03 06 16 WIS5 Imperfections 2006

CSWIP 3.
1 Welding Inspection
Welding & Materials Imperfections

TWI Training & Examination Services
Course Reference WIS 5 Course notes section reference 3, 6 & 16
World Centre for Materials Joining Technology
Copyright 2006, TWI Ltd
Welding Imperfections
All el!s "ave im#erfections Im#erfections are classe! as !efects "en t"e$ are of a t$#e, or si%e, not allo e! &$ t"e Acce#tance Stan!ar!
A !efect is an unacce#ta&le im#erfection A el! im#erfection ma$ &e allo e! &$ one Acce#tance Stan!ar! &ut &e classe! as a !efect &$ anot"er Stan!ar! an! re'uire removal(rectification
Stan!ar!s for Wel!ing Im#erfections )S E* IS+ 65,-.1(1998) Wel!ing an! allie! #rocesses / Classification of geometric im#erfections in metallic materials . 0art 11 2usion el!ing Im#erfections are classifie! into 6 grou#s, namel$1 1 Crac3s , Cavities 3 Soli! inclusions 4 5ac3 of fusion an! #enetration 5 Im#erfect s"a#e an! !imensions 6 6iscellaneous im#erfections
Stan!ar!s for Wel!ing Im#erfections E* IS+ 5718 (2
3) Wel!ing . 2usion. el!e! 9oints in steel,

nic3el, titanium an! t"eir allo$s :&eam el!ing exclu!e!; . <ualit$ levels for im#erfections
T"is main im#erfections given in E* IS+ 65,-.1 are liste! in E* IS+ 5718 it" acce#tance criteria at 3 levels, namel$ 5evel ) :"ig"est; 5evel C :interme!iate; 5evel = :general; T"is Stan!ar! is >!irectl$ a##lica&le to visual testing of el!s? @@@(!eld s"rfaces & macro e#amination)
Welding imperfections classification
Crac3s
Crac$s
Crac3s t"at ma$ occur in el!e! materials are cause! generall$ &$ man$ factors an! ma$ &e classifie! &$ s"a#e an! #osition@
Classifie! &$ S"a#e 5ongitu!inal Transverse C"evron 5amellar Tear Classifie! &$ 0osition AAB Centerline Crater 2usion %one 0arent metal
*ote1 Crac3s are classe! as 0lanar =efects@
Crac$s
5ongitu!inal #arent metal
Transverse
el! metal
5ongitu!inal
el! metal 5amellar tearing
Crac$s
Transverse crac3
5ongitu!inal crac3
Crac$s
6ain Crac3 T$#es
Soli!ification Crac3s A$!rogen In!uce! Crac3s 5amellar Tearing Re"eat crac3s
Crac$s
Soli!ification Crac3ing
+ccurs !uring el! soli!ification #rocess !uctilit$ at Steels it" "ig" sul#"ur im#urities content :lo elevate! tem#erature; Re'uires "ig" tensile stress +ccur longitu!inall$ !o n centre of el!
Crac$s
A$!rogen In!uce! Col! Crac3ing
Re'uires susce#ti&le "ar! grain structure, stress, lo tem#erature an! "$!rogen A$!rogen enters el! via el!ing arc mainl$ as result of contaminate! electro!e or #re#aration A$!rogen !iffuses out into #arent metal on cooling Crac3ing !evelo#ing most li3el$ in AAB
Crac$s
5amellar Tearing
Ste# li3e a##earance +ccurs in #arent material or AAB +nl$ in rolle! !irection of t"e #arent material Associate! it" restraine! 9oints su&9ecte! to t"roug" t"ic3ness stresses on corners, tees an! fillets Re'uires "ig" sul#"ur or non.metallic inclusions
Crac$s
Re.Aeat Crac3ing
+ccurs mainl$ in AAB of lo allo$ steels !uring #ost "eat treatment or service at elevate! tem#eratures +ccurs in areas of "ig" stress an! existing !efects 0revente! &$ toe grin!ing, elimination of #oor #rofile material selection an! controlle! #ost el! "eat treatment el!
Welding Imperfections Classification
Cavities
%as Ca&ities
Cas #ore Cluster #orosit$ Causes1 5oss of gas s"iel! =am# electro!es Contamination )lo "ole Aerring&one #orosit$ Arc lengt" too large =amage! electro!e flux 6oisture on #arent material Wel!ing current too lo Cas #ore D1@5mm )lo "ole@E1@6mm
Root #i#ing
%as Ca&ities
Porosit(
'oot piping
%as Ca&ities
Cluster #orosit$
Aerring&one #orosit$
Crater Pipe
Wel! crater
Crater #i#e
Crater Pipe
Crater #i#e is a s"rin3age !efect an! not a gas !efect, it "as t"e a##earance of a gas #ore in t"e el! crater Causes: Too fast a cooling rate Deoxidization reactions and liquid to solid volume change Contamination
Crater crac3s :Star crac3s;
Crater #i#e
Soli! Inclusions
Solid Incl"sions
Slag inclusions are !efine! as a non.metallic inclusion cause! &$ some el!ing #rocess Causes1 Slag originates from el!ing flux
Slag inclusions 5ac3 of si!e all fusion it" associate! slag
6AC an! TIC el!ing #rocess #ro!uce silica inclusions Slag is cause! &$ ina!e'uate cleaning +t"er inclusions inclu!e tungsten an! co##er inclusions from t"e TIC an! 6AC el!ing #rocess
0arallel slag lines
5ac3 of interun fusion F slag
Solid Incl"sions
Inter#ass slag inclusions
Elongate! slag lines
5ac3 of 2usion
T$#ical Causes of 5ac3 of 2usion1 el!ing current too lo
&evel angle too stee# root face too large :single.si!e! root ga# too small :single.si!e! incorrect electro!e angle linear misalignment el!ing s#ee! too "ig" el!ing #rocess relate! / #articularl$ !i#.transfer C6AW it" too muc" el! metal :&loc3ing +ut; el!; el!;
floo!ing t"e 9oint
)ac$ of *"sion
Causes1 0oor Incom#lete fille! groove F 5ac3 of si!e all fusion el!er s3ill
Incorrect electro!e mani#ulation Arc &lo
1 , 1@ 5ac3 of si!e all fusion ,@ 5ac3 of inter.run fusion
Incorrect el!ing current(voltage Incorrect travel s#ee! Incorrect inter.run cleaning
)ac$ of *"sion
5ac3 of si!e all fusion F incom#lete fille! groove
+verla#
+&erlap
An im#erfection at t"e toe or root of a el! cause! &$ metal flo ing on to t"e surface of t"e #arent metal it"out fusing to it
Causes1 Contamination Slo travel s#ee!
Incorrect el!ing tec"ni'ue Current too lo
+&erlap
Toe +verla#
Toe +verla#
Wel! Root Im#erfections
Weld 'oot Imperfections

