Duties of a Welding Inspector

General:
My duties are as a welding inspector to check that all welding and associated
activities are being carried out at the job site in accordance with the requirement of
the approved welding procedure specification and through my qualities of honesty,
integrity and knowledge. I also apply my knowledge in observing, measuring, and
recording; before, during and after welding.

Prior to welding
Before assembly:
I check;
Applicable codes, standards and project specification.
All applicable documents such as QIP, procedures, inspection formats and any special
safety requirements.
Approved WPS with supporting WPAR as per code
Welder qualification and identification as per WPS
Material; composition, condition, ratting and storage handling as procedure, MTCs
and drawings
Consumables; composition, type, size and baking requirement as per WPS
Surface preparation method and finish as WPS and to good workmanship
Welding machine validity as
Line-up clamp type and condition as WPS
After assembly:
I check:
Cleanliness of surface to good workmanship
Pre-heat as procedure
Purging dump to avoid oxidation as WPS
Weather condition as suitable to site/field

During welding.
I check:
Consumable and control as WPS and to good workmanship
Welding process as WPS
Line-up clamp; remove after completion of root pass as WPS
Laps timing between root and hot pass as WPS
Welding parameters such as voltage, amperage and polarity, welding technique, welddirection and run sequence.
Inter-pass cleaning to good workmanship
Inter-pass temperature minimum and maximum as WPS
Speed of travel as WPS

After welding
I check;
Compliance to WPS.
Weld and welder ID marked as drawing
Any modification or as-built add to drawing
Visual inspection as code or spec.
Post-heat to good workmanship and as WPS
Monitor post weld heat-treatment as procedure
Monitor NDT as code and specs
In case repair; as procedure
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Again after 48hrs to confirm hydrogen cracking

All relevant reports are available
Pressure/load test and calibration of gauges as procedure
Collect and collets all documents and keep for life time record

Welding processes
GTAW (tig) BS 3019
Drooping characteristics arc process (constant current).
Type of operation:
Normally manual but can be mechanized.
Mode of operation:
An arc is maintained between the end of tungsten electrode and parent metal. The current is
controlled by the of power source. Operator must control arc length and feed the filler wire
for correct welding. Normally argon gas is used for arc shielding to arc and weld pool to
prevent from atmospheric gases. No fluxes are used with the process. The arc is unstable at
low current. Special provision is made for starting.
Power source:
Generator, transformer and rectifier.
Current:
Normally operate at dcve but can be used with ac for light alloys.
Consumables metal:
Wires are according to BS 2901 Pt 1-5.
Gases according to BS 4105 & BS 4365
Shielding gases:
Normally argon gas is used for shielding but helium and nitrogen also can be
used.
Tungsten electrode:
Unactivated/Plain:
Activated 1% thoriated:
Activated 2% thoriated:
Activated zirconiated:

rarely used. Suitable for lower quality welds. May cause

of tungsten inclusion.
used with dcve for all materials except light alloys.
used where arc stability required with low amperage also used
with dcve for all materials except light alloys.
specifically used with ac on the light alloys.
Direct current 1-3.2mm
alternative current 1-6.4mm

Equipment:

Power source (dropping constant current)

Welding torch
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Gas cylinder
Welding cables
Welding helmet

Defect associated with this process:

Tungsten inclusion

Lack of fusion

Lack of penetration

Under cut

Burn through

Porosity

Excess penetration

Oxide inclusions.
Advantages:

Good quality of the weld

Good for thin material

Wide range of material

Clean weld, no slag, and no smoke.

Can be achieved high mechanical and metallurgical properties.

High root run quality.

Disadvantage:

High skill required for pipe welder

Very expensive as compare to other manual metal arc welding

Good surface cleaning required

Relatively slow process

GMAW (m.i.g. /m.a.g.)

Flat characteristics (constant voltage) arc process. It may be considered together because
same welding equipment and power source uses. Shielding gases and filler wire may be
differing to another.
Type of operation:
Manual, mechanized or automatic
Mode of operation:
An arc is maintained between the end of consumable electrode or wire, and work piece. Wire
is continuously fed from a coil through a special designed gun. The wire is fed at a constant
speed selected to give required current. An arc length is control by power source setting. An
arc length is not considerable for operator but depositing of the weld metal is considerable.
Arc and weld pool shielded by the shielding gas. No fluxes are used with this process.
Power source:
Generator, transformer and rectifier.

