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Welding DocumentBY : 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)

AWSAmerican Welding Society

Structural Welding Code Steel

มาตรฐานการเช่ือมเหลก็โครงสร้าง

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)

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

destructive examination

AWS A3.0 Standard welding terms and definitions

AWS A5.1Specification for carbon steel electrodes for shielded

metal arc welding

AWS A5.18Specification for carbon steel electrodes and rots for

gas shielded arc welding

AWS B1.10 Guide for the nondestructive examination of welds

AWS B2.1Specification for Welding Procedure and Performance

Qualification

AWS D8.1 Automotive spot welding

AWS D8.6 Automotive spot welding electrodes supplement

AWS D8.7Automotive spot welding recommendations

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

Metallurgical

Welding Procedures

Scope/ITP

Agenda

Criteria

Spect.

Basic of

Welding

Processing

Variable

Procedures

WPS

PQR

WQT

Testing

Tension

Bending

Impact

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

• Parent material

• Welding process

• Joint design

• Welding Position

• Welding Variables

• Thermal heat treatments

Welding Variable

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

Revision 0 Date Nov 20,2014

By Mr.Sakon P.

Authorized byMr.Manoosak R. Date Nov 20,2014

Type Manual Semi - Automatic

Machine Automatic

IDENTIFICATION WPS No IS-GMAW-001

COMPANY NAME IS

WELDING PROCESS(ES) GMAW

SUPPORTING PQR No.(S) Prequalify

• Type (Grouping)

• Thickness

• Diameter (Pipes)

• Surface condition

Parent material

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 ButtCruciform

Welding Joint

Compound weld

Fillet weldButt weld

Edge weld

Spot weld

Plug weld

4/23/2007

Joint PreparationIncluded angle

Root GapRoot Face

Angle ofbevel

Root FaceRoot Gap

Included angle

Root Radius

Single-V Butt Single-U Butt

Root GapRoot Face Root FaceRoot Gap

Root Radius

Single Bevel Butt Single-J Butt

Angle of bevel Angle of bevel

Land

Joint Preparation

Single Sided Butt Preparations

Single Bevel Single Vee

Single-J Single-U

Single sided preparations are normally made on thinner materials,

or when access form both sides is restricted

Double Sided Butt PreparationsDouble sided preparations are normally made on thicker materials, or when access form both sides is unrestricted

-VeeDouble-BevelDouble

- JDouble - UDouble

4/23/2007

Groove Weld Preparation

bevel angle

root face

root gap

included angle

Typical Dimensions

bevel angle 30 to 35°

root face ~1.5 to~2.5mm

root gap ~2 to ~ 4mm

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 PositionsPA 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

3G

Horizontal – 2G

Butt welds in pipe

Flat – 1G

axis: horizontal

pipe: rotated

H-L045-6G

axis: inclined at 45°

pipe: fixed

Horizontal – 2G

axis: vertical

pipe: fixed

Vertical up – 5G

axis: horizontal

pipe: fixed

Vertical down - 5G

axis: horizontal

pipe: fixed

J-L045-6G

axis: inclined at 45°

pipe: fixed

Fillet welds on plate

Flat – 1F Overhead – 4F

Vertical up - 3F Vertical down – 3F

Horizontal – 2F

Fillet welds on pipe

Flat – 1F axis: inclined at 45°

pipe: rotated

Overhead – 4F axis: vertical

pipe: fixed

Vertical up - 5F axis: horizontal

pipe: fixed

Vertical down – 5F axis: horizontal

pipe: fixed

Horizontal – 2F axis: vertical

pipe: fixed

Horizontal – 2FR axis: horizontal

pipe: rotated

PA / 1GPA / 1F

PC / 2GPB / 2F

PD / 4FPE / 4G PG / 3G

PF / 3G

Pipe Welding Positions

Weld: FlatPipe: rotatedAxis: Horizontal

PA / 1G

Weld: Vertical DownwardsPipe: FixedAxis: Horizontal

PG / 5G

Weld: Vertical upwardsPipe: FixedAxis: Horizontal

PF / 5G

Weld: Upwards Pipe: FixedAxis: Inclined

Weld: HorizontalPipe: FixedAxis: Vertical

PC / 2G

45o

Weld: Downwards Pipe: FixedAxis: Inclined

J-LO 45 / 6G

45o

H-LO 45 / 6G

PositionAWS 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

PositionAWS 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 3.1Prequalified Base Metal-Filler Metal Combinations forMatching 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

CompositionAr84% + Co216%

Electrode-Flux (Class) - Flow Rate10-18 L/min

Gas Cup Size20 mm.

