Indian Institute of Welding – ANB

Refresher Course – module 16

Quality Assurance of
Welded Structures
 Content

 Concept of Quality Assurance & Quality Control

 A Brief Discussion on ISO 3834
 Inspection of Welds
 WPS,PQR & WPQ- A Brief Discussion
 Comparison Between ASME Sec. IX and ISO 9606
 Weld quality and defects
 Limits of weld defects as per ISO 5817
 Testing of Welds
 Visual Testing
 VT- its Criteria as per AWS D 1.1 and BS 5289
 Concept of QA & QC
Some Definitions

 Quality- The totality of features and characteristics of a

product or service that bear on its ability to satisfy stated
and implied needs.
 Quality Management- That aspect of overall management
functions that determines and implement Quality System &
Policy.
 Quality System- The organisational structure,
responsibilities, procedures, processes and resources for
implementing Quality Management.
 Quality Assurance- All those systematic actions
necessary to provide adequate confidence that a product
or service will satisfy given requirement for quality.
 Concept of QA & QC
Some Definitions

 Quality Control- The operational techniques and activities

that are used to fulfill requirements for quality.
 Quality Document- All necessary papers required to
produce Quality Product/Service duly approved by
respective authorities.
 Quality Records- All necessary papers to demonstrate
the achievement of required quality and the effective
operation of the quality system.
 Quality Plan- A document setting out specific quality
practices, resources and sequence of activities relevant to
a particular product, service contract or project.
QUALITY ASSURANCE
&
QUALITY CONTROL OF
WELDING
Quality
Fitness for purpose or use.
Conformance to specified requirements.

The totality of features & characteristics of

a product or service that bear on its ability
to satisfy the stated and/or implied needs.

Degree to which a set of inherent

characteristics fulfils requirements.
 
Quality – New definition

Meeting & anticipating customer’s

requirements, stated or implied.
At a given time & over a period of time.
At a price the customer can afford and
is willing to pay.
Introducing new & better product s into
the market faster than competitor.
Continuously bringing down the cost of
manufacturing.
 
Quality

Quality of a Product (or Service) is

not what you put in to it; it is what
the Customer gets out of it.
Quality
 
REQUIREMENTS :
Need or expectation that is stated, generally
implied or obligatory.
 
GRADE :
Category or rank given to different quality
requirements for products, processes, or systems
having the same functional use .
Quality
CUSTOMER SATISFACTION :
Customer’s perception of the degree to which
the customer’s requirements have been
fulfilled.
 SYSTEM :
Set of interrelated or interacting elements.
 MANAGEMENT SYSTEM :
System to establish policy and objectives and to achieve those
objectives.
 QUALITY MANAGEMENT SYSTEM :
Management system to direct and control an organization with
regard to quality.
Quality
 Assurance: The act of giving
confidence, the state of being
certain or the act of making
certain.

Quality assurance: The
planned and systematic
activities implemented in a
quality system so that quality
requirements for a product or
service will be fulfilled.
Quality
 Control: An evaluation to
indicate needed corrective
responses; the act of guiding
a process in which
variability is attributable to
a constant system of chance
causes.

Quality control: The

observation techniques and
activities used to fulfill
requirements for quality.
Quality - Customer focus
Organizations depend on their
customers and therefore shall:

1. Understand customer needs and

expectations – Current & future
needs
2. Meet customer requirements

3. Strive to enhance customer

satisfaction
Quality - Defect

Anything that
dissatisfies the
Customer (internal
or external)
Quality - Customer focus
 Customer requirements are dynamic

 Lower the Defects

1. Lower Cycle time (Delivery in
time)
2. Lower Cost of production
3. Higher Customer Satisfaction
4. Higher People Satisfaction
5. Higher Profits
Quality - Customer focus

Two important questions:

1. Who are the customers?
2. What does it take to satisfy them?
Quality - Sequence of
approach

 Inspection Call from shop or fabricator

 Ensuring availability of Quality Plan,
Quality Control Procedures, Gauges
(calibration) etc.
 Verification of Purchase Orders
 Verification of Dimensional Report w.r.t
Purchase Order, Approved Drawing
Quality - Sequence of
approach
 Verification of raw material TCs
 Performing - Visual Examinations
 Ensuring - Job Identification details

 Dimensional Check
 Conducting LPI, MPI, RT / UT as
applicable.
 Confirming 1. LPI, MPI, RT / UT results.
2. Heat Treatment details
3. Verification of Heat
Treatment Charts and job correlation.
Quality - Sequence of approach

Ensuring before External Inspection /

Dispatch
 Surface Protection-Painting(DFT)
 Work Order Details, Color Code
 VCI Pellets, End Capping
 Final Clearance by Third Party
Inspection Agency / IBR
Quality - Document
Verification
 Firm / Product Approvals
 WPS/PQR ,Welder Qualifications
 Purchase Order
 Quality Plan / Quality Control Procedure
 Painting Schedule
 Work Order, Drawings, Design
Changes / Non Conformances Report
 Raw material / Pipes Test Certificate
Quality - Document
Verification
 Lab Test Reports
 NDE (LPI/MPI/RT/UT) Reports
 Heat Treatment Reports
 List of approved vendors for Electrodes /
Paints / NDE consumables
 List of approved service agencies for Lab
Testing, NDT, Heat Treatment
Quality - Prior to Fabrication
 Drawings &
Specifications
 Selection of Welding
Process
 Material Specification &
Inspection
 Inspection of
consumables
 Welding Procedures
 Welding Equipments
 Welder Qualifications
 Testing Facilities
Quality - During Fabrication

