Professional Documents
Culture Documents
1)
a)
b)
c)
d)
2)
a)
b)
c)
3)
a)
b)
c)
4)
a)
5)
a)
b)
6)
a)
QA vs QC vs INSPECTION
7)
a)
b)
c)
8)
a)
1)
a)
b)
c)
Main Responsibility
Code Compliance
Workmanship control
Documentation control
2) Personal Attributes
a) Honestly
b) Integrity
c) Knowledgeable
d) Good communicator
e) Physically fit
3) Duties Of Visual Welding Inspector And Welding Inspector
a) Duties Before Welding
b) Duties During Welding
c) Duties After Welding
d) If Any Repair
4) Basic
a) Observe
b) Record
c) Compare
5) Welding Checklist
a) Before Welding
Familiarization to the relevant code and specification
Check welding equipment and calibration certificates
Material identification (size, type and condition)
Consumables ( size, type, condition, storage and handling)
Review/withness WPS and PQR test and record
Joint preparation(check)
Welder qualification test( review/withness)
Welding process involved
Check pre-heating before welding( if required)
b)
During Welding
Check weather condition
Check clearance for welding/welder
Check welder indentification for weld
Check consumables as per wps used
Check welding parameters as per wps used
Check distartion control
Check interpass cleaning
Check run out length
Check interpass temperature
Check usage of line up clamps
Maintain daily log book
c)
After Welding
Perform visual inspection
Weld and welder indentification ( check)
Post weld heat treatment (if required)
Non-destructive testing (withness)
Acceptance standards of NDT
Repairs (if any)
Dimensional check (as per drawing)
Document control (welding reports)
d)
6)
1)
2)
3)
4)
5)
6)
7)
8)
9)
Before welding, the welding inspector shall be collect and familiarization with
all relevant document or information aid (membantu) to welding activities such as :
Familiarization with applicable codes, standards or clent specifications.
Approved and latest revision drawing (AFC).
Approved welding procedure specification carried with procedure qualification record.
To check, qualified welder with relevant valid certificates and expired date.
Also check the joint preparation to make sure it is are being prepared as per needed
by AFC drawing and as allowed by WPS or code, the joint preparation shall be
clean an free from contamination (percemaran).
Inspect the material size, type and condition, carried with mill or test certificates.
Check the consumables size, type and condition for electrode check type of flux
covering, i.e : basic, rutile, celloluse. Also check the treatment, storage and
handling of the electrode. Check the temperature shoukd baked the electrode.
Carried with batch certificate, when inspect.
Check the condition of welding machine, also review all calibration certificate for
measuring devices, i.e: welding machine, measuring tape, calipers,
electrode baking oven, pwht machine, pressure gauge and etc.
Check the preheat i.e: minimum and maximum interpass temperature and preheat
use flame type. The heating rate must be uniform.
5)
6)
7)
1)
2)
3)
4)
1)
2)
3)
4)
1)
Right after welding the inspector may perform visual inspection immediately to
detect all kind of surface defect and weld size
Before visual inspection carried out, the welded joint must be cleanliness and free
from oil or grease.
The inspector must withness Non-Destructive Testing( NDT) activities.
Inspector should monitor and withness pwht it the procee is required.
All the relevant record and report document involve during fabrication must submit
to higher authorities.
Event of the repair :
If the is any sign at detect are detected during his visual inspection and all repair
process shall be done before NDT and Pwht process.
2)
3)
4)
5)
6)
7)
WELD TERMINOLOGY
1)
a)
Welds
To joint two material by the aplication of heat or pressure.
2)
a)
Joints
A configuration of members.
3)
a)
b)
c)
d)
e)
f)
Type of joints
Edge
Corner
Lap
Tee
Cruciform
Butt
4)
a)
b)
c)
d)
e)
f)
Type of weld
Fillet
Spot
Butt
Edge
Plug
Compound
5)
a)
b)
c)
d)
e)
WELD TERMINOLOGY
6)
a)
b)
c)
d)
e)
f)
g)
h)
7)
a)
b)
c)
8)
a)
b)
c)
d)
WELD TERMINOLOGY
e)
1 = Root of Penetration
2 = Hot pass
3 & 4 = Fill pass
5,6 & 7 = Capping
f)
A = weld width
B = excess weld metal
C = excess penetration
D = root width
E = thickness of parent metal
g)
A = Nominal design
B = Actual throat thickness
C = Horizontal leg length
D = Vertical leg length
WELD TERMINOLOGY
*
h)
9)
b)
c)
WELDING PROCESS
1)
a)
General
Welding is the process of joining two or more pieces of material together by
bringing the atoms of each piece into such close contact that an atomic bond
takes place, i.e: the separate pieces fuse together to form one.
2)
a)
Type Of Welding
Smaw = shielded metal( menyelamatkan logam) Arch welding( lengkungan
menyatukan) (AWS)
Mma = manual metal Arch (BS)
b)
c)
d)
SAW
e)
f)
PAW
g)
ESW
= electroslag welding
WELDING PROCESS
2a)
a)
b)
c)
Process Diagram
WELDING PROCESS
Types of welding machine (Plant)
a)
b)
c)
d)
Transformer
Dc Rectifier
Engine Driven
Inverter
Type of flux covering used
a)
Basic = E 7018 CO
b)
c)
Rutile = E 6013 CO
Cellulose = E 6010 H
Functions of flux covering
a)
b)
c)
d)
e)
a)
b)
c)
WELDING PROCESS
Variables
a)
b)
c)
d)
e)
f)
Current
Voltage
Travel Speed
Electrode andle
Open circuit voltage ( O.C.V)
Polarity
Consumables
a)
b)
c)
d)
a)
b)
c)
a)
b)
c)
d)
e)
f)
Fumes
Electric shock
Burn skin
Arc rays
Fire
Explosion
WELDING PROCESS
Welder Contorls
a)
b)
c)
Arc length
Angle of electrode
Speed of travel
Main Electrode Covering Types
a)
b)
c)
a)
a)
Voltage too low = poor penetration, electrode freezes to work, possible stray arcs,
fusion detects, slag inclusions, unstable arc, irregular bead shape.
b)
Voltage too high = Parasity, spatter, arc wander, irregular bead, slag inclusions,
very fluid weld pool, positional welding difficult.
