You are on page 1of 36

MACRO-SECTION. TWI CSWIP 3.

WELDING INSPECTION MACRO-SECTION. PRACTICAL


Section 25.
World Centre for Materials Joining Technology
Copyright 2005, TWI Ltd

MACRO SECTIONS
1. ASSESS THE MACRO PHOTOGRAPH FOR WELD DEFECTS. 2. RECORD THE MAJOR DEFECTS ON THE REPORT SHEET. 3. SENTENCE THE DEFECTS RECORDED TO THE ACCEPTANCE CRITERIA GIVEN.

4. FOLLOW THE INSTRUCTIONS.


PLEASE DO NOT MARK THE PHOTOGRAPHS.
World Centre for Materials Joining Technology
Copyright 2005, TWI Ltd

MACRO INSTRUCTIONS.

World Centre for Materials Joining Technology


Copyright 2005, TWI Ltd

MACRO DEFECTS.
50mm

3mm ANGULAR DISTORTION = 3mm in 50mm


World Centre for Materials Joining Technology
Copyright 2005, TWI Ltd

MACRO DEFECTS.
INCOMPLETLEY FILLED GROOVE

1.5mm

MISALIGNMENT

World Centre for Materials Joining Technology


Copyright 2005, TWI Ltd

MACRO DEFECTS.
COLD LAP & POOR TOE BLEND GAS PORE / BLOW HOLE EXCESSIVE WELD METAL COLD LAP & POOR TOE BLEND

World Centre for Materials Joining Technology


Copyright 2005, TWI Ltd

Macro defects
INCOMPLETELY FILLED GROOVE

World Centre for Materials Joining Technology


Copyright 2005, TWI Ltd

MACRO DEFECTS.
LACK OF SIDE WALL FUSIO N LACK OF SIDE WALL FUSION & SLAG LACK OF SIDE WALL FUSION / INCOMPELTELY FILLED GROOVE

World Centre for Materials Joining Technology


Copyright 2005, TWI Ltd

MACRO DEFECTS.
COLD LAP LACK OF SIDEWALL FUSION / INCOMPLETELY FILLED GROOVE

GAS PORES

LACK OF ROOT FUSION


World Centre for Materials Joining Technology
Copyright 2005, TWI Ltd

MACRO DEFECTS.
INCOMPETELY FILLED GOOVE

SLAG INCLUSION GAS PORE

LACK OF ROOT FUSION


World Centre for Materials Joining Technology
Copyright 2005, TWI Ltd

MACRO DEFECTS.
LACK OF SIDEWALL FUSION LACK OF SIDEWALL FUSION & SLAG LACK OF SIDEWALL FUSION LACK OF ROOT PENETRATION
World Centre for Materials Joining Technology
Copyright 2005, TWI Ltd

LACK OF SIDEWALL FUSION

MACRO SECTIONS

QUESTIONS.

World Centre for Materials Joining Technology


Copyright 2005, TWI Ltd

MACRO DEFECTS.
LACK OF SIDEWALL FUSION CLUSTER / WORMHOLE POROSITY LAMINATIONS

LACK OF INTER-RUN FUSION & SLAG

LACK OF SIDEWALL FUSION & SLAG


ROOT UNDERCUT

LACK OF INTER-RUN FUSION


GAS PORES

World Centre for Materials Joining Technology


Copyright 2005, TWI Ltd

MACRO SAMPLE.
WELDING PROCESS : MAG

1 COLD LAP

5 LACK OF SIDEWALL FUSION


2 LACK OF SIDEWALL FUSION & GAS / SILICA

4 LACK OF INTERRUN FUSION

World Centre for Materials Joining Technology


Copyright 2005, TWI Ltd

3 COLD LAP

MACRO
NOTE: PHOTOGRAPH IS AT X10 MAGNIFICATION MATERIAL: LOW CARBON STEEL WELDING PROCESS: [MAG/GMAW]

8
# 1 2 3 4 5 6 7 8 9 10 11 12

DEFECT POOR TOE BLEND OVERLAP + 2 SMALL PORES LAMINATIONS/INCLUSIONS LACK OF SIDE WALL FUSION AS ABOVE +PORES OVERLAP LACK OF INTERRUN FUSION GAS PORE/PIPE LACK OF SIDE WALL FUSION + SILICA ANGULAR MISALIGNMENT EXCESS WELD METAL EXCESS PENETRATION

9 7 6

1 5 3

2
4

SIZE

ACCEPT/REJECT

Assess To Specification

World Centre for Materials Joining Technology


Copyright 2005, TWI Ltd

MACRO ACCEPTANCE.