 Inspection of prepared
material – Edge
Preparation, surface
condition etc.
 Assemblies – Fit up, Root
gap, position, orientation
etc.
 Welding Consumables –
E 7018, E 7018-A1 etc.
 Operators – Qualification,
Position, sequence etc.
 WPS Conformance
Quality - After Fabrication
 Visual Inspection
a) Surface Defects: Blow
Holes, Porosity, Unfilled
Crater, Un-fused welds
b) Surface Cracks
c) Damaged to parent
metal:
Undercut, Burning,
Overheating
d) Profile Defects:- Overlap,
Excess penetration,
Incomplete penetration
Quality - After Fabrication
e) Incorrect Finish:-
Ripple Mark
Weaving Faults
Chipping & Peening marks
Spatter
• Inspection of Weld
Dimensions – Fillet, Throat
size.
• Mech.Testing:- Test Coupons,
Results.
• NDE
 Quality - Records

Register
 Purchase Order
 Material Receipt / Account
 Raw material Test Certificates
 Welder’s Log Book
 NDE, Heat Treatment
 Inspection ( Internal / TPI / IBR )
 Audit Reports ( Internal / External )
Quality
“Quality is better defined
as…
 Error free or Defect
free performance.

 Do the right things

right the first time and
every time.
Welding Defects

 Small imperfections which affects the

property of the weld metal are called
discontinuities

 When the discontinuty is large and affect

the function of the joint is termed as defect.
Defects

A. External defects
B. Internal defects
C. Both internal&external defects
External defects

1. Undercut
2. Cracks
3. Blowhole and porosity
4. Slag inclusions
5. Edge of the plate melted off
6. Excessive convexity/oversized
weld/ Excessive Reinforcement
7. Excessive Concavity/Insufficient
Throat thickness/ Insufficient fill
 Contd

1. Incomplete Root penetration /Lack

of penetration
2. Excessive Root penetration
3. Overlap
4. Mismatch
5. Uneven/Irregular bead appearance
6. Spatters
Internal defects
1. Cracks
2. Blowhole and porosity
3. Slag Inclusions
4. Lack of fusion
5. Lack of Root penetration
6. Internal stresses or locked-up
stresses (or) Restrained joint
Both External And Internal
Defects
1. Blowhole
2. Slag inclusions
3. Lack of penetration (fillet weld)
4. Cracks
5. porosity
Dimensional defects
 Distortion
 Incorrect Joint Penetration
 Incorrect Weld Size
 Incorrect Weld Profile
Structural discontinuties
Porosity
Slag Inclusion
Under cut
Incomplete fusion
Incomplete penetration
Crack
Surface defects
Faulty weld size and profile
BUTT JOINT
 Lack of Reinforcement
 Excessive Reinforcement
 Irregular Profile
FILLET WELD
 Insufficient Throat
 Insufficient Leg Length
 Excessive Convexity(or)Concavity
 Unequal Leg Lengths
 Irregular Weld Face
Crack
Discontinuty caused by the tearing of
the metal

Hot crack
Cold crack
Crater crack
Crater cracks

Longitudinal Crater crack

(may(or)may not extend to the base
metal)

Transverse Crater crack

Star crater crack

Porosity
Group of gas pores in a weld due to
entrapment of gas during solidification
is termed as porosity.
Porosity: small spherical cavities
either clustered locally (or)scattered
Blow hole: single large cavity
piping (or)warm holes: Elongated (or)
tubular gas cavities
Reason
 Contamination of the base metal

 Moisture in the electrode

 Improper arc length

 Excessive current

 High travel speed

Slag inclusion
Entrapment of slag or Non- Metallic
inclusion
 incomplete deslagging of a previous
pass.
 Excessive weaving. (slag solidity at the
sides of the bead)
 Improper travel speed
 Excessive amount of slag ahead of the
arc.
Remedies

 Proper cleaning of slag

 Restrict the width of the

weaving(width of slag immediately
behind the weld puddle remains
molten.
Weld spatter

At the conclusion of a weld small

particles (or) globular of metal may
sometime be observed scattered around
the vicinity of the weld.this is known as
spatter.
Reason
 Arc blow:(making the Arc uncontrollable)
1. Too long an arc
2. An excessive current.
Under cut
 Continues or discontinues groove at
the toes of the weld pass and is
located on the base metal.
 Excessive current
 High travel speed
 Improper electrode angle.
 Improper electrode size
Incomplete Penetration
 Failure of weld metal to reach and fuse the
root of the joint.
 Reason :
 Less bevel angle
 High welding speed
 Low current
 Large dia electrode
 Insufficient Root gap
 Improper Electrode angle
Controlling factors
1. Proper travel speed

