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Comprehensive Weld Inspection Solutions From Fr om Manual Ma nual to Automated NDT Technologi Technologies es Olympus offers a wide range of innovative testing products to meet all requirements require ments related to the following technologies and inspection techniques: pulse-echo (PE), TOFD, combined TOFD/PE, phased array UT, linear scans, and sectorial scans. Solutions

Ultrasound / Eddy Current / Phased Array

Microscope Imaging / Optical Metrology

 X-Ray Fluorescence Fluorescence / XRD Analysis

Remote Visual Inspection / Videoscopes

www.olympus-ims.com

AUGUST 2015 / Vol. 18/ No. 3

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Guided Bend Testing Using Borescopes PMI Q&A Understanding Caulking

AUGUST 2015 / Vol. 18/ No. 3

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Guided Bend Testing Using Borescopes PMI Q&A Understanding Caulking

New OmniScan Solution for W Weld eld Inspections New phased arr obes, wedges, and improved oved versions of SetupBuilder SetupBuilder and and MXU MXU 4.2 4.2 softwar softwar for software use with the OmniScan niScan phased arr array ay fla flaw detector increase ease the e efficiency of weld inspections.

Compound Scan NDT  T SetupBuilder software software now offers the capability to t perform form compound scans scans in in which which aa single-gr single-group oup compound scan generates es similar coverage cover as two sectorial scans. • • • • •

Higher probability obability of detection det Inspection of thicker thick  material Higher inspection speed Shorter er setup and calibration calibr time Faster er data analysis

Weld Series Weld Series Probes Probes obes

Dual Dual Matrix Matrix Arr Array Array Probes Probes NEW  A31 and A32 Weld NEW W Series phased array arr probes and wedges simplify and standardize e inspections inspections with fewer designs. They improve ove signal-tosignal-t noise ratio atio and featur feature an ergonomic gonomic design for improved oved coupling.

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NEW NEW Dual matrix arr array (DMA) probes obes consisting consisting of two matrix arr array probes generate e tr transmit-receive longitudinall (TRL) sound longitudina beams to o dr drastically improve ove signal-t signal-to-noise ratio atio for the inspection of cladded pipes and austenitic enitic or nick nickel alloys.

www.olympus-ims.com .olympus-ims.com

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August 2015 Vol. 18 / No. 3

Features

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Cover photo: Internal orbital weld  inspection at Kreisler Industries using  a Hawkeye rigid borescope and video  system. (Photo courtesy of Gradient   Lens Corp., Rochester, N.Y.)

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A Guided Bend Testing Primer  by Albert J. Moore Jr. / Here’s a comprehensive look at guided bend testing / 17

Internal Weld Inspection Using Borescopes INSPECTION TRENDS (ISSN 1523-7168) is  published quarterly by the American Welding Society. Editorial and advertising offices are located at 8669 NW 36th St., Suite 130, Miami, FL 33166; telephone (305) 443-9353. Printed by R. R. Donnelley & Sons Co., Senatobia, Miss. Subscriptions $30.00 per year for noncertified, nonmembers in the United States and its  possessions; $50.00 per year in foreign countries; $20.00 per year for noncertified members and students; $10.00 single issue for nonmembers and $7.00 single issue for members. American Welding Society is located at 8669 NW 36th St., Suite 130, Miami, FL 33166; telephone (305) 443-9353. Periodicals postage paid in Miami, Fla., and additional mailing offices. POSTMASTER: Send address changes to Inspection Trends c/o American Welding Society, 8669 NW 36th St., Suite 130, Miami, FL 33166.

Readers of Inspection Trends may make copies of  articles for personal, archival, educational, or research purposes, and which are not for sale or resale. Permission is granted to quote from articles,  provided customary acknowledgment of authors and sources is made. Starred (∗) items excluded from copyright.

 by Douglas S. Kindred / These tips will help you select the right borescope for your application / 22

Tips for Better Positive Material Identification  by Alex Thurston / This Q&A offers insight into alloy material verification with X-ray fluorescence analyzers / 24

Understanding Caulking  by Brent E. Boling / What caulking is, where it comes from, and how it applies to structural steel work today is explained / 26

Departments Editor’s Note................................6

Mark Your Calendar...................36

 News Bulletins .............................8

Certification Schedule................38

Mail Bag ....................................12

Red Hots ....................................40

Print and Product Showcase ......14

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Just the Facts..............................30

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The Answer Is ............................32

Advertiser Index ........................44

AWS MISSION STATEMENT

The mission of the American Welding Society is to advance the science, technology, and  application of welding and allied joining  processes woldwide, including brazing, soldering, and thermal spraying.

Inspection Trends / Summer 2015

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Editor’s Note

By Mary Ruth Johnsen Dear Readers,

Publisher Andrew Cullison, [email protected] 

I’ve mentioned this before, but when I joined the staff of the Welding Journal more than 26 years ago — Inspection Trends hadn’t even been thought of back  then — the full extent of my welding knowledge was that it was used to join two  pieces of metal together. Since then, I’ve learned a lot about welding and I’m adding to my inspection knowledge as well. And I’ve tried my hand at welding enough times that I know for certain that I am lousy at it. My awareness of my own lack of ability has made me truly appreciate the people who are really good at it. Still, after not only researching and writing many articles for both  publications, but certainly in proofreading everything that goes into the magazines all these years, I would have thought I’d read something on every possible welding- and inspection-related topic out there. Goes to show me not to get too full of myself, because there’s still plenty I don’t know. This issue proves my point. I had never heard the term “caulking” associated with welding before. I knew what caulk was and what it meant to caulk something, that caulk is used to seal things such as around windows or bathtubs and showers to keep water from getting where it shouldn’t. But I never connected caulking with welding. Brent Boling has written an article for this issue to help you understand when and where caulking can or cannot be used. I found the historical background Brent provided very interesting, and think you will too. There’s lots of other good stuff in this issue as well. Al Moore gives a thorough explanation of guided bend testing. There’s a Q&A related to  positive material identification using X-ray fluorescence analyzers, and another feature article offers tips for selecting the right borescope for  your internal weld inspection application. If you like these articles or have ideas for topics you’d like to see covered in Inspection Trends, please call me at (800) 443-9353 ext. 238 or send me an e-mail to [email protected] . I look forward to hearing from you.

Editorial Editor Mary Ruth Johnsen, [email protected] 

Associate Editor Kristin Campbell, [email protected] 

Assistant Editors Melissa Gomez, [email protected]  Annik Babinski, [email protected] 

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Copyright Copyright © 2015 by American Welding Society in both printed and electronic formats. The Society is not responsible for any statement made or opinion expressed herein. Data and information developed by the authors of specific articles are for informational purposes only and are not intended for use without independent, substantiating investigation on the part of potential users.

 American Welding S 6

Inspection Trends / August 2015

News Bulletins Coldwater Machine Opens Weld Evaluation and Testing Lab Coldwater Machine Co.’s Solid State Joining Center recently opened a materials evaluation and testing lab for weld inspection. This on-site service provides prompt verification of weld integrity, which will help the company shorten development time for laser, solid-state, and arc welding customers. The company has invested in a new abrasive cut-off saw, metallurgical microscope with digital imaging, and a grinding/polishing station for the lab in order to provide microstructural evaluation in addition to its mechanical testing ca pability for weld tensile strength and hardness. Customers can bring in their weld samples for evaluation  by contacting the lab at (419) 678-4877 or e-mailing [email protected] .

AWS Certification Dept. Seeks Exam Questions The American Welding Society’s (AWS) Certification Dept. is asking students and experienced Certified Welding

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Inspection Trends / August 2015

Inspectors (CWIs) and Senior Certified Welding Inspectors (SCWIs) to submit questions they think would be a valuable addition to the CWI Fundamentals exam, which is an open  book exam. Submissions should include the question text, five answer choices, indication of the correct answer, and the corresponding specific reference information. Questions must be developed utilizing one of the following references: • AWS A1.1, Metric Practice Guide for the Welding Industry • AWS B2.1, Specification for Welding Procedure and Per formance Qualification • AWS B4.0, Standard Methods for Mechanical Testing of  Welds. Also, questions should come from the following subject areas: • Welding processes • Heat control and metallurgy (carbon and low-alloy steel) • Weld examination • Welding performance • Definitions and terminology • Symbols — welding and NDE • Test methods — NDE • Reports and records

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• Duties and responsibilities • Safety • Destructive tests • Cutting • Brazing • Soldering. To submit your question(s) and to see guidelines for writing good questions, visit www.aws.org/submit-questions.html . You will also be asked for your contact information and be given the opportunity to win a $100 AWS voucher.

YXLON Partners with Racing Team

YXLON recently became a partner of the Lotus F1 racing  team and has provided the team with a computed tomogra phy inspection system.

YXLON International, Hamburg, Germany, a producer  of X-ray and computed tomography systems, recently joined the British Lotus F1 Team as a technical partner. The company will provide its Y.MU2000-D X-ray system in a special configuration that includes variofocus tube and computed tomography. The team intends to carry out most of its inspection tasks with this system in the future.

ASQ Awards Scholarship to Education Company VP The American Society for  Quality (ASQ) recently awarded the first Paul Borawski Scholarship to Katie Berman, vice president of Curriculum Advantage, Inc., an education technology company. With the scholarship award, Berman will be part of a 21-member cohort in the ASQ Emerging Quality Leaders Program, which will include corporate visits, leadership seminars, virtual coursework, mentor sup port, and team projects.  Katie Berman The scholarship is named after Paul Borawski, who retired in 2014 after 27 years at ASQ. He was CEO of the organization at the time of his retirement.

Pennsylvania Company Offers NDE Classes Aerial Energy Resources, LLC (AER), Smithton, Pa., is offering nondestructive examination (NDE) training courses in Belle Vernon, Pa. Courses will be conducted over a six-week   period and potential attendees can sign up for one or more courses.

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Inspection Trends / Summer 2015

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All cour ses are taught by professionals utilizing hands-on learning techniques with traditional elements, and AER provides all the equipment needed. All courses are in compliance with ASNT SNT-TC-1A and CP-189 requirements. The instructor is an ASNT Level III in the method with mor e than 20,000 hours of field experience with phased array ultrasonic testing. Courses available are phased array basic, phased array advanced, phased array — advanced crack sizing, magnetic particle testing Level I and II, dye penetrant testing Level I and II, ultrasonic testing Level II, and visual inspection Level II. The schedule and additional information is available on the company’s website at www.aertesting.com . AER is a testing and research and development laboratory with a strong focus on advanced applications.

System One president and CEO. “As a combined national entity, we will offer our clients significant value and expertise on ensuring compliance with regulated industry qu ality guidelines.” Jeff Sengenberger, Quality Programs director, will assume the role of vice president, Quality Solutions, at System One.

Spectronics Selects Global Customer Service Manager

System One Acquires AECOM’s Quality Programs Business System One, Pittsburgh, Pa., recently acquired the Quality Programs business from AECOM. It will be integrated into System One’s Quality Solutions business to provide a full slate of work force solutions and quality engineering, product assurance, asset integrity, ins pection, and testing services.  Now known as Quality Programs, the oper ation previously was part of URS Corp., which joined AECOM in Octo ber 2014. “Quality Programs brings a wealth of knowledge, experiences, and best practices to the table,” said Troy Gregory,

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Inspection Trends / August 2015

 Debra Hammond 

Spectronics Corp., West bury, N.Y., recently promoted Debra Hammond to Global Customer Service Manager . She has been with the company more than 20 years. In her new  position, Hammond will be responsible for   streamlining the daily work flow of both the international and domestic customer service departments, which will be referred to as the Global Customer Service Dept. in the future.

OMS Launches Inspection Service Optical Metrology Services (OMS) recently began an inspection service to analyze the critical internal girth feature s

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of oil and gas pipeline welds in the firing line. The service, named Auga, combines high-resolution video camera technologies with laser scanning capabilities to gather detailed 360-deg pipe geometry data from within the entire girth weld. It can be attached directly to an internal line-up clamp and configured to report on a wide variety of  attributes. Additionally, traditional weld inspection processes may take up to an hour to complete, but Auga collects the data in minutes. The equipment can be integrated with OMS’s WeldAnalysis software, which is designed to capture, analyze, and report the results.

microstructure examination, and elemental analysis. In addition, compression testing, high cycle fatigue, creep testing, crack propagation/crack growth testing, evaluation of  welds for GE Aviation and Pratt & Whitney, and more was added to the lab’s list of previously approved mechanical, metallurgical, chemical, and specimen preparation services. The company has been Nadcap accredited in materials testing since 1994. In other news, the company recently added John Malack of Quakertown, Pa., as a customer service representative. Malack will service new and existing customers who  place orders for materials testing, nondestructive testing, and calibration services.

