X-Ray Welding Course

Lesson 1 • Regulatory Framework for Radiographic Testing

Surveys licensing requirements, radiation protection regulations, and inspection standards. Students map regulatory obligations to daily inspection workflows.

Lesson 2 • X-Ray Equipment and Components

Introduces X-ray tubes, generators, and control panels used in weld inspection. Students identify each component's role in producing a diagnostic image.

Lesson 3 • Radiation Safety and Dose Limits

Establishes ALARA principles, dose limits, and personal protective measures. Safety compliance is a prerequisite for all hands-on lab activities.

Lesson 1 • Volumetric Discontinuities

Covers porosity, slag inclusions, and tungsten inclusions as three-dimensional defects. Students predict their radiographic appearance based on shape and density.

Lesson 2 • Weld Joint Design and Terminology

Defines joint configurations, weld symbols, and dimensional terms used throughout the course. Shared vocabulary enables precise defect location reporting.

Lesson 3 • Acceptance Criteria and Defect Severity

Applies standard acceptance criteria to classify defects as rejectable or acceptable. Students practise accept/reject decisions using reference radiographs.

Lesson 4 • Planar and Linear Discontinuities

Addresses cracks, lack of fusion, and incomplete penetration as planar defects. Students distinguish these from volumetric defects using image geometry.

Lesson 1 • Image Quality Indicators

Explains wire-type and hole-type IQIs as sensitivity verification tools. Correct IQI placement and reading confirm that required sensitivity is achieved.

Lesson 2 • Radiographic Film Characteristics

Explains film speed, contrast, grain size, and latitude as key performance parameters. Parameter selection directly affects image quality and defect detectability.

Lesson 3 • Darkroom Processing Techniques

Details manual and automatic film processing steps, chemical replenishment, and temperature control. Consistent processing is essential for repeatable image density.

Lesson 4 • Digital Radiography Imaging Systems

Introduces computed radiography (CR) and direct digital radiography (DR) panels. Students compare digital workflow advantages and limitations versus film.

Lesson 1 • Exposure Variables and Technique Charts

Relates kilovoltage, milliamperage, and time to film density and contrast. Technique charts enable rapid setup for common weld configurations.

Lesson 2 • Technique Qualification and Verification

Establishes procedures for qualifying a new technique and documenting all parameters. Qualified techniques ensure reproducible results across inspectors and shifts.

Lesson 3 • Source and Film Arrangement Configurations

Describes single-wall, double-wall, and panoramic exposure arrangements for pipe and plate. Configuration choice determines coverage and required shot count.

Lesson 4 • Geometric Principles of Radiography

Covers source-to-object distance, object-to-film distance, and geometric unsharpness. Geometric control is the primary tool for maximising defect resolution.

Lesson 1 • Identifying Volumetric Indications

Trains recognition of porosity, slag, and inclusions by density, shape, and distribution. Students differentiate true indications from processing artefacts.

Lesson 2 • Identifying Planar and Crack Indications

Focuses on the subtle linear density changes that reveal cracks and lack of fusion. Orientation sensitivity limitations are addressed to prevent false-clear calls.

Lesson 3 • Viewing Conditions and Densitometry

Specifies illuminator luminance, ambient light, and density range requirements for interpretation. Proper viewing conditions are mandatory before any interpretation begins.

Lesson 4 • Measurement, Sizing, and Reporting

Applies magnification correction and IQI reference to size indications accurately. Students complete standardised radiographic reports meeting industry requirements.

Lesson 1 • Pipe Weld Radiography Procedures

Covers single-wall and double-wall techniques for small- and large-bore pipe welds. Students calculate shot count and angular spacing for full circumferential coverage.

Lesson 2 • Lab Practical Assessment

Students independently perform a full radiographic inspection from setup through report. Performance is evaluated against industry competency benchmarks.

Lesson 3 • Butt Weld Radiography Procedures

Applies technique setup and film placement to flat and curved butt welds. Students verify coverage, IQI placement, and density before final interpretation.

Lesson 4 • Fillet Weld and Nozzle Radiography

Addresses the geometric challenges of radiographing fillet welds and branch connections. Tangential and axial beam angles are selected to maximise defect sensitivity.

Lesson 1 • Nonconformance and Corrective Action

Defines nonconformance identification, root cause analysis, and corrective action closure. Effective corrective action prevents recurrence of inspection errors.

Lesson 2 • Inspector Qualification and Certification

Covers training hours, examination requirements, and certification levels for radiographic inspectors. Certification status must be verified before assigning inspection responsibilities.

Lesson 3 • QA Programme Structure and Documentation

Defines the elements of a written radiographic QA programme including procedures and records. Documentation traceability supports both internal audits and third-party reviews.

Lesson 4 • Equipment Calibration and Verification

Establishes calibration intervals and verification checks for X-ray units, densitometers, and illuminators. Calibrated equipment is a prerequisite for valid inspection results.

Lesson 1 • High-Energy Radiography with Gamma Sources

Compares gamma-ray isotopes to X-ray tubes for thick-section and field inspection. Students select the appropriate source based on material thickness and access constraints.

Lesson 2 • Automated Radiographic Inspection Systems

Surveys robotic crawlers, automated film changers, and AI-assisted defect detection systems. Students evaluate automation suitability for high-volume pipeline and structural inspection.

Lesson 3 • Computed Tomography for Weld Inspection

Introduces industrial CT scanning principles and three-dimensional defect characterisation. CT provides volumetric data that resolves ambiguous two-dimensional film indications.

Lesson 4 • Radiography of Dissimilar Metal Welds

Addresses exposure challenges caused by density and thickness variations in dissimilar metal joints. Compensating filters and dual-film techniques restore uniform image density.