term of welding

M.S.RogersCopyright © 2003 TWI Ltd

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CSWIP Welder TrainingDuties & Terms


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Main ResponsibilitiesMain Responsibilities

Code compliance

Workmanship control

Documentation control


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Personal AttributesPersonal Attributes

Honesty

Integrity

Knowledgeable

Good communicator

Physically fit.


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Duties of a Welding InspectorDuties of a Welding Inspector

Before Welding.before assembly.

after assembly.

During welding.

After welding.


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Duties Before WeldingDuties Before Welding

Check all documentation

Check all consumables

Check materials, dimensions and condition

Preheating, method and temperature

Check fit and set-up.

Ensure no undue stress is applied to the joint

Check welding equipment


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During WeldingDuring Welding

Check amperage, voltage, polarity

Ensure the correct technique, run sequence.

Check run out lengths, time lapses.

Cleaning between passes

Interpass temperatures

Consumable control

Maintenance of records and reports


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After WeldingAfter Welding

Post cleaning

Visual inspection of completed welded joint

Check weld contour and width

PWHT

Dimensional accuracy

Weld reports

Tie up with NDT

Monitor any repairs


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SummarySummaryIt is the duty of a Welding Inspector to ensure all the welding and associated actions are carried out in accordance with the specification and any applicable procedures.A Welding Inspector must:

ObserveObserveTo observe all relevant actions related to weld quality throughout production.

RecordRecordTo record, or log all production inspection points relevant to quality, including a final report showing all identified imperfections

CompareCompareTo compare all recorded information with the acceptance criteria and any other relevant clauses in the applied application standard


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Welding Inspectors EquipmentWelding Inspectors Equipment

Measuring device e.g flexible tape, steel rule

Temperature indicating crayons

Welding gauges e.g. TWI multi-purpose gauge

Voltmeter

Ammeter

Magnifying glass

Torch/flash light


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605040

0 1/4 1/2 3/41

05

1015

20

IN

MM

MM15

1/2

MMIN

Welding Inspection GaugesWelding Inspection Gauges

HI-L

O S

ingl

e Pu

rpos

e W

eldi

ng G

auge

1

2

3

4

5

6

Fillet Weld Gauges

G.A.L.

S.T.D.

10mm

12m

m

16mm

3mm

6mm

9mm

5mm

4mm

L

TWI Multi-purpose Welding GaugeMisalignment Gauges

An explanation on the use of these gauges will be give in the practical sessions

G.A.L.

S.T.D.

10mm

12m

m

16mm3m

m

6mm

9mm

5mm

4mm

T


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Amp/Volt MeterAmp/Volt Meter

Tongue Tester

Amp Meter

Volt Meter


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Any Questions?Any Questions?


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G Y QU 1. Give the three main responsibilities of a Welding Inspector

QU 2. Give the main attributes, which all Welding Inspectors must possess

QU 3. A Welding Inspector should refer to What documents and records

QU 4. Give six main duties of a Welding Inspector before welding

QU 5. Give six main duties of a Welding Inspector during welding

QU 6. Give six main duties of a Welding Inspector after welding

QuestionsQuestions


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Welding TermsWelding Terms


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A Joint:

A configuration of members

A Weld:

A union between materials caused by heat, and or pressure

Terminology and DefinitionsTerminology and Definitions


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Terminology Joint WeldsTerminology Joint Welds

Compound Fillet Butt

Edge Spot Plug


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Terminology Joint TypesTerminology Joint Types

Edge Open & Closed Corner Lap

Tee

Cruciform

Butt


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Types of Joint PreparationTypes of Joint Preparation

Included angle

Root GapRoot Face

Angle of bevel

Root FaceRoot Gap

Included angle

Root Radius

Single -V Butt Single - U Butt


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Root GapRoot Face Root Face

Root Gap

Root Radius

Single Bevel Butt Single J Butt

Angle of bevel

Angle of bevel

Land

Types of Joint PreparationTypes of Joint Preparation


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Single Butt Weld PreparationsSingle Butt Weld Preparations

