CSWIP 3.1 WIS5 DEFECT QL CL Han Ruby A B Chieu

Visual Welding Inspection
Course Reference WIS 1E

Copyright © 2003 TWI Ltd Faisal Yusof
CSWIP Certificate Scheme
Certification Scheme for Welding & Inspection
Personnel
10,000 certificate holders

CSWIP WI Certificate Scheme
 Level 1: 3.0 Visual Welding Inspector
 Level 2: 3.1 Welding Inspector
 Level 3: 3.2 Senior Welding Inspector
For further examination information please see website

www.cswip.com

Visual Welding Inspector Course Topics
Welding terms
Roles and duties of a
Welding Inspector
Welding defects
Welding process
Inspection reporting

Course Assessment
Exam after the course No continuous

is completed assessment

CSWIP 3.0 Examination
Closed book exam
Any code that is required for the examination will be provided on

the examination day with the exception of your chosen code.

Before attempting the examination, you must provide the
following
1. Two passport size photographs, with your name and
signature on reverse side.
2. Eye test certificate, the certificate must show near vision and
colour tests.
3. Completed examination Form, you can print from the
website www.twisea.com.
4. Your current CV / Resume, your CV must be emailed or
faxed to the following for evaluation by the examination
manager.
E-mail: shajprem@twisea.com
Fax: +60 3 61572378
 Practical : Inspection of a plate butt weld, code
provided.
1 Hour 30 mins
 Code : PH 6/WI/OO
 Practical : Inspection of a plate Fillet weld
1 Hour 15 mins
 Code : ISO 5817 Level D ( moderate level )

Notification of Results
70% pass
mark
For every section to be

awarded the certificate
2 copies of certificates and an identity card sent to

delegates’ sponsor
CSWIP Renewals
5 years 10 years
CV assessment Renewal examination

Certification Scheme for
Welding & Inspection Personnel
recognised worldwide

Welding Terms

Introduction

Terminology and Definitions
A Weld:
A union between materials caused by heat,
and or pressure
A Joint:
A configuration of members

Introduction

Terminology Joint Types
Edge Open & Closed Corner Lap
Tee Butt
Cruciform
Terminology Joint Welds
Compound Fillet Butt
Edge Spot Plug

Types of Joint Preparation
Included angle Included angle
Angle of
bevel
Root
Radius
Root Face Root Face

Root Gap Root Gap
Single -V Butt Single - U Butt

Types of Joint Preparation
Angle of Angle of
bevel bevel
Root
Radius
Root Face Root Face

Root Gap
Root Gap Land
Single Bevel Butt Single J Butt
Single Butt Weld Preparations
Single sided preparations are normally made on thinner
materials, or when access form both sides is restricted
Single Bevel Single Vee
Single J Single U
Double Butt Weld Preparations
Double sided preparations are normally made on thicker
materials, or when access form both sides is unrestricted
Double Bevel Double Vee
Double J Double U
Features of completed weld
Weld Toe Weld zone Weld metal
Heat affected
zone
Fusion zone Weld Junction

Root
Weld Toe

Butt Weld Features
Excess cap height

Weld cap width or weld reinforcement
Excess root
penetration Root bead width

Toe Blend Angle
6 mm
Most codes quote the weld
80° toes shall blend smoothly
This statement is not
quantitative and therefore open
Poor Weld Toe Blend Angle to individual interpretation
The higher the toe blend angle
3 mm the greater the amount of
stress concentration
20°
The toe blend angle should be
between 20o-30o
Improved Weld Toe Blend
Angle
Butt Weld Exercise
Butt Weld Features
Identify the butt weld features shown
10
7 8
9
2
1
5 3 4
6
Butt Weld Exercise Answers
Butt Weld Features
1.Excess weld metal
2. Weld toes
3. Weld junction 10
4. HAZ
7 8
9
5. Plate thickness 2
1
5 3 4
6
Butt Weld Exercise Answers
Butt Weld Features 10
6. Plate width
7 8
9
7. Plate & weld length
8. Weld width
9. Cap contour/ weld face

6
10. Convex cap
profile/smooth profile

Fillet Weld Features
Vertical leg length
Design throat
thickness
Horizontal leg length

