Welding Inspection Defects/Repairs Course Reference WIS 5
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1 Copy from Welding Inspection Defects/Repairs Course Reference WIS 5
2 Weld Defects Defects which may be detected by visual inspection can be grouped under five headings Cracks Surface irregularities Contour defects Root defects Miscellaneous
3 Weld Defects Other associated defects Cavities Solid inclusions Set up irregularities Parent material defects
4 Cracks The four essential crack mechanisms Hydrogen (HICC) Solidification (Hot tears) Reheat cracks Lamellar tearing
5 Cracks Longitudinal parent metal crack Transverse weld metal crack Longitudinal weld metal crack Lamellar tearing
6 Transverse crack Center line crack
7 Surface Irregularities
8 Undercut An irregular groove at the toe of a weld run in the parent metal Excessive amps/volts Excessive travel speed Incorrect electrode angle Excessive weaving Incorrect welding technique Electrode too large
9 Cap Undercut
10 Root undercut Cap undercut
11 Overlap An imperfection at the toe or root of a weld caused by metal flowing on to the surface of the parent metal without fusing to it Contamination Slow travel speed Incorrect welding technique Current too low
12 Overlap
13 Crater Pipe Crater pipe is a shrinkage defect and not a gas defect, it has the appearance of a gas pore in the weld crater Too fast a cooling rate Crater crack (Star crack) Deoxidization reactions and liquid to solid volume change Contamination
14 Crater Pipe Weld crater Crater pipe
15 Contour Defects
16 Contour Defects Incomplete filled groove Poor cap profile Incomplete filled groove + Lack of sidewall fusion Excessive cap height
17 Excess cap reinforcement Incomplete filled groove
18 Root Defects
19 Root Defects Low Amps/volts Large Root face Incomplete root fusion Small Root Gap Fast Travel Speed Incorrect Electrode Angle Incomplete root penetration Contamination
20 Root Defects Lack of root fusion Lack of root Penetration
21 Lack of root penetration Lack of root fusion
22 Root Defects A shallow groove, which may occur in the root of a butt weld Root faces too large Root gap too large Concave root Excessive back purge pressure during TIG welding Excessive root bead grinding before the application of the second pass
23 Concave Root
24 Root Defects Root penetration bead in excess in accordance with the relevant specification being used Root faces too small Root gap too large Excessive amps/volts Excessive root penetration Slow travel speed
25 Excessive Root Penetration
26 Concave root Excessive root penetration
27 Root Defects A shallow groove caused by contraction in the weld metal along each side of the penetration bead Insufficient weld metal deposited in the root pass Shrinkage groove Too fast a cooling rate during the application of the root bead pass Poor welding technique
28 Root Defects A localized collapse of the weld pool due to excessive penetration resulting in a hole in the root run High Amps/volts Small Root face Large Root Gap Burn through Slow Travel Speed
29 Burn Through Burn through
30 Root Coking/Oxidized Root Loss or insufficient back purging gas Most commonly occurs when welding stainless steels Purging gases include argon, helium and occasionally nitrogen
31 Miscellaneous Defects
32 Miscellaneous Defects Accidental striking of the arc onto the parent material Faulty electrode holder Poor cable insulation Arc strike Poor return lead clamping
33 Miscellaneous Defects Excessive current Damp electrodes Contamination Spatter Incorrect wire feed speed when welding with the MAG welding process
34 Inclusions
35 Gas Cavities Gas pore Cluster porosity Loss of gas shield Damp electrodes Contamination Blow hole Herringbone porosity Arc length too large Damaged electrode flux Moisture on parent material Root piping Welding current to low
36 Gas Cavities Porosity Root piping
37 Cluster porosity Single gas pore
38 Solid Inclusions Slag inclusions are defined as a non-metallic inclusion caused by some welding process Slag originates from welding flux Slag inclusions Lack of sidewall fusion with associated slag MAG and TIG welding process produce silica inclusions Slag is caused by inadequate cleaning Parallel slag lines Other inclusions include tungsten and copper inclusions from the TIG and MAG welding process
39 Interpass slag inclusions Elongated slag lines
40 Set-up Irregularities Plate/pipe Linear Misalignment (Hi-Lo) Poor fit-up Angular Misalignment
41 Linear Misalignment
42 Parent Material Defects A welding inspector should also inspect the parent material for any visible defects Mechanical damage Lap Lamination Segregation line
43 Plate Lamination
44 Weld Repairs
45 Weld Repairs A weld repair may be used to improve weld profiles or extensive metal removal Repairs to fabrication defects are generally easier than repairs to service failures because the repair procedure may be followed The main problem with repairing a weld is the maintenance of mechanical properties During the inspection of the removed area prior to welding the inspector must ensure that the defects have been totally removed and the original joint profile has been maintained as close as possible
46 The specification or procedure will govern how the defective areas are to be removed. The method of removal may be Grinding Chipping Machining Filling Arc air gouging Oxy-gas gouging Weld Repairs
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