VOL 15-AWS Inspection Trends_2012_01

Phased Array UT

Destructive Testing

CWI Ethics

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January 2012 / Vol. 15 / No. 1

THE MAGAZINE FOR MATERIALS INSPECTION AND TESTING PERSONNEL

Cover 2 Jan 2012_IT Spring 4/06 12/27/11 12:23 PM Page C1

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This second generation OmniScan flaw detector increases testing efficiencies, ensuring superior manual and advanced AUT application performance with faster setups, test cycles, and reporting, in addition to universal compatibility with all phased array modules.

The OmniScan MX2 offers a high acquisition rate and new powerful software features—in a portable, modular instrument—to efficiently perform manual and automated inspections.

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Vol. 15 / No. 1

Features

20

Using Phased Array Ultrasonics for Detecting and Sizing Cracks inWeldsby Michael Moles / The latest phased array technology and how it can beused for detecting and sizing cracks is explained / 14

Destructive Testing Basicsby J. R. Coulstring III / Details are provided on the types of destructivetests and how they are used for welder performance qualification / 20

Ethics Alert: Certified vs. Qualifiedby Joseph P. Kane / The article stresses the importance of the proper use ofterminology / 24

DepartmentsEditor’s Note................................6

News Bulletins .............................8

Print and Product Showcase ......12

The Answer Is ............................26

Mark Your Calendar...................29

Certification Schedule................30

Just the Facts ..............................31

Mail Bag ....................................33

Technology Notes ......................34

Advertiser Index ........................36

Inspection Trends / Winter 2012 5

INSPECTION TRENDS (ISSN 1523-7168) ispublished quarterly by the American WeldingSociety. Editorial and advertising offices are locatedat 550 NW LeJeune Rd., Miami, FL 33126;telephone (305) 443-9353. Printed by R. R.Donnelley & Sons Co., Senatobia, Miss.Subscriptions $30.00 per year for noncertified,nonmembers in the United States and itspossessions; $50.00 per year in foreign countries;$20.00 per year for noncertified members andstudents; $10.00 single issue for nonmembers and$7.00 single issue for members. American WeldingSociety is located at 550 NW LeJeune Rd., Miami,FL 33126-5671; telephone (305) 443-9353.Periodicals postage paid in Miami, Fla., andadditional mailing offices.

POSTMASTER: Send address changes to Inspection Trends c/o American Welding Society,550 NW LeJeune Rd., Miami, FL 33126-5671.

Readers of Inspection Trends may make copies ofarticles for personal, archival, educational, or research purposes, and which are not for sale or resale. Permission is granted to quote from articles,provided customary acknowledgment of authors and sources is made. Starred (*) items excluded fromcopyright.

AWS MISSION STATEMENTThe mission of the American Welding Society is to advance the science, technology, and application of welding and allied processesworldwide, including joining, brazing, soldering,cutting, and thermal spraying.

An OmniScan MX is used to performmanual phased array inspection oflarge-diameter pipe welds. (Photocourtesy of Olympus NDT, Waltham,Mass.)

TOC Layout January 2012_Layout 1 12/22/11 10:58 AM Page 5

Editor’s NoteBy Mary Ruth Johnsen

Dear Readers,

The heart of the AmericanWelding Society is its volunteers.That holds true throughout everysegment of the Society, whetherwe’re talking about the people whoaccept leadership roles in their localSections; the industry experts whoshape AWS standards andspecifications by taking positions on

the technical committees; or the long-time members who guide AWS bybecoming part of the organization’s national leadership.

Inspection Trends is no exception: Volunteers have influenced thismagazine and supplied content for it since its very first issue.

In fact, Inspection Trends has been blessed by the constancy of itsvolunteers. AWS published the inaugural issue of Inspection Trends insummer 1998, and Ken Erickson began answering questions for TheAnswer Is column that same issue. This issue starts his fifteenth year asa regular part of this magazine. Both he and Kip Mankenberg, whojoined Ken as part of The Answer Is team with the Winter 2000 issue,also provided articles for that first issue.

Lyndsey Deckard became an every issue contributor beginning withthe Fall 2001 Inspection Trends. Lyndsey first wrote the Exam Bankcolumn then took over Just the Facts in Spring 2004.

With this issue, you’ll see a change in The Answer Is. Because of aheavy work load, Kip Mankenberg recently informed me he can’tcontinue working on the column. However, he recommended Al Moorefor the job, and fortunately Al accepted. Al has written quite a fewfeature articles for the magazine over the past couple of years, so youprobably already recognize the depth of his knowledge.

In this issue, we’re also starting a new series related to the ethics ofbeing a CWI written by Joe Kane in collaboration with other membersof the Subcommittee on the Code of Ethics. Kane, a long-time memberof and now an advisor to the AWS Certification Committee, hascontributed other articles to Inspection Trends over the years.

Their work on this magazine isn’t the only contribution thesegentlemen make to the American Welding Society. Like Kane, most aremembers are other committees, are officers of their local Sections, orboth. So why do they commit all this time to the magazine and AWS,when they have full schedules already? Well, it sure isn’t for the pay —they don’t receive any. It’s not for the “fame” — we don’t even run theirphotos in the magazine. And it’s not because I’m their buddy — I’vemet Kip, Lyndsey, Al, and Joe in person, but Ken and I know each otheronly through e-mail. They seem to have purely altruistic intentions:They take pride in their profession and want to help others who do whatthey do be the best they can be at it.

I know this magazine and its readers have benefited from theirknowledge, experience, and willingness to share. I thank them for theirtime and loyalty to AWS; they make my job much easier.

If you’d like to join their ranks, please contact me [email protected] or (800) 443-9353, ext. 238.

PublisherAndrew [email protected]

EditorMary Ruth [email protected]

Associate EditorsHoward [email protected]

Kristin [email protected]

Production EditorZaida [email protected]

Senior Production CoordinatorBrenda [email protected]

National Sales DirectorRob [email protected]

Advertising Sales RepresentativeLea [email protected]

Senior Advertising Production ManagerFrank [email protected]

Subscriptions RepresentativeSylvia [email protected]

American Welding Society550 NW LeJeune Rd.Miami, FL 33126(800/305) 443-9353

Copyright

Copyright © 2012 by American Welding Society in bothprinted and electronic formats. The Society is not responsible for any statement made or opinion expressedherein. Data and information developed by the authors ofspecific articles are for informational purposes only andare not intended for use without independent, substantiating investigation on the part of potential users.

Inspection Trends / January 20126

Editor's Note IT Winter 2012_Layout 1 12/22/11 10:22 AM Page 6

June 12–13, 2012 / San Diego, Calif.

Register early and save. Earn PDHs toward your AWS recertification when you attend the conference.

For the latest conference information and registration, visit our web site at www.aws.org/conferences or call (800) 443-9353, ext. 264.

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WS recertification when you attend the conferenceAEarn PDHs toward your


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energy conf_FP_TEMP 12/20/11 3:25 PM Page 7

News Bulletins


Laser, Video, and Ultrasonic TechnologyCombined to Inspect Pipe Root Welds

A combination of laser, video, and ultrasonic inspectionmethods were recently used in a production environment toinspect the profile of root welds on pipes. The inspectionswere performed by UK-based Optical Metrology ServicesLtd. (OMS). The company believes this was the first timethese methods have been used in combination in the oil andgas industry.

The company was responsible for assessing the internalroot welds for any defects. Inspection requirements coveredthe full range of weld features including crown height,undercut, porosity, and melt-through. The on-site inspectorswere required to perform the inspection at weld temperatures(i.e., up to 482°F). The company adapted its own weldinspection technology to enable it to operate at those elevatedtemperatures. Cold, compressed air was blown over theinspection tool to combat the welding temperatures. A videocamera was then used in combination with a shaft encoder tofurther inspect areas for potential weld defects.

AWS agreement with ASNT offers ACCP toqualified CWIs & SCWIs.

Do you need visual testing certification which meets the guidelines for Recommended Practice No. SNT-TC-1A as required by somesections of the ASME Code? Through this agreement, qualified SCWIs and CWIs can obtain ACCP Level II VT certification without examination.

Enhance your credentials and satisfy work requirements with the addition of an ACCP credential.

To apply and for more details visitwww.asnt.org or call 614.274.6003 or 800.222.2768 US/Canada.

Opportunity Knocks.

Image © Longview Inspection

Optical Metrology Services designed a laser-basedmeasurement system that incorporated a slide rail, steppermotor, and optical laser sensor to inspect pipe root welds.This allowed the tool to be pushed in half-millimeter stepsthrough the pipes to inspect the profiles of the welds.

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News Bulletins Winter IT 2012_Layout 1 12/22/11 10:37 AM Page 8

“On this project, the pipes on the modular valvemanifold system were almost entirely lined with a specialcorrosion-resistant material,” explained Richard Gooch,OMS director of technology. “Our team of three inspectors,therefore, had to make sure they didn’t overheat thesecoatings while carrying out inspections. On average, it wastaking the customer around four days to complete a weld rootpass. If there were flaws in a weld, they would have to berepaired or cut out. Our inspections carried out theirinspections immediately after the hot pass.”

The initial inspection took about 10 min to complete. Atthat time, the company gave its initial verdict on whether itthought there was a problem with the root weld. “If we wereuncertain, the laser inspection procedure was repeated, butthis time at finer detail (every 0.5 mm) than before anddouble-checked using video-based inspection technology.The depth of the weld feature could then be examined moreclosely and a final verdict reached,” Gooch said.

Starna Scientific Appoints Director

Starna Scientific, a manufacturer of spectroscopyequipment, recently appointed Nathan Hulme as a director tohelp guide the company’s expansion plans.

Hulme’s main responsibilities will include assisting insetting out an overall business strategy for the company that

will address communications with customers and dealers aswell as involving leadership of the sales team.

Stork Materials Technology Changes Name to Element

Stork Materials Technology recently changed its name toElement Materials Technology. The company will specialize


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in materials testing, product qualification testing, and failureanalysis for the aerospace and defense, oil and gas, powergeneration, and transportation sectors. In this final stepventuring away from the Stork Group, Element becomes anindependent materials technology company in its own rightwith more than 180 years of experience.

Element has a team of 1000 scientists, engineers, andtechnicians working in laboratories located throughout theUnited States and Europe. More information is available atwww.element.com.

Strategic Alliance Formed for Work at Fossil-Fueled Power Plants

Structural Integrity Associates, Inc., San Jose, Calif., aleader in inspection and assessment of critical components inthe power generation industry, recently signed amemorandum of understanding with Wachs Energy ServicesCo., a construction and technical services company,establishing a strategic alliance between the two companies.The alliance address the remediation and repair of damagedcritical pressure parts and the fabrication and installation ofnew pressure part systems in conventional fossil-fired andcombined-cycle power plants.

“In partnership with WES, we can now provide turnkey,optimized solutions, including full-field implementation for

the emergency repair or replacement of any componentsdetermined to be unfit for continued operation as well as thedesign, fabrication, and erection of critical systems with aparticular emphasis on the new advanced creep strengthenhanced ferritic steels, e.g., P91,” said Laney Bisbee, CEOof Structural Integrity Associates.

