Advanced GMAW Process for Pipe Welding

Applications

Technical Assessment

1003166
Advanced GMAW Process for Pipe Welding Applications

1003166

Technical Assessment, December 2001

EPRI Project Manager

Greg Frederick

RRAC Coordinator

Neal Chapman, Entergy

EPRI-RRAC • 1300 W.T. Harris Blvd., Charlotte, NC 28262 • PO Box 217097, Charlotte, NC 28221 • USA
704.547.6100 • [email protected] • www.epri.com
DISCLAIMER OF WARRANTIES AND LIMITATION OF LIABILITIES
THIS DOCUMENT WAS PREPARED BY THE ORGANIZATION(S) NAMED BELOW AS AN ACCOUNT OF
WORK SPONSORED OR COSPONSORED BY THE ELECTRIC POWER RESEARCH INSTITUTE, INC. (EPRI).
NEITHER EPRI, ANY MEMBER OF EPRI, ANY COSPONSOR, THE ORGANIZATION(S) BELOW, NOR ANY
PERSON ACTING ON BEHALF OF ANY OF THEM:

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INFORMATION, APPARATUS, METHOD, PROCESS, OR SIMILAR ITEM DISCLOSED IN THIS DOCUMENT.

ORGANIZATION(S) THAT PREPARED THIS DOCUMENT

EPRI
Entergy Northeast
PCI Energy

NOTICE: THIS REPORT CONTAINS PROPRIETARY INFORMATION THAT IS THE INTELLECTUAL

PROPERTY OF EPRI, ACCORDINGLY, IT IS AVAILABLE ONLY UNDER LICENSE FROM
EPRI AND MAY NOT BE REPRODUCED OR DISCLOSED, WHOLLY OR IN PART, BY ANY
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Copyright © 2001 Electric Power Research Institute, Inc. All rights reserved.
 CITATIONS
This document was prepared by
EPRI, Repair and Replacement Application Center
1300 W.T. Harris Blvd.
Charlotte, NC 28262
Principal Investigator
G. Frederick
Entergy Northeast
P.O. Box 110
Lycoming, NY 13093
Principal Investigator
Neal Chapman
PCI Energy
One Energy Dr.
Lake Bluff, IL 60044
Principal Investigator
Roy Button
This document describes research sponsored by EPRI.
The publication is a corporate document that should be cited in the literature in the following
manner:
Advanced GMAW Process for Pipe Welding Applications, EPRI, Charlotte, NC: 2001. 1003166.

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ABSTRACT
During the last few years, advanced welding equipment has been developed with fuzzy logic
microprocessor technology and waveform control for gas-metal arc welding (GMAW). This
equipment allows arc conditions to be fine tuned for material thickness, wire diameter and
material type. The equipment reacts quickly to changes in welding conditions to permit high-
quality, high-deposition welding using a demand-pulsed short arc mode. The advanced
equipment generated interest in developing procedures for welding of heavy sections with solid
wire to provide higher productivity rates, shorter outage duration, and reduced man-rem
exposure. For overlay applications the process could minimize burn through and reduce
shrinkage with a higher deposition. The nominal pipe wall thickness that this process was
targeted for is approximately ½-in., which, for example, would cover up to Schedule 120 for 6-
in. pipe.
In prior Repair and Replacement Application (RRAC) programs the Lincoln Power Wave
450/STT was identified as the preferred power supply for open butt welding applications with
solid wire. The evaluations with the Lincoln power supply resulted in reproducible open butt
root welds for all position applications, joint geometry requirements and Procedure
Qualifications per ASME Section IX for carbon steel, stainless steel and 2 ¼ CrMo (P5) plate
materials. The advantages here is minimized burn thru, less shrinkage and relatively higher
deposition.
As a follow-up to the evaluation RRAC members requested that further development of the
process be conducted for manual and automatic pipe welding applications, which would include
RT verification, shrinkage evaluation (compared to FCAW and SMAW) and welding guidelines.
The results of the welding development are documented in this Technical Assessment.

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CONTENTS
1 INTRODUCTION..................................................................................... 1-1
2 TEST PROGRAM ................................................................................... 2-1
Manual GMAW Pipe Welding Demonstration ......................................................... 2-1
Open Root V-groove Welds .............................................................................. 2-1
Utility Demonstration ......................................................................................... 2-2
Overlay Welds................................................................................................... 2-2
Automated GMAW pipe welding demonstration ..................................................... 2-3
Welding Guidelines................................................................................................. 2-4

3 GMAW PIPE WELDING DEMONSTRATION ........................................ 3-1

Open Root V-groove Welds .............................................................................. 3-1
Utility Demonstration ......................................................................................... 3-3
Overlay Welds................................................................................................... 3-3
Automatic GMAW Welding................................................................................ 3-5
Guidelines-Training Manual .............................................................................. 3-7

4 CONCLUSIONS...................................................................................... 4-1
A APPENDIX - MANUAL GMAW PIPE WELDING GUIDELINES FOR
LINCOLN POWERWAVE 455.................................................................. A-1

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1
INTRODUCTION
During the last few years, advanced welding equipment has been developed with fuzzy logic
microprocessor technology and waveform control for gas-metal arc welding (GMAW). This
equipment allows arc conditions to be fine tuned for material thickness, wire diameter and
material type. The equipment reacts quickly to changes in welding conditions to permit high-
quality, high-deposition welding using a demand-pulsed short arc mode. The advanced
equipment generated interest in developing procedures for welding of heavy sections with solid
wire to provide higher productivity rates, shorter outage duration, and reduced man-rem
exposure. For overlay applications the process could minimize burn through and reduce
shrinkage with a higher deposition. The nominal pipe wall thickness that this process was
targeted for is approximately ½-in., which, for example, would cover up to Schedule 120 for 6-
in. pipe.
In prior Repair and Replacement Application (RRAC) programs the Lincoln Power Wave
450/STT (Figure 1-1) was identified as the preferred power supply for open butt welding
applications with solid wire. The evaluations with the Lincoln power supply resulted in
reproducible open butt root welds for all position applications, joint geometry requirements and
Procedure Qualifications per ASME Section IX for carbon steel, stainless steel and 2 ¼ CrMo
(P5) plate materials. The advantages here is minimized burn thru, less shrinkage and relatively
higher deposition.
As a follow-up to the evaluation RRAC members requested that further development of the
process be conducted for manual and automatic pipe welding applications, which would include
RT verification, shrinkage evaluation (compared to FCAW and SMAW) and welding guidelines.
The results of the welding development are documented in this Technical Assessment.
Section 2 describes the overall test matrix, Section 3 includes the test results of the GMAW
demonstrations, Section 4 lists conclusions and Appendix A documents the welding guidelines
or tutorial.

