Kerclse londiay condition PIP Saeed xpi lead > cTPR esa Duties of Welding Inspector wt Résponsiblites 2 exceuive interpars temp é ~ Code.complince tough ness on BPR “EET * ~ Workmanship consol ~ Rocumentaton contol attributes = Honesty), ntegriy(Al4),KnowedgetXI4, Communication Physica Visual Inspection (85 EN 1SO 17637) = 350-500 ur 600m / 20-30" = “Magnification x2 ~ 95, + Stage: defor, Duin. After meeing Terminology and Definitions ‘Autogenous weld : fusion weld made without filer meta(TIG Plasma, Electron Beam, Laser, Ony-fuel gas welding) Full Penetration weld: 4 88 84! Partial penetration weld : #8 82 84 “Types of Joint(Bs EN ISO 15607) = Homogeneous: SH FHS] BAN ADO Setsweo| wise Be = Heterogeneous: SH BH] BAY AWOL} sheeswo| ay Apolis we Dissimilar/Transition : BYUSUN F LMS] Fels AVOMt Set Sz} Ao] Ue BH. Weld Zone : contain Root rectus / Land > ni Jony prgpanaie. Filet weld Type Z = Leglegth Compound weld Tort O14 2 = 80 Vase State ae a [sa [Fn Dai Ree 2 — [oes Po [ar [rer et sep] [ote | pe 5756 [wo PG | eo es Ppt -A aton Fb 6 [roe Peston ‘Welding Process Number (BS EN ISO 15614-1 / EN 288-3) Ee Sas ae Wielding Procedures (ENSO.15614 /EN285) Welder Approval (5 EN 287) Quality Assurance Manual : Essentially what the QA manual sets out to achieved is the how the company is organized, to lay down the responsibilities and authority of the various departments, how these departments intertink ‘Quality Control Manual : Deparments and operations are organized nad controlled. [Normative Document (BM) : Document that provides rules, guidelines or characteristics for activities or their resis. (Standard, Technical specifications, codes of practice , regulations)‘Strandord(?1871@) : Document established by consensus and approved by a recognized body Code of practice( 4! $83.) : Document that recommends practices or procedures fo the design, manufacture, instalation, maintenance and utitzation of equipment, structure or products = Regulation(#8) : Document providing binding lejsative rules adopted by an authority Specfcation71A2) : Document stating requirements, meaningful data and its supporting medium stating needs or expectations Imperfection or crack 1. Sofdicaon cas: Weld metal OM WEEE. Centreine) ~ Weld metal has py GbE cote, ‘Weld preparation & Highiswessi/restrain) Disruption 2 ‘ heat flow condition (Stop Start Condition) high dluson ate proces SAW/BIMIG)MAG 535 fase) - ee 3% ighmanmanese & Law carbon contents feta tS . Minimise tes /.cestraint.& int Design Depth to With Ratios (W/D.2.2) High Quality parent materalsfow levels of impurities. Sulphur & phosphor 4. Clean joint prep contaminants 2. Uiquation Crack: Occur in coarse graln(CH Mt) HAZ 252} #28 Groin boundaries RIA}OIM low meting point consttventSl Hquationdl BREE OWE Yue oh we ouD crack 1. Hydrogen induced cracks: Occurs in HAZ(grain coarsened region) 4717 BE a4 ( H7ITIES Uo} UI BOM crake WASIA Bech b a - one Preheat: COOINgHateieduce| (susceptible microstructure®| WHS Ue + 2B) aa} 2 1g > Snleoones Teme. 44 « Reduce residal stress, Eliminate susceptible microstructures. 