Welding Inspection & Metallurgy API ICP Self Study Notes

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• Bring temperature up to preheat or interpass temperatures required by the WPS. • Reduce shrinkage stresses in the weld and base metal, which is especially important in weld joints with high restraint. • Reduce the cooling rate to prevent hardening and a reduction in ductility of the weld and base metal HAZ. • Maintain weld interpass temperatures. • Eliminate moisture from the weld area. • Meet the requirements of the applicable fabrication code, such as the ASME Boiler and Pressure Vessel Code, depending on the chemistry and thickness of the alloy to be welded.
If preheat is specified in the WPS it is important that the inspector confirms that the required temperature is maintained. This can be done using several methods, including (1) thermocouples, (2) contact pyrometer, (3) infrared temperature measuring instruments, or (4) temperature indicating crayons. The inspector should also remember that if preheat is required during welding the same preheat should be applied during tack welding, arc gouging and thermal cutting of the metal, all of which induce temperature changes similar to welding of the joint.
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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
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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
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: Preheating, for our purposes, is de
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 213 and 214: PWHT- Local
Page 221 and 222: 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
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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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