Figure 1-1. Lincoln Power Wave 455/STT Equipment

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2
TEST PROGRAM
A test program was established to evaluate and demonstrate GMAW process for pipe welding
applications. The program first looked at transferring technology developed for GMAW
qualifications on thick section plate material to manual GMAW pipe welding applications. To
verify the GMAW process radiographic testing (RT) would be used to compare the quality to
GTAW and SMAW processes. With successful demonstration of GMAW for manual pipe
welding applications the technology would be further demonstrated with automated systems.
Available pipe tracks and carriages (i.e. Pipeliner) would be used to adapt the process for
automated welding application. Finally with the procedures established in the process
demonstration a training manual would be developed for utility pipefitter/welders. Three task
were outlined to accomplish the scope of this activity:

• Manual GMAW pipe welding demonstration

• Automated GMAW pipe welding demonstration
• Welding Guidelines

Manual GMAW Pipe Welding Demonstration

Manual demonstration of the Lincoln Powerwave 450 STT will be conducted on pipe to compare
the process with GTAW, FCAW and SMAW process.

Open Root V-groove Welds

Manual demonstration of the Lincoln Powerwave 450 STT will be conducted on 6-in. schedule
120 pipe (.562-in. wall) to verify the process on pipe. A standard V-groove configuration shown
in Figure 2-1, will be used for all open root welding evaluations. Initial welds will be made with
parameters established in 2000 RRAC program for mechanical test specimens on thick section
plate. RT evaluation will be used to verify the welding process in the 2G and 6G positions
(Figure 2-2). The goal will be to demonstrate two successive RTs, with the same relative quality
as GTAW/SMAW. The test matrix is included in Table 2-1. Parameters and welding techniques
will be document to assist in developing guidelines for training of pipefitter/welders.

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Figure 2-1. V-groove configuration for open root evaluations.

Utility Demonstration
As a follow on to the initial welding demonstration, participating utilities will use technology to
independently verify the GMAW process on pipe welds. The goal will be to produce successive
acceptable RTs with manual welding with a typical pipefitter/welders. The process will be
repeated with a second utility welder.

Figure 2-2. Welding Positions

Overlay Welds
The GMAW process will be evaluated for weld shrinkage by applying a standard weld overlay
on identical pipe specimen with manual GMAW and FCAW, SMAW and automatic GMAW
processes (Table 2-1). Each process will be used to apply a two layer overlay approximately 1.5-
inches wide on the center of a set length of schedule 120 pipe (.562-inch wall) as seen in Figure
2-3. Axial shrinkage will be measured at the completion of each layer for all processes.

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.
-in
.5
>1
Figure 2-3. Schematic of overlay weld configuration.

Automated GMAW pipe welding demonstration

The Lincoln Powerwave 455/STT will be coupled with a manipulator system (i.e. Pipeliner,
Bug-O system) to demonstrate the process for automatic applications. The v-groove welding and
overlay specimens (Figure 2-2) will be duplicated as described above and in Table 2-1. The goal
will be to demonstrate acceptable RT with the same relative quality as GTAW/SMAW and
compare axial shrinkage with the manual processes (FCAW, SMAW, GMAW)

Table 2-1. Test Matrix for Evaluating the Lincoln Powerwave 455/STT
Process Location Application Position Quantity Test
Manual GMAW RRAC V-Groove 2G 2 RT
Manual GMAW RRAC V-Groove 6G 2 RT
Manual GMAW Utility V-Groove 2G 2 RT
Manual GMAW Utility V-Groove 6G 2 RT

GMAW RRAC Overlay 6G 1 Shrinkage

FCAW RRAC Overlay 6G 1 Shrinkage
SMAW RRAC Overlay 6G 1 Shrinkage

Automatic RRAC V-Groove 2G 2 RT

GMAW
Automatic Vendor V-Groove 6G 2 RT
GMAW

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Welding Guidelines
A training manual will be assembled with the data collected in the v-groove and overlay
evaluations described above. The training manual will be used to transfer technology to utility
pipefitter/welders. Information to be included in the manual will consist of welding terminology,
fitup, process familiarization, weld procedures (i.e. tack welding, root welding, fill and cap
passes).

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3
GMAW PIPE WELDING DEMONSTRATION
Manual demonstrations of the Lincoln Powerwave 450 STT were conducted 6-in. schedule 120
pipe specimens. Both overlay welds and v-groove welds were completed to assess the GMAW
process for open root welding applications and to compare the process with other manual
welding processes. Welding techniques and parameters were documented to assist with
developing a training manual during the welding demonstrations. Automatic GMAW welding
was also demonstrated with the technology to verify the capabilities of the equipment.

This section is divided into five tasks; Open Root V-Groove Welds, Utility Demonstration,
Overlay Welds, Automatic GMAW Welding and Guidelines-Training Manual

Open Root V-groove Welds

The evaluation of the GMAW process with solid wire was conducted with the Lincoln Power
Wave 450/STT power supply and Lincoln wire feeder (Figure 3-1) on carbon steel pipe material
(SA-516, Grade 70). Additional weld modes (programs) were added to the welding power
supply during the course of the welding evaluations to increase the capabilities of the equipment.

