Welding Inspector Duties

Introduction

The Welding Inspector should have knowledge on the

following subjects…

 Metallurgy
 Welding processes
 Welding qualifications
 Welding symbols
Introduction

The Welding Inspector should have knowledge on the

following subjects…

 Weld discontinuities
 Control of material
 Non destructive testing
 Destructive testing
Introduction

As a welding inspector, you are expected to perform all

of the inspections described in this module…
 Pre Weld Inspection

The final weld shall meet the following …

 Specification
 Procedure
 Code requirements
Pre Weld Inspection

 Obtain all relevant documentation…

 Relevant specifications
 Relevant procedures
 Copies of welders test certificates
 Copies of drawings
 Welding Procedure
The welding Inspector is responsible for verifying that
the welding procedure that is used has been
approved…
Material Conformance

The Welding Inspector verifies the following for material

conformance…

 Base Metals
 Welding filler metal
 Welding gases
Pre Weld Inspection

 Root face.
 Bevel angle.
 Root gap.
 Alignment
 Joint cleanliness.
 Ensure no undue stress is applied to the joint
Root Face

The Welding Inspector inspects the root face

preparation to verify it meets the requirements of the
welding procedure…

Root face
Bevel Angle

The Welding Inspector inspects the bevel angle

preparation to verify it meets the requirements of the
welding procedure…
Root Gap

The Welding Inspector inspects the root gap to verify it

meets the requirements of the welding procedure…

Electrode to be used
for the root
Pipe Alignment

The Welding Inspector inspects the pipe alignment to

verify it meets the requirements of the welding
procedure…
Joint cleanliness

The Welding Inspector inspects the cleanliness to

verify it meets the requirements of the welding
procedure…
Ensure no undue stress is applied to the joint

The Welding Inspector ensure that no undue stress is

applied to the joint
Pre Weld Inspection

 Ensure welder qualification.

 Correct material type condition etc.
 Correct equipment with certificates.
 Correct consumables type condition, size.
 Correct pre heat.
Welder Qualification

The Welding Inspector verifies that the welder is

qualified to make the specific weld…
Edge Preparation and Fit - up

The Welding Inspector inspects the weld end

preparation to verify it meets the requirements of the
welding procedure…

unacceptable bevel
preparation
High Low

The Welding Inspector inspects high low to verify it

meets the requirements of the welding procedure…
Weld Reinforcement

The Welding Inspector inspects weld reinforcement to

verify it meets the requirements of the welding
procedure…
Weld Equipment

The Welding Inspector should check to see that the

welding equipment is properly set up and is
acceptable working order…
Pre Heat

The Welding Inspector verifies that the required

minimum pre heat is obtained prior to welding…
In Process Weld Inspection

The same reasons for performing pre-weld inspections

also apply for performing in-process inspections…
Inspection During welding

 Check amperage, voltage, polarity.

 Ensure correct welding technique.
 Ensure correct welding direction.
 Check welding time.
 Ensure adequate cleaning between passes.
 Correct interpass temperature.
Amperage Voltage Polarity

The welding inspector verifies that the amperage,

voltage and polarity for the weld conforms to the
procedure and specification requirements…
Welding Technique

The welding inspector verifies that the welding

technique for the various passes conforms to the
procedure and specification requirements…
Ensure the correct welding direction

The welding inspector verifies that the welding is

carried in the right direction according to the WPS…
Ensure the time for welding passes

The welding inspector verifies that the welding is

carried out to correct time for each welding pass
according to the WPS…
Ensure adequate cleaning between welding
passes

The welding inspector verifies that the welding has

been cleaned adequately between each welding
pass..
In Process Welding Inspection

 Check root internally.

Root of the
weld
Inspection After welding

 Ensure welds are post cleaned.

 Visual inspection of welds for defects.
 Visually check for arc strikes.
 Check weld contour and weld width.
 Ensure joint is covered to retard cooling rate.
 Ensure monitor post weld heat treatment.
Inspection After welding

 Ensure welds are post cleaned.

