WIXLIB

OTHER FABRICATION SCARSDefinitionAny accidental groove or cut that penetratesthe surface of the metal. Sometimes callednicks, gouges or handling marks.Preventive Action1. Avoid dropping heavy or sharp objects onwelds and surrounding base material.2. Be careful when grinding, carbon arcing orusing scaling hammer.3. Use undercut gauge to verify scar acceptability.Corrective Action1. Grind the affected area until the unacceptable fabrication scar blends smoothly intothe base material or weld face.2. Weld repair the affected area, if needed.31Back toTable of Contents

POROSITY32Back toTable of Contents

POROSITYDefinitionOpen holes formed by gas that was trappedwhen the weld cooled. Sometimes called “pinholes.”Preventive Action1. Remove contaminants from the joint (rust,grease, moisture, etc.) prior to welding.2. Maintain filler metal control requirements.3. Maintain appropriate arc length/wire stickout.4. Adjust torch/rod angle.5. Use the largest size gas cup possible andkeep it free of spatter.6. Position wind screens between the weldingoperation and any heavy flow of air.Corrective Action1. Completely remove porosity from all intermediate weld areas.2. Grind or carbon arc the affected area until theunacceptable porosity is removed from theweld.3. Weld repair the affected area, if needed.33Back toTable of Contents

SPATTERA 1/8" wide x 1/8" deep notchis for verifying size of spatter1/4"34Back toTable of Contents

SPATTERDefinitionThe metal particles expelled during welding thatdo not form a part of the weld.Preventive Action1. Remove contaminants from the joint (rust,grease, moisture, etc.) prior to welding.2. Maintain filler metal control requirements.3. Use Refrasil to protect surrounding surfacesfrom secondary weld spatter.4. Adjust amps/volts.5. Adjust torch/rod angle.6. Maintain appropriate arc length/wire stickout.7. Use ceramic tape or approved metal backingstrap on areas with root gap.8. Consult local Welding Engineering in caseswhere the base material is magnetized.Corrective Action1. Completely remove spatter from all intermediate weld areas.2. Remove all loose spatter with a needle gun.3. Grind all tightly adhering, unacceptablespatter until it blends smoothly into the basematerial or weld.35Back toTable of Contents

SLAGA 1/8" wide x 1/8" deep notchis for verifying size of slag1/4"36Back toTable of Contents

SLAGDefinitionThe nonmetallic layer that forms on top of themolten metal.Preventive ActionNote: Slag is a byproduct of the welding processthat cannot be prevented. Below are someactions that make slag removal easier.1. Adjust amps/volts.2. Maintain a consistent travel speed.3. Maintain an appropriate arc length/wire stickout.4. Adjust torch/rod angle.5. Sequence weld passes so that the toes of thebeads sufficiently overlap one another,minimizing valleys.Corrective Action1. Completely remove slag from all intermediateweld areas.2. Remove all loose slag with a needle gun.3. Grind all tightly adhering, unacceptableslag from the surface of the base material orweld.37Back toTable of Contents

WELD REINFORCEMENT** Check local proceduresfor areas that haveheight restrictions.38Back toTable of Contents

WELD REINFORCEMENTDefinitionThe amount of weld that is above a straight linedrawn from the edges of the joint preparation of agroove weld.Preventive Action1.2.3.4.5.Adjust amps/volts.Increase travel speed.Maintain appropriate wire stickout.Adjust torch/rod angle.Sequence beads so that the toes do notexcessively overlap one another, creating highspots in the reinforcement.Corrective ActionGrind or carbon arc areas of weld reinforcementthat exceed the maximum allowable height (ifapplicable).39Back toTable of Contents

MELT THROUGH40Back toTable of Contents

MELT THROUGHDefinitionExcessive heat and/or penetration that resultsin irregularity on the surface of the backing ringor strip, fused root or adjacent base material.Preventive Action1. Reduce amps/volts.2. Increase travel speed.3. Maintain appropriate arc length/wire stickout.4. Use ceramic tape or approved metal backing strap on areas with root gap.Corrective Action1. Grind or carbon arc the weld to soundmetal.2. Weld repair the affected area, if needed.41Back toTable of Contents