Laboratory Testing Expands and Renews Nadcap Accreditation

 John Malack 

Laboratory Testing, Inc. (LTI), Hatfield, Pa., recently renewed and significantly expanded the scope of its Nadcap accreditation in materials testing for the aerospace industry. Nadcap is the Performance Review Institute’s aerospace industry accreditation  program. The lab has achieved accreditation for broader mechanical testing specimen preparation, metallurgical evaluation of welds,

T R E N D S

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      

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Inspection Trends / Summer 2015

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Mail Bag Reader Concerned about Lack of  Documentation I am a CWI who has been certified for 12 years. I have 40 years of experience in welding, fabrication, and erection. The issue that concerns me on the majority of the job sites where I am requested to perform an inspection is the lack of  compliance with the AWS code requirements when they are in the job specifications. When the general contractors are required to hire an erection/welding contractor to perform welding in accordance to AWS D1.1, etc., they fail to ensure that the welders’ certifications are up to date and on site when I arrive to  perform the inspection. The welders may or may not have the  proper documentation required to perform the work in accordance with the applicable code; the welder certification papers are out of date, not properly filled out by the company qualifier  or the CWI who performed the test; and the companies do not know they are required to have a WPS for review, or even know what a WPS is. The problem is when I bring this to their  attention, the arguments begin: “Well the other inspector never  asked for this,” or “this is the way we have always done it, why are you being hard on us,” etc. As an inspector, I try to keep my cool and explain to them that these are necessary to ensure the work is being performed as required by the Engineer of Record, job specifications, and applicable code requirements. I try to help everyone as much as I am allowed to without causing a conflict of interest. Sometimes I just want to throw my hands up and find another career  or retire altogether, but I have been doing this so long and it’s

all that I know. I keep on going and try to educate as many as I can on the importance of having their documents in order to do the job right. I enjoy the Inspection Trends magazine and the articles are very informative. Charles (Sandy) Arendsen  AWS CWI and NDE Level II   Apex Geoscience, Inc.

Making Welding Procedure Specifications More Useful Regarding “The Answer Is,” on pages 24 and 25 of the Winter 2015 Inspection Trends. Some ideas advanced in the codes have merit that never penetrates through the clouds to touch the earth. Welding Procedure Specifications rarely have an impact on commercial work in the San Francisco Bay area. There are many problems and Albert Moore put his finger on one of  them. His solution needs a little detail in the manner of working it up from each manufacturer’s data. Then the manufacturer  should provide the chart on each spool. ( Inspection Trends) brings practical, useful information re peatedly. Articles as valuable as this one should be accumulated on a website and accessed by teachers and trainers. Thanks. Keep up the good work. Thomas Troy  AWS CWI, ASNT Level II — UT 

BRING BRAND AWARENESS TO YOUR COMPANY

®

American Welding Society

By placing your product video on the AWS website.

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Contact AWS for more information at 800-443-9353 Sandra Jorgensen at Ext. 254, email: [email protected] / Annette Delagrange at Ext. 332 , email: [email protected]

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Inspection Trends / August 2015

Print and Product Showcase Borescopes Offer Annotation Feature Users of Hawkeye® V2 video  borescopes can now add notations to the still images and video footage they capture. Through use of the annotation feature, inspectors can now document their 

notes as well as the date of an inspection on their inspection images. The video  borescopes feature flexible, durable, tungsten sheaths and come with an LED light source that is 1.45 times brighter  than its predecessor in the 4-mm-diameter version and 2.1 times brighter in the 6-mm V2 version. The borescopes also offer four-way articulation. Gradient Lens Corp. www.gradientlens.com

American W Welding elding Society® STANDARDS ST  NDARDS

THE 1 KNOWN THE WORLD OVER

www.aws.org  www. a ws.org 

Ultrasound Camera Upgraded

D1.1 The company recently released a hardware upgrade to its DolphiCam ultrasound camera and accompanying Dol phiCam Expert software. It now offers a 12-dB signal-to-noise ratio. The software offers new functions including a new tablet mode with an improved user  interface, multiview support, and a new drilled hole inspection tool that makes it easy to size and measure interlaminate defects in drilled holes. The software update is available free of charge to existing customers. DolphiTech www.dolphitech.com

Ring Lights Provide Sectional Lighting

TAKING AKING KING PRE-ORDERS P NOW! visit W  Weld.ng/2015d1 ld.ng/2015d1 14

Inspection Trends / August 2015

The Models RL28Q and RL16Q ring lights provide sectional lighting

control under high magnification for  laboratory and inspection applications. They feature a sealed body with an IP 65 rating, a quadrant controller with a touchpad that transitions the brightness from off to full output. The four quadrant zones can be individually turned on and off. The compact products offer  several mounting options. Orled www.orled.com/IT04/28Q

Device Measures Intensity and Visible Light

ures both ultraviolet and visible light. The AccuPro™ Plus (XP-4000) three-inone multipurpose sensor can measure ultraviolet, visible, and blue light. They each feature a three-button interface that makes it easy to toggle between measurement modes. Overall accuracy is greater than ± 5% per NIST standards. Full-color display settings are available in English, French, German, Chinese, and Spanish. The units comply with ASTM specifications for magnetic particle and fluorescent particle inspection. Spectronics Corp. www.spectroline.com

Software Allows Real-Time Access to Inspection Data

The AccuPro™ series of digital radiometer/photometers can measure intensity and visible light simultaneously. The series includes two models: the standard AccuPro™ (XP-2000) has a dualwavelength sensor detector that meas-

InspectionWorks Connect provides real-time access to live inspection video and data from anywhere in the world. The secure, encrypted product is embedded in NDE devices without the use of any additional equipment. It is also zero-install, which means users only need a web browser to log in remotely. It provides live video streaming of inspections; collaboration tools,

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including two-way chat communication and telestration; cloud-based infrastructure; wireless connectivity; and over-the-air software updates. It is currently available for use with visual inspections on the GE XLG3 and Mentor  Visual IQ videoprobes, as well as the Mentor EM eddy current portable. GE Measurement & Control www.gemeasurement.com

Computed Radiography System Sets Up Quickly The HPX-Pro portable computed radiography system can be set up in less than 5 min to produce high-quality digital images for quick analysis and rapid reporting. The scanner weighs 35 lb, includes a replaceable air filter and vent to ensure the air is clean and adequately circulated inside the scanner. It features a fold-up entry and exit door with extensions that are held closed by a magnet to keep the scanner dust and dirt free. Carestream Health, Inc. www.carestream.com  — continued from page 43

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Inspection Trends / Summer 2015

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By Albert J. Moore Jr.

Feature

A Guided Bend Testing Primer The types of guided bend tests that can be used, and how test assemblies are prepared, tested, and evaluated are explained 

 Fig. 1 — The dashed lines show the orientation of two  specimens that are said to be transverse to the longitudinal  axis of the weld. The number of specimens required is  specified by the applicable welding standard. Note the direction of rolling. The properties of elongation as well as tensile strength and yield strength are influenced by the direction of rolling. A guided bend test is a destructive test used to evaluate a welded coupon. Most welding standards include bend testing as an acceptable method of  evaluating the soundness of a welded coupon to ensure it is free of defects such as incomplete fusion, incomplete  joint penetration, excessive porosity, slag inclusions, etc. Alternatives to the guided bend test may include radiographic examination or, in the case of API 1104, the nick break test. This article will explore what types of  guided bend tests can be used, and how the test assembly is prepared, tested, and evaluated. Hot rolled metals used for welded assemblies have mechanical properties that are anisotropic. That is, the mechanical properties parallel to the direction of rolling are superior to those perpendicular to the direction of  rolling or in the through-thickness

 Fig. 2 — The dashed lines show the orientation of the  specimen relative to the longtitudinal axis of the weld. The longitudinal specimen may be subdivided into shorter  lengths to provide the number of bend specimens required  by the applicable welding standard.

direction. The direction of roll is a factor to consider when laying out the test assembly that will be welded. The severity of the guided bend test may cause the welded sample to tear and fail to meet the acceptance criteria if  the orientation (direction of rolling) is incorrect. Figures 1 and 2 show the proper  relationship between the direction of  rolling and the longitudinal axis of the weld. There are two types of guided  bend tests. The one used most often is the transverse guided bend test, which is used when the test assembly consists of base metals that are the same specification, grade, or have similar  mechanical properties. When dissimilar   base metals with different mechanical  properties are joined, a longitudinal guided bend test is performed. A guided bend test deforms the specimen in a way that stretches the

outermost fiber of the convex surface  by some specified amount. The elongation required is a function of the  properties of the base metal and/or  filler metal used. The thickness of the test specimen must also be considered when determining the correct diameter  of the bend mandrel to use to ensure the required elongation is attained. The welding standard will specify the diameter of the bending mandrel or it will provide an equation used to calculate the appropriate mandrel diameter. One such equation can be found in the ASME Boiler and Pressure Vessel  Code Section IX, Article IV, and AWS B2.1, Specification for Welding   Procedure and Performance Qualification. Both welding standards use the same equation and require the same bend diameter. NAVSEA S9074AQ-GIB-010/248, Requirements for  Welding and Brazing Procedure and   Performance Qualification, also utilizes the same bend diameters. One must determine the base metal group of 

Inspection Trends / Summer 2015

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 Fig. 3 — Transverse face bend.

 Fig. 4 — Transverse root bend.

Fig. 5 — Transverse side bend.

 Fig. 6 — Longitudinal face bend.

 Fig. 7 — Longitudinal root bend.

 Fig. 8 — The weld is not properly centered on the convex surface of  the transverse bend. This is a common problem when testing  dissimilar base metals with different   properties of elongation. This is an unacceptable bend specimen.

the base metals being evaluated. ASME groups the base metals by P-numbers, AWS B2.1 groups them by Mnumbers, and NAVSEA S9074-AQ-GIB-010/248 groups the  base metals by S-numbers. Likewise, the filler metals are grouped by Fnumbers or by A-numbers. Generally, the properties of the filler metal match the elongation of the  base metal. There are exceptions, such as in the case of aluminum alloys. In the case of aluminum, the filler metal F-number must be considered when determining the proper bend mandrel diameter. The applicable welding standard will provide the necessary direction in selecting the proper bend mandrel diameter. AWS D1.2, Structural Welding Code — Aluminum, takes into consideration the properties of the base metal and the filler metal used. To select the proper bend mandrel diameter, one must know the M-number  of the base metal(s) and the F-number  of the filler metal. All aluminum test specimens must be machined to ⅛ in. thick prior to bend testing. The equation provided by ASME Section IX, Article IV, is

 A

=

T 

(100% - x % )  x%

where A (in customary units, inches) is the required bend mandrel diameter, T  is the thickness of the specimen to be

18

 bent, and x% is the elongation required  by the welding standard. An example is as follows: P/M/S number for carbon steel = 1 (from the applicable welding standard). The elongation of the base metal is specified as 20% or more (from the applicable welding standard based on the base metal group, i.e., P-number, M-number, etc.) The thickness of the specimen is ⅜ in.  A

=

0.375

(100-20 ) 20

=

0.375

80 20

=

1.5 in.