Causes1 5o Am#s(volts
5arge Root face
Incom#lete root fusion
Small Root Ca# 2ast Travel S#ee! Incorrect Electro!e Angle Contamination
Incom#lete root #enetration
Arc &lo
5ac3 of root #enetration
5ac3 of root fusion
5ac3 of Root 2usion
5ac3 of Root 0enetration


A s"allo groove cause! &$ contraction in t"e along eac" si!e of t"e #enetration &ea! el! metal
Causes: Insufficient weld metal deposited in the root pass Too fast a cooling rate during the application of the root bead pass
S"rin3age groove
Poor welding technique

A s"allo groove, "ic" ma$ occur in t"e root of a &utt Causes: xcessive bac! purge pressure during TI" welding xcessive root bead grinding before the application of the second pass welding current too high for #nd pass overhead welding root gap too large $ excessive %weaving& el!
Concave Root
Concave Root

Root #enetration &ea! in excess in accor!ance relevant s#ecification &eing use! it" t"e
Causes: 'oot faces too small 'oot gap too large
Excessive root #enetration
xcessive amps(volts
)low travel speed
Excessive root #enetration

Concave root
Excess root #enetration

A locali%e! colla#se of t"e el! #ool !ue to excessive #enetration resulting in a "ole in t"e root run Causes: *igh +mps(volts )mall 'oot face ,arge 'oot "ap )low Travel )peed
)urn t"roug"
)urn T"roug"
+#idi,ed 'oot ('oot Co$ing)

Causes: ,oss or insufficient bac! purging gas -ost commonl. occurs when welding stainless steels Purging gases include argon/ helium and occasionall. nitrogen
Im#erfect S"a#e an! =imensions
Weld Imperfections
T$#ical Causes of Im#erfect S"a#e :inclu!ing #oor toe &len!; 0oor el!ing tec"ni'ue is t"e usual cause t"ese im#erfections, suc" as1 electro!e si%e for t"e ca# #asses is too large el!ing s#ee! too slo el!ing current too lo :SAW an! C6AW;
arc voltage too lo
#oor mani#ulation of t"e electro!e incorrect el! &ea! #ositioning ( #lacement
S"rface and Profile
Incom#lete fille! groove