2. proper parameters
a.current
b.voltage
c.flow rate
3.proper edge preparation
a.Angle
b.Root gap
Contd

4.suitable diameter of electrode

5.Base metal preparation

6.Baking of electrode
Documentation

 Manual- Strategic Type,

Top Management Function
 Procedure- Tactical Type,
Departmental Function
 Work Instruction-
Operational Type,
Supervisory Function
 Records- Specific Type,
Related to all Function
QUALITY PLAN FOR MANUFACTURING / INSPECTION ACTIVITY
Importance Type Test Type Agency Column
MA = Major P = Test / Inspection to be performed 1= Customer
CR = Critical W = Test / Inspection to be Witnessed 2 = Organization
MI = Minor V = Verification of Documents/Test Records 3 = Consultant / Inspection Agency

Agency
S
l Item Type Extend Format
Characteristics Catego Reference Acceptanc
. Description. Method of of Remarks
N Checked ry Document e Norms P W V
/ Operation of Check Check report
o

Order / MTC
Chemical & 1
RAW Verificatio Specificati Lab
Physical 3
MATERIAL MA n 1 / Heat on Drg.Spec. Report 2
1 Properties 1
.
S MA U. T. 100% Order / Drg. Spec. Lab 2 UT for Plates >12 mm thick
Internal Flaws 3
Plate MA Verificatio 100% Specificati Drg. Spec. Report 2
Chemical 1
Rounds n on Lab
Properties only 3
Drawing Report

1 Heat
Verificatio Size 1
Chemical Lab
2 MI n Order / Drawing Drg.Spec. 2 3
.
FORGINGS Properties Report
MA Measure Spe Drawing Detail Drg. 2 1
Dimensions I. R.
ment cificati 3
on

Visual
1
Visual 100%
3
Fit up Dimensio 100% I. R.
MA Drg. Spec. Drg.Spec. 2 1
FABRI Welding n Order / I. R.
3 MI Drg. Spec. Drg.Spec. 2 3
.
CATED Quality UT, RT, Spe UT
CR Drg. Spec. Drg.Spec. 2 1
ITEMS NDT MPT LDP cificati Report
MA Drg. Spec. Detail Drg. 2 3
Dimensions Visual on I.R.
1
Measure 100%
3
ment

Painting
Drg. Spec. Certifica
Visual 1
4 MA 100% Drg. / Drg.Spec. te 2
.
PAINTING Paint Thickness Film 1
MI Sample Specificati Drg.Spec. Painting 2
Thickness 3
on. Certifica
te
 Quality Standards
 Basic Standards
Specifying general requirements with basic significance eg.Quality
Management Systems, drawings & tolerances
ISO 9000 ff, EN 4500 ff, ISO 17000 series
 Special Basic Standards
Specifying matters for several applications eg. Test procedures,
welding requirements, materials
ISO 3834
 Special Standards
Product or application standards eg. Pressure vessels, piping,
railway cars
ISO 16528, EN 1090, ISO/DIS 10721, EN 15085,
 Quality Management in Welding

 Basic Standard for QMS

ISO 9001 -2000
 Manufacturing
ISO 3834, EN 1011, ISO 5817
 Personnel
ISO 9606, EN 287, ISO 14731, ISO 14732
 Procedures
ISO 15607 – 15614
 Testing and Inspection Personnel
ISO 9712, EN 1289
 Materials and Calculation & Design
 Application of ISO 3834

 Certification of companies in accordance

with ISO – 3834 Parts 2, 3 or 4

 Certification of personnel in accordance

with ISO 14731
 ISO 14731 Requirements for
Welding Co-ordination Personnel
 Welding Co-ordination :
- Manufacturing operations for all welding and welding related
activities
- The sole responsibility of the manufacturer
- May be sub-contracted
- May be carried out by more than one person
 Welding Co-ordinator
- Responsible and competent person
- Specified tasks and responsibilities
- Qualified for each task
 Welding Inspection
- Is part of welding co-ordination
What is ISO 3834?

It is an international standard created by

welding
professionals
• ISO 9001 provides the requirements for a
quality management system; it does not
establish requirements for products.
ISO 3834 on the other hand, does provide the
quality requirements for a welded product
• It encourages a proactive process orientated
approach to managing and controlling
welding product quality in a workshop or
on site
• It is also a Factory Control System to control
activities for the manufacture of the product
2. Why adopt ISO 3834 when we have
ISO 9001?

• ISO 9001 is a comprehensive standard that lays

down quality management system requirements for
any organisation
• ISO 9001 however, does not prescribe specific
details for “special processes”.
Welding is regarded as a “special process”.
• ISO 3834 was developed to identify all factors that
could affect the quality of welded product and which
need to be controlled at all stages, before, during and
after welding.
3. What are the benefits of specifying the
ISO 3834 Standard for the purchaser & specifier

More assurance of contract delivery dates

• Greater assurance of the quality of welded
products
• Greater reliability and performance of plant
• Reduction in maintenance costs
• Reduction or elimination of third party
inspection costs
• More competent suppliers of welded
products
4. What are the benefits of using the
ISO 3834 Standard for the manufacturer?
 Less rework
 Jobs completed on time
 Local and international recognition as a competent
 organisation
 Meet the welding-related requirements of ISO 9001
 More efficient coordination of welding activities
 More pro-active and responsible workforce
 Increased opportunities and capability to bid on jobs
 Cost savings – more efficient technology
 Reduced surveillance audits and inspections by
purchasers with significant savings
5. What are the benefits of using the
ISO 3834 Standard for the individual
employees?

