AWS Certified Welding Inspector — Fundamentals flashcards
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GMAW Shielding Gas Flow
Flip cardThe rate at which shielding gas is delivered to the weld zone, critical for protecting the molten metal and arc from atmospheric contamination.
- Protects arc and weld puddle from oxygen and nitrogen.
- Affects arc stability, spatter, and porosity.
- Typical flow rates are 20-50 CFH (0.01-0.02 m³/min).
- Too low: contamination, porosity, unstable arc, spatter.
Memory trick: Gas flow, stickout, voltage, dirt—all mess up the arc.
Electroslag Welding (ESW) Characteristics
Flip cardElectroslag Welding (ESW) is a high-deposition, single-pass welding process used for very thick sections (typically 1/2 inch to 12 inches or more). It employs a molten slag bath to melt the electrode and base metal, resulting in deep penetration, high efficiency, and minimal distortion due to its vertical welding position and concentrated heat.
- Used for very thick sections (>1/2 inch).
- Extremely high deposition rates.
- Single-pass welding process.
- Vertical up welding position.
Memory trick: For 'Thick' and 'Fast', Electroslag is the 'Last' word.
FSW Tool Rotation
Flip cardThe rotating tool in Friction Stir Welding is central to the process, generating heat and mechanically stirring the material to achieve a solid-state weld.
- Generates frictional heat.
- Plasticizes the base metal.
- Mechanically stirs and forges material.
- No melting occurs.
Memory trick: Spinning tool, hot mix, strong bond, no melt.
GTAW Tungsten Contamination
Flip cardTungsten contamination in GTAW occurs when the hot tungsten electrode touches the molten weld pool or filler metal, leading to electrode degradation and weld defects.
- Causes arc instability.
- Electrode tip erodes, discolors, glows green.
- Results in tungsten inclusions (black spots) in weld.
- Prevented by proper technique and electrode maintenance.
Memory trick: Green glow, black spots, tungsten got hot and it lost its plots.
Electroslag Welding (ESW) Limitations
Flip cardESW is a high-deposition process for thick sections but has limitations, especially regarding heat distribution and grain structure for wide joints.
- High heat input leads to coarse grain structure.
- Single electrode struggles with wide gaps.
- Limited to vertical-up position.
- Not suitable for thin materials.
Memory trick: Slag bath needs even heat, or wide gaps mean defeat.
SAW Parameter Adjustment (Reinforcement/Width)
Flip cardAdjusting SAW parameters like travel speed, voltage, and current is critical for controlling weld bead shape, reinforcement, and penetration.
- Travel speed inversely affects reinforcement.
- Voltage affects bead width and profile.
- Current affects penetration and deposition rate.
Memory trick: Fast travel, flat weld; slow travel, tall weld.
GMAW Short-Circuit Limitations
Flip cardShort-circuit transfer in GMAW is a low heat input process with limitations on its use for thicker materials due to insufficient penetration.
- Low heat input, good for thin material.
- Prone to lack of fusion on thick sections.
- Risk of cold lap.
Memory trick: Short circuit on thick plate means a cold, poor fusion state.
RSW Expulsion Control
Flip cardExpulsion (spitting) in Resistance Spot Welding is the forceful ejection of molten metal, often indicating improper weld parameters, primarily excessive current.
- Reduces weld strength and quality.
- Caused by overheating and pressure.
- Galvanized steel is more prone.
Memory trick: Too much current, too much pop, weld strength will drop.
GTAW Tungsten Electrode Selection (DCEN)
Flip cardSelecting the correct tungsten electrode type for DCEN GTAW is crucial for arc stability, current capacity, and preventing contamination.
- DCEN concentrates heat on the workpiece.
- Alloyed tungstens (Th, La, Ce) improve electron emission.
- Pure tungsten is less efficient for DCEN.
Memory trick: DCEN needs doping, pure tungsten is a dud.
PAW Keyhole Mode Control
Flip cardIn Plasma Arc Welding's keyhole mode, the plasma gas flow rate is the primary parameter controlling the stability and penetration depth of the keyhole.
- Plasma gas creates the keyhole by displacing molten metal.
- Too low flow: incomplete penetration, keyhole collapse.
- Too high flow: excessive penetration, burn-through, keyhole instability.
