twi cswip visual inspection of weld

Copyright © 2004, TWI Ltd World Centre for Materials Joining TechnologyWorld Centre for Materials Joining Technology

TWI

CSWIP

VISUAL INSPECTION OF WELDS

TWI

CSWIP

VISUAL INSPECTION OF WELDS


TerminologyTerminologyButt JointsButt Joints

Single Sided Butt

Double Sided Butt

Square EdgedClosed Open

Vee Bevel

Vee Bevel


TerminologyTerminology

Fillet JointsFillet Joints

Lap

Corner

Tee



0-2 mm

2-4 mm

60-700

Included Angle

Root Gap Root Face



Butt Weld FeaturesButt Weld Features

1 2

3

45

6

78

9

10



Fillet Weld FeaturesFillet Weld Features

13

5

6

7

8

10

2

9

4


Joint DesignJoint Design

Butt Weld

Corner Joint

Lap Joint

Tee Joint

Edge Weld


Zones in Fusion Welds Zones in Fusion Welds

• Parent Material or Base Metal • Heat Affected Zone • Fusion Zone


When do I carry out inspections?• How do I carry out inspections?• What do I look for?• What equipment do I need?• How do I interpret the code or standard requirements?• What is the nature of the product?• What operating conditions will be present?• What is the quality of welding required?• Is there a code or standard available to inspect the welds against

Visual Inspection ProceduresVisual Inspection Procedures

Important things to considerImportant things to consider


Welding ChecklistWelding Checklist

• Documentation• Materials• Weld preparations• Fit up for welding• Welding equipment

Before Welding CommencesBefore Welding Commences



•Correct parameters•WPS at the work place• Inter run cleanliness and quality• Interpass temperature•Consumable control•Maintenance of preheat•Process control NDE regime•Weld records and maintenance of weld

maps

During WeldingDuring Welding



•Visual inspection and records•NDE•PWHT•Final testing•Cleaning, painting, preservation, packing•Final documentation

Welding CompletionWelding Completion


Features to ConsiderFeatures to Consider

Butt welds - SizeButt welds - Size

Excess weld metal height

Root penetration

Root bead width

Weld cap width



Fillet welds - SizeFillet welds - Size

Minimum and maximum leg length size

Excess weld metal

Actual throat thickness

Design throat thickness


Features to ConsiderFeatures to ConsiderImportance of Fillet weld leg length SizeImportance of Fillet weld leg length Size

4mm

6mm

8mm

4mm

What size is the Throat thickness of (a)What size is the Throat thickness of (a)

What size is the Throat thickness of (b)What size is the Throat thickness of (b)

(a) (b)


Features to ConsiderFeatures to ConsiderImportance of Fillet weld leg length SizeImportance of Fillet weld leg length Size

4mm

4mm

6mm

6mm

How much bigger is (a) in volume than (b)How much bigger is (a) in volume than (b)

(a) (b)



(a) volume =(a) volume =

4 x 4 4 x 4 = 8mm = 8mm22

22

(b) volume =(b) volume =

6 x 6 6 x 6 = 18mm = 18mm22

22

The volume of (b) is over doubledouble the volume of (a) Without the extra reinforcement being added

4mm

4mm

6mm

6mm

(a) (b)


Features to ConsiderFeatures to ConsiderFillet welds - Size & ShapeFillet welds - Size & Shape

Mitre

Concave

Convex


Features to ConsiderFeatures to ConsiderFillet welds - Toe BlendFillet welds - Toe Blend


EFFECTIVE THROAT THICKNESSEFFECTIVE THROAT THICKNESS“s” = Effective throat thickness

sa

“a” = Nominal throat thickness

Deep throat fillet welds from FCAW & SAW etc



Features to ConsiderFeatures to ConsiderButt welds - ProfileButt welds - Profile

x

x

x


Features to ConsiderFeatures to ConsiderButt welds - Toe BlendButt welds - Toe Blend

x

x

x



Butt welds - Weld WidthButt welds - Weld Width


A Weld : DefinitionsA Weld : Definitions

BS 499BS 499• A union between

pieces of metal at faces rendered plastic or liquid by heat,pressure or both.

