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-1

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-2

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-3

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-4

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-5

VISUAL INSPECTION
WORKSHOP Introduction
For Welding Inspection, VT Must Be Applied:
Before

Welding
During Welding
After Welding

1998 VIW-6

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-7

VISUAL INSPECTION
WORKSHOP Introduction
Hold Points Points in the Fabrication Sequence
where Inspection must be Performed
Before Fabrication can continue.

1998 VIW-8

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-9

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-10

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-11

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-12

Radiographs

Incomplete Joint Penetration

1998 VIW-13

Radiographs

Incomplete Joint Penetration

1998 VIW-14

Radiographs

Incomplete Joint Penetration

1998 VIW-15

Radiographs

Undercut - Should find Visually, not on RT

1998 VIW-16

Radiographs

Scattered Porosity
1998 VIW-17

Radiographs

Elongated Porosity (Wormhole)

1998 VIW-18

Radiographs

Slag Lines
1998 VIW-19

Radiographs

Slag Lines on Root Pass Face

1998 VIW-20

Radiographs

Tungsten Inclusions
1998 VIW-21

Radiographs

Incomplete Fusion (Severe)

1998 VIW-22

Radiographs

Longitudinal Crack
1998 VIW-23

Radiographs

Transverse Crack
1998 VIW-24

Radiographs

Transverse Cracks
1998 VIW-25

Radiographs

Pipe - Socket Welds (Stand Off)

1998 VIW-26

Radiographs

Pipe - Double Wall - Elliptical

1998 VIW-27

Radiographs

Pipe Elbow - Double Wall - Elliptical

1998 VIW-28

Radiographs

Pipe Branch and Butt Welds

1998 VIW-29

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-30

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-31

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-32

VISUAL INSPECTION
WORKSHOP Metal Weld
Samples
Examine

Metal Welds and Note

Discontinuities on Notepad
Review Results

1998 VIW-33

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-34

VISUAL INSPECTION
WORKSHOP Plastic Weld
Replicas
Review Each Type of Weld Replica
(Fillet A and B, Large and Small TJoints, 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-35

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-36

VISUAL INSPECTION
WORKSHOP Six Inch
Machinists 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
dont forget to subtract the 1
from result!

1998 VIW-37

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-38

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-39

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-40

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-41

VISUAL INSPECTION
WORKSHOP Palmgren Gage
Only

use to measure height

of groove weld reinforcement.
Dont 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-42

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-43

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-44

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-45

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-46

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-47

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-48

VISUAL INSPECTION
WORKSHOP Convex Fillet Weld
Gage Use - 3 of 3
Use Correct Size Gage
Too Large

5/8"

Correct

1/2"

Too

Gage

Small

7/16"
1998 VIW-49

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-50

VISUAL INSPECTION
WORKSHOP Concave Fillet
Weld Gage Use - 2 of 2
Use Correct Size Gage
Too Large
Correct

Too

- 3 point contact

Small

7/16"

5/16"

3/16"
1998 VIW-51

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-52

VISUAL INSPECTION
WORKSHOP Practice Exercises
Complete

20 question VIW Practice

Exercises using tensile, weld replicas
Review answers

1998 VIW-53

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

1998 VIW-54