*

ls::6916-1973
( Reaffirmed 1998 )

Indian Standard
C.ODE OF PRACTICE FOR
FABRICATION WELDING OF STEEL CASTINGS
( Second Reprint DECEMBER 1993 )

UDC

BUREAU
MANAK

621791 : 6691414

OF
BHAVAN,

INDIAN
9
NEW

Gr 7

BAHADUR

STANDARDS
SHAH

ZAFAR

MARG

DELHI-110002

December 1973

t8 : 6916- 1973

Indian Standard
CODE OF PRACTICE FOR
FABRICATION WELDING OF STEEL CASTINGS
Welding

General

Sectional

Members
SHRI J. K. AHLIJWALIA
SHRI M. M. GHOSH (Alternate )
SHRI N. C. BAQCHI
SHHI B. C. BISWAS ( Alternata)
SHRI S. BALASUBRAHYANYAY
SHRI D. P. CHATTERJEE
SHRI B. N. DAS
Sam S. P. DASQUPTA

SMDC

14

Represcnhng

Chairman
SHRI R. Glrosri

Committee,

Indian Oxygen Ltd, Calcutta

Stewarts

& Lloyds of India Ltd, Calcutta

National

Test House,

Calcutta

Binny Ltd, Madras

Directorate
General
of Supplies
& Disposals
( Inspection Wing )
National
Metallurgical
Laboratory
( CSIR ),
Jamshedpur
Central Mechanical Engineering Research Institute
( CSIR ), Durgapur

SHRI B. SEN ( Alternate )

ENGINEER ( DESICJN-I), Public Works Department, Government of Haryana,
Chandigarh
B & R BRAPCH,CHANDIQARE
EXECUTIVE ENQINEER ( ELECTRI- Central Public Works Department,
New Delhi
ELECTRICAL
DIVISION
CAL ),
No. 1, NEW DELHI
EXECUTIVE
ENGINEER
( ELECTRICAL ),
CENTRAL
ELECTRICAL DIVISION No. 1,
CALCUTTA ( Altirnotc)
Engineer-in-Chiefs
Branch, Army Headquarters
SHRI C. P. GEOSH
Maltk Electric Works, Bombay
SHRI S. K. HARI
SERI J. G. SINQH (Alternate)
Bharat Heavy Electricals Ltd, Tiruchirapalli
SHRI V. G. JAQANNATA
SIIRI R. VISVANATKAN ( Altemutr )
holr
A. P. JAMBULINQAM
Indian Society for Technical Education,
New Delhi
JOINT
DIRECTOR ( M (t C ), RDSO,
Ministry of Railways
LUCKNOW
CHEMIST
AND
METALLUROIST,
INTEQRAL COACH FACTORY,
PERAMBUIZ ( Altsmate I )
PRODUCTION
ENQINEER
( SHELL ), INTEQRAL COACH
FACTORY, PEllAMBUR ( Altrrnatc 11 )
( Continued on page 2 )
EXECUTIVE

@ Copyright 1973
BUREAU OF INDIAN STANDARDS
This publication
is protected
under the Indian Copyright Act (XIV
of 1957) and
reproduction in whole or in part by any means except with written permission of the
iublisher shall be deemed to be an infringement
of copyright under the said Act.

IS:6916 - 1973
( Continued from page I )
Represenhg

Members
SRRI $1. v.

1). T(AXIATII

SHKI C. s. KOIIII(AI.
Snc~ A. P. SAHYAL
SHRI S. MAJ~MDA~

Indian
Bharat
(Alternate

Engineering
Heavy Plate

Association,
Calcutta
& Vessels Ltd, Visakhapatnam

Directorate
General
New Delhi

of

Technical

Development,

SHRI I-1. K. SIIAR~IA ( Alternate )

Advani Oertikon
Private Ltd. Bombay
Srrn~ S. V. NAIIXARNI
SBRI P. S. VI5WANATK
( .-ihnate
)
Sam
R. NARAYANA RAO
Hindustan
Aeronautics
Ltd, Bangalore
SARIS. SATHYANARAYANAN
RAJU ( Alternate)
SHIU V. G. G. NAYA~
Power Cables Pvt Ltd, Bombay
SHRI A. h4. LOTHE (Alternate)
Directorate
General
of Employment
& Training,
COL S. G. PENDSE
New Delhi
.SHRI H. L. PRAUHARAI~
Larsen & Toubro Ltd, Bombay
Tata
Engineering
&
Locomotive
Co
Ltd,
SIIRI K. G. K. RAO
Jamshedpur
DR J. JAIN ( dIlernate)
SHRI P. B. RAO
Ministry
of Defence ( DGI )
REPRESENTATIVE
Braithwaite
and Co ( India ) Ltd, Calcutta
SHRI S. C. ROY
Central Boilers Board. New Delhi
SIIKI V. V. SATHYANARAYANA
Mining & Allied Machinery
Corporation,
Durgapur
SnRI N. KRU~H~A~~~<THY ( Affernale )
SHRI S. K. SENQUPTA
Hindustan
Steel Ltd, Ranchi
SHRI V. V. KAVISWAI~ ( iillernate )
~ultr N. K. SETH1
Bharat Heavy Electricals
Ltd, Hardwar
Slrnr V. R. SKJBRAMANIAN
Indian Oxygen Ltd, Calcutta
SI~ICIJ. C. ACIiARYA f lllfernale)
5 I I E I1 I N TEN D I N 0 I<SOTNEER, Public Works Department,
Government
of Tamil
<:ENTIl.41.h~ECH.4NI('AI. ~:IIIc.L1;,
Nadu, hladx-as
MAI)RAY
sHI1I T. s. \.ELU
Hindustan
Sllipvard
Ltd, Visakhapatnam
SHILI R. 1~. SRIVASTA\A.
Director
General.
IS1 CEx-o/ho Member)

Those

IS : 6916- 1973

Indian Standard
CODE OF PRACTICE FOR
FABRICATION WELDING OF STEEL CASTINGS
0.

FOREWORD

0.1 This Indian Standard was adopted by the Indian Standards Institution
on 27 February 1973, after the draft finalized by the Welding General
Sectional Committee had been approved by the Structural and Metals
Division Council.
0.2 Repair and rectification of steel castings by metal arc welding processes
This standard has been prepared
have been covered by IS : 5530-1969*.
to specify satisfactory procedures for welding together two or more of steel
castings to produce a larger cast fabrication or to form a part of a complete
welded system. In all such cases the use of welding should be taken into
account at the design and/or casting stages unlike the circumstances when
welding according to IS : 5530-1969 would be required.
0.3 Fabrication welding principles required that proven welding procedures
I are used and although full details on procedure and testing are included,
the requirements have been kept to the minimum necessary to ensure
Manual metal arc and gas-shielded arc and
sound joints are produced.
submerged arc welding processes are covered for the present. Other
fusion welding processes like electro slag welding will be included in due
course after the industry gains experience in adopting them for the
fabrication welding of steel castings.
0.4 The content of the standard follows the general pattern established in
IS : 5530-1969*.
Some typical
weld preparations have been included
but each joint has to be considered in respect of its particular characteristics
and it is for this reason that only guidance has been given in certain
clauses. Similarly, no acceptance levels for welded joints are specified
and these should be the subject of agreement between the contracting
patties if an application standard does not cover them. Care is needed
in the interpretation of the results of non-destructive testing bearing in
mind the allowable defects which may be present in the castings in the
vicinity of the welded joint.
*Code of procedure for repair and rectification of steel castingsby metal arc welding
process.
3

: IS : 6916 - 1973
0.5 This standard

keeps in view the manufacturing

and trade practices
being followed in the country in this field.
Assistance
has also been
derived
from BS : 4570 Part 2-1972 Specification
for fusion welding of
steel castings, Part 2 : Fabrication
welding ( metric units ) .
0.6 For the purpose
standard is complied
the result of a test
The
IS : 2-1960*.
off value should be

of deciding whether a particular

requirement
of this
with, the final value observed or calculated,
expressing
or analysis, shall be rounded off in accordance
with
number
of significant
places retained
in the rounded
the same as that of the specified value in this standard.

