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Phased

Array UT
Destructive
Testing
CWI Ethics
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January 2012 / Vol. 15 / No. 1
THE MAGAZINE FOR MATERIALS INSPECTION AND TESTING PERSONNEL
Cover 2 Jan 2012_IT Spring 4/06 12/27/11 12:23 PM Page C1
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olympus ndt_FP_TEMP 12/20/11 3:00 PM Page C2
Vol. 15 / No. 1
Features
20
Using Phased Array Ultrasonics for Detecting and Sizing Cracks in
Welds
by Michael Moles / The latest phased array technology and how it can be
used for detecting and sizing cracks is explained / 14
Destructive Testing Basics
by J. R. Coulstring III / Details are provided on the types of destructive
tests and how they are used for welder performance qualification / 20
Ethics Alert: Certified vs. Qualified
by Joseph P. Kane / The article stresses the importance of the proper use of
terminology / 24
Departments
Editors Note................................6
News Bulletins.............................8
Print and Product Showcase ......12
The Answer Is ............................26
Mark Your Calendar...................29
Certification Schedule................30
Just the Facts..............................31
Mail Bag ....................................33
Technology Notes ......................34
Advertiser Index ........................36
Inspection Trends / Winter 2012 5
INSPECTION TRENDS (ISSN 1523-7168) is
published quarterly by the American Welding
Society. Editorial and advertising offices are located
at 550 NW LeJeune Rd., Miami, FL 33126;
telephone (305) 443-9353. Printed by R. R.
Donnelley & Sons Co., Senatobia, Miss.
Subscriptions $30.00 per year for noncertified,
nonmembers in the United States and its
possessions; $50.00 per year in foreign countries;
$20.00 per year for noncertified members and
students; $10.00 single issue for nonmembers and
$7.00 single issue for members. American Welding
Society is located at 550 NW LeJeune Rd., Miami,
FL 33126-5671; telephone (305) 443-9353.
Periodicals postage paid in Miami, Fla., and
additional mailing offices.
POSTMASTER: Send address changes to
Inspection Trends c/o American Welding Society,
550 NW LeJeune Rd., Miami, FL 33126-5671.
Readers of Inspection Trends may make copies of
articles for personal, archival, educational, or
research purposes, and which are not for sale or
resale. Permission is granted to quote from articles,
provided customary acknowledgment of authors
and sources is made. Starred (*) items excluded from
copyright.
AWS MISSION STATEMENT
The mission of the American Welding Society
is to advance the science, technology, and
application of welding and allied processes
worldwide, including joining, brazing, soldering,
cutting, and thermal spraying.
An OmniScan MX is used to perform
manual phased array inspection of
large-diameter pipe welds. (Photo
courtesy of Olympus NDT, Waltham,
Mass.)
TOC Layout January 2012_Layout 1 12/22/11 10:58 AM Page 5
Editors Note
By Mary Ruth Johnsen
Dear Readers,
The heart of the American
Welding Society is its volunteers.
That holds true throughout every
segment of the Society, whether
were talking about the people who
accept leadership roles in their local
Sections; the industry experts who
shape AWS standards and
specifications by taking positions on
the technical committees; or the long-time members who guide AWS by
becoming part of the organizations national leadership.
Inspection Trends is no exception: Volunteers have influenced this
magazine and supplied content for it since its very first issue.
In fact, Inspection Trends has been blessed by the constancy of its
volunteers. AWS published the inaugural issue of Inspection Trends in
summer 1998, and Ken Erickson began answering questions for The
Answer Is column that same issue. This issue starts his fifteenth year as
a regular part of this magazine. Both he and Kip Mankenberg, who
joined Ken as part of The Answer Is team with the Winter 2000 issue,
also provided articles for that first issue.
Lyndsey Deckard became an every issue contributor beginning with
the Fall 2001 Inspection Trends. Lyndsey first wrote the Exam Bank
column then took over Just the Facts in Spring 2004.
With this issue, youll see a change in The Answer Is. Because of a
heavy work load, Kip Mankenberg recently informed me he cant
continue working on the column. However, he recommended Al Moore
for the job, and fortunately Al accepted. Al has written quite a few
feature articles for the magazine over the past couple of years, so you
probably already recognize the depth of his knowledge.
In this issue, were also starting a new series related to the ethics of
being a CWI written by Joe Kane in collaboration with other members
of the Subcommittee on the Code of Ethics. Kane, a long-time member
of and now an advisor to the AWS Certification Committee, has
contributed other articles to Inspection Trends over the years.
Their work on this magazine isnt the only contribution these
gentlemen make to the American Welding Society. Like Kane, most are
members are other committees, are officers of their local Sections, or
both. So why do they commit all this time to the magazine and AWS,
when they have full schedules already? Well, it sure isnt for the pay
they dont receive any. Its not for the fame we dont even run their
photos in the magazine. And its not because Im their buddy Ive
met Kip, Lyndsey, Al, and Joe in person, but Ken and I know each other
only through e-mail. They seem to have purely altruistic intentions:
They take pride in their profession and want to help others who do what
they do be the best they can be at it.
I know this magazine and its readers have benefited from their
knowledge, experience, and willingness to share. I thank them for their
time and loyalty to AWS; they make my job much easier.
If youd like to join their ranks, please contact me at
mjohnsen@aws.org or (800) 443-9353, ext. 238.
Publisher
Andrew Cullison
cullison@aws.org
Editor
Mary Ruth Johnsen
mjohnsen@aws.org
Associate Editors
Howard Woodward
woodward@aws.org
Kristin Campbell
kcampbell@aws.org
Production Editor
Zaida Chavez
zaida@aws.org
Senior Production Coordinator
Brenda Flores
bflores@aws.org
National Sales Director
Rob Saltzstein
salty@aws.org
Advertising Sales Representative
Lea Paneca
lea@aws.org
Senior Advertising Production Manager
Frank Wilson
fwilson@aws.org
Subscriptions Representative
Sylvia Ferreira
sferreira@aws.org
American Welding Society
550 NW LeJeune Rd.
Miami, FL 33126
(800/305) 443-9353
Copyright
Copyright 2012 by American Welding Society in both
printed and electronic formats. The Society is not
responsible for any statement made or opinion expressed
herein. Data and information developed by the authors of
specific articles are for informational purposes only and
are not intended for use without independent,
substantiating investigation on the part of potential users.
Inspection Trends / January 2012 6
Editor's Note IT Winter 2012_Layout 1 12/22/11 10:22 AM Page 6
June 1213, 2012 / San Diego, Calif.
Register early and save.
Earn PDHs toward your AWS recertification when you attend the conference.
For the latest conference information and registration, visit our web site
at www.aws.org/conferences or call (800) 443-9353, ext. 264.
AWS Conference on
The Energy Boom:
Get on the Bandwagon
Register early and save.
June 1213, 2012 / San Diego, Calif.
Register early and save.
June 1213, 2012 / San Diego, Calif.

June 1213, 2012 / San Diego, Calif.

at www
For the latest conference information and registration, visit our web site
Earn PDHs toward your

.aws.org/conferences or call (800) 443-9353, ext. 264. at www
For the latest conference information and registration, visit our web site
WS recertification when you attend the conference A Earn PDHs toward your
Register early and save.
.aws.org/conferences or call (800) 443-9353, ext. 264.
For the latest conference information and registration, visit our web site
WS recertification when you attend the conference
Register early and save.
.aws.org/conferences or call (800) 443-9353, ext. 264.
For the latest conference information and registration, visit our web site
WS recertification when you attend the conference
Register early and save.
.aws.org/conferences or call (800) 443-9353, ext. 264.
For the latest conference information and registration, visit our web site
. WS recertification when you attend the conference

energy conf_FP_TEMP 12/20/11 3:25 PM Page 7
News Bulletins
Inspection Trends / January 2012 8
Laser, Video, and Ultrasonic Technology
Combined to Inspect Pipe Root Welds
A combination of laser, video, and ultrasonic inspection
methods were recently used in a production environment to
inspect the profile of root welds on pipes. The inspections
were performed by UK-based Optical Metrology Services
Ltd. (OMS). The company believes this was the first time
these methods have been used in combination in the oil and
gas industry.
The company was responsible for assessing the internal
root welds for any defects. Inspection requirements covered
the full range of weld features including crown height,
undercut, porosity, and melt-through. The on-site inspectors
were required to perform the inspection at weld temperatures
(i.e., up to 482F). The company adapted its own weld
inspection technology to enable it to operate at those elevated
temperatures. Cold, compressed air was blown over the
inspection tool to combat the welding temperatures. A video
camera was then used in combination with a shaft encoder to
further inspect areas for potential weld defects.
AWS agreement with
ASNT offers ACCP to
qualified CWIs & SCWIs.
Do you need visual testing certification
which meets the guidelines for Recommended
Practice No. SNT-TC-1A as required by some
sections of the ASME Code? Through this
agreement, qualified SCWIs and CWIs
can obtain ACCP Level II VT certification
without examination.
Enhance your credentials and satisfy
work requirements with the addition
of an ACCP credential.
To apply and for more details visit
www.asnt.org or call 614.274.6003
or 800.222.2768 US/Canada.
Opportunity Knocks.
Image Longview Inspection
Optical Metrology Services designed a laser-based
measurement system that incorporated a slide rail, stepper
motor, and optical laser sensor to inspect pipe root welds.
This allowed the tool to be pushed in half-millimeter steps
through the pipes to inspect the profiles of the welds.
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News Bulletins Winter IT 2012_Layout 1 12/22/11 10:37 AM Page 8
On this project, the pipes on the modular valve
manifold system were almost entirely lined with a special
corrosion-resistant material, explained Richard Gooch,
OMS director of technology. Our team of three inspectors,
therefore, had to make sure they didnt overheat these
coatings while carrying out inspections. On average, it was
taking the customer around four days to complete a weld root
pass. If there were flaws in a weld, they would have to be
repaired or cut out. Our inspections carried out their
inspections immediately after the hot pass.
The initial inspection took about 10 min to complete. At
that time, the company gave its initial verdict on whether it
thought there was a problem with the root weld. If we were
uncertain, the laser inspection procedure was repeated, but
this time at finer detail (every 0.5 mm) than before and
double-checked using video-based inspection technology.
The depth of the weld feature could then be examined more
closely and a final verdict reached, Gooch said.
Starna Scientific Appoints Director
Starna Scientific, a manufacturer of spectroscopy
equipment, recently appointed Nathan Hulme as a director to
help guide the companys expansion plans.
Hulmes main responsibilities will include assisting in
setting out an overall business strategy for the company that
will address communications with customers and dealers as
well as involving leadership of the sales team.
Stork Materials Technology Changes
Name to Element
Stork Materials Technology recently changed its name to
Element Materials Technology. The company will specialize
Inspection Trends / Winter 2012 9
ASNT,
Bringing Thousands of Minds
To NDT Matters, Including Yours.
Join the Professional Society
That Brings the NDT Community &
Its Resources To You.
The American Society for Nondestructive Testing
Serving the Profession,
Creating a Safer World. www.asnt.org
Nathan Hulme
For info go to www.aws.org/ad-index
News Bulletins Winter IT 2012_Layout 1 12/22/11 10:37 AM Page 9
in materials testing, product qualification testing, and failure
analysis for the aerospace and defense, oil and gas, power
generation, and transportation sectors. In this final step
venturing away from the Stork Group, Element becomes an
independent materials technology company in its own right
with more than 180 years of experience.
Element has a team of 1000 scientists, engineers, and
technicians working in laboratories located throughout the
United States and Europe. More information is available at
www.element.com.
