ODonnell Consulting

Weld Consulting

weld testing and analysis

We perform a spectrum of weld consulting services – from weld testing and analysis, to weld overlay design and joint analysis, to procedure development and qualification, to (corrosion/ fatigue/ failure) troubleshooting and repair of non-conformance, distortion/cracking, and other Code compliant issues.

To see a more comprehensive list of equipment we have worked on, see Industries Served.

Our services also include Certified Weld Inspection Services (CWI) as well as engineering analysis – presenting effective repair solutions to challenging weld issues, often through the use of three-dimensional finite element analysis to quantify residual welding stresses, fatigue strength reduction due to lack of fusion, underpenetration, inclusions and other imperfections.

Our experience covers AWS D1.1, AWS D1.5 and the numerous ASME codes, resolving issues including:

  • Weld Defects/ Porosity
  • Weld Distortions
  • Weld Cracking
  • Fatigue of Welded Joints
  • PWHT/ Heat Treatment Issues
  • Corrosion/SCC Issues
  • Welding Metallurgy
  • Weld Non-conformance

To read more about our projects, see Portfolio.

Durable welding is what holds every plant together. Often, equipment design life is often compromised through inadequate manufacturing processes such as welding, thermal/ transient conditions, and high temperature conditions. At elevated temperatures, creep, and component strains occur, especially in welded connections.

Defects often occur in welded, cast and forged parts. Parts with complex geometries often include crack starters such as metallurgical notch effects. We provide Certified Weld Inspections (CWI) and Nondestructive Testing (NDT) including radiographic (RT) and ultrasonic (UT) to determine quality and serviceability. Read about the various types of NDT.

We are a team of experienced, multi-disciplined engineers, providing clients with support across the spectrum of welding and joining challenges - including troubleshooting, code compliance, weld and joint inspection, mechanical testing, and evaluation of welding procedure specifications (WPS), procedure qualification records (PQR), and welder performance qualifications (WPQ). Several of our senior engineers have developed patents, published technical reports, and have been active in Codes and Standards Committees including the American Society of Mechanical Engineers (ASME), the National Association for Corrosion Engineers (NACE), the American Nuclear Society (ANS) and the American Welding Society (AWS). Read our article about managing risk specific to weld failures in Fugitive Emissions Journal. (PDF)

For additional information on our weld engineering and repair services, see Metallurgy or our Publications or submit an inquiry through our Contact Page.
OCE - Handbook of Lessons Learned

Learn from the experience of others. Especially when one such “other” is Dr. William O’Donnell, PhD, PE, Founder and President of O’Donnell Consulting Engineers, Inc., and ASME “Engineer of the Year” - his 50 years of experience in analysis of components including fatigue and fracture safety evaluations and failure analyses are now comprised in this volume.

If you are interested learning more in Engineering Design, Manufacturing and Construction, as well as Failure Analysis, then this book is a must have!


* Does not include shipping, handling or tax.