1. SCOPE
1.1 This standard specifies requirements
for the joining together of steel
castings by fusion welding, where the components of the final fabrication
are designed for that purpose or when welding is introduced
at the foundry
planning stage.
1.1.1 It does not cover the welding of steel castings
nor the surface deposition of weld metal for applications,
resistance or hard facing.

to wrought steels,
such as corrosion

2. TERMINOLOGY

2.1 Terms used in this standard

shall have the meaning

assigned

to them

in IS : 812-1957t.

3. CASTINGS
3.1 This
Standards

standard
relates to steel castings
listed in Table 1.

conforming

to the

Indian

3.2 Condition of Casting - The casting prior to welding shall be sound

and free from defects in the vicinity
of the joint to be welded for a
minimum distance equal to the thickness of the casting at the joint.
4. DISSIMILAR STEELS

4.1 Where it is necessary to join steel castings of widely different chemical

composition,
special consideration
should be given to the choice of preheating temperature,
welding consumables
and post-weld heat treatment.
In general, the pre-heating
temperature
should be the higher temperature
recommended
for the steels being welded, but exceptions
to this may
*R&a for rounding off numerical values ( revised).
?Glowary of terms relating to welding and cutting of metals.

18I 6916- 1973

arise, for example, when one of the components is made of austenitic manganese-steel. No generalization
is possible regarding the choice of welding
consumables
or post-weld
heat treatment
which will be governed
by
meta!lurgical
and service considerations.
5. WELDING

CONSUMABLES

filler wire, filler wire/flux combinations,

5.1 Weld Metal - Electrodes,
filler rod and fusible inserts shall produce
weld metal that meets the
following requirements.
5.1.1 Mechanical Properties - The mechanical
properties
of the weld
metal shall generally be at least equal to the minimum in the specification
for the steel castings being joined together.
In some cases it is not necessary
to have matching
mechanical
properties and then it is permissible
to use weld metal having different
mechanical
properties
from those of the parent metal provided the
manufacturer
can demonstrate
its suitability for the service intended
after
any post-weld heat treatment
for the particular
fabrication,
or, alternatively, it is specified by the purchaser.
5.1.2 Chemical Composition - In general, weld metal shall be of similar
chemical composition
to that of the parent material,
although in certain
- instances it is not essential for design purposes, nor is it always desirable
In such cases it is perfor reasons of weldability
or behaviour in service.
missible to use weld metal having a different chemical composition
from
that of the parent material
provided the manufacturer
can demonstrate
its suitability
for the service intended,
or, alternatively,
it is specified by
the purchaser.
5.13 Electrodes, Filler Wires and Filler Rods - Details of the electrodes,
filler wires and filler rods that are appropriate
for various welding
processes are given in Table 1.
5.1.4 Submerged-Arc Welding Consumables - Flux/electrode
wire combinations shall be such that the weld metal chemical composition
is similar to
that of the parent metal or as otherwise agreed between the contracting
parties (see Appendix A).
Since welding conditions have a significant effect on the weld metal
chemical composition,
the required composition shall be established under
test conditions similar to those to be used on the actual fabrication.
Particular care shall be taken controlling welding conditions to ensure consistent
weld metal composition,
especially
where
the alloying
elements
are
contained
in the flux.

TABLE 1 RECOMMENDED
METHODS
OF WELD PREPARATION,
SELECTION
OF WELDING
CONSUMABLES,
PREq AND POST-WELD
TREATMENT
TEMPERATURES
FOR DIFFERENT
INDIAN
STANDARD
GRADES OR STEEL CASTINGS
(C6uuses3.1,5.1.3,
SL

STEEL'~YPE

SPECIFICATION
ANDGRADE

No.

13.2, 13.2.1 andl5.1)

REC0MbfENDATIONSFOR
METHOD
OF
h_-_----_--r------------_
WELD
Minimum
PREPARATION
Electrodes and Filler Material
_-----h______~
Preheat( seee
7.2 )

Manual
metal arc
-welding

(1)
1.

(2)
Low-carbon

Q\

(3)

(4)

Gas
shielded
welding

Submerged arE
welding
(7)

(6)

(5)

ing Tempeiature
( see 13 )
OC
(8)

G:
---7

Post-Weld
Heat Treatment Temperatu
( see I! I
(:

IS: 1030, Grade 3

IS : 2856, Grade
csw-c20
IS : 2985
IS : 2986
IS: 4491, Grades 1
&2
IS : 4899, Grade 1

a, b, c or d

IS : 814,
Groups 1
&2

IS : 6419,
S-l, s-3,
s-4

IS

: 3613

None.

580-650
(Note 1

IS : 814,
Group 2

IS : 6419,
s-2

IS

: 3613

Note 2

600-650
(Note3)

2.

0.25 to
0.35 c

IS : 1030, Grade 2
IS : 2856, Grade
CSW-C25

a, b, c or d

3.

0.35 to
0.45 c

IS

a, b, c or d

IS: 814,
Group 2,
( Note 4 )

IS : 6419,
s-2
( Note 4 )

4.

C-MO

IS : 3038, Grade 2

a, b, c or d

IS

Note 5

5.

1.5 Mn

IS
IS

a, b, c or d
( Note 6 )

IS : 814,
Group 2

IS

: 1030, Grade 1

IS : 4899, Gra.de 1

: 3038, Grade 1
: 2708, Grades 1

&2

FIE
;;,

: 1395

: 6419,

Siote

4)

150

600-650
( Note 3 )

Note 5

150

630-680
(Note 3 )

IS : 3613
( Note 4 )

150
( Note 7 )

IS: 3613

600-650
( Note 8 )

2f

6.

1.6 Mn

IS : 2708, Grade 3

a, b, c or d
( Note 6)

7.

Austenitic
manganese

IS

a, c, or d

8.

High tensile

IS

: 2644, Grades 1
&2

a, b, c or d
(Note 10)

Note 5

9.

1.25 Cr-Mo

IS

: 3038, Grade 5

a, b, c or d
(Note 10)

: 3038, Grade 5

a, b, c or d
(Note 11)

Cr-Mo

IS

: 276

10.

2,25

11.

5 Cr-Mo & 9

12.

9 Cr-Mo

IS

13.

Cr-MO-V

IS: 3038,

14.

