USE OF MEASURING TOOLS FOR THE AWS CERTIFIED WELDING INSPECTOR HANDS-ON EXAMINATION US EDUCATION DEPARTMENT AMERICAN WELDING SOCIETY, INC. 550 NW LE JEUNE RD. MIAMI, FLORIDA 33126Dl.1. During this part of the examination, you will be asked to PTAA TMNT NAG aeesticlicesLicocllllltanenllvenliwed have to refer to luis sample code to determine if the result of that measurement is acceptable in accordance with these coaé requirements. The purpose of this discussion is to familiarize those in- Gividuals taking the examination with the tools and their proper usage. Before describing Uleir operation, the list below in- cludes all of the tools contained in the kit: ~ © inch machinist's rule (or scale) in 1/32 and 1/64 inch graduations ~ 9 to 1 inch micrometer in 0.001 inch graduations (adjustable - hex wrench provided) ~ 150 wm metric dial caliper in 0.1 mm graduations ~ 2 inch diameter reading glass (6.50 dioptre) - Set of Fibre Metal template fillet weld gages (1/8 to 1 inch £illet weld sizes) - Palmgren weld gage Figure 1 is a picture showing all of the tools found in a typical toolkit for the examination. In addition to these tools, the kit also includes an il- luminated slide viewer containing pictures showing the equipment for several different nondestructive test methods. Other pic-~ tures shown in the viewer illustrate weld radiographs containing various types of weld discontinuities. Finally, the kit contains plastic replicas ot welds and destructive test specimens. These replicas include: a groove weld in a butt joint, single and multiple pass fillet welds onFigure 1, ‘Yools Found in the Examination Toolkit different sides of a I- or lap joint, a single pass fillet weld on a T-joint with porosity located in seqments identified on the sample, a rectangular tensile specimen, and a series of four face or root bends showing their convex surfaces after bending. Now that all of the components of the kit have been iden- tified, it's appropriate to describe how each particular instru- ment will be used by the inspector, either during the test or in normal day-to-day inspection activities.Use of the Tools for Measuring and weld Evaluation measuring With the 6 Inch Machinist's Rule The simplest, and probably the most conuon, measuring device ‘neluded in the toolkit is the 6 inch machinist's rule, sometimes MTT eceeaegural|2|lsnewl closeup of the type in- eluded in the kit. Figure 2, 6 Inch Machinist's Rule The particular type found in the kit is graduated in incre- PT the RMR stcoullllithelliatar gel mae indicate whole inches, and the smaller numbers indicate the appropriate number of 1/32 (or 1/64 inch increments, depending which side of the rule is being used. The significance of these graduations is depicted in Figure 3, Figure.3, Ruler Tuccements of one Inch Measuring With the 0 to 1 Inch Micrometer The next measuring device to he discussed here will be tne 0 to 1 inch micrometer. A micrometer, or "mike" for short, is an instrument that measures in thousandths of an inch (1/1000 inch). the type found in the test kit is adjustable, so there is an ac- companying hex wrench. These ilews are shown in Figure 4. in Figure 5, the various parts of the micrometer are iden- tified, including the frame, the barrel, the thimble, the spindle, and the anvil. On this particular model, there is also a friction stop. The friction stop, located at the end of theFigure 4, Adjustable Microméter with Hex Wrench FRICTION STOP. Fe warner Loen NUT, /4— FRAME Figure 5, Parts of a Micrometer | |thimble, can be used to tighten the micrometer on the object to be measured. Since the triction stop always slips at a particu- lar pressure, the micrometer can be tightcned the same amount for each measurement, allowing for more repeatable results. Since the micrometer found in the test kit is an adjustable type, the first operation involves checking to make certain that the micrometer is “zerowd.” To do this, hold the