Strategic Alliance Formed for Work at
Fossil-Fueled Power Plants
Structural Integrity Associates, Inc., San Jose, Calif., a
leader in inspection and assessment of critical components in
the power generation industry, recently signed a
memorandum of understanding with Wachs Energy Services
Co., a construction and technical services company,
establishing a strategic alliance between the two companies.
The alliance address the remediation and repair of damaged
critical pressure parts and the fabrication and installation of
new pressure part systems in conventional fossil-fired and
combined-cycle power plants.
In partnership with WES, we can now provide turnkey,
optimized solutions, including full-field implementation for
the emergency repair or replacement of any components
determined to be unfit for continued operation as well as the
design, fabrication, and erection of critical systems with a
particular emphasis on the new advanced creep strength
enhanced ferritic steels, e.g., P91, said Laney Bisbee, CEO
of Structural Integrity Associates.
The two companies have provided critical component
repair and systems fabrication to many fossil plants
worldwide.
GE to Expand Inspection Technologies
Headquarters
GE recently announced it will invest more than $10
million to expand its Inspection Technologies headquarters
site in Lewistown, Pa. Key features of the project include a
new global customer applications center and a nondestructive
testing academy for GE employees and customers.
The 52,000-sq-ft expansion project will increase the
facilitys floor space by more than 63% and is scheduled to
be completed this year. The company manufactures a wide
range of remote visual inspection, ultrasonic,
electromagnetic, advanced radiography, and computed
tomography systems, as well as data management software.
GEs Inspection Technologies business sees composites;
weld inspections and corrosion monitoring for bridges,
Inspection Trends / January 2012 10
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News Bulletins Winter IT 2012_Layout 1 12/22/11 10:38 AM Page 10
pipelines, and other structures; and rotating machinery
including jet engines and wheels as key growth areas.
Online Visual Inspection Course Available
Hobart Institute of Welding Technology, Troy, Ohio, has
introduced an online visual inspection course. The course
provides 1.4 continuing education credits and costs $195.
Topics covered include temperature indicators;
equipment requirements; terminology of weld defects;
general requirements for workmanship standards; making
repair welds; codes, procedures, and qualifications related to
visual inspection; and a visual inspection checklist.
Information is available at www.welding.org.
Extech Instruments Moves to New Hampshire
Extech Instruments/FLIR Systems recently moved to a
new headquarters building in Nashua, N.H. The opening of
the new facility signifies a milestone in Extech and Flirs
transition toward a unified organization.
The companies manufacture thermal imagers and a
variety of hand-held test and measurement instruments.
The new headquarters is located at 9 Townsend W.,
Nashua, NH 03063-1233.
AcousticEye Appoints New CEO
AcousticEye, Leusden, The Netherlands, recently
appointed Yoav Harel as chief executive officer. The
company produces equipment for noninvasive tube
inspection for the global heat exchanger industry.
Harel has more than 20 years experience leading both
startups and established companies. In his most recent
position, Harel was president for Europe and North America
at Orbotech.
TV Rheinland Opens NDE Services
Laboratory in Alabama
In an effort to expand its presence in the southern United
States, TV Rheinland Industrial Solutions, Inc., a subsidiary
of TV Rheinland North America Holding, Inc., recently
commisioned a new nondestructive examination laboratory in
Decatur, Ala. The new 8000-sq-ft facility will be equipped
with a variety of NDE equipment including computed
radiography and ultrasonics. Initially, seven people will staff
the facility, with employment expected to double or triple
within the first few years.
Inspection Trends / Winter 2012 11
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News Bulletins Winter IT 2012_Layout 1 12/22/11 10:38 AM Page 11
Print and Product Showcase
Inspection Trends / January 2012 12
TOFD System Offers Easy
Operation
The companys portable time-of-
flight diffraction (TOFD) inspection
system offers high probability of
detection, touch-screen operation,
automatic data file saving, easily
adjustable probe center separation, and
displays results in multiple languages.
One person can operate this hand-held
magnetic wheel scanner. The unit is
sensitive enough that an external
preamplifier is not needed.
MISTRAS
(609) 716-4000
www.mistrasgroup.com
Computed Radiography
System Combines High
Resolution with Portability
The CRx25P computed
radiography system features an
upgraded plate transport system that
optimizes plate handling, and accepts
flexible phosphor imaging plates up to
35 cm wide and of virtually any length.
The unit weighs 46 lb and can be easily
carried to the job site. The system can
operate at standard scan resolutions of
50 or 100 microns, where it is
particularly suitable for corrosion/
erosion inspection. It can also be
operated at scan resolutions of 17 and
25 microns, making it qualified for
weld inspections in compliance with
international standards. It can be used
with the companys Rhythm software
and its Flash!Filters to allow instant
image enhancement and faster defect
detection. A battery-powered version
enables autonomous operation in
special environments. Optional
accessories include a transport case,
drum extensions, and imaging plate
guides.
GE Energy, Measurement & Control
Solutions
(866) 243-2638
www.ge-mcs.com
XRF Analyzer Features Large
Touch-Screen Display
The X-MET7000 hand-held XRF
analyzer works faster and is smaller
and lighter than the companys
previous models. The new design was
based on extensive customer research
and offers an improved, easy-to-read
graphical user interface. It offers a
bright, high-contrast 4.3-in. Blanview
transmissive LCD touchscreen for
optimal outdoor viewing even in bright
sunlight; a result screen that is easily
customized to show only the elements
the user needs; and a history view that
allows easy browsing of old results and
spectra. The user interface is available
in 13 languages.
Oxford Instruments
(800) 447-4717
www.oxford-instruments.com/x-met7000
Rechargeable Hand-Held LED
Offers Five Operating Modes
The EXP-LED-RL-FX5R
explosion-proof, rechargeable LED
hand-held light produces 135 lumens
of bright light and offers five operating
modes that the user can cycle through
by simply activating the trigger. The
main light head is adjustable, allowing
the operator to set the light down and
adjust the head as needed for close
work or inspection activities. Its lantern
has a 12-h run time on a single charge
of its integral 6-VDC nickel metal
hydride batteries, and will accept up to
500 charge cycles before battery
performance degrades. The light is
impact, vibration, and water resistant,
and has no exposed metal or contacts,
making it useful for heavy-duty use in
industrial work environments.
Larson Electronics
(800) 369-6671
www.magnalight.com
Print & Product IT Winter 2012_Layout 1 12/22/11 1:05 PM Page 12
Inspection Trends / Winter 2012 13
Publications Address
Construction Industry Hazards
Construction Focus 4: Instructor
Guide and Student Handbook address
the top four construction industry
hazards and make it easy for safety
trainers to provide their trainees with
information on these topics. The
training materials are divided into four
sections: Fall Hazards; Caught-In or
Between Hazards; Struck-By
Hazards; and Electrocution Hazards.
MANCOMM
(800) 626-2666
www.mancomm.com
Laser Module Captures Pipe
Geometry Using Crawler-
Mounted Hardware
The WinCan laser module can
capture pipeline geometry using a
video inspection crawler outfitted with
practically any laser profiling
hardware. The module is an add-on
mode for WinCan V8 pipe inspection
and asset management software. The
module works in three modes,
depending on the laser hardware used.
In parallel laser mode, the camera
heads twin laser dots are oriented
perpendicular to the pipe wall and then
rotated 360 deg. The laser module
analyzes video from the crawler to
determine pipe diameter and
deformation at that single location;
additional tools allow defect
measurement using parallel lasers. In
ring mode, the module analyzes video
from the crawler, extracting the laser
ring pattern. Trending the diameter and
deformation of this ring frame by
frame yields data that can be converted
into a solid model, ovality graph, or
color plot. In scanning mode, the
module analyzes the laser dot pattern
cast by any properly equipped side-
scan camera, interpolating a ring to
determine diameter and deformation.
As in ring frame, these measurements
can be trended frame by frame.
Pipeline Analytics
(877) 626-8386
www.pipelineanalytics.com
Industrial Tech Guide App
Introduced
The company recently introduced
the Industrial Tech Guide App for the
iPhone and iPad. This free mobile
application contains two knowledge-
based sections designed for technicians
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Print & Product IT Winter 2012_Layout 1 12/22/11 1:06 PM Page 13
Feature
By Michael Moles
Inspection Trends / January 2012 14
Due to a number of technological
advantages, phased arrays are
becoming the inspection method of
choice for welds, including for work
done under the requirements of AWS
D1.1, Structural Welding Code
Steel. This article describes the current
AWS approach for detecting and sizing
cracks often the critical factor in
welding of infrastructure and some
further developments. Crack detection
is well established and generally good;
sizing is more problematic. Advanced
sizing developments are typically
beyond the D1.1 inspection
requirements, and may be beyond those
of any code, but are listed here as they
are technically available.
Why Cracking Is So Important
Cracks are often the life-limiting
factor in structures, be it a bridge,
amusement park ride, ship, or other
component. (The other major life-
limiting factor is corrosion.)
Unfortunately, failures due to cracking
are typically expensive, and may lead
to loss of life, forced outages, major
downtimes, problems with replacement
parts, environmental releases, etc. The
key issue with cracks is detection,
followed by sizing. Fortunately,
detection of cracks is not a major issue,
but sizing is, and most of this article
discusses sizing approaches.
Unfortunately, none of the major codes
[AWS (Ref. 1), ASME (Ref. 2), API
(Ref. 3), and ASTM (Ref. 4)] really
promotes sizing, though all have well-
established detection approaches.
Phased Arrays
Phased arrays use a series of small
elements, which are pulsed with a
calculated time delay to allow
phasing. Phasing allows constructive
and destructive interference of
waveforms, to build a coherent beam
that can replicate conventional
ultrasonic probes. Figure 1 shows an
example of a linear array used for weld
inspections. Linear arrays permit
scanning, sweeping, and focusing in
the horizontal axis (as illustrated in the
figure). Linear arrays tend to be
extensively used because they cost less,
require significantly less
instrumentation, and are easier to
program.
The key concept in phased arrays
is that phasing does not change the
physics of ultrasound. Phased arrays
are merely a method of generating and
receiving a signal (and also displaying
images). Consequently, if you obtain X
dB off a reflector using conventional
UT, you should obtain the same signal
amplitude using phased arrays. Results
from the field show this is commonly
the case, given the usual variations
with ultrasonics (Ref. 5).
Basic Phased Array Scans
From a practical viewpoint, phased
arrays can generate two basic scans: E-
scans (electronic scans at fixed angles)
and S-scans (swept angle scans). AWS
D1.1 only supports E-scans at this time
Using Phased Array Ultrasonics for Detecting and Sizing Cracks
in Welds
The current AWS approach for detecting and sizing cracks, as well as newer phased array
technology, are detailed
Fig. 1 Linear array for weld
inspections.
Fig. 2 Illustrations of E-scans at left, S-scans in middle plus dynamic depth
focusing.
Moles Feature IT Winter 2012_Layout 1 12/21/11 11:25 AM Page 14
Inspection Trends / Winter 2011 15
(Ref. 1) due to its Indication Rating
(IR) approach. The two scans are
illustrated in Fig. 2, along with
dynamic depth focusing.
Manual vs. Encoded Scans
To further complicate scan
patterns, there are two basic
approaches to scanning: manual and
encoded. Manual phased array
inspections are compatible with AWS
D1.1, using special probes and
calibrations to cover the 45-, 60-, and
70-deg angles. For manual inspections,
an S-scan is normally used, with
calibration on these three angles for
AWS indication ratings.
However, encoded linear AWS
scans have not yet been accepted in
D1.1, even using E-scans. E-scans are
similar to conventional ultrasonics in
that the inspection angle doesnt
change. Figure 3 gives an example of
an encoded linear scan on a weld.
These encoded inspections would
emulate AWS D1.1 inspections, and be
much faster (and more economical)
than raster scanning for a high-volume
weld profile. They would require a
specified raster and step size, and
would need to cover weld, heat-
affected zone, and any position errors.
