This document provides an introduction to welding inspection qualifications and outlines key responsibilities and testing methods. It discusses: 1) The duties of welding inspectors to ensure compliance with specifications before, during, and after welding; 2) Common weld imperfections that inspectors check for, such as cracks, porosity, lack of fusion; 3) Mechanical testing methods used to evaluate welds, including hardness testing, toughness testing, and tensile strength testing.

1. AN INTRODUCTION TO
CSWIP 3.1
By
MR ANSAR BALOCH

2. Contents
Terms & Definition
Types of Welds
Types of Joints
Weld Preparations
Types of Single Butt Preparation
Butt Welded Joint
Fillet Weld Profile
Effect of a Poor Toe Blend Angle
Summary of Terms
Duties of Welding Inspector
Responsibilities of Welding Inspector
Imperfections in Welded Joints
Mechanical Testing
Macro Inspection

3. A Joint:* A configuration of members
A Weld:* A union between materials caused by heat,
and or pressure
Text Page Ref 1:1

4. Butt welds:*
Fillet welds:*
Spot/Seam welds:*
Plug/Slot welds:*
Edge welds:*

5. Closed
corner
Open
corner*
T joints: *
Lap joints: *
Corner joints:*
Butt joints: *

6. Angle of bevel*
Included angle*
Root gap*
Root face*
Root radius*
Root landing*

7. Single V
Single bevel
Single J
Single U*

8. Double bevel
Double V
Double J
Double U*

9. A butt welded butt joint*
A fillet welded butt joint*
A compound welded butt joint*

10. A butt welded T joint*
A fillet welded T joint*
A compound welded T joint*

11. A compound welded Lap joint*
A spot welded Lap joint*
A fillet welded Lap joint*

12. A butt welded Closed Corner joint*
A fillet welded Closed Corner joint*
A compound welded Closed Corner joint*

13. An outside fillet welded Open Corner joint*
AnAn inside filletinside fillet welded Open Cwelded Open Corner jointrner joint**
A double fillet welded Open Corner joint*

14. 1 2
43
A
B
A + B = Excess Weld Metal**
Weld Face*
Weld Width*
Design Throat Thickness*1.2.3.4. Weld Toes*
Weld Root*
HAZ*
Actual Throat Thickness*

15. Weld face*
Vertical Leg Length*
Horizontal Leg Length*
Design throat*
Actual throat*
Excess weld metal **

17. 80°
20°
6 mm
3 mm*
Very Poor Weld Toe Blend Angle
Improved Weld Toe Blend Angle

18. Extremely poor toe blend, but excess weld metal is within limits*
3 mm90°

19. Weld Sizing (Fillets): DTT. ATT. Excess weld metal. Leg length *
Weld Sizing (Butts): DTT. ATT. Excess weld metal.
Weldment Terms: Weld face & root. HAZ. Weld toes.Weld width
Preparation Terms: Bevel/included angle. Root face/gap. Land/Radius
Types of Preparation: Bevel’s. V’s. J’s. U’s. Single & Double Sided.
Types of Joint: Butt. T. Lap. Corner (Open & Closed)
Types of Weld: Butt. Fillet. Spot. Seam Plug. Slot. Edge.
Weld Preparation: Preparing a joint to allow access and fusion.
Joint: A Configuration of members
Weld: A Union of materials

21. It is the duty of all welding inspectors:
To ensure that welding operations are carried out in
accordance with written, or agreed practices or
specifications
Before
During
After
*

22. Discuss the following
1) Safety:
Rules.
2) Documentation:
Spec. Drawings. Procedures. Welder approvals. Certificates. Mill sheets
3) Welding Process and accessories:
Equipment,Cables, Regulators, Ovens etc
4) Incoming Consumables:
Materials/welding consumables (Size. Condition. Specification. Storage)
5) Marking out preparation & set up:
Method. Angles/Root face/gap values. Distortion control. Pre-heat prior to
tack welding if applicable*
Before Welding:

23. During Welding:
1) Pre-Heating (Min 15 C as per UW-30 ASME Section VIII Div-I)
2) In process distortion control (Balance or sequence welding)
3) Consumable control. (Correct baking for E-7018 260-425 C and
storage 30-140 C prior to use)
4) Welding process (Related parameters i.e. volts/amps. gas flow rate)
5) Welding run sequence and inter-pass cleaning
6) Minimum/maximum Inter-pass temperatures (150 C for SS, 250 C
for CS.
7) Full compliance with all elements given on the WPS*

24. After Welding:
1) Visual Inspection
2) Non Destructive testing
3) Repairs*
4) Repair procedures (NDT/Welding/Welder approval)
5) PWHT
6) Hydro-static testing
7) Submission of all inspection reports to QC departments*

25. To Record
To Compare
To Observe Activities &
Imperfections*
Activities &
Imperfections*
Activities &
Imperfections*

26. A Welding Inspectors toolbox should contain*
A welding gauge (Cambridge style, or high low gauges etc)
A tape measure and scale
A wire brush
A magnifying glass
A torch and mirror
A specification, pen and report, or note paper