World Centre for Materials Joining Technology


Copyright 2005, TWI Ltd

MACRO EXCERCISES.AM1030
TRAINING SAMPLE ONLY
MACRO INSTRUCTION/REPORT SHEET [I.D: AM1030]
CHECK PHOTOGRAPH I.D MATCHES THIS REPORT I.D ALL DEFECTS TO BE REPORTED [AND SIZED IF REQUIRED] THEN SENTENCED TO ISO 5817 LEVEL B [STRINGENT] NOTE: PHOTOGRAPH IS AT X10 MAGNIFICATION MATERIAL: LOW CARBON STEEL WELDING PROCESS: [MMA/SMAW]

8 7 4

6 5

1
2

3 World Centre for Materials Joining Technology


Copyright 2005, TWI Ltd

MACRO EXCERCISES. AM 1030


# 1 2 3 4 5 6 7 8 9 10 11 12 DEFECT
Lack of side wall fusion and slag Misalignment Lack of root penetration Angular distortion Lack of side wall fusion Lack of inter run fusion and slag Lack of side wall fusion Excess weld metal

SIZE
8.6 0.2 N/A 0.5 2.5 4.2 2.5 3.2

ACCEPT/REJECT
Reject Accept Reject Accept Reject Reject Reject Reject

COMMENTS:

SIGNATURE: PRINT FULL NAME:

DATE:

World Centre for Materials Joining Technology


Copyright 2005, TWI Ltd

MACRO EXCERCISES. AM 1031


TRAINING SAMPLE ONLY
MACRO INSTRUCTION/REPORT SHEET [I.D: AM1031]
CHECK PHOTOGRAPH I.D MATCHES THIS REPORT I.D ALL DEFECTS TO BE REPORTED [AND SIZED IF REQUIRED] THEN SENTENCED TO ISO 5817 LEVEL B [STRINGENT] NOTE: PHOTOGRAPH IS AT X10 MAGNIFICATION MATERIAL: LOW CARBON STEEL WELDING PROCESS: [MMA/SMAW]

1
2 6

7 5

3
4

World Centre for Materials Joining Technology


Copyright 2005, TWI Ltd

MACRO EXCERCISES. AM 1031


# 1 2 3 4 5 6 7 8 9 10 11 12 DEFECT
Lack of side wall fusion/ underfill Lack of side wall fusion and slag Cold lap Misalignment Excess penetration Cold lap Slag inclusion Cold lap Excess weld metal

SIZE
0.7 7.5 0.5 1.8 3.3 0.3 0.7 0.5 3.5

ACCEPT/REJECT
Reject Reject Reject Reject Reject Reject Accept Reject Reject

COMMENTS:

SIGNATURE: PRINT FULL NAME:

DATE:

World Centre for Materials Joining Technology


Copyright 2005, TWI Ltd

MACRO EXCERCISES. AM 1032


MACRO INSTRUCTION/REPORT SHEET [I.D: AM1032]
CHECK PHOTOGRAPH I.D MATCHES THIS REPORT I.D ALL DEFECTS TO BE REPORTED [AND SIZED IF REQUIRED] THEN SENTENCED TO ISO 5817 LEVEL B [STRINGENT] NOTE: PHOTOGRAPH IS AT X10 MAGNIFICATION MATERIAL: LOW CARBON STEEL WELDING PROCESS: [MMA/SMAW]

8 1 2

World Centre for Materials Joining Technology


Copyright 2005, TWI Ltd

4 5 7 6

MACRO EXCERCISES. AM 1032


# 1 2 3 4 5 6 7 8 9 10 11 12 DEFECT
Lack of side wall fusion/underfill Lack of sidewall fusion & Slag Lack of side wall fusion & slag Slag inclusion Cold lap Misalignment Excess penetration Excess weld metal

