1、CERTIFICATION MANUAL For Welding Inspectors Fourth Edition American Welding Society e International Standard Book Number: 0-87 17 1-626-7 American Welding Society, 550 N.W. LeJeune Road, Miami, FL 33126 O 2000 by American Welding Society. All rights reserved Printed in the United States of America F
2、ourth Edition 2000 Revised 3/00 Reprinted 5/03 All rights reserved. No part of this book may be reproduced in any form or by any means, electronic or mechanical, in- cluding photocopying, recording, or by any information storage or retrieval system, without permission in writing from the publisher.
3、NOTE: Although care was taken in choosing and presenting the data in this guide, AWS cannot guarantee that it is error free. Further, this guide is not intended to be an exhaustive treatment of the topic and therefore may not include ail avail- able information, including with respect to safety and
4、health issues. By publishing this guide, AWS does not insure any- one using the information it contains against any liability or injury to property or persons arising from that use. Photocopy Rights Authorization to photocopy items for internal, personal, or educational classroom use only, or the in
5、ternal, personal, or educational classroom use only of specific clients, is granted by the American Welding Society (AWS) provided that the appropriate fee is paid to the Copyright Clearance Center, 222 Rosewood Drive, Danvers, MA 01923, Tel: 978-750-8400; online: http:/. Contents Page No . Chapter
6、1-The Welding Inspector 1 Introduction . 2 Important Qualifications for the Welding Inspector 3 Physical Condition . 3 Vision . 3 Professional Attitude 3 Knowledge of Welding and Inspection Terminology 3 Knowledge of Drawings and Specifications 4 Knowledge of Testing Methods . 4 Ability to Produce a
7、nd Maintain Records 4 Knowledge of Welding Processes 4 Ability to be Trained 4 Inspection Experience 4 Ethical Requirements for the Welding Inspector . 5 Introduction 5 Preamble 5 Integrity 5 Responsibility to the Public . 5 Public Statements . 5 Conflict of Interest . 5 The Solicitation of Employme
8、nt 6 Unauthorized Practice 6 Reporting Supervisor . 6 Welders 7 Welding Foremen or Supervisors . 7 Shop or Field Superintendent 8 Plant Manager 8 Welding Engineer . 8 Summary 8 Establishing Lines of Communication . 6 DesigdProject Engineers . 8 Review-Chapter 1-The Welding Inspector 9 Figure 1.1-Ind
9、ustries Utilizing Welding Inspectors 2 Figure 1.2-The Welding Inspector-A Communicator 6 Figure 1.3-Establishing Lines of Communication 7 Chapter 2-Welding Inspector Responsibilities . 1 1 Introduction . 12 Inspection Responsibilities During Welding . 12 Inspection Responsibilities After Welding 12
10、Inspection Responsibilities Before Welding 12 Knowledge of Drawings and Standatds . 12 Purchase Specifications Check 14 Job Material Verification 14 Chemical Analysis and Mechanical Properties Tests 14 Base Metal Defects Investigation . 16 Condition and Storage of Filler Materials Check 16 Inspectio
11、n Responsibilities Before Welding 12 . 111 Welding Equipment Check 16 Weld Joint Edge Geometry Check . 16 Weld Joint Fit Check 17 Weld Joint Cleanliness Check 17 Welding Procedure Qualification Check 17 Welder Qualification Check . 17 Preheat Temperature Check . 17 Check Production Welding for Compl
12、iance with Welding Procedure 18 Check the Quality of Individual Passes . 18 Check Interpass Cleaning 19 Check Interpass Temperature . 19 In-Process Nondestructive Examination (ME) 19 Check Final Weld Appearance . 20 Check Final Weld Sizes and Lengths . 20 Check Dimensional Accuracy of Completed Weld
13、ment . 23 Selection of Production Test Samples 23 Evaluation of Test Results 23 Final Nondestructive Examination . 23 Maintaining Records and Reports 23 Review-Chapter %Welding Inspector Responsibility . 24 Figure 2.2-Typical Example of a Mill Test Report . 15 Figure 2.3-Electrode Oven 16 Figure 2.4