- Critical for consistent, full penetration welds.
Memory trick: Plasma gas is the key to a steady hole; too much or too little, you lose control.
E7018 Electrode Handling
Flip cardE7018 are low-hydrogen SMAW electrodes requiring specific handling, baking, and storage procedures to maintain their moisture resistance and prevent hydrogen-induced cracking.
- Must be kept dry.
- Requires reconditioning (baking) if exposed to atmosphere.
- Stored in heated holding ovens (rod ovens).
Memory trick: Keep E7018 dry, or cracks will cry.
Cast Iron Welding Cracking
Flip cardWelding cast iron is challenging due to its brittleness, high carbon content, and sensitivity to thermal shock, making it highly susceptible to cracking.
- Preheat is essential to reduce thermal shock.
- Slow cooling is critical to minimize residual stress.
- Nickel-based electrodes are used for ductility.
- High carbon content forms brittle martensite in HAZ.
Memory trick: Cast iron is cold and brittle, cool it slow or it will fritter.
GTAW Pure Tungsten with DCEN
Flip cardUsing pure tungsten electrodes (EWP) with DCEN polarity in GTAW is generally not recommended, as it leads to arc instability, electrode melting, and potential weld contamination.
- Pure tungsten (EWP) is best for AC welding (aluminum, magnesium).
- Forms a stable balled end in AC.
- Poor electron emission characteristics on DCEN.
- Melts and contaminates weld pool easily on DCEN.
Memory trick: Pure tungsten on DCEN, an arc that won't stay keen.
SMAW E7024 Electrode
Flip cardAn iron powder, rutile-based electrode for SMAW, known for high deposition rates and a heavy, fluid slag, primarily used in flat and horizontal positions.
- High deposition rate
- Heavy, fluid slag
- Excellent bead appearance
- Limited to flat and horizontal positions
Memory trick: Heavy slag, flat and horizontal, fast weld, no climb.
Nickel Electrodes for Cast Iron
Flip cardNickel-based electrodes are commonly used for welding and repairing cast iron, particularly with SMAW. Their primary advantage is producing a soft, ductile weld deposit that can absorb stresses and accommodate the differential thermal expansion/contraction between the weld metal and the brittle cast iron, thereby minimizing the risk of cracking.
- Cast iron is brittle and prone to cracking.
- Nickel-based electrodes create ductile weld metal.
- Ductility absorbs thermal and contraction stresses.
- Reduces cracking in cast iron welds.
Memory trick: Cast iron is 'Cracky', so 'Nickel' makes it 'Sticky' and soft.
Cast Iron Weldability Challenges
Flip cardCast iron's high carbon content and brittle microstructure make it challenging to weld, prone to cracking in the HAZ due to martensite formation and in the weld metal due to solidification cracking.
- High carbon (2-4%) and silicon content.
- Forms brittle martensite in HAZ upon rapid cooling.
- Low ductility, poor tolerance to stress.
- Graphite flakes act as stress concentrators.
Memory trick: Carbon's high, makes it brittle, preheat and nickel, just a little.
GMAW Shielding Gas Additives (Oxygen)
Flip cardSmall amounts of oxygen added to argon in GMAW primarily enhance arc stability and wetting action for certain materials.
- Typically 1-2% oxygen in argon for stainless steel.
- Improves bead appearance and fusion.
- Helps overcome surface tension of molten metal.
Memory trick: Oxygen's a tiny helper, making arcs stable and welds wet.
RSW Galvanized Steel Challenges
Flip cardResistance Spot Welding (RSW) of galvanized steel is challenging due to the low-melting-point zinc coating, which can cause expulsion, porosity, and undersized nuggets.
- Zinc coating creates interface resistance.
- Zinc melts and vaporizes, causing expulsion.
- Requires higher electrode force to displace zinc.
- Shorter weld times, higher currents often used.
Memory trick: Zinc is tricky, force it out quick, or your nugget will be sick.
E7018 Low-Hydrogen Electrodes
Flip cardE7018 is a type of Shielded Metal Arc Welding (SMAW) electrode classified as 'low-hydrogen.' Its primary characteristic is the ability to deposit weld metal with very low levels of diffusible hydrogen, which is crucial for preventing hydrogen-induced cracking (HIC) in steels, particularly high-strength and heavy-section materials.