Once the required bend diameter  has been determined, the appropriate guided bend test is selected. If the base metals being joined are the same, a transverse bend test is used. If  dissimilar base metals are welded, a longitudinal bend test is used or  strongly recommended. Figure 1 depicts the orientation of the test specimen for a transverse guided bend test, and Fig. 2 depicts the orientation for a longitudinal guided bend test. The dimensions of the guided bend specimens are specified by the applicable welding standard. Generally, the specimens are 1½ in. wide T , where T is the thickness of the test specimen (when it is no more than ⅜ in. thick). The length must be adequate to fit the bending machine. Typically, 6 to 8 in. in length is sufficient. The dimensions for guided bend

Inspection Trends / August 2015

test specimens and the bend diameter  for API 1104 are not consistent with the other welding standards commonly used in the United States. Where ASME, AWS, and NAVSEA require a carbon steel bend specimen to elongate 20%, API 1104 requires a 9% elongation for a specimen thickness ⅜ in. API uses the same bend diameter  regardless of the properties or the thickness of the pipe material. AWS, ASME, and NAVSEA require multiple  bend mandrels, whereas API utilizes a one-size-fits-all approach. The transverse guided bend test can be a face, root, or side bend. The type is dependent on the thickness of  the test coupon. Specimens measuring ⅜ in. thick or less are usually bent as either face or root bend. Specimens ⅜ in. or thicker are usually tested using side bends. Guided face bends are bent in the testing machine so that the face of the weld is stretched (elongated), and the root of the bend is compressed. That is, once the specimen is bent, the face is centered on the convex surface and the root is centered on the concave surface. The guided root bend is bent so that the root of the weld is stretched and is centered on the convex surface

 Fig. 9 — Preparing the bend   specimen. of the bent specimen and the face is centered on the concave surface of the  bent specimen. When the test assembly is thicker than ⅜ in., a transverse side  bend can be used to eliminate the need to machine the specimens to ⅜ in. thick. There is no side bend option when using longitudinal bends. Longitudinal bends removed from coupons thicker than ⅜ in. must be machined to reduce the thickness to ⅜ in. In the case of a longitudinal face  bend, the root surface is removed by machining to reduce the thickness to ⅜ in. The face surface is machined to reduce the specimen to ⅜ in. thick  when a longitudinal root bend is required. Regardless of the type of   bend test, the specimens are bent so that the face surface, root surface, or  the full cross section of the weld is elongated. Figures 3–7 depict the face, root, and side bends, respectively. In Fig. 3, the transverse face bend elongates the face of the weld so the weld face forms the convex surface. The convex surface is examined and evaluated to determine whether it is in compliance with the acceptance criteria. The acceptance criteria specifies the maximum size of any open discontinuities and the sum of the dimensions of the discontinuities. The transverse root bend shown in Fig. 4 places the root of the weld in tension. The root of the weld is elongated and forms the convex surface, which is then evaluated to determine if the specimen meets the acceptance criteria of the welding standard. Open discontinuities such as cracks, porosity, incomplete fusion, etc., must be evaluated. The transverse side bend shown in Fig. 5 is used when the thickness of the test assembly is 3 thicker than  ⁄  8 in. It eliminates the need 3 to machine the specimens to  ⁄  8 in. thick. In all cases, the convex surface is visually examined for open

 Fig. 11 — Schematic of a wraparound bending machine.

 Fig. 10 — Plunger and die bending  machine. A transverse side bend is in  position and ready to bend. discontinuities. Cracks on the ends of  the bent specimen are not part of the evaluation. Open discontinuities on the convex surface are evaluated and compared to the acceptance criteria of  the applicable welding standard. This is where the differences between the welding standards come into play. The acceptance criteria of ASME is not the same as AWS D1.1 or API 1104, etc. The acceptance criteria of AWS D1.1 is different from API 1104. The acceptance criteria for guided bend tests in AWS D1.1 and NAVSEA S9074-GIB-AQ-010/248 are the same. It is important to note the differences in the acceptance criteria and the mechanics of the bend tests. The differences in acceptance criteria mean that a guided bend test that meets API 1104 does not meet the requirements of ASME Section XI, AWS D1.1, or NAVSEA S9074-AQGIB-010/248. A guided bend test that meets ASME Section IX does not meet AWS D1.1 or NAVSEA, but one that meets AWS D1.1 or NAVSEA does meet ASME Section IX. These differences should be noted when accepting WPSs or welders qualified to an alternate welding standard. Figures 6 and 7 show how longitudinal bends are used when two dissimilar metals are welded. The longitudinal guided bend test eliminates the possibility of the specimen shifting in the fixture when the bending load is applied. A transverse specimen (consisting of 

dissimilar metals) will often slip toward the more ductile base metal, thus the convex surface is properly centered and the sample cannot be evaluated properly. Longitudinal bends are permitted by some welding standards for thin sheet metal thicknesses that would require a small bend diameter. It is nearly impossible to keep the weld properly centered when the transverse bend test requires a small bend diameter — Fig. 8. The longitudinal bend test eliminates that problem. A drill of the proper  diameter can be gripped in a shop vise and the longitudinal specimen bent around the drill. The test specimens must be  properly prepared prior to bending. The face reinforcement, backing if used, or  root reinforcement must be removed flush with the surface of the specimen. The exception is when qualifying to the requirements of NAVSEA S9074-AQGIB-010/248. In that case, if the weld  joint is welded as a complete-joint penetration groove weld, without  backing, melt-through is left intact for  the transverse root bend. Grinding the specimen with a disk  grinder is commonly how specimens are prepared for bending — Fig. 9. The extent of grinding must be limited when removing weld reinforcement,  backing bars, and surface discontinuities such as undercut,  porosity, incomplete fusion, incomplete  joint penetration, etc., so the thickness of the weld and HAZ are not below the surfaces of the adjacent base metal. Scratches from grinding must be aligned along the long axis of the bend specimen so they are perpendicular to the axis of the bend. Scratches that are  parallel to the bend axis tend to act as stress risers and initiate cracks that must be evaluated. The longitudinal edges can be rounded with a grinder or  file to mitigate the probability of a

Inspection Trends / Summer 2015

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 Fig. 12 — Longitudinal guided bend   specimen with a failure due to incomplete fusion.

 Fig. 13 — Transverse side bend, double-V groove.

 Fig. 15 — Transverse root bend with  piping porosity.  Fig. 14 — Transverse root bend with corner tears.

 Fig. 16 — A specimen removed from a pipe assembly and subjected to a transverse face bend test. corner tear. Once again, the appropriate welding standard must be reviewed to determine the maximum allowable corner radius. The bending operation can  proceed once the specimens are  prepared. There are two common  bending machines used for this  purpose. The most common is the  plunger and die type. Figure 10 shows a plunger and die  bending machine that has been in use for more than thirty years. The diameter of the plunger and die are fixed. Different plunger and die sets are required for different properties of  elongation and each test thickness. A common mistake is to use the same  plunger and die for all types of base metals without regard for the specimen thickness or elongation. Another type of bending machine

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Inspection Trends / August 2015

is the wrap-around machine — Fig. 11. The wrap-around machine is easier to adapt to different base metals. Different diameter mandrels can be used to bend materials with different  properties of elongation and/or  thicknesses. This is handy when testing dissimilar metals or pipe having different wall thicknesses. It is a “must” when testing heat-treatable aluminum alloys that tend to concentrate the bend in the HAZ that has been softened by overaging. While it has not been mentioned  previously, all the welded samples must pass the applicable visual acceptance criteria before being cut and prepared for bending. Welded assemblies that fail to pass the visual examination are not subjected to a guided bend test. Proper evaluation of  the convex surface after the specimen has been bent is the next step in the  process. Only the “as bent” convex surface is evaluated. That is, no further  grinding or sanding of the convex surface is permitted before the final evaluation. Cracks or tears initiating on the ends of the specimen are typically disregarded unless there is clear  evidence of incomplete fusion, slag inclusions, incomplete joint  penetrations, etc. The applicable

welding standard must be reviewed to determine what acceptance criteria is applied. AWS D1.1 has the most stringent criteria when compared to ASME Section IX or API 1104, whereas API 1104 has the least stringent criteria. Figure 11 shows a schematic of the wrap-around-style bending machine. It shows the sample loaded and the handle in the starting position (solid lines). The handle is wrapped around the central mandrel so the cam follower  forces the specimen against and around the required mandrel diameter. Once the handle is moved to the final  position (dashed lines), the specimen is  bent through a full 180-deg arc. The convex surface is then compared to the acceptance criteria provided by the welding standard and either accepted or rejected. The acceptance criteria for most of  the welding standards are similar, but have minor variations. Generally, with the exception of corner cracks, any open discontinuity larger than ⅛ in. in any direction is rejected. AWS D1.1 goes a step further and states that the sum of all open discontinuities larger  1 than  ⁄  32 in., but less than ⅛ in., must be less than or equal to ⅜ in. The standard width of the specimen is typically 1½ in. Narrower bend specimens are  permitted for small-diameter pipe and API 1104. ASME does not limit the number of ⅛-in. open discontinuities, as long as they are not more than ⅛ in. This is not a subtle difference between ASME Section IX and AWS D1.1. It is a factor that should be considered carefully by the engineer when entertaining the thought of allowing the welder and WPSs to be qualified to an alternative welding standard. Figure 12 depicts a longitudinal guided bend specimen with a crack that resulted from incomplete fusion  between the weld and the adjacent Monel® base metal. This is a dissimilar   joint between HY80 and Monel. The weld displays a mottled appearance due to differences in the hardness of  the grains in the weld deposit. The sample failed because the length of the open defect is more than ⅛ in. Figure 13 shows a double Vgroove that failed the side bend. The open tears are due to incomplete fusion  between weld beads and the groove face. Each tear is less than ⅛ in., but the sum exceeds ⅜ in. The transverse side bend is used when the welded

assembly is thicker than ⅜ in. Figure 14 shows a pipe specimen subjected to a transverse root bend. The corner tears were probably the result of  improper specimen preparation. Notice the test specimen did not have the corners rounded. Had the sample been  prepared properly, it may have passed without the corner tears. The root of  the weld, harder than the base metal, is  pushed out slightly during the bending operation. The specimen curls up slightly at the ends of the weld, a telltale indication this is the root bend in a pipe sample. Figure 15 shows a transverse root  bend that failed due to piping porosity. The test assembly was welded using an E7018 electrode that was stored in an electrode oven. However, the oven was not plugged in because the contractor  said he was trying to save money by not wasting electricity. Figure 16 shows a specimen taken from a welded pipe. The specimen is a transverse face bend. Other than a few scratches, there are no open discontinuities. The specimen passed even though the corners were not rounded as permitted by the applicable welding standard.

welded assembly, removing, preparing, testing, and evaluating the test assembly as directed by the applicable welding standard. Every welding standard has unique requirements that must be understood in order to properly perform the test and to evaluate the specimen once it is bent. Time spent reviewing the welding standard to verify the proper  mandrel diameter is being used and the specimen is properly prepared and identified is time well spent.

 ALBERT J. MOORE JR. ([email protected]) is vice president, Marion Testing & Inspection, Canton, Conn. He is an AWS Senior Certified  Welding Inspector and an ASNT ACCP   NDT Level III in RT, UT, MT, and PT. He is also a member of the AWS Certification Committee and the Committee on Methods of Inspection of Welds.