micrometer as Shown in Figure 6, and turn the friction stop until the spindle and anvil are in contact. With the micrometer closed, the "0" on the thimble should be aligned with the “O" mark on the barrel, as shown in Figure 7. If this is not the case, then the instrument must be adjusted as explained below. Figure 6, Proper Way to Hold a Micrometer parney THIMBLE Figure 7, Testing the exactness of a 1 Inch Micrometer pane rtTo begin this adjustment, loosen the setscrew locatea near the friction stop end of the thimble, while holding the spindle stationary. Then move the thimble, until the “9 marks on both the barrel and the spindle are aligned as shown in Figure 7. The hex wrench can then be used to tighten the thimble in this posi- tion. The thimble should then be loosened and the, initial ster repeated to make certain that the instrument. is now Properly calibrated. The micrometer is naw ready to be used for measuring, HTN THAR Reheotezminel|ichellstzellceliconel es Meet Ml ATTA ARMA RGEC ead) dimensional!one hal meal The marks on the thimble represent 0.001 inch each. ay turning fhe thimble in the direction shown in Figure 8, the spindle moves TTT MINT ATMA AMNGENSReNchembLelelleuenan|ieal ect aul anny mark on the thimble is aligned with the "0" on the barrel, that Fepresents a distance between the spindle and anvil of 0.001 inch, as shown in Figure g. | 0.001" Figure 8, One Thousandth of an Inch (0.001") Additional turning in the same direction will move theMATAR ATTRA REA CHHaaEKM on lenell pares alls aligned with the thimble mark identified by the number "5", which is shown in Figure 9. This represents a dimension of 0.005 inch. —__@#r 0.00577 Figure 9, Five Thousandths of an Inch (0.005") Note that one complete turn of the thimble is 0.025 inch on the barrel, as depicted in Figire 10. For each complete revolu- MT NATTA Geel |cHimblalesvesllovar| onal maee mle the barrel. This means that each mark on the barrel is 0.025 inch, ‘ Me lo TE 20 0.025" Figure 10, Twenty-five Thousandths of an Inch (0.02 STA aTcnEnS ibarceallallallzies valves eee ee MTNA atameed Mi oMloccMlnn sell ag ama a 0.100, MAM COHnebeltescHllledgueall a aman eee position of thethimble for a ectting of 0.100 inch Figure 11, One Hundred Thousandths of an Inch (0,100") To find out how much the micrometer is opened (the distance between the anvil and the spindle) the marks on the barrel may be read like any ordinary rule, remembering that the numbers 1, 2, 3+ etc., mean 0.100, 0.200, 0.300 inch, etc. To this number, add the thousandths that show on the thimble. So, the measured dimension of some object is arrived at ny closing the spindle ana anvil around the object and adding the following indications on AI ATRRRTTAAeRRel semper lion|\chell barren || (ane aeiee ef 0.100 fneh), the smaller graduation on the barrel (increments of 0.025 inch), and the qraduation on the thimble aligned with « line on the barrel (increments of 0.001 inch). Figure 12 illustrates four different dimensions indicated on S micrometer. In Figure 12(A), the end of the thimble is alignea TAMARA aga elecerealanallenall-orllonllenll tamer lal HT TAMTTNT RAISERS HOR che parce lll patel Mea dimension of 0.200 inch. in Figure 12(B), the reading shown is 0.250 inch (or 0.200" WIMMERA ESeerelt2 (c)lll-cpresencallene|laimene ise olivesinen (or U.500" + 0,050" the measurement 0.0124"), + 0,012"), is shown to be 0.7874 inch Finally, in Figure 12(p), (or 0.700" + 0.075 + 5 1 ak () tro “20 See ews te) [Pema ' o.sea” os asese7 cis oy ifn TS every” Figure 12, Reading a MicrometerMeasuring With the Metric Dial caliper A closeup of the metric dial caliper included in the toolkit is shown in Figure 13, Figure 13, Closeup of Metric Dial Caliper RTT ReRee sedlleoslnckeurenallerenee ede TTA AMMAN Cs CBsectsallianilagaa sont gama ue such as Gepths or heights of steps can also be determined. This par- PATTI MNGTATMTAAARa|CelImeasucelldimensionel| salen ella