Welding Inspection & Metallurgy API ICP Self Study Notes

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1mm / 1mm 0.2mm 0.2+1+1= 2.2 mm <strong>API</strong> 582/ NOTE HV10 measurement for HAZ requires 0.04 in. (1 mm) minimum spacing between indentations. In some cases, it is acceptable that hardness measurement location is off-the line in order to satisfy the minimum spacing requirements. Figure 1- Location of Vickers Hardness Indentations
The properties of the cast structure can also be impaired by compositional variations in the microstructure called segregation. Because of the solubility of trace and alloying elements, such elements as carbon, sulfur, and phosphorous, can vary in a pure metal, these elements can cause variations in the solidification temperature of different microstructural phases within the melt. As the melt cools, these elements are eventually contained in the micro structural phases that solidify last in spaces between the grains. These grain boundary regions can have a much higher percentage of trace elements that the grains themselves, which may lead to reductions in ductility and strength properties. This effect can be minimized by using high purity melting stocks, by special melting practices (melting under vacuum or inert gas, for example) to minimize contamination and/or subsequent heat treatment to homogenize the structure. In many carbon steels this is achieved using oxygen scavengers such as aluminum and the steels are often described as “killed” or “fully killed” steels. Minimizing trace elements or “inclusions” at this stage is often important as they can provide sites for formation of in-service defects such as hydrogen induced cracking (HIC).
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 10 and 11: Phase Diagram http://www.azom.com/a
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 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
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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
Page 80 and 81:
Tensile testing - Tensile /Yield St
Page 82 and 83:
Page 84 and 85:
Page 86 and 87:
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
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10.4.1 Tensile and Yield Strength T
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For design purposes, the maximum us
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Note 1 A= proportional limit, B=ela
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Tensile Testing
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Actual tensile testing plot Elastic
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Elongation is the increase in gage
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The design of items should be based
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Bend Testing
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ASTM E290- Guided bend testing
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Bend Testing
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Bend Testing
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Knoop and Vickers Hardness Tester
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http://wes.ir/files/6936303material
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Rockwell hardness testing differs f
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Vickers hardness testing follows th
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http://www.twi-global.com/technical
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The type of notch and the impact te
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Online Metallurgy Course: http://ww
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Online Metallurgy Course http://210
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Online Metallurgy Course-Steel Maki
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Steels - The Structure of Engineeri
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Steels - The Structure of Engineeri
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Crystal Structures
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Phase Diagram
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Austenite
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This is a hypereutectoid alloy and
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Pearlite Pearlite is a phase mixtur
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This steel is of the eutectoid comp
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http://www.gowelding.com/met/carbon
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Martensite https://www.flickr.com/s
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Martensite https://www.flickr.com/s
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Bainite If the steel is cooled such
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FIGURE 2. The TTT diagram for aisi
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Bainite https://www.flickr.com/sear
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R e 0.2% Yield strength is the amou
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http://www.gowelding.com/weld/prehe
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End of reading! http://oregonstate.
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Preheating
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Preheating
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Preheating, for our purposes, is de
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If preheat is specified in the WPS
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10.6 POST-WELD HEAT TREATMENT Post-
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The primary reason for post-weld he
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PWHT (stress relief) can be applied
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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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Page 246 and 247:
Page 248 and 249:
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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Page 262 and 263:
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
Page 368 and 369:
11.2.2 Flow Rates Under most condit
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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
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Page 382 and 383:
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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
Page 391 and 392:
Since the transfer mode may be diff
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Hazards
Page 395 and 396:
Hazards
Page 397 and 398:
Mechanical Integrity
Page 399 and 400:
Competent Inspectors http://amirazl
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Welding Inspection & Metallurgy API ICP Self Study Notes

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