The development work consisted of parameter development including machine settings, joint
geometry evaluation and welding technique for welding open root pipe welds. RT testing was
conducted per ASME Section IX specifications to verify weld quality. Various welding
positions were selected (Figure 2-1), to assure welding in all positions could be accomplished. In
all cases, 0.045-in. diameter solid wire (ER70S-6, Lincoln L-56 70-6) was used for all passes
(root, hot, and fill passes). A downhill welding progression was used for all root pass welds, and
uphill and downhill progression was used for the hot and fill passes, depending on the Program
setting. No backing gas was utilized with the carbon steel (SA-516, Grade 70) material.

A number of manual open root v-groove welds were completed with the Lincoln Powerwave
455/STT system. Initial welding parameters matched the specifications developed for qualifying
thick section plate. As, new weld programs became available through Lincoln Electric
Company; other parameter variations were evaluated. Table 3-1 lists the welding parameters
used for various welding modes. Parameters were not altered for welding position. Detailed
parameters and welding techniques were documented during the welding evaluations and will be
included in the welding guidelines section (Appendix A).
Manual demonstration of the Lincoln Powerwave 450 STT were conducted on 6-in. schedule
120 pipe (.562-in. wall) with a standard V-groove configuration (Figure 2-1). All specimens
were RT tested for acceptability (Table 3-2). At least two specimens for each condition in Table
3-2 were considered acceptable per RT evaluation.

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Figure 3-1. Demonstration of open root V-groove (5G Position).

Table 3-1. Welding Specifications for Open Root V-Groove Welds

Program Wire Arc Trim Gas Travel Layer
Speed Control Speed
(in/min) (in/min)

Mode 119 120 5-10 .60 100% CO2 6-7 Root and Tack Welds
@ 25 cfh
Downhill weld
progression
Mode 117 120 5-10 .60 100% CO2 6-7 Hot and Fill Passes
@ 25 cfh
STT Mode (.045-in.) Downhill weld
progression
slight weave
Mode 22 135 +5 .98 92/8 6-7 Hot and Fill Passes
Argon/
Pulse Spray (.045-in.) Uphill weld progression
CO2
Mode slight weave
@ 25 cfh
Mode 5 215 Off 1.05 75/25 6-8 Hot and Fill Passes
Argon/
CV Mode (.045-in.) Uphill weld progression
CO2
slight weave
@ 25 cfh

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Table 3-2. RT Evaluations for GMAW

Quantity Position Process Test Evaluation Comments

2 2G Manual GMAW RT Small round indications near tack

welds and stop and starts
(acceptable)
2 6G Manual GMAW RT Small round indications near tack
welds and stop and starts
(acceptable)
2 6G Automatic GMAW RT Very clean, a few small round
indications

Utility Demonstration
As a follow on to the initial welding demonstration, participating utilities were supplied welding
parameters and technical support to reproduce open root welding with the GMAW process. The
utility pipewelder results were not available at the time this progress report was completed, but
will be included in the next progress report.

Overlay Welds
Overlay welds were applied on pipe sections to evaluate weld shrinkage relative to welding
process and deposition rate. Two layer overlays (Figure 2-3) were applied in the 6G position
with identical pipe specimen with GMAW, FCAW, SMAW and automatic GMAW processes
(Table 2-1). Welding specifications for each process evaluated for weld shrinkage is
documented in Table 3-3. Parameters are similar to the cap passes used for the v-groove welding
evaluation. All overlays were welded double up with the exception of the root pass which was
welded downhill. The FCAW process was considered to perform the best for all position welding
and had the best bead appearance for the manual processes (Figure 3-2). The automatic GMAW
process had the overall best appearance (Figure 3-3). The manual SMAW and GMAW
processes are illustrated in Figure 3-4 and 3-5, respectively.
The resulting axial shrinkage was measured at the completion of each layer and is documented in
Table 3-4. The axial shrinkage was similar for the GMAW, FCAW and the GMAW-AU
processes. The axial shrinkage caused by the SMAW process was twice that of the other
processes.

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Table 3-3. Welding Specifications for Overlay Specimens

Process Position Program Wire Feed Arc Voltage/ Trim Travel Comments
Speed Control amperage Speed
(in/min) (in/min)
GMAW 6G Mode 22 135 +5 105 6-8 .045-in. Lincoln
NC-10 L-56 70-6
92A-8CO2
FCAW 6G Mode 5 215 OFF 160 amps 22.5V 6-8 .045-in. Lincoln
NC-11 22.4 volts Elite-71
75A/25CO2
SMAW 6G 3/32-in. N/A N/A 100 amps 6-8 3/32-in. Lincoln
NC-12 7018 27-30 volts Jet-LH 78MR

Table 3-4. Shrinkage Evaluation for overlay weld specimens

Process Position Location Overall 1st layer Shrinkage 2nd layer Shrinkage
Length in. in. in. in.
in.
(build up) (ave.) (build up) (ave.)
GMAW 6G 0 5.914 5.897 .017 5.895 .017
Overlay 90 5.925 5.910 .015 5.910 .015
NC-10 180 5.954 5.932 (.160) .022 (.019) 5.932 (.300) .022 (.020)
270 5.976 5.953 .023 5.948 .028
GMAW 6G 0 4.310 4.290 .020
Overlay 90 4.342 4.318 .024
(auto.) 180 4.202 ------ (.300) ---- (0.22)
270 4.273 4.250 .023
FCAW 6G 0 5.891 5.878 .013 5.873 .018
Overlay 90 5.908 5.894 .014 5.894 .014
NC-11 180 5.922 5.900 (.130) .022 (.016) 5.891 (.260) .031 (.021)
270 5.954 5.939 .015 5.933 .021
SMAW 6G 0 5.927 5.886 .041 5.881 .046
Overlay 90 5.920 5.883 .037 5.871 .049
NC-12 180 5.987 5.956 (.160) .031 (.036) 5.951 (.320) .036 (.044)
270 5.969 5.933 .036 5.922 .047
Note: All Overlays were welded double up with the exception of the root weld.
Note: Overlays were approximately 1 1/2-in wide by 2 layers by full circumference

Figure 3-3. Overlay weld specimen with the manual FCAW process.

