Annex B
II - Part 3 GL 2000
Imperfections in Welded Joints in Aluminium
Chapter 2 Page B–1
Annex B Imperfections in Welded Joints in Aluminium Limits for imperfections in welded joints in aluminium (alloys) in accordance with the international standards EN 30042 / ISO 10042 (repoduced with the kind permission of the Deutsches Institut für Normung (DIN) e.V. Berlin [German Standards Institute ] Amendments or additions to the standards are shaded in grey. No.
Description of imperfections
Ref. No. in acc. with ISO 6520
Remarks
Limit for imperfections for quality levels low
medium
high
D
C
B
1
Cracks
100
All types of cracks except micro cracks (h × 1 < 1mm2), crater cracks, see No. 2
2
End crater crack
104
3
Gas inclusion
201
4
Pore
2011
5
Porosity
2012
6
Cluster of pores
2013
d £ 0,5 s + d £ 0,5 s + d £ 0,5 s + 0,05 s or 0,035 s or 0,02 s or 0,02 a 0,035 a 0,05 a max. max. max. 2 mm 1.5 mm 3 mm
7
Surface pore
2017
per 100 mm length:
not permitted h £ 0,2 s or 0,2 a
not permitted
The term "gas inclusion" encompasses per 100 mm length: porosity, cluster of pores and pores. The entire A £ 8 s or A £ 4 s or A £ 2 s or pore area within a cluster should be included: 8 a mm2 4 a mm2 2 a mm2 an envelope curve that encompasses all the pores or a circle with a diameter that matches d £ 0,5 s or d £ 0,3 s or d £ 0,25 s or 0,5 a mm2 0,3 a mm2 0,25 a mm2 that of the width of the weld. max. max. max. The permitted pore area should be localized. 5,5 mm 4,5 mm 3,5 mm The possibility that other irregularities are concealed should be allowed for. d £ 0,5 s + d £ 0,5 s + d £ 0,5 s + 0,035 s or 0,02 s or 0,01 s or 0,035 a 0,02 a 0,01 a max. max. max. 1 mm 2 mm 1,5 mm
A £ 2 t mm2 A £ 1 t mm2 A £ 0,5 t mm2 d £ 0,5 mm + d £ 0,5 mm+ d £ 0,5 mm +
0,035 s or 0,035 a max. 2 mm
8
9
Solid inclusions (other than copper and tungsten)
Tungsten inclusions
300
3041
Solid inclusions include oxide inclusions. If several inclusions h1, h2, h3 ... are present in a section, the sum is Sh = h1+ h2 + h3 ...
Copper inclusions
0,01 s or 0,01 a max. 1 mm
Long irregularities: not permitted Short irregularities: S h £ 0,1 s or 0,1 a max. max. 3 mm 1,5 mm
not permitted
h £ 0,1 s or 0,1 a
h £ 0,05 s or 0,05 a max. 0,8 mm
max. 3 mm 10
0,02 s or 0,02 a max. 1,5 mm
max. 1,5 mm
3042 not permitted
Chapter 2 Page B–2
No. 11
Annex B
Description of imperfections Lack of fusion
Imperfections in Welded Joints in Aluminium
Ref. No. in acc. with ISO 6520 401
II - Part 3 GL 2000
Limit for imperfections for quality levels
Remarks Where there are several instances of lack of fusion h1, h2, h3 ... the sum is S h = h1 + h2 + h3 ...
low
medium
high
D
C
B
Long irregularities: not permitted Short irregularities: not S h £ 0,1 s or 0,1 a permitted max. max. 3 mm
12
Incomplete penetration
402
Specified penetration Actual penetration
1,5 mm
A small number permitted, but not a regular occurrence h £ 0,4 s max. 3 mm
h
h £ 0,2 s max. 2 mm
s
not permitted
t
s
h
Fig. A
Specified penetration Actual penetration Fig. B Actual penetration Specified penetration
Fig. C Imcomplete penetration (fillet welds)
-
Long irregularities: not permitted Short irregularities:
a
12.1
h -
An excessive or inadequate gap between the components being joined.
a
Poor fit-up, fillet welds
h
13
Gaps exceeding the relevant limit may be compensated by a correspondingly larger throat thickness
h £ 0,3 a max. 2 mm
h £ 0,2 a max. 1,5 mm
h £ 0,1 a max. 1 mm
h £ 1mm h £ 0,5 mm h £ 0,5 mm + 0,2 a, + 0,15 a, + 0,1 a, max. max. max. 4 mm 3 mm 2 mm
No. 14
Annex B
Description of imperfections Undercut
Imperfections in Welded Joints in Aluminium
Ref. No. in acc. with ISO 6520 5011 5012
Chapter 2 Page B–3
Limit for imperfections for quality levels
Remarks Smooth transition is required.
h
II - Part 3 GL 2000
low
medium
high
D
C
B
Long irregularities: h £ 0,6 mm h £ 0,4 mm h £ 0,2 mm Short irregularities:
15
Excessive weld reinforcement
502
16
Excessive convexity
503
Smooth transition is required. b
h
h
h £ 1,5 mm h £ 1 mm h £ 0,5 mm Long and short irregularities: Not more than 10 % of the plate thickness in the case of undercuts vertical to the main direction of load
Actual weld thickness
h £ 1,5 mm h £ 1,5 mm h £ 1,5 mm + 0,3 b, + 0,15 b, + 0,1 b, max. max. max. 5 mm 4 mm 3 mm
h
b
Required weld thickness
h £ 1,5 mm h £ 1,5 mm h £ 1,5 mm + 0,20 b, + 0,15 b, + 0,1 b, max. max. max. 10 mm 7 mm 5 mm
h £ 1 mm + 0,3 a, max. 7 mm Actual weld thickness Specified weld thickness
Excessive weld thickness (fillet weld)
-
For many applications a weld thickness in excess of the specified size does not represent grounds for rejection.
