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8/9/2019 aaaaaaaaaaaaa....CSWIP Welding Inspection Notes and Questions

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GRINAKER LTA- WELDING INSPECTION - STEELS

CONTENTS PAGE

TERMINOLOGY 3

THE DUTIES OF A WELDING INSPECTOR 9

CODES AND STANDARDS 12

THE WELDING PROCEDURE 14

DESTRUCTIVE TESTING 20

SYMBOLS 27

MATERIALS 32

FOUR FACTORS FOR ESTABLISHING A WELD 37

WELDABILITY 38

RESIDUAL STRESS AND DISTORTION 44

HEAT TREATMENT 47

CALIBRATION 49

DEFECTS DETECTED BY SURFACE INSPECTION 50

INTERNAL DEFECTS 54

MACRO EAMINATION 58

NON!DESTRUCTIVE TESTING "1

REPAIR BY WELDING ""

CONSUMABLES 70

WELDING POSITIONS 75

PREPARED BY# VERA GOVENDER

WELDING PROCESSES

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MANUAL METAL ARC WELDING 78

TUNGSTEN INERT GAS WELDING 83

METAL INERT GAS WELDING 88

SUBMERGED ARC WELDING 94

AUTOMATIC METAL ARC WELDING 101

ELECTRON BEAM WELDING 103

ELECTRO!SLAG WELDING 105

TERMINOLOGY

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U$% &' ()% *&++%*( (%+,-.&/& -$ -,&+(.( CSWIP $%$ BS 499 $(.6+6 F+%%.(/ ()% (%+,$%/6: .6 ;&-.(: +% $%6 -.*&++%*(/ E$-* %/6$ *. >% $%6 (& ;&-. =+-&$ (%$ &' ;&-.($

TYPES OF OINT T)% '&//&-. +% $&,% (-*/ ;&-.($#

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BUTT

!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!

TEE

!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!

CORNER

!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!

LAP

PLATE EDGE PREPARATION FOR BUTT WELDS

T)% -//$(+(-&.$ $)& $(.6+6 (%+,-.&/& '&+ ()% =+-&$ '%(+%$ &' /(% %6% +%+(-&.$

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FEATURES OF A COMPLETED WELD

A >(( %/6 -. /(% ,6% > %/6-. '+&, >&() $-6%$ )$ (& %/6 '*%$ .6 '&+ (&%$ I. '// %.%(+(-&. %/6 ,6% '+&, &.% $-6% ()% +&(+6-. %/6 &. ()% .6%+$-6% -$ *//%6 ()% %.%(+(-&.

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T)% $)% &' '-//%( -. *+&$$!$%*(-&. -$ 6%$*+->%6 -. ()+%% (%+,$

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SIE OF WELDS

F// P%.%(+(-&. B(( W%/6$T)% %.%+/ +/%$ +%# 6%$-. ()+&( ()-*.%$$ ()-*.%$$ &' ()% ()-..%+ +( ;&-.%6

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THE DUTIES OF THE WELDING INSPECTOR

VISUAL INSPECTION

A( . &-.( -. ()% *&+$% &' %/6-. -% (*-. +&&( $$ '-//%+ $$ &+ *-. $$ >(

+(-*/+/ '&+ ()% +&&( .6 * 6%(-/%6 -.$%*(-&. , >% +%-+%6 B+-(-$) S(.6+6 5289# 197"-=%$ -6.*% &. (&&/$ .6 +%$&.$->-/-(-%$ (&%()%+ -() $%(*)%$ &' (-*/ 6%'%*($T)% -.$%*(&+ ( ()-$ &-.( ,$( !@ &>$%+=% -6%.(-' .6 %+)$ +%*&+6 ?,%$+%@ ()% '%(+%$ &' ()% %/6 >@ 6%*-6% )%()%+ ()% %/6 -$ **%(>/% -. (%+,$ &' ()% +(-*/+ /%=%/$ ()( +% %+,-((%6K 6%'%*(/%=%/$ , >% -.!)&$%: &+ .(-&./ *&6%$ &' +*(-*%W)%. ()% 6%'%*( $-% -$ -. %


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I//,-.(-&.# G&&6 /-)(-. -$ %$$%.(-/I.$%*(-&. L%.$%$# T)% ,.-'-*(-&. $)&/6 .&( %-.&*/+ ,-*+&$*&%O(-*/ =-%-. *. +&+%$$-=%/ 6%=%/& '+&, %%$-)( (& $% &' ).6 (&+*) .6 ,-++&+ (& ()%66-(-&. &' ,.-'-%+ .6 /-)( $&+*%I. &+6%+ (& *)-%=% **%$$->-/-( +%,&(% +&>% .-($ +% =-/>/% )-*) ,$( )=% ()% '&//&-. +&%+(-%$@ L+% '-%/6 &' =-$-&. >@ F+%%6&, '+&, 6-$(&+(-&. &' -,%*@ A**+(% +%$%+=(-&. &' *&/&+ =/%$6@ A6%* &' -//,-.(-&.

CODE OF PRACTICE

A *&6% &' +*(-*% '&+ . -.$%*(-&. 6%+(,%.( $)&/6 (% ()% '&+, &(/-.%6 >%/& I( -$+%*-(%6 ()( '// -,/%,%.((-&. &' ()% *&6% &/6 >% %% ',-/-+ -() ()% '&//&-.#@ A// /-*>/% 6&*,%.($ >@ W&+,.$)- $(.6+6$*@ A// )$%$ &' &&6 &+$)& +*(-*%6@ T&&/$ .6 ,%$+-. 6%=-*%$

INSPECTION BEFORE WELDING

B%'&+% A$$%,>/#C)%* A// /-*>/% 6&*,%.($

/-( /. -$ ()&+-$%6 .6 %.6&+$%6 -() $-.(+% 6(% .6 *&,. $(,

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P/.( .6 %-,%.( +% -. $'% *&.6-(-&. .6 6%(% '&+ ()% ;&> S'%( %+,-($ % )&( &+ %+,-( $ '+%% %+,-( %.*/&$%6 $*% *%+(-'-*(% +%

=-/>/% .6 =/-6

A'(%+ A$$%,>/C)%* D-,%.$-&.$ (&/%+.*%$ +%+(-&. '-(! .6 /-.,%.( +% -. **&+6.*% -() ()%

A+&=%6 6+-.$ .6 $(.6+6$ T* %/6$ >+-6-. -%*%$ */,-. .6 (% &' >*-. ! -' . $%6 +% *&++%*( C/%./-.%$$ &' &+ +% -$ ,-.(-.%6

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P+%)%( -. **&+6.*% -() +&*%6+%

NOTE G&&6 -.$%*(-&. +-&+ (& %/6-. *. %/-,-.(% *&.6-(-&.$ ()( /%6 (& ()% '&+,(-&. &'6%'%*($

INSPECTION DURING WELDING

C)%* T)% %/6-. +&*%$$ ,$( >% ,&.-(&+%6 P+%)%( .6 -.(%+$$ (%,%+(+%$ ,$( >% ,&.-(&+%6 I.(%+$$ */%.-. ! *)--. +-.6-. &-. ,$( >% ,&.-(&+%6 R&&( .6 $>$%%.( +. $%%.*% E$$%.(-/ =+->/%$ $*) $ *++%.( =&/(% (+=%/ $%%6 (& >% ,&.-(&+%6 F-//%+ ,%(/$ '/% *++-%6 &( (& $*%+(-. **%(>-/-( &' %+.*% &' %/6$

D-,%.$-&./ **+* (& >% $*%+(-.%6 C&.'&+,-( -() 6+-.$ .6 $(.6+6$ +%-+%,%.($ P&$( %/6 )%( (+%(,%.( -' . ,&.-(&+%6 .6 +%*&+6%6 NDT *++-%6 &( .6 +%&+($ $$%$$%6 A$$%$$ 6%'%*($ $ (& %-()%+ +%-+-. &+ /-*(-&. '&+ *&.*%$$-&. C++ &( . .%*%$$+ +%-+$ C&.(+&/ &' 6-$(&+(-&.

REPAIRS

R%-+ +&*%6+% .6 %/6-. *&6% $)&/6 >% ()&+-$%6

D%'%*( +% $)&/6 >% ,+%6 &$-(-=%/ .6 */%+/ C)%* )%. +(-// +%,&=%6 .6 '// +%,&=%6 ?=-$/ .6 NDT@ R%!%/6-. $)&/6 >% ,&.-(&+%6 R%!-.$%*( *&,/%(%6 +%-+

C&//(% // 6&*,%.($ .6 +%&+($ P$$ ()% 6&*,%.( *% &. (& )-)%+ ()&+-( '&+ '-./-.$%*(-&. +&=/ .6 $(&+%

THE WELDING INSPECTOR

RESPONSIBILITIESE.$+% *&,/-.*% -() $(.6+6 &+ *&6%E.$+% &+,.$)-E.$+% %/6-. *+-(%+- > &/-*-.: &+ .6 6&*,%.((-&.

ATTRIBUTESH&.%$( .6 -.(%+-(L-(%+*F-(.%$$ ! )$-*/ .6 %%$-)(

DUTIESO>$%+=%

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M%$+%I6%.(-'

CODES AND STANDARDSCLASS OF WOR

T)%+% +% ,. (%$ &' &+ )-*) +%-+% %.-.%%+-. ,(%+-/$ (& >% ;&-.%6 > %/6-. '&+%&6-%$ F&&6 +&*%$$-. /.(

T)% /-( +%-+%,%.($ &' ()% ;&-.($ -. ()%$% '>+-*(-&.$ 6%%.6 &. ()%-+ '-(.%$$!'&+!+&$% .6

6-''%+ $-.-'-*.(/ '+&, &.% /-*(-&. (& ()% .% )&( *-6-* /-&+$

B%/& +% /-$(%6 $&,% (-*/ *&6%$ &' +*(-*% .6 $(.6+6$ )-*) *&=%+ =+-&$ (%$ &'*&.$(+*(-&.$ '>+-*(%6 > %/6-.

C&6% C/$$ &' W&+ BS 5500 U.'-+%6 '$-&. %/6%6 +%$$+% =%$$%/$

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

()% %.%+/ )%6-. &' W%/6 P+&*%6+%

CODE OF PRACTICE

A *&6% &' +*(-*% -$ $%( &' +/%$ '&+ ,.'*(+-. $%*-'-* +&6*( I( $)&/6 *&.(-.#D%$-. R%-+%,%.($ % '-(! +%+(-&. .6 (% &' ;&-.($M(%+-/$ % (%$ ()-*.%$$ +.%$M.'*(+%+:$ W&+-. P+*(-*%I.$%*(-&. C+-(%+- % 100J =-$/ %+*%.(% &()%+ NDTA**%(.*% C+-(%+- % 6%'%*( $-% /-,-($ %(*W%/6-. P+&*%$$ % (% *&.$,>/%$

T%$ O' T&&/-. % $% &' $(+&.>*$C&.(+*(/ I.'&+,(-&.

T)% 6-''%+%.*% >%(%%. *&6% .6 $(.6+6 -$ ()( *&6% $((%$ )& (& 6& $%*-'-* ;&> .6 6&%$.&( *&.(-. // +%/%=.( -.'&+,(-&. >( +%'%+$ (& &()%+ $(.6+6$ '&+ 6%(-/$A *&6% &+ $(.6+6 %.%+// ,%.(-&.$ ()+%% +(-%$ ! ()% *$(&,%+ &+ */-%.( ()% ,.'*(+%+ &+ +&6*%+ .6 ()% -.$%*(-&. ()&+-( I. *&6% ()% (%+, $)//: ,%.$ ,.6(&+ ! ,$( >% 6&.%.6 ()% (%+, $)&/6: ,%.$ +%*&,,%.6%6 ! .&( *&,/$&+A *&.*%$$-&. -$ . +%%,%.( >%(%%. ()% *&.(+*(-. +(-%$ (& 6%=-(% '+&, ()% &+--./ *&6%+%-+%,%.($ ?BS 5135@

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THE WELDING PROCEDURE

A %/6-. +&*%6+% -$ &' *&.(+&//-. ()% %/6-. &%+(-&.