Speed of travel - the speed of travel affects heat input and therefore also effects
metallurgical and mechanical conditions.
a)
Travel speed too fast = norrow thin bead, slag inclusion, fast cooling,
(metallurgical problems), undercut, poor fusion/ penetration.
b)
Travel speed too slow = excessive deposition, cold laps, slag inclusions, irregular
bead shape.
WELDING PROCESS
Advantages
a)
b)
c)
d)
e)
f)
g)
h)
i)
a)
b)
c)
d)
e)
f)
g)
h)
low productivity
wastage of consumable
need proper interpass cleaning
produce fumes
not suitable for reactive material ( tatinium or zirconium)
need oven to bake or dry the electrode
not suitable for thick material
high skill welder required
Equipment Diagram
= Consumables electrode
= Core wire
= Arc
= Flux covering
Slag
Parent metal
Weld pool
Weld metal
WELDING PROCESS
2b)
a)
b)
c)
Process Characteristics
TIG is an arc welding process usess an arc between a non- consumable electrode to
the weld pool.
TIG may be used with or without filler rod ( Autogeneous)
Type of power source is constant current or dropping arc characteristic.
WELDING PROCESS
Process Diagram
Types Of Tungsten
a)
b)
c)
d)
i.e :
WELDING PROCESS
Types Of Polarity
a)
b)
c)
1) Electric charactertics
2) Heat distribution
3) Penetration
a)
b)
a)
b)
Types of torch
Air cool torch
Water cool torch
DC -
AC
WELDING PROCESS
Equipment Diagram
A = current conductor
B = shielding gas in
C = welding torch
D = contact tube
E = non consumable tungsten electrode
F = gaseous shield
G = welding wire
H = arc
I = weld metal
J = optional copper backing bar
K = gas nozzle
Types of gas
a)
b)
c)
d)
a)
b)
current
voltage
c)
d)
travel speed
gas flow rate
d)
e)
f)
electrode extension
torch angle
polarity
Consumable
a)
b)
c)
a)
b)
c)
WELDING PROCESS
Advantages
a)
b)
c)
d)
e)
f)
g)
a)
b)
c)
d)
e)
f)
a)
b)
c)
d)
e)
tungsten inclusion
silica inclusion (ferritic steel)
porosity
solidification crack (autogenous TIG with fusible insert ring)
root concavity
f)
crater pipe
g)
arc strike
Safety
a)
b)
c)
d)
e)
f)
arc rays
fumes
burn skin
electric shock
fire
explosion
WELDING PROCESS
2c)
Gas Metal Arc Welding & Metal Inert-Gas & Metal Active- Gas
Process characterics
Modes of transfer
Process diagram
Equipment diagram
Advantages & disadvantages
Variables
Typical of detects
Safety
a)
b)
Process characterics
MIG process, normally gas used : -Argon, Helium, Ar + Helium
MAG process, normally gas used : -CO , CO + Argon
: -Argon + O ( stainless steel)
c)
d)
MIG/MAG is an arc welding process used an arc between a continous filler wire to
the weld pool.
Type of power source is constant voltage or flat characterictics.
Modes of transfer
a)
b)
WELDING PROCESS
c)
d)
pulsed transfer : -(i) (utilised spray transfer during high current and low current for
background current)
(ii) (thin & thicker material welding, better fusion, low heat input)
Process diagram
WELDING PROCESS
Equipment diagram
~Gas nozzle
~Contact tube
~Nozzle to work distance
~Arc length
~Electrode extension
~Contact tube to work distance
~Work piece
a)
b)
a)
b)
a)
b)
a)
b)
c)
Type of roller
V Groove - steel
U Groove - AI
Knurled - FCAW
Variables
a)
Current
b)
c)
d)
e)
f)
g)
Voltage
Travel speed
Electrode ectension
Gas flow rate
Contant tube to work distance
Nozzle to work distance
a)
b)
c)
Consumables
size : -min 0.8mm - max 1.6mm
Type : -as per parent metal
Condition : -store at clean and dry area or keep inside it orginal container
WELDING PROCESS
c)
d)
Type of gas
CO (deeper penetration)
Argon (for non-ferrous material{aluminium} / not suitable for steel because poor
cap profile)
Helium
Argon + CO (less spatter butt less penetration)
a)
b)
c)
Types of material
Size : -min 0.8mm - max 15mm
Type : -carbon, alumi, stainless steel & alloy steel
Condition : -moderate cleaning
a)
b)
c)
d)
e)
f)
g)
Type of detects
Lack of sidewall fusion (dip transfer)
Solidification cracking (spray transfer)
Porosity
Undercut
Spatter
Crater pipe (star)
Silica inclusions (ferritic steel)
a)
b)
c)
d)
Safety
Arc rays
Fumes
Burn skin
Electric shock
e)
Fire
f)
Explosion
a)
b)
c)
d)
e)
f)
g)
h)
Advantages
less wastage of consumables
high productivity
can weld thin and thick materials
can weld most materials
range of modes of metal transfer
can be used for out of position (all welding position) < dip transfer spray } check
can be magenacel
minimum cleaning
a)
b)
WELDING PROCESS
a)
b)
c)
d)
e)
f)
g)
h)
2d)
Disadvantages
expensive welding machine
need gas for shielding
a lot of spatter (dip transfer)
difficult to manipulate the torch
high maintenance
high o zone level
need proper shielding when use on site
not suitable for restricted access
Submerged Arc Welding
Process characteristics
Types of flux
Types of power source
Types of polarity
Variables
Consumables
Materials
Types of detects
Advantages & Disadvantages
Process Characteristics
a)
b)
SAW is an arc welding process uses an arc between a continous bare wire to the
base metal.