13 Cr & 13
Cr-Mo

IS :3444, Grades I,
2&3

IS : 3038, Grades 6
&7

: 3038, Grade 7

Grade 3

a, c or d
(Note 10)

IS: 814,
Group 2

IS : 3613
( Note 4 )

200

600-650
(Note8)

Note 5

Note 9

None

Note 5

Note 5

200
( Note 11 )

600-650
f Notes
& 12)

IS : 1395,
Group C

IS : 6560,
SLA-3

Note 5

250

630-680

IS : 1395,
Group D

I,$ ;:;0,

Note 5

250

680-710
( Note 12 )

IS : 6560,
SLA-5

Note 5

300

650-720
( Note 13

IS : 5856,
S-B02,
MoL,
S-B02 MO
( Note 14 )

Note 5

300

650-720
(Note

IS : 6560
SLA-4
(Note 15 )

Notes 5
Br 15

250

680-7 10
( Notes 15
& 16)

IS : 5856,
S-BOlNb,
S-BO4,
S-B05Nb,
S-B02 MO
( Notes 14
& 17 )

Note 5

300

680-750
( Note 18)

IS :5206 or
any suitable
austenitic
electrode
with
or
without
a
facing
of
austenitic
manganese
steel

IS : 1395.
(Note5)

a, c or d
Kotc 5
( Note 10 )

a or
(Note

c
IO)

a or c
(Note 10)

Not<* 4

Notes 5 Sr
15
Note 5

13)

OI
I

( Contintred

) . ..

J
*

W.

TABLE 1 RECOMMENDED
METHODS
OF WELD PREPARATION,
SELECTION
OF WELDING
CONSUMABLES,
PRE. AND POST-WELD
TREATMENT
TEMPERATURES
FOR DIFFERENT
INDIAN
STANDARD
GRADES OR SIEEL CASTINGS-Confd
SL
No.

STEELTYPE

(1)

(2)

15.

SPECIFIC.~TION
AND GRADE

METROD OF
RECOYYBNDATIONSFOR
_---__
h---_----__----~
WELD
r---PREPARATION
Minimum
Electrodes and Filler Material
~--__-~-_--_-___
Preheat( see 7.2 )
Gas
Submerging TemManual
shielded
metal arc
cd arc
perature
welding
welding
welding
( y$
)
(4)

(3)

18 Cc 8 Ni

Ni/

IS

: 3444, Grade 6

16.

18 Cr8
Nb/Ti

17.

18 Cr 8 Ni
MO

18.

18 Cr 1ONi
2.5 MO

19.

18 Cr 10 Ni
2.5 Mo-Nb

IS

20.

18Cr 10Ni
3.5 MO

IS : 3444, Grade 10

IS

: 3444, Grades G,
7,8 & 9

(6)

a,cor
d
( Note 6 )

IS : 5206
(Note 14)
MAOl,
MBOlL

Ij ~$56,

a, c or d
( Note 6 )

IS : 5206
MB01 Nb

IS : 5856,
S-BOlNb

S:BOli
S-B0 1tib
(Note 19 )

(7)
Kores 5
& 19

(8)
IJone

(9)
1000-l 100
( Note 20 )

Note 5

None

Note 16

Note 5
IS : 5856,
IS : 5206,
S-BO2MoNb
MBO2Mo.
MB02MoL.
S-B02MoL
MB02MoNb

None

Note 16

Note 5

I
IS

(5)

Post-Weld
Heat Treatmen t Tcmperature
( sez;S )

I
: 3444, Grade 11 1 a, c or d
:

( Note 6 )

: 3444, Grades
12 & 13

I
J
a, cord
( Note 6 )

IS : 5206,
MB03Mo

IS : 5856.
S-B02Mo
S-B02MoL

Note 5

None

1000-1 150
!El,

p i d

;I,
y
o\

g
;:

TABLE f RECOMMENDED
METHODS
OF WELD-PREPARATION,
SELECTION
OF WELDING
CONSUMABLES,
PRE- AND POST-WELD
TREATMENT
TEMPERATURES
FOR DIFFERENT
INDIAN
STANDARD
GRADES OR STEEL CASTINGS - Contd

tf
*
$

NOTE 4 - The tensile strength

the yield stress is satisfactory.

s
1.
CI
3
w

of these filler materials

is rather

low compared

NOTE 5 -No
suitable electrode or fill& wire complying with an Indian
types are manufactured and marketed under various trade names.
NOTE 6 -

with that of the cast steel but

Standard

is available,

although

suitable

If any method except (a) is used, it shall be followed by grinding.

actual preheat temperature will depend on the chemical composition.

The value quoted is for
NOTE 7 -The
The application of a carbon equivalent formula
analysis which are towards the upper end of the composition range.
may be helpful in determining preheating temperatures for this grade of steel.
NOTE 8 - A lower post-weld heat treatment may be necessary for certain hardened and tempered castings in
order to maintain the specified tensile strength, but if this is done, the time at the hea: treatment temperature may
have to be extended to ensure adequate stress relief.
NOTE 9 z

This steel shall not be preheated and the interpass temperature

NOTE 10 - If any method except

followed by grinding.
NOTE 11 NOTE 12 -

Depends on composition

(a) is used,

the casting

shall

of steel; higher temperatures

shall not be allowed to exceed 200C.

be preheated

and the

preparation

shall

be

may be necessary.

For heavy sections and steels of certain compositions Note 13 may apply.

NOTE 13 - Extreme care is needed when weldmg these steels which require immediate
to minimize the risk of cracking.
NOTE 14 -These

filler materials have non-matching

NOTE 15 -Welds
NOTE 16-Welds

made using vanadium

post-weld heat treatment

compositions and/or properties to the parent casting.

bearing electrodes are susceptible

to carbide

embrittlement.

in this material shall be ground at the toes, before post-weld heat treatment,

if any.
NOTE 17 - In the case of steel castings to IS : 3038-1965, Grade 3 and IS : 3444-1966, Grade 1, the filler wires
In the case of these the following consideraspecified are not suitable for those parts of castings subject to abrasion.
tions also apply:
a) In all cases, particularly when it is intended to use austenitic filler wires to minimize the risk of cracking,
reference should first be made to the service requirements of the casting for hardness, corrosion and
abrasion resistance, fatigue and tensile properties and appearance.
b) A 13.percent chromium filler wire may be used provided a satisfactory weld can he made.
NOTE 18 - Extreme care is needed when welding this steel which requires immediate post-weld heaf treatment to
avoid cracking.
When certain austenitic steel electrodes or fi!lcr metals have been used it may not be essential to
apply any post-weld heat treatment.

NOTE 19 -

Weld

before

final heat treatment.

during pant-weld beat treatment the temper brittlencsr

range ( 540.65OC) i: to be avoided. Hold the casting within the prucribed range for not icsa than one hour per
25 mm of thiokneu. Quench all parts of ,thc casting uniformly
and as rapidly as porsible.
Material not stabilized
NOTE 20 -

In the case of high Cr and Cr Ni steel castings

with columbium
or titanium
should be cooled through the range of ( 920-540 ) in not more than three minutes.
The
rapid-cooling
should be continued
to below 425C.
Slower cooling rates may- be just as satisfactory
for some comp&
tion of the matciial
and conditions
of service.
NOT= 21 -

z
^

Should

not be used for surfaces

subject

to abrasion.

