EXAMINATION

Examination in 5 (or 8) Parts

(Each part has a 70% pass mark)
1. Technical Paper (1h 15min)
• 6 Questions given (4 answers required)
• Question #1 must be answered
• Answer 3 other questions from the remaining 5 questions
2. Interpretation of Welding Symbols (1h)
• Engineering drawing has welding symbols for 12 joints
• Interpret the symbols & comment on any errors or inconsistencies
3. Fracture Face Examination (1h)
• Examine fracture faces of 2 specimens & interpret modes of failure
4. NDT Reports (1h)
• Scrutinise 3 NDT Reports & list all errors and all omissions
5. Oral (~ 10 to 15 min)
• 1 Question: - subject will be related to supervision of welding inspectors
or to safety matters

Copyright © 2005, TWI Ltd World Centre for Materials Joining

 EXAMINATION
Examination in 5 (or 8) Parts
(Each part has a 70% pass mark)
If a candidate for the Senior Welding Inspector Examination does
not
hold a recognised qualification in Radiographic Interpretation
(a CSWIP or PCN Certificate) he is required to sit 3 additional
examination parts, namely: -

6. Radiographic Interpretation (1h 30min)

• 6 dense metal welds - steel

7. Multi-Choice Radiographic Theory Paper (30min)

• 30 questions

8. Radiographic Density & Sensitivity (1h)

• Densitometer calibration using a Density Strip
• Sensitivity calculations for 5 welds

Copyright © 2005, TWI Ltd World Centre for Materials Joining

 THE SENIOR WELDING INSPECTOR

A Senior Welding Inspector may be ‘Senior’ through

being put in charge of a team of Welding Inspectors.

In this role he may have a predominantly managerial

role that requires organising and supervising their
work and so may have title of ‘Team Leader’ or
‘Supervisor’.

In other circumstances he may have a more

technically demanding role that requires detailed
knowledge of particular activities.

The CSWIP Senior Welding Inspector Course is

intended to cover aspects of both these roles.

Copyright © 2005, TWI Ltd World Centre for Materials Joining

 THE SENIOR WELDING INSPECTOR
TYPICAL REQUIREMENTS - TECHNICAL KNOWLEDGE
Welding Technology
(Welding Inspector ………. plus)
• NDT Techniques
( ability to carry out / interpret)
• Codes/Application Standards
(ability to interpret)
• Planning Systems
(ability to understand and also supply
inspection scheduling to project schedule)
• Quality Assurance
(ability to plan & carry out some auditing)

Copyright © 2005, TWI Ltd World Centre for Materials Joining

 THE SENIOR WELDING INSPECTOR
LEADERSHIP / SUPERVISION

A Supervisor is a person who has been given

authority and responsibility for: -
• planning the work of others
• controlling this work

A Supervisor is a ‘man in the middle’ between

operators and management and subject to pressures
from both directions

Copyright © 2005, TWI Ltd World Centre for Materials Joining

 THE SENIOR WELDING INSPECTOR
LEADERSHIP

Is leadership an ability that a person is ‘born’

with or can it be acquired !!!!!! ?????

• Personality is very influential - hence

leadership sometimes considered to be in the
‘genes’ and a person referred to as ‘a born
leader’
• Ability to be a good leader can be improved by
experience & from knowledge of management
techniques through training

Copyright © 2005, TWI Ltd World Centre for Materials Joining

 THE SENIOR WELDING INSPECTOR
TYPICAL REQUIREMENTS - LEADERSHIP SKILLS /
ABILITY
Complex mixture of skills & attitudes - such as ……

• being prepared to accept responsibility

• willing to direct the work of others
• willing, and able, to delegate tasks to others
• having a commitment to one’s staff
• able to solve / overcome problems (from greater & wider
experience)
• able to do all (or most of) the work done by one’s staff
• able to communicate - ‘downwards’ & ‘upwards’ within the
Company

Copyright © 2005, TWI Ltd World Centre for Materials Joining

 THE SENIOR WELDING INSPECTOR
What Makes a Good Leader / Supervisor ?