NASANASA• A continuous

defect surrounded by parent material


WeldsWelds

An ideal weld must give a strong bond An ideal weld must give a strong bond between materials with the interfaces between materials with the interfaces disappearingdisappearing

To achieve this

• Smooth,flat or matching surfaces

• Surfaces shall be free from contaminants

• Metals shall be free from impurities

• Metals shall have identical crystalline structures


Electric Arc WeldingElectric Arc Welding

Power supply

Work piece

Electrode

Clamp(Earth)


Electric Arc WeldingElectric Arc Welding

• Electric discharge produced between cathode and anode by a potential difference (40 to 60 volts)

• Discharge ionises air and produces -ve electrons and +ve ions

• Electrons impact upon anode, ions upon cathode

• Impact of particles converts kinetic energy to heat (7000o C) and light

• Amperage controls number of ions and electrons, Voltage controls their velocity


Manual Metal Arc WeldingManual Metal Arc Welding

• Shielding provided by decomposition of flux covering

• Electrode consumable

• Manual process

Welder controls• Arc length• Angle of electrode• Speed of travel• Amperage settings



POWER SOURCE:-

Input 240v (single phase) or 415v ( 2 live phases of 3 phase supply)

Output AC (O.C.V. 80v) or DC (O.C.V. 50v) or both.AC for Shop

DC for site work as it is SAFER (lower OCV). Also for shop work..

Current adjustment control

TYPES:- Transformers – AC onlyTransformer/Rectifiers – AC and DCPetrol or Diesel driven Generators – Site work – DCInverters – AC and DC

POWER SOURCEPOWER SOURCE


Safety visor (With dark lens) *


Electrode oven

Power return cable

Power source. Transformer/RectifierHeated quiver

Inverter power source

Power cable

Power control panel

Electrodes

Electrode holder


Manual Metal Arc (MMA)Manual Metal Arc (MMA)


Inverter power source

Power cable

Flow-meter

Power control panel

Transformer/ Rectifier

Power control panel

Power return cable

Torch assemblies

Tungsten electrodes

Tungsten Inert Gas (TIG)Tungsten Inert Gas (TIG)


POWER SOURCE440v 50Hz 3 phase or 240v single phase input

Transformers for AC – aluminium alloysRectifiers for DC - steelsTransformer/rectifier for AC/DCInverters for AC/DC – more portable - expensive

TORCH Sizes/types vary depending on current/application

TORCH HOSE Flexible – may carry current, gas, cooling water.

RETURN LEAD Note that current actually flows from this lead

INERT GAS SUPPLY (Cylinder & regulator)

Correct type for application.(ar, he, ar/he mixture) Argon/hydrogen for austenitic stainless steel

FLOWMETER (graduated in ltr/min)

To deliver correct gas flow (velocity) depending on welding position and joint configuration.


POWER SOURCEPOWER SOURCE



THE POWER SOURCE

AC/DC

CONSTANT CURRENT

VARIABLE CURRENT CONTROLLER

WELDING LEAD + GAS SUPPLY

RETURN LEAD

EARTH*

I V

METERS (OPTIONAL)

TORCH

ARC

OUTPUT 80 OCV MAX

NORMALLY DC-VE

*CHECK WITH HSE GUIDANCE NOTE

ARC STRIKING DEVICE

INERT

GAS

GAS SUPPLY

++

__


Ceramic shield cup

Gas lens

Torch body

Tungsten electrodes

Spare ceramic shielding cup *

Gas diffuser

Split collet

Fitted ceramic shielding cup

Tungsten housing

On/Off switch



Power return cable*

Transformer/ Rectifier

Power cable & hose assembly

Liner for wire

Welding gun assembly

External wire feed unit

Power control panel

Internal wire feed system

15kg wire spool

Metal Inert Gas (MIG)Metal Inert Gas (MIG)


Metal Inert Gas (MIG)Metal Inert Gas (MIG)


Submerged Arc Submerged Arc


Welding DefectsWelding Defects

Classified by Shape• Longitudinal• Transverse• Branched• Chevron

CracksCracks

Classified by Position •HAZ•Centreline•Crater•Fusion zone•Parent metal



4 Crack Types• Solidification cracks• Hydrogen induced cracks• Lamellar tearing• Reheat cracks

CracksCracks



Solidification• Occurs during weld solidification process• Steels with high sulphur content (low

ductility at elevated temperature)• Requires high tensile stress• Occur longitudinally down centre of weld• e.g. Crater cracking

