Qualification of

Submerged Arc
Welding Consumables
and Procedures to ABS
Rules

Darren Begg
Reference: 6134C.FR
November 14, 2008
 6134C.FR

QUALIFICATION OF SUBMERGED ARC WELDING CONSUMABLES

AND PROCEDURES TO ABS RULES

FINAL REPORT

November 14, 2008

Submitted to:

ATI
5300 International Blvd
North Charleston, S.C.
29418

Submitted by:

BMT FLEET TECHNOLOGY LIMITED

311 Legget Drive
Kanata, ON
K2K 1Z8

BMT Contact: Darren Begg

Tel: 613-592-2830, ext 229
Fax: 613-592-4950
Email: [email protected]

Category B Government Purpose Rights

Approved for Public Release, Distribution is Unlimited

BMT Fleet Technology Limited accepts no liability for any errors or omissions or for any loss, damage, claim or other demand in
connection with the usage of this report, insofar as those errors and omissions, claims or other demands are due to any
incomplete or inaccurate information supplied to BMT Fleet Technology Limited for the purpose of preparing this report.
BMT Fleet Technology Limited 6134C.FR

ACKNOWLEDGEMENTS

The author would like to thank the following for their contribution and support throughout this
project:

• National Shipbuilding Research Program

• Advanced Technology Institute
• Mr. Mike Sullivan, Chief Welding Engineer, of General Dynamics NASSCO
• Mr. Lee Kvidahl, Northrop Grumman Ship Systems
• Mr. Don Haydock and Mr. Dan Oldford, ABS

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ABBREVIATIONS

ABS American Bureau of Shipping

ASTM American Society for Testing Materials
AWMT All Weld Metal Tensile
AWS American Welding Society
CTWD Contact Tip to Work Distance
ESO Electrical Stick Out
FCB Flux Copper Backing
HSLA High Strength Low Alloy
IPM Inches Per Minute
MPT Magnetic Particle Testing
NSRP National Ship Building Research Program
OSW One Sided Welding
SAW Submerged Arc Welding
UT Ultrasonic Testing
UTS Ultimate Tensile Strength
VBAC Variable Balance Alternating Current
YS Yield Strength
WFS Wire Feed Speed

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TABLE OF CONTENTS

1. BACKGROUND ..................................................................................................................... 1
2. SCOPE OF WORK .................................................................................................................. 2
3. TASKS ..................................................................................................................................... 3
3.1 Task 1: Welding Electrode Qualification ...................................................................... 3
3.2 Task 2: Welding Procedure Qualification ..................................................................... 3
4. RESULTS ................................................................................................................................ 4
4.1 Task 1: Welding Electrode Qualification ...................................................................... 4
4.1.1 High Cooling Rate Test (Low Heat Input) ....................................................... 5
4.1.2 Low Cooling Rate Test (High Heat Input) ....................................................... 6
4.2 Task 2: Welding Procedure Qualification ..................................................................... 8
4.2.1 HSLA-65 (1 inch thickness only): ................................................................. 11
4.2.2 EH36 (1/2" and 1 inch Thicknesses): ............................................................. 12
4.2.3 Welding Procedure Testing Results ............................................................... 12
5. SUMMARY ........................................................................................................................... 26

APPENDICES
Appendix A: Hobart Preliminary Test Results
Appendix B: Welding Electrode Low Heat Input Certification Lab Records
Appendix C: Welding Electrode High Heat Input Certification Lab Records
Appendix D: Welding Electrode Certification Test Results
Appendix E: Mill Test Reports
Appendix F: Lab Records and Welding Procedure Data Sheets
Appendix G: UT Reports
Appendix H: All Weld Metal Tensile Test Reports
Appendix I: Cross Weld Tensile Test Reports
Appendix J: Charpy Impact Test Reports
Appendix K: Hardness Results
Appendix L: Weld Metal Chemical Analysis Results
Appendix M: ABS Statement of Fact

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LIST OF FIGURES

Figure 4.1: Macro, 65-CT-LH ......................................................................................................... 5