This would require a significant
amount of electronic scanning, though
it would still be much faster than
conventional ultrasonics.
Imaging
Imaging is another advantage of
phased arrays: S-scans in particular
offer good imaging, and permit the
accurate location and characterizing of
defects, as shown in Fig. 4.
Phased arrays have been well
described in a number of books (Refs.
6, 7), and are not described in more
detail in this article.
Inspection Requirements in
AWS D1.1
Compared with other codes such
as ASME and API, the AWS Code is
prescriptive (Ref. 1). It specifies
exactly what probe frequency (2.25
MHz) and size (square or rectangular,
5
8 in. or greater) should be used. Defect
dispensation is by a specific AWS
technique, requiring measurement of
the indication level a, reference level
b, and attenuation factor c (2
dB/in.). This gives a calculation of the
Indication Rating:
a b c = d = Indication Rating
The IR values are based more on
empirical studies than on physics. For
example, modern steels tend to have
lower attenuation as they are cleaner,
so the IR values can overstate defect
severity. Hence, defect detection is
good. In addition, AWS has several
different defect categories, so the Code
is more accommodating than such
simplistic evaluations may seem.
Not surprisingly, manufacturers
have developed manual phased array
probes to fulfil the AWS D1.1 Code
requirements. These can generate 45-,
60-, and 70-deg beams from the same
wedge (Fig. 5), and can be used to scan
all three angles simultaneously. This
Fig. 3 Illustration of encoded scan.
Fig. 5 Drawings of the Olympus
NDT array for AWS D1.1.
Fig. 4 S-scan showing defect locations. Note that these
two defects are not related.
Moles Feature IT Winter 2012_Layout 1 12/21/11 11:25 AM Page 15
Inspection Trends / January 2012 16
speeds up scanning by a factor of up to
three, as well as providing good
imaging.
Calibration is relatively
straightforward: For example, the IIW
Mark 2 calibration block side-drilled
hole is used to calibrate 45, 60, and 70
deg, and scans are displayed in the
three A-scans and one S-scan display
Fig. 6.
Olympus NDT has developed
software to display any defects using
RayTracing software, as shown in
Fig. 7.
These developments effectively
push the AWS D1.1 Code to its limits
for manual inspections, though these
screen displays can be printed. As there
is no encoder, and hence recorded data,
it is not really possible to save the data
for posterity and subsequent auditing.
Alternative Sizing Techniques
As material requirements increase,
the demands on AWS to apply more
advanced sizing techniques will also
likely increase. For example, pipeline
manufacturers are planning on using
X100 material, which puts significantly
more emphasis on defect detection and
sizing.
Amplitude Drop
Sizing techniques based on
amplitude drop approaches have
been available for years. The beam is
scanned over the defect and mapped;
the operator can use 3, 6, and 20 dB
drops, but the results show that
accurately sizing defects varies
considerably with the defect itself, the
defect orientation, the operator, and so
on. Figure 8 shows an example of
sizing from a UK trial. Overall, the
results are not particularly
encouraging.
Zone Discrimination
This approach is specifically for
pipeline automated ultrasonic testing
(AUT), where speed, speed, speed
for detection and sizing is critical (Ref.
9). The technique uses well-focused
beams and tailored inspections, with an
Fig. 6 Display of calibrated scan with 45-, 60-,
and 70-deg beams.
Fig. 7 Display with A-, S-, and R-scans to show
defect location in the weld.
Fig. 8 Plot of defect sizing using multiple teams
and techniques (Ref. 8).
Fig. 9 Sample pipeline zone discrimination plot, showing
defects and geometry in red.
Moles Feature IT Winter 2012_Layout 1 12/21/11 11:26 AM Page 16
Inspection Trends / Winter 2012 17
automated scanner. As with the AWS
Indication Rating approach, detection
is not a major issue, though
characterization can be. Sizing is
typically to 11.5 mm (on a good
scan), and the defect sizes are used for
Engineering Critical Assessment
calculations. A sample plot is shown in
Fig. 9.
Diffraction Approaches Time-of-
Flight Diffraction
Time-of-flight diffraction (TOFD)
was developed by UKAEA Harwell,
but is now widely used and much more
cost effective than many other AUT
approaches (Ref. 8). It had a major
impact from 1980s PISC II round-robin
trials. TOFD uses diffracted tip signals
to accurately size, as well as detect,
cracks Fig. 10. The original use was
for raster scanning in the nuclear
industry, but since the 1990s, TOFD
has become widely used in
petrochemical and some other
industries using linear scanning.
TOFD offers good midwall defect
detection, accurate sizing of defects
using the times of arrival of diffracted
signals (to around 1 mm), defect
detection even if defects are mis-
oriented or located away from the weld
centerline, and rapid linear scanning. In
addition, TOFD offers nonamplitude
scanning and detection, and setup
independent of weld configuration.
While TOFD sounds like the
ideal NDE technique, it does have
limitations. It has a dead zone at the
top surface (OD), a dead zone at the
bottom surface (ID), and is limited to
sizing defects of >~3 mm. In addition,
analysis can be difficult, and TOFD is
sensitive to very small defects with a
risk of false calls. Some sizing errors
are possible from lateral positioning of
defects. Also, TOFD has a low signal-
to-noise ratio, so doesnt work well on
austenitic steels. Figure 11 shows a
typical TOFD display.
Tip Back Diffraction
Tip back diffraction is an
alternative approach to TOFD, but has
been around longer (Ref. 10). The
concept is simpler than TOFD, and is
shown in Fig. 12 (Ref. 11).
The back diffraction approach
works well, even with manual phased
arrays (Ref. 12), as shown in Fig. 13.
In Fig. 13, the defect tip is clearly
visible, though this is not always the
case.
Under good conditions, back
diffraction offers excellent sizing, as
shown in Fig. 14. Back diffraction can
size to similar accuracies to TOFD, but
Fig. 11 Typical TOFD display, showing labeled defects.
Fig. 10 The TOFD technique.
Fig. 12 Schematic showing tip diffraction A-scan (left)
and concept (right).
Fig. 13 Back diffraction S-scan with defect tip arrowed.
Moles Feature IT Winter 2012_Layout 1 12/21/11 11:26 AM Page 17
Inspection Trends / January 2012 18
can also size smaller defects. In
general, these errors are ~1 mm,
though careful practices have reduced
the error to ~0.5 mm.
Technical Limitations
Unfortunately, ultrasonics is not a
laser beam the beams have finite
width and a finite frequency spectrum.
For sizing, the major limiting accuracy is
probably data analysis. However, the
majority of defect detection and sizing in
industry is still practiced by very simple
approaches, e.g., the AWS Indication
Rating approach. Newer techniques,
particularly back diffraction using
phased arrays, are relatively low cost
and easy to apply. However, they also
require operator skill and training.
Conclusions
1. The AWS D1.1 Code can be
and has been fulfilled by manual
phased arrays.
2. Detection is generally
straightforward, as shown by AWSs
long history of defect detection.
3. Sizing is more limited under
AWS D1.1, as it is under all other
codes.
4. Alternative sizing techniques,
e.g., amplitude drop, TOFD, and back
diffraction are available, but not really
codified yet.
5. Sizing works better with
diffraction, but requires a good, well-
trained operator.
References
1. AWS D1.1/D1.1M: 2010,
Structural Welding Code Steel.
Miami, Fla.: American Welding Society.
2. ASME Boiler and Pressure
Vessel Code, 2010, Section V Article 4.
New York, N.Y.: American Society of
Mechanical Engineers.
3. See, for example, API 570,
Piping Inspection Code Inspection,
Repair, Alteration, and Rerating of In-
Service Piping Systems. Aug. 2003.
Washington, D.C.: American
Petroleum Institute.
4. ASTM 2192, Standard Guide
for Planar Flaw Height Sizing Using
Ultrasonics. 2008. West
Conshohocken, Pa.: American Society
for Testing and Materials.
5. Sjerve, E. M., Stewart, D. C.,
and Bryant, G. F. 2000. Comparison of
multi-probe and phased array girth
weld inspection systems. Proceedings
of International Pipeline Conference,
Calgary, Alb., Canada, Oct. 15.
6. Introduction to Phased Array
Ultrasonic Technology Applications
Olympus NDT Guideline. Aug. 2004.
Waltham, Mass.: Olympus NDT,
www.olympus-ims.com.
7. Phased Array Testing Basic
Theory for Industrial Applications.
Nov. 2010. Waltham, Mass.: Olympus
NDT, www.olympus-ims.com.
8. Charlesworth, J. P., and Temple,
J. A. G. 1989. Ultrasonic Time of
Flight Diffraction. Research Studies
Press.
9. Ginzel, E. A. Feb. 2006.
Automated Ultrasonic Testing for
Pipeline Girth Welds. Waltham, Mass.:
Olympus NDT.
10. Harumi, K. 1989. Japanese Tip
Echo Handbook, first edition.
11. Jacques, F., Moreau, F., and
Ginzel, E. 2003. Ultrasonic back
diffraction sizing using phased array
Developments in tip diffraction flaw
sizing. Insight, Vol. 45, No. 11.
12. Davis, J. M., and Moles, M.
2006. Resolving capabilities of phased
array sectorial scans (S-scans) on
diffracted tip signals. Insight, Vol. 48,
No. 4, p. 1.
Fig. 14 Back diffraction sizing of cracks in OPG headers. (Chart courtesy of
OPG.)
MICHAEL MOLES
(Michael.Moles@olympusndt.com) is
senior technology manager, Olympus
NDT, Waltham, Mass.
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Moles Feature IT Winter 2012_Layout 1 12/21/11 11:27 AM Page 18
welding fundamentals_FP_TEMP 12/21/11 12:45 PM Page 19
Feature
By J. R. Coulstring III
Destructive weld testing
encompasses many different types of
tests to provide information on
anything from the toughness of a
welded joint to its ultimate tensile
strength. When performing welding
procedure qualification testing, you
will encounter these varied test
methods depending on the particular
application of the welded joint. The
most common testing, however, would
be those methods used to determine a
welders proficiency with a particular
welding process; in other words,
welder performance qualification
testing.
Anyone involved with welder
qualification, whether as a testing
agency, a welding consultant, or a
quality control person, is familiar with
the following request: I need to
become a certified welder.
In responding to that question, the
first thing that would need to be asked
of the person would be What code do
you need to qualify in accordance
with? There are codes that need to be
Destructive Testing Basics
The fundamentals of destructive testing for welder qualification are outlined
Fig. 1 An AWS D1.1 unlimited test
assembly ready for cutting in the
abrasive saw.
Coulstring Feature IT Winter 2012_Layout 1 12/22/11 8:35 AM Page 20
Inspection Trends / Winter 2012 21
followed based on the particular
industry, the organization, or perhaps
even the geographic location. The two
codes most people are familiar with are
AWS D1.1, Structural Welding Code
Steel, and ASME Boiler and
Pressure Vessel Code, Section IX.
These codes share many similarities
when it comes to the destructive testing
portion of welder qualification. For this
article, any particular requirements are
in accordance with AWS D1.1.
While the following does not
pertain specifically to destructive
testing, it is worth mentioning. Once
the governing code is determined, you
are going to need a Welding Procedure
Specification (WPS) to follow. It may
be a prequalified WPS, a WPS that has
been qualified by testing, or one that is
found in the AWS B2.1-X-XXX series.
The WPS will provide the welder with
all pertinent information he or she
needs to perform the qualification test.
The WPS will include information such
as the welding process, joint design,
base and filler metals, preheat/interpass
temperature, and the electrical and
travel speed ranges.