The arc is shielded by a fused or aglomerated flux.
c)
The arc and molten weld metal are completely submerged beneath the layer of
d)
therefore unnecessary.
Submerged arc welding is normally fully mechanised,but may be used manually or
in a fully automatic mode.
shielding flux and are not visible to the eye, protection against the arc light is
a)
Types of flux
Fused : - (i) flacky appearance
(ii) high resistance to moisture absorbtion
(iii) good recycle
(iv) smooth profile
(v) good properties
WELDING PROCESS
b)
a)
b)
c)
d)
e)
f)
g)
h)
WELDING PROCESS
Process diagram
a)
b)
a)
b)
c)
DC + = (deep penetration)
DC - = (higher deposition)
AC = (prevent arc blow at higher current)
Variables
a)
current
b)
voltage
c)
d)
e)
f)
g)
travel speed
electrode extension
wire size
flux depth
direction of travel
a)
b)
c)
d)
Consumables
Size : -min 2.0mm - max 4.0 mm
Type : -as per parent metal
Condition : -size,store dry and clean area or keep inside it orginal container(wire)
Flux : (i) fused : -no bake required
(ii) aglomerated : -baked as per manufacturer recommendation
WELDING PROCESS
a)
b)
c)
Materials
Size : -min 6mm - max 15.04mm
Type : -carbon, stainless steel, alloy steel
Condition : -moderate cleaning
a)
b)
c)
d)
e)
f)
g)
h)
Types of detects
Solidification
Excessive weld metal
Burnthrough
Porosity
Lack of sidewall fusion
Slag inclusions
Root cancavity
Undercut
a)
b)
c)
d)
e)
f)
Advantages
Flux can be recycle
Low weld metal cost
Easily automated
Low levels of o zone
High productivity
No visible arc light
a)
b)
c)
d)
Disadvantages
Restricted welding positions
Arc blow on DC current
Shrinkage defects
Difficult penetration control
WELDING PROCESS
3)
Type of current
a)
b)
Duty cycle % = the ratio of arc time to the total time base on 10 minutes.
WELDING PROCESS
5)
a)
b)
c)
d)
6)
a)
b)
c)
Type of polarity
AC = Altternative current
DC + = Direct current electrode positive/ direct current srect positive
DC - = Direct current electrode negative / direct current reverse negative
AC
DC +
DC 6)
<Sample>
1)
2)
3)
WELDING IMPERFECTIONS
a)
a)
b)
c)
Imperfections
any discontiniuties that the size below the "ACCEPTANCE CRITERIA" of
"CODE & SPECIFICATIONS"
Defects
any discontiniuties which the size above the "ACCEPTANCE CRITERIA" of any
"CODE & SPECIFICATIONS".
defects can be lead to : -(i) Brittle failure
(ii) Fatigule failure
(iii) Stress concentration area(initiation point)
defects : -(i) volumetric(3 dimensional),type of defects which produce less stress
raisers.
(ii) planar(2 dimensional),type of defects which produce significance stress
raisers.
Definition
This is achieved as long as the following features apply:
Welds should consists of solid metal throughout a cross section at least equal to
that of parent metal.
(ii) All parts of a weld should be fully fused to the parent metal.
(iii) Welds should have smoothly blended weld.
a)
(i)
a)
Weld Defects
Defects which may be defected by visual inspection can be grouped under seven
headings.
~
~
~
~
~
~
~
Root defects
Contour defects
Surface irregularities
Cracks
Lack of solid metal
Lack of fusion
Miscellaneous
a)
Cracks
Process cracks
(i) Haz hydrogen cracking
(ii) Weld metal hydrogen cracking
(iii) Solidification cracking
(iv) Lamellar tearing
WELDING IMPERFECTIONS
b)
(i)
(ii)
~ classified shape = transverse
~ classified position = centreline(hot cracks)
Transverse weld metal cracks
(iii)
~ classified shape = longitudinal
~ classified position = centreline(hot cracks)
Longitudinal weld metal cracks
(iv)
~ classified shape = chevron
~ classified position = fusion zone
Lamellar tearing
(v)
~ classified shape = brached
~ classified shape = crater
Crater cracks
WELDING IMPERFECTIONS
~
*
*
~
*
*
a)
Incomplete penetration
other terms for the some defects are :
lack of penetration
lack of root penetration
in the case of double sided welds terms :
lack of inter-penetration
lack of cross- penetration
Face
(i)
Incomplete filled groove
(ii)
Poor cap profile
(iii)
Incomplete filled groove(+) lack of sidewall fusion
b)
(i)
Root
Incomplete root fusion
(ii)
Incomplete root penetration
(iii)
Lack of interun fusion
WELDING IMPERFECTIONS
Causes Of Weld Defects
a)
1)
2)
3)
4)
5)
6)
7)
b)
1)
2)
3)
4)
5)
Causes
Insufficient arc power to produce positive bead
Excessive backing pressure(GTAW)
Lack of welder skill
Slag flooding in backing bar groove
Root face too large
c)
1)
2)
d)
Inter-run imperfections
~ Irregular along the fusion line between weld beads
Causes
Low arc current resulting in low fludity of weld pool
Too high travel speed
Inaccurate bead replacement
Poor inter-run cleaning
1)
2)
3)
4)
WELDING IMPERFECTIONS
e)
1)
2)
3)
4)
5)
f)
1)
2)
3)
4)
g)
1)
2)
3)
4)
h)
Excess penetration
~ Projection of the root penetration bead beyond a specified limit
1)
2)
3)
4)
Causes
Weld input energy to high
Incorrect weld preparation i.e, excessive root gap, thin edge preparation & lack of
backing
Use electrode unsuited to welding position
Lack of welder skill
WELDING IMPERFECTIONS
i)
1)
2)
3)
1)
2)
3)
4)
5)
Poor fit-up
Angular misalignment
Gas pores/porosity
~ Gas pores trapped within the weld metal
~ Formed by entrapped gas during the solidification of molten metal
~ Other terms which relate to entrapped gas in welds are :
* Blowhole = a cavity generally over 1.5mm
* Wormhole (piping) = an elongated or tubular cavity
