AWS WI：2015 Welding inspection handbook

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以为是这些东东呢？！

Welding Handbook, Ninth Edition
Volume 1 Welding Science and Technology
Volume 2 Welding Processes, Part 1
Volume 3 Welding Processes, Part 2
Volume 4 Materials and Applications, Part 1
Volume 5 Materials and Applications, Part 2

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Contents
Chapter Page
Personnel....................................................................................................................................iii
Foreword......................................................................................................................................v
List of Tables ............................................................................................................................viii
List of Figures.............................................................................................................................ix
1 Scope and Application .................................................................................................1
2 Symbols........................................................................................................................3
3 Requirements for the Welding Inspector....................................................................13
4 Welding Inspection Operations..................................................................................21
5 Inspection Safety Considerations...............................................................................27
6 Quality Assurance......................................................................................................33
7 Ferrous Welding Metallurgy ......................................................................................37
8 Preheating and Postweld Heat Treating .....................................................................53
9 Weld and Weld Related Discontinuities.....................................................................57
10 Qualification of Welding Procedure Specifications...................................................75
11 Qualification of Welders and Welding Operators ......................................................91
12 Computerization of Welding Inspection and Quality...............................................103
13 Destructive Testing of Welds ...................................................................................111
14 Proof Tests................................................................................................................137
15 Nondestructive Examination Methods.....................................................................141
16 Qualification of Nondestructive Examination Personnel.........................................239
17 Codes and Other Standards......................................................................................241
18 Metric Practice .........................................................................................................255
Index.........................................................................................................................267

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List of Tables
Table Page
4.1 Sequence of Welding and Inspection Operations ...............................................................24
10.1 Welding Procedure Specification and Welder Qualification Factors
Which May Require Requalification .........................................................................81
13.1 Typical Hardness Conversion Table (Approximate) (for Carbon and
Low-Alloy Steels in Accordance with ASTM E140 and ASTM A370)..................120
15.1 Considerations when Selecting an NDE Method.....................................................143
15.2 Radiographic Isotopes Used in Industrial Radiography ..........................................155
15.3 Approximate Radiographic Equivalence Factors of Several Metals........................157
15.4 Resistivity and Conductivity of Some Metals and Alloys .......................................218
18.1 SI Base and Supplementary Units and Symbols......................................................255
18.2 SI Derived Units and Symbols.................................................................................256
18.3 SI Factors, Prefixes, and Symbols............................................................................256
18.4 Units Not Part of the SI System ...............................................................................257
18.5 SI Unit Conversion Factors ......................................................................................258
18.6 General Conversion Factors .....................................................................................258
18.7 Commonly Used Metric Conversions (Inch–Millimeter Conversion).....................262
18.8 Pressure and Stress Equivalents—psi and ksi to kPa and MPa................................263
18.9 Conversions for Fahrenheit–Celsius Temperature Scales........................................264

