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WELDING INSPECTION
VISUAL INSPECTION
DESTRUCTIVE TESTING
NON DESTRUCTIVE TESTING
VISUAL INSPECTION
Before welding
During welding
After welding
BEFORE WELDING
DURING WELDING
AFTER WELDING
WELD
DISCONTINUITY AND
WELD
DEFECT
Discontinuity
is some
feature, which
introduces an irregularity in an uniform
structure.
Defect is a specific discontinuity, which
can impair the suitability of the structure.
All defects are discontinuities but, all
discontinuities are not defects
Classification of weld
defects
Based on location
1) surface defects
2)
sub surface/ internal defect
Based on shape
3) Planar defects
4) Voluminar defects
CLASSIFICATION OF DEFECTS
1. DEFECTS INVOLVING INADEQUATE BONDING:
Incomplete fusion in fused weld.
Incomplete penetration.
2. FOREIGN INCLUSION:
Slag Inclusion.
Tungsten Inclusion.
3. GEOMETRIC DEFECTS:
Undercut.
Excessive Reinforcement.
Distortion.
Lack of know-how.
COMMON DISCONTINUITIES
Crack
Incomplete fusion
Incomplete penetration
Inclusions
Porosity
Undercut
Under fill
Overlap
Burn through
COMMON
DISCONTINUITIES
Weld reinforcement
Arc strike
Spatter
Lamination
Lamellar tear
Dimensional defect
Geometrical defect
CRACK
DEFINITION:
TYPES OF CRACK
surface crack
internal / sub surface crack
linear crack
transverse crack
cold crack
hot crack
delayed crack
TYPES OF CRACKS
BASED ON LOCATION WITH REFERENCE TO
VARIOUS PARTS OF THE WELD AGAIN
CLASSIFIED AS
Root crack
Throat crack
Toe crack
Crater crack
Under bead crack
HAZ crack
Base metal crack
VARIOUS TYPE OF
CRACKS
CRACK
CRACK
1)
2)
3)
4)
5)
6)
7)
INCOMPLETE FUSION
DEFINITION:
Fusion
INCOMPLETE FUSION
INCOMPLETE FUSION
INCOMPLETE JOINT
PENETRATION
DEFINITION:
The penetration of molten metal does not extent entirely
through the joint thickness where complete penetration is
required by specification
PROPERTIES:
Associated with groove welding
Location is always adjacent to weld root
REASONS:
Improper joint preparation
excess root face
narrow root gap
Improper selection of electrode
Improper manipulation
Improper selection of weld parameter
INCOMPLETE JOINT
PENETRATON
INCOMPLETE JOINT
PENETRATION
INCLUSIONS
DEFINITION:
Metallic or non metallic particle entrapped inside
the weld metal
PROPERTIES:
Appearing in the weld metal and surface of weld
metal
It is associated incomplete fusion
TYPES :
1.
Slag inclusion
2.
Tungsten inclusion
3.
