TWI

CSWIP

VISUAL INSPECTION OF WELDS

 Terminology
Butt Joints
Square Edged
Closed Open

Single Sided Butt

Vee Bevel

Double Sided Butt

Vee Bevel
 Terminology
Fillet Joints

Tee Lap

Corner
 Terminology

Included Angle
60-700

0-2 mm

2-4 mm

Root Gap Root Face

 Terminology
Butt Weld Features 10

8
7 9
1 2

4
5
3

6
 Terminology
Fillet Weld Features
10

9
4

7
2
5
3 8
1
6
 Joint Design
Butt Weld

Lap Joint
Corner
Joint

Tee Joint

Edge Weld
 Zones in Fusion Welds

• Parent Material or Base Metal

• Heat Affected Zone
• Fusion Zone
Visual Inspection Procedures
Important things to consider
When do I carry out inspections?
• How do I carry out inspections?
• What do I look for?
• What equipment do I need?
• How do I interpret the code or standard
requirements?
• What is the nature of the product?
• What operating conditions will be present?
• What is the quality of welding required?
• Is there a code or standard available to
inspect the welds against
 Welding Checklist
Before Welding Commences

• Documentation
• Materials
• Weld preparations
• Fit up for welding
• Welding equipment
 Welding Checklist
During Welding
• Correct parameters
• WPS at the work place
• Inter run cleanliness and quality
• Interpass temperature
• Consumable control
• Maintenance of preheat
• Process control NDE regime
• Weld records and maintenance of weld maps
 Welding Checklist
Welding Completion
• Visual inspection and records
• NDE
• PWHT
• Final testing
• Cleaning, painting, preservation, packing
• Final documentation
 Features to Consider
Butt welds - Size

Weld cap width

Excess weld
metal height

Root
penetration

Root bead width

 Features to Consider
Fillet welds - Size
Excess Actual throat
weld thickness
metal

Minimum and Design throat

maximum leg thickness
length size
 Features to Consider
Importance of Fillet weld leg length Size

(a) (b)

4mm 8mm

6mm 4mm

What size is the Throat thickness of (a)

What size is the Throat thickness of (b)
 Features to Consider
Importance of Fillet weld leg length Size

(a) (b)

4mm 6mm

4mm 6mm

How much bigger is (a) in volume than (b)

 Features to Consider
(a) (b)

4mm 6mm

4mm 6mm

(a) volume = (b) volume =

4 x 4 = 8mm2 6 x 6 = 18mm2
2 2

The volume of (b) is over double the volume of (a)

Without the extra reinforcement being added
 Features to Consider
Fillet welds - Size & Shape

Convex
Mitre

Concave
 Features to Consider
Fillet welds - Toe Blend
 Features to Consider
EFFECTIVE THROAT THICKNESS
“a” = Nominal throat thickness “s” = Effective throat thickness

a s

Deep throat fillet welds from FCAW & SAW etc

 Features to Consider
Butt welds - Profile

x
x x
 Features to Consider
Butt welds - Toe Blend

x
x x
 Features to Consider
Butt welds - Weld Width
 A Weld : Definitions

BS 499 NASA
• A union between • A continuous defect
pieces of metal at surrounded by
faces rendered parent material
plastic or liquid by
heat,pressure or
both.
 Welds
An ideal weld must give a strong bond
between materials with the interfaces
disappearing
To achieve this
• Smooth,flat or matching surfaces
• Surfaces shall be free from contaminants
• Metals shall be free from impurities
• Metals shall have identical crystalline structures
 Electric Arc Welding

Electrode

Power
supply

Work piece

Clamp(Earth)
 Electric Arc Welding
• Electric discharge produced between cathode
and anode by a potential difference (40 to 60
volts)

• Discharge ionises air and produces -ve

electrons and +ve ions

• Electrons impact upon anode, ions upon

cathode

• Impact of particles converts kinetic energy to

heat (7000o C) and light

• Amperage controls number of ions and

electrons, Voltage controls their velocity
 Manual Metal Arc Welding

• Shielding provided by Welder controls

decomposition of flux • Arc length
covering • Angle of electrode
• Electrode consumable • Speed of travel
• Manual process • Amperage settings
 Manual Metal Arc Welding
POWER SOURCE
POWER Input 240v (single phase) or
SOURCE:- 415v ( 2 live phases of 3 phase supply)

Output AC (O.C.V. 80v) or DC (O.C.V. 50v) or both.

