Fundamentals of Arc Welding – D05-003

SECTION 4 WELDING PROCEDURES There

are essentially three steps to be followed to ensure good welding:

1. Establishing good welding procedures

2. Use of pre-qualified welders

3. Availability of competent inspectors in shop and field

The term welding procedure is used to describe the complete process involved in
making a weld. It covers a record of all of the different elements, variables, and factors
such as choice of electrode, edge preparation, welding sequence, joint details, preheat,
welding parameters such as voltage, current, welding position, number of weld run to fill
the groove and post weld treatments (e.g. grinding, heat treatment etc.) that are involved
in producing a specific weld or weldment.

Welding procedures should be written whenever it is necessary to:

• Maintain dimensions by controlling distortion;

• Reduce residual or locked up stresses;

• Minimize detrimental metallurgical changes;

• Consistently build a weldment the same way;

• Comply with certain specifications and codes.

Elements of Weld Procedure

Some of the important elements of weld procedure are elaborated below.

1. Environment: Weld procedure must account for actual site conditions. In cold
regions, it may be necessary to heat steel up to 20%. The humid weather or
condensation might help formation of porosity. Electrodes must be kept in dry
condition. In moist / humid environments the electrodes may be kept in a warm
container to avoid moisture entrapment in the flux coating.

2. Welding position: Vertical welding is slower compared to welding in the flat

position. Overhead welding causes weld splutter and require special skills. It is better
avoided.

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3. Current: The current controls the heat input. A minimum current is required for
fusing the plate and to keep the arc stable. Generally a high current is used to obtain
quicker welding so as to reduce cost. It may not be possible to use maximum current
always, a specific example being welding in the overhead position. The current limit
for overhead use is 160A. Usually high current results in low impact properties.
Further very high value of current may cause cracks in the Heat-Affected Zone
(HAZ).

4. Shrinkage: While cooling after the welding operation, the hot metal in the welded
region contracts causing the joint to shrink. But this contraction is prevented by the
adjacent colder metal. This causes stress, sometimes even beyond yield stress, and
causes plastic deformation. This also might cause distortion of the member. By
following proper edge preparation and weld procedure, this can be minimised. After
the plastic deformation a residual stress pattern is formed in the joint. Tensile
stresses are formed in the weld metal and HAZ zones, whereas compression in the
adjacent steel.

5. Pre heating: Hydrogen induced cracking (cold cracking, delayed cracking) is a

serious problem affecting weldability. The degree of cracking occur due to the
combined effects of four factors:

• Brittle microstructure

• Presence of hydrogen in weld metal

• Tensile stresses in the weld area

• Temperature range (-100°C to 200°C)

Defining Essential Variables

Essential variables are those factors which must be recorded and if they are changed in
any way, the procedure must be retested and requalified. Essential variables involved in
the procedure usually include the following:

• The welding process and its variation

• The method of applying the process

• The base metal type, specification, or composition

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• The base metal geometry, normally thickness

• The base metal need for preheat or postheat

• The welding position

• The filler metal and other materials consumed in making the weld

• The weld joint, that is, the joint type and the weld

• Electrical or operational parameters involved

• Welding technique.

Non essential Variables

Some specifications also include nonessential variables. Non essential variables are
usually of less importance and may be changed within prescribed limits and the
procedure need not be re-qualified. These are usually the following:

• The travel progression (uphill or downhill)

• The size of the electrode or filler wire

• Certain details of the weld joint design

• The use and type of weld backing

• The polarity of the welding current.

The procedure write-up must include each of the listed variables and describe in detail
how it is to be done. The second portion of the welding procedure is the joint detail
sketch and table or schedule of welding conditions.

Pre-qualification of Welding Procedures

Welding procedures are necessary to produce welds that will meet the requirements of
commonly used codes. The American Welding Society (AWS) produces the Structural
Welding Code that is used for the design and construction of steel structures (AWS
D1.1). Another code that is used for the construction of steam boilers and pressure

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vessels is published by the American Society of Mechanical Engineers (ASME). Using

the appropriate welding code, along with the project drawings and specifications, the
welding inspector develops a welding procedure specification that meets the
requirements of the job. The different codes have somewhat different requirements for a
welding procedure, but in general a welding procedure consists of three parts as follows:

• A detailed written explanation of how the weld is to be made

• A drawing or sketch showing the weld joint design and the conditions for making
each pass or bead

• A record of the test results of the resulting weld.

If the weld meets the requirements of the code or specification and if the written
procedure is properly executed and signed it becomes a qualified welding procedure.

Once a welding procedure has been developed, welders are then required to perform a
Welding Performance Qualification test. After the test is complete, the weld specimens
are tested according to the requirements of the welding procedure specification. For
most codes, if a welder continues to use a particular process and procedure, the
welder’s qualification remain in effect indefinitely.

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