Welding Inspection & Metallurgy API ICP Self Study Notes

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Phase Diagram http://www.azom.com/article.aspx?ArticleID=313
Phase Diagram http://www.slideshare.net/slideshow/embed_code/27014256 http://www.slideshare.net/piyushvermaiitkgp/metallurgy-basics
Page 1 and 2: Welding Inspection & Metallurgy API
Page 3 and 4: Content: 10 METALLURGY 10.1 General
Page 5 and 6: 10.2 THE STRUCTURE OF METALS AND AL
Page 8 and 9: http://www.sv.vt.edu/classes/MSE209
Page 12 and 13: 10.2.1 The Structure of Castings Th
Page 14 and 15: HAZ- Heat Affected Zone
Page 16 and 17: HAZ http://www.oocities.org/ferrit
Page 18 and 19: 1mm / 1mm 0.2mm 0.2+1+1= 2.2 mm API
Page 20 and 21: Steel & Alloy- Grains
Page 22 and 23: Steel & Alloy- Microvoid Coalescenc
Page 24 and 25: Minimizing trace elements or “inc
Page 26 and 27: Casting
Page 28 and 29: Discussion: Why Wrought products ar
Page 30 and 31: Wrought materials may consist of on
Page 32: Hypoeutectic Steel - Annealed
Page 36 and 37: Steel & Alloy- Annealed Pearlite
Page 38 and 39: 1055 Steel Annealed 1055, used in s
Page 40 and 41: 4140 Steel http://en.wikipedia.org/
Page 42 and 43: 4140 Steel Q&T
Page 44 and 45: The metallurgy of each weld area is
Page 46 and 47: Dendritic - usually solidify in the
Page 48 and 49: Dendrite- usually solidify in the s
Page 50 and 51: Weld Macro- CS
Page 52 and 53: The heat-affected zone (HAZ) is adj
Page 54 and 55: http://www.twi-global.com/technical
Page 56 and 57: Overlay Welding
Page 58 and 59: The third component in a welded joi
Page 60 and 61:
An important factor in selecting sh
Page 62 and 63:
10.3.1 Melting Temperature The melt
Page 64 and 65:
Phase Diagram
Page 66 and 67:
Phase Diagram http://www.calphad.co
Page 69 and 70:
10.3.3 Electrical Conductivity The
Page 71 and 72:
Aluminum Welds
Page 73:
Metals with a high coefficient of t
Page 76 and 77:
Weld porosity
Page 78 and 79:
A gas with a higher density is more
Page 80 and 81:
Tensile testing - Tensile /Yield St
Page 82 and 83:
Page 84 and 85:
Page 86 and 87:
Charpy Testing Samples
Page 88 and 89:
Charpy impact testing
Page 90 and 91:
Hardness testing- Hardness tester
Page 92 and 93:
Hardness testing
Page 94 and 95:
Hardness testing
Page 96 and 97:
Ductility- Bend Tests
Page 98 and 99:
10.4.1 Tensile and Yield Strength T
Page 100 and 101:
For design purposes, the maximum us
Page 102 and 103:
Note 1 A= proportional limit, B=ela
Page 104:
Tensile Testing
Page 107 and 108:
Actual tensile testing plot Elastic
Page 109 and 110:
Elongation is the increase in gage
Page 111 and 112:
The design of items should be based
Page 113:
Bend Testing
Page 117 and 118:
ASTM E290- Guided bend testing
Page 119 and 120:
Bend Testing
Page 121 and 122:
Bend Testing
Page 123 and 124:
Knoop and Vickers Hardness Tester
Page 125 and 126:
http://wes.ir/files/6936303material
Page 129:
Rockwell hardness testing differs f
Page 132 and 133:
Vickers hardness testing follows th
Page 135 and 136:
http://www.twi-global.com/technical
Page 137:
The type of notch and the impact te
Page 141 and 142:
Online Metallurgy Course: http://ww
Page 143 and 144:
Online Metallurgy Course http://210
Page 145 and 146:
Online Metallurgy Course-Steel Maki
Page 147 and 148:
Steels - The Structure of Engineeri
Page 149 and 150:
Steels - The Structure of Engineeri
Page 151 and 152:
Crystal Structures
Page 154 and 155:
Phase Diagram
Page 156 and 157:
Austenite
Page 158 and 159:
This is a hypereutectoid alloy and
Page 161 and 162:
Pearlite Pearlite is a phase mixtur
Page 163 and 164:
This steel is of the eutectoid comp
Page 165 and 166:
http://www.gowelding.com/met/carbon
Page 167 and 168:
Martensite https://www.flickr.com/s
Page 169 and 170:
Martensite https://www.flickr.com/s
Page 171 and 172:
Bainite If the steel is cooled such
Page 173 and 174:
FIGURE 2. The TTT diagram for aisi
Page 175 and 176:
Bainite https://www.flickr.com/sear
Page 177 and 178:
R e 0.2% Yield strength is the amou
Page 179 and 180:
http://www.gowelding.com/weld/prehe
Page 181 and 182:
End of reading! http://oregonstate.