NOTX 22 - Care should be taken to ensure that the low temperature

weld metal properties
are appropriate
for
rervice conditions.
No~lp 23 -The
following standards
are referred to in Table 1 and the notes above.
IS : 276-1969 Specification for austenitic
manganese
steel castings (second rcuision)
IS : 814-1970 Specification
for covered electrodes for metal arc welding of structural
steel ( third r&&n ) ( Since rcviacd
and split into various parts ).
IS : 1030-1962 Specification
for steel castings for general engineering
purposes ( revised) ( Since revised ).
kS: 1395-1964 Specification
for molybdenum
and chromium
molybdenum
low alloy steel electrodes for metal-arc
welding ( reoised ) ( Since revised ).
IS : 2644-1969 Specification
for high tensile steel castings (4~1 revision )
IS : 2701-1964 Specification
for brush, carriage washing ( widrout handle )
IS: 2708-1964 Specification
for 1.5 percent manganese
steel castings
( Since revised ).
IS

: 2856-1964

Specification
for carbon steel castings suitable for high temperature
service ( fusion welding quality )
( Since revised ) .
IS : 2985-1964 Specification for steel castinga for ships structure
( Since revised ).
IS : 2986-1964 Specification
for steel castingr for marine engines and boilers
IS : 3038-1965 S ccification
for alloy steel castings for pressure containing
parts suitable for high temperature
service
(!LHAd).
IS : 3444-1966 Specification
for corrosion resistant steel castings
IS :,3613-1966
Specification
for acceptance
tests for wire flux combinations
for submerged-arc
welding equipment
( Since revised ).
IS: 4491-1968 Specification
for steel castings of high magnetic
permeability
IS : 4522-1966 Spccificarion
for heat resistant alloy steel castings
IS : 4898-1968 Specification
for steel castings for case carburizing
IS : 4899-1968 Specification
for ferritic steel castings for use at low temperatures
IS : 5206-1969 Specification
for corrosion-resisting
chromium
and chromium-nicklc
steel covered electrodes
for manual
metal arc welding.

3
w

IS

6916 - 1973

5.2 Storage and Handling - E?lectrodes, tiller wires and rods, and fluxes
shall be stored, handled and used in accordance
with the manufacturers
recommendations.
In certain cases re-drying or re-baking of electrodes
above the minimum temperature
recommended
by the manufacturer
may
be advantageous,
but the maximum
permissible temperature
for a particular electrode should be ascertained
from the manufacturer.
Electrodes,
filler wires and rods, and fluxes that show signs of damage or deterioration
shall not be used.
5.3 Shielding

and Purging Gases -

it shall be of the following quality,

When a gas or gas mixture

as appropriate:

The gas shall comply with the requirements

is used

of IS : 5760-

Argon -

bl

Carbon Dioxide -The

gas shall comply with the requirements
of
IS : 307~1966+.,
Gas Mixiurrs - The use of gas mixtures is permissible provided
that they have proved to be satisfactory as a result of procedure
qualification
tests.

1970*.

c>

When a gas mixture is used which has specified additions

the
variation of such additions shall not exceed f IO Fent
of stated value.
Moisture

content

shall

correspond

to a dew

point of - 30C or

lower.
6. EQ,UIPMENT
6.1 Welding plant, instruments, cables and accessories shall comply with
the requirements of the appropriate Indian Standard where available.
Their capacity shall be acje uate for the welding procedure proposed and
subsequently to .be qualifi 4 . The contractor shall maintain all welding
plant and ancillary equipmentin
good working order.
6.1.1 All electrical equipment used in connection
operation shall ,bc adequately earthed.

with

the welding

6.2 Adequate means of measuring current shall be available either as part

of the welding plant or by the provision of a portable ammeter. 1~ the
case of automatic and semi-automatic
welding, means shall be provided
for measuring accurately the arc voltage since this exerts considerable
influence on the form, composition
and soundness ( that is, porotity ) of
the weld.
6.3 When using a gas-shielded
gas flow shall be provided.

welding

process, means

%pecifiution for comprcuce argon.

tSpcification for carbon dioxide ( second rroision).
12

of measuring

the

IS t 6916- 1973
6.4 Where necessary, staging and protection from the weather shall be
provided to enable the welding operation to be performed properly. This
is particularly necessary when using a gas-shielded welding process.
7. PREPARATION

FOR WELDING

general, these should follow the

7.1 Types of Weld Preparation -In
same shapes as for wrought materials, based on thickness and access for
welding. Some typical preparations are given in Fig. 1 and 2.
Joint should take the form of butt welds between equal thickness
sections where possible, in order to facilitate welding and inspection.
7.2 Methods of Preparation - The following methods may be used,
but the final method of preparation shall be determined by the configuration required:
a) Mechanical methods, including machining;
b) Flame gouging;
c) Carbon-arc or metal-arc gouging in combination
with air or
oxygen or other suitable gases; and
d) Powder washing.
The suitability of these methods for specific steels is given in Table 1.
NOTE- Sound welding is more likely to be achieved if preparation for welding
is taken into account at the design and foundry stages. In some instances the casting
can be provided with a preparation
without
the need for further mechanical
or
thermal treatment, other than shot blasting.

7.3 Fusion Faces-The

foundation for welding shall be good and the
exposed material shall be sound and free from all foreign matter.
When the service conditions demand, it may be necessary to apply
suitable non-destructive testing to prove that the fusion faces and adjacent
areas are acceptable to the contracting parties. In certain cases, filamentary
shrinkage may be sealed-off by suitable means, subject to agreement between the contracting parties ( see Appendix A ).
8. BACKING STRIPS AND BARS
8.1 Backing Strips ( Permanent ) - In certain circumstances of access,
to ensure Full penetration with a single V or U preparation, a backing
strip may be used, in which case it shall be of a type agreed to between
the contracting parties. Careful consideration shall be given to the method
of attaching backing strips, for example, intermittent welding along the
edges to attach it to one or both members is not permissible where fatigue
conditions operate in service.
Backing strips shall not be attached by
welding all round their perimeter in order to minimize the risk of basal
cracking ( see Appendix A ).
13

(a)

b)

NoTII-T~~
dimension for the gap depends
on the welding
process
being
used and
whether a fusible insert is to be employed.

dimension for the gap depends on the welding process

NOTE -The
being used and whether a fusible insert is to be employed.

/-lOoMIN 7

3MIN

--+

lO*MIN
IOMIN

bpreparation may be used with or without a backing

NOTE -Each
strtr$ the dimension for the gap depends on the welding process being

(4

FIG. 1 TYPICAL

All dimensions in millimetres.

JOINT PRRPARATT~NI PIP Wa.r.nrNn

URCW

Om

Snm.

U:6916-1973,

( b)

(d)

NOTE - Certain
welding
procedures
achirve
full penetration
without
back
gouging, but where this cannot be proved, the back of the first run shouid be gouged
out by suitable means to clean sound metal before welding is started on the gouged
outside.
All dimensions

Fm. 2

in millimetres.

TYPICAL JOINT PREPARATIONSFORWELDING FROMBOTH SIDES

15

1s 16916 - 1973
8.2 Metal Backing Bars ( Temporary) - When a metal backing bar is
used it shall be of similar chemical composition
to that of the casting or
it shall be a carbon steel up to 026 percent
carbon provided that the
sulphur and phosphorus contents do not exceed O-04 percent each. Backing
bars shall not be welded all round their perimeter in order to minimize
the risk of basal cracking.
8.3 Copper Backing Bars - Copper backing bars shall only be used by
agreement
between
the contracting
parties since there is a danger of
copper pick-up in the weld metal ( see Appendix A ).
backing
bars shall be of
8.4 Non-ametal Backing Bars - Non-metal
non-combustible
materials and shall be completely
removed after completion of welding.
9. ASSEMBLY
9.1 To maintain
the required
alignment
and gap where used, during
welding,
the parts to be welded shall be securely
held in position
by
mechanical
means, welded-on
bridge pieces, or by tack welding. When
sufficient weld metal has been deposited
to make the fabrication
selfsupporting,
bridge pieces or mechanical
clamps shall be removed and
potential
distortion
controlled
by welding
sequence
rather
than
by
mechanical
restraint.
NOTE-Cracking
can result if bridge-pieces or mechanical
position during completion of the weld.