14、-Temperature-Sensitive Crayon for Measuring Mctal Temperature . 18 Figure 2.6-Proper Cleaning Between Weld Passes . 19 Figure 2.7-Cross Section of a Partial Penetration Groove Weld with Heavy Slag Inclusion . 19 Figure 2.8-Magnetic Particle Testing of a Partially Filled Groove Weld . 20 Figure 2.9-E
15、valuating Size with a Fillet Weld Gauge 21 Figure 2.10-Acceptable and Unacceptable Weld Profiles 22 Chapter 3-Safety . . 27 Introduction . 28 Managements Responsibility . 28 The Working Environment . 28 Oxyfuel Gas Welding, Cutting, Brazing, Soldering, and Submerged Arc Welding 29 Protective Clothin
16、g 29 Confined Spaces . 31 Welding Inspector Responsibilities During Welding 18 . Welding Inspector Responsibilities After Welding 20 Figure 2.1-Knowledge of Drawings and Standards is Important . 13 Figure 2.5-Tong Test Ammeter . 18 Eye and Face Protection 29 Ear Protection 30 Fumes and Gases . 30 Ha
17、ndling of Compressed Gases 32 Gases . 32 Oxygen . 32 Fuel Gases 32 Fuel Gas Fires 33 Shielding Gases 33 Electric Shock 33 Review Chapter 3-Safety 34 Table 3.1-Lens Shade Selector 30 iv Figure 3.1-Designated Welding Area . 28 Figure 3.2-Eye, Ear. and Face Protective Equipment . 29 Figure 3.3-Movable
18、Fume Extractor Positioned Near the Welding Arc . 31 Chapter Diagram Includes Some of the Property Changes Brought About by These Conditions (Also Shown is a CCT Diagram for a Steel, to Illustrate Why the Cooling Conditions Promote the Property Changes) 113 Figure 7.1 1-Effects of Tempering . 113 Fig
19、ure 7.12-Relation Between the Peak Temperatures Experienced by Various Regions in a Weld, and How Figure 7.13-Thema1 Expansion . 115 Figure 7.14-Shrinkage in a Weld Caused by Internal Restraint (Also Shown is the Nature of Residual Stress) . 116 Figure 7.15-Peening the Middle Weld Layer Distributes
20、and Balances Distortion 117 Figure 7.l-An Example of Migrating or Diffusing Atoms . 117 Figure 7.17-Chemical Interactions While Welding 119 Figure 7.18-Common Elements that can Cause Problems . 119 Figure 7.19-Shielded Metal Arc Welding . 120 Figure 7.20-Self-shielded Flux Cored Arc Welding 120 Figu
21、re 7.21-Schematic View of Submerged Arc Welding Processes . 120 Figure 7.22-Corrosion by Intergranular Attack (IGA) Caused by Sensitization of the HAZ . 122 Figure 7.23-For Stabilization Heat Treatment Use 1500F, No Quench Needed . 123 Figure 7.24-Revention of Corrosion in Welded Stainless Steel . 1
22、23 Figure 7.25-Welding in a Controlled Atmosphere 124 Solids vs . Liquids . 109 Welds Under the Microscope . 110 These Correlate with the Iron-Carbon Phase Diagram 114 vii Chapter 8-Destructive Testing . 129 Tensile Testing 131 Hardness Testing 136 Toughness Testing 139 Soundness Testing 143 Destruc
23、tive Tests for Chemical Properties 149 Metallographic Testing 150 Metric Conversions 151 Scientific Notation Examples 151 Examples of Prefixes for Powers of Ten 151 Review-Chapter &Destructive Testing . 157 Table 8.2-Rockwell Standard Hardness 140 Table 8.4-Commonly Used Metric Conversions . 152 Tab
24、le 8.5-General Conversions . 154 Table 8.6-Conversions for Common Welding Terms 156 Figure 8.2-Round Tensile Specimens . 132 Figure 8.5-Engineering Stress-Strain Diagram for Polycrystalline Copper . 135 Figure 8.7-Indenter Measurements . 139 Figure 8.8-Principle of the Rockwell Test 141 Arrangements
25、 142 Introduction . 130 Table 8.1-Brinell Hardness Numbers 138 Table 8.3-SI Prefixes . 151 Figure 8.1-Inspectors Must Be Able to Interpret Data from a Variety of Tests 130 Figure 8.3-Transverse Rectangular Tension Test Specimen (Plate) . 133 Figure 8.4-Abrupt Yielding of Yield Point in Mild Steel .
