Thursday, June 18, 2015

What Goes In a Visual Inspection Report?

Hi, Paul,

Could you let me know what information you think should be included in a visual welding inspection report?
I’m seeing a lot about what the inspector should be verifying, but not the actual items that should be in the report.
 I appreciate your help.
Best Regards,
 Anthony N.

Good question.  For NDE (nondestructive evaluation) we typically go to our code books to find the correct forms required.  Although using those specific forms isn’t a requirement, they are a great guide to determine what information we need to capture. 
Visual Inspection (VT [visual testing]) is a form of NDE, but I’m not aware of a code supplied form for recording it.  There is no simple form to download and fill out when it comes to VT.
In my day-to-day, I may use a spread sheet, a Word doc, or the old reliable composition note book.  It all depends on my situation.
As for what information to capture? My guidelines are; keep it simple... Let’s assume AWS D1.1 is our code. Sub-Clause 6.9 states, “All welds shall be visually inspected...”  That doesn’t leave a lot of “wiggle-room”.  We know we have to look at all welds.  It also states, “...and shall be acceptable if the criteria of Table 6.1 are satisfied.”  So now we know our acceptance criteria.
At a minimum your visual inspection (VT) report should state:
What was the date of fabrication?
What was the part/print number?
What was the welds location?
What was the acceptance criteria? (i.e.: AWS D1.1:2010 Table 6.1, Statically Loaded)
Did it meet the requirement?
Did anything restrict your inspection? (i.e.: Part was galvanized, Root was lot accessible, Roof decking covered weld face...)
Was it acceptable?
What is the date of inspection?
...and always add your name (legibly), signature and CWI# (if applicable).
Remember, listen to your customer to gage the level of detail requested, but always make the report clear enough so you understand what was written long after the project is complete.
Good Luck,

Wednesday, June 10, 2015

Combination GMAW & FCAW

I was wondering if you could shed some light on this subject. We have two different processes being used, GMAW and FCAW. The GMAW is used for tacking stiffeners to panels up to 60 feet long the joint configuration is a T joint. The tacks are between 1/8" and 3/16" weld sizes and they vary from 3" to 4" in length about every 18" in between tacks.  The FCAW is then used from a welding gantry, welding over the previous tack welds from the GMAW with the FCAW process with a continuous weld.

D1.1 2010 in table 4.5 PQR Essential Variables. Comparing the processes there are substantial variables. Our thought is to run a PQR using the two processes together on a V groove weld to qualify both processes. GMAW and FCAW using 100% CO2 welding the root pass with GMAW and then the second pass with FCAW mixing the two processes until the groove joint is completed. Clause 4 in table 4.4 groove test figure 4.23 1 G test.

Will this suffice what we're trying to achieve? I appreciate your input on the matter.

Best Regards.
Gabriel M.

There are a couple ways you could approach this.  First, are PQR's needed?  This should fall under prequalified unless I'm missing something.  If it is, all you'd need to do is write the prequalified WPS using both processes.

If it is not able to be considered prequalified you could do the required PQRs for each process (GMAW & FCAW).  Or, you could combine processes in your PQR's.  A GMAW root would be sufficient, then a FCAW fill and cover.  Don't switch back and forth between processes for the fill and cover, you are qualifying each to a depth (GMAW to about 3/16 and FCAW to the remainder).

Another option might be to qualify these fillet welds using a fillet welded T-Joint just like you do in production.

Keep in mind, all Welders shall be qualified.  If you are using both processes they will require qualification to both processes.