- SMAW electrode classification.
- Designated 'low-hydrogen' (suffix H4 or H8).
- Minimizes diffusible hydrogen in weld metal.
- Prevents hydrogen-induced cracking (HIC).
Memory trick: E7018: 'E'lectrode '70'ksi '18' all-position, but 'Low-Hydrogen' is the 'Key' to no cracks.
GTAW AC for Aluminum
Flip cardIn Gas Tungsten Arc Welding (GTAW), Alternating Current (AC) is predominantly used for welding aluminum and its alloys. The key benefit of AC is its cathodic cleaning action during the electrode positive (EP) half-cycle, which effectively removes the tenacious aluminum oxide layer, ensuring a clean and sound weld.
- Aluminum forms a tenacious oxide layer.
- Aluminum oxide has a higher melting point than aluminum.
- AC provides cathodic cleaning action.
- Electrode positive (EP) half-cycle performs cleaning.
Memory trick: DC is for steel and deep, AC is for aluminum and clean.
FCAW-S Stick-out Issues
Flip cardIn Self-Shielded Flux Cored Arc Welding (FCAW-S), proper electrode stick-out is crucial for effective shielding and arc stability. Excessive stick-out can cause defects.
- Excessive stick-out reduces current density.
- Affects flux decomposition and gas shielding.
- Can lead to wormholes and porosity.
- Increases smoke and fumes.
Memory trick: Stick-out too long, shielding's all wrong, smoke and holes will come along.
GTAW Stainless Steel Backing Gas
Flip cardBacking gas, typically argon, is essential in GTAW of stainless steel to protect the root side of the weld from atmospheric contamination and oxidation.
- Prevents 'sugaring' or chromium oxidation.
- Maintains corrosion resistance.
- Requires proper sealing and flow rates.
Memory trick: No back gas, sweet root, sour weld.
FSW Tunnel Defect
Flip cardA tunnel defect (or wormhole) in Friction Stir Welding is an internal void or channel, often appearing as a continuous surface groove, caused by insufficient material flow around the stirring pin.
- Caused by inadequate material flow or consolidation.
- Often linked to incorrect tool geometry, rotational speed, or travel speed.
- Reduces weld strength and fatigue life.
- Can be detected by radiography or ultrasonic testing.
Memory trick: Stirring too slow, a tunnel will show.
Electron Beam Welding (EBW) Applications
Flip cardElectron Beam Welding (EBW) is a high-energy density process used for precise, low-distortion welding of thin-to-thick materials, dissimilar metals, and reactive metals, often in a vacuum.
- High power density, deep penetration, narrow welds.
- Minimal Heat-Affected Zone (HAZ) and distortion.
- Performs in a vacuum, preventing oxidation.
- Excellent for reactive metals (Ti, Zr) and dissimilar metals.
Memory trick: Electron beam's fine, welds metals intertwined, no distortion you'll find.
LBW Porosity in Aluminum
Flip cardPorosity in Laser Beam Welds of aluminum alloys is commonly caused by the presence of tenacious oxide films and dissolved hydrogen, which become entrapped during solidification.
- Aluminum readily forms a high-melting point Al2O3 oxide film.
- Oxide films can trap hydrogen and other gases in the weld pool.
- Hydrogen solubility decreases significantly upon solidification.
- Requires careful surface preparation (cleaning, mechanical removal).
Memory trick: Oxides and hydrogen, a bubbly fusion.
GMAW Short-Circuit Transfer Limitations
Flip cardShort-circuit Gas Metal Arc Welding (GMAW-S) is a low heat input process where the consumable electrode repeatedly contacts the weld puddle, causing a short circuit. Its primary limitation is its suitability for thin materials and susceptibility to lack of fusion on thicker sections due to shallow penetration.
- Low heat input process.
- Electrode repeatedly shorts to the weld puddle.
- Limited to thin materials.
- Prone to lack of fusion on thick sections.
Memory trick: Spray is fast and hot, Globular is messy and big, Short-circuit is cool and thin.
GMAW Shielding Gas Effects
Flip cardThe choice of shielding gas in GMAW significantly impacts arc stability, penetration, spatter, and weld bead characteristics.
