Student Workbook Radiographic Film Interpretation _» of Weldments AeA ¢ Cf LOCC. Ry Quality Consulting Company, Inc. Milwaukie, OregonRadiographic Film Interpretation of Weldments Quality Consulting Company, Inc. Milwaukie, Oregon et it Radiographic Film Interpretation of Weldments - Student Manual - 1996 Radiographic Film Interpretation of Weldments Written and produced by Michael Rudarmel, Quality Consulting Company, Inc. Executive producer for the first printing - Bradley Thornton Edited by Lee E. Garrison Slides and illustrations by Michael Rudarmel, “The following people have been very instrumental in this production with their assistance and encouragement: Morrison-Knudsen, Boise, Idaho - Power Group: Rex Duke, Don Williams, ea John Cooley, Don Hoffstadt, Dave Marudas, Michael Dancisak Ruby Allen, Richard and Carol Stark, Harold Pinsch, Carl Shaw, Irene Fink, Karen Kemp, Bob and Leda Thorton. First Printing - 1984 Second Printing - 1996 © 1996 by Quality Consulting Company, Ine. All rights reserved. No part of this book may be repredneed in any form without permission in writing from Quality Consulting Company, inc. Printed in the United States of America @:; Quality Consulting Company, Inc. 5468 SE International Way, Milwaukie, Oregon 97222{WENDT Training Center u © @ Foreword This training program gives the instructor visual aids to train personnel in radiographic film interpretation of weldments. The visual aids are designed to initiate discussion and expansion of the subjects introduced in a classroom setting. It is intended to supplement curremt Level IL radiographic testing training programs in accordance with SNT-TC-1A. It can also be used to train non-Level II radiographic testing personnel who will be required to audit radiographic film. ‘This training program consists of an instructor's and student's text with illustrations, slides of », Tadiographs and illustrations, transparencies for overhead projectors, and tests. QW =s800 | gives general information on materials, joints, welding processes, radiographic techniques, codes. and standards. This lesson describes preliminary information. on radiography and welding necessary for the interpreter to make logical analysis when interpreting welds. , Lesson 2 covers false indications and their origins. Slides of false indications will be shown in this lesson. : Lesson 3 covers general discontinuities in weldments. The illustrations in this lesson are very valuable on the job site for assisting film interpreters in describing discontinuities on radiographs, Slides of discontinuities on radiographs will be shown in this lesson. Lesson 4 goes into the five basic welding processes: SAW, GMAW, GTAW, BCAW, and SMAW, and how each has unique discontinuities, Radiographic slides will be shown in this lesson as well as slides describing each welding process. A short test will be given at the end of each lesson to test competency. The preliminary examination, lessons 3 and 4 and the final examination have slides of radiographs as part of “tbe test. radiographic film interpreter is emerging as a professional engineer of stature and portance. This training program will give students the tools and basic knowledge necessary ‘o build their careers as professional radiographic testing interpreters. Interpretation of radiographs has always been subjective, varying by the degree of background and knowledge of the interpreter. This training program is designed to give interpreters a logical, systematic approach to interpretation, Most of the discontinuities shown on the slides have been verified visually on the surface of the weld or when they were ground out. There ‘may be some disagreement on the interpretations; that is expected. Use the knowledge gained in this course to argue the point and interesting discussions will develop. ‘WWW.NDT-IRAN.COM [email protected]iv Radiographic Film Interpretation of Weldments - Student Manual - 1996 ©BNE NDT Training Center Table of Contents Foreword .... Lesson Lesson * Lesson é Lesson Appendix A - Key to Radiographic Techniques .... Index of Terms... 1 - General Information. ‘The Radiographic Testing Method. ‘Steps in the Radiographic Test Factors Affecting the Interpretation of Test Results. Weld Joints and Processes. Procedures and Techniques. 2 - False Indications. Film Artifacts... Archival Storage of Conimercial Radiographs, Screen Problems and Film Fogging Scatter Radiation And X-Ray Difiraction.. False Indication Criteria. 3+ General Discontinuit Root Pass Discontinuities. Final Pass Discontinuities. Internal Weld Discontinuities. ‘Surface Preparatio 4 - Specific Welding Process Discontinuities ‘SAW - Submerged Arc Weldin, SMAW - Shielded Metal Arc Welding Definition of Radiographic Technique Symbols for Pipe Girth Welds Format for Radiographic Technique Symbolic Representation WWW.NOTIRAN.COM E-MAIL:[email protected]vi Radiographic Film Interpretation of Weldments - Student Manual - 1996 Q |Lesson 1 - General Information Lesson 1 - General Information A. Materials B. Joints C. Welding Processes D. Radiographic Techniques E. Codes and Standards ‘WWW.NDT-IRAN.COM E-MAIL:[email protected]@® Radiographic Film Interpretation of Woldments - Student Manual - 1996GNA NDT Training center Lesson 1 - General Information 3 e The Radiographic Testing Method f Film or Radioscopic é Screen: Flaw image A flaw such as a slag inclusion will allow more radiation to pass: through the flaw area of the weld than the surrounding areas creating a shadow image on the film or scintilating screen of an imager. Figure G-1. Producing the Image (Transparency # 1) ‘The Radiographic Testing Method is based on recording the varying degree of absorption of Penetrating radiation by an object, such as a weld. (Figure G-I), In conventional film radiography this varying degree of absorption produces a latent image of the object being examined on a film. The film is chemically processed, transforming the latent image into a permanent shadow image of the internal and external condition of the object. The rocessed film is called the radiograph. The radiograph can be interpreted and the integrity of e the object can be evaluated. WWW.NDTIRAN.COM E-MAIL:[email protected]RAVOSHGARAN BASER Q GOD fortrcinng con ee | 4 Radiographic Film, | | e Interpret - To give the meaning of; to explain. its - Student Manual - 1996 Evaluate - To determine the worth of something. Figure G-2. Key Words ‘The key function of the radiographic interpreter is to first interpret the radiograph or. give ~ meaning to the image produced on the film, Then second, to evaluate the condition of the pat of determine its worth for serviceability. (Figure G-2). i Indication A density change appearing on a radiograph False Film artifacts, screen problems, fog, Indications scatter, x-ray diffraction Discontinuity A Break in the test specimens structural continuity Defect A condition that renders the specimen unsuitable for intended service Figure G-3. Key Words ‘The terms presented in Figure G-3 are part of the vocabulary the interpreter uses to describe the condition of the radiograph or test object. ea ee ee, WWW NOTIRAN.COM [email protected]7A NOT Training Cen EE training Senter Lesson { - General information s& e Steps in the Radiographic Test Step 1 - Produce the radiograph Step 2 - Determine the quality of the radiographic image Step 3 - Interpret all indications Step 4 - Evaluate the test and test results Step 5 - Record and communicate test results oe Figure G-4. Basic Steps in the Radiographic Test Figure G-4 describes the five basic steps that are involved in the radiographic test. Step 1 - The radiographic technician is responsible for producing a radiograph that has, at least, the minimum quality level required by code or specification parameters. Step 2 - Upon receiving film from the technician, the interpreter must first determine the guality of the radiographic image. The interpreter must make an overall observation of the radiograph and determine if the parameters of the code or specification are met. These are some of the questions the interpreter must consider to determine the quality of the radiographic image: © Was the proper film used? é * Is the part and radiograph properly identified? * Have location markers been properly used? * Was the proper image quality indicator (I.Q.L. or penetrameter) used? Was it properly positioned? Have outline definition and hole or wire perceptbility requirements been met? * Is the density differential (if required) between the I.Q.1. and the weld within limits? iB + Is the density differential (if required) between the LQ. and the base metal or shim within limits? * Are false indications, such as diffraction, geometric distortion, or artifacts, present which may interfere with interpretation of the test object? WWW.NDTARAN.COM E-MAIL [email protected]6 Radiographic Film interpretation of Weldments - Student Manual - 1996 Even if the quality of the radiographic image is not acceptable, the rejectability of the object may still be determined by proceeding to step 3 and step 4, because other problems or obvious defects may be present. Step 3 - Next the interpreter must interpret all indications and determine their origins. © Are the indications on the film discontinuities, false indications, or artifacts? © If they are discontinuities, what kind are they? Are they slag inclusions, incomplete fusions, porosity, cracks, or what? Step 4- In this step the interpreter must evaluate the test and the test results, as required, by the applicable code or specification: © Is the radiographic test and image quality acceptable? @ If discontinuities are present, are they of such a size, location, or nature to render the object or weld rejectable? ; Step 5 - The final step in the radiographic test is recording the test results. The interpreter must not only be able to compile all of the information required in steps 1 through 4 on a written report or document, but als communicate the results to the proper individuals. In the case of poor or unacceptable radiographic images or technique, the interpreter must let the radiographer know of the problem, either verbally or by some written message, in order to make the appropriate corrections.BRIE _ NOT Training Center Lesson 1 - General Information Z Dato 9-gan-e4 Radiographic Examination Report [customer OGRA POSER MOAB SGPT Boise Power co. 361-200-1 Rov. 3 Jokn Miller Sob Raribar 361 pao waren M5-100-3 361-100-1 Rew 3 Carbon Steel and ANSI 831.1. Wo certify that the statements in this report are correct and that tho welds were oxamined in accordance with interpreter Customer Figure G-4a. Radiographic Examination Report WWW.NDT-IRAN.COM E-MAIL [email protected]8 Radiographic Film Interpretation of Woldments - Student Manual - 1996 Test results must always be récorded in the form of written reports and signed by the interpreter, These results must be clearly defined and legible. The report usually becomes a part of the master file of a component, is usually audited before final approval, and may be referred to many times during the life of the part. Clarity is crucial. ‘The proper fabricating, production, and/or