Qualities that are associated with a Good Supervisor are: -

• has good technical skill & knowledge and good at solving
problems
• has ability to quickly determine priorities
• is intelligent and confident
• shows good judgement
• has enthusiasm for work and is usually cheerful & optimistic
• sets a good example at work - high standards - leads by ‘example’
• has no ‘favourites’ and able to apply discipline fairly
• is approachable - good listener - and prepared to consult staff
• informs staff of important decisions affecting them and ‘backs his
team’
• is able to identify needs of ‘team’ and obtain equipment and
training
Copyright © 2005, TWI Ltd World Centre for Materials Joining
 THE SENIOR WELDING INSPECTOR

Morale & Motivation of Staff

What are the signs of low morale in the work

place ?
Compile a List

How can morale be raised ?

Apply good leadership qualities - list actions

Copyright © 2005, TWI Ltd World Centre for Materials Joining

 PRODUCTION PLANNING
PRESSURE VESSEL FABRICATION
T = Tier
N3
H = Head
N=
Nozzle

T1 T2 T3
N1 H1 H2
W1 W2

S1 N2 S2

W = Wrapper plate
S = Saddle

Copyright © 2005, TWI Ltd World Centre for Materials Joining

 PRODUCTION PLANNING
PRESSURE VESSEL: Typical Production Sequence
1. Prepare drawings & material list 11. Fit & weld - N1 + H1
2. Order materials - plate 12. Mark out, cut & roll wrapper
3. “ “ - fittings plates

4. “ “ - heads 13. Weld W1 & W2 to shell plates

5. “ “ - welding 14. Fit & weld nozzles N2 & N3

consumables
15. Cut, assemble & weld saddles S1
6. Mark out, cut & roll shell plates
7. Weld longitudinal & S2
seams
16. Fit & weld S1 & S2 to W1 & W2
8. Fit & weld - T3 to H2
17. Carry out all final inspection
9. “ “ - T2 to (T3 H2) 18. Pressure test
10. “ “ - N1 + H1 19. Blast & paint

20. Deliver

Copyright © 2005, TWI Ltd World Centre for Materials Joining

 PRODUCTION PLANNING
PRESSURE VESSEL: Typical Production Sequence
Bar Chart or Gantt Chart
OPERATION

17

19
20

24

27
10
11
12
13
14
15
16

18

21
22
23

25
26

28
29
30
1
2
3
4
5
6
7
8
9
1 Drawings
2 Material procurement - plate
3 - fittings
4 - heads
5 - welding
6 consumables
Mark, cut & roll shell plates
7 Weld longitudinal seams
8 Fit & weld T3 to H
9 Fit & weld T2 to T3H2
10 Fit & weld N1 to H1 - - - - - - -
11 Fit & weld N1H1 to T2T3H2
12 Cut & roll W1 & W2 - - - - - - - - -
13 Weld W1 & W2 to shell
14 Fit & weld N2 & N3
15 Cut, assemble & weld S1 & S2 - - - - - - - - - - - -
16 Fit & weld S1 & S2 to W1 & W2
17 Complete final Inspection
18 Pressure test
19 Shot blast & paint
20 Deliver

Can use forward or reverse-schedule planning

Copyright © 2005, TWI Ltd World Centre for Materials Joining
 Welding Procedure Qualification

A Preliminary Welding Procedure Specification (pWPS) is written for each test weld
required

• Welder makes a test weld in accordance with the pWPS

• Welding Inspector records all welding details used for making the test weld (‘as-
run’ details)
(EN standard states that an Independent Examiner or Examining Body or a Third
Party Inspector’ may be required to monitor the qualification process)
Finished test weld is subjected to NDT by the specified methods
(EN Standard requires visual, MT or PT & RT or UT)