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Current:
Normally dc +ve (constant voltage)
Shielding gases:
Argon, hydrogen, nitrogen, helium
Argon + oxygen (1-5)
Argon + Co2 (2-25)

for non-ferrous metal

stainless steel
carbon and low alloy steel

Consumable:
Solid wire, cored wire, self shielded wire, rutile cored wire, basic cored wire, metal cored
wire ( 0.8 mm ~ 1.6 mm). According to BS 2901.
Gases according to BS 4365 & BS 4105
Mode of metal transfer:
Spray or free flight:
Dip transfer:
Globular transfer:
Pulsed:

give high deposition rates and deep penetration welds.

Suited to thick materials except light alloys.
used for thinner section and for all positional welding including
v/down.
intermediate range between spray and dip transfer mode, no
manual application and success on mechanized and automatic.
arc is modified form of spray mode. Give high deposition rate
and for all positional welding. No lack of root runs, regular
penetration. No spatter, good profile, high quality welds.

Typical defect:
Lack of fusion occurs is dip transfer mode.
Centerline cracking in spray mode transfer
Porosity, under cut, incomplete penetration, excess penetration and excessive spatters.
Advantages:

High quality of the weld

Very clean, no inter pass cleaning required.

No slag with solid wire

Less skill required

Minimal wastage of electrode

Heavier weld bead produced

Faster welding process

Disadvantages:

Costly equipment

More maintenance required of equipment

Not portable

Increase the risk of porosity due to shield gases

High risk of lack fusion

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SAW (SA)
Flat arc process (constant) voltage
Type of operation:
Mechanized, automatic or semiautomatic.
Mode of operation:
The arc is maintained between the end of electrode bare wire and the work piece. As the
electrode is melted, it is fed in to the arc a set of rolls, driven by a governed motor. Wire feed
speed is automatically controlled to the equal the rate at which electrode is melted, thus arc
length is constant. Arc is under the granular flux. Some of flux is melt to provide a protective
blanket (slag) over the weld pool. Flux is unaffected and can be recycled.
Current:
Dc +ve
Dc ve
Ac

for best penetration.

fast burn of rate. For lower dilution
for multy wire. To avoid arc blow

Consumable:
Solid wire is used, 1.6 mm to 6 mm according to BS 4165, BS 5465, and AWS A5.17
Fused and agglomerated according to BS 4165, BS 5465, and AWS A5.17.
Defect:
Slag inclusion, under cut.
Advantages:

Good productivity

Good quality of welding

Good for thick material

Less skill required

Very clean

No spatter is sticks smoke.

No visible arc (no need eye protection)

Disadvantages:

Very costly equipment

Limited position of welding

Need accurate fit-up

Poor portability

No good for thin material

Manual Metal Arc Welding

Drooping characteristics (constant current)
Type of operation:
Manual

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Mode of operation:
Arc is created between the tip of electrode and work piece. Arc is formed by momentarily
touching the tip of electrode on the parent plate and then lift the electrode to give a gap 3 ~
6mm between the tip of electrode and the plate. Arc melts parent metal and electrode; the
molten metal so formed is transferred as small globules across the arc gap. Welder controls
arc length and electrodes feed rate by the hand movement. The slag must be removing after
each deposited layer. Normally a small degree of penetration, plat edge preparation required.
Power source:
Generator, transformer and rectifier.
Current:
Normally dc +ve but also use dc ve or ac.
Dc +ve
best penetration
Dc ve
deposit is high
Defect:
Porosity, slag inclusion, under cut, excessive penetration and spatters.
Equipment:

Power source
Welding cables
Electrode holders
Earth return
Welding shielding helmet

Consumable:
BS EN 499, AWS A5.1, ISO 2560, BS 2926, BS 2493
Basic:
E7018, E7015, E7016
Rutile:
E6013, E38 2R
Cellulasic:
E7010, E8010
Advantages:

Low cost equipment

Easy to operate at site

Easy shift to site

Easy and more deposit thickness

Wide range of material

Welding all position

Disadvantages:

Low production due cleaning required after every layer

Dirty and smoke production

Not sufficient to weld all material successfully.