Page 183 and 184:
Preheating
Page 185 and 186:
Preheating
Page 187 and 188:
Preheating, for our purposes, is de
Page 189 and 190:
If preheat is specified in the WPS
Page 191 and 192:
10.6 POST-WELD HEAT TREATMENT Post-
Page 193 and 194:
The primary reason for post-weld he
Page 195 and 196:
PWHT (stress relief) can be applied
Page 197 and 198:
Typical PWHT Chart
Page 199 and 200:
PWHT- Typical PWHT Chart
Page 201 and 202:
PWHT
Page 203 and 204:
PWHT
Page 205 and 206:
PWHT
Page 207 and 208:
PWHT
Page 209 and 210:
PWHT
Page 211 and 212:
PWHT
Page 213 and 214:
PWHT- Local
Page 215 and 216:
PWHT- Local
Page 217 and 218:
PWHT- Local
Page 219 and 220:
PWHT- Local
Page 221 and 222:
PWHT- Equipments
Page 223 and 224:
PWHT- Equipments
Page 225 and 226:
PWHT- Equipments
Page 227 and 228:
PWHT- Equipments
Page 229 and 230:
Fun-Photo: Induction Bending Pipe b
Page 231 and 232:
10.7 HARDENING Hardening or hardena
Page 233 and 234:
AISI 1040 / 4340 http://www.azom.co
Page 235:
AISI 4340 http://www.efunda.com/mat
Page 238 and 239:
Welding- Thick plate welding
Page 240 and 241:
Thick plate welding
Page 242 and 243:
Weld Macro- Geometry
Page 244 and 245:
Page 246 and 247:
Page 248 and 249:
Jominy Bar
Page 250 and 251:
Jominy Bar
Page 252 and 253:
Jominy Bar
Page 254 and 255:
Hardening of the weld and base meta
Page 256 and 257:
HIC- Hydrogen Induced Cracking
Page 258 and 259:
Page 260 and 261:
Page 262 and 263:
TTT Curve
Page 264 and 265:
Martensite
Page 266 and 267:
A product analysis is a statement o
Page 268 and 269:
Billets/Ingots
Page 270 and 271:
Billets/Ingots
Page 272 and 273:
Billets/Ingots
Page 274 and 275:
Billets/Ingots
Page 276 and 277:
Heat analysis- Billets/Ingots
Page 278 and 279:
Billets/Ingots- Steel Mill Ladle An
Page 280 and 281:
Product analysis- Pipe
Page 282 and 283:
i. Any supplemental information or
Page 284 and 285:
Grain size determination
Page 286 and 287:
Fracture toughness
Page 288 and 289:
Elevated mechanical property testin
Page 290 and 291:
The inspector should review the mat
Page 292 and 293:
http://www.slideshare.net/fullscree
Page 294 and 295:
Quiz 1) See the figure below for po
Page 296 and 297:
End of reading!
Page 298 and 299:
10.9 WELDABILITY OF STEELS There ar
Page 300 and 301:
10.9.1 Metallurgy and Weldability A
Page 302 and 303:
There are some elements present in
Page 304 and 305:
10.9.2 Weldability Testing One of t
Page 306 and 307:
Fabrication weldability tests that
Page 308 and 309:
Weld restraint induces stresses tha
Page 310 and 311:
Table 12—Weld Crack Tests
Page 312 and 313:
10.10.1 Austenitic Stainless Steels
Page 314 and 315:
The most common measure of weldabil
Page 316:
Weldability of austenitic stainless
Page 319 and 320:
Welding can reduce the corrosion re
Page 321 and 322:
Austenitic Stainless Steel Weld Cor
Page 323 and 324:
Stainless Weld
Page 325 and 326:
Inert Backing Gas
Page 327 and 328:
Inert Backing Gas
Page 329 and 330:
Inert Backing Gas
Page 332 and 333:
Inert Backing Gas
Page 334 and 335:
Inert Backing Gas
Page 336 and 337:
Inert Backing Gas
Page 338 and 339:
Inert Backing Gas
Page 340 and 341:
10.10.2 Nickel Alloys Nickel alloys
Page 342 and 343:
Sluggish tendency- LOF
Page 344 and 345:
Sluggish tendency- LOF
Page 346 and 347:
Nickel alloys are also susceptible
Page 348 and 349:
11 Refinery and Petrochemical Plant
Page 350 and 351:
11.1 GENERAL This section provides
Page 352 and 353:
Hot Tapping
Page 354 and 355:
Hot Tapping
Page 356 and 357:
Hot Tapping
Page 358 and 359:
Hot Tapping
Page 360 and 361:
Hot Tapping
Page 362 and 363:
Burn Through
Page 364 and 365:
Burn through: un-melted area beneat
Page 366 and 367:
Electrode Considerations http://www
Page 368 and 369:
11.2.2 Flow Rates Under most condit
Page 370 and 371:
For making attachment welds to equi
Page 372 and 373:
An appropriate flow rate should be
Page 374 and 375:
Case Study: Is it 36” or greater
Page 376 and 377:
Page 378 and 379:
Page 380 and 381:
Page 382 and 383:
Page 384:
Adverse effects can also occur from
Page 387 and 388:
11.3 LACK OF FUSION WITH GMAW-S WEL
Page 389 and 390:
The gas metal arc welding (GMAW) pr
Page 391 and 392:
Since the transfer mode may be diff
Page 393 and 394:
Hazards
Page 395 and 396:
Hazards
Page 397 and 398:
Mechanical Integrity
Page 399 and 400:
Competent Inspectors http://amirazl
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