clamps remain in

9.2 Preheating,
as required by 13, shall be applied and maintained
during
tack welding and the welding-on
of bridge pieces or other attachments.
9.3 Electrodes, filler rods or filler wires used for tack welding shall be of
the same type and class and of a size not larger than those used for
completing
the first run of weld metal.
9.4 Particular
attention
shall be paid to the quality of tack welds which
shall be made by qualified welders. The throat thickness of tack welds
made with filler metal shall be similar to that of the initial root run.
Where necessary,
the extremities
of these tack welds shall be dressed by
grinding or chipping to facilitate proper fusion when they are incorporated
in the root run. Any cracked tack weld made with or without filler metal
shall be completely
removed and retack-welded.
9.5 Care shall be taken when removing welded-on bridge pieces. Under no
circumstances shall they be knocked of, but removed by hack saw as disc grind=
at a point close to the surface of the casting. The remnants of the bridge
pieces and attaching
weld shall be removed by grinding or filing until the
surface contour of the casting is restored. The area embracing that exposed
16

IS : 6916 - 1993
by the welds that attached
the bridge pieces shall be examined
by nondestructive
means to determine
whether
rectification
is required
by
All welded-on
bridge pieces shall be removed
grinding
or by welding.
before applying
any post-weld heat treatment,
which shall include
the
area occupied by the bridge pieces,
10. DISTORTION

10.1 The welding procedure and production

sequence shall be chosen so
that distortion
is minimized;
this is particularly
important
when finished
machined castings are to be welded.
11. ARC STRIKES
11.1 Contact of the electrode or of the non-insulated
parts of electrode
holders with the casting shall be avoided.
A striking plate shall be used
for striking the arc or cleaning the tip of an electrode and not the casting.
NOTE- It is tecommcnded that electrode holders be of the fully insulated type.
11.2 Except when welding low carbon steel castings, an area on each side
of and adjacent
to the weld shall be protected
by suitable
insulating
means, so as to avoid arcing on,the casting surface. Welding return leads
shall be connected
to the work by some means that prevents damage by
sparking.
12. INTER-RUN

CLEANING

12.1 Each run of weld metal shall be cleaned

before a further
run is
applied, particular
attentioh being paid to the junctions
between the weld
metal and the fusion faces.
Visible defects, such as cracks, cavities and
other deposition faults shall be removed before deposition of further weld
metal.
13. PREHEATING

AND INTERPASS TEMPERATURES

13.1 Defidtions
13.1.1Preheating temperature
is the temperature
of the parent metal
in the welding region immediateIy
prior to. the absorption
of any heat
from the welding process and is anDlicable
to the first and all subsequent
runs.
13.13 Interpass tem+rature,
in a multi-run
weld, is the temperature
of a section of deposited
weld metal and adjacent
parent metal immediately prior to welding again at that section.
17

IS : 6916 - 1973
13.2 Preheating - No thermal
cutting or welding shall be carried out
when the temperature
of the castings is below 15C. Recommendations
for preheating
are given in Table 1 and during cutting or welding the
actual
preheating
temperature
prescribed
shall be maintained
in the
region of the weld.
13.2.1 If it is not possible to preheat the entire fabrication, either because
of its size or because the extent of the welding required is such that the
fabrication
will fall below the appropriate
temperature
specified in Table 1
before the completion of welding then local preheating
shall be used over
an area on each side of the weld having a width of at least three times
the thickness of the material.
Whichever method is used, it is preferable
to preheat
the fabrication
to a temperature
slightly higher than the
minimum
given in Table 1 so that either the weld is completed
before the
temperature
falls below the value stated or the number of reheatings
required is kept to a minimum.
14. COOLING AFTER WELDING
14.1 In general, low carbon steel and austenitic
cooled naturally
without precautions.
In the
shall be taken to ensure slow even cooling.

steel fabrications
may bc
case of other steels care

15. POST-WELD HEAT TREATMENT

15.1 The object of post-weld heat treatment
is to reduce stresses due to
welding, to reduce hardening,
to soften weld-hardened
zones or to achieve
specified properties.
Recommendations
for post-weld heat treatment
are
given in Table 1.
15.2 For many steels, the heat treatment
of the fabrication
shall be
considered
in relation
to any general heat treatment
to be applied to the
When such general
component
castings to provide specific properties.
heat treatment
has been applied before welding is done, it may be necessary to repeat the treatment
after welding.
15.3 The heat treatment
may be tif one of the following forms:
a) An immediate stress relief, where the fabrication
is stress relieved
before its temperature
falls below the minimum
preheating
temperature.
b) A final heat treatment
of the fabrication
carried out before its
temperature
falls below the minimum
preheating
temperature.
c) A stress relieving,
annealing,
normalizing
or quenching
and
tempering
heat treatment
carried out some time after the fabrication has cooled from the welding temperature.
When the
fabrication
has been
allowed
to go cold after welding,
the
temperature
of the furnace shall not be above 300C at ,the time
of inserting the fabrication.

IS I 6916 - 1973
15.4 Heat treatment shall be carried out by one of the following methods,
care being taken to ensure that the minimum stipulated temperature is
achieved uniformly through the thickness of the fabrication:
a) Heating in a stationary industrial furnace; and
b) Local heating using a portable muffle furnace, or induction coils,
or resistance heaters.
15.4.1

Manually-operated

gas torches shall not be used.

15.5 Where other methods of heating are the accepted practice in certain
industries these may be used by agreement between the contracting parties
but consideration should be given to the metalhtrgical effects of such
methods. The foregoing methods are, however, preferable ( JCGAppendix A).
15.6 The heatiug and cooling rates shall be appropriate to the material,
geometry and thickness which would be verified by the welding procedure
tests.
16. MEASUREMENT

OF TEMPERATURE

interpass and post-weld heat treatment

16.1 General - Preheating,
temperatures, where applicable, shall be checked during the period of
their application and all post-weld heat treatment conditions shall be
noted in the form of written records which shall be made available on
request.
16.2 Preheating and Interpass Temperatures - Preheating and interpass temperatures shall be checked by using thermocouples, pyrometers or
by temperature indicating paints or crayons when they are compatible
with the casting material.
indicating
paints
will not indicate by how much the
NOTE -Temperature
Some types of paint will not show, ooce the
minimum
temperature
is exceeded.
temperature
has been reached, that this temperature
is being maintained.
In these
cases the paint has to be re-applied if continued temperature observations
are to be
made.

16.2.1 When preheating is being applied by flame to the surface of the

casting being welded, the flame shall be removed for at least two minutes
before the temperature is checked.
16.3 Post-Weld Heat Treatment
Temperature
- Thermocouples shall
be used for recording post-weld furnace heat treatment temperatures.
16.3.1 For local treatment separately attached thermocouples shall be
used.
NOTE-Thermocouple
junctions
and wires should be protected
from flame
To. prevent direct radiation
from the heating elements on the hot
impingement.
junction when electrical resistance heating is used, thermocouples
should be covered
with a protective wrapping.

19

ts I 6916- 19?3
17. ALTERNATIVE

METHODS

OF STRESS

RELIEF

17.1 When fabrications

cannot
receive
planned
thermal
stress relief,
alternative
methods of stress relief may only be used by prior agreement
between the contracting
parties ( see Appendix A).