management individuals must be informed of resulis. A system for communicating test results should be established, if it does not exist already, so that all parties concemed receive the results accurately and efficiently. This system may consist of color coding parts or welds, lists or summary reports, or a combination of these. Accurate and efficient communicating of test and test results will determine the success of any radiographic operation.BOFE NOT Training center” Lesson 1 - General Information 8 Interpreter Deverops| A Log Ot Results ‘Log Gopy To | [Color Code* Weids| [Retain Log For Production Personnel From Log Future Reterence| [Make Summary Reports] @e From Log *Color Code: Black - Reshot Red - Reject Green - Accept Figure G-4b, Typical Radiographic Communication System WWW.NDTJRAN.COM E-MAIL [email protected]on & “10 Radiographic Film Intorpretation of Weidments - Student Manual - 1996 Factors Affecting the interpretation of Test Results 1. Type of material(s) being welded 2. Type of weld and joint preparation 3. Welding process(es) 4. Radiographic technique 5. The applicable code or standard Figure G-5. Factors Affecting the Interpretation of Test Results In order to interpret and evaluate weldments, the interpreter must aoquire a general knowledge and understanding of the items in Figure G-5. ‘+ Type of Material Being Welded Certain materials produce unique characteristic results when joined by welding. The study of ‘metallurgical characteristics will not be exarpined in depth in this course, since the study is a science in itself. But exposure to and experience of the film interpreter to different materials and their characteristic discontinuities is of great value to interpreting test results. Without having a knowledge of the material being examined, the interpreter cannot draw the correlation between characteristic discontinuities or welding problems associated with the material. An interpreter working with a new material should dedicate time and care 10 observe characteristics which may be unique to a given material. © Type of Weld and Joint Preparation Itis obvious that in order to interpret a radiograph of a weld, one must first know its shape or cross sectional profile, * Welding Process ‘There are some discontinuities that are common to many different welding processes, and there are many discontinuities that are unique to a given welding process. For example, tungsten inclusions can only be present when using a welding process that uses a tungsten electrode, while slag inclusions can be produced by all processes that use flux shielding. Even though a discontinuity is common to many welding processes, the size, shape, and orientation of the discontinuity can be unique for each welding process. A slag inclusion produced by the SAW welding process usually looks very different from one produced by the SMAW welding process.Lesson 4 - General Information 1 * Radiographic Technique The image quality indicators tell the interpreter only that a minimum level of quality has been achieved. The competeat film interpreter must investigate further: * How sharp is the image? * Is the graininess of the radiograph making certain discontinuities difficult to detect or interpret? ¢ Ace geometric configurations causing geometric distortions or forward scattering problems? The interpreter must be looking for these problems and the many others that can affect his work. There is also the possibility that an additional radiograph may be required of a questionable indication for clarity. The interpreter may request the radiographer use a different film speed, a change of the radiation source angle, or varying the technique in some way to assist evaluation. The re-shooting of welds for clarity should be used very sparingly since it is oe an additional cost factor. é * The Applicable Code or. Standard Study. the code. If there are some points that need clarifying, confer with a competent individual. Some acceptance and technique standards can be a litle tricky, so be sure 10 take the time to get a good understanding of them and refer to them frequently while making evaluations. Consulting with other interpreters is not an indication of incompetence but is a way of expanding your knowledge, not to mention a way to break the stress and tension usually associated with film interpretation. WWW.NOTIRAN.COM E-MAIL:[email protected]12 Radiographic Film interpretation of Weldments - Student Manual - 1996 Weld Joints and Processes Lap Corner Tt Tee Figure G-6. Types of Joints Butt Edge Figure G-6 shows the five basic types of joints used in welding. The butt, comer, and edge joints are the most likely to be radiographically tested. The most common type of joint radio- graphed is the butt joint. All examples of welds in this course will be butt joint welds,awa” Lesson 1 - General Information 13 e ZAG i Za st Single Bevel 2a B22 Double Bevel Figure G-7. Variations of Grooves AN \\ A\\ Figure G-7 shows six variations of grooves that can be used in the preparation for a butt weld. Knowing the type of groove assists the interpreter in determining the type and the location of welding discontinuities. : e WWW NOT-IRAN.COM E-MAIL [email protected]14 Radiographic Film Interpretation of Weldments - Student Manual - 1996 A Grooves Grooves =e Double-V Groove (Welded From Both Sides) Figure. G-8. Butt Welds aa Bevel Groove Tequired, welding processes to be used, economics, skill level of welders, and configuration of the item being welded.BWA __NDT Training Center Lesson 1 - General Information 16 e Groove Angle > Bevel Angie Size ot /\ > /* Weld i Material Thickness _. L. Root Opening Root Face Groove Face Figure G-9. Groove Weld Nomenclature Figure G-9 defines the components of a prepared weld joint. AUl codes and specifications list the specific tolerances of these components. These parameters are a part of the welding procedure used to weld the joint, and the edge preparation is examined by a welding inspector prior to welding. This information should be readily available to the film interpreter to assist , him. Definition of terms in Figure G-9: Groove Angle: ‘The total included angle between the groove faces of the members being joined. Bevel Angle: The angle formed between the groove face of a member being joined and a plane perpendicular to the surface of the member. Groove Face: The surface of a member included in the groove. Root Face: Groove face adjacent to the root of the joint. Root Opening: The separation between the members to be joined at the root of the joint, Material Thickness: Thickness of material being welded. Size of Weld: This welding symbol describes the type of joint preparation and reinforcement, as well as the size of the weld. [email protected]|16 Radiographic Film Interpretation of Weldments - Student Manual - 1996 Cover Pass Hot Pass(es) Filler Pass(es) Figure G-10, Weld Layers Figure G-{0 defines the different layers of weld in a full penetration butt weld: Root Pass: The initial weld pass that joins two sections of material, sometimes called a Bead, Root Bead, Stringer, or Stringer Bead. Hot Pass: The second and sometimes third weld pass in a joint. Used to reinforce the root pass and sometimes push it through. Also used to ‘burn out “wagon tracks” on pipeline welding. Filler Pass: These passes fill out the majority of the remaining prepared weld joint. Cover Pass: ‘The final and finish layer of the weld, sometimes called the Cap. Parent Metal: ‘The actual sections being joined, sometimes called Base Material or Base Metal.awa neral Information Bree ) Vey Fe WWW NDT-IRAN.COM18 Radiographic Film Interpretation of Weldments - Student Manual - 1996 Procedures and Techniques Type of material radiographed Material thickness range Type of radiation source Effective focal spot or source size Film brand or type and number of film in a cassette Type and thickness of intensifying screens and filters Blocking or masking techniques (if used) Minimum source to film distance Exposure conditions for procedure qualification 10. Type and size of image quality indicator (IQ) nvr CHOHNDAMNAW Figure G-12. Radiographic Technique - Minimum Information ‘Almost all codes requite that production radiographic examination be performed in accordance with a written procedure. This written procedure will usually reference production procedures that take the form of a written radiographic technique. Details of the radiographic technique will always be available to the auditing inspectors, client representatives, and others who are charged with reviewing and interpreting production radiographs. Each radiographic technique is usually required to have the minimum information presented in Figure G-12.w awe Lesson 1 - General Information _ e ay 3-40-52 Radiographic Technique Sheet Txkaiun 192 Fin Maniac 5 dimstes Eastman Kodak aly cs} a 3_ [as requires [Preparetoy ohm Witter B.Ug Factor = 0.010" C. Maximum Viowing Arca per Exposure {8 1.9inchos por wall Figure G-13. Radiographic Technique Sheet The film interpreter must verify that a written radiographic technique exists and that the production radiography has followed the parameters presented within it, Figure G-13 is an example of a typical written radiographic technique. WWWNOT-IRAN COM E-MAIL [email protected]20 Radiographic Film Interpretation of Weldments - Student Manual - 1996 Radiographic examination performed in accordance with a general Cade(s) or Specification(s) Development of a specific pri Radlographic Techniques Figure G-14, Radiographic Examination Procedures Itis obvious from the aforementioned material that the interpreter is responsible for verifying a great deal of required information as well as interpreting and evaluating the radiographs of ‘welds. But what is the applicable code or specification? How and why ate specific project or job radiographic examination procedures developed? Figure G4 helps shed some light on how codes, specifications, procedures, and techniques interface. Many times an owner, company, or manufacturer may be required by law, or decide on their own accord, to build a product or construction in accordance with a specific code or specification (such as ASMEJANSI, API or AWS). Many of these codes are very broad and may extend beyond the scope of a particular project. Sometimes a combination of codes, or one that the owrier, company, or manufacturer has developed, will be employed. ‘The broadness, generality, and actual physical bulkiness of these codes or procedures has led to the development of Specific Project Procedures (specifications) to eliminate (in theory) confusion, not to mention, sometimes, heated arguments. Contractors bidding for work on a project may be required to submit detailed Specific Project Procedures, Included in these are written procedures detailing production radiographic and other non-destructive testing examinations. This project Radiographic Examination Procedure is extracted from the applicable project requirements of the referenced general codes or specifications. Once approved by the owner company or manufacturer, the project Radiographic Examination Procedure becomes the guideline or specification