Deep penetration fillet Weld Dimensions
a = Nominal design throat

thickness
s = Effective design throat
thickness
b = Horizontal leg length
c
c = Vertical leg length
e.g
Leg length = 6mm
Design Throat = 6mm x 0.7
a Design Throat = 4.2mm
b s
The leg length should be approximately equal to the material
thickness
The design throat thickness is 0.7 of the leg length
Fillet Weld Profiles
Mitre fillet Convex fillet
A concave profile is
preferred for joints
subjected to fatigue loading
Concave fillet
Fillet Weld Exercise
Identify the fillet weld features shown
10
4
9
7
2 5
3 8
1
6
Fillet Weld Exercise Answers
1.Horizontal leg length
2. Vertical leg length

10
3. Plate thickness
4. Weld width 4
9
7
5. Plate/weld length
2 5
3 8
1
6
Fillet Weld Exercise Answers
6. Plate width
7. Plate height
10
8. Depth of root penetration
9. HAZ 4
9
7
10. Weld toe
2 5
3 8
1
6
Welding Positions
Flat position
UK (USA) 1G rotated UK (USA): 1G

ISO/EN PA ISO/EN: PA
Horizontal
position
UK (USA) 2G Fixed UK (USA): 2G

ISO/EN PC ISO/EN: PC
Welding Positions
Vertical Vertical
up down
UK (USA) 3G UK (USA) 3G
ISO/EN PF ISO/EN PG
Overhead Position Vertical Position

UK (USA) 4G Pipe fixed Horizontal
ISO/EN PE UK (USA) 5G
ISO/EN PF, PG Faisal Yusof
Copyright © 2003 TWI Ltd
Welding Positions
45o 45o
Inclined position fixed Inclined position Rotated

UK (USA) 6G UK (USA) 1FR
EN/ISO H-LO45 EN/ISO L 45/PA

How Do I Carry Out a Visual
Inspection?
 What is the nature of the product?
 What operating conditions will be
present?
 What is the quality of welding required?
 Is there a code or standard available to
inspect the welds against

Main Responsibilities
 Code compliance
 Workmanship control
 Documentation control

Personal Attributes
 Honesty
 Integrity
 Knowledgeable
 Good communicator
 Physically fit.

Duties of a Visual Welding Inspector
 Duties Before Welding
 Duties During Welding
 Duties After Welding

Welding Checklist
Before Welding Commences
 Familirization to the relevant code and specification
 Check welding equipment and calibration certificates
 Material identification,size,type and condition
 Consumables type,size,condition,storage and handling
 Review/witness WPS and PQR test and record
 Joint preparation( check)
 Welder qualification test( Review/witness)
 Welding process involved
 Check pre-heating before welding ( if required)
Welding Checklist
During Welding
 Check weather condition
 Check clearance for welding/welder
 Check welder identification for weld
 Check consumables as per WPS used
 Check welding parameters as per WPS used
 Check distortion control
 Check interpass cleaning
 Check run out length ( travel speed)
 Check interpass temperature
 Check usage of line up clamps
 Maintain daily log book
Welding Checklist
After Welding Completion
 Perform visual inspection
 Weld and welder identification ( check)
 Post weld heat treatment ( if required)
 Non-destructive Testing ( witness)
 Acceptance standards of NDT
 Repairs (if any)
 Dimensional check ( as per drawing)
 Document control - welding reports etc

Welding Inspectors Equipment
 Measuring device e.g flexible tape, steel rule

 Temperature indicating crayons
 Welding gauges e.g. TWI multi-purpose
gauge
 Voltmeter
 Ammeter
 Magnifying glass
 Torch/flash light
Welding Inspection Gauges
10mm 10mm 1
G.A.L. G.A.L. 3
4
L
S.T.D.
16mm
S.T.D.
16mm An explanation on the use 5
of these gauges will be 6
Fillet Weld Gauges give in the practical

sessions
HI-LO Single Purpose Welding Gauge

IN
0 1/4 1/2 3/4
Misalignment Gauges
TWI Multi-purpose Welding Gauge
Weld Imperfections

Introduction
A perfect butt weld joint, when subjected to an external
force, provide a distribution of stress throughout its
volume which is not significantly greater than parent
metal.