CracksCracks



Solidification CrackingSolidification Cracking



Deeper and narrow Deeper and narrow weld beads are prone weld beads are prone to solidification to solidification cracking (depth to cracking (depth to width ratio over 2:1)width ratio over 2:1)

In order to avoid In order to avoid solidification solidification cracking, reduce cracking, reduce penetration and penetration and increase bead width increase bead width (depth to width ratio (depth to width ratio 0,5:1)0,5:1)



Hydrogen Induced• Requires susceptible grain structure, stress

and hydrogen • Hydrogen enters via welding arc• Hydrogen source - atmosphere or

contamination of preparation or electrode• Moisture diffuses out into parent metal on

cooling• Most likely in HAZ

CracksCracks



Hydrogen CrackingHydrogen Cracking



Hydrogen Cracking



Lamellar Tearing• Step like appearance • Occurs in parent material or HAZ• Only in rolled direction of the parent material• Associated with restrained joints subjected to

through thickness stresses on corners, tees and fillets

• Requires high sulphur or non-metallic inclusions

CracksCracks



Lamellar TearingLamellar Tearing



Lamellar Lamellar Tearing Tearing

Restraint

High contractional stress

Lamellar tear



Re-design weld

Grind and infill with ductile weld metal

Control restraint

For critical work a forged “T” piece may be used

Forged “T” Piece

Lamellar Tearing Lamellar Tearing



Re-Heat Cracking• Occurs mainly in HAZ of low alloy steels

during post weld heat treatment or service at elevated temperatures

• Occurs in areas of high stress and existing defects

• Prevented by toe grinding, elimination of poor profile material selection and controlled post weld heat treatment

CracksCracks



Incomplete root penetrationIncomplete root penetration

Causes• Too small a root gap• Arc too long• Wrong polarity• Electrode too large for

joint preparation• Incorrect electrode angle• Too fast a speed of travel

for current


a) Excessively thick root facea) Excessively thick root face

b) Too small a root gapb) Too small a root gap

c) Misplaced weldsc) Misplaced welds

d) Power input too lowd) Power input too low

e) Arc (heat) input too lowe) Arc (heat) input too low



Too large Too large diameter diameter electrodeelectrode

Smaller (correct) Smaller (correct) diameter electrodediameter electrode

Lack of sidewall Lack of sidewall fusion due to arc fusion due to arc deflectiondeflection




Causes• Too small a root gap• Arc too long• Wrong polarity• Electrode too large for

joint preparation• Incorrect electrode angle• Too fast a speed of travel

for current

Incomplete root FusionIncomplete root Fusion



Root concavityRoot concavity

Causes• Root gap too large• Insufficient arc energy• Excessive back purge

TIG



Excess Root PenetrationExcess Root Penetration

Causes• Excessive amperage

during welding of root• Excessive root gap• Poor fit up• Excessive root grinding• Improper welding

technique



Root undercutRoot undercut

Causes• Root gap too large• Excessive arc energy• Small or no root face



Cap UndercutCap Undercut

Causes• Excessive welding

current• Welding speed too high• Incorrect electrode

angle• Excessive weave• Electrode too large



OverlapOverlap

Excess Excess weld weld

metalmetal



Lack of fusionLack of fusion

Causes• Contaminated weld preparation• Amperage too low• Amperage too high (welder increases speed of

travel)


Welding DefectsWelding DefectsIncompletely Filled GrooveIncompletely Filled Groove

& Lack of Side wall Fusion& Lack of Side wall Fusion

• Causes• Insufficient weld metal deposited• Improper welding technique



Inter run Incompletely Filled GrooveInter run Incompletely Filled Groove

Causes• Insufficient weld metal

deposited• Improper welding technique



Gas pores / PorosityGas pores / Porosity

Causes• Excessive moisture in flux or

preparation• Contaminated preparation• Low welding current• Arc length too long • Damaged electrode flux• Removal of gas shield