Summary Guided bend testing is one of the most widely used methods of  evaluating welded test assemblies. While it takes time and effort to  prepare the test specimens properly, it can be less expensive than radiographic examination, and it can provide quicker  results when the facilities needed to  perform radiography are not close at hand. Some welding standards require welder performance qualification coupons welded with the short circuiting transfer mode of gas metal arc welding (GMAW-S) to be evaluated using guided bend tests. Radiographic testing is not an acceptable method of qualifying a welder who welded the test assembly using GMAW-S. Once welders pass their   performance qualification tests, it is not uncommon for them to save the bend samples as visual evidence they passed the test. Passing the first performance test is a proud moment in a welder’s career. The inspector is responsible for   performing visual examination of the For info go to www.aws.org/ad-index

Inspection Trends / Summer 2015

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Feature

By Douglas S. Kindred

Internal Weld Inspection Using Borescopes The key to proper borescope inspection is choosing the right scope for your particular  application

 Inspection of internal orbital welds in an aircraft fuel system using a Hawkeye rigid  borescope and video system. Quality assurance professionals and weld inspectors often need to inspect internal welds — welds that are often deep inside a part or assembly, or are in some way not easily accessible. In these situations, borescopes are invaluable remote visual inspection tools, allowing you to get “your eye inside” the part. Borescopes are essentially the same as medical endoscopes, but are intended for industrial use to inspect any type of   bore. They allow production or quality control personnel to look inside small and complex parts and to visually inspect with great detail. Borescope diameters range from about 0.5 up to 10 mm, and lengths range from about 2 in. to more than 50 ft. There are three basic types: rigid borescopes, flexible fiberoptic borescopes, and flexible and rigid video borescopes — Fig. 1. Rigid borescopes use a series of  relay lenses to relay the image down a

22

long, narrow tube. They are always the  best option if you have a straight path to inspect. Rigid borescopes have the highest image quality, lowest price, and are more durable. Some can be used  both for straight ahead (0 deg) and 90deg viewing of the welds. These scopes can be used either by eye or they can be attached to a video camera. In a factorytype setting, a video camera is the way to go. Flexible fiber-optic borescopes use a bundle of optical fibers to relay the image down a long, flexible tube. They are necessary when the tubes are bent or  you just have to get around some type of  a bend or obstruction. They have lower  resolution due to the use of fiber optics rather than conventional lenses. Fiberoptic scopes are higher priced and are typically more fragile, but they will get you around the bend if that is what you need to do. Many hydraulic, fuel, and

Inspection Trends / August 2015

 pharmaceutical applications utilize bent tubes with welded fittings. These flexible scopes are just the ticket for that type of inspection. Video borescopes incorporate the latest technology. Rather than using the relay lens systems used in rigid  borescopes, or a fiber-optic image guide as in fiber scopes, video  borescopes have a micro video camera at the tip of the scope. This gives the user a flexible scope with much better  resolution, displayed directly onto a video monitor, handheld or desktop device, or laptop or desktop computer. Video borescopes deliver the quality of  a rigid scope, but with a flexible shaft. They often have two- or four-way articulation allowing the user to literally steer the scope around bends. These systems offer convenience and  portability. They feature everything you need to conduct a remote visual inspection, and the ability to capture still images or video, all in one small, lightweight, handheld package. One of the most common applications of borescopes is the inspection of orbital welds inside stainless steel tubes and fittings. These tubes are used in a variety of fields, including aircraft fuel systems (see lead  photo), power generation, hydraulic systems for aviation (Fig. 2) and heavy equipment, pharmaceutical manufacturing, food processing, chemical processing, and oil and gas equipment. Borescopic inspection is often the only way to look inside these difficult-to-reach parts and systems. In most cases, operators employ orbital welding with an integral filler  metal, machined directly into a fitting. Inspectors examine each weld to ensure there’s no lack of penetration of the weld  bead through the base metal, which typically is titanium, nickel, or stainless steel. For instance, the key factor in

 Fig. 2 — A weld inside an aircraft  hydraulic line. The HAZ and slag are evident.

 Fig. 1 — Examples of rigid, flexible, and video borescopes.

 Fig. 3 — Longitudinal weld inside a welded and drawn stainless steel tube.

 Fig. 4 — Shown are broken weld joints detected during inspection of an arterial stent with a rigid borescope.

making high-quality welds in titanium is cleanliness. Thus, inspectors look for  weld porosity or contamination. Performing a borescopic inspection on the first workpiece gives the welder or welding operator  immediate feedback on whether the  penetration is acceptable without waiting for X-ray results. Doing so  provides immediate feedback, reduces the cost of rework, and decreases the likelihood of a nonconforming part ever reaching the customer. This allows the operator to change welding  parameters as necessary to ensure a conforming part. There is also a big benefit to adding video capability to the inspection  process with the addition of a video system attached to the borescope. Video

systems provide blown-up views, so they give inspectors an enhanced picture of welded joints. Welders can just lay down a tube and twirl the scope around to easily and quickly inspect their work. The video system is also a great tool for  welder training on visual requirements. By using a borescope, the inspector  can get a great view of the heat-affected zone (HAZ), and can clearly see slag and voids in an imperfect weld. Another application for borescopic inspection is the manufacture of the tubing itself. The majority of stainless steel tubing is manufactured using the “welded and drawn” method — Fig. 3. Borescopes can be used to inspect the longitudinal weld joint inside these tubes as part of the quality control  process. This is particularly important

in medical tubing. Borescopes are used to inspect internal welds and braze joints in all kinds of assemblies in automotive, aviation, and heavy equipment. Typical examples include inspecting welds inside large aircraft oil coolers, radiators, and other heat exchangers. Structural welds that are difficult to access can be inspected as well. A wide variety of miniature medical  products are manufactured using microwelds. Medical products such as endoscopes and endoscope accessories, microvalves, and arterial stents are a few examples — Fig. 4. Very small-diameter   borescopes allow visual inspection of  these critical components. Video borescopes are also very useful for inspection of welds in structural steel in buildings, bridges, etc., in situations where you simply are not in a position to get a good look with the naked eye. The videoscope allows you to see the problem, capture the image, or  video the entire inspection. The key to proper borescope inspection is choosing the right scope for  your particular application. Inspectors sometimes want one tool to do it all. That’s a nice concept, but it doesn’t always work. If the path is straight, use a high-quality rigid scope. If the path is  bent or extra long, you’ll either need a fiberscope or a flexible video borescope. The right high-quality borescope makes all the difference.  DOUGLAS S. KINDRED is  president and chief scientist, Gradient Lens Corp., maker of Hawkeye  precision borescopes, Rochester, N.Y., www.gradientlens.com .

Inspection Trends / Summer 2015

23

Feature

By Alex Thurston

Tips for Better Positive Material Identification  An experienced inspector discusses alloy material verification with X-ray fluorescence analyzers analysis accuracy of XRF can detect significant deviations in specified chemistry and alert the user to potential problems or the need for laboratory analysis.

Q: As someone heavily involved in PMI testing, what are the main benefits you see for welding-related applications?

A: X-ray flourescence allows for a

 A handheld XRF analyzer being used for positive material identification of a weld in a metal beam. In the world of alloy fabrication, material inspection, and plant piping system maintenance, handheld X-ray fluorescence (XRF) analyzers, with their simple point and shoot functionality, have become the standard choice for quickly identifying material mixups and improving material control. Recently, George Fairbanks, owner of Fairbanks Inspection & Testing, was interviewed regarding his positive material identification (PMI) tricks of  the trade. Fairbanks has more than 30 years of experience with PMI and is a long-time user of the X-ray tube-based XRFs commonly used today. A longtime member of the American Welding Society (AWS), Fairbanks served eight years as the District 9 Director.

Q: Can you tell us how field instrumentation has changed since the 1980s?

A: When I was introduced to positive material identification, our instrumenta-

24

tion filled a 16-ft room. In the early ‘90s, we purchased a portable optical emission spectrometry (OES) instrument the size of a desk. While these early OES analyzers were large, they provided a level of  accuracy that made me feel comfortable  putting my name on a report. In the mid’80s, I had my first experience with field-portable XRF. They were isotope based systems in those days. It was not until 2005 that I actually  purchased my first X-ray tube-based handheld analyzer. This first analyzer  was great at testing 300 and 400 series stainless, nickel alloys, titanium, cobalt, and some copper alloys. While XRF analyzers are not able to detect carbon content, they are still a valuable tool for evaluation. For exam ple, XRF can identify a whole host of alloys with reasonable accuracy. Also, XRF can differentiate increasing chromium levels between carbon steel, carbon ½ Mo and 1¼ Cr up to the specifications of the 13 Cr in 400 series stainless steel (SS) grades. The individual element

Inspection Trends / August 2015

quick and accurate verification of materials prior to the start of fabrication, during fabrication, and at the completion. It is beneficial to precheck carbon steel, SS, Cr, Ni, Al, Ti, Cu, and Co grades. This includes both base metals and filler metals. Oftentimes, not all of  the materials being repaired or replaced have paperwork on the original materials used in fabrication. X-ray flourescence can determine what type of material will be welded or used to replace the current material. We see this a lot with equipment made not only in the USA but also by foreign manufacturers. A good set of reference books is invaluable for verification of foreign or   proprietary materials to compare criteria or find the closest match. X-ray fluorescence is a great aid for  checking flux cored arc welding filler  metal to American Society of Mechanical Engineers (ASME) requirements for  Mn maximum limits based on the A numbers in iron-based specifications. A small breach in a quality system can result in a catastrophic failure. X-ray flourescence is successful in detecting wrong filler metals by looking at the actual chemistry compared to looking for a grade. For example, on a 9 Cr fabrication, an analysis determined that the base metals met the 9 Cr requirements, but several of the weld chemistries fell between 1.5 and 3% Cr, and were also low in Mo content. These weld chemistries were too low as a result of incorrectly using ER70S-2 filler metal.

 An example of an analysis report.

Q: On the other hand, what are the drawbacks or points of concern for handheld XRF with regard to welding-related PMI applications?

A: There are four common sources of  confusion: 1. First, there’s a lack of familiarity with material specs for the base metal. 2. Second, confusion caused by the filler metal chemistry not exactly matching the base metal chemistry. The filler metal is typically overalloyed to account for dilution. 3. Third, when the filler metal is very different from the base materials,  perhaps when joining carbon steel to stainless or nickel alloys, the resulting weld fails to resemble any of the  preweld material chemistries. 4. And, fourth, when materials meet more than one classification, from overlapping chemistry ranges. Another area that can be tricky to test has to do with the sample’s size, shape, and distance from the XRF analyzer, which can influence test results. For example, some of the materials that are influenced by these factors are ex panded metals, very small or inaccessi ble fillet welds, and thin filter screens. For an inspector, knowing when to use the analyzer’s collimator function is important for the best accuracy. Testing with the standard beam spot size (10 mm) on small parts or using the smaller  collimated beam spot size (3 mm) on

Screen shot showing grade for ER316  weld material. larger surface areas may create an unwanted influence on the test results.

Screen shot displaying grade match  for 316 stainless steel base metal. stamped from the mill that is what it is supposed to be, and do not pay attention to the chemistry.

Q: What other things have you learned that you feel might add to this discussion?

A: By having a procedure in place, it enables inspectors to follow a systematic testing process. Incorporating reference materials into our standard operating procedure keeps us from re porting erroneous results and allows verification of accuracy with unknown materials. Reviewing the accuracy deviation, plus or minus, will keep you from thinking you found something out of spec by 0.002%. Knowing that the XRF elemental analysis accuracy is 10% helps with looking at minor   percentages that are over or under a required spec. Having a known reference standard to check your instrument against after standardizing is critical. Developing and using separate chemistry libraries for common base metals and filler metals are critical for  accurate PMI. The XRF operators should be aware that numerous alloys can overlap specified chemistry ranges for two separate grades, such as SS303 and SS304, and other exam ples can be found when looking at the 400 series SS. Too many times the operators look at the base metal specification only, or think since something is

Q: In an industrial setting, productivity and value are always a concern. Is there anything you would like to add on this topic?

A: Performing PMI when materials are received and stamping them as ap proved increases the likelihood that the final product meets the intended specification. Verifying materials at the start of the job prevents costly rework and the removal of incorrect materials. Re pair work is costly and often results in unacceptable delays. Catching incorrect materials prevents reduced service life and can prevent serious accidents from unexpected failures. While handheld XRF delivers onthe-spot material compositions and alloy grades, a key component of an effective field inspection is qualified inspectors. Developing a training program to ensure personnel are well aware of differences and similarities in material specifications and applications is a plus for any company.

 ALEX THURSTON is applications scientist, Metallurgical  Group Leader, Olympus Scientific Solutions Americas, Waltham, Mass., www.olympus-ims.com.

Inspection Trends / Summer 2015

25

Feature

By Brent E. Boling

Understanding Caulking  A look at the history of its use can help us understand whether we can or cannot use caulking today

 Fig. 2 — A weld with no chisel marks.

 Fig. 1 — Caulking to hide a crater crack. Caulking is a condition that can occur from the improper use of slag removal tools. This article will examine what caulking is, where it comes from, and how it applies to our work in structural steel today. As AWS CWIs, we need to be careful about not only what we say, but when and how we say it. Rather than a lack of knowledge or training on the  part of the inspector, welder, and/or fabricator management, communications can simply be misunderstood. For example, I recently discovered a welder on my shift had just completed grinding down the entire width and length of a weld, about 20 ft, because another third party inspector working with me had marked it for “caulking.” He had only marked a short area of the weld, but the welder got the word from his supervisor  and believed that everywhere a chipping gun had been used was caulking and needed to be ground for correction. That was not what the inspector had said nor  marked on the part, but was how the communication came down the chain of  command to the welder. I was not able to use the same weld to show the welder what was being marked for repair (probably a good

26

thing in many ways), and had to use a different weld entirely to point out what I believed was happening. The next day, I made sure the other inspector and I were on the same page as to how we looked at the issue. That evening, I clarified everything with the welder and shift lead person.