The two companies have provided critical componentrepair and systems fabrication to many fossil plantsworldwide.

GE to Expand Inspection TechnologiesHeadquarters

GE recently announced it will invest more than $10million to expand its Inspection Technologies headquarterssite in Lewistown, Pa. Key features of the project include anew global customer applications center and a nondestructivetesting academy for GE employees and customers.

The 52,000-sq-ft expansion project will increase thefacility’s floor space by more than 63% and is scheduled tobe completed this year. The company manufactures a widerange of remote visual inspection, ultrasonic,electromagnetic, advanced radiography, and computedtomography systems, as well as data management software.GE’s Inspection Technologies’ business sees composites;weld inspections and corrosion monitoring for bridges,


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pipelines, and other structures; and rotating machineryincluding jet engines and wheels as key growth areas.

Online Visual Inspection Course Available

Hobart Institute of Welding Technology, Troy, Ohio, hasintroduced an online visual inspection course. The courseprovides 1.4 continuing education credits and costs $195.

Topics covered include temperature indicators;equipment requirements; terminology of weld defects;general requirements for workmanship standards; makingrepair welds; codes, procedures, and qualifications related tovisual inspection; and a visual inspection checklist.

Information is available at www.welding.org.

Extech Instruments Moves to New Hampshire

Extech Instruments/FLIR Systems recently moved to anew headquarters building in Nashua, N.H. The opening ofthe new facility signifies a milestone in Extech and Flir’stransition toward a unified organization.

The companies manufacture thermal imagers and avariety of hand-held test and measurement instruments.

The new headquarters is located at 9 Townsend W.,Nashua, NH 03063-1233.

AcousticEye Appoints New CEO

AcousticEye, Leusden, The Netherlands, recentlyappointed Yoav Harel as chief executive officer. Thecompany produces equipment for noninvasive tubeinspection for the global heat exchanger industry.

Harel has more than 20 years’ experience leading bothstartups and established companies. In his most recentposition, Harel was president for Europe and North Americaat Orbotech.

TÜV Rheinland Opens NDE ServicesLaboratory in Alabama

In an effort to expand its presence in the southern UnitedStates, TÜV Rheinland Industrial Solutions, Inc., a subsidiaryof TÜV Rheinland North America Holding, Inc., recentlycommisioned a new nondestructive examination laboratory inDecatur, Ala. The new 8000-sq-ft facility will be equippedwith a variety of NDE equipment including computedradiography and ultrasonics. Initially, seven people will staffthe facility, with employment expected to double or triplewithin the first few years.


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Print and Product Showcase


TOFD System Offers EasyOperation

The company’s portable time-of-flight diffraction (TOFD) inspectionsystem offers high probability ofdetection, touch-screen operation,automatic data file saving, easilyadjustable probe center separation, anddisplays results in multiple languages.One person can operate this hand-heldmagnetic wheel scanner. The unit issensitive enough that an externalpreamplifier is not needed.

MISTRAS(609) 716-4000www.mistrasgroup.com

Computed RadiographySystem Combines HighResolution with Portability

The CRx25P computedradiography system features anupgraded plate transport system thatoptimizes plate handling, and acceptsflexible phosphor imaging plates up to35 cm wide and of virtually any length.The unit weighs 46 lb and can be easilycarried to the job site. The system canoperate at standard scan resolutions of50 or 100 microns, where it isparticularly suitable for corrosion/

erosion inspection. It can also beoperated at scan resolutions of 17 and25 microns, making it qualified forweld inspections in compliance withinternational standards. It can be usedwith the company’s Rhythm softwareand its Flash!Filters to allow instantimage enhancement and faster defectdetection. A battery-powered versionenables autonomous operation inspecial environments. Optionalaccessories include a transport case,drum extensions, and imaging plateguides.

GE Energy, Measurement & ControlSolutions(866) 243-2638www.ge-mcs.com

XRF Analyzer Features LargeTouch-Screen Display

The X-MET7000 hand-held XRFanalyzer works faster and is smallerand lighter than the company’sprevious models. The new design wasbased on extensive customer researchand offers an improved, easy-to-readgraphical user interface. It offers abright, high-contrast 4.3-in. Blanview®transmissive LCD touchscreen foroptimal outdoor viewing even in bright

sunlight; a result screen that is easilycustomized to show only the elementsthe user needs; and a history view thatallows easy browsing of old results andspectra. The user interface is availablein 13 languages.

Oxford Instruments(800) 447-4717www.oxford-instruments.com/x-met7000

Rechargeable Hand-Held LEDOffers Five Operating Modes

The EXP-LED-RL-FX5Rexplosion-proof, rechargeable LEDhand-held light produces 135 lumensof bright light and offers five operatingmodes that the user can cycle throughby simply activating the trigger. Themain light head is adjustable, allowingthe operator to set the light down andadjust the head as needed for closework or inspection activities. Its lanternhas a 12-h run time on a single chargeof its integral 6-VDC nickel metalhydride batteries, and will accept up to500 charge cycles before batteryperformance degrades. The light isimpact, vibration, and water resistant,and has no exposed metal or contacts,making it useful for heavy-duty use inindustrial work environments.

Larson Electronics(800) 369-6671www.magnalight.com

Print & Product IT Winter 2012_Layout 1 12/22/11 1:05 PM Page 12


Publications AddressConstruction Industry Hazards

Construction Focus 4: InstructorGuide and Student Handbook addressthe top four construction industryhazards and make it easy for safetytrainers to provide their trainees withinformation on these topics. Thetraining materials are divided into foursections: Fall Hazards; Caught-In or –Between Hazards; Struck-ByHazards; and Electrocution Hazards.

MANCOMM(800) 626-2666www.mancomm.com

Laser Module Captures PipeGeometry Using Crawler-Mounted Hardware

The WinCan™ laser module cancapture pipeline geometry using avideo inspection crawler outfitted withpractically any laser profiling

hardware. The module is an add-onmode for WinCan V8 pipe inspectionand asset management software. Themodule works in three modes,depending on the laser hardware used.In parallel laser mode, the camerahead’s twin laser dots are orientedperpendicular to the pipe wall and thenrotated 360 deg. The laser moduleanalyzes video from the crawler todetermine pipe diameter anddeformation at that single location;additional tools allow defectmeasurement using parallel lasers. Inring mode, the module analyzes video

from the crawler, extracting the laserring pattern. Trending the diameter anddeformation of this ring frame byframe yields data that can be convertedinto a solid model, ovality graph, orcolor plot. In scanning mode, themodule analyzes the laser dot patterncast by any properly equipped side-scan camera, interpolating a ring todetermine diameter and deformation.As in ring frame, these measurementscan be trended frame by frame.

Pipeline Analytics(877) 626-8386www.pipelineanalytics.com

Industrial Tech Guide AppIntroduced

The company recently introducedthe Industrial Tech Guide App for theiPhone® and iPad®. This free mobileapplication contains two knowledge-based sections designed for technicians

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— continued on page 35

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FeatureBy Michael Moles


Due to a number of technologicaladvantages, phased arrays arebecoming the inspection method ofchoice for welds, including for workdone under the requirements of AWSD1.1, Structural Welding Code —Steel. This article describes the currentAWS approach for detecting and sizingcracks — often the critical factor inwelding of infrastructure — and somefurther developments. Crack detectionis well established and generally good;sizing is more problematic. Advancedsizing developments are typicallybeyond the D1.1 inspectionrequirements, and may be beyond thoseof any code, but are listed here as theyare technically available.

Why Cracking Is So Important

Cracks are often the life-limitingfactor in structures, be it a bridge,amusement park ride, ship, or othercomponent. (The other major life-limiting factor is corrosion.)Unfortunately, failures due to cracking

are typically expensive, and may leadto loss of life, forced outages, majordowntimes, problems with replacementparts, environmental releases, etc. Thekey issue with cracks is detection,followed by sizing. Fortunately,detection of cracks is not a major issue,but sizing is, and most of this articlediscusses sizing approaches.Unfortunately, none of the major codes[AWS (Ref. 1), ASME (Ref. 2), API(Ref. 3), and ASTM (Ref. 4)] reallypromotes sizing, though all have well-established detection approaches.

Phased Arrays

Phased arrays use a series of smallelements, which are pulsed with acalculated time delay to allow“phasing.” Phasing allows constructiveand destructive interference ofwaveforms, to build a coherent beamthat can replicate conventionalultrasonic probes. Figure 1 shows anexample of a linear array used for weldinspections. Linear arrays permit

scanning, sweeping, and focusing inthe horizontal axis (as illustrated in thefigure). Linear arrays tend to beextensively used because they cost less,require significantly lessinstrumentation, and are easier toprogram.

The key concept in phased arraysis that phasing does not change thephysics of ultrasound. Phased arraysare merely a method of generating andreceiving a signal (and also displayingimages). Consequently, if you obtain XdB off a reflector using conventionalUT, you should obtain the same signalamplitude using phased arrays. Resultsfrom the field show this is commonlythe case, given the usual variationswith ultrasonics (Ref. 5).

Basic Phased Array Scans

From a practical viewpoint, phasedarrays can generate two basic scans: E-scans (electronic scans at fixed angles)and S-scans (swept angle scans). AWSD1.1 only supports E-scans at this time

Using Phased Array Ultrasonics for Detecting and Sizing Cracksin Welds

The current AWS approach for detecting and sizing cracks, as well as newer phased arraytechnology, are detailed

Fig. 1 — Linear array for weldinspections.

Fig. 2 — Illustrations of E-scans at left, S-scans in middle plus dynamic depthfocusing.

Moles Feature IT Winter 2012_Layout 1 12/21/11 11:25 AM Page 14


(Ref. 1) due to its Indication Rating(IR) approach. The two scans areillustrated in Fig. 2, along withdynamic depth focusing.

Manual vs. Encoded Scans

To further complicate scanpatterns, there are two basicapproaches to scanning: manual andencoded. Manual phased arrayinspections are compatible with AWSD1.1, using special probes andcalibrations to cover the 45-, 60-, and70-deg angles. For manual inspections,an S-scan is normally used, withcalibration on these three angles forAWS indication ratings.

However, encoded linear AWSscans have not yet been accepted inD1.1, even using E-scans. E-scans aresimilar to conventional ultrasonics inthat the inspection angle doesn’tchange. Figure 3 gives an example ofan encoded linear scan on a weld.These encoded inspections wouldemulate AWS D1.1 inspections, and bemuch faster (and more economical)than raster scanning for a high-volumeweld profile. They would require aspecified raster and step size, andwould need to cover weld, heat-affected zone, and any position errors.This would require a significantamount of electronic scanning, thoughit would still be much faster thanconventional ultrasonics.

Imaging

Imaging is another advantage of

phased arrays: S-scans in particularoffer good imaging, and permit theaccurate location and characterizing ofdefects, as shown in Fig. 4.

Phased arrays have been welldescribed in a number of books (Refs.6, 7), and are not described in moredetail in this article.