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Figure 3-4. Overlay weld specimen with the GMAW-AU process (Courtesy of PCI-Energy).

Figure 3-5. Overlay weld specimen with the SMAW process.

Figure 3-6. Overlay weld specimen with the GMAW process.

Automatic GMAW Welding

The Lincoln Powerwave 455/STT was further evaluated for automatic welding applications. The
system was first coupled with the Magnatech Pipeliner II system for evaluating root welding
capabilities (Figure 3-7). A number of root welds were applied to 12-inch pipe specimens with
welding parameters identical to the manual welding parameters and similar joint fitup and

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geometry (Figure 2-1). Limitations of the Pipeliner’s control system did not allow for complete
360-degree welds to be completed, at this time. PCI Energy utilized their proprietary track
system coupled with the Lincoln Powerwave 455/STT to complete both v-groove welds and
overlay weld specimens.
The overlay welds were specified to the match the manual overlay welds, which consisted of two
layers approximately 1.5-inches wide welded in the 6G position. The results were reported with
the manual welds in Table 3-4. Figure 3-8 illustrates typical root weld quality of the automatic
GMAW system.
Welding specifications for the automatic welding process are documented in Table 3-5. The
overlay parameters are similar to the cap passes used for the v-groove welding evaluation. All
the GMAW-AU overlay welds were welded double up with the exception of the root pass, which
was welded downhill. All RT evaluations of the automatic process were considered acceptable
and were reported in Table 3-2 with the manual welding evaluations.

Figure 3-7. Automatic setup with Pipeliner II and Lincoln Powerwave 455/STT.

Figure 3-8. Typical appearance of root weld (ID and OD view).

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Table 3-5. Welding Specifications for automatic GMAW process (Courtesy of PCI-Energy).
Process Position Program Wire Feed Arc Trim Travel Comments
Speed Control Speed
(in/min) (in/min)
GMAW 6G Mode 8 216 off 1.03 5.5 ½-in. oscillation
Overlay .045-in.wire
75A/25CO2
grind all starts
GMAW 6G Root, 260 off 1.06 5.5 <1/4-in. oscillation
V-groove Mode112 .045-in.wire
75A/25CO2
Fill, 210-212 off 1.06 5.5 75A/25CO2
Mode 12

Guidelines-Training Manual

The Lincoln Power Wave 455/STT was evaluated through welding trials and RT Evaluations in
the manual and automatic welding modes. The welding parameters and techniques were
documented throughout the welding evaluations and are illustrated in the Welding Guidelines
attached in Appendix A. The welding guidelines are intended to be used as a training manual for
utility pipewelders. The welding guidelines will be updated to include utility comments in the
next progress report.

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4
CONCLUSIONS

The Lincoln Powerwave 455/STT was evaluated for manual pipe welding applications with an
open root v-groove, overlay repair applications, and automatic welding applications. The basic
conclusions are listed below:

• Acceptable RT evaluations were achieved with manual welding in 2G and 6 G positions.

• Welding parameters and techniques were documented for technology transfer to utility
pipefitters/welders.
• Overlay welds were completed with FCAW, SMAW, GMAW and GMAW-AU to evaluate
axial shrinkage.
• FCAW, GMAW and GMAW-AU produced similar axial shrinkage (~.021-in over 6-
inches).
• SMAW produced had approximately .044-inches of shrinkage over 6-inches.
• Automatic welding was completed with Pipeliner II system and PCI Energy system with
excellent results for both the overlay configuration and open root V-groove.
• Welding training manual was developed with techniques and parameters developed in the
welding demonstrations (Appendix A).
• Technology transferred to participating utilities for further evaluations.

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A APPENDIX - MANUAL GMAW P IPE WELDING
GUIDELINES FOR LINCOLN POWERWAVE 455

The guidelines for full penetration open root welding with the GMAW process is divided into 4
lesson plans. The lesson plans (1-4) should be completed in approximately 4-6 hours. Lesson
plan can be duplicated for different material and welding positions. Actual welding practice time
should be less than 40-hours.

Lesson 1: GMAW Process Review

Objectives: Familiarization with basic terminology, design and set-up of open root v-groove
welds. Student/Trainee should be able to measure and verify that the joint preparation (groove
geometry) matches working drawings or written instructions. Lesson 1 is divided into two tasks;
1) GMAW Equipment Review and 2) Welding Process Description

Time: 1 hour review time

GMAW Equipment Review

Gas Metal Arc Welding Process (GMAW) - Commonly know as MIG or wire welding. Basic
components of the Lincoln 455 Powerwave are shown in Figure L1-1.

Figure L1-1 Components of the Lincoln Powerwave 455, GMAW system.

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Mode – Mode is a setting that allows the machine to optimally perform according to welding
process, welding position, material thickness, and wire diameters. The modes available with the
Lincoln Powerwave 455 are listed below:

CV Mode: GMAW and FCAW processes. A preprogrammed voltage is set for each wire
feed speed. Preset voltage can be altered by the Wire feeder’s voltage control.

Pulse GMAW Mode: Pulse settings for GMAW process. Pulse parameters are adaptively
controlled to accommodate changes in the stickout length.

STT Mode: STT Mode is a current control process and is neither a CC or a CV process.
The current is altered very quickly to changes in the arc. Oftne referred to as the short
circuit mode.

Arc Control – Inductance or Wave Control. Arc control is adjustable between –10.0 and 10.0.
Arc control may vary depending on the welding Mode at described below:

CV Mode: ARC CONTROL adjusts the inductance, which directly relates to the heat
input to the weld. Increasing the arc control number lowers the inductance resulting in a
colder arc. Decreasing the arc control number increases the inductance resulting in a
wider hotter arc.

