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    Welding Design, Welding Procedure and Performance Qualification

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    kmas1612
    The document discusses welding design, procedures, and qualifications. It covers topics like joint types and edge preparations, applicable welds for different joints, essential variables in welding procedure specifications, filler metal and base metal classifications, and requirements for procedure and performance qualifications. Diagrams illustrate different joint configurations and welding positions.

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    Attribution Non-Commercial (BY-NC)
    Download as PPT, PDF, TXT or read online from Scribd

    Welding Design, Welding Procedure and Performance Qualification

    Uploaded by

    kmas1612
    3K views34 pages
    The document discusses welding design, procedures, and qualifications. It covers topics like joint types and edge preparations, applicable welds for different joints, essential variables in welding procedure specifications, filler metal and base metal classifications, and requirements for procedure and performance qualifications. Diagrams illustrate different joint configurations and welding positions.

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    Welding Design

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    The document discusses welding design, procedures, and qualifications. It covers topics like joint types and edge preparations, applicable welds for different joints, essential variables in welding procedure specifications, filler metal and base metal classifications, and requirements for procedure and performance qualifications. Diagrams illustrate different joint configurations and welding positions.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    3K views34 pages

    Welding Design, Welding Procedure and Performance Qualification

    Uploaded by

    kmas1612
    The document discusses welding design, procedures, and qualifications. It covers topics like joint types and edge preparations, applicable welds for different joints, essential variables in welding procedure specifications, filler metal and base metal classifications, and requirements for procedure and performance qualifications. Diagrams illustrate different joint configurations and welding positions.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    You are on page 1of 34

    WELDING DESIGN,

    WELDING PROCEDURE
    AND PERFORMANCE
    QUALIFICATION
    Edge Preparation - Need

    Poor penetration
    Poor access at root
    Poor strength

    Good penetration
    Good access at root
    Good joint strength
    Basic Joint Types

    butt

    lap
    tee

    corner
    edge
    Applicable Welds for Butt joint
    Square Groove weld V Groove weld

    Bevel Groove weld U Groove weld

    J Groove weld
    Applicable Welds for Butt joint

    Double V Groove Double Bevel Groove


    weld weld

    Double U Groove Double J Groove


    weld weld
    Applicable Welds for Tee joint
    Applicable Welds for Lap joint

    Fillet weld

    Plug / slot weld


    Spot / seam weld
    Applicable Welds for Corner Joint
    Butt joint
    Single V Groove angle 
    Groove weld

    Root face
    Root gap

    Double V
    Groove weld

    Groove angle

    Single U Root radius


    Groove weld

    Root gap Root face


    Weld Reinforcement

    Correct Excess Under


    reinforcement reinforcement reinforcement
    Minimum cost High cost
    Good joint Poor joint Poor joint
    strength strength strength
    Butt joint – Complete Joint
    penetration

    Weld from face side Backing weld from root side

    Back gouging Back gouging from face side

    Back weld Weld from face side


    Tee Joint

    leg throat leg throat leg throat

    leg leg leg

    Flat profile Convex Concave


    profile profile
    Tee Joint – Full penetration joint

    Groove
    angle

    leg = throat leg = throat


    Welding Position – Groove

    1G

    3G

    2G
    4G
    Welding Position – Groove

    1G 2G

    5G 6G

    45°
    Welding Position – Fillet

    1F

    2F
    3F

    4F
    Welding Position – Fillet
    1F

    2F

    5F
    Dilution
    Area A

    Area B

    Dilution is the amount of base metal present in the


    weld metal and given by (Area B / (Area A + Area B))
    Dilution depends on the welding process and heat
    input.
    High dilution alters the chemical composition of weld
    metal
    Weld Metal Requirements
    • Matching strength with the parent metal
    • Good notch toughness at the operating
    temperature
    • Corrosion resistance
    • Creep resistance for elevated temperature
    application
    • Resistance to wear, erosion etc
    Filler Metal Selection
    • Mechanical / chemical properties required
    • Welding process
    • Type of electrode, current, power range
    • Metal to be joined and its thickness
    • Weld joint design and welding position
    • Shop or Field weld / surface condition
    • Number of passes / amount of weld metal
    Welding Procedure Specification
    It is a written document that provides direction
    to the welder for making production welds in
    accordance with code requirements.
    Any WPS must be qualified by the
    manufacturer.
    WPS specifies the condition (ranges) under
    which welding must be performed called
    variables.
    WPS addresses essential, supplementary
    essential and non essential variables
    Purpose of WPS Qualification

    To determine that the weldment is capable of


    providing the required properties for the
    intended application.