4 Ceeenmeyosonme (mci ren 20 9. h. i Multirun 3 22 ol, ‘Austenitic ocnckelfiler AH : avoid susceptible microstructure / allow hydrogen to diffuse Dey shielding gases: reduce hydrogen content. (Gleanyfust : aod hydrogen contamination from moisture Reduce residual stress k Ble i LAMELLAR TEARING 1. Occur cause caves 1. Gasportilted / Unto Ciste ner porsty elongated cnt / sre pow) © Cae 2 (RRR coro elcvade MA / SAW ©. REE Hyrocaoon / ater contain mm,Incorect shielding gas (MAG)Copper inclusion + Hot cred sl ME EXCESS WELD METAL ~ cess are energyMAG SAW), Shallow edge pep, Fulty electrode manipulation or build-up sequence, Incotet electrode size, Travel speed too slow, Incorrect electrode angel, Wrong polarty use DC-ve (MMASAN) EXCESS PENETRATION Heat input too high, Incorrect weld preplarge root gap thin edge, lack of backing, Use of electrode unsuited to welding postion, Lack of welders overrar Poor electrode manipulation cessive weaving) High heat inpu/Low travel speed, Incoet Poston, Too high @ uty electrode coating type IRREGULAR WIDTH : Excessive variation in width of weld Severe arc blow, regular weld bead surface oor CONCAVITY ~ Incorrect prep/fi-upoct gop too lage, nsufcient arc ener, Excessive back purge TIG Lack of welder sil Slag flooding in backing bar groove BURN-THROUGH :A collapse of the weld pool resulting in a hole inthe weld ~ _Insufcient travel speed, Excessive welding cuent, Lack of welder sil Excessive grinding of root face Excessive root gop STRAY ARC (ARC STRIKE) = Poor acess to the work, Missing insulation on electrode holder or torch Faure to insulated electrode holder or torch Loose curent return damp, Adjusting wire feed(MAG) without Kolation welding cuent SPATTER, = High arc curent Long a: Length, Magnetic ar blow, ncoretseting(GMAW), Damp electrodes, Wrong sheng gas(100% CO2) ‘TORN SURFACE : Surface damage due to removal by facture of temporary Weld Decay 1. Occurs: HAZ has been sensitized by the 2. Chromium carbides: 690~850°C 1 Grain Boundares 1 Chromium O| Carbon ® BePshWM zc 3 ont | IES. b Ts sunun /deelum (TO) ‘b. PWHT(I100°C O14) Quenching BCH. Et High Distortion 0] ‘28 2tCt. fe ce Ae Destructive Testing SEENED boo wate Oak ig Tre 1 UME: 87H68 28 FALE AL ELMechanical propery) Tense Tes Hrdness Tet, Charpy V-notch ters, CTOD 2 Qualitative: Jit BUR B7101 18 LA (Good fusion & Fe rom defects) Bend Test Macro, fctr nic venk Mechanical properties 1. Matesiliy@l3-112 2) —witand deformation under stati compresve loading without pure 2. Ductilty( 28) ~ undergo plastic deformation under static tensile loading without ruptuc 3. Toughness( 214) - withstand bending or the application of shear stresses by impact loading without rupt 4. Hardness(@) ~ surface resistance to indentation from another material by static load 5. Tensile Strength(2!) ~ Measurement of the maximum force required to fracture a materials bar of unit cross-sectional area in tension, HARDNESS TEST (Measurement of resistance of a material against penetration an indenter under @ constant load) 3A: Asesing restance toners TR se re SY - ase 88 a. Brinell unit BHN-W {Steel BalKADpi) b. Vickers: unit HV / Diamondt36) Rockwell unit : Re / Stee! Ball. 6P) (120 IMPACT TEST (Charpy V-Notch impact Test) = $44 : assessing resistance toward brite fracture / toughness = Specimen Dimensions according ASTM €236 Brite: F 1. ite 100% Duct ure Ductile / Brite Transition Curve ant Puctile (Brittle transition potat 215 TENSE TEST 1. _TWansvers Tense : Measuring the overl strength ofthe weld ont ~ QUES rs = "Steet x CSA 25mm x Ym load = 220 KN = 220000N / (5x12) = 7333 Nm) : Rit wat tneh-osaane x 199 ox «Original 50 / crease 64 (65 VSO * 100 Elongation % ‘onion 100 (ex: Original 50 / tr 64: (65-S0YS0 * 100 = 28) obi, Ollset prot Frensth 2. Al Weld Metal Tensile Tet(@S 705 / BS EN 10002) + 8889) 7 Wee Bee / Bee 7 Ae Bel Eo SAWN EL USB a eo MACRO / MICRO Examination male 1. MACRO face heavy etched to show all weld uns & ll HAZ /IDY free from defects 2 MIO: wd oon 8 en hy et ANI scene ts a BEND TEST (Soundhess ofthe weld zane / assesment of weld zone ductility) 1. Type of bend test for welefS EN 910) = 121 O18: Root / Face bend, 12¢ O14 : Side bend 2. Diameter of former: SHO 4 x thik Former AB FRACTURE TEST: Filet O14 Root¥2l WEG 271 seb mal AVG, NICK-BREAK TEST: SU¥S UG 8U¥9 Aue Non-Destructive Testing Penetrant Testing(PT) 1. 