Module 9

(1)

C

airo

I

nspection

C

ompany

Eng. Ibrahim Eldesoky

ASNT –NDT-LEVEL III

ASME AUTHORIZED INSPECTOR

Module 9

Weld and Base

Metal

(2)

Cairo Inspection Company (CIC) Www. CIC-Egypt.com Eng. Ibrahim Eldesoky

“

Any interruption in the uniform

nature of an item

”

(3)

3

Discontinuities



Seams and laps



Laminations



Weld undercut



Weld cracks



Weld porosity

(4)

Defect

“

A non-conforming discontinuity

”

All discontinuities are not defects.

All defects are discontinuities.

(5)

5

Discontinuity Criticality



Linear - non-linear



End condition - sharpness



Surface - sub-surface



Loading - uniform, non-uniform



Fatigue



Impact

(6)

6

Crack

“

A

fracture

type

discontinuity

characterized by a sharp tip and

high ratio of length and width

(depth) to opening displacement

”

(7)

7

Crack Types



Hot/cold



Delayed/underbead



Longitudinal



Transverse



Throat/toe/root



HAZ/base metal

(8)

8

(9)

10

(10)

(11)

13

(12)

14

Crater Cracks in

Aluminum Weld

(13)

15

Propagation of Crater

(14)

16

(15)

17



Often delayed cracking



Caused by hydrogen



Difficult to detect



Avoid with low H2 process

(16)

18

“

A weld discontinuity in which

fusion did not occur between

weld metal and fusion faces or

adjoining weld beads

”

(17)

19

Locations of

(18)

20

Incomplete Fusion

at Weld Face

(19)

22

Incomplete Fusion Between

(20)

23

Radiograph of Side-Wall

Incomplete Fusion

(21)

24

“

Weld metal does not extend

entirely

through

the

joint

thickness.

The term is used

only for groove welds.

”

Incomplete Joint

Penetration

(22)

25

Examples of Incomplete

Joint Penetration

(23)

26

Incomplete Joint

Penetration

(24)

28

“

Penetration not required to

be complete by designer

”

(25)

29

“

Entrapped

foreign

solid

material such as slag, flux,

tungsten or oxide

”

(26)

31

(27)

32

Radiograph of Elongated

(28)

33

Radiograph of

(29)

Cairo Inspection Company (CIC) Www. CIC-Egypt.com Eng. Ibrahim Eldesoky 34

“

Cavity type discontinuities formed

by gas entrapped during weld

metal solidification

”

(30)

35

Scattered Surface

Porosity

(31)

36

Linear Surface Porosity

(32)

37

(33)

38

Elongated Surface

Porosity

(34)

39

Radiograph of

(35)

Cairo Inspection Company (CIC) Www. CIC-Egypt.com Eng. Ibrahim Eldesoky

40

Radiograph of Cluster

Porosity

(36)

Cairo Inspection Company (CIC) Www. CIC-Egypt.com Eng. Ibrahim Eldesoky

41

Radiograph of Linear

Porosity

(37)

Cairo Inspection Company (CIC) Www. CIC-Egypt.com Eng. Ibrahim Eldesoky

43

“

A groove melted into the base

metal adjacent to the weld toe

or weld root and left unfilled by

weld metal

”

(38)

Cairo Inspection Company (CIC) Www. CIC-Egypt.com Eng. Ibrahim Eldesoky

44

Typical Appearance

of Undercut

(39)

Cairo Inspection Company (CIC) Www. CIC-Egypt.com Eng. Ibrahim Eldesoky

45

Undercut Adjacent

to Fillet Weld

(40)

Cairo Inspection Company (CIC) Www. CIC-Egypt.com Eng. Ibrahim Eldesoky

46

Radiograph of Surface

Undercut

(41)

Cairo Inspection Company (CIC) Www. CIC-Egypt.com Eng. Ibrahim Eldesoky

48

“

A condition in which the weld

face or the root surface is below

the adjacent surface of the base

metal

”

(42)

