PRACTICAL VISUAL

INSPECTION OF WELDS
 Features to Consider
Butt welds - Size

Weld cap width

Excess weld
metal height

Root
penetration

Root bead width

 Features to Consider
Butt welds - Profile

x
x x
 Features to Consider
Butt welds - Toe Blend

x
x x
 Features to Consider
Butt welds - Weld Width
 Welding Defects
Incomplete root penetration

Causes
• Too small a root gap
• Arc too long
• Wrong polarity
• Electrode too large for joint
preparation
• Incorrect electrode angle
• Too fast a speed of travel for current
Welding Defects
a) Excessively thick root face

b) Too small a root gap

c) Misplaced welds

d) Power input too low

e) Arc (heat) input too low

Welding Defects

Too large diameter

electrode

Smaller (correct)
diameter electrode

Lack of sidewall
fusion due to arc
deflection
 Welding Defects
Incomplete root Fusion

Causes
• Too small a root gap
• Arc too long
• Wrong polarity
• Electrode too large for joint
preparation
• Incorrect electrode angle
• Too fast a speed of travel for
current
 Welding Defects
Root concavity

Causes
• Root gap too large
• Insufficient arc energy
• Excessive back purge TIG
 Welding Defects
Excess Root Penetration

Causes
• Excessive amperage during
welding of root
• Excessive root gap
• Poor fit up
• Excessive root grinding
• Improper welding
technique
 Welding Defects
Root undercut

Causes
• Root gap too large
• Excessive arc energy
• Small or no root face
 Welding Defects
Cap Undercut

Causes
• Excessive welding current
• Welding speed too high
• Incorrect electrode angle
• Excessive weave
• Electrode too large
 Welding Defects

Overlap

Excess weld
metal
 Welding Defects
Lack of fusion

Causes
• Contaminated weld preparation
• Amperage too low
• Amperage too high (welder increases speed of
travel)
 Welding Defects
Incompletely Filled Groove
& Lack of Side wall Fusion

• Causes
• Insufficient weld metal deposited
• Improper welding technique
 Welding Defects
Inter run Incompletely Filled Groove

Causes
• Insufficient weld metal deposited
• Improper welding technique
 Welding Defects
Gas pores / Porosity

Causes
• Excessive moisture in flux or preparation
• Contaminated preparation
• Low welding current
• Arc length too long
• Damaged electrode flux
• Removal of gas shield
 Welding Defects
Gas pores / Porosity
 Welding Defects
Inclusions - Slag

Causes
• Insufficient cleaning between passes
• Contaminated weld preparation
• Welding over irregular profile
• Incorrect welding speed
• Arc length too long
 Welding Defects
Inclusions - Slag

Causes
• Insufficient cleaning between passes
• Contaminated weld preparation
• Welding over irregular profile
• Incorrect welding speed
• Arc length too long
Welding Defects

Poor (convex) weld bead

profile resulted in pockets
of slag being trapped
between the weld runs

Smooth weld bead

profile allows the slag
to be readily removed
between runs
 Welding Defects
Inclusions - Tungsten

Causes
• Contamination of weld Caused by tungsten touching
weld metal or parent metal during welding using the
TIG welding process
 Welding Defects
Burn Through

Causes
• Excessive amperage during welding of root
• Excessive root grinding
• Improper welding technique
 Welding Defects
Spatter

Causes
• Excessive arc energy
• Excessive arc length
• Damp electrodes
• Arc blow
 Welding Defects
Arc Strikes

Causes

• Electrode straying onto

parent metal

• Electrode holder with

poor insulation

• Poor contact of earth

clamp
 Welding Defects
Mechanical Damage

Chisel
Chisel Marks
Marks Pitting Corrosion Grinding Marks
 Welding Defects
Non-alignment of two abutting edges

2mm

Also Known as: Hi Low. Mismatch. or Misalignment

 Welding Defects

50mm

3mm

Angular distortion.
Measure the distance to the edge of the plate (50mm).
Use a straight edge (rule) to find the amount of distortion then measure
the space (3mm).
This reported as Angular distortion 3mm in 50mm
 Welding Defects
Linear
Excess weld metal height
Lowest plate to highest point

3 mm
Excess penetration Lowest Linear misalignment
plate to highest point measured in mm

Angular

3mm
Angular misalignment measured in mm
 Page 1 of 3 EXAMPLE PLATE REPORT
Name: [Block capitals] Mr. I C Plenty Signature: I C Plenty Test piece ident: 001
Code/Specification used: TWI 09-09-03 Welding process: MMA/SMAW Joint type: Single V Butt

Welding position: Flat /PA Length & thickness of plate: 300mm x 10 mm Date 22/08/2003
MEASURE

WELD FACE

A B C
Lack of
sidewall fusion Gas pore Undercut smooth
1.5 Ø 1.5 max
FROM

87 236
22 230
30
THIS

51 8 153 40
Arc Strike
Slag
Centreline 241
inclusion
DATUM

crack
NOTES: Cap height : 4mm.
Weld width: 12-14mm
Toe blend: Poor
Misalignment: 2mm
EDGE

Angular Distortion 3mm in 50mm

Spatter along weld length or scale on the plate surface
Page 2 of 3
MEASURE EXAMPLE PLATE REPORT

WELD ROOT

A B C
Root concavity
2 deep LACK OF ROOT
FUSION
FROM

23 247
10 20
THIS

128 50

Incomplete root
penetration
DATUM

NOTES: Penetration height : 4mm.