• Test weld subjected to destructive testing according to specified methods

• Application Standard or Client may require additional tests such as impact tests,
hardness tests (for some materials - corrosion tests)

• Welding Procedure Qualification Record (WPQR) prepared giving range of

qualification allowed by the Welding Standard (EN or ASME IX)
• WPQR ‘package’ submitted to Independent Examiner for endorsement (& usually
to Client)

Copyright © 2005, TWI Ltd World Centre for Materials Joining

 Welder Qualification

A WPS is written for a each test weld required

• Welder makes a test weld in accordance with the WPS

• Welding Inspector checks that weld is made according to the WPS requirements
(EN standard states that an Independent Examiner or Examining Body or a Third
Party Inspector’ may be required to monitor the qualification process)

Finished test weld is subjected to NDT by the specified methods

(EN Standard requires visual, MT or PT & RT or UT)

• Test weld may need to be destructive tested for certain materials or welding
processes

• A Welder Qualification Certificate is prepared giving range of qualification

allowed by the Welding Standard (EN or ASME IX)
• The Welder Qualification certificate is submitted to Independent Examiner for
endorsement

Copyright © 2005, TWI Ltd World Centre for Materials Joining

 Destructive Testing
WELD PROCEDURE QUALIFICATION TESTING
(example)

1 2 3 4
5

SPECIMEN TYPE
POSITIONS

pipe diameters 6 macro + hardness 1, 9, 11

12 7
11 > 323.9mm transverse tensile 2, 8, 10,
8 12
Charpy – weld metal 3, 5, 6
Charpy – fusion line 4, 7

10 9

Copyright © 2005, TWI Ltd World Centre for Materials Joining

 Destructive Testing
QUANTITATIVE TESTS & QUALITATIVE TESTS

QUANTITATIVE TESTS
• for measuring a ‘quantity’ ( ‘quantity’ = a mechanical property
)
• typical mechanical tests - tensile test
- hardness test
- Charpy V-notch test (& CTOD)
QUALITATIVE TESTS
• for assessing joint ‘quality’ (‘quality’ = good fusion & free from
defects)
• typical qualitative tests - bend tests
- macro examination
(micro examination for some metals)

- fillet fracture & nick-break tests

Copyright © 2005, TWI Ltd World Centre for Materials Joining
 Destructive Testing
Tensile Testing - Transverse Tensile Test
gauge
lengt
h

weld

Position of failure not usually in weld metal but in base

material or HAZ
TEST OBJECTIVE
To measure the Tensile Strength of the welded joint
RESULTS
Satisfactory if Tensile Strength greater than min.
specified for base metal
(Some standards accept 95% of base material Tensile Strength)

Copyright © 2005, TWI Ltd World Centre for Materials Joining

 Destructive Testing
Tensile Testing: All-Weld Tensile
Test

from WPQ test piece electrode classification test

piece

gauge length: all weld

metal
TEST OBJECTIVE
To measure Yield Strength & Tensile Strength of weld
metal (% Elongation also measured & usually also %
Reduction of Area)
RESULTS
Satisfactory if all values are not less than minimum
specified for base metal (or required by desig) at ambient or
at elevated
Copyright World Centre for Materials Joining
© 2005, TWI temperature
Ltd
 Destructive Testing
MECHANICAL TESTING: Charpy V-notch Test
Positions
For each notch position 3 specimens are tested . May need to take
test pieces from weld metal, fusion line, fusion line + 2, fusion line
+ 5 from both weld faces and from root - total of 36 tests

weld metal
(surface)

weld metal (root)