• Helps to do the job more satisfactorily

• Greater job security
• Higher regard by other people
• Professional recognition
• Satisfied employer and customer
• More rewarding job position
• Develops team spirit
6. How important are welding
personnel?
A key feature of ISO 3834 is the requirement to
ensure that people with welding responsibilities are
competent to discharge those responsibilities

This is achieved by incorporation of another

standard, namely, ISO 14731 “Welding coordination
– Tasks and responsibilities”

The specifying of minium requirements for personnel

dealing with welding coordination and welding
inspection personnel
7. What is the definition of a
manufacturer?

• ISO 3834 defines a manufacturer as a ‘person or

organization responsible for the welding production’.

The Standard uses this term to describe any such

organisation, including manufacturing organisations
supplying welding services, either for new products or
for repair and maintenance, as well as other
organisations where the application of the
requirements of ISO 3834 are relevant

• A manufacturer may be involved in manufacture,

fabrication, construction, repair or maintenance.
8. What are the types of manufacturing
organisation that
ISO 3834 can be applied to?

Fabrication companies
• Construction companies - on-site work
• Repair and maintenance contractors
• Manufacturers of products
• Welding workshops on sites under the same
technical and quality management
• Owners of plant with their own workshop(s)
9. What are the types of other organisation that
ISO 3834 can be applied to?

Those which, though not creating welded product

themselves, are specifying or requiring such work from
others and are thus involved in weld design, contract
development, and review of technical requirements and
competencies of subcontractors namely

• Asset owners without own workshops, both private

and government
• Project management companies
• Design companies
• Consultants
• Government agencies
10. How many parts does ISO 3834 have?

ISO 3834: 2005 “Quality requirements for fusion welding of

metallic materials” consists of 6 parts:

• ISO 3834-1:2005, Criteria for the selection of the

appropriate level of quality requirements

• ISO 3834-2:2005, Comprehensive quality requirements

• ISO 3834-3:2005, Standard quality requirements

• ISO 3834-4:2005, Elementary quality requirements

• ISO 3834-5:2005, Applicable documentation (not full title)

• ISO/TR 3834-6:2007, Guidelines on implementing ISO 3834

11. How does ISO 3834 link in with ISO 9001?

• ISO 3834 does not replace ISO 9001 as a quality

management system however it contains many
attributes that will be important for a welding
manufacturer, in both workshops and at field
installation sites, seeking ISO 9001 certification

• Elements of ISO 9001 should be considered when

implementing ISO 3834 quality requirements and
seeking ISO 3834 certification

• The specific complementary elements of ISO 9001

are detailed in ISO 3834

• WTIA TGN-3834-06 2007 gives more detailed

information
12. Describe how the flexibility of ISO 3834
can be applied?

ISO 3834 describes the following four situations where ISO

3834 can control welding:
• Case 1: To provide specific requirements in specifications
which require the manufacturer to have a quality
management system in accordance with ISO 9001:2000

• Case 2: To provide specific requirements in specifications

which require the manufacturer to have a quality
management system other than ISO 9001:2000

• Case 3: To provide specific guidance for a manufacturer

developing a quality management system for fusion welding.

• Case 4: To provide detailed requirements for specifications,

regulations or product standards that require control of
Fusion welding activites
13. What are the implications to satisfy Case 1: “To provide specific
requirements in specifications which require the manufacturer to
have a quality management system in accordance with
ISO 9001:2000

• For the purchaser - it implies that they want the

manufacturer
to have a quality management system in accordance with ISO
9001 and want to ensure that the supplier manages the quality
of the product. To achieve this the purchaser must detail the
requirements contained in ISO 3834 into the welding
specification.
• For the Manufacturer - it implies that their quality
management system must comply with ISO 9001 and that
they need to meetthe requirements of ISO 3834. . It is
recommended that the supplier incorporates the
requirements of ISO 3834 into their
ISO 9001 quality management system using it as a ‘bolt on’
14. What are the implications to satisfy satisfy Case 2: “To provide
specific requirements in specifications which require the
manufacturer to have a quality management system other than
ISO 9001:2000”

• For the purchaser - it implies that they want the manufacturer

to have a quality management system but not necessarily in
accordance with ISO 9001. Additionally the purchaser wants to
ensure that the manufacturer manages the quality of the
product. To achieve this the purchaser must detail the
requirements contained in ISO 3834 into the welding
specification or contract documents.

• For the Manufacturer - it implies that they must have a quality

management system and meet the requirements of ISO 3834. It
is recommended that the manufacturer adopts ISO 3834 and
incorporate some elements from ISO 9001 to satisfy this requirement
 15. What are the implications to satisfy Case 3: “To provide specific
guidance for a manufacturer developing a quality management
system for fusion welding.”

