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Visual Inspection

of
WELDS

INSPECTION
An item or component or product
which is manufactured is required
to perform certain function.The act
of checking whether it actually
does so or not is inspection.

TYPES OF INSPECTION

VISUAL & DIMENSIONS


NON DESTRUCTIVE TESTING
DESTRUCTIVE TESTING
FUNCTIONAL AND PERFORMANCE
TESTING

IMPORTANCE OF
VISUAL INSPECTION

FIRST IN THE CHAIN


SIMPLE
ESSENTIAL
PREVENTIVE IN NATURE
CRITICAL FOR DECISION MAKING
CAN BE SUPPLEMENTED
ELIMINATES COSTLY REPAIRS

VISION REQUIREMENT
NEAR VISION
COLOUR VISION

Stages in Weld Testing


Before welding
During welding
After welding

Visual Inspection
Before Welding

Dimensions
Fit up
Surface condition damage, rust, paint etc.
Lamination in welding edge

Visual Inspection
Before Welding
Review drawings & Spec.
Check qualification of procedure, welders,
consumables, machines
Establish check points
Recording of result plan
Review of materials to be used
Base metal discontinuities
Fit up & alignment
Pre - heat

Visual Inspection
Before Welding
JOINT FIT UP

Groove Angle
Joint Alignment
Backing
Consumable Insert
Joint cleanliness
Tack welds
Pre heat

VISUAL TESTING
During Welding
Quality of root weld bead
Inter - layer NDT

Pre - heat and inter pass temperature


Sequence of weld passes
Inter pass cleaning
Conformance to welding WPS

Visual Inspection
After Welding

Final weld appearance


Final Weld Size
Weld Length
Dimensional Accuracy
Distortion
Post Heating
Post weld heat treatment

Visual Inspection
Welding Discontinuities
Surface Porosity
Incomplete Fusion
Incomplete
Penetration
Undercut

Overlap
Crack
Slag Inclusion
Excess
Reinforcement

CRACKS
2,10,13

2,5,1
13 3
12

1
11

2,5,8,13

11,3

6
7,13

9,12

FILLET WELDS

Actual Throat

Convexity
Leg &
Size

Effective Throat

Theoretical Throat

CONVEX FILLET WELD

Concavity
Leg &
Size

Leg
Size

Actual Throat &


Effective Throat

Theoretical Throat

CONCAVE FILLET WELD

Leg
Size

OVERLAP & UNDERFILL

OVERLAP
UNDERFILL

INCOMPLETE PENETRATION &


LACK OF FUSION

INCOMPLETE
PENETRATION

LACK OF FUSION

REINFORCEMENT
Weld Face
Face
Reinforcement
Root
Reinforcement

Weld Toe

Temperature Measurement
For checking the Pre heat , Post heat and
Inter pass temperature
Thermal chalk
Melting
Color Changing

Thermal crayons
Thermo couples

Visual Inspection
May or may not use accessories
Gauges for identifying the dimensions of
surface
Magnifying glasses
Borescope for internal inspection
Thermal chalks, Thermocouple, for the
temperature measurement
Etching for checking surface condition

Accessories for VT
Magnifiers
Surface comparator
Measuring magnifier
Low, Medium, high power magnifiers

Borescopes
Rigid
Flexible
Video

Accessories for VT
Machine vision technology
Computer aided
Automatic
Image processing

Replication
Cellulose acetate
Fracture surface analysis
Microstructure
Strain replication

Silicone rubber replication


Wear Analysis

Accessories for VT
Etchants
Reveals welds, gain boundaries, segregation,
laps, seams, cracks, HAZ
Methods Immersion, swabbing
Parameters Etching time, Temperature

Etching
For identification of gross
metallurgical discontinuity
such as in welds.
For detecting the surface
opening Fore runner to
Penetrant Testing
Different Etchants available
for different metals

Accessories for VT
WELD GAGE

Weld Profiles

Acceptable Fillet weld profiles

Unacceptable bead profile

Reinforcement

Weld thick <3 mm

R < 2.3 mm

3-4.7 mm

< 3.0 mm

4.7 - 13

< 3.9 mm

13- 25 < 4.7 mm

Advantages &
Disadvantages
Advantages
Simple
Less training required
Relatively less costly equipment
Disadvantages
Slow
Inspector Fatigue is more
Surrounding environmental factors are
important

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