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Destructive Weld Testing

1/3/2023

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Machinery, automobiles, aircraft, and office/residential buildings all require welding to help society function with safety and ease. While many activities have a margin for error, welding is not one of them. Just imagine the devastating consequences of poor welding on a nuclear power plant!
Thankfully, the welding industry has various means to test the strength of welds before they are used in production. There are destructive tests which involve physically destroying a completed weld to assess its infrastructure; and non-destructive tests, which check for defects and discontinuities without causing damage to the part.
Understanding the different testing methods and what each evaluates gives your quality control team options for ensuring your weld is fit for service. Whether used for failure analysis, welder performance qualification, or sample or research inspections, destructive weld tests detect crack initiation and other defects before it's too late. ​
Fillet Weld Break Test
​

As its name suggests, fillet weld break tests involve breaking a fillet weld that is fused on only one side. The test is most often conducted on a 6 to 12-inch section.
 
The break (destruction) occurs by using a press to apply weight to the unwelded side until the weld fails. The sample is then examined for flaws.

This test is typically used to check for the following defects:
 
·      Slag inclusions
·      Internal porosity
·      Lack of fusion
·      Linear fusion defects
 
Because it reveals discontinuities within the length of the weld, the fillet weld break test is the way to go to determine the EXTENT of a weld’s defects.
Guided Bend Test
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Once again, this test keeps to its name. A welding specimen is bent to a predetermined radius along a wraparound bend test jig or another test machine. Welders can conduct both face and root bend tests using this method, using side bends to assess thicker sections.

Guided bend tests are particularly adept at assessing:

·      Ductility
·      The soundness of welded joints
·      Linear fusion defects

This is also the most commonly used assessment in welder performance qualification tests.

Macro Etch Testing

Macro etch testing is a highly successful test that removes small samples from the welded joint. The samples are polished at their cross sections before a mild acid mixture (which varies depending upon the base material) is used to etch the joint. The etching, with particular focus on the fusion line, provides insights into the internal structure of the weld.

Characteristics that this test appraises are:

·      Fusion (or lack thereof)
·      Penetration depth
·      Cracking and inclusions
·      Internal porosity

To understand the OVERALL weld-length quality of production welds at the cross-section, use the macro etch testing method. 
Traverse Tension Test

The traverse tension test is used to evaluate a welded joint’s tensile properties. The test is conducted by exerting pulling forces on specimens until the joint fails. Welders then divide the maximum load required during testing by the cross-sectional area to read the units of tension per cross-sectional area.

Because tensile properties of welds (which involve ductility and soundness) are vitally important to manufacturing designs, this test is one of the most crucial to the industry.
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Teach to the Test?

In many industries, the concept of “teaching to the test” is generally frowned upon. The thought is that teaching skills exclusively to achieve certain test scores restricts a student’s capacity for creativity and real-world scenarios. However, when it comes to welding, meeting the criteria of the welding code for your application can mean the difference between life and death for customers. 

From its pervasive role in everything from transportation and housing to tools and technology, welding is an integral part of modern society. It is the welding industry’s responsibility to ensure that welded products maintain the integrity to perform their intended tasks.

If you need destructive or non-destructive weld testing, give the Earlbeck Technical Center team a call at (410) 687-8400 and we will help you select and implement the correct test for your product's service. 

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weld discontinuities

9/8/2022

1 Comment

 
We've compiled a list of the most common weld discontinuities and how to correct them. A discontinuity is a flaw in the weld, but they are only considered to be weld defects when they exceed the limit allowed by the welding code. Learn more about welding codes here. Each code determines the extent of the discontinuity before it is classified as a defect and must be repaired. 

For example, if a welding code acceptance criteria allows for undercut up to 1/32" deep and the welding inspector measures undercut that is 1/16" deep, then that weld is rejectable. If the undercut measured was 1/32" or less, then the weld is acceptable. 

All defects are discontinuities, but not all discontinuities are defects. Understanding this forms the key to the proper analysis of any weld performed in accordance with the requirements of a welding code or specification. 

Porosity

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​

Porosity is a cavity-type discontinuity caused by trapped gas in the weld during the solidification of the weld metal. 

Possible Causes
Long Arc Length
Dirty Base Metal
Inadequate Gas Coverage

Possible Cures
Use Proper Arc Length
Clean Base Metal
Check for Proper Gas Coverage

Undercut

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​

Undercut is a groove melted into the base metal adjacent to the weld toe or weld root and left unfilled by weld metal.