Inspection Requirements inAWS D1.1

Compared with other codes suchas ASME and API, the AWS Code isprescriptive (Ref. 1). It specifiesexactly what probe frequency (2.25MHz) and size (square or rectangular,5⁄8 in. or greater) should be used. Defectdispensation is by a specific AWStechnique, requiring measurement ofthe indication level “a,” reference level“b,” and attenuation factor “c” (2dB/in.). This gives a calculation of theIndication Rating:a – b – c = d = Indication Rating

The IR values are based more onempirical studies than on physics. Forexample, modern steels tend to havelower attenuation as they are cleaner,so the IR values can overstate defectseverity. Hence, defect detection isgood. In addition, AWS has severaldifferent defect categories, so the Codeis more accommodating than suchsimplistic evaluations may seem.

Not surprisingly, manufacturershave developed manual phased arrayprobes to fulfil the AWS D1.1 Coderequirements. These can generate 45-,60-, and 70-deg beams from the same

wedge (Fig. 5), and can be used to scanall three angles simultaneously. This

Fig. 3 — Illustration of encoded scan.

Fig. 5 — Drawings of the OlympusNDT array for AWS D1.1.

Fig. 4 — S-scan showing defect locations. Note that thesetwo defects are not related.



speeds up scanning by a factor of up tothree, as well as providing goodimaging.

Calibration is relativelystraightforward: For example, the IIWMark 2 calibration block side-drilledhole is used to calibrate 45, 60, and 70deg, and scans are displayed in thethree A-scans and one S-scan display— Fig. 6.

Olympus NDT has developedsoftware to display any defects usingRayTracing™ software, as shown inFig. 7.

These developments effectivelypush the AWS D1.1 Code to its limitsfor manual inspections, though thesescreen displays can be printed. As thereis no encoder, and hence recorded data,

it is not really possible to save the datafor posterity and subsequent auditing.

Alternative Sizing Techniques

As material requirements increase,the demands on AWS to apply moreadvanced sizing techniques will alsolikely increase. For example, pipelinemanufacturers are planning on usingX100 material, which puts significantlymore emphasis on defect detection andsizing.

Amplitude Drop

Sizing techniques based on“amplitude drop” approaches havebeen available for years. The beam is

scanned over the defect and mapped;the operator can use –3, –6, and –20 dBdrops, but the results show thataccurately sizing defects variesconsiderably with the defect itself, thedefect orientation, the operator, and soon. Figure 8 shows an example ofsizing from a UK trial. Overall, theresults are not particularlyencouraging.

Zone Discrimination

This approach is specifically forpipeline automated ultrasonic testing(AUT), where “speed, speed, speed”for detection and sizing is critical (Ref.9). The technique uses well-focusedbeams and tailored inspections, with an

Fig. 6 — Display of calibrated scan with 45-, 60-,and 70-deg beams.

Fig. 7 — Display with A-, S-, and R-scans to showdefect location in the weld.

Fig. 8 — Plot of defect sizing using multiple teamsand techniques (Ref. 8).

Fig. 9 — Sample pipeline zone discrimination plot, showingdefects and geometry in red.



automated scanner. As with the AWSIndication Rating approach, detectionis not a major issue, thoughcharacterization can be. Sizing istypically to ± 1–1.5 mm (on a goodscan), and the defect sizes are used forEngineering Critical Assessmentcalculations. A sample plot is shown inFig. 9.

Diffraction Approaches — Time-of-Flight Diffraction

Time-of-flight diffraction (TOFD)was developed by UKAEA Harwell,but is now widely used and much morecost effective than many other AUTapproaches (Ref. 8). It had a majorimpact from 1980s PISC II round-robintrials. TOFD uses diffracted tip signalsto accurately size, as well as detect,cracks — Fig. 10. The original use wasfor raster scanning in the nuclear

industry, but since the 1990s, TOFDhas become widely used inpetrochemical and some otherindustries using linear scanning.

TOFD offers good midwall defectdetection, accurate sizing of defectsusing the times of arrival of diffractedsignals (to around ±1 mm), defectdetection even if defects are mis-oriented or located away from the weldcenterline, and rapid linear scanning. Inaddition, TOFD offers nonamplitudescanning and detection, and setupindependent of weld configuration.

While TOFD sounds like the“ideal” NDE technique, it does havelimitations. It has a dead zone at thetop surface (OD), a dead zone at thebottom surface (ID), and is limited tosizing defects of >~3 mm. In addition,analysis can be difficult, and TOFD issensitive to very small defects with arisk of false calls. Some sizing errors

are possible from lateral positioning ofdefects. Also, TOFD has a low signal-to-noise ratio, so doesn’t work well onaustenitic steels. Figure 11 shows atypical TOFD display.

Tip Back Diffraction

Tip back diffraction is analternative approach to TOFD, but hasbeen around longer (Ref. 10). Theconcept is simpler than TOFD, and isshown in Fig. 12 (Ref. 11).

The back diffraction approachworks well, even with manual phasedarrays (Ref. 12), as shown in Fig. 13.In Fig. 13, the defect tip is clearlyvisible, though this is not always thecase.

Under good conditions, backdiffraction offers excellent sizing, asshown in Fig. 14. Back diffraction cansize to similar accuracies to TOFD, but

Fig. 11 — Typical TOFD display, showing labeled defects.Fig. 10 — The TOFD technique.

Fig. 12 — Schematic showing tip diffraction A-scan (left)and concept (right).

Fig. 13 — Back diffraction S-scan with defect tip arrowed.



can also size smaller defects. Ingeneral, these errors are ~1 mm,though careful practices have reducedthe error to ~0.5 mm.

Technical Limitations

Unfortunately, ultrasonics is not alaser beam — the beams have finite

width and a finite frequency spectrum.For sizing, the major limiting accuracy isprobably data analysis. However, themajority of defect detection and sizing inindustry is still practiced by very simpleapproaches, e.g., the AWS IndicationRating approach. Newer techniques,particularly back diffraction usingphased arrays, are relatively low costand easy to apply. However, they alsorequire operator skill and training.

Conclusions

1. The AWS D1.1 Code can be —and has been — fulfilled by manualphased arrays.

2. Detection is generallystraightforward, as shown by AWS’slong history of defect detection.

3. Sizing is more limited underAWS D1.1, as it is under all othercodes.

4. Alternative sizing techniques,e.g., amplitude drop, TOFD, and backdiffraction are available, but not reallycodified yet.

5. Sizing works better withdiffraction, but requires a good, well-trained operator.

References

1. AWS D1.1/D1.1M: 2010,Structural Welding Code — Steel.Miami, Fla.: American Welding Society.

2. ASME Boiler and PressureVessel Code, 2010, Section V Article 4.

New York, N.Y.: American Society ofMechanical Engineers.

3. See, for example, API 570,Piping Inspection Code — Inspection,Repair, Alteration, and Rerating of In-Service Piping Systems. Aug. 2003.Washington, D.C.: AmericanPetroleum Institute.

4. ASTM 2192, Standard Guidefor Planar Flaw Height Sizing UsingUltrasonics. 2008. WestConshohocken, Pa.: American Societyfor Testing and Materials.

5. Sjerve, E. M., Stewart, D. C.,and Bryant, G. F. 2000. Comparison ofmulti-probe and phased array girthweld inspection systems. Proceedingsof International Pipeline Conference,Calgary, Alb., Canada, Oct. 1–5.

6. Introduction to Phased ArrayUltrasonic Technology Applications —Olympus NDT Guideline. Aug. 2004.Waltham, Mass.: Olympus NDT,www.olympus-ims.com.

7. Phased Array Testing — BasicTheory for Industrial Applications.Nov. 2010. Waltham, Mass.: OlympusNDT, www.olympus-ims.com.

8. Charlesworth, J. P., and Temple,J. A. G. 1989. Ultrasonic Time ofFlight Diffraction. Research StudiesPress.

9. Ginzel, E. A. Feb. 2006.Automated Ultrasonic Testing forPipeline Girth Welds. Waltham, Mass.:Olympus NDT.

10. Harumi, K. 1989. Japanese TipEcho Handbook, first edition.

11. Jacques, F., Moreau, F., andGinzel, E. 2003. Ultrasonic backdiffraction sizing using phased array —Developments in tip diffraction flawsizing. Insight, Vol. 45, No. 11.

12. Davis, J. M., and Moles, M.2006. Resolving capabilities of phasedarray sectorial scans (S-scans) ondiffracted tip signals. Insight, Vol. 48,No. 4, p. 1.

Fig. 14 — Back diffraction sizing of cracks in OPG headers. (Chart courtesy ofOPG.)

MICHAEL MOLES([email protected]) issenior technology manager, Olympus

NDT, Waltham, Mass.

T R E N D S


welding fundamentals_FP_TEMP 12/21/11 12:45 PM Page 19

FeatureBy J. R. Coulstring III

Destructive weld testingencompasses many different types oftests to provide information onanything from the toughness of awelded joint to its ultimate tensilestrength. When performing weldingprocedure qualification testing, youwill encounter these varied testmethods depending on the particular

application of the welded joint. Themost common testing, however, wouldbe those methods used to determine awelder’s proficiency with a particularwelding process; in other words,welder performance qualificationtesting.

Anyone involved with welderqualification, whether as a testing

agency, a welding consultant, or aquality control person, is familiar withthe following request: “I need tobecome a certified welder.”

In responding to that question, thefirst thing that would need to be askedof the person would be “What code doyou need to qualify in accordancewith?” There are codes that need to be

Destructive Testing Basics

The fundamentals of destructive testing for welder qualification are outlined

Fig. 1 — An AWS D1.1 unlimited testassembly ready for cutting in theabrasive saw.

Coulstring Feature IT Winter 2012_Layout 1 12/22/11 8:35 AM Page 20


followed based on the particularindustry, the organization, or perhapseven the geographic location. The twocodes most people are familiar with areAWS D1.1, Structural Welding Code— Steel, and ASME Boiler andPressure Vessel Code, Section IX.These codes share many similaritieswhen it comes to the destructive testingportion of welder qualification. For thisarticle, any particular requirements arein accordance with AWS D1.1.

While the following does notpertain specifically to destructivetesting, it is worth mentioning. Oncethe governing code is determined, youare going to need a Welding ProcedureSpecification (WPS) to follow. It maybe a prequalified WPS, a WPS that hasbeen qualified by testing, or one that isfound in the AWS B2.1-X-XXX series.The WPS will provide the welder withall pertinent information he or sheneeds to perform the qualification test.The WPS will include information suchas the welding process, joint design,base and filler metals, preheat/interpasstemperature, and the electrical andtravel speed ranges.

Now the welder has theinformation he or she needs to begintesting. The actual preparation for andperformance of the weld test would betopics worthy of another article, buttoday we will fast forward todestructive testing.

Visual Examination

Imagine that you have a weldedassembly ready for testing. It is nowtime for the first step, a visualexamination (so much for jumping tothe cutting and the bending). Many ofthe weld defects that can be observedin the visual examination will lead tosubsequent failures in the destructivetesting.