The History of Caulking To understand caulking, I believe we need to look back to see where the term came from and how it became part of our current welding terminology. Some of the earliest references available on caulking are related to  boats and ships made of wood and other materials. After all other work  had been completed, they would use a dull chisel-style tool to drive various materials into the seams to seal or  “caulk” them. This practice continued for sealing wooden barrels, storage tanks, and other items. This method was also used extensively for doing repairs as the wood aged, dried out between fillings of liquids, and went through various stages of degradation or decomposition.

Inspection Trends / August 2015

As time passed, steel became a material of choice for many purposes, especially in the shipbuilding industry. Early on, rivets were the primary fastening system as welding had not yet  been perfected and proven in application. Having worked as a boilermaker   back in the late 1970s through the mid 1980s, I was fortunate to have worked with some elderly welders who had worked during the time when rivets were used in many applications. They worked on projects like boilers, ships, storage tanks, and other fabricated items with riveted joints. The amount of overlap, spacing of the rivets, and methods of installation would vary de pending upon the application, pressure, material thickness, and several other  variables. One method that remained  basically the same as in previous generations was the sealing of the seams. The dull chisel tool and a hammer of  earlier times remained in use. They were used to place repeated light blows on the edge of the overlapped steel to deform the corner so it “caulked” the seam. The practice was used even more extensively to complete repairs of leaks. Changes in temperature, pressure, stress-

es, and other in-service conditions would loosen the joints and allow movement. Sometimes leaks would develop that required attention. They were treated by caulking the seam — driving more of the corner material into it. This was sometimes combined with welding added material onto the corner first, then caulking it into the seam. It is important to our application to note that repeated light blows were used to push material into the joint and caulk  the seams, thus sealing off the leaks. Heavy blows would weaken the joint at the rivets and cause more leakage. Light  blows can cause plastic deformation and are directly attributed to caulking, so telling the inspector that you weren’t hitting it hard enough to caulk the weld was not a valid position. Welds can be caulked using light or heavy blows. Plastic deformation is the issue. The American Welding Society (AWS) was established in 1919, at the close of WWI, when it was decided an organization with a wide variety of  membership from industry including educators, researchers, welders, inspectors, engineers, and management was essential to further the development of welding and incorporate it into American productivity. The work began during the war when many industry experts came together to help develop welding as an integral part of manufacturing and maintenance of wartime equipment. This work included development of codes, standards, and specifications to establish a baseline of procedures that would give the greatest potential for successful com pletion of welding projects. Rivets, caulking, and then the establishment of welding and all of its procedures made up the foundation of the knowledge available. This would obviously make for a practical application of  caulking as it applied to work being done during this transition between riveting procedures and those for welding.

Caulking Defined With this information as our background, let’s look at how AWS currently defines caulking. We will begin with D1.1: 2010, Structural Welding Code  — Steel , Clause 5.28: “Caulking shall  be defined as plastic deformation of  weld and base metal surfaces by mechanical means to seal or obscure discontinuities. Caulking shall be prohibited for base metals with minimum specified yield strength greater than 50

 Fig. 3 — A weld showing limited marks.

 Fig. 4 — A weld showing many marks and no caulking. ksi [345 MPa]. “For base metals with minimum specified yield strength of 50 ksi [345 MPa] or less, caulking may be used,  provided: “1. All inspections have been com pleted and accepted “2. Caulking is necessary to prevent coating failures “3. The technique and limitations on caulking are approved by the Engineer.” Secondly, in the Commentary, section C-5.23 Caulking: “The code has historically prohibited any plastic deformation of the weld or base metal surfaces for the purpose of obscuring or sealing discontinuities. However, since some minor discontinuities may interfere with the integrity of the coating system, limited caulking may now

 be used for the softer welds and base metals when approved by the Engineer. “There are no prohibitions against the use of mastic or nonmetallic fillers for cosmetic reasons provided that all required inspections of the weld and  base metal have been completed and accepted prior to application.” Finally, A3.0:2010, Welding Terms and Definitions, defines caulking as “plastic deformation of weld and adjacent base metal surfaces by mechanical means to seal or obscure discontinuities.” The term plastic deformation has  been introduced, which I should explain since many of you do not deal with it on a daily basis. Think back to your basic metallurgy from the seminar and/or selfstudy in preparing for the CWI exams. Once the stresses applied to a member 

Inspection Trends / Summer 2015 27

 Fig. 5 — An example of overlap. take it beyond the elastic limit, it will take on a permanent deformation, plastic deformation, which does not allow it to return fully to its original condition. The term applies to any material that has its shape, profile, and/or structure altered by any means or force so that it cannot return to its original state. This is not limited to the forces that put a bend in a  beam, but also includes items like a chisel and hammer used to alter the profile of a weld. In this article, we will narrow our  attention to a threefold purpose as ap plied to D1.1: 1) Identify caulking in today’s applications, 2) identify when caulking is acceptable, and 3) identify when caulking is unacceptable/ rejectable.

Applying the Definitions Take note of the phrases “to seal or  obscure discontinuities,” and “for the  purpose of obscuring or sealing discontinuities.” Both apply directly to the obscuring of discontinuities so that an inspector would overlook them. When we see a weld the welder has deformed extensively, thus changing the weld  profile, we wonder what discontinuity he or she is trying to obscure — Fig. 1. Is it undercut, overlap, porosity, or a crack? Can we prove the welder was attempting to obscure a discontinuity? Since caulking is a condition that requires the inspections to be completed  prior to it being done for any purpose, it will require correction most of the time. If the original contour of the weld has been altered, it has undergone plas-

28

tic deformation. AWS CWIs should know what an untouched finished weld looks like —  Fig. 2. The question is, how many blows constitute caulking? One well-placed  blow with a chisel over a crack can deform the weld face and caulk the crack. This brings us to the issue of intent. Has the weld undergone plastic deformation in order to obscure or seal an area of unacceptable discontinuities? Obviously there is only one way to be 100% sure. Were you in the production area enough to see the weld before it was caulked? Was the welder  experiencing some difficulty and then instead of removing the bad weld just grabbed the chipping gun and caulked it? Are remnant indications of discontinuities visible so you can document your decision to mark the weld for correction? If you did not see it prior to the caulking, did the welder admit there was a problem when questioned about the appearance of the weld because he or she did not know it was an unacceptable repair method?

A Call For Caution One blow can be cause for correction if the presence of discontinuities can  be affirmed. But we must take reasonable care when calling a condition caulking. The slight indications remaining after running the chipping gun down the weld to remove slag do not qualify as  plastic deformation or caulking. If the marks have reasonable distance between them, there are no indications of the  presence of discontinuities, or the face of 

Inspection Trends / August 2015

the weld is not totally obscured in its ap pearance, then the chipping hammer was not used to caulk the weld and hide a discontinuity — Figs. 3, 4. Referring to Figs. 1 and 5, we were able to prove that caulking was  performed to obscure discontinuities. The weld in Fig. 1 had crater cracks and the one in Fig. 5 had overlap/excessive reinforcement. Corrective action was performed, but the excessiveness of the plastic deformation was sufficient in these two cases to support corrective action without the witness of  the discontinuities, especially when  performed prior to inspections being completed. Why? Once the weld has  been caulked, any discontinuities are not visible, and it is thus unknown if  they were present and rejectable. Root passes can be a problem at times for slag removal when either  shielded metal arc or flux cored arc welding are used. Welders may use the needle scaler or chipping gun more aggressively to accomplish this slag removal. They may even cause more deformation than we would really like to see. An inspector must use good judgment in ascribing cause and motive. If  you are present and observing the operation, you can easily witness the presence or absence of discontinuities as the slag comes loose and even caution the welder about continued use of the tool following slag removal. Fabricators and their personnel should be trained well enough to realize the inherent problems they may be creating when they peen or caulk welds, es pecially root and cover passes. The effects of peening and caulking upon cooling rates, grain boundaries, stress risers, and other factors is worth keeping in mind in order to not jeopardize the structural integrity of the project. While D1.1 is clear that caulking is a consideration when ascribed directly to the obscuring and/or sealing of  discontinuities, that does not mean there are no other considerations because of the stresses that will be created as a result of caulking, especially in the root pass and on the weld face of  the final pass/layer. Instead of covering up a problem, they may well be creating an additional problem. Cracks can  be initiated from this process and remain unnoticed unless magnetic particle or ultrasonic testing is required. Those processes should find the discontinuity regardless of its visibility to the unaided eye. If you have been

trained properly, why would you cover  up a problem that you are only going to have to go back and fix later anyway? Why not just stop and fix it correctly  before adding even more weld metal that will also need to be removed to get to the problem? Chipping guns should not be used to open up the groove to make sure the following pass has sufficient room to receive adequate penetration and fusion. It clearly constitutes  plastic deformation when you are moving material that much. A grinder or air  carbon arc gouging equipment should  be used for opening up such areas. After having made a case for using caution with caulking, it is also important for the inspector to know the conditions under which caulking may be used. First is the condition that all inspections are complete and any visible discontinuities do not render the part unacceptable. Second, caulking is necessary to  prevent coating failures. Finally, caulking, though allowed under the above listed circumstances, is only allowed with limited material applications and when approved by the engineer. That approval will often take time that the fabricator doesn’t have. Unless you have some good extenuating circumstances, why even bother? Make sure the welders are properly trained to complete acceptable welds that will not need caulking.

and the welds are determined to be acceptable per Table 6.1 and all applica ble specifications. 2. D1.1 requires caulking to be corrected when used to deform weld profiles because of the inability to determine if rejectable discontinuities were  present before caulking took place. These rejectable discontinuities could be items such as porosity, undercut, overlaps, and/or cracks — Figs. 1, 5. 3. The use of caulking is rejectable if applied to a weld prior to inspections  being completed even if it was not used to hide a discontinuity and/or if the prior approval of the engineer had not

 been obtained. It is impossible to tell if  there are discontinuities hidden under  the surface.

 BRENT E. BOLING ([email protected]) is  president of Arc-Tech Welding, Inc.,  Prescott Valley, Ariz. He is also an  AWS CWI with a Bolting   Endorsement, and an ASNT Level II  in VT.

