Control strategies and inspection methods for welded part

Abstract: Present and future demonstrator designs were used to demonstrate the quality assurance of welds. The NDT methods tested on prototype demonstrator parts are: visual inspection, radius gauges, throat size gauge, liquid-penetrant testing, magnetic particle testing and ultrasonics with pulse echo and phased array. The other methods like eddy current, time of flight diffraction, radiography, impression test, macro test and infrared thermographs are currently being analyzed along with their inspection costs.   The control plans for present and future designs with corresponding present and future NDT methods are suggested to minimize a shift in process. Magnetic particle testing revealed a lack of fusion and cracks for fillet welds, whereas ultrasonic pulse echo and phased array identified an internal lack of fusion, inner pores/slag inclusions on butt welds. Ultrasonic PAUT & TOFD could be used for accurate defect identification and thermography for online identification of lack of penetration, depth of penetration and weld parameters.