A particular defect that is seenconsistently is underfill on the face ofthe weld. Underfill is when the weld isnot filled to at least the top surface ofthe base metal. While excessivereinforcement (not to exceed 1⁄8 in.) isalso undesirable, many people couldavoid a visual failure if they just filledup the joint. Likewise, the root is ofequal importance. If you are welding

from one side without backing you donot want excessive concavity or melt-through. If you are welding withbacking, and you can pull the backeroff with pliers or it falls off, you arecertainly having some issues with theroot pass.

Undercut and cracking are alsotypical problems to look out for. D1.1has a thorough section on visualexamination criteria, complete withweld profile examples that addressundercut and cracking morethoroughly.

Specimen Removal

After a successful visualexamination, it is time to remove the

destructive testing specimens. Thereare particular tests associated withvarious types of weld tests to beperformed. These include bend (face,root, or side), macro etch, and filletweld break tests. The figures and tablesin the code will direct you on thequantity and type of specimens, thelocation for removal, and the requireddimensions. Removal of the specimensis often accomplished with bandsawing, thermal, waterjet, or abrasivecutting. Keep in mind if you usethermal cutting for side bend specimenremoval, allow for at least 1⁄8 in. on eachside of the sample to be removed toavoid any heat-related issues. There isan abrasive weld test cutting machinemanufactured by Triangle Engineering,

Fig. 2 — An example of a macro etch sample.

Fig. 3 — A fillet weld break specimen.


Inc., that is designed to removespecimens. This machine uses holdingfixtures designed to clamp weldedassemblies while a 20-in. abrasiveblade is hydraulically pushed throughthe cut — Fig. 1. Indexing featuresallow you to remove appropriatespecimen sizes with the push of a

button and rapid cut rates make ituseful for high-volume testing.

Specimen Preparation andTesting

With the specimens removed, it isnow time to prepare them for testing.

Correct preparation is important toensure that an accurate and reliabledestructive test can be performed.

Macro Etch Test. This testrequires only a belt sander (or otherpolishing means) and some nitric acid.Cross sections of the welded joint areremoved, then polished and etchedwith the acid — Fig. 2. This willprovide a detailed view of the basemetal, heat-affected zone (HAZ), andweld metal layers. The samples shouldbe belt sanded or polished; start with alow grit, then work your way up to ahigher grit to achieve a suitable finish.For the purposes of welderqualification in D1.1, you may onlyneed to take the finish to 100 or 180grit. This should provide an adequatefinish to check for weld sizes,incomplete fusion, inadequatepenetration, cracks, and undercut.

Once the sample is polished, youonly need a 25% nitric acid solution toetch the sample. This is typically onepart nitric acid and three parts water.Carbon- and low-alloy steels requirevery little exposure to this solution topresent a good macro etch. Quite often,

Fig. 4 — Examples of a plunger and die bend (left) and a wraparound bend (right).

Fig. 5 — A wraparound style bendmachine.



10 s or less will be sufficient.Fillet Weld Break Test. This is

the simplest of the three basic welderqualification destructive tests. The testinvolves placing a load on the filletweld so that it places the root of theweld in tension — Fig. 3. The load isremoved once the joint fractures or thespecimen has been folded flat ontoitself. Depending on the size of theweld and the base material, you may beable to accomplish this in a vise oreven with a sledge hammer. Heavierspecimens will require a press ortension testing machine. If thespecimen does fold flat onto itself, youhave a satisfactory test result. If itfractures, you need to confirm there iscomplete fusion to the root and thereare not excessive inclusions orporosity. The sum of all inclusions andporosity cannot be greater than 3⁄8 in.

Bend Tests. The final and mostinvolved method of destructive testingis bend testing. Bend tests for welderqualification are predominantlyassociated with groove welds, but thereis one fillet weld test that employsbend tests as well. There are threetypes of bend tests: side, face, and rootbends. The face and root bends areused in some cases and the side bendsin others. Face and root bends areusually used on 3⁄8 in. and less plate andwall thicknesses, while side bends areused on 3⁄8 in. and greater plate and wallthicknesses. However, there are someinstances when face and root bends aremade on thicknesses greater than 3⁄8 in.As you can see, for 3⁄8 in. thickness youmay use either side bends or face androot bends. Arguments could and havebeen made for either method. A facebend or root bend, as the names imply,puts either the face or the root of theweld in tension, and that is the surfacethat will be examined. A side bend willput the entire cross section of the weldin tension.

Your side bends are going to be 3⁄8in. wide and as thick as the base metalused for testing. In some cases wherethe base metal is greater than 11⁄2 in.thick, the sample may be cut into equalstrips and both strips would be tested torepresent one side bend. The face androot bends would be 11⁄2 in. wide and asthick as the base metal. A 1-in.-wide

sample may be used for pipe or tubeequal to or less than 4 in. in diameter.

Preparing the bend samples fortesting involves grinding, belt sanding,or machining the samples. The weldreinforcement and backing should beremoved flush with the surface of thespecimen for all bends. Whenremoving heavy backing bars, youshould try to remove the bulk of thematerial with a heavy grinder orthrough mechanical cutting ifavailable. For face bends onthicknesses greater than 3⁄8 in., removematerial from the root side to bring thespecimen to 3⁄8 in. thickness; for rootbends, remove material from the face.Don’t get too aggressive with the finishon your bends; gouges and heavy grindmarks could form a crack starter on aweld that otherwise may have beensound. Grind marks should always beparallel to the specimen. Edges of thespecimen should have a 1⁄8-in.maximum radius.

To bend the specimens there aretwo basic styles of guided bend testingequipment, the plunger and die styleand the wraparound style. Figure 4shows a plunger and die bend on theleft and a wraparound bend on theright. The wraparound style allows afull 180 deg of specimen bending withminimized stresses on the sample.Different die post diameters can bechanged out in a couple minutes and atypical bend takes about a minute to setup and test. Figure 5 shows awraparound style bender from TriangleEngineering. Regardless of which styleyou use, you are going to need todetermine what bend radius to use. Themajority of side, face, and root bendson 3⁄8 in. thicknesses will be tested at a¾ in. radius. The only exception to thiswould be when qualifying on basemetals with yield strength greater than50 ksi.

When examining the bend tests fordefects and discontinuities, whether

they are side, face, or root bends, youshould look at the convex surface, theoutside circumference of the bend. Anyincomplete fusion, slag inclusion, ordiscontinuity measuring greater than 1⁄8in. is a rejection. Even if you keep thediscontinuities 1⁄8 in. and under, youmay still be in trouble because youmay also have a rejection based on thecumulative length of smallerdiscontinuities. Add up everydiscontinuity greater than a 1⁄32 in. but≤1⁄8 in. If the total is greater than 3⁄8 in.,that is a failure. Corner cracks areallowed provided they do not exceed ¼in., unless they look to be the result ofslag or fusion problems, then theycannot exceed 1⁄8 in. On the bright side,it is permissible to have manydiscontinuities, provided they aresmaller than a 1⁄32 in.

J. R. COULSTRING III([email protected]) is quality control

manager, Triangle Engineering, Inc., Hanover, Mass.

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Bend tests for welder

qualification are predominantly

associated with groove welds,

but there is one fillet weld test

that employs bend tests.




FeatureBy Joseph P. Kane

This article is the first in a four-part series related to the Code ofEthics found in AWS QC-1: 2007,Standard for AWS Certification ofWelding Inspectors. Joseph P. Kanewrote this article in collaboration withKent Baucher, Neal Chapman, LyndseyDeckard, and Phillip Martin, fellowmembers of the CertificationCommittee’s Subcommittee on the Codeof Ethics.

Frequently in their daily speech,end users, employers, engineers, shopand field managers, governmentregulators, welders, and even AWSCertified Welding Inspectors use thewords “certified” and “qualified”interchangeably. In addition, thismisuse of terms is often found inwritten documents such as contractspecifications. This misuse mostlyinvolves routine communication andthere is often no real harm done whenthese words are interchangeably used.To help clarify these terms, in thewelding field the certification is thesigned document that attests to the factthe welder has successfully passed aqualification test to a specific code.

In the pressure vessel business,“ASME certified” or “ASMEcertification” are often used whenreferring to welder performancequalification tests performed inaccordance with the American Societyof Mechanical Engineers Boiler andPressure Vessel Code, Section IX.

In pipelining, the terms “APICertified” or “API certification” areoften used when referring to welderperformance qualification tests

performed in accordance withAmerican Petroleum Institute STD1104, Welding of Pipeline and RelatedFacilities.

In the structural welding field, theterms “AWS certified” or “AWScertification” are often used whenreferring to welder performancequalification in accordance with theprovisions of the American WeldingSociety D1.1, Structural Welding Code— Steel, or other AWS standards.

Often contractors call in a CWIand ask him or her to “certify” theirwelders to AWS, ASME, or API, sothat they can perform welding on acontract. Many times the contractorwants the welders to be certified forwelding “everything,” with “allprocesses.” Good economic thoughtmeans the contractors want someversatility and durability with thepaperwork, and so they also specifythat these “certifications” must be good“anywhere” and “forever.”

Legally, the contractors are usuallyresponsible for the qualification andcertification of their welders. In reallife — even with contractors who havebeen around welding for a long time —many contractors have little knowledgeof what is involved in welderperformance qualification or how toget it. They all seem to know it will becostly, but few seem to know it willtake some period of time that theydon’t have. (They all need it“yesterday.”) This lack of knowledge isone reason why they hire a CWI toperform their qualification testing.

Any CWI should know there is nosuch thing as a “universal certification”

that covers all processes, all positions,all joint configurations, all productforms, all electrodes, and is valid“everywhere” and “forever.”

Prudent CWIs will ask to read thecontract specifications, so they canproceed with professional confidenceand conduct the proper testing for theclient. At this point, prudent CWIsshould educate their clients — usingthe proper terminology — and describewhat the contract specifications arecalling for and what they can do toassist their clients. Clients must thenreevaluate their priorities, and tell theCWIs what they want and need forcontract compliance.

Imprecise use of terms such asqualification and certification at thispoint can cause misunderstanding,confusion, or both. In the structuralfield, “AWS certified” might just meanwelder performance qualification to theprovisions of AWS D1.1. Of course, itcould also refer to a person who hassuccessfully taken Welder PerformanceQualification testing at an AWSAccredited Testing Facility (ATF), inaccordance with AWS QC-7,supplement “G,” and has a card issuedby the American Welding Society thatplaces the welder in the NationalRegistry. Nonstandard use ofterminology in this case reveals theimportance of the proper use ofterminology in any type of contractualagreement either verbal or written. Thewelding inspector should be clear inhis/her explanations to the client, to becertain the client understands there is adifference between a certification perAWS D1.1 and a nationally registered

Ethics Alert: Certified vs. Qualified

Members of the Ethics Subcommittee explain the importance of the proper use ofterminology

Kane Feature IT Winter 2012_Layout 1 12/22/11 10:19 AM Page 24


certification from AWS through testingperformed at an ATF.

AWS Code of Ethics

Recently, there was an allegedviolation of the AWS QC-1 Code ofEthics in which the complainant saidthe CWI gave a “generic” D1.1 welderperformance qualification test, but thecomplainant wanted a “NationalRegistry Certification.”