2B Simple to se /Inexpensie / Quick Rut / Can be any Non porous material / Portable / Low Si 2 S18 Only Suace breaking defect ite ination of ep contaminate Suace repation ti! / Post desning requies/ Potential aTSOUsce /Terpeatre dependant 3, MTS al BB Easy interpret rest / No power lw sil all material 44 MIQh-ULa. 8: Good surface ned slowly / cheicals(heatisatey) Magnetic Parc testing) 1. 28 Simple ose / Inexpensive Rap est ite sriace prep reuited / Posse to inspect though thin coating 2. SB Sufce or sight sub-surface detcton / RRRRSREGLONY/ WOIMBRBIGATEAIED / Oy sRGBRTGE SEC / Daecton is epred te drecons 3. PTSP lid BH: PTACH MECH / GAtACl Wt / Near-surface WH BU / PTACH RABY|AEH 7 CHBOLS SICH. 4. PTD} Uz EE :Ony Ferromagnetic material / USO] HR / need to de-magnetseDH8 A4¢O18)ULTRASONIC TESTING(UT) 1 BO: MERA / BO BOIS BAH / PISCE / AAI Yol Fa He / O18 2. GE :High sil / Good surface / BI BH7 BHA BCH Couplante| LA / SPAM 71RLO| Cb / ARO] Basic ‘nly Ferrite Material 3. RISE UID GW : Planar defectOl Ct / Thick THKOL BCH / HAM Wat / HA ointOlE 7s / NEL AHS / 01801 & Cf) AMEN RICE YO ASEH / AaIOe we 4 RTgt ulm Gal : SFA 71H RVC. / thin jlnt 1000 Amp > Flat 4 drooping 01 Fat SSC BHO] WBC (SLA Arc Length TERSI7I018) ot 542 SMeaMUstSRE 22 OB ZUSHE 715) Ate Length = Are Vinge oem ts TT RRCENeray CUI nr, (ex 240, $=300 mm / min : (24x240) / (300/60) = 1152 J/mm = 1.152 ki/mm) ‘Are Energy x thermal eee: SAW: 1.0, 716 / Plasma :0.6, L012]: 0.8) Heat Input Mechanical Properties tonghnegs, & Strength Hardness: ak a + W/L ‘Hs WY: Se electrode @ rsebee Ls Mo oMse Generator: Produces welding current Defects: Siag inclusions Are strikes, porosity undercut, Incomplete root fusion / penetration, Hydrogen crack, Shape prof age of commer ‘pesos gh Weer oh ee tae toon cont! ating ba) Stott poems est the ton MAG SAN FOO Sine eaipmert 2 High level of fumes / 12 cold eracking ‘Thin slag layer with nace weld profi 4 igh yegen coer) High cok wreny aiphecae igh Spaner {ow Oepston ras ‘et sutton ste Net ute ovr tek BH «= 2._Rutle: general purpose 2, GommainNR slag -> ar stabizerboth OCBAQ) walang postion Easy to arc strike, ess spatter, Excellent for positional weing eee ‘ verti a _GonibelargLOWerthaicontentibutbakING ¢ 4. ..( 0° elulesié > PF Caente'> c oa EAD Rutile + alt port Tren Power » PA PR orb)12971 se gh ie open ate 25-Dom09) iad gee ans = at oes ee 3. (Basie slow hydrogen) : eee 3 = en ie — meee eae oes el es = eee = oe = Wl Met Renny Coe area(s ee | yon coer ‘ebdoe*C* Rate“ A> ale Newry Cased A BO TIG |e Cw = = aca TIP angle a = = Penetration Increase Bead width IncreaseCTungsten Inclusions) Electrode extension Unstable arc Overheating(Tungsten inclusions) Arc iittion method: Ut ar / HF stort Conair 1. Fusible Inserts : Root (Back bead2| B40 S288 Ech 2_ Shielding gases ee er rere oo one matents tune eeraige man | eames eee eee ‘ool acaey ‘oh enon pt eee ese aera uae ay Won coe» —_——— * Slope-up / Slope-Out flow rate SB 7A ICem man a er cent aes 1 st rt NEW TPO Defects: Tungsten inclsion(ow skillwrong vertex angle), Surface porosity, Crater pipes(slope out tech), Root concavity, ack of penetrator/fusion, Cvidation(Poar back purging) ae ie dhe (aaa) ne errr ae ~ High yBeepipenetrainy xcessive-> Digging Arc, UC, Burn through, Solficaton Crack = Low: Wider Bead, ‘xcessive->Incomplete Fusion/Penetration, unstable Are) Voltage = High : Wider