​Possible Causes

Improper Welding Technique
Excessive Voltage
​Too low wire feed speed

Possible Cures
Reduce Arc Length
Reduce Travel Speed
Use Proper Electrode Angle

Incomplete Fusion

Picture
Incomplete fusion is a weld discontinuity in which fusion didn't occur between the weld metal and the fusion faces or the adjoining weld beads.

​Possible Causes
“Cold” Welding Procedures
Travel Speed Too Slow
Travel Speed Too Fast

Possible Cures
Increase Current
Use Proper Travel Speed

Incomplete Joint Penetration

Picture
Incomplete joint penetration is a joint root condition in a groove weld in which weld metal does not extend through the joint thickness.

​Possible Causes

“Cold” Welding Procedures

Travel Speed Too Slow
Travel Speed Too Fast
Improper Joint Detail

Possible Cures
Increase Current
Use Proper Travel Speed

Excessive Reinforcement 

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Excessive reinforcement is a discontinunity caused by the weld being too big or has too much build up.

​Possible Causes

Travel Speed Too Slow
​“Cold” Welding Procedures
​

Possible Cures
Increase Travel Speed
​Increase Current 

underfill

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Underfill is a groove weld condition in which the weld face or root surface is below the adjacent surface of the base metal.

​Possible Causes

Insufficient Weld Metal
​

Possible Cures
Reduce Travel Speed 

Concave Root Surface (Suck-back) 

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Concave root surface is a groove weld exhibiting underfill at the root surface.

Possible Causes

Too Much Current
Arc Length Too Long
Root Face Too Small
​

Possible Cures
Reduce Current
Maintain Proper Arc Length
Use Proper Joint Fitup 
​

Overlap

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Overlap is extra filler metal that spreads out beyond the weld bead.

Possible Causes

Travel Speed Too Slow

Possible Cures
Use Proper Travel Speed​

Arc Strikes 

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​

Arc strike is considered a weld discontinuity resulting from an arc.

​Possible Causes

Improper Welding Technique
​

Possible Cures
Initiate Arc Inside the Weld Joint 

Slag Inclusions

Picture
​

Slag inclusions are a weld discontinuity consisting of slag entrapped in weld metal or at the weld interface.

Possible Causes
Improper Welding Technique
​

Possible Cures
Use Correct Welding Technique
​Clean Weld Between Passes

Earlbeck Technical Center

Still need some help? The Earlbeck Technical Center offers welder training and weld testing services in the Mid-Atlantic Area. Not only do we conduct testing services to any code, but we provide training to ensure you are ready to take your certification test. Click here to learn more. 

1 Comment

Maryland Bridge Welder Certification

3/29/2016

4 Comments

 
Bridge Construction
In March 2004, the Maryland State Highway Administration (MDOT SHA) discontinued the testing of welders at their facility and adopted a regional welder certification program in conjunction with the Federal Highway Administration's Mid-Atlantic Structural Committee for Economic Fabrication (SCEF).

Welders must certify at an AWS Accredited Test Facility (ATF), in order to perform D1.5 Bridge Welding Code work on highway projects in the Mid-Atlantic region, including the State of Maryland. Welders needing certification for bridge welding must contact an ATF center and request to be tested in accordance with D1.5 Bridge Welding. This certification will be accepted by the following States Department of Transportation (DOT): Maryland, Delaware, Virginia, West Virginia, Washington D.C. and Pennsylvania. 
​
Earlbeck Gases & Technologies is Maryland's first ATF center, and can test you in accordance with the bridge welder certification requirements. 

Register to take the md bridge welding certification
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AWS Accredited Test Facility (ATF) Program

3/29/2016

30 Comments

 
Welder at ATF Center
Most welding codes require that each manufacturer or contractor certify their own welders. This means a welding test taken for XYZ Company cannot be transferred to another company if you change employment.  So, if XYZ Company had you take a test to become certified for the work you were doing there, it is not at all valid under another company. You will have to start the certification process from scratch at a new employer. The American Welding Society (AWS) has established a program to help with this requirement in some industries.

Under this program, referred to as the Accredited Test Facility (or ATF) program. This program establishes high standards for test facilities, their personnel, and equipment to qualify for accreditation to test and qualify welders. Once you successfully pass a certification test at an ATF center, you will receive a card from AWS which can be taken to any employer without having to recertify. You will be also listed in the National Registry of Welders, where potential employers can search to find certified welders in their area.