for Radiographic Examination. It is advisable that acceptance standards be included in this document to avoid cross referencing.BRIE NDT Troining Center —__ Lesson 1 - General Information bal Many codes will require that specific Written Radiographic Techniques supplement the @ Ruliographic Examination Procedure, providing a detailed account of how cach type of component is examined. Unique written radiographic techniques are usually required for each type or size of component or variation in the radiographic test. i Often the general code or specification is specific enough in its description of radiographic examinations that only the written radiographic techniques are required. It is possible that the radiographic contractor will be required to supplement the written radiographic technique with actual radiographs to demonstrate ability. No matter how or why the applicable code or specification is developed, itis the responsibility Of the interpreter to define, locate, and assure that all of the requirements are met. Ignorance of the requirements is no defense for improper film interpretation. e WWW NOTJRAN.COM E-MAIL:[email protected]22 Radiographic Film Interpretation of Woldments - Student Manual - 1996Lesson 2 - False Indications au NDT Training Center Lesson 2 - False Indications 23 A. Film Artifacts B. Screen Problems C. Scatter D. Diffraction E-MAIL [email protected]24 graphic Film Interpretation of Weldments - Student Manual - 1996BRPA NDT Training Center Lesson 2 - False Indications 25 False Indications Film Artifacts - Indications produced by improper manufacture or handling of film Screens - Film density changes due to flawed, damaged, or improperly cared for | screens | Fog - Density increase due to various radiation | sources | Scatter - A masking fog on a radiograph caused | by scatter radiation Diffraction- A reflected x-ray beam resulting in film mottling Figure F-1, False Indications this lesson, we will define, illustrate, and view some slides of false indications. False \dications are density changes on a radiograph that do not represent a true shadow image of the test specimen. Film artifacts, screen problems, fogging, excessive scatter radiation, and x- ray diffraction are examples of false indications. The film interpreter must be able to identify false indications, and distinguish them from indications of true discontinuities. (Figure F-1). WWW NOT-IRAN.COM E-MAIL [email protected]26 Radiographic Film Interpretation of Weldments - Student Manual - 1996 Film Artifacts SERRE Eee Protective Coating Emulsion Layer Acetate Base Emulsion Layer Protective Coating Figure F-2. Industrial X-Ray Film Film artifacts arc false indications produced by the improper. manufacture, handling, or processing of radiographic film. The following is a description of some of the many different film artifacts: Air Bells: Air bubbles formed on the surface of the film while developing. Light spots that are round will appear on the film 8 Contamination: ‘The cross mixing of processing chemicals in an automatic processor. Dark, smudged areas will appear on the film. Crimp Marks: Dark or light crescent shaped marks caused by sharp bends in the film that break-down the emulsion layer and protective coating. Most frequently, crimp marks are dark. Frilling: The loosening of film emulsion from its base caused by too warm or exhausted fixer solution. Light Leaks: Irregular black areas resulting from the exposure of film to light, Pi (n) Line: When using automatic processors with 1” rollers, the leading odge of the film strikes the first roller in the developer solution, producing a buildup of developer on the roller. After a full rotation of the roller, the buildup will be left on the film 3.14” from the leading edge of the film, producing a sharp or diffused dark line. Additional pi lines also are found at 3.14” intervals if the buildup is e excessive. Pressure Marks: Light or dark areas caused by physical damage to the film from pressure or blows,awe Lesson 2 - False Indications 27 Reticulation: Static Marks: Scratches Streaks, Water Spots: ‘Yellow Stain: Archival Storage Puckered of net-like film surfaces resulting from sudden extreme temperature changes during processing. Black matks with spider legs coming out of them, caused by discharge of static electricity. Scratches that damage the undeveloped emulsion will appear black after processing. Streaks are caused by dirty film hanger clips, insufficient agitation, film held in front of a safe-light after development (due to exposure of film to a safe-light while developer is running down), no wetting agent in wash cycle, and improper transport through rollers in a dryer (automatic dryets). May be caused by old, oxidized developer, omission of arresting development step (stop bath or rinse), or exhausted fixer. of Commercial Radiographs )Residual thiosulfate from fixer chemicals will deteriorate the finished radiograph with the passing of time. The film will become brittle and tum brown. For archival storage, film should have a minimum thiosulfate residue, which can be accomplished by proper washing after development. Some codes restrict the maximum level of thiosulfate residue allowed on processed film. Commercial test kits are available to test thiosulfate levels. Other storage considerations for storage of commercial radiographs: ¢ Temperature and humidity control. * Store film in interleaving folders inside of storage envelope. * Protect from’ bright light or sunlight. * Avoid pressure damage from stacking or forcing into storage area. WWW NDTIRAN COM E-MAIL [email protected]28 Radiographic Film Interpretation of Weldments - Student Manual - 1996 e Screen Problems and Film Fogging pie bog to bot bob go bobo bod Herororoer db totor go otor boy et terete YVVVVVVVVVVVVVYVVYV Back Lead Screen Figure F-3, Screen Problems: Figure F-3 shows how poorly maintained and damaged screens can result in false indications, by varying the quantities of electrons striking a film. Scratches may increase electrons striking a film, due to an increase in electron emitting surface, resulting in dark lines. Dirt, lint, grease, paper, etc., will absorb electrons, resulting ina decrease in film density.te KAVOSHGARAN BASER NDT Training Center Lesson 2 - False Indications ae Fogging is the result of excessive exposure to: 1. Radiation 2. Light (safelights included) 3. Heat 4, Humidity oe 5. Harmful vapors and gases © 6. Time (film is dated) Figure F-4, Sources of Fog ~ Precautionary measures should be taken to reduce the possibility of fogging film before or after exposure. Figure F-4 shows some possible sources. é WWWNOTIRAN.CO} [email protected]30 Radiographic Film Intesprstation of Weldments - Student Manual - 1986 Scatter Radiation And X-Ray Diffraction PRIMARY RADIATION Wall Flaws Specimen Floor a And Film Holder Figure F-5, Scatter and Diffraction Use Figure F-5 10 draw some sources of scatter radiation and x-tay diffraction, Scatter must be kept to a minimum so it does not interfere with interpretation of the test specimen. X-ray diffraction, the reflecting of the x-ray beam, can be identified by re-shooting an object, from a different angle to see a change in diffraction pattern, and can be reduced or eliminated by a change in radiation wavelength2 Muomoaan pacer NDT Training Center Lesson 2 - False Indications bat False Indication Criteria When does the appearance of a false indication render a radiograph unacceptable? Most codes and specifications state that any false indication that can mask or hide any true indication or in any other way interfere with the interpretation of a test object is unacceptable. WWW,NDTARAN.COM [email protected]32 Radiographic Film interpretation of Weidments - Student Manual - 1996434 Mevgsticanan nase Fd _ NOT Training Senter Lesson 3 - General Discontinuities 33 Lesson 3 - General Discontinuities A. Welding Discontinuities B. Surface Preparation C. Base Metal Discontinuities WWW.NDTIRAN.CO! E-MAIL [email protected]34 Radiographic Film interpretation of Weldments - Student Manual - 1896 e301 KAVOSHGARSH BASER FA MOT Trsining Center Lesson 3 - General Discontinuities 38 Discontinuities Discontinuity, for use in the nondestructive testing vocabulary, is a term that means any kind of flaw or lack of continuity in a material. In this lesson we will first define coramon terms used to describe these flaws, then look at some slides of actual discontinuities on radiographs. For demonstration simplicity, the illustrations of weld profiles, in this lesson, will be of single bevel open root butt welds, with root landings. Many other weld joint preparations are possible, as shown in Lesson 1, and it is imperative that the interpreter be aware of the joint configuration to make proper interpretations of weld discontinuities. Root Pass Discontinuities The root pass is the first weld layer in a weld joining two sections of pipe or material. An initial temporary weld of short length used to bold two sections of pipe or material together after proper alignment is called a tack weld. Whether the tack weld is removed, feathered, consumed, or is bonded to by the root pass is important information for the film interpreter. MAIL:[email protected]WAWNDT-IRAN.COM E-MAIL KBI@Kavoshgaranbaser. com19 MAVOSHGARAN BASER FA_ HDT Training Center Lesson 3 - Ganoral Discontinuities 37 e. Inadequate Penetration of Weld Groove - Top of Figure D-1 This discontinuity is defined as the incomplete filling (penetration) and tying-in (melting down and bonding) of the weld to the prepared weld groove at the root opening and/or root face, For single bevel welds, this discontimuity occurs at the bottom of the root opening and the groove bevel is not melted down, but is open to the surface. For weld joint preparations that require two-sided welding, this discontinuity is in the center of the weld and not open to the surface. Possible causes for this condition: (1) insufficient root gap at fit-up or when welding stresses reduced or closed root gap, (2) excessive root face, (3) welder skated the root and did not allow weld to penetrate root gap. This discontinuity appears on a radiograph as a-continuous ot intermittent line, raost often dark, but sometimes light, or parallel ines with a width that varies from thin and sharp to broad. * Inadequate Penetration Due to High-Low - Bottom of Figure D-1 High-low is a condition defined as the misalignment of pipe or material surfaces. Inadequate penetration due to high-low is where one edge of the root is exposed and has not been tied-in due to a high-low condition. This discontinuity appears on a radiograph as a continuous or intermittent line along the edge of the root pass, and most often appears dark, but sometimes appears white. ? WWW. NDTIRAN.COM IC [email protected]ing Center: mts - Student Manual - 1996 KA@VOSHGERSN BASER MDT Troini ‘lm Interpretation of Weldme: ii Radiographic Film SB | : é |NBD resonance 7 AMDT Training Center Lesson 9 - General Discontinuities Sad * Root Concavity (Suck Back) - Top Of Figure D-2 Root Concavity, Internal Concavity, Concave Root Surface, Concavity at the Root of the Weld, and Suck Back are terms