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Material Inspection

Steels can be classified by many different codes and standards, depending on material type and intended use. Mechanical Damage can be defined as any surface material damage caused during the manufacturing process.

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Ahmed Gomaa
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339 views

Material Inspection

Steels can be classified by many different codes and standards, depending on material type and intended use. Mechanical Damage can be defined as any surface material damage caused during the manufacturing process.

Uploaded by

Ahmed Gomaa
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
You are on page 1/ 25

TWI CSWIP 3.

1 WIS 5 WELDING INSPECTION MATERIALS INSPECTION SECTION 6


World Centre for Materials Joining Technology
Copyright 2005, TWI Ltd

MATERIALS INSPECTION
Rolling Imperfections
Direction of rolling
Cold Laps*

Laminations
Segregation
World Centre for Materials Joining Technology
Copyright 2005, TWI Ltd

MATERIALS INSPECTION.
Plate Inspection
Material Traceability
Specification Thickness Length

Width
Other checks may need to be made such as: distortion tolerance, number of plates and storage*
World Centre for Materials Joining Technology
Copyright 2005, TWI Ltd

STRUCTURAL STEELS.
Steels can be classified by many different codes & standards, depending on material type & intended use. Typical BS EN Standards for structural steels; BS EN 10025 - Non-alloy structural steels. BS EN 10113-2-Fine grain normalised structural steels. BS EN 10113-3-Fine grain thermomechanical rolled steels.

BS EN 10207- Steels for simple pressure vessels.

World Centre for Materials Joining Technology


Copyright 2005, TWI Ltd

STRUCTURAL STEELS.
BS EN 10025 - Non-alloy structural steels. Impact Strength Structural Steel

-J = min 27j
-K = min 40j De-oxidation method (Opt) Test temp for impact tests: -R =+20C -0 = 0C -2 = -20C

S 355 J2 G3
Min YS for t 16mm: -235

-275
-355
Copyright 2005, TWI Ltd

World Centre for Materials Joining Technology

MATERIALS INSPECTION
Plate Inspection
Material Condition

Lapping

Corrosion
Lamination

Mechanical Damage

World Centre for Materials Joining Technology


Copyright 2005, TWI Ltd

MATERIALS INSPECTION.
MECHANICAL DAMAGE
Mechanical damage can be defined as any surface material damage cause during the manufacturing process. This can included damage caused by: Grinding Hammering Chiselling Chipping

Breaking off welded attachments (torn surfaces)


Chisel Marks Chisel Marks Grinding Marks

World Centre for Materials Joining Technology


Copyright 2005, TWI Ltd

MATERIALS INSPECTION.
Mill Scale & Rusting
Rust Grade A
Steel surface largely covered with adherent millscale with little or no rust

Rust Grade B
Steel surface which has begun to rust and from which millscale has begun to flake

World Centre for Materials Joining Technology


Copyright 2005, TWI Ltd

MATERIALS INSPECTION
Rusting
Rust Grade D
Steel surface on which millscale has rusted away. General pitting visible under normal vision.

Rust Grade C
Steel surface on which the millscale has rusted away or from which it can be scrapped. Slight pitting visible under normal vision

World Centre for Materials Joining Technology


Copyright 2005, TWI Ltd

MATERIALS INSPECTION.
Lapping

World Centre for Materials Joining Technology


Copyright 2005, TWI Ltd

MATERIALS INSPECTION.
Lapping

World Centre for Materials Joining Technology


Copyright 2005, TWI Ltd

MATERIALS INSPECTION.

Lamination

World Centre for Materials Joining Technology


Copyright 2005, TWI Ltd

MATERIALS INSPECTION
Pipe Inspection
Material Traceability

Diameter & Ovality

Length

Specification, Heat / Batch No


Other checks may need to be made such as: distortion tolerance, number of pipes and storage conditions*
World Centre for Materials Joining Technology
Copyright 2005, TWI Ltd

MATERIALS INSPECTION
Pipe Inspection
Material Condition.

Mechanical Damage

Corrosion / Pitting

Other checks may also need to be made; distortion, number of pipes & storage conditions.
World Centre for Materials Joining Technology
Copyright 2005, TWI Ltd

MATERIALS INSPECTION.
BS EN 10204- METALLIC MATERIALS. Types of documents.
Non-Specific Inspection -Type a
Inspection document type 2.1
Declaration of compliance with order. Statement of compliance with order. Validated by manufacturer.

