Welding Inspection & Metallurgy API ICP Self Study Notes

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Hardening of the weld and base metal HAZ are important because of hydrogen assisted cracking that occurs in carbon and low-alloy steels. As the hardness of the base metal HAZ increases so does the susceptibility to hydrogen assisted cracking. The hardness limits currently recommended for steels in refinery process service are listed in Table 11. Hardness values obtained in excess of these usually indicate that post-weld heat treatment is necessary, regardless of whether specified on the welding procedure specification. In those instances where PWHT is needed, an alternate welding procedure qualified with PWHT is necessary. Hardness in excess of those listed can result in stress corrosion cracking in service due to the presence of sulfides in the process. The 200 BHN limit for carbon steel is equally as important in sulfur containing oils as is the limit for Cr-Mo steels.
Typical Hardness Values Table 11—Brinell Hardness Limits for Steels in Refining Services
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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
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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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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
Page 238 and 239: Welding- Thick plate welding
Page 240 and 241: Thick plate welding
Page 242 and 243: Weld Macro- Geometry
Page 248 and 249: Jominy Bar
Page 256 and 257: HIC- Hydrogen Induced Cracking
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 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
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Page 298 and 299: 10.9 WELDABILITY OF STEELS There ar
Page 300 and 301: 10.9.1 Metallurgy and Weldability A
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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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