Figure 4.2: Macro, 65-CT-HH ........................................................................................................ 6
Figure 4.3: Location of Mechanical Test Specimens ...................................................................... 7
Figure 4.4: Sample Macro, ½” OS Weld Procedure ....................................................................... 9
Figure 4.5: Sample Macro, ½” DS Weld Procedure ..................................................................... 10
Figure 4.6: Sample Macro, 1” OS Weld Procedure ...................................................................... 10
Figure 4.7: Sample Macro, 1” DS Weld Procedure ...................................................................... 11
Figure 4.8: Face and Root Bend Tests, 36-OSW-1/2 .................................................................... 15
Figure 4.9: Face and Root Bend Tests, 65-OSW-1/2 .................................................................... 15
Figure 4.10: Side Bend Tests, 65-DS-1/2 ..................................................................................... 16
Figure 4.11: Side Bend Tests, 36-DS-1/2 ..................................................................................... 16
Figure 4.12: Side Bend Tests, 36-OSW-1 ..................................................................................... 17
Figure 4.13: Side Bend Tests, 65-OSW-1 ..................................................................................... 17
Figure 4.14: Side Bend Tests, 36-DS-1......................................................................................... 18
Figure 4.15: Side Bend Tests, 65-DS-1......................................................................................... 18

LIST OF TABLES

Table 4.1: Welding Electrode Formulation ..................................................................................... 4

Table 4.2: Test Weld Analysis ........................................................................................................ 4
Table 4.3: Tensile Test Results ....................................................................................................... 7
Table 4.4: High and Low Cooling Rate Weld Metal Impact Test Results...................................... 8
Table 4.5: All Weld Metal Tension Test Results .......................................................................... 13
Table 4.7: 36-OSW-1/2 Charpy V-notch Impact Test Results ..................................................... 19
Table 4.8: 36-DS-1/2 Charpy V-notch Impact Test Results ......................................................... 20
Table 4.9: 65-DS-1/2 Charpy V-notch Impact Test Results ......................................................... 21
Table 4.10: 36-OSW-1 Charpy V-notch Impact Test Results ...................................................... 22
Table 4.11: 36-DS-1 Charpy V-notch Impact Test Results .......................................................... 23
Table 4.12: 65-DS-1 Charpy V-notch Impact Test Results .......................................................... 23
Table 4.13: 65-OSW-1 Charpy V-notch Impact Test Results ...................................................... 24

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1. BACKGROUND
The welding procedures developed under NSRP/ASE Project 2005-386 demonstrated significant
productivity enhancements along with mechanical properties that comfortably met stringent
NAVSEA requirements. Productivity enhancements as high as 1200% were identified with
potential cost reductions approaching 65%, with weld metal deposition rates exceeded 110 lbs/hr,
significantly higher compared to current practice. General Dynamics NASSCO requested that
the results of this recently completed project be used to produce and qualify highly productive
welding procedures under American Bureau of Shipping (ABS) Rules for HSLA-65 and EH36
steels, using variable balance AC (VBAC) submerged arc welding (SAW) and metal cored
electrode technologies. The procedures included the single pass one-sided welding (OSW) onto
flux copper backing (FCB) and one pass per side two sided welding no with backgouging
techniques, both in a tandem arrangement.

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2. SCOPE OF WORK
The main deliverables in this project are ABS qualified highly productive welding procedures for
one-sided and two sided welding that will allow shipyards to readily adopt these techniques into
practice. Each shipyard that implements these technologies will expect to significantly reduce
their labor costs per foot of completed weld joint and also decrease their electrode and flux
consumption requirements.

The following welding procedures were qualified and registered under ABS Rules:

• Single pass OSW of ½” and 1 inch thick EH36 and HSLA-65 steels onto a FCB
• Single pass per side two sided welding (no backgouging) of ½ and 1 inch thick EH36 and
HSLA-65 steels

OSW procedures were developed and qualified with Kobelco PFI-50R backing flux to be aligned
with the current production techniques used at GD NASSCO. The welding electrode/flux
combination was also qualified under this testing matrix.

All developmental work, welding of test plates, and mechanical testing of specimens were
performed by BMT FTL, with all welding of test plates and testing of mechanical property
specimens being witnessed by an ABS representative.

