WELDING INSPECTION AND QUALITY

CONTROL
Upon completion of this module you will be able to:
1. Identify the different inspection methods used
in non destructive testing.
2. The uses and the limitations of the different
inspection methods.

Common methods used in NDE

Visual Inspection (VT)
Magnetic Particle Inspection (MT)
Liquid (Dye) Penetrant Inspection (PT)
X-Ray inspection (RT)
Ultrasonic testing (UT)
Air or water pressure testing (LT)

VISUAL INSPECTION VISUAL TEST (VT)

I. What is Visual Inspection?
A. NDT process non destructive testing is the original term
used to identify a method of inspection that does not destroy a
product usefulness. Current terms include nondestructive
inspection (NDI) or nondestructive evaluation or examination
(NDE)
B. Examination with the eye therefore you are only able to
DETECT SURFACE DISCONTINUITIES.
C. Most important and most extensively used NDE/NDI/NDT
method (before any NDT or DT be applied.)
II. Advantages
A. Usually inexpensive - the majority of expense will be in the
inspectors wage.
B. Equipment is small and inexpensive theres a lot of
equipment to aid in visual inspection, but all small and
inexpensive.

C. No powered required this makes VT the most portable NDT

process.
D. Can avoid defects and costly repairs by able to make
intermittent inspection
II. DISADVANTAGES
A. Requires training and experience the inspector should be
familiar with all the welding process.
B. Must have a good eyes the AWS requires 20-40 natural or
corrected distance acuity for a certified welding inspector.
C. May not detect internal defects limited to surface
discontinuities only, but it might give indication of substance
indication. Then can be supplemented by some other NDT
method.
D. No permanent records the inspector must maintain a written
log, supplemented by pictures, and tape recorded report.
E. Subject to human error must spend adequate time to prevent
errors.

IV. Five steps of Visual Inspection.

A. Inspection practice establish a definite procedure to insure
adequate and consistent coverage.
B. Inspection prior to welding
C. Inspection during welding
D. Inspection after welding
E. Marking and making repairs
V. Equipment required.
F. Flashlight used to remove shadows when an extension lamp
cant be used.
G. Magnifying glass low power can be used with caution, if
allowed by customer or code.
H. Protective lenses pocket viewer with proper shade lens to
watch the welding taking place.
I. Weld gage are hand held measuring devices used to assist
during welding and for final inspection.

E. Hammer and chisel to remove spatter or slag from weld prior

to inspection.
F. Temperature Indicating Devices some method must be used
to determine the preheating, interpass and postheating
temperatures. Pyrometer and tempelstick or crayons are
commonly used.
G. Magnet a magnet can be used to help determine a materila
type.
VI. Inspection Before Welding
A. Drawing drawing are complete and accurate?
B. Position of welds does the position called for correspond to
the procedure or specification? In vertical is direction of travel
correct?
C. Welding symbols if they are used are they complete and
accurate?
D. Welding procedure is the procedure complete and accurate
according to the code or specification?

E. Material
1. Did purchasing obtain the correct material such as base
metal type and size. The correct electrode type size and the
correct shielding gas type and grade.
2. Materials should be checked for defects. Base metal should
be checked rust, mill, scale, laminations or delaminations.
3. Is the material preparation correct and according to
procedure, such as angles and condition after preparation.
F. Assembly
4. Inspect for proper fit up, as this will prevent discontinuities
from occuring.
5. Jigs and fixtures will assure proper alignment. Make sure they
are clean and free spatter and not damaged.
6. The tack welds are only short welds, but the quality must be
the same as all other welds. The tack welds must be made
with the same electrodes that are used for the rest of the
welds.

4. Pre heat will be used to slow the cooling rate and prevent
distortion. The pre heat could be used prior to tacking and / or
prior to welding.
G. Equipment
1. Inspect the equipment for any damaged such as damaged
cables, damaged ground clamps, or electrode holders. Inspect
the arc voltage and amperage meters making sure they are
with in range.
VII. Inspection DURING welding.
A. Electrodes inspect for usage of proper electrodes, types,
size and storage. Low hydrogen type must be stored in a
stabilizing oven.
B. Root pass the first layer or root pass is the most important
and is particularly susceptible to cracking. Thicker material will
crack and will require more pre heat.
C. Subsequent passes inspection of successive layers is
sometimes carried out with the assistance of workmanship

Standard. Check for contour or undercut as these are good places

for slag to be trapped. Check for proper cleaning between
passes as this can prevent slag entrapment.
D. Crater formation make sure crater are filled as this are areas
where crack are easily formed.
E. Weld size and sequence are the weld size according to the
print and is the layer and sequence according to the procedure?
The use of various gages will determine this.
VIII. Inspection After welding
A. The applicable code or standard it will list acceptance
standards They will generally cover the following areas;
1. Weld size use gages to check conformance to prints
2. Contour and finish is the contour convex or concave, and
what was called for in print? Is finish smooth and free from
surface irregularities.
3. Cracks the code or standard will state if any is acceptable
and what size.

4. Overlap it is an indication of lack of fusion

5. Undercut if allowed how much?
6. Spatter what is excessive?
IX. Making repairs
A. When marking areas to be repaired the marking should be
positive and clear. It should be a method that is understood by
all involved, should be permanent enough to be evident after the
repair has been made and inspected, and the marking must not
damaged the part.

Visual Inspection (VT)

Fillet gauges measure

The Legsof the weld
Convexity

(weld rounded outward)

Concavity

(weld rounded inward)

Flatness