List of Figures
Figure Page
2.1 AWS Standard Welding Symbols ................................................................................4
2.2 Comparison of Welding Symbol and Written Explanation..........................................6
2.3 Examples of Typical Fillet Welds Showing the Corresponding Symbols
and Dimensions............................................................................................................7
2.4 Examples of Typical Groove Welds Showing the Corresponding
Symbols and Dimensions.............................................................................................8
2.5 Standard Location of Elements for NDE Symbols ......................................................9
2.6 Examples of Typical Nondestructive Examination Symbols.......................................9
2.7 Master Chart of Welding, Allied Processes, and Thermal Cutting............................10
5.1 SDS Sheet ..................................................................................................................28
7.1 Iron-Carbon Phase Diagram.......................................................................................38
7.2 Crystal Structure of Cold Rolled Steel in Weld Area ................................................39
7.3 Martensite Showing Needle-Like or Acicular Structure
(500X Before Reduction)...........................................................................................40
7.4 Example of Delayed Cracking in HAZ......................................................................42
7.5 Corrosion Attack of Sensitized Stainless Steel in Acid Environment .......................46
7.6 Microfissure in Austenitic Stainless Steel (100X).....................................................47
7.7 Closeup of Lamellar Tear Under a Fillet Weld Showing Typical Stepped
Appearance (Magnification 8X) ................................................................................48
9.1 Typical Distortion of Welded Joints...........................................................................59
9.2 Overlap.......................................................................................................................61
9.3 Weld Sizes..................................................................................................................61
9.4 Incomplete Joint Penetration and Incomplete Fusion ...............................................63
9.5 Underfill.....................................................................................................................65
9.6 Various Types of Cracks.............................................................................................66
9.7 Porosity ......................................................................................................................70
10.1 AWS Structural Welding Code, Welding Procedure Example Form.........................79
10.2 Example of a Suggested Procedure Qualification Record (PQR)..............................86
10.3 ASME Welding Procedure Qualification Record Example Form .............................88
11.1A Test Plate for Unlimited Thickness—Welder Qualification ......................................93
11.1B Optional Test Plate for Unlimited Thickness—Horizontal Position—
Welder Qualification ..................................................................................................93
11.2A Tubular Butt Joint—Welder Qualification—Without Backing..................................94
11.2B Tubular Butt Joint—Welder Qualification—With Backing.......................................94
11.3A Positions of Groove Welds.........................................................................................95
11.3B Positions of Fillet Welds ............................................................................................96
11.4 Positions of Test Plates for Groove Welds.................................................................97
11.5 Positions of Test Pipe or Tubing for Groove Welds...................................................98
11.6 Positions of Test Plate for Fillet Welds......................................................................99
11.7 Positions of Test Pipes for Fillet Welds ...................................................................100
x
11.8 Suggested Form for Welding Performance Qualification........................................101
12.1 A Welding Inspection Database...............................................................................105
13.1 Typical Photomacrographs.......................................................................................114
13.2 Photomicrograph Illustrating the Appearance of a Crack in the
Heat-Affected Zone (Approximately 100X)............................................................114
13.3 Photomicrographs ....................................................................................................115
13.4 Typical Stress-Strain Diagram Used in the Offset Method......................................121
13.5 Standard Tension Specimens....................................................................................123
13.6A Transverse Face- and Root-Bend Specimens...........................................................126
13.6B Transverse Side-Bend Specimens ............................................................................127
13.7 Fixture for Guided Bend Test...................................................................................128
13.8A Transverse Rectangular Tension Test Specimen (Plate) ..........................................130
13.8B Longitudinal Rectangular Tension Test Specimen (Plate).......................................131
13.9 Typical Fillet Weld Break and Macroetch Test for Fillet Welder or
Welding Operator Qualification...............................................................................132
13.10 Charpy (Simple-Beam) Impact Test Specimens ......................................................134
13.11 Charpy (Simple-Beam) Impact Test.........................................................................135
15.1 Welding Engineer Data Sheet ..................................................................................146
15.2  Rulers, Measuring Tapes, and Gauges for Checking Fitup and Weld Dimensions .147
15.3 Weld Bead Contours ................................................................................................148
15.4 Workmanship Standard ............................................................................................149
15.5 Sketches of Weld Undercut and Overlap .................................................................150
15.6 Photographs of Weld Undercut and Overlap............................................................151
15.7 Weld Inspection Gauges...........................................................................................152
15.8 Typical “Shadow Graph” .........................................................................................154
15.9 The Penumbral Shadow ...........................................................................................158
15.10 Geometric Principles of Shadow Formation............................................................159
15.11 Factors Affecting Quality of Radiographic Image...................................................162
15.12 Sources of Scattered Radiation ................................................................................164
15.13 Characteristic Curve For a Typical Industrial X-Ray Film......................................166
15.14 The “Tools of The Trade” for the Radiographer ......................................................169
15.15 Typical Penetrameter Design ...................................................................................170
15.16 Typical Radiographic Exposure Arrangements .......................................................172
15.17 Typical Radiographs of Weld Discontinuities..........................................................177
15.18 Block Diagram, Pulse-Echo Flaw Detector .............................................................179
15.19 Decibel-To-Screen Height or Voltage Nomograph ..................................................181
15.20 Snell’s Law of Reflection and Refraction ................................................................183
15.21 Amplitude Calibration Using Flat Bottom Holes ....................................................185
15.22 Shear Wave Ultrasonic Beam...................................................................................185
15.23 Amplitude Calibration..............................................................................................186
15.24 Ultrasonic Ruler Application ...................................................................................190
15.25 Flaw Orientation.......................................................................................................191
15.26 Sound Beam Propagation Showing Sound Path Distance .......................................191
15.27 Magnetic Field in a Bar Magnet ..............................................................................194
15.28 Magnetic Field in a Bar Magnet That Has Been Cut in Half...................................195
15.29 Magnetism Around a Notch Cut in a Bar Magnet ...................................................196
15.30 Magnetic Field Around a Conductor Carrying Current...........................................197
15.31 Field of Ferromagnetic Conductor is Confined Almost Entirely to the
Conductor Itself........................................................................................................197
15.32 Magnetic Particles Near a Defect are Attracted to the Local Poles.........................197
15.33 In Large Parts, Local Areas Can Be Magnetized; Arrows Indicate Field................198
15.34 Part to be Inspected Can Be Magnetized by Making it the Core of a Solenoid.......199
15.35 Crack in Large Plate is Indicated by Alignment of Particles Between Prods..........200
15.36 Dry Powder Magnetic-Particle Inspection of Welds with Portable
Equipment ................................................................................................................202
15.37 Wet Fluorescent Magnetic-Particle Inspection to Show Fine Surface Defects........203
15.38 Typical Indication of Surface Crack in a Weld ........................................................207
15.39 Indication of a Subsurface Crack in a Weld (The Dry Magnetic
Particles Assume a Less Defined Pattern)................................................................208
15.40 Liquid Penetrant Comparator...................................................................................213
15.41 Frequencies Used for Various Test Problems ..........................................................215
15.42 Cross-Sectional View of a Bar with a Small Crack, Surrounded by an
Exciting Coil and a Pickup Coil, Showing Eddy Current Distribution....................216
15.43 Relative Conductivity of Metals and Alloys Related to Eddy Current
Meter Readings ........................................................................................................217
15.44 Influence of Impurities on the Conductivity of Pure Copper...................................219
15.45 Typical B/H (Hysteresis) Curve...............................................................................220
15.46 Lines of Magnetic Flux Surrounding a Solenoid.....................................................220
15.47A Instrumentation Readout for Electromagnetic Testing ............................................221
15.47B Typical Eddy Current Readout from Strip Chart Illustrating Good and Bad
Weld Areas...............................................................................................................221
15.48 Production of Eddy Currents by an Alternating Field .............................................222
15.49 Testing Coils Carrying Alternating Current.............................................................223
15.50 Examples of Electromagnetic Probe Coils...............................................................224
15.51 Eddy Current Strength Drops Off With Distance From Surface .............................224
15.52 Eddy Current Flaw Detection Equipment................................................................225
15.53 Microstructure of Austenitic Weld Specimen..........................................................232
15.54 Schaeffler Diagram for Stainless Steel Weld Metal.................................................233
15.55 DeLong Diagram for Stainless Steel Weld Metal....................................................234
15.56 Typical Flow Diagram from Contract to Approved Operations Procedures............235

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