27. Welding imperfections can be categorized into groups:
3) Solid Inclusions
4) Lack of fusion
1) Cracks
6) Mechanical or Surface damage
5) Profile & Lack of Filling
2) Gas Pores & Porosity
7) Misalignment*

28. A HAZ hydrogen crack, initiated at the weld toe
Most cracks are initiated from stress concentrations *

29. Surface breaking porosity
Fine cluster porosity
Blow hole > 1.6 mm Ø
Hollow root bead An isolated internal porosity
Coarse cluster porosity
Shrinkage cavity*

30. Internal solid inclusion causing
a lack of sidewall fusion
Surface breaking solid inclusion
Internal solid inclusion causing
a lack of inter-run fusion*
Solid inclusions caused by
undercut in the previous weld
run
Internal solid inclusion

31. Lack of root fusion
Overlap (Causing cold laps)
Lack of inter-run fusion Lack of sidewall fusion
Lack of sidewall fusion &
incompletely filled grove*

32. An Incompletely filled groove
Lack of root fusion
Spatter
A
Poor toe blend
Bulbous, or irregular contour
Arc Strikes
Incomplete root penetration
B
*

33. Root Run or “Hot pass” undercut
Parent metal, surface undercut
Weld metal, surface undercut*

34. Weld metal, surface undercut Parent metal, “top toe” undercut*

35. Any surface damage caused by:
Grinding
Hammering/chisel marks
Slag chipping hammer marks
Arc strikes

36. Linear misalignment measured in mm (over 13mm to 19mm
as per UW 33 of ASME Sec VIII Div-I)
3 mm
Angular misalignment measured in degrees*
15°
Excess weld metal height
Lowest plate to highest point
Linear
Angular

37. Why ?* To establish the level of mechanicalTo establish the level of mechanical propertiesproperties*
Which properties ?*
4) Ductility*
3) Tensile strength*
2) Toughness (Impact Test)*
1) Hardness*

38. We test welds to establish minimum levels of mechanical
properties, and soundness of the welded joint*
We divide tests into Quantitative & Qualitative methods:*
1) Quantitative tests: (Have units)*1) Quantitative tests: (Have units)*
2) Qualitative tests: (Have no units)*2) Qualitative tests: (Have no units)*

39. Types of tests include:
1) Quantitative tests:
Hardness tests
Toughness tests
Tensile strength tests*
1) Quantitative tests:
Hardness tests
Toughness tests
Tensile strength tests*
2) Qualitative tests:
Macro tests
Bend tests
Fracture tests*
2) Qualitative tests:
Macro tests
Bend tests
Fracture tests*

40. The specimen below has been polished and is
ready to be hardness tested
= Hardness Survey
Thickness
Base metal HAZ Fusion boundary Weld metal

41. Generally we use a diamond or steel ball to form an indentation
We measure the width of the indentation to gauge the hardness*

42. 1)1) Vickers Diamond Pyramid:Vickers Diamond Pyramid: Always uses a diamond*
2)2) Brinell hardness test:Brinell hardness test: Always uses a steel ball*
3)3) Rockwell hardness test:Rockwell hardness test: Uses a ball, or diamond
depending on the scale*

43. 10 x 10 mmMachined notch
Pendulum Hammer
Location of specimen
The specimen may be tested from different areas of the weld.*
Graduated scale
of absorbed
energy in Joules*

44. 1)1) Charpy V test:Charpy V test: 10 x 10 (Specimen horizontal) Joules*
2)2) Izod test:Izod test: 10 x 10 (Specimen vertical) Ft.lbs*

45. Weld
HAZ
Plate material
Test gripping area
Radius
(For radius reduced test specimens only)
Reduced Section
Used to assess the tensile strength of the weld metal
Direction of test

46. Tensile test piece cut
along weld specimen.
Direction of the test *
All Weld Metal Tensile Testing

47. Firstly, before the tensile test 2 marks are made 50mm
During the test, Yield point & Tensile strength are measured
The specimen is put together and the marks are re-measured
A new measurement of 75mm will indicate Elongation E50 %*
50 mm
75 mm

48. 3) Lack of Root Fusion
1) Excess Weld Metal Height 7) Poor Toe Blend*
4) Slag inclusion & Lack of inter-run fusion
2) Lack of Sidewall Fusion
5) Root Penetration
6)Porosity

49. Bend tests are used to establish fusion in the area under test
Former
Test Piece
Lack of root fusion shown here*
Further tests include face, side and longitudinal bend tests*
For material over 12 mm thickness, side bend test may be
used*
Force
A Guided root bend test*Guide

50. Specimen prior to test* Specimen after test*

51. The main difference between Macro & Micro is that Micro is
the study of the micro-structure at much higher magnification
The limit of Macro inspection is magnification < X 10
The specimen is usually cut from a stop/start in the test piece

52. Remember! The process of inspection is to first:
Observe, then Report, then Compare!*