* Hollow bead = elongated porosity in the root bead (pipe line terminology)
* Herving bone porosity = wormholes side by side taking on a herring bone pattern
Causes
Damp fluxes/corroded elctrode
Grease/hydrocarbon/water contamination of prepared surface
Air entrapment in gas shield
Too high arc voltage/ arc length
Incorrect/ insufficient deoxidant in electrode, filler or parent metal
WELDING IMPERFECTIONS
k)
1)
2)
3)
4)
l)
1)
2)
3)
4)
5)
m)
Surface porosity
~ Gas pores which break the surface of the weld
Causes
Damp or contaminated surface of electrode
Low fluxing activity
Excess sulphur (particularly free-cutting steels) producing sulphur oxide
Loss of gas shield gas due to long arc or high breezes(GMAW)
Crater pipe
~ other terms for the same defects are :
* crater crack
* star crack
~ A shrinkage cavity at the end of a weld run where the arc is terminated (the welder
remove the welding holder were fast from parent metal)
Causes
Lack of welder skill due to using process with too high current
Inoperative crater filler (GTAW)
Too fast a coding rate
Deoxidization reactions and liquid to solid volume change
Contamination
1)
Arc strikes
~ Random area of fused metal where the electrode, the holder, or current return
clamp accidentally touched the work and produced a short duration arc
Causes
Poor access to work
2)
3)
Failure to provide on insulated resting place for the electrode holder or torch when
4)
not is use
Loose current return clamp
n)
1)
2)
3)
4)
Spatter
~ small droplets of electrode material can be projected clear of the weld and may
fused to the parent metal
Causes
High arc power
Magnetic arc blow
Incorrect setting for GMAW process
Damp electrode
WELDING IMPERFECTIONS
o)
1)
2)
3)
4)
p)
1)
2)
3)
4)
q)
Undercut
~ An irregular groove at the toe of a run in the parent metal or in previously deposited
welding,
Causes
Melting of top edge due too high welding current (especially at free edge) or high
travel speed
Attempting on HV fillet weld leg length > 9mm
Excessive / incorrect weaving
Incorrect electrode angle
Overlap
~ An imperfection at the toe of a weld caused by metal flowing on the surface of the
parent metal without fusing to it,
Causes
Poor electrode manipulation
High energy input/ low travel speed causing surface flow of fillet weld
Incorrect positioning of weld
Electrode having too high a fluidity
Misalignment
~ The non-alignment of two abutting edges in a butt joint
1)
2)
* Linear misalignment
* Angular misalignment
Causes
Inaccuracies in assembly procedures or distrotion from other welds
Excessive "out of flatness" in hot rolled plate or sections.
r)
Burn through
1)
2)
3)
4)
~ a localized collapse of the weld pool due to excessive penetration resulting in a hole
in the root run
~ RT film = burn through = black
Causes
High amps/ volts
Small root face
Large root gap
Slow travel speed
WELDING IMPERFECTIONS
s)
Inclusions
~
*
*
*
~
1)
2)
3)
4)
5)
Record
only
Area (L,W)
L,D
L Only
L,H
L,D
L Only
Area (L,W)
L Only
Area (L,W)
Area (L,W)
L Only
L Only
L,H
L,D
L Only
L,H
L,H
Only
L,W
MECHANICAL TESTING
a)
b)
c)
a)
Mechanical testing is destructive testing of welded joints are usually carried out to :
Approve welding procedures
Approve welders
Production quality control
Definition of mechanical testing
The ultimate means by which the mechanical strength and toughness of a prepared
test object can be determined by subjecting it to mechanical forces beyond the limits
of its own mechanical resistance.
a)
b)
c)
d)
e)
f)
g)
h)
Properties of steel
~ mechanical properties :
Hardness - a measure of the resistance to penetration
Tensile strength - a metal's ability to with stand stress in tension
Compresive strength - a metal's ability to with stand a pressing or squeezing together
Shear strength - a metal's ability to resist a sliding past type of action
Fatigue strength - ability to take repeated loading
Toughness - ability to resist shock
Ductility - ability of a metal's to stretches before it breaks
Brittleness - metal does not stretches before it fracture
a)
b)
Mechanical testing is the following test have units and are termed qualitative tests
Macro testing
Bend
Hardness testing
hardness test for measurements made by indenting the metal with a penetrator under
a known load
b) determined by :
(i) load applied
(ii) how load is applied
(iii) configuration of penetration
a)
c)
(i)
(ii)
(iii)
(iv)
Various methods
Brinell
Rockwell
Vicker
Knoop
MECHANICAL TESTING
c(i)
~
~
~
D = Size of indentor
d = Depth of indentation
P = Load
c(ii)
~
~
c(iii)
~
~
~
HV = 1.825 P = 350VPN
d
c(iv)
~
a)
MECHANICAL TESTING
c)
d)
~
MECHANICAL TESTING
Tensile Test
a) Various methods
(i) Transverse tensile
(ii) All - weld metal tensile test
(iii) Cruciform tensile test
(iv) Short tensile test
a(i)
~
~
Reporting results
Type of specimen ( e.g - reduced section)
Whether weld reinforcement is removed
Dimensions of test specimen
The ultimate tensile strength in N/mm, psi or mpa
Location of fracture
Location and type of any flows present if any
Elongation = EXTENSION
X 100
ORGINAL LENGTH
X 100
MECHANICAL TESTING
~
Elongation % = 14 X 100
50
Elongation = 28 %
Reporting results
Type of specimen (e.g. reduced section)
Dimensions of test specimen
The u.t.s, yield
Macro/ Micro
Objectif of test
Macro/microscope examinations are used to give a visual evaluation of a
cross- section of a welded joint.
