Welding Document

BY : MANOOSAK RERGPANEE
NDT: ISO 9712,EN 473 PT/MT/RT LEVEL III
ASNT PT/MT/UT/RT LEVEL II
IIW: INTERNATIONAL WELDING ENGINEER (IWE)
EUROPIAN WELDING FEDERATION (EWF)
 AWS
American Welding Society

Structural Welding Code Steel

AWS D 1.1 Structural welding (steel)

AWS D 1.2 Structural welding (aluminum)

AWS D 1.3 Structural welding (sheet steel)

AWS D 1.4 Structural welding (reinforcing steel)

AWS D 1.5 Bridge welding

AWS D 1.6 Structural welding (stainless steel)

 Standard symbols for welding, brazing, and non-
AWS A2.4
destructive examination

AWS A3.0 Standard welding terms and definitions

Specification for carbon steel electrodes for shielded
AWS A5.1
metal arc welding

Specification for carbon steel electrodes and rots for

AWS A5.18
gas shielded arc welding

AWS B1.10 Guide for the nondestructive examination of welds

Specification for Welding Procedure and Performance
AWS B2.1
Qualification
AWS D8.1 Automotive spot welding
AWS D8.6 Automotive spot welding electrodes supplement
Automotive spot welding recommendations
AWS D8.7
supplement
AWS D8.8 Automotive arc welding (steel)
AWS D8.9 Automotive spot weld testing
AWS D8.14 Automotive arc welding (aluminum)
AWS D9.1 Sheet metal welding
AWS D10.10 Heating practices for pipe and tube
AWS D10.11 Root pass welding for pipe
AWS D10.12 Pipe welding (mild steel)
 Welding Procedures
Producing a welding procedure involves:
Planning the tasks
Collecting the data
Writing a procedure for use of for trial
Making a test welds
Evaluating the results
Approving the procedure
Preparing the documentation
 Welding Procedures

Scope/ITP Basic of Procedures Testing

Welding
Agenda Processing WPS Tension

Variable PQR Bending

Spect.
Metallurgical WQT Impact
Criteria
experience

Code Standard
Variable
Weld ability of the part
a) Suitability for welding:
- chemical composition
- metallurgical properties
- physical properties
b) Welding safety:
- structural design
- state of stresses
c) Possibility for welding:
- preparation for welding
- execution of the welding works
- post treatment
 Welding Variable
Parent material
Welding process
Joint design
Welding Position
Welding Variables
Thermal heat treatments
 Welding Procedures
WPSs: Prequalification Welding Procedure Specification
Before procedure approval.

WPS: Welding Procedure Specification

After procedure approval

PQR: Procedure Qualification Record

Welding procedure test record
WQT : Welder Qualification Test Record
After PQR approval
 WPS
Welding Procedure Specification
IDENTIFICATION WPS No IS-GMAW-001
COMPANY NAME IS

WELDING PROCESS(ES) GMAW

SUPPORTING PQR No.(S) Prequalify

Revision 0 Date Nov 20,2014

By Mr.Sakon P.
Authorized by Mr.Manoosak R. Date Nov 20,2014
Type Manual Semi - Automatic
Machine Automatic
 Parent material

Type (Grouping)
Thickness
Diameter (Pipes)
Surface condition
Welding process
Type of process
- SMAW,
- GMAW(MIG/MAG)
- GTAW(TIG)
- FCAW
- SAW .etc

Equipment parameters

Amps, Volts, Travel speed

Welding Process
JOINT DESIGN USED
Type: BUTT WELD
Single Double Weld
Backing : Yes No
Backing Material : ASTM A36
Root Opening - Root Face -
Groove Angle : - Radius(J-U) -
Back Gouging : Yes No Method -

POSITION
Position of Groove: 3G Fillet : -
Vertical Progression : Up Down
Base Matals
Material Spec: ASTM A36
Type or Grade -
Thickness
Groove : 10 mm Fillet -
Diameter (Pipe): -
Joint design
Edge preparation

Root gap, root face

Jigging and tacking

Type of backing
 Welding Joint

Edge Open & Closed Corner Lap

Tee Butt
Cruciform
 Welding Joint

Butt weld Spot weld

Fillet weld

Edge weld Plug weld

Compound weld
 Joint Preparation
Included angle Included angle

Angle of
bevel

Root
Radius

Root Face Root Face

Root Gap Root Gap
Single-V Butt Single-U Butt

4/23/2007
 Joint Preparation
Angle of bevel Angle of bevel

Root
Radius

Root Face Root Gap Root Face

Root Gap Land
Single Bevel Butt Single-J Butt
 Single Sided Butt Preparations
Single sided preparations are normally made on thinner materials,
or when access form both sides is restricted

