Kod Kertas H023-4 / M15 / KP03 Muka surat: 1 drp 5
INSTITUT KEMAHIRAN BELIA NEGARA
KEMENTERIAN BELIA DAN SUKAN MALAYSIA
KERTAS PENERANGAN
KURSUS H-023-4 PEMBANTU JURUTERA KIMPALAN (FABRIKASI)
TAHAP EMPAT (4)
NO DAN TAJUK
MODUL 15: WELDING INSPECTION
07.01 Determine method of inspection, testing & scope of inspection
07.02 Conduct Visual Inspection on materials, consumables, equipment,
workshop facilities & environment.
07.03 Conduct Visual Inspection before, during and after welding.
TUGASAN
07.04 Supervise Non-Destructive testing NDT
07.05 Review welding inspection report & test result.
07.06 Compile inspection report.
Check design, drawing, specification, fabrication materials &
consumable characteristic and evaluate source inspection report by
OBJEKTIF
referring to codes of practices, examine physically and mill certificate so
PENCAPAIAN
that it meets all requirement and welding can be carried out and
complied with the specifications
TAJUK PENGENALAN KEPADA JENIS-JENIS KECACATAN
Kertas penerangan ini akan menjelaskan mengenai:
1. Jenis-jenis kecacatan permukaan.
TUJUAN
2. Jenis-jenis kecacatan dalaman
3. Sebab, kesan dan bagaimana mencegah.
Modul 15-Kertas Penerangan Cawangan Pembangunan Kurikulum 2010(Versi1)
Kod Kertas H023-4 / M15 / KP03 Muka surat: 2 drp 5
PENERANGAN :
PENGENALAN KEPADA JENIS-JENIS KECACATAN DALAM KIMPALAN
This paper describes on-line quality monitoring technique to detect susceptibility of weld defect
formation by using real time monitoring of welding parameters: Arc voltage. Work angle and traveling
angle. SMAW (Shielded metal arc welding process) was selected in this study. This experiment
implemented voltage measurement and angle sensor speed sensor to measure real-time welding
variables. The experimental consisted of a welding variables signal measurement system and data
processing, SMAW of carbon steel ASTM A36 was performed in flat and horizontal fillet welding position.
Welding procedure specification was set to obtain required weld quality. Welding test pieces were done by
group of amateur welders. The results showed that voltage variation outside controlled range can cause
significant amount of spatters and irregular bead shape. For non-uniform and incorrect parameters,
humping bead and irregular bead shape were observed. As well as work angle, at too low or too high
angle caused unequal filet leg size in horizontal fillet position. Exact location of welding defect can be
easily located through on-line monitoring system as soon as weld defect was developed. The proposed
technique can be implemented in real fabrication in term of quality control system to detect susceptibility
of weld defect formation that can be missed during actual visual inspection.
1. Introduction
The SMAW is well known for its versatility because it can be used in both production and repair situations. It
requires no special equipment and can be operated easily in remote locations. It is strictly a manual
welding process. For developing country like Thailand, the manual welding is crucial since the country still
uses a large amount of labor. Nevertheless, the welder skill is one of the major problems in industries. In term
quality control of weld quality is largely depending on extensive weld inspection through various nondestructive
testing (NDT) techniques. However, time and cost become a major limitation in weld inspection. Most of
the works were partially inspected by implementing concept of statistical process. This study proposes on-
line quality monitoring technique to detect susceptibility of weld defect formation by using real time monitoring
of welding parameters: arc voltage, work angle and traveling angle. These welding parameters are essential
variables in welding processes which rely on welder skill. [1], [2]
2. Experimental procedure
The experimental equipment consisted of a signal
measurement system and data processing. Welding
experiment was conducted by using SMAW. Bead-on-plate
was done in flat position. Fillet weld on T-joint was
done in horizontal fillet position. ASTM A 36 and its
matching filler metal of AWS A5.1 E 6013 were
selected in this study. Specimen size was 30x150x9
mm. Welding current was set at 95 A and welding
speed was about 27 cm/min. Stringer bead technique
was used. Figure 1 shows an experimental setup
consisting of welding table, microcontrollers which are incorporate in a control unit for processing signal from
sensors. Then signal was recorded with computer program. The experimental procedure has two phases;
first, the welding data was collected from skill welder for standardize of tolerance limits referred to
international skill standard, ISO 5817. Second phase; testing of amateur welders were perform and all
Modul 15-Kertas Penerangan Cawangan Pembangunan Kurikulum 2010(Versi1)
Kod Kertas H023-4 / M15 / KP03 Muka surat: 3 drp 5
collected welding parameters data were also recorded and analyzed. Samples were also visually
inspected according to ISO 5817.