that mean the root pass of a weld has penetrated and fused to the root face or weld groove opening, but the center of the weld is below the surface of the adjacent base. This condition can be caused by lack of sufficient weld filler material, improper welding travel speed, excessive joint fit-up gaps, and out-of-position welding. Root concavity appears as a darkened area in the root image. + Barn Through - Bottom Of Figure D-2 A Bum Through area is the portion of the root pass where excessive penetration or high heat has caused the weld puddle to be blown out of or through the root pass, leaving a round, elliptical or irregular hole in the root. The radiographic image is a round, elliptical, smooth, sharp or irregular dark indication in the root pass image. E-MAIL [email protected]8 & & 3 3 ag \uasicenan sasen 9 A__NDT Training Canter ee ti jeldments - Student hic Film Interpretation of Zi4 Root Pass (intemal) Undercut Fy Ml (Radiographic Image) Incomplete Fusion of Root Pass Sharp Straight Line {Radiographic Image) Figure 0-3. Root Pass Discontinuties WWW.NDT-IRANCOM E-MAIL:[email protected]if KAYOSHGARAN BASER FG NDT Training Center Lesson 3 - Genaral Discontinuities a4 e * Root Pass (Internal) Undereut - Top Of Figure D-3 Root pass or internal undercut is a discontinuity defined as a groove cut into the base material ‘on either or both sides of the edge of the root weld that is left unfilled by weld metal. This condition is usually jagged on the base material side, often appearing as a fingemail-type image, and somewhat straight on the weld side of the roct pass. ‘The darkness of the image of this discontinuity on a radiograph is determined by the severity of the condition (depth of the groove). Many times the internal undercut image is mistaken for | slag because of appearance. Possible causes for this discontinuity: (1) high-low, (2) to high of amperage, (3) wrong electrode angle, (4) welding out of position. * Incomplete Fusion Of Root Pass - Bottom Of Figure D-3 Incomplete fusion or fack of fusion of the root pass is the failure of the root face or root, area base material to be melted and fused to the deposited weld metal. This discontinuity will appeat as a sharp staight line along te edge ofthe root pass. Whenever a high-low condition exists, the interpreter should use an opaque mask to assure that the dark line is truly a : discontinuity, and not an optical illusion known as a mock band. WWW NOT-IRAN.COM E-MAIL:KBI@Kavoshgaranbaser comKAVOSHGARAN BASER raining Center NOT Tr igi jadiographic Film Interpretation of Weldmenis - Student Manual - 1 nt (High-Low) Misalignme: oo Ke at902 KAVOSHGERAN BASER 9A MOT Training Center Lesson 3 - General Discontinuities 43 * Hollow Bead - Top of Figure D-4 Hollow bead is an elongated gas pocket that tunnels down through the center of the root pass in the direction of welding. This discontinuity appears as a smooth, long dark indication in the center of the root and is sometimes confused with slag inclusions. * Misalignment (High-Low) - Bottom Of Figure D-4 Misalignment, sometimes called high-low or mismatch, refers to the centerline offset of two base materials being joined by welding. Misalignment is noticeable on a radiograph by the appearance of one side-of the weld being darker than the other side of the weld. WWW NOTIRAN.COM E-MAILKBI@Kavoshgaranbaser com12) KSYOSHSARSN BASER HDT Training Center 4a Radiographic Film interpratation of Weldments - Student Manual - 1996 (Radiographic Image) Vi, LT Oxidized Root (Radiographic Image) Figure D-4a. Root Pass Discontinuities WWW_.NOTIRAN.COM E-MAIL [email protected]AQ KAVOSHGARAN BASER 639 “Stor rrnng canter Lesson 3 - General Discontinuities as * Unconsumed insert - Top of Figure D-4a This discontinuity is the result of the consumable root insert not being melted and fused to the root joint. A high density area and outline of the insert will appear on the radiograph, * Oxidized Root - Bottom Of Figure D-da Oxidized root is the result of the root pass inside surface not having adequate protection from the atmosphere (shielding). The radiographic image of this condition will show a jagged and irregular transition at the root edges between the root pass and the adjacent parent metal. Weld tacks that have not been removed and were oxidized during fit-up are a common place to find oxidation. ~_ WWW NDTIRAN.COM [email protected]101 ty a6 Radiographic Film Interpretation of Weldments - Student Manual - 1996 Final Pass Discontinuities e The final pass, cover pass, or eap i he inal ayer of weld in a weld groove. The following are some discontinuities found in the final pass. Vi incomplete Fill of Weld Groove Straight Line (Radiographic image) 9 Incomplete Fusion (Top of Weld Groove) 8 Sharp Straight Line (Radiographic image) Figure D-5. Final Pass Discontinuities WWW NOTIRAN.COM [email protected]a KAVOSHGARAN BASER Pa__NOT Training center Lesson 3 - General Discontinui a7 * Incomplete Fill of Weld Groove - Top of Figure D-5 Incomplete fill occurs when the weld groove has not been filled with filler weld material, This condition appears as a dark straight line, along either edge of the cover pass. The image wicth and darkness will be determined by the amount of weld material not present. * Incomplete Fusion (Top of Weld Groove) - Bottom of Figure D-S Incomplete fusion at the top of the weld groove is the result of the base material not being melted and fused (bonded) to the filler weld material. This discontinuity appears as a dark, sharp straight line along the edge of the cover pass. ‘WWW.NOT-IRAN.COM, EAMAIL:KBI@Kavoshgaranbaser comZ dercut ACG . (Radiographic Image) aa ray ) YY Inadequate Reinforceme: (Weld Darker Than Parent Metal) 0 [Radiographic Image) Figure D6. Final Pass DiscontinuitiesLOL Seinen Lesson 3 - General Discontinuities ag * External Undercut - Top of Figure D-6 External undercut is a groove cut into the base material on either side of the top of the weld groove when welding the final pass that is left unfilled by weld metal. This discontinuity appears as a darkened image tat is usualy jagged and progresses out from the edge of the al layer. * Inadequate Reinforcement - Bottom of Figure D-6 ‘The inadequate reinforcement of the weld groove by weld material will result in a radiographic image of the weld being darker than the adjacent base material. WWW NOT-IRAN.COM E-MAIL:[email protected]ZA Excessive Reinforcement YZ 2 8 = g 3 2 & = < 5 3 2 " a \\' ¥ele & Boho Epa 2 el N Els « 2g 1 s N eB 6 ke 7 le im ¢ a & (Extremely Light Appearing Weld) : i ri 7 N kate i a (UG WWW NOT-IRAN.COM E-MAIL:KBI@Kavoshgaranbaseraa KAYOSHGARSN BSASER NDT Training Center Lesson 3 - General Discontinuities 51 * Excessive Reinforcement - Top of Figure D-7 Excessive reinforcement of the weld groove will result in a weld image that is extremely light and makes a sharp transition in density where the weld and base material meet. * Surface Porosity - Bottom Of Figure D-7 Surface porosity, or pinholes, are gas pockets that appear open to the weld surface. These discontinuities will appear as round dark images anywhere in the weld image. WWW.NDT-IRAN.COM E-MAIL [email protected]Internal Weld Discontinuities 7 ~—_Discontinuities that occus in the weld and that are not open to the surface are sometimes called internal weld discontinuities, * Slag Lines eee {Radiographic image) Slag Inclusions {CH {Radiographic image) Figure D-8, Internal Weld Discontinuities WWW NOTIRAN.COM E-MAIL:[email protected]i¢ KAVOSHGGRAN BASER NDT Training Center Lesson 3 - General Discontinuities 53 * Non-Metallic Inclusions (Slag Inclusions) Slag inclusions are oxides, flux, or other non-metallic inclusions that are trapped in the weld metal or between weld and base material. Sources of slag inclusions: (1) molten fluxes employed in welding process, (2) oxidized or dirty weld grooves, (3) failure to remove slag between passes. * Slag Lines - Top Of Figure D-8 Slag lines will follow a straight line in the direction of welding and will be located along the weld groove edge or between passes, following a valley left by each side of the weld groove between the root pass and hot pass. Slag lines produce straight, irregularly shaped dark lines of varying density on a radiograph. «Slag Inclusions - Bottom of Figure D-8 Slag inclusions may exist as isolated conditions or in random groups, and may take any shape or appear anywhere on the radiographic image. : E-MAIL;[email protected]Incomplete Fusion (Cold Lap) aight Line On One Edge Tungsten Inclusions Ee ° {Radiographic Image) Figure D-9. intemal Weld DiscontinuitiesGBA yesregicnn semen FA _NDT Training Center Lesson 3 - General Discontinuities 55 * Incomplete Fusion (Cold Lap) - Top of Figure D-9 Incomplete fusion, sometimes called lack of fusion or cold lap, is the lack of bond between the weld and the weld groove (base material) or between adjacent weld passes. Incomplete fusion may have slag associated with it, and is sometimes mistaken for slag. Incomplete fusion will appear as a sharp, straight, continuous, or intermittent dark line. It is sometimes straight on one side and irregular on the other where slag is trapped with the cold lap. + Tungsten Inclusion - Bottom of Figure D-9 When the tungsten electrode used in gas tungsten arc welding touches the base material or molten weld, pieces of tungsten from the electrode sometimes transfer into the weld and become trapped. Tungsten has a much higher radiation attenuation than steel and appear as extremely light spots in the weld image. E-MAIL [email protected]12) KAVOSHGERAN BASER 7 A__ NDT Training Center 56 Radiographic Film Interpretation of Weldments - Student Manual - 1996 Individual Cluster Wormhole Hollow Pores : Porosity. Porosity Bead Figure D-10. Intemal Weld Discontinulies * Porosity Or Gas Pockets - Figure D-10 Porosity or gas pockets are voids found in welds, Porosity occurs when gases in the molten weld metal do not escape to the atmosphere before solidification of the weld metal. Porosity usually appears as round dark spots with well defined contours, but may appear elongated. Random gas pockets appearing anywhere in the weld image are sometimes called individual ores, or if there are none adjacent to it within a certain distance, isolated pores. Cluster porosity is a group or cluster of pores. Wormhole or piping porosity is an elongated pore or a pore with a tail. A hollow bead is an elongated gas pocket that tunnels down the Center of the root pass and follows the direction of welding. EEE SEES WWW NDTIRAN.COM [email protected] __ Wwewapninascom meeeHQ] Gostesren secre FA__ NDT Training Center Lesson 3 - General Discontinuities 57 (Section Cut Through Centerline of Weld) On Figure 0-11. Weld Disconfinuities - Cracks | © Cracks - Figure D-11 Cracks are discontinuities resulting from the rupture of metal under stress. Cracks may occur anywhere excessive stresses exist (weld metal and/or base metal), and may have any orientation. A crack will appear as a dark, intermittent, broad, or narrow line, and may be | é straight, wavy, or zigzag. The following are the descriptive categories of eracks: Longitudinal Cracks Cracks that are approximately