Now the welder has the
information he or she needs to begin
testing. The actual preparation for and
performance of the weld test would be
topics worthy of another article, but
today we will fast forward to
destructive testing.
Visual Examination
Imagine that you have a welded
assembly ready for testing. It is now
time for the first step, a visual
examination (so much for jumping to
the cutting and the bending). Many of
the weld defects that can be observed
in the visual examination will lead to
subsequent failures in the destructive
testing.
A particular defect that is seen
consistently is underfill on the face of
the weld. Underfill is when the weld is
not filled to at least the top surface of
the base metal. While excessive
reinforcement (not to exceed
1
8 in.) is
also undesirable, many people could
avoid a visual failure if they just filled
up the joint. Likewise, the root is of
equal importance. If you are welding
from one side without backing you do
not want excessive concavity or melt-
through. If you are welding with
backing, and you can pull the backer
off with pliers or it falls off, you are
certainly having some issues with the
root pass.
Undercut and cracking are also
typical problems to look out for. D1.1
has a thorough section on visual
examination criteria, complete with
weld profile examples that address
undercut and cracking more
thoroughly.
Specimen Removal
After a successful visual
examination, it is time to remove the
destructive testing specimens. There
are particular tests associated with
various types of weld tests to be
performed. These include bend (face,
root, or side), macro etch, and fillet
weld break tests. The figures and tables
in the code will direct you on the
quantity and type of specimens, the
location for removal, and the required
dimensions. Removal of the specimens
is often accomplished with band
sawing, thermal, waterjet, or abrasive
cutting. Keep in mind if you use
thermal cutting for side bend specimen
removal, allow for at least
1
8 in. on each
side of the sample to be removed to
avoid any heat-related issues. There is
an abrasive weld test cutting machine
manufactured by Triangle Engineering,
Fig. 2 An example of a macro etch sample.
Fig. 3 A fillet weld break specimen.
Coulstring Feature IT Winter 2012_Layout 1 12/22/11 8:35 AM Page 21
Inc., that is designed to remove
specimens. This machine uses holding
fixtures designed to clamp welded
assemblies while a 20-in. abrasive
blade is hydraulically pushed through
the cut Fig. 1. Indexing features
allow you to remove appropriate
specimen sizes with the push of a
button and rapid cut rates make it
useful for high-volume testing.
Specimen Preparation and
Testing
With the specimens removed, it is
now time to prepare them for testing.
Correct preparation is important to
ensure that an accurate and reliable
destructive test can be performed.
Macro Etch Test. This test
requires only a belt sander (or other
polishing means) and some nitric acid.
Cross sections of the welded joint are
removed, then polished and etched
with the acid Fig. 2. This will
provide a detailed view of the base
metal, heat-affected zone (HAZ), and
weld metal layers. The samples should
be belt sanded or polished; start with a
low grit, then work your way up to a
higher grit to achieve a suitable finish.
For the purposes of welder
qualification in D1.1, you may only
need to take the finish to 100 or 180
grit. This should provide an adequate
finish to check for weld sizes,
incomplete fusion, inadequate
penetration, cracks, and undercut.
Once the sample is polished, you
only need a 25% nitric acid solution to
etch the sample. This is typically one
part nitric acid and three parts water.
Carbon- and low-alloy steels require
very little exposure to this solution to
present a good macro etch. Quite often,
Fig. 4 Examples of a plunger and die bend (left) and a wraparound bend (right).
Fig. 5 A wraparound style bend
machine.
Coulstring Feature IT Winter 2012_Layout 1 12/22/11 8:36 AM Page 22
Inspection Trends / Winter 2012 23
10 s or less will be sufficient.
Fillet Weld Break Test. This is
the simplest of the three basic welder
qualification destructive tests. The test
involves placing a load on the fillet
weld so that it places the root of the
weld in tension Fig. 3. The load is
removed once the joint fractures or the
specimen has been folded flat onto
itself. Depending on the size of the
weld and the base material, you may be
able to accomplish this in a vise or
even with a sledge hammer. Heavier
specimens will require a press or
tension testing machine. If the
specimen does fold flat onto itself, you
have a satisfactory test result. If it
fractures, you need to confirm there is
complete fusion to the root and there
are not excessive inclusions or
porosity. The sum of all inclusions and
porosity cannot be greater than
3
8 in.
Bend Tests. The final and most
involved method of destructive testing
is bend testing. Bend tests for welder
qualification are predominantly
associated with groove welds, but there
is one fillet weld test that employs
bend tests as well. There are three
types of bend tests: side, face, and root
bends. The face and root bends are
used in some cases and the side bends
in others. Face and root bends are
usually used on
3
8 in. and less plate and
wall thicknesses, while side bends are
used on
3
8 in. and greater plate and wall
thicknesses. However, there are some
instances when face and root bends are
made on thicknesses greater than
3
8 in.
As you can see, for
3
8 in. thickness you
may use either side bends or face and
root bends. Arguments could and have
been made for either method. A face
bend or root bend, as the names imply,
puts either the face or the root of the
weld in tension, and that is the surface
that will be examined. A side bend will
put the entire cross section of the weld
in tension.
Your side bends are going to be
3
8
in. wide and as thick as the base metal
used for testing. In some cases where
the base metal is greater than 1
1
2 in.
thick, the sample may be cut into equal
strips and both strips would be tested to
represent one side bend. The face and
root bends would be 1
1
2 in. wide and as
thick as the base metal. A 1-in.-wide
sample may be used for pipe or tube
equal to or less than 4 in. in diameter.
Preparing the bend samples for
testing involves grinding, belt sanding,
or machining the samples. The weld
reinforcement and backing should be
removed flush with the surface of the
specimen for all bends. When
removing heavy backing bars, you
should try to remove the bulk of the
material with a heavy grinder or
through mechanical cutting if
available. For face bends on
thicknesses greater than
3
8 in., remove
material from the root side to bring the
specimen to
3
8 in. thickness; for root
bends, remove material from the face.
Dont get too aggressive with the finish
on your bends; gouges and heavy grind
marks could form a crack starter on a
weld that otherwise may have been
sound. Grind marks should always be
parallel to the specimen. Edges of the
specimen should have a
1
8-in.
maximum radius.
To bend the specimens there are
two basic styles of guided bend testing
equipment, the plunger and die style
and the wraparound style. Figure 4
shows a plunger and die bend on the
left and a wraparound bend on the
right. The wraparound style allows a
full 180 deg of specimen bending with
minimized stresses on the sample.
Different die post diameters can be
changed out in a couple minutes and a
typical bend takes about a minute to set
up and test. Figure 5 shows a
wraparound style bender from Triangle
Engineering. Regardless of which style
you use, you are going to need to
determine what bend radius to use. The
majority of side, face, and root bends
on
3
8 in. thicknesses will be tested at a
in. radius. The only exception to this
would be when qualifying on base
metals with yield strength greater than
50 ksi.
When examining the bend tests for
defects and discontinuities, whether
they are side, face, or root bends, you
should look at the convex surface, the
outside circumference of the bend. Any
incomplete fusion, slag inclusion, or
discontinuity measuring greater than
1
8
in. is a rejection. Even if you keep the
discontinuities
1
8 in. and under, you
may still be in trouble because you
may also have a rejection based on the
cumulative length of smaller
discontinuities. Add up every
discontinuity greater than a
1
32 in. but

1
8 in. If the total is greater than
3
8 in.,
that is a failure. Corner cracks are
allowed provided they do not exceed
in., unless they look to be the result of
slag or fusion problems, then they
cannot exceed
1
8 in. On the bright side,
it is permissible to have many
discontinuities, provided they are
smaller than a
1
32 in.
J. R. COULSTRING III
(jr@trieng.com) is quality control
manager, Triangle Engineering, Inc.,
Hanover, Mass.
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Bend tests for welder
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Coulstring Feature IT Winter 2012_Layout 1 12/22/11 8:36 AM Page 23
Inspection Trends / January 2012 24
Feature
By Joseph P. Kane
This article is the first in a four-
part series related to the Code of
Ethics found in AWS QC-1: 2007,
Standard for AWS Certification of
Welding Inspectors. Joseph P. Kane
wrote this article in collaboration with
Kent Baucher, Neal Chapman, Lyndsey
Deckard, and Phillip Martin, fellow
members of the Certification
Committees Subcommittee on the Code
of Ethics.
Frequently in their daily speech,
end users, employers, engineers, shop
and field managers, government
regulators, welders, and even AWS
Certified Welding Inspectors use the
words certified and qualified
interchangeably. In addition, this
misuse of terms is often found in
written documents such as contract
specifications. This misuse mostly
involves routine communication and
there is often no real harm done when
these words are interchangeably used.
To help clarify these terms, in the
welding field the certification is the
signed document that attests to the fact
the welder has successfully passed a
qualification test to a specific code.
In the pressure vessel business,
ASME certified or ASME
certification are often used when
referring to welder performance
qualification tests performed in
accordance with the American Society
of Mechanical Engineers Boiler and
Pressure Vessel Code, Section IX.
In pipelining, the terms API
Certified or API certification are
often used when referring to welder
performance qualification tests
performed in accordance with
American Petroleum Institute STD
1104, Welding of Pipeline and Related
Facilities.
In the structural welding field, the
terms AWS certified or AWS
certification are often used when
referring to welder performance
qualification in accordance with the
provisions of the American Welding
Society D1.1, Structural Welding Code
Steel, or other AWS standards.
Often contractors call in a CWI
and ask him or her to certify their
welders to AWS, ASME, or API, so
that they can perform welding on a
contract. Many times the contractor
wants the welders to be certified for
welding everything, with all
processes. Good economic thought
means the contractors want some
versatility and durability with the
paperwork, and so they also specify
that these certifications must be good
anywhere and forever.
Legally, the contractors are usually
responsible for the qualification and
certification of their welders. In real
life even with contractors who have
been around welding for a long time
many contractors have little knowledge
of what is involved in welder
performance qualification or how to
get it. They all seem to know it will be
costly, but few seem to know it will
take some period of time that they
dont have. (They all need it
yesterday.) This lack of knowledge is
one reason why they hire a CWI to
perform their qualification testing.
Any CWI should know there is no
such thing as a universal certification
that covers all processes, all positions,
all joint configurations, all product
forms, all electrodes, and is valid
everywhere and forever.
Prudent CWIs will ask to read the
contract specifications, so they can
proceed with professional confidence
and conduct the proper testing for the
client. At this point, prudent CWIs
should educate their clients using
the proper terminology and describe
what the contract specifications are
calling for and what they can do to
assist their clients. Clients must then
reevaluate their priorities, and tell the
CWIs what they want and need for
contract compliance.
Imprecise use of terms such as
qualification and certification at this
point can cause misunderstanding,
confusion, or both. In the structural
field, AWS certified might just mean
welder performance qualification to the
provisions of AWS D1.1. Of course, it
could also refer to a person who has
successfully taken Welder Performance
Qualification testing at an AWS
Accredited Testing Facility (ATF), in
accordance with AWS QC-7,
supplement G, and has a card issued
by the American Welding Society that
places the welder in the National
Registry. Nonstandard use of
terminology in this case reveals the
importance of the proper use of
terminology in any type of contractual
agreement either verbal or written. The
welding inspector should be clear in
his/her explanations to the client, to be
certain the client understands there is a
difference between a certification per
AWS D1.1 and a nationally registered
Ethics Alert: Certified vs. Qualified
Members of the Ethics Subcommittee explain the importance of the proper use of
terminology
Kane Feature IT Winter 2012_Layout 1 12/22/11 10:19 AM Page 24
Inspection Trends / Winter 2012 25
certification from AWS through testing
performed at an ATF.
AWS Code of Ethics
Recently, there was an alleged
violation of the AWS QC-1 Code of
Ethics in which the complainant said
the CWI gave a generic D1.1 welder
performance qualification test, but the
complainant wanted a National
Registry Certification.