Carried out on full thickness specimens
The width of the specimen should include HAZ, weld and parent place
test :- macro
cut the specimen
grind of file
polishing ( P200,P400,P600,P800,P1200)
etching nital - 2% - 5% (1% - 2%)
magnification x 10 ( x1000)
They maybe cut from a stop/ start area on a welders approval test
macro/micro (will reveal)
weld soundness
distribution of inclusions
number of weld passes
metallurgical structure of weld,fusion zone and HAZ
location and depth of penetration of weld
~
a)
b)
(i)
(ii)
(iii)
Bend Test
object of test
To determine the soundness of the weld zone. Bend testing can also be used to
given an assessment of weld zone ductility
There are three ways to perform a bend test :
Face bend
Root bend
Side bend (generally for materials above 12mm thickness)
MECHANICAL TESTING
Reporting result
Thickness and dimensions of specimen
Direction of bend (root,face or side)
Angle of bend (90,120,180)
Diameter of former (typical 47T)
Appearance of joint after bending (e.g. type and location of any flaws)
~
a)
b)
c)
d)
e)
~
a)
b)
Reporting results
Thickness of parent material
Throat thickness and leg length
c)
Location of fracture
d)
e)
f)
Depth of penetration
Defects present on fracture surfaces
MECHANICAL TESTING
~
a)
b)
c)
d)
e)
~
a)
b)
c)
d)
e)
Reporting results
Thickness of parent material
Width of specimen
Appearance of joint after fracture
Depth of penetration
Defects present on fracture surfaces
WELDABILITY
a)
(i)
(ii)
b)
(i)
(ii)
Metallurgical properties
structure and properties of the weld metal
structure and properties of the h.a.z
c)
(i)
(ii)
(iii)
(iv)
Physical properties
thermal resistance
coefficient of thermal expansion
elastic modulus
viscosity of molten material
d) Chemical properties
(i) oxidation resistance
(ii) surface films
(iii) impurities
a)
(i)
(ii)
(iii)
Classification of steel
Plain carbon steels
low carbon steel 0.01 - 0.3%
medium carbon steel 0.3 - 0.6%
high carbon steel 0.6 - 1.4%
b)
~
c)
~
Alloy
a mixture of two or more elements and one of the element is steel
: Low alloy steels < 7%
: High alloy steels > 7%
Carbon
WELDABILITY
a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
k)
l)
a)
b)
c)
WELDABILITY
~
a)
b)
c)
d)
~
HAZ
the extent of changes will be dependent upon the following :
material composition
cooling rate, fast cooling higher hardness
heat input, high inputs wider HAZ
the HAZ can not be eliminated in a fusion weld
Formula calcute arc energe
ARC ENERGY = V X A
T.Speed
Question
Amps = 200 Volts = 32
Travel speed = 240mm/min
Heat input
= Amps X volts
Travel speed mm/sec X 1000
Heat input
= 200 X 32 X 60
240 X 1000
WELDABILITY
Heat Input
a)
(i)
(ii)
b)
(i)
(ii)
(iii)
a)
b)
c)
d)
e)
WELDABILITY
f)
= phosphorus
cu = copper
g)
List of Gas
H = Hidrogen
HE = Helium
NE = Neon
Ar = Argon
Kr = Kripton
Xe = Xeon
Rn = Radon
F = Fluorin
CI = Klorin
Br = Bromin
I
= Iodin
O
S
Se
N
P
= Oksigen
= Sulphur
= Selenium
= Nitrogen
= Fosforus
= Karbon
= Boron
WELDABILITY
a)
b)
c)
d)
Weldability
weldability can be defined as the ability of a material to be welded by most of the
common welding processes,and retain the properties for which it has been designed
a steel which can be welded without any real dangerous consequences is said to
possess good weldability
a steel which can not be welded without any dangerous consequences occuring is
said to possess poor weldability. Poor weldability normally generally results in the
accurrence of some sort of cracking problem
Weldability is a function of many inter-related factors but these may be
summarised as :
1) composition of parent material
2) joint design and size
3) process and technique
4) access
e)
f)
Other factors affecting weldability are welding position and welding techniques
a)
b)
c)
d)
e)
a)
b)
c)
a)
b)
c)
d)
d)
Objectif of P.W.H.T
Post weld heat treatments are used to change the properties of the weld metal,
controlling the formation of structure. Pre-heat treatments are used basically to
increase weld ability,control expansion and contraction forces during welding.
PWHT process in which metal in the solid state is subjected to one or more
controlled heating cycles after welding
PWHT is normally carried out for the purpose of stress relief, i.e : the reduction
of localised residual stresses.
This pwht process methods for stress relief of a welded assembly.
a)
b)
c)
d)
e)
f)
a)
b)
c)
5(a) Annealing
~ similar with normalizing except that cooling takes place still more slowly in
temperature controlled oven.