fusion line +
fusion line fusion line +
5mm
2mm
Copyright © 2005, TWI Ltd World Centre for Materials Joining
 Destructive Testing
MECHANICAL TESTING: Charpy V-notch Impact
Testing
TEST OBJECTIVE
To measure the
impact toughness of
each region of the
weld joint (weld
metal, HAZ & base
metal) at a specified
temperature that is
related to the
service conditions
RESULTS
Satisfactory if all
values are not less
the minimum
specified by the
Application Standard
Copyright © 2005, TWI Ltd World Centre for Materials Joining
 Welding Technology
HAZ
TOUGHNESS
unwelded
unwelded ‘degraded’
Toughness fine HAZ
grained
Charpy
V-notch
steel
no
energy
significant
(Joules) change in
HAZ toughness
HAZ
transition temp. has
toughness if
shifted to a higher
good moderate
temperature
toughness in heat input
steel at used (caused by high heat
design temp. input welding)

low
toughness in
HAZ at design
temp. design Impact Test
temperature Temperature

Copyright © 2005, TWI Ltd World Centre for Materials Joining

 Welding Technology
THE HEAT AFFECTED ZONE

Temperatur
Maximum (HAZ)

e solid solid-liquid transition zone

weld
meta grain growth zone
l
recrystallised
zone
partially transformed
zone
tempered
zone
unaffected base
material

Copyright © 2005, TWI Ltd World Centre for Materials Joining

 Destructive Testing
MECHANICAL TESTING: Hardness Testing
usually the hardest
region ~1.5 to 3mm
fusion line
(fusion HA HA
boundary) Z Z

HARDNESS TEST METHODS

Vickers example 248 HV10
Rockwell example Rc 22
Brinell example 220 BHN-W (not usually used on
macro sections)
TEST OBJECTIVE To measure the max. hardness in the weld
joint (always in HAZ for steels)

RESULTS Satisfactory if no values are above the

max. specified by the Application
Standard

Copyright © 2005, TWI Ltd World Centre for Materials Joining

 Welding Technology
HAZ Hardness of Carbon-Manganese
Steels

HAZ
intermediate heat-input will
Hardness give satisfactory hardness

low heat-input
welding tends
to give a high
HAZ hardness
high heat-
input welding
tends to give a
softer HAZ

fast Rate of Cooling of slow

HAZ
Copyright © 2005, TWI Ltd World Centre for Materials Joining
 Welding Technology
HAZ Hardness of Low-Alloy
Steels (such as the higher Cr-Mo
grades)
HAZ
Hardness

low heat-input high heat-input

welding welding
HAZ hardness always high (> ~ 400
HV)

fast Time to slow

cooling Cool cooling

Copyright © 2005, TWI Ltd World Centre for Materials Joining

 Destructive Testing
QUALITATIVE TESTS: Bend Tests

for joint thicknesses

< ~ 12mm

face in tension = face bend root in tension = root bend

for joint
thicknesses > ~
12mm

full thickness of joint in tension = side

bend

Copyright © 2005, TWI Ltd World Centre for Materials Joining

 Destructive Testing
QUALITATIVE TESTS: Fillet Fracture & Nick Break
Tests
Tests are used instead of radiography or ultrasonic examination
to show
• that satisfactory fusion has been achieve
• that the weld is has no defects
FILLET FRACTURE NICK-BREAK

machined
force machined slot
slot

fracture from
root
Copyright © 2005, TWI Ltd World Centre for Materials Joining
 PWHT
• Steels are given a PWHT to reduce residual stresses caused
by welding [and also to temper (soften) the hardest regions of
the HAZ]
• The main benefit of reducing residual stresses is to improve
resistance to brittle fracture - explained as follows: -
• Residual stresses can be higher than the max. allowed
design stress and are powerful driving forces for propagating
flaws (usually cracks)
• In the as-welded condition, the steel joint has a lower
tolerance to flaws that may become initiation points for
brittle cracks
• A crack that could cause brittle fracture is called a ‘critical’
crack
• The size of a critical crack depends on the material
toughness and total stress that the crack experiences in the
joint (design + residual)
• An©as-welded
Copyright 2005, TWI Ltd jointWorld
may only be able
Centre to tolerate
for Materials a small
Joining
 PWHT