18. DRESSING
18.1 Dressing
reasons:

of the weld area

a) To facilitate

may

non-destructive

be necesrary

for any of the following

testing;

b) To remove notches, that would impair fatigue properties;

c) For service in corrosive environments;
and
d) To minimize
the risk of stress relief cracking
in the case of
Cr-MO-V steel and stabilized austenitic stainless steels.
The method of dressing shall be one of those given as (a), (b) and
(c) in 7.2.
When a thermal process is used the requirements
and precautions in 7 to 13 shall apply.
In such cases careful grinding shall follow
the thermal dressing.
Any post-weld
heat treatment
shall follow this
grinding.
Grinding
wheels for use on austenitic
stainless steels shall be
of the iron free type and shall have been used only on such steels.
19. INSPECTION
OF COMPLETED
WELDS
19.1 The method or combination
of methods and frequency of inspection

with the standard of acceptance

for completed
welds shall be as specified
in the standard for particular
application
or as agreed to between the contracting parties at the time of the enquiry and/or order (see Appendix A).
20. RECTIFICATION

OF FAULTY

WELDS

20.1 When welds fail to comply wholly or partly with the standard of
acceptance
derived in accordance
with 19, all unacceptable
defects shall
Preparation
and re-welding
shall be in accordance
with the
be removed.
requirements
of IS : 5530-1969*.
20.2 A repaired
weld shall be subjected,
as a minimum
requirement,
to
the same testing and inspection requirements
as the original weld.
2 1. PROCEDURE
QUALIFICATION
21.1 General
-The
object of procedure qualification
tests. is to prove the
feasibility
of a manufacturers
particular
welding
procedure
as distinct
from the ability of an individual
welder to deposit sound weld metal.
*Code
procclkr.

of procedure

for repair

and rectification

20

of steel carting

by metal arc weldimg

IS : 6916 - 1973

21.X.1 A manufacturer shall be exempt from making procedure qualification tests in accordance with this clause when he can show that for the
previous three years he has successfully undertaken welding in the fabrication of steel castings in compliance with satisfactcry welding procedures
in respect of welding process, type of steel, filler metal and approximate
thickness.
A manufacturer shall also be exempt when he can show that
he has previously made successful procedure tests of the type required.
21.1.2 In other cases, welding procedure qualification tests shall be
carried out before a manufacturer can be permitted to weld castings in
For each of the steels in Table 1 for
accordance with this standard.
which approval is required, the welding procedures shall specify the
details given in 21.2, including the operational ranges for each relevant
feature.
These welding procedures shall be submitted for approval by
the purchaser if requested.
21.1.3 Separate procedure qualification tests are not necessarily required
for each type of steel where proof of satisfactory performance does not
exist. Where welding procedures are similar with respect to welding
process, welding position, preheating, post-weld heat treatment, electrodes,
filler material, flux or shielding gas, then one welding procedure qualmfication test may be sufficient. When separate procedure tests are required
this shall be stated in the enquiry and/or order.
21.1.4 It is recommended that welding procedure qualification tests
carried out in accordance with this standard and witnessed by an independent inspecting authority should be accepted by other inspecting authorities
provided that all the provisions have been fulfilled.
records of the procedure
21.2 Procedkre
Test Records -The
fication tests shall specifically include the following details:

quali-

4 Type of steel;
b) Welding process;
cl Joint preparation;
4 Method of preparation;

e>Welding

f)

g)

position;
Preheating;
Welding technique and sequence;

J4 Electrodes,
j) Electrodes,
both;
J4 Electrical

filler materials,

flux and shielding gas;

or filler material
characteristics

size, or interpass,

and welding speed;

21

temperature

or

iS I 6916 - 1973

4
4

Post-weld heat treatment

heating and cooling rates);

( temperature,

time

at

temperature,

Test results; and

P) Identification

of inspecting

authority.

21.3 Requalification
of Procedure - A new procedure
qualification
test is required consequent
upon a change in any of the following:

4
b)

Type

of steel, subject

to relaxation

Welding process;
A change from a backed

c>

given in 21.1;

weld to an unbacked

weld;

subject to the extent of qualification

given
Welding
position,
in 21.6;
4 Any change in preheating or interpass temperature, or post-weld
heat treatment,
except when preheating is increased by not more
than 100C; and
f 1 Type of electrode, filler material, flux or shielding gas.
21.3.1 Any change in the make or size of electrodes or filler material
shall be reported to the purchaser, but this will not necessarily
result in
requalification.

21.3.2 In the absence of a change in any of the above items, the qualification of a procedure shall remain in force indefinitely.
21.4 Types of Test Joint - The joint used for a procedure qualification
test shall be representative
of that to be employed in production.
As it is
normally impracticable
to use actual production
castings for this purpose,
the test joint may be made between two cast p!ates or two cast pipes
according
to which are most representative
of the production
work to
which the procedure
being qualified is to relate. In all cases the material
for the test pieces shall be made by the same casting process and be of the
same type of steel as those used for production
work (see also 21.1 and
Appendix A ) .
21.4.1 For procedure
qualification
purposes, a test joint shall be made
for one or more of the following types of joint or weld, as stated in the
enquiry and/or as agreed to at the time of the order:
a) A butt joint ( plate and/or pipe ),
b) A fillet weld ( plate ), and
c) A branch connection
(pipes).
22

IS I 6916 - 1973
21.5 Position
21.5.1 Butt Joint or Fillet Weld Bttwetn Platts - A test joint shall be
made in each of the following welding positions that is to be used in
production:
a) Flat,
b) Horizontal-vertical,
c) Vertical,

and

d) Overhead.
Qualification
under (c) includes qualification
under (a) and qualification under (d) qualifies the procedure for use in all positions.
NOTE- Welding position is not an essential variable for branch connections.
21.5.2 Butt joint Bctwcrn Pipes - A test joint shall be made with the
pipes in one or more of the following positions according to which is most
representative
of production conditions:
a) Horizontal

rdtating,

b) Vertical fixed,
c) Horizontal fixed, and
d) 45 to horizontal tixcd.
cation

Qualification
under (c) includes
under (d) includes qualification

qualification
under (a) and qualifiunder (a) and (b).

21.6 Pipe Diameter for Butt Joints or Branch Connections -A

test
on pipe or branch pipe of outside diameter D shall qualify for diameters
in the range 0.50 - 1*5D.
21.7

Tests

Butt Joints Bctwrm Plates or Pipes

21.7.1.1&on-destructive examination - All test joints

21.7.1

shall be visually
If found to be acceptable and if radiography is to be used for
examined.
the examination
of.production
work, the test joints shall then be radiographed before the cutting of test specimens. Radiography
shall be carried
out in accordance
with the requirements
of either IS : 118%1967*
or
IS :4853-1368t
using the same technique as that to be used for production
work.
The-standard
of acceptance for each method of examination shall be
that determined in accordance with the riquirements
of 19.
-*Recommended practice for radiographic examination of fusion welded butt jointr in
steel plates (Jirsf rcuki~n ).
tRecommended
practice for radiographic
joints in steel pipes.

examination

23

of fusion wddcd

circumferential

__I_*
--.......__

..__~__.l_,I..

IS : 6916 - 1973
21.7.1.2

Transverse

be machine
cut
IS : 3600-1966*.
various thickness
has been used, it
The tensile
requirements
of
minimum
tensile

tensile iest - Transverse

tensile test specimens shall
from each test joint to the dimensions
specified. in
The number of test required to qualify a procedure
for
ranges shall be as shown in Table 2. If a backing strip
shall be removed prior to testing.
strength of specimens when tested in accordance with the
IS : 1608-196Ot shall be at least equal to the specified
strength for the casting material.

