THE MAGAZINE FOR MATERIALS INSPECTION AND TESTING PERSONNEL · PDF fileTHE MAGAZINE FOR MATERIALS INSPECTION AND TESTING PERSONNEL ... diffraction ultrasonic testing, digital radiography,

$Page 1: THE MAGAZINE FOR MATERIALS INSPECTION AND TESTING PERSONNEL · PDF fileTHE MAGAZINE FOR MATERIALS INSPECTION AND TESTING PERSONNEL ... diffraction ultrasonic testing, digital radiography,$
www.aws.org

October 2011 / Vol. 14 / No. 4

THE MAGAZINE FOR MATERIALS INSPECTION AND TESTING PERSONNEL

Best Practices InVisual InspectionBest Practices InVisual Inspection

October 2011 Cover _IT Spring 4/06 9/22/11 4:15 PM Page C1

For Info go to www.aws.org/ad-index See us at FABTECH booth #7109

OLYMPUS_FP_TEMP 9/21/11 8:52 AM Page C2

Vol. 14 / No. 4

Features

15

Laser Tool Offers Alternative for Precise Visual Weld Inspectionby J. Noruk, B. Holmes, and B. Bruss /Three-dimensional, hand-held laserprecision measurement technology offers increased productivity for visualweld inspection/ 15

How to Deal with the Unexpected by H. K. Jones / An experiencedCWI offers advice on how to handle difficult inspection situations / 18

Visual Inspection Tips from the Prosby M. R. Johnsen / Several Senior Certified Welding Inspectors share some ofthe visual inspection ‘best practices’ they’ve developed over the years/ 21

Departments

Editor’s Note................................6

News Bulletins .............................8

Print and Product Showcase.......13

The Answer Is ............................25

Mark Your Calendar...................26

Certification Schedule................27

Just The Facts.............................28

Technology Notes.......................30

Classifieds..................................32

Advertiser Index ........................32

INSPECTION TRENDS (ISSN 1523-7168) ispublished quarterly by the American WeldingSociety. Editorial and advertising offices are locatedat 550 NW LeJeune Rd., Miami, FL 33126;telephone (305) 443-9353. Printed by R. R.Donnelley & Sons Co., Senatobia, Miss.Subscriptions $30.00 per year for noncertified,nonmembers in the United States and itspossessions; $50.00 per year in foreign countries;$20.00 per year for noncertified members andstudents; $10.00 single issue for nonmembers and$7.00 single issue for members. American WeldingSociety is located at 550 NW LeJeune Rd., Miami,FL 33126-5671; telephone (305) 443-9353,Periodicals postage paid in Miami, Fla., andadditional mailing offices.

POSTMASTER: Send address changes to Inspection Trends c/o American Welding Society,550 NW LeJeune Rd., Miami, FL 33126-5671.

Readers of Inspection Trends may make copies ofarticles for personal, archival, educational, or research purposes, and which are not for sale or resale. Permission is granted to quote from articles,provided customary acknowledgment of authors and sources is made. Starred (*) items excluded fromcopyright.

AWS MISSION STATEMENTThe mission of the American Welding Society is to advance the science, technology, and application of welding and allied processes, including joining, brazing, soldering, cutting, and thermal spray.

Inspection Trends / Fall 2011 5

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Editor’s NoteBy Mary Ruth Johnsen

Inspection Trends / October 20116

Dear Readers,

You might call this the back-to-basics issue of Inspection Trends. That’s because all of the articles arerelated to visual inspection. Because so many of you carry multiplecertifications, we try to cover all of the nondestructive examinationmethods in the magazine. And, yes, methods such as time-of-flightdiffraction ultrasonic testing, digital radiography, and infraredthermography may seem to have more pizzazz than visual testing, youknow as well as I do that visual testing is the most widely usedinspection method in the world. You also know that many welds receiveno other examination beyond visual inspection. Since visual testing isyour particular bailiwick, and so much depends on having good, strongwelds, we want you to have the information you need to do your job thebest that you can.

This issue has three visual testing-related articles. The first, by JeffNoruk, Blake Holmes, and Bob Bruss, on page 15 discusses a laser toolthat you can use as an alternative to weld measurement gauges. I querieda group of SCWIs and asked them to tell me some of the things they’velearned over the years that might just help you do your job better. You’llfind their tips on page 21. Howard K. Jones, an experienced CWI,discusses situations that no one expects to occur but somehow doanyway, then gives you his experience-based advice on how to deal withthem. You’ll find that article on page 18.

With this issue, we’re closing out another year of Inspection Trends.The end of the year is always jam-packed in terms of both our work andpersonal lives. There are quarterly and annual reports to submit, fiscaland calendar years to close out, and stacks of paperwork to finish, whileat the same time we’re attempting to spend time with family and friends,get our work done despite days off for the holidays, and oftenattempting to squeeze in some final vacation time as well. I wish you allsome peace during the end-of-the-year insanity and want you to knowthat we’ve got plenty of useful things planned for Inspection Trends in2012. — Mary Ruth Johnsen

PublisherAndrew [email protected]

EditorMary Ruth [email protected]

Associate EditorsHoward [email protected]

Kristin [email protected]

Production EditorZaida [email protected]

Senior Production CoordinatorBrenda [email protected]

National Sales DirectorRob [email protected]

Advertising Sales RepresentativeLea [email protected]

Senior Advertising Production ManagerFrank [email protected]

Subscriptions RepresentativeSylvia [email protected]

American Welding Society550 NW LeJeune Rd.Miami, FL 33126(800/305) 443-9353

Copyright

Copyright © 2011 by American Welding Society in bothprinted and electronic formats. The Society is not responsible for any statement made or opinion expressedherein. Data and information developed by the authors ofspecific articles are for informational purposes only andare not intended for use without independent, substantiating investigation on the part of potential users.

Editor's Note IT Fall 2011_Layout 1 9/22/11 1:35 PM Page 6

Expand your credentials with an endorsement that fulfills your recertification requirements. Recertification every nine years requires either 80 hours of documented continuing education, retaking the “Part B” Practical Exam, or an endorsement to your certification. You can do this at any time, so why not do it now and secure the prestige and enhanced career potential of a credential in an additional welding code?

www.aws.org/certification(800) 443-9353 ext 273

A CWI or SCWI can take a Supplemental Inspection Exam anytime during the nine-year cycle. Qualifying for and passing one of these exams meets the requirements for recertification. Endorsements are listed on your endorsement card. Endorsements to codebooks require passing a two-hour Open-Book Code Application exam on one of the following codes:

Seminars to prepare you for the two-hour exam on D1.1 or API 1104 are available at numerous seminar sites across the country. Three new code clinics will be offered at FABTECH in Chicago:

D1.5 Bridge Code Clinic – Nov. 14D15.1 Railroad Code Clinic – Nov. 14

ASME Section IX, B31.1 and B31.3 Code Clinic – Nov. 15 One other stand-alone credential can serve as an endorsement credit and also fulfills your recertification requirement. At any time during your nine-year cycle, if you meet the prerequisites, you can apply to become certified as an AWS Certified Radiographic Interpreter (CRI).The five-day CRI seminar is designed to ensure that you have the knowledge to properly assess indications produced on radiographic media. It will prepare you for the CRI certification exam, which is given at the end of each seminar week. This is a valuable certification that fulfills your nine-year requirement. Upcoming seminars and exams for CRI are:

If you don’t want to take any exams at all, you can fulfill the 80-hour education requirement by attending a six-day AWS 9-Year Recertification Course. Courses are scheduled for:

One more option is to recertify by taking the “Part B” CWI Practical Exam. This exam and refresher Visual Inspection Workshop seminars are offered at convenient CWI seminar/exam sites across the country. Our new Advanced Visual Inspection Workshops in Miami are specifically designed to prepare you for this exam.

ASME Section IX, B31.1 and B31.3 Boiler and Pressure Vessel

ASME Section VIII, Div. 1 and Section IX Boiler and Pressure Vessel

AWS D1.1 Structural Welding

AWS D1.5 BridgeAWS D15.1 RailroadAPI 1104 Pipeline

Even if your nine-year recertification ®

Plan ahead.

Qualifying for and passing one of these exams meets the requirements for recertification. CWI or SCAA

Qualifying for and passing one of these exams meets the requirements for recertification. CWI or SCWI can take a Supplemental Inspection Exam anytime during the nine-year cycle.



API 1

WAAWWAAW

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Seminars to prepare you for the two-hour exam on D1.1 or

two-hour Open-Book Code Endorsements are listed on your endorsement card. Endorsements to codebooks require passing a Qualifying for and passing one of these exams meets the requirements for recertification.

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Endorsements are listed on your endorsement card. Endorsements to codebooks require passing a

indications produced on radiographic media. It will prepare you for the CRI certification exam, which The five-day CRI seminar is designed to ensure that you have the knowledge to properly assess you can apply to become certified as an recertification requirement. One other stand-alone credential can serve as an endorsement credit and also fulfills your

seminar sites across the countrySeminars to prepare you for the two-hour exam on D1.1 or

indications produced on radiographic media. It will prepare you for the CRI certification exam, which The five-day CRI seminar is designed to ensure that you have the knowledge to properly assess you can apply to become certified as an

At any time during your nine-year cycle, if you meet the prerequisites, recertification requirement. One other stand-alone credential can serve as an endorsement credit and also fulfills your

ASME Section IX, BD15.1 Railroad Code Clinic – Nov

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31.1 and B31.3 Code Clinic – NovASME Section IX, BD15.1 Railroad Code Clinic – Nov

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fered at convenient CWI seminar/exam sites across the This exam and refresher One more option is to recertify by taking the “Part B” CWI Practical Exam.

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aws cert (endorsements)_FP_TEMP 9/21/11 9:09 AM Page 7

News Bulletins


Phoenix Inspection Systems Equipment TestingLarge Floating Oil Production Facility

Ultrasonic testing equipment from Phoenix InspectionSystems, Warrington, UK, is being used to test the mooringchains for one of the world’s largest floating production,storing, and offloading (FPSO) vessels.

The vessel is located in the Schiehallion oilfield, 175 miles

west of the Shetlands off the coast of the United Kingdom.Owned by BP and in operation since 1998, the FPSO features aprocessing capacity of around 200,000 barrels of oil a day andhas a storage capacity of about 950,000 barrels.