P+&$% &' +&*%6+%#1@ T& +&=% ;&-.( *. ,%%( 6%$-. +&*%6+% ! consistency2@ I.$(+*(-&. '&+ %/6%+ 3@ E.$+% repeatability

W%/6 +&*%6+%$ +% +&=%6 (& %.$+% ()% +% '.*(-&./ .6 '/'-/ ()% )$-*/ .6 ,%*).-*/ +&%+(-%$ .%*%$$+ (& +%*) ()% +%-+%6 $(.6+6 ?(& %$(>/-$) ()% %$$%.(-/ =+->/%$ '&+*&.(+*(/ &>/-(-&.$@ W%/6%+$ +% +&=%6 (& %.$+% +(-*/+ %/6%+ -$ *>/% &' %/6-. (& +&*%6+% .6&>(-.-. +%$/( ()( ,%%($ $%*-'-*(-&.

T)% ($ &' *&//%*(-. ()% 6( .6 6+'(-. ()% 6&*,%.((-&. -$ &'(%. +%'%++%6 (& $ +-(-.: %/6 +&*%6+% I. ,. $ ()-$ -$ . .'&+(.(% (%+, $ ()% +-(-. &' 6&*,%.($ -$ ()% /$( -. $%%.*% &' ($$

P+&6*-. %/6 +&*%6+% -.=&/=%$KP/..-. ()% ($$C&//%*(-. ()% 6(W+-(-. +&*%6+% '&+ $% &+ '&+ (+-/M-. (%$( %/6$E=/(-. ()% +%$/($ &' ()% (%$($

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A+&=-. ()% +&*%6+% &' ()% +%/%=.( *&6%P+%+-. ()% 6&*,%.((-&.

I. %*) *&6% +%'%+%.*% -$ ,6% (& )& ()% +&*%6+%$ +% (& >% 6%=-$%6 .6 )%()%+ +&=/ &'()%$% +&*%6+%$ -$ +%-+%6 I. ,&$( *&6%$ +&=/ -$ ,.6(&+ .6 (%$($ (& *&.'-+, ()% $-// &'()% %/6%+ +% $%*-'-%6 D%(-/$ +% /$& -=%. &' **%(.*% *+-(%+- '&+ ()% '-.-$)%6 ;&-.(

T)% +&*) $%6 6%%.6$ &. ()% *&6% '&+ %


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A. %$$%.(-/ =+->/% -$ =+->/% ()( -// -.'/%.*% &+ *).% ()% ,%*).-*/ &+ ,%(//+-*/ +&%+(-%$ &' ()% %/6%6 ;&-.( ! *).%$ ''%*(-. ()% +&*%6+% +&=/ A. *).% -. . %$$%.(-/=+->/% +%-+%$ .% %/6-. +&*%6+% $%*-'-*(-&. ?WPS@E$$%.(-/ =+->/%$ -.*/6%# // ()-*.%$$ ;&-.( 6%$-. +&*%$$ ,(%+-/$ *&.$,>/%$ %/6-. &$-(-&. 6-+%*(-&. )%( -.( ?=&/(% ,%+% (+=%/ $%%6@ )%( (+%(,%.(

APPROVING THE PROCEDURE

W)%. ()% 6( )$ >%%. *&//%*(%6 ()% +&*%6+% ,$( >% =/-6(%6 > +&6*-. .6 (%$(-. (+-/%/6I' ()% +&*%6+% -$ (& >% $%6 &. '>+-*(-&. )-*) )$ >%%. 6%$-.%6 (& ,%%( ()% +%-+%,%.($ &' *&6% ()% (%$( %/6 -$ 6&.% .6%+ ()% $%+=-$-&. &' . -.6%%.6%.( -(.%$$ T)% 6%(-/%6++.%,%.($ '&+ ()% (%$( +% $>;%*( (& +%%,%.( >%(%%. ()% *&.(+*(-. +(-%$A .,>%+ &' B+-(-$) S(.6+6$ ,% *+&$$!+%'%+%.*% (& .&()%+ $(.6+6 )-*) *&=%+$ +&=/(%$(-. O()%+ *&6%$ &' +*(-*% -.*/6% ()%-+ &. %/6 +&*%6+% %/6%+ +&=/ -.'&+,(-&. I.%.%+/ ()% -.*/6% $(.6+6 '&+,( )-*) *. >% $%6 (& +%&+( ()% +%$/($ &' . +&=/ (%$(

R.% &' +&=/ ?%/%$ , /(%+ -()&( +%-+-. .% %/6-. +&*%6+% &+ %/6%+ +&=/V+->/%$ -.*/6% ()-*.%$$ ?% 12 6&. (& 2< >&=%@ 6-,%(%+ ?% 12 6&. (& 12 >&=%@,(%+-/$ ?6-''%+%.( ,(%+-/$ *. >% *&=%+%6@ &$-(-&. +&*%$$ +%.( /(% +& .6*&.$,>/%$

R%!+&=/ &' %/6-. +&*%6+% -$ .%*%$$+ -' ()%+% -$ *).% &' . &' ()% %$$%.(-/ =+->/%$&+ *&.$-6%+>/% 6%'%*( +%!&**++%.*%

ABBREVIATIONS

WPS %/6-. +&*%6+% $%*-'-*(-&. ! . +&=%6 .6 **%(%6 %/6-. +&*%6+%K .()&+-$%6 6&*,%.(

PR +&*%6+% /-'-*(-&. +%*&+6$ ! +&&' ()% +&*%6+% &+$ ! +%*&+6 &' (%$($.6%+(%. (& /-' +&*%6+%

WAC %/6%+ +&=/ *%+(-'-*(% ! +%-+%6 (& %.$+% +(-*/+ %/6%+ -$ *>/% &'%/6-. (& +&*%6+%

WATC %/6%+ +&=/ (%$( *%+(-'-*(%WAR %/6%+ +&=/ +%*&+6WPAR %/6-. +&*%6+% +&=/ +%*&+6WT %/6%+ /-'-*(-&. (%$( WPS +%/-,-.+ WPS ! .()&+-$%6 ?*&.(-.$ // %$$%.(-/ =+->/%$ .6 '(%+ %/6-. ()%

(%$( -%*% .6 // NDT .6 6%$(+*(-=% (%$($ )=% >%%. **%(%6 ()%. ()% WPS *. >%+&=%6@

WPS .6 WPAR -=% '-./ WPS ?=+-&$ WPS *. 6%+-=% '+&, &.% WPS@

DOCUMENTATION

T)% &>;%*(-=%$ &' +&*%6+% &+ %/6%+ +&=/ (%$( +%# (& +&=% ()% +&*%6+% ,%%($ ()% .%*%$$+ +%-+%,%.($ -() +%'%+%.*% (& '%$->-/-(,%*).-*/ $(+%.() %(* > (& +&=% ()% %/6%+$ +% *&,%(%.( (& &+ &. +(-*/+ ;&>

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I' *$(&,%+ %+-%$ -( %=-6%.*% *. .6 &/6 >% $/-%6 (& +&=% =/-6-(

A+&=/ T%$( S%*-'-*(-&.$ *// '&+ %+ +%*&+6 )-*) *. >% .&. $#P+&*%6+% %/6%+ +&=/ *%+(-'-*(%P+&*%6+% %/6%+ +&=/ +%*&+6P+&*%6+% %/6%+ +&=/ +%&+(

T)% '&//&-. +%*&+6$ $)&/6 /$& >% %(# NDT +%&+($R%*&+6$ &' =-$/ % '&+ $*)%6/-. +%!(%$($ (& =&-6 6/-*(-&. &. +&*%6+% +&=/

WELDER APPROVAL

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

)%()%+ &+ .&( ()% %/6%+ *. 6& $& .6%+ %=%+ +&6*(-&. *&.6-(-&. F&+ ()%$% +%$&.$ *&,/%(%+%/-.*% $)&/6 .&( >% /*%6 &. ()%$% /-'-*(-&.$ ! +&6*(-&. %/6$ $)&/6 >% -.$%*(%6 +%/+/(& %.$+% ()( ()% $(.6+6 -$ >%-. %(

T%$ O' A+&=/ T%$($T%$($ ()( +% +%$*+->%6 > ,&$( *&6%$ .6 $(.6+6$ +% -. ()% ,-. $-,-/+ C&,,&. (%$($ +%# P/(% .6 $(+*(+/ ,%,>%+$ > P-% %/6-.* P&$-(-&.$ &' %/6-.6 T%$(-. &' +&=/ (%$( -%*%$% R%!(%$($

P/(% .6 $(+*(+/ ,%,>%+$T)% +%-+%,%.($ '&+ %/6%+$ &' /(% .6 $(+*(+/ +($ ?-.*/6-. +%$$+% =%$$%/$@ $// +%-+%()% %/6%+ (& ,% &.% &+ ,&+% (%$( %/6$ &. /(% &+ -% $$%,>/-%$ -() ()% /-'-%6 %/6-. +&*%6+% E*) %/6 -$ (%$(%6 -. $%*-'-* ,..%+ &'(%. >&() 6%$(+*(-=%/ .6 .&.!6%$(+*(-=%/T)% +%-+%,%.($ .&+,// $((% ()% /-*>-/-( &' ,(%+-/ ()-*.%$$ .6 %/6-. &$-(-&.$ ()( -///-' '&+ +&6*(-&. &+ O()%+ 6%(-/$ -// *&=%+ ;&-.( (% .6 6-+%*(-&. &' %/6-. )%.6%&$-(-. =%+(-*/ %/6$ ?=%+(-*// &+ =%+(-*// 6&.@

> P-% %/6-.

1"

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T)% +%-+%,%.($ '&+ ()% +&=/ &' %/6%+$ '&+ -% %/6-. 6-''%+$ '+&, ()&$% '&+ %/6-. /(%.6 $(+*(+/ ,%,>%+$ *)-%'/ -. ()% (% &' (%$( $$%,>/-%$ .6 (%$( &$-(-&.$ A$ +/% ()% %/6$,$( >% ,6% &. -% .6 .&( /(% I. $&,% *$%$ ()% $*% -()-. )-*) ()% (%$( -%*% ,$( >%%/6%6 , >% +%$(+-*(%6 -' ()% +&6*(-&. &+ -.=&/=%$ %/6-. -. *+,%6 *&.6-(-&.$ A$ %.%+/ +/% %/6%+$ )& /-' '&+ *%+(-. ;&-.($ &. -% .%%6 .&( /-' '&+ /(% &+ >(/-'-*(-&.$ &. /(% 6& .&( / (& -% &+

* P&$-(-&. &' %/6-.A+&=/ (%$($ +% .&+,// %% ,6% -. ()% ,&$( 6-''-*/( &$-(-&.$ ()( -// >%%.*&.(%+%6 -. +&6*(-&. %/6-. F&+ %%.6 (%$($ .6 $%*-,%.$ '&+ ,*+& %% +%-+%6 -. *&.;.*(-&. -() ()% ,%*).-*/ (%$($O()%+ +&%+(-%$ +%-+%6 &' ()% +&*%6+% /-'-*(-&. %/6$ $*) $ (%.$-/% $(+%.() )+6.%$$ %(*