SIZE
0.5 2.8 4.5 1.5 0.3 1.8 2.0 3.3

ACCEPT/REJECT
Reject Reject Reject Reject Reject Reject Accept Reject

COMMENTS:

Plate laminations noted

SIGNATURE: PRINT FULL NAME:

DATE:

World Centre for Materials Joining Technology


Copyright 2005, TWI Ltd

MACRO EXCERCISES. AM 1033


TRAINING SAMPLE ONLY MACRO INSTRUCTION/REPORT SHEET [I.D: AM1033] CHECK PHOTOGRAPH I.D MATCHES THIS REPORT I.D ALL DEFECTS TO BE REPORTED [AND SIZED IF REQUIRED] THEN SENTENCED TO ISO 5817 LEVEL B [STRINGENT] NOTE: PHOTOGRAPH IS AT X10 MAGNIFICATION MATERIAL: LOW CARBON STEEL WELDING PROCESS: [MAG/GMAW]

8 7

1 6

World Centre for Materials Joining Technology


Copyright 2005, TWI Ltd

5 4 3

MACRO EXCERCISES. AM 1033


# 1 2 3 4 5 6 7 8 9 10 11 12 DEFECT
Cold Lap/ Overlap Lack of sidewall fusion & gas Cold lap / Overlap Misalignment Lack of interrun fusion & gas Lack of sidewall fusion Blow hole Excess weld metal

SIZE
2.8 8.0 0.3 0.6 2.0 2.6 1.5 5.0

ACCEPT/REJECT
Reject Reject Reject Accept Reject Reject Reject Reject

COMMENTS:

Plate laminations noted Poor toe blend

SIGNATURE: PRINT FULL NAME:

DATE:

World Centre for Materials Joining Technology


Copyright 2005, TWI Ltd

MACRO EXCERCISES. AM 1034


TRAINING SAMPLE ONLY MACRO INSTRUCTION/REPORT SHEET [I.D: AM1034] CHECK PHOTOGRAPH I.D MATCHES THIS REPORT I.D ALL DEFECTS TO BE REPORTED [AND SIZED IF REQUIRED] THEN SENTENCED TO ISO 5817 LEVEL B [STRINGENT] NOTE: PHOTOGRAPH IS AT X10 MAGNIFICATION MATERIAL: LOW CARBON STEEL WELDING PROCESS: [MMA/SMAW]

10

1
8 2

7
World Centre for Materials Joining Technology
Copyright 2005, TWI Ltd

3
6 5 4

MACRO EXCERCISES. AM 1034


# 1 2 3 4 5 6 7 8 9 10 11 12 DEFECT
Lack of sidewall fusion & slag Lack of sidewall fusion Lack of inter-run fusion & slag Angular distortion Misalignment Excess penetration Lack of inter-run fusion & slag Lack of side wall fusion Spatter Excess weld metal

SIZE
2.8 1.0 2.0 6in13 0.5 0.1 5.5 5.0 0.1 3.6

ACCEPT/REJECT
Reject Reject Reject Accept Reject Reject Reject Reject Accept Reject

COMMENTS:

Plate laminations noted Poor toe blend

SIGNATURE: PRINT FULL NAME:

DATE:

World Centre for Materials Joining Technology


Copyright 2005, TWI Ltd

Macro defects

World Centre for Materials Joining Technology


Copyright 2005, TWI Ltd

Macro defects

World Centre for Materials Joining Technology


Copyright 2005, TWI Ltd

Macro defects

World Centre for Materials Joining Technology


Copyright 2005, TWI Ltd

Macro defects

World Centre for Materials Joining Technology


Copyright 2005, TWI Ltd

Macro defects

World Centre for Materials Joining Technology


Copyright 2005, TWI Ltd

Macro defects

World Centre for Materials Joining Technology


Copyright 2005, TWI Ltd

Macro defects

World Centre for Materials Joining Technology


Copyright 2005, TWI Ltd

Macro defects

World Centre for Materials Joining Technology


Copyright 2005, TWI Ltd

Macro defects

World Centre for Materials Joining Technology


Copyright 2005, TWI Ltd

Macro defects

World Centre for Materials Joining Technology


Copyright 2005, TWI Ltd