parallel to the axis of the weld. ‘Transverse Cracks Cracks that are close to being perpendicular to the weld seam. Crater Cracks Cracks that radiate out in many directions from a depression in a ; weld (Star Cracks). Base Metal Cracks Cracks that occur in the base metal in any orientation to the weld seam axis. WWW.NDT-IRAN.COM E-MAILKBI@Kavoshgaranbaser. comRadiographic Film Interprotation of Weldments - Student Manual - 1996 Excessive Weld Ripp! Weld Ripples And High Contrast a SS© RBA Stiyaremenn ores B50 “nor tcining center Lesson 3 - General Discontinuities 59 Surface Preparation ‘Most welds are subject to visual inspection by quality control inspectors prior to radiographic inspection. The inspector should assure that surfaces satisfy the requirements of the applicable material, welding, and visual acceptance specifications. Acceptance criteria should not only have parameters for open to surface discontinuities, maximum high-low, and weld seinforcement, but should include a statement such as the following: Surface preparation shall be required, as is necessary, to perform subsequent radiographic tests. Material surfaces, weld ripples, or weld surfaces irregularities on both the inside (where accessible) and outside, shall be removed by any suitable process to such degree that the resulting radiographic image, due to any irregularities, cannot mask or be confused with the image of any discontinuity. Figure D-12 gives examples of weld ripples or weld surfaces imegularities that make abrupt changes in contrast in the radiographic weld image which may mask or be confused with true discontinuities. WWWNDTARAN.COM ‘E-MAIL: [email protected]60 Radiographic Film Interpretation of Weldments - Student Manual - 1996 eBOD “otrinng center Lesson 4 - Specific Welding Process. Discontinuities Lesson 4 - Specific Welding Process Discontinuities A. SAW B. GMAW Cc. GTAW D. FCAW E. SMAW E-MAIL:[email protected] 6462 Radiographic Film Interpretation of Weldments - Student Manual - 1996 eLG] eeiceaan Basen NOT Training Center Lesson 4 - Specific Welding Process Discontinuities 83 @e SAW Submerged Are Welding GMAW _ Gas Metal Arc Welding | GTAW Gas Tungsten Arc Welding FCAW Flux-Cored Arc Welding SMAW Shielded Metal Arc Welding Figure WP-1. The Five Basic Welding Processes Figure WP-1 lists the five basic welding processes that are discussed in this lesson. As mention in Lesson 1, the interpreter must be aware of the welding process or processes used in making the weld that is being interpreted. Shielding used Weld metal composition Joint preparation and fit up Type of electrode Type of filler metal Welding pattern Figure WP-2. Factors Affecting Welding . NAwAWNE Figure WP-2 lists the general factors that differ from one welding process to another. Shielding quality Base metal quality Filler metal quality Base metal & weld metal compatibility Heat input angle of electrode Travel speed Current & voltage Welding position é CP RPNAWEWN YE Figure WP-3. Welding Variables Affecting Quality e@ Figure WP-3 lists some of the variables that affect weld quality. As we look at each of the five basic welding processes in this lesson, we will talk about these variables and how discontinuities are introduced when the variable parameters are exceeded. WWW.NDTIRAN.COM E-MAIL:[email protected]AGS “Stories cance ss. Discontint Lesson 4 - Specific Walding Pri 85 SAW - Submerged Arc Welding ‘The Submerged Arc Welding Process is symbolically represented by SAW. It is a process where the weld arc is totally submerged and not seen. * SAW Equipment Figure SAW-1 shows the equipment used in the SAW process. A flux blanket is laid down in the weld joint by the flux hopper. The filler wire, which also acts as the electrode, travels along the weld groove completely submerged by the flux blanket. The electrode wire feed rate and position are controlled by the wire feed motor and head control. The power supply controls the voltage and amperage. This process can be used semi-antomatically by the welder manually using a welding gun (orith a flux hopper attached) that automatically feeds and guides the electrode and flux at an automatic deposition rate. This process can also be used with fully automatic equipment where oo the work piece or the equipment is automatically manipulated. * How SAW Welds Are Made Figure SAW-2 shows how a molten weld metal puddle is formed when an electric current passing through the electrode wire produces an arc between the electrode and base metal. The granular flux blanket shields the arc and the molten weld puddle (which consists of molten weld metal and molten flux). The flux may contain deoxidizers, scavengers, and alloying ingealente tat modify the weld meal corapestion. Some fares contain powdered meal which actually becomes part of the weld metal. ‘The flux segregates (since it is Tighter) to the top of the weld puddle, where it solidifies over the top of the solidifying weld metal, creating a hard blanket (slag) that helps control the cooling rate. When the weld metal solidifies too quickly, gases can become trapped in the weld metal (porosity), and the weld metal can also tap the molten flux, before it segregates from the weld metal, and form slag inclusions. Also, if the root pass or base metal below the arc is too thin, e are will burn right through it. © Weld Layers And Joint Preparation Figure SAW-3 shows how two typical SAW joints are prepared. The left illustration would have the root pass welded by another welding process. ‘The right illustration shows how the root layer can be welded using SAW with the use of a backing bar. Square butt joints with no root gap and flux backing are used in double submerged arc welding procedures when the joint is Welded from both sides. « Typical SAW Discontinuities ‘When the molten weld metal does not melt the weld groove base metal or the edge of the adjacent weld pass, incomplete fusion is created and may have some slag trapped with it. Also along the edges of the weld puddle, slag may be trapped when the molten weld metal in that area cools too fast, or the flux is contaminated to a point that the molten slag does not easily float to the top of the weld puddle. These types of discontinuities will be in straight lines following the welding travel direction. NOT-IRAN.COM E-MAIL:[email protected]WAG S .. Gas Metal Arc Welding Figures GMAW, 2, &HG “Soriraming comer” Lesson 4 - Specific Welding Process Discontinuities 67 GMAW - Gas Metal Arc Welding GMAW represents the gas metal arc welding process. In this process the heat for welding is generated by an arc between the consumable electrode and the base metal. Shielding gas is supplied through an otifice in the electrode holder to provide a welding atmosphere for the electrode, arc, weld puddle, and base metal in the weld area. * GMAW Equipment Figure GMAW-I shows the equipment used in the GMAW process. A wire feed motor supplies the electrode gun with the consumable electrode wire. Shielding gas is supplied by tanks, of one form or another, and distributed over the weld area and electrode through a cup in the electrode gun to supply a suitable atmosphere for welding. The control system regulates the gas flow, current, voltage, and wire feed speed. &. How GMAW Welds Are Made Figure GMAW-2 shows the shielding gas coming out of the nozzle and creating a protective atmosphere over electrode, arc, molten weld metal, and adjacent base metal. The arc melts the electrode wire and base metal. The weld raetal is deposited by either globular, transfer spray, short circuiting transfer, or pulsed arc welding. Weld Layers and Joint Preparation Figure GMAW-3 shows a typical layering and sequence of welding with GMAW process. GMAW has relatively low base metal penetration characteristics, making it ideal on thin wall sections less than 0.375” thick. GMAW is also used on thicker wall sections. * Typical GMAW Discontinuities ‘Two of the most often found discontinuities are cold lap and incomplete penetration, due to its low penetrating abilities. Loss of the shielding atmosphere or improper shielding mixes will create porosity in the weld. Although no flux is used in this welding process, slag or other non-metallic material may be drawn into the molten puddle from oxides in the base metal WWW.NDT-IRAN.COM E-MAIL [email protected]Radiographic Film interpretation of Weldments - Student Manual - 1996 GTAW-3, Figures GTAW-1, 2, & 3. Gas Tungsten Arc Welding<3] Syosisenen, BASER FA NDT Training Center Lesson 4 - Specific Welding Process Discontinuities 63 @ GTAW - Gas Tungsten Arc Welding GTAW represents the gas tungsten arc welding process. In this welding process the electric arc created between an unconsumable tungsten electrode and the base metal produces the heat for welding. * GTAW Equipment Figure GTAW-1 shows that inert gas supplies the shielding at the arc through orifices in the torch. A tungsten electrode is located in the torch, as are cooling jackets to dissipate heat from welding. A foot pedal to control the heat input is often used. GTAW is used manually or fully automatic. * How GTAW Welds Are Made Figure GTAW-2 shows that the are between the tungsten electrode and base metal produces Wiib: teat to melt the base, metal and filler material and form a weld puddle. Gas shielding, coming from the water cooled torch, creates the shielding atmosphere that protects the arc, molten weld metal, filer rod, and adjacent weld areas. © Weld Layers And Joint Preparation Figure GTAW-3 shows the typical sequences and how GTAW welds are layered. High ~ quality welds with good base metal penetration are possible with high operator skill level. © Typical GTAW Discontinuities Loss of the shielding atmosphere or improper shielding gas can create porosity. The loss of intemal purge on stainless steel welds, and with other materials requiring intemal purge or backing, can cause oxidation of the root pass. Incomplete fusion, cold lap, and tungsten inclusions are common discontinuities. WWWNOT-IRAN.COM E-MAIL:[email protected]Radiographic Film Interpretation of Weldments - Student Manual - 1996 Figures FCAW-1, 2, & 3. Flux Cored Arc Welding e1OL Sores" Lesson 4 - Speelfic Welding Process Discontinui 71 FCAW - Flux Cored Arc Welding FCAW represents Flux-Cored Arc Welding. In this welding process the heat for welding is ovided by an electric arc between the tubular consumable electrode and the base metal. : hiclding for welding is produced by the flux inside the tbalar consumable electrode. ‘Auxiliary shielding may be provided as in the GMAW and GTAW processes. © FCAW Equipment : : Figure FCAW-1 shows the hardware used in the FCAW process includes an electrode gun writh an operation trigger, a wire feeder, elecuode wire spool, power supply, and control system. The use of shielding gas is optional and dependent on the wire and type of material being welded. | FCAW may be used roanually or with automatic equipment. * How FCAW Welds Are Made Figure FCAW-2 shows the shielding coming from the flux in the core of the wire and extemal : gas shielding the welding. The flux bubbles out of the weld puddle, becorsing molten slag and since itis lighter, it floats