WI 3.

Welding Inspection

Practical Plate Exercise

Copyright © 2004 TWI Ltd M.S.Rogers
WI 3.1 Plate Sample 6A Cap
Welding Process MMA (SMAW)

?
Incomplete Filled Groove
?
Porosity Lack of
?
fusion
Slag Cap Undercut Cap Undercut
?
Inclusion ?
Intermittent ?
Intermittent

Cap Undercut
Intermittent ? ?
Arc Strike
?
Arc Strike

Note: spatter and surface slag requires removal, arc strikes

require blending and crack detection
Copyright © 2004 TWI Ltd M.S.Rogers
WI 3.1 Plate Sample 6A Root
Welding Process MMA (SMAW)

Excess
?
Penetration
Excess
?
Penetration
?
Root porosity

Root Undercut
?
Linear Misalignment

?
Surface Slag Lack of Root
? ?
Fusion

Note: Spatter and surface slag require removal

Copyright © 2004 TWI Ltd M.S.Rogers

WI 3.1 Plate Sample 6B Cap
Welding Process MMA (SMAW)

?
Incomplete Filled Groove
?Porosity Lack of Sidewall
?
Lack of Sidewall Fusion Fusion?

?
Surface Slag

Overlap and Excess Cap Height Full Weld Length ?

Note: Surface slag requires removal and poor toe blending full
weld length
Copyright © 2004 TWI Ltd M.S.Rogers
WI 3.1 Plate Sample 6B Root
Welding Process MMA (SMAW)

? ?
Slag Inclusion
Crater Pipe

?
Lack of Root Fusion
?
Lack of Root ?
Lack of Root Fusion
Penetration

Copyright © 2004 TWI Ltd M.S.Rogers

WI 3.1 Plate Sample 6C Cap
Welding Process FCAW

Incomplete
?
Cap Undercut
Filled Groove +
Lack of
Sidewall
?
Surface slag & Spatter ?
Fusion Longitudinal
?
Crack

?
Slag Inclusion
?
Incomplete Filled
Groove + Lack of
Sidewall Fusion + Cap
Undercut Intermittent

Note: Spatter and surface slag requires removal

Copyright © 2004 TWI Ltd M.S.Rogers

WI 3.1 Plate Sample 6C Root
Welding Process FCAW

Mechanical Damage
?
Burn Through
? Poor Stop/Start + Lack of
?
Root Penetration
?Excess Penetration

?
Lack of Root Fusion

Lack of Root Fusion

?

Copyright © 2004 TWI Ltd M.S.Rogers

WI 3.1 Plate Sample 6D Cap
Welding Process MMA (SMAW)

?
Porosity
Incomplete
?
Filled Groove
Excess Cap Cap Lack of Sidewall Cap
Height ? ?
Undercut ?
Fusion ?
Undercut

?
Overlap between Capping Passes

Note: Excess cap height and poor cap profile throughout.

Copyright © 2004 TWI Ltd M.S.Rogers

WI 3.1 Plate Sample 6D Root
Welding Process MMA (SMAW)

?
Mechanical Damage

?
Lack of Root Fusion

Lack of Root Fusion

?

Copyright © 2004 TWI Ltd M.S.Rogers

WI 3.1 Plate Sample 6E Cap
Welding Process MMA (SMAW)

Lack of
?
Sidewall
Fusion
?
Cap Undercut Intermittent ?
Cap Undercut Intermittent

?
Incomplete Filled Groove
Excess Cap Height
?
Incomplete Filled Groove
?

Copyright © 2004 TWI Ltd M.S.Rogers

WI 3.1 Plate Sample 6E Root
Welding Process MMA (SMAW)

?
Poor Stop/Start + Crater Pipe ?
Lack of Root Fusion
?
Lack of Root Fusion
?
Root Undercut

?
Excess Root Penetration
?
Excess Root
Penetration

?
Crater Pipe
?Lack of Root
fusion

Copyright © 2004 TWI Ltd M.S.Rogers

WI 3.1 Plate Sample 6F Cap
Welding Process MMA (SMAW)

Mechanical
Damage
?

?
Lack of Sidewall fusion
Crater pipe?

Poor Toe Blend

? ?
Lack of Sidewall Fusion + Incomplete Filled Groove

Arc
?
Tack Weld ?
Strikes

Note: Arc strikes require blending and crack detection

Copyright © 2004 TWI Ltd M.S.Rogers

WI 3.1 Plate Sample 6F Root
Welding Process MMA (SMAW)

Poor Stop/Start + Lack of Root

?
Penetration + Crater Pipe ?
Blow Hole
?
Arc Strikes Lack of Lack of
Mechanical Damage +
?
Lack of Root Fusion
Root
?
Fusion ?
Root
Fusion

?
Lack of Root Fusion
?
Arc Strikes

Arc Strikes
?

