Visual Inspection

Objective:
To understand the principals of visual inspection and acceptance criteria and be able to perform
visual inspection and understand NDT test report.

Scope:
 Overview
 Visible defect types
 Dimension checks
 What to look for before, during and after welding
 Inspection tools
 Reporting
 Standards (ISO 17637, ISO 5817)

Learning Outcomes:
1. Understand the purpose of visual inspection at all stages of welding .
2. Understand the purpose and limitations of tools used to aid visual inspection.
3. Able to perform visual inspection and report in detail the defects identified during an inspection

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 Visual Inspection
1. Overview

Visual testing is the basic nondestructive testing method and is necessary ~ before, during, and
after fabrication of any weldment; Visual interpretation is basic to all other methods of
nondestructive testing because all final results are interpreted visually.
Magnetic particle and liquid penetrant test may be considered aids to visual testing in the same
category with magnifying glasses and proper illumination. Both magnetic particle and liquid
penetrant testing in addition to radiographic, ultrasonic and eddy current testing will detect
discontinuities not discernible to the eye.
This is the main reason behind the development of nondestructive test. The final result and
interpretation, however, may be accomplished, visually. the reading of radiographs is an excellent
example; Visual testing covers the entire spectrum of the welding process and the value of visual
testing, more than any other inspection method, is in direct proportion to the inspector. Visual testing,
if properly used, can detect and aid in the elimination of discontinuities that might become defects in
the final weldment. Therefore, personnel visual testing should be familiar with design and weld
requirements. A simple checklist or sign-off sheet for each job should be developed to aid the
inspector
Visual testing is limited the detection of surface discontinuities. However, as pointed out
previously, visual testing applied during the welding process may eliminate subsurface
discontinuities as well: It has been shown that visual testing, conscientiously applied before, during,
and after welding, can result in elimination of 80 to 90 percent of the discontinuities that would be
detected by the other testing methods
There is a tendency to downgrade the value of visual testing because, too often, it is begun too
late in the sequence of operation. When properly applied, visual testing should commence long
before any weld metal is deposited. If this is done, the overall cost of fabrication may be substantially
reduced. One example would be fit up; welds deposited in properly fitted joints cost less because
fewer pounds of weld metal are required. Another example would be the cost savings realized for
nondestructive tests conducted after the welding is completed; ultrasonic testing of a weld joint with a
borderline indication due to lack of back gouging is very slow and expensive. This ability to
eliminate many' discontinuities before the weld is completed is perhaps the most important feature of
visual testing.

There are 3 basic technique for visual inspection:

1.1. Direct Visual
Direct visual examination may usually be made when access is sufficient to place the eye within 24
in. (610 mm) of the surface to be examined and at an angle not less than 30 deg. to the surface to
be examined.

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 Mirrors may be used to improve the angle of vision, and aids such as a magnifying lens may be
used to assist examinations. Illumination (natural or supplemental white light) for the specific part,
component, vessel, or section thereof being examined is required. The minimum light intensity at
the examination surface/site shall be 100 footcandles (1000 lux). The light source, technique used,
and light level verification is required to be demonstrated one time, documented, and maintained
on file. Personnel shall have an annual vision test to assure natural or corrected near distance acuity
such that they are capable of reading standard J-1 letters on standard Jaeger test type charts for near
vision. Equivalent near vision tests are acceptable.

1.2. Remote Visual

In some cases, remote visual examination may have to be substituted for direct examination.
Remote visual examination may use visual aids such as mirrors, telescopes, boroscopes, fiber
optics, cameras, or other suitable instruments. Such systems shall have a resolution capability at
least equivalent to that obtainable by direct visual observation.

1.3. Translucent Visual Examination

Translucent visual examination is a supplement of direct visual examination.
The method of translucent visual examination uses the aid of artificial lighting, which can be
contained in an illuminator that produces directional lighting.
The illuminator shall provide light of an intensity that will illuminate and diffuse the light evenly
through the area or region under examination.
The ambient lighting must be so arranged that there are no surface glares or reflections from the
surface under examination and shall be less than the light applied through the area or region under
examination.
The artificial light source shall have sufficient intensity to permit “candling” any translucent
laminate thickness variations.

