Welding Process and Defetc

WI 3.
Welding Inspection
Practical Plate Exercise

Copyright 2004 TWI Ltd
M.S.Rogers
Plate Sample 6A Cap
WI 3.1
Welding Process MMA (SMAW)
Porosity
Slag
Inclusion
Cap Undercut
Intermittent
Cap Undercut
Intermittent
Arc Strike
Incomplete Filled Groove

Lack of
fusion
Cap Undercut
Intermittent
Arc Strike
Note: spatter and surface slag requires removal, arc strikes

require blending and crack detection
M.S.Rogers
Plate Sample 6A Root
WI 3.1
Excess
Penetration
Excess
Penetration
Gas Pore
Linear Misalignment
Surface Slag Lack of Root

Fusion
Root Undercut
Note: Spatter and surface slag require removal

M.S.Rogers
Plate Sample 6B Cap
WI 3.1
Lack of Sidewall Fusion
?Porosity
Lack of Sidewall
Fusion
Surface Slag
Overlap and Excess Cap Height Full Weld Length
Note: Surface slag requires removal and poor toe blending full
weld length
M.S.Rogers
Plate Sample 6B Root
WI 3.1
?
Crater Pipe
Lack of Root Fusion
Slag Inclusion
Lack of Root
Penetration
Lack of Root Fusion
M.S.Rogers
Plate Sample 6C Cap
WI 3.1
Welding Process FCAW

Incomplete
Filled Groove +
Lack of
Sidewall
Longitudinal
Fusion
Crack
Cap Undercut
Surface slag & Spatter
Slag Inclusion
Incomplete Filled
Groove + Lack of
Sidewall Fusion + Cap
Undercut Intermittent
Note: Spatter and surface slag requires removal

M.S.Rogers
Plate Sample 6C Root
WI 3.1
Welding Process FCAW

Mechanical Damage
Burn Through
?Excess Penetration
Poor Stop/Start + Lack of

Root Penetration
Lack of Root Fusion
Lack of Root Fusion
M.S.Rogers
Plate Sample 6D Cap
WI 3.1
Porosity
Incomplete
Filled Groove
Excess Cap
Height
Cap
Undercut
Cap
Undercut
Lack of Sidewall
Fusion
Overlap between Capping Passes
Note: Excess cap height and poor cap profile throughout.

M.S.Rogers
Plate Sample 6D Root
WI 3.1
Mechanical Damage
Lack of Root Fusion
Lack of Root Fusion
M.S.Rogers
Plate Sample 6E Cap
WI 3.1
Lack of
Sidewall
Fusion
Cap Undercut Intermittent
Excess Cap Height
M.S.Rogers
Plate Sample 6E Root
WI 3.1
Poor Stop/Start + Crater Pipe
?
Lack of Root Fusion
?
Excess Root Penetration
Lack of Root Fusion
Root Undercut
Excess Root
Penetration
Crater Pipe
of Root
?Lack
fusion
M.S.Rogers
Plate Sample 6F Cap
WI 3.1

Mechanical
Damage
?
?
Crater pipe
Lack of Sidewall fusion
Poor Toe Blend
Lack of Sidewall Fusion + Incomplete Filled Groove
Tack Weld
Arc
?
Strikes
Note: Arc strikes require blending and crack detection

M.S.Rogers
Plate Sample 6F Root
WI 3.1

Poor Stop/Start + Lack of Root
Penetration + Crater Pipe
Arc Strikes
Mechanical Damage +
Lack of Root Fusion
Lack of Root Fusion

?
Blow Hole
Lack of
Root
Fusion
Lack of
Root
Fusion
Arc Strikes
Arc Strikes
Note: Arc strikes require blending and crack detection

M.S.Rogers
Plate Sample 6G Cap
WI 3.1
Parent Material Damage
Arc Strikes
Arc Strikes
Lack of Sidewall Fusion +

Poor Toe Blend + Excess Cap Height

Porosity
Note: Arc strikes require blending and crack detection, Seek advise
on parent material damage
M.S.Rogers
Plate Sample 6G Root
WI 3.1

Parent material
gas cavities
Plate corrosion
Poor Stop/Start
Lack of Root Fusion
Crater pipe
? slag
Surface
Surface Slag
Linear Misalignment
Note: Surface slag requires removal, plate corrosion requires

wire brushing
M.S.Rogers
Plate Sample 6H Cap
WI 3.1
Arc Strikes
Arc Strikes
Arc Strikes
Slag Inclusion
Arc Strikes
Cap Undercut
Arc Strikes
Note: Parent plate damage throughout, seek advice. Arc strikes

require blending and crack detection.
M.S.Rogers
Plate Sample 6H Root
WI 3.1
Crater pipe
Excessive root penetration