TABLE 2 TYPE AND NUMBER OF TEST SPEClMENS AND RANGE OF

THICKNESSES QUALIFIED (PROCFJJURES ) QUALIFICATIONS
THICKNESS,

:, or

TEST PLATE OR
PIPEAS WELDED

mm
1.5 to 10 including
Over 10, under 20
20 and over

OP THI~X~~E~~ES
TYPB AND Nvxsmt op T~CET
QUALIFIED
&!XJVIRED*
A---p-A------.
r-FaCe
MitB
MO%
Side
Root
ywdgd
mm
mm
Bend
Bend
Bend
Tension
2
2
1.5
2
2tt
5
2t
2
2
2
5
20
4
2
RANQE

*Either the face and root bend tests or the side bend tcrtr may be used for thicknroa
from 10 to 20 mm.
tThe maximum thickness qualified with pipe amaIler than 125 mm ir two timo the
thicknaa of the pipe brit not more than 20 nun.

21.7.1.3 Si& bead test -Side

bend test rpecimen shall be machine cut
from each test joint to the dimensions rpec&d
in IS: 3600-1966..
The
number of tests required to qualify a. procedure for various thickness ran es
shall be as shown in Table 2. If a backing strip has been used, it shall II c
removed prior to testing. The specimen shall be tested in accordance with
the requirements of IS: 36(H)-1966Yby bending it through at least 90
round a former of a diameter equal to bur times the thickness of the
specimen. When the parent metal is incapable of withstanding this test,
the former diameter and angle of bend should be modified accordingly.
After bending, the specimen shall show no signs of failure, although slight
premature tearing at the edges of the specimen need not be considered as
cause for rhjection.
21.7.1.4 Face and root bend test-Face
and root bend test specimens
shall be machine cut from each test joint to the dimensions specified in
IS : 3600-19668. The number of tests required to qualify a procedure for
various thickness ranges shall be as shown in Table 1. Weld reinforcement
and backing strip, if any, shall be removed flush with the surface of the
*Code of proc.cdurc for testing of ftuion welded joints and-weld metal in &eel. ( Sinoa
levimadaad
t&thod a#+t
or t~%?%~g%t!k!
products other than sheet, strip, wire and tube.
(Sincerevised).
24

IS t 6916 - 1973
specimen. If a recess strip is used, this surface of the specimen may be
machined to a depth not exceeding the depth of the recess to remove the
strip. The specimen shall be bent with a jig in accordance with IS :36001966*. Face bend specimens shall be placed such that the face surface
becomes the convex side of the bend specimen. In the case of the root
bend test the specimens shall be placed such that the root of the weld
becomes the convex side of the bend specimen. The specimen shall be
bent until the curvature of the specimen is such that 0.8 mm diameter
wire cannot be passed between the curved portion of the male member of
the jig and the specimen. The diameter of the former shall be equal to
four times the thickness of the specimen.
When the parent metal is incapable of withstanding this; test, the
former diameter and the angle of bend shall be modified accordingly.
After bending the specimen shall be examined for the appearance of
opened out defects. Any specimen having any such open defects exceeding
3 mm measured in any direction shall be considered as having failed.
Cracks occurring on the corners of the specimen during bending shall be
disregarded.
21.7.1.5 Macro-examination
-Each
test joint shall be sectioned at
These sections shall be prepared for
three places for macro-examination.
macro-etching and etched to give a clear indication of the weld structure.
The standard of acceptance shall be determined in accordance with the
requirements of 19.
21.7.2 Fillet Welds Between Plates and Branch Connections Between Pipes
21.7.2.1

test joints shall be visually examined,

being that determined in accordance with the

Visual examination-All

the standard of acceptance

requirements of 19.

21.7.2.2 Macro-examination
- Each test joint shall be sectioned at
These sections shall be prepared for
three places for macro-examination.
macro-etching and etched to give a clear indication of the weld structure.
The standard of acceptance shall be that determined in accordance with
the requirements of 19.
23.7.3 Hardness survey for All Test Joints - A hardness survey shall be
conducted across a cross section of the test weld and the results shall be
recorded for comparison with results of hardness surveys on production
welds when required.
The method of hardness testing shall be in accordance with IS : 1Sol-19687.
21.7.4 Imfiact Test -When
relevant from the point of view of service
conditions, impact tests shall be included in the assessment of the welding
*Code of procedure for testing of fusion weldedjoints and weld metal in steel. (Since
revised and split into variour parts ) .
tMethod for Vickera hardnesstest for steel (first rcuisron ).
25

iiil r 6916 - 1973

procedure. The number of test specimens, position of notches and impact
values to be obtained shall be mutually agreed between the manufacturer
and the purchaser. The method of testing shall be in accordance
with
IS : 3600-1966*.

21.7.5Repeat Tests - If any of the above tests show that the welds do
not meet the required standard,
two further test joints shall be made and
the tests repeated.
If either of these additional
test joints does not meet
the required standard,
the welding procedure
shall not be regarded as
capable of meeting the requirements
of this standard without modification.
22. WELDER QUALIFICATION
22.1 General - Welders employed on welding castings in accordance
with this standard shall have been successfully tested by the manufacturer
to the satisfaction
of an inspecting
authority
which shall be given the
opportunity
of witnessing the tests. In all cBses, complete records of such
tests- shall be available for inspection.
22.1.1 The welder who satisfactorily
completes the procedure
fication tests is thereby exempt from undergoing
separate welder
fication tests involving the same range of procedures.

qualiquali-

22.1.2 A welders qualification

to a particular
procedure shall remain
valid provided that it can be shown that the welder has, subsequent to the
test, been employed with reasonable continuity
on that procedure and has
continued
to produce satisfactory
welds as verified by non-destructive
examination.
Requalification
shall be required if:
a) during the preceding
six months or more the welder has not
been engaged in welding to this procedure, or
b) there is some specific reason to question the welders ability, or
c) it is necessary to requalify
the welding procedure,
unless the
change concerns only the preheating
temperature
or post-weld
heat treatment.
22.1.3 It is recommended
that welder qualification
tests witnessed and
accepted by one inspecthrg authority should be accepted by other inspecting authorities
so long as the welder remains in the employment
of the
same manufacturer.
22.2 Types of Test Joint - The joint used for a welder qualification
As it
test shall be representative
of that to be employed in production.
is normally impracticable
to use actual production castings for this purpose,
the test joint may be made between two cast plates or two cast pipes
according
to which are most representative
of the production
work to
*Code of procedure for
r&scdsndqlitintovariouapam).

testing of fusion welded joints and weld metal in steel. (She

i

26

I!i : 6916- 1973

Jn all cases the material
which the welder being qualified is to relate.
for the test pieces shall be made by the same casting process and be of the
same type of steel as those used for production work ( see Appendix A).
22.2.1 For welder qualification
purposes, a test joint shall be made for
one or rnore of the following types of joint or weld as stated in the enquiry
and/or as agreed to at the time of the order:
a) A butt joint

( plate and/or pipe ),

b) A fillet weld ( plate ), and

c) A branch

connection

Qualification
22.3

( pipes ).

under (a) includes

qualification

under (b).

Position

22.3.1 ButtJoint or Fillet Weld Behem Plates - A test joint shall be made
for each welding position that is to be used in production (flat, horizontalvertical, vertical or overhead ).
Qualification
in the horizontal-vertical
and vertical positions also
Qualification
in the vertical and
qualifies for welding in the flat position.
overhead
positions also qualifies for welding in the flat and horizontalvertical positions.
22.3.2 Butt Joint Between Pipes- A test joint shall be made with the
pipes in one or more of the following positions according to which is most
representative
of production conditions:
a) Horizontal
bj

Vertical

c) Horizontal

rotating,

fixed,
fixed, and

d) 45 to horizontal

fixed.

