Welding and inspection

• Presented to the
people in need
 Course on
WELDING AND INSPECTION

Presentation on
“Welding fundamentals,application , Symbol,inspection
An Overview”
by

V UMASHANKAR
Info.umashankar@gmail.com

Chennai
 Introduction
• Trainer’s background info …
• 15Years in Welding Inspection by Visual and
NDT
• Heavy Equipment Fabrication Construction
equipment
• Trainer in Manufacturing Quality, QMS,
• Six sigma Green Belt, TPM Facilitator, Quality
Circle 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=
ELECTRICAL ENERGY
WELDING
 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
SHIELDED METAL ARC WELD
SUBMERGED ARC WELDING
Metal inert gas welding,MIG
TUNGSTEN INERT GAS WELDING
BRAZE WELDING
 B) ELECTRICAL
RESISTANCE WELDING
• Spot Welding
• Seam Welding
• Projection welding
• Flash butt Welding
• Electro slag Welding
• Stud Welding
C) ELECTRICAL INDUCTION
WELDING
• Induction Presuure 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
• Absorbtion or loss Moisture
• Cracking & discaling covering
• Contamination
• Oxidation of the cored wire
• Formation of deposits on the surface
 Absorbtion or loss Moisture
& INFLUANCE
• Porosity in weld metal
• Excessive Projection
• Spattering arc instability
• Visual worsening of seam suface
• Scouring / Blistering in cellulose coating
• Difficulty in removing slag
• Cracking caused by hydrogen
 Formation of deposits on the
surface
• Absorbtion 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)
Monitering
For right welding at first
Time and any time
Continuous Improvement Model
Welding parameter entry
Trend Chart

GOAL

Check
TIME

RESULT Set alingment

 
EVALUATION

REPAIR,
ACTION PLAN IDENTIFY 100%
PARETO
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.

Rollequality

RUST
CHECK POINTS
Torch setting
Key Decisions Made
Ensure proper welding
parameter
Set appropriate Time
Alingnment
Correct and monitor the process
Input material
Quality
Machine
truness
 Requirement

Weld width
•Leading Consultants for 6σ
and Cycle time Reduction
•Clients:Citicorp, PwC, ICI,
3M, Telstra
Meet spec Penetration

Quantum Improvement in
terms of
Quality
Side wall
fusion Cost
Cycle time
Six Sigma’s definition of Defect
 ll welds shall be inspected. A weld
subject to inspection shall be
Circumferentia acceptable if inspection shows:
NDE l Butt Weld
Inspection a) No surface cracks

b) No Visible lack of fusion

between welds and base metal

c) No craters Repairable

d) Uniform Weld profiles

e) That frequency of visible

porosity in fillet welds does not
exceed one in each 100 mm of
length and the maximum diameter
does not exceed 2.4 mm That
groove welds have no visible
porosity.

g) Undercut is not more than 0.5

mm deep.