5(b) Hardnenig/Quenching
~ a controlled cooling process which causes metals to harden
~ materials must be heated at any elevated temperature, but if hardness in
important, the materials should be heated above the upper critical temperature
5(c) Normalizing
~ involved heating the material above the upper critical temperature and cooling it
slowly in room temperature
Quenching
(EFFECTS)
hardens
strengthens
causes brittleness
causes internal stresses
causes distortion
causes cracking
Is a fast cooling process
Hardness = Decreased
Strength = Decreased
Toughness = Increased
Brittleness = Decreased
Ductility
= Increased
Internal stresses = Decreased
Distortion = Reduced
Cracking = Reduced
Combined Thickness
CRACK
a)
b)
c)
Process cracks
hydrogen induced cold cracking (HICC)
solidification cracking (HOT TEARING)
weld decay
a)
b)
c)
d)
When considering any type of crack mechanism, three elements must be present
for it's occurrence :
Stress = stresses > 0.5 of the yield stress
Temperature = < 300C
Hardness = > 350 VPN
Hydrogen content = 15ml / 100gm of deposited weld metal
a)
b)
c)
Cracks
characteristics
causes influence
controllor avoidavce
a)
Hydrogen cracking
Hydrogen causes general embrittlement and in welds may lead directly to cracking
Hydrogen cracking
causes :
microstructure
a)
b)
c)
d)
Stress
a)
b)
c)
CRACK
Hydrogen
Hydrogen
Hydrocarbon
Hydrated oxides
Damp flux
a)
b)
c)
d)
a)
b)
c)
d)
e)
f)
g)
also known as hydrogen induced cold cracking, delay cracking, underbead cracking
and chevron.
hydrogen is the major influence to this type of cracking.
source of hydrogen may be from maisture or hydrocarbon such as grease, paint on
the parent material, damp welding fluxes or from condensation of parent material.
hydrogen is absorbed by the weld pool from the arc atmosphere.
during cooling,much of this hydrogen escapes from the solidified bead by the
diffusion but some also diffuses into the HAZ of the parent metal.
type of cracking is intergranular along grain boundaries or transganular.
requires susceptible grain structure, stress and hydrogen and low temperature is
reached.
h)
most likely in HAZ for carbon manganese steel and in weld meatl for HSLA steel.
a)
CRACK
b)
c)
d)
e)
f)
g)
h)
a)
b)
c)
d)
a)
b)
convex
control depth to width ratio
c)
control ferrite%
Solidification cracking
causes
mechanical
a) stresses thick materials poor joint design
b) restraint poor fit-up
a)
b)
CRACK
a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
k)
= Solid crack
= Sulfur anrich liqued/filler
= Shrinkage stain
a)
b)
c)
d)
e)
f)
g)
h)
CRACK
Lamellar Tearing
causes : (a) poor through thickness ductility sulfide or silicate high sulphur
(b) stress poor fit-up poor joint high strength weld metal
(c) hydrogen hydrocarbon hydrated oxides damp flux
(d) Restrain Thick materials
a)
b)
c)
d)
a)
b)
c)
d)
e)
f)
g)
h)
i)
CRACK
i)
a)
b)
c)
d)
e)
f)
g)
h)
c > 0.1%
a)
b)
c)
d)
e)
CRACK
a)
b)
c)
a)
b)
c)
d)
e)
a)
b)
c)
d)
e)
f)
a)
b)
c)
d)
e)
,
SYMBOLS
BS 499 PART 2
BS EN 22533/ISO 2553
AWS 2.4
a)
BS 499 PART 2
Arrow profile
Reference Line
Tail
Arrow Line
b)
SYMBOLS
c)
SYMBOLS
d)
SYMBOLS
f)
other side
g)
Type of Arrow
Plug weld
Spot weld
Seam weld
SYMBOLS
h)
Joint detail
a)
b)
SYMBOLS
c)
d)
e)
Type of arrow
Plug weld
Spot weld
Seam weld
Surfacing
Arrow profile
RESIDUAL STRESS
Level of residual stress
~ yield strength of parametal at room temperature.
Level of residual stress after P.W.H.T.
~ yield strength of parent metal during P.W.H.T
Disdebion of stress
A'=
B'=
C'=
D'=
Normal stress
~ stress arising from a force perpendicular to the cross
Shear stress
~ stress arising from forces which are parallel to and lief in the plane of the cross
sectional are.
example :
most critical (100 % NDT)
RESIDUAL STRESS
a)
b)
c)
d)
e)
Hoop stress
Stress acting circumferentially around a pipe due to internal pressure
i)
j)
a)
b)
c)
f)
g)
h)
RESIDUAL STRESS
a)
b)
c)
d)
~
~
~
~
~
DIRECTION OF DISTORTION
Bowing Distortion
Transverse Distortion
Angular Distortion
a)
b)
c)
d)
e)
f)
g)
WELDING CONSUMABLES
a)
b)
c)
d)
e)
Objectif
Consumables used in arc welding may be a combination of wire and flux, or bare
solid wire.
Flux may be present either as a core-for some m.a.g applications.
Flux coating present for SAW process.
M.I.G and T.I.G process which use bare solid wire and no flux.
Consumables which are added separately to the weld pool may be know as filler rods
or filler wires,if they are part of the welding circuit providing one end of the arc,they
are know as electrodes.
Electrode code(samples)
BS EN 440 1994( G 463 M G3 Si 1)
G = wire electrode and/or deposit/ gas shielded metal arc welding.
46 = strength and elongation in the all weld metal condition(i.e 460 minimum yield
strength N/mm, 530-680 tensile strength N/mm, 20% minimum elongation).
3 = impact properties,temperature for minimum average impact energy of 47J.
m = shielding gas as to BS EN 439. The symbol "m" for mixed gasses,the symbol "c"
for shielding gasses.
G3 Si 1 = chemical composition of the wire electrode(i.e silicon,manganese,aluminium
etc. contents.)
a)
b)
Aws (E 7018m)
E = electrode
70 = 70,000 psi specified minimum ultimate tensile strength.