Fourteen mooring chains, each 6.25 in. in diameter,anchor the FPSO to piles in the seabed below. The chains aredue for replacement but must be inspected first to ensure theycan be safely removed. The entire operation is taking placeunderwater, with the equipment being carried by divers andfixed into position. The inspection is focusing on the pointwhere the chains fix onto the ship.

Prototype Robot Inspects for StructuralDamage in Nuclear Reactors

The Welding Institute (TWI), Abington, UK, hasdesigned a prototype inspection robot to detect structuraldamage in aging nuclear reactors. The work is part of theapproximately $1.9 million NozzleInspect project. Nozzlesections made from austentitic steel can be susceptible torapid crack growth due to thermal fatigue and stresscorrosion. Early detection of cracks is essential to ensure safeoperation of the facility.

Currently, conventional ultrasonic probes are used to dothe inspections. But because the probes need to be changed toallow full inspection of the nozzle weld areas, and each

This ultrasonic scanner from Phoenix Inspection Systems isbeing used to inspect the mooring chains holding one of theworld’s largest FPSOs in place. Here it is shown in place ona section of chain during trials.

See Us At The FABTECH booth #6200

News Bulletins IT Fall 2011_Layout 1 9/22/11 1:37 PM Page 8


change requires completion of a recalibration, defectdetection and sizing capabilities are not optimum. Inaddition, operators are exposed to a certain amount ofradiation during installation.

TWI’s prototype uses 128 piezoelectric elements placedin a circular formation. The automatic robot assembly willcarry a novel matrix phased array probe that will becombined with 3-D beam steering to enable a large area ofthe weld to be inspected in a single operation.

The design is currently undergoing final testing.Additional information is available at www.nozzleinspect.eu.

Former Shipyard Worker Sentencedfor False Certifications

Robert Raymond Ruks of Portsmouth, Va., wassentenced in August to 37 months in prison, followed by aterm of three years supervised release for making falsestatements to Navy officials and federal agents. He falselycertified that he had inspected welds on the hulls of Navyships and submarines. Subsequent inspections found certainwelds on these vessels to be defective.

“Lying on weld inspection reports is a dangerous crimethat threatens the safety of our men and women who serve inthe U.S. Navy,” said U.S. Attorney Neil H. MacBride.“Because of his lies, the Navy and its shipbuilding partnershad to conduct a thorough technical review and reinspectionof the affected vessels to ensure the ships’ safety. My office iscommitted to ensuring that government contractors are heldresponsible when they attempt to defraud the government andput our Navy personnel in danger.”

According to court documents, Ruks worked forNorthrop Grumman Shipbuilding, Newport News, Va., as aNDT inspector. He admitted to his supervisors on May 14,2009, that he had falsely certified he had inspected three liftpad welds on a Navy submarine when in fact he had not.Ruks was later questioned by agents of the Naval CriminalInvestigative Service (NCIS) and, although he admitted thefalse certifications of the lift pad welds, he lied to the agentsregarding the number of other ship and submarine hulls hehad failed to inspect. NCIS determined Ruks had been falselycertifying weld inspections on various hulls from 2007through 2009. Based upon archived inspection reports,Northrop Grumman officials estimated Ruks performedapproximately 9500 weld inspections on as many as sixsubmarines that he certified in the company’s electronicrecords system. A reinspection of all the welds Ruks hadcertified revealed that 14 structural welds and two pipe welds(one of which was a SUBSAFE, critical weld) weredetermined to be defective/unsatisfactory. There were also aconsiderable number of welds Ruks certified that werelabeled as “inaccessible” due to their location.

The reinspections required 18,906 worker hours, whichincluded the correction of the defective weld joints, at a costof approximately $654,000.

A search of American Welding Society records revealedRuks has never been a Certified Welding Inspector.




Test Equipment Distributors Selects National Sales Manager

Clarence Wyland was recentlynamed national sales manager, anew position, for Test EquipmentDistributors, Troy, Mich., a supplierof NDE equipment and suppliesnationwide.

Wyland is a 27-year veteran of theNDE industry and has worked in salesat American NDT Products and MetChem Testing Laboratories.

TÜV SÜD America Appoints President/CEOto Americas Operations

Ian Nicol has recently been namedpresident and CEO for the Americasoperations of TÜV SÜD America,Inc. This includes TÜV SÜD Canada,TÜV SÜD América de México, andTÜV SÜD America do Brasil. Thecompany, based in Peabody, Mass., isa global testing, inspection, andcertification services firm.

Nicol has served in numeroussenior management roles in thecertification, inspection, and testingIan Nicol

Fischer’s Feritscope® FMP30 is the ideal solution for fast, precise measurement of ferritecontent of constructional steels,welded claddings, austenitic stainless steels and duplex steels.

• Non-destructive measurement in the range of 80% Fe or 0-120WRC number.

• Battery or AC powered• Large, backlit display• Automatic probe recognition • Statistical evaluation• USB interface• Multiple application memories• FISCHER DataCenter Software

1-800-243-8417 • 1-860-683-0781 • Fax: 1-860-688-8496www.Fischer-Technology.com • [email protected]

Measurementof the Ferrite Content in Austenitic

and Duplex Steel

FERITSCOPE® FMP30

Clarence Wyland



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industries, most recently as senior vice president of SGSIndustrial Services NAM.

Fluke Donates Test Tools for UnitedAssociation’s Mobile Training Trailers

Fluke Corp., Everett, Wash., a manufacturer of portableelectronic test and measurement equipment, recently donatedmore than $4000 of test tools to the United Association ofJourneymen and Apprentices of the Plumbing and Pipe FittingIndustry of the United States and Canada (UA) to help equiptwo new mobile training trailers. The heating, ventilation, air-


ASNT,Bringing Thousands of MindsTo NDT Matters, Including Yours.

Join the Professional SocietyThat Brings the NDT Community & Its Resources To You.

The American Society for Nondestructive Testing

Serving the Profession,

Creating a Safer World. www.asnt.org

Fluke Corp. donated two sets of tools to the UnitedAssociation for use in its HVACR training trailers.

For info go to www.aws.org/ad-indexSee Us At The FABTECH booth #7006

For info go to www.aws.org/ad-index


conditioning, and refrigeration (HVACR) trailers will be used totrain apprentices and journeymen on the latest equipment usedin the industry.

The two 53-ft-long trailers are the UA’s first HVACRmobile training labs. The UA has 40 fully equipped mobiletraining centers in all. The new units will be utilized invarious locations around the United States.

The Fluke donation includes two units each of a completesuite of tools, from airflow, temperature, humidity, and carbonmonoxide meters designed for HVAC and indoor air qualitycontrol to digital multimeters and clamp meters for electricalmeasurement, as well as infrared and contact digitalthermometers.

Boulder Imaging Names Senior OpticalSolutions Engineer

Neil Vanasse recently joined Boulder Imaging, Boulder,Colo., as a senior optical solutions engineer. The companymanufactures high-performance quality inspection, machinevision, and high-speed imaging equipment.

Vanasse has more than 15 years of experience as anoptical and mechanical engineer.

TÜV Rheinland to Acquire Dutch NDE Firm

TÜV Rheinland, Cologne, Germany, is acquiringSonovation B.V., a specialized nondestructive examinationservices provider based in The Netherlands. Among other

services, the company provides weld examination and pipesystem and pressure equipment corrosion inspection.

Sonovation was founded in 1988 and employs 50people. It has locations in The Netherlands, UnitedKingdom, Belgium, and Germany. Its revenues in 2010were approximately $17 million. The company will berenamed TÜV Rheinland Sonovation.

Exova Introduces Pipeline Weld IntegrityTest Service

Exova recently introduced a new immersion ultrasonictesting technique for girth weld inspection in the oil and gasindustry.

The immersion technique will be added to the company’sautomated ultrasonic testing process to identify if all defectsare accurately located and none is missed. Due to the highersignal-to-noise ratio, the immersion testing environment usedwith high-accuracy robotics is useful for every type ofmaterial inspections where small defects have to be detected.The system will allow Exova to identify an increased numberof defects, such as cracking, porosity, incomplete penetration,inclusions, incomplete sidewall fusion, and others that cancompromise the strength of pipeline girth welds.

Sander van Nieuwenhuijzen, operational manager for thecompany in The Netherlands, said, “Due to the increaseddemands on pipeline integrity, it is important that any defectin the welds is detected, accurately located, sized, andreported quickly.”


AWS agreement with ASNT offers ACCP toqualified CWIs & SCWIs.

Do you need visual testing certification which meets the guidelines for Recommended Practice No. SNT-TC-1A as required by somesections of the ASME Code? Through this agreement, qualified SCWIs and CWIs can obtain ACCP Level II VT certification without examination.

Enhance your credentials and satisfy work requirements with the addition of an ACCP credential.

To apply and for more details visitwww.asnt.org or call 614.274.6003 or 800.222.2768 US/Canada.

Opportunity Knocks.

Image © Longview Inspection

For info go to www.aws.org/ad-index See Us At The FABTECH booth #7006

News Bulletins IT Fall 2011_Layout 1 9/23/11 8:48 AM Page 12

Inspection Kit Useful for NDEand Mining Inspection

The Spectroline® EK-3000EagleEye UV-A/white light LEDinspection kit features the palm-sizedEagleEye inspection lamp that isengineered with two ultrahigh-intensityUV-A (365-nm) LEDs. An adjustablestrap allows the lamp to be worn on ahard hat or directly on the head forhands-free operation. A lampmount/sprayer attachment allows thelamp and a spray can to be mountedtogether for single-handed fluorescentyoke inspection. The patent-pending kitis designed for fluorescent magneticparticle and penetrant testing, mininginspection, and other operations. Thelamp produces a nominal steady-stateUV-A intensity of 4500 μW/cm2 at 15 in.It features a built-in fan and is poweredby a rechargeable lithium-ion batterythat provides up to 75 min of continuousinspection. It comes with a lanyard, tworeplacement splash guards with integralparticulate filters, three batteries, abattery-charging cradle with AC and DCcords, UV-absorbing spectacles, and acarrying case.