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3. TASKS
The objectives of this project were met with the completion of the following tasks:

3.1 Task 1: Welding Electrode Qualification

Prior to the welding procedure qualification phases of this project, the welding electrode and flux
combination required qualification. The welding parameters selected resulted in the highest and
lowest cooling rate that this combination would likely be used in during production welding. The
target deposited weld metal properties are as follows:

• EH36 Weld Metal Targets

o Min. 58ksi Yield Strength, 71 to 95ksi Ultimate Tensile Strength, and 20%
Elongation
o Charpy V-notch Impacts of 20ft-lbs @ -20°F
• HSLA-65 Weld Metal Targets
o Min. 65ksi Yield Strength, 20% Elongation
o Charpy V-notch Impacts of 30 ft-lbs @ -20°F

3.2 Task 2: Welding Procedure Qualification

The welding procedures were qualified under the requirements of NAVSEA Technical
Publication 248 using the highest heat input that each plate thickness would be subjected to in
production for each type of joint design.

Target mechanical properties for each welding procedure are as follows:

• EH36 Weld Metal Targets

o Min. 58ksi Yield Strength Weld Metal, 71 to 95ksi Ultimate Tensile Strength (all
weld metal and cross weld), and 20% Elongation (weld metal)
o Charpy V-notch Impacts of 17ft-lbs @ -4°F and -40°F
ƒ 5 samples tested, highest and lowest values disregarded, average 3
remaining values
• HSLA-65 Weld Metal Targets
o Min. 65ksi Yield Strength (all weld metal), 20% Elongation (all weld metal), 78-
100 ksi Ultimate Tensile Strength (cross weld tensile)
o Charpy V-notch Impacts of 30 ft-lbs @ -20°F
ƒ 5 samples tested, highest and lowest values disregarded, average 3
remaining values

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4. RESULTS

4.1 Task 1: Welding Electrode Qualification

The objective of the welding electrode certification testing is to evaluate the properties of the
deposited undiluted weld metal over a range of heat inputs (and resulting cooling rates).

The formulation of the welding electrode is provided in Table 4.1. The electrode is classified as
AWS A5.23 ECM3, and the trade name is TriMark Metalloy M3S.

Table 4.1: Welding Electrode Formulation

Prior to sending the electrodes to BMT, the electrode manufacture Hobart/Trimark produced a
series of test welds on flat plate in accordance with AWS A5.23 to determine the undiluted
chemistry of the weld deposit using two fluxes, i.e., Hobart/TriMark HN-511 and Lincoln MIL-
800H. The result of this analysis is shown in Table 4.2.

Table 4.2: Test Weld Analysis

In addition, Hobart conducted some preliminary testing of the electrode with TriMark HN-511
flux in accordance with AWS A5.23 to examine the resulting mechanical properties. The
welding conditions used as well as the results of this testing is given as Appendix A. To
summarize, the weld metal demonstrated the following:

• Yield Strength: 95.4 ksi

• Ultimate Tensile Strength: 104.2 ksi
• Elongation: 23.9%
• Charpy V-notch Impact @ -40°F: 93, 89, 71, 84, 70 ft-lbs
• Charpy V-notch Impact @ -76°F: 62, 61, 32, 52, 72 ft-lbs

Test plates for the electrode/flux qualification tests were made from 1-inch thick, 40-inch long
HSLA-65 plate. The welds were manufactured using a single electrode with DCEP polarity. The
5/32” diameter Metalloy M3S electrode’s lot number was N812342301611. The Lincoln MIL-
800H flux used for all welding had a stock and lot number of ED020925 and 11471002,
respectively.

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Each of the welds fabricated were subjected to 100% visual inspection, as well as Magnetic
Particle Testing (MPT) and Ultrasonic Testing (UT). The welding conditions as witnessed by
ABS were as follows:

4.1.1 High Cooling Rate Test (Low Heat Input)

The conditions and tests used for the high cooling rate test weld, identified as 65-CT-LH, are
summarized below:

• 5/32” diameter Single Electrode – DCEP

• 30° included angle, ½” root opening
• 30-40 kj/in heat input
o Amperage: 475A
o Voltage: 28V
o Travel Speed: 20 ipm
o Electrical Stick-out: 1-1/2”
o Wire Feed Speed: 70 – 115 ipm
• Preheat and Interpass Temperature: 75-150°F
• Extract and test two (2) all weld metal tensile and five (5) weld metal Charpy V-notch
impacts tested at -20oF

The test weld required 13 passes to fill the joint, two passes per fill layer and three cap passes, as
shown in Figure 4.1. The lab records of the parameters as witnessed and signed by ABS are
provided as Appendix B.

