TWI
CSWIP 3.1
WIS 5
WELDING INSPECTION
INSPECTION
EQUIPMENT.
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MEASURING IN WELDING.
The
purposes of
measuring
Demonstration of Welding
conformance to process
specified control
requirements Amperage
Equipment calibration
Voltage
Travel
Dimensional accuracy
speed
Pre-heat/ inter-pass temp
Shielding gas flow rate
Humidity
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INSPECTION EQUIPMENT.
• Steel rule
• Flexible tape measure
• Bevel angle gauge
• Root gap gauge
• Misalignment gauge
• Fillet gauge
• Height / depth gauge
• Voltmeter
• Ammeter
• Polarity indicator
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INSPECTION EQUIPMENT.
• Temp indicating crayons / pyrometer
• Contour gauge
• Torch or other light source
• Mirror
• Magnifying glass - 5x magnification
• Paint stick / marking crayon
• Pea shooter type flow meter
• Hard stamp/ soft stamp
• Stop watch
• Modelling clay / resin
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INSPECTION EQUIPMENT.
Other equipment the Welding Inspector
may be required to use;
Computers
Digital cameras
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INSPECTION EQUIPMENT.
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TWI CAMBRIDGE MULTI-PURPOSE
WELDING GAUGE:
Visual
Visual Inspection
Inspection of
of Welds
Welds Using
Using
the
the
Cambridge
Cambridge
Multi-Purpose
Multi-Purpose Welding
Welding Gauge:
Gauge:
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HI-LO GAUGE.
1
Internal Root gap
HI-LO Single Purpose Welding Gauge
alignment dimension
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THE MULTI-METER.
This piece of equipment can
be used to measure;
AMPERAGE
ARC VOLTAGE
RESISTANCE
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THE TONGUE TEST
AMMETER.
Ammeter.
An instrument that
measures and indicates in
amperes the flow of
electricity through a circuit.
Can be clipped around either
the welding lead or return
lead.
Usually measured as close
to the welding arc as
practicable.
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THE VOLT METER.
Arc Voltage.
The voltage required to
maintain the arc during
welding
Two leads are attached and
connected across the arc.
Usually measured as close
to the welding arc as
practicable.
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TRAVEL SPEED
MEASUREMENT.
Definition: the rate of weld progression
measured in case of mechanised and
automatic welding processes.
Two methods most commonly used;
Stop watch - measures time taken to
complete a single weld pass over a set
distance.
Run Out Length (ROL)- the length of a
single electrode used for depositing a
single weld pass with manual metal arc
welding.
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TRAVEL SPEED
MEASUREMENT.
Travel speed =
60 seconds over 300mm
Travel speed =
30 seconds over
300mm
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TRAVEL SPEED
MEASUREMENT.
Run Out Length (ROL)= 200mm
Run Out Length (ROL) =
100mm
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PAMS (Portable Arc Monitor
System)
The
purposes of
a PAMS
For For
measuring calibrating
and and
recording validating
the welding the welding
parameters equipment
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PAMS (Portable Arc Monitor
System)
What does a PAMS
measure?
Welding
current Print out
Gas flow
rate
Arc Wire feed
voltage speed
Temperature
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GAS FLOW RATE
MEASUREMENT.
Definition:
the rate at which gas
is caused to flow
set with a gas
regulator
can be checked with a
flow-meter
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TEMPERATURE TEST
EQUIPMENT
Temperature
sensitive materials:
•crayons, paints and
pills
•cheap
•
•convenient, easy the
to
doesn’t measure
use
actual temperature!
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TEMPERATURE TEST
EQUIPMENT.
HOW MANY TEMPERATURE
INDICATING CRAYONS WOULD BE
REQUIRED TO CHECK THAT THE
MINIMUM & MAXIMUM PREHEAT
TEMPERATURES HAVE BEEN
ACHIEVED?
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TEMPERATURE TEST
EQUIPMENT.
PRE-HEAT RANGE IDEAL TEMPERATURE
INDICATING CRAYON
MIN / MAX
Minimum 50°C 50°C MUST
melt
Maximum 100°C 101°C MUST NOT
melt
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TEMPERATURE TEST
EQUIPMENT
Contact thermometer
•use bimetallic strips -
steel + INVAR (36% Ni -
64% Fe alloy)
•accurate
•easy to use
•gives the actual
temperature
•need calibration
•suitable for moderate
temperatures
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TEMPERATURE TEST
EQUIPMENT
Thermistors
are temperature-sensitive
resistors whose resistance
varies inversely with
temperature
used when high sensitivity
is required
gives the actual
temperature
need calibration
can be used up to 320°C
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TEMPERATURE TEST
EQUIPMENT
Thermocouple
based on measuring the thermoelectric
potential difference between a hot junction
(on weld) and a cold junction
accurate method
measures over a wide range of temperatures
gives the actual temperature
need calibration
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TEMPERATURE TEST
EQUIPMENT
Devices for contactless measurement
IR radiation and
optical pyrometer
measure the radiant
energy emitted by the
hot body
contactless method,
can be used for
remote
measurements
very complex
for measuring high
temperatures
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QUESTIONS ?
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