Introduction
This is achieved as long as the following features

apply :-
• Welds should consists of solid metal throughout a cross

section at least equal to that of parent metal.
• All parts of a weld should be fully fused to the parent
metal.
•Welds should have smoothly blended surfaces.

Introduction
If any of these requirements are not fulfilled then the weld
Is imperfect and the stress distribution through the joint
Is disrupted

Types of imperfections
Weld imperfections can be grouped into five distinct
according to it nature and shape.
 Cracks
 Lack of solid metals
 Lack of fusion
 Lack of smoothly
blended surfaces
 Miscellaneous

Cracks

Cracks
Cracks that may occur in welded materials are caused
generally by many factors and may be classified by
shape and position, cracks are classed as planar.
Classified by Shape Classified by Position

 Longitudinal  HAZ
 Transverse  Centreline
 Branched  Crater
 Chevron  Fusion zone

 Parent metal

Cracks
Weld metal hydrogen cracking

HAZ hydrogen cracking
Solidification cracking Lamellar Tearing

Transverse crack Longitudinal crack
LACK OF SOLID METALS

POROSITY
Description : Gas pores trapped within the weld metal
Causes :
• Damp fluxes/ corroded electrode
•Grease/hydrocarbon/water contamination of prepared surface
•Air entrapment in gas shield
•Too high arc voltage/arc length
•Incorrect/insufficient deoxidant in electrode, filler or parent
metal

Gas Cavities
Porosity
Root piping
Cluster porosity Herring bone porosity
Crater Pipe
A shrinkage cavity at the end of a weld run where the arc is
terminated
Causes : Preventation :
•Lack of welder skill due to using • Retrain welder
processes with too high current.
•Use correct crater filling
•Inoperative crater filler ( GTAW ) technique

Crater Pipe/Cracks
Crater Cracks
Crater pipe

Root concavity
A shallow groove, which may occur in the root of a butt weld
Causes :
•Insufficient arc power to produce positive bead
•Excessive backing pressure ( GTAW )
•Lack of welder skill
•Slag flooding in backing bar groove
root concavity
Underfill
A weld with thickness less than that of the parent metal
Causes :
•Insufficient weld metal
•Irregular weld bead surface

Underfill
Slag Inclusions
Slag or other matters trapped during welding. The imperfection is of
an irregular shape and thus differs in appearance from a gas pore
Causes :
•Heavy millscale/rust on work surface
•Incomplete slag removal from underlying surface of multipass
weld
•Slag flooding ahead of the arc
•Entrapment of slag in work surface
•Unfused flux due to damage coating
Interpass slag inclusions Elongated slag lines
Inter- run Imperfections
Irregular along the fusion line between weld beads
Causes :
•Low arc current resulting in low
fludity of weld pool
•Too high travel speed
•Inaccurate bead replacement

Lack of Fusion

Incomplete root penetration
Failure of the weld metal to extend into root of a joint
Causes :
•Excessively thick root face, insufficient root gap or failure to cut back
sound metal in a ‘back gouging’ operation
•Low heat input
•Excessive inductance in GMAW dip transfer
•SMAW electrode too large( low current density )
•Use of vertical down welding
Root Defects
Lack of root fusion Lack of root Penetration

Lack of root penetration Lack of root fusion
Lack of sidewall fusion
Lack of fusion between weld metal and parent metal at one side of weld
Causes :
•Low heat input to weld
•Molten metal flowing ahead of arc
•Oxide or scale on weld preparation
•Excessive inductance in GMAW dip transfer welding

Lack of Smoothly
Blended Surfaces

Surface porosity
Gas pores which break the surface of the weld
Causes :
•Damp or contaminated surface of electrode
•Low fluxing activity
•Excess sulphur ( particularly free – cutting steels) producing sulphur
oxide
•Loss of gas shield gas due to long arc or high breezes ( GMAW )
Excess Weld Metal ( Reinforcement )
Reinforcement is the extra metal which produces convexity in fillet
welds and a welds thickness than the parent metal plate in butt welds.
Causes :
•Excess arc energy ( GMAW,SAW )
•Shallow edge preparation
•Faulty electrode manipulation
•Incorrect electrode size