Figure 4.1: Macro, 65-CT-LH

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4.1.2 Low Cooling Rate Test (High Heat Input)

The conditions and tests used for the low cooling rate test weld, identified as 65-CT-HH, are
summarized below:

• 5/32” diameter Single Electrode – DCEP

• 30° included angle, ½” root opening
• >75 kJ/in heat input
o Amperage: 600A
o Voltage: 32V
o Travel Speed: 15ipm
o Electrical Stick-out: 1-1/2”
o Wire Feed Speed: 120-180 ipm
• Preheat and Interpass Temperatures: 275-325°F
• Extract and test two (2) all weld metal tensiles and five (5) weld metal charpy V-notch
impacts tested at -20F

The test weld required 6 passes to fill the joint as shown in Figure 4.2. The lab records pf the
parameters as witnessed and signed by ABS are provided as Appendix C.

Figure 4.2: Macro, 65-CT-HH

Visual inspection as well as MPT and UT revealed no flaws within the weld metal. From each of
the test plates fabricated, 2 all weld metal tensile specimens and 5 weld metal notched Charpy V-
notch impact specimens were extracted and tested. The specimens were extracted as per Figure
4.3, at the T/2 location.

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Figure 4.3: Location of Mechanical Test Specimens

The results of the tensile and impact testing are summarized in Tables 4.3 and 4.4, respectively,
and the reports as signed and witnessed by ABS are given as Appendix D.

Table 4.3: Tensile Test Results

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Table 4.4: High and Low Cooling Rate Weld Metal Impact Test Results
Procedure Location Specimen Temperature Absorbed Energy
ft/lbs
65-CT-HH WM 1 -20°F 85
T/2 2 105
3 105
4 108
5 108
Average 106
65-CT-LH WM 1 -20°F 68
T/2 2 100
3 75
4 78
5 95
Average 83

The results show that the tensile, yield, and impact requirements are comfortably met over the
entire heat input range, however the elongation on the high heat input welds were below
minimum requirements. On the fracture surface of the high heat input tension specimens and
throughout their gauge lengths, there appeared to be evidence of cracking. The surfaces were
bright and had the characteristics of hydrogen embrittlement. None of this cracking was detected
during NDT of the test plates and it is therefore believed the cracking occurred during the low
strain rate tension testing. It is possible that a post weld aging treatment of the tension specimen
would have released all traces of hydrogen in the specimen and thus enhanced the elongation
properties achieved in the results. Regardless, the yield and ultimate tensile properties meet the
minimum requirements.

In addition, diffusible hydrogen tests were conducted on the electrode flux combination using
75% of the highest amperage range used, i.e., 450A. The travel speed and voltage for each test
specimen was held constant at 22ipm and 27V, respectively. Hydrogen analysis was conducted
in accordance with AWS A4.3 using the under mercury method. The results of the hydrogen
analysis in 4 specimens after being held at 45°C for 72 hrs were 2.2, 2.4, 2.4, and 2.5 ml/100g of
weld metal deposited.

4.2 Task 2: Welding Procedure Qualification

Welding procedures were qualified in EH36 and HSLA-65 material using the Trimark Metalloy
M3S and Lincoln MIL-800H flux combination. The mill test reports for these base materials are
included as Appendix E.

The ABS signed lab work sheets along with welding procedure data sheets for each of the welds
fabricated are provided as Appendix F.