Gas pores / PorosityGas pores / Porosity



Inclusions - SlagInclusions - Slag

Causes• Insufficient cleaning between passes• Contaminated weld preparation• Welding over irregular profile• Incorrect welding speed• Arc length too long


Poor (convex) weld Poor (convex) weld bead profile resulted in bead profile resulted in pockets of slag being pockets of slag being trapped between the trapped between the weld runsweld runs

Smooth weld bead Smooth weld bead profile allows the profile allows the slag to be readily slag to be readily removed between removed between runsruns




Inclusions - TungstenInclusions - Tungsten

Causes• Contamination of weld Caused by tungsten

touching weld metal or parent metal during welding using the TIG welding process



Burn ThroughBurn Through

Causes• Excessive amperage during welding of root• Excessive root grinding• Improper welding technique



SpatterSpatter

Causes• Excessive arc energy• Excessive arc length• Damp electrodes• Arc blow



Arc StrikesArc Strikes

Causes

• Electrode straying onto parent metal

• Electrode holder with poor insulation

• Poor contact of earth clamp



Mechanical DamageMechanical Damage

Chisel MarksChisel MarksChisel Marks Pitting Corrosion Grinding Marks


Non-alignment of Non-alignment of two abutting two abutting edgesedges



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I C Plenty001

EXAMPLE WELD INSPECTION REPORT/SENTENCE EXAMPLE WELD INSPECTION REPORT/SENTENCE SHEETSHEET

SPECIMEN NUMBER

EXTERNAL DEFECTS Defects Noted

Code or Specification Reference

Defect Type Pipe/Plate Section

1

AccumulativeTotal

2

Maximum

Allowance3

Section/Table No

4

Accept/Reject5

Excess weld metal height

Excess weld metal appearance A-C Poor blend Smooth 19 Reject

Incomplete filling A-C 22mm None 8 Reject

Inadequate weld width A-C NONE ------------ ---------- Accept

Slag Inclusions A-C 1x 8mm long 2mm 3 Reject

Undercut A-C 1.5mm depth 1mm 11 Reject

Surface Porosity A-C 1.5mm 1mm 2 Reject

Cracks/Crack-like defects A-C 40mm NONE 1 Reject*

Lack of fusion A-C 22mm NONE 5 Reject

Arc strikes A-C 30x25 ------------ 12 Seek advise***

Mechanical damage A-C NONE ------------ ---------- Accept

Laps/Laminations A-C NONE ------------ ---------- Accept

Misalignment (Linear) A-C 2mm 2mm 9 Accept

Longitudinal seams A-C NONE ------------ ---------- Accept

PRINT FULL NAME

AC 4mm 3mm 15 Reject


Signature......................................................... Date.....................................................................................*Delete which is not applicable. Use the other side for any comments.

This *pipe/plate has been examined to the requirements of code/specification .........................................and is accepted/rejected accordingly.

TWI 09-09-03

22nd August 2003I C Plenty

Misalignment A-C 2mm 2mm 9 Accept

Excessive Root Penetration A-C 4mm 2mm 16 Reject

Incomplete Root Penetration A-C 50mm NONE 6 Reject

Lack of Root Fusion A-C 20mm NONE 5 Reject

Root Concavity A-C 2mm depth 1mm 20 Reject

Root Undercut A-C NONE ------------ ---------- Accept

Cracks/Crack-like defects A-C NONE ------------ ---------- Accept

Slag inclusions A-C NONE ------------ ---------- Accept

Porosity A-C NONE ------------ ---------- Accept

Laps/Laminations A-C NONE ------------ ---------- Accept

Root DefectsRoot Defects

Comments:* Request MPI testing to confirm crack and length.** Large amount of spatter on weld face. Recommend this is removed and re

inspected.*** Recommend arc strikes are ground flush prior to MPI testing for crack

detection.


