Weld Inspection Basics

Agricultural Mechanics &

Metal Technologies
C9D
 Visual Examination of Welds
Visual examination is the
observation of that portion of
components, joints, and other
elements that are or can be
exposed for examination
before, during or after
fabrication, assembly,
erection, or testing.
Visual examination includes
verification of Code and
engineering requirements for
materials, components,
dimensions, joint preparation,
alignment, welding, and the
performance of any required
heat treatment and
nondestructive testing.
Visual Examination of Welds
Visual inspection is often Visual inspection
the most cost-effective requires little
method, but it must take equipment. Aside from
place prior to, during good eyesight and
and after welding. Many sufficient light, all it
standards require its use takes is a pocket rule, a
before other methods, weld size gauge, a
because there is no point magnifying glass, and
in submitting an
possibly a straight edge
obviously bad weld to
and square for checking
sophisticated inspection
straightness, alignment
techniques.
and perpendicularity.
 Visual Inspection

is the best buy in non-destructive

examination (NDE), but it must
take place prior to, during and
after welding.
Visual Examination of Welds
An effective program of visual
inspection will result in the
discovery of the vast majority of
those defects which would be
found later using some other
more expensive non-destructive
test method.

Typically, 70 80% all weld defects

are found through visual
examination.
Visual Examination of Welds
The only way visual inspection
can be considered to effectively
evaluate the quality of welds is
to apply it at every step of the
fabrication process.

This enables the problems to be

discovered soon after they occur
as possible so they can be
corrected most efficiently.
 Welding Inspection Checklist:
Before Welding
Review applicable documentation.
Check welding procedures.
Check individual welder qualifications.
Establish hold points (if required).
Develop inspection plan (if required).
Develop plan for recording inspection results and maintain those records.
Develop system for identification of rejects.
Check condition of welding equipment.
Check quality and condition of base and filler materials to be used.
Check weld preparations.
Check joint fit-up.
Check adequacy of alignment devices.
Check weld joint cleanliness.
Check preheat (when required).
Check calibration (if required).
Check gas and gas flow (when required).
 Welding Inspection Checklist:
During Welding

Check welding variables for compliance with

welding procedure.
Check quality of root pass.
Check quality of individual weld passes.
Check interpass cleaning.
Check interpass temperature.
Check placement and sequencing of individual
weld passes.
Check back gouged surfaces (when required).
Monitor in-process NDT (if required).
 Welding Inspection Checklist:
After Welding
Check finished weld appearance.
Check weld size.
Check weld length (when required).
Check dimensional accuracy of
weldments.
Monitor in-process NDT (if required).
Monitor postweld heat treatment (if
required).
Prepare inspection reports (if required).
 Typical Welding Defects:
Porosity

Porosity in the weld is generally due to

ingress of gases (H2 and N2, normally) into
the weld pool.
Examples of Porosity
Typical Welding Defects: Lack of
Fusion

Lack of fusion or incomplete fusion is

characterized by areas where the arc fails to
melt the parent metal before the weld metal
contacts it and the molten metal rests against
the base material without fusing to it.
Example of lack of fusion
Typical Welding Defects: Solidification
Cracks
During cooling, segregation of lower
melting point materials can occur that may
open up if the weld is exposed to tensile
stress during solidification.

Also know as hot cracking; known to be

promoted in steels by phosphorous and
sulfur which tend to form low melting point
phases. (a problem with thick sections of
347 SS).
Example of solidification
cracking
 Typical welding defects: Cold
cracking

Cold cracking is produced with a combination

of a hard microstructure (usually martensite
in the HAZ) and hydrogen dissolved in the
metal. Occurs when weld is cold up to 24-48
hrs. after welding; also known as delayed
hydrogen cracking.
Example of cold cracking