AC for Shop

DC for site work as it is SAFER (lower OCV). Also for

shop work..

Current adjustment control

TYPES:- Transformers – AC only

Transformer/Rectifiers – AC and DC
Petrol or Diesel driven Generators – Site work – DC
Inverters – AC and DC
 Manual Metal Arc Welding

Power control
panel Power source.
Transformer/
Rectifier
Electrode oven
Heated quiver

Electrodes
Inverter
Power return power source
cable
Electrode
holder
Safety visor
(With dark lens) Power cable
*
Manual Metal Arc (MMA)
 Tungsten Inert Gas (TIG)

Power Transformer/
control Rectifier
panel
Power return Inverter
cable power source

Torch Power
assemblies control panel

Power cable
Tungsten
electrodes
Flow-meter
 Tungsten Inert Gas (TIG)
POWER SOURCE

POWER SOURCE Transformers for AC – aluminium alloys

440v 50Hz 3 phase or Rectifiers for DC - steels
240v single phase Transformer/rectifier for AC/DC
input Inverters for AC/DC – more portable - expensive

TORCH Sizes/types vary depending on current/application

TORCH HOSE Flexible – may carry current, gas, cooling water.

RETURN LEAD Note that current actually flows from this lead

INERT GAS SUPPLY Correct type for application.(ar, he, ar/he mixture)
(Cylinder & regulator) Argon/hydrogen for austenitic stainless steel
FLOWMETER To deliver correct gas flow (velocity) depending on
(graduated in ltr/min) welding position and joint configuration.
 Tungsten Inert Gas (TIG)
GAS
TORCH WELDING LEAD + SUPPLY
METERS
GAS SUPPLY (OPTIONAL)
VARIABLE
NORMALLY CURRENT I
ARC DC-VE CONTROLLER N
E
THE POWER I V R
SOURCE T
_ G
OUTPUT AC/DC
80 OCV A
MAX + CONSTANT S
CURRENT

RETURN ARC
EARTH* LEAD STRIKING
*CHECK WITH HSE GUIDANCE NOTE DEVICE
 Tungsten Inert Gas (TIG)

Tungsten Tungsten
housing electrodes

Fitted ceramic Ceramic

shielding cup shield cup
On/Off switch
Gas lens
Split collet
Gas diffuser

Spare ceramic Torch body

shielding cup *
Tungsten Inert Gas (TIG)
 Metal Inert Gas (MIG)
External wire Transformer/
feed unit Rectifier

Internal wire
feed system Power cable &
hose assembly
Power control
panel
Liner for wire
15kg wire spool

Power return Welding gun

cable* assembly
Metal Inert Gas (MIG)
Submerged Arc
 Welding Defects
Cracks
Classified by Shape Classified by Position
• Longitudinal •HAZ
• Transverse •Centreline
•Crater
• Branched •Fusion zone
• Chevron •Parent metal
 Welding Defects
Cracks
4 Crack Types
• Solidification cracks
• Hydrogen induced cracks
• Lamellar tearing
• Reheat cracks
 Welding Defects
Cracks
Solidification
• Occurs during weld solidification process
• Steels with high sulphur content (low ductility at
elevated temperature)
• Requires high tensile stress
• Occur longitudinally down centre of weld
• e.g. Crater cracking
Welding Defects
Solidification Cracking
Welding Defects

Deeper and narrow weld

beads are prone to
solidification cracking
(depth to width ratio
over 2:1)

In order to avoid
solidification cracking,
reduce penetration and
increase bead width
(depth to width ratio
0,5:1)
 Welding Defects
Cracks
Hydrogen Induced
• Requires susceptible grain structure, stress and
hydrogen
• Hydrogen enters via welding arc
• Hydrogen source - atmosphere or contamination of
preparation or electrode
• Moisture diffuses out into parent metal on cooling
• Most likely in HAZ
Welding Defects
Hydrogen Cracking
Welding Defects
Hydrogen Cracking
 Welding Defects
Cracks
Lamellar Tearing
• Step like appearance
• Occurs in parent material or HAZ
• Only in rolled direction of the parent material
• Associated with restrained joints subjected to
through thickness stresses on corners, tees and
fillets
• Requires high sulphur or non-metallic inclusions
 Welding Defects
Lamellar Tearing
 Welding Defects
Lamellar Tearing