Spectrolinewww.spectroline.com

Small-Sized Impact MarkerDesigned for Test StandApplications

The Model 78 Mite-E-Mark line ofimpact markers is useful for markingone or two characters that need to be

permanently stamped into steel,aluminum, plastic, and othercomponents. The markers are designedfor cycle times (advanced and return) inunder four tenths of a second for morethan 2 million cycles. They are availablein 1- or 2-in. stroke models and feature a

return cylinder indicator option thatallows the user to sense its return, whichis useful for automated applications forwhich it is necessary to know when themarker is clear when the part transfers.The models are available with either an“A” rod style for multiple characters or a

Print and Product Showcase


Handheld XRF

The S1 TURBOSD XRF analyzer uses innovative SDD technology which provides fast and accurate alloy analysis. www.bruker.com/hhxrf

[email protected]

S1 TURBOSD

Technology

you can trust

Fast alloy ID and chemistry Completely non-destructive Prevents material mix-up

Innovation with Integrity

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CMF-steel type or “B” style for single,robust round CM7X-marker inserts.

Columbia Marking Toolswww.columbiamt.com

LED Work Light FeaturesExplosion-Proof Plug

The company’s 2-ft-long LEDMagnalight work light features 100 ft ofcord ending in an explosion-proof plug.It is designed to allow users to connectthe light to explosion-proof outletswithin a hazardous workplace. The lamp

produces a glare-free wide flood of lightand is useful for close work andinspection activities where contrast andcolor rendering are critial. The ModelEPL-FL1524-LED-100-1523 lampfeatures a high lumen per watt outputand efficient reflector design. It isaproved for Class 1 Div. 1 and Class 2Div. 2 locations.

Larson Electronicswww.magnalight.com

Spectrometer Offers PreciseMetal Analysis

The updated version of theSpectrolab metal analyzer is easier to useand offers reduced operating costs.Components that require maintenanceare placed in easy-to-access locations.The optical emission spectrometerfeatures an extended diagnosis and logfile system that helps users to monitorthe instrument’s status and performaccurate troubleshooting. The analyzer

features optimized excitation parametersand a readout system that enablespermanent enhancements for leadanalysis with a focus on batterytechnology or in the analysis of preciousmetals. Among the metals the instrumentis able to analyze with a single hardwareconfiguration are aluminum,magnesium, and titanium alloys. Itfeatures optimized optical resolution anda focal width of 750 nm in both opticalsegments.

SPECTRO Analytical Instrumentswww.spectro.com.

Precious Metal AnalyzerFeatures Easy Operation

The company’s Niton LX2precious metal analyzer combinespoint-and-shoot operation with lab-quality nondestructive analysis toprovide exact metal content in seconds.The instrument comes with a mobiletest stand, battery and battery charger,PC connection cables, locking carryingcase, and belt holster. It provides on-the-spot sorting and valuation of allprecious metals as well asquantification of other desirable andundesirable elements.

Thermo Fisher Scientific, Inc.www.thermoscientific.com/niton

PublisherAndrew Cullison [email protected], Extension 249General Management,Reprint Permission,Copyright Issues

EditorMary Ruth [email protected], Extension 238Feature Articles

Production Editor Zaida [email protected], Extension 265Design and Production

Advertising Sales Director Rob Saltzstein [email protected], Extension 243Advertising Sales

Advertising Production ManagerFrank [email protected]; Extension 465Advertising Production

Advertising Sales & Promotion Coordinator

Lea Garrigan [email protected], Extension 220Production and Promotion

Welding Journal Dept. 550 N.W. LeJeune Rd. Miami, FL 33126 (800) 443-9353; FAX (305) 443-7404

CAN WE TALK?The Inspection Trends staff encourages an exchange of ideas with you, our readers. If you’d like to ask a question, share an idea

or voice an opinion, you can call, write, e-mail or fax. Staff e-mail addresses are listed below, along with a guide to help you inter-act with the right person.

Print & Product Fall IT 2011_Layout 1 9/22/11 1:59 PM Page 14

Feature


By Jeff Noruk, Blake Holmes, and Bob Bruss

For many years, manual weldgauges have remained the go-to toolfor every inspector performingnondestructive visual weld inspection.Examples of these type gauges areshown in Fig. 1.

Simple in design, these gaugeshave done what they were intended todo: give simple feedback as to whethera weld meets the minimum weldquality standard requirements.However, these devices are limited tothe types of joints and weld sizes theycan measure, and various joints requiredifferent gauges and techniques. Manytypes of gauges are on the markettoday, with most doing only onespecific task. In fact, one companyeven sells a fanny pack to carry allthese gauges. Even with the correctgauge for an application, the inspectorgets only a go/no-go result since mostmanual gauges do not give actualmeasurements. These gauges are alsoonly useful for basic welds and jointsso, for example, if a fillet weld hasunequal leg sizes or an angle that is not90 deg, additional calculations andequipment are required to accurately

measure the weld. These subjectivemeasurements are then typicallyrecorded manually making the wholeprocess quite time consuming and opento possible errors.

Three-dimensional laser precisionmeasurement technology has beenaround for decades, but due toequipment size, cost, and complexityhas been mainly reserved for roboticand hard automation applications. Withrecent developments in computercomponent size, battery life, andwireless technologies, laser-basedmeasurement tools have beendeveloped for hand-held weldinspection purposes. With simpleinterfaces not unlike a current-generation smart phone (Fig. 2), thesetools are easy to use, small in size for

tight-area access (Fig. 3), andrepeatable so that subjectivity isreduced, thus minimizing thepossibility of error. A simple click of atrigger can yield many usefulmeasurements such as leg sizes,convexity/concavity, and toe angles, aswell as the detection of discontinuitiessuch as undercut and porosity. Figure 4offers a pictorial view of the possiblemeasurements with a T fillet weldjoint. This information can then bedownloaded and saved into a databasefor reporting or to be maintained as apermanent record. If this sounds toogood to be true, it’s not, it’s simplycombining the technology that’salready available today into a wirelesshand-held device.

To help point out the advantages ofthe laser precision tool, the followingscenario of measuring a skewed fillet(Fig. 5) is reviewed.

Laser Tool vs. Fillet Gauge for aSkewed Fillet Weld

Fillet Gauge

1. Choose correct fillet gauge forspecific weld.

2. Consult AWS D1.1, StructuralWelding Code — Steel, to get correctcalculations for the skewed joint.

3. Determine the included angle ofthe fillet joint.

4. Consult the skewed filletcalculator.

5. Measure the leg sizes of the fillet.6. Decide if the weld fits within

the pass/fail criteria.7. Manually record results.

Laser Tool Offers Alternative for Precise Visual Weld InspectionThree-dimensional laser precision measurement technology is now available for hand-held visual weldinspection purposes

Fig. 1 — A variety of commerciallyavailable manual weld gauges.

Fig. 2 — User interface screen.

Noruk Feature Fall IT 2011_Layout 1 9/22/11 2:01 PM Page 15


Results Found: Angle of skewedfillet joint, go/no-go evaluation of theleg sizes and throat.

Laser Inspection Tool

1. Select fillet weld task in thedrop-down menu.

2. Scan the fillet weld in question(included angle of the skewed fillet isirrelevant to the scan) — Fig. 6.

3. Store results in a database.4. Open results in an Excel®

software format for viewing andreporting.

Results Found: Angle of skewedfillet joint, leg sizes, throat size, weldarea, undercut on legs 1 and 2,convexity/concavity, toe angle on legs1 and 2.

It is faster to take the measurementof a weld with the laser inspection tool,and it yields more-precise results andstores the data for easy retrieval andreporting.

InspectionApplications

With one laserinspection tool,joints such as T,butt, corner, and lapcan all be measuredby simply switchingtasks from one typejoint to the next.Typical weld sizescan range fromsmall gas tungstenarc welds tomultipass

submerged arc welds. It is even possibleto measure joints before welding, thusgiving you an opportunity to preventproblems from occurring earlier in themanufacturing process. Since thesedevices can yield so much informationabout your welding operations, it givesengineers the opportunity to improvequality, reduce overwelding, and findupstream problems in part and toolingpreparation.

Best Practices

Visual weld inspection is the mostprevalent nondestructive examination(NDE) method used today to ensurethat the welding manufacturing processis done correctly and meets allapplicable standards. Because of thecapabilities of this new laser-basedprecision measuring tool, you need tolook at the existing best practicesassociated with traditional visual weld

inspection and determine how thesewill change. Let’s look at some specificareas of the visual testing process.

Qualified People: As is true withall NDE methods, you need to startwith the people side of the equation tomake sure the person doing the visualweld inspection is qualified to do thework with respect to using themeasuring tool and is familiar with therequirements to be met. Using a lasermeasurement tool does not change thisrequirement, but because there is thepossibility to preprogram theinspection tool, the inspector doing thework only needs to know how to usethe tool properly to do a validinspection.

Measuring Tools andMethodology: Gauge repeatability andreproducibility are fundamental tousing any type of gauge or measuringdevice correctly. Typical manualgauges used for weld inspectionnormally change only from wear so acalibration is not really relevant.However, there is a large margin forerror with respect to how the inspectoruses the gauge, and thus two inspectorsmay get different results. A laserinspection tool, such as the WikiScan,when used per the approved operatinginstructions, is quite repeatable whenmeasuring standard AWS-type weldjoints and welds. Subjectivity is largelyeliminated, thus reducing the need forredundant inspections and the falloutfrom those redundancies, which is toincrease unnecessary repairs.

Do the Job Right the First Time:Typically, inspection is seen as

Fig. 3 — Checking weld size on heavy-plate pressure vessels.

Fig. 5 — The skewed fillet to be measured with a fillet gauge.

Fig. 4 — Weld feature measurements and defects detected.

Noruk Feature Fall IT 2011_Layout 1 9/23/11 8:33 AM Page 16


occurring after the weld is made andthe results are locked in stone. Whilethere have been attempts to use gaugesfor weld joint fitup checking, theirgo/no-go nature has made it difficult toget quantifiable data to act on.However, with laser-based measuringtools, you can accurately check fitup(included groove angle, mismatch, etc.)before starting welding, thus givingyou the chance to prevent making abad weld. Even further upstream, youcan use this tool during the procedurequalification work so as to accuratelydetermine the robustness of the designand welding process.