There is no proof in the complaint
that the complainant specified the QC-
7 National Registry qualification and
certification test. However, there is
nothing yet to show that the CWI
educated his client (the complainant)
about the different types of testing, the
services he could perform, and where
the client would have to go if he
wanted to get his welders on the
National Registry.
The Ethics Subcommittee now has
to evaluate the complaint and the
evidence in the complaint. The
committee will decide whether the
allegation is complete enough on its
face to show that the CWI probably
violated the AWS QC-1 Code of Ethics
by not properly educating the client.
Then the subcommittee members will
vote whether or not to recommend the
issue be referred to a hearing panel.
The hearing panel is the AWS
equivalent of an administrative trial. It
is where CWIs can find themselves
losing their certificates.
Basic integrity issues addressed in
Paragraphs 11.1, 11.2.1, and 11.2.6, of
Section 11 of AWS QC-1 2007,
Standard for the Certification of
Welding Inspectors, apply here. The
members of the Ethics Subcommittee
feel it is incumbent on the CWI to
explain the differences to the
contractor/client, because the CWI is
the most knowledgeable party.
What Happens Next
In the future, the Ethics
Subcommittee will take an adverse
view toward the CWI in an ethics
violation complaint if there is no
evidence he or she has attempted to
educate the client by adequately
explaining the different options to that
client.
JOSEPH P. KANE
(joseph.kane11@verizon.net) is with Pen-
noni Associates, King of Prussia, Pa. He
is an advisor to the AWS Certification
Committee and a member of the Subcom-
mittee on the Code of Ethics. He is an
AWS Senior Certified Welding Inspector.
Collaborators on this article were Kent
Baucher, Neal Chapman, Lyndsey
Deckard, and Phillip Martin.
Kane Feature IT Winter 2012_Layout 1 12/22/11 10:19 AM Page 25
The Answer Is
By K. Erickson and A. Moore
Inspection Trends / January 2012 26
The Society is not responsible for any statements made or opinion expressed herein. Data and information developed by the authors are for specific
informational purposes only and are not intended for use without independent, substantiating investigation on the part of potential users.
Q: I am currently a welder qualified
to the shielded metal arc welding
requirements of AWS D1.1 in the 1G
and 2G positions (2007). Prior to
completing the qualification weld, I
was instructed to grind the weld cap
flush when completed. The plate was
then sectioned for bend testing. Just
recently, I tested in the 3G position
and, upon completion, the inspector
failed the test coupon visually. My
question is why in one case was no
visual inspection performed, while in
the other case, a visual inspection
was performed for which I failed?
A (from K. Erickson): I would
certainly hope that these were two
separate testing facilities and inspectors
for which you tested; otherwise, this
practice needs to be brought up to their
responsible management. The
individual who instructed you to
remove the weld cap upon completion
of the 2G test was not performing
his/her duties correctly and completely.
The bottom line is that visual
inspection is required for welders,
welding operators, and tack welders
who are performing qualification
performance tests. This is a
requirement within AWS D1.1 and so
indicated directly on the qualification
test record. The entire performance test
should be monitored by a competent
individual overseeing each test.
Individuals who are applying the visual
acceptance criteria need to be
knowledgeable and understand each
visual inspection checkpoint and how it
applies to both fillet and groove welds.
Use any failed test as a learning
tool to better yourself and your welding
skills. Ask questions to understand
what is expected from you before the
test, why your test coupon has failed,
and what needs to be corrected and/or
changed to rectify these conditions.
Q: Titanium tubing is generally
listed under what AWS material
numbers?
A: Material numbers 51, 52, and 53.
Refer to B2.1/B2.1M: 2009,
Specification for Welding Procedure
and Performance Qualification.
Q: When can the CWI examination
be expected to include questions
involving the measurement of
skewed T-joint weld sizes, and how
can those welds be measured?
A (from A. Moore): Since the
publication of Bob Wiswessers article
on skewed joints in the Summer 2011
Inspection Trends, I have received
several inquiries regarding this topic. I
dont know when questions on skewed
T-joints will appear, but maybe I can
show how they are measured.
The AWS D1.X Structural
Welding Codes are the only welding
standards we are familiar with that
address welded skewed T-joints and
include special requirements regarding
sizing the weld between skewed
members. It is interesting to note that
the subject of skewed T-joints has
evolved over time. In the recent past,
the codes simply called out the weld
joining the skewed members as a fillet
welded skewed T-joint and the
designers used the fillet weld symbol to
specify the welding requirements;
however, the 2008 and 2010 editions of
D1.1, Structural Welding Code
Steel, no longer use the words fillet
weld or fillet welded when
addressing the skewed joints between
members when the acute angle is less
than 80 deg. I see the logic in the
changed terminology. A review of
acceptable and unacceptable fillet weld
profiles depicted in D1.1:2008, Fig.
5.4, shows that an acceptable fillet
weld must have fusion to the joint root.
It is interesting to note that the
2010 edition of AWS D1.1 no longer
includes the sketches of acceptable and
unacceptable fillet weld profiles that
were included in the earlier editions. Is
it an oversight or is incomplete fusion
to the root of the fillet weld acceptable
now? The presence of incomplete
fusion has a direct bearing on the throat
of the fillet weld and thus its strength.
Therefore, I wouldnt think there
would be a change in the need to have
fusion to the root of the fillet weld.
Consider the test results required when
evaluating a fillet weld break test; the
failed weld must exhibit fusion to the
root, but not necessarily beyond the
root (reference AWS D1.1:2010,
Clause 4.9.4.1). When the dihedral
angle is less than 60 deg, it is
recognized that the weld joining the
skewed members may not have fusion
to the root. That being the case, the
basic requirements of an acceptable
fillet weld profile cannot be met. With
that in mind, it makes perfect sense not
to refer to the weld joining the skewed
members as a fillet weld when fusion
to the root is not expected.
The Society is not responsible for any statements made or opinion expressed herein. Data and information developed by the authors are for specific
informational purposes only and are not intended for use without independent, substantiating investigation on the part of potential users.
The Answer Is IT Winter 2012_Layout 1 12/22/11 2:32 PM Page 26
Inspection Trends / Winter 2012 27
You might ask the question,
When does the weld on the acute side
of the skewed T-joint not meet the
profile requirements of a fillet weld?
AWS D1.1:2010, Clause 2.4.3.3,
states that when the acute angle between
the members is less than 60 deg, the
weld size must be adjusted to account
for the expected Z-loss. The anticipated
Z-loss is tabulated in AWS D1.1:2010,
Tables 2.2 (nontubular connections) and
2.9 (prequalified PJP T, Y, and K tubular
connections). In other words, experience
has demonstrated that when the acute
angle of the skewed joint is less than 60
deg, incomplete fusion to the root can
be expected. The Z-loss, i.e., incomplete
fusion at the root, gets larger as the
dihedral angle gets smaller.
The code has a provision stating
that the design drawings, i.e., the
structural drawing, produced by the
Engineer (the Owners
representative/design professional) is to
specify the required throat dimension
for the welded skewed joint. That is, the
design drawing does not have to include
the Z-loss dimension listed in Tables 2.2
and 2.9.
Reading further, the structural code
has provisions that state the fabricator
must provide details showing the leg
dimensions that take into account the
expected Z-loss and the required throat
dimension.
However, since the deposited weld
does not meet the requirements of a fillet
weld, i.e., we should not expect the weld
to have fusion to the root, should the
fillet weld symbol be used to specify the
weld requirements of the skewed T-joint?
While my response may be at odds with
the opinions of some other people, I take
the position that if the weld cannot meet
the basic requirements of a fillet weld,
the fillet weld symbol is inappropriate.
Is there an existing weld symbol that
adequately specifies the weld? My
response is No. That being the case, the
best way to specify the weld for the
skewed T-joint is to include a section view
through the skewed joint depicting the
expected Z-loss and the required weld
dimensions. The detailer is burdened with
the task of including a detail of the skewed
T-joint on the shop drawing. The detail is
a section through the skewed T-joint that
shows the calculated value of the face
width and both legs showing dimensions
of both the fused and unfused portions of
the weld joining the skewed members.
Lets try an example:
Angle of the skew = 45 deg
Z-loss:
1
8 in.
Throat:
3
8 in.
Total Throat = Z-Loss + Throat =
1
8 +
3
8
=
1
2 in.
Calculate Leg (root to face) = 0.5/cos
(45/2) = 0.5/(cos 22.5) = 0.5/0.924
= 0.541
Calculate Face = sin 45 deg 0.541
= 0.707 0.541 = 0.383 in.
It may make it easier to visualize
the weld and the various dimensions if
we draw a sketch of the example we
just worked through.
Now that the dimensions have
been calculated by the detailer and a
detail included on the shop drawing, it
is a relatively easy matter to measure
the weld to verify it meets the
minimum size as specified.
The verification of the face width
of the completed weld isnt without
issue. Fillet weld gauges available from
most suppliers are not made for
measuring welded skewed T-joints.
They are fine for a T-joint where one
member is nearly perpendicular to the
other, but that is not the case with
skewed T-joints. My solution is to
make the gauge needed to measure the
face of the welded skew T-joint. It is a
simple matter to find a piece of heavy
band strap such as typically used for
securing loads to wooden pallets. Then
the band strap can be cut and trimmed
to the appropriate size.
Measuring the completed weld is a
relatively simple exercise if the
fabrication drawing includes the
section detail I have suggested. It
becomes a simple matter to measure
the weld with the appropriate gauge to
verify the minimum dimensions are
present. Since the common fillet
gauges may not be appropriate, the
inspector will have to make a gauge for
this purpose. All it takes is a pair of
aircraft-style tin snips and a 6-in. ruler.
Use the ruler to measure and lay out
the band strap and cut it as needed with
the tin snips. With a little care, the
dimensions can be easily held to within
a few thousandths of an inch.
I keep a couple of lengths of band
strap in my tool box for this purpose. A
gauge can be made to fit into tight
corners or to suit unusual conditions.
The length of the gauge should be
sufficient to provide a stable base.
The Answer Is IT Winter 2012_Layout 1 12/22/11 2:33 PM Page 27
Inspection Trends / January 2012 28
A gauge that is within a few
thousandths of an inch should suffice
for most work. After all, the weld size
specified by the drawing is usually
considered to be the minimum size.
Dont forget that Table 6.1 of AWS
D1.1 allows the welds to run slightly
undersized. In addition to allowing
welds to run slightly undersized, AWS
D1.1 permits a
1
16-in. separation
between the members to be joined
without correction. Most reasonable
people should not take issue with the
accuracy of the homemade gauge that
is within
1
32 in.
Inspection Trends encourages
question and answer submissions. Please
mail to the editor (mjohnsen@aws.org).
KENNETH ERICKSONis manager of
quality at National Inspection & Consult-
ants, Inc., Ft. Myers, Fla. He is an AWS
Senior Certified Welding Inspector, an
ASNT National NDT
Level III Inspector in four methods, and
provides expert witness review and analysis
for legal considerations.
ALBERT J. MOORE JR. is vice president,
Marion Testing & Inspection,
Canton, Conn. He is an AWS Senior
Certified Welding Inspector and an ASNT
ACCP NDT Level III. He is also a
member of the AWS Certification
Committee and the Committee on
Methods of Inspection of Welds.
Change of Address?
Moving?
Make sure delivery of your Inspection
Trends is not interrupted. Contact
Maria Trujillo in the Membership
Department with your new address in-
formation (800) 443-9353, ext. 204;
mtrujillo@aws.org.
Want to be a
Inspection Trends
Advertiser?
For information, contact
Rob Saltzstein at
(800) 443-9353, ext. 243,
or via e-mail at
salty@aws.org.