Pulse GMAW Mode: ARC CONTROL adjusts the pulse frequency. Typically used for
fine tuning for various weld positions. Increasing the arc control number raises the pulse
rate. Decreasing the arc control number decreases the pulse rate.

STT Mode: ARC CONTROL is a coarse adjustment in the heat input to the weld.
Increasing the arc control number produces a more fluid puddle (potentially spatter).
Decreasing the arc control number makes a colder weld (potential wire stubbing).

Trim – Controllable between 0.500 and 1.500. TRIM may vary depending on the welding Mode
at described below:

CV Mode: TRIM controls the welding voltage.

Pulse GMAW Mode: TRIM is an adjustment of the arc length. A TRIM setting greater
than 1.000 increase the arc length. A TRIM setting of less than 1.000 decreases the arc
length.

STT Mode: TRIM is a fine adjustment of heat input to the weld.

Wire Feed Speed – The wire feed speed is the main control over all other welding variables. The
welders can control the WFS to vary weld size, penetration, heat input, etc.

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Welding Process Description

Welding Position – The welding position is based on the position of the pipe and is the pipe is
held stationery or rotated. Welding positions are described below and illustrated in Figure L2-1.
Horizontal pipe position: 1G if pipe is rotated, 5G if pipe is in a fixed position
Vertical pipe position: 2G, Inclined at +150
Inclined pipe position: 6G, pipe in fixed position, inclined at a 45 0 +50

Figure L1-2 Pipe Welding Positions

Joint Preparation – The weld preparation for a full penetration pipe weld using the GMAW
process typically consists of a single V-groove configuration with an open root. Details of the
joint preparation are described below and correspond to Figure L1-3.

1. Groove Angle – Total included angle between the two sections of pipe. Typically 75-degrees

2. Bevel Angle – The angle prepared on one section of the pipe. Measured from a plane
perpendicular to the prepared surface of the pipe. Typically 37.5 degrees.

3. Root opening – The opening or distance between the two workpieces. Root opening typically
0.08-in. up to 0.11-in.

4. Land Thickness - The length of the surface of the workpiece adjacent to the root. Typically
0.070-in.

5. Groove Surface or Face – Surface of the workpiece included in the groove.

6. Pipe or Plate Wall Thickness – Overall thickness of the pipe or plate being joined.

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7. Root Face or Land Face – The portion of the groove face that is adjacent to the root opening.

8. Alignment – Distance the surface of one pipe section is offset from the other.

Figure L1-3. Weld Joint Design (numbers correspond to descriptions in the Joint Preparation
Section)

Shielding – The protective gas used to protect the molten puddle from atmospheric
contamination. Could also refer to gas purging. 100% CO2 is typically used for short arc
applications including the root welds. Alternative gases such 92% Argon and 8% CO2 are used
when pulse spray modes are used.

Weld Passes – Weld passes are divided into layer of progression including tack welds, root weld,
hot pass, fill passes and cap passes. Details of the weld passes are described below and
correspond to Figure L1-4.

8. Tack Weld – Tack welds are considered part of the root weld and should be sufficient
in size and number to maintain the root opening and joint alignment.

8. Root Weld – The root pass is the first weld pass applied to completely bridge the gap
between the pipe. For the GMAW process the root weld will typically by an open root
weld (no backing ring). An attempt is made to make the root pass continuous between
tack welds for manual welding.

9. Hot Pass – The hot pass is typically a single weld pass that fuses the root weld and
both groove faces together. A split hot pass has been beneficial for 2G welding and
where the root opening is larger than normal.

10. Fill Passes – Weld passes between the hot pass and the cap passes.

11. Cap Passes – Typically welded in a similar manner as the fill passes. Must provide
complete fill of joint cavity.

A-4
Figure L1-4 Bead Sequence and description (numbers correspond to descriptions in the Joint
Preparation Section)

Weld Progression – Refers to the travel direction in which the weld is applied.

Downhill – welding with a downward progression typical of root welding and tack welds
when utilizing the short circuit mode or STT mode.

Uphill – welding with a upward progression, typical of hot passes, fill and cap passes
when utilizing pulse spray mode.

Travel Angle – Is the angle from a perpendicular line from the weld joint to the welding gun
relevant to the travel direction. Typically referred as push angle or drag angle.

Push angle – The welding gun is pointing in the same direction of the travel.

Drag angle – The welding gun is pointing in the opposite direction of the travel.

Weld passes are divided into layers including tack welds, root weld, hot pass, fill passes and cap
passes. Details of the weld passes are described below and correspond to Figure L1-4.

8. Tack Weld – Tack welds are considered part of the root weld and should be sufficient
in size and number to maintain the root opening and joint alignment.

8. Root Weld – The root pass is the first weld pass applied to completely bridge the gap between
the pipe. For the GMAW process the root weld will typically by an open root weld (no backing
ring). An attempt is made to make the root pass continuous between tack welds for manual
welding.

Weld Defect typical of GMAW welding include lack of fusion (LOF), Inclusions, Porosity, and
Undercut.

Lack of Fusion (LOF) – Often refered to as incomplete fusion. LOF is when weld metal

A-5
 is not completely fused to the base metal. LOF can be caused by excessive travel speed,
low current poor joint preparation (interpass cleanup), poor bead placement.

Undercut – An underfill of the weld joint at the toes or root of the weld. Undercut can be
caused by excessive welding parameters (i.e. current, voltage, travel speed), and
inconsistent oscillation of welding gun.

Inclusions – Inclusions include oxides and slags. Inclusions can be caused by excessive
travel speed, poor interpass cleaning and low voltage.
.
Porosity – Gas pockets in the weld metal. Porosity can be caused by inadequate
shielding, excessive welding parameters (i.e. current, voltage, stickout, travel speed), and
contaminants on or in the base metal.

