Section 25.: World Centre For Materials Joining Technology

MACRO-SECTION.
TWI
CSWIP 3.1
WELDING INSPECTION
MACRO-SECTION.
PRACTICAL
Section 25.
World Centre for Materials Joining Technology

Copyright © 2005, TWI Ltd
MACRO SECTIONS
1. ASSESS THE MACRO PHOTOGRAPH FOR WELD
DEFECTS.
2. RECORD THE MAJOR DEFECTS ON THE
REPORT SHEET.
3. SENTENCE THE DEFECTS RECORDED TO THE

ACCEPTANCE CRITERIA GIVEN.
4. FOLLOW THE INSTRUCTIONS.

PLEASE DO NOT MARK THE PHOTOGRAPHS.

MACRO INSTRUCTIONS.

MACRO DEFECTS.
50mm
3mm
ANGULAR DISTORTION = 3mm in 50mm

MACRO DEFECTS.
INCOMPLETLEY FILLED
GROOVE
1.5mm
MISALIGNMENT

MACRO DEFECTS.
EXCESSIVE WELD
METAL COLD
COLD LAP LAP &
& POOR POOR
TOE TOE
BLEND BLEND
GAS
PORE /
BLOW
HOLE

Macro defects
INCOMPLETELY FILLED GROOVE

MACRO DEFECTS.
LACK OF SIDE WALL FUSION /
INCOMPELTELY FILLED
LACK GROOVE
OF
SIDE
WALL
FUSIO
N
LACK OF
SIDE
WALL
FUSION
& SLAG

MACRO DEFECTS.
LACK OF SIDEWALL FUSION /
COLD LAP INCOMPLETELY FILLED
GROOVE
GAS
PORES
LACK OF ROOT FUSION

MACRO DEFECTS.
INCOMPETELY FILLED GOOVE
SLAG
INCLUSION
GAS
PORE
LACK OF ROOT FUSION

MACRO DEFECTS.
LACK OF
SIDEWALL
FUSION
LACK OF
SIDEWALL
FUSION &
SLAG
LACK OF LACK OF
SIDEWALL SIDEWALL
FUSION FUSION
LACK OF ROOT PENETRATION

MACRO SECTIONS
QUESTIONS.

MACRO DEFECTS.
CLUSTER / WORMHOLE
LACK OF POROSITY
SIDEWALL FUSION LAMINATIONS
LACK OF INTER-RUN
FUSION & SLAG
LACK OF LACK OF INTER-RUN
SIDEWALL FUSION FUSION
& SLAG
GAS PORES
ROOT UNDERCUT

MACRO SAMPLE.
WELDING PROCESS : MAG
1 COLD LAP
5 LACK OF SIDEWALL
FUSION
4 LACK OF INTER- 2 LACK OF SIDEWALL
RUN FUSION FUSION & GAS / SILICA
3 COLD LAP
MACRO
NOTE: PHOTOGRAPH IS AT X10 MAGNIFICATION
MATERIAL: LOW CARBON STEEL WELDING PROCESS: [MAG/GMAW]
1
9
8 2
7 3
6 5 4
# DEFECT SIZE ACCEPT/REJECT
1 POOR TOE BLEND
2 OVERLAP + 2 SMALL PORES
3 LAMINATIONS/INCLUSIONS
4 LACK OF SIDE WALL FUSION
5 AS ABOVE +PORES Assess
6 OVERLAP To
7 LACK OF INTERRUN FUSION Specification
8 GAS PORE/PIPE
9 LACK OF SIDE WALL FUSION + SILICA
10 ANGULAR MISALIGNMENT
11 EXCESS WELD METAL
12 EXCESS PENETRATION
MACRO ACCEPTANCE.