- CO2: Deep penetration, more spatter, harsher arc.
- Argon: Stable arc, good for spray transfer, less spatter.
- Argon-CO2 mixtures: Balance of penetration, arc stability, and reduced spatter.
Memory trick: Gas makes the arc smooth or rough, like a calm or stormy sea.
Cast Iron Welding Preheat
Flip cardPreheating cast iron before welding is essential to manage its inherent brittleness and susceptibility to cracking from thermal stresses.
- Reduces thermal gradients.
- Slows cooling rate.
- Allows for hydrogen diffusion.
Memory trick: Preheat makes cast iron less stressed and cracked.
SMAW Arc Length Control
Flip cardArc length in SMAW is the distance between the electrode tip and the weld puddle. Proper control is essential for weld quality.
- Too long an arc can lead to porosity and spatter.
- Too short an arc can cause stubbing and poor fusion.
- Specific electrodes require specific arc length control.
Memory trick: Short arc, strong weld, no hydrogen woe.
SAW High Heat Input Effects
Flip cardIn Submerged Arc Welding, high heat input leads to slower cooling rates, which can coarsen grain structures and reduce mechanical properties, particularly impact toughness.
- Slower cooling rates in HAZ and weld metal.
- Coarsens grain structure (e.g., bainite, ferrite).
- Reduces impact toughness (Charpy V-notch energy).
- Increases residual stress and distortion.
Memory trick: Hot and slow makes it tough to take a blow.
Electron Beam Welding (EBW)
Flip cardElectron Beam Welding (EBW) is a fusion welding process that uses a high-velocity beam of electrons to melt and join materials. It is characterized by extremely deep and narrow welds, a very small heat-affected zone (HAZ), low distortion, and high precision. It typically operates in a vacuum, which helps prevent contamination.
- Uses high-velocity electron beam.
- Produces deep and narrow welds.
- Very small heat-affected zone (HAZ).
- Minimal distortion.
Memory trick: For extreme 'Precision' and 'Narrow' welds, think 'Beam' (Electron or Laser).
GMAW Pulsed-Spray Heat Control
Flip cardPulsed-spray GMAW uses alternating peak and background currents to achieve spray transfer at lower average currents, making it ideal for thin materials and out-of-position welding.
- Peak current for droplet detachment.
- Background current for arc maintenance.
- Pulse frequency controls average current/heat input.
- Ideal for thin materials and aluminum.
Memory trick: Pulses per second, higher the count, lower the heat, like a gentle fountain.
E6010 Electrode Characteristics
Flip cardE6010 is a cellulosic, high-cellulose sodium electrode primarily used for DC+ polarity, known for deep penetration, strong arc, and suitability for root passes and dirty surfaces.
- Deep penetration
- Strong, forceful arc
- Can weld through contaminants
- Excellent for root passes
Memory trick: E6010 digs deep, even when it's messy.
GTAW Stainless Steel Discoloration
Flip cardDiscoloration (heat tint) on stainless steel welds, particularly bluish-purple, indicates oxidation due to inadequate shielding gas protection during welding or cooling.
- Caused by atmospheric oxygen reacting with hot stainless steel.
- Indicates chromium oxidation, reducing corrosion resistance.
- Ranges from straw to blue to black depending on severity.
- Prevented by proper shielding gas coverage (front, back, trailing).
Memory trick: Colors mean oxygen got in, your shield was thin.
FCAW Contact Tip-to-Work Distance (CTWD)
Flip cardThe distance from the contact tip to the workpiece in FCAW, significantly impacting current, arc stability, and weld quality.
- Also known as 'stick-out' in some processes.
- Affects resistance heating of the electrode.
- Crucial for maintaining consistent weld parameters.
Memory trick: Long stick-out, low current, lots of trouble.
GTAW Stainless Steel Purging
Flip cardWhen Gas Tungsten Arc Welding (GTAW) stainless steel, especially for critical applications like tubing, internal purging with an inert gas (e.g., argon) is essential. Its primary purpose is to displace atmospheric oxygen from the inside of the component, thereby preventing oxidation, 'sugaring,' and loss of corrosion resistance on the root side of the weld.
- Stainless steel susceptible to oxidation at high temperatures.
