Welding Inspection & Metallurgy API ICP Self Study Notes

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Due to this inherent nature of the welding process the BPV Code Section IX, restricts this process by: a. Requiring welders qualify with mechanical testing rather than by radiographic examination. b. Limiting the base metal thickness qualified by the procedure to 1.1 times the test coupon thickness for coupons less than 1/2 in. thick (12.7 mm) per variable QW-403.10. c. Limiting the deposited weld metal thickness qualified by the procedure to 1.1 times the deposited thickness for coupons less than 1/2 in. thick (12.7 mm) per variable QW-404-32. d. Making variable QW-409.2 an essential variable when qualifying a welder for the GMAW-S process.
Since the transfer mode may be difficult to determine without an oscilloscope, some general characteristics are listed in a National Board Classic Bulletin, Low Voltage Short Circuiting- GMAW, from January 1985, to assist the inspector in determining the transfer mode being used. http://www.weldsmith.co.uk/dropbox/cranu/110523_waveforms_GMAW_steel/waveforms_GMAW_steel.html
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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
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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
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
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: The gas metal arc welding (GMAW) pr
Page 393 and 394: Hazards
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Page 397 and 398: Mechanical Integrity
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Welding Inspection & Metallurgy API ICP Self Study Notes

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