• For the purchaser - it implies increased confidence in their

supplier for its recognition of the importance of controlling the
quality of the welded product

• For the Manufacturer - it implies that they recognise the

importance of managing the quality of the product that they
produce. To achieve this they need to use ISO 3834 as a set of
guidelines to identify the key areas that need to be controlled.

In addition it lists the elements of ISO 9001 that need to be

considered when developing a quality management system
16. What are the implications to satisfy Case 4: “To provide detailed
requirements for specifications, regulations or product standards
that require control of fusion welding activities “

• For the purchaser and the Manufacturer - it implies

that there is an industry-wide recognition of the
benefits that ISO 3834 has on the quality of welded
products.

This ISO 3834 Standard will be specified in

specifications, regulations and product standards
across all industry sectors such as pressure
equipment, mining, building and construction,
pipelines, railway etc. Therefore why not take
Advantage of these benefits now.
17. What are the main welding
requirements covered in ISO 3834 ?

• Review of requirements
• Technical review
• Subcontracting
• Welding personnel
– Welders and welding operators, Welding coordination
personnel
• Inspection & testing personnel
– Welding Inspection personnel; Non-destructive
testing personnel
• Equipment
– Production and testing equipment; Description of
equipment; Suitability of equipment; New
equipment; Equipment maintenance
Welding and related activities
– Production planning; Welding procedure
specifications (WPS); Qualification of the welding
procedures; Work instructions; Procedures for
preparation and control of documents
• Welding Consumables
– Batch testing; Storage and handling
• Storage of parent materials
• Post-weld heat treatment
Inspection and testing
– Inspection & testing before welding; Inspection &
testing during welding; Inspection & testing after
welding; Inspection & test status
• Non-conformance and corrective actions
• Calibration and validation of measuring,
inspection and testing equipment
• Identification & traceability
• Quality records
Quality requirements as per
ISO 3834
 Selection of Welding Quality
Requirement as per ISO:3834
Contract Welding Requirement Quality Requirement

When quality system When quality system

conforming to ISO conforming to ISO
9001 is required 9001 is not
required

Comprehensive quality requirement Use ISO 3834-2 Use ISO 3834-2

Standard quality requirement Use ISO 3834-2 Use ISO 3834-3

Elementary quality requirement Use ISO 3834-2 Use ISO 3834-4

 Comparison of Welding quality
requirements with regard to ISO 3834-2,
3834-3 And 3834-4

Elements ISO 3834-2 ISO 3834-3 ISO 3834-4

Contract review Full documented Less extensive review Establish that capability and information is
review available
Design review Design for welding to be confirmed
Subcontractor Treat like a main fabricator Shall comply with all requirement
Welders, Operators Approved in accordance with ISO 9606
Welding coordination Welding coordination personnel with appropriate Not required but personal responsibility of
technical knowledge manufacturer
Inspection personnel Sufficient and competent personnel to be available Sufficient and competent third parties
access are needed
Production equipment Required to prepare, cut, weld, transport, lift, together No specific requirement
with safety equipment and protective clothes
Equipment maintenance Shall be carry out, No specific requirements, No requirement
maintenance shall be adequate
plan
necessary
Production plan Necessary Restricted plan necessary No requirement
Welding procedure Instruction to made available to welder No requirement
specification (WPS)
Welding procedure approval In accordance with the appropriate part of ISO No specific requirement
9956,approved as application standard or
contract demands
 Comparison of Welding quality
requirements with regards to ISO 3834-2,
3834-3 And 3834-4
Elements ISO 3834-2 ISO 3834-3 ISO 3834-4
Work instructions Welding procedure specification (WPS) or dedicated No requirement
work instructions to be available
Documentation Necessary Not specified No requirement
Batch testing of Necessary Not specified No requirement
consumables
Storage and handling of According to supplier’s recommended minimum
welding consumables
Storage of parent Protection required from influences by the No requirement
materials environment, identifications to be maintained
Post-weld heat treatment Specification and complete Confirmation to No requirement
record necessary specification
necessary
Inspection before, during As required for specified operations Responsibilities as specified in
and after welding contract
Non-conformances Procedures shall be available
Calibration Procedures shall be Not specified
available
Identification Required when appropriate Required when Not specified
necessary
Traceability Not specified
Quality records Shall be available to meet the rules for product liability As required by contract
Retained for 5 years minimum
 Inspection of Welds

 Definition of Inspection as per ISO Std. –

 Inspection is that quality control action by

means of examination, observation or
measurement to determine the conformance of
material parts, components, system,structures
as well as processes and procedures with
predetermined quality requirements.
Nine Essential Variables of
Welding

 1) Joints
 2) Base metal
 3) Filler metal
 4) Position
 5) Pre-heat
 6) PWHT
 7) Shielding Gas
 8) Electrical Characteristics
 9) Technique
Inspection Before Welding
 1) Application Standard
 2) WPS,PQR,WPQ
 3) Drawings
 4) Material Composition
 5) Condition of Material
 6) Type of edge preparation,method & finish
 7) Consumables
 8) Welding process
 9) Clearance dimensions,Type of backing(if
any)
 10) Alignment, Tack welds,Presets etc.
 11) Pre-heat (if any)
 WPS,PQR and WPQ

 WPS  Welding Procedure Specification is a written

document to provide direction for making
production weld to the code requirement.