2. Surface / Visible types of Discontinuity/Defect

Crack
An imperfection produced by a local rupture in the solid state which may
arise from the effect of cooling or stresses
Microcrack
A crack only visible under the microscope
Longitudinal crack
A crack essentially parallel to the axis of the weld. It may be situated:
– in the weld metal
– at the weld junction
– in the heat-affected zone
– in the parent metal.

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Transverse crack
A crack essentially transverse to the axis of the weld. It may be situated:
– in the weld metal
– in the heat-affected zone
– in the parent metal

Radiating cracks
Cracks radiating from a common point. They may be situated:
– in the weld metal
– in the heat-affected zone
– in the parent metal.
NOTE: Small cracks of this type are called „star cracks“.

Crater crack
A crack in the crater at the end of a weld which may be:
– longitudinal
– transverse
– radiating (star cracking).

Group of disconnected cracks

A group of disconnected cracks in any direction which may be situated:
– in the weld metal
– in the heat-affected zone
– in the parent metal

Branching cracks
A group of connected cracks originating from a common crack and
distinguishable from a group of disconnected cracks (105) and from
radiating cracks (103). They may be
situated:
– in the weld metal
– in the heat-affected zone
– in the parent metal.

Surface pore
A gas pore which breaks the surface of the weld.

Crater pipe
A shrinkage cavity at the end of a weld run and not eliminated before or
during subsequent weld runs

End crater pipe

An open crater reducing the cross-section of the weld.

Puckering
In certain cases, especially in aluminium alloys, gross oxide film
enfoldment can occur due to a combination
of unsatisfactory protection from atmospheric contamination and
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turbulence in the weld pool
lack of root fusion
Lack of union between the weld metal and the parent metal at the root of
weld

Incomplete root penetration

One or both fusion faces of the root are not melted

Imperfect shape
Imperfect shape of the external surfaces of the weld or defective joint
geometry

Undercut
An irregular groove at a toe of a run in the parent metal, or in previously
deposited weld metal due to welding
Continuous undercut
Undercut of significant length without interruption
Inter run undercut (inter-pass undercut)
Undercut in the longitudinal direction between weld runs
Local intermittent undercut
Short undercuts, irregularly spaced, on the side or on the surface of the
weld runs

Shrinkage groove
Undercuts visible on each side of the root run

Excess weld metal

Excess weld metal at the face of a butt weld.

Excessive convexity
An excess of weld metal at the face of a fillet weld

Excess penetration
Excess weld metal protruding through at the root of a weld. This may be:
Local excess penetration, Continuous excess penetration, Melt through.

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Incorrect weld toe
Too small an angle (a) between the plane of the parent metal surface and
a plane tangential to the weld run surface at the toe of the weld

Overlap
Excess weld metal covering the parent metal surface but not fused to it.
This may be: Toe overlap at the weld toe, Root overlap at the weld root

Linear misalignment
Misalignment between two welded pieces such that while their surface
planes are parallel, they are not in the required same parallel plane. This
may be: Linear misalignment between plates, Linear misalignment
between tubes

Angular misalignment
Misalignment between two welded pieces such that their surface planes
are not parallel or at the intended angle.

Sagging
Weld metal collapse due to gravity. According to the circumstances, it
may be:
– sagging in the horizontal position
– sagging in the flat or overhead position
– sagging in a fillet weld
– sagging (melting) at the edge of the weld

Burn through
A collapse of the weld pool resulting in a hole in the weld.

Incompletely filled groove

A longitudinal continuous or intermittent channel in the surface of a
weld due to insufficient deposition of weld filler metal.