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The identification system used for each of the welding procedures was as follows:

½” Thickness
• 36-OSW-0.5 = EH36 Base Metal, One Sided Welded
• 36-DS-0.5 = EH36 Base Metal, Two Sided Weld, no backgouging
• 65-OSW-0.5 = HSLA-65 Base Metal, One Sided Weld
• 65-DS-0.5 = HSLA-65 Base Metal, Two Sided Weld, no backgouging

1” Thickness
• 36-OSW-1 = EH36 Base Metal, One Sided Weld
• 36-DS-1 = EH36 Base Metal, Two Sided Weld, no backgouging
• 65-OSW-1 = HSLA-65 Base Metal, One Sided Weld
• 65-DS-1 = HSLA-65 Base Metal, Two Sided Weld, no backgouging

All tandem SAW work was performed using Miller Summit Arc 1000 power sources and
witnessed by ABS. Sample macrosections from ½” and 1” OSW and DS welds are shown in
Figures 4.4 to 4.7.

Figure 4.4: Sample Macro, ½” OS Weld Procedure

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Figure 4.5: Sample Macro, ½” DS Weld Procedure

Figure 4.6: Sample Macro, 1” OS Weld Procedure

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Figure 4.7: Sample Macro, 1” DS Weld Procedure

The mechanical test matrix is described following in Sections 4.2.1 and 4.2.2.

4.2.1 HSLA-65 (1 inch thickness only):

Each plate welded was subjected to 100% Visual, MPT, and UT. The procedures qualified
include high heat input single pass OSW onto FCB with variable balance AC tandem SAW. The
test matrix included:

• Two (2) all weld metal tensiles

• Two (2) cross weld tensiles
• Four (4) side bends
• Five (5) weld metal cvn's at -20°F
• Five (5) HAZ cvn's at -20°F

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4.2.2 EH36 (1/2" and 1 inch Thicknesses):

Each plate welded was subjected to 100% Visual, MPT, and UT. The procedures qualified
include high heat input single pass OSW onto FCB with variable balance tandem SAW, and, two
sided tandem SAW (with no backgouging).

½" Plates

• Two (2) Cross Weld Tensiles

• One (1) Macro / Micro / Hardness
• Two (2) Root Bends and Two (2) Face Bends for One Sided Welds
• Four (4) Side Bends for Two (2) Sided Welds
• Charpy V-notch Impact @ T/2 location - *Ten (10) samples at each location (CL & FL)
with Five (5) tested at -4°F and Five (5) at -40°F

1" Plates

• Two (2) Cross Weld Tensiles

• Two (2) All Weld Metal Tensile (centered at ¼" below Side #1 surface), except EH36
One Sided Weld Procedure, only One (1) specimen required.
• One (1) Macro / Micro / Hardness
• Four (4) Side Bends
• Charpy V-notch Impact @ 1/16" from Side #1 Surface - *Ten (10) samples at each
location (CL & FL) with Five (5) tested at -4°F and Five (5) at -40°F

Weld metal chemical analysis samples were also extracted from each fractured all weld metal
tensile specimens from the 1” thick test plates.

4.2.3 Welding Procedure Testing Results

The results of the visual and MPT revealed no surface flaws. The UT inspection reports are
included as Appendix G.

The results of the mechanical testing are summarized below.

4.2.3.1 All Weld Metal Tension Test Results

Each all weld metal tension specimen was machined and tested in accordance with ASTM E8.
The results are summarized following in Table 4.5, and the ABS witnessed signed test reports
and stress strain curves are included as Appendix H.

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Table 4.5: All Weld Metal Tension Test Results

4.2.3.2 Cross Weld Tension Test Results

Full thickness cross weld tension specimen were machined and tested in accordance with ASTM
E8. The results are summarized below in Table 4.6, and the ABS witnessed signed test reports
and stress strain curves are included as Appendix I.

Table 4.6: Cross Weld Tension Test Result Summary

Procedure Specimen Ultimate Tensile Strength Failure Location

(Psi)
1 50,279 Weld*
36-OSW-1/2
2 42,257 Weld*
1 86,335 Weld
65-OSW-1/2
2 88,172 Base Metal
1 79,936 Base Metal
36-DS-1/2
2 79,216 Base Metal
1 87,842 Base Metal
65-DS-1/2
2 88,907 Base Metal
1 82,420 Base Metal
36-OSW-1
2 80,033 Base Metal
1 83,990 Base Metal
65-OSW-1
2 79,790 Weld
1 81,504 Base Metal
36-DS-1
2 80,422 Base Metal
1 84,962 Base Metal
65-DS-1
2 84,899 Base Metal

* Specimens extracted from run on and run off tab locations and failed due to solidifcation
cracks in specimens.