Single Bevel Single Vee

Single-J Single-U
 Double Sided Butt Preparations
Double sided preparations are normally made on thicker materials, or when
access form both sides is unrestricted

Double -Bevel Double -Vee

Double - J Double - U
 Groove Weld Preparation

bevel angle
included angle

root face
root gap

Typical Dimensions
bevel angle 30 to 35
root face ~1.5 to~2.5mm
root gap ~2 to ~ 4mm

4/23/2007
Figure 3.4 (Continued)-Prequalified CJP Groove Welded Joint Details (see 3.13)
Figure 3.4 (Continued)-Prequalified CJP Groove Welded Joint Details (see 3.13)
POSITION
Position of Groove: 3G Fillet : -
Vertical Progression : Up Down

Welding Position
Location, shop or site

Welding position e.g. 1G, 2G, 3G etc.

 Welding Positions
PA 1G / 1F Flat / Downhand

PB 2F Horizontal-Vertical

PC 2G Horizontal
PD 4F Horizontal-Vertical (Overhead)

PE 4G Overhead

PF 3G / 5G Vertical-Up

PG 3G / 5G Vertical-Down

H-L045 6G Inclined Pipe (Upwards)

J-L045 6G Inclined Pipe (Downwards)

 Butt welds in plate

Flat 1G Overhead 4G

Vertical up
3G

Vertical down Horizontal 2G

3G
 Butt welds in pipe

Vertical up 5G Vertical down - 5G

Flat 1G axis: horizontal axis: horizontal
axis: horizontal pipe: fixed pipe: fixed
pipe: rotated

H-L045-6G J-L045-6G Horizontal 2G

axis: inclined at 45 axis: inclined at 45 axis: vertical
pipe: fixed pipe: fixed pipe: fixed
 Fillet welds on plate

Flat 1F Horizontal 2F Overhead 4F

Vertical up - 3F Vertical down 3F

 Fillet welds on pipe

Flat 1F Horizontal 2F Overhead 4F

axis: inclined at 45 axis: vertical axis: vertical
pipe: rotated pipe: fixed pipe: fixed

Horizontal 2FR Vertical up - 5F Vertical down 5F

axis: horizontal axis: horizontal axis: horizontal
pipe: rotated pipe: fixed pipe: fixed
PA / 1G
PA / 1F
PF / 3G

PB / 2F
PC / 2G

PE / 4G PG / 3G
PD / 4F
 Pipe Welding Positions

PF / 5G PG / 5G
PA / 1G
Weld: Flat Weld: Vertical upwards Weld: Vertical Downwards
Pipe: rotated Pipe: Fixed Pipe: Fixed
Axis: Horizontal Axis: Horizontal Axis: Horizontal

45o 45o

PC / 2G
H-LO 45 / 6G J-LO 45 / 6G
Weld: Horizontal Weld: Upwards Weld: Downwards
Pipe: Fixed Pipe: Fixed Pipe: Fixed
Axis: Vertical Axis: Inclined Axis: Inclined
 Position
AWS D1.1, Table 4.1, WPS Qualification
CJP Groove Weld (Plate or Tubular)

Position Tested Position Qualified*

1G, 1G (Rotated) F
2G F, H
3G V
4G OH
5G F, V, OH
(2G+5G), 6G, 6GR All
 Position
AWS D1.1, Table 4.1, WPS Qualification
Fillet Weld (Plate or Tubular) Qualification Test:

Position Tested Position Qualified

1F, 1F (Rotated) F
2F, 2F (Rotated) F, H
3F V
4F (Plate) OH
4F (Tubular) F, H, OH
5F All
BASE METALS
Material Spec. ASTM A36
Type of Grade -
Thickness: Groove 10 mm. Fillet -
Diameter (Pipe) -

- Data from Mill Certificate

- Go to AWS D1.1 Table 3.1
Prequalified Base Metal-Filler Metal Combinations for
Matching Strength
 Parent material

Table 3.1 prequalified Base Material Filler Metal

Combinations for Matching Strength
Parent material
FILLER METALS
AWS Specification A 5.18
AWS Classification ER 70 S-6

SHIELDING

Flux - Gas Ar + Co2

Composition
Ar84% + Co216%
10-18 L/min
Electrode-Flux (Class) - Flow Rate
20 mm.
Gas Cup Size
Welding Consumables
Type /diameter of consumable