 PQR  Procedure Qualification Record is a record of

the welding data used to weld a test coupon. It
is also contains the test results of the test
specimen.
 WPQ  Welding Performance Record determines the
ability of the welder/welding operator to achieve
the minimum requirement specified for an
acceptable weldment.
 ASME Code

 ASME code widely used in India

 WPS Format - QW 482

 PQR Format - QW 483

 WPQ Format – QW 484

WPS Format as per
ASME Section IX

QW-482 Front side

Inspection During Welding

 1) Welding Process Parameter

 2) Inter pass Temperature
 3) Filler metal/Electrode condition
 4) Inter pass cleaning
 5) Distortion
 6) Flux /Shielding gas flow
 Inspection After Welding

 1) Dimensional accuracy
 2) Appearance of the weld
 3) Post Weld Heat Treatment (if any)
 4) Evaluation of internal and surface defects
with or without the aid of Destructive/Non-
destructive testing.
 Comparison Between ASME Sec. IX
and ISO 9606- Scope
 As per ASME Sec. IX
 The rules in this section
apply to the preparation of
WPS, PQR and qualification
of welders and welding
operators for all types of
manual and machine
welding permitted in this
section.
 As per ISO 9606-1:1994
 This part of ISO 9606
specifies requirements,
ranges of approval, test
conditions, acceptance
requirements and
certification for approval
testing of welder
performance for the welding
of steels.
 Comparison Between ASME Sec. IX
and ISO 9606- Reference
 As per ASME Sec. IX  As per ISO 9606-1:1994

 ASME Sec.VIII and ASME  ISO 857,1106-1,1106-2,

B 31 1106-3, 2560, 3452, 3580,
3581, 4063, 5173, 5817,
6520,6949, 9956-2 and
9956-3
 Comparison Between ASME Sec. IX
and ISO 9606- Definition

 As per ASME Sec. IX  As per ISO 9606-1:1994

 As per QW- 492  1) Welder

a) Manual &
b) Welding operator
2) Examiner Or Test Body
3) WPS
4) Range of Approval
5) Test Piece
6) Test Specimen
7) Test
 Comparison Between ASME Sec. IX
and ISO 9606- Variables
 As per ASME Sec. IX  As per ISO 9606-1:1994

 Joints ( QW-402)  Welding Processes

 Base Metal ( QW-403)  Joint Type
 Filler Metal ( QW-404)  Material Group
 Position ( QW-405)  Filler metal, Shielded gas
 Preheat (QW-406) and flux
 Postweld Heat Treatment (QW-  Dimensions
407)
 Gas ( QW-408)  Welding position
 Electrical Characteristics ( QW-
409)
 Technique (QW-410)
Note- Varies with different welding
processes
 Comparison Between ASME Sec. IX
and ISO 9606- Material Grouping
 As per ASME Sec. IX  As per ISO 9606-1:1994

 Steel & Steel alloys  Low-carbon unalloyed steels and/or

 Aluminium & Al. base alloys
 Copper & Cu. base alloys
 Nickel & Ni. base alloys
 Titanium & Ti. base alloys
 Zirconium & Zr. base alloys
low alloyed steels (W01)
 Cr-Mo and/or Cr Mo V creep
resistant steels (W02)
 Fine grained structural steels
normalised,quenched and tempered
as well as thermomechanically
treated steels and nickel steel with
Ni content 2% to 5%
 Ferritic or martensitic stainless
steels with Cr content 12% to 20%.
 Stainless ferritic-austenitic and
stainless Cr-Ni steels.
Comparison Between ASME Sec. IX
and ISO 9606- Position-Plate-Butt

 As per
ASME
Sec IX

 As per
ISO
9606
Comparison Between ASME Sec. IX
and ISO 9606- Position-Plate-Fillet

 As per
ASME
Sec IX

 As per
ISO
9606
Comparison Between ASME Sec. IX
and ISO 9606- Position-Pipe-Fillet

