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    Weld and Base Metal Discontinuities

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    tuvu
    This document discusses various types of discontinuities that can occur in welds and base metals, including cracks, inclusions, porosity, undercut, overlap, and laminations. It defines each discontinuity and provides examples of what they look like. The document also covers how discontinuities can form and their potential effects on fatigue strength. Various testing methods are mentioned for finding discontinuities like radiography and visual testing.

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    © All Rights Reserved
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    Weld and Base Metal Discontinuities

    Uploaded by

    tuvu
    555 views69 pages
    This document discusses various types of discontinuities that can occur in welds and base metals, including cracks, inclusions, porosity, undercut, overlap, and laminations. It defines each discontinuity and provides examples of what they look like. The document also covers how discontinuities can form and their potential effects on fatigue strength. Various testing methods are mentioned for finding discontinuities like radiography and visual testing.

    Original Description:

    aws cwi welding inspector certification

    Original Title

    module 9

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    This document discusses various types of discontinuities that can occur in welds and base metals, including cracks, inclusions, porosity, undercut, overlap, and laminations. It defines each discontinuity and provides examples of what they look like. The document also covers how discontinuities can form and their potential effects on fatigue strength. Various testing methods are mentioned for finding discontinuities like radiography and visual testing.

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    555 views69 pages

    Weld and Base Metal Discontinuities

    Uploaded by

    tuvu
    This document discusses various types of discontinuities that can occur in welds and base metals, including cracks, inclusions, porosity, undercut, overlap, and laminations. It defines each discontinuity and provides examples of what they look like. The document also covers how discontinuities can form and their potential effects on fatigue strength. Various testing methods are mentioned for finding discontinuities like radiography and visual testing.

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    of 69

    Module 9

    Weld and Base


    Metal
    Discontinuities
    WI
    T

    9- 1

    Discontinuity
    Any interruption in the
    uniform nature of an item

    WI
    T

    9- 2

    Discontinuities
    Seams and laps
    Laminations
    Weld undercut
    Weld cracks
    Weld porosity
    Many others

    WI
    T

    9- 3

    Defect
    A non-conforming
    discontinuity
    All discontinuities are not
    defects.
    All defects are discontinuities.
    WI
    T

    9- 4

    Discontinuity Criticality
    Linear - non-linear
    End condition - sharpness
    Surface - sub-surface
    Loading - uniform, non-uniform

    Fatigue
    Impact

    WI
    T

    9- 5

    Crack
    A fracture type discontinuity
    characterized by a sharp tip and
    high ratio of length and width
    (depth) to opening displacement

    WI
    T

    9- 6

    Crack Types
    Hot/cold
    Delayed/underbead
    Longitudinal
    Transverse
    Throat/toe/root
    HAZ/base metal
    and many more

    WI
    T

    9- 7

    Longitudinal Crack

    WI
    T

    9- 8

    Transverse Crack

    WI
    T

    9- 9

    Throat Crack

    WI
    T

    9- 10

    Toe Crack

    WI
    T

    9- 11

    Crater Cracks in Aluminum


    Weld

    WI
    T

    9- 12

    Propagation of Crater Crack


    in Aluminum Weld

    WI
    T

    9- 13

    Underbead Cracks

    WI
    T

    9- 14

    Underbead Cracking
    Often delayed cracking
    Caused by hydrogen
    Difficult to detect
    Avoid with low H2 process

    WI
    T

    9- 15

    Incomplete Fusion
    A weld discontinuity in which fusion
    did not occur between weld metal
    and fusion faces or adjoining weld
    beads

    WI
    T

    9- 16

    Locations of Incomplete
    Fusion

    WI
    T

    9- 17

    Incomplete Fusion at Weld


    Face

    WI
    T

    9- 18

    Incomplete Fusion Between


    Weld Metal and Base Metal

    WI
    T

    9- 19

    Radiograph of Side-Wall
    Incomplete Fusion

    WI
    T

    9- 20

    Incomplete Joint
    Penetration
    Weld metal does not extend
    entirely through the joint
    thickness. The term is used
    only for groove welds.