TA TTTTRCRMC aa ebel eae deel eee allele ele caliper include: main beam (with 10 mm increments), slider, dial (with 0.1 mm increments), bezel (movable rim of dial used for Feroiug), inside jaws, outside jaws, thumb wheel (for moving slider), and depth indicator. riguee 14 aepicts how the caliper S-12Inside Depth Figure 14, Positioning Dial caliper for Various Measurements As with the micrometer, the first step toward using the dial - Hinanialinateterminelliieliaevollcrqoar i Hm This io ac- complished by moving the slider until the outside jaws are com- pletely closed. While holding the slider in this position, move Rial aamanett + isha atest nasearor | Meee centered over the mark on the dial. Once the instrument is properly zeroed, it is now ready for Use." Depending on the type of dimension desired (outside, in- *ide, depth or step height) the dial caliper will be positioned MTA CTR Ele lhseeer|l staae eceses ell ee dimen- ANITA GHNSne outsiaall dave llonecesal| eel ee depth in- 8-13dicator are identical. The dimension of the object can then be Getermined by observing the positions of the main beam and dial TAMARACK auicamenston|oclevellowaeee| Milan sum of TTT TMNT MAINA CRATE NPeemllandicaeeel waren a gradua- FTIR SPSetalMl roll ehaelllenaace eel Mal Ml added the dial indication. This allows for the measurement of objects to an accuracy of 0.1 mm. Figure 1> shows a slider position and th rresponding dimension measurement. Figure 15, Reading a Dial Caliper looking at this Figure, the main beam indicator is posi- PTAA Gael ezalizollcrsousttonsillllaenalliss Hall ee then points to the exact number of millimeters to be added to the TTA TTA ENE) ween lean solllcorensalleramerell| eHe iA fal dimension is equal to.10 mm (from main beam) plus 7.85 mm (frum diai indicator) for a total of 17.85 mm. As shown, this is the dimension, regardless of whethe: the measurement is an out- side, an inside, a depth, or a step height. 8-14Ua Using the Reading Glass RMB tell talltenellalllenculigaamee ae reading glass, er magnifier, which is shown in Figure 16. Figure 16, 2? Inch Diameter Reading Glass ‘The primary purpose of this instrument is to magnify objects 50 they can be more accurately andlyzed. As far as the use of the reading glass, it is positioned between the eye and the ob- ject being viewed to produce a magnified image. an example of its use for the examination might be in the measurement of Porosity occurring in the fillet weld. ‘The combined use of th teading glass with one of the measuring instruments will allow for the most accnrate determination of the purosity size.Measuring Fillet Weld Size with the Fibre Metal Template Gages Tie Fibre Metal template fillet weld gages are sold in a set as shown in Fignre 17. Figure 17, Fibre Metal Tomplate Fillet weld cages ‘This set of gages permits the accurate measurement of fillet welds trom 1/8 to 1 inch, regardless of whether the contour of the fillet weld ie flat, convex ur concave. Before discussing the application of these gages, it is ap Propriate to briefly mention what is meant by fillet weld size. AWS defines the size of a fillet weld as being the size of the largest right isosceles triangle which can be totally contained within the cross section of the fillet weld. with this in mind,ie becomes spparont that vie part of the fillet weld limiting the Size of this theoretical triangle is different depending on whether the weld is convex (humped up) or concave (dished in) For the convex fillet weld, its size is determined by the leg RANMA AAAGTeeN el ellconcaveliciiieet|werallllenalle ney ¢ RATATAT CAT TMANNRNARAREH ecru consequently!lilieneealltegnigiee weld gages have been designed to facilitate the moaaurement of either of these dimensions, depending on which part of the gage is used. tm Figure 18, one of these template gages is shown. It is noted that there are two different shapes of cutouts present. One shape (shown on the bottom