 As per
ASME
Sec IX

 As per
ISO
9606
Comparison Between ASME Sec. IX
and ISO 9606- Position-Pipe-Butt

 As per
ASME
Sec IX

 As per
ISO
9606
 Comparison Between ASME Sec. IX
and ISO 9606- Type of Test

 As per ASME Sec. IX  As per ISO 9606-1:1994

A) For Butt Weld  Visual

i) Transverse side bend,  Radiography
ii) Transverse Face Bend  Bend
iii) Transverse Root Bend  Fracture
B) For Fillet Weld  MPI or LPT
i) Fracture Test  Macro (Without Polishing)
ii) Macro Examination
C) Visual
D) Radiographic Examination
Comparison Between ASME Sec. IX and ISO 9606-
Expiry or Renewal of Qualification
 As per ASME Sec. IX
 When the welder has not welded
with a process during a period of 6
months or more, his qualifications
for that process shall expire;
unless, within the six months period
to his expiration of qualification
a) A welder has welded using a manual
or semiautomatic welding which will
maintain his qualification for manual
and semiautomatic welding with
that process.
b) A welding operator has welded
using a machine or automatic
welding which will maintain his
qualification for machine and
automatic welding with that
process.
 There shall be no specific reason to
question the welder’s skill and
knowledge
 As per ISO 9606-1:1994
 A welder’s approval shall remain valid
for a period of 2 years providing that
the relevant certificate is signed at six-
months intervals by employer/co-
ordinator and that all following
conditions at fulfilled
a) The welder shall be engaged with
reasonable continuity on welding work
within the current range of approval.
An interruption for a period no longer
than 6 months is permitted.
b) The welder’s work shall be in
accordance with the technical
conditions under which the approval
test is carried out.
 There shall be no specific reason to
question the welder’s skill and
knowledge
 Weld Quality

Discontinuity
 An interruption of the typical structure of a material, such as a
lack of homogeneity in its mechanical, metallurgical, or physical
characteristics.
 A discontinuity is not necessarily a defect but all defects are
discontinuities.

Defect
 A defect is a rejectable discontinuity, which occurs in an amount
great enough to render a particular object or structure unsuitable
for its intended service based on criteria in the applicable code.
 Classification of Defects

 Planar defects / Two dimensional defects --

E.g. cracks, lack of fusion, lack of penetration, are
crtical in nature and are not tolerated to any extent.
 Voluminar defects / Three dimensional defects --
E.g. slag inclusion, cavities, porosities, etc are
tolerated to a certain extent depending on the
product class and applicable code.
 Geometric defects-- E.g. excess reinforcement,
underfill, root suckback, distortion are also permitted
to a certain extent.
 Misalignment (hi-lo)

 Definition: Amount a joint is out

of alignment at the root

• Cause: Carelessness. Also due to joining different

thicknesses (transition thickness)
• Prevention: Good Workmanship.

• Repair: Grinding. Careful on surface finish and

direction of grind marks.
 Undercut

• Definition: A groove cut at the

toe of the weld and left unfilled.

• Cause: High amperage, electrode

angle, long arc length, rust.

• Prevention: Set machine on scrap metal. Clean metal before

welding.
• Repair: Weld with smaller electrode, sometimes must be low
hydrogen with preheat. Sometimes must gouge first.
Undercut
 Insufficient Fill on the Root Side
(Suck back)

• Definition: The weld surface is below the adjacent

surfaces of the base metal at the weld root.
• Cause: Typically improper joint preparation or
excessive weld pool heat.
• Repair: Back weld to fill. May require removal of weld
section by grinding for access to the joint root.
Suck back
 Excessive Concavity or
Convexity
 Definition: Concavity or convexity of a fillet weld which
exceeds the specified allowable limits

• Cause: Amperage and travel speed

• Prevention: Observe proper parameters and techniques.

• Repair: Grind off or weld on. Must blend smoothly into the base
metal.
Concavity
Convexity
 Reinforcement

The amount of a groove weld which extends

beyond the surface of the plate Face Reinforcement

 Excessive
 Insufficient
 Improper contour

Root Reinforcement
 Excessive Reinforcement

 Definition: Specifically defined by the standard. Typically,

Reinforcement should be flush to 1/16”(pipe) or flush to
1/8” (plate or structural shapes).

• Cause: Travel speed too slow, amperage too low

• Prevention: Set amperage and travel speed on scrap
plate.

• Repair: Remove excessive reinforcement and feather

the weld toes to a smooth transition to the base plate.
Excessive reinforcement
 Insufficient Reinforcement

• Definition: Specifically defined by the standard. Typically,

Underfill may be up to 5% of metal thickness, not to exceed
1/32” as long as the thickness is made up in the opposite
reinforcement. Not applied to fillet welds.
• Cause: On root reinforcement - Too little filler metal will cause
thinning of the filler metal. In OH position, too hot or too wide
will cause drooping of the open root puddle.
• Prevention: Use proper welding technique. Use backing or
consumable inserts. Use back weld or backing.
• Repair: Possibly simply increase the face reinforcement. If back
welding is not possible, must remove and reweld.
Insufficient reinforcement
 Burn-through
• Definition: When an undesirable open hole has been
completely melted through the base metal. The hole may or
may not be left open.

• Cause: Excessive heat input.

• Prevention: Reduce heat input by increasing travel speed, use

of a heat sink, or by reducing welding parameters.
• Repair: Will be defined by standards. Filling may suffice.
Otherwise, removal and re welding may be required.
Burn-through
 Lack Of Penetration
• Definition: When the weld metal does not extend to the required
depth into the joint root

• Cause: Low amperage, low preheat, tight root opening, fast

travel speed, short arc length.

• Prevention: Correct the contributing factor(s).

• Repair: Back gouge and back weld or remove and reweld.

Lack Of Penetration
 Incomplete Fusion
• Definition: Where weld metal does not form a cohesive bond
with the base metal.

• Cause: Low amperage, steep electrode angles, fast travel

speed, short arc gap, lack of preheat, electrode too small,
unclean base metal.
• Prevention: Eliminate the potential causes.

