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Aws visual inspection1998 viw
Aws visual inspection1998 viw
Aws visual inspection1998 viw
Aws visual inspection1998 viw
Aws visual inspection1998 viw
Aws visual inspection1998 viw
Aws visual inspection1998 viw
Aws visual inspection1998 viw
Aws visual inspection1998 viw
Aws visual inspection1998 viw
Aws visual inspection1998 viw
Aws visual inspection1998 viw
Aws visual inspection1998 viw
Aws visual inspection1998 viw
Aws visual inspection1998 viw
Aws visual inspection1998 viw
Aws visual inspection1998 viw
Aws visual inspection1998 viw
Aws visual inspection1998 viw
Aws visual inspection1998 viw
Aws visual inspection1998 viw
Aws visual inspection1998 viw
Aws visual inspection1998 viw
Aws visual inspection1998 viw
Aws visual inspection1998 viw
Aws visual inspection1998 viw
Aws visual inspection1998 viw
Aws visual inspection1998 viw
Aws visual inspection1998 viw
Aws visual inspection1998 viw
Aws visual inspection1998 viw
Aws visual inspection1998 viw
Aws visual inspection1998 viw
Aws visual inspection1998 viw
Aws visual inspection1998 viw
Aws visual inspection1998 viw
Aws visual inspection1998 viw
Aws visual inspection1998 viw
Aws visual inspection1998 viw
Aws visual inspection1998 viw
Aws visual inspection1998 viw
Aws visual inspection1998 viw
Aws visual inspection1998 viw
Aws visual inspection1998 viw
Aws visual inspection1998 viw
Aws visual inspection1998 viw
Aws visual inspection1998 viw
Aws visual inspection1998 viw
Aws visual inspection1998 viw
Aws visual inspection1998 viw
Aws visual inspection1998 viw
Aws visual inspection1998 viw
Aws visual inspection1998 viw
Aws visual inspection1998 viw
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Aws visual inspection1998 viw

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  • Reference Page 0-1
    REVIEW:
    1.Traditional Inspection - post production
    Based on sorting good from bad only
    2.Welding Inspection -- aims at detecting irregularities before becoming problems
    3.Based on elements listed on slide
    However, weld problems may develop at any stage of the operation
  • Reference Page 0-1
    REVIEW the WORKSHOPS AIMS
    1.Engender understanding of the relationship of welding variables to weld quality
    2.24-point Welding Inspection Program -- Table 1.2
    3.Show the basis of ‘Quality Plan’ development --avoidance of opportunities for error.
    4.Enumerate the steps applicable in determining weld quality, before during and after welding.
    5.EMPHASIZE - Quality conformance to Specification
  • Reference Page 0-2
    REVIEW:
    1.Specifications -- Purchaser mandated Quality criteria
    2.Discontinuity -- interruption to an object’s uniformity
    3.Defect -- non-conforming discontinuity
    4.Quality Plan -- detailed list of checks and inspections
    5.CWI Examination -- 3 parts, as set out in QC-1
    6.Limitations of any inspection program, including NDE
  • Transcript

    • 1. VISUAL INSPECTION WORKSHOP Introduction Review Slides - Introduction Review AWS B1.10, B1.11, and VIW Manual Examine Metal Weld Samples Review AWS Part B Specification Review Plastic Weld Replicas Practice Use of Hand Tools Practice Exercise and Review Practical Exam and Review 1998 VIW-1
    • 2. VISUAL INSPECTION WORKSHOP Introduction Visual Inspection (VT) is the Basic Element of any Quality Control System. It must be done, however, by Trained Personnel. 1998 VIW-2
    • 3. VISUAL INSPECTION WORKSHOP Introduction “It has been shown repeatedly that an effective program of Visual Inspection (VT), conducted by properly trained personnel, will result in the discovery of the vast majority of those defects which would otherwise be discovered later by some more expensive nondestructive test method.” 1998 VIW-3
    • 4. VISUAL INSPECTION WORKSHOP Introduction While VT is limited to the visible, external surfaces only, it should be recognized that the external surfaces of the components most often see the highest stresses in service, and are most often the more critical portions of the components. 1998 VIW-4
    • 5. VISUAL INSPECTION WORKSHOP Introduction VT Is Very Cost Effective …. Relatively Simple To Perform Minimal Equipment Required Problems Found As They Occur Early Repairs Easier To Accomplish 1998 VIW-5
