Welding Inspection & Metallurgy API ICP Self Study Notes

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10.4.1 Tensile and Yield Strength Tensile testing is used to determine a metals ultimate tensile strength, yield strength, elongation and reduction in area. A tensile test is performed by pulling a test specimen to failure with increasing load. Stress is defined as the force acting in a given region of the metal when an external load is applied. The nominal stress of a metal is equal to the tensile strength. The ultimate tensile strength of a metal is determined by dividing the external load applied by the cross sectional area of the tensile specimen. Strain is defined as the amount of deformation, change in shape, a specimen has experienced when stressed. Strain is expressed as the length of elongation divided by the original length of the specimen prior to being stressed.
When the specimen is subjected to small stresses, the strain is directly proportional to stress. This continues until the yield point of the material is reached. If the stress were removed prior to reaching the yield point of the metal, the specimen would return to its original length and is, considered elastic deformation. However, stress applied above the yield point will produce a permanent increase in specimen length and the yielding is considered plastic deformation. Continued stress may result in some work hardening with an increase in the specimen strength. Uniform elongation will continue, and the elongation begins to concentrate in one localized region within the gage length, as does the reduction in the diameter of the specimen. The test specimen is said to begin to “neck down.” The necking-down continues until the specimen can no longer resist the stress and the specimen separates or fractures. The stress at which this occurs is called the ultimate tensile strength.
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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
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 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 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
Page 113: Bend Testing
Page 117 and 118: ASTM E290- Guided bend testing
Page 119 and 120: Bend Testing
Page 121 and 122: Bend Testing
Page 123 and 124: Knoop and Vickers Hardness Tester
Page 125 and 126: http://wes.ir/files/6936303material
Page 129: Rockwell hardness testing differs f
Page 132 and 133: Vickers hardness testing follows th
Page 135 and 136: http://www.twi-global.com/technical
Page 137: The type of notch and the impact te
Page 141 and 142: Online Metallurgy Course: http://ww
Page 143 and 144: Online Metallurgy Course http://210
Page 145 and 146: Online Metallurgy Course-Steel Maki
Page 147 and 148: 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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