Macro

MACRO-SECTION.
TWI
CSWIP 3.1
WELDING INSPECTION
MACRO-SECTION.
PRACTICAL
Section 25.
World Centre for Materials Joining Technology
Copyright 2005, TWI Ltd
MACRO SECTIONS
1. ASSESS THE MACRO PHOTOGRAPH FOR WELD
DEFECTS.
2. RECORD THE MAJOR DEFECTS ON
THE
REPORT SHEET.
3. SENTENCE THE DEFECTS RECORDED TO THE
ACCEPTANCE CRITERIA GIVEN.
4. FOLLOW THE INSTRUCTIONS.
PLEASE DO NOT MARK THE
PHOTOGRAPHS.

MACRO INSTRUCTIONS.

MACRO DEFECTS.
50m
m
3mm
ANGULAR DISTORTION = 3mm in
50mm
MACRO DEFECTS.
INCOMPLETLEY FILLED
GROOVE
1.5mm
MISALIGNMENT

MACRO DEFECTS.
COLD LAP
GAS
POOR
PORE /
TOE
BLOW
BLEND
HOLE
EXCESSIVE WELD
METAL
&

COLD
LAP &
POOR
TOE
BLEND
Macro defects
INCOMPLETELY FILLED
GROOVE

MACRO DEFECTS.
LACK
OF
SIDE
WALL
FUSIO
N
LACK OF
SIDE
WALL
FUSION
& SLAG
LACK OF SIDE WALL

FUSION / INCOMPELTELY
FILLED GROOVE

MACRO DEFECTS.
COLD LAP
LACK OF SIDEWALL
FUSION / INCOMPLETELY
FILLED GROOVE
GAS
PORES
LACK OF ROOT FUSION

MACRO DEFECTS.
INCOMPETELY FILLED GOOVE
SLAG
INCLUSIO
N
GAS
PORE
LACK OF ROOT FUSION

MACRO DEFECTS.
LACK OF
SIDEWALL
FUSION
LACK OF
SIDEWALL
FUSION &
SLAG
LACK OF
SIDEWALL
FUSION
LACK OF ROOT PENETRATION
LACK OF
SIDEWALL
FUSION
MACRO SECTIONS
QUESTIONS.

MACRO DEFECTS.
LACK OF
SIDEWALL FUSION
CLUSTER / WORMHOLE
POROSITY
LAMINATIONS
LACK OF INTER-RUN
FUSION & SLAG
LACK OF
SIDEWALL FUSION
& SLAG
LACK OF INTER-RUN
FUSION
GAS PORES
ROOT UNDERCUT
MACRO SAMPLE.
WELDING PROCESS : MAG
1 COLD LAP
5 LACK OF SIDEWALL
FUSION
4 LACK OF INTERRUN FUSION
3 COLD LAP
2 LACK OF SIDEWALL
FUSION & GAS / SILICA

MACRO
NOTE: PHOTOGRAPH IS AT X10 MAGNIFICATION
MATERIAL: LOW CARBON STEEL WELDING PROCESS: [MAG/GMAW]
8
#
1
2
3
4
5
6
7
8
9
10
9
7
6
DEFECT
POOR TOE BLEND
OVERLAP + 2 SMALL PORES
LAMINATIONS/INCLUSIONS
LACK OF SIDE WALL FUSION
AS ABOVE +PORES
OVERLAP
LACK OF INTERRUN FUSION
GAS PORE/PIPE
LACK OF SIDE WALL FUSION +
SILICA
ANGULAR MISALIGNMENT
SIZE
11
EXCESS WELD METAL
12
EXCESS PENETRATION

1
2
4
ACCEPT/REJECT
Assess
To
Specification
MACRO ACCEPTANCE.

MACRO
EXCERCISES.AM1030
TRAINING SAMPLE ONLY
MACRO INSTRUCTION/REPORT SHEET [I.D: AM1030]
CHECK PHOTOGRAPH I.D MATCHES THIS REPORT I.D
ALL DEFECTS TO BE REPORTED [AND SIZED IF REQUIRED]
THEN SENTENCED TO ISO 5817 LEVEL B [STRINGENT]
MATERIAL: LOW CARBON STEEL
WELDING PROCESS: [MMA/SMAW]
8
7
4
6
5
1
2
3
MACRO EXCERCISES. AM
1030
#
1
2
3
4
5
6
7
8
9
10
11
12
DEFECT
Lack of side wall fusion and
slag
Misalignment
Lack of root penetration
Angular distortion
Lack of side wall
fusion
Lack of inter run fusion and slag
Lack of side wall
fusion
Excess weld metal
SIZE
ACCEPT/REJECT
8.6
0.2
N/A
0.5
2.5
4.2
2.5
3.2
COMMENTS:
SIGNATURE:
DATE:
PRINT FULL NAME:

Reject
Accept
Reject
Accept
Reject
Reject
Reject
Reject
1031
1
2
6
5

1031
#
1
2
3
4
5
6
7
8
9
10
11
12
DEFECT
Lack of side wall fusion/ underfill
Lack of side wall fusion and slag
Cold lap
Misalignment
Excess penetration
Cold lap
Slag inclusion
Cold lap
Excess weld metal
SIZE
ACCEPT/REJECT
0.7
7.5
0.5
1.8
3.3
0.3
0.7
0.5
3.5
COMMENTS:
SIGNATURE:
DATE:
PRINT FULL NAME:

Reject
Reject
Reject
Reject
Reject
Reject
Accept
Reject
Reject
1032
8
1
3
4
5
7 6

1032
#
1
2
3
4
5
6
7
8
9
10
11
12
DEFECT
Lack of side wall fusion/underfill

Lack of sidewall fusion & Slag
Lack of side wall fusion & slag
Slag inclusion
Cold lap
Misalignment
Excess penetration
Excess weld metal
COMMENTS:
Plate laminations
noted
SIGNATURE:
SIZE
ACCEPT/REJECT
0.5
2.8
4.5
1.5
0.3
1.8
2.0
3.3
DATE:
PRINT FULL NAME:

Reject
Reject
Reject
Reject
Reject
Reject
Accept
Reject
1033
WELDING PROCESS: [MAG/GMAW]
1
6
5
4
3
7
2

1033
#
1
2
3
4
5
6
7
8
9
10
11
12
DEFECT
Cold Lap/ Overlap

Lack of sidewall fusion & gas
Cold lap / Overlap
Misalignment
Lack of interrun fusion & gas
Lack of sidewall fusion
Blow hole
Excess weld metal
COMMENTS:
SIZE
ACCEPT/REJECT
2.8
8.0
0.3
0.6
2.0
2.6
1.5
5.0
Plate laminations
noted
Poor toe blend

SIGNATURE:
DATE:
PRINT FULL NAME:

Reject
Reject
Reject
Accept
Reject
Reject
Reject
Reject
1034
10
1
2
8
7
3
6 5

1034
#
1
2
3
4
5
6
7
8
9
10
11
12
DEFECT
Lack of sidewall fusion & slag

Lack of sidewall fusion
Lack of inter-run fusion & slag
Angular distortion
Misalignment
Excess penetration
Lack of inter-run fusion & slag
Lack of side wall fusion
Spatter
Excess weld metal
COMMENTS:
SIZE
ACCEPT/REJECT
2.8
1.0
2.0
6in13
0.5
0.1
5.5
5.0
0.1
3.6
Plate laminations
noted
Poor toe blend

SIGNATURE:
DATE:
PRINT FULL NAME:

Reject
Reject
Reject
Accept
Reject
Reject
Reject
Reject
Accept
Reject
Macro defects

Macro defects

Macro defects

Macro defects

Macro defects

Macro defects

Macro defects

Macro defects

Macro defects

Macro defects


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MACRO-SECTION.

World Centre for Materials Joining Technology

World Centre for Materials Joining Technology

World Centre for Materials Joining Technology

World Centre for Materials Joining Technology

World Centre for Materials Joining Technology

LACK OF SIDE WALL

World Centre for Materials Joining Technology

LACK OF ROOT FUSION

LACK OF ROOT FUSION

World Centre for Materials Joining Technology

4 LACK OF INTERRUN FUSION

World Centre for Materials Joining Technology

EXCESS WELD METAL

World Centre for Materials Joining Technology

World Centre for Materials Joining Technology

PRINT FULL NAME:

World Centre for Materials Joining Technology

World Centre for Materials Joining Technology

PRINT FULL NAME:

World Centre for Materials Joining Technology

World Centre for Materials Joining Technology

Lack of side wall fusion/underfill

PRINT FULL NAME:

World Centre for Materials Joining Technology

World Centre for Materials Joining Technology

Cold Lap/ Overlap

Poor toe blend

PRINT FULL NAME:

World Centre for Materials Joining Technology

World Centre for Materials Joining Technology

Lack of sidewall fusion & slag

Poor toe blend

PRINT FULL NAME:

World Centre for Materials Joining Technology

World Centre for Materials Joining Technology

World Centre for Materials Joining Technology

World Centre for Materials Joining Technology

World Centre for Materials Joining Technology

World Centre for Materials Joining Technology

World Centre for Materials Joining Technology

World Centre for Materials Joining Technology

World Centre for Materials Joining Technology

World Centre for Materials Joining Technology

World Centre for Materials Joining Technology

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