to be hardness tested = Hardness Survey
Thickness
Base metal
1)
2)
3)
Machined notch
10 x 10 mm
The specimen may be tested from different areas of the weld.* Graduated scale of absorbed energy in Joules* Pendulum Hammer
Location of specimen
1)
2)
Radius (For radius reduced test specimens only) Weld Test gripping area HAZ
Reduced Section
During the test, Yield point & Tensile strength are measured
The specimen is put together and the marks are re-measured
75 mm
A new measurement of 75mm will indicate Elongation E50 %*
6)Porosity
2) Lack of Sidewall Fusion 3) Lack of Root Fusion 4) Slag inclusion & Lack of inter-run fusion
5) Root Penetration
Bend tests are used to establish fusion in the area under test Guide A Guided root bend test* Lack of root fusion shown here*
Further tests include face, side and longitudinal bend tests* For material over 12 mm thickness, side bend test may be used*
The main difference between Macro & Micro is that Micro is the study of the micro-structure at much higher magnification
The limit of Macro inspection is magnification < X 10