1998 VIW-1

VISUAL INSPECTION WORKSHOP Introduction

Review Slides - Introduction Review AWS B1.10, B1.11, and VIW Manual Examine Metal Weld Samples Review AWS Part B Specification Review Plastic Weld Replicas Practice Use of Hand Tools Practice Exercise and Review Practical Exam and Review

1998 VIW-2

VISUAL INSPECTION WORKSHOP Introduction

Visual Inspection (VT) is the Basic Element of any Quality Control System. It must be done, however, by Trained Personnel.

1998 VIW-3

VISUAL INSPECTION WORKSHOP Introduction

“It has been shown repeatedly that an effective program of Visual Inspection (VT), conducted by properly trained personnel, will result in the discovery of the vast majority of those defects which would otherwise be discovered later by some more expensive nondestructive test method.”

1998 VIW-4

VISUAL INSPECTION WORKSHOP Introduction

While VT is limited to the visible, external surfaces only, it should be recognized that the external surfaces

of the components most often see the highest stresses in service, and are most often the more critical portions of the components.

1998 VIW-5

VISUAL INSPECTION WORKSHOP Introduction

VT Is Very Cost Effective ….

Relatively Simple To Perform Minimal Equipment Required Problems Found As They Occur Early Repairs Easier To Accomplish

1998 VIW-6

VISUAL INSPECTION WORKSHOP Introduction

For Welding Inspection, VT Must Be Applied:

Before Welding During Welding After Welding

1998 VIW-7

VISUAL INSPECTION WORKSHOP Introduction

Organizing The Inspection Effort …. Become Familiar w/ Welding Requirements Specify Timing for Inspections Develop Appropriate ‘Hold Points’ Develop Applicable VT Techniques Develop Repair/Re-Inspection Procedures Develop Procedure for Reports and

Maintenance of Records

1998 VIW-8

VISUAL INSPECTION WORKSHOP Introduction

Hold Points -

Points in the Fabrication Sequence where Inspection must be Performed Before Fabrication can continue.

1998 VIW-9

VISUAL INSPECTION WORKSHOP Introduction

Applying The Inspection Effort ‘Before’…. Welding Equipment - Type, Suitability Filler Metals - Type, Storage, Size Weld Joint Cleanliness Weld Joint Fitup - Bevels, Faces, RO, etc. Preheat Requirements Others

1998 VIW-10

VISUAL INSPECTION WORKSHOP Introduction

Applying The Inspection Effort ‘During’…. Tack Weld Quality - Feathering Root Pass Quality - Size Intermediate Pass Cleaning Gouging to Remove Defects Distortion Preheat/Interpass Temp. Maintenance

1998 VIW-11

VISUAL INSPECTION WORKSHOP Introduction

Applying The Inspection Effort ‘After’…. Final Pass Cleaning, Finishing Weld Sizes Post-Weld Heat Treatment Distortion & Final Dimensions Other NDE Reports

1998 VIW-12

VISUAL INSPECTION WORKSHOP AWS B1.10

Review B1.10 - NDE of Welds

Table 1, Discontinuities (page 3) Figures (pages 4-9) Terminology (pages 10-12) Table 2 (page 13) NDE, Tables 3 & 4 (pages 15-28) Appendices (pages 29-34)

1998 VIW-13

Radiographs

Incomplete Joint Penetration

1998 VIW-14

Radiographs

Incomplete Joint Penetration

1998 VIW-15

Radiographs

Incomplete Joint Penetration

1998 VIW-16

Radiographs

Undercut - Should find Visually, not on RT

1998 VIW-17

Radiographs

Scattered Porosity

1998 VIW-18

Radiographs

Elongated Porosity (Wormhole)

1998 VIW-19

Radiographs

Slag Lines

1998 VIW-20

Radiographs

Slag Lines on Root Pass Face

1998 VIW-21

Radiographs

Tungsten Inclusions

1998 VIW-22

Radiographs

Incomplete Fusion (Severe)