Documentation and InformationSharing in a 24/7 World: The olderpractice of using a gauge to measure aweld, writing the results down on apiece of paper, transposing them to acomputer spreadsheet or database, andthen printing a report is labor intensive,prone to error, and slow. The around-the-clock world we live in withengineering being done in one country,the product manufactured in another,and the actual use of the product takingplace in yet another, means informationmust be in an electronic format that iseasily transmitted. With a lasermeasuring tool, not only can youautomatically do the inspection and getthe results entered into an Excel file asnoted in the skewed fillet scenario, butthen you can add a picture to the recordas well as verbal comments and e-mail

this to anyone in the world. Imaginebeing onsite doing a critical weldinspection and being able toimmediately send all this informationto your manager, the owner of theproduct being inspected, or anyone elsewho needs to know the result to make atimely decision.

Welder Training andAssessment: Welder training andassessment methodology had remainedfairly static for many years until thecomputer started impacting this field.The computer has made virtual reality(VR) a very useful tool for teachingwelding without having to burn asmuch wire and make as much smoke.Whether VR or conventional training isemployed, the techniques used toevaluate the welder’s skills still involveeyeballing and manual weld gauging.Laser vision measurement allows youto precisely measure the weld size andcheck for defects, thus quantifying theresults such that an accurate score canbe given. This benchmark can then beused later to determine whether the

welder’s skills are improving,degrading, or staying the same.

Conclusion

Now that the digital era is here forsurface profile weld inspection, thepossibility for advancements is endless.Useful tools such as a pyrometer formeasuring preheat, interpass, andpostheat temperatures could be asimple upgrade or attachment. There iseven the possibility of such upgradesbeing available in an “app store” whereprograms are downloaded from theInternet and installed directly into thedevice.

JEFF NORUK ([email protected]) is president and BLAKE

HOLMES ([email protected]) iswelding engineer, Servo-Robot, Corp.,

Milwaukee, Wis. BOB BRUSS([email protected]) is president,

Fusion Consulting Services LLC,Muskego, Wis.

Fig. 6 — The same skewed fillet shownin Fig. 5 being scanned with the hand-held laser inspection tool.


Noruk Feature Fall IT 2011_Layout 1 9/23/11 9:13 AM Page 17

FeatureBy Howard K. Jones


As an inspector, you need to beable to think on your feet. You can findyourself in some unexpected situations.For instance, you could start yourinspection career at an outage. Outagesare fast paced, and the companiesinvolved have a lot at stake. Outagescan be difficult even for seasonedinspectors, let alone someone freshfrom taking the CWI test.

We’ll start with some generaladvice and then move on to fourspecific situations you do not expect toencounter, but very well might.

Preparing for the Job

During an outage, you may beworking 12-h days, 7 days a week. Thiscan get tedious, so you need to stayfocused. In addition, you will becovering a lot of ground. If you’re thequality control (QC) person on thenight shift, you may be working byyourself, and even if you’re on the dayshift, most likely it will be just you andthe site QC manager.

Here are some tips that may helpyou to be prepared.• Keep the welders’ names and their

stencils with you.• Keep a copy of the scope of work for

the job on your desk because thecustomer may have added someadditional inspection requirements.

• Make sure you have the qualitycontrol plan for the outage, as well asa copy of the quality control manualand the Welding ProcedureSpecifications (WPSs).

• Keep a memo book with you at all

times. In your memo book, list all thebase metals, wall thicknesses, pipeoutside and inside diametermeasurements, preheat temperatures,filler metals, and the WPSidentification numbers for eachprocess by system.

• Know what code each system is inthat you will be inspecting. Keep acopy of those codes on your desk,and review the visual inspectionrequirements each time you get backto your desk.

But, remember, if you are stayingon top of everything like you should,you won’t have time to be in the officebecause you need to be in the field —and vice versa. So be prepared, becausethat’s the way it is for the inspectorduring an outage.

Maintain Good Relationshipswith Other Workers

• It is advisable to include the safetyperson in your work. Regularlyinvite that person to make yourrounds with you. He or she willalmost always be happy to team upwith you and join you on yourrounds.

• Be fair, honest, and act in aprofessional manner with everyoneon the job site.

• Maintain your integrity, and guardyour language for your own respectand that of the company yourepresent. Doing this will increaseyour chances that the customer willwant you back later on for anotherquality-minded, professional job, not

to mention you will earn the respectof the people you work with.

• When you do reject a craftsperson’swork, treat that person with respect.Give the person a measurement,show him or her what was wrong,and state what the code requires andwhat it will take to make it right.Don’t just say, “Fix it, it’s wrong.”

Scenario 1: Dealing with aWelder Who Has Failed a Test

Here’s one of those situations younever thought about when you weretaking your CWI test:

After testing welders all day long,you finally get back to your hotel onlyto find yourself face to face with fourangry welders whom you have failedthat day, and a mad hotel manager whois losing four paying customers.

Here are some tips about what youcan do at the job site to help youprevent “the angry welder” situation.• Introduce yourself to all the welders

with a smile and a hand shake.• Look the welders in the eye when

you talk to them.• Treat welders with respect.• Print out and post all visual

inspection requirements for the test,the test shop rules, and the requiredhold points. Go over these with thewelders being tested, and ask them ifthey have any questions prior to thestart of the test.

• Identify the welders by checkingtheir identification. Record allinformation, as well as list all therequired documents, immediately on

How to Deal with the Unexpected

A long-time CWI offers some experienced-based advice to help you deal with thosesituations that occur on the job that you never expected to face

Jones Feature IT Fall 2011_Layout 1 9/23/11 8:33 AM Page 18


the Test Shop Log. Immediatelymatch the welders’ test coupons totheir names and IDs.

• Help each welder set up, and havehim or her tack the coupon at theproper angle as you hold it there.

• Always be available during testing.• If welder fails the test, use a

measurement tool to show thatperson the exact spot that did notmeet the inspection requirement, sothat he or she can clearly see wherethe problem occurred.

The following references mighthelp you. Visual inspectionrequirements for D1.1:2010, StructuralWelding Code — Steel, are found inpart C at 4.31.1.The Code then refersyou to 4.9.1 for acceptance criteria.Section 4.31.5 for root, face, andsidebend specimens refers you to4.9.3.3 for the acceptance criteriaspecimens. Welder performancequalification can be found in QWArticle 1 (QW 100 through QW 190)of Section IX of the ASME Boiler andPressure Vessel Code. Additionalinformation is also available in ArticleIII QW-300 through QW-380. Bendtest acceptance criteria can be found atQW-163.

Scenario 2: Sticking to theTask at Hand

Imagine the following scene: Thetest shop is full, and you are in themiddle of testing. One of the craftsuperintendents walks up to you anddemands that you leave to look atsomething that has to be inspected rightnow.

What should you do? Here aresome experience-based tips to help youdeal with this situation. First and mostimportantly, don’t refuse butrespectfully tell the craftsuperintendent you will have to get aqualified person there to witness andconduct the testing in your absence.

Stand your ground, but if he or sheinsists, suspend the testing. Collect thecoupons and take them to the office.

The advice here is that, as a CWI,you actually have no choice. Do notgive in to the person’s demands, and donot sign off on anything you have notactually witnessed. It is not worth the

damage it will do to your reputation forintegrity or that of your fellow CWIs.Most importantly, this one job isdefinitely not worth losing your CWIcard over, which you should if youmake the decision to sign forsomething you did not witness.Inspection is not a matter of trust, butof verified records.

Remember that you are bound bythe Code of Ethics, Rules of Conduct,and Practice found in Section 11 ofAWS QC1:2007, Standard for AWSCertification of Welding Inspectors. Inaddition, ASME Section IX, QW-103.1, under “Responsibility:” states:“Welding. Each manufacturer orcontractor (which is whom yourepresent) is responsible for thewelding done by his organization andshall conduct the test required in thissection to qualify the weldments heuses in this code, and the performanceof the Welders and Welding Operators,who apply these procedures.” Thismeans the entire test, not just part of it.

Scenario 3: Contract Violation

The construction manager bringsyou a stack of prints and wants you tostart inspecting roughly three acres offiberglass spool pieces that have beenlying in the sun for weeks and tells youto start transferring the stencils on thespool pieces to the prints.

In this situation, you know howlong the spools have been lying there,by the date next to the stencils.However, there are no system IDs, lineIDs, nothing. The advice here is for theinspector to print out all coderequirements.

With that information, you startinspecting. Because of the exposure tosunlight — when they beveled the pipe,nearly every spool was left without theprotective coating — you have no choicebut to reject the fit. The fitters were nottested when the spools were made up.The glue was stored improperly. You, asthe inspector, suggest going to theEngineer of Record and themanufacturer to see if there is a way toresolve the issue. Managementimmediately gets very upset andeveryone quits talking to you. Theyimmediately began hauling the pipe tothe site and installing it. Things from that

point go from bad to worse.So what should have been done in

a case like this? You should have left.That’s right, you should have left assoon as you had all the inspectioncriteria and the facts concerning thefabrication of the spool pieces.Unfortunately, there is nothing else youcan do. With this much pipe and moneyat stake, coupled with everyone’sreactions, you must realize thecompany will win at your expense. It iswhat it is. A situation like this is rare,but it happens. You do not need torepresent any contractor who acts andworks like this. It might not seem so atthe time, but believe it or not, there isanother job down the road.

Scenario 4: Refusing to Followthe Procedure

In this situation, the inspector is ona large outage with several inspectorson each shift. The problem is weldingstarts, and from the very beginning,electrodes are left everywhere. Thereare either no rod caddies or they are notassigned to anyone. There is nopreheating, no supervision.

As you move down the weld lines,you get to the heavy-wall, 21⁄4 chromewelds, and you can’t believe what youare seeing. Four fits are made luggedoff, right on top of the paint; no weldprep; no preheat, nothing.

The advice here is don’t get angry;keep a professional demeanor. Print acopy of the filler metal controls and theWPSs concerning the 21⁄4 chrome weldsand give it to the supervisor. (Theyshould already be posted in the workarea or at the rod shack.) Go over thesewith that supervisor again. Write anonconformance report, and make themrefit the welds according to theprocedure. Brief the rod room attendantand have each weld team go over thefiller metal controls. Explain howimportant this is and how it will beenforced. Take pictures. Andimmediately inform your supervisor.

Keep inspecting, documenting, andenforcing the procedure — confiscatingwelding rods on the spot, if necessary.Do no name calling. Hold onto yourintegrity and strictly enforce all holdpoints.

