NONMANDATORY APPENDIX K SECTIONING OF WELDED JOINTS

ETCH TESTS
K-1 (a) Carbon and Low Alloy Steels. Etching solutions suitable for carbon and low alloy steels, together with directions for their use, are suggested as follows. (1) Hydrochloric Acid. Hydrochloric (muriatic) acid and water equal parts by volume. The solution should be kept at or near the boiling temperature during the etching process. The specimens are to be immersed in the solution for a sufcient period of time to reveal all lack of soundness that might exist at their cross-sectional surfaces. (2) Ammonium Persulfate. One part of ammonium persulfate to nine parts of water by weight. The solution should be used at room temperature and should be applied by vigorously rubbing the surface to be etched with a piece of cotton saturated with the solution. The etching process should be continued until there is a clear denition of the structure in the weld. (3) Iodine and Potassium Iodide. One part of powdered iodine (solid form), two parts of powdered potassium iodide, and ten parts of water, all by weight. The solution should be used at room temperature and brushed on the surface to be etched until there is a clear denition of outline of the weld. (4) Nitric Acid. One part of nitric acid and three parts of water by volume.
CAUTION: Always pour the acid into the water. Nitric acid causes bad stains and severe burns.

be preserved by coating it with a thin clear lacquer. (c) Aluminum Alloy. The following etching solution is suggested for revealing the macrostructure of welded aluminum alloy specimens:
Hydrochloric Acid (conc.) Hydrouoric Acid (48%) Water 15 ml 10 ml 85 ml

This solution is used at room temperature and etching is accomplished by either swabbing or immersion of the specimen. The surface to be etched should be smoothed by ling or machining or by grinding on No. 180 Aloxite paper. With different alloys and tempers the etching period will vary from 15 sec to several minutes and should be continued until the desired contrast is obtained.

CLOSURE OF OPENINGS RESULTING FROM SECTIONING

K-2 (a) Holes in welded joints left by the removal of trepanned plug specimens may be closed by any welding method approved by the authorized inspector. Some suggested methods for closing round plug openings by welding are as follows. (1) Insert and weld in special plugs of which some acceptable types are shown in Fig. K-2. Type (a) is adapted to welding from both sides and should be used wherever that method is practicable, and Types (b) and (c) when access is possible only from one side. The diameter of the ller plug shall be such as to make a snug t in the hole to be lled. Each layer of weld metal as deposited shall be thoroughly peened to reduce residual stresses. The 14 in. (6 mm) hole in the center of the plugs shown in Fig. K-2 may afterwards be closed by any reasonable method. Plain plugs without a hole may be used. (2) For joints where the thickness of the thinner plate at the joint is not greater than one-third of the diameter of the hole, place a backing plate on the inside of the shell over the opening and ll the hole completely
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The solution may be used at room temperature and applied to the surface to be etched with a glass stirring rod. The specimens may also be placed in a boiling solution of the acid but the work should be done in a well-ventilated room. The etching process should be continued for a sufcient period of time to reveal all lack of soundness that might exist at the cross-sectional surfaces of the weld. (b) The appearance of the etched specimens may be preserved by washing them in clear water after etching, removing the excess water, immersing them in ethyl alcohol, and then drying them. The etched surface may then

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K-2
1/ in. (6 mm) 4 1/ in. (3 mm) min. 8

NONMANDATORY APPENDIX K
1/ in. (6 mm) 4 1/ in. (3 mm) min. 8 1/ in. (6 mm) 4 1/ in. (3 mm) min. 8

K-3

1/ in. (3 mm) min. 8

D
(a)

D
(b)

D
(c)

FIG. K-2 SOME ACCEPTABLE TYPES OF FILLER PLUGS

with weld metal applied from the outside of the shell. Rebuild llet welds where cut. (3) For joints where the thickness of the thinner plate at the joint is not less than one-third, nor greater than two-thirds the diameter of the hole, ll the hole completely with weld metal applied from both sides of the shell. Rebuild llet welds where cut. (4) For butt joints where the thickness of the thinner plate at the joint does not exceed 78 in. (22 mm), chip a groove on one side of the plate each way along the seam from the hole. The groove at the opening shall have sufcient width to provide a taper to the bottom of the hole, and the length of the groove on each side of the opening is to have a slope of approximately one to three. Use a backing plate on the side opposite that on which the chipping is done or a thin disk [not over 18 in. (3 mm) thick] at the bottom of the hole and ll the groove and the hole with weld metal. (5) For butt joints, and for plates of any thickness, chip a groove on both sides of the plate each way along

the seam from the hole. The groove at the opening shall have sufcient width to provide a taper to the middle of the plate, and the length of the groove on each side of the opening is to have a slope of approximately one to three. Place a thin disk [not over 18 in. (3 mm) thick] in the hole at the middle of the plate and ll the grooves and the hole on both sides with weld metal. (b) The following is a suggested method for closing openings cut with a spherical saw: For butt welded joints place a backing plate, where necessary, on the inside of the vessel shell over the opening. For lap-welded joints, a part of the parent plate remaining opposite the removed weld will usually serve as a backing plate. Fill the opening completely with the weld metal. Rebuild llet welds where cut. K-3 Where gas welding is employed, the area surrounding the plugs shall be preheated prior to welding.

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535

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