Inspection document type 2.2


Test report Statement of compliance with order, with indication of non-specific inspection results. Validated by manufacturer

a. Non-specific inspection may be replaced by specific inspection if specified in the material standard or order

World Centre for Materials Joining Technology


Copyright 2005, TWI Ltd

MATERIALS INSPECTION.
BS EN 10204- METALLIC MATERIALS. Types of documents.
Specific Inspection -Type b
Inspection document type 3.1
Statement of compliance with order, with indication of results of specific inspection. Validated by manufacturers authorised inspection representative, independent of manufacturing.

Inspection document type 3.2


Statement of compliance with order, with indication of results of specific inspection. Validated by manufacturers authorised inspection representative, independent of the manufacturing department, and either the purchasers authorised inspection representative or the inspector designated by official regulations.

World Centre for Materials Joining Technology


Copyright 2005, TWI Ltd

b. Quality management system of the material manufacturer certified by a competent body established within the community and having undergone a specific assement for materials

QUESTIONS ?
World Centre for Materials Joining Technology
Copyright 2005, TWI Ltd

MATERIALS INSPECTION.

QUESTIONS ?
World Centre for Materials Joining Technology
Copyright 2005, TWI Ltd

MATERIALS INSPECTION.
Iron and steels specifications can be classified a number of different codes and standards, depending on the material type and intended use. For example API 5LX or ASTM are American standards for the designation of line pipe. A common standard used to designate plate material is BSEN 10025. ( Hot rolled products of non-alloy structural steels). Typical Examples of steel using BS EN 10025 designation would be S275 JRG1 / S355K2G3.

World Centre for Materials Joining Technology


Copyright 2005, TWI Ltd

MATERIALS INSPECTION.
S = Structural Steel. 275 / 355 = Minimum Yield Strength: N/mm at T 16mm JR = Longitudinal Charpy, 27Joules @ Room Temperature JO = Longitudinal Charpy, 27Joules @ 0C J2 = Longitudinal Charpy, 27Joules @ - 20C K2 = Longitudinal Charpy, 40Joules @ - 20C G1 = Rimming Steel G2 = Rimming Steel not permitted G3 = Normalised or normalised rolled G4= At manufacturers discretion.
World Centre for Materials Joining Technology
Copyright 2005, TWI Ltd

MATERIALS INSPECTION.
Iron Fe Carbon C is for Strength Manganese Mn is for Toughness Silicon Si < 0.3% Deoxidiser Aluminium Al Grain refiner, <0.008% Deoxidiser + Toughness Chromium Cr Corrosion resistance Molybdenum Mo 1% is for Creep resistance Vanadium V Strength Nickel Ni Low temperature applications Copper Cu Used for weathering steels (Corten) Sulphur S Residual element (can cause hot shortness) Phosphorous P Residual element Titanium Ti Grain refiner, Used a a micro alloying element (S&T) Niobium Nb Grain refiner, Used a a micro alloying element (S&T) (S&T) = Strength & Toughness
World Centre for Materials Joining Technology
Copyright 2005, TWI Ltd

Lapping

World Centre for Materials Joining Technology


Copyright 2005, TWI Ltd

MATERIALS INSPECTION
Pipe Inspection
(Corrosion, Damage, Wall thickness Ovality, Laminations & Seam)

Condition

Welded seam

Length

Specification, Heat / Batch No


Other checks may need to be made such as: distortion tolerance, number of pipes and storage conditions*
World Centre for Materials Joining Technology
Copyright 2005, TWI Ltd

MATERIALS INSPECTION.
BS EN 10204-Type of documents.
Non -Specific Inspection Documents
Type 2.1. Declaration of compliance with the order Content: statement of compliance with the order (doesnt include test results!) Who validates it - the manufacturer
Copyright 2005, TWI Ltd

Type 2.2 Name: Test report Content: statement of compliance with the order (include test results!) Who validate it - the manufacturer

World Centre for Materials Joining Technology

MATERIALS INSPECTION.
BS EN 10204-Type of documents.
Specific Inspection Documents
Type 3.1.
Name: Inspection certificate 3.1 Content: statement of compliance with the order (include specific test results!) Who validate it - the manufacturer inspection (independent of manufacturing department!)

Type 3.2

Content: statement of compliance with the order (include specific test results!) Who validate it - the manufacturer inspection (independent of manufacturing department!) + purchasers/official designated authorised inspector

World Centre for Materials Joining Technology


Copyright 2005, TWI Ltd

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