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74 Cards in this Set
- Front
- Back
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What British Standard covers welding inspection? |
BS EN ISO 5817 Quality Levels for Imperfections |
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What are the assessment levels of welds in BS EN ISO 5817? |
B, C & D, with B being the least stringent and D the most |
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What is weld reinforcement? |
Deposited weld metal that is surplus to that required for a flush butt weld or 45º mitre on a T-fillet weld |
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Identify types of weld defects |
Insufficient penetration Excess penetration Poor weld appearance Burn through Undercut Lack of fusion Excess spatter Porosity Inclusions Cracking Excess overfill/reinforcement Underfill Overlap/Cold lapping Arc strikes |
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Identify types of parent metal generated defects |
Laminations Delaminations Lamellar tears Fatigue
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What is a welding gauge used for? |
Angle of preparation Fillet weld throat size Fillet weld leg length height of butt weld metal |
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How would the inside of a short welded pipe be inspected? |
A torch and mirror on a telescopic stick with a swivel head
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How would the inside of a long welded pipe be inspected? |
Borescope, intrascope or endaprobe - which are all fibre optic lenses |
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Identify the different methods of non-destructive testing |
DPI - Dye Penetrant Inspection
MPI - Magnetic Particle Inspection
UI - Ultrasonic Inspection
Radiography (X-rays)
Radioactive Isotopes (gamma rays) |
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Identify the different methods of destructive testing |
Face bend test
Root bend test
Side bend test
Side bend test
Tongue bend test
Nick break test
T-fillet test
Macro-Examination |
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What does TWI stand for and what is it? |
The Welding Institute
A UK regulating body that oversees standards, monitors quality and develops joining processes |
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What does EWF stand for and what is it? |
The European Federation for Welding, Joining and Cutting
A European regulating body that oversees standards, monitors quality and develops joining processes
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What does IIW stand for and what is it? |
The International Institute of Welding
An international regulating body that oversees standards, monitors quality and develops joining processes |
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What body oversees welding quality and Standards in the Shipbuilding, tankers and oil rig industries? |
Lloyds registry |
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What is ISO/NP 15609-1? |
Coding for specification and qualification of welding procedures for metallic materials
Welding procedure specification -- Part 1: Arc welding |
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What body oversees welding quality and Standards in the rail and bridge industries? |
IORW
The Institute of Rail Welding |
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What body oversees welding quality and Standards in the aircraft industry? |
CAA
Civil Aviation Authority |
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What body oversees welding quality and Standards in the pressure pipework and vessels industry? |
ASME
The American Society of Mechanical Engineers |
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What body oversees welding quality and Standards in the petrochemical industry? |
API
American Petroleum Industry |
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What is BS 4872 - 1 1982? |
Coding for fusion welding of steel
less stringent standard (75% root penetration)
Welding procedure not required |
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What is EN 287 - 1 2004? |
Coding for fusion welding of steel (part 1)
Critical standard (100% root penetration)
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What is EN 288? |
Coding for welding procedures for metallic materials
Superseded by EN ISO 15614 |
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What is EN ISO 15614 Part 1? |
Coding for arc welding of steel, nickel and nickel alloys
Most widely used standard
Formerly EN 288 Part 3 |
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What is EN ISO 15614 Part 2? |
Coding for arc welding of aluminium and it's alloys
Formerly EN 288 Part 4 |
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What is EN ISO 15614 Part 4? |
Coding for finishing welding of aluminium castings |
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What is EN ISO 15614 Part 5? |
Coding for welding of titanium, zirconium and their alloys |
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What is EN ISO 15614 Part 6? |
Coding for arc and gas welding copper and it's alloys |
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What is ASMI IX (ABPV)? |
Coding for welding of boilers and pressure vessels
Critical standard (100% root penetration) |
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What does WPS stand for and what is it? |
Welding Procedure Specifications
An instruction sheet that details how a weld must be made, and that the company has the ability to produce them satisfactorily
Details specified in EN ISO 15609 |
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What stages need to qualify a welding procedure? |
1. A weld procedure specification
2. Welding of a test piece within the specifications necessary, visually examined and witnessed by an inspection body
3. Test piece is then subjected to destructive testing, as defined by the welding procedure and witnessed by an inspection body
4. Successful tests are awarded appropriate docents by the testing body |
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What documents are awarded for successful WPS? |
E1 - Welding Procedure Approval Test Certificate
E2 - Details of Weld Test
E3 - Test Results
E4 - Welder Approval Test Certificate |
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Forms E1, E2, E3 and E4 are referred to as what? |
WPAR - Welding Procedure Approval Record
or
WPQR - Welding Procedure Qualification Record |
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What changes in the welding process will require a new welding procedure? |
Change in parent metal type
Change in welding process
Change in diameter or thickness (<0.5 or >2 x diameter/thickness)
Any other change required by the welding standard |
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What codings are required for the welding of pressurised systems? |
ASME IX |
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What codings are required for the qualification of welders where welding procedure is not required? |
BS 4872 |
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How many groups of metal are there in codings? |
10 |
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What are the variables in welder qualification standards? |
Welding process
Parent material
Welding consumables
Material thickness / pipe diameter / range of approval
Welding position
Weld details
Joint type
Heat Treatment
Destructive and non-destructive testing required
Period of validity
Confirmation of validity
Certificate |
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Inclined position welding upwards is designated by what code? |
H - LO45 |
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Inclined position welding downwards is designated by what code? |
J - LO45 |
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Pipe position for welding upwards is designated by what code? |
PH |
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Pipe position for welding downwards is designated by what code? |
PJ |
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In welder qualification standards, what is covered by 'weld details' |
Welding Sequence
Polarity
Voltage
Amperage
Wire feed speed
Shielding gas & pressure
Backing gas
Number of runs |
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What does the following weld detail abbreviation stand for?
