1. Welding Inspection and Metallurgy

2. Welding Inspection and Metallurgy
Objectives
Become familiar with definitions and welding inspection terminology
Understand the tasks and processes required to perform welding inspections.
- Tasks Prior to Welding.
- Tasks during Welding Operations
- Tasks Upon Completion of Welding
- Non-conformances and Defects
- NDE Examiner Certification
- Safety Precautions

3. Welding Inspection and Metallurgy
Objectives
Introduce the welding process types and their advantages and disadvantages based on intended application, these include:
- Shielded Metal Arc Welding (SMAW)
- Gas Tungsten Arc Welding (GT AW)
- Gas Metal Arc Welding (GMAW)
- Flux Core Arc Welding (FCAW)
- Submerged Arc Welding (SAW)
- Stud Arc Welding (SW)

4. Welding Inspection and Metallurgy
Objectives
Introduce Non-Destructive Examinations methods not covered in previous class lessons and their applications, to include;
- Types of Discontinuities
- Materials Identification methods
- Visual Examination (VT)
- Alternating Current Field Measurement (ACFM)
- Eddy Current Inspection (ET)
- Hardness Testing
- Pressure and Leak Testing (LT)
- Weld Inspection Data Recording

5. Welding Inspection and Metallurgy
Objectives
Outline basic application of metallurgy to the welding processes, including;
- The Structure of Metals and Alloys
- Physical Properties
- Mechanical Properties
- Preheating
- Post-weld Heat Treatment
- Hardening
- Material Test Reports
- Weldability of Steels
- Weldability of High-alloys

6. Welding Inspection and Metallurgy
Objectives
Present the nature of and remedies for Refinery and Petrochemical Plant Welding Issues, such as;
- General Issues in welding
- Hot Tapping and In-service Welding
- Lack of Fusion with GMAW-S Welding Process
Other Items to be discussed
Welding Terminology and Welding Symbols
Actions to Address Improperly made production welds.
Guide to common filler metals selection
Example RT reports

7. Welding Inspection and Metallurgy
Definitions
‘Some of the less known’
autogenous weld: A fusion weld made without filler
metal. ( The most common of these types of welds is made on tubing and performed with Gas Tungsten Arc Welding often using an automated welding device)

8. Welding Inspection and Metallurgy
Definitions
- actual throat: The shortest distance between the weld
root and the face of a fillet weld.

9. Welding Inspection and Metallurgy
Definitions
- direct current electrode negative (DCEN): The
arrangement of direct current arc welding leads in which the
electrode is the negative pole and work piece is the positive
pole of the welding arc. (Commonly known as straight polarity).

10. Welding Inspection and Metallurgy
This Section is to detail the tasks that are considered the responsibility of the Inspection group as well other concerned parties who will design, examine, or perform welding.

11. Welding Inspection and Metallurgy
Tasks Prior to Welding
Preplanning will eliminate most mistakes before they happen. A good repair plan will always include a preplanning stage for the welding part of the repair.
Drawings, Codes, Standards requirements should be clearly defined and understood.
Quality Control Items to Assess Include:
Welding symbols and sizes
Weld joint designs clearly defined
Weld maps for major projects that specify the WPS used.

12. Welding Inspection and Metallurgy
Tasks Prior to Welding
Quality Control Items to Assess Include:
Potential for weld distortion addressed
Welding consumable handling addressed (rod ovens ect.)
Base metal requirements addressed (type, impact tests.)
Mechanical testing required and acceptance criteria
Protection for welding such as wind and rain barriers

13. Welding Inspection and Metallurgy
Tasks Prior to Welding
Potential Inspector actions:
The inspector’s responsibilities prior to welding can include;
Look for missing details and information
Determine if the planned testing is adequate
Look for Code and specification violations in the plan
Identify possible welding problems ( Example: inadequate root spacing or a bevel that will not allow full penetration)

14. Welding Inspection and Metallurgy
Tasks Prior to Welding
Weldment Requirements
Quality Control Items to Assess Include:
Competency of the Welding Organization to meet requirements of Codes and Standards to be used
Competency of the Inspection Organization
The roles and responsibilities of the various parties involved
Independence of the Inspection Organization from the Production group.

15. Welding Inspection and Metallurgy
Tasks Prior to Welding
The other issues that the inspector must address as part of tasks prior to welding are;
NDE Information
Welding Equipment and Instruments
Heat Treatment and Pressure Testing
Materials
Weld Preparation
Preheat
Welding Consumables
The items above are very similar in there language as to the individual of the various group’s responsibilities, concentrate on the INSPECTOR’S tasks during your studies.

16. Welding Inspection and Metallurgy
Tasks During Welding Operations
Welding inspection during welding operations include things to be checked for conformance to the WPS.
Quality Assurance
Establish a quality assurance and quality control relationship with the welding organization, the inspector should make it clear what is expected during the job.

17. Welding Inspection and Metallurgy
During Welding Operations
Quality Control items to assess;
Make sure all involved know that the welder is responsible for the quality of the welds he makes
Make sure the welder meets the qualification requirements
Determine if the welder understands the welding procedure and requirements this includes any inspection hold points.

18. Welding Inspection and Metallurgy
Tasks During Welding Operations
Welding Parameters and Techniques
Quality Control Items to Assess:
Make sure essential variables are maintained during welding. Such as;
The correct filler metal, fluxes and gasses are used.
2. Purge techniques, flow rate, gas analysis, etc.
3. Rod warmers are used or maximum time out of the rod oven is followed.

19. Welding Inspection and Metallurgy
Tasks During Welding Operations
Quality Control Items to Assess:
4. Make sure they use the specified preheat during tack welding as well as during the actual welding.
5. Verify equipment setting are in compliance with the WPS. Such as voltage, amperage, wire speed, etc.
6. Verify that interpass temperatures are be observed.
7. Where it applies confirm weld travel speed. This is a key element in control of heat input.

20. Welding Inspection and Metallurgy
Tasks During Welding Operations
Weldment Examination
Perform visual examination and possibly in-process NDE
Quality Control Items to Assess:
Confirm tack welds are acceptable.
Weld root pass has adequate penetration and quality.
That cleaning between passes and back gouged surfaces are adequate.
Witness or perform NDE between passes as required.
Verify in-process repairs and defect removal
Ferrite measurements when required are recorded
Verify final butt-weld reinforcement or fillet weld size

21. Welding Inspection and Metallurgy
Tasks During Welding Operations
Potential Inspector Action;
Reject unacceptable workmanship.

22. Welding Inspection and Metallurgy
Tasks Upon Completion of Welding
Read and become familiar with all of the following;
Appearance and Finish;
Quality Control Items to assess
Inspector action.
Other topics include;
NDE Review
PWHT
Pressure Testing
Documentation Audit
Non-Conformances and Defects
NDE Examiner Certifications
Safety Precautions

23. Class Quiz
1. An autogenous weld is a fusion weld made ____filler metal.
a. with
b. without
c. with or without
Fill in the blanks:
2. The inspector’s responsibilities prior to welding can include a. ________________b.____________________
c._______________________ d.__________________

24. Solutions 1. An autogenous weld is a fusion weld made ____filler
metal.
b. without
2. The inspector’s responsibilities prior to welding can include a. ________________ b.____________________
c._______________________ d.__________________
a. Look for missing details and information
b. Determine if the planned testing is adequate
c. Look for Code and specification violations in the plan
d. Identify possible welding problems