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Copyright © 2005, TWI Ltd

World Centre for Materials Joining TechnologyWorld Centre for Materials Joining Technology

TWITWICSWIP 3.1CSWIP 3.1

WELDING INSPECTIONWELDING INSPECTION

MACRO-SECTION.MACRO-SECTION.PRACTICALPRACTICAL

TWITWICSWIP 3.1CSWIP 3.1

WELDING INSPECTIONWELDING INSPECTION

MACRO-SECTION.MACRO-SECTION.PRACTICALPRACTICAL

MACRO-SECTION.MACRO-SECTION.MACRO-SECTION.MACRO-SECTION.

Section 25.Section 25.



MACRO SECTIONSMACRO SECTIONS

1. ASSESS THE MACRO PHOTOGRAPH FOR WELD1. ASSESS THE MACRO PHOTOGRAPH FOR WELD

DEFECTS. DEFECTS.

2. RECORD THE MAJOR DEFECTS ON 2. RECORD THE MAJOR DEFECTS ON THETHE

REPORT SHEETREPORT SHEET..3. SENTENCE THE DEFECTS RECORDED TO THE3. SENTENCE THE DEFECTS RECORDED TO THE

ACCEPTANCE CRITERIA GIVEN.ACCEPTANCE CRITERIA GIVEN.

4. FOLLOW THE INSTRUCTIONS. 4. FOLLOW THE INSTRUCTIONS.

PLEASE PLEASE DO NOTDO NOT MARK THE MARK THE PHOTOGRAPHS.PHOTOGRAPHS.



MACRO INSTRUCTIONS.MACRO INSTRUCTIONS.



MACRO DEFECTS.MACRO DEFECTS.

3mm3mm

50m50mmm

ANGULAR DISTORTION = 3mm in 50mm




1.5mm1.5mm

MISALIGNMENT

INCOMPLETLEY FILLED GROOVE




GAS PORE / BLOW HOLE

COLD LAP & POOR TOE BLEND

EXCESSIVE WELD METAL COLD

LAP & POOR TOE BLEND



Macro defectsMacro defects

INCOMPLETELY FILLED INCOMPLETELY FILLED GROOVEGROOVE




LACK OF SIDE WALL FUSIONLACK OF SIDE WALL FUSION & SLAG

LACK OF SIDE WALL FUSION / INCOMPELTELY FILLED GROOVE




LACK OF ROOT FUSION

LACK OF SIDEWALL FUSION / INCOMPLETELY FILLED GROOVE

COLD LAP

GAS PORES




INCOMPETELY FILLED GOOVE

LACK OF ROOT FUSION

SLAG INCLUSION

GAS PORE




LACK OF ROOT PENETRATION

LACK OF SIDEWALL FUSION


LACK OF SIDEWALL FUSION & SLAG




MACRO SECTIONSMACRO SECTIONS

QUESTIONS.QUESTIONS.



MACRO DEFECTS.MACRO DEFECTS.CLUSTER / WORMHOLE POROSITY

LAMINATIONS

LACK OF INTER-RUN FUSION

ROOT UNDERCUT

GAS PORES

LACK OF SIDEWALL FUSION & SLAG

LACK OF INTER-RUN FUSION & SLAG




MACRO SAMPLE.MACRO SAMPLE.

1 COLD LAP

2 LACK OF SIDEWALL FUSION & GAS / SILICA

3 COLD LAP

4 LACK OF INTER-RUN FUSION

WELDING PROCESS : MAGWELDING PROCESS : MAG

5 LACK OF SIDEWALL FUSION



MACROMACRONOTE: PHOTOGRAPH IS AT X10 MAGNIFICATION

MATERIAL: LOW CARBON STEEL WELDING PROCESS: [MAG/GMAW]

## DEFECTDEFECT SIZESIZE ACCEPT/REJECTACCEPT/REJECT11 POOR TOE BLENDPOOR TOE BLEND 22 OVERLAP + 2 SMALL PORESOVERLAP + 2 SMALL PORES 33 LAMINATIONS/INCLUSIONS LAMINATIONS/INCLUSIONS 44 LACK OF SIDE WALL FUSIONLACK OF SIDE WALL FUSION 55 AS ABOVE +PORESAS ABOVE +PORES 66 OVERLAPOVERLAP 77 LACK OF INTERRUN FUSION LACK OF INTERRUN FUSION 88 GAS PORE/PIPE GAS PORE/PIPE 99 LACK OF SIDE WALL FUSION + LACK OF SIDE WALL FUSION +

SILICASILICA

1010 ANGULAR MISALIGNMENTANGULAR MISALIGNMENT

1111 EXCESS WELD METALEXCESS WELD METAL

1212 EXCESS PENETRATIONEXCESS PENETRATION

AssessAssessToTo

SpecificationSpecification

2

6

98

34

1

75



MACRO ACCEPTANCE.MACRO ACCEPTANCE.