There is no proof in the complaintthat the complainant specified the QC-7 National Registry qualification andcertification test. However, there isnothing yet to show that the CWIeducated his client (the complainant)about the different types of testing, theservices he could perform, and wherethe client would have to go if hewanted to get his welders on theNational Registry.

The Ethics Subcommittee now has

to evaluate the complaint and theevidence in the complaint. Thecommittee will decide whether theallegation is complete enough on itsface to show that the CWI probablyviolated the AWS QC-1 Code of Ethicsby not properly educating the client.Then the subcommittee members willvote whether or not to recommend theissue be referred to a “hearing panel.”The hearing panel is the AWSequivalent of an administrative trial. Itis where CWIs can find themselveslosing their certificates.

Basic integrity issues addressed inParagraphs 11.1, 11.2.1, and 11.2.6, ofSection 11 of AWS QC-1 2007,Standard for the Certification ofWelding Inspectors, apply here. Themembers of the Ethics Subcommitteefeel it is incumbent on the CWI toexplain the differences to thecontractor/client, because the CWI isthe most knowledgeable party.

What Happens Next

In the future, the EthicsSubcommittee will take an adverseview toward the CWI in an ethicsviolation complaint if there is noevidence he or she has attempted toeducate the client by adequatelyexplaining the different options to thatclient.

JOSEPH P. KANE([email protected]) is with Pen-noni Associates, King of Prussia, Pa. He

is an advisor to the AWS CertificationCommittee and a member of the Subcom-

mittee on the Code of Ethics. He is anAWS Senior Certified Welding Inspector.

Collaborators on this article were KentBaucher, Neal Chapman, Lyndsey

Deckard, and Phillip Martin.

Kane Feature IT Winter 2012_Layout 1 12/22/11 10:19 AM Page 25

The Answer IsBy K. Erickson and A. Moore


The Society is not responsible for any statements made or opinion expressed herein. Data and information developed by the authors are for specificinformational purposes only and are not intended for use without independent, substantiating investigation on the part of potential users.

Q: I am currently a welder qualifiedto the shielded metal arc weldingrequirements of AWS D1.1 in the 1Gand 2G positions (2007). Prior tocompleting the qualification weld, Iwas instructed to grind the weld capflush when completed. The plate wasthen sectioned for bend testing. Justrecently, I tested in the 3G positionand, upon completion, the inspectorfailed the test coupon visually. Myquestion is why in one case was novisual inspection performed, while inthe other case, a visual inspectionwas performed for which I failed?

A (from K. Erickson): I wouldcertainly hope that these were twoseparate testing facilities and inspectorsfor which you tested; otherwise, thispractice needs to be brought up to theirresponsible management. Theindividual who instructed you toremove the weld cap upon completionof the 2G test was not performinghis/her duties correctly and completely.The bottom line is that visualinspection is required for welders,welding operators, and tack welderswho are performing qualificationperformance tests. This is arequirement within AWS D1.1 and soindicated directly on the qualificationtest record. The entire performance testshould be monitored by a competentindividual overseeing each test.Individuals who are applying the visualacceptance criteria need to beknowledgeable and understand eachvisual inspection checkpoint and how itapplies to both fillet and groove welds.

Use any failed test as a learningtool to better yourself and your weldingskills. Ask questions to understandwhat is expected from you before thetest, why your test coupon has failed,and what needs to be corrected and/orchanged to rectify these conditions.

Q: Titanium tubing is generallylisted under what AWS materialnumbers?

A: Material numbers 51, 52, and 53.Refer to B2.1/B2.1M: 2009,Specification for Welding Procedureand Performance Qualification.

Q: When can the CWI examinationbe expected to include questionsinvolving the measurement ofskewed T-joint weld sizes, and howcan those welds be measured?

A (from A. Moore): Since thepublication of Bob Wiswesser’s articleon skewed joints in the Summer 2011Inspection Trends, I have receivedseveral inquiries regarding this topic. Idon’t know when questions on skewedT-joints will appear, but maybe I canshow how they are measured.

The AWS D1.X StructuralWelding Codes are the only weldingstandards we are familiar with thataddress welded skewed T-joints andinclude special requirements regardingsizing the weld between skewedmembers. It is interesting to note thatthe subject of skewed T-joints hasevolved over time. In the recent past,the codes simply called out the weldjoining the skewed members as a filletwelded skewed T-joint and thedesigners used the fillet weld symbol tospecify the welding requirements;however, the 2008 and 2010 editions ofD1.1, Structural Welding Code —Steel, no longer use the words “filletweld” or “fillet welded” whenaddressing the skewed joints betweenmembers when the acute angle is lessthan 80 deg. I see the logic in thechanged terminology. A review ofacceptable and unacceptable fillet weldprofiles depicted in D1.1:2008, Fig.5.4, shows that an acceptable filletweld must have fusion to the joint root.

It is interesting to note that the2010 edition of AWS D1.1 no longerincludes the sketches of acceptable andunacceptable fillet weld profiles thatwere included in the earlier editions. Isit an oversight or is incomplete fusionto the root of the fillet weld acceptablenow? The presence of incompletefusion has a direct bearing on the throatof the fillet weld and thus its strength.Therefore, I wouldn’t think therewould be a change in the need to havefusion to the root of the fillet weld.Consider the test results required whenevaluating a fillet weld break test; thefailed weld must exhibit fusion to theroot, but not necessarily beyond theroot (reference AWS D1.1:2010,Clause 4.9.4.1). When the dihedralangle is less than 60 deg, it isrecognized that the weld joining theskewed members may not have fusionto the root. That being the case, thebasic requirements of an acceptablefillet weld profile cannot be met. Withthat in mind, it makes perfect sense notto refer to the weld joining the skewedmembers as a fillet weld when fusionto the root is not expected.

The Society is not responsible for any statements made or opinion expressed herein. Data and information developed by the authors are for specificinformational purposes only and are not intended for use without independent, substantiating investigation on the part of potential users.

The Answer Is IT Winter 2012_Layout 1 12/22/11 2:32 PM Page 26


You might ask the question,“When does the weld on the acute sideof the skewed T-joint not meet theprofile requirements of a fillet weld?”

AWS D1.1:2010, Clause 2.4.3.3,states that when the acute angle betweenthe members is less than 60 deg, theweld size must be adjusted to accountfor the expected Z-loss. The anticipatedZ-loss is tabulated in AWS D1.1:2010,Tables 2.2 (nontubular connections) and2.9 (prequalified PJP T, Y, and K tubularconnections). In other words, experiencehas demonstrated that when the acuteangle of the skewed joint is less than 60deg, incomplete fusion to the root canbe expected. The Z-loss, i.e., incompletefusion at the root, gets larger as thedihedral angle gets smaller.

The code has a provision statingthat the design drawings, i.e., thestructural drawing, produced by theEngineer (the Owner’srepresentative/design professional) is tospecify the required throat dimensionfor the welded skewed joint. That is, thedesign drawing does not have to includethe Z-loss dimension listed in Tables 2.2and 2.9.

Reading further, the structural codehas provisions that state the fabricatormust provide details showing the legdimensions that take into account theexpected Z-loss and the required throatdimension.

However, since the deposited welddoes not meet the requirements of a filletweld, i.e., we should not expect the weld

to have fusion to the root, should thefillet weld symbol be used to specify theweld requirements of the skewed T-joint?While my response may be at odds withthe opinions of some other people, I takethe position that if the weld cannot meetthe basic requirements of a fillet weld,the fillet weld symbol is inappropriate.

Is there an existing weld symbol thatadequately specifies the weld? Myresponse is “No.” That being the case, thebest way to specify the weld for theskewed T-joint is to include a section viewthrough the skewed joint depicting theexpected Z-loss and the required welddimensions. The detailer is burdened withthe task of including a detail of the skewedT-joint on the shop drawing. The detail isa section through the skewed T-joint thatshows the calculated value of the facewidth and both legs showing dimensionsof both the fused and unfused portions ofthe weld joining the skewed members.

Let’s try an example:Angle of the skew = 45 degZ-loss: 1⁄8 in.Throat: 3⁄8 in.

Total Throat = Z-Loss + Throat = 1⁄8 + 3⁄8= 1⁄2 in.

Calculate Leg (root to face) = 0.5/cos(45/2) = 0.5/(cos 22.5) = 0.5/0.924= 0.541

Calculate Face = sin 45 deg × 0.541= 0.707 × 0.541 = 0.383 in.It may make it easier to visualize

the weld and the various dimensions ifwe draw a sketch of the example wejust worked through.

Now that the dimensions havebeen calculated by the detailer and adetail included on the shop drawing, itis a relatively easy matter to measurethe weld to verify it meets theminimum size as specified.

The verification of the face widthof the completed weld isn’t withoutissue. Fillet weld gauges available frommost suppliers are not made formeasuring welded skewed T-joints.They are fine for a T-joint where onemember is nearly perpendicular to theother, but that is not the case withskewed T-joints. My solution is tomake the gauge needed to measure theface of the welded skew T-joint. It is asimple matter to find a piece of heavyband strap such as typically used forsecuring loads to wooden pallets. Thenthe band strap can be cut and trimmedto the appropriate size.

Measuring the completed weld is arelatively simple exercise if thefabrication drawing includes thesection detail I have suggested. Itbecomes a simple matter to measurethe weld with the appropriate gauge toverify the minimum dimensions arepresent. Since the common filletgauges may not be appropriate, theinspector will have to make a gauge forthis purpose. All it takes is a pair ofaircraft-style tin snips and a 6-in. ruler.Use the ruler to measure and lay outthe band strap and cut it as needed withthe tin snips. With a little care, thedimensions can be easily held to withina few thousandths of an inch.

I keep a couple of lengths of bandstrap in my tool box for this purpose. Agauge can be made to fit into tightcorners or to suit unusual conditions.The length of the gauge should besufficient to provide a stable base.



A gauge that is within a fewthousandths of an inch should sufficefor most work. After all, the weld sizespecified by the drawing is usuallyconsidered to be the minimum size.Don’t forget that Table 6.1 of AWSD1.1 allows the welds to run slightlyundersized. In addition to allowingwelds to run slightly undersized, AWSD1.1 permits a 1⁄16-in. separationbetween the members to be joinedwithout correction. Most reasonablepeople should not take issue with theaccuracy of the homemade gauge thatis within ±1⁄32 in.

Inspection Trends encourages question and answer submissions. Pleasemail to the editor ([email protected]).

KENNETH ERICKSON is manager of quality at National Inspection & Consult-ants, Inc., Ft. Myers, Fla. He is an AWSSenior Certified Welding Inspector, an

ASNT National NDT Level III Inspector in four methods, and

provides expert witness review and analysisfor legal considerations.

ALBERT J. MOORE JR. is vice president,Marion Testing & Inspection,

Canton, Conn. He is an AWS SeniorCertified Welding Inspector and an ASNT

ACCP NDT Level III. He is also amember of the AWS CertificationCommittee and the Committee onMethods of Inspection of Welds.

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ASNT 21st Annual Research Symposium and SpringConference. March 19–23, Sheraton Dallas Hotel, Dallas,Tex. Contact American Society for Nondestructive Testing,(800) 222-2768 or www.asnt.org.

