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A Quick Guide to Welding and Weld Inspection


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Table of Contents

Foreword by Series Editor Introduction A 10 Minute Guide 1 What is the difference between the main welding processes? (four minutes) 2 Why use welding symbols? (one minute) 3 What are codes and standards? (one minute) 4 What is welding procedure qualification? (one minute) 5 Why does a welder need qualification? (one minute) 6 What are welding defects? (two minutes) Chapter 1: Abbreviations, Terminology and Welding Symbols Abbreviations Common terms Joint terminology Weld terminology Drawing rules and weld symbols Chapter 2: Duties of a Welding Inspector Before welding During welding After welding Repairs Chapter 3: Analysis of a Fusion Weld Components of a welded joint What makes a good fusion weld? Weld joint: preparation methods Weld joint: shape Residual stress and distortion Minimising stresses and distortion Chapter 4: Materials and Their Weldability Carbon equivalency Classification of steels Alloying elements Material properties Heat treatment of steels Chapter 5: Welding Processes Manual metal arc (MMA)/shielded metal arc welding (SMAW) Metal inert gas (MIG)/metal active gas (MAG)/gas metal arc welding (GMAW) Flux-cored arc welding (FCAW) Tungsten inert gas (TIG)/gas tungsten arc welding (GTAW) Submerged arc welding (SAW) Chapter 6: Non-destructive and Destructive Testing Liquid penetrant testing (PT) Magnetic particle testing (MT) Ultrasonic testing (UT) Radiographic testing (RT) Tension tests Bend tests Charpy tests Hardness testing Macro samples Micro samples Fillet fracture test Butt weld fracture test (nick break) Chapter 7: Fracture Modes and Welding Defects Imperfection categories Hydrogen-induced cold cracking (HICC) Solidification cracking Reheat cracking Lamellar tearing Weld decay Porosity Solid inclusions Lack of fusion Incomplete root penetration Root concavity Excessive root penetration Overlap Underfill Undercut Crater pipe Burn-through Root oxidation Arc strike Spatter Magnetic arc blow Chapter 8: Codes, Standards and Documentation Codes and standards The PED and UK PER Welding procedure qualifications Procedure qualification record (PQR) Welding procedure specification (WPS) Welder qualifications Chapter 9: Health and Safety Health and Safety at Work Act Electrical safety Welding/cutting process safety Personal protective equipment (PPE) Gases and fumes COSHH and workplace exposure limits (WEL) Lifting equipment/pressure system requirements Hand tools and grinding machines Other precautions before welding starts Causes of accidents Permit-to-work Tanks and drums Index

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