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Weld_Inspection_Checklist.pdf

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WELD_INSPECTION_CHECKLIST
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Defect Type Defect Description/ Visual Appearance Was this type of Defect Found during the Audit? # of Defects Found or Total Defective Length of Weld in (in/mm) Sketch/Photo Typical Causes NCO's Cracks (Longitudinal or Transverse) Cracks are defined as fracture-type discontinuies characterized by a sharp tip and high ratio of length and width displacement. They can occur in weld metal or heat affected zone (HAZ) Current Too High. Travel Speed too Low. Combination of high current and low travel speed Crater Cracks Occur in the crater of the weld when welding in improperly terminated. Crater Cracks are found in the starts or stops of the weld metal Improper Electrode manipulation. Improper parameter tapering at the weld stop Unconsumed Weld Wire Weld Wire sticking out of the weld metal poor workmanship Incomplete Fusion Failure of the weld metal to fuse completely at some portion of the weld zone or adjacent base metal. This includes incomplete fusion of consumable inserts Improper weld joint preparation. Improper electrode manipulation. Current too low. Travel speed too high Incomplete Joint Penetration A joint root condition in a groove weld in which weld metal does not extend through the joint thickness Improper weld joint preparation. Improper electrode manipulation. Current too low. Voltage too high. Travel speed too high Irregular bead profile Underfill, valleys, sharp notches at root face, undercuts and surface ripples See Figure #1 below Poor weld bead spacing. Poor wettability due to incorrect weld parameters, such as low voltage or high travel speed WELD INSPECTION CHECK LIST Note: SQE must review the GE Acceptance Criteria for the part while filling out this Inspection ChecklistOverlap (Roll Over/Cold Roll) The protrusion of weld metal beyond the weld toe or weld root Travel speed too slow. Welding electrodes too large for the parameters or position Slag Inclusion A discontinuity consisting of slag entrapped in weld metal or at the weld interface Welds in joint too narrow a joint angle or initial joint gap. In multipass welds, improper bead spacing can result in a valley , between beads with too narrow a gap or side walls with too narrow a joint angle Surface Porosity Gas bubbles frozen in the solidified weld metal Typically caused by contamination on the base metal or filler metal. Too high a weld travel speed, loss of shielding, arc length too long Undercut Is a groove melted into the base metal adjacent to the weld toe or weld root and left unfilled by weld metals Current too high. Voltage too high. Travel speed too high. Combination of these variables Underfill Is a condition in which the weld face or root surface of a groove weld extends below the adjacent surface of the base metal Travel speed to high. Poor electrode manipulation. Current too low Spatter Globular drops of weld metal that are deposited on the weld or base material during welding, which do not form part of the weld Arc Blow. Incorrect parameters such as current too high, voltage to high or both. Excessive weld Reinforcement In groove welds, weld reinforcement is weld metal in excess of the quantity required to fill a joint Welder applied more weld metal then what was required Fillet Weld Leg is Undersized Weld leg is not the correct height or width , not in complaince with drawing, or weld legs are unequal Welder did not apply enough weld metal per the requirement Fillet Welds too Convex Weld is convex in nature has overfill or excessive weld appearance Welder applied more weld metal then what was required Fillet Welds too Concave Weld is concave in nature has sunken in or underfill weld appearance Welder did not apply enough weld metal per the requirement 0 MLI #:_______ Figure #1 SQE NAME: _________________________________ DATE:__________ GE PO #: _____________ UNIT # _____ SUPPLIER NAME: _______________________________ Total Number of Defects
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