to'the top and forms a slag blanket. ©. Weld Layers And Joint Preparation Figure FCAW-3 shows the typical layering and welding sequences of welding with FCAW. ‘The left side ilustration shows how FCAW is layered when another welding process is used for the root pass. The right side illustration shows how FCAW can be used 100% with the use of a backing bar. + ‘Typical FCAW Discontinuities ‘The FCAW process has good penetrating capabilities, but the main discontinuities are slag entrapment and porosity, SEE Cee EE EEE PEE eee EEE PEE PEE EEE eee WWW.NDT-IRAN.COM E-MAIL [email protected]Radiographic Film Interpretation of Weldments ~ Student Manual + 1986 SMAW-3 Figures SMAW-1, 2, & 3. Shielded Metal Arc Weldingfag KAVOSHGARAN BASER ‘HDT Training Center Lesson 4 - Specific Welding Process Discontinuities 73 SMAW - Shielded Metal Arc Welding : SMAW represents the Shielded Metal Arc Welding process, commonly known as stick welding. * SMAW Equipment Figure SMAW-1 shows the hardware of this welding process is the electrode holder or stinger, a flux covered consumable electrode or rod, and a ground clamp. This welding process is extremely portable and versatile. * How SMAW Welds Are Made Figure SMAW-2 shows. how the electric are established between the flux covered electrode and base metal creates the heats necessary for welding. This heat melts the electrode's solid wire core and the base: metal, while at the same time decomposes and combusts the flux ating on the electrode. The decomposing flux coating creates a gas shielding atmosphere for the weld puddle and adjacent areas, and molten slag. “The molten slag acts as a scavenger of impurities, and since it is lighter than the weld metal, it floats to the surface of the weld. On the surface of the weld, it cools and forms a slag blanket. © Weld Layers And Joint Preparation Figure SMAW-3 shows one of the many possible welding sequences and layering used with SMAW, * Typical SMAW Discontiaui SMAW welding can have almost the entire spectrum of welding discontinuities. This welding process is considered by many the most difficult for making radiographic interpretations. The reasons for this are: © General Surface Condition - Although many highly skilled welders make smooth and & precise cover and root passes, the weld surfaces will, many times, have valleys and ripples that make interpretation difficult. ; © Discontinuity Orientation - Slag, incomplete fusion, porosity, and other discontinuities have a more random orientation in the weld than with other welding processes. © Identifying Specific Type of Discontinuity - A slag indication in a weld which, with a certain code, has an acceptable length, may be easily confused with incomplete fusion, in the SMAW process, or visa-versa, which makes final evaluation of a weld difficult - especially if incomplete fusion is not acceptable. ‘WWW.NOT-IRAN.COM E-MAIL:[email protected]74 Radiographic Flim Interpretation of Weldments - Student Manual - 1996KAVOSHGARAN BASER NDT Training Center Appendix A - Key to Radiographic Techniques Appendix A - Key to Radiographic Techniques WWW.NDT-IRAN.COM [email protected] 7576 Radiographic Film Interpretation of Woldments - Student Manual - 1996 Definition of Radiographic Technique Symbols for Pipe Girth Welds © Diameter of Pipe: Nominal pipe diameter and/or true diameter © Film Type: Kodak Products R,M, T, TMX, AA, AX GAF Products 100, 200, 400, 800 AGFA Gevaert Products D2, D4, DS, D7 Dupont Products 45, 55, 65,75 © Pipe Schedule or Wall Thickness: If thickness is not represented on pipe chart schedule, use actual thickness to nearest 0.001” with thicknessés less than one inch, and nearest 0.05” for thicknesses greater than one inch, .* Type of Exposure: D Double wall er Panoramic S Single wall E Elliptical + Source Position, Radiation Path, or Type of Viewing: C Source is in contact with the outside wall, opposite of the weld being examined/film outside (Always single wall viewing). 6 Symbols that correspond to Single Wall Exposure (S) (always single wall viewing): I Source inside on opposite wall of weld being examined / film outside. © Source outside / film inside ‘Symbols that correspond to elliptical exposures: 1 Single wall view (May have increased SFD or FFD to meet Ug Factor). D_ . Double wall view. S1' Superimposed weld / single wall view $2 Superimposed weld / double wall view Panoramic has no corresponding symbol and stands alone (always single wall viewing).G1 Sorin ane” Appendix A - Key to Radiographic Techniques e * Additional Information Radiation Source: CO6O Colbalt 60 XR X-ray generator blank Iridium 192 Other: (VLT) . Vesselet type welds WWW.NDTIRAN.COM E-MAIL:[email protected] 777a Radiographic Film Interpretation of Weldments - Student Manual - 1996 Format for Radiographic Technique Symbolic Representation * Table of Examples [ecinique ‘Symbol J 3M-40-D [4M-80-E1 a) somsTDP | 10(55)-655-DC “3D5-40-ED (XR) Damen [| ate | | * | ‘Type of Exposure Source Position / Radiation Path /BGG Mor training center Appendix A - Key to Radiographic Techniques 79 @ * Lescription of Examples 1.3M-40-DC 3 M 40 D c (blank) 2. 4M-80-El (VLT) 4 3. 30M-STD-P 30 4, 10(55)-655-DC 5.3DS-40-ED (KR) é 3” Nominal pipe diameter Kodak “M” film Schedule 40 Pipe Double wall exposure Contact position (always single wall view) Iridium 192 source 4” Nominal pipe diameter Kodak “M” film Schedule 80 Pipe Elliptical Exposure Single wall view Iridium 192 source technique developed for a vesselet type attachment to Pipe 30” Nominal pipe diameter Kodak “M” film Standard wall thickness Panoramic exposure (always single wall view) Iridium 192 source 10” Nominal pipe diameter Dupont 55 film 0.655” wall thickness Double wall Contact position (always single wall view) Iridium 192 source 3” Nominal pipe diameter Agfa Geveart D-5 film Schedule 40 Pipe Elliptical exposure Double wall viewing X-ray radiation source WWW. NOTIRAN COM [email protected]80 Radiographic Film Interpretation of Weldments - Student Manual - 1996 Index of Terms cold lap. consumable electrode. contamination 23 ‘conventional film radiography 3 corner joint. 1 cover pass. 15, 36 cracks. crimp marks... cross sectional profile. D iftaction iscontinuit discontinuity orientatio high-low. hollow bes hot pass... I image quality indicator. image quality indicator (LQD, joint configuration. L lack of fesion.. ‘stent image. light leaks. location longitudinal cracks.. M material thickness. misalignment. 0 oxidized root.BOL rosisenar BASER FA_ NOT Training Center Index of Terms 81 a : ae 33,37 UL, 14, 30, 31, 49 50, 51, 53, 55, 57 3 9, 47 16, 56, 58 6,7 scratches . screen problems... 7 shielded metal arc welding single walt ...->. size of weld stag inclusions... slag lines. source position.. specification ® tungsten inclusion u ee oe ‘WW NDT-IRAN.COM E-NAIL:[email protected],a2 Radiographic Film Interpretation of Woldments - Student Manual - 1996Asm sec 8 Owl @ bon dey > frssre vessel Gale APPENDIX 4 ROUNDED INDICATIONS CHARTS ACCEPTANCE STANDARD FOR RADIOGRAPHICALLY DETERMINED ROUNDED INDICATIONS IN WELDS 4 APPLICABILITY OF THESE STANDARDS ‘Thee sundards ate applicable 10 Ferrite, austenite. and nonioarous. materials 2 TERMINOLOGY (0) Rounded fndicotions. Indications with a maximum length of three times the width of fess on the radiograph ate defined as rounded indications. These indications may fe cirplar, elliptical, comteal. or regular in shape lind may tase wails, When evaluating the size of 2 Chcaton. the tail shall be included. The indication mop be ftom any imperfection in che weld, such 35 poroay. slag. oF tangsten ‘hy tligned Indications, A sequence of four oF more rounded indications shall be considered to be alizned when they touch a line parallel to the length of the Weld drawn through the center of the two outer rounded nications. {c) Thucbvess 1 is the thickness of the weld, ‘excluding any allowable reinforcement. For a-butt weld Joining to members kaving ‘diferent. thicknesses at the weld 75 the thinnet of these (wo thicknesses. IF 4 fall penetration weld inchudes a filler weld, the Uhicknes of the throat oF the fillet shall he included 43 \ ACCEPTANCE CRITERIA * tay Image Density. Density within the image of the indicamn may vary and i nok a enterion for acceptance we reocton ont anoricaa gociety of Mechanical: Segsaeers SoU ny Tatormeion sandliog Services hy Relevant Indicamions. (See Table +1 for exam ples.) Only those rounded indication. which exceed the ‘dimensions shall be considered fetevant fu for Tess than ig 19, (3.2 cum fain for F team "ein. t@ Sy iw. & 6 sna. incl Vip in for greater han “% in. to 2 in 16 ee to 31mm). int Ve tt for F greater chan 2 (84 ct fe) Maximum Size nf Reninked Inicton (See Table 4-1 for examples) The masimuin permisuible size of any indacanon shall he “t,or i. chen), whichever js smaller except that an isplated indication separated from an adjacent indication by 1 in, 23 «mm or more nay be "at, oF Ye i. (6 mim). whichever 1s hss For f areater than 2 in, SE mumd the maximum permissible sire of an isolated indication shall be ancreased 10° in, (10 wom) 1d) Alngned Rounded Indicunons Niignoh rovndes ‘edicaions ave acceptable when the sumntatvn of the diameters of the indications is less than f in.a length of 12: See'Fig. 4: The length of groups of aligned rounded indications and the spacing between the soups Shall meet the requirements of Fig. +2. (@) Spacing. The distance between adjacent rounded indications 4s not a factor in determining acceptance fr rection, except as required for isolated indications foe groups: of align indications, (fi Rounded bidicctton Chars. The wdc se tions characterized ss immperCecrens shall aot cxeeed that shown in the charts. The charts n Figs, 4-3 ewouh {28 ilustate various cypes of assured. randomly dis+ persed and clustered rounded indications fr diferent field thicknesses wreater than '% rn. (32 many, These chars repeesent the maximum acceptable concentration w for eounded indications The cuts for cach200} SECTION VS ~ DIVISION t 43 ' TABLE thickness range represent fulkscale 6 radiographs, Tr Ey and sha not De enfarged of reed The dearbutons ae tet shown are not necessaints the putters that may appess Maxinum Size of ‘on the radiograph, but are typrcal of the concent Accepuable Rowse and size of wdications permned Maxiour Size of ‘enrsieart 1g) Weld Thickness 1 less than "y fo. (22 mo). For tess than ' in, (32 mm) the maximum nursber of rounded indications stall aot exceed (2 in a 6 i (152 me) length of weld. A proportionally fewer amber of indications shall be permitted in welds less than fn, 152 a) 99 kenge {iy Chotered Indes The Susans for shi a aon tered indications show up 0 four times a5 many indie _ so tons in tcal ea a that sha wt the tases : aes oot for random mditons The length 0 a9 accepablc Closer shall not evesd the leser of Lom (23 9m) Oe aon fr 2r Where more thon ne cht preset the 3s Naa eae 308 OF the lengths of the sey stall ot exezel “ See. boat (25 mm) in a 6 in. (152 mms lenyth weld, : Mowe ons S95 now St Units i : iar Si _ ‘Acceptable Rounded aN Rae ena Sa of Wits rion ‘me Rowen tained tact, asad ose ue Soe st 2 tue a on aramess 33 aon a8 ye ur Se ' vata on Be 3m 5p of Blom ba °° ' 19.010 50.8, lect. 396 eas a7 Owrsns 3m 953 te nore 1 Fe Table coos examples ony sit Anecican society of Machaaical Sogineers oy Tulocwation Baadiiag Services‘4 SnoULwoIaN! oaaNnOY OBNETTY Jo SanoUD 2-914 pou a zon . | a + g - ! 