Welding Inspection & Metallurgy API ICP Self Study Notes

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There are some elements present in carbon and alloy steels that are not deliberately added that can have an affect on weldability. These include (1) sulfur, (2) phosphorus, (3) tin, (4) antimony and (5) arsenic. These elements will sometimes be referred to as tramp elements. One tool has been developed to help evaluate the weldability of carbon and alloy steel and that is the carbon equivalent (CE) equation. The CE calculates a theoretical carbon content of the metal and takes into account not only carbon, but also the effect of purposely added alloying elements and tramp elements. Several different equations for expressing carbon equivalent are in use. One common equation is:
Typically, ■ ■ ■ Steels with a CE less than 0.35 require no preheat. Steels with a CE of 0.35 – 0.55 usually require preheating, and Steels with a CE greater than 0.55 require both preheating and a PWHT. However, requirements for preheating should be evaluated by considering other factors such as hydrogen level, humidity, and section thickness.
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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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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
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 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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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
Page 304 and 305: 10.9.2 Weldability Testing One of t
Page 306 and 307: 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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Page 316: Weldability of austenitic stainless
Page 319 and 320: Welding can reduce the corrosion re
Page 321 and 322: Austenitic Stainless Steel Weld Cor
Page 323 and 324: Stainless Weld
Page 325 and 326: Inert Backing Gas
Page 340 and 341: 10.10.2 Nickel Alloys Nickel alloys
Page 342 and 343: Sluggish tendency- LOF
Page 344 and 345: Sluggish tendency- LOF
Page 346 and 347: Nickel alloys are also susceptible
Page 348 and 349: 11 Refinery and Petrochemical Plant
Page 350 and 351: 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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