Jones Feature IT Fall 2011_Layout 1 9/22/11 3:08 PM Page 19


Conclusion

Here is the final scenario. You arehired by a company you have neverworked for before. The job is thereplacement of the main steamdistribution boxes commonly known asthe Wyes. The power company hasbrought a man out of retirement tooversee this replacement on two unitsat this station. At the first meeting, heexplains that this is a very importantand critical system replacement, andthe power company wants it done tothe letter at all costs.

You make sure everyone is inagreement with each step, everythingfrom the postweld heat treatment(PWHT), to verifying all dimensionalchecks, and from the boilersuperintendent to the power comzpanyrepresentative. You post the weldingprocedures on the scaffold at eachunit. Every electrode used comes outof a brand-new can and is checkedbefore it leaves the rod room. As soonas it hit the scaffold, it is immediatelyput in a caddy, with the temperature

being checked often.The temperature at the weld is

checked with a temperature-indicatingcrayon, in addition to PWHTmonitoring. Every pass is cleaned andinspected. The boiler superintendentwho is in charge is a pleasure to workwith. He knows his work and makes sureeverything is 100% exactly the way itshould be. The welders are as good asthey come. They take pride in their workand stay focused every minute of their12-h shift. You are out of the office andon the scaffolds before the shift starts.You keep moving back and forth untilthe shift is over and you go back to theoffice. You have made the rounds somany times you know there are 250steps between each weld station.

This is the job that keeps youcommitted to continuing on, thatassures you there are above-average,first-class craftspeople out there.

HOWARD K. JONES([email protected]) is a AWS CWI and

CWE, Ellijay, Ga.

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Jones Feature IT Fall 2011_Layout 1 9/22/11 2:03 PM Page 20

If you need some advice on how todo your job better and easier, whosebrain should you pick? InspectionTrends thought it should be those whohave plenty of inspection experience,so it turned to a group of AWS SeniorCertified Welding Inspectors and askedthem to share their best practices withregard to visual inspection.

The Benefits of Good Lighting

Bob Wiswesser: One of the keytips I can contribute is to emphasize theneed for proper use of sufficientlighting when performing visual weldinspection. I have often seen CWIsattempting to perform weldmeasurement and flaw evaluationwithout the use of auxiliary lightingsuch as a good flashlight or extension“drop” light, which might be necessaryto flood the examination area with atleast 50 foot-candles of generallighting or 100 foot-candles forperforming critical flaw evaluation.

Most of the modern “high-tech”flashlights an inspector can use todayare capable of producing theseminimum white light intensities atsensible distances such as 10–15 in.from the inspection surface. Thedistance needed to meet the requiredlight intensity can be verified simplyby checking the flashlight or drop lightsource with a white light meter.

The use of a handy portable lightsource is more often than not necessaryin the fab shop environment becauseoverhead fixed shop lighting rarely isadequate to provide even the minimumvisual inspection white light intensityreferenced in some of the older visualweld inspection standards including theASNT Visual Inspection Handbook, of32.5 foot-candles. Most of today’scurrent ASTM standards for NDEsurface flaw detection methods do

require the minimum light intensity tobe 100 foot-candles for critical flawevaluation, so this should be ourminimum standard lightingrequirement for CWIs whileperforming visual weld inspection.

Bob Wiswesser is operations chief,Welder Training & Testing Institute,Allentown, Pa. He is chair of the AWSCertification Committee. He is also aCertified Radiographic Interpreter, andhas earned endorsements to AWS D1.5and D1.2, API 1104, ASME SectionsVIII and IX, and for bolting inspection.

Things to Do before WorkEven Begins

James Ivy: Here are things to lookfor prior to the start of welding:

1. Ensure that all welders know thesafety requirements.

2. Meet with the contractor, soeveryone is on the same page for• Welder/tacker performance, weld

procedures, code and visualinspection requirements.

• Fitup tolerances, weld sizes, and howto use weld gauges.

When everyone is aware of whatto expect, the job will run smootherwith rework reduced or eliminated. Itwill come within budget and have zerosafety issues.

James Ivy is projectmanager/welding inspector in theFacilities Dept. at Ingalls Shipbuilding.His current duties include inspectionsfor the launch pontoon, tugboat,storage tanks, rail track welding, utilitypiping, and other items as projects areimplemented. He has held manypositions in the local AWS Section andis a past District 9 director.

Take Good Field Notes

Al Moore: The inspector should

write field notes with the thought inmind that there is only one opportunityto gather information. The final reportsubmitted to the client is based on thedata and information gathered duringthat inspection. The details included inthe final report should be substantiatedby the details included in the fieldnotes. The final report may not includeall the details recorded in the fieldnotes, but the inspector can rarely adddetails to the final report that were notincluded in the field notes.

The name of the project, locationof the inspection, date of theinspection, name of the inspector, andnames of the individuals whoparticipated in any conversationsrelevant to the project should beincluded in the field notes. Always listthe drawings and the revisions usedwhen the inspection was performed.

Field notes should be descriptiveand include details of the nature andextent of the nonconformance. The partnumber of the assembly and thecomponent that is deficient should belisted. It is not enough to say the weldwas cracked. The field notes have todefine the type of crack, location of thecrack, length of the crack, and anyother relevant information that may behelpful in writing the final reportsubmitted to the client. Don’t overlookincluding the type of tools or gaugesused to measure or evaluate thediscrepancy. The level of detailrecorded in the field notes should bemore than what is needed in the finalreport.

A good quality digital camera isthe inspector’s best friend wheninspecting welds or other items.Photographs should be logged in thefield notes with a date and withidentification. Digital cameras identifythe photographs in memory with a filenumber. The photo file number with adescription of the condition the

Feature


By Mary Ruth Johnsen

Visual Inspection Tips from the Pros

Several experienced inspectors offer good advice that you can use on the job

Johnsen Feature IT Fall 2011_Layout 1 9/23/11 8:34 AM Page 21


photograph depicts should be includedin the field notes. Otherwise, theinformation and the particulars can belost or forgotten by the time the actualreport is written. It is a good idea toinclude a ruler in the photograph whenthere is an issue relating to physicaldimensions. The ruler will provide asense of scale for the person looking atthe photograph.

Details, details, and more details:they are the backbone of a goodinspection report and key to a successfulcase should litigation become necessary.

Albert J. Moore Jr. is vice president,Marion Testing & Inspection, Canton,Conn. He is an ASNT ACCP NDT Level III.He is also a member of the AWSCertification Committee and the Committeeon Methods of Inspection of Welds. He hasheld numerous offices in the local AWSSection, including chair.

Practices of EffectiveInspectors

Steve Snyder: Most inspectorshave certain habits or project practicesthey learn along the way and then take

with them through their careers. It ishoped these are positive traits that onlyaid their success and professionaldevelopment and help them do theirjobs more efficiently and accurately.

A few that come to mind I haveconsciously and frequently practicedare as follows:

1. Know what’s therequirements of the job before itbegins. Become completely familiarwith the inspection requirements andacceptance criteria before the projectbegins instead of trying to determinewhat they are during the productionphase of the project. I’m well awarethat sometimes kickoff meetings arelate, are not required, or project workhas started before the inspector getsinvolved, therefore complicating thisfor the CWI or SCWI. However, oftenall it takes to clarify what therequirements are and what is expectedof you is an informal e-mailcorrespondence. I suggest you keep arecord of any technical clarifications(Table 1) that arise during meetings orprepare a formal request andagreement. These can prove to be

essential as a project progresses in theevent of selective amnesia.

2. Have your own set of gauges.Many inspectors, especiallyexperienced third-party inspectors,show up expecting the quality control(QC) person to do all inspection intheir witness or presence using theQC’s gauges so they say they don’tneed or require their own inspectiongauges. Others feel it is simply not partof his or her role on the project. Whilethat may well be the case, I feel it isessential that you have the requiredinspection tools and gauges to performthe project inspections required by QC,even if you are acting as a third partyinspector. This sends the message thatyou understand what is required and, ifneed be, will verify it yourself.

3. Set up a good tracking system.Having good systems, forms, anddocumentation practices to track theweld procedure qualifications and/orproduction acceptances and status on aproject is essential to stayingorganized. Every inspector has his orher own way of doing this. Table 2 is asample of a form I have used on

Table 1 — Technical Qualification Form

CLIENT: DATE: September 9, 2008 REVIEWER:PROJECT: STSCONTRACT TYPE:File No. 2008-011 REVISION: Submittal

Item No. Clause Qualification Reason Status

General

1. Scope of Work Proposal is based on execution of the work Basis of proposal. Qualificationclearly identified in the attached remains open.“Method Statements” for each respective pkg A, B, C, and D.

7-30-08 (MOC). Package A is the only scope being awarded at this time. Method Statements are not clear to MOC and not agreed to as of this date.MOC to review Technical proposal and propose acceptable wording to for closure.

08-13-08 (S7). Awaiting MOC response to sections T2, T16, and T17 of Technical Tender GM-08-009.

9-8-08 (MOC). T2 and T16 do not represent the project scope and need to be revised with the agreed scenario. T17 is this very document we are working on closure.

2. Company It is assumed that all Company-provided materials Depending upon the Options, Agreed 7/30/08provided items would be delivered to nominated location in due may wish to receive CPMs at

time to not delay any of the operations. various locations in the GOM.

7-30-08 (MOC) S7 to provide sufficient lead noticefor delivery.

Johnsen Feature IT Fall 2011_Layout 1 9/22/11 2:07 PM Page 22


projects regardless of any otherreporting required. This form helps mein tracking my day-to-day activities orstatus of any and all weld procedurequalifications. Using or updating theform daily has proved essential toproviding timely feedback to the client.

Steven T. Snyder is technicalmanager, Oil States Industries (Asia) PteLtd.-Singapore. He is an AWS CWE,CSWIP-PAUT, ASNT Level III, ICC-S1and S2, ASQ CQA with more than 23years of multiple industry experience.

Welding and Repair ofGalvanized Coatings

Robert Hay: The incorporation ofzinc into weldments has a negativeimpact on the integrity of welds. Thiswould include coatings at the fusedsurfaces of fillet welds as well as thegroove faces of groove welds. Oftenthere is no forethought given byfabricators in regard to the welding ofsurfaces with zinc coatings. All zinccoatings should be removed prior to

welding as required in AWS D1.1,Structural Welding Code — Steel,Section 5.15 Preparation of BaseMetal. The specific degree of zincremoval (i.e., distance from weld toe,removal of all intermetallic layers)should be thoroughly discussed withthe inspection agency and weldingcontractor prior to welding operations.The WPS utilized on the project shouldaddress coatings and any surfacepreparation. Proper galvanized coatingremoval can be labor intensive andcostly. Quite often, the removal andsubsequent repairs are not anticipatedwhile bidding projects.