+% .&( %.%+// $%*-'-%6 -. %/6%+ +&=/ (%$($ $-.*% ()%$% +&%+(-%$ 6%%.6 +-,+-/ &. ()% +%.( .6 '-//%+ ,(%+-/$ $%6 &. +&*%6+% 6%(-/$ ()( +% >%&.6 ()% -.6-=-6/ %/6%+$ *&.(+&/W%/6%+$ )&$% (%$( %/6$ ,%%( ()% +%-+%,%.($ +% /-'-%6 (& $% ()% +&*%$$ .6 (& %/6 -() ()%'-//%+ ,%(/$ .6 +&*%6+%$ $-,-/+ (& ()&$% $%6 -. (%$(-. I( $)&/6 >% ,%.(-&.%6 ()( %/6%+)& )$ $**%$$'// %/6%6 +&*%6+% (%$( $%*-,%. -$ .&( +%-+%6 (& .6%+& . +&=/ (%$(./%$$ ()% +%-+%,%.($ &' +&6*(-&. %/6-. +% 6-''%+%.( '+&, ()&$% &' ()% +&*%6+% -. )-*) )%)$ /-'-%6

% R%!(%$($T)% *-+*,$(.*%$ '&+ ()% +%!(%$(-. &' %/6%+ -.*/6% ()% '&//&-.#1 F-/+% &' ()% -.-(-/ (%$( %/6$

2 A $-.-'-*.( *).% -. %/6-. +&*%6+%3 A %/6%+ )$ .&( >%%. %.%6 -. %/6-. '&+ . %-/-(5 C).% &' %,/&,%.( -()&( ()% (+.$'%+ &' )-$ +&=/ *%+(-'-*(%$

CHEC LIST FOR WELDER AND PROCEDURE APPROVAL

1 T)% (%$( >%-. *++-%6 &( -$ ()% *&++%*( &.% +%-+%62 W%/6%+$ +% -. &$$%$$-&. &' // +%/%=.( -.'&+,(-&. *&.*%+.-. ()% (%$(3 T%$( ,(%+-/$ *&.'-+, -. // +%$%*($ (& +%-+%,%.($4 &-.( *&.'-+(-&. .6 (&/%+.*%$ +% *&++%*(5 W%/6-. /.( .6 *&.$,>/%$" T)% %/6%+$ -6%.(-'-*(-&. -$ */%+/ ,+%6 &. ()% (%$( -%*%7 W)%+% -( -$ $%*-'-%6 '&+ +&&( +. (& >% $(&%6 .6 +%$(+(%6 -. *%+(-. &$-(-&. ()( ()-$

&$-(-&. -$ */%+/ ,+%68 I. ()% *$% &' ;&-.($ %/6%6 -. '-


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ASME $%*(-&. I -( $((%$ ()( ()% %+$&. $%+=-$-. ()% (%$( , -' -. )-$ &-.-&. )% *&.$-6%+$ ()(()% %/6%+ -// .&( ,%%( ()% +%-+%6 $(.6+6 (%+,-.(% ()% (%$( ( . (-,% I' -( -$ .%*%$$+ (&/ ()-$ +/-. -( -$ $%$(%6 ()( '// +%$&.$ '&+ (%+,-.(-&. >% +%*&+6%6 I( -$ '+()%++%*&,,%.6%6 ()( ()% (%$( -%*% $)&/6 /$& >% %( '&+ $)&+( %+-&6 $ ,%.$ &' >*-. +-((%. $((%,%.(I' ()% (%$( -$ (& >% $%+=-$%6 > +%+%$%.((-=% &' . -.6%%.6%.( ()&+-( )% $)&/6 >% -=%. //()% +%/%=.( 6%(-/$ &' ()% (%$(-. +%-+%6W)%+% B+-(-$) $(.6+6$ +% -.=&/=%6 ()% %.%+// $((% ()( -' ()% %/6%+ -$ &' ()% &-.-&. ()( )-$'-+$( ((%,( , .&( $$ . $>$%%.( (%$(-. )% , -())&/6 -( .6 %/6 $%*&.6 I. ()-$ *$%-( -$ ()% $%*&.6 (%$( -%*% ()( -$ $>,-((%6 '&+ %%+ > 6(% &' (%$(* $(.6+6 &' *&6% -. '// % B+-(-$) S(.6+6 4872 PT 1# 19826 (%$( -%*% 6%(-/$ -.*/6-. ,(%+-/ $%*-'-*(-&.% %-,%.( .6 *&.$,>/% 6%(-/$' %% %.6&+$%6 > *&,. $(,

18

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20/133

(%.$-&. A./% &' >%.6 .6 6-,%(%+ &' '&+,%+ $)&/6 >% $ $%*-'-%6 -. ()%+&+-(% $(.6+6

R%&+(-. R%$/($#1 T)-*.%$$ &' $%*-,%.2 D-+%*(-&. &' >%.6 ?+&&( &+ '*%@3 A./% &' >%.6

4 D-,%(%+ &' '&+,%+ 5 A%+.*% &' ;&-.( '(%+ >%.6-. % (% .6 /&*(-&. &' '/$

+&&( >%.6 '*% >%.6 '&+*% '&+*%

()-$ $-6% -. (%.$-&. '&+ '*% >%.6F F

()-$ $-6% -. (%.$-&. '&+ +&&( >%.6 R R R R

S+'*% -. *&.(*( -() '&+,%+ +&.6 '/( R +&//%+ $&+( F '&+,%+ &' $%*-'-%6 +6-$

SIDE BEND TEST

O>;%*(# T& 6%(%+,-.% ()% $&.6.%$$ &' ()% %/6 ,%(/ .6 HA -. *+&$$ $%*(-&. T)-$ , >% +%'%++%6 (& ()% (+.$=%+$% >%.6 (%$( &. ()-* ,(%+-/$ I( -$ /$& $%6 &. +&*%$$%$&+ +&*%6+%$ %%.63 D-,%(%+ &' '&+,%+4 A%+.*% &' ;&-.( '(%+ >%.6-. % (% .6 /&*(-&. &' '/$

'&+*% 10,,

F

()-*.%$$&' /(%

R R()-$ $-6% -. (%.$-&. '&+ R +&//%+ $&+($-6% >%.6 F '&+,%+ &' $%*-'-%6 +6-$

TRANSVERSE TENSILE TEST

O>;%*(# U$%6 (& ,%$+% ()% (+.$=%+$% (%.$-/% $(+%.() .6%+ $((-* /&6-. &' >(( ;&-.(%,/&-. >(( %/6$T)% +%6*%6 $%*(-&. (%.$-/% (%$( .&+,// '-/$ -. ()% +%.( ,%(/ .6 $& -( -$ .&(6%$-.%6 (& -=% ()% (%.$-/% $(+%.() &' ()% %/6T)% +6-$ +%6*%6 (%.$-/% (%$( -$ (%$( &' ()% $ 6%&$-(%6 6-/(%6 %/6 ,%(/

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T)% // %/6 (%.$-/% (%$( $-. /&.-(6-./ $%*(-&. '+&, ()% %/6 &./ -$ $%6 (&*)%* ()% $ 6%&$-(%6 .6-/(%6 %/6 ,%(/ ?U$// $%6 > *&.$,>/%,.'*(+%+$@

M%()&6# T)% (%$( -%*% -$ */,%6 ( %*) %.6 .6 /&6 -$ /-%6 > . )6+/-* &+ $*+%,%*).-$, T)% /&6 -$ -.*+%$%6 .(-/ '+*(+% &**+$

R%&+(-. R%$/($#1 T% &' $%*-,%. ?% +%6*%6 $%*(-&.@2 W)%()%+ %% $((%6

5 L&*(-&. .6 (% &' . '/$ +%$%.( &. ()% '+*(+% $+'*%

/&6 /&6

.&(*) -. %/6

/&6 /&6

+%6*%6 $%*(-&. (%.$-/% (%$( +6-$ +%6*%6 (%.$-/% (%$(

T)% (%$( -=%$ ,%$+% &' %+*%.(% %/&.(-&. %+*%.(% +%6*(-&. -. +% .6 /(-,(% (%.$-/%$(+%.()

UTS ?-%/6 $(+%$$ $(+%.() &-.(@

-%/6 &-.(

UTS /(-,(% (%.$-/% $(+%.() STRAIN ?N@

%/$(-* /$(-*

STRESS ?,,@

21

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T)% (%.$-/% (%$( -=%$ ,%$+% &' DUCTILITY?-. N%(&.$ %+ ,, $+%6 *&,>-.(-&. &' %+*%.(% %/&.(-&. .6 %+*%.(% +%6*(-&. -.+%

T%$ &' '-/+%$

BRITTLE B+%

S+'*%

B+-((/% '+*(+% -$ '/( .6 '%(+%/%$$

DUCTILE

B+% S)%+ /-$

S+'*%

A 6*(-/% '+*(+% (%+$ ( 45° (& ()% /&6

C)%=+&. ,+$IN!SERVICE BRITTLE FRACTURE

S+'*%A '/( $+'*% -() *)%=+&. ,+-.$ ()( &-.( (& ()% ,(%+-/ 6%'%*( ()( -.-(-(%6 ()% '+*(+%

C+=%$FATIGUE FAILURE

S+'*%

A '/( $+'*% -() .&(-*%>/% *+=%$

CHARPY V NOTCH IMPACT TEST

O>;%*(# T& 6%(%+,-.% ()% ,&.( &' %.%+ >$&+>%6 -. '+*(+-. $(.6+6-$%6 (%$(-%*% ( $%*-'-%6 (%,%+(+%

M%()&6# A ,*)-.%6 .&(*)%6 $%*-,%. -$ >+&%. > &.% >/& '+&, %.6/, B%*$%$*((%+ &**+$ -. ()% +%$/($ ( /%$( ()+%% $%*-,%.$ +% $%6 (& $$%$$ ()% ;&-.(+%+%$%.(%6

22

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T%$(-. -$ *++-%6 &( ( (%,%+(+% $%*-'-%6 -. ()% +&+-(% /-*(-&.$(.6+6T)% B+-(-$) $(.6+6 -$ BS 131# PT 2# 1972

R%&+(-. R%$/($#1 L&*(-&. .6 &+-%.((-&. &' ()% .&(*)2 T%$(-. (%,%+(+%3 E.%+ >$&+>%6 -. ;&/%$4 D%$*+-(-&. &' '+*(+% %+.*%5 L&*(-&. &' . 6%'%*($

H,,%+ >/& '+&, ()-$ $-6% )

6

10,, A

B 55,,

10,, (

+&&( +6-$ ! .=-/025 ,, ( ! (%$(-%*%

) ! ),,%+ 6 ! 6-/ */->+(%6 -. ;&/%$ ! &-.( +%*)%6 '(%+ '+*(+%

2 ,, E.%+ >$&+>%6 6+-. '+*(+% 45° -$ +&&+(-&./ (& ?A ! B@

CHARPY TEST PIECE CHARPY IMPACT MACHINE

T)% C)+ -,*( (%$( ,%$+%6 -. ;&/%$ -$ . $$%$$,%.( &' TOUGHNESS

T+.$-(-&. (%,%+(+% ?*+=%@ -. $(%%/ D*(-/% F-/+%

CS SS

&/%$

23

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T%,%+(+%B+-((/% F-/+% ?)-)%+ (&).%$$ @

FILLET WELD FRACTURE TEST

O>;%*(# T& >+% ()% ;&-.( ()+&) ()% %/6 (& %+,-( %%.6 $ *(

NIC: BREA ?BEND@ TEST

O>;%*(# A$ '&+ '-//%( %/6 '+*(+% $%6 &. >(( %/6$

M%()&6# T)% $%*-,%. -$ *( (+.$=%+$%/ (& ()% %/6 .6 $ *( -$ /-%6 /&. ()% *%.(+%&' ()% %/6 '*% T)% >%$( /*% '&+ ()% *( -$ ( $(+( $(& T)% $%*-,%. -$'+*(+%6 > >%.6-. &+ > ),,%+ >/&$ T)% .-* >%.6 (%$( -// '-.6 -.(%+./6%'%*($

R%&+(-. R%$/($#1 T)-*.%$$ &' ,(%+-/2 W-6() &' $%*-,%.3 L&*(-&. &' '+*(+%4 A%+.*% &' ;&-.( '(%+ '+*(+%

24

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MACRO SECTION

O>;%*(# T& %/ '-./ */%.-() *%(&.% .6 ,&.( -. B%/-(%@ T)% $%*-,%. -$ ()%. -.$%*(%6 ( (& 10!<,.-'-*(-&.