Scale inclusion
SLAG INCLUSION
TUNGSTEN INCLUSION
POROSITY
DEFINITION:
It is a cavity type discontinuity formed by gas
entrapment during solidification
PROPERTIES:
Least detrimental discontinuity in structural
welding, characterized by spherical shape
But detrimental in pressure vessels and pipe
welding
TYPES OF POROSITY
POROSITY
REASON:
presence of contaminations
POROSITY
PIPING POROSITY
WORM HOLES
DEFINITION :
Elongated porosity at surface
PROPERTIES:
It occurs in SAW process
REASONS:
Granular flux depth is very excessive
Entrapped gas not allowed to escape
WORM HOLE
( ELONGATED POROSITY)
UNDERCUT
DEFINITION:
Surface discontinuity , occurs as linear groove in
base metal, adjacent to the weld at toe or root
PROPERTIES:
Detrimental to the structure
Act as stress raisers
REASONS:
Travel speed too high
Improper manipulation
Excess welding current/ excess heat/ excess
melting of base metal
UNDERCUT
UNDERCUT
UNDERFILL
DEFINITION:
Groove like surface discontinuity
PROPERTIES:
Associated with groove welding
Occurs in face as well root of the weld
Reduces the cross section area of the weld
REASONS:
Travel speed too high in sealing pass
Excessive heating of root pass during the second
pass
UNDERFILL
UNDERFILL
OVERLAP
DEFINITION:
Protrusion of weld metal beyond the toe or root of the
weld
PROPERTIES:
It is detrimental, act as stress raisers
It occurs on the surface
It can hide some defects
It occurs in groove weld and fillet weld
REASONS:
Slow travel speed
Improper angle
Too fluidity of filler metal
OVERLAP
OVERLAP
CONVEXITY
DEFINITION:
WELD REINFORCEMENT
DEFINITION:
REASONS:
WELD REINFORCEMENT
MISALIGNMENT
LINEAR MISALIGNMENT
Misalignment between two welded pieces such
that while their surface planes are parallel, they
are not in the required same plane.
Causes
Inaccuracies in assembly procedures or distortion
from other welds
Excessive out of flatness in hot rolled plates or
sections
Prevention
Adequate checking of alignment prior to welding
coupled with the use of clamps and wedges
Check accuracy of rolled section prior to welding
MISALIGNMENT
MISALIGNMENT
ANGULAR MISALIGNMENT
Description
Misalignment between two welded
pieces such that their surface planes
are not parallel or at the intended
angle
Causes and prevention
Same as for linear misalignment
SPATTERS
DEFINITION: Metal particles stick to the base metal
adjacent to the weld metal
PROPERTIES:
SPATTERS
ARC STRIKES
DEFINITION:
ARC STRIKE
EN ISO 5817-2007
Quality level for imperfections
EN ISO 5817-2007
Quality level for imperfections
The quality level necessary in each case
should be defined by
1. the application standard
2. the responsible designer in conjunction
with the manufacturer,
3. user and/or other parties concerned.
EN ISO 5817-2007
Quality level for imperfections
The choice of quality level for any application
should take account of
design considerations,
EN ISO 5817-2007
Quality level for imperfections
Quality level
Description of the quality of a weld on the
basis of type, size and amount of
selected imperfections
Fitness-for-purpose
Ability of a product, process or service to
serve a defined purpose under specific
conditions
EN ISO 5817-2007
Quality level for imperfections
Short imperfections
In cases when the weld is 100 mm long or longer,
imperfections are considered to be shortimperfections if, in the 100 mm which contains the
greatest number of imperfections, their total length
is less than 25 mm in cases when the weld is less
than 100 mm long, imperfections are considered to
be short imperfections if their total length is less than
25 % of the length of the weld
Systematic imperfection
Imperfections that are repeatedly distributed in the
weld over the weld length to be examined, the size of
a single imperfection being within the specified limits
EN ISO 5817-2007
Quality level for imperfections
Assessment of imperfections
If, for the detection of imperfections, microexamination is used, only those imperfections shall
be considered which can be detected with a
maximum of tenfold magnification. Excluded from
this are micro lack of fusion.
EN ISO 5817-2007
Quality level for imperfections
Assessment of imperfections
EN ISO 5817-2007
Quality level for imperfections
a - nominal throat thickness of the fillet weld (see also
ISO 2553)
b -width of weld reinforcement
d -diameter of gas pore
h -height or width of imperfection
l -length of imperfection in longitudinal direction of
the weld
s -nominal butt weld thickness (see also ISO 2553)
t -wall or plate thickness (nominal size)
z -leg length of a fillet weld (see also ISO 2553)
angle of weld toe
angle of angular misalignment
ACCEPTANCE CRITERIA
Imperf
ection
design
ation
Remarks
Surfac
e pore
Maximum
dimension
of a single
pore for
butt
welds
fillet
welds
t
mm
0,5 to 3
0,5 to 3
>3
butt
welds
>3
d 0,3 Not
s
permitted
d 0,3
a
d 0,2 s,
d 0,3 but max. 2
s, but
mm
max. 3
mm
d 0,2 a,
Not
permitted
Not
permitted
Not
ACCEPTANCE CRITERIA
Imperf
ection
design
ation
Remarks
Incompl
ete root
penetra
tion
Only for
single side
butt welds
t
mm
0,5
Short
imperfect
ions:
Not
h 0,2 t, permitted
but max.