The repair of galvanized coatingsis very important after weldingoperations have been completed. TheCWI is often asked to review the zincrepairs although most have no formaltraining to do so. Improperly appliedcoatings can prematurely fail resultingin unprotected weldments. It is myexperience that the performance ofcold galvanized coatings is contingenton the quality of the surface

preparation prior to application. Therepair coating should meet therequirements of ASTM C780 for therepair of damaged hot dip galvanizedcoatings. It is critical the surfaces befree of oil, moisture, rust, dirt, or othercontamination prior to application.

Solvent cleaning (SSPC-SP1) isusually sufficient for new steelsurfaces. However, surfaces that wererepaired or welded might require wirebrush cleaning (SSPC-SP2), power toolcleaning (SSPC-SP3), or commercialblast cleaning (SSPC-SP6) in order toremove all welding-associatedproblems that could compromise thecoating. Some manufacturers requirethat a needle gun finish be performed(SSPS-SP11) on repaired surfaces. It isimportant that the coatingmanufacturer’s surface preparation andapplication instructions be followed.

Robert Hay is a senior projectexecutive for Flood Testing Labs,Chicago, Ill., the largest employer ofCWIs in the state. His primary functionat the company is as lead technical

Table 2 — Sample Form Used on Projects



specialist for building materials. He isan ASNT NDT Level III magneticparticle, dye penetrant, ultrasonic, andvisual inspection; and an ICCStructural Steel Bolting SpecialInspector, Steel Welding SpecialInspector, Masonry Special Inspector,Prestress Concrete Special Inspector,and Master of Special Inspection. He isa member of the AWS Subcommittee onCertification of Structural Inspectors.

Beware of UnscrupulousCompanies and Individuals

Eugene Hornberger: A few yearsago, I received a phone call from asteel erector contractor who said he hadsome Welder PerformanceQualification records that had mysignature on them, and he felt theywere not right. I asked him to send mecopies of them. I received copies of 20welder performance records. He wascorrect in that they were not right; theyhad been altered.

My signature was in the sameplace on each document. My SCWIstamp was in the same place on each

document. The original welder’s namewas whited out and another name typedin. A typeface different than the one Iuse had been used to type in the newwelders’ names.

As I investigated what hadhappened, I found out the correct story.The steel erector contractor (prime) didnot have enough help to erect the steelfor a school so he hired a subcontractor(sub) to do the job for him. The primecontractor told the subcontractor that hehad to supply welder certification papersfor his welders. The subcontractorfinished the job but never supplied thewelder certification papers. The primesaid, “No papers, no money.” The primeand sub battled through lawyers until thesub produced the bogus paperwork thatwas later sent to me.

I tried to no avail to dispute thealtered documents. No one else disputedthe alterations: Not the Engineer ofRecord, no CWI, nor the primecontractor. No one. While I don’t knowhow to prevent a situation such as thisfrom happening, I do know we all needto be on guard for unscrupulouscompanies and individuals.

If anyone involved in an unethicalpractice is an AWS SCWI or a CWI, acomplaint can be brought against them.The procedure for that is outlined inAWS QC9-98, AdministrativeProcedures for Alleged Violations ofAWS Certification Programs, whichcan be downloaded for free from theAWS Web site, www.aws.org.

Eugene Hornberger is the ownerof Eugene G. Hornberger, Consultant,LLC, for which he tests welders andprepares Welding ProcedureSpecifications and Welding ProcedureQualifications for companies. He is aLife Member of the American WeldingSociety, and has served as chair of theEducation Committee and on the Boardof Directors of the American WeldingSociety.

MARY RUTH JOHNSEN([email protected]) is Editor of

Inspection Trends.

For info go to www.aws.org/ad-index For info go to www.aws.org/ad-index


The Answer Is


The Society is not responsible for any statements made or opinion expressed herein. Data and information developed by the authors are for specificinformational purposes only and are not intended for use without independent, substantiating investigation on the part of potential users.

By K. Erickson and C. Mankenberg

Q: I am a certified Level II liquidpenetrant and magnetic particle NDEinspector. Many times, I am sent outto perform these examinations onstainless steel and carbon steel welds.Although I am not a CWI, the welds

oftentimes have surface indicationssuch as undercut and porosity thatare not corrected. I thought that allwelds require some form of visualinspection prior to any NDE beingperformed?

A: I cannot speak for every project;however, if nondestructiveexaminations are required, the majorityof governing standards used todaywould also require visual inspections tobe performed and accepted by acertified individual to a determinedacceptance criteria prior to other NDE.You can always inquire if the visualinspections have been completed,accepted, and documented prior toperforming your examinations.

In today’s industries and variety ofapplications, it is not uncommon tohave separate inspectors for both visualtesting and other NDE purposes. Manywelding and fabrication shops willcontract out the nondestructiveexaminations as opposed to having andmaintaining this program in-house.

Also for consideration may be thesimple fact that whoever is responsiblefor performing the visual inspection(s) iseither not performing this task or is notcompetent and/or certified to beinspecting welds. In this case, youshould bring this to the attention of yourimmediate supervisor or manager forinvestigation and resolution. NDEacceptance criteria may and will differfrom visual acceptance criteria, so it isimportant to establish and acknowledgewhat it is you are signing for in

Inspection Trends encouragesquestion and answer submissions. Pleasemail to the editor ([email protected]).

KENNETH ERICKSON is manager of qual-ity at National Inspection & Consultants,Inc., Ft. Myers, Fla. He is an AWS SeniorCertified Welding Inspector, an ASNT Na-

tional NDT Level III Inspector in four meth-ods, and provides expert witness reviewand analysis for legal considerations.

CLIFFORD (KIP) MANKENBERG is aconstruction supervisor for Shell Interna-tional Exploration & Production, Hous-ton, Tex. He is an AWS Senior Certified

Welding Inspector and an ASNT NationalNDT Level III Inspector in five methods.gradientlens.com 800.536.0790

Your Eye Inside™

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Hawkeye® Borescopes quickly identify the quality and integrity of any weld, even in long tubes or complex parts!In combination with our Luxxor® Video Systems, you can also capture, document, and e-mail inspection images. Our video systems are compatible with any Hawkeye Borescope, and most other borescopes as well.

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— continued on page 32

The Answer Is Fall IT 2011_Layout 1 9/22/11 2:11 PM Page 25

ASNT Fall Conf. and Quality Testing Show. Oct. 24–28,Palm Springs Convention Center, Palm Springs, Calif.Contact American Society for Nondestructive Testing, (800)222-2768 or www.asnt.org.

VISION 2011, International Trade Fair for MachineVision. Nov. 8–10, Stuttgart Trade Fair Center, Stuttgart,Germany. Contact Landesmesse Stuttgart GmbH, 49-711-18560-0; or visit www.messe-stuttgart.de/vision.

FABTECH. Nov. 14–17, McCormick Place, Chicago, Ill.Contact American Welding Society, (800/305) 443-9353, ext.264; or visit www.fabtechexpo.com or www.aws.org. TheAWS conference schedule during FABTECH is as follows:

National Welding Education Conference, Nov. 15,contact Monica Pfarr at (800/305) 443-9353, ext. 461, [email protected].

Welding Technology to the Rescue, Nov. 148th Conference on Weld Cracking, Nov. 15What’s New in Power Sources, Nov. 16Thermal Spray Technology: High-Performance

Surfaces, Nov. 16For more information, contact Zoey Oliva at (800/305)

443-9353, ext. 264, or [email protected].

ASNT 21st Annual Research Symposium and SpringConference. March 19–23, 2012, Sheraton Dallas Hotel,Dallas, Tex. Contact American Society for NondestructiveTesting, (800) 222-2768 or www.asnt.org.

65th Annual Assembly of the International Institute ofWelding. July 8–13, 2012, Hyatt Regency Hotel Denver andColorado Convention Center. Sponsored by the AmericanWelding Society, Edison Welding Institute, and WeldingResearch Council. Visit www.iiw2012,com.

Review of Progress in Quantitative NondestructiveEvaluation (QNDE). July 15–20, 2012, Hyatt Regency TechCenter, Denver, Colo. Contact [email protected] orwww.qndeprograms.org.

Educational OpportunitiesNDE Classes. Moraine Valley Community College, PalosHills, Ill., offers NDE classes in PT, MT, UT, RT, RadiationSafety, and Eddy Current, as well as API 510 exam prep andweld inspection. For more information, contact (708) 974-5735; [email protected]; morainevalley.edu/NDE.

CWI Prep Course and AWS CWI Seminar and Exam.The Prep Course prepares candidates for the AWS CertifiedWelding Inspector (CWI) seminar and examination. OfferedOct. 17–21. The CWI seminar covers how to reference AWScodes, examine welds, and prepare for the CWI exam on thatfollowing Saturday (proctored by AWS). Offered Oct. 23–29.Contact Lincoln Electric’s Welding School at (216) 383-8325or visit www.lincolnelectric.com.

EPRI NDE Training Seminars. EPRI offers NDE technicalskills training in visual examination, ultrasonic examination,ASME Section XI, UT operator training, etc. Contact SherrylStogner, (704) 547-6174, e-mail: [email protected].

Nondestructive Examination Courses. A course schedule isavailable from Hellier, 277 W. Main St., Ste. 2, Niantic, CT06357, (860) 739-8950, FAX (860) 739-6732.

NDE Training Courses. GE Inspection Technologies offerstraining on topics such as eddy current, digital radiography,and remote visual inspection. For the complete schedule,contact (866) 243-2638; [email protected];www.ge.com/inspectiontechnologies.

Positive Material Identification Seminars. Topics coveredwill include basics of X-ray fluorescence (XRF) analysis,APRI RP 578, and recommended PMI procedures. For moreinformation or to register, contact Thermo Fisher Scientific,Inc., at www.niton.com/News-and-Events.

