Welding Inspection & Metallurgy API ICP Self Study Notes

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10.3.1 Melting Temperature The melting temperature of different metals is important to know because the higher the melting point, the greater the amount of heat that is needed to melt a given volume of metal. This is seldom a problem in arc welding since the arc temperatures far exceed the melting temperatures of carbon and low-alloy steels. The welder simply increases the amperage to get more heat, thus controlling the volume of weld metal melted per unit length of weld at a given, voltage or arc length and travel speed. A pure metal has a definite melting temperature that is just above its solidification temperature. However, complete melting of alloyed materials occurs over a range of temperatures. Alloyed metals start to melt at a temperature, which is just above its solidus temperature, and, because they may contain different metallurgical phases, melting continues as the temperature increases until it reaches its liquidus temperature.
Alloyed metals start to melt at a temperature, which is just above its solidus temperature, and, because they may contain different metallurgical phases, melting continues as the temperature increases until it reaches its liquidus temperature. http://practicalmaintenance.net/?p=1255
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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
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 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 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
Page 104: Tensile Testing
Page 107 and 108: Actual tensile testing plot Elastic
Page 109 and 110: Elongation is the increase in gage
Page 111 and 112: 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
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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
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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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Welding Inspection & Metallurgy API ICP Self Study Notes

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