22.3.2.1
Qualification
under (c) includes qualification
qualification
under (d) qualifies for welding in all positions.

under (a) and

22.3.2.2
Qualification
on a butt joint between pipes also qualifies
for welding butt joints and fillet welds between plates for the same welding position.
22.3.2.3
connections.

Welding

position

is not an essential

variable

for branch

22.4 Pipe Diameter for Butt Joints or Branch Connections - A test

on pipe or branch pipe of outside diameter D shall qualify for diameters
in the range 0.50 - 1.50,
27

18 : 6916- 1973
22.5 Tests
22.5.1

Butt Joints Between Plates or Pips

22.5.1.1 Jfon-destructive examination -All

test joints shall be visually
examined.
If found to be acceptable and if radiography is to be used for
the examination of production work, the test joints shall then be radiographed before the cutting of test specimens.
Radiography shall be
carried out in accordance with the requirements of either IS : 118%1967*
or IS : 4853-1968t
using the same technique as that to be used for
production work.
The standard of acceptance
be that determined in accordance

for each method of examination

with the requirements of 19.

shall

22.5.1.2 Side bend test - Side bend test specimens shall be machine
cut from each test joint to the dimensions specified in IS : 3600-1966$.
The number of tests required to qualify a procedure for various thickness
ranges shall be as given in Table 3. If a backing strip has been used, it
shall be removed prior to testing.
3 TYPE AND NUMBER
OF TEST SPECIMENS
AND RANGE
THICKNESSES
QUALIFIED
( WELDERS PERFORMANCES
)

TABLE

THICKNESS

t. OF

RANGE

PIPEAS

bk.DED

mm

OF Tmc$mces

TYPE

QUALIBIED

TEST PLATE OR

Min

AND NUMBEROB TESTS

REQUIRED*

~--_--h-__--~

#-------_h----~

Ma.%

mm

OF

mm

1.5 to 10 including

1.5

2t

Over 10, under 20t

21

Over 10, under 20t

2r

20 and over

Mwa&t:dbe

Side
Bend

Face
Bend

Root
Bend
1

*A total of four specimens are required to qualify for horizontal-fixed position.

tEither the face and root bend tests or the side bend tests may be used for thicknesses
from 10 to 20 mm.

Each specimen shall be tested in accordance with the requirements

of IS: 3600-1966$ by bending it through at least 90 round a former of a
diameter equal to four times the thickness of the specimen.
When the
*Recommended
practice for radiographic
in steel plates (firsf f&ion ).

examination

of fusion welded butt joints

iRecommendedpractice for radiographicexamination of fusion welded circumferential joints in Steel pipes.

$Code of procedure for testing of fusion welded joints and weld metal in steet: (Since
revisedand split into variousparta ) .
28

IS t 6916- 1973
parent metal is incapable
and angle of bend should

of withstanding
this test, the former diameter
be modified accordingly.

After bending, the specimen shall show no signs of failure, although

slight premature
tearing at the edges of the specimen need not be considered as cause for rejection.
22.5.1.3 Face and root bend tests - Face and root bend test specimens
shall be machine
cut from each test joint
to the dimensions
specified
The number of tests required to qualify a procedure
in IS : 3600-1966*.
for various
thickness
ranges shall be as shown in Table 2.
Weld
reinforcement
and backing strip, if any, shall be removed
fiush with
If a recess strip is used, this surface of the
the surface of the specimen.
specimen
may be machined
to a depth not exceeding
the depth of the
recess to remove the strip.
The specimen shall be bent with a jig in
Face bend specimens shall be placed
accordance
with IS : 3600-1966*.
such that the face surface becomes the convex side of the bend specimen.
In the case of the root bend test the specimens shall be placed such that
the root of the weld becomes the convex side of the bend specimen.
The
specimen shall be bent until the curvature
of the specimen is such that,
8 mm diameter wire cannot be passed between the curved portion of the
The diameter
of the former
male member of the jig and the specimen.
shall be equal to four times the thickness of the specimen.
When the parent metal is incapable
of withstanding
this test, the
former diameter
and the angle of bend shall be modified accordingly.
After bending
the specimen shall be examined
for the appearance
of
opened
out defects.
Any specimen
having
any such opened defects
exceeding 3 mm measured in any direction shall be considered
as having
failed.
Cracks occurring on the corners of the specimen during bending
shall be disregarded.
22.5.1.4 Macro-examination -Each
cross sections for macro-examination.
macro-etching

and etched

test joint shall provide two weld

These sections shall be prepared for
to give a clear indication
of the weld structure.

The standard of acceptance

with the requirements
of 19.
25.5.2

Fillet

22.5.2.1

the standard
requirements

shall be that

Weld Between Plates and Branch

Visual examination -

of acceptance
of 19.

being

determined

in accordance

Connections Between Pifws

All test joint sh.all be visually examined,

that determined
in accordance
with the

*Code of procedure for testing of fusion welded joints and weld metal in steel. ( Since
mvbal and split into variow parts ).

29

IS t 6916- 1973
22.5.2.2 Macro-examination -Each
test joint shall be sectioned at
These sections shall be prepared for
three places for macro-examination.
macro-etching and etched to give a clear indication of the weld structure.

The standard of acceptance

with the requirements of 19.

shall be that determined

in accordance

22.5.3 Repeat Test - If any of the above tests show that the welds do
not meet the required standard, two further test joints shall be made and
the tests repeated.
If either of these additional test joints does not meet
the required standard, the welder shall not be regarded as capable of meeting the requirements of this standard without further training.

APPENDIX
A
(Clauses5.1.4, 7.3, 8.1, 8.3,15.5, 17.1, 19.1, 21.4and22.2)
ITEMS

FOR AGREEMENT
CONTRACTING

A-l. The following, where applicable,

between the contracting parties:

BETWEEN
PARTIES
are

THE

the items for

agreement

a>Flux/electrode
b)

wire combinations
for subinerged-arc welding
( 5.1.4 ).
Acceptability
of fusion faces when non-destructive testing is
used ( 7.3 ).
Sealing-off of filamentary shrinkage ( 7.3 ).
Type of backing strip ( 8.1).

4
4
4 Use
f-1 Use

of copper backing bar ( 8.3 ).

of alternative methods of heating for post-weld heat treatment ( 15 ).
d Alternative method of stress relief ( 17 ).
h) Inspection of completed welds ( 19 ).
j) Types of test joint for procedure qualification ( 21.4 ).
k) Types of test joint for welder qualification ( 22.2 ).

30

1 t 6916 - 1973
( Continuedfrom

pugs 2 )

Members
S~sr D. P. CEATTEWJEE
SHRI l-3.HILL
SHEI H. S. RAO ( Al&mats )
SERI V. G. JAOANNATH
SHRX R. VISVANATHAN (Al&m&
SSSI S. V. NADKA~NI
SHRI K. RAMA RAO
REPRESENTATIVE
REPRESENTATIVB

Rapresenting
Directorate
General
of Supplies
&
New Delhi
Lloyds Register of Shipping, Calcutta

&-Is,

Bharat Heavy Electric&

Ltd, Tirucbirapalli
)
Advani-Oerlikon
Pvt Ltd, Bombay
The K. C. P. Ltd, Madras
Central BoiIera Board, New Delhi
Heavy Vehicles Ltd, Madras

31

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