Preparatory and Visual Weld Inspection Courses. One-and two-week courses presented in Pascagoula, Miss.,Houston, Tex., and Houma and Sulphur, La. Contact RealEducational Services, Inc., (800) 489-2890;[email protected].

CWI/CWE Course and Exam. A ten-day program presentedin Troy, Ohio. Contact Hobart Institute of Welding Technology(800) 332-9448; www.welding.org; [email protected].

T.E.S.T. NDT, Inc., Courses. CWI preparation, NDEcourses, including ultrasonic thickness testing and advancedphased array. On-site training available. T.E.S.T. NDT, Inc.,193 Viking Ave., Brea, CA 92821; (714) 255-1500; FAX(714) 255-1580; [email protected]; www.testndt.com.

NDE Training. NDE training at the company’s St. Louis-area facility or on-site. Level III services available. For aschedule of upcoming courses, contact Quality TestingServices, Inc., 2305 Millpark Dr., Maryland Heights, MO63043; (888) 770-0103; [email protected];www.qualitytesting.net.

CWI/CWE Prep Course and Exam and NDT InspectorTraining Courses. An AWS Accredited Testing Facility.Courses held year-round in Allentown, Pa., and at customers’facilities. Contact: Welder Training & Testing Institute(WTTI). Call (800) 223-9884, [email protected], or visitwww.wtti.edu.

Welding Inspection, INTEG, Welding Health and Safety,and Welding Supervisor Courses. Contact the CanadianWelding Bureau for schedule at (800) 844-6790, or visitwww.cwbgroup.org.


Mark Your Calendar

Mark Your Calendar IT Fall 2011_Layout 1 9/22/11 2:12 PM Page 26

Certification Schedule

Certified Welding Inspector (CWI)LOCATION SEMINAR DATES EXAM DATEAtlanta, GA Oct. 30–Nov. 4 Nov. 5Dallas, TX Nov. 6–11 Nov. 12Sacramento, CA Nov. 6–11 Nov. 12Spokane, WA Nov. 6–11 Nov. 12Chicago, IL Exam only Nov. 17Syracuse, NY Dec. 4–9 Dec. 10Miami, FL Dec. 4–9 Dec. 10Houston, TX Dec. 4–9 Dec. 10Reno, NV Dec. 4–9 Dec. 10Los Angeles, CA Dec. 4–9 Dec. 10St. Louis, MO Exam only Dec. 10Corpus Christi, TX Exam only Dec. 31Beaumont, TX Jan. 8–13 Jan. 14Fresno, CA Jan. 8–13 Jan. 14Charlotte, NC Jan. 15–20 Jan. 21 Long Beach, CA Jan. 22–27 Jan. 28Seattle, WA Jan. 22–27 Jan. 28Pittsburgh, PA Jan. 29–Feb. 3 Feb. 4Birmingham, AL Jan. 29–Feb. 3 Feb. 4Denver, CO Jan. 29–Feb. 3 Feb. 4Waco, TX Feb. 5–10 Feb. 11 Milwaukee, WI Feb. 26–Mar. 2 Mar. 3 Atlanta, GA Feb. 26–Mar. 2 Mar. 3 San Diego, CA Feb. 26–Mar. 2 Mar. 3 Miami, FL Feb. 26–Mar. 2 Mar. 3 Houston, TX Mar. 4–9 Mar. 10Norfolk, VA Mar. 4–9 Mar. 10Kansas City, MO Mar. 4–9 Mar. 10Indianapolis, IN Mar. 11–16 Mar. 17Portland, OR Mar. 11–16 Mar. 17Phoenix, AZ Mar. 11–16 Mar. 17Boston, MA Mar. 18–23 Mar. 24Anchorage, AK Mar. 18–23 Mar. 24Chicago, IL Mar. 18–23 Mar. 24Miami, FL Mar. 25–30 Mar. 31Dallas, TX Apr. 15–20 Apr. 21Springfield, MO Apr. 15–20 Apr. 21Portland, ME Apr. 15–20 Apr. 21Las Vegas, NV Apr. 15–20 Apr. 21San Francisco, CA Apr. 29–May 4 May 5Nashville, TN Apr. 29–May 4 May 5Jacksonville, FL Apr. 29–May 4 May 5

9–Year Recertification Seminar for CWI/SCWI For currentCWIs and SCWIs needing to meet education requirements withouttaking the exam. The exam can be taken at any site listed under Cer-tified Welding Inspector. LOCATION SEMINAR DATES EXAM DATENew Orleans, LA Nov. 7–12 No exam

Miami, FL Dec. 12–17 No examNew Orleans, LA Jan. 9–14 No Exam Denver, CO Feb. 6–11 No Exam Dallas, TX Mar. 12–17 No Exam Miami, FL Apr. 16–21 No Exam Sacramento, CA Apr. 30–May 5 No Exam

Certified Welding Supervisor (CWS)LOCATION SEMINAR DATES EXAM DATEAtlanta, GA Jan. 9–13 Jan. 14New Orleans, LA Apr. 16–20 Apr. 21CWS exams are also given at all CWI exam sites.

Certified Radiographic Interpreter (CRI)LOCATION SEMINAR DATES EXAM DATEAllentown, PA Nov. 7–11 Nov. 12Seattle, WA Feb. 27–Mar. 2 Mar. 3Houston, TX Apr. 16–20 Apr. 21The CRI certification can be a stand-alone credential or can exemptyou from your next 9-Year Recertification.

Certified Welding Sales Representative (CWSR)CWSR exams will be given at CWI exam sites.

Certified Welding Educator (CWE)Seminar and exam are given at all sites listed under Certified Weld-ing Inspector. Seminar attendees will not attend the Code Clinic por-tion of the seminar (usually the first two days).

Certified Robotic Arc Welding (CRAW)WEEK OF LOCATION CONTACTOct. 31 OTC Daihen, Inc., Tipp City, OH (937) 667-0800Nov. 7 ABB, Inc., Auburn Hills, MI (248) 391–8421Dec. 12 OTC Daihen, Inc., Tipp City, OH (937) 667-0800On request: MATC, Milwaukee, WI (414) 297-6996

Certified Welding Engineer (CWEng)Exam can be taken at any site listed under Certified Welding Inspec-tor. No preparatory seminar is offered.

Senior Certified Welding Inspector (SCWI)Exam can be taken at any site listed under Certified Welding Inspec-tor. No preparatory seminar is offered.

Advanced Visual Inspection WorkshopLOCATION SEMINAR DATES EXAM DATEMiami, FL Feb. 9-10 Feb. 11Miami, FL May 17-18 May 19Miami, FL Aug. 16-17 Aug. 18

International CWI Courses and Exams Schedules Please visit www.aws.org/certification/inter_contact.html.


Important: This schedule is subject to change without notice. Please verify your event dates with the Certification Dept. and confirm your coursestatus before making your travel plans. For information, visit www.aws.org/certification, or call (800/305) 443–9353, ext. 273, for Certifica-tion; or ext. 455 for Seminars. Apply early to avoid paying the $250 Fast Track fee.

Seminars, Code Clinics, and ExaminationsApplication deadlines are six weeks before the scheduled seminar or exam. Late applications will be assessed a $250 Fast Track fee.

Certificaion Schedule IT Fall 2011_Layout 1 9/23/11 8:35 AM Page 27

Just the FactsBy Lyndsey Deckard


Some, among the more than 30,000AWS Certified Welding Inspectors andSenior Certified Welding Inspectors, arecertified in one or more methods of

nondestructive examination (NDE). Manyothers are not. A CWI or SCWI is notrequired to be certified in any NDEmethod(s). They are, however, required to

have a basic knowledge of the major NDEmethods and recognize their advantagesand limitations in order to determine theappropriateness of their application in any

Verifying the Proper Choice of Nondestructive Examination

— continued on next page

Examination Method Selection Guide

Typical Equipment Applications Advantges Limitations

Visual

Light source, magnifiers, color Detection of surface The method is economical The method is limited toenhancement, protractors, other discontinuities only. and expedient, and requires surface conditions only andmeasurement equipment, i.e., Verification of fitup and joint relatively little training and by the experience and visualrulers, micrometers, optical configuration, weld relatively little equipment for acuity of the inspector.comparators. dimensions, and profiles. many applications.

Liquid Penetrant

Fluorescent or visible dye Detection of surface The equipment is portable Surface films such as coatings,penetrant, developers, cleansers discontinuities only. and relatively inexpensive. scale, smeared metal may mask(solvents, emulsifiers, etc.). The examination results are or hide discontinuities. BleedSuitable cleaning gear. expedient. Results are easily out from porous surfaces canUltraviolet light source if interpreted. Requires no also mask indications. Partsfluorescent dye is used. electrical energy except for must be cleaned before and

light sources. after examination.

Magnetic Particle

Prods, yokes, coils suitable for Detection of surface or near- The method is relatively The method is applicable onlyinducing magnetism into the surface discontinuities only. economical and expedient. to ferromagnetic materials.weld. Power source (electrical). Examination equipment is Parts must be cleaned beforeMagnetic powders — some considered portable. Unlike and after examination. Thickapplications require special dye penetrants, magnetic coatings may mask rejectablefacilities and ultraviolet lights. particle can detect some discontinuities. Some

discontinuities slightly below applications require the partthe surface. to be demagnetized after

examination. Magnetic particleexamination requires use ofelectrical energy for mostapplications.

Radiography (Gamma)

Gamma ray sources, gamma Detection of voluminous The method is generally not Planar discontinuities must beray camera projectors, film discontinuities such as restricted by type of material favorably aligned withholders, film, lead screens, film porosity, incomplete joint or grain structure. The radiation beam to be reliablyprocessing equipment, film penetration, slag, etc. method detects surface and detected. Radiation poses aviewers, exposure facilities, Lamellar-type discontinuities subsurface discontinuities. potential hazard to personnel.radiation monitoring such as cracks and incomplete Radiographic images aid in Cost of radiographicequipment. fusion can be detected with a characterizing discontinuities. equipment, facilities, safety

lesser degree of reliability. It The film provides a programs, and related licensingmay also be used in certain permanent record for future is relatively high. A relativelyapplications to evaluate review. long time between exposuredimensional requirements process and availability ofsuch as fitup, root results. Accessibility to bothconditions, and wall sides of the weld required. Usethickness. and disposal of processing

chemicals.