    • 6. VISUAL INSPECTION WORKSHOP Introduction For Welding Inspection, VT Must Be Applied: Before Welding During Welding After Welding 1998 VIW-6
    • 7. VISUAL INSPECTION WORKSHOP Introduction Organizing The Inspection Effort …. Become Familiar w/ Welding Requirements Specify Timing for Inspections Develop Appropriate ‘Hold Points’ Develop Applicable VT Techniques Develop Repair/Re-Inspection Procedures Develop Procedure for Reports and Maintenance of Records 1998 VIW-7
    • 8. VISUAL INSPECTION WORKSHOP Introduction Hold Points Points in the Fabrication Sequence where Inspection must be Performed Before Fabrication can continue. 1998 VIW-8
    • 9. VISUAL INSPECTION WORKSHOP Introduction Applying The Inspection Effort ‘Before’…. Welding Equipment - Type, Suitability Filler Metals - Type, Storage, Size Weld Joint Cleanliness Weld Joint Fitup - Bevels, Faces, RO, etc. Preheat Requirements Others 1998 VIW-9
    • 10. VISUAL INSPECTION WORKSHOP Introduction Applying The Inspection Effort ‘During’…. Tack Weld Quality - Feathering Root Pass Quality - Size Intermediate Pass Cleaning Gouging to Remove Defects Distortion Preheat/Interpass Temp. Maintenance 1998 VIW-10
    • 11. VISUAL INSPECTION WORKSHOP Introduction Applying The Inspection Effort ‘After’…. Final Pass Cleaning, Finishing Weld Sizes Post-Weld Heat Treatment Distortion & Final Dimensions Other NDE Reports 1998 VIW-11
    • 12. VISUAL INSPECTION WORKSHOP AWS B1.10 Review B1.10 - NDE of Welds Table 1, Discontinuities (page 3) Figures (pages 4-9) Terminology (pages 10-12) Table 2 (page 13) NDE, Tables 3 & 4 (pages 15-28) Appendices (pages 29-34) 1998 VIW-12
    • 13. Radiographs Incomplete Joint Penetration 1998 VIW-13
    • 14. Radiographs Incomplete Joint Penetration 1998 VIW-14
    • 15. Radiographs Incomplete Joint Penetration 1998 VIW-15
    • 16. Radiographs Undercut - Should find Visually, not on RT 1998 VIW-16
    • 17. Radiographs Scattered Porosity 1998 VIW-17
    • 18. Radiographs Elongated Porosity (Wormhole) 1998 VIW-18
    • 19. Radiographs Slag Lines 1998 VIW-19
    • 20. Radiographs Slag Lines on Root Pass Face 1998 VIW-20
    • 21. Radiographs Tungsten Inclusions 1998 VIW-21
    • 22. Radiographs Incomplete Fusion (Severe) 1998 VIW-22
    • 23. Radiographs Longitudinal Crack 1998 VIW-23
    • 24. Radiographs Transverse Crack 1998 VIW-24
    • 25. Radiographs Transverse Cracks 1998 VIW-25
    • 26. Radiographs Pipe - Socket Welds (Stand Off) 1998 VIW-26
    • 27. Radiographs Pipe - Double Wall - Elliptical 1998 VIW-27
    • 28. Radiographs Pipe Elbow - Double Wall - Elliptical 1998 VIW-28
    • 29. Radiographs Pipe Branch and Butt Welds 1998 VIW-29
    • 30. VISUAL INSPECTION WORKSHOP AWS B1.11 Review B1.11 - VT of Welds Weld Discontinuity Figures (pages 5-21) Visual Inspection Aids (pages 22-27) Appendix A - Technical Society Contacts (page 29) Appendix B - Supplementary Reading List 1998 VIW-30
    • 31. VISUAL INSPECTION WORKSHOP Amps, Arc Length, Travel Speed SMAW Welds A - Proper parameters B - Amps too low C - Amps too high D - Arc length too short E - Arc length too long F - Travel speed too slow G - Travel speed too fast 1998 VIW-31
    • 32. VISUAL INSPECTION WORKSHOP VIW Reference Manual VIW Reference Manual - Self-Study review for NDE and Tool usage Mod 1 Visual Inspection Mod 2 NDE (review Figures) Mod 3 Weld Discontinuities Mod 4 Part B Specification (review actual Part B Spec) Mod 5 Measurements (review tool use) 1998 VIW-32
    • 33. VISUAL INSPECTION WORKSHOP Metal Weld Samples Examine Metal Welds and Note Discontinuities on Notepad Review Results 1998 VIW-33
    • 34. VISUAL INSPECTION WORKSHOP AWS Part B Specification Review Part B Specification in Detail Table of Contents Conversion Table and SI Prefixes Appendices and Usage Footnotes and Tolerances (e.g. underrun) 1998 VIW-34
    • 35. VISUAL INSPECTION WORKSHOP Plastic Weld Replicas Review Each Type of Weld Replica (Fillet A and B, Large and Small TJoints, Bend Tests, Tensile Samples) Must be able to identify each type Measure correct Weld and Zone (eg - Fillet A, Side 3, Zone 0-1) 1998 VIW-35
    • 36. VISUAL INSPECTION WORKSHOP Hand Tool Kit Demonstrate Use of Each Tool 6 inch Rule 1 inch Micrometer Metric Dial Caliper Palmgren Gage Undercut Gage Fillet Weld Gages 1998 VIW-36
