PRACTICAL VISUAL
INSPECTION OF WELDS
Features to Consider
Butt welds - Size
Weld cap width
Excess weld
metal height
Root
penetration
Root bead width
Features to Consider
Butt welds - Profile
x
x x
Features to Consider
Butt welds - Toe Blend
x
x x
Features to Consider
Consider
Butt welds - Weld Width
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
2mm
Also Known as: Hi Low. Mismatch. or Misalignment
Welding Defects
50mm
3mm
Angular distortion.
Measure the distance to the edge of the plate (50mm).
Use a straight edge (rule) to find the amount of distortion then measure
the space (3mm).
This reported as Angular distortion 3mm in 50mm
Welding Defects
Linear
Excess weld metal height
Lowest plate to highest point
3 mm
Excess penetration Lowest Linear misalignment
plate to highest point measured in mm
Angular
3mm
Angular misalignment measured in mm
EDGE DATUM THIS FROM MEASURE
A
51
NOTES:
Slag
8
inclusion
87
22 Lack of
sidewall fusion
Page 1 of 3 EXAMPLE PLA
4mm. 153
12-14mm Name: [Block capitals] Mr. I C Plenty Signature: I C
Poor Centreline
Code/Specification used: TWI 09-09-03
B Welding process
2mm crack 40
3mm in 50mm Welding position: Flat /PA Length & thickness of
WELD FACE
length or scale on the plate surface
230
Gas pore
1.5 Ø
236
241
Undercut
30 smooth
1.5 max
Arc Strike
C
EDGE DATUM THIS FROM MEASURE
A
23
NOTES:
10 Root concavity
2 deep
height : 4mm.
lignment: 2mm
tortion: 3mm in 50mm
n plate surface
128
Page 2 of 3 EXAMPLE PL
Incomplete root B
penetration
50
WELD ROOT
247
LACK OF ROOT
20FUSION
C
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
A-C 4mm 3mm 8 Reject
Excess weld metal appearance A-C Poor blend Smooth 8 Reject
Incomplete filling A-C 22mm None 5 Reject
Inadequate weld width (PIPE) A-C N/A ------------ ---------- Accept
Slag Inclusions A-C 70mm long 50mm 9 Reject
Undercut A-C 1.5mm depth 1mm 6 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 3 Reject
Arc strikes A-C 30x25 ------------ 7 Seek advice***
Mechanical damage A-C NONE ------------ ----------- Accept
Laps/Laminations A-C NONE ------------ ----------- Accept
Misalignment (Linear) A-C 2mm 2mm 15 Accept
Longitudinal seams (PIPE) A-C N/A ------------ ---------- Accept
Root Defects
Misalignment A-C 2mm 2mm 9 Accept
Excessive Root Penetration A-C 4mm 2mm 15 Reject
Incomplete Root Penetration A-C 50mm NONE 13 Reject
Lack of Root Fusion A-C 20mm NONE 11 Reject
Root Concavity A-C 2mm depth 1mm 10 Reject
Root Undercut A-C NONE ------------ 12 Accept
Cracks/Crack-like defects A-C NONE ------------ ---------- Accept
Slag inclusions A-C NONE ------------ 9 Accept
Porosity A-C NONE ------------ 2 Accept
Laps/Laminations A-C NONE ------------ ---------- Accept
This *pipe/plate has been examined to the requirements of code/specification TWI-N/WIS-PI
.........................................
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 cracks.
I C Plenty 22nd August 2003
Signature......................................................... 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
TWI CAMBRIDGE
CAMBRIDGE MULTI-
MULTI-
PURPOSE
PURPOSE WELDING
WELDING GAUGE:
GAUGE:
Visual Inspection of Welds Using the
Cambridge
Multi-Purpose Welding Gauge:
TWI
TWI CAMBRIDGE
CAMBRIDGE MULTI-PURPOSE
MULTI-PURPOSE
WELDING
WELDING GAUGE:
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
TWI CAMBRIDGE
CAMBRIDGE MULTI-PURPOSE
MULTI-PURPOSE
WELDING
WELDING GAUGE:
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
TWI CAMBRIDGE
CAMBRIDGE MULTI-
MULTI-
PURPOSE
PURPOSE WELDING
WELDING GAUGE:
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
TWI CAMBRIDGE
CAMBRIDGE MULTI-
MULTI-
PURPOSE
PURPOSE WELDING
WELDING GAUGE:
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.