Excessive asymmetry of fillet weld (excessive unequal leg length)

Explanation not necessary

Irregular width
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Excessive variation in width of the weld.
Irregular surface
Excessive surface roughness
Root concavity
A shallow groove due to shrinkage of a butt weld at the root (see also
5013).

Root porosity
Spongy formation at the root of a weld due to bubbling of the weld metal
at the moment of solidification
Poor restart
A local surface irregularity at a weld restart. It may occur
– in the capping run
– in the root run.

Excessive distortion
Dimensional deviation due to shrinkage and distortion of welds
Incorrect weld dimensions
Deviation from prescribed dimensions of the weld

Excessive weld thickness

Weld thickness is too large

Excess weld width

Weld width is too large

Insufficient throat thickness

The actual throat thickness of the fillet weld is too small

Excessive throat thickness

The actual throat thickness of the fillet weld is too large

Stray arc
Local damage to the surface of the parent metal adjacent to the weld,
resulting from arcing or striking the arc outside the weld groove
Spatter
Globules of weld metal or filler metal expelled during welding and
adhering to the surface of parent metal or solidified weld metal
Tungsten spatter
Particles of tungsten transferred from the electrode to the surface of
parent metal or solidified weld metal
Torn surface
Surface damage due to the removal by fracture of temporary welded
attachments.
Grinding mark
Local damage due to grinding
Chipping mark
Local damage due to use of a chisel or other tools
Underflushing
Lack of thickness of the workpiece due to excessive grinding

Misalignment of opposite runs

Difference between the centerlines of two runs made from opposite sides
of the joint

Temper colour (visible oxide film)

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Lightly oxidized surface in the weld zone, e. g. in stainless steels
Scaled surface
Heavily oxidized surface in the weld zone.
Flux residue
Flux residue is not sufficiently removed from the surface
Slag residue
Adherent slag is not sufficiently removed from the surface of the weld

Incorrect root gap for fillet welds

An excessive or insufficient gap between the parts to be joined

Swelling
Imperfection due to a burning on welded joints in light alloys resulting
from a prolonged holding time in the solidification stage

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3. What to look for before, during and after welding
3.1. Visual testing of joint preparation
When visual testing is required prior to welding. the joint shall be examined to check that:
a) the shape and dimensions of the weld preparation meet the requirements of the welding
procedure specification;
b) the fusion faces and adjacent surfaces are clean and any required surface treatment has been
carried out in accordance with the application or product standard;
c) the parts to be welded are correctly fixed in relation to each other according to drawings. or
instructions

3.2. Visual testing during welding

When required, the weld shall be tested during the welding process to check that:
a) each run or layer of weld metal is cleaned before it is covered by a further run, particular
attention being paid to the junctions between the weld metal and the fusion face;
b) b) there are no visible imperfections, e.g. cracks or cavities; if imperfections are observed, they
shall be reported so that remedial action can be taken before the deposition of further weld metal;
c) c) the transition between the runs and between the weld and the parent metal is so formed that
satisfactory melting can be accomplished when welding the next run;
d) d) the depth and shape of gouging is in accordance with the WPS or compared with the original
groove shape in order to assure complete removal of the weld metal as specified;
e) e) after any necessary repairs/remedial action, the weld conforms to the original requirements of
the WPS

3.3. Visual testing of the finished weld

The finished weld shall be examined to determine whether it meets the requirements of the application
or product standard or other agreed acceptance criteria.
Finished welds shall at least be examined in accordance with the requirements
a) Cleaning and dressing
The weld shall be examined to check that:
 all slag has been removed by manual or mechanical means in order to avoid imperfections
being obscured
 there are no tool impressions or blow marks;
 when weld dressing is required, overheating of the joint due to grinding is avoided and that
grinding marks and an uneven finish are also avoided
 for fillet welds and butt welds to be dressed flush, the joint merges smoothly with the parent
metal without under flushing
If imperfections (caused by dressing or otherwise) are observed, they shall be reported so that
remedial action can be taken

b) Profile and dimensions

The weld shall be examined to check that;
 the profile of the weld face and the height of any excess weld metal meet the requirements of
the acceptance standard;
 the surface of the weld is regular: the pattern and the pitch of weave marks present an even
and satisfactory visual appearance; the distance between the last layer and the parent metal
or the position of runs has been measured where required by the WPS;
 the weld width is consistent over the whole of the joint and that it meets the requirements
given in the weld drawing or acceptance standard; in the case of butt welds, the weld
preparation shall be checked to ensure that it has been completely filled