Restraint

High
contractional
stress
Lamellar tear
 Welding Defects
Lamellar Tearing
Grind and infill with
ductile weld metal Re-design weld

Control
restraint

For critical work a forged

“T” piece may be used
Forged “T” Piece
 Welding Defects
Cracks
Re-Heat Cracking
• Occurs mainly in HAZ of low alloy steels during
post weld heat treatment or service at elevated
temperatures
• Occurs in areas of high stress and existing defects
• Prevented by toe grinding, elimination of poor
profile material selection and controlled post weld
heat treatment
 Welding Defects
Incomplete root penetration

Causes
• Too small a root gap
• Arc too long
• Wrong polarity
• Electrode too large for joint
preparation
• Incorrect electrode angle
• Too fast a speed of travel for
current
Welding Defects
a) Excessively thick root face

b) Too small a root gap

c) Misplaced welds

d) Power input too low

e) Arc (heat) input too low

Welding Defects
Too large diameter
electrode

Smaller (correct)
diameter electrode

Lack of sidewall
fusion due to arc
deflection
 Welding Defects
Incomplete root Fusion

Causes
• Too small a root gap
• Arc too long
• Wrong polarity
• Electrode too large for
joint preparation
• Incorrect electrode angle
• Too fast a speed of travel
for current
 Welding Defects
Root concavity

Causes
• Root gap too large
• Insufficient arc energy
• Excessive back purge TIG
 Welding Defects
Excess Root Penetration

Causes
• Excessive amperage during
welding of root
• Excessive root gap
• Poor fit up
• Excessive root grinding
• Improper welding
technique
 Welding Defects
Root undercut

Causes
• Root gap too large
• Excessive arc energy
• Small or no root face
 Welding Defects
Cap Undercut

Causes
• Excessive welding current
• Welding speed too high
• Incorrect electrode angle
• Excessive weave
• Electrode too large
 Welding Defects

Overlap

Excess weld
metal
 Welding Defects
Lack of fusion

Causes
• Contaminated weld preparation
• Amperage too low
• Amperage too high (welder increases speed of
travel)
 Welding Defects
Incompletely Filled Groove
& Lack of Side wall Fusion

• Causes
• Insufficient weld metal deposited
• Improper welding technique
 Welding Defects
Inter run Incompletely Filled Groove

Causes
• Insufficient weld metal deposited
• Improper welding technique
 Welding Defects
Gas pores / Porosity

Causes
• Excessive moisture in flux or preparation
• Contaminated preparation
• Low welding current
• Arc length too long
• Damaged electrode flux
• Removal of gas shield
 Welding Defects
Gas pores / Porosity
 Welding Defects
Inclusions - Slag

Causes
• Insufficient cleaning between passes
• Contaminated weld preparation
• Welding over irregular profile
• Incorrect welding speed
• Arc length too long
 Welding Defects
Inclusions - Slag

Causes
• Insufficient cleaning between passes
• Contaminated weld preparation
• Welding over irregular profile
• Incorrect welding speed
• Arc length too long
Welding Defects

Poor (convex) weld bead

profile resulted in pockets
of slag being trapped
between the weld runs

Smooth weld bead

profile allows the slag
to be readily removed
between runs
 Welding Defects
Inclusions - Tungsten

Causes
• Contamination of weld Caused by tungsten touching
weld metal or parent metal during welding using the
TIG welding process
 Welding Defects
Burn Through

Causes
• Excessive amperage during welding of root
• Excessive root grinding
• Improper welding technique
 Welding Defects
Spatter

Causes
• Excessive arc energy
• Excessive arc length
• Damp electrodes
• Arc blow
 Welding Defects
Arc Strikes
Causes

• Electrode straying onto

parent metal

• Electrode holder with

poor insulation

• Poor contact of earth

clamp
 Welding Defects
Mechanical Damage

Chisel
Chisel Marks
Marks Pitting Corrosion Grinding Marks
 Welding Defects
Non-alignment of
two abutting edges
 Page 1 of 3 EXAMPLE PLATE REPORT
Name: [Block capitals] Mr. I C Plenty Signature: I C Plenty Test piece ident: 001
Code/Specification used: TWI 09-09-03 Welding process: MMA/SMAW Joint type: Single V Butt