of this gage) is a single ap- proximately circular cutout (or,arc). The other shape noted (shown on the top of this gage) consists of two circular cutouts for arcs) on either side of a flat surface. THE FIBREMETAL -sGONCURDVILLE, Figure 18, Typical Fibre Metal Template GageThe different cutout shapes are to be applied to different MTT allehehwerallaevest el eee convex, the single arc MMMM petted ll seme ra ey eal double arc por- tion of the gage is used for MAAC uel =2zelleellalllcgueunn fillet weld. heir typical application is shown in Figure 19, CONVEX WELDS. CONCAVE WELDS Figure 19, “Typical Application or ripre Metal Gages MMT Gage wetalllaizeloaliigue waa by placing the HHMI EMMA AlN alsaschesainsellenelieea lie metal surfaces. RTM MN MRageecel to linellcnalliacea imme ail on the gage if HT iRananaalCe| ebellgagal touchanlicwel Meal am or the weld toe when positioned as shown in Figure 19 (bottom left illustration). HMMA Tae eellalliconcavalleszrael meal lal found by Positioning tne proper portion of the gage against the two base metal reference surfaces. This weld is then considered to be the TINIAN SoSH Sell chell etael eer touches:HMMA Rela sdellitelinadallinltshell suey ail shown in LE of the fillet weld being measured varies depending on whether it wS convex Or concave, the actual sizes of the welds will be iden- HATTA ATMAATAM AMAT ecchedlionithallisacallaure ace ie Il same. Figure 20 illustrates the proper application uf these types of gages for several different conditions. Meosuring Concave fila, Files ceca menirewhot gop wAONG noc sit6" lowe hase Are 2 type Measuring 45° Fla Flats With Eqvol tag Tanna 2 Tomer (deel Filet Shope) ine Masig Fl When hap Het Appee ies ni ee ail terasoneee Figure 20, using the Fibre Metal Type Fillet weld Gages s~19It is noted in these examples that multiple applications of tho gage may be necessary in order to Properly measure a fillet HATTA TMNT AN geeealezelcupedzealllsalll yaaa increments fillet weld sizes can be determined only te the closest 1/32 inch. So, the inspector will have to make a judgment as to which gage comes closest to actual weld size ATTN AMCCRSsoer|ichel eonaunaneee Mal convex £i1- HATTA GRzSlexampTe lle nil eee el two separate gages (1/4 and 5/16 inch) were applied, but the weld appeared larger than 1/4 inch but less than the 5/16 inch. In this case, the in- ATMA MMMNTTATNTGH eects tonllsclicollensenl gel eel em gages comes Closest to the actual weld cize. rf tne weld appears to be less TMNT ARNG RTacE Nepean eteltt alleen gael Ie be class- MATT AA a neallivera ll owayer tly elle ee measurement showed that the weld size was less than 1/32 inch smaller than the 5/16 inch gage. it would then be tonsidered to be a 5/16 inch fillet weld. s 20 | | |of Let 2s, ial ich jes wee tes iss yaa "16 et Using the Palmgren weld Gage nT MTA CNGelieelldzecuesealineral ellen Palmgren weld gage. It is pictured in Figure 21. this gage can be utilized to measure a number of different weld dimensions, including: weld reinforcement, convex Fillet weld size, concave fillet weld size, maximum convexity, 1/8 inch root opening, and 5/16 inch root opening. Poa Figure 71, Palngren we1d Gage While a number of different dimensions can be determined HNN TAN ARA ene ehaelipaxc|lociienelluagall gen: ase la measure fhe amount o€ weld reinforcement will be needed for the hands-on test. This gage is not really anited for measucing the tillet TTT TTT RTaH A RaRNaEfonllibecaucellle mall ame Meal Ma large $-21enough to properly position the gage To utilize this gage for measuring the height of weld roin- forcement present on a groove weld, the gage is positioned as TAT MMNTNRRTNTT Meese hehellbczelliene lie where the root opening spacers are attached)’ of the gage is Positioned such that ania Cahettheriesdellee eal reinforcement. Once STATING eatdeel asl tnenliaer ele sa it is in contact wich fhe highest point of the weld reinforcement The amount of wela