A-6
Lesson 2: Tack Welds

Objectives: Teach set up procedures, tack welding techniques and terminology. At the
completion of Lesson 2, welders should be able to set up and verify pipe joint geometry matches
specifications, align and tack weld two sections of pipe and prepare pipe sections for root weld.
This lesson is divided into three categories; 1) Terminology, 2) Setup, and 3) Welding

Time: 1.5 hours practice and demonstration of knowledge

Terminology
Tack welds are used to hold the root opening and maintain the pipe to pipe alignment while the
root pass is being installed. Tack welds are considered a part of the root pass and should have
the same quality as the root pass. Details of the root weld are described below and correspond to
Figure L1-3 and Figure L2-1.

3. Root opening – A root opening that is too narrow can result in incomplete penetration.
Excessive root open can be difficult to weld without melt through. The root opening is typically
held by inserting a wire of the same dimension into the root opening. The wire is removed after
the tacks are completed.

13. Root pass contour – The contour of the tack weld exposed to the OD surface, often referred
to as the weld crown, is typically ground to reduce the convexity of the weld. A high crown
often traps slag and makes it difficult to apply the root weld without inclusions and lack of fusion
(LOF).

14. Root Surface – The root surface in the weld metal exposed to the ID surface. The geometry
of the root surface can be concave (underfill) to convex. The shape of the root surface is
governed by the degree of melt through, gravity, and welder technique. A slight convex root
surface is desired.

15. Melt Through - Root reinforcement typically measured from the ID surface.

A-7
Figure L2-1. Tack weld and Root Weld Terminology

Setup
Demonstrate the ability to verify joint geometry (i.e. bevel angle, land, etc.) meets specifications
prior to tack welding. Measure and record joint geometry in Table L2-1 (refer to Figure L2-2).

Set root opening, using a short section of wire or rod of appropriate diameter to maintain the gap
while tacking the coupons together. Alignment of the pipe coupons should be held within 0.30-
inch misalignment. Alignment for training coupons can be accomplished by using v-blocks, or
pipe clamps. A minimum number of tacks should be utilized and tacks should be located to allow
a continuous weld from one tack to the next. All tack locations and length of the tacks should by
marked on the pipe prior to welding.

For 6-inch pipe coupons a minimum of 4 tacks, 90-degrees apart is recommended. Tacks 90-
degrees apart corresponds to a 4 to 5-inch weld distance between tacks, which most welders can
easily accomplish without stopping. Tacks should be located at the 0, 90, 180, and 270 location
(0 at top and 180 at the bottom of the pipe) for pipes positioned in the 5G and 6G position, so the
welder doesn’t have to reposition himself in the middle of the root weld. The first two tacks
should be placed approximately 180 degrees apart and root gap should be adjusted if necessary
before remainder of tacks is applied. To assure tacks do not break during the root weld a tack
length between ¾ and 1-inch is recommended. Also, shorter tacks may result in an overlap of
the root weld at the starts and stops on the tack welds. The overlap could produce excessive
weld build up, which could potentially result in LOF or inclusion.

Note: ½-in. plate coupons with similar joint preparation as the pipe coupons can be used for
initial practice welds. Plate coupons will allow easy inspection of joint geometry, root face and
cross section of root weld.

A-8
Table L2-1 Joint Geometry Verification (Figure 2-2)
Target Dimension Actual Dimension After tack weld
1. Groove Angle 75-degrees
2. Bevel Angle 37.5-degrees
3. Root opening dimension 0.8 to 0.11-inches
4. Land Thickness 0.050-0.070-inches
6. Wall thickness 0.562-inches
8. Pipe alignment 0.0-inches

Figure L2-2. Typical Weld Joint Dimensions

Welding
Set up and tack 6-in. schedule 120 (.5-in. wall) coupons with specified root opening and
alignment. Typical root welding parameters are referenced in Table L2-2.

Table L2-2. Welding Specifications for Tack Welds

Program Wire Speed Arc Trim Gas Travel Technique
(in/min) Control Speed
(in/min)

Mode 120 5-10 .60 100% CO2 6-7 Tack at 0, 90,180 and 270.
119 @ 25 cfh Minimum ¾-in. in length.
Slight oscillation

A-9
Welding Technique
The tack weld should be initiated on the groove face as illustrated in Figure L2-3. Starting the
weld on the groove face allows the weld to be eased into the root opening and bridge the gap
without excessive melt through or wire stubbing (whiskers). Similar to the start, the tack weld
should be terminated on the groove face, to eliminate the crater at the end of the weld. Typical
tack weld is shown in Figure L2-4. The weld crater is a potential source of porosity and cracks
that affect the subsequent weld layers. The excess weld metal on the groove face will be blended
or ground away prior to welding the root weld. Weld progression should be downhill when
applicable (i.e. 90 and 270-degree locations for 5G and 6G pipe positions). The torch angle can
be perpendicular to the root opening or oriented with a slight drag angle (up to 15-degrees). A
slight oscillation of the weld torch is used to control the weld puddle and weld geometry (i.e.
melt through and root face contour). Typically no more than 1/16-in. oscillation is necessary for
tack welds.

Figure L2-3. Tack weld progression

Figure L2-4. Typical appearance of a tack weld with weld initiation on groove face

A-10
The cross section of the tack weld should be similar to anticipated root weld. A convex root
surface with minimal reinforcement is desired. The resulting tack weld should have an overall
thickness, before cleanup, of approximately 3/16-inch. The TRIM setting on the power supply
can be adjusted to help control the melt through. Figure L2-5 illustrates the effects of TRIM on
the ID reinforcement. Lower trim increases ID reinforcement, while a higher trim produces a
more concave geometry.

Figure L2-5. Cross section of typical tack/root welds in relation to the TRIM setting.

Cleanup
Proper preparation of the tack weld before the root weld is applied is important and can
significantly reduce weld defects (i.e. LOF) at the tack locations. Preparation of the tack welds
should include grinding and wire brushing to remove slag, and to blending the crown with the
groove face. Figure 2-6 illustrates the desired contour (cross section) of the tack welds.