Brand/classification

Heat treatments/ storage

 Welding Consumables
Each consumable is critical in respect to:
Size, (diameter and length)
Classification / Supplier
Condition
Treatments e.g. baking / drying
Handling and storage is critical for consumable control
Handling and storage of gases is critical for safety
SMAW Welding Consumables
Plastic foil sealed cardboard box
rutile electrodes
general purpose basic electrodes

Tin can
cellulosic electrodes

Vacuum sealed pack

extra low hydrogen electrodes
 AWS A5.1 Alloyed Electrodes

E 60 1 3

Covered Electrode
Tensile Strength (p.s.i)
Welding Position
Flux Covering
 AWS A5.5 Alloyed Electrodes
E 70 1 8 M G

Covered Electrode
Tensile Strength (p.s.i)
Welding Position
Flux Covering
Moisture Control
Alloy Content
 TYPES OF ELECTRODES
(for C, C-Mn Steels)
AWS A5.1
Cellulosic EXX10
EXX11
Rutile EXX12
EXX13
Rutile Heavy Coated EXX24
Basic EXX15
EXX16
EXX18
 MIG/MAG Welding Consumables
Welding wires:
carbon and low alloy wires may be copper coated
stainless steel wires are not coated

Courtesy of Lincoln Electric Courtesy of ESAB AB

wires must be kept clean and free from oil and dust
flux cored wires does not require baking or drying
MIG/MAG shielding gases

Type of material Shielding gas

Carbon steel CO2 , Ar+(5-20)%CO2

Stainless steel Ar+2%O2

Aluminium Ar
 MIG/MAG shielding gases
Ar Ar-He He CO2

Argon (Ar):
higher density than air; low thermal conductivity the arc has
a high energy inner cone; good wetting at the toes; low
ionisation potential
Helium (He):
lower density than air; high thermal conductivity uniformly
distributed arc energy; parabolic profile; high ionisation
potential
Carbon Dioxide (CO2):
cheap; deep penetration profile; cannot support spray
transfer; poor wetting; high spatter
 MIG/MAG shielding gases
Gases for Short-Circuiting transfer:
CO2: carbon steels only: deep penetration; fast welding speed;
high spatter levels
Ar + up to 25% CO2: carbon and low alloy steels: minimum
spatter; good wetting and bead contour
90% He + 7.5% Ar + 2.5% CO2:stainless steels: minimises
undercut; small HAZ
Ar: Al, Mg, Cu, Ni and their alloys on thin sections
Ar + He mixtures: Al, Mg, Cu, Ni and their alloys on thicker
sections (over 3 mm)

75 of 691
 MIG/MAG shielding gases
Gases for spray transfer
Ar + (5-18)% CO2: carbon steels: minimum spatter; good
wetting and bead contour
Ar + 2% O2: low alloy steels: minimise undercut; provides
good toughness
Ar + 2% O2 or CO2: stainless steels: improved arc stability;
provides good fusion
Ar: Al, Mg, Cu, Ni, Ti and their alloys
Ar + He mixtures: Al, Cu, Ni and their alloys: hotter arc than
pure Ar to offset heat dissipation
Ar + (25-30)% N2: Cu alloys: greater heat input

76 of 691
 Gas Metal Arc Welding
Types of Shielding Gas
MAG (Metal Active Gas)
Active gases used are Oxygen and Carbon Dioxide
Argon with a small % of active gas is required for all steels
(including stainless steels) to ensure a stable arc & good
droplet wetting into the weld pool
Typical active gases are
Ar + 20% CO2 for C-Mn & low alloy steels
Ar + 2% O2 for stainless steels
100% CO2 can be used for C - steels

77 of 691
MIG/MAG - metal transfer modes
Electrode diameter = 1,2 mm
Voltage
WFS = 8,3 m/min
Current = 295 A
Voltage = 28V

Globular Spray
transfer transfer

Electrode diameter = 1,2 mm

WFS = 3,2 m/min
Current = 145 A

Short-Circuit Voltage = 18-20V

Current

Current/voltage conditions 78 of 691

 Current type influence

+ - + - + -
+ - + - + -
+ - + - + -

Current type & polarity DCEN AC (balanced) DCEP

Heat balance 70% at work 30% 50% at work 50% 35% at work 65%
at electrode at electrode at electrode
Penetration Deep, narrow Medium Shallow, wide
Oxide cleaning action No Yes - every half cycle Yes
Electrode capacity Excellent (e.g. 3,2 mm/400A) Good (e.g. 3,2 mm/225A) Poor (e.g. 6,4 mm/120A)
 Tungsten Electrodes
Old types: (Slightly Radioactive)
Thoriated: DC electrode -ve - steels and most metals
1% thoriated + tungsten for higher current values
2% thoriated for lower current values
Zirconiated: AC - aluminum alloys and magnesium