Note: Arc strikes require blending and crack detection

Copyright © 2004 TWI Ltd M.S.Rogers

WI 3.1 Plate Sample 6G Cap
Welding Process MMA (SMAW)

?
Parent Material Damage
?
Arc Strikes
?
Arc Strikes
Lack of Sidewall Fusion +
?
Incomplete Filled Groove

?
Poor Toe Blend + Excess Cap Height

Porosity
?

Note: Arc strikes require blending and crack detection, Seek advise
on parent material damage
Copyright © 2004 TWI Ltd M.S.Rogers
WI 3.1 Plate Sample 6G Root
Welding Process MMA (SMAW)

Parent material
?
gas cavities

?
Plate corrosion
?
Poor Stop/Start

?
Lack of Root Fusion

?
Crater pipe ? slag
Surface
?
Surface Slag

Linear Misalignment
?

Note: Surface slag requires removal, plate corrosion requires

wire brushing
Copyright © 2004 TWI Ltd M.S.Rogers
WI 3.1 Plate Sample 6H Cap
Welding Process MMA (SMAW)

Incomplete Filled Groove ? ?

Arc Strikes ? ?
?
Arc Strikes
Slag Inclusion Arc Strikes

Arc Strikes
?
Cap Undercut Intermittent ?
Cap Undercut
?
Arc Strikes
?

Note: Parent plate damage throughout, seek advice. Arc strikes

require blending and crack detection.
Copyright © 2004 TWI Ltd M.S.Rogers
WI 3.1 Plate Sample 6H Root
Welding Process MMA (SMAW)

?
Crater pipe
?
Excessive root penetration
Linear misalignment +
?
lack of root fusion

Lack of root fusion

?
? Poor stop/start
?
Lack of root fusion ?
Arc strikes

Arc strikes

Note: Arc strikes require blending and crack detection, Seek advise
on parent material damage
Copyright © 2004 TWI Ltd M.S.Rogers
WI 3.1 Plate Sample 6I Cap
Welding Process MMA (SMAW)

? ?
Spatter
Cap undercut
?
Arc strikes

?
Poor toe blend full weld length

Note: Arc strikes require blending and crack detection. Spatter

requires removal.
Copyright © 2004 TWI Ltd M.S.Rogers
WI 3.1 Plate Sample 6I Root
Welding Process MMA (SMAW)

Arc strike

?
Lack of root penetration ?
Burn through
?
Poor stop/start ?

?
Linear misalignment

?
Lack of root penetration ?
Lack of root fusion

?
Mechanical damage ?
Lack of root fusion
+ poor stop/start

Note: Arc strikes require blending and crack detection, Seek advise
on parent material damage
Copyright © 2004 TWI Ltd M.S.Rogers
WI 3.1 Plate Sample 6J Cap
Welding Process MMA (SMAW)

Suspect crater cracking

?
Cap undercut ?
Arc strikes
?
Cap undercut
?
Porosity

Cap undercut intermittent

?
Cap undercut
?

Note: Material damage throughout, seek advice. Arc strikes require

blending and crack detection.
Copyright © 2004 TWI Ltd M.S.Rogers
WI 3.1 Plate Sample 6J Root
Welding Process MMA (SMAW)

?
Mechanical damage
? fusion
Lack of root
Linear misalignment +
?
lack of root fusion

Lack of root penetration

?
Linear misalignment +
lack of root fusion
?

Note: Material damage seek advice on course of action.

Copyright © 2004 TWI Ltd M.S.Rogers

WI 3.1 Plate Sample T4 Cap
Welding Process MMA (SMAW)

Mechanical damage
?
?
Cap undercut ?
Cap undercut

Spatter/irregular cap profile

?

Note: Grinding marks throughout seek advice on course of action.

Excess cap height and poor cap profile throughout.
Copyright © 2004 TWI Ltd M.S.Rogers
WI 3.1 Plate Sample T4 Root
Welding Process MMA (SMAW)

Root undercut
?
Arc strike
?
intermittent

?
Lack of penetration intermittent

?
Ground flush root

Copyright © 2004 TWI Ltd M.S.Rogers

WI 3.1 Plate Sample H8 Cap
Welding Process MMA (SMAW)

?
Surface slag
?
Arc strikes
Mechanical
damage
? ?
Cap undercut intermittent

?
Cap undercut intermittent

Mechanical
?
damage

Note: Mechanical damage seek advice on course of action.

Excess cap height and poor cap profile throughout. Arc
strikes require blending and crack detection.
Copyright © 2004 TWI Ltd M.S.Rogers
WI 3.1 Plate Sample H8 Root
Welding Process MMA (SMAW)

?
Arc strike ?
Lack of root
fusion

?
Lack of root ?
Spatter
?
Lack of root
fusion
?
Lack of root
fusion
fusion

Spatter ?
Root undercut intermittent
?

Note: Arc strikes require blending and crack detection. Spatter

requires removal
Copyright © 2004 TWI Ltd M.S.Rogers
WI 3.1

Any Questions

Copyright © 2004 TWI Ltd M.S.Rogers