    • 37. VISUAL INSPECTION WORKSHOP Six Inch Machinist’s Scale Accuracy to 1/64” or about 15 mils, 0.015” Align vertically on part, not flat, for best accuracy Best to measure starting from the 1” mark rather than the end, which may be worn, but don’t forget to subtract the 1” from result! 1998 VIW-37
    • 38. VISUAL INSPECTION WORKSHOP 1 Inch Micrometer Clean jaw faces, close Zero Micrometer or, Use ‘Tare’ Approach. If Micrometer ‘zeroes’ at a plus 0.003, take measurement of parts and subtract the 0.003 from result; (converse if it ‘zeroes’ a minus.) 1998 VIW-38
    • 39. VISUAL INSPECTION WORKSHOP 1 Inch Micrometer Accuracy to plus or minus 1 mil, 0.001” Each small, unmarked thimble division equals 1 mil Can estimate to nearest 1/2 mil, 0.0005 1998 VIW-39
    • 40. VISUAL INSPECTION WORKSHOP 1 Inch Micrometer One complete thimble rotation equals 25 mils, or 0.025 inches. Four complete thimble rotations equals 100 mils, or 0.100 inches 1998 VIW-40
    • 41. VISUAL INSPECTION WORKSHOP Metric Dial Caliper Accuracy to 0.1 mm, or about 4 mils Can estimate to nearest 0.05 mm, or about 2 mils Some calipers have both metric and U.S. Customary scales but SI only for Exam 1998 VIW-41
    • 42. VISUAL INSPECTION WORKSHOP Palmgren Gage Only use to measure height of groove weld reinforcement. Don’t use for measuring fillet weld sizes since plastic welds are too small to do accurately. Rotate ‘legs’ of gage to just touch toes of weld for best accuracy 1998 VIW-42
    • 43. VISUAL INSPECTION WORKSHOP V-WAC Undercut Gage - 1 of 2 Accuracy is 1/64”, or about 15 mils Calibrate on flat, smooth surface Position on weld, rotate sharp point into undercut, read scale at other end Can measure porosity depth, but not diameter 1998 VIW-43
    • 44. VISUAL INSPECTION WORKSHOP V-WAC Undercut Gage - 2 of 2 Measures undercut up to 1/4 inch depth in 64ths of an inch Also can be used to measure weld reinforcement height up to 1/4 inch in 64ths of an inch 1998 VIW-44
    • 45. VISUAL INSPECTION WORKSHOP Fillet Weld Gage Use Determine if Weld is Concave or Convex Pick Appropriate Gage Type - 2 types Scribed Lines on Gages for Estimating Size of Adjacent leg Measure Smallest Weld Size Location Measure Both Legs for Convex welds Gages from 1/8” to 1/2” - 1/16” increments Gages from 1/2” to 1” - 1/8” increments 1998 VIW-45
    • 46. VISUAL INSPECTION WORKSHOP Fillet Weld Shapes Three Weld Shape Options: Convex - use convex gage only - minimum leg size Concave - use concave gage only - throat size Flat - either gage type will give accurate result 1998 VIW-46
    • 47. VISUAL INSPECTION WORKSHOP Convex Fillet Weld Gage Use - 1 of 3 Determine shape of fillet weld, select convex gage Use scribed lines on gage for estimating size of second leg, or: For convex welds, measure both legs for best accuracy; select minimum leg as size 1998 VIW-47
    • 48. VISUAL INSPECTION WORKSHOP Convex Fillet Weld Gage Use - 2 of 3 Measure both legs Weld size is the lesser of the two legs for convex welds Weld size shown is 3/8, not 1/2 1/2" 3/8" 1998 VIW-48
    • 49. VISUAL INSPECTION WORKSHOP Convex Fillet Weld Gage Use - 3 of 3 Use Correct Size Gage Too Large Correct Gage Too Small 5 " /8 1 " /2 7/16" 1998 VIW-49
    • 50. VISUAL INSPECTION WORKSHOP Concave Fillet Weld Gage Use - 1 of 2 Determine type of fillet weld, select concave gage Use scribed lines on gage for estimating size of weld legs if needed On concave welds, insure 3-point contact between gage and weld 1998 VIW-50
    • 51. VISUAL INSPECTION WORKSHOP Concave Fillet Weld Gage Use - 2 of 2 Use Correct Size Gage Too Large 7 6 /1 " Correct - 3 point contact 51 " / 6 Too Small 3 6 /1 " 1998 VIW-51
    • 52. VISUAL INSPECTION WORKSHOP Student Hands-On Tool Practice Measure the Following and Note Results: Width of 6 inch scale in mm & mils Thickness of 6 inch scale in mm & mils Thickness of Palmgren Gage in mm & mils Thickness of Fillet Gage in mm & mils Outside Diameter of Mag. Glass in mm Review Student Results for Accuracy 1998 VIW-52
    • 53. VISUAL INSPECTION WORKSHOP Practice Exercises Complete 20 question VIW Practice Exercises using tensile, weld replicas Review answers 1998 VIW-53
    • 54. VISUAL INSPECTION WORKSHOP Practice Examination Complete VIW Practice Exam - 2 to 2 1/2 hours; (Student should jot down page number from Part B where answers are found to aid exam review) Review Answers 1998 VIW-54

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