3 Ps 2 5 SNOLLYOIONI OBONNOY GANDHI TP DLs 121 40 8u9] ©) vow Bae us "7 24740 wns 3L0N WHENED i q a, sy of 4 g2001 SECTION Vill — DIVISION 1 Fig 4 U1 sintesmm | tine) | (b)totated indication (See Note (21 {e) Custer r Nores: [Typical concentration and site permitted in any Bin. (252 mm’ iength of wets 12) Maximum size perTable 4.1, FIG. 4.3 CHARTS FOR ¢ EQUAL TO % in. to Yin, INCLUSIVE 1025 ene tin (25mm) \ to) teolated incation (See Note (21 fe) Custer Notts: Fb Typical concentration and ste permined in any 6 in. 1152 mi tenth of wei. 12} Masimam size perTable 41 FIG. 44 CHARTS FOR COVER % in. to % in, INCLUSIVE, 586 ir Anectcan saciaty of Mechanical EaginoersAPPENDIX 4 — MANDATORY Fig 45 Bie 28mm) f | tn. 25 me (b) ttotated indication See Note (2H (eicuster ores: UG) Typical concentration and size parmitiad in any 6 in. (152 mimi length of wel. (2) Maxcenom size perTable 4-1 Mechanical Sagiceers Jel ep"Eaicrmation ‘wading Secvices7 200} SECTION VIE — DIVISION 1 {a} Random Rounded indications [See Note (1) : . . 1 (28 mem) +n. 25 nm) {8 lectnte indication (See Note (2) {eraser ores 11) Typica! concentration and size permitted in any 8 in. (152 mm} length of weld. {2} Macmur ae perTable 41. @ FA. 44 CHATS FOR VER % mo 2, NELUSVE Secitey af mechanical Bra: Taation saad! ing ServsceeAPPENDIX 4 — MANDATORY {a1 Random Rounded Indiestions [See Note (1}] (b) isolated Indication (See Note (2 {e)Cuscer ores: 1) Typieat concentration and size permite in any 6 (152 meena of wate {2} Mosimam size per Table 41, FIG, 47 CHARTS FOR £ OVER 2 in, to # in, INCLUSIVE 359fig os 2001 SECTION Vill — DIVISION ' l in (25 mony Tin. (25 mm) oe (6) tnoated lication [See Note (21 focuser NOTES: 11) Typical concentration and sizapermitad in any 6 in. (152 me} length of weld (2) Maximum size per Table 4-1 . FIG. 4.8 CHARTS FOR £ OVER 4 in. Quvowseccnase:API Sticano 1104 SECTION S—INSPECTION AND TESTING OF PRODUCTION WELDS: 5.1. Rights of Inspection ‘The company shall have the right to inspect all welds by nondestructive means or by removing welds and subject- ing them to mechanical tests. The inspection may be made uring the welding or after the weld has been completed. ‘The frequency of inspection shall be as specified by the company. 5.2 Methods of Inspection Nondestructive testing may consist of radiographic in- spection or another method specified by the company. The ‘method used shall produce indications of defects that can ‘be accurately interpreted and evaluates. The welds shall be evaluated on the basis of either Section 6 or, at the com- pany’s option, the appendix to this standard. tn the latter case, more extensive inspectiog to determine the flaw size is required, si Destructive testing shall consist of the removal of com- pleted welds, the sectioning of them into specimens, and the ‘examination of the specimens. The specimens shall be pre- _ pared in accordance with and shall meet the requirements of 3.5, The company shall have the right to accept or reject any ‘weld that does not meet the requirements for the method by which it was inspected. The welder or welders who make a weld that fils vo comply with the requirements may be dis- {qualified from further work. ‘Operators of nondestructive inspection equipment may be required 10 demonstrate the inspection procedure's capability to detect ejectable defects and the operator's ability to prop ‘tly interpret the indications given by the equipment. ‘Trepanning methods of testing shall not be used. 5.3. Qualification of Inspection Personnel ‘Welding inspection personne! shall be qualified by expesi- ‘ence and training for the specified inspection task they per- form. Their qualifications shall be acceptable to the company. Documentation of these qualifications shal! be retained by the company and shall include but is not limited to he following. a. Education and experience Training Results of any qualification examinations. 5.4 Certification of Nondestructive Testing Personnel 8.4.1. PROCEDURES Nondestructive testing personrel shall be certified in ac cordance with the recommendations of ASNT Recom ‘mended Practice SNT-TC- 1A for the test method used. Only Level I or HT personne shall interpret test results, 542 RECORD A record of cerified nondestrctve testing personne! sball be kept by the company. The record shall include the resus of certification tess, the agency and person granting cerif cation, and the date of certification. Nondestructive vesting personnel may be required tobe recertified atthe companys ‘option or if any question arises about cheie ability. Level ‘and I nondestructive testing personel shall be recertified at least every three years. Level IIT nondestructive testing per- sonoel shall be recertified atleast every five years. SECTION 6—ACCEPTANCE STANDARDS FOR NONDESTRUCTIVE TESTING 6.1 General “Te accepaice standards presented in this Seton apply > discontinuities located by ediographie, magne parle. iquid penetrant, and ultrasonic test methods. They may also applied ro sual inspection, Nondestructive testing sal tor be used to select welds hat are subjected 0 desetve testing in accordance with SL 6.2 Rights of Rejection All nondestrucuve test methods are limited in the informa- ‘uon that can be derived from ihe indications they produce. The company may therefore reject any weld that appears 0 meet these acceplance standards if, in its opinion, the depth ‘ofa discontinuity may be detrimental co the weld. 6.3 Radiographic Testing Noe: Al densest on 6.1 hough 63.42 ar based 09 magne ‘ages 62.1 Iwapequare PeNeTRaTiON( L. op) Inadequate penetration without high-low (IP) is defined as the incomplete Filling of the weld root. This condition is shown schematically in Figure [3. IP shall be unacceptable ‘when any of the following conditions exists:Weioe oF Prune ano RewareD Faces a th sent tg we cm tt npn ttn + Figure 13—Inadequate Penetration Without High- Low (IP) ‘The kagth of an individual indication of I exceeds 1 inch (25.4 reillimeter) ». The aggregate length of indications of IP in any continu- cous !2-inch (304 8.ilimete) lenge of weld exceeds 1 inch (25.4 millimeters). , . The aggregate length of indications of IP exceeds 8 per- cent of the weld length in any weld less chan 12 inches (304.8 millimeters) in length 6.3.2 INADEQUATE PENETRATION DUE TO HIGH-LOW Inadequate penetration due o high-low (IPD) is defined as ‘the condition that exists when one edge of the root is ex- posed (or unbonded) because adjacent pipe or firing joints {¢ misaligned. This condition is shown schematically in Figure 14. [PD shall be unacceptable when any of the fol lowing conditions exists: 1. The length of an individual indication of IPD exceeds 2 inches ($0.8 millimeters). '. The aggregate fength of indications of IPD in any contin- ‘uous 12-inch (304.8-millimeter) length of weld exceeds 3 inches (76.2 millimeters). 6.3.3 INCOMPLETE FUSION ¢ LoF) Incomplete fusion (IF) is defined as a discontinuity be- tween the weld metal and the base metal that is open to the surface. This condition is shown schematically in Figure 15. IF shal! be unacceptable when any of the following condi- sions exists 4. The length of an individual indication of IF exceeds t inch (25.4 millimeters). , The aggregate length of indications of IF in any continu. jas !Z-inch (304 f-nllimeter) length of weld exceeds I inch 25.4 milhimeters) ‘The aggregate length of indicztions of IF exceeds 8 per cent of the weld Jength in any weld less than 12 inches, (304.8 millimeters) in Fength, Ce arp sai 6.3.4 INCOMPLETE FUSION DUE TO COLD LAP Incomplete fusion due o cold lap (IFD) is defined as adis- ‘continuity between two adjacent weld beads or between the ‘weld metal and the base metal that is not open to the surface ‘This condition is shown schematically in Figure 16. [FD shalt ‘be unacceptable when any of the following conditions exists 4. The length of an individual indication of IFD exceeds 2 inches (50-8 millimeters). '. The aggregate length of indications of [FD in any contin- uous {2-inch (304.8-millimeter) length of weld exceeds 2 inches (508 millimetes) . The aggregate length of indications of IFD exceeds 8 per- cet ofthe weld length. 6.3.5 INTERNAL CONCAVITY Internal concavity (C) is defined in 1.2.2.13 and is shown’ ‘schematically in Figure 17. Any length of internal concavity is acceptable, provided the density of the radiographic image ‘of the internal concavity does not exceed that of the thinnest ‘adjacent base metal. For areas that exceed the density of the thinnest adjacent base metal, the criterie for burn-through ‘Gee 6.3.6) are applicable. 6.3.6 BURN-THROUGH 6.3.6.1 A bun-through (BT) is defined as a portion of the root bead where excessive penetration has caused the weld ‘Puddle to be blown into the pipe 6.3.6.2 For pipe with an outside diameter greater than or ‘equal to 2K inches (60.3 millimeters), « BT shall be unac- ceptable when any of the following conditions exists: ‘a. The maxixaum dimension exceeds ' inch (6.35 millime- ters) and the density of the BT's image exceeds that of the thinnest sdjacent base metal 'b. The maximura dimension exceeds the thinner of the nom- inal wall thicknesses joined, and the density of the BT's im- ‘age exceeds that of the thinnest adjacent base metal ‘c. The sum of the maximum dimensions of separate BTs ‘whose image density exceeds that of the thinnest adjacent base metal exceeds 2 inch (12.7 millimeters) in any contin. ‘vous 12-inch (304 $-millimeter) length of weld or the (oral ‘weld length, whichever is less. 6.3.6.3 For pipe with an outside dismeter less than 2% inches (60.3 millimeters), a BT shall be unacceptable when any of the following conditions exists: 1, The maximum dimension exceeds % inc: (6.35 nullime: ters) and the density of the BT's image exceeds that of the thinnest adjacent base metal ». The maximum ¢ mension exceeds the thinner of the nom. inal wall thicknesses joined, and the density of the BT's im. age exceeds that of the thinnest adjacent base metal Siegese beet st Figure 14— inadequate Penetration due to High-Low (IPO) ordi abeant| ‘S ortace connected Figure 15—Incomplete Fusion at Root of Baad of Top ot Joint (IF) Cota tp betwen Colt ap betwen ‘djacent beads ‘wold Dead and base mata Nowe: The cold ap sbown ot surface cognate. Figure 16—Incompieta Fusion due to Cold Lap (IFD) Root omad s fused to both surfaces, uk comte ef root paso sight Below ‘be ploe'sinsce sutaco Figure 17—Interal Concavity (IC)Wena oF Peeines mp RELarco Facues 2 ‘5 More than one BT of any size is preseat and the density of ‘oce than one of the images exceeds that ofthe thinnest ad- jacent base mesal 6.3.7 SLAG INCLUSIONS. 6.3.7.1. A slag inclusion is defined as « nonmetalic solid entrapped in the weld metal or between the weld metal and the pipe metal. Elongated slag inclusions (ESIs)—for exam- ple, continuous or broken slag lines or wagon tracks—are usually found at the fusion zone. Isolated slag inclusions (SIs) are iegularly shaped and may be located anywhere in the weld. For evahuation purposes, whea the sizeof aradio- _graphic indication of slag is measured, the indication's max- imum dimension shall be considered its length. 