Excess cap reinforcement
Excessive Penetration
Projection of the root penetration bead beyond a specified limit
Causes :
•Weld input energy too high
•Incorrect weld preparation i.e excessive root gap, thin edge
preparation, lack of backing
•Use electrode unsuited to welding position
•Lack of welder skill
Excessive root penetration
Undercut
An irregular groove at the toe of a run in the parent metal or in
previously deposited welding, cause by welding
Causes :
•Melting of top edge due too high welding current ( especially at free
edge) or high travel speed
•Attempting an HV fillet weld leg length
>9.0 MM
• Excessive/Incorrect weaving
•Incorrect electrode angle
Cap Undercut
Measured in both Length & Depth

Root undercut Cap undercut
Overlap
An Imperfection at the toe of a weld caused by metal flowing on to the
surface of the parent metal without fusing to it
Causes :
• Poor electrode manipulation
• High energy input/low travel speed causing surface flow of
fillet weld
• Incorrect positioning of weld
• Electrode having too high a fluidity
Profile Defects
Poor stop/starts

Miscellaneous

Misalignment
The non – alignment of two abutting edges in a butt joint
Causes :
• Inaccuracies in assembly
procedures or distortion from
other welds
• Excessive ‘out of flatness' in hot
rolled plate or sections

Arc strikes
Random areas of fused metal where the electrode, the holder, or current
return clamp accidentally touched the work and produced a short
duration arc
Causes :
• Poor Access to work
• Missing insulation on electrode holder or torch
• Failure to provide an insulated resting place for the
electrode holder or torch when not in use
• Loose current return clamp
Spatter
Small droplets of electrode material can be projected clear of the weld
and may fused to the parent metal
Causes:
• High arc power
• Magnetic arc blow
• Incorrect setting for GMAW process
• Damp electrodes
Burn Through
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
 Slow Travel Speed

Burn through

Root Defects
Burn
Through
Copyright © 2003 TWI Ltd

Burn through Faisal Yusof
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

Mechanical Damage

Mechanical Damage
Mechanical damage can be defined as any surface material
damage cause during the manufacturing process.
This can included damage caused by:
 Grinding
 Hammering
 Chiselling
 Chipping
 Breaking off welded attachments (torn surfaces)
 Using needle guns to compress weld capping runs

Parent Material Defects
A welding inspector should also inspect the parent
material for any visible defects
Mechanical damage Lap
Lamination
Segregation line

Plate Lamination

Welding Processes

Welding Processes chart
Fusion Pressure
Welding Welding
Resistance Solid state

Welding Welding
Arc Oxy fuel Electroslag Thermit Power Beam

Welding Welding Welding Welding Welding
MMA TIG MIG,MAG, SAW PAW EBW LBW

FCAW
Manual Metal Arc Process (MMA)
USA: SMAW

Manual Metal Arc Process (MMA)

MMA Welding Basic Equipment
Control panel Power source

(amps, volts)
Electrode Holding oven

oven
Electrodes Inverter power
source
Return lead
Electrode holder
Welding
visor/filter Power cables
glass

Tungsten Inert Gas (TIG)
USA: GTAW

Tungsten Inert Gas (TIG)
USA: GTAW

TIG Welding Basic Equipment
Power source
Power control
panel Inverter power
source
Return lead Source control

panel
Torch
assembly Power cable hose
Tungsten Flow-meter
electrodes

TIG Torch Assembly
Tungsten Tungsten
housing electrode
Fitted ceramic Ceramic

shielding cup shield cup
On/Off switch Gas lens
Split collet
Gas diffuser
Torch body
Spare ceramic
shielding cup

Metal Active/Inert Gas (MAG/MIG)
USA: GMAW

Metal Active/Inert Gas (MAG/MIG)
USA: GMAW

MAG Welding Basic Equipment
External wire External wire

feed unit feed motor
control panel
Transformer/
Power Rectifier
control panel
Power cable &
15kg wire spool hose assembly
Power return Spare contact
cable tips
Welding gun Liner for wire
assembly

MAG/MIG Internal Wire Drive
Plain top roller
Half grooved Wire guide

bottom roller

Metal Transfer Modes for MAG/MIG
 Dip Transfer: Voltage < 22 Amperage < 200
Thin materials positional welding

 Spray Transfer: Voltage > 27 Amperage > 220
Thicker materials, limited to flat welding positions,
high deposition.

