macro practical exercise qa.ppt

Macro TestingMacro Testing

Practical Exercise – PCN WI Level 2Practical Exercise – PCN WI Level 2

2 Photographs taken from original 2 Photographs taken from original MacrosMacros

Assess Accept/Reject in Accordance withAssess Accept/Reject in Accordance with

BS EN ISO 5817:2003 – Table 1 Quality BS EN ISO 5817:2003 – Table 1 Quality Level BLevel B

Macro Sample 1

Macro Sample 1

Slag with Lack of Sidewall Fusion5 x 2 mmReject

Slag Inclusion1 x 0.6 mmAccept

Gas Pore0.5 mmAccept

Sample is Rejected

Undercut0.4 mmAccept

Reject

Angular

Distortion

Macro Sample 2

Macro Sample 2

Slag Inclusion0.5 mmAccept

Elongated Gas Pore or Slag1.6 x 0.5 mmAccept

Elongated Gas Pore or Slag1.4 x 0.4 mmAccept

Cap Height4 mmAccept

Sample is Accepted

Macro Sample 3

Macro Sample 3Porosity 6 x 3 mm = 18 mmLess than 4%Accept

Root Concavity1 mm DeepReject

Undercut0.4 mm DeepAccept

Sample is Rejected

Approx 100°

Angular

Distortion Reject

Macro Sample 4

Macro Sample 4

Incomplete Filled Groove0.7 mm Deep - Reject

Undercut 0.4 mm Deep Accept

Lack of Root FusionReject

Sample is Rejected

Misalignment

1.5mmAccept

Macro Sample 5

Macro Sample 5

Slag Inclusion2.5 x 2 mmReject

Slag Inclusion1.5 x 1 mmAccept

Root UndercutAccept

Sample is Rejected

Angular DistortionReject

Macro Sample 6

Macro Sample 7

Macro Sample 6

Slag Inclusion1.5 x 1 mmAccept

Slag Inclusion1 x 1 mmAccept

Incomplete Filled Groove0.4 mm Deep - Accept

Sample is Accepted

Macro Sample 7

Lack of Root FusionReject

Sample is Rejected

90°

Incorrect Weld ToesReject

90°

Angular Distortion

Accept

Macro Sample 8

Macro Sample 8

Lack of Root PenetrationReject

Sample is Rejected

90°

Incorrect Weld ToeReject Poor Profile (crack starter)

Angular Distortion

Reject

Macro Sample 9

Macro Sample 9

Porosity 7 x 14 mm = 98 mm²26% of Weld AreaMore than 4% - Reject

Total Weld Area15 x 25mm = 375 mm²

Sample is Rejected

Macro Sample 10

Macro Sample 10

Sample is Rejected

CrackReject

Undercut 0.4 mm Deep Accept

Lack of Root Fusion both Sides of Root = Lack of Root Penetration - Reject

Approx.100°

Angular Distortion

Reject

Macro Sample 11

Macro Sample 11

Lack of Root PenetrationReject

Sample is Rejected

Slag Inclusion2.5 x 1 mmReject

Lack of Root PenetrationReject

90°

Incorrect Weld ToeReject

Angular Distortion

Reject

Macro Sample 12

Macro Sample 12

Lack of Root Fusion both Sides of Root = Lack of Root Penetration - Reject

Lack of Sidewall FusionReject

Undercut 0.4 mm Deep Accept

Sample is Rejected

Approx.100°

Incorrect Weld ToeReject

Angular Distortion

Reject

Macro Sample 13

Macro Sample 13

Lack of Root FusionReject

Cap Height4 mmAccept

Slag Inclusion2.5 x 1 mmReject

Misalignment 2mmAccept

Sample is Rejected

Macro Sample 14

Macro Sample 14

Lack of Root Fusionwith Slag 4 x 1 mmReject

Slag Inclusion1.5 x 1 mmAccept

Cap Height5.5 mmReject

Sample is Rejected

Macro Sample 15

Macro Sample 15

Slag Inclusion1.5 x 1 mmAccept

Slag Inclusion1 x 1 mmAccept

CrackReject

Incomplete Filled Groove0.4 mm Deep - Accept

Sample is Rejected

Macro Sample 16

Macro Sample 16

Slag Inclusion1.5 x 1 mmAccept

Porosity 3 x 3 mm = 9 mm²Less than 4%Accept

Incomplete Filled Groove0.4 mm Deep - Accept

Sample is Accepted

Macro Sample 17

Macro Sample 17

CrackReject

Incomplete Filled Groove0.7 mm Deep - Reject

Undercut 0.4 mm Deep Accept

Sample is Rejected

Angular Distortion

Reject

Macro Sample 18

Macro Sample 18

Lack of Sidewall FusionReject

Lack of Inter-run FusionReject

Elongated Gas Pore1.5 x 0.5 mmAccept

Sample is Rejected

Angular Distortion -Accept