WELDING

&
NON DESTRUCTIVE
TESTING

Welding - definition
Welding A joining process of two materials,
metals/non-metals, that are coalesced by the
application of pressure and/or temperature.
Welding Local coalescence of two similar or
dissimilar metallic parts at their faying surfaces.
Weldment The assemblage of two or more
elements
Sometime a filler material is needed to facilitate
coalescence in Arc/Fusion welding process.
Autogenous welding without filler materials

Advantage - disadvantage
Advantage: Welding is portable,
permanent, stronger than the parent
materials with a filler metal, the most
economical method to join.
Disadvantage: Manual Labor, high
energy and dangerous, does not
allow disassemble and defects

Classification of welding processes

Welding
Soldering and brazing
Solid state welding

Fusion welding

Resistance welding

Soldering

Cold welding

Brazing

Friction welding
Diffusion welding
Flash welding

Electrical energy

Chemical energy
Oxyacetylene welding

Ultrasonic welding

Oxyfuel gas welding

Explosion welding

Consumable
electrode

Non
consumable
electrode

Other processes

Gas metal arc welding

Gas tungsten arc welding

Laser beam welding

Shielded metal arc welding

Atomic hydrogen welding

Thermit welding

Submerged arc welding

Plasma arc welding

Electron beam welding

Flux cored arc welding

Electrogas welding
Electroslag welding

Types of joints
Butt joint
Corner joint
Lap joint
Tee joint
Edge joint

Weld Joint
Types of Welds
Fillet weld
Groove weld
Plug and slot welds
Spot and Seam welds
Flange and Surfacing welds

Weld Orientation
Plate groove positions 1G, 2G, 3G, 4G
Pipe groove positions 1G, 2G, 5G, 6G
Plate fillet positions 1F, 2F, 3F, 4F
Pipe fillet positions 1F, 2F, 2FR, 4F, 5F

GROOVE WELDS IN PLATE

TEST POSITIONS

GROOVE WELDS IN PIPE TEST

POSITIONS

FILLET WELDS IN PLATE TEST

POSITIONS

FILLET WELDS IN PIPE TEST

POSITIONS

Features of a Fusion Welded

Joint
Weld
Interface
Reinforcement

HAZ

Fusion zone
BM

Fusion zone: a mixture of filler metal and base metal

melted together homogeneously due to convection
as in casting. Epitaxial grain growth (casting)
Weld interface a narrow boundary immediately
solidified after melting.
Heat Affected Zone (HAZ) below melting but
substantial micro structural change in the base
material (heat treating)

Weldability
Similar to Machinability, it defines the capacity of a
metal to be welded into a suitable design and the
resulting weld joint to perform satisfactorily in the
intended service.
The factors affecting weldability, welding process,
base metal, filler metal and surface condition.
Base metal melting point, thermal conductivity and
CTE
Moisture and oxide film affects porosity and fusion
respectively.
Carbon Equivalent(CE)= %C + %Mn/6 +
(%Cr+Mo+V)/5 + (%Cu+Ni)/15

Metals
Ferrous

Nonferrous

Carbon steels

Aluminium,copper,
Nickel

Low carbon steels

0.3%]

[Carbon 0.01 to

Medium carbon steels [Carbon 0.3-0.6%]

High carbon steels
1.4%]

[carbon 0.6 to

Low alloy steels [ Mn, Cr,Ni,Mo < 7%

total]
High alloy steels [Mn, Cr,Ni,Mo > 7%
total]

Purpose of WPS & PQR

To
determine
that
the
weldment
proposed
for
construction is capable of
having the required properties
for its intended application

WPS
A WPS is a written qualified welding
procedure prepared to provide
direction for making production welds
to Code requirements.
The WPS or other documents may be
used to provide direction to the
welder or welding operator to assure
compliance with the Code
requirements.

PQR
A PQR is a record of the welding data used
to weld a test coupon.
The PQR is a record of variables recorded
during the welding of the test coupons. It
also contains the test results of the tested
specimens. Recorded variables normally
fall within a small range of the actual
variables that will be used in production
welding.

Points to be considered for

establishing WPS
Code of
construction
Detailed drawing of
weldment
Material
Thickness
Configuration
Process

Contract/Customer/
Code/TPI
Preheat/Postheat/
PWHT requirements
Skilled welder
Good welding m/c
with accessories
Application

Essential Variables
A change in welding condition which
will affect the mechanical properties of
the weldment.
(Change in P Number, Welding process,
Filler metal, Electrode, Pre-heat, PWHT,
etc.)