FABTECH Canada 2012. March 20–22, Toronto CongressCentre, Toronto, Ont., Canada. Sponsored by the AmerianWelding Society, Society of Manufacturing Engineers, andFabricators & Manufacturers Association, Int’l. Visitwww.fabtechcanada.com; show updates will be posted onTwitter and LinkedIn.

65th Annual Assembly of the International Institute ofWelding. July 8–13, Hyatt Regency Hotel Denver andColorado Convention Center. Sponsored by the AmericanWelding Society, Edison Welding Institute, and WeldingResearch Council. Visit www.iiw2012.com.

Review of Progress in Quantitative NondestructiveEvaluation (QNDE). July 15–20, Hyatt Regency TechCenter, Denver, Colo. Contact [email protected] orwww.qndeprograms.org.

ASNT Fall Conference and Quality Testing Show. Oct.29–Nov. 2, Rosen Shingle Creek Resort, Orlando, Fla.Contact American Society for Nondestructive Testing, (800)222-2768 or www.asnt.org.

FABTECH 2012. Nov. 12–14, Las Vegas Convention Center,Las Vegas, Nev. Sponsored by the American Welding Society,Society of Manufacturing Engineers, and Fabricators &Manufacturers Association, Int’l. Visit www.fabtechexpo.com.

Educational Opportunities

NDE Classes. Moraine Valley Community College, PalosHills, Ill., offers NDE classes in PT, MT, UT, RT, RadiationSafety, and Eddy Current, as well as API 510 exam prep andweld inspection. For more information, contact (708) 974-5735; [email protected]; morainevalley.edu/NDE.

CWI Prep Course and AWS CWI Seminar and Exam.The Prep Courses prepare candidates for the AWS CertifiedWelding Inspector (CWI) seminar and examination. OfferedJuly 16–20 and Oct. 15–19. The CWI seminar covers how toreference AWS codes, examine welds, and prepare for theCWI exam on that following Saturday (proctored by AWS).Offered July 22–28 and Oct. 21–27. Contact LincolnElectric’s Welding School at (216) 383-8325 or visitwww.lincolnelectric.com.

EPRI NDE Training Seminars. EPRI offers NDE technicalskills training in visual examination, ultrasonic examination,ASME Section XI, UT operator training, etc. Contact SherrylStogner, (704) 547-6174, e-mail: [email protected].

Nondestructive Examination Courses. A course schedule isavailable from Hellier, 277 W. Main St., Ste. 2, Niantic, CT06357, (860) 739-8950, FAX: (860) 739-6732.

NDE Training Courses. GE Inspection Technologies offerstraining on topics such as eddy current, digital radiography,and remote visual inspection. For the complete schedule,contact (866) 243-2638; [email protected];www.ge.com/inspectiontechnologies.

Positive Material Identification Seminars. Topics coveredwill include basics of X-ray fluorescence (XRF) analysis,APRI RP 578, and recommended PMI procedures. For moreinformation or to register, contact Thermo Fisher Scientific,Inc., at www.niton.com/News-and-Events.

Preparatory and Visual Weld Inspection Courses. One-and two-week courses presented in Pascagoula, Miss.,Houston, Tex., and Houma and Sulphur, La. Contact RealEducational Services, Inc., (800) 489-2890;[email protected].

CWI/CWE Course and Exam. A ten-day program presentedin Troy, Ohio. Contact Hobart Institute of Welding Technology(800) 332-9448; www.welding.org; [email protected].

T.E.S.T. NDT, Inc., Courses. CWI preparation, NDEcourses, including ultrasonic thickness testing and advancedphased array. On-site training available. T.E.S.T. NDT, Inc.,193 Viking Ave., Brea, CA 92821; (714) 255-1500; FAX(714) 255-1580; [email protected]; www.testndt.com.

NDE Training. NDE training at the company’s St. Louis-areafacility or on-site. Level III services available. For a scheduleof upcoming courses, contact Quality Testing Services, Inc.,2305 Millpark Dr., Maryland Heights, MO 63043; (888) 770-0103; [email protected]; www.qualitytesting.net.

CWI/CWE Prep Course and Exam and NDT InspectorTraining Courses. An AWS Accredited Testing Facility.Courses held year-round in Allentown, Pa., and at customers’facilities. Contact: Welder Training & Testing Institute (WTTI).Call (800) 223-9884, [email protected], or visit www.wtti.edu.

Welding Inspection, INTEG, Welding Health and Safety,and Welding Supervisor Courses. Contact the CanadianWelding Bureau for schedule at (800) 844-6790, or visitwww.cwbgroup.org.

Mark Your Calendar


Mark Your Calendar IT winter 2012_Layout 1 12/21/11 4:09 PM Page 29

Certification Schedule

Certified Welding Inspector (CWI)LOCATION SEMINAR DATES EXAM DATE

Corpus Christi, TX Exam only Mar. 3Milwaukee, WI Feb. 26–Mar. 2 Mar. 3 Atlanta, GA Feb. 26–Mar. 2 Mar. 3 San Diego, CA Feb. 26–Mar. 2 Mar. 3 Miami, FL Feb. 26–Mar. 2 Mar. 3 Houston, TX Mar. 4–9 Mar. 10Norfolk, VA Mar. 4–9 Mar. 10Kansas City, MO Mar. 4–9 Mar. 10Indianapolis, IN Mar. 11–16 Mar. 17Portland, OR Mar. 11–16 Mar. 17Phoenix, AZ Mar. 11–16 Mar. 17Boston, MA Mar. 18–23 Mar. 24Anchorage, AK Mar. 18–23 Mar. 24Chicago, IL Mar. 18–23 Mar. 24Mobile, AL Exam only Mar. 24Rochester, NY Exam only Mar. 24York, PA Exam only Mar. 24Miami, FL Mar. 25–30 Mar. 31Miami, FL Exam only Apr. 12Knoxville, TN Exam only Apr. 14Dallas, TX Apr. 15–20 Apr. 21St. Louis, MO Exam only Apr. 21Springfield, MO Apr. 15–20 Apr. 21Portland, ME Apr. 15–20 Apr. 21Las Vegas, NV Apr. 15–20 Apr. 21San Francisco, CA Apr. 29–May 4 May 5Nashville, TN Apr. 29–May 4 May 5Jacksonville, FL Apr. 29–May 4 May 5Waco, TX Exam only May 5Baltimore, MD May 6–11 May 12Detroit, MI May 6–11 May 12Albuquerque, NM May 6–11 May 12Corpus Christi, TX May 6–11 May 12Miami, FL May 6–11 May 12Long Beach, CA Exam only May 26Spokane, WA June 3–8 June 9Oklahoma City, OK June 3–8 June 9Birmingham, AL June 3–8 June 9Hartford, CT June 10–15 June 16Pittsburgh, PA June 10–15 June 16Beaumont, TX June 10–15 June 16

9–Year Recertification Seminar for CWI/SCWI For currentCWIs and SCWIs needing to meet education requirements with-out taking the exam. The exam can be taken at any site listedunder Certified Welding Inspector. LOCATION SEMINAR DATES EXAM DATE

Denver, CO Feb. 6–11 No exam Dallas, TX Mar. 12–17 No exam Miami, FL Apr. 16–21 No exam Sacramento, CA Apr. 30–May 5 No exam Pittsburgh, PA June 4–9 No exam San Diego, CA July 9–14 No exam Miami, FL July 16–21 No exam

Certified Welding Supervisor (CWS)LOCATION SEMINAR DATES EXAM DATE

New Orleans, LA Apr. 16–20 Apr. 21 Minneapolis, MN July 16–20 July 21CWS exams are also given at all CWI exam sites.

Certified Radiographic Interpreter (CRI)LOCATION SEMINAR DATES EXAM DATE

Seattle, WA Feb. 27–Mar. 2 Mar. 3 Houston, TX Apr. 16–20 Apr. 21Las Vegas, NV May 7–11 May 12Miami, FL June 4–8 June 9 Dallas, TX July 16–20 July 21 The CRI certification can be a stand-alone credential or can ex-empt you from your next 9-Year Recertification.

Certified Welding Sales Representative (CWSR)CWSR exams will be given at CWI exam sites.

Certified Welding Educator (CWE) Semi-nar and exam are given at all sites listed under Certified Weld-ing Inspector. Seminar attendees will not attend the Code Clinicportion of the seminar (usually the first two days).

Certified Robotic Arc Welding (CRAW)WEEKS OF, FOLLOWED BY LOCATION AND PHONE NUMBER

Feb. 10, May 11, Aug. 10, Nov. 9 atABB, Inc., Auburn Hills, MI; (248) 391–8421

Feb. 20, May 21, Aug. 20, Dec. 3 atGenesis-Systems Group, Davenport, IA; (563) 445-5688

Feb. 27, Mar. 2, Oct. 22, Oct. 26 at Lincoln Electric Co., Cleveland, OH; (216) 383-8542

Feb. 6, Apr. 23, July 9, Oct. 15 atOTC Daihen, Inc., Tipp City, OH; (937) 667-0800

Mar. 12, May 7, July 9, Sept. 10, Nov. 5 atWolf Robotics, Fort Collins, CO; (970) 225-7736

On request at MATC, Milwaukee, WI; (414) 297-6996

Certified Welding Engineer (CWEng) andSenior Certified Welding Inspector (SCWI)Exams can be taken at any site listed under Certified WeldingInspector. No preparatory seminar is offered.

Advanced Visual Inspection WorkshopLOCATION SEMINAR DATES EXAM DATE

Miami, FL Feb. 9, 10 Feb. 11Miami, FL May 17, 18 May 19Miami, FL Aug. 16, 17 Aug. 18

International CWI Courses and Exams Schedules Please visit www.aws.org/certification/inter_contact.html.

Important: This schedule is subject to change without notice. Please verify your event dates with the Certification Dept. and confirm your coursestatus before making your travel plans. For information, visit www.aws.org/certification, or call (800/305) 443–9353, ext. 273, for Certifica-tion; or ext. 455 for Seminars. Apply early to avoid paying the $250 Fast Track fee.

Seminars, Code Clinics, and ExaminationsApplication deadlines are six weeks before the scheduled seminar or exam. Late applications will be assessed a $250 Fast Track fee.


Certificaion Schedule IT Winter 2012_Layout 1 12/21/11 4:14 PM Page 30

Just the FactsBy Lyndsey Deckard

Several years ago, I was the qualitymanager for the owner of a major U.S.airport project. The project was aDesign, Build, Operate, and Maintain(DBOM) contract for an AutomatedPeople Mover, utilizing a steel-fabricated guideway. Thethree-mile-long elevated guideway wasrequired to be welded in accordancewith AWS D1.5, Bridge Welding Code,and AASHTO (American Association ofState Highway Transportation Officials).

Outriggers were mounted to thevertical wall surfaces of the boxedbeam design guideway. Theseoutriggers were to support the manymiles of wiring and cables used todeliver the power, controls, andauxiliary equipment required for thesystem. The outriggers were L-shapedbrackets approximately 2 ft longattached to the vertical walls with ½-in.-diameter weld studs.