R%&+(-. R%$/($#1 M(%+-/2 W%/6-. +&*%$$3 S%*-,%. -6%.(-'-*(-&.4 S%.(%.*-. $(.6+65 T)-*.%$$" G%&,%(+-* '/$ ! (% $-% .6 /&*(-&.

7 I.(%+./ '/$ ! (% $-% .6 /&*(-&.8 P+%.( ,%(/ '/$ ! (% $-% .6 /&*(-&.9 A**%( &+ +%;%*( (& $(.6+6 '&+ %*) '/

C&,+-$&. &' ,*+& $%*(-&. .6 ,-*+& $%*(-&.#

MACRO MICROM.-'-*(-&. 10 1000F-.-$) "00 +-( 1 ,-*+&. ?)-) /%=%/ &/-$)@F%(+%$6%'%*($ *+*$ $/ LOF %(* -.(%++./+ $(+*(+%U$%$ +&*%6+%%/6%+ /-'-*(-&. +%$%+*)'-/+% ./$-$

TYPES OF TEST

.(-((-=% ?,%$+>/%@ /-((-=%

T%.$-/% B%.6 (%$(C)+ N-* >+% H+6.%$$ M*+&CTOT ?*+* (- &%.-. (%$(@ F-//%( '+*(+%

SYMBOLS

25

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WELD SPECIFICATIONS

W%/6$ ,$( >% $%*-'-%6 > */%+ -.$(+*(-&.$ .6 // $('' -.*/6-. +&6*(-&. %+$&..%/ ,$(.6%+$(.6 ()% %/6 $,>&/$ $%*-'-%6I( , >% .%*%$$+ (& $%*-' ,&+% 6%(-/$ >&( ()% %/6 % $-% &+ %/%*(+&6% (& >% $%6 &+ %=%.()% '// 6%(-/$ &' %/6 +&*%6+% , >% .%%6%6T)% ,%()&6$ ,&$( *&,,&./ $%6 (& $%*-' %/6 +%#

W+-((%. $((%,%.(W%/6 Y -$ (& >% $-./% V >(( %/6%6 '+&, ()% &($-6% &' ()% =%$$%/ T)% $+'*% &' ()%

%/6 -$ (& >% +&.6 '/$) T)% +&&( -$ (& >% $%/%6 -() %/6 +. 6%&$-(%6 '+&, -.$-6% ()% =%$$%/T)% *&,/%(%6 %/6 -$ (& >% +6-&+)%6

S,>&/$ &. 6+-.#

RAD 123

B&() ()% >&=% -=% ()% $,% -.'&+,(-&.

S(.6+6$ '&+ %/6 $,>&/$#A/()&) ()% ,-. '%(+%$ &' %/6 $,>&/$ +% -.(%+.(-&./ =+-(-&.$ -. 6%(-/ &**+ '+&,*&.(+ (& *&.(+ S,>&/$ +% $%*-'-%6 > .(-&./ $(.6+6$

UBSEN 22553USAAWS 24

I. ()-$ (%&/$ +% -. **&+6.*% -() BSEN 22553 )-*) $%+*%6%$ BS 499 .6 -$

-6%.(-*/ (& ()&$% -. ISO 2553

WELD DETAILS

I.6-*(-. ;&-.( &$-(-&.#A. ++& -.6-*(%$ ()% &$-(-&. &' ()% ;&-.( T)% ++& &-.($ (& &.% $-6% &' ()% ;&-.( T)-$ -$*//%6 ()% ARROW SIDE T)% $-6% +%,&(% '+&, ()% ++& -$ *//%6 ()% OTHER SIDE

++& $-6% &()%+ $-6% ++& $-6%

&()%+ $-6%

W%/6 -.'&+,(-&.#I.'&+,(-&. >&( ()% %/6 -$ -=%. &. +%'%+%.*% /-.% ((*)%6 (& ()% ++& ( -=&( T)%+%'%+%.*% /-.% -$ /$ )&+-&.(/ .6 ()% ++& *. $-. >&( ()% -=&( (& &-.( ( ()%

2"

2"


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%/6 D%(-/$ &' ()% %/6 &. ()% ++& $-6% &' ()% ;&-.( +% -=%. &. ()% $&/-6 /-.% O()%+ $-6%-.'&+,(-&. -$ &. ()% 6&((%6 /-.% )-*) *. >% $)&. >&=% &+ >%/& ()% $&/-6 /-.%

-=&( +%'%+%.*% /-.% ++& $-6% -.'&+,(-&.

&()%+ $-6% -.'&+,(-&.++&

A '-//%( %/6 -$ -.6-*(%6 > (+-./% /*%6 &. ()% +%'%+%.*% /-.%

A (+-./% &. ()% +%'%+%.*% /-.%$%*-'-%$ '-//%( %/6 &. ()% arrow side &' ()% ;&-.(

A (+-./% &. ()% 6&((%6 /-.%

*//$ '&+ '-//%( %/6 &. ()% other side &' ()% ;&-.(

TYPES OF BUTT WELD

T)% *&,,&. (%$ &' %6% +%+(-&. $$&*-(%6 -() >(( %/6 +% -.6-*(%6 $ '&//&$#

$+% %6% +%+(-&. $-./% V +%+(-&.

6&>/% V +%+(-&. $-./% U +%+(-&.

U$-. $,>&/$ -( -$ .&( .%*%$$+ (& 6+ ()%6&>/% U +%+(-&. $)% &' ()% %/6 %6% +%+(-&. O. .

6+-. ()% ;&-.( -$ /$ $)&. $ $-./%/-.%

ASYMMETRICAL PREPARATIONS

I. $&,% ;&-.($ &./ &.% *&,&.%.( -$ +%+%6 % $-./% >%=%/ >(( &+ $-./% >(( I. ()%$% *$%$()% ++& &-.($ ( ()% %6% )-*) -$ (& >% +%+%6 T)% =%+(-*/ +-)( &' ()% $,>&/ -$ /$ (&()% /%'( &. ()% +%'%+%.*% /-.%

27

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DIMENSIONING FILLET WELDS

T)% /% /%.() &' '-//%( %/6 -$ /&*(%6 (& ()% /%'( &' ()% %/6 $,>&/ ?(+-./%@ T)% 6-,%.$-&. -$ -.,-//-,%(+%$ +%*%6%6 -() ()% /%((%+ T)+&( ()-*.%$$ -$ -.6-*(%6 -. ()% $,% >( -$ +%*%6%6 > ()% /%((%+ I' .& /%((%+ -$ $)&. &. 6+-. ()%. $$,% ()% 6-,%.$-&. -$ /% /%.()

10 7 10 ,, /% /%.() '-//%( %/6 -() 7 ,,

'-//%( %/6 6%$-. ()+&( ()-*.%$$

F&+ 6%% %.%(+(-&. %/6$ ()% 6-,%.$-&.$ +% -.6-*(%6 % S8 "T)-$ -.6-*(%$ %/6 &' " ,, 6%$-. ()+&( -() . 8 ,,*(/ ()+&( 6%$-+%6 T)% *(/ ()+&( ()-*.%$$ -$ +%*%6%6 > S

I.(%+,-((%.( '-//%( %/6$ +% 6-,%.$-&.%6 > -=-.# . < / ?%@.,>%+ &' %/6 %/%,%.($ ? . @/%.() &' %/6 %/%,%.( ? / @6-$(.*% >%(%%. %/6 %/%,%.($ ? % @

O'(%. ()% .,>%+ &' %/6 %/%,%.($ ?.@ -$ .&( $%*-'-%6 $// >%*$% -( -$ .&( .&.

T)% $,>&/ *. /$& >% +-((%. $ / ?%@ / ()% /%.() >%-. +%%(%6 T)% /%.() -$ -. *%.(-,%(+%$

A $,>&/ ()$ . < / ?%@ &. 6&>/% '-//%( ,%.$ ()% %/6 %/%,%.($ +% (& >%$(%+%6 &. %-()%+ $-6% &' ()% ;&-.(

$(%+%6

" 10?20@ 10 " ,, ()+&( '-//%( %/6$ &' 10 *, /%.() -() &' 20 *, >%(%%. %*) %/%,%.( $(%+%6 &. %-()%+ $-6%

&' ()% ;&-.( '&+ ()% )&/% ;&-.(:$ /%.()

COMPOUND WELDSA *&,&.6 %/6 -$ *&,>-.(-&. &' 6-''%+%.( %/6$ &. ()% $,% ;&-.(

8

A '// %.%(+(-&. $-./% >%=%/ (%% ;&-.( -() . 8 ,, '-//%( +%-.'&+*%,%.(

28

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8 8

" A. 8 ,, +(-/ %.%(+(-&. (%% ;&-.(-() . 8 ,, '-//%( +%-.'&+*%,%.( .6 " ,, '-//%( &. ()% &()%+ $-6% &' ()%

;&-.(

A $-./% V >(( %/6 -() $%/-. +./&. ()% +&&( $-6% &' ()% %/6

SURFACE PROFILES

T)% $+'*% +&'-/% *. >% -.6-*(%6 > . %&/ /*%6 &. (& &' ()% %/6 $,>&/

$-./% V >(( %/6 -() '/(

$+'*% ?$// '/$)%6 '(%+%/6-. > +-.6-.@

*&.*=% '-//%( %/6

*&.=%< '-//%( %/6

'-//%( %/6 -() >/%.6%6 (&%$

SUPPLEMENTARY SYMBOLS

O()%+ $,>&/$ -. %.%+/ $%#

29

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%/6 // +&.6 ()% *&,&.%.(

66-(-&./ -.'&+,(-&. ?()% >&< &. ()% (-/ &'()% +%'%+%.*% /-.% *. *&.(-. -.'&+,(-&. %

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$&( %/6 $%, %/6

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>(( %/6 >%(%%. /(%$ -() +-$%6 %6%$

BS 499

I. ()% &/6%+ $(/% -. BS 499 $(.6+6 ()% ,-. 6-''%+%.*% $ ()( ()%+% $ .& 6&((%6 +%'%+%.*%

/-.% $& >%/& ()% +%'%+%.*% /-.% $ ()% ++& $-6% .6 >&=% ()% +%'%+%.*% /-.% $ ()% &()%+ $-6%

&()%+ $-6%++& $-6%

MATERIALSALLOYING ADDITIVES

T)% (%+, $(%%/: -$ $%6 (& 6%$*+->% ,. 6-''%+%.( ,%(/$ T)% +% // //&$ >$%6 &. -+&. >( ()%//&-. 66-(-&.$ $*) $ *+>&. ,..%$% $-/-*&. *)+&,-, %(* $-./ &+ -. *&,>-.(-&. +&6*% +.% &' ,%(/$ -() -6%/ 6-''%+-. )$-*/ .6 ,%*).-*/ +&%+(-%$ $ %// $ -(%6-''%+%.( %/6->-/-(

IRON F% ()% >$-* *&.$(-(%.(

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CARBON C -=%$ )+6.%$$ .6 $(+%.()MANGANESE M. -=%$ (&).%$$ .6 $(+%.() N%(+/-$%$ $/)+SILICON S- 6%&&() +-. +%'-.%+$ .6 $(>-/-$-. %.($ T)% +%=%.( NIOBIUM N> -.(%++./+ *&++&$-&. .6 %/6 6%* U$%6 -. $(%.-(-* $(%%/$VANADIUM V -=%$ )+6.%$$ .6 $(+%.()SULPHUR S *&.(,-..( ?M-. *$% &' $&/-6-'-*(-&. *+*-. ! )&(

$)&+(.%$$@ NICEL N- -=%$ /& (%,%+(+% (&).%$$ .6 $(+%.()COPPER C *&.(,-..( ! *$%$ /&(-&. *+*$ ?T)&) /$& $%6 '&+

%()%+-. $(%%/ .6 &$$->/% +-. +%'-.%+@PHOSPHORUS P *&.(,-..(

STEEL COMPOSITIONS

R-,,-. S(%%/C&,&$-(-&.# 009J C 09J M. +%$-6/$W%/6>-/-(# T)% %/6 &&/ -// +%-+% (& )=% 66%6 6%&&. S(%%/C&,&$-(-&.# 045J C 09J M. +%$-6/$W%/6>-/-(# T)% )-) *+>&. *&.(%.( -.6*%$ )6+&%. *+*-. -. ()% HA $ ()% $%*(-&.