Welding process defects

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1 - Weld decay
Weld decay?
Weld decay is corrosion between grains.
Causes?
The reduction of the chromium from grains is main cause of the weld decay. When material is
over heated 600 C~800 C, chromium comes out from the grains, joins with carbon and
becomes chromium carbide on the grain boundaries. It happens in the heat-affected zone.
Chromium is retard corrosion. Corrosion occurs between the grains as chromium is reduced.
Avoidance?
We can avoid weld decay
By using the low carbon content material such as 316L & 304L instead of 304 &
316.
By using the stabilized stainless steel such as 321 & 347.
By adding the titanium and niobium. Titanium and niobium join the carbon and
become titanium and niobium carbide. Titanium and niobium give stabilization to
chromium.
By the keeping of appropriate heat input.
By the keeping of appropriate inter pass temperature.

2 - Solidification cracking
Solidification cracking?
Solidification cracking is hot cracking, hot shortness, and centerline cracking in the weld
metal
Causes?
Sulphur, stress and joint design are the main causes of the solidification cracking.
Sulphur comes from parent metal, joins with the iron and becomes iron sulphied.
Iron sulphied has low solidify temperature than steel. Iron sulphied becomes a thin
film in liquid form between the solidify grains on the center of the weld. Iron
sulphied possess a very little tensile strength. Any stress makes a solidification
crack at this moment.
Avoidance?
We can avoid solidification cracking

By the using low sulphur content material

By changing of joint design.

By good cleaning of joint.

By the adding of manganese to join the Sulphur to become manganese

sulphied. Manganese sulphied has a same temperature to solidify with steel.
Manganese reduces Sulphur content and discrete the iron sulphied. Therefore, less
chance to crack.

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3 - Lamellar tearing
Lamellar tearing?
Lamellar tearing has characteristics step like crack.
Occurrence?
It occurs in the thick section in the T, Y, K, and corner joints, wrought plate, in the HAZ of
steels, where fusion boundary of the weld and only in the rolled direction of parent material.
Causes?
Poor through thickness ductility, stress and high Sulphur contents are main causes of lamellar
tearing. Although, others non-metallic inclusions may also play a part. The presence of the
hydrogen increases steels susceptibility to lamellar tearing quite significantly.
Avoidance?
Lamellar tearing can be avoided:

By reducing the size of the weld, try to use fillet weld instead of butt weld.

By changing the joint design, where stress moving in the roll direction.

By using the low Sulphur content steel.

By buttering layer

By using z quality plate that has been stra tested.

Assessed?
Assess by short tensile test according to BS 5135.

4 - Hydrogen cracking
Hydrogen cracking?
Hydrogen cracking is known as cold cracking, hydrogen induced cracking (HICC) and
delayed crack.
Cause?
Hydrogen cracking can be occurred when:

Hydrogen is exceeds 15ml/100gms of the weld metal.

Stress exceeds yield stress

Temperature is less than 350 C

Hardness exceeds 400VPN (Vickers pyramid hardness)

Oil/greasy surface

Moisturized flux
Avoidance?
Hydrogen cracking can be avoided by:

Appropriate baking of flux covered electrode.

Appropriate pre-heating

Adequate inter pass temperature

Appropriate heat in put.

Post-heating to defuse hydrogen and reduce the residuals stresses.

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Using the hydrogen controlled electrode

Consumables
Welding consumables are the electrodes, wires, fluxes and gases. Each consumable is critical
in respect to specification/supplier, condition and treatment (if any).
Many codes are covered the various consumables.
Covered electrodes:
BS EN 499, AWS A5.1, ISO 2560, BS 2493, BS 2926.
Gas shield wires:
BS 2901 Part 1-5
Gases:
BS 4365, BS 4105
Fluxes & wires (SAW)
BS 4165 (CS), BS 5465 (A/SS), AWS A5.17 (CS)
Function of shielding gases (TIG/MIG/MAG):

It provides a suitable, ionize able atmosphere for the electric arc.

It protects the weld pool from the atmospheric contamination.

