231127_Eargle_ISO5817 VT-4 Training Material.pptx

Click to insert Picture Application of Visual Welding Inspection with EN ISO 5817 Quality Level B Acceptance Criteria  Mr. Sidney Eargle  Weld Inspector  KION NA - Summerville, SC © 2021 Holdren Engineering VT Application - ISO 5817 Application of visual welding inspection for weldments • Cod...

Click to insert Picture Application of Visual Welding Inspection with EN ISO 5817 Quality Level B Acceptance Criteria  Mr. Sidney Eargle  Weld Inspector  KION NA - Summerville, SC © 2021 Holdren Engineering VT Application - ISO 5817 Application of visual welding inspection for weldments • Code inspection requirements • Practical application of visual inspection • Weld discontinuities and defects with EN ISO 5817- Quality Level B acceptance criteria • Basics of fillet weld measurement 2 © 2021 Holdren Engineering VT Application - ISO 5817 Inspection of Work and Records • Size, length, and location of Welds − Inspector shall make certain that the size, length, and location of all welds conform to the requirements of the drawings − Inspector shall also assure that no unspecified welds have been added without Engineering approval 3 © 2021 Holdren Engineering VT Application - ISO 5817 Extent of Examination • Inspector shall examine all welds to assure that they comply with drawing requirements and applicable acceptance criteria • Size and contour of welds shall be checked, using suitable gages when necessary • While not required, visual aids such as auxiliary lighting and magnifiers may be used to more closely evaluate irregularities in welds and base metals 4 © 2021 Holdren Engineering VT Application - ISO 5817 Assessment of imperfections per EN ISO 5817 (Clause S) • Imperfections may be examined at a maximum magnification of lOX • A weld should be assessed separately for each individual type of imperfection • Limits for multiple imperfections are only applicable for cases where requirements for a single imperfection are not exceeded • Any two adjacent imperfections separated by a distance smaller than the major dimension of the smaller imperfection shall be considered as a single imperfection 5 © 2021 Holdren Engineering VT Application - ISO 5817 Common visual inspection tools 6 © 2021 Holdren Engineering VT Application - ISO 5817 Introduction to weld discontinuities and defects • Intended to provide descriptions and appearances of common weld discontinuities in steel components for lift trucks produced for and by KION NA. • In addition, applicable acceptance criteria are provided for the following welding standards: − EN ISO 5817 - Quality Level B − AWS D14.4- Quality Level Ill 7 © 2021 Holdren Engineering VT Application - ISO 5817 Applicability • The information provided here shall apply to the inspection of lift truck parts produced for and by KION NA. • The same criteria shall apply regardless of who performs the inspection, including but not limited to: − Welders − Inspectors − Quality Engineers − Welding Specialists − Design Engineers − Welding Engineers − Other applicable individuals 8 © 2021 Holdren Engineering VT Application - ISO 5817 Definitions • discontinuity [referred to as "imperfection" in EN ISO 5817]. An interruption of the typical structure of a material, such as a lack of homogeneity in its mechanical, metallurgical, or physical characteristics • defect a discontinuity or discontinuities that by nature or accumulated effect render a part or product unable to meet minimum applicable acceptance standards or specifications. The term designates rejectability. 