On April 27, 2009, the Earlbeck Technical Center was awarded accreditation as an AWS Accredited Test Facility. 

Schedule an ATF Test in md
30 Comments

Does a Welding Certification Expire?

3/18/2016

25 Comments

 
Welding Fillet Weld
If you are an AWS Certified welder and your test was done through an AWS Accredited Test Facility (ATF) you will need to renew your certification regularly with AWS to keep them current. The back of your AWS card lists the certifications you are qualified in and the expiration date for each. Certifications in accordance with Supplement C or D9.1 for the Sheet Metal Welding Code require maintenance every 12 months. Certifications in accordance with D1.1 and all other codes require maintenance every 6 months.  The cost for renewal is $15.00. You must also keep an auditable record of welding activity within every 6 month period. 
If you are an AWS Certified Welder in need of renewing your certification, download the form below, fill out and send in by the expiration date to properly maintain your certification.
maintenance of welder certification form
If you did not take your test through an ATF center, or elected not to take the ATF upgrade, you will not need to submit maintenance forms. However, you still must keep an auditable record of welding activity within every 6 month period. 

Not sure if you took an ATF test? An easy way to check is if you received a wallet card from AWS . If necessary, call the center that you tested with to verify. 
25 Comments

What Welding Certification Do I Need?

3/18/2016

67 Comments

 
Picture
If you need to take a welding certification test, you might be wondering which test do I take? This is the big question. There is not a single welding certification test that will certify you to weld everything. Most welding certification tests are done under the codes written by AWS (the American Welding Society) or ASME (American Society of Mechanical Engineers.) There is a specific code written for virtually every application of welding- AWS has published 240 codes alone. Knowing which code to be certified to is essential, as welders are only certified to weld within the code parameters of the test they have taken.
​
There are two common scenarios in which someone will seek certification- you would like to add to your credentials, or it is required for a specific job.

If you would like to get a certification to add to your credentials, you should seek a certification that would cover you for the type of welding you most frequently use. You will need to know what welding process (Stick, TIG or MIG), material types and thickness, and what positions you will use in production. 

One of the most common welding codes is AWS D1.1, which covers structural steel welding like I-beams, channel, or a handrail. If you test and pass on a 3/8" thick plate, using a single vee groove with backing in the vertical position, you would then be qualified to weld in the flat, horizontal and vertical positions on 1/8"-3/4" thick steel members. The test is also offered in 1" thick plate which would also cover all positions, but with no limits on the plate thickness.

If you are welding pipe that is being used to contain fluid or gas, such as a high pressure water line, then ASME Section IX is probably the way to go. If you test and pass on a 5" Schedule 80 (3/8" thick wall) steel pipe in the 6G (45 degree incline position), you will be qualified to weld 2.875" OD pipe, 3/4" wall thickness and less, in all positions.
​
If neither AWS D1.1, nor ASME Section IX would cover the work you most commonly do, it is best to speak to a welding engineer or CWI to help with your selection. 

If you are seeking certification for a specific job, check the blueprints or project documents to see if a specific code is referenced and if there is not, please consult with the customer to determine which code they intend for you to use.

Once you have identified the code you will be working to, you will need to determine if you need to have a Welding Procedure Specification (WPS) written for you. All code work requires written welding procedures. A WPS is essentially the recipe for a weld. It documents the combination of variables that are to be used in production such as welding process, base material, travel speed, position, etc. Once the WPS is written, it will need to be tested to ensure that these variables are being combined to make a sound weld. The next step is to test each welder that will be welding in production using the parameters in the WPS. To go back to the recipe analogy, this is like a team of chefs being individually quizzed on their ability to follow through a recipe. 

Some codes have "pre-qualified" procedures, meaning they already have the recipe written for you, using known variables that have a long history of producing quality welds. Because of this, it bypasses the requirement for the WPS to be tested. However, it does not bypass the requirement for each welder to be individually tested following the WPS. Testing is still required for the WPS if any variables are changed from the accepted pre-qualified procedures.


If you need help selecting the applicable code and certification test, or need to have a procedure written, it is recommended to work with a welding engineer. Please give us a call for any questions you may still have, we have a team of engineers and CWI's that can assist you with any problems you face. 

67 Comments

How do I Become a Certified Welder?