• Repair: remove and reweld, being careful to

completely remove the defective area. This is
sometimes extremely difficult to find.
Incomplete Fusion
 Arc Strike

• Definition: Arc strikes result when the arc is initiated on

the base metal surface away from the weld joint either
intentionally or accidentally

• Cause: Carelessness of welder

• Prevention: In difficult areas, adjacent areas can be protected
using fire blankets.
• Repair: Where applicable, arc strikes must be grinded smooth
and tested for cracks. If found, they must be remove and
repaired using a qualified repair procedure and inspected as
any other weld.
 Slag Inclusion
• Definition: Slag entrapped within the weld

• Cause: Low amperage, improper technique, Trying to weld in

an area that is too tight. Improper wire brushing / cleaning
between passes.

• Prevention: Increase amperage or preheat, grind out tight areas

to gain access to bottom of joint.

• Repair: Remove by grinding. Reweld.

Slag inclusion
 Tungsten Inclusion

• Definition: A tungsten particle embedded in a weld. (Typically

GTAW only)

• Cause: Tungsten electrode too small, amperage too high,

electrode dipped into the weld pool or touched with the fill rod.

• Prevention: Thoriated or Zirconiated tungsten electrodes are

used in place of pure tungsten electrodes.

• Repair: Grind out and reweld

Tungsten inclusion
 Spatter

• Definition: Small particles of weld metal expelled from the

welding operation which adhere to the base metal surface.

• Cause: Long arc length, severe electrode angles, high

amperages.

• Prevention: Correct the cause.

• Repair: Remove by grinding or sanding.

Spatter
 Cracks

 Longitudinal
 Transverse
 Crater
 Throat
 Toe
 Root
 Under bead and Heat-affected zone
 Hot
 Cold or delayed
Cracks
Cracks
 Laminations
•Base Metal Discontinuity
•May require repair prior to welding
•Formed during the milling process
 Porosity - Types

Porosity is gas pores found in the solidified

weld bead.
 Single Pore
 Uniformly Scattered
 Cluster
 Linear
Porosity
Clustered Porosity
 Testing

 It is defined as the physical performance of

operations to determine quantitative
measure of certain properties of a process
– It aim to determine quantity i.e. to
discover facts regardless of the implication
of the result.
 Types of Destructive & Non-
destructive Testing

 Destructive  Non-destructive

 Tensile Test  Ultrasonic Test (UT)

 Macro Test  Magnetic Particle Test (MPT)
 Charpy Test  Liquid Penetrant Test (LPT)
 Fracture Test  Radiography Test (RT)
 Bend Test  Visual Test (VT)
Defects and their Limits as per ISO 5817 -2003
Defects and their Limits as per ISO 5817 -2003 contd.
Defects and their Limits as per ISO 5817 -2003 contd.
Defects and their Limits as per ISO 5817 -2003 contd.
Defects and their Limits as per ISO 5817 -2003 contd.
Defects and their Limits as per ISO 5817 -2003 contd.
Surface Cracks- Detectable by VT
Surface Irregularities-Detectable by VT
Contour Defects- Detectable by VT
Root Defects- Detectable by VT
Visual Inspection Acceptance Criteria as per AWS D 1.1

Discontinuity Category Static Loaded Dynamic Loaded All Loads

&Inspection Criteria (Nontubular) (Nontubular) (Tubular)

Underrun-In fillet weld upto 1.6 mm Applicable Applicable Applicable

subject to it does not exceed 10% of the
weld length. No underun is permitted for
web-to-flange welds of girder

Undercut-Upto 1 in. not to exceed 1mm. Applicable Not-Applicable Not-Applicable

For an accumulated length of 2inch in
any 12 inch for material above 1in.
Undercut above 1.6mm not allowed.

Porosity-No porosity in the butt weld Applicable Not-Applicable Not-Applicable

traverse to tensile strength. In other butt
welds and for fillet weld the size of
1mmin linear inch of weld and shall not
exceed 19 mm in 12 in length of weld

Porosity-In fillet weld the frequency of Not-Applicable Applicable Applicable

porosity shall not exceed one in 100mm
of weld length and the maximum
diameter shall not to exceed 2mm.
Visual Inspection Acceptance Criteria

Discontinuity Category Static Loaded Dynamic Loaded All Loads

&Inspection Criteria (Nontubular) (Nontubular) (Tubular)

Crack- The weld shall have no crack Applicable Applicable Applicable

Weld/Base-Metal Fusion-Through fusion shall Applicable Applicable Applicable

exist between weld metal to weld metal and
base metal

Crater- All crater shall be filled up to the full Applicable Applicable Applicable
cross section except for the ends of the
intermittent fillet welds outside the effective
length

Weld Profiles-Weld profiles shall be in Applicable Applicable Applicable

conformance to 5.24

Time of Inspection- Immediately after the Applicable Applicable Applicable

completed weld reaches the ambient temp.For
ASTM A514,A517,A709 not less than 48 Hrs.
Visual Inspection Acceptance Limit-Piping

 As per BS 5289
 Acknowledgements
We gratefully acknowledge the contributions of
the following faculty members for developing
this module

 Mr.A.K.Bose
 Mr.N.Sadasivan
 R.Banerjee
Thank You