No Imperfection Comments Allowance

1 Cracks Confirm with penetrant testing

Not permitted

2 Porosity Individual pore Ø Maximum 1mm

3 Solid Inclusions Non metallic. Individual size Maximum 1mm

4 Solid Inclusions Metallic. Individual size Not permitted

5 Lack of Fusion Side wall/Root/Inter-run Not permitted

6 Incomplete Root Penetration

Not permitted

7 Overlap/Cold lap Weld face/Root Not permitted

8 Incompletely filled groove Not permitted

9 Linear Misalignment 0.2t Maximum 4mm

10 Angular Misalignment Maximum 10º

11 Undercut Smoothly blended 10%t Maximum d 1mm

12 Arc Strikes Area to be tested by MPI Seek advice

13 Laminations Not permitted

14 Mechanical Damage Not permitted

15 Cap Height Shall fall below plate surface 0 –3mm h Maximum

16 Penetration Bead 0 –2mm h Maximum

17 Toe Blend Smooth

18 Spatter Clean & Re-inspect Refer to manufacturer

19 Weld Appearance All runs shall blend smoothly Regular

20 Root concavity 10%t Maximum

Inspection Practice Specification Inspection Practice Specification Number Number TWI 09-09-03 TWI 09-09-03 All dimensions are given in mmAll dimensions are given in mm


TWI CAMBRIDGE MULTI-PURPOSE WELDING GAUGE:


Visual Inspection of Welds Using the

Cambridge Multi-Purpose Welding Gauge:

Visual Inspection of Welds Using the

Cambridge Multi-Purpose Welding Gauge:


TWI CAMBRIDGE MULTI-PURPOSE WELDING GAUGE::

TWI CAMBRIDGE MULTI-PURPOSE WELDING GAUGE::Angle of preparation:Angle of preparation:

This scale reads from 00 to 600 in steps of 50. The angle is read against the chamfered edge of the plate or pipe.




The gauge may be used to measure misalignment of members by placing the edge of the gauge on the lower member and rotating the segment until the pointed finger contacts the higher member.

Linear Misalignment:Linear Misalignment:




The scale is used to measure excess weld metal or root penetration, by placing the edge of the gauge on the plate and rotating the segment until the pointed finger contacts the excess weld metal or root bead at its highest point.

Excess Weld Metal/Root penetration:Excess Weld Metal/Root penetration:




The gauge may be used to measure the depth of undercut by placing the edge of the gauge on the plate and rotating the segment until the pointed finger contacts the lowest depth of the undercut. The reading is taken on the scale to the left of the zero mark in mm or inches.

Undercut / mechanical damage (grinding etc)Undercut / mechanical damage (grinding etc)




Fillet Weld Actual Throat Thickness:Fillet Weld Actual Throat Thickness:

The small sliding pointer reads up to 20mm, or ¾ inch. When checking the throat you measure the actual throat thickness also note! that there is a ‘nominal’ design throat thickness,




Fillet Weld Leg Length:Fillet Weld Leg Length:

The gauge may be used to measure fillet weld leg lengths of up to 25mm, as shown

on left.


TWI CSWIP 3.0

INSPECTION OF FILLET WELDS

TWI CSWIP 3.0

INSPECTION OF FILLET WELDS


Fillet Weld InspectionFillet Weld Inspection

CSWIP 3.0 Fillet Welded T Joint

Part of the CSWIP 3.0 examination is to inspect & assess a Fillet welded Tee for it’s size & visual acceptance to the applicable code.

F 123


1. The plate reference number must be recorded in the top left hand corner of the report sheet, then the thickness of the plate must be measured and entered in the top right hand corner of the report sheet in the boxes provided.

Specimen Number F123 Material thickness: 6mm



2) Both the Vertical and Horizontal fillet weld leg lengths must be measured to find the minimum and maximum size’s. These values are entered in the boxes provided on the report sheet.

Use the gauge as shown below:


Fillet Weld Leg Length:

The gauge may be used to measure fillet weld leg lengths up to a maximum of 25mm, as shown on left.


3) The minimum and maximum throat thickness are measured and entered in the boxes provided on the report sheet.

These values are measured as shown below:


Fillet Weld Throat Thickness:

The small sliding pointer reads up to 20mm, or ¾ inch.

When measuring the throat it is supposed that the fillet weld has a nominal throat thickness, as an effective throat thickness cannot be measured in this manner.