The tack welds should also be of an appropriate length to allow both ends to be taper ground and
to allow starting and stopping of the root weld to be applied without overlapping. Recommended
taper is approximately 3:1 (Figure L2-7) and should be feathered to a knife-edge. The taper will
allow the welder to ease into the open gap and maintain a constant melt through with the root
weld. Tack welds 3/4 to 1-inch in length is typically sufficient (Figure L2-8).

Root weld should not be welded out until instructor has inspected for proper cleanup and
preparation for root weld.

A-11
Figure L2-6. Tack Cleanup and Preparation

4. Land Thickness
6. Pipe Wall Thickness
8. Tack Length
9. 3:1 Taper

Figure L2-7. Tack Weld Taper (~3:1).

Figure L2-8. Tack Weld after post-weld cleanup.

A-12
Lesson 3: Root Pass
Objectives: Teach basic root weld techniques and requirements. At the completion of this
lesson the welder should be familiar with equipment setup and capable of completely welding
out the root of a 6-in. Schedule 120 pipe coupon. This lesson is divided into three categories ; 1)
Terminology, 2) Setup and 3) Welding

Time: 1.5 hours practice and demonstration of knowledge

Terminology
Root welds should have the same quality and geometry as described for the tack welds. Details
of the root weld are described below and correspond to Figure L1-3 and Figure L2-1.

3. Root opening (Figure L1-3) – A root opening that is too narrow can result in incomplete
penetration. Excessive root open can be difficult to weld without melt through. The tack welds
typically hold the root opening.

13. Root pass contour – The contour of the tack weld, often referred to as the weld crown, is
typically ground to reduce the convexity of the weld. A high crown often traps slag and makes it
difficult to apply the root weld without inclusions and lack of fusion (LOF).

14. Root Surface (Figure L2-2) – The root surface in the weld metal exposed to the ID surface.
The geometry of the root surface can be concave (underfill) to convex. The shape of the root
surface is governed by the degree of melt through, gravity, and welder technique. A slight
convex root surface is desired.

15. Melt Through - Root reinforcement typically measured from the ID surface.

Setup
Test coupon should meet required dimensions (root opening) and alignment specified in Lesson
2. The 6-in. schedule 120 coupons prepared in Lesson 2 with tack welds completed should be
utilized for root weld demonstration. Check tack weld cleanup to make sure the appropriate taper
and surface preparation was completed.

Note: ½-in. plate coupons with similar joint preparation as the pipe coupons can be used for
initial practice welds. Plate coupons will allow inspection of joint geometry, root face and cross
section of root weld with minimal effort.

Welding
Set up and complete root pass on the 6-in. schedule 120 (.5-in. wall) coupons with tack welds
already in place. Root welding parameters are referenced in Table L3-1. The welding
parameters used for the root weld are typical of the tack weld parameters.

A-13
Table L3-1. Welding Specifications for Root Weld
Program Wire Speed Arc Trim Gas Travel Technique
(in/min) Control Speed
(in/min)

Mode 120 5-10 .60 100% 6-7 Slight oscillation,

119 CO2 @ continuous from tack to
25 cfh tack, downhill weld
progression

Welding Technique
The welder should be in a position to allow a continuous root weld between tacks to be
performed without having to reposition during welding. Weld progression should be downhill
when applicable (i.e. 5G and 6G pipe positions). The torch angle can be perpendicular to the
root opening or oriented with a slight drag angle (up to 15-degrees). The root weld should be
initiated on the groove face (Figure L3-1) above the tapered area. The weld should proceed
down the taper and ease into the root opening and bridge the gap with a melt through consistent
with the tack weld. Similar to the start, the root weld should be terminated above the tapered
area on the groove surface on the next tack. This will eliminate the crater at the stops and
reduces excessive melt through at the starts of the weld. This technique typically eliminates
weld defects (i.e. porosity, cracks, inclusions, LOF) at the start and stop locations. Figure L3-2
shows a typical root weld with weld initiation and termination on the groove face.

Figure L3-1. Root Weld Progression

A-14
A slight oscillation of the weld torch is used to control the weld puddle and geometry (i.e. melt
through and root face contour). Typically no more than 1/16-in. oscillation is necessary for root
welds with standard root opening of .08 to .11-inch. Root openings up to .156 may need to lower
trim and a slight increase in the oscillation. Root openings up to 0.25-in. may require lower trim ,
lower wire feed speed and an increase in the oscillation.

If the root weld in terminated prior to the next tack. The termination should be prepared with a
taper grind similar to the tack welds. The weld should be restarted in the same manner and
terminated on the next tack.

The cross section of the root weld should be consistent with the tack weld geometry. A convex
root surface with minimal reinforcement is desired. The TRIM setting on the power supply can
be adjusted to help control the melt through. Figure L2-5 illustrates the effects of TRIM on the
ID reinforcement. Lower trim increases ID reinforcement, while a higher trim produces a more
concave geometry. The ID melt through and weld bead geometry should be coincide with the
center drawing in Figure L2-5.

Figure L3-2. Termination and Initiation of Root Weld on Groove Face

Cleanup
The crown of the root pass is typically convex (similar to the tack welds, Figure L3-2) and
creates a narrow cavity with the groove face. The narrow cavity may trap slag and makes it
difficult to weld the hot pass without LOF and inclusions. The toes of the root weld should be
cleaned up by grinding and/or wire brush to remove slag and severity of the transition from the
root weld to the groove face. The excess weld metal caused by the starts and stops at the tack
locations should also be ground or blended into the groove face. This will allow a continuous
hot pass to be performed without interruptions. Typical appearance of root weld cleanup at tack
location is shown in Figure L3-3.

The root pass should be consistent around the entire groove and should be evaluated by the
instructor prior to continuing with the hot pass.

A-15
Figure L3-3. Start and stop location at tack weld before and after preparation for hot pass.

A-16
Lesson 4: Hot pass and Fill Pass

Objectives: Teach basic weld techniques to assist welder in equipment setup and welding
techniques to apply the hot pass and fill passes. At the completion of this lesson the welder
should be capable of completing the hot pass, fill passes and cap passes with successful RT
evaluation. This lesson is divided into three categories; Terminology, Setup and Welding.

