Welding Inspection & Metallurgy API ICP Self Study Notes

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The heat-affected zone (HAZ) is adjacent to the weld and is that portion of the base metal that has not been melted, but whose mechanical properties or microstructure have been altered by the preheating temperature and the heat of welding. There will typically be a change in grain size or grain structure and hardness in the HAZ of steel. The size or width of the HAZ is dependent on the heat input used during welding. For carbon steels, the HAZ includes those regions heated to greater than 1350°F (700°C). Each weld pass applied will have its own HAZ and the overlapping heat affected zones will extend through the full thickness of the plate or part welded.
Each weld pass applied will have its own HAZ and the overlapping heat affected zones will extend through the full thickness of the plate or part welded. Unaffected HAZ
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 28 and 29: Discussion: Why Wrought products ar
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 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 86 and 87: Charpy Testing Samples
Page 88 and 89: Charpy impact testing
Page 90 and 91: Hardness testing- Hardness tester
Page 92 and 93: Hardness testing
Page 94 and 95: Hardness testing
Page 96 and 97: Ductility- Bend Tests
Page 98 and 99: 10.4.1 Tensile and Yield Strength T
Page 100 and 101: 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
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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
Page 141 and 142:
Online Metallurgy Course: http://ww
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Online Metallurgy Course http://210
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Online Metallurgy Course-Steel Maki
Page 147 and 148:
Steels - The Structure of Engineeri
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Steels - The Structure of Engineeri
Page 151 and 152:
Crystal Structures
Page 154 and 155:
Phase Diagram
Page 156 and 157:
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.
Page 183 and 184:
Preheating
Page 185 and 186:
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
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
Page 270 and 271:
Billets/Ingots
Page 272 and 273:
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
Page 280 and 281:
Product analysis- Pipe
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i. Any supplemental information or
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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
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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
Page 308 and 309:
Weld restraint induces stresses tha
Page 310 and 311:
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
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 327 and 328:
Inert Backing Gas
Page 329 and 330:
Inert Backing Gas
Page 332 and 333:
Inert Backing Gas
Page 334 and 335:
Inert Backing Gas
Page 336 and 337:
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
Page 344 and 345:
Sluggish tendency- LOF
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Nickel alloys are also susceptible
Page 348 and 349:
11 Refinery and Petrochemical Plant
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11.1 GENERAL This section provides
Page 352 and 353:
Hot Tapping
Page 354 and 355:
Hot Tapping
Page 356 and 357:
Hot Tapping
Page 358 and 359:
Hot Tapping
Page 360 and 361:
Hot Tapping
Page 362 and 363:
Burn Through
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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
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Page 378 and 379:
Page 380 and 381:
Page 382 and 383:
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
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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