18
Reduced weld thickness (fillet weld)
-
A fillet weld with an obviously smaller weld thickness should not be regarded as a defect provided that the actual weld thickness is compensated by a deeper penetration and by so doing achieving the specified size.
h £ 1 mm + 0,2 a, max. 6 mm
h £ 1 mm + 0,15 a, max. 5 mm
a
h
17
Long irregularities: not permitted Short irregularities: h £ 0,2 a max. 1,5 mm
h £ 0,1 a max. 1 mm
h £ 4 mm
h £ 3 mm
a
h
Actual weld thickness h £ 0,3 a max. Required weld 2 mm thickness
h £ 5 mm
504
t
Excessive root reinforcement
b
h
19
Chapter 2 Page B–4
No. 20
Annex B
Description of imperfections Misalignment of edges
Imperfections in Welded Joints in Aluminium
Ref. No. in acc with ISO 6520 507
II - Part 3 GL 2000
Limit for imperfections for quality levels
Remarks
low
medium
high
D
C
B
The deviation limits relate to the correct position. Unless otherwise specified, the correct position is when the centre lines coincide.
t
t
h
t
t
h
t relates to the smaller thickness
h £ 0,5 mm h £ 0,5 mm h £ 0,5 mm + 0,25 t, + 0,15 t, + 0,1 t, max. max. max. 4 mm 3 mm 2,5 mm
Fig. A - Plates and longitudinal welds
t
t
h
h £ 0,5 t max. 4 mm
max. 3 mm
max. 2,5 mm
Fig. B - Circumferential welds Incompletely filled groove
511
Long irregularities: not permitted
Smooth transition is required. b
Short irregularities:
t
h
21
Excessively unequal leg lengths of fillet welds
512
It is assumed that an asymmetric fillet weld has not been expressly prescribed.
h £ 0,1 t max. 1,5 mm
h £ 3 mm + 0,3 a
h £ 2 mm h £ 1,5 mm + 0,25 a + 0,2 a
h £ 0,05 t max. 1,0 mm
h
z1 515
Smooth transition is required.
h
Root concavity
Long irregularities: not permitted Short irregularities:
Root notch
5013
h
23
a
z2
22
h £ 0,2 t max. 2 mm
h £ 0,2 t max. 2 mm
h £ 0,1 t max. 1,5 mm
h £ 0,05 t max. 1 mm
Remarks For thicknesses s £ 10 mm or a £ 10 mm, special parameters may be necessary h2
-
Chapter 2 Page B–5
Limits for imperfections for quality levels
h1
Multiple irregularities in the section
Ref. No. in acc. with ISO 6520
h5
24
Description of imperfections
Imperfections in Welded Joints in Aluminium
h1 + h 2 + h 3 + h 4 + h 5 £ S h
h3
No.
Annex B
h4
II - Part 3 GL 2000
low
medium
high
D
C
B
Maximum size of short irregularities S h 0,3 s or 0,3 a, max. 10 mm
0,25 s or 0,25 a, max. 10 mm
0,2 s or 0,2 a, max. 10 mm
h1
h2
h4
h5 h3
h6
h 1 + h2 + h 3 + h4 + h5 + h6 £ S h This table, taken from the international standards EN 30042 resp. ISO 10042 specifies requirements for three levels of acceptance for imperfections in joints of aluminium and it's weldable alloys and for thicknesses of 3 mm to 63 mm. It may be used, where applicable, for other fusion welding processes or weld thicknesses. No. 24 shows multiple imperfections, a theoretically possible accumulation of individual imperfections. In this case, the total of all permitted deviations for the determined figures of the several classification levels should be reduced. However, the value of a single imperfection ³ h, e.g. for a single pore, should not be exceeded. The requirements given in this table should not treated as absolute limits but rather as limits that should not be exceeded with more than a defined probability. It should be noted that imperfections exceeding the size limits given are often present in a weld without impairing it's fitness-for-purpose. This table may be used in conjunction with the IIW-Catalogue ISO 10042 which contains realistic illustrations. They show the size of the permissible imperfections for the various quality levels by means of photographs of the face and root side and/or reproductions of radiographs and of photos of macrographs of the cross-section of the welds. The catalogue and it's reference cards may be used to assess the various imperfections and may be employed when opinions differ as to permissible size of imperfections. Symbols The following symbols are used in the table: A area of gas cavity a nominal fillet weld throat thickness (fillet thickness) b width of weld reinforcement d diameter or pore h size (height or weight) of imperfection l lenght of imperfection s nominal butt weld thickness or, in the case of partial penetration, the precribed depth of penetration t wall or plate thickness z nominal leg length of fillet welds (in case of isosceles right angle triangular section z = a × Ö 2)
Short imperfection: One or more imperfections of total length not greater than 25 mm in any 100 mm length of the weld or a maximum of 25 % of the weld length for a weld shorter than 100 mm. Long imperfection: One or more imperfections of total length greater than 25 mm in any 100 mm length of the weld or a minimum of 25 % of the weld length for a weld shorter than 100 mm.