 Globular Transfer: Between Dip & Spray Transfer
Limited commercial, Used only in some mechanised
MAG process using CO2 shielding gas

 Pulsed transfer: Combination between spray
transfer ( peak current ) and low current
( background current)

Sub-arc (SAW)

Submerged-arc (SAW)
Filler wire spool

Flux hopper
Power supply
- +
Slide rail
Wire electrode
Flux

Weld Repairs

Welding Repairs
In the event of repair
 Authorization for repair
 Removal and preparation for repair
 Testing of repair - visual and NDT

Weld Repairs
The specification or procedure will govern how the defective
areas are to be removed. The method of removal may be
 Grinding
 Chipping
 Machining
 Filling
 Oxy-Gas gouging
 Arc air gouging
Air air gouging
Any
Any Questions?
Questions?

Visual Welding
Inspection Practical

Plate Inspection Practice
The purpose of this session is to practice the reporting
format required by CSWIP in the practical plate
examination part of the CSWIP 3.0 Visual Welding
Inspectors exam
The responsibilities of a Visual Welding Inspector are:
 Observe
 Report
 Compare

Observe
To observe welding imperfections you are required to have

good close vision acuity
A close vision acuity test will be given to you before your
exam to establish if your vision meets the minimum standard
required
Its not just the project that must meet the

standard!!
You will also require a thorough knowledge of welding
imperfections and their likely location, causes and
implications

Specialist Welding Gauges
A number of specialist welding gauges are available to
measure the various elements that need to be measured
in a welded fabrication including
 TWI Multi-function weld gauge for measuring many

different weld measurements.
 Fillet weld gauges for measuring leg lengths and throat
thickness.
 Hi-Lo gauge for measuring misalignment and root gaps
 Angle gauges for measuring weld preparation angles

IN
1/4 1/2 3/4
0
Angle of preparation
The scale reads from 0o to 60o in steps of 5o.
The angle is read against the chamfered
edge of the segment

IN
1/4 1/2 3/4
0
Misalignment
The scale is used to measure misalignment of
components by placing the edge of the gauge on
the lower one and rotating the segment until the
pointer contacts the higher piece
IN
1/4 1/2 3/4
0
Undercut
The scale reads from 0 in the negative up
to 5m. The segment is rotated until the
pointer reaches the full depth of the
undercut.
IN
1/4 1/2 3/4
0
Excess weld metal

The scale is used to read off these
dimensions up to a maximum of 25mm
and 1 inch

IN
1/4 1/2 3/4
0
Fillet weld leg length

The scale is used to read off these
dimensions up to a maximum of
25mm and 1 inch.

3/4 1/2 0
1/4
IN
Fillet throat thickness

The sliding pointer reads up to 20mm and 3/4
inch. In measuring throat thickness it is
assumed that the fillet weld has normal root
penetration
Fillet Weld Gauges
10mm
G.A.L.
L S.T.D.
16mm
Leg Length Gauge
10mm
G.A.L.
S.T.D.
16mm
Throat Thickness Gauge

HI-LO Welding Gauge
Internal Root gap

HI-LO Single Purpose Welding Gauge
alignment dimension

Plate Inspection Practice
Remember in the CSWIP 3.0 Welding Inspectors

examination your are required to conduct a practical
examination of a plate test weld, complete a thumb print
sketch and a final report on your findings
 Time allowed 1 hour and 30 minutes
 The code is provided

Plate Inspection Points
1) Use a pencil for the arrow lines, but make all

written comments and measurements in ink only
2) Report everything that you can observe
3) Do not forget to compare and sentence your report
4) Do not forget to date & sign your report
5) Make any observations, such as recommendations

for further investigation for crack-like imperfections.

Thumb Print Report Sketch
After you have observed an imperfection and determined
its type, you must be able to take measurements and
complete the thumb print report sketch
The first thumb print report sketch should be in the form

of a repair map of the weld. (i.e. All observations are
Identified Sized and Located)
The thumb print report sketch used in CSWIP exam will

look like the following example.

