Beruflich Dokumente
Kultur Dokumente
Radiographic Interpretation
M.S.Rogers
TECHNOLOGY
M.S.Rogers
TECHNOLOGY
Mechanical damage
Misalignment (set-up
Miscellaneous
irregularities)
Gas pores and porosity
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TECHNOLOGY
Cracks
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TECHNOLOGY
Cracks
Cracks that may occur in welded materials are caused
generally by many factors and may be classified by
shape and position, cracks are classed as planar.
Classified by Shape
Classified by Position
Longitudinal
HAZ
Transverse
Centreline
Branched
Crater
Chevron
Fusion zone
Parent metal
M.S.Rogers
TECHNOLOGY
Process Cracks
Hydrogen induced cold cracking
(HICC)
Solidification cracking (Hot Tearing)
Lamellar tearing
Re heat cracking
M.S.Rogers
TECHNOLOGY
Cracks
Lamellar tearing
M.S.Rogers
TECHNOLOGY
Transverse crack
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Longitudinal crack
M.S.Rogers
TECHNOLOGY
Inclusions
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TECHNOLOGY
Gas Cavities
Gas pore <1.5mm Blow hole.>1.6mm
Gas pore
Cluster porosity
Blow hole
Herringbone porosity
Root piping
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TECHNOLOGY
Gas Cavities
Porosity
Root piping
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M.S.Rogers
TECHNOLOGY
Cluster porosity
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Herringbone porosity
M.S.Rogers
TECHNOLOGY
Solid Inclusions
Slag inclusions are defined as a non-metallic inclusion
caused by some welding process
Slag originates from welding
flux
Slag inclusions
Lack of sidewall
fusion with
associated slag
TECHNOLOGY
TECHNOLOGY
Lack of Fusion
M.S.Rogers
TECHNOLOGY
Lack of Fusion
Poor welder skill
Incorrect electrode
manipulation
Incomplete filled groove
+ Lack of sidewall fusion
Arc blow
Incorrect welding
1
2
current/voltage
Incorrect travel speed
Incorrect inter-run cleaning
M.S.Rogers
TECHNOLOGY
Overlap
An imperfection at the toe or root of a weld caused by
metal flowing on to the surface of the parent metal
without fusing to it
Contamination
Slow travel speed
Incorrect welding technique
Current too low
M.S.Rogers
TECHNOLOGY
Overlap
Toe Overlap
Butt weld
Toe Overlap
Fillet weld
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TECHNOLOGY
Contamination
Arc blow
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TECHNOLOGY
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TECHNOLOGY
TECHNOLOGY
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TECHNOLOGY
TECHNOLOGY
TECHNOLOGY
Poor stop/starts
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TECHNOLOGY
Miscellaneous Defects
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TECHNOLOGY
Miscellaneous Defects
Spatter
Excessive current
Damp electrodes
Contamination
Incorrect wire feed speed
when welding with the MAG
welding process
Arc blow
M.S.Rogers
TECHNOLOGY
Miscellaneous Defects
Accidental striking of the arc
onto the parent material
Faulty electrode holder
Poor cable insulation
Poor return lead clamping
Arc strike
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M.S.Rogers
TECHNOLOGY
M.S.Rogers
TECHNOLOGY
Cap Undercut
M.S.Rogers
TECHNOLOGY
Root undercut
Copyright2003
2004TWI
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Copyright
Cap undercut
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M.S.Rogers
TECHNOLOGY
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TECHNOLOGY
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TECHNOLOGY
Concave Root
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TECHNOLOGY
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TECHNOLOGY
Excessive root
penetration
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M.S.Rogers
TECHNOLOGY
Concave root
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2004TWI
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TECHNOLOGY
M.S.Rogers
TECHNOLOGY
Burn Through
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TECHNOLOGY
M.S.Rogers
TECHNOLOGY
Crater Pipe
Weld crater
Crater pipe
M.S.Rogers
TECHNOLOGY
Crater Pipe
Crater pipe is a shrinkage defect and not a gas defect, it
has the appearance of a gas pore in the weld crater
Crater cracks
(Star cracks)
Crater pipe
M.S.Rogers
TECHNOLOGY
Mechanical Damage
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TECHNOLOGY
Mechanical Damage
Mechanical damage can be defined as any surface material
damage cause during the manufacturing process.
This can included damage caused by:
Grinding
Hammering
Chiselling
Chipping
Breaking off welded attachments (torn surfaces)
Using needle guns to compress weld capping runs
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M.S.Rogers
Mechanical Damage
TECHNOLOGY
Chipping Marks
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TECHNOLOGY
Set-up Irregularities
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TECHNOLOGY
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TECHNOLOGY
Set-up Irregularities
Linear misalignment is
measured from the lowest
plate to the highest point.
Plate/pipe Linear Misalignment
(Hi-Lo)
Angular misalignment is
measured in degrees
Angular Misalignment
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M.S.Rogers
TECHNOLOGY
Set-up Irregularities
Linear Misalignment
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M.S.Rogers
TECHNOLOGY
Set-up Irregularities
Linear Misalignment
M.S.Rogers
TECHNOLOGY
Any Questions
?
Copyright 2004 TWI Ltd
M.S.Rogers
TECHNOLOGY
Questions
Weld Defects
QU 1. Give two main causes for the occurrence of a burn through
QU 2. Give two main causes for the occurrence of excessive root
penetration on a single-V butt weld
QU 3. Give five defects, which may occur when welding carbon
steel using the MMA welding process with the current
setting
to low
QU 4. Give three possible causes for the occurrence of lack of
side wall fusion
QU 5. Sketch the following defects
a. Lack of root wall fusion b. Lack of root penetration
c. Incomplete filled groove d. Concave root
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M.S.Rogers
TECHNOLOGY
Material Inspection
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TECHNOLOGY
Material Inspection
All materials arriving on site should be inspected for:
Size / dimensions
Condition
Type / specification
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TECHNOLOGY
Material Inspection
Parent material defects include:
Mechanical damage
Lap
Lamination
Segregation line
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TECHNOLOGY
Material Inspection
Plate Lamination
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TECHNOLOGY
Weld Repairs
Copyright
Copyright2004
2004TWI
TWILtd
Ltd
M.S.Rogers
M.S.Rogers
TECHNOLOGY
Weld Repairs
In the event of repair
Authorization for repair
Removal and preparation for repair
Testing of repair - visual and NDT
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TECHNOLOGY
Weld Repairs
A weld repair may be used to improve weld profiles or
extensive metal removal
Repairs to fabrication defects are generally easier than
repairs to service failures because the repair procedure
may be followed
The main problem with repairing a weld is the
maintenance of mechanical properties
During the inspection of the removed area prior to welding
the inspector must ensure that the defects have been
totally removed and the original joint profile has been
maintained as close as possible
Copyright 2004 TWI Ltd
M.S.Rogers
TECHNOLOGY
Weld Repairs
The specification or procedure will govern how the defective
areas are to be removed. The method of removal may be
Grinding
Chipping
Machining
Filing
Oxy-Gas gouging
Arc air gouging
Copyright 2004 TWI Ltd
M.S.Rogers
TECHNOLOGY
Any Questions
?
Copyright 2004 TWI Ltd
M.S.Rogers