OFFSET42Back toTable of Contents

OFFSETDefinitionA situation where base materials creating a buttor corner joint have moved out of alignment orposition. Sometimes called “misalignment.”NOTE: Offset is one of the major causes of inservice failures!Preventive Action1. Ensure installing trade provides proper fit-upprior to welding.2. Use approved temporary attachments(strongbacks, flatbar, etc.), as needed toreduce distortion.3. Gauge for offset acceptability prior to tackwelding with bridgecam or finger gauges.4. Apply sufficient block tacks prior to welding.Note: Stop welding and immediately notify yourforeman anytime unacceptable offsetoccurs.Corrective Action1. Installing trade may have to cut apart and re-fitthe joint within tolerance.2. Offset may be repaired by applying weld buildup to the appropriate taper.43Back toTable of Contents

OXIDATIONcoppernickelsteel44Back toTable of Contents

OXIDATIONDefinitionA condition resulting from partial or completelack of purge of a surface which is heated duringwelding resulting in formation of oxide on thesurface. This condition may range from slightoxidation evidenced by a multicolored or tightlyadhering black film to the extreme of a very roughsurface having crystalline appearance (referred toas “sugaring.”)Preventive Action1. Ensure adequate pipe purge is maintainedprior to and throughout the welding process.2. Remove contaminants from the joint (rust,grease, moisture, etc.) prior to welding.Corrective Action1. Grind the weld to sound metal.2. Weld repair the affected area, if needed.45Back toTable of Contents

CRATER PIT46Back toTable of Contents

CRATER PITDefinitionA hole extending into the weld resulting fromshrinkage during cooling.Preventive Action1. Remove contaminants from the joint (rust,grease, moisture, etc.) prior to welding.2. When breaking the arc for TIG welding, rapidly pop the trigger several times to avoidsudden pull-offs. This will provide sufficientpost purge of the weld puddle.Corrective Action1. Grind the weld to sound metal.2. Weld repair the affected area, if needed.47Back toTable of Contents

PAINT48Back toTable of Contents

PAINTDefinitionA pigmented oil or liquid that forms a coloring orprotective coating when dry. May be found on theweld face or in the weld inspection area.Preventive ActionEnsure installing trade adequately removes paint,paint stick markings and metal marker writings inthe weld zone prior to fitting and welding.Corrective ActionGrind, wire wheel or needle gun the weld zonefree of paint prior to welding.49Back toTable of Contents

Types of Weld Joints(Square)Butt(Single V)(Double V)(Single U)Tee(Square)(Single Bevel)(Single J)(Double Bevel)50Back toTable of Contents

Types of Weld JointsCorner(Square)(SingleBevel)(Single J)(Single U)51Back toTable of Contents

Types of Weld JointsLapEdge52Back toTable of Contents

Parts of a Weld* This represents the theoretical throat (the minimum specified leg size multiplied by 0.7) which is the shortest distancefrom the joint root to the hypotenuse (straight line drawn toeto toe) of the largest right triangle that can be drawn withinthe fillet weld cross section.53Back toTable of Contents

B2V.3Structural JointNumbering SystemFirst character (Letter)Designates type of joint:B - ButtC - CornerT - TeeL - LapPT - Partial PenetrationE - EdgeSecond Character (Number)Designates Number of SidesWelded:1 - Welded One Side2 - Welded Both SidesThird Character (Letter)Designates Configuration ofJoint:S - Square GrooveV - Beveled or V GrooveU - U-Shaped GrooveJ - J-Shaped GroovePeriod Used for SeparationFourth Character (Number)Is Assigned In Sequence, 1,2,3,Etc., to Cover Distinctive JointDifferences such as Bevel Angle,Root Opening, With Backing,Without Backing, Etc.54Back toTable of Contents

Structural JointNumbering SystemEXAMPLESC1V.2Single BeveledGrooveCorner JointWelded One Side55Back toTable of Contents

Structural JointNumbering SystemEXAMPLEST2V.2Tee JointDouble BeveledGrooveWelded Both Sides56Back toTable of Contents