Cairo Inspection Company (CIC) Www. CIC-Egypt.com Eng. Ibrahim Eldesoky

49

Underfill in

Groove Welds

(43)

Cairo Inspection Company (CIC) Www. CIC-Egypt.com Eng. Ibrahim Eldesoky

50

Overlap

“

The protrusion of weld

metal beyond the weld

toe or weld root

”

(44)

Cairo Inspection Company (CIC) Www. CIC-Egypt.com Eng. Ibrahim Eldesoky

51

Overlap

(45)

Cairo Inspection Company (CIC) Www. CIC-Egypt.com Eng. Ibrahim Eldesoky

52

Overlap in

Fillet and

Groove Welds

(46)

Cairo Inspection Company (CIC) Www. CIC-Egypt.com Eng. Ibrahim Eldesoky

53

Undercut & Overlap

in Fillet Weld

Overlap

Undercut

(47)

Cairo Inspection Company (CIC) Www. CIC-Egypt.com Eng. Ibrahim Eldesoky

54

Fillet Weld Convexity

“

The maximum distance from

the face of a convex fillet weld

perpendicular

to

a

line

joining the weld toes

”

(48)

Cairo Inspection Company (CIC) Www. CIC-Egypt.com Eng. Ibrahim Eldesoky

55

(49)

Cairo Inspection Company (CIC) Www. CIC-Egypt.com Eng. Ibrahim Eldesoky

56

“

Weld metal in excess of

the quantity required to

fill a joint

”

(50)

Cairo Inspection Company (CIC) Www. CIC-Egypt.com Eng. Ibrahim Eldesoky

57

Face and Root

Reinforcement

(51)

Cairo Inspection Company (CIC) Www. CIC-Egypt.com Eng. Ibrahim Eldesoky

58

Face Reinforcement on both

sides when welded from both

(52)

Cairo Inspection Company (CIC) Www. CIC-Egypt.com Eng. Ibrahim Eldesoky

59

Effect of Weld

Reinforcement

angle on

Fatigue

Strength

(53)

Cairo Inspection Company (CIC) Www. CIC-Egypt.com Eng. Ibrahim Eldesoky

60

Improper and Acceptable

Treatment of Weld

(54)

61

Cairo Inspection Company (CIC) Www. CIC-Egypt.com Eng. Ibrahim Eldesoky

Arc Strike

“

A discontinuity resulting from

an arc, consisting of any

localized remelted metal,

heat-affected metal, or change in

the surface profile of any

metal object

”

(55)

Cairo Inspection Company (CIC) Www. CIC-Egypt.com Eng. Ibrahim Eldesoky

62

Photomicrograph of Martensitic

Structure Produced by an Arc

(56)

Cairo Inspection Company (CIC) Www. CIC-Egypt.com Eng. Ibrahim Eldesoky

63

“

Metal

particles

expelled

during fusion welding that do

not form part of the weld

”

(57)

Cairo Inspection Company (CIC) Www. CIC-Egypt.com Eng. Ibrahim Eldesoky

64

Crack Formed at

Weld Spatter

(58)

Cairo Inspection Company (CIC) Www. CIC-Egypt.com Eng. Ibrahim Eldesoky

65

“

A discontinuity with separation

or weakness generally aligned

parallel to the worked surface

of a metal

”

(59)

Cairo Inspection Company (CIC) Www. CIC-Egypt.com Eng. Ibrahim Eldesoky

66

Cracking and Delamination

Due to Lamination

(60)

Cairo Inspection Company (CIC) Www. CIC-Egypt.com Eng. Ibrahim Eldesoky

67

“

Separation of a lamination

under stress

”

(61)

Cairo Inspection Company (CIC) Www. CIC-Egypt.com Eng. Ibrahim Eldesoky

68

“A subsurface terrace- and

step-like separation in the base metal,

parallel to the surface, caused by

tensile stresses in the

through-thickness direction.

(62)

Cairo Inspection Company (CIC) Www. CIC-Egypt.com Eng. Ibrahim Eldesoky

69

(63)

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