WELDING QUALITY CONTROL

FOR THE
FABRICATION INDUSTRY

}VELDINGQUALITY CONTROL
FOR THE
FABzuCATIONINDUSTRY

CONTENTS:

SECTION

TEfu\,{INOLOGY
CODESA}ID STA\IDAI{DS
WELD PROCEDI,E.ES
& PROCEDLT.E& WELDERAPPROVAL
MECHANICAI TESTING
S\.1\{BOLS
MATEzuALS
CONSIJ']\4ABLES
THE FOI-,T.FACTORSFORESTABLISHINGA WELD
MANUAL METAI ARC WELDING
TLINGSTENINERT GASWELDING
DEFECTSWHICH MAY BE DETECTEDBY SIJRFACEINSPECTION
METAL INERT GAS WELDING
Sl,tsIvIERGEDARC WELDING
CALIB RATION OF EQT,'IPMENT
RESIDUALSTRESSAND DISTORTION
WELDABILITY
T]EATTREATMENTS
NON DESTRUCTI\ETESTING
RIPAIR BY WELDING
GAS WELDING, CUTTING& GOUGING
INTERNAL DEFECTS& TIIEIR INTERPRETATION
APPENDIX

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TIIE WELDINd U'{STITLqE

SECTION1

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TI{E WELDINC tfiSTfItrTE

TERMINOLOGY
Use of the correctterminology
is important.Thiscourse

B S4 s 9 .

GENERALTERMINOLOGY
WELDS and JOINTS
Frequentlythe terms \reld' and loint' are used incorrectly. Exact
definitionsare given in BS 499 Welding terms and symbols'.
fiPES OF WELD

BUTTWELD

FILLETWELD

EDGEWELD

tlt.tl

hd.nt.

on,

SPOTWELD

lllustrationdepicts resistanceweld. Spot welds can be madewith

MIG or TIG processes.
WELDINGTECHNOLOGY
lssue 0191

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WELD ING bISTITLIT-E

TYPES OF JOINT
The four basic welds can be used to join varioustypes of joints.
The followingare some typicaljoints
TYPE OF JOINT

EXAMPLES

BUTT

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TEE
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CORNER

LAP

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1.2

WELDINGTECHNOLOGY
r
IssueOlgl

T\VI

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THE WELDING INSTITIJTE

PLATE EDGEPREPARATION
FOR BUTTWELDS
The illustrationsshow standardterminologyfor the variousfeaturesof plate
aria o nre nar2tin ne

i i ---t'

S i n g l e- V

D o u b l e- V

Single bevel
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-

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FEATURESOF COMPLETEDWELD
\'

A bLrttweld in a plate, made by weldingfrom both sides, has two weld faces,
four toes. In a full penetrationweld made from one side, the protrudingweld
on the undersideis the penetrationbead.
f..

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/
Fa<a

WELDING TECHNOLOGY

lssue0191

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THE WELDING I1\-ST

rFLr-IE

lf a weld is sectioned,polishedand etched,the fusionboundarycan be

established. Metal lying betweenthe two fusion boundariesis weld metal, a
mixtureof depositedmetal and plate materialthat has been melted. Adjacent
to the fusion boundaryis the heat affectedzone (HAQ, in which the plate
material has a metallurgicalstructuremodified by the heat of weloing.

Filletweldsalso have
Toes
A weld face
A root
A fusionboundary
A heataffectedzone

aoda

The shapeof a filletweldin cross-sectionis describedbVthreeterms

n
*i,-:\=

'

)/'

Mitre fillet
,

Convexfillet
Concave fillet

/'

.-

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e-\

!1

'. -'L' :1. *- ,

- -

Excessweld metal,as illustrated,

is oftenrcterredto as \reld reinforcement'.
does
This
not necessarily
meanit strengthensa joint.

WELDING TECHNOLOGY
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T\VI

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TIIE WELDING D,-STITIJTE

SIZEOF WELDS
For full penetrationbutt welds,the general rule is: design throatthickness,t,
thicknessof the thinnerpartjoined.
Partial penetrationbutt welds
The term partial penetrationstrictlyimplies butt welds that are designedto
have less than full penetration. Failure to achievefull penetrationwhen itis
wanted should be listed as the defect INCOMPLETEPENETMTION.

The throat thicknessof a partialpenetrationweld madefrom both sides is ! +

t, and the designthroatthicknesst + t.'. Notethatthe degreeof penetration
must be known.

: t

Fillet weld sizes are calculatedby referenceto allowableshear stress on the

throat area, i.e. throat area = design throat thicknessx length of weld. The
size required is specifiedon drawingsin terms of leg length ( / ).

For fillet welds with equal leg lengths:

I = 1.4tt
where t'l is as definedfor mitre and convex fillets.

WELDING TECHNOLOGY

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THE WELDING O.TSTITIJ-|E

lf an asymmetricalfillet weld is required,both leg lengthsare specifiedand t,

taken as the minimumthroatdimension.

Deep penetrationfillet wetd

With highcurrentdensityprocesses,
e.g.submergedarc and MIG (spray)..
penetrationalongthe joint linecan be produced.
This givesan increasein throatthicknesswith no changein leg length.

1 A

WELDINGTECHNOLOGY
Issue 0191

hEl^E['l'lGPOSTTIONS(BS 499: 199'1/ISo 6947)

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toe Ietcer
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\&ELDING INSI|;UTE - -

QUESTIONS
TERMINOLOGY
Sketcha singlevee buttjoint and a singlebevelbuttjoint
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t'

Q2.

Sketcha teejointand indicatefor filletweros:

a) leg length
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Completethe necessary
featuresof the sketch:

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