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AN INTRODUCTION TO

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 union between materials caused by heat, and or pressure

A Joint:*

A configuration of members

Text Page Ref 1:1

Butt welds:*

Fillet welds:*

Spot/Seam welds:*
Plug/Slot welds:* Edge welds:*

Butt joints: * T joints: * Lap joints: *

Corner joints:*

Closed corner

Open corner*

Angle of bevel* Root face*

Included angle*
Root gap*

Root radius*

Root landing*

Single bevel

Single V
Single J

Single U*

Double bevel

Double V

Double J

Double U*

A butt welded butt joint*

A fillet welded butt joint*

A compound welded butt joint*

A fillet welded T joint*

A butt welded T joint*

A compound welded T joint*

A fillet welded Lap joint*

A spot welded Lap joint*

A compound welded Lap joint*

A fillet welded Closed Corner joint*

A butt welded Closed Corner joint*

A compound welded Closed Corner joint*

An inside fillet welded Open Corner joint*

An outside fillet welded Open Corner joint*

A double fillet welded Open Corner joint*

Actual Throat Thickness* 1.2.3.4. Weld Toes*


1
A

Weld Face* Weld Width* Design Throat Thickness*


2

HAZ* Weld Root*

A + B = Excess Weld Metal**

Vertical Leg Length*

Weld face*

Horizontal Leg Length* Excess weld metal ** Design throat* Actual throat*

6 mm
80

Very Poor Weld Toe Blend Angle


3 mm*

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.

Weld Sizing (Fillets):

DTT. ATT. Excess weld metal. Leg length *

It is the duty of all welding inspectors:


To ensure that welding operations are carried out in accordance with written, or agreed practices or specifications

Before During After

Discuss the following Before Welding:


1) Safety: Rules. 2) Documentation: Spec. Drawings. Procedures. Welder approvals. Certificates. Mill sheets

3) Welding Process and accessories: Equipment,Cables, Regulators, Ovens etc


4) Incoming Consumables:

Materials/welding consumables (Size. Condition. Specification. Storage)


5) Marking out preparation & set up: Method. Angles/Root face/gap values. Distortion control. Pre-heat prior to tack welding if applicable*

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)

4) Welding process (Related parameters i.e. volts/amps. gas flow rate)


5) Welding run sequence and inter-pass cleaning 6) Minimum/maximum Inter-pass temperatures (150 C for SS, 250 C for CS. 7) Full compliance with all elements given on the WPS*

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

Activities & Imperfections* Activities & Imperfections* Activities & Imperfections*

To Record

To Compare

A Welding Inspectors toolbox should contain*

A welding gauge (Cambridge style, or high low gauges etc)


A tape measure and scale A wire brush

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)

Mechanical or Surface damage Misalignment*

A HAZ hydrogen crack, initiated at the weld toe Most cracks are initiated from stress concentrations *

Surface breaking porosity


Shrinkage cavity* Coarse cluster porosity Fine cluster porosity Blow hole > 1.6 mm

Hollow root bead

An isolated internal porosity

Surface breaking solid inclusion


Internal solid inclusion causing a lack of inter-run fusion* Internal solid inclusion causing a lack of sidewall fusion

Internal solid inclusion

Solid inclusions caused by undercut in the previous weld run

Lack of sidewall fusion & incompletely filled grove*

Overlap (Causing cold laps)

Lack of inter-run fusion

Lack of sidewall fusion Lack of root fusion

Spatter

An Incompletely filled groove

Lack of root fusion


Arc Strikes Bulbous, or irregular contour Poor toe blend

Incomplete root penetration

Root Run or Hot pass undercut

Parent metal, surface undercut

Weld metal, surface undercut*

Weld metal, surface undercut

Parent metal, top toe undercut*

Any surface damage caused by:


Grinding Hammering/chisel marks Slag chipping hammer marks Arc strikes

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 ?*

To establish the level of mechanical properties*

Which properties ?* 1) 2) 3) 4) Hardness* Toughness (Impact Test)* Tensile strength* Ductility*

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

HAZ Fusion boundary Weld metal

Generally we use a diamond or steel ball to form an indentation

We measure the width of the indentation to gauge the hardness*

1)

Vickers Diamond Pyramid: Always uses a diamond*

2)

Brinell hardness test:

Always uses a steel ball*

3)

Rockwell hardness test:

Uses a ball, or diamond depending on the scale*

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)

Charpy V test: 10 x 10 (Specimen horizontal) Joules*


Izod test: 10 x 10 (Specimen vertical) Ft.lbs*

Radius (For radius reduced test specimens only) Weld Test gripping area HAZ

Direction of test Plate material

Reduced Section

Used to assess the tensile strength of the weld metal

All Weld Metal Tensile Testing

Direction of the test *

Tensile test piece cut along weld specimen.

Firstly, before the tensile test 2 marks are made 50mm 50 mm

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 %*

1) Excess Weld Metal Height

7) Poor Toe Blend*

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*

Former Test Piece Force

Further tests include face, side and longitudinal bend tests* For material over 12 mm thickness, side bend test may be used*

Specimen prior to test*

Specimen after test*

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

The specimen is usually cut from a stop/start in the test piece

Remember! The process of inspection is to first:

Observe, then Report, then Compare!*

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