There are three parts in the system such as input,
processing and output. Input: the input of the
system can be described into voltage, amperage, and
angle. All of them are implemented by using the
sensor and IC converter such as distance sensor
(GP2D12), Clamp meter, A/D converter, and
Accelerometer sensor respectively. Additionally, the
welding table has a rack for carrying a reflective wall for speed measurement and the angle
measurement. Processing: all data detected from sensors and converters is sent to the Microcontroller
MCS 51 with C Programming. Output: The data will send to the Personal Computer via Serial Port then the all
data will be recorded and presented by using the Microsoft Visual Basic as a graphic user interface. Fig.2
Block diagram software system
Fig.2 the software was written in C language with Microcontroller MCS-51 used to control the sensors.
The program was complied to the microcontroller as Hex file. Then all data from the microcontroller will
send to the Visual Basic program on PC computer as a text file via Serial Port. In the Visual Basic, the
program will be written in Basic language and it is used to process data or calculate data with
algorithms such as speed calculation. For the output, the data will be collected as database and present as
a form of Graphic User Interface. Testing Plan: Subjects are assigned to do two positions of welding
such as flat and Tee-Joint. Before welding, subjects must read the Welding Procedure Specification.
Then the computer will record all variables including speed, angle of electrode, and arc length.
3. Results and Discussion
After the collecting signal data for appropriate work piece showed that mean voltage obtained from skill
welder is 29.16 V, and standard deviation is 1.22 V as shown in figure 3. Tolerance limits was considered as
principle of statistic with confidence level of 95 % [3]. Tolerance limits was 25.5 32.82 V. Work angle was
80-90oin flat position and 40-50o for Tee joint. Travel angle was 15-30o. Figure 4 showed an acceptable weld
bead where all weld variables are all in range.
Fig.3 Tolerance limits data for appropriate work piece
Modul 15-Kertas Penerangan Cawangan Pembangunan Kurikulum 2010(Versi1)
Kod Kertas H023-4 / M15 / KP03 Muka surat: 4 drp 5
Fig.4 a work piece in tolerance limits
Fig.5 Comparison between voltage signal and visual bead in amateur welder.
Figure 5 illustrated a comparison between the voltage signal from amateur welder and visual welded
bead results. The picture showed the different sections of
welded bead on plate at the beginning, center, and end. These red
line presents location of welded bead where were out of tolerance
limits and effected welded shape. The location out of tolerance
limits had inappropriate bead shape as shown in cross section.
Then Figure 6 presented a comparison between the voltage
signal of skill welder and its visual welded bead. It can be
noticed that bead position where stable signal within tolerance
had acceptable weld bead shape. The comparisons identified
that an unstable signal where out of tolerance caused
inappropriate welded shape.
Fig.6 Comparison between voltage signal and visual bead in
skill welder.
Figure 7 showed the correct work angle that affects to the outcome of welding. amateur welder, subject did
not know this parameter and he made a mistake. The molten pool is too small and wrong location at
Modul 15-Kertas Penerangan Cawangan Pembangunan Kurikulum 2010(Versi1)
Kod Kertas H023-4 / M15 / KP03 Muka surat: 5 drp 5
section B and C. skill welder, subject controlled the work angle in the range of upper and lower limit
at section A, B,and C. The molten pool is deeper and sound welded.
Fig.7 Comparison of welding amateur welder and skill welder for Tee-joint
4. Conclusion
This paper describes on-line quality monitoring technique to detect susceptibility of weld defect formation
by using real time monitoring of welding parameters: Arc voltage, Work angle and traveling angle.
SMAW was selected in this study. It can be concluded that voltage variation outside controlled range
can cause significant amount of spatters and irregular bead shape. For non-uniform and incorrect
parameters, humping bead and irregular bead shape were observed. As well as work angle, at too low
or too high work angle caused unequal filet leg size in horizontal fillet position. Exact location of
welding defect can be easily located through on-line monitoring system as soon as weld defect was
developed. The proposed technique can be implemented in real fabrication in term of quality control
system to detect susceptibility of weld defect formation that can be missed during actual visual inspection.
5. Reference
[1] P.J Modenesi.,1999, The Influence of Small Variations of Wire Characteristics on Arc Welding Process
Stability, Journal of materials processing Technology, pp.266-232.
[2] Sacks, R.J., 1984, In Essential of Welding, Bennett Publishing Company, Illinois, pp. 1-36, 234-289.
th
[3] Montgomery, D.C., 2001, Design and Analysis of Experiments, 5 ed., John Wiley & sons, New York
Modul 15-Kertas Penerangan Cawangan Pembangunan Kurikulum 2010(Versi1)