- Internal oxidation is called 'sugaring' or 'carbide precipitation'.
- Purging gas (usually argon) displaces oxygen.
- Protects the root side of the weld.
Memory trick: Stainless needs 'Shielding' 'Inside' and 'Out' to prevent 'Sugaring'.
GTAW Tungsten Electrode Types (AC)
Flip cardDifferent types of tungsten electrodes are alloyed to optimize performance for specific welding currents (AC/DC) and materials, affecting arc stability and electrode life.
- Pure Tungsten (EWP): AC only, balls easily, lower current capacity, prone to spitting.
- Zirconiated Tungsten (EWZr-1): Excellent for AC, very stable arc, resists contamination, good current capacity.
- Thoriated Tungsten (EWTh-2): Primarily DC, high current capacity, good arc start, radioactive.
- Ceriated/Lanthanated Tungsten: DC/AC (non-balled), good for low amps, non-radioactive.
Memory trick: Tungsten's purpose is pure, but AC needs a zircon-cure.
GMAW Pulsed-Spray Heat Input
Flip cardIn pulsed-spray GMAW, the average current is the primary parameter controlling the overall heat input to the workpiece, influencing the total energy delivered over time.
- Average current = (Peak Current * Peak Time + Background Current * Background Time) / Total Pulse Time.
- Higher average current means higher heat input.
- Affects weld penetration, bead size, and HAZ.
- Allows for precise heat control compared to conventional spray.
Memory trick: Average current, like a steady diet, controls the total heat's might.
SAW Heat Input Control
Flip cardHeat input in SAW is critical for controlling microstructure and mechanical properties. It is directly influenced by current, voltage, and travel speed.
- High heat input: Larger HAZ, coarse grain structure, reduced toughness.
- Low heat input: Smaller HAZ, finer grain structure, risk of lack of fusion or cracking.
- Travel speed is a major factor in heat input.
Memory trick: Heat input is the oven, travel speed is the timer; too slow, and it's overcooked.
GMAW Spray Transfer Limitations (Root Pass)
Flip cardGas Metal Arc Welding (GMAW) spray transfer is characterized by high heat input, deep penetration, and high deposition rates. While excellent for fill and cap passes on thick materials, its high heat makes it generally unsuitable for open-root passes, as it can easily lead to burn-through, excessive melt-through, or an overly large and uncontrolled root bead, especially on pipe.
- High heat input transfer mode.
- Deep penetration.
- Continuous stream of molten droplets.
- Unsuitable for open-root passes.
Memory trick: For 'Root' passes, 'Spray' is 'Too Hot', leading to 'Holes'.
Heat Input Calculation (kJ/in)
Flip cardHeat input is a measure of the energy transferred to the workpiece per unit length of weld. It is a critical parameter for controlling microstructure, mechanical properties, and distortion in welding. For arc welding, it's typically calculated using voltage, amperage, and travel speed.
- Formula: HI = (Voltage × Amperage × 60) / (Travel Speed × 1000).
- Units: Volts (V), Amperes (A), Inches per Minute (ipm).
- Resulting unit: Kilojoules per Inch (kJ/in).
- Critical for material properties (e.g., toughness, hardness).
Memory trick: Volts Amps Time over Speed is your Energy per Length.
Confined Space Oxygen Deficiency
Flip cardWelding in a confined space without adequate ventilation can rapidly consume oxygen, leading to an oxygen-deficient atmosphere (below 19.5% oxygen), which can cause dizziness, unconsciousness, and death.
- Welding processes consume oxygen.
- Confined spaces restrict air circulation.
- Symptoms include dizziness, rapid breathing, confusion.
- Atmospheric testing is crucial before entry and continuously during work.
Memory trick: Confined Welding: Fumes, Fire, and Fatal Oxygen Failures.
Nickel-Based Electrodes for Cast Iron
Flip cardNickel-based electrodes are specifically designed for welding cast iron, primarily to improve weld ductility and prevent cracking caused by brittle carbide formation.
- Prevents formation of hard, brittle iron carbides.
- Minimizes differences in thermal expansion between weld and base metal.
- Results in more ductile welds, reducing crack susceptibility.
Memory trick: Cast iron's brittle nature makes welding a delicate dance, cracking the unwary.