The contractor began shootingstuds using inadequate equipment forthe stud diameter and no testing ofwelds prior to each shift. The weldsproduced were incomplete and did notmeet the visual requirements of properstud welds. AWS B4.0: 2007, StandardMethods for Mechanical Testing ofWelds, in Section 11.1 “Stud WeldTest” explains and illustrates the twoacceptable methods of stud weldtesting. Section 11.1 is quoted below:11.1.1 Scope

11.1.1.1 This subclause coversmechanical testing of stud welds. Whentesting of stud welds is required, theprocedure shall conform to thisstandard. This standard does notspecify requirements or acceptancecriteria.

11.1.1.2 When specified, thisstandard is applicable to the following:

1) Qualification of materials,welding operators, and weldingprocedure;

2) Information, basisof inspection andfabrication quality control(when acceptance criteriahave been established);and

3) Research anddevelopment.

11.1.1.3 When thesetests are specified, thefollowing informationshall be furnished:

1) Weld procedure(process and parameters);

2) The specific tests and number ofspecimens that are required;

3) Base metal specification/identification;

4) Position of welding;5) Stud analyses or specification

(part number), or both;6) Type of testing;7) Acceptance criteria; and8) For bend testing, the maximum

angle of bend must be specified, andfor torque testing, the torque to be usedmust be specified.

11.1.2 Normative References. Thefollowing standards contain provisionswhich, through reference in this text,constitute mandatory provisions of thistest. For undated references, the latestedition of the referenced standard shallapply. For dated references,subsequent amendments to, orrevisions of, any of these publicationsdo not apply.

AWS Documents:AWS C5.4, Recommended

Practices for Stud WeldingAWS D1.1, Structural Welding

Code — Steel11.1.3 Summary of Method. The

specimen is tested by one of twomethods:

1) The stud is bent by striking witha hammer or bending it using a lengthof tube or pipe, or

2) A tensile load is applied to thestud using an appropriate fixture. Thiscommonly is accomplished by use of atorque wrench and a stand-off sleeve.

11.1.4 Significance11.1.4.1 Mechanical testing of arc

welded studs is used to evaluate weldsoundness, tensile properties, andductility of the stud weld.

11.1.4.2 These tests are primarilyused as a welding procedurequalification method to evaluatewelding parameters and surfacepreparation.

11.1.5 Apparatus. Apparatus usedshall be capable of firmly holding thetest assembly and applying the bend-ing force or torque as needed.

11.1.6 Specimens11.1.6.1 Test specimens shall be

prepared by welding the studs beingtested (qualified) to specimen plates ofthe appropriate base metal as specifiedin 11.1.1.3.

11.1.6.2 Test specimens shall bemade using the appropriate automatictiming, voltage, current, and gunsettings for lift and plunge as recordedin 11.1.1.3.

11.1.7 Procedure. The followingare two test procedures as specified inPart 11.1.3:

1) Bend Testing. The requirednumber of welded specimens shall be


Stud Weld Testing

Fig. 11.1.1 — Equipment for bend tests for weldedstuds.

Just the Facts IT Winter 2012_Layout 1 12/21/11 4:19 PM Page 31

tested by bending the requirednumber of degrees from theiroriginal axis. Bending may be doneby striking the stud with a hammeror by bending it using a length oftube or pipe as shown in Fig.11.1.1; and

2) Torque Testing. The requirednumber of stud welded specimensshall be tested by applying a torqueusing equipment as shown in Fig.11.1.2. A steel sleeve or washers, ofappropriate size, are placed overthe stud. A nut of the same material

as the stud istightened against thewasher bearing onthe sleeve, using atorque wrench.Tightening the nutapplies the tensileload to the weld.Torque is applieduntil the specifiedlevel is reached orthe weld fails. Theresults of this testmay be significantly

affected by friction. Care should betaken to minimize this effect.

11.1.8 Report. In addition to therequirements of applicable documents,the report shall include the following:

1) Test results and observations,2) The information listed in Part

11.1.1.3, and3) Drawings showing shapes and

dimensions of studs and arc shields.For additional information on stud

welding process selection, application,and visual acceptance criteria, refer toAWS C5.4: 1993, RecommendedPractices for Stud Welding.


STUD

WASHER

WELDAREA

MEMBER

Note: The dimension shall be appropriateto the size of the stud. The threads of thestud shall be clean and free of lubricantother than the residue of cutting oil.

SLEEVE

STEELNUT

Fig. 11.1.2 — Equipment for applying a tensile load to awelded stud using torque.

Lyndsey Deckard ([email protected]) is quality manager of theVehicle Division of Parsons Brinckerhoff

Transit & Rail Systems, Inc. He is an AWSSenior Certified Welding Inspector, anASQ Certified Quality Auditor, and a

member of the AWS Certification Committee, Examination Question BankSubcommittee, and Ethics Subcommittee.

Just the Facts IT Winter 2012_Layout 1 12/21/11 4:19 PM Page 32

Reader Decries Military’s Stance on CWIs

I am writing this letter in response to the article on page 9 of theFall (October) 2011 issue of Inspection Trends titled “FormerShipyard Worker Sentenced for False Certifications.”

Please understand that I am not defending the individual named,nor condoning his actions, but unlike others, I do feel somesympathy and concern for his situation.

In the last sentence, it is stated, “A search of the AmericanWelding Society records revealed the individual has never been aCertified Welding Inspector.”

As an ASNT Level III in three methods, including visual testing,as well as being a SCWI, CWS, and CWE, I have worked manymilitary contracts similar to the one mentioned in your article andknow all too well that the Navy, nor any branch of the Departmentof Defense for that matter, will accept a CWI for visual inspection.

I have an appreciation for what a CWI learns and his or hercertification, but the military obviously does not, and will onlyaccept a Level II in VT, per T9074-AS-GIB-010/271.

Too many times, I have seen people certified as Level IIs in VTunder false pretenses. Please let me explain.

A CWI learns about various welding processes, discontinuitiesand defects, both mechanical (destructive) and nondestructivetesting methods, Welding Procedure Specifications, electrode andconsumables handling and control, material test reports, properinspection tools, codes, standards, specifications, etc.

On the other hand, the Level II in VT who goes through trainingby using the ASNT Level II Study Guide for Visual and OpticalTesting, and ANSI/ASNT CP-105: ASNT Standard Topical Outlinesfor Qualification of Nondestructive Testing Personnel, does notlearn hardly any of that.

If the Level II receives proper training as recommended byASNT, he or she will learn about the parts of the eye, lighting,inspection angle, borescopes and fiberscopes, reflection, refraction,diffraction, fasteners, castings, etc., and very little about weldinginspection. Some, but little.

My point: Many people being certified to Level II VTrequirements for use on military contracts are going through trainingthat is attempting to cram a 40-h CWI curriculum into a 24-h VTcourse with lackluster results. Then, the inspector is placed — withlittle confidence or experience — in an unfriendly environment withinadequate skills or knowledge to adequately and professionallyperform the assigned task.

Many certified today under those conditions are frustrated, feeltrapped because they are not confident in their certificationexperience, seldom if ever receive additional customized trainingabove and beyond the 24-h requirement, and are forced to performinspections in a hurry-up atmosphere to codes and standards theyhave probably never seen before. Many are just going through themotions to survive.

My hopes are that AWS, ASNT, and the Department of Defense,will one day recognize this situation and work out a resolutionwhere a CWI can be used in the military industry. I also hope thatAWS will incorporate some of the Level II VT curriculum into itsCWI curriculum; for example, the effects of magnification,psychological and physiological effects, proper lighting andinspection angle, fatigue factors, materials besides welds, etc.

I would gladly volunteer my services to work on a Committee to

help make it happen.Thanks for the opportunity to present my views and opinions.

Again, I am not defending nor condoning the individual, and amprobably wrongly assuming the circumstances under which hemight have worked.

The article did not state whether the individual had any othertraining, as required by military contracts, only that he was not aCWI. Sadly, however, I see the circumstances I described, alive andwell and happening every single day in our industry.

Jackie MorrisMorris Marine Consulting, LLCAWS SCWIASNT Level III, MT, PT, VT

Mail Bag


PublisherAndrew Cullison [email protected], Extension 249General Management, Reprint Permission,Copyright Issues

EditorMary Ruth [email protected], Extension 238Feature Articles

Production Manager Zaida [email protected], Extension 265Design and Production

National Sales Director Rob Saltzstein [email protected], Extension 243Advertising Sales

Advertising Sales Representative Lea [email protected], Extension 220Production and Promotion

Advertising Production Manager Frank [email protected]; Extension 465Senior Advertising Production Manager

Welding Journal Dept. 550 N.W. LeJeune Rd. Miami, FL 33126 (800) 443-9353; FAX (305) 443-7404

CAN WE TALK?The Inspection Trends staff encourages an exchange of

ideas with you, our readers. If you’d like to ask a question, sharean idea or voice an opinion, you can call, write, e-mail or fax.Staff e-mail addresses are listed below, along with a guide tohelp you interact with the right person.

Mailbag IT Winter 2012_Layout 1 12/21/11 4:21 PM Page 33

Technology NotesInterpretations: D1.6, Structural Welding Code — Stainless Steel

Subject: Torque test for threaded studs below 50°FCode Edition: D1.6:2007Code Provision: 7.7.1.4AWS Log: D1.6-07-I05Inquiry: Is the requirement of AWS D1.6/D1.6M:2007 subclause 7.7.1.4 for torque testing of threaded studs related or restricted to tem-peratures below 50°F?Response: No.

Subject: Torque test for threaded studs in preproductionCode Edition: D1.6:2007Code Provisions: Figure 7.4, Tables 7.3 and 7.4, and clause 7.7.1.4AWS Log: D1.6-07-I06Inquiry: Is it intended in AWS D1.6:2007 that preproduction testing of threaded studs in 7.7.1.4 be performed by a torque test to values inTables 7.3 or 7.4 instead of torqued to destruction?Response: Yes.

Subject: Torque test for threaded studs and welding operatorCode Edition: D1.6:2007Code Provisions: 7.7.1.4 and 7.7.4AWS Log: D1.6-07-I07Inquiry: Is it intended in AWS D1.6:2007 that the torque test for preproduction testing of threaded studs in subclause 7.7.1.4 also be usedfor operator qualification in subclause 7.7.4?Response: Yes.

Errata D1.1/D1.1M:2010 Structural Welding Code — Steel

The following errata have been identified and will be incorporated into the next reprint-ing of this document.

Page 23, 2.27.1.1 — Correct “2.24” reference to “2.25”.Page 150, note e — Correct “(see 4.12.4.2)” reference to “(see 4.13.4.2)”.Page 202, 5.22.1.1 — Correct “2.13” reference to “2.14”. Page 231, 6.26.6.4 — First sentence, fourth line, correct “… or be …” to “… or by

...”.Page 281, 7.1 — Correct “C7.6.1” reference to “C-7.6.1”. Page 496, C-Table 6.7 — Correct three “Table 6.6” references to “Table 6.7”. Page 497, C-6.26.6 — This paragraph appears twice. Delete the first appearance.Page 507, C-7.2.5 — Correct last entry “CL ≤ 0.125 in” to read “CL ≤ 0.125 in

[3.2 mm]”.Page 533, Index, PJP groove welds — Correct entry “4.14.4.20” to read “4.14, 4.21”.

