Radiography of Full Penetration Welds in Flex Hose for Safety and Reliability

Published by Lauren Russo

Steven Mingis & John Czerwinski

Branham Industrial LLC

An LGG Industrial Company

100% Radiographic Inspection of the weldment is a crucial requirement for ensuring the quality, reliability, and safety of welded joints in the production of flex hoses for those applications used in chemical transfer. Radiographic inspection, specifically employing techniques like X-rays or gamma rays, provides a non-destructive means of insuring mechanical integrity and absence of defects for long term performance. Dye Penetrant examination and subsequent Hydrostatic and/or Pneumatic pressure testing are each valuable procedures for detecting any leak, but they can only provide evidence of “leak free” at the time of the test.


Conversely, 100% radiography provides physical evidence of any defects, imperfections such as voids, porosity, cracks, incomplete fusion and lack of penetration within the weld zone. Identifying these issues early on is essential to prevent the compromise of structural integrity, which is particularly critical in applications where safety is paramount, such as in the construction of flex hoses for Highly Hazardous, Highly Toxic and/or high temperature process applications. By thoroughly examining the entire circumferential weldment, this procedure ensures compliance to ASME Section IX. This is particularly significant when recognizing the criticality of joining a schedule 80 pipe fitting to a corrugated tube hose with a wall thickness of 0.016”, when even minor flaws can lead to premature catastrophic failures.


Radiography provides the end user a level of confidence in the structural soundness of these welds, reducing the risk of unexpected failures and subsequent operational disruptions. Safety considerations are at the forefront of the importance of inspecting welds. Flaws within welded joints can lead to leaks, structural failures, or other hazardous situations. Radiographic inspection acts as a preventive measure, identifying potential issues before they escalate into serious problems. This is crucial in industries dealing with volatile substances, high pressures, or other conditions where the failure of a welded joint could have severe consequences.


Reading and evaluating the film from the 100% radiography is the responsibility of the Level III

Certified Weld Inspector (CWI) at Hartford, which Branham utilizes as an objective 3rd party

contractor. To the untrained eye the 2 images below might not appear all that much different.