$-% -.*+%$%$ G+%(%+ (). 038J C &$$->/ +%-+%$ )%( (+%(,%.(

H-) C+>&. S(%%/C&,&$-(-&.# 08J C 09J M. +%$-6/$W%/6>-/-(# T)% %/6 &&/ -$ $>;%*( (& $&/-6-'-*(-&. (% *+*-. .6 ()% HA $''%+$

)6+&%. *+*-. N&( $-(>/% '&+ %/6-. A (&&/ $(%%/

C+>&.!M..%$% S(%%/C&,&$-(-&.# 02J C 15J M. +%$-6/$ , /$& *&.(-. T- N- .6 VW%/6>-/-(# T)%$% )-) ,..%$% $(%%/$ )=% &&6 (&).%$$ +(-*/+/ ()% (-(.-,

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C&,&$-(-&.# 04J C 10J M. 08J C+ 03J M& T- &+ A/ +%$-6/$W%/6>-/-(# T)%$% $(%%/$ +% 6-''-*/( (& %/6 .6 6%'%*( '+%% %/6$ -() &&6 ,%*).-*/

+&%+(-%$ +% &./ &>(-.%6 > $-. ()% +%(%$( *+%

H-) T%,%+(+% S(%%/C&,&$-(-&.# 025 ! 9J C+ 025 ! 3J M& (+*%$W%/6>-/-(# T)% %/6>-/-( &' ()% /& *)+&,-, -$ 6-''-*/( G&&6 +-. *+%% +%$-$(.*%

L& T%,%+(+% S(%%/C&,&$-(-&.# 35 ! 9J N- (+*%$W%/6>-/-(# T)% )-)%+ .-*%/ *&.(%.( -$ $>;%*( (& $&/-6-'-*(-&. *+*-.

M-*+& A//&%6 S(%%/ ?HSLA@C&,&$-(-&.# 025J C 15J M. ?0002J V 0005J N> 0003J T- ,-.-,,@W%/6>-/-(# T)%$% $(%%/$ , $''%+ )6+&%. *+*-. -. ()% %/6 ,%(/ ! ()% &./ %/6

,%(/ (& 6& $& HSLA ! H-) S(+%.() L& A//&

STAINLESS STEELS

M+(%.$-(-* S(-./%$$ S(%%/C&,&$-(-&.# 11J C+ 008J C +%$-6/$W%/6>-/-(# P&&+ 6% (& )6+&%. *+*-.

F%++-(-* S(-./%$$ S(%%/C&,&$-(-&.# 12 ! 27J C+ 008J C +%$-6/$W%/6>-/-(# P&&+ 6% (& *+*-. >+-((/%.%$$ .6 (%,%+ %,>+-((/%,%.(

A$(-.-(-* S(-./%$$ S(%%/C&,&$-(-&.# 18 ! 27J C+ 8 ! 22J N- 008J C +%$-6/$W%/6>-/-(# P+&>/%,$ -() $&/-6-'-*(-&. *+*-. .6 %/6 6%* ! >( 6&%$ .&( $''%+

)6+&%. *+*-. NB ()-$ -$ non-magnetic $(%%/

CARBON EUIVALENCY

C+>&. %-=/%.* ?CE@ -$ $%6 (& -=% . &=%+// *+>&. %+*%.(% (& %$(-,(% ()% +-$ &'*+*-. T)% )-)%+ ()% *+>&. *&.(%.(K ()% )+6%+ ()% $(%%/ ! ()% ,&+% $$*%(->/% -( -$ (& *+*-.A *+>&. %-=/%.* &' 004J .6 >&=% -=%$ +%(%+ +-$ &' *+*-.

CE J C J M. J C+ M& V J N- C& %(*" 5 15

REVIEW OF STEELS

T%$ &' $(%%/ $%6 -. %/6%6 *&.$(+*(-&.$ !

L& *+>&. ! T)%$% $(%%/$ +% +%6-/ %/6>/% >( , >% $>;%*( (& %/6 ,%(/ *+*-. -.()% *)%%+ /-(-%$

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> M%6-, *+>&. ! A$ ()% *+>&. *&.(%.( +&*)%$ 04J $(%%/$ >%*&,% +&.% (& +%.(,%(/ *+*-.

* L& *+>&./& //& ! T)% 66-(-&./ //&-. %/%,%.($ *(-. -. $-,-/+ (& *+>&.-. +&6*% 6-''-*/(-%$ -. %/6-.

6 H-) //& $(%%/$ ! T)% $(%.-(-* $(-./%$$ $(%%/$ +% +&.% (& %/6 ,%(/ .6 +%)%( *+*-.6% (& ()%+,/ *&.6*(-=-( *)+*(%+-$(-*$

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MATERIALS INSPECTION

A +%( =+-%( &' ,(%+-/$ , +%-+% (& >% -.$%*(%6 -() =-% (& $(-$'*(&+ %/6-. T)%,-. (&-*$ -. ,(%+-/ -.$%*(-&. +% S-% T% .6 C&.6-(-&.

S%*-'-*(-&.I( -$ .&( -. %.%+/ $'% '&+ ()% -.$%*(&+ (& -6%.(-' ,(%+-/$ > *&,&$-(-&. '+&, ,-//$)%%( $-.*% =%+ $,// =+-(-&.$ &+ 66-(-&.$ (& ()% ,%(/ , -=% +-$% (& $-.-'-*.( *).%$-. +&%+(-%$ .6 %/6>-/-( H&%=%+ /-,-(%6 $%/%*(-=-( -$ %+,-$$->/% $*) $ %+*%.(%

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*+>&. ,%+

S/-%+T)-$ *. >% '&.6 &. ()% G&&6$ I.+6$ 6&*,%.($ &+ ()% +%*%-( 6&*,%.($ &+&**$-&.// &. *-. &+ %=%. ,+%6 &. ()% ,%(/

.(-(T)% .(-( >%-. -.$%*(%6 $)&/6 /$ >% .&(%6 $ %// $ ()% $,/% $-% -' 100 J-.$%*(-&. -$ .&( >%-. %,/&%6

S-%S-%$ ,$( >% *)%*%6 '&+ $%*&.6+ -6%.(-'-*(-&. $ %// $ *&.'&+,.*% T)% -.$%*(&+-// $ +&+-(% >% -=%. (&/%+.*%$ &. $-% ()( +% %+,-$$->/% C)%* /%.() >+%6()()-*.%$$ .6 6-,%(%+

D-$(&+(-&.A *)%* -$ &'(%. +%-+%6 &. ()% 6%+%% &' 6-$(&+(-&. -%F/(.%$$

S+%.%$$S(+-)(.%$$O=/-(C&.$-$(%.( // ()-*.%$$

C&.6-(-&.R$( -.( .6 +%$% &. ()% $+'*% &' ()% ,%(/ +% // )+,'/ (& %/6-. .6 ,$( $// >% +%,&=%6 ( /%$( .%+ (& ()% *(/ %/6 G-6.*% -$ .&+,// -=%. (& ()% -.$%*(&++%+6-. **%(>/% /%=%/$ &+ ()% (+%(,%.( ()( -$ +%-+%6 A. -.$%*(&+ $)&/6 >% /%+( (&+6/ *).%$ $*) $ -.*+%$%6 *&++&$-&. C+%'// ,-.(-.%6 $%*-,%.$ $)&-.**%(>/% *&.6-(-&.$ +% &'(%. ()% >%$( ,%()&6 H%( (+%(,%.( *&.6-(-&. ..%/%6

.&+,/-$%6 %(* $)&/6 // >% +%*&+6%6

D%'%*($I. +&)( +&6*($ ()% ,&$( *&,,&. 6%'%*($ +% /$ .6 /,-.(-&.$ ?A/$& &+&$-( .6$%+%(-&. >.6$@ T)%$% -// .&+,// >% $>$+'*% $& ./%$$ NDE -$ %,/&%6 &./ ()%%6%$ &' ()% /(% .6 +(-*/+/ *( %6%$ *. >% -.$%*(%6 T)% //,-.(-&. -//%+ $ .++& >/* /-.% +//%/ (& ()% $+'*%

S(&+%

A'(%+ -.$%*(-&. .6 +&=/ '&+ $% -( -$ %$$%.(-/ ()( ()% ,%(/ -$ $(&+%6 -. $*) $ (&,-.(-. -($ &&6 *&.6-(-&. P+&(%*( '+&, *&++&$-&. .6 ,%*).-*/ 6,%

MATERIALS INSPECTION CHEC LIST

INSPECTION OF

SIE TYPE CONDITION

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()-*.%$$ *&,&$-(-&. )$-*/ ,%*).-*/ /%.() +6% -6() *+>&. %-=/%.( $+'*% )%( (+%(,%.(

6-,%(%+ (+6% .,% $*/%&=/-( &-/+%$% ..%/%6'/(.%$$ -6%.(-'-*(-&. ,+ -.( .&+,/-$%6.(-( +$( %.*) (%,%+%6

,&-$(+%

)+6 $(,-.(%(*) ()%+,&!,%*).-*/(+%(,%.(

6-$(&+(-&.-.$( ,-// $)%%(,(%+-/ *%+(-'-*(% 6%'%*($

**%(>/% (&/%+.*%$ **%(>/% **%(>/%

ACCEPTANCE OF MATERIAL

UESTIONS TO BE ASED

1 D& ()% ,+-.$ &. ()% ,(%+-/ ,(*) ()&$% &. ()% +&*%6+% $)%%( &+ 6+-.2 A+% ()% 6-,%.$-&.$ *&++%*(3 I$ ()% $+'*% *&.6-(-&. $(-$'*(&+ '&+ %/6-.

THE FOUR ESSENTIAL FACTORS FOR ESTABLISHING A WELD

W%/6-. -$ $// +%+6%6 $ ;&-.-. +&*%$$ -. )-*) ()% &+ -%*%$ +% -. (&,-* *&.(*( &'(%.-() '-//%+ ,%(/ -() >+&6/ $-,-/+ +&%+(-%$ H%.*% $&/6%+-. .6 >+-. +% %( >&()$&/-6 $((% .6 '$-&. %/6-. +% -.*/6%6

S&/-6 $((% +&*%$$%$ -.*/6%#F&+% %/6-.F+-*(-&. %/6-.

