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Overlay (Required Tests)

This document provides thickness limits and test requirements for qualifying hard-facing (wear-resistant) and corrosion-resistant overlays. It specifies that for procedure qualification of overlays under 1 inch thick, a single test coupon of the nominal base metal thickness is qualified to unlimited thickness. For overlays 1 inch thick or over, a test coupon of the nominal base metal thickness qualifies overlays up to 1 inch thick. Performance qualification allows unlimited qualification for all thicknesses under 1 inch, and thickness over 1 inch requires a test coupon of that thickness. The document provides notes specifying test coupon dimensions and requirements, examination methods, specimen removal locations, and other testing details.

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936 views1 page

Overlay (Required Tests)

This document provides thickness limits and test requirements for qualifying hard-facing (wear-resistant) and corrosion-resistant overlays. It specifies that for procedure qualification of overlays under 1 inch thick, a single test coupon of the nominal base metal thickness is qualified to unlimited thickness. For overlays 1 inch thick or over, a test coupon of the nominal base metal thickness qualifies overlays up to 1 inch thick. Performance qualification allows unlimited qualification for all thicknesses under 1 inch, and thickness over 1 inch requires a test coupon of that thickness. The document provides notes specifying test coupon dimensions and requirements, examination methods, specimen removal locations, and other testing details.

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laz_k
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2011a SECTION IX

QW-453
PROCEDURE/PERFORMANCE QUALIFICATION THICKNESS LIMITS AND TEST
SPECIMENS FOR HARD-FACING (WEAR-RESISTANT) AND CORROSION-
RESISTANT OVERLAYS
Corrosion-Resistant Overlay Hard-facing Overlay (Wear-Resistant)
[Note (l)] [Note (2)]
Thickness of Test Nominal Base Metal
I
Type and Number of Nominal Base Metal
I
Type and Number
Coupon (T) Thickness Qualified ( T) Tests Required Thickness Qualified (T) of Tests Required
Procedure Qualification
Testing
Less than 1 in. (25 mm) T T qualified to unlimited
1
T qualified up to 1 in.
)
1 in. (25 mm) and over T
1 in. (25 mm)
Notes (4), (5), and (9)
(25 mm)
Notes (3), (7), (8), and (9)
to unlimited 1 in. (25 mm) to
unlimited
Performance
Qualification
Testing
Less than 1 in. (25 mm) T T qualified to unlimited
1
T qualified to unlimited
1
1 in. (25 mm)
Note (6)
1 in. (25 mm)
Notes (8) and (IO)
1 in. (25 mm) and over T
to unlimited to unlimited
NOTES:
(1) The qualification test coupon shall consist of base metal not less than 6 in. (150 mm) x 6 in. (ISO mml. The weld overlay cladding shall be
a minimum of 1 Yz in. (38 mm) wide by approximately 6 in. (ISO mm) long. For qualification on pipe, the pipe length shall be a minimum
of 6 in. (150 mm), and a minimum diameter to allow the required number of test specimens. The weld overlay shall be continuous around
the circumference of the test coupon. For processes (performance qualification only) depositing a weld bead width greater than Yz in. (13 mm)
wide, the weld overlay shall consist of a minimum of three weld beads in the first layer.
(2) The test base metal coupon shall have minimum dimensions of 6 in. (150 mm) wide x approximately 6 in. (150 mm) long with a hard-faced
layer a minimum of 1 Yz in. (38 mm) wide x 6 in. (ISO mm) long. The minimum hard-faced thickness shall be as specified in the Welding
Procedure SpeCification. Alternatively, the qualification may be performed on a test base metal coupon that represents the size of the production
part. For qualification on pipe, the pipe length shall be 6 in. (ISO mm) minimum, and of a minimum diameter to allow the required number
of test specimens. The weld overlay shall be continuous around the circumference of the test coupon.
(3) The hard-facing surface shall be examined by the liquid penetrant method and shall meet the acceptance standards in QW-195.2 or as specified
in the WPS. Surface conditioning prior to liquid penetrant examination is permitted.
(4) The corrosion-resistant surface shall be examined by the liquid penetrant method and shall meet the acceptance standards as specified in QW-195.
(5) Following the liquid penetrant examination, four guided side-bend tests shall be made from the test coupon in accordance with QW-161. The
test specimens shall be cut so that there are either two specimens parallel and two specimens perpendicular to the direction of the welding,
or four specimens perpendicular to the direction of the welding. For coupons that are less than in. (10 mm) thick, the width of the side-
bend specimens may be reduced to the thickness of the test coupon. The side-bend specimens shall be removed from locations specified in
QW-462.S(c) or QW-462.5(d).
(6) The test coupon shall be sectioned to make side-bend test specimens perpendicular to the direction of the welding in accordance with QW-161.
Test specimens shall be removed at locations specified in QW-462.S(c) or QW-462.S(d).
(7) After surface conditioning to the minimum thickness specified in the WPS, a minimum of three hardness readings shall be made on each of
the specimens from the locations shown in QW-462.S(b) or QW-462.5(e). All readings shall meet the requirements of the WPS.
(8) The base metal shall be sectioned transversely to the direction of the hard-facing overlay. The two faces of the hard-facing exposed by sectioning
shall be polished and etched with a suitable etchant and shall be visually examined with x 5 magnification for cracks in the base metal or the
heat-affected zone, lack of fusion, or other linear defects. The overlay and the base metal shall meet the requirements specified in the WPS.
All exposed faces shall be examined. See QW-462.S(b) for pipe and QW-462.5(e) for plate.
(9) When a chemical composition is specified in the WPS, chemical analysis specimens shall be removed at locations specified in QW-462.5(b)
or QW-462.5(el. The chemical analysis shall be performed in accordance with QW-462.5(a) and shall be within the range specified in the
WPS. This chemical analysis is not required when a chemical composition is not specified on the WPS.
(10) At a thickness greater than or equal to the minimum thickness specified in the WPS, the weld surface shall be examined by the liquid
penetrant method and shall meet the acceptance standards in QW-195.2 or as specified in the WPS. Surface conditioning prior to liquid
penetrant examination is permitted.
151

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