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 c) Weld root and surfaces

The visually accessible parts of the weld, i.e. the weld root for a single-sided butt weld and the
weld surfaces, shall be examined for deviations from the acceptance standard. The weld shall be
examined to check that:
 in the case of single-sided butt welds, the penetration, root concavity and any burn-through
or shrinkage grooves are within the limits specified in the acceptance standard over the
whole of the joint;
 any undercut is within the requirements of the acceptance standard;
 any imperfections such as cracks or porosity, detected using optical aids when necessary, in
the weld surface or heat affected zones comply with the appropriate acceptance criteria;
 any attachments temporarily welded to the object to facilitate production or assembly and
which are prejudicial to the function of the object or the ability to examine it are removed so
that the object is not damaged; the area where the attachment was fixed shall be checked to
ensure freedom of cracks;
 any arc strikes are within the limits of the acceptance standard

d) Post-weld heat treatment

Further testing may be required after post-weld heat treatment

3.4. Visual testing of repaired weld

 When welds fail to comply wholly or in part with the acceptance criteria and repair is
necessary, the welded joint shall be examined in accordance with a and bellow, prior to re-
welding.
 Every repaired weld shall be re-examined to the same requirements as the original weld
a. Partially removed weld
 The excavation shall be sufficiently deep and long to remove all imperfections. The
excavation shall be tapered from the base of the cut to the surface of the weld metal at both
the ends and sides of the cut.
 The width and profile of the cut shall be such that there is adequate access for re-welding
b. Completely removed weld
 When a defective weld has been completely removed, with or without the need for a new
section to be inserted, the shape and dimensions of the weld preparation shall meet the
specified requirements for the original weld

4. Inspection tools
4.1. The following is a list of equipment typically used for carrying out visual tests of welded joints:
a) straight edge or measuring tape with a graduation of 1 mm or finer;
b) vernier calliper in accordance with ISO 3599;
c) feeler gauge with a sufficient number of feelers to measure dimensions between 0,1 mm and 3
mm in steps of 0,1 mm at most;
d) radius gauge;
e) magnifying lel1s with a magnification x 2 to x 5; the lens should preferably have a scale, see
ISO 3058;
f) lamps.

4.2. The following equipment may also be needed:

a) profile measuring device with a wire diameter or width ~ 1 mm, where each wire end is
rounded;
b) material for impression of welds, e.g. cold setting plastic or clay;
c) for visual inspection of welds with limited accessibility, mirrors, endoscopes, boroscopes, fibre
optics, or TV-cameras may be used;
d) other measurement devices e.g. specifically designed welding gauges, height/depth gauges,
rulers or protractors.
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4.3. Other typical measurement devices and gauges are may be used;

 NOTE These devices and gauges are included as examples of testing equipment, Some of the
designs may be registered designs or the subject of patents,

5. Test records

When test records me required, at least the following information should be included in the report:
a) name of the component manufacturer;
b) name of the testing body, if different from a);
c) identity of the object tested;
d) material; e) type of joint;
1) material thickness; g) welding process;
h) acceptance criteria;
i) imperfections exceeding the acceptance criteria and their location;
j) the extent of testing with reference to drawings as appropriate;
k) test devices used;
I) result of testing with reference to acceptance criteria;
m) name of tester and date of test.

Welds that have been tested and approved should be suitably marked or identified.

If a permanent visual record of an examined weld is required, photographs or accurate sketches or

both should be made with any imperfections clearly Indicated.

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