Documente Academic
Documente Profesional
Documente Cultură
INSPECTION OF WELDS
Features to Consider
Butt welds - Size
Root
penetration
x
x x
Features to Consider
Butt welds - Toe Blend
x
x x
Features to Consider
Butt welds - Weld Width
Welding Defects
Incomplete root penetration
Causes
• Too small a root gap
• Arc too long
• Wrong polarity
• Electrode too large for joint
preparation
• Incorrect electrode angle
• Too fast a speed of travel for current
Welding Defects
a) Excessively thick root face
c) Misplaced welds
Smaller (correct)
diameter electrode
Lack of sidewall
fusion due to arc
deflection
Welding Defects
Incomplete root Fusion
Causes
• Too small a root gap
• Arc too long
• Wrong polarity
• Electrode too large for joint
preparation
• Incorrect electrode angle
• Too fast a speed of travel for
current
Welding Defects
Root concavity
Causes
• Root gap too large
• Insufficient arc energy
• Excessive back purge TIG
Welding Defects
Excess Root Penetration
Causes
• Excessive amperage during
welding of root
• Excessive root gap
• Poor fit up
• Excessive root grinding
• Improper welding
technique
Welding Defects
Root undercut
Causes
• Root gap too large
• Excessive arc energy
• Small or no root face
Welding Defects
Cap Undercut
Causes
• Excessive welding current
• Welding speed too high
• Incorrect electrode angle
• Excessive weave
• Electrode too large
Welding Defects
Overlap
Excess weld
metal
Welding Defects
Lack of fusion
Causes
• Contaminated weld preparation
• Amperage too low
• Amperage too high (welder increases speed of
travel)
Welding Defects
Incompletely Filled Groove
& Lack of Side wall Fusion
• Causes
• Insufficient weld metal deposited
• Improper welding technique
Welding Defects
Inter run Incompletely Filled Groove
Causes
• Insufficient weld metal deposited
• Improper welding technique
Welding Defects
Gas pores / Porosity
Causes
• Excessive moisture in flux or preparation
• Contaminated preparation
• Low welding current
• Arc length too long
• Damaged electrode flux
• Removal of gas shield
Welding Defects
Gas pores / Porosity
Welding Defects
Inclusions - Slag
Causes
• Insufficient cleaning between passes
• Contaminated weld preparation
• Welding over irregular profile
• Incorrect welding speed
• Arc length too long
Welding Defects
Inclusions - Slag
Causes
• Insufficient cleaning between passes
• Contaminated weld preparation
• Welding over irregular profile
• Incorrect welding speed
• Arc length too long
Welding Defects
Causes
• Contamination of weld Caused by tungsten touching
weld metal or parent metal during welding using the
TIG welding process
Welding Defects
Burn Through
Causes
• Excessive amperage during welding of root
• Excessive root grinding
• Improper welding technique
Welding Defects
Spatter
Causes
• Excessive arc energy
• Excessive arc length
• Damp electrodes
• Arc blow
Welding Defects
Arc Strikes
Causes
Chisel
Chisel Marks
Marks Pitting Corrosion Grinding Marks
Welding Defects
Non-alignment of two abutting edges
2mm
50mm
3mm
Angular distortion.
Measure the distance to the edge of the plate (50mm).
Use a straight edge (rule) to find the amount of distortion then measure
the space (3mm).
This reported as Angular distortion 3mm in 50mm
Welding Defects
Linear
Excess weld metal height
Lowest plate to highest point
3 mm
Excess penetration Lowest Linear misalignment
plate to highest point measured in mm
Angular
3mm
Angular misalignment measured in mm
Page 1 of 3 EXAMPLE PLATE REPORT
Name: [Block capitals] Mr. I C Plenty Signature: I C Plenty Test piece ident: 001
Code/Specification used: TWI 09-09-03 Welding process: MMA/SMAW Joint type: Single V Butt
Welding position: Flat /PA Length & thickness of plate: 300mm x 10 mm Date 22/08/2003
MEASURE
WELD FACE
A B C
Lack of
sidewall fusion Gas pore Undercut smooth
1.5 Ø 1.5 max
FROM
87 236
22 230
30
THIS
51 8 153 40
Arc Strike
Slag
Centreline 241
inclusion
DATUM
crack
NOTES: Cap height : 4mm.
Weld width: 12-14mm
Toe blend: Poor
Misalignment: 2mm
EDGE
WELD ROOT
A B C
Root concavity
2 deep LACK OF ROOT
FUSION
FROM
23 247
10 20
THIS
128 50
Incomplete root
penetration
DATUM
Comments:
* Request MPI testing to confirm crack and length.
** Large amount of spatter on weld face. Recommend this is removed and re inspected.
*** Recommend arc strikes are ground flush prior to MPI testing for cracks.
I C Plenty
Signature.........................................................
22nd August 2003
Date................................................. ....................................
*Delete which is not applicable. Use the other side for any comments.
Inspection Practice Specification
Number TWI 09-09-03
All dimensions are given in mm
No Imperfection Comments Allowance
1 Cracks Confirm with penetrant testing Not permitted