26、135 Figure 8.6-Shapes and Types of Indenters Used with Various Hardness Tests 137 Figure 8.9-Knoop and Vickers Microhardness Testing 141 Figure 8.10-ASTM Standard Dimensions for the Type A Charpy V-Notch Specimen and the Striker-Anvil Figure 8.1 l-Schematic of Typical Charpy Testing Machine 143 Figu
27、re 8.12-Relation Between Energy Transition and Fracture Appearance Transition in Charpy V-Notch Impact Specimens with Changes in Temperature . 144 Figure 8.13A-Face and Root Bend Specimens . 145 Figure 8.13B-Side Bend Specimens . 146 Figure 8.14A-Guided Bend Test Jig . 147 Figure 8.14B-Alternative R
28、oller-Equipped Guided Bend Test Jig for Bottom Ejection of Test Specimen . 148 Figure 8.14C-Alternative Wraparound Guided Bend Test Bend Jig 148 Figure 8.15-Nick-Break Test Specimen 149 Figure 8.16-Method of Testing Fillet Weld Break Specimen . 150 Figure 8.17-Typical Weld Photomacrograph (Crack Adj
29、acent to the Weld) 150 Chapter 9-Welding Procedure and Welder Qualification . 161 Introduction . 162 Welding Procedure Specification . 162 Contents . 162 Welding Procedure Qualification . 166 Code Qualification Requirements 167 Welding Inspector Responsibilities 168 Welder and Brazer Qualification .
30、 168 Qualification Testing 168 Retests 172 . v111 Code Requirements 172 Destructive Test Qualification 174 Summary 174 Review-Chapter 9-Welding Procedure and Welder Qualification 181 Table 9.1-Welder Performance Qualification Tests 177 Figure 9.1-Joint Design and Tolerances 163 Figure 9.2-Joint Prep
31、aration and Cleaning of Surfaces for Welding 163 Figure 9.3-Positions of Groove Welds 164 Figure 9.4-Positions of Fillet Welds . 165 Figure 9.5-Peening the Middle Layer of a Weld Distributes and Balances Stresses 166 Figure 9.6-Marking a Completed Weldment 166 Figure 9.8-Test Plate for Unlimited Thi
32、ckness-Welder Qualification . 170 Figure 9.9-Optional Test Plate for Unlimited Thickness-Horizontal Position-Welder Qualification 170 Figure 9.10-Test Plate for Limited Thickness-A11 Positions-Welder Qualification 171 Figure 9.1 l-ptional Test Plate for Limited Thickness-Horizontal Position-Welder Q
33、ualification . 171 Figure 9.12-Fillet Weld Break and Macroetch Test Plate-Welder Qualification-Option 1 172 Figure 9.13-Fillet Weld Root Bend Test Plate-Welder Qualification-Option 2 . 173 Figure 9.14-Typical Tubular Butt Joint Welder Qualification 174 Figure 9.15-Positions of Test Pipes or Tubing f
34、or Fillet Welds 175 Figure 9.16-Positions of Test Pipe or Tubing for Groove Welds 176 Figure 9.17-Positions of Test Plates for Groove Welds 179 Figure 9.18-Positions of Test Pipes for Fillet Welds 180 Figure 9.7-Sample Specimens for Destructive Testing . 167 Chapter 1-Welding. Brazing. and Cutting P
35、rocesses . 183 Introduction . 184 Limiting Factors 184 Dimensions of Material . 184 Welding Position 184 Back Side Accessibility . 184 Joint Preparation 186 Availability of Welding Equipment . 186 Shielded Metal Arc Welding (SMAW) 186 Gas Metal Arc Welding (GMAW) . 189 Flux Cored Arc Welding (FCAW)
36、. 191 Gas Tungsten Arc Welding (GTAW) . 193 Plasma Arc Welding (PAW) . 195 Submerged Arc Welding (SAW) 197 Electroslag Welding (ESW) . 199 Oxyacetylene Welding (OAW) 202 Stud Welding (SW) 203 Brazing (B) . 203 Torch Brazing (TB) 205 Furnace Brazing (FB) 205 Induction Brazing (IB) . 205 Resistance Brazing (RB) 206 Dip Brazing (DB) . 206 Infrared Brazing (IRB) . 206 Diffusion Brazing (DFB) . 206 Root Requirements 184 Welding Processes 186 ix
