Welding Inspection & Metallurgy API ICP Self Study Notes

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10.10.2 Nickel Alloys Nickel alloys, such as Alloy C276 or Alloy 625 suffer from similar problems as austenitic stainless steels. In general most nickel alloy materials are considered to have less weldability than austenitic stainless steels. Some nickel alloys, such as Alloy 825, 600 and 625 have similar welding characteristic to austenitic stainless steels. While Alloy 200, Alloy 400 and Alloy B2 will have very different welding characteristics compared to austenitic stainless steels. Similar welding characteristic to austenitic SS: Alloy 825, 600 and 625 Very Different welding characteristic to austenitic SS : Alloy 200, Alloy 400 and Alloy B2
One of the main differences between nickel alloy and carbon steels, and austenitic stainless steels, is there tendency to be sluggish during welding. This means for nickel alloys that the molten weld pool will not move as easily as it does for other metals. This sluggish tendency means the welder should move the weld pool with a weave or oscillation pattern to ensure good sidewall fusion. If some oscillation is not used, a high convex weld contour will result which cause sidewall lack of fusion, weld undercut or slag inclusions. The formation of a slightly concave weld bead profile will be more resistant to centerline cracking. It is also important that the bevel angle for nickel alloys be wide enough to allow for this necessary oscillation of the welding torch. The wider weld bevel will also be beneficial with respect to weld penetration. Nickel alloys also suffer from shallower weld penetration as compared to carbon steels and austenitic stainless steel. To overcome this, the weld joint is modified by having a wider bevel and thinner root face.
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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
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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
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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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
Page 314 and 315: The most common measure of weldabil
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 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
Page 352 and 353: Hot Tapping
Page 362 and 363: Burn Through
Page 364 and 365: Burn through: un-melted area beneat
Page 366 and 367: Electrode Considerations http://www
Page 368 and 369: 11.2.2 Flow Rates Under most condit
Page 370 and 371: 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
Page 384: Adverse effects can also occur from
Page 387 and 388: 11.3 LACK OF FUSION WITH GMAW-S WEL
Page 389 and 390: 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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