Inspection After welding

 Visual inspection for weld defects

Inspection After welding

 Visual inspect for arc strikes

Inspection After welding

 Check the weld contour and weld width

Inspection After welding

 Ensure joints are covered to retard the cooling rate

Inspection After welding

 Ensure and monitor post weld heat treatment

Visual Inspection

The welding inspector inspects the welds for

conformance to weld size, length and location
specified in the drawing…
We use Non Destructive Testing (NDT) when we wish to
assess the integrity of a structure without destroying it
The 4 of the common types of NDT used when assessing
weldments are:
 Procedure
First the work must be cleaned thoroughly, then a
penetrant is applied for a specified time*
Once the contact time has elapsed, the penetrant is
removed and a developer is then applied*
Any penetrant that has been drawn into a crack by
capillary action will be drawn out into the developer*
Two types of penetrants are:
1) Colour contrast 2) Fluorescent Penetrant*
 Method

Apply Penetrant Clean then apply Developer Result*

 Advantages Disadvantages

1) Low operator skill level 1) Highly clean metal

2) All materials (Non Porous) 2) Surface flaws only

3) Low cost method 3) Extremely messy

4) Simple equipment 4) No permanent record*

 Procedure

First the work must be cleaned and a whitener applied for

contrast. A magnetic flux is then applied by permanent magnet,
electro magnet, or straight current*

A magnetic ink is applied which will concentrate in areas of

flux leakage, as those caused by flaws*

The weld length must be crossed at 90° by the magnetic field*

The types of magnetic media used are:

1) Wet ink 2) Dry powder 3) Fluorescent ink*
 Method

Contrast paint Magnet & Ink Result*

 Advantages Disadvantages

1) Low operator skill level 1) Fe Magnetic metal only

2) Sub surface flaws 2) De-magnetize after use

3) Relatively cheap 3) Can cause arc strikes #

4) Simple equipment 4) No permanent record*

# When using the straight current prod technique

 Procedure

First the work must be cleaned thoroughly, then a couplant is

applied to increase sound transmission*

A probe is then applied with the correct angle for the weld
preparation and sound waves are transmitted*

Any imperfections will rebound the sound waves causing a

signal to occur on the cathode ray tube*
 Method

Apply Couplant Sound wave Result*

CRT display

Signal rebounded
from Lack of fusion
 Advantages Disadvantages

1) Can find lack of fusion 1) High operator skill

2) Most materials 2) Difficult to interpret

3) No safety requirements 3) Requires calibration

4) Portable/instant results 4) No permanent record*

 Procedure

A film is placed inside a cassette between lead screens.

It is then placed to the rear of the object to be radiographed
A radiographic source, is exposed to the work and film for a
pre-calculated time*

Any imperfections in line with the beam of radiation will be

shown on the film after exposure and development*

The 2 types of radiation used in industrial radiography:

1) X rays (from Cathode Ray Tube)
2) Gamma rays (from a Radioactive Isotope)*
 Method

Load film Exposure to Radiation Interpret Graph

Radioactive source Developed

Graph
IQI

Film cassette Latent image on the film

 Advantages Disadvantages

1) A permanent record ? 1) High operator skill

2) Most materials 2) Difficult interpretation

3) Assess root pen’ in pipe 3) Lack of sidewall fusion

4) Gamma ray is portable 4) Safety requirements*

Why ?* To establish the level of mechanical properties*

Which properties ?*
1) Hardness*
2) Toughness*
3) Tensile strength*
4) Ductility*
Mechanical:* Describes the actions of “force & motion”

Properties:* Something that makes one material useful for a

job. These include the properties of:

Hardness:* The ability of a material to resist indentation

Toughness:* The ability of a material to absorb impact energy

Tensile strength:* The ability to resist the action of a pulling force

Ductility:* The ability to deform plastically under tension*

We test welds to establish minimum levels of mechanical
properties, and soundness of the welded joint*

We divide tests into Quantitative & Qualitative methods:*

1) Quantitative tests: (Have units)*

2) Qualitative tests: (Have no units)*

Types of tests include:

1) Quantitative tests:
Hardness tests
Toughness tests
Tensile strength tests*

2) Qualitative tests:
Macro tests
Bend tests
Fracture tests*
The test weld is usually cut into sections as follows:
The location of specimens will depend upon the standard

Charpy V test Bend test*

Tensile test Macro/Hardness test

Start/ Stop
 The specimen below has been polished and is
ready to be hardness tested

= Hardness Survey

Thickness

Base metal HAZ Fusion boundary Weld metal

Further hardness surveys may be taken as the thickness
of the specimen increases*
Generally we use a diamond or steel ball to form an indentation

We measure the width of the indentation to gauge the hardness*

1) Vickers Diamond Pyramid: Always uses a diamond*

2) Brinell hardness test: Always uses a steel ball*

3) Rockwell hardness test: Uses a ball, or diamond

depending on the scale*
Machined notch 10 x 10 mm

The specimen may be tested from different areas of the weld.*

Graduated scale Pendulum

of absorbed Hammer
energy in Joules*

Location of specimen
1) Charpy V test: 10 x 10 (Specimen horizontal) Joules*

2) Izod test: 10 x 10 (Specimen vertical) Ft.lbs*

3) CTOD test: Specimen used is actual design size.

Detailed fracture report. mm*
Mn < 1.6 % increases Joules absorbed
toughness in steels*

Transition Ductile Fracture

47 Joules
Zone
Three specimens are normally
tested at each temperature.
28 Joules

Transition Temperature Range

Brittle Fracture
-40 -30 -20 -10 0 +10 +20 +30 + 40
Testing temperature
A Section of weld is cut, or machined out across the test piece
and tested in tension to failure. The units are usually in N/mm²

Transverse reduced test piece*

 Radius
(For radius reduced test specimens only)

Weld
Test gripping area HAZ

Direction of test

Plate material
Reduced Section

Used to assess the tensile strength of the weld metal

 BS 709 / BS En 10002
All Weld Metal Tensile Testing

Direction of the test *

Tensile test piece cut

along weld specimen.
Firstly, before the tensile test 2 marks are made 50mm apart

50 mm

During the test, Yield point & Tensile strength are measured
The specimen is put together and the marks are re-measured

75 mm

A new measurement of 75mm will indicate Elongation E50 %*

1) Excess Weld Metal Height 8) Poor Toe Blend*
7) Laminations

6)Porosity

2) Lack of Sidewall Fusion

5) Root Penetration
3) Lack of Root Fusion

4) Slag inclusion & Lack of inter-run fusion

 Bend tests are used to establish fusion in the area under test
Guide A Guided root bend test*
Lack of root fusion shown here*

Former
Test Piece
Force

Further tests include face, side and longitudinal bend tests*

For material over 12 mm thickness, side bend test may be used*
Specimen prior to test* Specimen after test*
 Saw cut 1 2 3

Hammer blow
X Line of fusion
1 3

Fracture line

Full fracture
X
2 3

1 2
Y Any strait line indicates a
Inspect both surfaces
“Lack of root fusion”*
 Saw Cuts Hammer blow

A
Fracture line

B Inspect both surfaces

Lack of root penetration Inclusions on fracture line*

or fusion
 We test welds to establish minimum levels of mechanical
properties, and soundness of the welded joint

We divide tests into Qualitative & Quantitative methods:*

Quantitative: (Have units) Qualitative: (Have no units)

Hardness (VPN & BHN) Macro tests
Toughness (Joules & ft.lbs) Bend tests
Strength (N/mm2 & PSI) Fillet weld fracture tests
Ductility/Elongation (E%) Butt Nick break tests*
The main difference between Macro & Micro is that Micro is
the study of the micro-structure at much higher magnification
The limit of Macro inspection is magnification < X 10

The specimen is usually cut from a stop/start in the test piece

The cut specimen is polished to a fine finish (400 grit)

The specimen must be inspected, before etching*