6.3.7.2 For pipe with an outside diameter greater than or ‘equal 10 24 inches (60.33 millimetcrs), sag inclusions shall be unacceptable when any ofthe following conditions exists: a. The length of an ESI indication exceeds 2 inches (50.8 snillimeters). ‘hal be soniezed sept intvcaions, '. The aggregate length of ESI indications in any continuous 12-inch GOA. 8-millimeter) length of weld exceeds 2 inches (508 millimeter). , The width of un ESI indicatiom exceeds Yo inch (1.$9 mil limeters) d. The aggregate length of ISI indications in any continuous 12-inch (304 8-millimeter) length of weld exceeds 4 inch (127 millimeters) «. The widih of an ISI indication exceeds 4 inch G17 mil fimerers). {. More than four ISt indications withthe maximum width ‘of & inch (3.17 millimeters) are present in any continuous 12-inch (304.8-millimeter) length of weld. 1. The aggregate length of ESI and ISI indications exceeds 8 percent ofthe weld length {8.3.7.3 For pipe with an outside diametes less than 2 ‘ches (60.3 millimeters). slag inclusions shall be waaceept- able when any of the following conditions exists a The length of an ESI indication exceeds three times the thinner of the norsinal wall thicknesses joined. ‘owe: Pale ESI ndcabons separa by approimately be wit of he “oor bead gon ack) shalt De Coasidered using adcaion ones he Pian ot cide oem exccds ic (075 ieee. na even ey rat be somsered wpurme indicatons 5. The width of an ESI indication exceeds Ms inch (1.59 rail- larmeters), = The aggregate length of ISt indications exceeds two times. the thinner of the nomiaal wall thicknesses joined and the width exceeds one-half the thinner of the nominal wall thick: nesses joined. 4. The aggregate length of ESI and ISI indications exceeds 8 percent of the weld length. 63.8 POROSITY 6.3.8.1 Porosity is defined as gas trapped by solidifying weld metal before the gas has » chance to rise to the surface Of the molten puddle and escape. Porosity is generally spherical but may be elongated or irregular in shape, such as piping (wormhole) porosity. When the size of the radio- graphic indication produced by s pore is measured. the max- imum dimension of the indication shall apply to the criteria given in 6.3.8.2 through 6.3.8.4. 6.3.8.2 Individual or scattered porosity (P) shall be unac ceptable when any of the following conditions exists 1 The size of an individual pore exceeds inch (3.17 millimeters). b. The size of an individual pore exceeds 25 percent of the thinner of the norninal wall thicknesses joined. ¢. The distribution of scattered porosity exceeds the concen tration permitted by Figure 18 or 19. 6.3.8.3 Cluster porosity (CP) that occurs in any pass ex- ccept the finish pass shall comply withthe criteria of 6.3.8.2, CP that occurs in the finish pass shall be unacceptable when any of the following conditions exists ‘a. The diameter of the cluster exceeds inch (12.7 millime- tes). b. The aggregate length of CP in any continuous 12-inch (306.8-millimeter) length of weld exceeds % inch (12.7 millimeters). cc Am individual pore within a cluster exceeds Minch (1.59 sillimeters) in size, 6.3.8.4 Hollow-bead porosity (HB) is defined as elongated linear porosity that occurs im the root pass. HB shall be un- acceptable when any of the following conditions exist: a The length of an individual indication of HB exceeds * inch (12.7 millimeters). b. The aggregate length of indications of HB in any contin- ‘yous 12-inch (304.8-millimeter) length of weld exceeds 2 inches (50.8 millimeters) ¢, Individual indications of HB, each greater than % inch {6.35 millimeters) in length, are separated by less than 2 inches ($0.8 millimeters). 4. The aggregate length of all indications of HB excceds percent of the weld length: 63.9 CRACKS Cracks (C) shall be unacceptable when any of the follow. ing conditions exists®e. peso 0 =— pete | ae sttile aie e@ Ce eed Not: The sie ofthe as pokes is ot deve scale: for dimension, eft 6.3.4. Figure 18—Maximum Distribution of Gas Pockets: Wall Thicknesses Less Than (oF Equal to 4 Inch (12.7 Milimaters)Now: The of the gs port it no drawn 0 sl: for dimensions. fer 196.38 Figure 19—Maximum Distribution of Gas Pockets: Wail Thicknesses Greater Than # Inch (12.7 Millimeters)ai Tne crass} any size er location in the weld, is not a Jnatios rater rack or star crack, 2. The crack ss a shallow crater crack or star crack whose fength exceeds % inch (3.96 millimeters). Due Shallow cit cas or star rseks a oct ate sopping pia ef seid beat and a he esl of weld metal conrcons Sucng rca, 63.10 UNDERCUTTING Undercutting is defined as a groove melted into the base etal adjacent tothe toe oF root of the weld and left unfilled by weld metal. Uadercutting adjaceat tothe cover pass (EU) ‘oF r00t pass (TL) shall be unacceptable when any ofthe fol- sing conditions exists The aggregate length of indications of EU and 1U, in any scbinaion, in aty continuous 12-inch (308 8-milimeter) sength of weld exceeds 2 inches (50.8 millimeters). > The azgregste length of indications of EU and {U, in any -auion, exceeds one-sith of the weld length Se See sj for accepance standards for ytdercuting whe visual ant Nemnaica seahurerens ar employed 6.3.11 ACCUMULATION OF DISCONTINUITIES Excluding incomplete penetration dve to high-low and un The agaregate length of indications exceeds 8 percent of the weld length 6.3.12 PIPE OR FITTING DISCONTINUITIES ‘Arc burns, long seam discontinuities, and other disconti- ties in the pipe or firings detected by radiographic esting shall be reported to the company. Their disposition by repair *servovat shall be as directed by the company. 6.4 Magnetic Particle Testing 6.8.1 CLASSIFICATION OF INDICATIONS 6.4.1.1 Indications produced by magnetic particle testing are not necessarily defects. Magnetic and metallurgical vari ations may produce indications that are similar to those pro duced by discontinuities but that are not relevant to acceptability, The criteria given in 6.4.1.2 and 6.4.1.3 apply wiven indications are evaluated 6.4.1.2 Any indication with a maximum dimension of % ach (1 $9 millimeters) or less shall be classified as eonrel- ‘evant, Any larger indication believed to be nonrelevant shall ve cegarded as relevant until reexamined by magnetic pari- le oF another rondesiructive testing method to determine whether or not an actual discontinuity exists. The surface ‘may be ground or otherwise conditioned before reexamina- tion. After an indication is determined to be nonrelevant, ‘ether nonrelevant indications of the same type need not be reexamined, 6.4.4.3 Relevant indications are those caused by disconti- nuities. Linear indications are whose in which the length is ‘more than three times the width. Rounded indications are those in which the length is three times the width or less. 6.4.2 ACCEPTANCE STANDARDS Relevant indications shall be unacceptable when any of the following conditions exists: 4. Linear indications evaluated as crater cracks or sta cracks exceed Ms inch (3.96 millimeters) in length. Linear indications are evaluated as cracks other than crater racks or star cracks. ©. Linear indications aze evaluated as IF and exceed 1 inch (25.4 eillimeters) in total length in a continuous 12-inch (G08.8-millimeter) length of weld or 8 percent ofthe weld Jeng. Rounded indications shal be evaluated according to the cr- teria of 6.3.8.2 and 6.3.8.3, applicable. For evaluation pur- ses, the maximurn dimension of a rounded indication sha be considered its size. Nowe: When dove exit abou te 1p of dscmnity being daiosed by A fein, verction may be Sane by osing oder nondesratve testing metoss 6.4.3 PIPE OR FITTING DISCONTINUITIES Laminations. are burns, long seam discontinuities, and other discontinuities in the pipe or fitings detected by mag. etc particle testing shall be reported to the company Taeir . Linear indications are evaluated as cracks other than crater cracks or star cracks. <. Linear indications are evaluated as fF and exceed 1 inch (25.4 millimeters) in total length ja a continuous 12-inch 304.8.mitlimeter) length of weld oF 8 percent of the weld tengt. Rounded indications shall be evaluated according tothe cri- len of 6.3.8.2 and 6.3.83, a applicable. For evaluation pure poses, the maximum dimension of a rounded indication shall be doasidered its sie ‘ute Whea dob esse abou the ype of decomianty bing disclosed by Sriicavon,veriieston may be obuned by Using her Aondestctve caving nebo 6.5.3 PIPE OR FITTING DISCONTINUITIES Laminations, arc burs, long seam discontinuities, and other discontinuities in the pipe or finings detected by liquid pene- twant testing shail be reported 10 the company. Their disposi- tion by repair oF removal shal be as directed by the company. 6.6 Ultrasonic Testing 6.6.1 ACCEPTANCE STANDARDS: Ultrasonic indications shall be evaluated to the acceptance wandands given 19 66.2 and 6.6.3. Weione oF Preanes ne Rewren Fucus 2 66.2 LINEAR INDICATIONS All indications that produce 2 response greater than 20 percent of the reference level shall, o the degree possible, be investigated to determine the location, shape. extent, and type of reflectors and shall be evaluated according to the fot lowing criteri: 1. Linear indications inverpreted to be shallow crater cracks or star cracks, located at the weld surface, with a length less than %a inch (3.96 millimeters) are acceptable. All other cracks are ‘unacceptable, regardless of size or location in the weld >. Linear indications (other than cracks) interpreted to be ‘open to the surface are unacceptable if they exceed I inch (25.4 millimeters) in total leageh in a continuous 12-inch (304.8-millimeter) length of weld or 8 percent of the weld length. «. Lineas indications interpreted to be buried within the weld are unacceptable if they exceed 2 inches (50.8 millimeters) in total length in a continuous 12-inch length of weld or 8 percent of the weld length 6.6.3 PIPE OR FITTING DISCONTINUITIES Laminations, long seam discontinuities, and other discon- timuities in the pipe or fitings detected by ultrasonic testing shall be reported to the company. Their disposition by repair ‘or removal shall be as directed by the company. 6.7 Visual Acceptance Standards for Undercutting 6.7.1 GENERAL Undercutting is defined in 6.3.10. The acceptance stan- dards in 6.7.2 supplement but do not replace visual inspec tion requirements found elsewhere inthis standard, 6.72 ACCEPTANCE STANDARDS: ‘When visual and mechanical means are used to determine depth, undercutting adjacent to the cover of root bead shail not exceed the dimensions given in Table 4. When boih me- chanical and radiographic measurements are available. the ‘mechanical measutements shall govern Table 4—Maximum Dimensions of Undercutting Det Lene Se iach (07 illo or 212.5% oF PE ‘eallinekness, wcheer ss saller > inch (04 plier of 24712 5% of pe nal tacks, hichover mallee ot pipe wt ew cepatte ier wel Tegth oF he a length wtuchever omer Accept regan