Conclusions There are several lessons we can learn from this information: • Inspectors need to be careful when answering questions posed by the welders. • We inspectors need to do our research to make sure we are correctly interpreting and applying terminology from the applicable code. • Inspectors need to be eyewitnesses as much as possible to the work in  progress on the job. • Caulking is a real concern that the inspector should be educated on to not abuse in application. Keeping these points in mind, we then draw these conclusions regarding our threefold purpose: 1. The use of caulking is acceptable under D1.1 when approved by the engineer and according to the parameters listed in the code for material strength. Caulking may occur only after inspections have been completed

Inspection Trends / Summer 2015

29

 Just the Facts

By Jim Merrill

 Preheat/interpass temperatures need to be considered as they relate to the production welding that will be performed. The question of minimum preheat/interpass temperature and “qualified” procedures per AWS D1.1:2010, Structural Welding Code — Steel 1, is a question routinely asked by both CWIs and fabricators. The two most frequently asked questions are 1. Can I qualify out of minimum  preheat/interpass altogether or can I qualify for a lower preheat than is prescribed in Table 3.2? 2. Is the minimum preheat/inter pass temperature that was used to develop the procedure qualification to be used for all welding procedures qualified by that procedure qualification record (PQR) regardless of material thickness (thicker or thinner) or restraint? The overall premise of AWS D1.1 concerning preheat/interpass temperature is stated in clause 5.5 as follows: “The preheat and interpass temperature shall be sufficient to prevent cracking. Table 3.2 shall be used to determine the minimum preheat and interpass temperatures for steels listed in the code.” While it is understood that this is quoted from the prequalified section of  the code, the purpose for preheat/inter pass temperature is clearly stated “…sufficient to prevent cracking.” When searching Section 4 Qualification, the code gives further direction on  preheat/interpass temperature as it relates to qualifying a welding procedure. Clause 4.7.4 reads in part as follows: “The minimum preheat and inter pass temperature should be established on the basis of steel composition as shown in Table 3.1. Alternatively, rec-

ognized methods of prediction or  guidelines such as those provided in Annex I, or other methods may be used. Preheat and interpass temperatures lower than required per Table 3.2 or calculated per Annex I may be used  provided they are approved by the Engineer and qualified by WPS testing.” Therefore, the answer to question number 1, “Can I qualify out of minimum preheat/interpass altogether or  can I qualify for a lower preheat than is  prescribed in Table 3.2?” is yes, provided a number of conditions are met. 1. It’s sufficient to prevent cracking 2. It has been approved by the Engineer  3. It has been qualified by Welding Procedure Specification (WPS) testing 4. However, if the preheat/inter pass temperature is less than Table 3.2,  but has been calculated per Annex I, the Engineer’s approval and WPS testing are not required. The decision to attempt to utilize a lower preheat or no preheat at all should be considered and engineered very carefully. Many CWIs and fabricators suggest that if a PQR test plate is  produced and it does not exhibit cracking and all of the mechanical tests results are within the acceptable range, that is sufficient evidence the preheat utilized is adequate, and therefore, the  procedure should be accepted. It must  be taken into consideration that the PQR test plate and the production weld may be very different in mass, length, and restraint. These differences may create a very different heat transfer, weld restraint, and time between individual passes being placed. The differ-

ence in time may allow the interpass temperature to become much lower  than was experienced during PQR testing. Depending on the joint configuration and the material’s placement in a fabrication or erection, the level of restraint may be very different from that of the PQR. Even plates that are welded with free edges may have a very different level of restraint due to the weight of the material being welded. When considering a deviation from the  prescribed preheat/interpass temperatures, the PQR test plate needs to be evaluated by the engineer to determine if it is a reasonable representation of  the production welding that it will be representing. Only when the Engineer  is convinced that the PQR test plate is a sufficient representation of the actual  production welding should he or she give his/her approval. The second question: “Is the minimum preheat/interpass temperature that was used to develop the procedure qualification to be used for all welding  procedures qualified by that PQR regardless of material thickness (thicker  or thinner) or restraint?”  No is the simple answer to this question. There are examples where CWIs have enforced excessive preheat/ inter pass temperatures on relatively thin  plate based on an unlimited thickness  procedure qualification. An example would be the qualification of A572 grade 60 or 65 for a change in joint geometry. Table 3.2 requires a preheat of 150°F for material more than ¾ through 1½ in. thick. The material thickness for unlimited qualification is  — continued on page 43

1. Note that when D1.1:2015 is released, Table 3.2 will be Table 3.3 and Annex I will be Annex H.

30

Inspection Trends / August 2015

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2015

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DATE

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July 29 - August 2

Ohio State Fair

Columbus, OH OH

 August 6-9

NSRA Str Street eet Rod Nationals

Louisville, KY KY

 August ugust 13 13-16

Indiana State Fair

Indiana Indianapolis, polis, IN

 August 18

Discovery Disco very Center Museum

Rockford, IL IL

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Des Moines, IA  IA 

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October 20-22

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October 28-31

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The Answer Is

By K. Erickson and A. Moore

The Society is not responsible for any statements made or opinion expressed herein. Data and information developed by the authors are for specific informational purposes only and are not intended for use without independent, substantiating investigation on the part of potential users.

Q: I am a vendor auditor with a large company located in the northeast United States. I recommend and qualify numerous fabrication contractors for projects nationwide. I often am presented information relative to companies having standard American Welding Society (AWS) welding qualifications and Certified Welding Inspectors (CWIs) on staff  and in the field. I find this is only partly accurate as the majority of the time CWIs are only contracted out as/when needed. Is this ethical?

A (by K. Erickson): Good question. I have come across this same scenario many times. Companies have marketed their fabrication and field services with the representation of directly employing an in-house AWS CWI. When doing so, this does provide greater credence to the potential customer that the welding and quality program is established and is being overseen by a certified individual on a continuous basis. The reality may be that an AWS CWI is contracted out as/when needed and utilized for the capacity of only those projects that require a CWI as the responsibility of the contractor to provide for. Fabricators could also have an agreement with a local inspection com pany or independent CWI to provide for services again as needed but who is not directly employed by the fabrication company. There is no doubt that the wording and presentation by a potential vendor  may not be totally accurate or correct,  but does provide it the flexibility of  having an AWS CWI at its disposal when required without the cost of directly employing a full-time CWI. If it is a condition of qualification for your  company that the vendor currently (a specific time period) employs active CWI(s) on staff full time, then this can  be verified with minimal effort. 1. Obtain a copy of the CWI’s current certification and confirm this information through the AWS website. 2. Confirm that each individual is a direct employee of the fabricator and

 Fig. 1 — The general setup for demagnetizing the pipe. Multiple coils consisting of several cable wraps spaced along the length of the pipe distribute the magnetic field along the entire length of the pipe. The piece of scrap steel and  electrode are used as the on/off switch to eliminate the need to switch the power supply on and off under a load (not good for the machine). If a DC power   supply is used, the polarity must be reversed each time the system is energized  with the electrode. Reverse the polarity by moving the C-clamp to the scrap  steel and striking the arc onto the steel piece the clamp was attached to. Then, with the next cycle, switch the clamp and strike the arc against the scrap steel   plate again. With both AC and DC, the process must be repeated at least 20 times, reducing the current a small amount each time followed by removing  the cable wraps one at a time. for how long each has been employed at the company without any breaks in employment. 3. Ask what are the tasks and functions of each CWI. 4. Review the welder qualifications, Procedure Qualification Records (PQRs), and Welding Procedure Specifications (WPSs) for the vendor. You can expect some updates, revisions, and additions to welders and weld procedures annually. If you notice that the majority of the welding documentation is dated from many years past, you may want to search deeper and determine why the welding program is not current. 5. Ask for copies of previous inspection reports from similar and/or  current projects to confirm the inspection information they contain. 6. Note: This can also be applied for nondestructive examination qualification and inspections.

In regard to weld inspection and ap plying WPSs and general welding requirements by company, it is important that each CWI is knowledgeable about this information and can couple this with each contract specification. Consistency is the key and documentation is the proof that applies prior to, during, and upon completion of each project.

Q: We are having a difficult time welding a load of steel pipe that was recently purchased. The welders said the reason for the welding problems is because the pipe is magnetized. What would cause the pipe to become magnetized, and what can we do to correct the problem?

A (by A. Moore): The pipe could be magnetized, as suggested by your  welders, and the causes are many. The residual magnetic field could be caused  —continued on page 34

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Inspection Trends / August 2015

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Save the Date FOR 2015 FABTECH CONFERENCE LINE-UP So You’re the New Welding Engineer November 10-11, 2015 This popular two-day conference is now a FABTECH mainstay. Learn from industry experts how to ask the right questions that will get you the results you need, help you save money, and keep you out of trouble.

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 —continued from page 32

 by the influence of the earth’s magnetic field. Transporting long, slender ferromagnetic materials in a northerlysoutherly direction can produce a residual magnetic field in the members. Another cause could be grinding the bevel on the ends of the pipe in preparation for welding. If the pipe ends were machined, the cutting action of a single point cutting tool can also induce a residual magnetic field in the pipe. With that in mind, if the welders attempt to correct the problem by wrapping the welding cable around the  pipe, the problem could be amplified. A longitudinal magnetic field is developed in the pipe when an electrical current is passed through the welding ca bles wrapped around the pipe. In other  words, the welders just turned the pipe into an electromagnet. The intensity of  the magnetic field is proportional to the current and to the number of cable wraps around the pipe. The intensity of  the longitudinal magnetic field is increased if the number of cable wraps is increased or if the current flowing through the cable is increased. Once the pipe is magnetized, from whatever cause, it is necessary to de-

magnetize the pipe before attempting to weld it. There are several methods used to demagnetize the pipe. If the strength of the residual field is limited, a sharp blow or two from a hammer  may be sufficient to reduce the strength of the residual field. If the strength of  the field is too strong and the hammer   blows are not sufficient to destroy the residual field, more complicated means will have to be employed. If an AC  power supply is available, it can be used to reduce the residual magnetic field. If a DC power supply is available, it can be used, but the technique required is more involved. The strength of the magnetic field is most intense when the magnetizing current is flowing through a conductor. The strength of the residual magnetic field is greatly reduced when the magnetizing current stops flowing and the magnetic field collapses. We use that  principle to our advantage to demagnetize the pipe. We reduce the residual magnetic field in the pipe in a series of steps. The strength of the induced magnetic field must be greater than the residual field strength of the pipe. My recom-

mendation is to wrap the welding cable around the pipe 12 to 15 times. Briefly energize the coils with the maximum current available from the AC power  supply. Deenergize the coil and reduce the current by 10 to 15 A and reenergize the coil briefly. Deenergize the coil and reduce the current another 10 to 15 A. Repeat the process until the  power supply is at the minimum current setting. Always reduce the current while the system is deenergized. Once the power supply is at its lowest current setting, start removing one wrap of  welding cable and reenergize the coil and deenergize the coil. Remove another wrap of welding cable and reenergize and deenergize. Repeat the sequence until there are no more wraps of welding cable around the pipe. The same process can be used if a DC power supply is available. There is one complication when using a DC power supply, the polarity must be reversed each time the coils are deenergized. The sketch shows how the pipe can be set up for demagnetizing — Fig. 1. When done properly, the residual magnetic field left in the pipe should  be negligible.

Inspection Trends encourages question and answer submissions.  Please mail to the editor  ([email protected]).  KENNETH ERICKSON is manager of  quality at National Inspection & Con sultants, Inc., Ft. Myers, Fla. He is an  AWS Senior Certified Welding Inspector, an ASNT National NDT Level III Inspector in four methods, and provides expert  witness review and analysis for legal  considerations.  ALBERT J. MOORE JR. is vice  president, Marion Testing & Inspection, Canton, Conn. He is an AWS Senior  Certified Welding Inspector and an  ASNT ACCP NDT Level III. He is also a member of the AWS Certification Committee and the Committee on  Methods of Inspection of Welds.

For info go to www.aws.org/ad-index

34

Inspection Trends / August 2015

Mark Your Calendar  Note: A diamond (♦) denotes an AWS-sponsored event.

NDT 2015 and Materials Testing 2015. September 8–10. The International Centre, Telford, UK. Contact British Institute of NonDestructive Testing, +44 (0)1604 89 3811, www.bindt.org , or  [email protected] .

25th ASNT Research Symposium. April 11–14, 2016. Astor  Crowne Plaza New Orleans, New Orleans, La. Contact American Society for Nondestructive Testing, (800) 222-2768 or  www.asnt.org .

International Symposium Non-Destructive Testing in Civil Engineering (NDT-CE). September 15–17. Technical University Berlin, Peter Behrens Halle, Berlin, Germany. Contact BAM Federal Institute for Materials Research and Testing, www.ndtce2015.net/home.

19th World Conference on Non-Destructive Testing. June 13–17, 2016. International Congress Centre, Munich, Germany. Contact German Society for Non-Destructive Testing, 49 30 67807-120; e-mail: [email protected], or www.wcndt2016.com.

ASNT Annual Conference 2015. October 26–29. Salt Palace Convention Center, Salt Lake City, Utah. Contact American Society for   Nondestructive Testing, (800) 222-2768 or www.asnt.org .

Educational Opportunities

Ill. Contact American Welding Society, (800) 443-9353, or  www.fabtechexpo.com.

GE Inspection Academy Courses. Online e-courses, on-site classes, and week-long classroom programs in the major industrial evaluation techniques. For information, visit www.geinspectionacademy.com.

World Conference on Acoustic Emission. November 10–13. Hilton Hawaiian Village Waikiki Beach Resort, Honolulu, Hawaii. Contact International Society on Acoustic Emission, Conference Secretariat Dr. Zhanwen Wu, [email protected] or +86-1059068313.