Having made all the above measurements they can be assessed to a set of values that may be simply calculated from the plate thickness.


a) The minimum leg length size is the plate thickness

b) The maximum leg length size is:The plate thickness + 3mm

c) The minimum throat thickness is:The plate thickness x 0.7

d) The maximum throat thickness is:The plate thickness + 0.5mm


For example if the plate thickness is 6mm then the following will apply:


6mmF 123

a) The minimum leg length size is 6mm (Plate thickness)

b) The maximum leg length size is 9mm(Plate thickness + 3mm)

c) The minimum throat thickness is 4.2mm(Plate thickness x 0.7)

d) The maximum throat thickness is 6.5mm (Plate thickness + 0.5mm


This means that the measurements taken must fall inside BOTH the tolerances calculated i.e.

Leg lengths must be between 6mm – 9mm

Throat thickness must be between 4.2 and 6.5mm

If all the values are within these tolerances they are acceptable. If any of the values fall outside of the calculated tolerances then it becomes unacceptable.

It is important to remember that any change in thickness will change the acceptance values calculated above.



Vertical Leg LengthLowest leg measurement 7mmHighest leg measurement 8mm

Actual Throat ThicknessLowest throat measurement 4.5mmHighest throat measurement 8mm

Horizontal Leg LengthLowest leg measurement 5mmHighest leg measurement 10mm



Practical Exam Report Sheet

Specimen Number F123 Material thickness: 6mm 1) Measure and record the following details: VERTICAL LEG LENGTH (Max & Min) = Max 8mm Min 7mm

HORIZONTAL LEG LENGTH (Max & Min) = Max 10mm Min 5mm

DESIGN THROAT THICKNESS (Max & Min) = Max 8mm Min 4.5mm



2) Sentence the fillet weld dimensions using the following design criteria: MINIMUM LEG LENGTH: Material thickness (6mm)MAXIMUM LEG LENGTH: Material thickness + 3mm (9 mm) MINIMUM THROAT THICKNESS: Material thickness x 0.7 (4.2 mm)MAXIMUM THROAT THICKNESS: Material thickness + 0.5mm (6.5 mm)

The VERTICAL LEG LENGTH Please state: ACCEPT ACCEPT or REJECT?

The HORIZONTAL LEG LENGTH Please state: REJECT ACCEPT or

REJECT? The THROAT THICKNESSPlease state: REJECT ACCEPT or REJECT?



Having assessed the weld for its size an inspection can then be made on the surface to locate any imperfections. Firstly; the report sheet requests the inspector to indicate the number of locations that the following imperfections occur, if any? 3) The number of places that they occur should now be entered in the box as follows: UNDERCUT APPEAR? 3 placesOVERLAP APPEAR? None LACK OF FUSION APPEAR? NoneCRACKS APPEAR? None POROSITY APPEAR? 2 AreasSOLID INCULSIONS? 1 Slag InclusionMISC: [ARC STRIKES etc] Spatter



4) For the defects recorded state: MAXIMUM length (and DEPTH if applicable) of each defect

UNDERCUT: Length: 15 mm Depth:

Smooth 1.0mm OVERLAP: Length: -------- Depth: --------- LACK OF FUSION:Length: -------- Depth: --------- CRACKS: Length: -------- Depth: ---------

POROSITY: Length: 6mm Depth: Maximum Ø SOLID INCLUSIONS: Length: 4mm Depth: ---------

MISC:[ ARC STRIKES] Length: Spatter Depth: ---------



5) Then, assess the levels of imperfections allowed by the applicable code which is provided:

UNDERCUT: ACCEPT (Accept or

Reject?)OVERLAP: ACCEPT (Accept or

Reject?)LACK OF FUSION: ACCEPT (Accept or

Reject?)CRACKS: ACCEPT (Accept or Reject?)POROSITY: REJECT (Accept or Reject?)SOLID INCLUSION: REJECT (Accept or Reject?)MISC: [ARC STRIKES] REJECT* (Accept or Reject?)

* All spatters should have been removed prior to submission for inspection



6) Finally accept or reject the weld used for your visual inspection as follows:

IS THE WELD ACCEPTABLE? NO YES/NO?

Signature: I C Plenty

Name: I C Plenty

Date: 01-01-04

This now completes the Fillet Welded T Joint Inspection Assessment.


twi cswip visual inspection of weld

Documents

pointed finger

materials

welding defectslamellar

tungsten inert

welding defectshydrogen

metal inert

fillet weld

actual throat