Welding Consumables

• Type /diameter of consumable

• Brand/classification

• Heat treatments/ storage

Welding ConsumablesEach 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 ConsumablesPlastic 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

Covered Electrode

Tensile Strength (p.s.i)

Welding Position

Flux Covering

E 60 1 3

AWS A5.5 Alloyed Electrodes

Covered Electrode

Tensile Strength (p.s.i)

Welding Position

Flux Covering

Moisture Control

Alloy Content

E 70 1 8 M G

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 ConsumablesWelding wires:

• carbon and low alloy wires may be copper coated

• stainless steel wires are not coated

•wires must be kept clean and free from oil and dust

•flux cored wires does not require baking or drying

Courtesy of Lincoln Electric Courtesy of ESAB AB

MIG/MAG – shielding gases

Type of material Shielding gas

Carbon steel

Stainless steel

Aluminium

CO2 , Ar+(5-20)%CO2

Ar+2%O2

Ar

MIG/MAG shielding gases

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

Ar Ar-He He CO2

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MIG/MAG shielding gasesGases 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)

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MIG/MAG shielding gasesGases 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

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Gas Metal Arc WeldingTypes 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

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MIG/MAG - metal transfer modes

Current/voltage conditions

Current

Voltage

Short-Circuit

Spray

transfer

Globular

transfer

Electrode diameter = 1,2 mm

WFS = 3,2 m/min

Current = 145 A

Voltage = 18-20V

Electrode diameter = 1,2 mm

WFS = 8,3 m/min

Current = 295 A

Voltage = 28V

Current type influence

++

+

++

+

++

+

--

-

--

-

--

-

Electrode capacity

Current type & polarity

Heat balance

Oxide cleaning action

Penetration

DCEN DCEPAC (balanced)

70% at work 30% at electrode

50% at work 50% at electrode

35% at work 65% at electrode

Deep, narrow Medium Shallow, wide

No Yes - every half cycle Yes

Excellent (e.g. 3,2 mm/400A) Good (e.g. 3,2 mm/225A) Poor (e.g. 6,4 mm/120A)

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

Tungsten Electrodes

AWS A 5.12

AWS A 5.12

Electrode tip for DCEN

Electrode tip prepared for low current welding

Electrode tip prepared for high current welding

Vertex angle

Penetration increase

Increase

Bead width increase

Decrease

2-2

,5 t

ime

s e

lect

rod

e d

iam

ete

r

Electrode tip for AC

Electrode tip groundElectrode tip ground and then

conditioned

Tungsten electrodes

The electrode diameter, type and vertex angle are all critical factors

considered as essential variables. The vertex angle is as shown

Vetex angle

Note: when welding

aluminium with AC current,

the tungsten end is

chamfered and forms a ball

end when welding

DC -ve

Note: too fine an angle will

promote melting of the

electrodes tip

AC

TIG Welding Variables

Shielding gas requirements

Preflow

and

Postflow

(6-10 l/min)

Preflow Postflow

Shielding gas flow

Welding current

Flow rate too low

Flow rate too high

TIG Welding ConsumablesWelding 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

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Fusible Inserts

Before Welding

Pre-placed filler material

After Welding

Other terms used include:

EB inserts (Electric Boat Company)

Consumable socket rings (CSR)

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Fusible InsertsConsumable 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

Fusible InsertsApplication of consumable inserts

Shielding gases for TIG weldingArgon

• 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

Pass

or

Layer

Process

Filler Metals CurrentAmps/Wire

Feed SpeedVolts

Travel

Speed

(cm/min)

Joint DetailsClass

Dia

mm.

Type/

Polarity

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