NDE Classes. Moraine Valley Community College, Palos Hills, Ill., offers NDE classes in PT, MT, UT, RT, Radiation Safety, and Eddy Current, as well as API 510 exam prep and weld inspection. For more information, contact (708) 974-5735; [email protected] ; morainevalley.edu/NDE .

◆ FABTECH 2015. November 9–12. McCormick Place, Chicago,

EPRI NDE Training Seminars. EPRI offers NDE technical skills training in visual examination, ultrasonic examination, ASME Section XI, UT operator training, etc. Contact Sherryl Stogner, (704) 5476174, e-mail: [email protected]. Nondestructive Examination Courses. A course schedule is available from Hellier, 277 W. Main St., Ste. 2, Niantic, CT 06357; (860) 7398950; FAX (860) 739-6732. Preparatory and Visual Weld Inspection Courses. One- and twoweek courses presented in Pascagoula, Miss., Houston, Tex., and Houma and Sulphur, La. Contact Real Educational Services, Inc.; (800) 489-2890; [email protected] . CWI/CWE Course and Exam. A ten-day program presented in Troy, Ohio. Contact Hobart Institute of Welding Technology, (800) 3329448; www.welding.org; [email protected] . T.E.S.T. NDT, Inc., Courses. CWI preparation, NDE courses, including ultrasonic thickness testing and advanced phased array. On-site training available. T.E.S.T. NDT, Inc., 193 Viking Ave., Brea, CA 92821; (714) 255-1500; FAX (714) 255-1580; [email protected]; www.testndt.com. NDE Training. NDE training at the company’s St. Louis-area facility or on-site. Level III services available. For a schedule of upcoming courses, contact Quality Testing Services, Inc., 2305 Millpark Dr., Maryland Heights, MO 63043; (888) 770-0103; [email protected] ; www.qualitytesting.net . CWI/CWE Prep Course and Exam and NDT Inspector Training Courses. An AWS Accredited Testing Facility. Courses held yearround in Allentown, Pa., and at customers’ facilities. Contact: Welder  Training & Testing Institute (WTTI). Call (800) 223-9884, [email protected], or visit www.wtti.edu. For info go to www.aws.org/ad-index

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Inspection Trends / August 2015

Certification Schedule Certified Welding Inspector (CWI) Location

Baton Rouge, LA Chicago, IL Las Vegas, NV Philadelphia, PA Seattle, WA Rochester, NY Mobile, AL Portland, ME Charlotte, NC San Diego, CA Minneapolis, MN San Antonio, TX Salt Lake City, UT Anchorage, AK Miami, FL Idaho Falls, ID St. Louis, MO Houston, TX  New Orleans, LA Fargo, ND Portland, OR Pittsburgh, PA Anchorage, AK Miami, FL Long Beach, CA Indianapolis, IN Tulsa, OK  Nashville, TN Shreveport, LA S. Plainfield, NJ Beaumont, TX Atlanta, GA Des Moines, IA Detroit, MI Roanoke, VA Corpus Christi, TX Cleveland, OH Spokane, WA Sacramento, WA Miami, FL Annapolis, MD Dallas, TX Chicago, IL St. Louis, MO Los Angeles, CA Orlando, FL Reno, NV Houston, TX Miami, FL Corpus Christi, TX

Seminar Dates

Exam Date

Aug. 2–7 Aug. 2–7 Aug. 2–7 Aug. 2–7 Aug. 2–7 Exam only Aug. 9–14 Aug. 9–14 Aug. 9–14 Aug. 16–21 Aug. 16–21 Aug. 16–21 Aug. 16–21 Exam only Sept. 13–18 Sept. 13–18 Sept. 13–18 Sept. 13–18 Sept. 27–Oct. 2 Sept. 27–Oct. 2 Sept. 27–Oct. 2 Sept. 27–Oct. 2 Sept. 27–Oct. 2 Exam only Oct. 4–9 Oct. 4–9 Oct. 4–9 Oct. 4–9 Oct. 11–16 Oct. 11–16 Oct. 11–16 Oct. 18–23 Oct. 18–23 Oct. 18–23 Oct. 18–23 Exam only Oct. 25–30 Oct. 25–30 Nov. 1–6 Nov. 1–6 Nov. 1–6 Nov. 1–6 Exam only Exam only Dec. 6–11 Dec. 6–11 Dec. 6–11 Dec. 6–11 Exam only Exam only

Aug. 8 Aug. 8 Aug. 8 Aug. 8 Aug. 8 Aug. 8 Aug. 15 Aug. 15 Aug. 15 Aug. 22 Aug. 22 Aug. 22 Aug. 22 Sept. 19 Sept. 19 Sept. 19 Sept. 19 Sept. 19 Oct. 3 Oct. 3 Oct. 3 Oct. 3 Oct. 4 Oct. 8 Oct. 10 Oct. 10 Oct. 10 Oct. 10 Oct. 17 Oct. 17 Oct. 17 Oct. 24 Oct. 24 Oct. 24 Oct. 24 Oct. 31 Oct. 31 Oct. 31 Nov. 7 Nov. 7 Nov. 7 Nov. 7 Nov. 12 Dec. 12 Dec. 12 Dec. 12 Dec. 12 Dec. 12 Dec. 17 Dec. 19

9-Year Recertification Seminar for CWI/SCWI For current CWIs and SCWIs needing to meet education requirements without taking the exam. The exam can be taken at any site listed under Certified Welding Inspector. Location

Orlando, FL Denver, CO Dallas, TX Seattle, WA  New Orleans, LA Miami, FL

Seminar Dates

Aug. 16–21 Sept. 13–18 Oct. 4–9 Oct. 18–23 Oct. 25–30 Dec. 6–11

Certified Welding Educator (CWE) Seminar and exam are given at all sites listed under Certified Welding Inspector. Seminar attendees will not attend the Code Clinic portion of the seminar (usually the first two days).

Certified Welding Sales Representative (CWSR) CWSR exams will be given at CWI exam sites.

Certified Welding Supervisor (CWS) CWS exams are also given at all CWI exam sites. Location

Cleveland, OH  Norfolk, VA

Seminar Dates

Exam Date

Sept. 28–Oct. 2 Oct. 12–16

Oct. 3 Oct. 17

Certified Radiographic Interpreter (CRI) The CRI certification can be a stand-alone credential or can exempt you from your next 9-Year Recertification. Location

Seminar Dates

Exam Date

Dallas, TX Chicago, IL Pittsburgh, PA Miami, FL

Aug. 17–21 Sept. 28–Oct. 2 Oct. 12–16 Exam Only

Aug. 22 Oct. 3 Oct. 17 Nov. 14

Certified Robotic Arc Welding (CRAW) ABB, Inc., Auburn Hills, MI; (248) 391–8421 OTC Daihen, Inc., Tipp City, OH; (937) 667-0800, ext. 218 Lincoln Electric Co., Cleveland, OH; (216) 383-8542 Genesis-Systems Group, Davenport, IA; (563) 445-5688 Wolf Robotics, Fort Collins, CO; (970) 225-7736 On request at MATC, Milwaukee, WI; (414) 456-5454

IMPORTANT: This schedule is subject to change without notice. Please verify your event dates with the Certification Dept. to confirm your course status before making travel plans. Applications are to be received at least six weeks prior to the seminar/exam or exam. Applications received after that time will be assessed a $250 Fast Track fee. Please verify application deadline dates by visiting our website www.aws.org/certification/docs/schedules.html  . For information on AWS seminars and certification programs, or to register online, visit www.aws.org/certification or call (800/305) 443-9353, ext. 273, for Certification; or ext. 455 for Seminars.

38

Inspection Trends / August 2015

NDT Red Hot Product Listings Why Wait for Weeks When You Can Have It In days! We specialize in eddy current  probes, ultrasonic transducers, adapters, cables, and reference standards. UT wedges for both regular and  phase arrays. We repair and calibrate all brand of Eddy Current and Ultrasound Flaw Detectors. Andrew NDT Engineering, Corp. Contact: Cuong Le (408) 710-0342 [email protected] www.andrewndt.com

E-Course Highlights Weld Discontinuities and Defects

For the second time Carestream NDT has been recognized by Frost & Sullivan for an outstanding product. The HPX-PRO portable CR system was awarded the New Product Innovation Award. The HPX-PRO CR system is built for image quality, improved productivity and extreme portability. It’s quick to deploy and rapidly produces images with a new single-pass scan/erase protocol. The INDUSTREX software allows for fast set-up and imaging, with batch mode capability to keep up with extreme process conditions like pipeline imaging.

Paul Biver (585) 627-8051 www.carestream.com

   7    6    6    5    S    h    t   o   o    B    H    C    E    T    B    A    F    t   a   s    U   e   e    S

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Inspection Trends / August 2015

Concentrating on identifying and defining various types of discontinuities and defects to determine the common causes of those welding problems, this e-course covers: • Weld inspector responsibilities related to discontinuities and defects • Identification and definition of weld discontinuities and defects • Common causes of discontinuities related to shape, size and contour • Common causes of discontinuities related to internal inconsistencies and weld metal irregularities • Common causes of discontinuities related to weld and base metal properties. This course is intended to assist anyone involved in arc welding inspection, quality control, engineering, or supervision. At your own pace from your computer, take the Discontinuities and Defects E-Course today. Hobart Institute of Welding Technology 400 Trade Square East, Troy, OH 45373 (800) 332-9448 • Fax (937) 332-9550 www.welding.org

   7    2    0    9    N    h    t   o   o    B    H    C    E    T    B    A    F    t   a   s    U   e   e    S

NDT Red Hot Product Listings Booth # N28044  ®  2    0  1   5   

Weld-i Zoom HD Weld Monitoring Camera System The Weld-i ® Zoom Full HD 3G-SDI Camera captures real-time, detailed color video images of your welding process with 10x magnified views of the weld. Post weld inspections are performed quickly and keep the operator at a safe, standoff distance. InterTest, Inc. 303 Route 94 Columbia, NJ 07832 Office: (908) 496-8008 [email protected] www.intertest.com

• Reduces time for periodic inspections/tests. • Installs on both smooth and corrugated jacketing. • Patented design seals and protects against corrosion under theinsulation (CUI), chemical, and UV exposure of the elastomer sleeve.

[email protected] • 800-261-6261 Booth # N28044 ®

2    0  1   5   

Weld-i 1000 Weld Monitoring Camera System The iShot® Weld-i® 1000 camera system saves resources and time by verifying the quality of automated welds in real time. This inspection system combines a specially housed, high-resolution color CCD camera with air or water cooling capabilities, allowing it to withstand the punishing environments of automated welding. The camera head is compact, measuring 1 inch in outer diameter and 3 inches in length. The CCU allows control of focus and iris for the ever-changing weld process conditions. BEST SELLER!

Saint-Gobain Saint-Gobain is a world class manufacturer of equipment and consumables for the thermal spray coatings industry. Our expansive equipment experience dates back to 1920 with the development of the first oxyacteylene flame wire gun followed by Rokide® Spray Systems, Plasma Spray Systems, PTA and many innovative materials. We offer a wide range of consumables in the form of powder, flexible cords, Rokide® rods and wire for use in many different applications and industries. We supply our own raw materials, and this enables us to develop a product to meet your exact needs.

InterTest, Inc. 303 Route 94 Columbia, NJ 07832 USA Office: (908) 496-8008 [email protected] www.intertest.com

1 New Bond Street, Worcester, MA 01615 (800) 243-0028 • (508) 795-2380 [email protected] www.coatingsolutions.saint-gobain.com

(800) 940-1471 • (281) 424-3200 [email protected] • www.iris-inspection.com

Inspection Trends / Summer 2015

41

Advertiser Logo Page

42

Inspection Trends / August 2015

 Just the Facts

Print and Product

 — continued from page 30

1 in. There are inspectors who will enforce 150°F preheat/interpass temperature on material ⅛ to ¾ in. in thickness due to the 150°F PQR preheat/interpass temperature. by this logic, we could also assume that it would be ap propriate to use 150°F for material that is more than 1½ in. thick. Clearly this is not a high enough preheat/interpass temperature for, say, a 3-in.thick highly restrained weldment of  the same material. Preheat/interpass temperatures need to be considered as they relate to the production welding that will be  performed. Table 3.2 should in most cases be considered the minimum  preheat/interpass value to be used in  production. There are a number of  welding situations where these minimum values will not be sufficient and the values will need to be pushed higher. There are relatively few situations where the weld will benefit from lower preheat/interpass values.