3/18/2016

1 Comment

 
Weld Examination
Unlike the plumbing or electrical crafts, welding certification is not a "license". There is not a single welding certification test that will certify you to weld everything. In order to become a certified welder, you need to take a welding test to a specific code. This test is a practical exam that explores your ability to make sound welds. There is no written test for any commonly used code.*

In the US, most organizations accept and operate under the codes written by AWS (the American Welding Society). The first step is to identify which welding code to be certified to, as welders are only certified to weld within the code parameters of the test they have taken. For more information on how to select a welding code to test to, please visit our other blog article, What Welding Certification Do I Need?

AWS has accredited test facilities (commonly known as ATFs) throughout the US, where a welder certification test can be taken. For more information on the ATF program, as well as where to find one in your area, please visit AWS's website-AWS ATF Program. Earlbeck Gases & Technologies operates Maryland's only ATF center.

A certification test can also be administered at a test center that is not accredited by AWS, however, they do not have the ability to issue AWS certified welder ID cards and your certifications will not be listed under the national AWS certified welder registry. These certifications done by non-ATF facilities are still valid under audit, however they are not portable between employers.
​
Once you have selected your testing center, call to set up an appointment. When you arrive, they will give you instructions on the fit-up required for your test. Once the piece is in position and welding begins, it must remain in that position until completed. This includes grinding. Though none of the Codes impose a time limit on the welding of a test piece, most qualification tests can be completed by a skilled welder in less than 4 hours. When completed, the weld will be visually inspected as well as bend tested. If the test passes, you will receive your certification for that code.

* No AWS or ASME code requires a written exam for welder certification. The only commonly used code that does is the Department of Denfense's military publication NAVSEA S9074-AQ-QIB-010/248 which is typically used for welding machinery on military shops.


1 Comment

Why Become a Certified Welder?

3/18/2016

29 Comments

 
Weld Testing
Though you can work as a professional welder without ever becoming certified, there are quite a few reasons to become a certified welder. There is no single certification that certifies a welder for all process, metals or positions. However, even having one certification can expand opportunities for the welder.
By becoming a certified welder, you will open more career opportunities. Certified welders are in demand in a variety of industries, including construction, manufacturing, automotive, aerospace, and more. 
Many employers will hire certified welders because it is a tangible record of skill. Certification is a great way to demonstrate the welders level of training and experience while job hunting. A certified welder is also more appealing to an employer because statistics have shown that those that are certified have a lower rate of on the job incidents and injuries in comparison to non certified welders. 
Once you've acquired a job, you will be able to command a higher rate of pay. Bureau of Labor statistics indicate a certified welder can earn up to 60% more than non certified welders. You will also have better job security. When companies reduce their welding staff, they're more likely to retain a certified welder because their certification makes them harder to replace in the future. 

Most importantly, a certification may be required if it is called out in a contract or project blueprints. If this is the case, it is imperative that the welder doing the work is certified to the correct code specified. If awarded a project, make sure you have read all requirements and you are in compliance with the requirements. 
​
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Baltimore, MD

​8204 Pulaski Hwy
Baltimore, MD 21237

​
Welding Supply & Gas Showroom
Hours: Mon- Fri 7:30 AM - 5PM
Phone: (410) 687-8400
Fax: (410) 687-1394

Welder Training & Testing Center
Phone: (410) 687-8400

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Beltsville, MD

10792 Tucker St
Beltsville, MD 20705
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Welding Supply & Gas Showroom
Hours: Mon-Fri  7:30AM - 4:30PM
Phone: (301) 937-8884
​Fax: (301) 937-1811

The College of Southern Maryland's Center for Trades and Energy  Training 
6170 Hughesville Station Place
​Hughesville, MD 20637

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Welder Training & Testing Center
​Phone: (410) 687-8400

York, PA

​95 Aberdeen Rd
York, PA 17406

Welding Supply & Gas Showroom
Hours: Mon-Fri  7:30AM - 4:30PM
Phone: (717) 916-6611
​Fax: (717) 764-1281

Welder Training & Testing Center
​
Phone: (410) 687-8400

AACC Clauson Center for Innovation and Skilled Trades

101 College Parkway
Arnold, MD 21012

​Welder Training & Testing Center
​Phone: (410) 687-8400
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Scranton, PA

4961 Birney Ave
Scranton, PA 18507

Welding Supply & Gas Showroom
Hours: Mon-Fri 7:30AM - 5:00PM
Phone: (570) 457-8954

Scranton, PA at Johnson College
3427 N Main Ave
Scranton, PA 18508

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Welder Training & Testing Center
​Phone: (410) 687-8400

  • Products & Services
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