The Answer Is IT Winter 2012_Layout 1 12/22/11 2:34 PM Page 28
Quality Expo Texas. March 14, 15, Ft. Worth Convention
Center, Ft. Worth, Tex. Contact UBM Canon, (310) 445-
4200, www.qualityexpotexas.com.
ASNT 21st Annual Research Symposium and Spring
Conference. March 1923, Sheraton Dallas Hotel, Dallas,
Tex. Contact American Society for Nondestructive Testing,
(800) 222-2768 or www.asnt.org.
FABTECH Canada 2012. March 2022, Toronto Congress
Centre, Toronto, Ont., Canada. Sponsored by the Amerian
Welding Society, Society of Manufacturing Engineers, and
Fabricators & Manufacturers Association, Intl. Visit
www.fabtechcanada.com; show updates will be posted on
Twitter and LinkedIn.
65th Annual Assembly of the International Institute of
Welding. July 813, Hyatt Regency Hotel Denver and
Colorado Convention Center. Sponsored by the American
Welding Society, Edison Welding Institute, and Welding
Research Council. Visit www.iiw2012.com.
Review of Progress in Quantitative Nondestructive
Evaluation (QNDE). July 1520, Hyatt Regency Tech
Center, Denver, Colo. Contact heidil@iastate.edu or
www.qndeprograms.org.
ASNT Fall Conference and Quality Testing Show. Oct.
29Nov. 2, Rosen Shingle Creek Resort, Orlando, Fla.
Contact American Society for Nondestructive Testing, (800)
222-2768 or www.asnt.org.
FABTECH 2012. Nov. 1214, Las Vegas Convention Center,
Las Vegas, Nev. Sponsored by the American Welding Society,
Society of Manufacturing Engineers, and Fabricators &
Manufacturers Association, Intl. Visit www.fabtechexpo.com.
Educational Opportunities
NDE Classes. Moraine Valley Community College, Palos
Hills, Ill., offers NDE classes in PT, MT, UT, RT, Radiation
Safety, and Eddy Current, as well as API 510 exam prep and
weld inspection. For more information, contact (708) 974-
5735; wdcs@morainevalley.edu; morainevalley.edu/NDE.
CWI Prep Course and AWS CWI Seminar and Exam.
The Prep Courses prepare candidates for the AWS Certified
Welding Inspector (CWI) seminar and examination. Offered
July 1620 and Oct. 1519. The CWI seminar covers how to
reference AWS codes, examine welds, and prepare for the
CWI exam on that following Saturday (proctored by AWS).
Offered July 2228 and Oct. 2127. Contact Lincoln
Electrics Welding School at (216) 383-8325 or visit
www.lincolnelectric.com.
EPRI NDE Training Seminars. EPRI offers NDE technical
skills training in visual examination, ultrasonic examination,
ASME Section XI, UT operator training, etc. Contact Sherryl
Stogner, (704) 547-6174, e-mail: sstogner@epri.com.
Nondestructive Examination Courses. A course schedule is
available from Hellier, 277 W. Main St., Ste. 2, Niantic, CT
06357, (860) 739-8950, FAX: (860) 739-6732.
NDE Training Courses. GE Inspection Technologies offers
training on topics such as eddy current, digital radiography,
and remote visual inspection. For the complete schedule,
contact (866) 243-2638; www.geit-info@ge.com;
www.ge.com/inspectiontechnologies.
Positive Material Identification Seminars. Topics covered
will include basics of X-ray fluorescence (XRF) analysis,
APRI RP 578, and recommended PMI procedures. For more
information or to register, contact Thermo Fisher Scientific,
Inc., at www.niton.com/News-and-Events.
Preparatory and Visual Weld Inspection Courses. One-
and two-week courses presented in Pascagoula, Miss.,
Houston, Tex., and Houma and Sulphur, La. Contact Real
Educational Services, Inc., (800) 489-2890;
info@realeducational.com.
CWI/CWE Course and Exam. A ten-day program presented
in Troy, Ohio. Contact Hobart Institute of Welding Technology
(800) 332-9448; www.welding.org; hiwt@welding.org.
T.E.S.T. NDT, Inc., Courses. CWI preparation, NDE
courses, including ultrasonic thickness testing and advanced
phased array. On-site training available. T.E.S.T. NDT, Inc.,
193 Viking Ave., Brea, CA 92821; (714) 255-1500; FAX
(714) 255-1580; ndtguru@aol.com; www.testndt.com.
NDE Training. NDE training at the companys St. Louis-area
facility or on-site. Level III services available. For a schedule
of upcoming courses, contact Quality Testing Services, Inc.,
2305 Millpark Dr., Maryland Heights, MO 63043; (888) 770-
0103; training@qualitytesting.net; www.qualitytesting.net.
CWI/CWE Prep Course and Exam and NDT Inspector
Training Courses. An AWS Accredited Testing Facility.
Courses held year-round in Allentown, Pa., and at customers
facilities. Contact: Welder Training & Testing Institute (WTTI).
Call (800) 223-9884, info@wtti.edu, or visit www.wtti.edu.
Welding Inspection, INTEG, Welding Health and Safety,
and Welding Supervisor Courses. Contact the Canadian
Welding Bureau for schedule at (800) 844-6790, or visit
www.cwbgroup.org.
Mark Your Calendar
Inspection Trends / Winter 2012 29
Mark Your Calendar IT winter 2012_Layout 1 12/21/11 4:09 PM Page 29
Certification Schedule
Certified Welding Inspector (CWI)
LOCATION SEMINAR DATES EXAM DATE
Corpus Christi, TX Exam only Mar. 3
Milwaukee, WI Feb. 26Mar. 2 Mar. 3
Atlanta, GA Feb. 26Mar. 2 Mar. 3
San Diego, CA Feb. 26Mar. 2 Mar. 3
Miami, FL Feb. 26Mar. 2 Mar. 3
Houston, TX Mar. 49 Mar. 10
Norfolk, VA Mar. 49 Mar. 10
Kansas City, MO Mar. 49 Mar. 10
Indianapolis, IN Mar. 1116 Mar. 17
Portland, OR Mar. 1116 Mar. 17
Phoenix, AZ Mar. 1116 Mar. 17
Boston, MA Mar. 1823 Mar. 24
Anchorage, AK Mar. 1823 Mar. 24
Chicago, IL Mar. 1823 Mar. 24
Mobile, AL Exam only Mar. 24
Rochester, NY Exam only Mar. 24
York, PA Exam only Mar. 24
Miami, FL Mar. 2530 Mar. 31
Miami, FL Exam only Apr. 12
Knoxville, TN Exam only Apr. 14
Dallas, TX Apr. 1520 Apr. 21
St. Louis, MO Exam only Apr. 21
Springfield, MO Apr. 1520 Apr. 21
Portland, ME Apr. 1520 Apr. 21
Las Vegas, NV Apr. 1520 Apr. 21
San Francisco, CA Apr. 29May 4 May 5
Nashville, TN Apr. 29May 4 May 5
Jacksonville, FL Apr. 29May 4 May 5
Waco, TX Exam only May 5
Baltimore, MD May 611 May 12
Detroit, MI May 611 May 12
Albuquerque, NM May 611 May 12
Corpus Christi, TX May 611 May 12
Miami, FL May 611 May 12
Long Beach, CA Exam only May 26
Spokane, WA June 38 June 9
Oklahoma City, OK June 38 June 9
Birmingham, AL June 38 June 9
Hartford, CT June 1015 June 16
Pittsburgh, PA June 1015 June 16
Beaumont, TX June 1015 June 16
9Year Recertification Seminar for CWI/SCWI For current
CWIs and SCWIs needing to meet education requirements with-
out taking the exam. The exam can be taken at any site listed
under Certified Welding Inspector.
LOCATION SEMINAR DATES EXAM DATE
Denver, CO Feb. 611 No exam
Dallas, TX Mar. 1217 No exam
Miami, FL Apr. 1621 No exam
Sacramento, CA Apr. 30May 5 No exam
Pittsburgh, PA June 49 No exam
San Diego, CA July 914 No exam
Miami, FL July 1621 No exam
Certified Welding Supervisor (CWS)
LOCATION SEMINAR DATES EXAM DATE
New Orleans, LA Apr. 1620 Apr. 21
Minneapolis, MN July 1620 July 21
CWS exams are also given at all CWI exam sites.
Certified Radiographic Interpreter (CRI)
LOCATION SEMINAR DATES EXAM DATE
Seattle, WA Feb. 27Mar. 2 Mar. 3
Houston, TX Apr. 1620 Apr. 21
Las Vegas, NV May 711 May 12
Miami, FL June 48 June 9
Dallas, TX July 1620 July 21
The CRI certification can be a stand-alone credential or can ex-
empt you from your next 9-Year Recertification.
Certified Welding Sales Representative (CWSR)
CWSR exams will be given at CWI exam sites.
Certified Welding Educator (CWE) Semi-
nar and exam are given at all sites listed under Certified Weld-
ing Inspector. Seminar attendees will not attend the Code Clinic
portion of the seminar (usually the first two days).
Certified Robotic Arc Welding (CRAW)
WEEKS OF, FOLLOWED BY LOCATION AND PHONE NUMBER
Feb. 10, May 11, Aug. 10, Nov. 9 at
ABB, Inc., Auburn Hills, MI; (248) 3918421
Feb. 20, May 21, Aug. 20, Dec. 3 at
Genesis-Systems Group, Davenport, IA; (563) 445-5688
Feb. 27, Mar. 2, Oct. 22, Oct. 26 at
Lincoln Electric Co., Cleveland, OH; (216) 383-8542
Feb. 6, Apr. 23, July 9, Oct. 15 at
OTC Daihen, Inc., Tipp City, OH; (937) 667-0800
Mar. 12, May 7, July 9, Sept. 10, Nov. 5 at
Wolf Robotics, Fort Collins, CO; (970) 225-7736
On request at
MATC, Milwaukee, WI; (414) 297-6996
Certified Welding Engineer (CWEng) and
Senior Certified Welding Inspector (SCWI)
Exams can be taken at any site listed under Certified Welding
Inspector. No preparatory seminar is offered.
Advanced Visual Inspection Workshop
LOCATION SEMINAR DATES EXAM DATE
Miami, FL Feb. 9, 10 Feb. 11
Miami, FL May 17, 18 May 19
Miami, FL Aug. 16, 17 Aug. 18
International CWI Courses and Exams Schedules
Please visit www.aws.org/certification/inter_contact.html.
Important: This schedule is subject to change without notice. Please verify your event dates with the Certification Dept. and confirm your course
status before making your travel plans. For information, visit www.aws.org/certification, or call (800/305) 4439353, ext. 273, for Certifica-
tion; or ext. 455 for Seminars. Apply early to avoid paying the $250 Fast Track fee.
Seminars, Code Clinics, and Examinations
Application deadlines are six weeks before the scheduled seminar or exam. Late applications will be assessed a $250 Fast Track fee.
Inspection Trends / January 2012 30
Certificaion Schedule IT Winter 2012_Layout 1 12/21/11 4:14 PM Page 30
Just the Facts By Lyndsey Deckard
Several years ago, I was the quality
manager for the owner of a major U.S.
airport project. The project was a
Design, Build, Operate, and Maintain
(DBOM) contract for an Automated
People Mover, utilizing a steel-
fabricated guideway. The
three-mile-long elevated guideway was
required to be welded in accordance
with AWS D1.5, Bridge Welding Code,
and AASHTO (American Association of
State Highway Transportation Officials).
Outriggers were mounted to the
vertical wall surfaces of the boxed
beam design guideway. These
outriggers were to support the many
miles of wiring and cables used to
deliver the power, controls, and
auxiliary equipment required for the
system. The outriggers were L-shaped
brackets approximately 2 ft long
attached to the vertical walls with -
in.-diameter weld studs.