1 = welding position suitable (all position)
8 = flux type and electrical characteristic
m = resistant to moisture pick up
c)
Aws (E 7018G)
E = Electrode
70 = 70,000 psi specified minimum ultimate tensile strength
1 = Welding position suitable(all position)
8 = Flux type and electrical characteristic
G = Low alloy steel (alloy content)
WELDING CONSUMABLES
d)
3) Electrode content
(i)a) MMA/SMAW (i) Basic
Note : Polarity DC + OR AC
(ii) Rutile
E7016 = Potasium
E7018 = Iron powder,calcium carbonate
E9015 = Sadium
Note : Polarity DC +
(iv) Iron powder
b)
c)
d)
e)
WELDING CONSUMABLES
(ii)a) Each consumables is critical in respect to
(i) Size
(ii) Classification/supplier
(iii) Condition
(iv) Handling and storage
(v) Treatments (e.g baking/drying)
(iii)a) Welding consumables for mmA/SMAW
(1) Consist of a core wire typically between 350 - 450mm in length and from 2.5-6mm
in diameter.
(2) The wire is covered with an extruded flux coating.
(3) The core wire is generally of a low quality rimming steel.
(4) The weld quality is refined by the addition of refining agents in the flux coating.
(5) The flux coating many elements and components that all have a variety of functions
during welding.
Sample :
E 51 33B
160 20H
b)
Rutile electrodes :
used mainly on general purpose work
low pressure pipe work,support brackets
c)
d)
WELDING CONSUMABLES
e)
f)
Cellulose electrodes :
Used mainly for pipeline welding
Suitable for welding in all position especially vertical down,stove technique
They produce a gas shield high in hydrogen
Deep penetration/fusion characteristic
g)
h)
i)
j)
Basic electrodes :
Used mainly for high pressure work and for materials of high tensile strength.
They are capable of producing welds of a low hydrogen content.
Prior to use they may be baked to give a low hydrogen potential typically 300C for
1 hour plus.
WELDING CONSUMABLES
k)
l)
m)
(v)
a)
WELDING CONSUMABLES
b)
Electrode : E6013
: Dried max 120C
c)
Electrode : E6010
: Never baked or dried
: Batch certificate
WELDING PROCEDURE
(i)a)
~
~
~
~
~
A welding procedure showns all the variable involved with the production welding
Welding process
Technique
Consumable type
Material
Preheat
b)
Once the content of a written procedure has been approved, a weld is made in
accordance with the requirements of that procedure,this is known as a welding
procedure test or welding procedure qualification test (PQR).
c)
The welding procedure made,this will depend on whetever the proposed change is an
essential or non-essential variable.
d)
Do all welding procedures need to be written most production welding procedure are
formatted on written documents or computer spread sheet,but they need not be
written and may be a product of experience.
e)
f)
(ii)
a)
Once the weld has been completed it is usually visually inspected,then radiography
or ultrasonic testing is usually applied.
b)
Finally, and most important mechanical test are performed to ensure that the desired
level of mechanical properties have been meet.
d)
From this data, a workable document for production welding is prepared and called a
welding procedure specification(WPS).
e)
A cswip 3.2 senior welding inspector is normally responsibles for the testing welding
procedure specification.
b)
c)
(iv)
a)
b)
c)
d)
e)
(v)
(vi)
a)
b)
c)
d)
e)
f)
g)
Each welding procedure will show a range to which the procedure is approved
(extent of approval)
c)
Variables are required for metals for which other section specify notch- toughness
test are in addition to the essential variables for each welding process.
(e.g. change group no,base metal thickness limit,pwht, preheat temperature and etc)
(xv) ASME
a) Shall
~ a mondatory practise which will require change of WPS if not followed.
b)
Should
~ a recommended practise.
2)
(i)
a)
WELDER TEST
Objectif
A welder test,also known as a welder qualification test (W.Q.T), or welder approval
test is carried out to ensure the welder is a able to produce a sound weld that meets
the requirements of the relevant welding procedure and application specification.
b)
c)
To give maximum confidence that the welder meets the requirement of the approved
procedure(WPS)
d)
The test weld should be carried out on the some material and some conditions as for
this site welds.
e)
The welder who carries out the procedure qualification weld automatically qualify
when the procedure qualifies.
Welding variables
Parent material type
Consumable or shielding gas type
Dimensions of parent material
Welding position
Types of joint
Preheat temperature
Post weld heat treatment procedure
(ii)
a)
b)
b)(i) Defines
(iv)
Testing requirements
(v)
Acceptance requirements
(vi)
Re test
NON-DESTRUCTIVE TESTING
Penetrant Testing
Magnetic Particle Testing
Eddy Current Testing
Ultrasonic Testing
Radiographic Testing
NOTE :
(i)
a)
(i)
(ii)
(iii)
b)
c)
d)
e)
f)
g)
surface defects
internal defects
Penetrant Testing
Objectif
also known as a
Dye Penetrant inspection(DPI)
Penetrant flaw detection(PFD)
Liquid penetrant inspection(LPI)
this surface inspection con't applicable to all non-parous,non-absoring material.
penetrating fluid(penetrant) applied on to component and drawn into defect by
capillary action.
this type of testing uses the forces of capillary action to defect surface breaking
defects.
it is impossible to defects which do not break the surface with this method.
but it can be used on both magnetic and non-magnetic materials providing they are
non-porous.
there are several types of penetrant system,this included the following which are
shown in a descending order of flaw detection sensitivity.
i)
One of the most common site used penetrant systems use solvent based colour
contrast penetrants in aerosls. A typical sequence of operations on a steel test item
is as follows.