    WI
    T

    9- 21

    Examples of Incomplete Joint


    Penetration

    WI
    T

    9- 22

    Incomplete Joint Penetration

    WI
    T

    9- 23

    Radiograph of Penetration
    Faults
    at Bead Starts and Stops

    WI
    T

    9- 24

    Partial Joint Penetration


    Penetration not required to
    be complete by designer

    WI
    T

    9- 25

    Inclusions
    Entrapped foreign solid
    material such as slag, flux,
    tungsten or oxide

    WI
    T

    9- 26

    Surface Slag Inclusion

    WI
    T

    9- 27

    Radiograph of
    Elongated Slag
    Inclusions

    WI
    T

    9- 28

    Radiograph of Tungsten
    Inclusions

    WI
    T

    9- 29

    Porosity
    Cavity type discontinuities formed by
    gas entrapped during weld metal
    solidification

    WI
    T

    9- 30

    Scattered Surface Porosity

    WI
    T

    9- 31

    Linear Surface Porosity with


    Connecting Crack

    WI
    T

    9- 32

    Isolated Surface Porosity

    WI
    T

    9- 33

    Elongated Surface Porosity

    WI
    T

    9- 34

    Radiograph of Scattered
    Porosity

    WI
    T

    9- 35

    Radiograph of Cluster Porosity

    WI
    T

    9- 36

    Radiograph of Linear Porosity

    WI
    T

    9- 37

    Undercut
    A groove melted into the base metal
    adjacent to the weld toe or weld root
    and left unfilled by weld metal

    WI
    T

    9- 38

    Typical Appearance of
    Undercut

    WI
    T

    9- 39

    Undercut Adjacent to
    Fillet Weld

    WI
    T

    9- 40

    Radiograph of Surface
    Undercut

    Surface undercut should be found with VT,


    NOT RT !
    WI
    T

    9- 41

    Underfill
    A condition in which the weld face or
    the root surface is below the
    adjacent surface of the base metal

    WI
    T

    9- 42

    Underfill in Groove Welds

    WI
    T

    9- 43

    Overlap
    The protrusion of weld metal
    beyond the weld toe or weld
    root

    WI
    T

    9- 44

    Overlap Examples

    Overla
    p
    Overla
    p

    WI
    T

    9- 45

    Overlap in Fillet and Groove


    Welds

    WI
    T

    9- 46

    Undercut & Overlap in Fillet


    Weld
    Undercut

    Overlap
    WI
    T

    9- 47

    Fillet Weld Convexity


    The maximum distance from the face
    of a convex fillet weld perpendicular
    to a line joining the weld toes

    WI
    T

    9- 48

    Fillet Weld Convexity

    WI
    T

    9- 49

    Weld Reinforcement
    Weld metal in excess of the
    quantity required to fill a
    joint

    WI
    T

    9- 50

    Face and Root


    Reinforcement

    WI
    T

    9- 51

    Face Reinforcement on both


    sides when welded from
    both sides

    WI
    T

    9- 52

    Effect of Weld
    Reinforcemen
    t angle on
    Fatigue
    Strength

    WI
    T

    9- 53

    Improper and Acceptable


    Treatment of Weld
    Reinforcement

    WI
    T

    9- 54

    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

    WI
    T

    9- 55

    Photomicrograph of Martensitic
    Structure Produced by an Arc
    Strike

    WI
    T

    9- 56

    Spatter
    Metal particles expelled during fusion
    welding that do not form part of the
    weld

    WI
    T

    9- 57

    Crack Formed at Weld


    Spatter

    WI
    T

    9- 58

    Lamination
    A discontinuity with separation or
    weakness generally aligned parallel
    to the worked surface of a metal

    WI
    T

    9- 59

    Cracking and
    Delamination Due to
    Lamination

    WI
    T

    9- 60

    Delamination
    Separation of a lamination under
    stress

    WI
    T

    9- 61

    Lamellar Tear
    A subsurface terrace- and step-like
    separation in the base metal, parallel to
    the surface, caused by tensile stresses
    in the through-thickness direction.

    WI
    T

    9- 62

    Lamellar Tearing

    WI
    T

    9- 63

    Seams and Laps


    Longitudinal base metal surface
    discontinuities found in wrought
    products

    WI
    T

    9- 64

    Deep Seam on Surface of


    Semi-Finished Rolled
    Product

    WI
    T

    9- 65

    Cluster Seams on Surface of


    Semi-Finished Rolled
    Product

    WI
    T

    9- 66

    Lap on Surface of Rolled Steel


    Billet

    WI
    T

    9- 67

    Dimensional
    Size irregularities
    Shape imperfections
    Distortion

    WI
    T

    9- 68

    Discontinuities in EBW and


    LBW
    Unique to the special attributes of the
    high-energy beams and narrow weld
    width
    Beam deflection (missed joint)
    Root Porosity
    Shrinkage voids
    Hot cracks
    Lack of fusion (spiking)

    WI
    T

    9- 69

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