Plate Thumb Print Report Example
Name (Block capitals) Joe BLOGGS Signature Joe Bloggs Test piece identification Example 1
Code used BW/VI/00 Welding process MMA (SMAW) Joint type Single V Butt
Welding position Flat 1G/PA Length & thickness L=300mm t = 12.5mm Date 16/07/0
A B C
Note: all dimensions in mm

Plate Sample Cap
Welding Process MMA (SMAW)
Slag Cap Undercut 100 Lack of Cap Undercut

sidewall fusion Intermittent
5 Inclusion 25 Intermittent 160 L= 15 ,D= 1.0 max
L= 10,W=4 L= 15 ,D= 1.0 max L= 10
Cap Undercut Cluster

Intermittent 50 Porosity
15 L= 30,D= 1.6 L=5 w = 3 200 Arc Strike 10
15
•Note: All dimension in mm

Spatter and surface slag requires removal, arc strikes require grind smooth and check with MT
Poor cap profile full weld length
Linear misalignment full weld length D = 1.0 max

Final Report
After you have completed your thumb print report sketch of

your test plate the next step is to complete your final report
again the report must be completed in ink (no pencil).
The report must be completed to your thumb print sketch,

do not leave any boxes empty, every box must be
completed or dashed out. You must also make any
comments you feel are necessary regarding any defects
observed.
The report form used in CSWIP will look like the following
example.


CSWIP 3.1 WIS5 DEFECT QL CL Han Ruby A B Chieu

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Visual Welding Inspection

Course Reference WIS 1E

10,000 certificate holders

 Level 1: 3.0 Visual Welding Inspector

 Level 2: 3.1 Welding Inspector

 Level 3: 3.2 Senior Welding Inspector

For further examination information please see website

Copyright © 2003 TWI Ltd Faisal Yusof

Copyright © 2003 TWI Ltd Faisal Yusof

Exam after the course No continuous

Copyright © 2003 TWI Ltd Faisal Yusof

Closed book exam

Any code that is required for the examination will be provided on

Copyright © 2003 TWI Ltd Faisal Yusof

 Practical : Inspection of a plate Fillet weld

Copyright © 2003 TWI Ltd Faisal Yusof

For every section to be

2 copies of certificates and an identity card sent to

CV assessment Renewal examination

Copyright © 2003 TWI Ltd Faisal Yusof

Copyright © 2003 TWI Ltd Faisal Yusof

Copyright © 2003 TWI Ltd Faisal Yusof

Copyright © 2003 TWI Ltd Faisal Yusof

Copyright © 2003 TWI Ltd Faisal Yusof

Copyright © 2003 TWI Ltd Faisal Yusof

Edge Open & Closed Corner Lap

Compound Fillet Butt

Edge Spot Plug

Root Face Root Face

Single -V Butt Single - U Butt

Copyright © 2003 TWI Ltd Faisal Yusof

Root Face Root Face

Single Bevel Single Vee

Double Bevel Double Vee

Weld Toe Weld zone Weld metal

Fusion zone Weld Junction

Copyright © 2003 TWI Ltd Faisal Yusof

Excess cap height

Copyright © 2003 TWI Ltd Faisal Yusof

9. Cap contour/ weld face

Copyright © 2003 TWI Ltd Faisal Yusof

Vertical leg length

Horizontal leg length

a = Nominal design throat

Mitre fillet Convex fillet

2. Vertical leg length

UK (USA) 1G rotated UK (USA): 1G

UK (USA) 2G Fixed UK (USA): 2G

Overhead Position Vertical Position

Inclined position fixed Inclined position Rotated

Copyright © 2003 TWI Ltd Faisal Yusof

Copyright © 2003 TWI Ltd Faisal Yusof

Copyright © 2003 TWI Ltd Faisal Yusof

Copyright © 2003 TWI Ltd Faisal Yusof

 Duties Before Welding

 Duties During Welding

 Duties After Welding

Copyright © 2003 TWI Ltd Faisal Yusof

Copyright © 2003 TWI Ltd Faisal Yusof