Argon:

Helium:
Nitrogen:

provides a smooth arc at low arc voltage with dc-ve also gives cleaning action
with ac for light alloys.
In addition of hydrogen, provides a high arc voltage and gives deeper
penetration also increase speed on stainless steel.
less than argon therefore high flow rate (2~2.5 times) required to achieve same
effectiveness with argon. Produces high arc voltage and heat suitable for thick
section. More cost expensive than argon.
inert gas in the room but becomes active with oxygen therefore unsuitable for
majority of material but gives good result on the copper. More cost
effectiveness than argon or helium.

Function of fluxes:

Provides a gas shield to protect the weld pool and arc from atmospheric
oxygen and nitrogen.

Provides a slag, which gives additional shielding to the weld pool and assists
in manipulation during the welding.

Improves the physical properties of the arc (arc initiation and stability)

Introduces weld metal alloys such as iron powder, de-oxidant etc.

Improves metallurgical properties to lowering oxygen and nitrogen levels.

Increasing deposition factors and over all efficiency

Types of fluxes (MMA):

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Rutile, cellulose and basic fluxes are the common types of covering s for MMA electrodes;
others include acid and oxidizing coverings.
Rutile:

Constituents; titanium dioxide, clay and sodium silicate.

Medium weight of titanium dioxide plus fluorspar.
Used for general purpose such as ms fabrication, low pressure pipe work,
supports, structure and bracket etc.
Gives fluid fast freezing slag, suitable to easy use in all positions but not for
vertical down.
Should be kept dry but never baked.

Cellulose:
Constituents cellulose (wood pulp), titanium dioxide, sodium silicate.
High cellulose content produces a large volume of gas around the arc.
Shield gas consist on H2, Co, CO2 & H2o
Most important gas is hydrogen, which increases the arc voltage and
corresponding in power, which cause for deep penetration.
Rapid, rate of burn.
Produces fast freezing weld pool and thin slag, suitable for vertical down and
overhead work.
Main use on stovepipe welding of high strength large diameter pipelines and
storage tanks.
Good quality of penetration bead.
Rough appearance and uneven ripples of completed weld.
Spatter content higher than other electrode.
Hydroscopic flux designed to hold between 4-7% moisture.
Must be kept dry but never baked.
Basic:

High limestone and fluorspar content to produce weld metal with low hydrogen
content.
Limestone has good stabilizing and produces carbon dioxide gas shield.
May be bake up to 500C approximately or depending on the manufacturer.
Ability to weld low alloy, high & medium tensile strength with high sulphur
content without any cracking, also reduce the possibility of the hydrogen induced
cracking in the weld metal and heat-affected zone, but dependant upon the
properly dried.
BS 639 certifies for MMA as hydrogen controlled. Must be less than
15ml/100gms of the weld metal but can be reduced less than 5 ml/100gms of the
weld metal with proper control.
Need higher degree of skill and must be used vertical up technique.
Productive and expensive.
Constituents; limestone (calcium carbonate) gas former, Co2 secondary ionizer,
fluorspar slag former, sodium/potassium silicate main ionizer.

Filler wire & Fluxes (SAW):

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Solid wire is used, 1.6 mm to 6 mm according to BS 4165.

Fused and agglomerated according to BS 4165.

Fused flux (granular):

Manufactured at high temperature, glassy appearance like crystal.

Good chemical mix achieved.

Do not attract moisture.

Good handling, storage, used and weld ability

Each removal of impurities and fine particle during recycling

Agglomerated flux:
Dry mixed and then bonded with either potassium or sodium silicate
manufactured at high temperature.
Absorb moisture and limited recycling.
Weld appearance not good.

Advantages and disadvantages

Radiography Testing
Advantages:

Permanent record.

Good for thin material.

Wide range of material.

No skill required for gamma rays.

No surface cleaning required.

No power required for gamma rays.

Disadvantages:

Dangerous for health.

Lamination and lack of sidewall fusion cannot detect.

Expensive film.

Affected all other activities.

Power source required for X-rays.

Not good for thick material.

High skill required for X-rays.

Ultrasonic Testing
Advantages:

Give accurate location and depth of defect.

No health hazard.

No need power supply.

Not affected other activities.

Good for thick material.

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Lamination and lack of sidewall fusion can detect.

Portable.

Disadvantages:

No permanent record.

High skill required.

Surface defect cannot detect.

Smooth surface required.

Not good for thin material.