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4.2.3.3 Bend Test Results

Root, face and side bend tests were conducted in a bend test jig using a mandrel diameter of 1.5
inches. All of the test specimens were bent 180° using a pneumatic ram. Each of the specimens
revealed no visible discontinuities to the surface that exceeded the maximum requirement of 1/8”.
The surfaces of each series of bend tests are shown in Figures 4.8 to 4.15.

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Figure 4.8: Face and Root Bend Tests, 36-OSW-1/2

Figure 4.9: Face and Root Bend Tests, 65-OSW-1/2

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Figure 4.10: Side Bend Tests, 65-DS-1/2

Figure 4.11: Side Bend Tests, 36-DS-1/2

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Figure 4.12: Side Bend Tests, 36-OSW-1

Figure 4.13: Side Bend Tests, 65-OSW-1

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Figure 4.14: Side Bend Tests, 36-DS-1

Figure 4.15: Side Bend Tests, 65-DS-1

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4.2.3.4 Charpy V-notch Impact Test Results

Full size impact specimens were machined and tested in accordance with ASTM E23. The
requirement for the EH36 impact testing is an average of 17 ft-lbs at -4°F and -40°F, and that
only one sample of the averaged three specimens may be lower, but not lower than 70% of 17 ft-
lbs (i.e. 11.9ft-lbs). The requirement for the HSLA-65 impact testing is an average of 30 ft-lbs at
-20°F. The results of the impact testing are summarized in Tables 4.7 to 4.13, and the witnessed
signed test reports are included as Appendix J.

Table 4.7: 36-OSW-1/2 Charpy V-notch Impact Test Results

Procedure Location Specimen Temperature Absorbed Energy
ft/lbs
36 OSW ½” WM 1 -4°F 111
2 111
3 114
4 116
5 112
Average 112
-40°F 90
7 85
8 83
9 73
10 85
Average 84

36 OSW ½” HAZ 1 -4°F 19

2 21
3 24
4 22
5 24
Average 22
6 -40°F 18
7 18
8 13
9 16
10 14
Average 16

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Table 4.8: 36-DS-1/2 Charpy V-notch Impact Test Results

Procedure Location Specimen Temperature Absorbed Energy
ft/lbs
36 DS ½” HAZ 1 -4°F 51
2 50
3 51
4 60
5 50
Average 51
6 -40°F 30
7 47
8 21
9 23
10 24
Average 26

36 DS ½” WM 1 -4°F 105
2 113
3 108
4 117
5 111
Average 114
6 -40°F 89
7 100
8 100
9 100
10 78
Average 96

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Table 4.9: 65-DS-1/2 Charpy V-notch Impact Test Results

Procedure Location Specimen Temperature Absorbed Energy
ft/lbs
65 DS ½” HAZ 1 -20°F 28
2 39
3 47
4 30
5 65
Average 38
WM 1 -20°F 81
2 83
3 89
4 89
5 89
Average 87

65 OSW ½” HAZ 1 -20°F 43

2 41
3 69
4 44
5 77
Average 51
WM 1 -20°F 91
2 107
3 97
4 91
5 107
Average 98

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Table 4.10: 36-OSW-1 Charpy V-notch Impact Test Results

Procedure Location Specimen Temperature Absorbed Energy

ft/lbs
36 OSW 1” HAZ 1 -4°F 28
2 25
3 30
Average 28
4 -40°F 26
5 53
6 19
Average 33

36 OSW 1” WM-1 1 -4°F 44

1/16” Below Cap 2 44
3 30
Average 39
4 -40°F 32
5 24
6 35
Average 30

36 OSW 1” WM-2 1 -4°F 45

T/2 2 38
3 42
Average 42
4 -40°F 31
5 31
6 25
Average 29

36 OSW 1” WM-3 1 -4°F 47

1/16” above root 2 43
3 53
Average 48
4 -40°F 44
5 47
6 48
Average 46

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Table 4.11: 36-DS-1 Charpy V-notch Impact Test Results