Non Essential Variables

A change in welding condition which will NOT
affect the mechanical properties of the
weldment.
(Change in Joint Design, Methods of Back
gauging, Cleaning, etc.)

Supplementary Essential
Variables
A change in welding condition which will affect
the Notch-Toughness (Impact) properties of
the weldment.
(Change in Heat input, Uphill or Down Vertical
welding, Diameter of Electrode, Position, etc.)

Base Metal Classification

Why P numbers?

To reduce the number of welding procedure

qualifications, base metals have been assigned
P-nos and for ferrous base metals which have
specified impact test requirements, group
numbers within P-nos are again given
P no's depend on composition, weldability &
mechanical properties.
Group no's classify metals within P nos for
procedure qualification where notch toughness
requirements are specified.
The above assignments do not imply that base
metals can be substituted without consideration of
metallurgical properties,etc.,

Base Metals

P. Number
Group Number
Specification
Chemical Analysis & Mechanical
Properties
Thickness Range
Pipe Diameter Range

Filler Metals

AWS Number
SFA Number
F. Number
A. Number

Size of Filler
metal
Flux trade name
Consumable
insert
Electrode flux
class

CLASSIFICATION OF ELECTRODES (AWS 5.1)

EXXXX
Electrode

60 Psi
70
80
90
100
110
120

Welding
position

Coating and
current conditions

Type of defects
PLANAR
CRACKS, LAMELLAR TEARS
LACK OF FUSION
LACK OF PENETRATION
VOLUMINAR
POROSITY
SLAG
TUNGSTEN INCLUSION

Definition of NDT
The use of noninvasive
techniques to determine
the integrity of a
material,
component or structure
or
quantitatively measure
some characteristic of
an object.
i.e. Inspect or measure without doing harm.

What are Some Uses

of NDE Methods?
Flaw Detection and Evaluation
Leak Detection
Location Determination
Dimensional Measurements

Fluorescent penetrant
indication

Structure and Microstructure Characterization

Estimation of Mechanical and Physical Properties
Stress (Strain) and Dynamic Response
Measurements
Material Sorting and Chemical Composition
Determination

When are NDE Methods

Used?
To assist in product development
To screen or sort incoming materials
To monitor, improve or control
manufacturing processes
To verify proper processing such as heat
treating
To verify proper assembly
To inspect for in-service damage

Six Most Common NDT

Methods

Visual
Liquid
Penetrant
Magnetic
Ultrasonic
Eddy Current
Radiography

Liquid Penetrant
Inspection
A liquid with high surface
wetting
characteristics is applied to the surface of the
part and allowed time to seep into surface
defects.
breaking
The excess
liquid is removed from the
surface of the part.
A developer (powder) is applied to pull the
trapped penetrant out the defect and
spread it on the surface where it can be
seen. inspection is the final step in the
Visual
process. The penetrant used is often
loaded with a fluorescent dye and the
inspection is done under UV light to
increase test sensitivity.

Magnetic Particle
Inspection

The part is magnetized. Finely milled iron particles coated with a dye pigment
are then applied to the specimen. These particles are attracted to magnetic
flux leakage fields and will cluster to form an indication directly over the
discontinuity. This indication can be visually detected under proper lighting
conditions.

Magnetic Particle Crack Indications

Radiography
The radiation used in radiography
testing is a higher energy (shorter
wavelength) version of the
electromagnetic waves that we
see as visible light. The radiation can
come from an X-ray generator or a
radioactive source.

High Electrical Potential

Electrons
+

X-ray
Generator or
Radioactive
Source Creates
Radiation

Radiation
Penetrate
the Sample
Exposure Recording Device

Film Radiography
The part is placed between the
radiation source and a piece of film.
The part will stop some of the
radiation. Thicker and more dense
area will stop more of the radiation.

X-ray film

Top view of developed film

The film darkness

(density) will vary
with the amount of
radiation reaching the
film through the test
object.= less
exposure
= more
exposure

Ultrasonic Inspection
High frequency sound waves are introduced into a
material and they are reflected back from surfaces or
flaws.
Reflected sound energy is displayed versus time, and
f
inspector can visualize a cross section of the
specimen showing the depth of features that reflect
sound.
initial
pulse

crack
echo

back surface
echo

crack
0

Oscilloscope, or
flaw detector
screen

10

plate

Thank you