F$-&. %/6-. +&*%$$%$ -.*/6%#O,%+%6 +* %/6-. ?SAW@E/%*(+&!$/ %/6-. ?ESW@

FUSION WELDING FACTORS

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1 F$-&. T)% ,%(/ ,$( >% ,%/(%6 )-*) +%-+%$ )-)-.(%.$-( )%( $&+*%

2 A(,&$)%+-* +&(%*(-&. C&.(,-.(-&. '+&, ()% (,&$)%+% ,$( >% =&-6%6

3 S+'*% +&(%*(-&. T)% +&*%$$ ,$( +%,&=% . &%(%%. -+% .6 &+/*%(,&$)%+-* +&(%*(-&. +&. $$+'*% +&(%*(-&. 6%&/ +%&$( %/6 )%(

(+%(,%.(@

MMA '$-&. $&+*% %/%*(+-* +* >%(%%. %/%*(+&6% .6 &+/*%(,&$)%+-* +&(%*(-&. $%&$ $)-%/6 '+&, '/%%/6%6 -()&( +-$ +&=-6%6 *%+(-. +%*(-&.$ +% (%. &+ *%+(-. +%! &+ &$(! %/6-.

(+%(,%.($ +% *++-%6 &( T)% (%+, .%/6>/% $(%%/$: -$ .+%/-$(-* A. $(%%/ *. >% %/6%6 +&=-6%6 *&++%*( ,%(//+-*/ *&.6-(-&.$ +% *)&$%. S&,%(-,%$ )&%=%+ ()%$% *&.6-(-&.$ , >%-,&$$->/% (& +%/-$% -. +*(-*/ +&6*(-&. &+

WELDABILITY OF STEEL

W%/6>-/-( -$ '.*(-&. &' ,. -.(%+!+%/(%6 '*(&+$ >( ()%$% , >% $,,+-$%6 $#1 P+&*%$$ .6 (%*).-%2 C&,&$-(-&. &' +%.( /(%3 &-.( 6%$-. .6 $-%

3"

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INFLUENCE OF PROCESS E*) +&*%$$ -// -=% *)+*(%+-$(-* -.(%.$-( &' &%+ P+&*%$$%$ ()( &''%+ ()% )-)%+ &%+-.(%.$-( &''%+ 6=.(%$ -. '$-&. %/6-. >%*$% ()% %$$%.(-/ ,%/(-. *. >% &>(-.%6 -()&(%% $$%$$%6 (& 6%(%+,-.% ()% /%=%/ &' +%)%(1 M(%+-/ (%2 C&,>-.%6 ()-*.%$$3 H%( -.( &(%.(-/ ?%/6-. +&*%$$@4 &-.( (%

INFLUENCE OF COMPOSITION

T)% *&,&$-(-&. &' ()% $(%%/ .6 -($ %''%*( &. %/6>-/-( , >% 6-=-6%6 -.(& (& +($#1S%+%(-&. %''%*($ +(-*/+/ ()( &' $/)+W)%. $(%%/ $&/-6-'-%$ ()%+% -$ (%.6%.* '&+ ()% -+&. (& $&/-6-' '$( .6 '&+ ()% //&-.

%/%,%.($ (& >% **,/(%6 -. ()% *%.(+% &' ()% -.&( T)-$ *&.'-+(-&. -$ +%(-.%6 %=%. '(%+ +&/&.%6 .6 $%=%+% +&//-. .6 +%$/($ -. )-) *&.*%.(+(-&.$ &' $/)+ -. ()% *%.(+/ /%+$ &' ()% /(% T)%$% /%+$ )=% /-((/% $(+%.() .6 +% /-%/ (& *+* -' $(+%$$%6

2 T)% (%.6%.* &' ()% $(%%/ (& )+6%.

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T)% )+6%.-. *)+*(%+-$(-*$ &' $(%%/ +% ,%.(-&.%6 -. ()% )%( (+%(,%.( $%*(-&. A$ ()%*+>&. &+ //& *&.(%.( &' ()% $(%%/ -.*+%$%$ ()% /-%/-)&&6 &' /& 6*(-/-( .6 )+6%.%6,-*+&$(+*(+%$ '&+,-. /$& -.*+%$%$ .6 $)&/6 $(+%$$%$ %&. .6 &()%+ //& %/%,%.($ +%$/( -. >+-((/% &.%$ +&.6 ()% %/6 > H-) *&&/-. +(%$ '(%+ %/6-. -.*+%$% ()% )+6.%$$ )-*) -.*+%$%$ ()% $$*%(->-/-( (&

*&/6 *+*-.* &-.( +%$(+-.( +%=%.($ *&.(+*(-&. '(%+ %/6-. )-*) *. /%6 (& -.(%+./ *+*-.6 H6+&%. -. ()% %/6 >%6 *. /%6 (& )6+&%. -.6*%6 *&/6 *+*-.% C&.(,-..($ /-% $/)+ .6 )&$)&+$ *$% $%+%(-&. &+ $&/-6-'-*(-&. *+*-.' L,%//+ (%+-. *$%6 > -.*/$-&.$ /%+-. 6+-. +&//-. +%$/(-. -. 6%(%+-&+(-&. &' ()%

()+&)!()-*.%$$ +&%+(-%$

C+*-. $// &**+$ -. ()% .,%/(%6 +%$ 6;*%.( (& %/6 >%6 ?-. ()% )%( ''%*(%6 &.%

HA@ T)-$ &.% -$ ,6% &' . +% ()( )$ >%%. )%(%6 (& >&=% >&( 800°C ?(& >%*&,%

$(%.-(%@ .6 . +% )%(%6 >&=% 723°C ?.6 +(-// (+.$'&+,%6@ T)% '// $(%.-(-* +%-&.

;$( 6;*%.( (& ()% '$-&. &.% -$ &'(%. ()% ,&$( >+-((/% +% &' ()% %/6 6% (& ()% +-. +&() ()()$ &**++%6 )-/% ()% ,%(/ $ ( ()-$ (%,%+(+% T)% +-. $-% +6// 6%*+%$%$ ,&=-. '+&, ()% '$-&. &.% (& ()% +(-// (+.$'&+,%6 +%-&. G+-. +%'-.%,%.( &**+$ )%+% )-*) -$*&.$-6%+%6 >%.%'-*-/ ()% +-. $-% >%-. $,//%+

T)% *&,&$-(-&. &' ()% $(%%/ +(-*/+/ ()% *+>&. /%=%/ 6%(%+,-.%$ ()% )+6.%$$ .6 >+-((/%.%$$ &' >&() ()% %/6 .6 ()% HA O. *&&/-. $(%.-(% (+.$'&+,$ (& '%++-(% C+>&. -$$&/>/% -. $(%.-(% >( /%$$ $& -. '%++-(% I+&. *+>-6%$ +% +%*--((%6 )%. ()-$ (+.$'&+,(-&.(%$ /*% T)%$% *. >% ++.%6 -. /,%//+ '&+, ?$ %+/-(%@ )-*) -=%$ ()% $(+*(+% +%$&.>/%$(+%.() .6 6*(-/-(

T)% HA *. >% ()% +%-&. )%+% ()% )-)%$( *&&/-. +(%$ &**+ +(-*/+/ -. ()-*%+

$%*(-&. /(% H-) *&&/-. +(%$ (%.6 (& /&* ()% *+>-6%$ -. $&/-6 $&/(-&. '&+,-. ,+(%.$-(%T)-$ /%6$ (& )-) -.(%+./ $(+%$$ .6 )+6 >+-((/% $(+*(+%$

TYPICAL WELDABILITY DEFECTS

1 SOLIDIFICATION CRACINGA/$& .&. $ )&( *+*-. &+ *%.(+%/-.% *+*-. A/$ &**+$ -. ()% %/6 ,%(/C$%$ ! I. *+>&. ,..%$% $(%%/$K $/)+ -. ()% +%.( /(% $)% &' ()% %/6 $(+%$$ ! /$.%%6%6

S/)+

D+-. $&/-6-'-*(-&. ()% *%.(+% &' ()% %/6 -$ ()% /$( (& *&&/ S/)+ '+&, ()% +%.( /(% '&+,$-+&. $/)-6% -() -+&. '+&, ()% %/6 &&/ T)% -+&. $/)-6% '&+,$ ()-. /--6 '-/, &. ()% +-. >&.6+-%$ )-*) )$ /&%+ ,%/(-. &-.( (). -+&. $& $ ()% %/6 *&&/$ -( -$ $)%6 (&+6$ ()%*%.(+% &' ()% %/6 T)% -+&. $/)-6% )$ =%+ /-((/% (%.$-/% $(+%.() $& $ -( *&&/$ ()% %/6 -$ .6%+$(+%$$ .6 *+*-. -// +%$/( P)&$)&+&$ *&.(,-.(-&. -. ()% ,(%+-/ *. /$& *$%$&/-6-'-*(-&. *+*-.

A=&-6.*% ! R%6*% $/)+ ?*)%* ,-// $)%%($ '&+ /%=%/$


39/133

A66 ,..%$% (& ()% +%.( /(% =- ()% '-//%+ -+% ?'&+,$ ,..%$% $/)-6% ()(,%/($ *&&/$ ( +&%6 *+*-. )+6 &.% *+*-. .6 )6+&%. -.6*%6 *&/6 *+*-.?HICC@ T)-$ )%.&,%.&. *. &**+ 6+-. ()% %/6-. &' )+6%.>/% $(%%/$ .6 -$ .&+,// HA )%.&,%.&. H6+&%. -$ ,&+% $&/>/% -. $(%.-(% (). '%++-(% ! -( *. %$-/ >% -*%6 > ()%%/6 ,%(/ W)%. '%++-(% -$ '&+,%6 ()% )6+&%. $&/>-/-( 6%*+%$%$ .6 )6+&%. 6-''$%$ (& ()%HA )%+% -( *. *&.(+->(% (& *+* +&(-&.

T)%+% +% '&+ '*(&+$ -.=&/=%6 -. )6+&%. *+*-. A=&-6 &.% '*(&+ .6 )6+&%. *+*-. -//.&( &**+

F*(&+$1 )6+&%. Q 15 ,/ )6+&%. %+ 100 , %/6 ,%(/

2 (%,%+(+% 350° C

3 )+6.%$$ Q 400 VPN ?V-*%+$ +,-6 .,>%+@4 $(+%$$ Q 50 J -%/6 ?*..&( >% ,%$+%6 $& $$,% -( -$ Q 50 J -%/6@

A=&-6.*%1 H6+&%. @ +%.( ,(%+-/ 6+-%6 ?'+%% '+&, ,&-$(+%@

>@ /& )6+&%. +&6$ ?>%6 (& /%$$ (). 5 ,/ %+ 100 ,@*@ $% /&%+ &(%.(-/ )6+&%. +&*%$$

?)6+&%. &(%.(-/ ! %/%*(+&. TIG MIGMAG SAW MMA ?/& H@ MMA ?+(-/%@@

6@ )%( (+%(,%.( ?+% .6 &$( %/6@2 T%,%+(+% &$( %/6 )%( (+%(,%.( ?%% ( )-)%+ (%,%+(+% $ /&. $ &$$->/% (&

)%/ )6+&%. 6-''$-&. NDT $ /(% $ &$$->/% ! 72 )&+$@3 H+6.%$$ @ +%)%(-. ?(& +%6*% ()% *&&/-. +(%@

>@ %% -.(%+$$ (%,%+(+% (& ,-.-,,*@ )-)%+ )%( -.( ?-=%$ /+%+ +-. $-%@6@ &$( %/6 )%( (+%(,%.( !(%,%+$ )+6 HA +%,&=%$ H2 +%6*%$ $(+%$$

4 S(+%$$ @ ;&-.( 6%$-. >@ '-( *@ 6-$(&+(-&. *&.(+&/6@ $(+%$$ +%/-%=% (+%(,%.( ?+% .6 &$( %/6@

O. )-) ,-*+& //& $(%%/$ -( , &**+ -. ()% %/6 ,%(/ &()%+-$% &./ -. ()% HA

3 LAMELLAR TEARINGA $(% /-% *+* ()( &**+$ -. ()-* $%*(-&. (%% ;&-.($ .6 */&$%6 *&+.%+ ;&-.($

$(+%$$

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/,%//+ (%+-.)$ $(% /-%:%+.*%