Procedure Location Specimen Temperature Absorbed Energy
ft/lbs
36 DS 1” WM 1 -4°F 105
2 111
3 109
4 118
5 100
Average 108
HAZ 1 -4°F 169
2 125
3 77
4 68
5 48
Average 90

Table 4.12: 65-DS-1 Charpy V-notch Impact Test Results

Procedure Location Specimen Temperature Absorbed Energy

ft/lbs
65 DS 1” WM 1 -20°F 142
2 134
3 125
4 137
5 130
Average 134
HAZ 1 -20°F 74
2 92
3 38
4 92
5 70
Average 79

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Table 4.13: 65-OSW-1 Charpy V-notch Impact Test Results

Procedure Location Specimen Temperature Absorbed Energy
ft/lbs
65 OSW 1” WM 1 -20°F 67
2 78
3 70
4 65
5 82
Average 72
HAZ 1 -20°F 20
2 22
3 13
4 43
5 32
Average 25

4.2.3.5 Hardness Test Results

Hardness measurements were conducted on each of the welding procedures at the subsurface and
T/2 locations, along with sample weld metal hardnesses along the weld centreline. Specimens
were prepared to a 0.5 micron finish and tested with a 5kg load. The results are summarized in
Appendix K.

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4.2.3.6 Weld Metal Chemical Analysis Results

Samples were extracted form the gauge length of the fractured tension specimens. This method
gives a correlation between the chemical analysis of the undiluted weld metal and the resulting
tensile properties. The results are provided as Appendix L.

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5. SUMMARY
A welding electrode formulation was manufactured by Hobart/Trimark as trade name Metalloy
M3S under classification AWS A5.23 ECM3. The electrode was subjected to high and low
cooling rate tests using Lincoln MIL-800H flux. Mechanical test specimens were extracted to
determine all weld metal tension and impact properties under the two cooling rate conditions.
The results show that the yield strength, ultimate tensile strength, and impact properties
comfortably meet minimum requirements. The elongation of the high heat input weld however
did not meet the requirements likely as the result of hydrogen embrittlement.

The electrode flux combination was then used to qualify welding procedures in EH36 and HSLA-
65 steels of 0.5 and 1.0 inch thickness. The procedures consisted of single pass tandem one sided
welding onto Kobelco backing flux as well as tandem two sided welding (one pass per side)
without backgouging. The welds were subjected to cross weld and all weld metal tensile testing,
weld metal and HAZ impact testing, and bend testing. All results met the minimum requirements
for ultimate tensile and yield strength, impact toughness, and ductility. The 1.0 inch thick welds
were further examined for hardness and all weld metal chemical analysis, and the results are
reported.

All welding of test plates and testing of specimens was witnessed by ABS. A copy of ABS’s
Statement of Fact is included as Appendix M.