Single Bevel VeeSingle

Single J Single U

Single sided preparations are normally made on thinner materials, or when access form both sides is restricted


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

VeeDoubleBevelDouble

JDouble UDouble


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A_________Welded butt jointButt

A_________Welded butt jointFillet

A____________Welded butt jointCompound

Welded Butt JointsWelded Butt Joints


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A_________Welded T jointFillet

A_________Welded T jointButt

A____________Welded T jointCompound

Welded Fillet JointsWelded Fillet Joints


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Welded Lap JointsWelded Lap Joints

A_________Welded lap jointFillet

A_________Welded lap jointSpot

A____________Welded lap jointCompound


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A_________Welded closed corner jointFillet

A_________Welded closed corner jointButt

A____________Welded closed corner jointCompound

Welded Closed Corner JointsWelded Closed Corner Joints


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A_______________Welded open corner jointOutside fillet

Welded Open Corner JointsWelded Open Corner Joints

A_______________Welded open corner jointInside fillet

A_______________Welded open corner jointDouble fillet


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Weld Zone TerminologyWeld Zone Terminology

Weld metal

RootFusion zone

Heat affectedzone

Weld zone

Weld Junction

Weld Toe

Weld Toe


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Butt Weld FeaturesButt Weld Features

Weld cap width

Excess root penetration Root bead width

Excess cap heightor weld reinforcement


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Butt Weld FeaturesButt Weld Features

A

B

A & B = Excess weld metal

Actual throat

1,2,3,4 = Weld toes

1 2

3 4

Cap or Face

Cap widthDesign throat

Fusion zone

Weld Junction

HAZ Root


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Fillet Weld FeaturesFillet Weld Features

Horizontal leg length

Ve

rtic

al le

g

len

gth Nominal

design throat thickness

Weld face


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Fillet Weld DimensionsFillet Weld Dimensions

a

a = Nominal design throat thickness

s

s = Effective design throat thickness

b

b = Horizontal leg lengthcc = Vertical leg length

The leg length should be approximately equal to the material thicknessThe design throat thickness is 0.7 of the leg length

e.gLeg length = 6mmDesign Throat = 6mm x 0.7Design Throat = 4.2mm


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Fillet Weld ProfilesFillet Weld Profiles

Mitre fillet Convex fillet

Concave fillet

A concave profile is preferred for joints subjected to fatigue loading


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Toe Blend AngleToe Blend Angle

6 mm

80°

Poor Weld Toe Blend Angle

Improved Weld Toe Blend Angle

20°

3 mm

Most codes quote the weld

toes shall blend smoothly

This statement is not

quantitative and therefore

open to individual interpretation

The higher the toe blend

angle the greater the amount

of stress concentration

The toe blend angle should

be between 20o-30o


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Welding PositionsWelding Positions

Flat positionFlat position

UK (USA) 1G rotatedISO/EN PA

UK (USA): 1G ISO/EN: PA

UK (USA) 2G FixedISO/EN PC

UK (USA): 2G ISO/EN: PC

Horizontal Horizontal positionposition


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Vertical down

UK (USA) 3GISO/EN PG

UK (USA) 3G ISO/EN PF

Vertical up

UK (USA) 4G ISO/EN PE

Overhead Position

UK (USA) 5G ISO/EN PF, PG

Vertical PositionPipe fixed Horizontal



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45o

Inclined position fixed

UK (USA) 6GEN/ISO H-LO45

Inclined position Rotated

UK (USA) 1FREN/ISO L 45/PA

45o



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Range of approval according to welding position

BS EN 287


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Any Questions?Any Questions?


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QuestionsQuestionsQU 1. Sketch a single-U butt joint and indicate the following

a. Root face b.Root gap c.Included angle d. Root radius

QU 2. Sketch a tee joint, fillet welded and indicate the followinga. Leg length b.Throat thickness c. Root d. Weld toes

QU 3. Sketch five joint types in addition to a butt joint

QU 4. Identify the the following features from the sketch

E

F

C

AB

D

term of welding

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