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    RI Defects

    Uploaded by

    Muhammad Zariq
    note ri

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd

    RI Defects

    Uploaded by

    Muhammad Zariq
    170 views49 pages
    note ri

    Copyright

    © © All Rights Reserved

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    PPT, PDF, TXT or read online from Scribd

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    note ri

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    170 views49 pages

    RI Defects

    Uploaded by

    Muhammad Zariq
    note ri

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
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    TECHNOLOGY

    Radiographic Interpretation

    Weld Defects
    Course reference WIS 20
    Copyright 2004 WI Ltd

    M.S.Rogers

    TECHNOLOGY

    Faults in Fusion Welds


    Defects which may be detected by visual inspection
    can be grouped under the following headings
    Lack of fusion
    Cracks
    Solid inclusions

    Mechanical damage

    Surface and profiles

    Parent material damage

    Misalignment (set-up

    Miscellaneous

    irregularities)
    Gas pores and porosity

    Copyright 2004 WI Ltd

    M.S.Rogers

    TECHNOLOGY

    Cracks

    Copyright 2004 WI Ltd

    M.S.Rogers

    TECHNOLOGY

    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

    Copyright 2004 WI Ltd

    M.S.Rogers

    TECHNOLOGY

    Process Cracks
    Hydrogen induced cold cracking
    (HICC)
    Solidification cracking (Hot Tearing)
    Lamellar tearing
    Re heat cracking

    Copyright 2004 WI Ltd

    M.S.Rogers

    TECHNOLOGY

    Cracks

    Longitudinal parent metal crack

    Longitudinal weld metal crack


    Copyright 2004 WI Ltd

    Transverse weld metal crack

    Lamellar tearing
    M.S.Rogers

    TECHNOLOGY

    Transverse crack
    Copyright 2004 WI Ltd

    Longitudinal crack
    M.S.Rogers

    TECHNOLOGY

    Inclusions

    Copyright 2004 WI Ltd

    M.S.Rogers

    TECHNOLOGY

    Gas Cavities
    Gas pore <1.5mm Blow hole.>1.6mm
    Gas pore

    Cluster porosity

    Loss of gas shield


    Damp electrodes
    Contamination

    Blow hole
    Herringbone porosity

    Arc length too large


    Damaged electrode flux
    Moisture on parent material

    Root piping
    Copyright 2004 WI Ltd

    Welding current too low


    M.S.Rogers

    TECHNOLOGY

    Gas Cavities

    Porosity

    Root piping
    Copyright 2004 WI Ltd

    M.S.Rogers

    TECHNOLOGY

    Cluster porosity
    Copyright 2004 WI Ltd

    Herringbone porosity
    M.S.Rogers

    TECHNOLOGY

    Solid Inclusions
    Slag inclusions are defined as a non-metallic inclusion
    caused by some welding process
    Slag originates from welding
    flux

    Slag inclusions

    Lack of sidewall
    fusion with
    associated slag

    Parallel slag lines Lack of interun


    fusion + slag
    Copyright 2004 WI Ltd

    MAG and TIG welding


    process produce silica
    inclusions
    Slag is caused by
    inadequate cleaning
    Other inclusions include
    tungsten and copper
    inclusions from the TIG and
    MAG welding process
    M.S.Rogers

    TECHNOLOGY

    Interpass slag inclusions


    Copyright 2004 WI Ltd

    Elongated slag lines


    M.S.Rogers

    TECHNOLOGY

    Lack of Fusion

    Copyright 2004 WI Ltd

    M.S.Rogers

    TECHNOLOGY

    Lack of Fusion
    Poor welder skill
    Incorrect electrode
    manipulation
    Incomplete filled groove
    + Lack of sidewall fusion

    Arc blow
    Incorrect welding

    1
    2

    1. Lack of sidewall fusion


    2. Lack of inter-run fusion
    Copyright 2004 WI Ltd

    current/voltage
    Incorrect travel speed
    Incorrect inter-run cleaning

    M.S.Rogers

    TECHNOLOGY

    Overlap
    An imperfection at the toe or root of a weld caused by
    metal flowing on to the surface of the parent metal
    without fusing to it
    Contamination
    Slow travel speed
    Incorrect welding technique
    Current too low

    Copyright 2004 WI Ltd

    M.S.Rogers

    TECHNOLOGY

    Overlap

    Toe Overlap
    Butt weld

    Toe Overlap
    Fillet weld

    Copyright 2004 WI Ltd

    M.S.Rogers

    TECHNOLOGY

    Weld Root Defects


    Low Amps/volts
    Large Root face
    Incomplete root fusion

    Small Root Gap


    Fast Travel Speed
    Incorrect Electrode Angle

    Incomplete root penetration

    Copyright 2004 WI Ltd

    Contamination
    Arc blow

    M.S.Rogers

    TECHNOLOGY

    Weld Root Defects

    Lack of root fusion

    Copyright 2004 WI Ltd

    Lack of root Penetration

    M.S.Rogers

    TECHNOLOGY

    Lack of root penetration


    Copyright 2004 WI Ltd

    Lack of root fusion


    M.S.Rogers

    TECHNOLOGY

    Surface & Profile

    Copyright 2004 WI Ltd

    M.S.Rogers

    TECHNOLOGY

    Weld Profile Defects

    Incomplete filled groove


    Poor cap profiles and
    excessive cap reinforcements
    may lead to stress
    concentration points at the
    weld toes and will also
    contribute to overall poor toe
    blend
    Copyright 2004 WI Ltd