New types: (Not Radioactive)

Cerium: DC electrode -ve - steels and most metals
Lanthanum: AC - Aluminum alloys and magnesium
AWS A 5.12
AWS A 5.12
 Electrode tip for DCEN
Penetration
increase
2-2,5 times electrode

Increase

Vertex
diameter

angle

Decrease

Bead width
increase
Electrode tip prepared for low Electrode tip prepared for high
current welding current welding
 Electrode tip for AC

Electrode tip ground and then

Electrode tip ground
conditioned
 TIG Welding Variables
Tungsten electrodes
The electrode diameter, type and vertex angle are all critical factors
considered as essential variables. The vertex angle is as shown

DC -ve AC

Vetex angle

Note: too fine an angle will Note: when welding

promote melting of the aluminium with AC current,
electrodes tip the tungsten end is
chamfered and forms a ball
end when welding
 Shielding gas requirements
Shielding gas flow

Welding current

Preflow
and
Postflow Preflow Postflow

(6-10 l/min) Flow rate Flow rate

too low too high
 TIG Welding Consumables
Welding consumables for TIG:
Filler wires, Shielding gases, tungsten electrodes
(non-consumable).
Filler wires of different materials composition and
variable diameters available in standard lengths,
with applicable code stamped for identification
Steel Filler wires of very high quality, with copper
coating to resist corrosion.
shielding gases mainly Argon and Helium, usually
of highest purity (99.9%).
Welding rods:
supplied in cardboard/plastic tubes

must be kept clean and free from oil and dust

might require degreasing
 Fusible Inserts
Pre-placed filler material

Before Welding After Welding

Other terms used include:

EB inserts (Electric Boat Company)

Consumable socket rings (CSR)

90 of 691
 Fusible Inserts
Consumable inserts:
used for root runs on pipes
used in conjunction with TIG welding
available for carbon steel, Cr-Mo steel, austenitic stainless
steel, nickel and copper-nickel alloys
different shapes to suit application

Radius
91 of 691
 Fusible Inserts
Application of consumable inserts
 Shielding gases for TIG welding
Argon
low cost and greater availability

Helium
costly and lower availability than Argon
lighter than air - requires a higher flow rate compared with argon (2-3
times)

Nitrogen
not an inert gas
high availability - cheap
added to argon (up to 5%) - only for back purge for duplex stainless,
austenitic stainless steels and copper alloys
not used for mild steels (age embritlement)
 Shielding gases for TIG welding
Hydrogen
not an inert gas - not used as a primary shielding gas
increase the heat input - faster travel speed and
increased penetration
better wetting action - improved bead profile
produce a cleaner weld bead surface
added to argon (up to 5%) - only for austenitic stainless
steels and nickel alloys
flammable and explosive
Welding Variables

Run sequences

Back gouging

Interpass temperatures
TECHNIQUE

Stringer or Weave Bead Stringer or Weave Bead

Multi-pass or Single Pass(per side) Multi-pass

Number of Electrodes 1
Electrode Spacing
Longitudinal -
Lateral -
Angle -
Contact Tube to Work Distance 15-20 mm.
Peening -
Interpass Cleaning Wire Brush
PREHEAT
Preheat Temp.,Min -
Interpass Temp.,Min - Max -

POST WELD HEAT TREATMENT

Temp -
Time -
Thermal heat treatments
Preheat
- Table 3.2 Prequalified Minimum Preheat and
Interpass Temperature

Post weld heat treatments

Chapter 5.8 Stress Relief Heat Treatment pg.196
- Table 5.2 Minimum Holding Time page.208
- Table 5.3 Alternate Stress Relief Heat Treatment
page.208
WELDING PROCEDURE
Filler Metals Current
Pass Travel
Amps/Wire
or Process Dia Type/ Volts Speed Joint Details
Class Feed Speed
Layer mm. Polarity (cm/min)

1 GMAW ER 70 S-6 1.2 DCEP 100-120 18 8

2 GMAW ER 70 S-6 1.2 DCEP 120-160 20 10
3 GMAW ER 70 S-6 1.2 DCEP 120-160 20 10
THE END