Linear Misalignment: 2mm
Angular Distortion: 3mm in 50mm
Any scale on plate surface
EDGE
EXAMPLE WELD INSPECTION REPORT/SENTENCE SHEET

PRINT FULL NAME I C Plenty

SPECIMEN NUMBER 001
EXTERNAL DEFECTS Defects Noted Code or Specification Reference

Defect Type Pipe/Plate Accumulative Maximum Section/ Accept/Reject

Section Total Allowance Table No 5
1 2 3 4

Excess weld metal height

A-C 4mm 3mm 8 Reject
Excess weld metal appearance A-C Poor blend Smooth 8 Reject
Incomplete filling A-C 22mm None 5 Reject
Inadequate weld width (PIPE) A-C N/A ------------ ---------- Accept

Slag Inclusions A-C 70mm long 50mm 9 Reject

Undercut A-C 1.5mm depth 1mm 6 Reject

Surface Porosity A-C 1.5mm  1mm 2 Reject

Cracks/Crack-like defects A-C 40mm NONE 1 Reject*

Lack of fusion A-C 22mm NONE 3 Reject

Arc strikes A-C 30x25 ------------ 7 Seek advice***

Mechanical damage A-C NONE ------------ ----------- Accept
Laps/Laminations A-C NONE ------------ ----------- Accept

Misalignment (Linear) A-C 2mm 2mm 15 Accept

Longitudinal seams (PIPE) A-C N/A ------------ ---------- Accept

 Root Defects

Misalignment A-C 2mm 2mm 9 Accept

Excessive Root Penetration A-C 4mm 2mm 15 Reject

Incomplete Root Penetration A-C 50mm NONE 13 Reject

Lack of Root Fusion A-C 20mm NONE 11 Reject

Root Concavity A-C 2mm depth 1mm 10 Reject

Root Undercut A-C NONE ------------ 12 Accept

Cracks/Crack-like defects A-C NONE ------------ ---------- Accept

Slag inclusions A-C NONE ------------ 9 Accept

Porosity A-C NONE ------------ 2 Accept

Laps/Laminations A-C NONE ------------ ---------- Accept

This *pipe/plate has been examined to the requirements of code/specification TWI-N/WIS-PI

.........................................
and is accepted/rejected accordingly.

Comments:
* Request MPI testing to confirm crack and length.
** Large amount of spatter on weld face. Recommend this is removed and re inspected.
*** Recommend arc strikes are ground flush prior to MPI testing for cracks.

I C Plenty
Signature.........................................................
22nd August 2003
Date................................................. ....................................
*Delete which is not applicable. Use the other side for any comments.
 Inspection Practice Specification
Number TWI 09-09-03
All dimensions are given in mm
No Imperfection Comments Allowance
1 Cracks Confirm with penetrant testing Not permitted

2 Porosity Individual pore Ø Maximum 1mm

3 Solid Inclusions Non metallic. Individual size Maximum 1mm
4 Solid Inclusions Metallic. Individual size Not permitted
5 Lack of Fusion Side wall/Root/Inter-run Not permitted
6 Incomplete Root Penetration Not permitted
7 Overlap/Cold lap Weld face/Root Not permitted
8 Incompletely filled groove Not permitted
9 Linear Misalignment 0.2t Maximum 4mm
10 Angular Misalignment Maximum 10º
11 Undercut Smoothly blended 10%t Maximum d 1mm
12 Arc Strikes Area to be tested by MPI Seek advice
13 Laminations Not permitted
14 Mechanical Damage Not permitted
15 Cap Height Shall fall below plate surface 0 –3mm h Maximum
16 Penetration Bead 0 –2mm h Maximum
17 Toe Blend Smooth
18 Spatter Clean & Re-inspect Refer to manufacturer
19 Weld Appearance All runs shall blend smoothly Regular
20 Root concavity 10%t Maximum
 TWI CAMBRIDGE MULTI-
PURPOSE WELDING GAUGE:
Visual Inspection of Welds Using the
Cambridge
Multi-Purpose Welding Gauge:
 TWI CAMBRIDGE MULTI-
PURPOSE WELDING GAUGE:
Angle of preparation:

This scale reads from 00 to 600 in steps of 50.

The angle is read against the chamfered edge of
the plate or pipe.
TWI CAMBRIDGE MULTI-PURPOSE
WELDING GAUGE:
Linear Misalignment:
The gauge may be used to measure misalignment
of members by placing the edge of the gauge on
the lower member and rotating the segment until
the pointed finger contacts the higher member.
 TWI CAMBRIDGE MULTI-
PURPOSE WELDING GAUGE:
Excess Weld Metal/Root penetration:
The scale is used to measure excess weld metal or
root penetration, by placing the edge of the gauge
on the plate and rotating the segment until the
pointed finger contacts the excess weld metal or
root bead at its highest point.
 TWI CAMBRIDGE MULTI-
PURPOSE WELDING GAUGE:
Undercut / mechanical damage (grinding etc)
The gauge may be used to measure the depth of
undercut by placing the edge of the gauge on the
plate and rotating the segment until the pointed
finger contacts the lowest depth of the undercut.
The reading is taken on the scale to the left of
the zero mark in mm or inches.