    WPS establishes the properties of the


    weldment and not the skill of the welder.
    Procedure Qualification
    PQR is a record of welding data to weld a test
    coupon. It also contains test results.
    Completed PQR shall document all essential
    variables including ranges.
    PQR to be certified accurate and shall not be
    subcontracted.
    If more than one process is employed then
    weld deposit thickness for each process and
    filler metal to be recorded.
    Base Metal Classification
    Base metals classified into various P Nos
    depending on composition, weldability &
    mechanical properties.

    P1 - P11 Steel
    P21 - P25 Al alloys etc.

    Group nos within P nos classify metals for


    procedure qualification where notch
    toughness requirements are specified.
    Filler Metal Classification
    F Numbers are based on usability
    characteristics i.e ability of welders to make
    satisfactory welds with given filler
    e.g. F1 - E XX20, F2 - E XX12,
    F3 - E XX10, F4 - E XX18 etc.

    A Numbers are based on chemical


    composition
    e.g. A1 - Mild steel A2 - C - Mo steel etc.
    WPS for SMAW
    Essential variables

    Change in qualified Thickness


    Change in P no
    Change in F no of filler metal
    Change in A no of filler metal
    Change in deposited metal thickness
    Decrease of more than 100° F in preheat
    Change in PWHT
    WPS for SMAW
    Welded Qualified
    Px – Px Px – Px
    Px – Py Px – Py
    P3 – P3 P3 – (P3 / P1)
    P4 – P4 P4 – (P4 / P3 / P1)
    P5A – P5A P5A – (P5A / P4 / P3 / P1)
    P5A – (P4 / P3 / P1) P5A – (P4 / P3 / P1)
    P4 – (P3 / P1) P4 – (P3 / P1)
    Procedure Qualification
    Thickness limits
    T (mm) Range of T max t Tests

    <1.6 T - 2T 2t 2T, 2 FB, 2 RB


    1.6 – 10 1.6 - 2T 2t -do-
    10 - 19 4.8 - 2T 2t -do-
    19 - 38 4.8 - 2T 2t if t<19 2T, 4 SB
    2T if t>19
    >38 4.8 - 203 2t if t<19 -do-
    203 if t>19
    Welding Performance Qualification

    The performance qualification tests are


    intended to determine the ability of welders to
    make sound welds
    A welder is qualified by radiography of a test
    coupon or by radiography of initial production
    welding or by bend tests taken from a test
    coupon
    Welding Performance Qualification
    Variables for SMAW

    Removal of backing
    Change in Pipe diameter
    Change in P number
    Change in F Number
    Change in thickness of weld deposit
    Change in welding position
    Change in vertical welding
    Welding Performance Qualification

    Thk (mm) Max tk of dep. Metal Test


    <13 2t 1FB, 1RB
    >13 Max to be welded 2SB

    OD of test coupon Range of OD qualified


    <25 Size welded - unlimited
    25 - 71 25 - unlimited
    > 71 71 - unlimited
    Welding Performance Qualification
    Welded Qualified
    Without Backing
    Fx Fx
    With Backing
    F1 F1
    F2 F2, F1
    F3 F3, F2, F1
    F4 F4, F3, F2, F1
    F5 F5, F1
    Welding Performance Qualification

    Weld Plate & pipe Pipe of OD


    >610 mm OD 71- 610 mm
    Plate 1G F F
    Plate 2G F, H F, H
    Plate 3G F, V F
    Plate 4G F, O F

    Pipe 1G F F
    Pipe 2G F, H F, H
    Pipe 5G F, V, O F, V, O
    Pipe 6G All All
    Thank you

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