GMAW 100% Argon on Carbon Steel
Flip cardUsing 100% Argon shielding gas for GMAW of carbon steel results in an unstable arc, poor bead shape (ropy/humped), excessive undercut, and poor wetting.
- Argon is an inert gas.
- Suitable for aluminum and some stainless steels.
- On carbon steel, it leads to an unstable arc.
- Causes poor wetting, humped beads, and undercut.
Memory trick: Carbon steel needs a kick; pure argon leaves it sick.
Arc Flash Eye Protection
Flip cardSpecialized eye protection, such as welding helmets or goggles with appropriate filter shades, is essential to protect against the harmful ultraviolet (UV), infrared (IR), and intense visible light radiation produced by arc welding processes.
- UV radiation causes 'arc eye' or 'welder's flash'.
- IR radiation can cause retinal burns and cataracts.
- Visible light intensity requires filtration to prevent temporary blindness and eye strain.
- Standard safety glasses are insufficient for arc welding.
Memory trick: UV, IR, and Bright Light: Arc welding's eye-damaging trinity.
GMAW High Shielding Gas Flow
Flip cardAn excessively high shielding gas flow rate in GMAW leads to turbulent gas flow, drawing in atmospheric contaminants, which results in porosity, spatter, and unstable arc.
- Causes turbulence around the weld pool.
- Entrains atmospheric air (oxygen, nitrogen).
- Leads to porosity, spatter, and arc instability.
- Wastes shielding gas.
Memory trick: Shielding gas flow is a delicate balance; too much turbulence can ruin everything.
Hot Work Fire Watch Distance
Flip cardAccording to NFPA 51B, a fire watch is required when hot work is performed within 35 feet (10.7 meters) of combustible materials, or if combustibles are adjacent to partitions, walls, or ceilings that can conduct heat.
- 35 feet is the minimum radius for fire watch initiation.
- Combustibles must be removed or protected if within this distance.
- Fire watch personnel monitor for fires during and for a period after hot work.
- NFPA 51B is the governing standard for hot work fire prevention.
Memory trick: Hot Work's 35-Foot Rule: Clear the zone or get a fire watch to zone in!
Heat Input Calculation (SAW)
Flip cardHeat input for welding processes like SAW is a measure of the energy transferred to the workpiece per unit length of weld, calculated as (Voltage × Amperage × 60) / (Travel Speed × 1000) in kJ/inch.
- Expressed in kJ/inch or kJ/mm.
- Directly affects metallurgical properties like grain size and toughness.
- High heat input can lead to coarse grain structure and reduced toughness.
- Low heat input can lead to lack of fusion or cracking.
Memory trick: Heat input: Voltage, Amperage, Travel Speed – the V.A.T. of weld energy.
PAW Orifice Gas Flow (Low)
Flip cardInsufficient orifice gas flow in Plasma Arc Welding (PAW) leads to a less constricted arc, reducing energy density, penetration, and making keyhole formation difficult.
- Orifice gas constricts the arc through a small nozzle opening.
- Constriction increases arc temperature and velocity.
- Low flow reduces constriction, leading to a wider, less focused arc.
- Results in lower energy density and shallower penetration.
Memory trick: Plasma's power comes from a tight squeeze; too little gas, and the arc loses its ease.
Compressed Gas Cylinder Securing
Flip cardCompressed gas cylinders must always be secured in an upright position with chains, straps, or other approved methods to prevent them from falling over, which can lead to valve damage and uncontrolled gas release.
- Falling cylinders can become dangerous projectiles.
- Valve damage can cause rapid gas release.
- Securing prevents property damage and serious injury.
- Chains or straps are common securing methods.
Memory trick: Secure Your Cylinder: Don't let it fall or it'll fly!
EWTh-2 (Thoriated) Tungsten with DCEN
Flip cardThoriated tungsten electrodes (EWTh-2) used with DCEN provide high electron emission, superior current carrying capacity, and excellent arc stability, typically with a pointed tip, making them suitable for welding steels and stainless steels.
- High electron emission.
- Higher current carrying capacity than pure tungsten.
- Excellent arc stability.
- Typically ground to a pointed tip for DCEN.
Memory trick: GTAW electrodes are like specific tools, each with a unique power and purpose.