The contractor began shooting
studs using inadequate equipment for
the stud diameter and no testing of
welds prior to each shift. The welds
produced were incomplete and did not
meet the visual requirements of proper
stud welds. AWS B4.0: 2007, Standard
Methods for Mechanical Testing of
Welds, in Section 11.1 Stud Weld
Test explains and illustrates the two
acceptable methods of stud weld
testing. Section 11.1 is quoted below:
11.1.1 Scope
11.1.1.1 This subclause covers
mechanical testing of stud welds. When
testing of stud welds is required, the
procedure shall conform to this
standard. This standard does not
specify requirements or acceptance
criteria.
11.1.1.2 When specified, this
standard is applicable to the following:
1) Qualification of materials,
welding operators, and welding
procedure;
2) Information, basis
of inspection and
fabrication quality control
(when acceptance criteria
have been established);
and
3) Research and
development.
11.1.1.3 When these
tests are specified, the
following information
shall be furnished:
1) Weld procedure
(process and parameters);
2) The specific tests and number of
specimens that are required;
3) Base metal specification/
identification;
4) Position of welding;
5) Stud analyses or specification
(part number), or both;
6) Type of testing;
7) Acceptance criteria; and
8) For bend testing, the maximum
angle of bend must be specified, and
for torque testing, the torque to be used
must be specified.
11.1.2 Normative References. The
following standards contain provisions
which, through reference in this text,
constitute mandatory provisions of this
test. For undated references, the latest
edition of the referenced standard shall
apply. For dated references,
subsequent amendments to, or
revisions of, any of these publications
do not apply.
AWS Documents:
AWS C5.4, Recommended
Practices for Stud Welding
AWS D1.1, Structural Welding
Code Steel
11.1.3 Summary of Method. The
specimen is tested by one of two
methods:
1) The stud is bent by striking with
a hammer or bending it using a length
of tube or pipe, or
2) A tensile load is applied to the
stud using an appropriate fixture. This
commonly is accomplished by use of a
torque wrench and a stand-off sleeve.
11.1.4 Significance
11.1.4.1 Mechanical testing of arc
welded studs is used to evaluate weld
soundness, tensile properties, and
ductility of the stud weld.
11.1.4.2 These tests are primarily
used as a welding procedure
qualification method to evaluate
welding parameters and surface
preparation.
11.1.5 Apparatus. Apparatus used
shall be capable of firmly holding the
test assembly and applying the bend-
ing force or torque as needed.
11.1.6 Specimens
11.1.6.1 Test specimens shall be
prepared by welding the studs being
tested (qualified) to specimen plates of
the appropriate base metal as specified
in 11.1.1.3.
11.1.6.2 Test specimens shall be
made using the appropriate automatic
timing, voltage, current, and gun
settings for lift and plunge as recorded
in 11.1.1.3.
11.1.7 Procedure. The following
are two test procedures as specified in
Part 11.1.3:
1) Bend Testing. The required
number of welded specimens shall be
Inspection Trends / Winter 2012 31
Stud Weld Testing
Fig. 11.1.1 Equipment for bend tests for welded
studs.
Just the Facts IT Winter 2012_Layout 1 12/21/11 4:19 PM Page 31
tested by bending the required
num- ber of degrees from their
original axis. Bending may be done
by striking the stud with a hammer
or by bending it using a length of
tube or pipe as shown in Fig.
11.1.1; and
2) Torque Testing. The required
number of stud welded specimens
shall be tested by applying a torque
using equipment as shown in Fig.
11.1.2. A steel sleeve or washers, of
appropriate size, are placed over
the stud. A nut of the same material
as the stud is
tightened against the
washer bearing on
the sleeve, using a
torque wrench.
Tightening the nut
applies the tensile
load to the weld.
Torque is applied
until the specified
level is reached or
the weld fails. The
results of this test
may be significantly
affected by friction. Care should be
taken to minimize this effect.
11.1.8 Report. In addition to the
requirements of applicable documents,
the report shall include the following:
1) Test results and observations,
2) The information listed in Part
11.1.1.3, and
3) Drawings showing shapes and
dimensions of studs and arc shields.
For additional information on stud
welding process selection, application,
and visual acceptance criteria, refer to
AWS C5.4: 1993, Recommended
Practices for Stud Welding.
Inspection Trends / January 2012 32
STUD
WASHER
WELD
AREA
MEMBER
Note: The dimension shall be appropriate
to the size of the stud. The threads of the
stud shall be clean and free of lubricant
other than the residue of cutting oil.
SLEEVE
STEEL
NUT
Fig. 11.1.2 Equipment for applying a tensile load to a
welded stud using torque.
Lyndsey Deckard (Deckard@
pbworld.com) is quality manager of the
Vehicle Division of Parsons Brinckerhoff
Transit & Rail Systems, Inc. He is an AWS
Senior Certified Welding Inspector, an
ASQ Certified Quality Auditor, and a
member of the AWS Certification
Committee, Examination Question Bank
Subcommittee, and Ethics Subcommittee.
Just the Facts IT Winter 2012_Layout 1 12/21/11 4:19 PM Page 32
Reader Decries Militarys Stance on CWIs
I am writing this letter in response to the article on page 9 of the
Fall (October) 2011 issue of Inspection Trends titled Former
Shipyard Worker Sentenced for False Certifications.
Please understand that I am not defending the individual named,
nor condoning his actions, but unlike others, I do feel some
sympathy and concern for his situation.
In the last sentence, it is stated, A search of the American
Welding Society records revealed the individual has never been a
Certified Welding Inspector.
As an ASNT Level III in three methods, including visual testing,
as well as being a SCWI, CWS, and CWE, I have worked many
military contracts similar to the one mentioned in your article and
know all too well that the Navy, nor any branch of the Department
of Defense for that matter, will accept a CWI for visual inspection.
I have an appreciation for what a CWI learns and his or her
certification, but the military obviously does not, and will only
accept a Level II in VT, per T9074-AS-GIB-010/271.
Too many times, I have seen people certified as Level IIs in VT
under false pretenses. Please let me explain.
A CWI learns about various welding processes, discontinuities
and defects, both mechanical (destructive) and nondestructive
testing methods, Welding Procedure Specifications, electrode and
consumables handling and control, material test reports, proper
inspection tools, codes, standards, specifications, etc.
On the other hand, the Level II in VT who goes through training
by using the ASNT Level II Study Guide for Visual and Optical
Testing, and ANSI/ASNT CP-105: ASNT Standard Topical Outlines
for Qualification of Nondestructive Testing Personnel, does not
learn hardly any of that.
If the Level II receives proper training as recommended by
ASNT, he or she will learn about the parts of the eye, lighting,
inspection angle, borescopes and fiberscopes, reflection, refraction,
diffraction, fasteners, castings, etc., and very little about welding
inspection. Some, but little.
My point: Many people being certified to Level II VT
requirements for use on military contracts are going through training
that is attempting to cram a 40-h CWI curriculum into a 24-h VT
course with lackluster results. Then, the inspector is placed with
little confidence or experience in an unfriendly environment with
inadequate skills or knowledge to adequately and professionally
perform the assigned task.
Many certified today under those conditions are frustrated, feel
trapped because they are not confident in their certification
experience, seldom if ever receive additional customized training
above and beyond the 24-h requirement, and are forced to perform
inspections in a hurry-up atmosphere to codes and standards they
have probably never seen before. Many are just going through the
motions to survive.
My hopes are that AWS, ASNT, and the Department of Defense,
will one day recognize this situation and work out a resolution
where a CWI can be used in the military industry. I also hope that
AWS will incorporate some of the Level II VT curriculum into its
CWI curriculum; for example, the effects of magnification,
psychological and physiological effects, proper lighting and
inspection angle, fatigue factors, materials besides welds, etc.
I would gladly volunteer my services to work on a Committee to
help make it happen.
Thanks for the opportunity to present my views and opinions.
Again, I am not defending nor condoning the individual, and am
probably wrongly assuming the circumstances under which he
might have worked.
The article did not state whether the individual had any other
training, as required by military contracts, only that he was not a
CWI. Sadly, however, I see the circumstances I described, alive and
well and happening every single day in our industry.
Jackie Morris
Morris Marine Consulting, LLC
AWS SCWI
ASNT Level III, MT, PT, VT
Mail Bag
Inspection Trends / Winter 2012 33
Publisher
Andrew Cullison
cullison@aws.org, Extension 249
General Management, Reprint Permission,
Copyright Issues
Editor
Mary Ruth Johnsen
mjohnsen@aws.org, Extension 238
Feature Articles
Production Manager
Zaida Chavez
zaida@aws.org, Extension 265
Design and Production
National Sales Director
Rob Saltzstein
salty@aws.org, Extension 243
Advertising Sales
Advertising Sales Representative
Lea Paneca
lea@aws.org, Extension 220
Production and Promotion
Advertising Production Manager
Frank Wilson
fwilson@aws.org; Extension 465
Senior Advertising Production Manager
Welding Journal Dept.
550 N.W. LeJeune Rd.
Miami, FL 33126
(800) 443-9353; FAX (305) 443-7404
CAN WE TALK?
The Inspection Trends staff encourages an exchange of
ideas with you, our readers. If youd like to ask a question, share
an idea or voice an opinion, you can call, write, e-mail or fax.
Staff e-mail addresses are listed below, along with a guide to
help you interact with the right person.
Mailbag IT Winter 2012_Layout 1 12/21/11 4:21 PM Page 33
Technology Notes
Interpretations: D1.6, Structural Welding Code Stainless Steel
Subject: Torque test for threaded studs below 50F
Code Edition: D1.6:2007
Code Provision: 7.7.1.4
AWS Log: D1.6-07-I05
Inquiry: Is the requirement of AWS D1.6/D1.6M:2007 subclause 7.7.1.4 for torque testing of threaded studs related or restricted to tem-
peratures below 50F?
Response: No.
Subject: Torque test for threaded studs in preproduction
Code Edition: D1.6:2007
Code Provisions: Figure 7.4, Tables 7.3 and 7.4, and clause 7.7.1.4
AWS Log: D1.6-07-I06
Inquiry: Is it intended in AWS D1.6:2007 that preproduction testing of threaded studs in 7.7.1.4 be performed by a torque test to values in
Tables 7.3 or 7.4 instead of torqued to destruction?
Response: Yes.
Subject: Torque test for threaded studs and welding operator
Code Edition: D1.6:2007
Code Provisions: 7.7.1.4 and 7.7.4
AWS Log: D1.6-07-I07
Inquiry: Is it intended in AWS D1.6:2007 that the torque test for preproduction testing of threaded studs in subclause 7.7.1.4 also be used
for operator qualification in subclause 7.7.4?
Response: Yes.
Errata D1.1/D1.1M:2010 Structural Welding Code Steel
The following errata have been identified and will be incorporated into the next reprint-
ing of this document.
Page 23, 2.27.1.1 Correct 2.24 reference to 2.25.
Page 150, note e Correct (see 4.12.4.2) reference to (see 4.13.4.2).
Page 202, 5.22.1.1 Correct 2.13 reference to 2.14.
Page 231, 6.26.6.4 First sentence, fourth line, correct or be to or by
....
Page 281, 7.1 Correct C7.6.1 reference to C-7.6.1.
Page 496, C-Table 6.7 Correct three Table 6.6 references to Table 6.7.
Page 497, C-6.26.6 This paragraph appears twice. Delete the first appearance.
Page 507, C-7.2.5 Correct last entry CL 0.125 in to read CL 0.125 in
[3.2 mm].
Page 533, Index, PJP groove welds Correct entry 4.14.4.20 to read 4.14, 4.21.
