Welding and inspection

Introduction
• Inspector’s background info …
• 25Years in Welding Inspection by Visual and
NDT.
• Heavy Equipment Fabrication Construction
equipments.
• In-Process Inspection of Pressure vessels.
• Quality Control Team Leader, Welding Quality,
NDT Ultrasonic testing and Quality concept.
 WELDING THEORY
• “… Welding is joining two pieces of
materials.
• Solid+solid Welding = Solid state bonding
• Liquid+Liquid welding=Fusion Welding
• Solid+Liquid Welding=Braze Welding
• Oxy-Aceteline=Gas Welding
• Thermit =
• Atomic hydrogen=
 A) ELECTRICAL ARC
WELDING
• FCAW -Flux cored Arc Welding
• CAW -Carbon arc Welding
• SMAW -Shielded metal arc Welding
• GMAW -Gas metal arc Welding
• GTAW -Gas Tungsten arc Welding
• SW -Stud Welding
• PAW -Plasma Arc Welding
 B) ELECTRICAL
RESISTANCE WELDING
• Spot Welding
• Seam Welding
• Projection welding
• Flash butt Welding
• Electro slag Welding
• Stud Welding
C) ELECTRICAL INDUCTION
WELDING
• Induction Pressure Welding
• Induction Brazing
 MECHANICAL ENERGY
• Friction Welding
• Ultrasonic Welding, High freq sound waves
• Explosive Welding
SPECIAL SOURCE WELDING
• Electron Beam Welding
• Laser Welding
 ELECTRODE DAMAGE &
INFLUANCE
• Absorption or loss Moisture
• Cracking & discaling covering
• Contamination
• Oxidation of the cored wire
• Formation of deposits on the surface
 Absorption or loss Moisture
& INFLUANCE
• Porosity in weld metal
• Excessive Projection
• Spattering arc instability
• Visual worsening of seam surface
• Scouring / Blistering in cellulose coating
• Difficulty in removing slag
• Cracking caused by hydrogen
 Formation of deposits on the
surface
• Absorption or loss Moisture
• Cracking & discaling covering
• Contamination
• Oxidation of the cored wire
Welding inspection

• Crack
• Bead shift
• Burn through
• Porosity
• Pin holes
• Waviness
• Under cut
• Weld appearance
Weldments - Symbols and Drawing Practices
 DWGA130 Overview (Cont.)
Primary Reference -
• ISO 2553:1992
Secondary References -
• AWS A2.4:1998
Welding Symbol, Weld Symbol

FIGURE 1: Elements of a Welding Symbol

 Elementary Weld Symbols

• Most common are fillet, square groove and

flare bevel weld joints
 Supplementary Weld Symbols

• Contour symbols not used much in the past

 Weld Symbol Orientation

• Reference lines and

weld symbol details
remain the same
regardless of which
end the arrow is on.
 Weld Both Sides
• Appropriate weld
symbols above and
below reference
lines.
• Dashed line not
required where the
weld joint is
exactly symmetric.
 Combined Weld Symbols
• More than
one weld
type.
• Size specified
individually
for each.
 Fillet Weld Size

• Required minimum
weld size dimension
(mm)
z = leg dimension
a = throat dimension
 Butt/Groove Weld Size
• Required minimum
throat dimension
(mm)
• No direct
measurement -
requires destructive
test and evaluation
 Intermittent Weld Dimensions
• ISO vs AWS (App 2)
• Size convention is the
same
• Number and length of
segments
• Spacing between
segments vs AWS ctr
to ctr method
 Symmetric Intermittent Weld
• Same weld symbol
and dimensions
both sides
• Dashed line not
required
• Anchor welds at
each end
 Staggered Intermittent Weld
• Usually specified to
avoid weld distortion
or interference
• Offset dimension
specified in detail vs
default
• Anchor welds - Z denotes staggered
standard shop practice intermittent weld
 Intermittent Weld on Circular Part

• If necessary, start location

must clearly be identified
• Weld size
• Number and length of
segments
• Spacing between segments
(chord dimension)
 Weld All Around
• Simplified details
• Exactly the same
joint conditions and
welds all the way
around
 Testing methods

Visual Destructive
Mechanical,
inspection Chemical,
Testing

Ultrasonic
Testing DP
Testing ,
MPT,ECT,
X-RAY
AET,LEAK,
NRT,
 Good welding Practice summary
Right Welding parameter
at any time

Setting
With
error
WELDING No
proof
interlock SOUNDNESS Adjustment
(Poka
yoke)
Monitoring
For right welding at first
Time and any time
Continuous Improvement Model
Welding parameter entry
Trend Chart

GOAL

TIME
Check

RESULT Set alingment

EVALUATION

REPAIR,
PARETO
ACTION PLAN IDENTIFY 100% ANALYSIS
Action Name Date
 PM Good Welding
CURRENT

Wire feed

VOLTAGE

WIRE
Alingment POSITION
Setting

Input DIFT
Quality,
Good
Fittment,
Job
TIME
position,
GOOD WELDING CONTRIBUTION

METHOD MACHIN
27% E
34%

OTHERS
9%
MATERI WELDER
AL 16%
14%
 Flux baking
•Check incoming component
FITUP GAP
•Clean and remove rust, oil
Spool
quality •Ensure proper welding.

Roll equality

CHECK RUST
POINTS Torch Key Decisions Made
setting • Ensure proper welding
parameter
• Set appropriate Time
Alignment
Input • Correct and monitor the
material process
Quality
Machine
trueness
 Requirement
Weld appearance
Weld width Weld cap angle
(Abt use angle) •Leading Consultants for 6
Uniform weld bead and Cycle time Reduction
Uniform reinforcement
•Clients:Citicorp, PwC, ICI,
3M, Telstra
TO ACHIVE
Meet spec Penetration

•Quantum Improvement
in terms of
•Quality
Side wall
fusion
•Cost
•Cycle time