Welding position: Flat /PA Length & thickness of plate: 300mm x 10 mm Date 22/08/2003
MEASURE

WELD FACE

A B C
Lack of
sidewall fusion Gas pore Undercut smooth
1.5 Ø 1.5 max
FROM

87 236
22 230
30
THIS

51 8 153 40
Arc Strike
Slag
Centreline 241
inclusion
DATUM

crack
NOTES: Cap height : 4mm.
Weld width: 12-14mm
Toe blend: Poor
Misalignment: 2mm
EDGE

Angular Distortion 3mm in 50mm

Spatter along weld length or scale on the plate surface
Page 2 of 3
MEASURE EXAMPLE PLATE REPORT

WELD ROOT

A B C
Root concavity
2 deep LACK OF ROOT
FUSION
FROM

23 247
10 20
THIS

128 50

Incomplete root
penetration
DATUM

NOTES: Penetration height : 4mm.

Linear Misalignment: 2mm
Angular Distortion: 3mm in 50mm
Any scale on plate surface
EDGE
EXAMPLE WELD INSPECTION REPORT/SENTENCE SHEET

PRINT FULL NAME I C Plenty

SPECIMEN NUMBER 001
EXTERNAL DEFECTS Defects Noted Code or Specification Reference

Defect Type Pipe/Plate Accumulative Maximum Section/ Accept/Reject

Section Total Allowance Table No 5
1 2 3 4

Excess weld metal height AC 4mm 3mm 15 Reject

Excess weld metal appearance A-C Poor blend Smooth 19 Reject
Incomplete filling A-C 22mm None 8 Reject

Inadequate weld width A-C NONE ------------ ---------- Accept

Slag Inclusions A-C 1x 8mm long 2mm 3 Reject

Undercut A-C 1.5mm depth 1mm 11 Reject

Surface Porosity A-C 1.5mm  1mm 2 Reject

Cracks/Crack-like defects A-C 40mm NONE 1 Reject*

Lack of fusion A-C 22mm NONE 5 Reject

Arc strikes A-C 30x25 ------------ 12 Seek advise***

Mechanical damage A-C NONE ------------ ---------- Accept

Laps/Laminations A-C NONE ------------ ---------- Accept

Misalignment (Linear) A-C 2mm 2mm 9 Accept

Longitudinal seams A-C NONE ------------ ---------- Accept

 Root Defects

Misalignment A-C 2mm 2mm 9 Accept

Excessive Root Penetration A-C 4mm 2mm 16 Reject

Incomplete Root Penetration A-C 50mm NONE 6 Reject

Lack of Root Fusion A-C 20mm NONE 5 Reject

Root Concavity A-C 2mm depth 1mm 20 Reject

Root Undercut A-C NONE ------------ ---------- Accept

Cracks/Crack-like defects A-C NONE ------------ ---------- Accept

Slag inclusions A-C NONE ------------ ---------- Accept

Porosity A-C NONE ------------ ---------- Accept

Laps/Laminations A-C NONE ------------ ---------- Accept

This *pipe/plate has been examined to the requirements of code/specification TWI 09-09-03
.........................................
and is accepted/rejected accordingly.

Comments:
* Request MPI testing to confirm crack and length.
** Large amount of spatter on weld face. Recommend this is removed and re inspected.
*** Recommend arc strikes are ground flush prior to MPI testing for crack detection.

I C Plenty
Signature.........................................................
22nd August 2003
Date................................................. ....................................
*Delete which is not applicable. Use the other side for any comments.
 Inspection Practice Specification
Number TWI 09-09-03
All dimensions are given in mm
No Imperfection Comments Allowance
1 Cracks Confirm with penetrant testing Not permitted