Just the Facts Fall IT 2011 New_Layout 1 9/22/11 2:13 PM Page 28


particular situation.It is important for the CWI or SCWI to

recognize a situation in which the best NDEmethod for a particular set of circumstancesis in use and determine if that method isindeed being employed. The certifiedinspector is expected to recognize the properapplication of each major method. While theAWS CWI is not required to be certified inany NDE method, he or she is expected to beable to identify each method and process,and its proper application.

AWS B1.10M/B1.10:2009, Guide for theNondestructive Examination of Welds,Annex A, “Examination Method SelectionGuide,” offers an excellent synopsis of theequipment needs, applications, advantages,and disadvantages of the eight most commonand popular NDE methods. This will presenta good review for knowledgeable individualsand perhaps broaden the knowledge base ofothers who may not deal with each of theseNDE methods on a regular basis. Annex Abegins on page 28.

Lyndsey Deckard ([email protected]) is quality manager of theVehicle Division of Parsons Brinckerhoff

Transit & Rail Systems, Inc. He is an AWSSenior Certified Welding Inspector, anASQ Certified Quality Auditor, and a

member of the AWS Certification Committee, Examination Question BankSubcommittee, and Ethics Subcommittee.

Examination Method Selection Guide

Typical Equipment Applications Advantges Limitations

Radiography (X-rays)

X-ray sources (machines), Same application as Same as previous page, except High initial cost of X-rayelectrical power source, same previous page. that X-ray radiography can use equipment. Not generallygeneral equipment as used with adjustable energy levels, and considered portable. Also,gamma sources (previous page). it generally produces higher same limitations as

quality radiographs than previous page.gamma sources. The processalso enjoys the sameadvantages as previous page.

Ultrasonic

Pulse-echo instrument capable The method can detect most The method is most sensitive Surface condition must beof exciting a piezoelectric weld discontinuities including to planar-type discontinuities. suitable for coupling ofmaterial and generating cracks, slag inclusions, and The test results are known transducer. A liquid couplant isultrasonic energy within a incomplete fusion. It can also immediately. The method is required. Small, thin welds mayweld, and a suitable cathode be used to verify base metal portable, and most ultrasonic be difficult to inspect.ray tube scope or digital display thickness. flaw directors are battery Reference standards and acapable of displaying the operated. The method has relatively skilled operator ormagnitudes of received sound high penetration capability. inspector are required.energy. Calibration standards, Method may be used when Materials with large grainliquid couplant. access to only one side of the structures may be difficult to

joint is available. inspect. The method is lesssensitive to roundeddiscontinuities.

Eddy Current

An instrument capable of Detection of discontinuities Equipment used with surface Relatively shallow depth ofinducing electromagnetic fields on or near the surface. Alloy probes is generally examination. Many materialwithin a weld and sensing the content and heat treatment lightweight and portable. and test variables can effect theresulting electrical currents condition may affect results. Painted or coated welds can test signal.(eddy) so induced with a be inspected. The method cansuitable probe or detector. be partially or completelyCalibration standards. automated for a high speed,

relatively inexpensiveexamination.

Leak Testing

Leak testing requires a gas or Detection of through- Relatively cheap and easy to Requires a source of water orliquid medium, a pump to thickness discontinuities do if visual detection of leaks other medium, a means ofapply a differential pressure to is possible. Special mediums disposing of the medium, andone side of a weldment and a such as helium require more the weldment may requiredevice to contain the pressure if sophisticated equipment to cleaning after testing.the weldment is not a closed detect. However, helium leakstructure. A detection testing is very sensitive.instrument if the mediumpenetrating the weld cannot bedetected visually may also berequired.

Just the Facts Fall IT 2011 New_Layout 1 9/22/11 2:14 PM Page 29


Technology NotesErrata AWS D17.1 and D17.2 Aerospace Welding Specifications

Errata — AWSD17.1/D17.1M:2010

Specification for FusionWelding for Aerospace

Applications

The following errata have been iden-tified and will be incorporated into thenext reprinting of this document.

Page 9 — Figure 5.1, S.S. No. — Re-move “S.S. No.” from the top of the sug-gested test record form.

Page 18 — Figure 5.7, Note — Cor-rect “Suggested dimension” to “Wheremember differ in thickness more than10% of the thicker member, the capsheet shall be the thicker member”

Page 18 — Figure 5.7, Footnote a— Correct “Where member differ inthickness more than 10% of the thickermember, the cap sheet shall be thethicker member” to “Suggested dimen-sion”

Page 22 — 5.4.2 Procedure Quali-fication, Numbering sequence — Cor-rect “(8) filler metal used” to “(9) fillermetal used”, “(9) joint design” to “(10)joint design”, “(10) electrical character-istics” to “(11) electrical characteris-

tics”, “(11) preheat requirements” to“(12) preheat requirements”, “(12) post-weld heat requirements” to “(13) post-weld heat requirements”, and “(13)other variables required by the Engi-neering Authority” to “(14) other vari-ables required by the Engineering Au-thority”

Page 34 — Table 7.1, Mismatch Be-tween Members after Welding — Cor-rect “Refer to Paragraph 6.14.4 & Fig-ure 6.2 Includes A, B & C Class ofWelds” to “Refer to Paragraph 7.5.2.1 &Figure 7.2 Includes A, B, & C Class ofWelds”

Page 36 — Figure 7.1, WIDTH OFWELD FACE OR INDIVIDUALSURFACE BEAD, W — Correct “W > 5⁄16 in TO W < 1 in [25 mm]” to “W > 5⁄16

in [8 mm] TO W < 1 in [25 mm]”Page 36 — Figure 7.1, Footnote a

— Correct “a Refer to 4.3.8.2” to “a

Refer to 5.3.8.2”Page 37 — Figure 7.2, Extra hori-

zontal line within table — Remove hor-izontal line between “OFW, SMAW,GTAW, GMAW” and “PAW, VP-PAW,FCAW, SAW”

Page 49 — Figure A.1(d), Missinghorizontal line within table — Add

horizontal line between “PAWa” and“GMAW FCAW SAW”

Page 58 — Table A.1, ComparableFillet Weld Size for Same Strength(in [mm]) — Correct “1.23 [21.2]” to“1.23 [31.2]”

Page 65 — Table C.3, Missing linewithin table — Add vertical line be-tween “T1” and “W”, “Max.” and“Min.”, and “6” and “7”

Page 82 — G4.14 Welding andWeldments — Correct “Figure 6.2 dic-tates maximum mismatch at the com-pleted weld joint.” to “Figure 7.2 dic-tates maximum mismatch at thecompleted weld joint.”

Errata: AWSD17.2/D17.2M:2007

Specification for Resistance Welding for Aerospace

Applications

The following erratum has been iden-tified and will be incorporated into thenext reprinting of this document.

Page 14, Figure 7, annulus width — Cor-rect “0.15 Sm” to “0.15 Rm”

Errata: D1.5M, Bridge Welding Code

Standard: AASHTO/AWS D1.5M/D1.5: 2010, Bridge Welding CodeThe following erratum has been identified and will be incorporated into the next reprinting of this document.Page 82, Table 4.1 (Continued), Matching Filler Metal Requirements for WPSs Qualified in Conformance with 5.12.Correct “ER90C-XXX” to read “E90C-XXX” in the Welding Processes and Electrode Specification Classifications column.

This is the fifth entry from the bottom of the column.

Official Interpretation

D1.1, Structural Welding Code — Steel

Subject: Qualifying two welders on one joint for pipeCode Edition: D1.1:2006Code Provision: 4.30.3.1 and 4.19.1.1AWS Log: D1.1-06-I20

Inquiry: Based on 4.30.3.1, is it allowed to qualify two welders on the same joint, each of them welding half pipe circumference,from top center to bottom center (either uphill or downhill progression)?

Response: No.

Technology Notes Fall It 2011_Layout 1 9/22/11 2:14 PM Page 30


Addenda Issued for D1.9, Structural Welding Code — Titanium

The following addenda has been made and incorporated into the current edition of this document.

AWS Standard: D1.9/D1.9M:2007, Structural Welding Code — TitaniumAddenda No.: ADD1Subject: Radiographic Crack Allowance in Table 5.2

Page 81: Add a row above “Fine Scattered Porosity” to Table 5.2 for cracks discontinuity types as follows:

Technology Notes Fall It 2011_Layout 1 9/22/11 2:15 PM Page 31

American Society for Nondestructive Testing . . .11, 12www.asnt.org . . . . . . . . . . . . . . . . . . . . .(800) 222-2768

AWS Certification Services . . . . . . . . . . . . . . . . . . . . .7www.aws.org . . . . . . . . . . . . . . . . . . . . .(800) 443-9353

AWS Member Services . . . . . . . . . . . . . . . . . .8, 10, 20www.aws.org . . . . . . . . . . . . . . . . . . . . .(800) 443-9353

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NDT Seals, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24www.ndtseals.com . . . . . . . . . . . . . . . . .(800) 261-6261

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The Answer Is

accepting or rejecting each weld. Keep in mind that withevery separate set of eyes viewing a weld, this may initiate adifferent evaluation and interpretation of the subject weld.

The exception to this may involve the examination ofbase materials alone. For specific applications and byengineering request, certain base materials may requireonly a nondestructive examination both for surface and/orsubsurface (volumetric) defects prior to any welding beingperformed.

— continued from page 28

An Important Eventon Its Way?

Send information on upcoming events to InspectionTrends, 550 NW LeJeune Rd., Miami, FL 33126. Itemscan also be sent via FAX to (305) 443-7404 or bye-mail to [email protected].

OCT 2011 it classified index_Layout 1 9/22/11 2:58 PM Page 32

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To verify the integrity of your process sytems, take matters into your own hands.

The requirement for positive material identification (PMI)

in alloys used throughout the physical plant is more critical

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vessels

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Moving science forward

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THERMO FISHER_FP_TEMP 9/21/11 8:42 AM Page C3

November 14-17, 2011 | McCormick Place | Chicago, IL

IT’S ALL HERE. Discover the most innovative technologies, resources and ideas. Engage with industry experts.Find solutions to improve productivity and keep your business competitive.

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Documents

THE MAGAZINE FOR MATERIALS INSPECTION AND TESTING PERSONNEL · PDF fileTHE MAGAZINE FOR MATERIALS INSPECTION AND TESTING PERSONNEL ... diffraction ultrasonic testing, digital radiography,