0oor ca# #rofiles an! excessive ca# reinforcements ma$ lea! to stress concentration #oints at t"e el! toes an! ill also contri&ute to overall #oor toe &len!
0oor ca# #rofile
Excessive ca# "eig"t
S"rface and Profile
Excess ca# reinforcement
Incom#lete fille! groove
S"rface and Profile
0oor Ca# 0rofile & 0oor Toe )len!
S"rface and Profile

0oor Sto# ( Starts
Cap and 'oot -nderc"t

An irregular groove at t"e toe of a el! run in t"e #arent metal Causes1 Excessive am#s(volts Excessive travel s#ee! Incorrect electro!e angle Excessive eaving
Incorrect el!ing tec"ni'ue Electro!e too large Arc lengt" too "ig"
Cap -nderc"t
Intermittent Ca# Gn!ercut

-nderc"t
Root un!ercut
Ca# un!ercut
6iscellaneous Im#erfections
6iscellaneous Im#erfections Arc stri3e or stra$ arc1 acci!ental stri3ing of an arc on to &ase material loss of el!ing ca&le insulation #oor connection of ?current return? ca&le excessive current or voltage Torn surface
S#atter1 Crin!ing mar3 ( mec"anical !amage1
Miscellaneo"s Imperfections
Causes: xcessive current
Damp electrodes Contamination Incorrect wire feed speed when welding with the -+" welding process +rc blow
S#atter
Miscellaneo"s Imperfections
Causes1 Acci!ental stri3ing of t"e arc onto t"e #arent material 2ault$ electro!e "ol!er 0oor ca&le insulation 0oor return lea! clam#ing
Arc stri3e
6ec"anical =amage
Mec.anical /amage
6ec"anical !amage can &e !efine! as an$ surface material !amage cause !uring t"e manufacturing #rocess@ Crin!ing Aammering C"iselling C"i##ing )rea3ing off el!e! attac"ments :torn surfaces; Gsing nee!le guns to com#ress el! ca##ing runs
Mec.anical /amage
C"i##ing 6ar3s
6ec"anical =amage(Crin!ing 6ar3
Set.G# Irregularities
-ne0"al )eg )engt.s

A variation of leg lengt"s on a fillet el!
*ote1 Gne'ual leg lengt"s on a fillet el! ma$ &e s#ecifie! as #art of t"e !esign, in "ic" case it ill not &e consi!ere! as a !efect@
Set1-p Irreg"larities
5inear misalignment is measure! from t"e lo est #late to t"e "ig"est #oint@ 0late(#i#e 5inear 6isalignment :Ai.5o; Angular misalignment is measure! in !egrees
Angular 6isalignment
5inear 6isalignment
5inear 6isalignment
An$ <uestions
2"estions
Wel! Im#erfections1 <G 1@ Cive t o main causes for t"e occurrence of a &urn.t"roug" <G ,@ Cive t o main causes for t"e occurrence of excessive root #enetration on a single.I &utt <G 3@ Cive five !efects, using t"e 66A all fusion <G 5@ S3etc" t"e follo ing !efects a@ 5ac3 of root all fusion &@ 5ac3 of root #enetration c@ Incom#lete fille! groove !@ Concave root el!ing #rocess el! "en el!ing car&on steel "ic" ma$ occur
it" t"e current setting to lo
<G 4@ Cive t"ree #ossi&le causes for t"e occurrence of lac3 of si!e
Material Inspection
Material Inspection
All materials arriving on site s"oul! &e ins#ecte! for1 Si%e ( !imensions Con!ition T$#e ( s#ecification
In a!!ition ot"er elements ma$ nee! to &e consi!ere! !e#en!ing on t"e materials form or s"a#e
Pipe Inspection
Condition
(Corrosion, Damage, Wall thickness Ovality, Laminations & Seam)
Specification Welded seam
L!"
Si e
Other checks may need to #e made s$ch as% distortion tolerance, n$m#er of plates and storage&
Plate Inspection
Condition (Corrosion, Mechanical damage, Laps, 'ands & Laminations) Specification
"L
Si e
Other checks may need to #e made s$ch as% distortion tolerance, n$m#er of plates and storage&
'olling Imperfections
Direction of rolling
Cold Laps&
Laminations Segregatio n
Parent Material Imperfections