Showcase In addition, CWIs need not enforce relatively high preheat/interpass values in situations where they are not warranted or needed. The preheat/ interpass values developed in the PQR  serve to validate the temperatures  prescribed in Table 3.2 for t he materials and thickness they represent for  most situations.

 JIM MERRILL, PE  ([email protected]), is senior   principal engineer with AMEC Foster  Wheeler, Environment & Infrastructure, San Diego, Calif. He is an AWS  Certified Welding Inspector, a registered metallurgical engineer, and a member of the AWS D1 Structural  Welding Committee, D1Q Subcommittee on Steel Structures, D1I Subcommittee on Reinforcing Steel, and D1 Task Group 4 on Inspection.

 — continued from page 15

CMOS X-Ray Detector Delivers High Resolution The Rad-icon 2022 CMOS X-ray detector features 2064 x 2236 pixel resolution, an active area of 20.4 x 22.1 cm, and 99-micron pixel size. The detectors deliver real-time imaging of up to 30 frames/s, high sensitivity, and high resolution in a large-area device that is fully integrated and available with a fast Gigabit ethernet or Camera Link interface. It is suitable for industrial X-ray inspection, scientific imaging, and nondestructive examination including weld inspection, wire bond, and printed circuit board inspection, computed tomography, and other industrial imaging applications. It offers an 8-in. by 9-in. format. Teledyne DALSA www.teledynedalsa.com

CAN WE TALK? The Inspection Trends staff encourages an exchange of ideas with you, our readers. If you’d like to ask a question, share an idea, or voice an opinion, you can call, write, e-mail or fax. Staff e-mail addresses are listed below, along with a guide to help you interact with the right person. Publisher  Andrew Cullison  [email protected] , Extension 249

Peer Review Coordinator Sonia Aleman [email protected]

Editor Mary Ruth Johnsen  [email protected] , Extension 238

Managing Editor Zaida Chavez  [email protected] , Extension 265 Design and Production

Associate Editor Kristin Campbell  [email protected] , Extension 257

Senior Production Coordinator Brenda Flores  bfl[email protected], Extension 330 Production

Assitant Editor  Annik Babinski  [email protected] , Extension 256

Senior Advertising Executive  Annette Delagrange  [email protected], Extension 332  Advertising Sales

Assitant Editor Melissa Gomez  [email protected] , Extension 275

Senior Advertising Executive Sandra Jorgensen  [email protected], Extension 254  Advertising Sales

Manager of Advertising Sales Operation Lea Paneca  [email protected] , Extension 220 Promotion and Advertising Senior Advertising Production Manager Frank Wilson  [email protected] , Extension 465  Advertising Production

Welding Journal Dept. 8669 NW 36th St. #130 Miami, FL 33166 (800) 443-9353 FAX (305) 443-7404

Inspection Trends / Summer 2015

43

Advertiser Index American Society for Nondestructive Testing . . . . . . . . . . . . . . . . . . . . . . . .9 www.asnt.org . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(800) 222-2768

J. P. Nissen Co. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .OBC www.nissenmarkers.com . . . . . . . . . . . . . . . . . . . . . . . . . . . .(215) 886-2025

Atlas Evaluation & Inspection Services/Inst. of Nondestructive Testing . . .8 www.indt.com . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(908) 463-0041

 NDT Seals, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 www.ndtseals.com . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(800) 261-6261

AWS Education Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13, 33, 35, 39 www.aws.org/education . . . . . . . . . . . . . . . . . . . . . .(800) 443-9353, ext. 455

Olympus NDT, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .IFC www.olympus-ims.com . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(781) 419-3900

AWS Foundation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31 www.aws.org/foundation . . . . . . . . . . . . . . . . . . . . .(800) 443-9353, ext. 250

OCI-Orange County Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36 www.orangecountyinspections.webs.com . . . . . . . . . . . . . . .(714) 345-2770

AWS Member Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16, 37 www.aws.org/membership . . . . . . . . . . . . . . . . . . . .(800) 443-9353, ext. 480

SciAps, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .IBC www.sciaps.com . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(339) 927-9455

AWS Publications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29 www.aws.org/publications . . . . . . . . . . . . . . . . . . . . . . . . . . .(800) 443-9353

Triangle Engineering, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 www.trieng.com . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(781) 878-1500

AWS Technical Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 www.aws.org/technical . . . . . . . . . . . . . . . . . . . . . .(800) 443-9353, ext. 340

United Technical, LLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 www.unitedtechllc.com . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(249) 667-9185

FABTECH 2015 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 www.fabtechexpo.com . . . . . . . . . . . . . . . . . . . . . . .(800) 443-9353, ext. 297

Welder Training & Testing Institute . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 www.wttiweldtestcoupons.com . . . . . . . . . . . . . . . . . . . . . . .(800) 223-9884

FlawTech, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 www.flawtech.com . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(704) 795-4401

 NDT Red Hot Product Listings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40, 41 Inspection Trends Advertiser Logos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

Gradient Lens Corp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 www.gradientlens.com . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(800) 536-0790 Hobart Institute of Welding Technology . . . . . . . . . . . . . . . . . . . . . . . . . . .15 www.welding.org . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(800) 332-9448

IFC = Inside Front Cover  IBC = Inside Back Cover  OBC = Outside Back Cover 

ISTUC/Instituto de Soldadura y Tecnologias de Union . . . . . . . . . . . . . . . .34 www.istuc.com . . . . . . . . . . . . . . . . . . . . . . .(52) - 442-2201486 & 2201699

Visit Our Interactive Ad Index: www.aws.org/ad-index

Classified Ads

Place Your Classified Ad Here!

Call the AWS sales team at (800) 443-9353 Sandra Jorgensen at ext. 254 [email protected]  Annette Delagrange at ext. 332 [email protected]

44

Inspection Trends / August 2015

AWS MEMBERSHIP APPLICATION  Join or Renew: 

Mail: Form with your payment, to AWS

Call: Membership Department at (800) 443-9353, ext. 480

 

Fax: Completed form to (305) 443-5647

Online: www.aws.org/membership

CONTACT INFORMATION q New Member q Renewal q Mr. q Ms. q Mrs. q Dr.

Please print • Duplicate this page as needed

Last Name:_______________________________________________________________________________ First Name:___________________________________________________________________ M.I:_______ Birthdate: _____________________________ E-Mail:____________________________________________ Cell Phone (

)__________________________ Secondary Phone (

Were you ever an AWS Member?

q YES q NO

)______________________

If “YES,” give year________ and Member #: ____________________

Company (if applicable):__________________________________________________________ _________ Address:________________________________________________________________________________ _______________________________________________________________________________________ City:_____________________________________State/Province:__________________________________ Zip/PostalCode:_____________________Country:______________________________________________  Who pays your dues?: q Company

q Self-paid

 Education level: q High school diploma

 Sex: q Male q Female

q Associate’s

q Bachelor’s

q Master’s

q Doctoral

q Check here if you learned of the Society through an AWS Member? Member’s name:_______________________Member’s # (if known):________ q

Check here if you would prefer not to receive email updates on AWS programs, new Member benefit s, savings opportunities and events.

INDIVIDUAL MEMBERSHIP è q

Please check each box that applies to the Membership or service you’d like, and then add the cost together to get your Total Payment.

AWS INDIVIDUAL MEMBERSHIP (One Year)......................................................................................................$86 AWS INDIVIDUAL MEMBERSHIP �Two Years� SAVE $25 New Members Only ....................................$147

q

New Member Initiation Fee ...........................................................................................................................................$12

OPTIONS AVAILABLE TO AWS INDIVIDUAL MEMBERS ONLY:

A.) OPTIONAL Book Selection (Choose from 25 titles; up to a $192 value; includes shipping & handling) q Individual Members in the U.S..................................................................................................................................$35 q

Individual Members outside the U.S  (includes International shipping) ...........................................................................$85

ONLY ONE SELECTION PLEASE. For more book choices visit https://app.aws.org/membership/books q  Jefferson’s Welding Encyc.(CD-ROM only) q

Design & Planning Manual for Cost-Effective Welding q Welding Metallurgy  q Welding Inspection Handbook  Welding Handbook Selections: q WH  (9th Ed., Vol. 5) q WH  (9th Ed., Vol. 4) q WH  (9th Ed., Vol. 3) q WH  (9th Ed., Vol. 2) q WH  (9th Ed., Vol. 1) Pocket Handbook Selections: q PHB-1 (Arc Welding Steel) q PHB-2 (Visual Inspection) q PHB-4 (GMAW / FCAW)

B.) OPTIONAL Welding Journal Hard Copy (for Members outside North America) q Individual Members outside North America (note: digital delivery of WJ is standard)..............................................$50 INDIVIDUAL MEMBERSHIP TOTAL PAYMENT..................................................................................$_____________ NOTE: Dues include $16.80 for Welding Journal subscription and $4.00 for the AWS Foundation.

STUDENT MEMBERSHIP è

Please choose your Student Membership option below.

q

AWS STUDENT MEMBERSHIP (One Year)...................................................................................................................$15 Digital delivery of Welding Journal magazine is standard for all Student Members.

q

AWS STUDENT MEMBERSHIP (One Year)...................................................................................................................$35 Includes one-year Welding Journal hard copy subscription. Option available only to students in U.S., Canada & Mexico.

STUDENT MEMBERSHIP TOTAL PAYMENT......................................................................................$_____________ PAYMENT INFORMATION

Payment can be made (in U.S. dollars) by check or money order (international or foreign), payable to the American Welding Society, or by charge card. q Check q Money Order q AMEX

q Diners Club

q MasterCard

q Visa

q Discover

q Other

CC#:____________ / ____________ / ____________ / ____________ Expiration Date (mm/yy) ________ / ________ Signature of Applicant:_________________________________________ Application Date:_______________________ OFFICE USE ONLY

Source Code: IT REV. 11/14

Check #:___________________ ____________ Account #__________________ __________________ Date:____________________ _____________ Amount:_____________________ ________________

8669 NW 36 St, # 130 Miami, FL 33166-6672  Telephone (800) 443-9353 FAX (305) 443-5647 Visit our website: ww w.aws.org Type of Business (Check ONE only) A q Contract construction B q Chemicals & allied products C q Petroleum & coal industries D q Primary metal industries E q Fabricated metal products F q Machinery except elect. (incl. gas welding) G q Electrical equip., supplies, electrodes H q Transportation equip. — air, aerospace I q Transportation equip. — automotive J q Transportation equip. — boats, ships K q Transportation equip. — railroad L q Utilities M q Welding distributors & retail trade N q Misc. repair services (incl. welding shops) O q Educational Services (univ., libraries, schools) P q Engineering & architectural services (incl. assns.) Q q Misc. business services (incl. commercial labs) R q Government (federal, state, local) S q  Other  Job Classification (Check ONE only) 01 q President, owner, partner, officer 02 q Manager, director, superintendent (or ass istant) 03 q Sales 04 q Purchasing 05 q Engineer — welding 20 q Engineer — design 21 q Engineer — manufacturing 06 q Engineer — other 10 q Architect designer 12 q Metallurgist 13 q Research & development 22 q Quality control 07 q Inspector, tester 08 q Supervisor, foreman 14 q Technician 09 q Welder, welding or cutting operator 11 q Consultant 15 q Educator 17 q Librarian 16 q Student 18 q Customer Service 19 q Other Technical Interests (Check all that apply) A q Ferrous metals B q Aluminum C q Nonferrous metals except aluminum D q Advanced materials/Intermetallics E q Ceramics F q High energy beam processes G q Arc welding H q Brazing and soldering I q Resistance welding J q Thermal spray K q Cutting L q NDT M q Safety and health N q Bending and shearing O q Roll forming P q Stamping and punching Q q Aerospace R q Automotive S q Machinery T q Marine U q Piping and tubing V q Pressure vessels and tanks W q Sheet metal X q Structures Y q Other Z q Automation 1 q Robotics 2 q Computerization of Welding

For Info, go to www.aws.org/ad-index