Bead, Flux consumption, Reduce porosity, Help bridging root gap ‘Excessive -> "Hat-shaped” Bead:> Crack, UC, Difficult remove slag Low : titer ar, resists arc blow, ‘xcessive->High narrow bead, Difcuit slag removal ‘Travel speed High : Decrease Heat Input [Excessive -> UC, Are blow, Porosity = Excessive Low :"Hatshaped” Bead -> Crack, ough bead, slag inclusion ‘Travel angle effect Earth Postion i a v s So Seb = 2 Ayer a toma hoe ph ener cae ome ea Ai ose pay peasConsumable Copper Coating Wire : Good electric contact, smooth feed, protection against corrosion FLUK: shield molten weld pool from atmosphere, lean weld pool, Chemical composition, Prevent rapid escape of heat, Influence bead shape, ‘void porosity. SE 5 7 tower ty tages Backeren| porary 2 tow mente dotnet so : tow ery Cont reapn coda tse Neyo tl ete Soa wad pote sn = i Tepe Re Fra) tage Te Gen at an car Dut ey spd ae i no ion ty a og ret ona wee we va Coot cunt omspey ay sage rng No yon _| tay ata oad jg een eter eu eu ft eno rye et nt, oy wie OTS 5 3 a WISKS #6 A 2 Tete nope ‘Wet a tnoat pope Me US tl rt peta te ve tie din rena Conposten fw ectde Impact et ene MIG/MAG Wire feed speedi= Bum-off te 8B45)9} BUCH Wire Burn-off ratet= Current} IUHSZ Bech Inductance 1_Dip wansfer mode only Enathive current high spect Va ie igh sputter ss Cdr > Ue wie gp ote > Mee Prtraton Comex weld, Mae Spt ay Wal pol ett Mere hl wold pool > Rt, ost od profle in mere ~__Thin materials All positional welding, CO2 -> low residual stress & distortion ow Egy ondtons slow a poten weg {ae of son Ping nthe tn on sg wee, Tend tghesutechoanee BO BS Globular Transfer (Between Dip & Spray) 41. Limited commercial, Only CO2 shielding gas, Hence severe spatter (Large drops), High Heat input -> High residual stress & distortion 1. Thick materials, Only at High Heat Input -> Good fusian, High Residual stress & Distortion, High weld deposition rate, mall droplets,‘Welding current q = Taonane voltage: Taine pean own wt MGMIGE 1 WH TE) aes > Pay ptr UC ‘Travel speed pas] aneraee travel ‘Speed Tie pein od WOR OE Electrode extension Tarenne etctension, Shielding Gas 7A Neer ll AC ‘Acie gases ut (One Caron De) Ms common he gs gen ‘gen wh ast face ga regu fr a se» sabe we, Good let ‘gon + Halu > Hote a> There toe we ghee cndtiy| tpl ace ges 10% Co? > Cals be Ate He Con, = ites 7 Higher Dest no Low thermal ond has high nergy con, God wen th foes. Low ein poet Tone owt deny tn igh ml osu. nto a ey Pb pt gh natn utel_crets_peesafio's igh ting “arten Dee (€02 inp, Deep Pereaton Sry Taner! B17, oo Weg, sew; Hgh ter Consumable 71h # Shielding TYPE: -> Ar, He, Ar+He /°R > ArsH2 /7 > Ar CO2 oF O2 /C =>. COR, CO2+O2Weldability of Steel Stel Alloying Elements Mo long erent Seg slaven wih uae on TAZ ee rr rent ugh & thy HEH for arden we ee Creep etree & non etanGnai amp, Ries i ‘Usd mans sel Hh ian t carosen fe ck ese ogi aah Aer arersbiy, ss seep roe Benes, gh parti rede 8 ep a Materials raion cre ste Sera ow tp psn Westiering eso BER Cou tt sore) MERC sores) Catton Stee Low strength and moderate toughness Carbon-Manganese Stee Carbon stels with improved toughness due to addons of Manganese Low Alloy Stel: Grain refining elementiAl Nb, V) @ SEK7%OI8) A7HHO| svength a toughness S LE Ale) Stee. SLA) 1. Elevated Temp Service 2SHRCEISSINE) /SRCEREESEMGI?