InterpretationAWS D1.3

Structural Welding Code — Sheet Steel

Subject: Welder Qualification forSMAW ElectrodesCode Edition: D1.3:1998Code Provision: Clause 4.7.1.3AWS Log: D1.3-98-I05

Inquiry: Is a welder qualified usingE7018 SMAW electrodes, F4, qualifiedto run E6022 SMAW Electrodes, F1?Response: No, see table listing inclause 4.7.1.3.

ErrataAASHTO/AWS

D1.5M/D1.5:2010 Bridge Welding Code

The following erratum has been iden-tified and will be incorporated into thenext reprinting of this document.

Page 82, Table 4.1 (Continued),Matching Filler Metal Requirements forWPSs Qualified in Conformance with5.12.

Correct “ER90C-XXX” to read“E90C-XXX” in the Welding Processesand Electrode Specification Classifica-tions column. This is the fifth entry fromthe bottom of the column.

ErrataD17.2/D17.2M:2010

Specification for ResistanceWelding for Aerospace

Applications

The following errata have been iden-tified and will be incorporated into thenext reprinting of this document.

Page 11, Table 5.2, Samples of Al-loys Contained in Material groups Ithrough VIIIa. Correct “Ti-6Al-4V 2/” to“Ti-6Al-4Vc”.

Page 18, Figure 5.7, 8[200], Remove“ ‘ ” after “8[200]”

Page 26, Table 6.1, Gas Require-ments. Correct Oxygen Specification“B-O-925” to “BB-O-925.”

Page 62, Table C.1, Base MetalGroup. Correct “Ia” to “IA”, “Ib” to“IB”, “IIa” to “IIA”, “IIb” to “IIB”,“IIIb” to “IIIB”.

Unified Number & Common De-scription. Remove “S15500 & 15-5PHstainless steel”, “S17400 & 17-4PHstainless steel”, “S35000 & AM350 PHstainless steel”, “S35500 & AM355 PHstainless steel”, “S4500 & Custom 450”,“S45500 & Custom 455”.


Technology Notes IT Winter 2012_Layout 1 12/21/11 4:39 PM Page 34


performing ultrasonic flaw detectionand X-ray fluorescence inspections. Itis available for download from theApple App Store. The Ultrasonic Techguide lists the acoustic properties ofmost common materials, and includes acalculator for common beamparameters used in test setup andinterpretation. The XRF Tech Guideincludes an alloy materials guide thatprovides a quick and easy look-up ofthe chemistry specifications forcommon alloy grades using tradenames or alloy families.

Olympus NDT(781) 419-3900www.olympus-ims.com

UV-LED Black Light Offers50,000 Hours of Bulb Life

The VIBRANCE® EV5000 UVblack light features four high-outputLED clusters that offer 50,000 h of bulblife. Each light is individually tested andcertified with a wavelength of 365±5 nmand comes with a certificate ofcompliance and unique serial number.The company is also providing a limitedlifetime warranty that includes free useof a loaner light for the duration of anyservice work performed. The lightweighs 2 lb, and features anergonomically designed hand grip andan angular design that places less stresson hand-held users. It also provides abuilt-in eyelet for fixed positioning.

Magnaflux(847) 657-5300www.magnaflux.com

Radiometer/PhotometerMeasures Ultraviolet andVisible Light

The Spectroline® AccuMax™XRP-3000 digital radiometer/photometer uses a dual-wavelengthsensor detector to measure bothultraviolet and visible light. Themicroprocessor-controlled meterfeatures automatic zeroing, integration,and signal hold. It provides standardUV intensity data as well as readouts ofvisible irradiance in units and iscapable of accurately measuring a widevariety of NDE light sources.

Spectronics Corp.(800) 274-8888www.spectroline.com

Video Borescope OffersRemote Focus

The INVIZ Vuman RA-Y long-length video borescope can be fullyarticulating while completely coiled onthe reel. The system uses an advancedmicrocompressor that allows the tip ofthe borescope to be steered up to 100 ftwhile wrapped on the storage reel orpassed through unlimited bends, ratherthan only being able to articulate whenit is laid end to end in a straight line.Compressed air is pushed through thelength of the video borescope tomanipulate the tip. The system also canbe remotely focused, allowing it toprovide high-resolution images over avariety of distances without the need tochange tip adapters. Other features ofthis lightweight, durable borescope arean internal 320-GB hard drive for

storing jpeg and mpeg video, powerfulHID light source, easy-to-use menus,and on-board operators’ guide.

Advanced Inspection Technologies(321) 348-4650www.aitproducts.com

Laser-Based Tool MeasuresWeld Discontinuities

The WiKi-SCAN laser-based weldinspection tool provides a 3-D scan ofjoints and weld beads. It measures avariety of features including size,porosity, and undercut. Results can beaugmented with a picture of the weld,then saved and e-mailed anywhere. Thetool helps inspectors measure the sizeand number of discontinuities andcompare them to the applicablewelding standard.

Servo-Robot(262) 238-4625 www.servorobot.com

Tool Can Inspect Larger-Diameter Tubing

The company’s Dolphin G3™ tooloffers fast inspection of tubes up to 4-in. ID in any shape or material. Thetool reaches inspection speeds as fastas 10 s per tube and features patentedacoustic pulse reflectrometrytechnology. It offers automatedanalysis and report generation. The toolcan be used to identify defects anddiscontinuities such as holes,blockages, erosion, and pitting in hard-to-inspect tubes including U-bends,boiler units, and heat exchanger types.

AcousticEye(888) 874-4779www.acousticeye.com

— continued from page 13


Applied Bolting Technology . . . . . . . . . . . . . . . . . . . . . . . .11www.appliedbolting.com . . . . . . . . . . . . . . . .(800) 552-1999

American Society for Nondestructive Testing . . . . . . . . .8, 9www.asnt.org . . . . . . . . . . . . . . . . . . . . . . . . .(800) 222-2768

AWS Education Services . . . . . . . . . . . . . . . . . . .7, 19, OBCwww.aws.org . . . . . . . . . . . . . . . . . . . . . . . . .(800) 443-9353

AWS Member Services . . . . . . . . . . . . . . . . . . . . . .25, 28, 32www.aws.org . . . . . . . . . . . . . . . . . . . . . . . . .(800) 443-9353

EST Group/Curtis Wright Flow Contol Co. . . . . . . . . . . . .13www.estgroup.cwfc.com . . . . . . . . . . . . . . . .(800) 355-7044

G.A.L. Gage Co. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13www.galgage.com . . . . . . . . . . . . . . . . . . . . .(269) 465-5750

Iris Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10www.iris-inspection.com . . . . . . . . . . . . . . . .(800) 940-1471

NDT Seals, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10www.ndtseals.com . . . . . . . . . . . . . . . . . . . . .(800) 261-6261

Olympus NDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .IFCwww.olympusNDT.com . . . . . . . . . . . . . . . . .(781) 419-3900

Thermo Fisher Scientific/Niton Analyzers . . . . . . . . . . . .IBCwww.thermo.com/niton . . . . . . . . . . . . . . . . .(978) 670-7460

World Spec Online NDT Training . . . . . . . . . . . . . . . . . . . .23www.worldspec.org . . . . . . . . . . . . . . . . . . . .(877) 506-7773

IFC = Inside Front CoverIBC = Inside Back CoverOBC = Outside Back Cover

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Statement of Ownership, Management, and Circulation for U.S. Postal Service (Required by U.S.C. 3685)

1. TITLE OF PUBLICATION: Inspection Trends 2. PUBLICATION NO.: ISSN 1523-71683. DATE OF FILING: September 26, 2011 4. FREQUENCY OF ISSUE: Quarterly5. NO. OF ISSUES PUBLISHED ANNUALLY: 4 6. ANNUAL SUBSCRIPTION: $30.007. MAILING ADDRESS OF KNOWN OFFICE OF PUBLICATION: 550 NW LeJeune Rd., Miami, Miami-Dade County, Florida 331268. MAILING ADDRESS OF THE HEADQUARTERS OR GENERAL BUSINESS OFFICES OF THE PUBLISHERS:

550 NW LeJeune Rd., Miami, Miami-Dade County, Florida 331269. NAMES AND COMPLETE ADDRESS OF PUBLISHER, EDITOR, AND MANAGING EDITOR:

PUBLISHER: Andrew Cullison, AWS, 550 NW LeJeune Rd., Miami, Florida 33126EDITOR: Mary Ruth Johnsen, AWS, 550 NW LeJeune Rd., Miami, Florida 33126

10. OWNER: NAME: American Welding Society,Inc. ADDRESS: 550 NW LeJeune Rd., Miami, Florida 3312611. KNOWN BONDHOLDERS, MORTGAGEES, AND OTHER SECURITY HOLDERS OWNING OR HOLDING 1 PERCENT OR MORE

OF TOTAL AMOUNT OF BONDS, MORTGAGES, OR OTHER SECURITIES: None12. The purpose, function, and nonprofit status of this organization and the exempt status for Federal income tax purposes:

Has not changed during preceding 12 months13. Publication Title: Inspection Trends 14. Issue Date for Circulation Data Below: Fall October 201115. EXTENT AND NATURE OF CIRCULATION:

Average No. Copies Each Actual No. Copies of Issue during Preceding Single Issue Published

12 Months Nearest to Filing Date

A. Total No. Copies Printed (Net Press Run) 23,502 24,000B. Paid and/or Requested Circulation

1. Paid/Requested Outside-County Mail Subscriptions Stated on Form 3541 22,879 23,0592. Paid In-County Subscriptions Stated on Form 3541 None None3. Sales through Dealers and Carriers, None None

Street Vendors, Counter Sales, and Other Non-USPS Paid Distribution4. Other Classes Mailed through the USPS None None

C. Total Paid/Requested Circulation 22,879 23,059D. Free Distribution by Mail (Samples, Complimentary and Other Free)

1. Outside-County as Stated on Form 3541 78 772. In-County as Stated on Form 3541 None None3. Other Classes Mailed through the USPS None None4 Free Distribution Outside the Mail (Carriers or Other Means) None None

E. Total Free Distribution 78 77F. Total Distribution 22,957 23,136G. Copies Not Distributed 545 864H. Total 23,502 24,000I. Percent Paid and/ or Requested Circulation 99.6% 99.6%

16. Statement of Ownership will be printed in the Winter January 2012 issue of this publication.I certify that the statements made by above are correct and complete:Andrew Cullison, Publisher

JAN 2012 it classified index_Layout 1 12/21/11 4:10 PM Page 36

©20

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To verify the integrity of your process sytems, take matters into your own hands.

The requirement for positive material identification (PMI)

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to Thermo Scientific Niton XRF analyzers.

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The all-new Thermo Scientific Niton XL2 GOLDD and Niton XL3t GOLDD+ join our

Speed, accuracy, value – either way, you gain the advantage.

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Automated WeldingAWS Conference on

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VOL 15-AWS Inspection Trends_2012_01

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