Structural JointNumbering SystemEXAMPLESB2V.1Butt JointSingle VGrooveWelded Both Sides57Back toTable of Contents

Structural JointNumbering SystemEXAMPLESB1V.1Butt JointSingle VGrooveWelded One Side58Back toTable of Contents

Structural JointNumbering SystemEXAMPLESB2V.3Butt JointDouble V GrooveWelded Both Sides59Back toTable of Contents

Standard Welding SymbolLayoutWeld SizeS(Far or Other Side)(Near or Arrow Side)Elements in thisarea as shownregardless ofarrow orientationReference ArrowWeld all aroundSymbolReference LineWeld Symbolor Reference60Back toTable of Contents

Standard Welding SymbolsFillet Near SideFillet Far SideFillet Both Sides61Back toTable of Contents

Standard Welding SymbolsV Groove Near SideV Groove Far SideV Groove Both Sides62Back toTable of Contents

Standard Welding SymbolsSingle Bevel Near SideSingle Bevel Far SideDouble Bevel63Back toTable of Contents

Standard Welding SymbolsSingle Beveled Tee JointWelded One Side / Fillet ReinforcedT1V.1Joint hasa bevelFillet sizenear side64Back toTable of Contents

Standard Welding SymbolsSingle Beveled Tee JointWelded Both Sides / Fillet ReinforcedT2V.1Fillet sizefar sideJoint hasa bevelFillet sizenear sideNote: Backgouge and visualinspection required65Back toTable of Contents

Standard Welding SymbolsPartial PenetrationDouble Bevel Tee JointWelded both sides / Fillet ReinforcedExample of PT2V.1S fillet sizeB depth of bevelBSBFillet sizefar sideJoint isbeveledboth sidesSFillet sizenear sideB3/8 Filletsize farsideJoint isbeveled1/2 deepboth sides3/81/23/8S3/8 Filletsize nearside66Back toTable of Contents

Using Finger Gauge to Measure:ConcavityCheck Concavity usingthe Proper Size WireConvexityCheck Convexity usingthe Proper Size WireOverlap/Roll OverOverlap angleless than 90 67Back toTable of Contents

Use Finger Gauge to Measure SkewedFillet and Fillet Reinforced WeldsGauging Skewed WeldsFinger gauges are the only gauges capable ofgauging skewed welds.Note that when the angle of the joint preparationis less than 90 the actual length of the weld legswill increase.68Back toTable of Contents

Finger Gauge to Measure Spatter/SlagA 1/8" wide x 1/8" deep notch isfor verifying size of k toTable of Contents

Using Bridgecam Gauge To Measure:Fillet Weld ThroatRead from theoreticalthroat scale.Fillet Leg Length70Back toTable of Contents

Using Bridgecam Gauge To Measure:ReinforcementOffset71Back toTable of Contents

Using Gauges to Measure:UndercutUNDERCUT GAUGE72Back toTable of Contents

Definitions1. Completed weld – A weld that is completed and isready for final visual inspection.2. Defect – Any harmful discontinuity that must be repairedto be acceptable.3. Discontinuity – Any imperfection in the normal structureor configuration of a weld or the base material that mayor may not need to be repaired.4. Final visual inspection of welds– Visual inspectionperformed on a completed weld in the final surfacecondition and heat-treated condition.5. Finished weld – A weld that has received finalinspection and has been accepted.6. In-process visual inspection of welds- Visualinspection performed on intermediate passes of multipass welds.7. Sound metal – Metal that contains no defects.8. Skewed fillet welds - Fillet or fillet reinforced weld that isless than 85 or greater than 95 . NDT – Nondestructive TestingVT Visual InspectionMT Magnetic Particle InspectionPT Liquid Penetrant InspectionUT Ultrasonic InspectionRT Radiographic InspectionET Eddy Current Inspection73Back toTable of Contents

Scale Divisions 32- 5mm0- 5.4mmNote: For training purposes only. Not to Scale!Back toTable of Contents

Visual Inspection Responsibilities. 1. When – Final visual inspections must be performed: a) When the weld is complete, and in the final sur-face and heat treated conditions b) Before other NDT (when required) c) Before being made inaccessible for inspection 2. Where – the weld inspection