9 © 2021 Holdren Engineering VT Application - ISO 5817 Discontinuity criticality • Linear vs. non-linear − Linear length more than 3X width • End condition - sharpness • Surface vs. sub-surface • Loading - uniform, non-uniform − Fatigue − Impact 10 © 2021 Holdren Engineering VT Application - ISO 5817 Crack • A fracture type discontinuity characterized by a sharp tip and high ratio of length and width to opening displacement − Linear with a sharp end condition − Generally considered to be most critical type of discontinuity − Almost always considered a defect, regardless of length 11 © 2021 Holdren Engineering VT Application - ISO 5817 Crack types • Hot/ cold • Orientation − Longitudinal − Transverse • Location (weld) − Throat − Toe − Root • Location (weldment) − WMZ − HAZ − BMZ • Underbead (delayed) 12 © 2021 Holdren Engineering VT Application - ISO 5817 Longitudinal cracks 13 © 2021 Holdren Engineering VT Application - ISO 5817 Transverse cracks 14 © 2021 Holdren Engineering VT Application - ISO 5817 Throat crack (in fillet weld) • Typically through to the throat and the entire weld. 15 © 2021 Holdren Engineering VT Application - ISO 5817 Toe cracks • Weld flat to reduce the tension • High tensile • Hydrogen • Hardness 16 © 2021 Holdren Engineering VT Application - ISO 5817 Crater cracks in aluminum weld 17 © 2021 Holdren Engineering VT Application - ISO 5817 Crater cracks 18 © 2021 Holdren Engineering VT Application - ISO 5817 Acceptance criteria - cracks • EN ISO 5817: not permitted • AWS D14.4: none 19 © 2021 Holdren Engineering VT Application - ISO 5817 Incomplete Fusion (IF) [Lack of Fusion (LOF)] • A weld discontinuity in which fusion did not occur between weld metal and fusion faces or adjoining weld beads 20 © 2021 Holdren Engineering VT Application - ISO 5817 Locations of incomplete fusion Per EN ISO 5817, this condition is referred to as lack of penetration, but acceptance criteria is the same - Not permitted 21 © 2021 Holdren Engineering VT Application - ISO 5817 Incomplete fusion at weld face 22 © 2021 Holdren Engineering VT Application - ISO 5817 Incomplete fusion Robotic weld 23 © 2021 Holdren Engineering VT Application - ISO 5817 Incomplete fusion? Rejectable Acceptable 24 © 2021 Holdren Engineering VT Application - ISO 5817 Interbead IF “Cold Lap” 25 © 2021 Holdren Engineering VT Application - ISO 5817 IF between WM and BM 26 © 2021 Holdren Engineering VT Application - ISO 5817 Acceptance criteria - IF • EN ISO 5817: not permitted • AWS D14.4: sum of all indications shall not exceed 1 in [25 mm] in 12 in [300 mm] 27 VT Application - ISO 5817 © 2021 Holdren Engineering Incomplete joint penetration (IJP) [Per EN ISO 5817 - Lack of penetration (LOP)] • A joint root condition in a groove weld in which weld metal does not extend through the joint thickness • Partial joint penetration weld A groove weld in which incomplete joint penetration exists 28 © 2021 Holdren Engineering VT Application - ISO 5817 JP / LOP 29 © 2021 Holdren Engineering VT Application - ISO 5817 IJP / LOP 30 © 2021 Holdren Engineering VT Application - ISO 5817 IJP / 31 LOP © 2021 Holdren Engineering VT Application - ISO 5817 Acceptance criteria - IJP / LOP • EN ISO 5817: not permitted in CJP welds • AWS D14.4: 1/3T or½ in [13 mm] maximum length 32 © 2021 Holdren Engineering VT Application - ISO 5817 Inclusions • Entrapped foreign solid material such as slag, tungsten, copper, or oxide Surface slag inclusions 33 © 2021 Holdren Engineering VT Application - ISO 5817 Acceptance criteria - inclusions With GMAW, slag inclusions will not occur since no flux is used; surface oxides shall be removed using wire brushing or other suitable means; in multipass welds, these shall be removed prior to deposition of subsequent weld passes • EN ISO 5817: not permitted on surface; some amounts permitted subsurface • AWS D14.4: no criteria 34 VT Application - ISO 5817 © 2021 Holdren Engineering Porosity • A cavity-type discontinuity formed by gas entrapped during weld metal solidification • A weld metal discontinuity unless base metal is a cast material • Types − Isolated − Scattered − Piping − Elongated − Aligned − Cluster 35 © 2021 Holdren Engineering VT Application - ISO 5817 Scattered porosity 36 © 2021 Holdren Engineering VT Application - ISO 5817 Aligned porosity with connecting crack 37 © 2021 Holdren Engineering VT Application - ISO 5817 Piping porosity 38 © 2021 Holdren Engineering VT Application - ISO 5817 Elongated and piping porosity 39 © 2021 Holdren Engineering VT Application - ISO 5817 Cluster porosity No shielding gas as coming around corner 40 © 2021 Holdren Engineering VT Application - ISO 5817 Evaluation of cluster porosity 41 © 2021 Holdren Engineering VT Application - ISO 5817 Porosity in aluminum welds 42 © 2021 Holdren Engineering VT Application - ISO 5817 Acceptance criteria - porosity • EN ISO 5817 − maximum single pore 0.2a, but no more than 1/8 in [3mm] − maximum cluster diameter 15mm, but no more than ½ weld width • AWS 014.4: sum of diameters 1/16 in [2 mm] or greater shall not exceed¼ in [6 mm] in any linear inch [25 mm] of weld, or½ in [13 mm] in 12 in [300 mm] length 43 © 2021 Holdren Engineering VT Application - ISO 5817 Undercut • A groove melted into the base metal adjacent to the weld toe or weld root and left unfilled by weld metal 44 © 2021 Holdren Engineering VT Application - ISO 5817 Measuring undercut 45 © 2021 Holdren Engineering VT Application - ISO 5817 Acceptance criteria - undercut • EN ISO 5817: maximum depth 0.0St, but no more than 1/64 in [0.5 mm], with smooth transition • AWS D14.4: maximum depth 1/32 in [1 mm] 46 © 2021 Holdren Engineering VT Application - ISO 5817 Underfill [EN ISO 5817 Incompletely filled groove] • A groove weld condition in which the weld face or the root surface is below the adjacent surface of the base metal Per EN ISO 5817, this condition is referred to as root concavity, but acceptance criteria is the same as for incompletely filled groove 47 © 2021 Holdren Engineering VT Application - ISO 5817 Underfill 48 © 2021 Holdren Engineering VT Application - ISO 5817 Acceptance criteria - underfill • EN ISO 5817: maximum depth 0.0St, but no more than 1/64 in [0.5 mm], with smooth transition • AWS D14.4: none permitted - grooves shall be filled flush as a minimum 49 VT Application - ISO 5817 © 2021 Holdren Engineering Overlap • The protrusion of weld metal beyond the weld toe or weld root Overlap exists when the reentrant angle is less than 90° 50 © 2021 Holdren Engineering VT Application - ISO 5817 Overlap in fillet weld Remove profile with grinder and retest to see if a crack. 51 © 2021 Holdren Engineering VT Application - ISO 5817 Undercut & overlap in fillet weld 52 © 2021 Holdren Engineering VT Application - ISO 5817 Overlap 53 © 2021 Holdren Engineering VT Application - ISO 5817 Acceptance criteria - overlap • EN ISO 5817: not permitted • AWS D14.4: none 54 © 2021 Holdren Engineering VT Application - ISO 5817 Evaluating reentrant (toe) angle 55 © 2021 Holdren Engineering VT Application - ISO 5817 Convexity • The maximum distance from the face of a convex fillet weld perpendicular to a line joining the weld toes 56 © 2021 Holdren Engineering VT Application - ISO 5817 Convexity • A slight amount of convexity can be desirable • Depends on direction of applied load − If parallel  excessive convexity adds to load capacity − If transverse  excessive convexity reduces toe angle, increases stress concentration, and provides site for fatigue crack initiation 57 © 2021 Holdren Engineering VT Application - ISO 5817 Convexity measurement • While most welding standards limit convexity in terms of its dimension, that dimension is impossible to directly measure • •From an inspection standpoint, convexity should be limited by minimum toe angle, which can be easily