bs |
Welding from both sides |
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What does the following weld detail abbreviation stand for?
lw |
Leftward welding |
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What does the following weld detail abbreviation stand for?
mb |
Welding with backing |
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What does the following weld detail abbreviation stand for?
ml |
Multi layer
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What does the following weld detail abbreviation stand for?
nb |
Welding without backing |
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What does the following weld detail abbreviation stand for?
rw |
Rightward welding |
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What does the following weld detail abbreviation stand for?
sl |
Single layer |
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What does the following weld detail abbreviation stand for?
ss |
Single side welding |
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What does the following weld detail abbreviation stand for?
FW |
Fillet Weld |
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What does the following weld detail abbreviation stand for?
BW |
Butt Weld |
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In Welder qualifications, what does 'confirmation of validity' mean? |
The welding co-ordinator (or responsible person) must confirm very 6 months that the welder is working with the qualification specifications
If the welder doesn't work for 6 months after testing, the certificate is no longer valid |
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What is the qualification code needed by a weld coordinator? |
BS EN ISO 14713 : 2006 Welding Coordination - Tasks and Resposibilities |
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What are assigned to a welding coordinator? |
Position and responsibilities
Authorisation to sign procedures off on behalf of the company/organisation
Authorisation to carry out assigned tasks |
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What qualifications are recommended for Welding Coordinators in Annex A? |
IWE - International Welding Engineer
IWT - International Welding Technologist
IWS - International Welding Specialist
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What is the qualification code for 'Quality Requirements for Fusion Welding of Metallic Materials' |
BS EN ISO 3834 |
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Personnel involved in non destructive testing should be should be approved by what independent validating body? |
CSWIP - Certification Scheme for Welding Inspection Personnel |
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What is BS EN ISO 3834? |
'Quality Requirements for Fusion Welding of Metallic Materials' |
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What temperature should welding not be done below? |
-18ºC |
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What is the maximum wind velocity allowed when using gas shielded welding processes? |
5 mph |
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What defects does wind cause to a weld? |
Porosity Inclusions Poor weld appearance |
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What affect does humidity have on a weld? |
None on the weld itself, but electrodes exposed to humidity lead to porosity and cracking |
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What affect does surface wetness have on a weld? |
Cracking |
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What affect does low temperatures have on a weld? |
Micro-cracking |
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What are the main factors that cause brittle fracture of steel vessels? |
Low temperature
Loading
Susceptible Steel
Stress Risers |
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What factors cause susceptibility of steel? |
Steel composition
Hydrogen cracks
Environmental stress |
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What causes Inclusions? |
Dirt, grease, slag or mill scale Joint too tight Current too low Electrode tho large Speed too fast Arc too long |
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What causes undercut? |
Current too high Voltage too high Excessive weaving Incorrect angle on positional work |
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What causes electrode sticking? |
Current too low arc length too short |
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What helps prevent arc blow? |
Welding towards an existing tack or weld Reducing current and voltage Check electrode coating is concentric Return clamp placed carter away at the cart or end of the weld Changing fixture position De-magnetising the fixture |
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What helps prevent hot cracking? |
Ensure the end of the weld has plenty of weld metal added before finishing Preheating to reduce shrinkage stresses Clean consumables and base metal Increase cross-sectional size of weld bead Use a base metal low in sulphur, phosphorous or lead Use consumables high in manganese, which acts as a de-oxidiser |
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Why are arc strikes not permitted outside the weld zone? |
They can encourage cracking |
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What causes excess spatter? |
Current too high Voltage too high Arc length too long Damp, old or poor quality electrodes |