2 mm
Not permitted
ACCEPTANCE CRITERIA
Imperfecti
on
designatio
n
Continuous
undercut
Intermittent
undercut
Remark
s
t
mm
Smooth
0,5 to 3
transitio
n is
required.
This is
not
regarded
as a
>3
systemat
ic
imperfec
tion
Short
Short
imperfect imperfection
ions:
s:
Not permitted
h 0,2 t
h 0,1 t
h 0,2 t,
h 0,05 t,
but max. h 0,1 t,
but max. 0,5
1 mm
but max. 0,5 mm
mm
ACCEPTANCE CRITERIA
Imperfect Remarks
ion
designati
on
Excess
weld
metal
(butt weld)
Smooth
transition
is
required.
t
mm
0,5
h 1
mm +
0,25 b,
but max.
10 mm
0,5
Excessive
convexity
(fillet
weld)
h 1
mm +
0,25 b,
but max.
5 mm
h 1 mm + h 1 mm + 0,1
0,15 b,
b,
but max. 7
But max. 5 mm
mm
h 1 mm +
0,15 b,
h 1 mm + 0,1
but max. 4
b,
mm
but max. 3 mm
Not
ACCEPTANCE CRITERIA
Imperfect Remarks
ion
designati
on
Excessive
asymmetr
y of
fillet weld
(excessive
unequal
leg
Length)
t
mm
In cases
where an
0,5
asymmetr
ic fillet
weld has
not been
prescribed
h 2 mm h 2 mm + h 1,5 mm +
+ 0,2 a
0,15 a
0,15 a
ACCEPTANCE CRITERIA
Imperfect Remarks
ion
designati
on
t
mm
Insufficient Not
throat
applicable 0,5 to 3
thickness
to
processes
with proof
of
greater
depth of
penetratio
n
>3
Short
Short
imperfect imperfectio
ions:
ns
h 0,2
mm +
0,1 a
Not permitted
h0,2 mm
Not permitted
h 0,3
mm +
0,1 a,
h 0,3 mm
+ 0,1 a,
but max. 1
ACCEPTANCE CRITERIA
Imperfectio
n
designation
Remarks
Excessive
throat
thickness
The actual
throat
thickness
of the fillet
weld is
too large.
t
mm
Unlimited h 1 mm
0,5 .
+ 0,2 a,
but max. 4
mm
h 1 mm +
0,15 a,
but max. 3 mm
ACCEPTANCE CRITERIA
Imperfectio
n
designation
Stray arc
Remarks
t
mm
Permitted Not
0,5 , if the
permitted
propertie
s of the
parent
metal are
not
affected.
Not permitted
ACCEPTANCE CRITERIA
Imperfectio
n
designation
Remarks
t
mm
Spatter
0,5
Acceptance
depends on
application
Acceptance
depends on
application
e.g.
material,
e.g. material,
Corrosion
protection
Corrosion
protection
Acceptance depends
on application
e.g. material,
Corrosion protection
ACCEPTANCE CRITERIA
Imperf
ection
design
ation
Lack of
fusion
Micro
lack of
fusion
Remarks
-------
Only
detectable
by micro
examination
t
mm
0,5
Not
permitt
ed
0,5
Not
permitted
Not
permitted
permitted
permitt
ed
permitted
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