measured 58 © 2021 Holdren Engineering VT Application - ISO 5817 Convexity measurement A 7/16” concave fillet weld gage can be used to approximate the amount of convexity permissible for a ¼” fillet weld 59 © 2021 Holdren Engineering VT Application - ISO 5817 Acceptance criteria - convexity • EN ISO 5817: maximum permitted ¾ 1/32 in [1 mm] + 0.1 x face width, but no more than 1/8 in [3 mm] • AWS D14.4: no limit - controlled by limit on toe reentrant angle 60 VT Application - ISO 5817 © 2021 Holdren Engineering Weld reinforcement [EN ISO 5817 — Excess weld metal (butt weld) • Weld metal in excess of the quantity required to fill a weld groove Face reinforcement. Weld reinforcement on the side of the joint where welding was done Root reinforcement. Weld reinforcement on the side of the joint opposite from where welding was done 61 © 2021 Holdren Engineering VT Application - ISO 5817 Face and root reinforcement * Excessive weld reinforcement Welded from one side Face and root reinforcement Welded from both sides Face reinforcement both sides 62 © 2021 Holdren Engineering VT Application - ISO 5817 Weld reinforcement measurement * Excessive weld reinforcement Note: V-WAC (undercut) gage can also be used to measure weld reinforcement up to ¼ in [6mm] 63 © 2021 Holdren Engineering VT Application - ISO 5817 Treatment of excess weld reinforcement * Reduce stress concentration 64 © 2021 Holdren Engineering VT Application - ISO 5817 Acceptance criteria - weld reinforcement • EN ISO 5817: maximum permitted <1/32 in [1 mm]+ 0.1x face width, but no more than 3/16 in [5 mm] • AWS D14.4: no limit - controlled by limit on toe reentrant angle 65 VT Application - ISO 5817 © 2021 Holdren Engineering Weld profile limited by toe reentrant angle [EN ISO 5817 — Incorrect weld toe] • reentrant angle. The angle between lines tangent to the weld profile surfaces at the junction of those surfaces. • toe reentrant angle. The reentrant angle between the base metal and weld face at the weld toe or root surface at the weld root 66 © 2021 Holdren Engineering VT Application - ISO 5817 Acceptance criteria - toe reentrant angle [incorrect weld toe] • EN ISO 5817 − Butt weld: a > 150O − Fillet weld: a > 110O • AWS D14.4 − Butt weld: a > 135O − Fillet weld: a >1 10O 67 © 2021 Holdren Engineering VT Application - ISO 5817 Arc strike [EN ISO 5817 — stray arc] • A discontinuity resulting from an arc, consisting of any localized remelted metal, heataffected metal, or change in the surface profile of any metal object Normally associated with a welding arc, but can also occur at the work connection or during magnetic particle testing with the prod method. In these cases, copper pick-up can occur, which can lead to greater susceptibility for cracking. 68 © 2021 Holdren Engineering VT Application - ISO 5817 Arc strike Martensitic structure and resulting cracking from arc strike on high strength steel 69 © 2021 Holdren Engineering VT Application - ISO 5817 Acceptance criteria - arc strike • Arc strikes are to be avoided. If present, they shall be ground flush and checked to assure soundness. EN ISO 5817: not permitted AWS D14.4: 70 © 2021 Holdren Engineering none VT Application - ISO 5817 Spatter • Metal particles expelled during fusion welding that do not form part of the weld 71 © 2021 Holdren Engineering VT Application - ISO 5817 Crack formed at weld spatter 72 © 2021 Holdren Engineering VT Application - ISO 5817 Acceptance criteria - spatter • EN ISO 5817: Acceptance depends on application, e.g. material, corrosion protection • AWS D14.4: none 73 VT Application - ISO 5817 © 2021 Holdren Engineering Dimensional discontinuities • Incorrect joint geometry • Incorrect weld size • Incorrect final dimensions 74 © 2021 Holdren Engineering VT Application - ISO 5817 Incorrect joint