    Poor cap profile

    Excessive cap height


    M.S.Rogers

    TECHNOLOGY

    Excess cap reinforcement


    Copyright 2004 WI Ltd

    Incomplete filled groove


    M.S.Rogers

    TECHNOLOGY

    Weld Profile Defects

    Poor stop/starts

    Copyright 2004 WI Ltd

    M.S.Rogers

    TECHNOLOGY

    Miscellaneous Defects

    Copyright 2004 WI Ltd

    M.S.Rogers

    TECHNOLOGY

    Miscellaneous Defects
    Excessive current
    Damp electrodes
    Contamination
    Spatter

    Incorrect wire feed speed


    when welding with the MAG
    welding process
    Arc blow

    Copyright 2004 WI Ltd

    M.S.Rogers

    TECHNOLOGY

    Miscellaneous Defects
    Accidental striking of the arc
    onto the parent material
    Faulty electrode holder
    Poor cable insulation
    Poor return lead clamping

    Arc strike
    Copyright 2004 WI Ltd

    M.S.Rogers

    TECHNOLOGY

    Cap & Root Undercut


    An irregular groove at the toe of a weld run in the
    parent metal
    Excessive amps/volts
    Excessive travel speed
    Incorrect electrode angle
    Excessive weaving
    Incorrect welding technique
    Electrode too large

    Copyright 2004 WI Ltd

    M.S.Rogers

    TECHNOLOGY

    Cap Undercut

    Intermittent Cap Undercut


    Copyright 2004 WI Ltd

    M.S.Rogers

    TECHNOLOGY

    Root undercut
    Copyright2003
    2004TWI
    WI Ltd
    Copyright
    Ltd

    Cap undercut
    M.S.Rogers
    M.S.Rogers

    TECHNOLOGY

    Weld Root Defect


    A shallow groove caused by contraction in the weld
    metal along each side of the penetration bead
    Insufficient weld metal
    deposited in the root pass
    Too fast a cooling rate during
    the application of the root
    bead pass
    Shrinkage groove

    Copyright 2004 WI Ltd

    Poor welding technique

    M.S.Rogers

    TECHNOLOGY

    Weld Root Defect


    A shallow groove, which may occur in the root of a butt weld
    Root faces too large
    Root gap too large
    Excessive back purge pressure
    during TIG welding
    Concave root

    Copyright 2004 WI Ltd

    Excessive root bead grinding


    before the application of the
    second pass

    M.S.Rogers

    TECHNOLOGY

    Weld Root Defect

    Concave Root

    Copyright 2004 WI Ltd

    M.S.Rogers

    TECHNOLOGY

    Weld Root Defect


    Root penetration bead in excess in accordance with the
    relevant specification being used
    Root faces too small
    Root gap too large
    Excessive amps/volts
    Excessive root penetration

    Copyright 2004 WI Ltd

    Slow travel speed

    M.S.Rogers

    TECHNOLOGY

    Weld Root Defect

    Excessive root
    penetration
    Copyright 2004 WI Ltd

    M.S.Rogers

    TECHNOLOGY

    Concave root
    Copyright2003
    2004TWI
    WI Ltd
    Copyright
    Ltd

    Excess root penetration


    M.S.Rogers
    M.S.Rogers

    TECHNOLOGY

    Weld Root Defect


    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
    Burn through

    Copyright 2004 WI Ltd

    Slow Travel Speed

    M.S.Rogers

    TECHNOLOGY

    Weld Root Defect

    Burn
    Through

    Copyright 2004 WI Ltd

    Burn through

    M.S.Rogers

    TECHNOLOGY

    Oxidized Root (Root Coking)


    Loss or insufficient back
    purging gas
    Most commonly occurs
    when welding stainless
    steels
    Purging gases include
    argon, helium and
    occasionally nitrogen

    Copyright 2004 WI Ltd

    M.S.Rogers

    TECHNOLOGY

    Crater Pipe

    Weld crater

    Crater pipe

    Copyright 2004 WI Ltd

    M.S.Rogers

    TECHNOLOGY

    Crater Pipe
    Crater pipe is a shrinkage defect and not a gas defect, it
    has the appearance of a gas pore in the weld crater

    Crater cracks
    (Star cracks)

    Too fast a cooling rate


    Deoxidization
    reactions and liquid to
    solid volume change

    Crater pipe

    Copyright 2004 WI Ltd

    Contamination

    M.S.Rogers

    TECHNOLOGY

    Mechanical Damage

    Copyright 2004 WI Ltd

    M.S.Rogers

    TECHNOLOGY

    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
    Copyright 2004 WI Ltd

    M.S.Rogers

    TECHNOLOGY

    Set-up Irregularities

    Copyright 2004 WI Ltd

    M.S.Rogers

    TECHNOLOGY

    Unequal Leg Lengths


    A variation of leg lengths on a fillet weld

    Note: Unequal leg lengths on a fillet weld may be specified


    as part of the design, in which case it will not be
    considered as a defect.
    Copyright 2004 WI Ltd

    M.S.Rogers

    TECHNOLOGY

    Set-up Irregularities
    Linear misalignment is
    measured from the lowest
    plate to the highest point.
    Plate/pipe Linear Misalignment
    (Hi-Lo)

    Angular misalignment is
    measured in degrees
    Angular Misalignment
    Copyright 2004 WI Ltd

    M.S.Rogers

    TECHNOLOGY

    Set-up Irregularities

    Linear Misalignment
    Copyright 2004 WI Ltd

    M.S.Rogers

    TECHNOLOGY

    Set-up Irregularities

    Linear Misalignment

    Copyright 2004 WI Ltd

    M.S.Rogers

    TECHNOLOGY

    Any Questions

    ?
    Copyright 2004 WI Ltd

    M.S.Rogers

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