Welding Inspection & Metallurgy API ICP Self Study Notes

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Discussion: Why Wrought products are superior than Cast product?
Cast VS. Wrought 1. Cast ingot has less casting defects dues to its simplicity. 2. The cast defects if any will be flatten/dispersed during wrought forming. 3. Post wrought working heat treatment will harmonized the product which may includes stress relieving, grain refinements, modifying the physical and mechanical properties. 4. Others?
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 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 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
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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
Page 102 and 103:
Note 1 A= proportional limit, B=ela
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Tensile Testing
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Actual tensile testing plot Elastic
Page 109 and 110:
Elongation is the increase in gage
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The design of items should be based
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Bend Testing
Page 117 and 118:
ASTM E290- Guided bend testing
Page 119 and 120:
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
Page 129:
Rockwell hardness testing differs f
Page 132 and 133:
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
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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
Page 171 and 172:
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.
Page 183 and 184:
Preheating
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Preheating
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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-
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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
Page 217 and 218:
PWHT- Local
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PWHT- Local
Page 221 and 222:
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
Page 238 and 239:
Welding- Thick plate welding
Page 240 and 241:
Thick plate welding
Page 242 and 243:
Weld Macro- Geometry
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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
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Billets/Ingots
Page 272 and 273:
Billets/Ingots
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Billets/Ingots
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Heat analysis- Billets/Ingots
Page 278 and 279:
Billets/Ingots- Steel Mill Ladle An
Page 280 and 281:
Product analysis- Pipe
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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
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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
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
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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
Page 323 and 324:
Stainless Weld
Page 325 and 326:
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
Page 338 and 339:
Inert Backing Gas
Page 340 and 341:
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
Page 352 and 353:
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
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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
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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Welding Inspection & Metallurgy API ICP Self Study Notes

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