geometry • To be checked once joint has been fit and prior to welding • Groove [butt] welds − Misalignment (high-low) • EN ISO 5817 limit: maximum permitted < 1/16 in [2 mm] + O.1t, but no more than 1/8 in [3 mm] • AWS D14.4 limit: maximum permitted < 10% t thinner, but no more than 1/8 in [3 mm] 75 © 2021 Holdren Engineering VT Application - ISO 5817 Incorrect joint geometry • Fillet welds − Root opening [incorrect root gap] • EN ISO 5817 limit: maximum permitted < 1/64 in [0.5 mm] + 0.1a, but no more than 1/16 in [2 mm] • AWS D14.4 limit: maximum permitted = 3/16 in [5mm]; when > 1/16 in [2 mm] required leg size shall be increased by amount of the gap 76 © 2021 Holdren Engineering VT Application - ISO 5817 Introduction to fillet weld measurement • Fillet welds comprise the majority of the welds typically examined by visual welding inspectors • This examination requires the inspector to visually evaluate characteristics, including: − Size − Length − Profile − Soundness 77 © 2021 Holdren Engineering VT Application - ISO 5817 Fillet weld size • Measurement of fillet weld size important, but often performed incorrectly • Topics of discussion − Definition of fillet weld size − Theoretical measurement − Practical scheme for measurement of production fillet welds 78 © 2021 Holdren Engineering VT Application - ISO 5817 Fillet weld size • A3.0 definition: For equal leg fillet welds,the leg lengths of the largest isosceles right triangle that can be inscribed within the fillet weld cross section. For unequal leg fillet welds, the leg lengths of the largest right triangle that can be inscribed within the fillet weld cross section. • OK - So what does that mean???? 79 © 2021 Holdren Engineering VT Application - ISO 5817 Fillet weld size • Isosceles triangle  two of three sides of equal length • Right triangle  one angle= 90° (right angle) • So, a right isosceles right triangle = 80 © 2021 Holdren Engineering VT Application - ISO 5817 Fillet weld size - equal leg • The largest right isosceles triangle that can be contained within the fillet weld cross-section 81 © 2021 Holdren Engineering VT Application - ISO 5817 Fillet weld size - measurement • Since fillet weld size is determined by the size of the inscribed triangle, the measurement technique must be capable of determining the size of this triangle • Depending on the shape of the fillet weld, i.e. convex or concave, different features of the triangle must be gaged 82 © 2021 Holdren Engineering VT Application - ISO 5817 Fillet weld profile • Convex: weld face extends outward from weld toes • Concave: weld face "dished in" toward weld root 83 © 2021 Holdren Engineering VT Application - ISO 5817 Fillet weld size - equal leg • The largest right isosceles triangle that can be contained within the fillet weld cross-section 84 © 2021 Holdren Engineering VT Application - ISO 5817 Fillet weld size - measurement • We are measuring the triangle inside • Since fillet weld size is determined by the size of the inscribed triangle, the measurement technique must be capable of determining the size of this triangle • Depending on the shape of the fillet weld, i.e. convex or concave, different features of the triangle must be gaged − Consequently, different shapes of gages required to measure the different fillet weld profiles 85 © 2021 Holdren Engineering VT Application - ISO 5817 Template-type fillet weld gages Sizes (in) • 1/8 • 3/16 • 1/4 • 5/16 • 3/8 • 1/2 • 5/8 • 3/4 • 7/8 •1 86 © 2021 Holdren Engineering VT Application - ISO 5817 Measuring convex fillet weld • That feature of a convex fillet weld limiting the maximum size of the inscribed triangle is the leg length 87 © 2021 Holdren Engineering VT Application - ISO 5817 Measuring convex fillet weld 88 © 2021 Holdren Engineering VT Application - ISO 5817