1998 VIW-23

Radiographs

Longitudinal Crack

1998 VIW-24

Radiographs

Transverse Crack

1998 VIW-25

Radiographs

Transverse Cracks

1998 VIW-26

Radiographs

Pipe - Socket Welds (Stand Off)

1998 VIW-27

Radiographs

Pipe - Double Wall - Elliptical

1998 VIW-28

Radiographs

Pipe Elbow - Double Wall - Elliptical

1998 VIW-29

Radiographs

Pipe Branch and Butt Welds

1998 VIW-30

VISUAL INSPECTION WORKSHOP AWS B1.11

Review B1.11 - VT of Welds Weld Discontinuity Figures (pages 5-21) Visual Inspection Aids (pages 22-27) Appendix A - Technical Society Contacts

(page 29) Appendix B - Supplementary Reading List

1998 VIW-31

VISUAL INSPECTION WORKSHOP Amps, Arc Length,

Travel Speed

SMAW Welds

A - Proper parameters

B - Amps too low

C - Amps too high

D - Arc length too short

E - Arc length too long

F - Travel speed too slow

G - Travel speed too fast

1998 VIW-32

VISUAL INSPECTION WORKSHOP VIW Reference

Manual

VIW Reference Manual - Self-Study review for NDE and Tool usage

Mod 1 Visual Inspection Mod 2 NDE (review Figures) Mod 3 Weld Discontinuities Mod 4 Part B Specification

(review actual Part B Spec) Mod 5 Measurements (review tool

use)

1998 VIW-33

VISUAL INSPECTION WORKSHOP Metal Weld

Samples

Examine Metal Welds and Note Discontinuities on Notepad

Review Results

1998 VIW-34

VISUAL INSPECTION WORKSHOP AWS Part B

Specification

Review Part B Specification in Detail

Table of Contents Conversion Table and SI Prefixes Appendices and Usage Footnotes and Tolerances (e.g. underrun)

1998 VIW-35

VISUAL INSPECTION WORKSHOP Plastic Weld

Replicas

Review Each Type of Weld Replica

(Fillet A and B, Large and Small T-Joints, Bend Tests, Tensile Samples)

Must be able to identify each type Measure correct Weld and Zone

(eg - Fillet A, Side 3, Zone 0-1)

1998 VIW-36

VISUAL INSPECTION WORKSHOP Hand Tool Kit

Demonstrate Use of Each Tool

6 inch Rule 1 inch Micrometer Metric Dial Caliper Palmgren Gage Undercut Gage Fillet Weld Gages

1998 VIW-37

VISUAL INSPECTION WORKSHOP Six Inch

Machinist’s Scale

Accuracy to 1/64” or about 15 mils, 0.015”

Align vertically on part, not flat, for best accuracy

Best to measure starting from the 1” mark rather than the end, which may be worn, but don’t forget to subtract the 1” from result!

1998 VIW-38

VISUAL INSPECTION WORKSHOP

1 Inch Micrometer Clean jaw faces, close Zero Micrometer or, Use ‘Tare’ Approach.

If Micrometer ‘zeroes’ at a plus 0.003, take measurement of parts and subtract the 0.003 from result; (converse if it ‘zeroes’ a minus.)

1998 VIW-39

VISUAL INSPECTION WORKSHOP

1 Inch Micrometer

Accuracy to plus or minus 1 mil, 0.001”

Each small, unmarked thimble division equals 1 mil

Can estimate to nearest 1/2 mil, 0.0005

1998 VIW-40

VISUAL INSPECTION WORKSHOP

1 Inch Micrometer

One complete thimble rotation equals 25 mils, or 0.025 inches.