Time: 2.5 hours practice and demonstration of knowledge

Terminology
Definition of machine Modes are listed below since the remainder of the welding (hot passes, fill
passes, cap passes) can be completed with different machine settings.

CV Mode: GMAW and FCAW processes. A preprogrammed voltage is set for each wire
feed speed. Preset voltage can be altered by the Wire feeder’s voltage control.

Pulse GMAW Mode: Pulse settings for GMAW process. Pulse parameters are adaptively
controlled to accommodate changes in the stickout length.

STT Mode: STT Mode is a current control process and is neither a CC nor a CV process.
The current is altered very quickly to changes in the arc. Often referred to as the short
circuit mode.

Descriptions of the weld passes are described below and correspond to Figure L4-1.

8. Root Weld – The root pass is the first weld pass applied to completely bridge the gap
between the pipe. For the GMAW process the root weld will typically by an open root
weld (no backing ring). An attempt is made to make the root pass continuous between
tack welds for manual welding.

9. Hot Pass – The hot pass is typically a single weld pass that fuses the root weld and
both groove faces together. A split hot pass has been beneficial for 2G welding and
where the root opening is larger than normal.

10. Fill Passes – Weld passes between the hot pass and the cap passes.

11. Cap Passes – Typically welded in a similar manner as the fill passes. Must provide
complete fill of joint cavity.

6. Pipe Wall Thickness

A-17
Figure L4-1. Bead Sequence and description

Setup
The hot pass through the cap passes are typically welded with similar parameters, machine
settings and techniques. The machine settings, shielding gases and techniques will differ from
those used for the root pass and tack welds. Before welding verify the machine settings and gas
selection (i.e. type and flow rates).

The hot, fill and cap passes can be completed in the CV Mode (GMAW or FCAW), Pulse
GMAW Mode, STT Mode. Pulse GMAW is recommended for the highest quality weld deposit
and minimal interpass cleaning. Welding progression with the STT Mode is downhill (Figure 4-
2) and uphill with the CV Mode and Pulse GMAW Mode.

No matter what mode selected, bead placement is critical to assure the joint cavity is completely
filled without excessive OD buildup, LOF and inclusions. Correct bead placement can also
significantly reduce interpass cleaning and grinding. Starts and stops of the weld beads should
be altered to avoid stacking the stop and start locations through the complete weld thickness.

The hot pass is typically completed with a single pass, although in some welding positions (i.e.
2G position) a split hot pass may be beneficial with the STT Mode.

Figure L4-2. Bead Oscillation and Weld Direction for the STT Mode.

A-18
Welding
Set up and complete hot pass, fill passes and cap passes on the 6-in. schedule 120 (.5-in. wall)
coupons with root welds already in place (Lesson 3). Welding parameters are referenced in
Table L4-1. Note: ½-in. plate coupons with similar joint preparation as the pipe coupons can be
used for initial practice welds.

Table L4-1. Welding Specifications for Hot pass through Cap Passes.
Program Wire Arc Trim Gas Travel Technique
Speed Control Speed
(in/min) (in/min)

Mode 117 120 5-10 .60 100% CO2 6-7 Downhill weld progression
.045-in. @ 25 cfh slight weave
STT Mode
Mode 22 135 +5 .98 92/8 6-7 Uphill weld progression
.045-in. Argon/ CO2 slight weave
Pulse Spray
@ 25 cfh
Mode
Mode 5 215 Off 1.05 75/25 6-8 Uphill weld progression
.045-in. Argon/ CO2 slight weave
CV Mode
@ 25 cfh
* Mode 5 voltage is controlled by the Trim

Welding Technique
The welder should be in a position to complete as long a weld bead as possible without stopping.
The torch angle can be perpendicular to the root opening or oriented with a slight drag angle (up
to 15-degrees for the STT Mode and up to a 15-degree push angle for CV and Pulsed GMAW
Modes.
Hot Pass
The hot pass should tie together the root weld with both groove faces (Figure L4-1). If a split
bead is used the first hot pass should cover approximately one half the root weld. If necessary
the first hot pass should be wire brushed and ground to assure the second bead can successfully
tie in with the root weld, other groove face and first hot pass. For a single hot pass, the weld
torch is oscillated from one toe of the root weld to the other (approximately 1/8 to 3/16-inch
depending on the size of the root pass) as seen in Figure L4-2.
Fill Passes
The remaining fill passes and cap passes need to completely fill the groove cavity without
excessive OD build up. Bead sequence should be carefully planned in an alternating pattern as
seen in Figure L4-1. Each bead location should make sure an adequate geometry remains for the
subsequent weld beads. If a narrow cavity is formed between weld beads or between the groove
face and the weld bead, LOF or inclusions (i.e. slag) could result. An effort should be made to
grind out the area to eliminate or improve the geometry before welding continues.

A-19
The oscillation for fill passes is approximately 0.25-inches, with a resulting weld bead size of
approximately .4 to .5-inches for the STT Mode. Oscillation and bead size may be slightly larger
with the Pulse GMAW and CV Mode. A typical ½-inch thick pipe with a 37.5-degree bevel will
consist of 5 to 7 total passes with the Pulse GMAW Mode and CV Mode, compared to 9-11
passes with the STT Mode.

Cleanup
Interpass cleaning and grinding should be completed to remove poor geometry created by weld
bead placement and to remove slag. The start and stop locations within each layer should also be
ground and tapered to accept the subsequent weld bead. This assures a good tie in with the
subsequent weld and removes any defects associated with the weld crater (i.e. porosity, crater
cracks). After each layer is complete the stop and starts should be cleaned up with a grinder
before the next layer is initiated. The degree of grinder and cleanup depends on the weld bead
geometry and may not be necessary in many cases. Figure L4-3 illustrates typical cleanup of hot
pass prior to initiating the fill pass sequence.

Figure L4-3. Start and stop location of hot pass before and after preparation for fill passes.

A-20
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