welding process and Defetc

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WI 3.1

M.S.RogersCopyright © 2004 TWI Ltd

Welding InspectionWelding Inspection

Practical Plate ExercisePractical Plate Exercise

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Plate Sample 6A CapPlate Sample 6A Cap

Cap Undercut Intermittent


Slag Inclusion

Arc Strike

Porosity Lack of fusion


Arc Strike

Incomplete Filled Groove

Note: spatter and surface slag requires removal, arc strikes require blending and crack detection

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Welding Process MMA (SMAW)Welding Process MMA (SMAW)

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Plate Sample 6A RootPlate Sample 6A Root

Excess Penetration

Lack of Root Fusion

Excess Penetration

Gas Pore

Root UndercutLinear Misalignment

Surface Slag

Note: Spatter and surface slag require removal

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Plate Sample 6B CapPlate Sample 6B Cap

Lack of Sidewall Fusion


Overlap and Excess Cap Height Full Weld Length

Surface Slag

Porosity Lack of Sidewall Fusion

Note: Surface slag requires removal and poor toe blending full weld length

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Lack of Root Fusion

Plate Sample 6B RootPlate Sample 6B Root

Lack of Root Fusion

Crater Pipe

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??Lack of Root Penetration??

Slag Inclusion??


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Longitudinal Crack

Surface slag & Spatter

Plate Sample 6C CapPlate Sample 6C Cap

Cap Undercut

Incomplete Filled Groove + Lack of Sidewall Fusion

Slag InclusionIncomplete Filled Groove + Lack of

Sidewall Fusion + Cap Undercut Intermittent

Note: Spatter and surface slag requires removal

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Welding Process FCAWWelding Process FCAW

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Plate Sample 6C RootPlate Sample 6C Root

Lack of Root Fusion

Burn Through

Excess Penetration

Lack of Root Fusion

Poor Stop/Start + Lack of Root Penetration

Mechanical Damage

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Welding Process FCAWWelding Process FCAW

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Cap Undercut

Cap Undercut

Excess Cap Height

Plate Sample 6D CapPlate Sample 6D Cap

Porosity



Overlap between Capping Passes

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Note: Excess cap height and poor cap profile throughout.

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Plate Sample 6D RootPlate Sample 6D RootWelding Process MMA (SMAW)Welding Process MMA (SMAW)

Lack of Root Fusion

Mechanical Damage

Lack of Root Fusion

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Plate Sample 6E CapPlate Sample 6E Cap



Excess Cap Height




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Plate Sample 6E RootPlate Sample 6E Root

Lack of Root Fusion

Excess Root Penetration

Poor Stop/Start + Crater Pipe

Excess Root Penetration

Lack of Root Fusion

Crater Pipe Lack of Root fusion

Root Undercut

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Plate Sample 6F CapPlate Sample 6F Cap

Poor Toe Blend

Lack of Sidewall fusion

Mechanical Damage

Lack of Sidewall Fusion + Incomplete Filled Groove

Arc StrikesTack Weld

Note: Arc strikes require blending and crack detection

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??Crater pipe

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Plate Sample 6F RootPlate Sample 6F Root

Lack of Root Fusion

Arc Strikes

Poor Stop/Start + Lack of Root Penetration + Crater Pipe

Mechanical Damage + Lack of Root Fusion

Arc Strikes

Arc Strikes

Lack of Root Fusion

Blow Hole

Lack of Root Fusion

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Note: Arc strikes require blending and crack detection


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Plate Sample 6G CapPlate Sample 6G Cap

Poor Toe Blend + Excess Cap Height

Arc Strikes

Porosity

Lack of Sidewall Fusion + Incomplete Filled Groove

Arc StrikesParent Material Damage

Note: Arc strikes require blending and crack detection, Seek advise on parent material damage

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Linear Misalignment

Plate Sample 6G RootPlate Sample 6G RootWelding Process MMA (SMAW)Welding Process MMA (SMAW)

Plate corrosion

Lack of Root Fusion

Poor Stop/Start

Surface Slag

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Note: Surface slag requires removal, plate corrosion requires wire brushing

Parent material gas cavities??

Crater pipe?? Surface slag??

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Plate Sample 6H CapPlate Sample 6H CapWelding Process MMA (SMAW)Welding Process MMA (SMAW)



Arc Strikes

Arc StrikesArc Strikes Slag Inclusion

Cap Undercut

Arc Strikes

Arc Strikes

Note: Parent plate damage throughout, seek advice. Arc strikes require blending and crack detection.

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Plate Sample 6H RootPlate Sample 6H RootWelding Process MMA (SMAW)Welding Process MMA (SMAW)

Crater pipe??

Poor stop/startLack of root fusion

Arc strikes

??Lack of root fusion

Excessive root penetration

Arc strikes????

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Linear misalignment + lack of root fusion??

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Plate Sample 6I CapPlate Sample 6I CapWelding Process MMA (SMAW)Welding Process MMA (SMAW)

Cap undercut

Poor toe blend full weld length

SpatterArc strikes?? ?? ??

??

Note: Arc strikes require blending and crack detection. Spatter requires removal.

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Plate Sample 6I RootPlate Sample 6I RootWelding Process MMA (SMAW)Welding Process MMA (SMAW)

Linear misalignment??

??Lack of root penetration

??Mechanical damage

??Lack of root penetration

??Burn through

??Lack of root fusion

??Poor stop/start ??Arc strike

??Lack of root fusion + poor stop/start


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Plate Sample 6J CapPlate Sample 6J CapWelding Process MMA (SMAW)Welding Process MMA (SMAW)

Suspect crater cracking

??Cap undercut

Cap undercut??

??Arc strikes ??Cap undercut

Cap undercut intermittent??

Porosity??

Note: Material damage throughout, seek advice. Arc strikes require blending and crack detection.

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Plate Sample 6J RootPlate Sample 6J RootWelding Process MMA (SMAW)Welding Process MMA (SMAW)

Mechanical damage

Linear misalignment + lack of root fusion

Lack of root fusion

Lack of root penetration

Linear misalignment + lack of root fusion

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Note: Material damage seek advice on course of action.

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Plate Sample T4 CapPlate Sample T4 CapWelding Process MMA (SMAW)Welding Process MMA (SMAW)

Mechanical damage

Cap undercut Cap undercut

Spatter/irregular cap profile

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Note: Grinding marks throughout seek advice on course of action.Excess cap height and poor cap profile throughout.

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Plate Sample T4 RootPlate Sample T4 RootWelding Process MMA (SMAW)Welding Process MMA (SMAW)

Root undercut intermittent

Ground flush root

Lack of penetration intermittent

Arc strike

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Plate Sample H8 CapPlate Sample H8 CapWelding Process MMA (SMAW)Welding Process MMA (SMAW)

Arc strikesMechanical

damage

Mechanical damage

Cap undercut intermittent

Cap undercut intermittent

Surface slag?? ??

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Note: Mechanical damage seek advice on course of action.Excess cap height and poor cap profile throughout. Arc

strikes require blending and crack detection.

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Plate Sample H8 RootPlate Sample H8 RootWelding Process MMA (SMAW)Welding Process MMA (SMAW)

Arc strike

Spatter

Lack of root fusion

Lack of root fusion

Root undercut intermittent

Lack of root fusion

Lack of root fusion

Spatter

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Note: Arc strikes require blending and crack detection. Spatter requires removal

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Any QuestionsAny Questions

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welding process and Defetc

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