Four complete thimble rotations equals 100 mils, or 0.100 inches

1998 VIW-41

VISUAL INSPECTION WORKSHOP Metric Dial Caliper Accuracy to 0.1 mm,

or about 4 mils Can estimate to

nearest 0.05 mm, or about 2 mils

Some calipers have both metric and U.S. Customary scales but SI only for Exam

1998 VIW-42

VISUAL INSPECTION WORKSHOP Palmgren Gage

Only use to measure height of groove weld reinforcement.

Don’t use for measuring fillet weld sizes since plastic welds are too small to do accurately.

Rotate ‘legs’ of gage to just touch toes of weld for best accuracy

1998 VIW-43

VISUAL INSPECTION WORKSHOP V-WAC Undercut

Gage - 1 of 2

Accuracy is 1/64”, or about 15 mils Calibrate on flat, smooth surface Position on weld, rotate sharp point into

undercut, read scale at other end Can measure porosity depth, but not diameter

1998 VIW-44

VISUAL INSPECTION WORKSHOP V-WAC Undercut

Gage - 2 of 2

Measures undercut up to 1/4 inch depth in 64ths of an inch

Also can be used to measure weld reinforcement height up to 1/4 inch in 64ths of an inch

1998 VIW-45

VISUAL INSPECTION WORKSHOP Fillet Weld Gage

Use Determine if Weld is Concave or Convex Pick Appropriate Gage Type - 2 types Scribed Lines on Gages for Estimating Size

of Adjacent leg Measure Smallest Weld Size Location Measure Both Legs for Convex welds Gages from 1/8” to 1/2” - 1/16” increments Gages from 1/2” to 1” - 1/8” increments

1998 VIW-46

VISUAL INSPECTION WORKSHOP Fillet Weld Shapes

Three Weld Shape Options:

Convex - use convex gage only - minimum leg size

Concave - use concave gage only - throat size

Flat - either gage type will give accurate result

1998 VIW-47

VISUAL INSPECTION WORKSHOP Convex Fillet Weld

Gage Use - 1 of 3 Determine shape of fillet

weld, select convex gage Use scribed lines on gage

for estimating size of second leg, or:

For convex welds, measure both legs for best accuracy; select minimum leg as size

1998 VIW-48

VISUAL INSPECTION WORKSHOP Convex Fillet Weld

Gage Use - 2 of 3

Measure both legs Weld size is the

lesser of the two legs for convex welds

Weld size shown is 3/8, not 1/2

1/2"

3/8"

1998 VIW-49

VISUAL INSPECTION WORKSHOP Convex Fillet Weld

Gage Use - 3 of 3

Use Correct Size Gage Too Large

Correct Gage

Too Small

5/8"

1/2"

7/16"

1998 VIW-50

VISUAL INSPECTION WORKSHOP Concave Fillet

Weld Gage Use - 1 of 2 Determine type of fillet

weld, select concave gage

Use scribed lines on gage for estimating size of weld legs if needed

On concave welds, insure 3-point contact between gage and weld

1998 VIW-51

VISUAL INSPECTION WORKSHOP Concave Fillet

Weld Gage Use - 2 of 2

Use Correct Size Gage Too Large

Correct - 3 point contact

Too Small

7/16"

5/16"

3/16"

1998 VIW-52

VISUAL INSPECTION WORKSHOP Student Hands-On

Tool Practice

Measure the Following and Note Results:

Width of 6 inch scale in mm & mils Thickness of 6 inch scale in mm & mils Thickness of Palmgren Gage in mm & mils Thickness of Fillet Gage in mm & mils Outside Diameter of Mag. Glass in mm

Review Student Results for Accuracy

1998 VIW-53

VISUAL INSPECTION WORKSHOP Practice Exercises

Complete 20 question VIW Practice Exercises using tensile, weld replicas

Review answers

1998 VIW-54

VISUAL INSPECTION WORKSHOP Practice

Examination

Complete VIW Practice Exam - 2 to 2 1/2 hours; (Student should jot down page number from Part B where answers are found to aid exam review)

Review Answers