MACRO EXCERCISES.AM1030
TRAINING SAMPLE ONLY
MACRO INSTRUCTION/REPORT SHEET [I.D: AM1030]
CHECK PHOTOGRAPH I.D MATCHES THIS REPORT I.D
ALL DEFECTS TO BE REPORTED [AND SIZED IF REQUIRED]
THEN SENTENCED TO ISO 5817 LEVEL B [STRINGENT]

MATERIAL: LOW CARBON STEEL
WELDING PROCESS: [MMA/SMAW]
7
6 1
5
4 2
3
MACRO EXCERCISES. AM 1030
1 Lack of side wall fusion and slag 8.6 Reject
Accept
2 Misalignment 0.2
3 Lack of root penetration N/A Reject
4 Angular distortion 0.5 Accept
5 Lack of side wall fusion 2.5 Reject
6 Lack of inter run fusion and slag 4.2 Reject
8 Excess weld metal 3.2 Reject
9
10
11
12
COMMENTS:
SIGNATURE: DATE:
PRINT FULL NAME:


9
8 1
2
7
3
6
4
5
1 Lack of side wall fusion/ underfill 0.7 Reject
2 Lack of side wall fusion and slag 7.5 Reject
3 Cold lap 0.5 Reject
4 Misalignment 1.8 Reject
5 Excess penetration 3.3 Reject
7 Slag inclusion 0.7 Accept
10
11
12
COMMENTS:
SIGNATURE: DATE:
PRINT FULL NAME:


8
1
2
3
4
5
7 6
1 Lack of side wall fusion/underfill 0.5 Reject
2 Lack of sidewall fusion & Slag 2.8 Reject
3 Lack of side wall fusion & slag 4.5 Reject
4 Slag inclusion 1.5 Reject
7 Excess penetration 2.0 Accept
9
10
11
12
COMMENTS:
Plate laminations noted
SIGNATURE: DATE:
PRINT FULL NAME:

WELDING PROCESS: [MAG/GMAW]
8
1
7
6
5 2
4
3
1 Cold Lap/ Overlap 2.8 Reject
2 Lack of sidewall fusion & gas 8.0 Reject
3 Cold lap / Overlap 0.3 Reject
4 Misalignment 0.6 Accept
5 Lack of interrun fusion & gas 2.0 Reject
6 Lack of sidewall fusion 2.6 Reject
7 Blow hole 1.5 Reject
9
10
11
12
COMMENTS:
Poor toe blend
SIGNATURE: DATE:
PRINT FULL NAME:

9 10
1
8 2
7 3
5 4
6
1 Lack of sidewall fusion & slag 2.8 Reject
2 Lack of sidewall fusion 1.0 Reject
3 Lack of inter-run fusion & slag 2.0 Reject
4 Angular distortion 6in13 Accept
6 Excess penetration 0.1 Reject
7 Lack of inter-run fusion & slag 5.5 Reject
9 Spatter 0.1 Accept
11
12
COMMENTS:
Poor toe blend
SIGNATURE: DATE:
PRINT FULL NAME:

Macro defects

Macro defects

Macro defects

Macro defects

Macro defects

Macro defects

Macro defects

Macro defects

Macro defects

Macro defects


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MACRO-SECTION.

World Centre for Materials Joining Technology

3. SENTENCE THE DEFECTS RECORDED TO THE

4. FOLLOW THE INSTRUCTIONS.

World Centre for Materials Joining Technology

World Centre for Materials Joining Technology

ANGULAR DISTORTION = 3mm in 50mm

World Centre for Materials Joining Technology

World Centre for Materials Joining Technology

World Centre for Materials Joining Technology

World Centre for Materials Joining Technology

World Centre for Materials Joining Technology

LACK OF ROOT FUSION

World Centre for Materials Joining Technology

LACK OF ROOT FUSION

World Centre for Materials Joining Technology

World Centre for Materials Joining Technology

World Centre for Materials Joining Technology

World Centre for Materials Joining Technology

NOTE: PHOTOGRAPH IS AT X10 MAGNIFICATION

PRINT FULL NAME:

World Centre for Materials Joining Technology

NOTE: PHOTOGRAPH IS AT X10 MAGNIFICATION

PRINT FULL NAME:

World Centre for Materials Joining Technology

NOTE: PHOTOGRAPH IS AT X10 MAGNIFICATION

PRINT FULL NAME:

World Centre for Materials Joining Technology

PRINT FULL NAME:

World Centre for Materials Joining Technology

PRINT FULL NAME:

World Centre for Materials Joining Technology

World Centre for Materials Joining Technology

World Centre for Materials Joining Technology

World Centre for Materials Joining Technology

World Centre for Materials Joining Technology

World Centre for Materials Joining Technology

World Centre for Materials Joining Technology

World Centre for Materials Joining Technology

World Centre for Materials Joining Technology

World Centre for Materials Joining Technology

World Centre for Materials Joining Technology

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