Welding Inspection & Metallurgy API ICP Self Study Notes

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Further Reading: http://practicalmaintenance.net/?p=948
Steels - The Structure of Engineering Steels Topics Covered 1. Introduction 2. Crystal Structures 3. Ferrite 4. Austenite 5. Cementite 6. Pearlite 7. Martensite 8. Bainite http://www.azom.com/article.aspx?ArticleID=399
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Welding Inspection & Metallurgy API
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Content: 10 METALLURGY 10.1 General
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10.2 THE STRUCTURE OF METALS AND AL
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http://www.sv.vt.edu/classes/MSE209
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Phase Diagram http://www.azom.com/a
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10.2.1 The Structure of Castings Th
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HAZ- Heat Affected Zone
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HAZ http://www.oocities.org/ferrit
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1mm / 1mm 0.2mm 0.2+1+1= 2.2 mm API
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Steel & Alloy- Grains
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Steel & Alloy- Microvoid Coalescenc
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Minimizing trace elements or “inc
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Casting
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Discussion: Why Wrought products ar
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Wrought materials may consist of on
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Hypoeutectic Steel - Annealed
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Steel & Alloy- Annealed Pearlite
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1055 Steel Annealed 1055, used in s
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4140 Steel http://en.wikipedia.org/
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4140 Steel Q&T
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The metallurgy of each weld area is
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Dendritic - usually solidify in the
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Dendrite- usually solidify in the s
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Weld Macro- CS
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The heat-affected zone (HAZ) is adj
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http://www.twi-global.com/technical
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Overlay Welding
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The third component in a welded joi
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An important factor in selecting sh
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10.3.1 Melting Temperature The melt
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Phase Diagram
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Phase Diagram http://www.calphad.co
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10.3.3 Electrical Conductivity The
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Aluminum Welds
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Metals with a high coefficient of t
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Weld porosity
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A gas with a higher density is more
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Tensile testing - Tensile /Yield St
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Charpy Testing Samples
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Charpy impact testing
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Hardness testing- Hardness tester
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Hardness testing
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Hardness testing
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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: 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
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PWHT- Typical PWHT Chart
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PWHT
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PWHT
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PWHT
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PWHT
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PWHT
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PWHT
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PWHT- Local
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PWHT- Local
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PWHT- Local
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PWHT- Local
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PWHT- Equipments
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PWHT- Equipments
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PWHT- Equipments
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PWHT- Equipments
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Fun-Photo: Induction Bending Pipe b
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10.7 HARDENING Hardening or hardena
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AISI 1040 / 4340 http://www.azom.co
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AISI 4340 http://www.efunda.com/mat
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Welding- Thick plate welding
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Thick plate welding
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Weld Macro- Geometry
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Jominy Bar
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Jominy Bar
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Jominy Bar
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Hardening of the weld and base meta
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HIC- Hydrogen Induced Cracking
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TTT Curve
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Martensite
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A product analysis is a statement o
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Billets/Ingots
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Billets/Ingots
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Billets/Ingots
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Billets/Ingots
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Heat analysis- Billets/Ingots
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Billets/Ingots- Steel Mill Ladle An
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Product analysis- Pipe
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i. Any supplemental information or
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Grain size determination
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Fracture toughness
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Elevated mechanical property testin
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The inspector should review the mat
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http://www.slideshare.net/fullscree
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Quiz 1) See the figure below for po
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End of reading!
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10.9 WELDABILITY OF STEELS There ar
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10.9.1 Metallurgy and Weldability A
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There are some elements present in
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10.9.2 Weldability Testing One of t
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Fabrication weldability tests that
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Weld restraint induces stresses tha
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Table 12—Weld Crack Tests
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10.10.1 Austenitic Stainless Steels
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The most common measure of weldabil
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Weldability of austenitic stainless
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Welding can reduce the corrosion re
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Austenitic Stainless Steel Weld Cor
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Stainless Weld
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Inert Backing Gas
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Inert Backing Gas
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Inert Backing Gas
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Inert Backing Gas
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Inert Backing Gas
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Inert Backing Gas
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Inert Backing Gas
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10.10.2 Nickel Alloys Nickel alloys
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Sluggish tendency- LOF
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Sluggish tendency- LOF
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Nickel alloys are also susceptible
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11 Refinery and Petrochemical Plant
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11.1 GENERAL This section provides
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Hot Tapping
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Hot Tapping
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Hot Tapping
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Hot Tapping
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Hot Tapping
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Burn Through
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Burn through: un-melted area beneat
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Electrode Considerations http://www
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11.2.2 Flow Rates Under most condit
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For making attachment welds to equi
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An appropriate flow rate should be
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Case Study: Is it 36” or greater
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Adverse effects can also occur from
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11.3 LACK OF FUSION WITH GMAW-S WEL
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The gas metal arc welding (GMAW) pr
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Since the transfer mode may be diff
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Hazards
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Hazards
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Mechanical Integrity
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Competent Inspectors http://amirazl
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Welding Inspection & Metallurgy API ICP Self Study Notes

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