Removal of Residual Stress

Cr-Mo steel - • At PWHT temp. the

Yield 500 typical
yield strength of steel
Strength
reduced so that it it is
(N/mm2 ) 400
C-Mn steel - not strong enough to
typical give restraint.
300
• Residual stress
reduced to very low
200
level by straining
(typically < ~ 0.5%
100 strain)

100 200 300 400 500 600 700

Temperature
(°C)
Copyright © 2005, TWI Ltd World Centre for Materials Joining
 PWHT
Other Benefits of PWHT

• The toughness of the HAZ may be improved - particularly for

the more hardenable low alloy steels & improves brittle
fracture resistance
• Removal of residual stress will give steels resistance to stress
corrosion cracking in certain media - for example in sour
oil/gas, in ammonia or in contact with nitrates and chlorides
• It enables a welded component to be machined to accurate
tolerances that may otherwise be impossible due constant ‘re-
balancing’ of tensile and residual stresses when metal is
removed during machining. This may be referred to as a
stabilising* PWHT

(* not to be confused with stabilised when referring to stabilising

stainless steels by alloying additions of Nb or Ti)

Copyright © 2005, TWI Ltd World Centre for Materials Joining

 PWHT
PWHT Procedures - Basic Requirements
A PWHT should specify the following: -
• The max. heating rate
– usually from 300 or 400°C depending on Code or item to ensure
temp. gradients are not excessive (up to ~ 200°C/h max. may be
allowed)
– large temp. gradients cause high stresses which may give
cracking or distortion
• The ‘soak’ temperature
– depends on steel type and usually specified by Code (~550 to
~750 °C )
• The ‘soak’ time
– to ensure full thickness, and whole item, is at soak temp.
– Codes typically require 1h per 25mm of max. joint thickness

• The max. cooling rate

Copyright –
©usually
2005, TWIto
Ltd400 orWorld
300°C Centre
- same reasons as for heating
for Materials Joiningrate
 PWHT
PWHT Procedures -Additional Considerations
Before a PWHT commences it is necessary to: -
• Decide the number of thermocouple attachments and their
positions
– so that the temperature of the whole component is monitored

• If the item needs to be given any additional support

– to avoid distortion due to self-weight because it is relatively
weak at the soak temp.
For Localised PWHT
Need to also specify: -
• The width of the heated band
– to ensure that residual stresses at a distance from the weld are
removed
• The width of the temp. ‘decay’ bands beyond the heated
zone
– to ensure high stresses are not produced by large temperature
Copyright © 2005, TWI Ltd
gradients World Centre for Materials Joining
 Post Weld Heat Treatment
Localised PWHT
PWHT procedures also need to also specify: -
• The width of the heated band
– to ensure that residual stresses at a distance from the weld are
removed
– should be specified by Code

• The width of the temp. ‘decay’ bands beyond the heated

zone
– to ensure high stresses are not produced by large temperature
gradients
– should be specified by Code - usually same width as heated band

• The position of the thermocouples to monitor the width of

temp
heated bands and heatedgradient temp
the temp. in the decay bands
. .
band
deca deca
y y
pipeline
weld
Copyright © 2005, TWI Ltd World Centre for Materials Joining
 Cracking in Weld Joints
RE-HEAT CRACKING
• Cracking that occurs when weld joints in certain steels when
they are being heated to their PWHT temperature or are put into
elevated temp. service without PWHT
( this gives this type of cracking the name
‘re-heat’ )
• Susceptible PWHT temp.range ~ 500 to ~ 650°C or service 350
- 550 °C
• Cracking occurs in the HAZ - usually in the zone that has the
largest grain size (the ‘grain growthgrain
zone growth
nearest to the
fusion line) zone