> improved strength at high temp & good creep resistance 2 Low Temp Service :SI59/ISBNE-> good toughness at low temp High Alloy Steel : 7%01 2% S7+8tO} Material©| 82@ UHE steel, 1. (GBTAITETGE - TeRECEEBRENG Wide Range(Low temp & High temp) Moderate corrosion resistance, Non-Magnetic Low thermal ‘conductivity, High coefficient of expansion(More distortion) , pre @ post Het ggg. 2. Feriticeoortenstc Grade: (3G 1SIECRRRERK, Magretsed Not low temp 3. Duplex Grades : 22RSCEREISRNI / 2SRKCrSNE) Magnetised, Corrosion resistance, Not very low temp. Good very High temp CCEV (Carbon Equivalent Formula) : Higher briteness, Lower weldabiity, CEV = 96¢-+ 52 4 Sous Statt 1. Mid Steel (CE less stress © Bulld-Up sequence 4. Welding Sequence ones 8. Transverse Shrinkage 7. Fillet: O.imm per weld, Leg length not exceed 3/4 plate thi 1L.Butt: 15 ~ 3mm per weld for 60° V Joint. 'b. Longitudinal Shrinkage 7. Filet: 0mm per 3m of weld Le Butt: 3mm per 3m of weld Pre-setting: WE WE OLFMO} Oz] Wasi Zw ZoletOl setting Using attackment : Wedges, Strongback, Jig, Clamp, Stiffeners(Thin Pate) Reduce No of Passes Using balanced welding, Back Step welding, Skip weldingprea > Decrease bp Hard nay Heat Treatment Requirement ~ UBS S7-> HM Ue, ce G7 > OA S7, +208 S7 > O18 87), SM St > 1st 2, H13h — Remove moisture, Diffuse out hydrogen, Decrease cooling ratelreduce hardening) 3. Temp should be higher than Min Preheat Temp, Hold during welding, '& 10°C for thin plate t 65mm / EHO sd-250c" Inter pass Temp should be lower than MAX Inter-pass temp. (200-250°C) Post Heating : Maintaining Temp Prelieat(Min) relieve residual hydrogen PWHT(Post weld Heat Treatment): to remove Residual Stress 1. Heating Rate : 69~200°C/Hour from 300°C -> 600°C 2. Holding Time: 2 3M sum eh 3. Cooling rate: Slow controlled in furnace from 600 -> 300°C 4. Below 300°C: Ai cooling Heat treatment for steel SR aor aie te ‘S20 ol for acer tine 206 Fl tetenton (hal santo {6a sutton Hol sow cong enact | Wt Sow ona Ti cok gomeh Rat rot | Sow cg nae Sow noe eleva eal er Pree ce in urn ant | Feat ghost Oecenes estes ees ounen (riders conte) ete ral ess omer at sss ran ntact gh ese svat tres | ates yogi el 508700 ade sie tine Cutting Process Oxyfuel Gas Cutting Process. 1. Oxide Fe304 by exothermic reaction 2 fuel Gos syene hin, 100%, Methane (2770'0, Horan (ick, 261570, Hyerogen (282510 3. Flamedl kon powder A719 FES] Metall Cutting’ Cb “ Tore sp AREER > pert, TBS AB 7H = pen bung. | Hgh sl Wie HAZ Sly es Sow ces Utd ere of Commie et sutton pa ste on cn, Con lw ys, Godt | ste ac ny Plasma Cutting 1. Gases: Ais A, N2, 02, mix of ArsH2, N2WH2 2, A Plasma : Incease speed , need special electrodes 3. Shielging o25 optional 4, Wisinessataneeaiaminkon enc sin shest.carbon steel Are Air Gouging Only DCE, Special gouging(Copper coated carbon, Carbon & Low aly Sel & Austenitic Stainless steels & Nonferrous materials, CLEAN/ORY require, Fast rate of removaaso complex shape defect Grinding ofcarbured layer Not qualified welder IMMA gouging: Arc formed between fux cated electrode & workpecer-Qerorzng Flame. aes ~ Has Excest OF OXYGEN ¢ (aEniPrED BY AN INNER WHITE Cone ween is SHORTER f SHARPER Than NueTRat cone. SurTaace for wWecomg Att Brace, Beonee , ZC. — Has Wo Practice AppeicaTion sen W cUTT WG. Cargyeizig FLame. Se ~ Hosp SUGAT excess oF neeTYLENE 5% 3 vase Ob ny SoroWelding SE SYMBAS. . Lp Aws Ady BS AN das (350 253) A clomentany S¥rbol “Cemvention of dimensice. Ea = Design thront thik - $= Depth of Penet rection , Theor th'he > Leg legth Cmin_ material th'k) Ad fillet = leg, lagh oust > Depth of the doier preprmtion . ¥ Supplemanary signbol Aree he grown! smenhhy 2 yy © Heat tech Beebo) APT &. | = > Design Hvoar thok S+ Repth a pewtetion . Theat tek 2 > Ley logth az one : VM D> number of nell clerent | | = length of exch weld” element | pus or $\ CE) = distemco between rch weld element nxl _— eee ey Ba assy © 689