GTAW Stainless Steel Heat Tint
Flip cardHeat tint (blue-to-purple discoloration) on GTAW stainless steel indicates excessive oxidation due to inadequate shielding or high heat input, leading to reduced corrosion resistance.
- Caused by exposure of hot stainless steel to oxygen.
- Results in a surface oxide layer (chromium oxides).
- Depletes chromium from the underlying metal, reducing corrosion resistance.
- Color ranges from straw (minimal) to blue, purple, gray (severe).
Memory trick: Stainless's shine depends on shielding; blue means corrosion's beginning.
Steel Microstructure and Toughness
Flip cardThe internal crystalline structure of steel, composed of various phases (e.g., ferrite, pearlite, bainite, martensite), which significantly dictates its mechanical properties, particularly toughness and resistance to brittle fracture.
- Toughness is critical for low-temperature and impact applications.
- Fine, equiaxed grains generally improve toughness.
- Tempered martensite offers excellent strength and toughness.
- Coarse microstructures (e.g., coarse bainite, coarse pearlite) and large, brittle carbides reduce toughness.
Memory trick: Coarse bainite breaks tough steel at cold temps.
Single-Bevel Groove Weld
Flip cardA groove weld where only one of the joint members is prepared with a single bevel.
- Symbol below reference line = arrow side member beveled.
- Symbol above reference line = other side member beveled.
- Bevel symbol orientation indicates which plate is beveled.
Memory trick: Bevels point the way to the prepared plate.
Carburizing
Flip cardA case hardening heat treatment process where carbon is diffused into the surface of a low-carbon steel component to increase its surface carbon content, allowing for subsequent hardening of the surface while retaining a ductile core.
- Increases surface hardness and wear resistance.
- Maintains a tough, ductile core.
- Requires a carbon-rich atmosphere at elevated temperatures.
- Typically followed by quenching and tempering to harden the case.
Memory trick: Carburizing 'C'reates a 'C'ase for 'C'ore ductility.
PWHT for Cr-Mo Steels
Flip cardPost-weld heat treatment (PWHT) applied to Chromium-Molybdenum (Cr-Mo) steels, typically involving heating to a specific temperature and holding, to mitigate adverse metallurgical effects of welding.
- Primarily reduces welding-induced residual stresses.
- Tempering of hard, brittle microstructures (e.g., martensite) in HAZ and weld metal.
- Improves ductility and toughness, reducing risk of brittle fracture.
- Essential for high-temperature service to prevent creep and stress corrosion cracking.
Memory trick: PWHT: Peace, Warmth, Harmony for Welds.
Field Weld Symbol
Flip cardA supplementary symbol, a circle at the junction of the reference line and the arrow, indicating that a weld is to be made at the place of final erection or assembly, not in the shop.
- Circle at arrow/reference line junction.
- Indicates on-site welding.
- Distinguishes from shop welds.
Memory trick: Supplementary symbols add extra instructions, like a field trip.
Weld Repair Documentation
Flip cardThorough documentation of weld repairs must confirm that the original defect was completely removed, that the repair welding was performed to a qualified procedure, and that the repaired area was subsequently re-inspected and found acceptable.
- Ensures defect eradication before re-welding.
- Verifies quality of the repair itself.
- Critical for traceability and structural integrity.
Memory trick: Defect gone, repair done, quality won.
Quenching and Tempering
Flip cardA heat treatment process involving rapid cooling (quenching) followed by reheating to an intermediate temperature (tempering) to improve hardness, strength, and especially toughness and ductility.
- Quenching forms martensite, a hard but brittle structure.
- Tempering reduces martensite's brittleness by forming fine carbides.
- Results in an optimal balance of strength, hardness, and toughness.
- Crucial for steels used in low-temperature or high-impact applications.
Memory trick: Cold steel needs a QuT (Cut) to be tough.
Groove Weld Depth of Preparation
Flip cardFor groove welds, especially partial penetration, the depth of the weld preparation is indicated by a dimension placed to the left of the groove weld symbol.
- Located to the left of the weld symbol.
- Specifies the depth of the groove.
- Critical for partial penetration welds.
Memory trick: Depth on the left, root below, angle inside, watch it grow.