6ec"anical !amage 5amination 5a#
Segregation line 5aminations are cause! in t"e #arent #late &$ t"e steel ma3ing #rocess, originating from ingot casting !efects@ Segregation &an!s occur in t"e centre of t"e #late an! are lo melting #oint im#urities suc" as sul#"ur an! #"os#"orous@ 5a#s are cause! !uring rolling fuse to t"e &ase material@ "en overla##ing metal !oes not
Lapping
)apping
Lapping
Lamination
)aminations
0late 5amination
Material imperfections
An$ <uestions
2"estions
Wel! Re#airs1
<G 1@ State six #oints of im#ortance of re#air re#air <G 3@ State t"ree !ocuments, refer to <G 4@ In some cases "ic" t"e ins#ector s"oul! a "en carr$ing out re#airs@ "$ mig"t a s#ecification not allo el!ing@ el! <G ,@ State t o *=T met"o!s t"at ma$ &e a##lie! in a
crac3 to &e re#aire!, regar!less of si%e or orientationH
3lements
Iron Car&on 6anganese Silicon Aluminium C"romium 2e C 6n Si Al Cr is for Strengt" is for Toug"ness D -@3J =eoxi!iser Crain refiner, D-@--7J =eoxi!iser F Toug"ness Corrosion resistance 1J is for Cree# resistance
6ol$&!enum 6o
3lements
Iana!ium *ic3el Co##er Cu Sul#"ur S 0"os#"orous Titanium *io&ium I *i Strengt" 5o tem#erature a##lications Gse! for eat"ering steels :Corten;
Resi!ual element :can cause "ot s"ortness; 0 Ti *& Resi!ual element Crain refiner, Gse! a a micro allo$ing element :S&T; Crain refiner, Gse! a a micro allo$ing element :S&T; :S&T; K Strengt" & Toug"ness
Stainless Steel

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CSWIP 3.

Welding & Materials Imperfections

World Centre for Materials Joining Technology

Copyright 2006, TWI Ltd

World Centre for Materials Joining Technology

Copyright 2006, TWI Ltd

3) Wel!ing . 2usion. el!e! 9oints in steel,

World Centre for Materials Joining Technology

Copyright 2006, TWI Ltd

Welding imperfections classification

World Centre for Materials Joining Technology

Copyright 2006, TWI Ltd

*ote1 Crac3s are classe! as 0lanar =efects@

World Centre for Materials Joining Technology

Copyright 2006, TWI Ltd

5ongitu!inal #arent metal

el! metal 5amellar tearing

World Centre for Materials Joining Technology

Copyright 2006, TWI Ltd

World Centre for Materials Joining Technology

Copyright 2006, TWI Ltd

World Centre for Materials Joining Technology

Copyright 2006, TWI Ltd

World Centre for Materials Joining Technology

Copyright 2006, TWI Ltd

World Centre for Materials Joining Technology

Copyright 2006, TWI Ltd

World Centre for Materials Joining Technology

Copyright 2006, TWI Ltd

World Centre for Materials Joining Technology

Copyright 2006, TWI Ltd

Welding Imperfections Classification

World Centre for Materials Joining Technology

Copyright 2006, TWI Ltd

World Centre for Materials Joining Technology

Copyright 2006, TWI Ltd

World Centre for Materials Joining Technology

Copyright 2006, TWI Ltd

World Centre for Materials Joining Technology

World Centre for Materials Joining Technology

Copyright 2006, TWI Ltd

Crater crac3s :Star crac3s;

World Centre for Materials Joining Technology

Copyright 2006, TWI Ltd

Welding Imperfections Classification

World Centre for Materials Joining Technology

Copyright 2006, TWI Ltd

0arallel slag lines

5ac3 of interun fusion F slag

World Centre for Materials Joining Technology

Copyright 2006, TWI Ltd

Inter#ass slag inclusions

Elongate! slag lines

World Centre for Materials Joining Technology

Copyright 2006, TWI Ltd

Welding Imperfections Classification

World Centre for Materials Joining Technology

Copyright 2006, TWI Ltd

floo!ing t"e 9oint

World Centre for Materials Joining Technology

Copyright 2006, TWI Ltd

Incorrect electro!e mani#ulation Arc &lo

1 , 1@ 5ac3 of si!e all fusion ,@ 5ac3 of inter.run fusion