$(+%$$

C$%$ ! P&&+ ()+&) ()-*.%$$ 6*(-/-( -. +%.( /(% )%+% )-) $)+-.% $(+-.$ ?()+&)()-*.%$$ $(+%$$@ *( ()+&) ()% /(% ()-*.%$$ -. *&,>-.(-&. -() +%.( ,%(/ -.*/$-&.$ T)%-.*/$-&.$ *. >% /,%//+ -.*/$-&.$ $,// ,-*+& -.*/$-&.$ &+ (+, %/%,%.($ O./ &**+$ &. ()%/% -() $(+%$$%$ &. ()% .&.!+&//-. 6-+%*(-&. ()+&) ()-*.%$$

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WELDING OF LOW ALLOY STEELS

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WELDING OF HIGH YIELD UENCH AND TEMPERED STEELS

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SUMMARY

BS 5135 $((%$ ()( %/6>-/-( -$ ()% >-/-( &' ,(%+-/ (& >% ;&-.%6 > ,&$( &' ()% %/6 +&*%$$%$.6 $(-// ,-.(-. ,&$( &' ()% )$-*/,%*).-*/ +&%+(-%$ '&+ )-*) -( $ &+--.// 6%$-.%6

G&&6 %/6>-/-( ! /& +-$ &' HICC >( $&/-6-'-*(-&. *+*-. +-$ 6% (& &&+ +-. $(+*(+%L-,-(%6 %/6>-/-( ! , +-$ )+6%.-. %''%*($ ()+&) %/6-. *((-. .6 HICCL,%//+ (%+-. ! &&+ ()+&) ()-*.%$$ 6*(-/-( .6 /(% 6%'%*($

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RESIDUAL STRESS AND DISTORTION

RESIDUAL STRESS

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DISTORTION

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C&.(+&/ &' 6-$(&+(-&. -$ *)-%=%6 -. &.% &+ ,&+% &' ()+%% ,-. ,%()&6$#1P+%$%((-. ! $& ()( ()% ,%(/ 6-$(&+($ -.(& ()% +%-+%6 &$-(-&.2C/,-. ! (& +%=%.( 6-$(&+(-&. >( ()-$ -.*+%$%$ ()% /%=%/ &' +%$-6/ $(+%$$%$3W%/6-. $%%.*% ! -% >/.*%6 '&+ %*$- %/6-.

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HEAT TREATMENT

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MONITORING THE HEAT TREATMENT

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6@ A// 6&*,%.((-&. .6 +%*&+6$ +% -. &+6%+

CALIBRATION OF WELDING EQUIPMENT

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

CHECLIST FOR CALIBRATING ARC WELDING EUIPMENT

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I. +%*%.( %+$ ,&+% ((%.(-&. )$ >%%. -=%. (& /-( $$+.*% -. +* %/6-. &%+(-&.$ .6 -.,. *$%$ -( -$ &' +,&.( -,&+(.*% (& %.$+% ()( ()% *&++%*( %/6-. +,%(%+$ +% >%-.$%6 -. &+6%+ (& ,%%( ()%$% +%-+%,%.($ A**+(% */->+(-&. &' %-,%.( ()%+%'&+% -$ .%*%$$+.6 *%+(-'-*(%$ &' */->+(-&.: +% +%-+%6 '&+ // %-,%.( -% %/6-. %-,%.( ,%$+-.%-,%.( $(&+% &=%.$ %(*

DEFECTS DETECTED BY SURFACE INSPECTION

D%'%*($ )-*) *. >% 6%(%*(%6 > =-$/ -.$%*(-&. *. >% +&%6 .6%+ '-=% )%6-.$

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2 SURFACE IRREGULARITIES

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S((%+S(+ /&>/%$ &' %/6 ,(%+-/ &. +%.( /(% &($-6% ()% %/6

C$%$ ! 6, %/%*(+&6%$ (&& )-) =&/(% (&& )-) *++%.( '/< ,-$$-.

S(+ '/$) ?$(+ +*-.@T)% 6,% &. ()% +%.( ,(%+-/ +%$/(-. '+&, ()% **-6%.(/ $(+--. &' . +* '+&,()% %/6 A $,// =&/,% &' >$% ,(%+-/ -$ ,%/(%6 )%. ()% +* -$ $(+* T)-$ ,&/(%. &&/-$ %.*)%6 6% (& ()% +-6 6-''$-&. &' )%( ()+&) ()% /(% T)-$ , /%6 (& ()%'&+,(-&. &' *+(%+ ()( /%.6$ -($%/' (& *+*-. &+ *).% -. +-. $(+*(+% > *+%(-. ,+(%.$-(-* &+ >+-((/% +-. $(+*(+% -. ()% +% &' ()% +* $(+-% T)%$% 6-$*&.(-.-(-%$ ,/%6 (& %%$%6 $ -6%?T)% -6%/ +&'-/% -$ (& +%,&=% ()% * .6 /%=% ()% %/6 '/$) -() ()% 6;*%.( $+'*%$T)-$ &/6 -.*+%$% ()% '(-% /-'% &' ()% ;&-.( > '*(&+ &' 3@

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A66-(-&./ %/6 ,%(/ >&=% ()% $+'*% /.% &' ()% +%.( ,(%+-/ &+ +%(%+ (). ()% 6%$-+%6 ()+&( &.'-//%( %/6$

L* &' '$-&.A *&.(-.&$ &+ -.(%+,-((%.( +&&=% /&. ()% $-6% &'()% %/6 -() ()% &+--./ %/6 +% '*% $(-// -.(*(C$%$ ! .&( %.&) +.$ &%+(&+ %++&+

I.*&,/%(%/ '-//%6 +&&=%A *&.(-.&$ &+ -.(%+,-((%.( *)..%/ -. ()% $+'*% &'()% %/6 +..-. /&. -($ /%.() 6% (& -.$''-*-%.(%/6 ,(%+-/ T)% *)..%/ , >% /&. ()% *%.(+% &+ /&. &.% &+ >&() %6%$ &' ()% %/6C$%$ ! .&( %.&) +.$ ! +&*%6+% %++&+ %/%*(+&6%(&& $,// A/$& *//%6 -.$''-*-%.( ()+&(

B/>&$ *&.(&+

N&( BS 499 (%+, ?&$$->/ .6%+ *&.(&+ (&% >/%.6@ U.%=%./ $-%6 *-. +.$C$%$ ! %/%*(+&6% (% +* =&/(% *&.6-(-&.$ %/6%+ (%*).-%

U.%/ /%$ N&( BS 499 (%+, V+-(-&. &' /% /%.() &. '-//%(%/6C$%$ ! (-/( ./% +. $%%.*%

NB U.%/ /%$ , >% $%*-'-%6 $ +( &' ()% 6%$-. !-. )-*) *$% ()% +% .&( 6%'%*($

4 ROOT DEFECTS

I.*&,/%(% +&&( %.%(+(-&.F-/+% &' %/6 ,%(/ (& %- $,// -.*/6%6 ./% )%( -.( (&& /&

L* &' +&&( '$-&.L* &' .-&. ( ()% +&&( &' ;&-.(C$%$ ! &&+ %/6 +% .%=%. >%=%/ +&&( '*% (&&/+% /-.%+ ,-$/-.,%.( */%.-.

E%6E


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R&&( *&.*=-( ?$*!>* .6%+$)-.@A $)//& +&&=% )-*) , &**+ -. ()% +&&( &' >(( %/6C$%$ ! +% +%$$+% -6% +&&( .6 +%$-6/ $(+%$$%$-. +&&(

S)+-.% +&&=%A $)//& +&&=% /&. %*) $-6% &' %.%(+(-&. >%6C$%$ ! *&.(+*(-&. &' ()% ,%(/ /&. %*) $-6% &' ()% >%6 )-/% -. ()% /$(-* *&.6-(-&.

B+.()+&) ?,%/( ()+&) >/&()+&)@A /&*/-$%6 *&//$% &' ()% ,&/(%. &&/ +%$/(-. -. )&/% -. ()% %/6 +.C$%$ ! %%(%%. (&%/6%6 -%*%$ $*) ()( ()%-+ $+'*% /.%$ +% .&( +//%/ &+ ( ()% -.(%.6%6 ./%$

E ()% +%,&=/&' ()% $+'*% &' %/6 .6 6;*%.( +%$ (& >%/&()% $+'*% &' ()% +%.( ,%(/

G+-.6-. ,+G+&&=%$ &. ()% $+'*% &' ()% +%.( ,%(/ &+ %/6 ,%(/ ,6% > +-.6-. )%%/ &+$+'*-. (&&/

T&&/ ,+A. -.6%.((-&. -. ()% $+'*% &' ()% +%.( ,%(/ &+ %/6 ,%(/ +%$/(-. '+&, ()% /-*(-&.&' (&&/ % *)--. (&&/ -. +%+(-&. &+ 6+%$$-.

H,,%+ ,+A. -.6%.((-&. -. ()% $+'*% &' ()% +%.( ,%(/ &+ %/6 ,%(/ 6% (& ),,%+ >/&

T&+. $+'*%A $+'*% -++%/+-( 6% (& ()% >+%-. &'' &' (%,&++ ((*),%.($

S+'*% -((-.A. -,%+'%*(-&. -. ()% $+'*% &' ()% +%.( ,%(/ $// -. ()% '&+, &' $,// 6%+%$$-&.$

51

51


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INTERNAL DEFECTS

DEFINITIONS

L* &' '$-&. L* &' .-&. -. %/6 >%(%%. %/6 ,%(/ .6 +%.( ,%(/ > >%(%%. +%.( ,%(/ .6 +%.( ,%(/ * >%(%%. %/6 ,%(/ .6 %/6 ,%(/

L* &' $-6%// '$-&. L* &' .-&. >%(%%. %/6 ,%(/ .6 +%.( ,%(/ ( $-6% &' %/6

L* &' -.(%+!+. '$-&. L* &' .-&. >%(%%. 6;*%.( +.$ &' %/6 ,%(/ -. ,/(-!+.

;&-.(

I.*/$-&. S/ &+ &()%+ '&+%-. ,((%+ %.(+%6 6+-. %/6-. T)% 6%'%*( -$,&+% -++%/+ -. $)% (). $ &+%

O %.(+%6 $6+-. ()% $&/-6-'-*(-&. &' ,&/(%. ,%(/

W&+,)&/% A. %/&.(%6 &+ (>/+ *=-( '&+,%6 > %.(+%6 $ 6+-. ()%$&/-6-'-*(-&. &' ,&/(%. ,%(/

GENERAL CAUSES

52

52


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P&+&$-( I$ ()% +%$/( &' $ >%-. %.(+%6 -()-. ()% $&/-6-'-. %/6 ,%(/ P&+&$-( -// >% +%$%.( -. %/6 -' ()% %/6-. (%*).-% ,(%+-/$ $%6 &+ *&.6-(-&. &' ()% %/6 ;&-.( +&,&(%$ $ '&+,(-&. I' ()% ,&/(%. %/6 ,%(/ *&&/$ $/&/ .6 //&$ // $(& +-$% (& ()% $+'*% >%'&+% $&/-6-'-*(-&. ()% %/6 &/6 >% =-+(// '+%% &' &+&$-(I$&/(%6 &+ .-'&+, &+&$-(# T)% *$% &' ()-$ '&+, &' $-./+ &+&$-( -$ %.%+//'/( %/6-. (%*).-% &+ 6%'%*(-=% ,(%+-/ &+ >&()C/$(%+ &+ +& &+&$-(# I$ /&*/-$%6 +& &' &+%$ ()( , +%$/( '+&, -,+&%+ -.-(-(-&. &+ (%+,-.(-&. &' ()% %/6-. +*L-.%+ &+&$-(# A/$ '&+,$ $(+-)( /-.% /&. +. &' %/6 .6 -$ *$%6 > $%=&/=-. '+&, *&.(,-..($