Interpretation
AWS D1.3
Structural Welding Code
Sheet Steel
Subject: Welder Qualification for
SMAW Electrodes
Code Edition: D1.3:1998
Code Provision: Clause 4.7.1.3
AWS Log: D1.3-98-I05
Inquiry: Is a welder qualified using
E7018 SMAW electrodes, F4, qualified
to run E6022 SMAW Electrodes, F1?
Response: No, see table listing in
clause 4.7.1.3.
Errata
AASHTO/AWS
D1.5M/D1.5:2010
Bridge Welding Code
The following erratum has been iden-
tified and will be incorporated into the
next reprinting of this document.
Page 82, Table 4.1 (Continued),
Matching Filler Metal Requirements for
WPSs Qualified in Conformance with
5.12.
Correct ER90C-XXX to read
E90C-XXX in the Welding Processes
and Electrode Specification Classifica-
tions column. This is the fifth entry from
the bottom of the column.
Errata
D17.2/D17.2M:2010
Specification for Resistance
Welding for Aerospace
Applications
The following errata have been iden-
tified and will be incorporated into the
next reprinting of this document.
Page 11, Table 5.2, Samples of Al-
loys Contained in Material groups I
through VIII
a
. Correct Ti-6Al-4V 2/ to
Ti-6Al-4V
c
.
Page 18, Figure 5.7, 8[200], Remove
after 8[200]
Page 26, Table 6.1, Gas Require-
ments. Correct Oxygen Specification
B-O-925 to BB-O-925.
Page 62, Table C.1, Base Metal
Group. Correct Ia to IA, Ib to
IB, IIa to IIA, IIb to IIB,
IIIb to IIIB.
Unified Number & Common De-
scription. Remove S15500 & 15-5PH
stainless steel, S17400 & 17-4PH
stainless steel, S35000 & AM350 PH
stainless steel, S35500 & AM355 PH
stainless steel, S4500 & Custom 450,
S45500 & Custom 455.
Inspection Trends / January 2012 34
Technology Notes IT Winter 2012_Layout 1 12/21/11 4:39 PM Page 34
Inspection Trends / Winter 2012 35
performing ultrasonic flaw detection
and X-ray fluorescence inspections. It
is available for download from the
Apple App Store. The Ultrasonic Tech
guide lists the acoustic properties of
most common materials, and includes a
calculator for common beam
parameters used in test setup and
interpretation. The XRF Tech Guide
includes an alloy materials guide that
provides a quick and easy look-up of
the chemistry specifications for
common alloy grades using trade
names or alloy families.
Olympus NDT
(781) 419-3900
www.olympus-ims.com
UV-LED Black Light Offers
50,000 Hours of Bulb Life
The VIBRANCE EV5000 UV
black light features four high-output
LED clusters that offer 50,000 h of bulb
life. Each light is individually tested and
certified with a wavelength of 3655 nm
and comes with a certificate of
compliance and unique serial number.
The company is also providing a limited
lifetime warranty that includes free use
of a loaner light for the duration of any
service work performed. The light
weighs 2 lb, and features an
ergonomically designed hand grip and
an angular design that places less stress
on hand-held users. It also provides a
built-in eyelet for fixed positioning.
Magnaflux
(847) 657-5300
www.magnaflux.com
Radiometer/Photometer
Measures Ultraviolet and
Visible Light
The Spectroline AccuMax
XRP-3000 digital radiometer/
photometer uses a dual-wavelength
sensor detector to measure both
ultraviolet and visible light. The
microprocessor-controlled meter
features automatic zeroing, integration,
and signal hold. It provides standard
UV intensity data as well as readouts of
visible irradiance in units and is
capable of accurately measuring a wide
variety of NDE light sources.
Spectronics Corp.
(800) 274-8888
www.spectroline.com
Video Borescope Offers
Remote Focus
The INVIZ Vuman RA-Y long-
length video borescope can be fully
articulating while completely coiled on
the reel. The system uses an advanced
microcompressor that allows the tip of
the borescope to be steered up to 100 ft
while wrapped on the storage reel or
passed through unlimited bends, rather
than only being able to articulate when
it is laid end to end in a straight line.
Compressed air is pushed through the
length of the video borescope to
manipulate the tip. The system also can
be remotely focused, allowing it to
provide high-resolution images over a
variety of distances without the need to
change tip adapters. Other features of
this lightweight, durable borescope are
an internal 320-GB hard drive for
storing jpeg and mpeg video, powerful
HID light source, easy-to-use menus,
and on-board operators guide.
Advanced Inspection Technologies
(321) 348-4650
www.aitproducts.com
Laser-Based Tool Measures
Weld Discontinuities
The WiKi-SCAN laser-based weld
inspection tool provides a 3-D scan of
joints and weld beads. It measures a
variety of features including size,
porosity, and undercut. Results can be
augmented with a picture of the weld,
then saved and e-mailed anywhere. The
tool helps inspectors measure the size
and number of discontinuities and
compare them to the applicable
welding standard.
Servo-Robot
(262) 238-4625
www.servorobot.com
Tool Can Inspect Larger-
Diameter Tubing
The companys Dolphin G3 tool
offers fast inspection of tubes up to 4-
in. ID in any shape or material. The
tool reaches inspection speeds as fast
as 10 s per tube and features patented
acoustic pulse reflectrometry
technology. It offers automated
analysis and report generation. The tool
can be used to identify defects and
discontinuities such as holes,
blockages, erosion, and pitting in hard-
to-inspect tubes including U-bends,
boiler units, and heat exchanger types.
AcousticEye
(888) 874-4779
www.acousticeye.com
continued from page 13
Print & Product IT Winter 2012_Layout 1 12/22/11 1:06 PM Page 35
Applied Bolting Technology . . . . . . . . . . . . . . . . . . . . . . . .11
www.appliedbolting.com . . . . . . . . . . . . . . . .(800) 552-1999
American Society for Nondestructive Testing . . . . . . . . .8, 9
www.asnt.org . . . . . . . . . . . . . . . . . . . . . . . . .(800) 222-2768
AWS Education Services . . . . . . . . . . . . . . . . . . .7, 19, OBC
www.aws.org . . . . . . . . . . . . . . . . . . . . . . . . .(800) 443-9353
AWS Member Services . . . . . . . . . . . . . . . . . . . . . .25, 28, 32
www.aws.org . . . . . . . . . . . . . . . . . . . . . . . . .(800) 443-9353
EST Group/Curtis Wright Flow Contol Co. . . . . . . . . . . . .13
www.estgroup.cwfc.com . . . . . . . . . . . . . . . .(800) 355-7044
G.A.L. Gage Co. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
www.galgage.com . . . . . . . . . . . . . . . . . . . . .(269) 465-5750
Iris Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
www.iris-inspection.com . . . . . . . . . . . . . . . .(800) 940-1471
NDT Seals, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
www.ndtseals.com . . . . . . . . . . . . . . . . . . . . .(800) 261-6261
Olympus NDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .IFC
www.olympusNDT.com . . . . . . . . . . . . . . . . .(781) 419-3900
Thermo Fisher Scientific/Niton Analyzers . . . . . . . . . . . .IBC
www.thermo.com/niton . . . . . . . . . . . . . . . . .(978) 670-7460
World Spec Online NDT Training . . . . . . . . . . . . . . . . . . . .23
www.worldspec.org . . . . . . . . . . . . . . . . . . . .(877) 506-7773
IFC = Inside Front Cover
IBC = Inside Back Cover
OBC = Outside Back Cover
Visit Our Interactive Ad Index: www.aws.org/ad-index
Advertiser Index
Inspection Trends / January 2012 36
Statement of Ownership, Management, and Circulation for U.S. Postal Service (Required by U.S.C. 3685)
1. TITLE OF PUBLICATION: Inspection Trends 2. PUBLICATION NO.: ISSN 1523-7168
3. DATE OF FILING: September 26, 2011 4. FREQUENCY OF ISSUE: Quarterly
5. NO. OF ISSUES PUBLISHED ANNUALLY: 4 6. ANNUAL SUBSCRIPTION: $30.00
7. MAILING ADDRESS OF KNOWN OFFICE OF PUBLICATION: 550 NW LeJeune Rd., Miami, Miami-Dade County, Florida 33126
8. MAILING ADDRESS OF THE HEADQUARTERS OR GENERAL BUSINESS OFFICES OF THE PUBLISHERS:
550 NW LeJeune Rd., Miami, Miami-Dade County, Florida 33126
9. NAMES AND COMPLETE ADDRESS OF PUBLISHER, EDITOR, AND MANAGING EDITOR:
PUBLISHER: Andrew Cullison, AWS, 550 NW LeJeune Rd., Miami, Florida 33126
EDITOR: Mary Ruth Johnsen, AWS, 550 NW LeJeune Rd., Miami, Florida 33126
10. OWNER: NAME: American Welding Society,Inc. ADDRESS: 550 NW LeJeune Rd., Miami, Florida 33126
11. KNOWN BONDHOLDERS, MORTGAGEES, AND OTHER SECURITY HOLDERS OWNING OR HOLDING 1 PERCENT OR MORE
OF TOTAL AMOUNT OF BONDS, MORTGAGES, OR OTHER SECURITIES: None
12. The purpose, function, and nonprofit status of this organization and the exempt status for Federal income tax purposes:
Has not changed during preceding 12 months
13. Publication Title: Inspection Trends 14. Issue Date for Circulation Data Below: Fall October 2011
15. EXTENT AND NATURE OF CIRCULATION:
Average No. Copies Each Actual No. Copies of
Issue during Preceding Single Issue Published
12 Months Nearest to Filing Date
A. Total No. Copies Printed (Net Press Run) 23,502 24,000
B. Paid and/or Requested Circulation
1. Paid/Requested Outside-County Mail Subscriptions Stated on Form 3541 22,879 23,059
2. Paid In-County Subscriptions Stated on Form 3541 None None
3. Sales through Dealers and Carriers, None None
Street Vendors, Counter Sales, and Other Non-USPS Paid Distribution
4. Other Classes Mailed through the USPS None None
C. Total Paid/Requested Circulation 22,879 23,059
D. Free Distribution by Mail (Samples, Complimentary and Other Free)
1. Outside-County as Stated on Form 3541 78 77
2. In-County as Stated on Form 3541 None None
3. Other Classes Mailed through the USPS None None
4 Free Distribution Outside the Mail (Carriers or Other Means) None None
E. Total Free Distribution 78 77
F. Total Distribution 22,957 23,136
G. Copies Not Distributed 545 864
H. Total 23,502 24,000
I. Percent Paid and/ or Requested Circulation 99.6% 99.6%
16. Statement of Ownership will be printed in the Winter January 2012 issue of this publication.
I certify that the statements made by above are correct and complete:
Andrew Cullison, Publisher
JAN 2012 it classified index_Layout 1 12/21/11 4:10 PM Page 36

2
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To verify the integrity of your process sytems, take
matters into your own hands.
The requirement for positive material identification (PMI)
in alloys used throughout the physical plant is more critical
than ever. Simply relying on spot testing of parts and
subassemblies is too risky and unacceptable. While that may
seem like a challenge, its now a surprisingly easy task thanks
to Thermo Scientific Niton XRF analyzers.
kapldly verlfy allcy grade and chemlstry
keccver materlal traceablllty
lsclate fnlshed welds tc valldate fller materlal and dllutlcn
Ccnfrm the lntegrlty cf prccess plplng, valves, and reactlcn
vessels
Fcr mcre lnfcrmatlcn cn cur handheld XkF analyzers, vlslt
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Moving science forward
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or cu 800-443-9353, ext. 264.
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automated conf_FP_TEMP 12/20/11 3:24 PM Page C4

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