Copyright © 2005, TWI Ltd World Centre for Materials Joining

 Cracking Mechanisms
RE-HEAT CRACKING
Re-heat cracking occurs because: -
• some strengthening of the steel occurs during heating to the
PWHT temp. (or if in as-welded condition while in service at an
elevated temp.)
• strengthening occurs by carbide formation
- steels with Vanadium, Chromium and Molybdenum are most
susceptible because these elements are strong carbide
formers
• the carbides & nitrides strengthen the grains so that relief of
residual stresses takes place by all the strain concentrating at
the weaker grain boundaries
• if the steel contains certain levels of impurities (such as Tin,
Arsenic & Phosphorus) they concentrate at the grain
boundaries and reduce their rupture strength
• the presence of large grains in the HAZ means that the
impurities are more concentrated and such regions become
Copyright © 2005, TWI Ltd World Centre for Materials Joining
 Cracking Mechanisms
AVOIDING RE-HEAT CRACKING
The risk of re-heat cracking can be minimised by: -
• using steel that has very low impurity levels
• various formulas have been developed to relate sensitivity to
cracking to levels of impurities
• for particularly sensitive steels (usually those with higher
Vanadium) ensure that: -
– weld bead positions and heat input are controlled to give a
fine grained HAZ (temper-beading)
– avoid stress concentrations - poor fit-up and sharp weld
toes
– heat through the sensitive temperature range quickly
during PWHT

Copyright © 2005, TWI Ltd World Centre for Materials Joining

 Quenched & Tempered Steels
Q & T STEELS
• Steels that are strengthened by rapid cooling from an elevated
temperature (quenching)
• Quenching temperature depends on steel composition but typically
~900°C
• Steels are very strong in the quenched condition but ductility and
toughness usually too low for any application
• Tempering reduces the as-quenched strength and gives ‘usable’
ductility and toughness
• Tempering temperatures typically ~550 to 760°C
• Strengthening by quenching is achieved by certain alloying additions
that allow the stronger phases (martensite & bainite) to form (rather
than the ferrite)
• The % of the alloying elements that allow strengthening must be
high enough to allow the stronger phases to form through the full
thickness
• For some steels, the alloying levels need to be higher in thick
sections to ensure ‘through- hardening’

Copyright © 2005, TWI Ltd World Centre for Materials Joining

 Quenched & Tempered Steels
EXAMPLES of Q & T STEELS
Typical Mechanical Properties
STEEL TYPE C Si Mn Cr Mo Ni Nb V Yield / 0.2%PS Tensile Strength Elongation
(N/mm2) (N/mm2) (% on 50mm)
AISI 4130 water quenched & tempered at 595 to 480°C
UNS G41300 - 0.40 0.8 (100mm round section)
W. Nr. 1.7218 0.04 0.60 1.1 - - -
540 to 655 703 to 800 20 to 25
ASTM A 505, 646
0.28 0.15
AISI 8630 0.33 0.25 water quenched & tempered at 595 to 480°C
UNS G86300 0.15 0.70 0.40 0.40 (100mm round section)
W. Nr. 1.6545 0.30 0.90 0.60 0.70 - - 495 to 595 660 to 780 21 to 26
ASTM A 322, 331, 505
AISI 4140 oil quenched & tempered at 650 to 540°C
UNS G41400 0.70 0.80 0.15 (100mm round section)
W. Nr. 1.7225 1.00 1.10 0.25 - - - 580 to 685 772 to 883 19 to 23
ASTM A 322, 331, 505, 519, 646
0.38 0.15
AISI 4340 0.43 0.30 oil quenched & tempered at 650 to 540°C
UNS G43400 0.60 0.70 0.20 1.65 (100mm round section)
W. Nr. 1.6565 0.80 0.90 0.30 2.00 - - 786 to 1000 924 to 1138 16 to 20
ASTM A 332, 505, 519, 547, 646