O=%+/ ?C&/6 /+&// &=%+@ U$// *$%6 > -.*&++%*( ,.-/(-&. &' %/6-. +&*%6+%$-% /& *++%.( *&,>-.%6 -() +&. (+=%/ $%%6 T)-$ 6%'%*( *. &**+ &. ()%'$-&. '*% $ %// $ ()% * +. -' ()% '$-&. '*% *&.(-.$ (-)(/ 6)%+-. &% 6%(%*(%6 > NDT .6 +&>>/ -.(%++%(%6 $ /* &' '$-&.@O=%+/ , >% 6%'-.%6 $ $+'*% *&..%*(%6 6-$*&.(-.-( ()( '&+,$ $%=%+%,%*).-*/ .&(*) +//%/ (& ()% %/6 ()% $)-%/6-. $

SPECIFIC CAUSES AND REMEDIES

CAUSE REMEDY

P&+&$-(

E-. .653

53


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&+ &. ;&-.( $+'*%$ $(&+-. %/%*(+&6%$K +%)%( ()% >$% ,%(/

H-) $/)+ >$% ,%(/ U$% %/%*(+&6%$ -() >$-* $/-. +%*(-&.$

I.*/$-&.$

F-/+% (& +%,&=% $/ C/%. $+'*% .6 +%=-&$ %/6 >%6

E.(+,%.( &' +%'+*(&+ &+$) ()% +%=-&$ >%6

T.$(%. -. ()% %/6 ,%(/ A=&-6 *&.(*( >%(%%. ()% %/%*(+&6% .6&+-%*%K $% /+%+ %/%*(+&6%

I,+&%+ ;&-.( 6%$-. I.*+%$% >%=%/ ./% &' ;&-.(

O* $(% &+ >/&* %/6-. $%%.*%

E((%+ ()% ;&-.('*%$ +-&+ (& %/6-.

D%'%*(-=% %/%*(+&6%$ C).% (& .% %/%*(+&6%K >% %/%*(+&6%$ (&+%,&=% ,&-$(+%

P&&+ '-(! R%6*% +&&( &%.-.K >-/6 ()% %6%$ -()%/6 ,%(/

S,// %/6 >%6 I.*+%$% %/%*(+&6% $-%K +-$% %/6-. *++%.(K+%6*% (+=%/ $%%6

H-) $/)+ >$% ,%(/ U$% '-//%+ ,%(/ /& -. $/)+

A./+ 6-$(&+(-&. C).% (& >/.*%6 %/6-. &. >&() $-6%$ &' ;&-.(

C+(%+ *+*-. F-// *+(%+ >%'&+% %%6

B$% ,%(/ *+*-.54

54


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H6+&%. -. %/6-. (,&$)%+% U$% /& )6+&%. %/6-. +&*%$$K +%)%( .6)&/6 '&+ (& )&+$ '(%+ %/6-. &+ &$( %/6 )%((+%( -,,%6-(%/

H&( *+*-. U$% /& )%( -.(K 6%&$-( ()-. /%+$K *).% >$% ,%(/

L& 6*(-/-( U$% +%)%(K ..%/ ()% >$% ,%(/

H-) +%$-6/ $(+%$$%$ R%6%$-. ()% %/6,%.(K *).% %/6-. $%%.*%K/ -.(%+,%6-(% $(+%$$ +%/-%' )%( (+%(,%.(

H-) )+6%.>-/-( P+%)%(K -.*+%$% )%( -.(K )%( (+%( -()&(*&&/-. (& +&&, (%,%+(+%

B+-((/% )$%$ -. ()% ,-*+&$(+*(+% S&/(-&. )%(!(+%( +-&+ (& %/6-.

MACRO EXAMINATION

T)-$ $%*(-&. *&=%+$ ()% -.(%++%((-&. &' -.(%+./ 6%'%*($ .6 ()%-+ +%&+(-. -() +%+6 (& ()% M*+&%


56/133

D+-. -.(%++%((-&. -( -$ .%*%$$+ (& -6%.(-' $$&*-(%6 6%'%*($

%%*$% &' &&+**%$$

% $$%$$,%.( &' ()% %/6 '*%

5"

5"


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S/ -.*/$-&.$ -// >% */%+/ =&/,%(+-* -.$( $-/-* -.*/$-&.$ ()( -// )=% /%.() .6 /-,-(%6-6()

%.6$

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M*+& -6%.(-'-*(-&. ,(%+-/ %/6-. +&*%$$ $%.(%.*-. $(.6+6A// -.(%+./ 6%'%*($ -() (% $-% .6 **%(+%;%*(A// $+'*% 6%'%*($ -() (% $-% .6 **%(+%;%*(G%&,%(+-* 6%'%*($ ?% ,-$/-.,%.(@ -() (% $-% .6 **%(+%;%*( N,% $-.(+% .6 6(%

A// 6%'%*($ $)&/6 >% ++&%6 .6 .,>%+%6 &. ()% +%&+( F&+ CSWIP ()% $%.(%.*-. $(.6+6 -$ISO 5817 /%=%/ B ?$(+-.%.(@

NON DESTRUCTIVE TESTING

ULTRASONIC INSPECTION

T% &' &%+(-&.#M./ &+ ,%*).-$%6

58

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E-,%.(#M-. .-( *&,+-$-. /$% %.%+(&+ 6-$/ &$*-//&$*&% +&>% ?*)&$%. (& $-(&+@

M&6% &' &%+(-&.#A /$% &' %/%*(+-*/ %.%+ -$ '%6 (& ()% +&>% -. )-*) -%&!%/%*(+-* *+$(/*&.=%+($ -( (& ,%*).-*/ =->+(-&.$ ( . /(+$&.-* '+%%.* T)% =->+(-&.$ +%(+.$,-((%6 ?=- /%+ &' +%$% (& %% */*/(%6

M(%+-/$M&$( ,%(/ %% '+%%.* 1 ! 5MHP&+(>-/-( G&&6A**%$$ G&&6 ?*. >% >((%+ &%+(%6@T)-*.%$$ +.% 5 ! 500,,M-.-,, 6%'%*( $-% 5,, -6%

O=%+// 6=.(%$I,,%6-(% +%$%.((-&. &' +%$/($

N&( .%*%$$+ (& %=*(% %+$&..%/C. >% >((%+ &%+%6D%() /&*(-&. &' 6%'%*($

O=%+// /-,-((-&.$T+-.%6 .6 $-//%6 &%+(&+ .%%6%6 N& -*(&+-/ +%*&+6

S'%(M&6%+(% *+% .%%6%6 $ '&+ // %/%*(+-*/ %-,%.(

MAGNETIC PARTICLE INSPECTION

T% &' &%+(-&.M./ &+ ,%*).-$%6

E-,%.(P&%+ $/ C&.(*($ &+ *&-/ U/(+!=-&/%( /, ?&(-&./@ P&+(>/% &+ '-


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T)% &+ -$ ,.%(-$%6 %-()%+ > $$-. *++%.( ()+&) -( &+ ()+&) *&-/$++&.6-. -( D%'%*($ &. &+ .%+ ()% $+'*% 6-$+( ()% ,.%(-* '-%/6 ?./%$$ ()%+% +//%/ (& -(@ A ,.%(-* +(-*/% '/-6 $$%.$-&. -$ /-%6 )-*) *&.*%.(+(%$+&.6 ()% 6%'%*($ T)% &+ -$ =-%%6 %-()%+ 6-+%*(/ &+ > /(+!=-&/%( /-)( $-. 6% )-*) '/&+%$*%$ ! -% %,-($ =-$->/% /-)( ?()-$ ,$( >% 6&.% )%+% .&+,/ /-)(-.-$ $>6%6@ A'(%+ (%$(-. &+ , >% 6%,.%(-$%6 -' +%-+%6

M(%+-/$M.%(-* ,(%+-/$ &./ ! '%++-(-* $(%%/$ .6 $&,% .-*%/ //&$

O%+(-. +,%(%+$C++%.( 500 ! 10000 A,$ ?AC &+ DC@S/ /&6 1 ! 100 VAP&+(>-/-( &&6A**%$$ +%$(+-*(%6M-.-,, 6%'%*( $-% 0025,, -6% ( $+'*%T%$(-. (-,% 10 ! 80 $%*&.6$

T-*/ %/6-. /-*(-&.$

R-6 -.$%*(-&. &' %/6%6 $(+*(+/ 6%(-/$P+&6*(-&. +(% -.$%*(-&. &' $,// *&,&.%.($

O=%+// 6=.(%$D-+%*( -.6-*(-&. &' 6%'%*( /&*(-&.I.-(-/ -.$%*(-&. > .$-//%6 />&+S&,% -.6-*(-&. &' $>!$+'*% 6%'%*($ >( &' /& $%.$-(-=-( N&( *+-(-*// 6%%.6%.( &. $+'*% *&.6-(-&.

O=%+// /-,-((-&.$ N& $% '&+ .&.!,.%(-* ,(%+-/$

D%'%*( 6%(%*(-&. *+-(-*// 6%%.6%.( &. /-.,%.( *+&$$ ,.%(-* '-%/6S>!$+'*% '/$ +%-+% $%*-/ +&*%6+%$

S'%(M&6%+(% *+% .%%6%6 -. ).6/-. %/%*(+-*/ %-,%.( .6 '/,,>/% '/-6$

RADIOGRAPHY

G,, R6-&+)

T% &' &%+(-&.S((-* ! 6%=%/&,%.( , >% ,%*).-$%6

E-,%.(R6-&*(-=% -$&(&% -. $(&+% *&.(-.%+ R%,&(% ).6/-. %+ L-)(+&&' *$$%((%P)&(&+)-* 6%=%/&,%.( '*-/-(-%$ D++&&, .6 -//,-.(&+ '&+ $$%$$,%.(

M&6% &' &%+(-&.

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G,, +$ $-,-/+ (& !+$ >( &' $)&+(%+ =%/%.() +% %,-((%6 *&.(-.&$/'+&, ()% -$&(&% I( *..&( >% $-(*)%6 &'': $& )%. .&( -. $% -( -$ %( -. )%=$(&+% *&.(-.%+ ()( >$&+>$ +6-(-&. T)% $$ ()+&) ()% &+ (& >% -.$%*(%6P+($ &' ()% &+ +%$%.(-. /%$$ &>$(+*(-&. (& ,, +$ $*) $ *=-(-%$ &+-.*/$-&.$ //& -.*+%$%6 % 6+%+ -,%$ S%*(-&. ()-*.%$$-.*+%$%$ ?$*) $ %/6@ %+ $ /%$$ 6%.$% -,%$

O%+(-. +,%(%+$W=%/%.() &' +6-(-&. 0001 ! 0015 .,

001 ! 1 ., ?125M%V ! 80%V@P&+(>-/-( &&6 ?%/%$ .6 $'%( $ '&+ !+ +6-&+)

!+ R6-&+)

T% &' &%+(-&.S((-* &+ (+.$&+(>/%

E-,%.(!+ (>% S(.6 .6 *&.(+&/ %+ L-)(+&&' *$$%((% P)&(&+)-* 6%=%/&,%.('*-/-(-%$ D+ +&&, .6 -//,-.(-&. '&+ $$%$$,%.(

M&6% &' &%+(-&.!+$ +% %,-((%6 '+&, ()% (>% .6 $$ ()+&) ()% &+ (& >% -.$%*(%6 P+($ &'()% &+ +%$%.(-. /%$$ &>$(+*(-&. (& !+$ $*) $ *=-(-%$ &+ -.*/$-&.$ //&-.*+%$%6 % 6+%+ -,%$ S%*(-&. ()-*.%$$ -.*+%$%$ ?$*) $%/6 .6%+!>%6@ %+ $ /%$$ 6%.$% -,%$

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