TWI
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‘THE WELDING INSTITUTE
SENIOR WELDING INSPECTOR
COURSE REF: WIS10
TWI
LLM
TWI Ltd
Training & Examination Services
Granta Park
Great Abington
Cambridge, CB1 6AL, UK
Copyright © 1991 TWI Ltd TWI
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THE WELDING INSTITUTE
SENIOR WELDING INSPECTOR
COURSE DETAIL
ALL COURSE MEMBERS PLEASE READ CAREFULLY
1. The general working programme is attached.
2. Any alterations will be announced by the course tutor.
3. The lectures and tutorials etc are supported by the course text,
please read as appropriate.
4. Question papers are included at both welding and senior inspector level and
will be used to reinforce most sessions please attempt the questions.
5. The end of course assessments are marked and the results recorded.
6. CSWIP 3.2 examination candidates are reminded that examination success is
based not only on course attendance, but also previous experience, (i.e.
CSWIP require a minimum of five years experience as a Senior Welding
Inspector, or hold a CSWIP 3.1 qualification for two years). Candidates are
therefore advised to attend other courses in welding inspection or NDT (if
appropriate) in order to improve their knowledge and competence. Discussion
with the course tutor is advised.
Standards reproduced with the permission of British Standards Institute. TWI
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SN THE WELDING INSTITUTE
KEY KNOWLEDGE FOR WELDING INSPECTION PERSONNEL
The information contained in this course text supplements the lectures given
in courses WIS 5 and WIS 10.
Terminology given in the test is that recommended in BS 499 Pt.1:1983; Weld
Symbols to BS 499 Pt 2: 1980. To supplement this further, however, an
indication of both International (ISO) and American standards is given.
The sections are written in general terms and do not include all of the
conditions that may apply to a specific fabrication or product.
The examining body, CSWIP, expect candidates, for the Senior Welding
Inspectors' Examination, to have sufficient knowledge of both 3:1 and 3:2
levels. Because of this, the text is based on the established Welding
Inspectors’ course and additional information required for the senior level has
been included.
It is assumed course members have previously attended course WIS 5. TWI
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‘THE WELDING INSTITUTE
SENIOR WELDING INSPECTOR
COURSE REF: WIS10
CONTENTS SECTION
TERMINOLOGY 1
THE DUTIES OF A WELDING INSPECTOR
& THE SENIOR WELDING INSPECTOR
CODES AND STANDARDS,
WELDING PROCEDURES, PROCEDURE WELDER APPROVAL
& DOCUMENTATION
MECHANICAL TESTING
SYMBOLS.
MATERIALS
CONSUMABLES
THE FOUR FACTORS FOR ESTABLISHING A WELD
MANUAL METAL ARC WELDING
TUNGSTEN INERT GAS WELDING
DEFECTS WHICH MAY BE DETECTED BY SURFACE INSPECTION
METAL INERT GAS WELDING
SUBMERGED ARC WELDING
CALIBRATION OF EQUIPMENT
RESIDUAL STRESS AND DISTORTION
on
BSSISARSNASoOroOua
WELDABILITY
HEAT TREATMENTS
NON DESTRUCTIVE TESTING
REPAIR BY WELDING
GAS WELDING, CUTTING & GOUGING 21
ARC CUTTING 22
OTHER WELDING SYSTEMS 23
INTERNAL DEFECTS & THEIR INTERPRETATION 24
WELD FAILURES. 2
SAFETY 26
APPENDIX. TWI
SS THE WELDING INSTITUTE
TERMINOLOGY
Use of the correct terminology is important. This course uses BS 499.
GENERAL TERMINOLOGY
WELDS and JOINTS
Frequently the terms ‘weld’ and ‘joint’ are used incorrectly. Exact
definitions are given in BS 499 ‘Welding terms and symbols’.
TYPES OF WELD
BUTT WELD
FILLET WELD Ales
EDGE WELD
>>
I= 1.4,
where t, is as defined for mitre and convex fillets, RS)
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WELDING TECHNOLOGY
Issue 0191 15 TWI
‘THE WELDING INSTITUTE
If an asymmetrical fillet weld is required, both leg lengths are specified and t, is
taken as the minimum throat dimension.
Deep penetration fillet weld
With high current density processes, e.g. submerged arc and MIG (spray).
penetration along the joint line can be produced.
This gives an increase in throat thickness with no change in leg length.
WELDING TECHNOLOGY
1.6 Issue 0191 TWI
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‘THE WELDING INSTITUTE
THE DUTIES OF THE WELDING INSPECTOR
VISUAL INSPECTION
At any point in the course of welding, i.e. tacking, root pass, filler pass or
capping pass, but particularly for the root and cap, a detailed inspection may
be required. British Standard 5289 : 1976 gives guidance on tools and
responsibilities together with sketches of typical defects.
The inspector at this point must -
a) observe, identify and perhaps record the features of the weld.
b) decide whether the weld is acceptable in terms of the particular levels
which are permitted; defect levels may be ‘in-house’ or National Codes
of Practice.
When the defect size is in excess of the permitted level then either a
concession must be applied for (from a competent person) or the weld
rejected.
CODE OF PRACTICE FOR VISUAL INSPECTION
A code of practice for an inspection department could take the form outlined
below. It is appreciated that full implementation of the code would be
extremely costly and therefore it may be necessary to reduce the amount of
inspection to less than is theoretically required.
AIDS OF VISUAL INSPECTION
Mlumination: Good lighting is essential
Inspection lenses: The magnification should not exceed 2-2’ diameters.
If higher magnification is required use a binocular
microscope.
Optical viewing devices area progressive development from the use of a hand
torch and mirror, frequently with the addition of a magnifier and light source.
In order to achieve accessibility probe units are available down to a diameter,
properties for which are:
1. Large field of vision.
2. Freedom from distortion of image.
3. Accurate preservations of colour values.
4. Adequacy of illumination.
WELDING TECHNOLOGY
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