1. Welding and inspection

2. Introduction Inspector’s background info …
25Years in Welding Inspection by Visual and NDT.
Heavy Equipment Fabrication Construction equipments.
In-Process Inspection of Pressure vessels.
Quality Control Team Leader, Welding Quality, NDT Ultrasonic testing and Quality concept.

3. WELDING THEORY “… Welding is joining two pieces of materials.
Solid+solid Welding = Solid state bonding
Liquid+Liquid welding=Fusion Welding
Solid+Liquid Welding=Braze Welding
Oxy-Aceteline=Gas Welding
Thermit =
Atomic hydrogen=

4. A) ELECTRICAL ARC WELDING
FCAW Flux cored Arc Welding
CAW Carbon arc Welding
SMAW Shielded metal arc Welding
GMAW Gas metal arc Welding
GTAW Gas Tungsten arc Welding
SW Stud Welding
PAW Plasma Arc Welding

5. B) ELECTRICAL RESISTANCE WELDING
Spot Welding
Seam Welding
Projection welding
Flash butt Welding
Electro slag Welding
Stud Welding

6. C) ELECTRICAL INDUCTION WELDING
Induction Pressure Welding
Induction Brazing

7. MECHANICAL ENERGY Friction Welding
Ultrasonic Welding, High freq sound waves
Explosive Welding

8. SPECIAL SOURCE WELDING
Electron Beam Welding
Laser Welding

9. ELECTRODE DAMAGE & INFLUANCE
Absorption or loss Moisture
Cracking & discaling covering
Contamination
Oxidation of the cored wire
Formation of deposits on the surface

10. Absorption or loss Moisture & INFLUANCE
Porosity in weld metal
Excessive Projection
Spattering arc instability
Visual worsening of seam surface
Scouring / Blistering in cellulose coating
Difficulty in removing slag
Cracking caused by hydrogen

11. Formation of deposits on the surface
Absorption or loss Moisture
Cracking & discaling covering
Contamination
Oxidation of the cored wire

12. ROLE OF WELDING OPERATOR
ENSURING GOOD WELDING QUALITY ALL TIMES

13. Welding inspection Crack Bead shift Burn through Porosity Pin holes
Waviness
Under cut
Weld appearance

14. Weldments - Symbols and Drawing Practices

15. DWGA130 Overview (Cont.) Primary Reference - ISO 2553:1992
Secondary References -
AWS A2.4:1998

16. Welding Symbol, Weld Symbol
FIGURE 1: Elements of a Welding Symbol

17. Elementary Weld Symbols
Most common are fillet, square groove and flare bevel weld joints

18. Supplementary Weld Symbols
Contour symbols not used much in the past

19. Weld Symbol Orientation
Reference lines and weld symbol details remain the same regardless of which end the arrow is on.

20. Weld Both Sides
Appropriate weld symbols above and below reference lines.
Dashed line not required where the weld joint is exactly symmetric.

21. Combined Weld Symbols More than one weld type.
Size specified individually for each.

22. Fillet Weld Size Required minimum weld size dimension (mm)
z = leg dimension
a = throat dimension

23. Butt/Groove Weld Size Required minimum throat dimension (mm)
No direct measurement - requires destructive test and evaluation

24. Intermittent Weld Dimensions
ISO vs AWS (App 2)
Size convention is the same
Number and length of segments
Spacing between segments vs AWS ctr to ctr method

25. Symmetric Intermittent Weld
Same weld symbol and dimensions both sides
Dashed line not required
Anchor welds at each end

26. Staggered Intermittent Weld
Usually specified to avoid weld distortion or interference
Offset dimension specified in detail vs default
Anchor welds - standard shop practice
Z denotes staggered intermittent weld

27. Intermittent Weld on Circular Part
If necessary, start location must clearly be identified
Weld size
Number and length of segments
Spacing between segments (chord dimension)

28. Weld All Around Simplified details
Exactly the same joint conditions and welds all the way around

29. Testing methods Visual inspection Ultrasonic Testing Destructive
Mechanical,
Chemical,
Testing
Visual
inspection
Ultrasonic
Testing
D P
Testing ,
MPT,ECT,
X-RAY
AET,LEAK,
NRT,

30. Good welding Practice summary
Right Welding parameter at any time
Setting
With error proof interlock
(Poka yoke)
WELDING
SOUNDNESS
No Adjustment
Monitoring
For right welding at first
Time and any time
METRICS & REACH OUT GOALS

31. Continuous Improvement Model
Welding parameter entry
RESULT
EVALUATION
TIME
Trend Chart
GOAL
Check
PARETO
ANALYSIS
100%
Set alingment
REPAIR,
IDENTIFY
ACTION PLAN
Action Name Date

32. PM Good Welding CURRENT Wire feed VOLTAGE WIRE POSITION Alingment
Setting
DIFT
Input Quality,
Good Fittment,
Job position,
TIME

33. GOOD WELDING CONTRIBUTION

34. Input material Quality
CHECK POINTS
Roll equality
Spool quality
Alignment
Torch setting
Flux baking
FITUP GAP
RUST
Input material Quality
Machine trueness
Check incoming component
Clean and remove rust, oil
Ensure proper welding.
Key Decisions Made
Ensure proper welding parameter
Set appropriate Time
Correct and monitor the process

35. Quantum Improvement in terms of
Requirement
Weld appearance
Weld cap angle
(Abt use angle)
Uniform weld bead
Uniform reinforcement
TO ACHIVE
Quantum Improvement in terms of
Quality
Cost
Cycle time
Weld width
Leading Consultants for 6 and Cycle time Reduction
Clients:Citicorp, PwC, ICI, 3M, Telstra
Meet spec
Penetration
Side wall fusion