2 Porosity Individual pore Ø Maximum 1mm

3 Solid Inclusions Non metallic. Individual size Maximum 1mm
4 Solid Inclusions Metallic. Individual size Not permitted
5 Lack of Fusion Side wall/Root/Inter-run Not permitted
6 Incomplete Root Penetration Not permitted
7 Overlap/Cold lap Weld face/Root Not permitted
8 Incompletely filled groove Not permitted
9 Linear Misalignment 0.2t Maximum 4mm
10 Angular Misalignment Maximum 10º
11 Undercut Smoothly blended 10%t Maximum d 1mm
12 Arc Strikes Area to be tested by MPI Seek advice
13 Laminations Not permitted
14 Mechanical Damage Not permitted
15 Cap Height Shall fall below plate surface 0 –3mm h Maximum
16 Penetration Bead 0 –2mm h Maximum
17 Toe Blend Smooth
18 Spatter Clean & Re-inspect Refer to manufacturer
19 Weld Appearance All runs shall blend smoothly Regular
20 Root concavity 10%t Maximum
TWI CAMBRIDGE MULTI-PURPOSE
WELDING GAUGE:
Visual Inspection of Welds Using the
Cambridge
Multi-Purpose Welding Gauge:
TWI CAMBRIDGE MULTI-PURPOSE
WELDING GAUGE:
Angle of preparation:

This scale reads from 00 to 600 in steps of 50.

The angle is read against the chamfered edge of
the plate or pipe.
TWI CAMBRIDGE MULTI-PURPOSE
WELDING GAUGE:
Linear Misalignment:
The gauge may be used to measure misalignment
of members by placing the edge of the gauge on
the lower member and rotating the segment until
the pointed finger contacts the higher member.
TWI CAMBRIDGE MULTI-PURPOSE
WELDING GAUGE:
Excess Weld Metal/Root penetration:
The scale is used to measure excess weld metal or
root penetration, by placing the edge of the gauge
on the plate and rotating the segment until the
pointed finger contacts the excess weld metal or
root bead at its highest point.
TWI CAMBRIDGE MULTI-PURPOSE
WELDING GAUGE:
Undercut / mechanical damage (grinding etc)
The gauge may be used to measure the depth of
undercut by placing the edge of the gauge on the
plate and rotating the segment until the pointed
finger contacts the lowest depth of the undercut.
The reading is taken on the scale to the left of
the zero mark in mm or inches.
TWI CAMBRIDGE MULTI-PURPOSE
WELDING GAUGE:
Fillet Weld Actual Throat Thickness:
The small sliding pointer reads up to 20mm, or ¾
inch. When checking the throat you measure the
actual throat thickness also note! that there is a
‘nominal’ design throat thickness,
TWI CAMBRIDGE MULTI-PURPOSE
WELDING GAUGE:
Fillet Weld Leg Length:
The gauge may be used to measure fillet weld
leg lengths of up to 25mm, as shown on left.
 TWI
CSWIP 3.0

INSPECTION OF
FILLET WELDS
 Fillet Weld Inspection
CSWIP 3.0 Fillet Welded T Joint

F 123

Part of the CSWIP 3.0 examination is to inspect &

assess a Fillet welded Tee for it’s size & visual
acceptance to the applicable code.
 Fillet Weld Inspection
1. The plate reference number must be
recorded in the top left hand corner of
the report sheet, then the thickness of
the plate must be measured and
entered in the top right hand corner of
the report sheet in the boxes provided.

Specimen Number F123 Material thickness: 6mm

 Fillet Weld Inspection
2) Both the Vertical and Horizontal fillet weld leg lengths
must be measured to find the minimum and maximum
size’s. These values are entered in the boxes provided
on the report sheet.

Use the gauge as shown below:

Fillet Weld Leg Length:

The gauge may be used to
measure fillet weld leg
lengths up to a maximum of
25mm, as shown on left.
 Fillet Weld Inspection
3) The minimum and maximum throat thickness are
measured and entered in the boxes provided on the
report sheet.

These values are measured as shown below:

Fillet Weld Throat Thickness:

The small sliding pointer reads up
to 20mm, or ¾ inch.
When measuring the throat it is
supposed that the fillet weld has a
nominal throat thickness, as an
effective throat thickness cannot
be measured in this manner.
 Fillet Weld Inspection
Having made all the above measurements they can be
assessed to a set of values that may be simply calculated
from the plate thickness.
a) The minimum leg length size is the plate thickness

b) The maximum leg length size is:

The plate thickness + 3mm

c) The minimum throat thickness is:

The plate thickness x 0.7

d) The maximum throat thickness is:

The plate thickness + 0.5mm
 Fillet Weld Inspection
For example if the plate
thickness is 6mm then the F 123
6mm
following will apply:

a) The minimum leg length size is 6mm (Plate thickness)

b) The maximum leg length size is 9mm

(Plate thickness + 3mm)

c) The minimum throat thickness is 4.2mm

(Plate thickness x 0.7)

d) The maximum throat thickness is 6.5mm

(Plate thickness + 0.5mm
 Fillet Weld Inspection
This means that the measurements taken must fall inside
BOTH the tolerances calculated i.e.

