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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