SAAT TTNAE BEc sec llecall enon | yell directly from the scale dabelled “butt weld reinforcement.” Maxus MN 1132 BUTT weLn Figure 22, Measuring Weld Reinforcemontot at ce uh 1a le Summary: This section ig intended to provide an individual preparing for the AWS CWI Examination with information about what to expect during the closed-book “Practical Hands-on Portion of the test. Tt's primary purpose is to explain the'use of the various tools in the test kit. TT some instrument simply from Some written explanatiun, each individual 48 urged to practice with each of these tools Prior to the day of the test, Only then will it be Possible to most efficiently spy these too1s during the brief test period. References ater aee oe Sg) ArEMetalllsorsigechae leah eae (mcknight end McKnight Publishing Company, Bloomington; Tilinois, 1962) “Stick Electrode Welding Guide" (zincoin), Pages 48 and 49 oto Nn accompanying adjustable micrometer and dial caliper Fibre Metal Products Company, sales literature accompanying £il- let weld template gages PTTRee cra ateralesanloslichellcenlloeing|meagucaapr eel al machinist's ruler shown in the sketch below? a. 1-23/32 in, b. 1-23/64 in. ¢. 1-21/64 int 4. 1-21/32 in. ®. none of the above rectesometer is being used to measure the width of a ie tangular tensile specimen. what is ite-dimension if the micrometer appears as shown below? a. 0.658 in. b. 0.568 in. ©. 0.762 in. i d. 0.678 in. ) i €. mone of the above The dial caliper is being used to measure! thé thickness oF the rectangular tensile specimen in the question above. What is its dimension if the dial caliper p= Pears as shown below? a. 18.90 mm b. 10.87 mm 2) C. 187.0 mm d. 18.70 mm 2 €. none of the abovePRACTICE QUIZ FOR USE OF cwr HANDS-on TOOLKIT, Page Using a conversion factor Provided on the back pe Salina what is the equivalent dimension in er units for t width shown in question 3-2 above? a. 22.76 mm b. 20.69 mm ©. 19.35 mm 4 4.19225 mm e. 18277 mm FO AAA page what is the equivatent dimension in U's, customar unite for the thickness shown in question s°o above? a. 0.936 in. 7 b. 0.778 int c. 0.887 i a. 0.966 euolase 8. 0.777 in? ana 501.29 mm? b. 0.555 in? and 358.06 mm2 ¢+ 0.738 in? and 476.13. mm2 ®. 0.561 in® and 361/85 mm €. none of the above gf the tensile specimen above failed at a load of ~ 81,550 pounds, what is the ultimate tensile strength of this metal? a. 91,890 psi b. 82,800 psi ©. 66,400 psi 4. 37,000 psi €. none of the abovePRACTICE QUIZ FOR USZ OF CWI HAKNS-ON TOOLKIT, Page 3 s-8 Bnetapet weld gage is being used to mensuro the size of Khe fillet weld shown below. Prom this sketch, what would be the size of this weld. a. 5/16, inch R. 1/4 inch c. less than 1/4 inch a. cannot properly measure this weld with the gage shown @. mone of the above 8-9 The fillet weld shown below is being measured to deter- mine if it satisties the drawing requirement of 3/8 inch, What can be said about the measurement being made in the sketch? a. This weld is not acceptable because it is too large. b. This weld is acceptable. | c- This weld is not acceptable because it is too small. d. Unable to accurately determine if the weld is of Proper size, because the wrong gage is being used. €. none of the’ abovea -10 PEACTTCE QUIZ FOR USE OF CW1 HANDS-ON TOOLKIT, Page 4 The groove weld sliown below is required to have a maxi- mun weld reinforcement of 1/32 inch, Judging Erom the measurement shown in the sketch, what would you say about this weld? a. The weld is unacceptable, because there is nut enough weld reinforcement. b. The weld is unacceptable, because there is too much weld reinforcement. ¢. This weld is unacceptable, because the requirement only applies to face reinforcement and the root reinforcement is being measured. d. The weld is acceptable, as far as the amount of Permissible weld reinforcement. . none of the above Conversion Factors To Convert From to Multiply By in, mm 25.4 sm in. 3.937 x 1072