Leg lengths must be between 6mm – 9mm

Throat thickness must be between 4.2 and 6.5mm

If all the values are within these tolerances they are

acceptable. If any of the values fall outside of the
calculated tolerances then it becomes unacceptable.

It is important to remember that any change in thickness

will change the acceptance values calculated above.
 Fillet Weld Inspection
Vertical Leg Length
Lowest leg measurement 7mm
Highest leg measurement 8mm

Actual Throat Thickness

Lowest throat measurement 4.5mm
Highest throat measurement 8mm

Horizontal Leg Length

Lowest leg measurement 5mm
Highest leg measurement 10mm
 Fillet Weld Inspection
Practical Exam Report Sheet

Specimen Number F123 Material thickness: 6mm

1) Measure and record the following details:

VERTICAL LEG LENGTH (Max & Min) = Max 8mm Min 7mm

HORIZONTAL LEG LENGTH (Max & Min) = Max 10mm Min 5mm

DESIGN THROAT THICKNESS (Max & Min) = Max 8mm Min 4.5mm
 Fillet Weld Inspection
2) Sentence the fillet weld dimensions using the following design criteria:

MINIMUM LEG LENGTH: Material thickness (6mm)

MAXIMUM LEG LENGTH: Material thickness + 3mm (9 mm)

MINIMUM THROAT THICKNESS: Material thickness x 0.7 (4.2 mm)

MAXIMUM THROAT THICKNESS: Material thickness + 0.5mm (6.5 mm)

The VERTICAL LEG LENGTH

Please state: ACCEPT ACCEPT or REJECT?

The HORIZONTAL LEG LENGTH

Please state: REJECT ACCEPT or REJECT?

The THROAT THICKNESS

Please state: REJECT ACCEPT or REJECT?
 Fillet Weld Inspection
Having assessed the weld for its size an inspection can then be
made on the surface to locate any imperfections. Firstly; the
report sheet requests the inspector to indicate the number of
locations that the following imperfections occur, if any?

3) The number of places that they occur should now be entered

in the box as follows:

UNDERCUT APPEAR? 3 places

OVERLAP APPEAR? None
LACK OF FUSION APPEAR? None
CRACKS APPEAR? None
POROSITY APPEAR? 2 Areas
SOLID INCULSIONS? 1 Slag Inclusion
MISC: [ARC STRIKES etc] Spatter
 Fillet Weld Inspection
4) For the defects recorded state:
MAXIMUM length (and DEPTH if applicable) of each defect

UNDERCUT: Length: 15 mm Depth: Smooth 1.0mm

OVERLAP: Length: -------- Depth: ---------

LACK OF FUSION: Length: -------- Depth: ---------

CRACKS: Length: -------- Depth: ---------

POROSITY: Length: 6mm Depth: Maximum Ø

SOLID INCLUSIONS: Length: 4mm Depth: ---------

MISC:[ ARC STRIKES] Length: Spatter Depth: ---------

 Fillet Weld Inspection
5) Then, assess the levels of imperfections allowed by the
applicable code which is provided:

UNDERCUT: ACCEPT (Accept or Reject?)

OVERLAP: ACCEPT (Accept or Reject?)
LACK OF FUSION: ACCEPT (Accept or Reject?)
CRACKS: ACCEPT (Accept or Reject?)
POROSITY: REJECT (Accept or Reject?)
SOLID INCLUSION: REJECT (Accept or Reject?)
MISC: [ARC STRIKES] REJECT* (Accept or Reject?)

* All spatters should have been removed prior to submission for

inspection
 Fillet Weld Inspection
6) Finally accept or reject the weld used for your visual
inspection as follows:

IS THE WELD ACCEPTABLE? NO YES/NO?

Signature: I C Plenty

Name: I C Plenty

Date: 01-01-04

This now completes the Fillet Welded T Joint Inspection

Assessment.