Large grain size material defect cannot detect.

Dye Penetrant Testing

Advantages:

Can check all materials.

No need power source.

Low cost.

Direct indicate to defect location.

No high skill required.

Disadvantages:

For surface defect.

More dwell time as compare to MT.

Magnetic Particle Inspection

Advantages:

Surface and sub-surface defect can check.

Low cost.

Less time and more output.

Direct indicate to defect location.

Disadvantages:

Cannot use for non-ferrous.

May be danger for operator.

Power required.

Difference between microscopic and macroscopic.

Microscopic

For grain structure analysis

Cross-section view at high magnification e.g. 100x or 1000x
Some defects could also be detected and assessed.
The degree of preparation is much higher than macroscopic examination, e.g. for
ferrite steel; P1200 grade finished followed by 1um polish using a diamond paste
then an etch using 1-5% nital

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This test is primarily used by the metallurgists

Macroscopic

For welder/procedure qualification

To view the cross-section view magnification is required 5x ~ 10x
To detect the weld defect and also to measure the actual defects already detects.
Carried out on full thickness specimen included reinforcement
Width of cross-section should include the heat-affected zone plus some parent
material.
Same test piece is sometimes used for hardness testing after macro examination
Specimen transversely cut from the weld
Each test specimen is then ground, polished and etched to the degree required by
the specification, e.g. for ferrite steels P400 grade finish with an acid etch using
10-15% nital (nitric acid + alcohol)
Test specimen examined visually
The intent is to disclose any cracks, lack of fusion, porosity, slag etc.

Steel properties
Chemical properties of steel
1.
2.

3.

4.

5.

6.
7.

Aluminum;
i.
De-oxidizer, grain refiner for improved toughness
Carbon;
i.
Hardening agent
ii.
Increases Strength
iii.
Reduces weld ability as increase carbon
Chromium;
i.
Creep resistance and resist oxidation.
ii.
Corrosion resistance
iii.
Hardening element
iv.
Increase the strength of steel
Cobalt;
i.
Known as red hardness
ii.
Used where high strength, high hardness at high temperatures
are desired
Manganese;
i.
De-oxidant, grain refiner, increase toughness at low
temperature
ii.
Increase strength by increasing harden ability
Molybdenum;
i.
Creep resistance
ii.
Increase hardness also improve corrosion resistance qualities
Nickel;
i.
Grain refiner
ii.
Increase harden ability

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iii.

8.

9.

10.

11.

12.

Improves toughness and ductility even with strength and

hardness
iv.
Improve toughness at low temperatures
v.
Increase tensile strength about 6000psi for each additional 1%
of nickel
Phosphors;
i.
< 0.015%
ii.
Usually found in all steels
iii.
Hardened steel
iv.
Cause to embrittelment
v.
Improves machine ability of high-carbon steel
vi.
Improve strength and corrosion resistance of low carbon steel
Silicon;
i.
De-oxidizer (0.2 0.3%)
ii.
Promotes fluidity of molten steel
iii.
Also contributes to the strength of LA steel
Vanadium;
i.
Grain refiner
ii.
Promotes control of grain size, grain refine
iii.
Increase harden ability
Sulphur;
i.
Undesirable impurity (less than 0.04%)
ii.
Cause brittleness and reduce weld ability
iii.
Improve machine ability
Niobium
i.
Grain refiner
ii.
Increase harden ability
iii.
Also known as columbium

Mechanical properties of metals

Strength
The ability of material to withstand an applied load
Tensile strength shear strength, torsional strength impact strength and fatigue
strength
Tensile: the ability of metal to resist failure
Yield: that strength level at which the materials response to loading changes from
elastic to plastic
If the hardness increased, the tensile strength increases also and vice versa
If temperature increases, the strength decreases
Ductility
The ability of material to deform, or stretch under load without failing
Ductility increases as temperature increase
High ductility is referred to as ductile and low ductility is referred to as brittle
Hardness
The ability of material to resist indentation or penetration
Hardness increases as strength increases, or vice versa
If hardness is known possible to estimate tensile strength
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Toughness
The ability of material to absorb energy
Toughness decreases as the temperature is reduced
Toughness decreases as the hardness is increased
Fatigue strength
That strength necessary to resist failure under repeated load applications.

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