Copyright © 2005, TWI Ltd World Centre for Materials Joining

 Quenched & Tempered Steels
EXAMPLES of Q & T STEELS

Other Mechanical Properties

STEEL TYPE C Si Mn Cr Mo Ni Nb V N Yield / 0.2%PS Tensile Strength Elongation
(N/mm2) (N/mm2) (% on 50mm)
A 335-P91 Al
X10CrMoVNb9-1 0.08 - 0.30 8.00 0.85 - 0.06 0.18 0.030 - = 415 585 = 22
(steel number 1.4903) 0.12 0.50 0.60 9.50 1.05 0.40 0.10 0.25 0.070 0.040

12CrMoV11-1 0.17 0.30 10.0 0.80 0.30 - 0.20 - - = 500 700 -850 = 16
(steel number 1.4922) 0.23 0.40 1.0 12.5 1.20 0.80 0.35
0.10 0.10 0.30 8.50 0.90 0.20 0.06 0.15 0.050 W
A 335-P911 0.13 0.30 0.60 9.50 1.10 0.40 0.10 0.25 0.080 0.90
1.10 = 440 = 620 = 22

Copyright © 2005, TWI Ltd World Centre for Materials Joining

 Quenched & Tempered Steels
EXAMPLES of Q & T STEELS

Typical Chemical Composition Typical Mechanical Properties (t=25mm)

STEEL TYPE Yield/0.2%PS Tensile Strength Elongation
C Si Mn Cr Mo Ni Nb V Ti Al Other (N/mm2) (N/mm2) (% on 50mm)
WELDOX 700 - - - - - - - - - - N (min) 0.0015
0.20 0.60 1.60 0.70 0.70 2.0 0.04 0.09 0.04 0.015 B (max) 0.005 = 700 780 - 930 = 18
WELDOX 900 - - - - - - - - - - N (min) 0.0015
0.20 0.50 1.60 0.70 0.70 2.0 0.04 0.06 0.04 0.018 B (max) 0.005 = 900 940 - 1110 = 16
WELDOX 960 - - - - - - - - - - N (min) 0.0015
0.20 0.50 1.60 0.70 0.70 2.0 0.04 0.06 0.04 0.018 B (max) 0.005 = 960 980 -1150 = 16
WELDOX 1100 - - - - - - - - - - N (min) 0.0015
0.21 0.50 1.40 0.80 0.70 3.0 0.04 0.08 0.02 0.020 B (max) 0.005 = 1100 1250 - 1550 = 12

WELDOX is a registered Trade Name of SSAB Oxelosund

Chemical compositions and tensile properties of some HSLA steels used for structural applications

Copyright © 2005, TWI Ltd World Centre for Materials Joining

 Quenched & Tempered Steels
Welding of Q & T Steels
• Alloying additions used to achieve strengthening also will
give hardening of the HAZ
• Higher HAZ hardness give higher risk of cracking and the
need to always use low Hydrogen welding processes and
also the need to use pre-heat for most grades
• Higher HAZ hardness usually mean that many of these
steels require PWHT to improve resistance to brittle
fracture
• Careful control of heat input - not too high - may be
needed for some steel types to avoid softening of the HAZ
and loss of strength
• For the highest strength grades there may be difficulty in
achieving matching strength weld metal that has good
toughness and ductility

Copyright © 2005, TWI Ltd World Centre for Materials Joining

 Pre-Heat & Interpass Temperature

Pre-Heat Temperature
• Applied to reduce risk of cracking - helps to allow H to
escape from the weld joint and can reduce hardness of HAZ
for some steels
• Pre-heat temperature should be checked on both sides of
the joint at a distance of at least 75mm from joint edge
• Pre-heat should be checked on the other side from the pre-
heated side - if access allows
• If hand held gas pre-heating is used, temp. should be
checked a short time after the heating torch has been
removed

Interpass Temperature
• This is the temp. at the position that the welder will re-
start welding in a muti-run weld
• Temperature should be measured on the steel as close as
practical
Copyright to Ltd
© 2005, TWI the re-start
Worldposition (it can
Centre for be taken
Materials on the
Joining