Linear misalignment +
lack of root fusion
Lack of root fusion
Poor stop/start
Lack of root fusion
Arc strikes
Arc strikes
M.S.Rogers
Plate Sample 6I Cap
WI 3.1
Cap undercut
Spatter
Arc strikes
Poor toe blend full weld length
Note: Arc strikes require blending and crack detection. Spatter

requires removal.
M.S.Rogers
Plate Sample 6I Root
WI 3.1

Arc strike
Lack of root penetration
Burn through
Poor stop/start
Linear misalignment
Mechanical damage
Lack of root fusion
Lack of root fusion

+ poor stop/start
M.S.Rogers
Plate Sample 6J Cap
WI 3.1
Suspect crater cracking
Cap undercut
Arc strikes
Cap undercut
Porosity
Cap undercut intermittent

Cap undercut
Note: Material damage throughout, seek advice. Arc strikes require

blending and crack detection.
M.S.Rogers
Plate Sample 6J Root
WI 3.1
?
Mechanical damage
? fusion
Lack of root
?
lack of root fusion
lack of root fusion
Note: Material damage seek advice on course of action.

M.S.Rogers
Plate Sample T4 Cap
WI 3.1

Mechanical damage
Cap undercut
Cap undercut
Spatter/irregular cap profile
Note: Grinding marks throughout seek advice on course of action.

Excess cap height and poor cap profile throughout.
M.S.Rogers
Plate Sample T4 Root
WI 3.1
Arc strike
Root undercut
intermittent
Lack of penetration intermittent
Ground flush root
M.S.Rogers
Plate Sample H8 Cap
WI 3.1
Arc strikes
Surface slag
Mechanical
damage

Mechanical
damage
Note: Mechanical damage seek advice on course of action.

Excess cap height and poor cap profile throughout. Arc
strikes require blending and crack detection.
M.S.Rogers
Plate Sample H8 Root
WI 3.1
?
Arc strike
?
Lack of root
fusion
Spatter
Lack of root
fusion
Lack of root
fusion
Lack of root
fusion
Spatter
Root undercut intermittent
Note: Arc strikes require blending and crack detection. Spatter

requires removal
M.S.Rogers
WI 3.1
Any Questions
M.S.Rogers

Welding Process and Defetc

Uploaded by

Copyright:

Available Formats

Welding Process and Defetc

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Welding Process and Defetc

Uploaded by

Copyright:

Available Formats

WI 3.

Practical Plate Exercise

Plate Sample 6A Cap

Welding Process MMA (SMAW)

Incomplete Filled Groove

Note: spatter and surface slag requires removal, arc strikes

Plate Sample 6A Root

Welding Process MMA (SMAW)

Surface Slag Lack of Root

Note: Spatter and surface slag require removal

Plate Sample 6B Cap

Welding Process MMA (SMAW)

Incomplete Filled Groove

Lack of Sidewall Fusion

Plate Sample 6B Root

Welding Process MMA (SMAW)

Lack of Root Fusion

Copyright 2004 TWI Ltd

Lack of Root Fusion

Plate Sample 6C Cap

Welding Process FCAW

Surface slag & Spatter

Note: Spatter and surface slag requires removal

Plate Sample 6C Root

Welding Process FCAW

Poor Stop/Start + Lack of

Lack of Root Fusion

Lack of Root Fusion

Copyright 2004 TWI Ltd

Plate Sample 6D Cap

Welding Process MMA (SMAW)

Overlap between Capping Passes

Note: Excess cap height and poor cap profile throughout.

Plate Sample 6D Root

Welding Process MMA (SMAW)

Lack of Root Fusion

Lack of Root Fusion

Copyright 2004 TWI Ltd

Plate Sample 6E Cap

Welding Process MMA (SMAW)

Cap Undercut Intermittent

Cap Undercut Intermittent

Incomplete Filled Groove

Excess Cap Height

Incomplete Filled Groove

Copyright 2004 TWI Ltd

Plate Sample 6E Root

Welding Process MMA (SMAW)

Poor Stop/Start + Crater Pipe

Excess Root Penetration

Lack of Root Fusion

Copyright 2004 TWI Ltd

Plate Sample 6F Cap

Welding Process MMA (SMAW)

Lack of Sidewall fusion

Poor Toe Blend

Lack of Sidewall Fusion + Incomplete Filled Groove

Note: Arc strikes require blending and crack detection

Plate Sample 6F Root