MACRO EXCERCISES.AM1030

MACRO EXCERCISES.AM1030

TRAINING SAMPLE ONLYMACRO INSTRUCTION/REPORT SHEET [I.D: AM1030]

CHECK PHOTOGRAPH I.D MATCHES THIS REPORT I.DALL DEFECTS TO BE REPORTED [AND SIZED IF REQUIRED]

THEN SENTENCED TO ISO 5817 LEVEL B [STRINGENT]

NOTE: PHOTOGRAPH IS AT X10 MAGNIFICATIONMATERIAL: LOW CARBON STEELWELDING PROCESS: [MMA/SMAW]

1

2233445566

77

88



MACRO EXCERCISES. AM 1030


# DEFECT SIZE ACCEPT/REJECT123456789101112

COMMENTS:

SIGNATURE: DATE:

PRINT FULL NAME:

Lack of side wall fusion and slag

Lack of root penetration

Lack of side wall fusionLack of inter run fusion and slag

Lack of side wall fusion

Misalignment

Angular distortion

Excess weld metal

Reject

Reject

RejectReject

RejectAccept

Reject

Accept8.6

0.2

0.52.5

4.2

2.53.2

N/A







THEN SENTENCED TO ISO 5817 LEVEL B [STRINGENT]


11

22

33

55

6677

8899

44






COMMENTS:

SIGNATURE: DATE:

PRINT FULL NAME:

Lack of side wall fusion/ underfill

Cold lapMisalignment

Excess penetration

Slag inclusion

Lack of side wall fusion and slag

Cold lap

Excess weld metalCold lap

Reject

Reject

Reject

Reject

Reject

Reject

AcceptRejectReject

0.7

7.5

0.51.8

3.3

0.3

0.70.53.5





11

2233

4455

MACRO INSTRUCTION/REPORT SHEET [I.D: AM1032]CHECK PHOTOGRAPH I.D MATCHES THIS REPORT I.D

ALL DEFECTS TO BE REPORTED [AND SIZED IF REQUIRED]THEN SENTENCED TO ISO 5817 LEVEL B [STRINGENT]


6677

88






COMMENTS:

SIGNATURE: DATE:

PRINT FULL NAME:

Lack of side wall fusion/underfill

Misalignment

Lack of side wall fusion & slag

Cold lap

Excess weld metal

Lack of sidewall fusion & Slag

Excess penetration

Reject

Reject Reject

Reject

Reject

Reject

Accept

Slag inclusion

0.5

2.84.51.5

0.3

1.8

2.03.3 Reject

Plate laminations noted







THEN SENTENCED TO ISO 5817 LEVEL B [STRINGENT]NOTE: PHOTOGRAPH IS AT X10 MAGNIFICATION

MATERIAL: LOW CARBON STEELWELDING PROCESS: [MAG/GMAW]

11

22

334455

6677

88






COMMENTS:

SIGNATURE: DATE:

PRINT FULL NAME:

Cold Lap/ Overlap

MisalignmentCold lap / Overlap

Lack of interrun fusion & gas

Excess weld metal

Lack of sidewall fusion & gas Reject

Reject Reject AcceptReject

Reject

RejectBlow hole

2.8

8.00.30.6

2.0

2.6

1.55.0 Reject


Poor toe blend

Lack of sidewall fusion




MACRO EXCERCISES. AM 1034TRAINING SAMPLE ONLY

MACRO INSTRUCTION/REPORT SHEET [I.D: AM1034]CHECK PHOTOGRAPH I.D MATCHES THIS REPORT I.D

ALL DEFECTS TO BE REPORTED [AND SIZED IF REQUIRED]THEN SENTENCED TO ISO 5817 LEVEL B [STRINGENT]


11

2233

445566

7788

99 1010






COMMENTS:

SIGNATURE: DATE:

PRINT FULL NAME:

Lack of sidewall fusion & slag

Misalignment

Lack of inter-run fusion & slag

Lack of inter-run fusion & slag

Excess weld metal

Lack of sidewall fusion Reject

Reject Reject AcceptReject

Reject

RejectLack of side wall fusion

2.8

1.02.0

6in13

0.5

0.1

5.55.0 Reject


Poor toe blend

Angular distortion

Excess penetration

Spatter

3.6

0.1 Accept

Reject



Macro defectsMacro defects

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