TYPICAL WELDING FAULTS

Typical Welding Faults

Unmelted edge Undercutt

Root faults Fusion faults Slag inclusions Pores Cracks

Typical Welding Faults

Typical Welding Faults

Typical Welding Faults

Root faults Edge preparation

35 70 1,5mm 2-2,5mm

Typical Welding Faults

Root faults Amperage setting

Manipulating electrode

Typical Welding Faults

Fusion faults Amperage setting Too low amperage setting

Manipulating electrode
90

Edge preparation Included angle not sufficient

Typical Welding Faults

Fusion faults

Typical Welding Faults

Slag inclusions Amperage setting Manipulating electrode Placing of runs

Trapped slag

Manipulating electrode

Not removing slag

Typical Welding Faults

Trapped slag

Typical Welding Faults

Pores Hydrogen pores From moist electrodes Other sources are: Rust, oil, paint or condensation along welding groove

N2

O2

O2 N2

Oxygen pores Long arc or other reasons for insufficient arc shielding

Typical Welding Faults

Bead Crown

Reinforcement: 1,6 mm for manual welding 3,2 mm for automated welding

Typical Welding Faults

Stresses are distributed more uniformly through a flat or concave fillet weld.

Typical Welding Faults

Fusion faults

Typical Welding Faults

Fusion faults

Typical Welding Faults

Max undercut according to ASME: Undercut deeper than 0,8 mm and longer than 6 mm is unacceptable Undercut less than 0,8 mm but longer than 6 mm must be evaluated form case to case depending on circumstances

Typical Welding Faults

Heat Cracks
Impurities in base material Tension across weld

Cold Cracks
Hydrogen cracks HAZ cracks

Shrinkage Cracks
Lengthwise shrinkage

Typical Welding Faults

Fusion faults

Typical Welding Faults

Fusion faults

Typical Welding Faults.

Spray on Cleaner

Apply Penetrant

Wipe surface clean

Spray on Developer

Inspect

Defects will show as bright red lines in white developer

Typical Welding Faults.

Typical Welding Faults

Magna Flux Crack Detection Kit 3 pcs. Cleaner 2 pcs. Penetrant 3 pcs. Developer Cleaner SKC-S 10 pcs. of 400 ML in box Penetrant SKL-SP1 10 pcs. of 400 ML in box Developer SKD-S2 10 pcs of 400 ML in box 193-653535

193-653543 193-653550 193-653568

Typical Welding Faults

Typical Welding Faults

Typical Welding Faults

INSPEKSJON AV SVEISEARBEID
FR SVEISING Er grunnmaterialet i henhold til spesifikasjon? Kvalitet Type Dimensjon Primer Er overflaten fri for rust, olje, fett eller annen forurensning? Er materialflatene rette/i fasong, og uten skr? Er fugeforbindelsen i henhold til spesifikasjon? ( vinkler, nesehyde, rotpning) Er sveisemetoden i henhold til spesifikasjon? (Elektroder,TIG,MIG/MAG,UP) Er tillsettmaterialet ( Elektroder, trd, pulver ) I henhold til spesifikasjon? (AWS,EN) Er tilsettet godkjent i klasseselskap? (DNV,ABS,BV,GL,LR) Er gradering korekt? ( 3Y H10 for skrogkvalitet stl ) Er godkjennelsen oppdatert? Har tilsettmaterialet blitt lagret korekt? Elektroder,trd og pulver skal lagres i upnede originale forpakninger 15- 25C Max 50% Relativ fuktighet >25C Max 40% Relativ fuktighet Er det krav til forvarming av tilsettet fr sveising? Basiske og rustfrie elektroder kan for kritiske aplikasjoner forvarmes til 300- 350C i 2 timer Har sveiseren den ndvendige kompetanse/ Godkjennelse?

INSPECTION OF WELDED JOINTS

Quality Type Dimension Primer Is the surface free for rust, oil, grease or any other contamination? Is the material straight/ the right shape, and without cuts? Is the edge preparation according to specification? ( angels, root face, root opening) Is the welding method according to specification? (Electrode,TIG,MIG/MAG,UP) Is the consumable( Electrodes, wire, flux ) according to specification? (AWS,EN) Is the consumable approved by the classification society? (DNV,ABS,BV,GL,LR) Is the grading to standard? ( 3Y H10 for ship quality steel ) Is the approval up to date? Has the consumable been correctly stored? Electrodes, wire and flux must be stored in unopened original containers 15- 25C Max 50% Relative humidity >25C Max 40% Relative humidity Is there a requirement for re-drying of consumables before use? Basic and stainless electrodes can for critical applications be heated to 300- 350C for 2 hours Dos the welder have the necessary approval for the work at hand? PRIOR TO WELDING Is the base material according to specification?

INSPEKSJON AV SVEISEARBEID
UNDER SVEISING Er det krav til forvarming av grunnmaterialet fr sveising?( Ce + Tykkelse) Kontroller at sveiseparameterne er i henhold til sveiseprosedyren (polaritet, ampere, volt etc) Blir mellomlagstemperaturen overholdt? ( interpas temperature ) Ved flerlags sveis, sjekk rotstrengen for full gjennombrenning Inspiser hvert lag fr neste lag ( pse god rengjring mellom lagene) Er det krav til varmebehanling etter sveising?

Underkutt

ETTER SVEISING Kontroller sveisens overflate for sprekker, porer, slagginnslutninger, underkutt samt at endekratere er fylt. Kontroller dimensjonelle variasjoner ved hjelp av skyvelret Kontroller A- ml for: Oversveising Undersveising Maks underkutt I henhold Kontroller likebenhet til ASME: Kontroller konveksitet Underkutt dypere en 0,8 mm
og lenger en 6 mm er uakseptabelt Overhyde: 1,6 mm for manual sveising 3,2 mm for automatisert sveising Underkutt mindre en 0,8 mm men lenger en 6 mm m vurderes fra sak til sak avhengig av forholdene

Flat eller konkav

Konveks

INSPECTION OF WELDED JOINTS

DURING WELDING Is there a requirement for pre-heating of base material before welding?(Ce + thickness) Control that the welding parameters are in accordance with the welding procedure (polarity, amperage, voltage) Are the interpass temperature requirements followed ? When doing multi-layer welding, check that the root run have full penetration Inspect every run before next run ( clean for slag between layers) Is there a requirement for post weld heat treatment? Undercut AFTER WELDING Inspect the weld surface for cracks, porosity, slag inclusions, undercut and that end crater is filled. Check dimensional variations using a welders gauge Check that reinforcement is sufficient but not to high Check equal leg length Check for convexity
Reinforcement: 1,6 mm for manual welding 3,2 mm for mechanized welding Max undercut according to ASME: Undercut deeper than 0,8 mm and longer than 6 mm is unacceptable Undercut less than 0,8 mm but longer than 6mm must be evaluated from case to case

Flat or concave

Convexity