NON-DESTRUCTIVE TESTING
(ii)
How to apply
a)
clean are using wire brush,cloth and solvent. On aluminium,other soft alloys and
plastic,wire brushing should not be used,as there is a danger that surface breaking
defects may be closed.
b)
apply penetrant- leave for 15 minutes.colour contrast penetrants are normally red in
colour and should remain on the part long enough to be drawn into any surface
discontinuities. This time can vory from about ten minutes to several hours depending
on the type of material and size/type of defects sought.
c)
remove surface penetrant using cloth and solvent. Apply solvent to the cloth and not
directly on to the work piece. Clean thoroughly.
d)
apply developer- leave for 15 minutes. The developer draws any penetrant remaining
in any surface breaking discontinuities with a blotting action.
e)
interpet area. Any discontinuities are indicated by a red mark, (e.g. line or dot
againts a white background. Fluorescent penetrants would show green-yellow when
viewed with an ultraviolet(UV-A) light.
(iii)
Advantages
a)
b)
c)
very sensitive
can be uses on non-ferrous metals,some plastics and class
small objects with complex geometry can be inspected
d)
e)
f)
(iv)
a)
b)
c)
d)
e)
f)
g)
Disadvantages
can only detect defects open to the surface
surface penetration is critical
the method is time consuming
messy process
interpretation sometimes difficult
do not applied to pointed objects
effluent problem with waste
NON-DESTRUCTIVE TESTING
(i)
a)
This method of NDT may defect surface and in certain cases,slight sub-surface
discontinuities up to 2-3 mm below the surface.
b)
c)
d)
e)
f)
g)
h)
When m.p.i. is carried out using fluoresent inks the use of an ultraviolet(UV-A) light is
necessary to cause fluorescence of the particles,although there is no need to aplly
a contrast paint.
i)
Fluorescent ink methods are more sensitive than black ink methods.
(ii)
a)
b)
c)
d)
e)
f)
Advantages
Will detect some sub-surface defects
Rapid and simple to unders
Pre-cleaning not as critical as with DPI
Will work through thin coatings
Cheap rugged equipment
Direct test method (simple tv use, little surface preparation requires)
NON-DESTRUCTIVE TESTING
(iii)
a)
b)
c)
d)
e)
f)
Disadvantages
Ferromagnetic materials only
Requirement to test in 2 directions
Demagnetisation may be required
Odd shaped parts difficults to test
Not suited to batch testing
Can damage the component undertest
Ultrasonic testing
(i)
Advantages
a)
b)
Deep of defects
(Both surface & sub-surface detection)
(Safe)
(Capable of measuring the depth defects)
(Portable)
NON-DESTRUCTIVE TESTING
Radiographic Testing
(i)
a)
b)
(ii)
Film interpet
= 0.32
NON-DESTRUCTIVE TESTING
Advantages RT
1)
2)
3)
4)
5)
6)
Permanent record
Little surface preparation
Defect identificates
No material type limitation
No so reliant upon operator skill
Thin material
Disadvantages
1)
2)
3)
4)
5)
6)
7)
8)
Expensive consumables
Bulky equipment(X-ray)
Harmful radiation
Can't defect lamination
Defect require significant depth in relation to the radiation beam
Slow result
Very little indication of depth
Access to both side required
ETC
a)
AWS
~ American Welding Society
b)
ASNI
~ American National Standards Institute
c)
ASME
~ The American Society Of Mechanical Engineers
d)
ASNT
~ American Society Of Non destructive Testing
e)
ASTM
~ American Society For Testing and Material
f)
WPS
~ Welding Procedure Specification
g)
PQR
~ Procedure Qualification Record
h)
PJP
~ Partial Joint Penetration
i)
CPJ
~ Completed Joint Penetration
j)
WOQ
~ Welding Operator Qualification
k)
WQT
~ Welder Qualified Test
l)
WQR
~ Welding Qualified Test
m)
WPQR
~ Welding Performance Qualification Record
ETC
n)
AFC
~ Approved For Construction
o)
PWHT
~ Post Weld Heat Treatment
p)
CR
~ Calibration Records
q)
ITP
~ Inspection Test Plan
r)
MIR
~ Material Inspection Record
s)
WTR
~ Weld Traceability Record
t)
MRN
~ Material Received Note
u)
NDT
~ Non Destructive Testing
v)
DT
~ Destructive Testing
w)
RT
~ Radiographic Testing
x)
UT
~ Ultrasonic Testing
y)
DPT
~ Dye Penetrant Testing
z)
RIS
~ Radiation Imaging System
ETC
A)
MPI
~ Magnetic Particle Inspection
B)
API
~ American Petrolium Institute
C)
JIS
~ Japan Industrial Standards
D)
BS
~ British Standards
E)
CSWIP
~ Certification Scheme For Welding and Inspection Personnel
F)
PCN
~ Personnel Certifiation in Non-Destructive Testing
u
~ Vessel (ASME & Dev 1)
(ii)
u
~ Vessel (ASME & Dev 2)
(iii)
S
~ Boiler (ASME 1)
(iv)
P
~ Piping (ASNI B31.1)
(v)
R
~ Repair work boiler
ETC
(B)
ASME CODE
(i)
ASME 1(I)
~ Boiler/ fired vessel fabrication
(ii)
(iii)
(iv)
(v)
ASME 5(V)
~ Non-Destructive Testing
(vi)
(vii)
(viii)
ASME 9 (IX)
~ WPS & Welder performance
(ix)
ASNI B 31.1
~ Power Piping(boiler)
(x)
ASNI B 31.3
~ Chemical plant
ETC
CALIBRATION CALCUTION
a)
b)
c)
d)
3 reading (x),(y),(z)
(A) = Actual
(P) = Preset
(D) = Deviation
x+y+z
3
A-P
P
maximum 10%
minimum 1%
if (-)
rejected
10
1
preset - 100
actual reading(average) - 92
% maximum +10% & % minimum -1%
1)
a)
~ Down hand & position 1G/F
b)
~ Horizontal & position 2G/H
c)
~ Vertical & position 3G/V
d)
~ Overhead & position
ETC
2)
3)
required test 500 p.s.i x not less than 1.5 = 750 p.s.i
(we can select pressure gauge not less than 750 p.s.i)