Qualification of SAW Consumables and Procedures to ABS Rules 26

BMT Fleet Technology Limited 6134C.FR

APPENDIX A

HOBART PRELIMINARY TEST RESULTS

Qualification of SAW Consumables and Procedures to ABS Rules A-1

BMT Fleet Technology Limited 6134C.FR

Qualification of SAW Consumables and Procedures to ABS Rules A-2

BMT Fleet Technology Limited 6134C.FR

APPENDIX B

WELDING ELECTRODE LOW HEAT INPUT CERTIFICATION LAB RECORDS

Qualification of SAW Consumables and Procedures to ABS Rules B-1

BMT Fleet Technology Limited 6134C.FR

Qualification of SAW Consumables and Procedures to ABS Rules B-2

BMT Fleet Technology Limited 6134C.FR

APPENDIX C

WELDING ELECTRODE HIGH HEAT INPUT CERTIFICATION LAB RECORDS

Qualification of SAW Consumables and Procedures to ABS Rules C-1

BMT Fleet Technology Limited 6134C.FR

Qualification of SAW Consumables and Procedures to ABS Rules C-2

BMT Fleet Technology Limited 6134C.FR

APPENDIX D

WELDING ELECTRODE CERTIFICATION TEST RESULTS

Qualification of SAW Consumables and Procedures to ABS Rules D-1

BMT Fleet Technology Limited 6134C.FR

Qualification of SAW Consumables and Procedures to ABS Rules D-2

BMT Fleet Technology Limited 6134C.FR

Qualification of SAW Consumables and Procedures to ABS Rules D-3

BMT Fleet Technology Limited 6134C.FR

APPENDIX E

MILL TEST REPORTS

Qualification of SAW Consumables and Procedures to ABS Rules E-1

BMT Fleet Technology Limited 6134C.FR

Qualification of SAW Consumables and Procedures to ABS Rules E-2

BMT Fleet Technology Limited 6134C.FR

Qualification of SAW Consumables and Procedures to ABS Rules E-3

BMT Fleet Technology Limited 6134C.FR

Qualification of SAW Consumables and Procedures to ABS Rules E-4

BMT Fleet Technology Limited 6134C.FR

Qualification of SAW Consumables and Procedures to ABS Rules E-5

BMT Fleet Technology Limited 6134C.FR

APPENDIX F

LAB RECORDS AND WELDING PROCEDURE DATA SHEETS

Qualification of SAW Consumables and Procedures to ABS Rules F-1

BMT Fleet Technology Limited 6134C.FR

Qualification of SAW Consumables and Procedures to ABS Rules F-2

BMT Fleet Technology Limited 6134C.FR

Qualification of SAW Consumables and Procedures to ABS Rules F-3

BMT Fleet Technology Limited 6134C.FR

Qualification of SAW Consumables and Procedures to ABS Rules F-4

BMT Fleet Technology Limited 6134C.FR

Qualification of SAW Consumables and Procedures to ABS Rules F-5

BMT Fleet Technology Limited 6134C.FR

WPS No.:
Welding Procedure Data __________________________

Sheet WPDS No.:

36-OSW-0.5

Welding Process: SAW Electrode Type: Metal Cored Flux: Lincoln MIL-800H

Filler Metal Identification: AWS A5.23 ECM3

Material Specification: EH36

Preheat Temperature (°C): 66

Interpass Temperature (°C): N/A

Preheat Method: Torch

Position of Welding: Flat

Travel Direction Lead Wire: 0°Drag Travel Direction Trail Wire: 15°Push Angle

Current: CV Polarity: AC (66% DCEP 34%DCEN)

Manual, Semi-Auto, Auto,Machine: Machine

Single or Multiple Arc: Multiple (Tandem Arc)

Single or Multipass: Single

Cleaning Method: Grind to remove scale 2” in all directions of joint

Ө = 50° Included Angle Rg = 0 Rf = 1/8

Wire Feed Flux Contact Travel Electrode

Material Tandem Electrode
Weld Sequence Speed Depth Amps Volts Tip to Speed Spacing
Thickness Process Size
Plate

In. Wire Side Layer Pass In’s ipm In. A V In. ipm In.

Lead 1 1 1 5/32 140-145 1 900 30.5 1-1/4

1 30 7/8
Trail 1 1 1 5/32 120-130 1 1/2 660 35 1-1/2

Procedure Qualification Record No.: Procedure Notes: Approval:

Fill groove in copper backing bar flush with flux.
Date: Copper backing bar shall fit tight to back of
plate.
FTL:
Flux shall be baked and held in a holding oven
at temperatures within manufacturer’s specified
range.

Qualification of SAW Consumables and Procedures to ABS Rules F-6

BMT Fleet Technology Limited 6134C.FR

WPS No.:
Welding Procedure Data __________________________

Sheet WPDS No.:

36-DS-0.5

Welding Process: SAW Electrode Type: Metal Cored Flux: Lincoln MIL-800H

Filler Metal Identification: AWS A5.23 ECM3

Material Specification: EH36

Preheat Temperature (°C): 66

Interpass Temperature (°C): 66

Preheat Method: Torch

Position of Welding: Flat

Travel Direction Lead Wire: 0°Drag Travel Direction Trail Wire: 15°Push Angle

Current: CV Polarity: AC (66% DCEP 34%DCEN)

Manual, Semi-Auto, Auto,Machine: Machine

Single or Multiple Arc: Multiple (Tandem Arc) Weld first side of joint, flip plate and weld side 2.
Rg = 0
Single or Multipass: Single

Cleaning Method: Grind to remove scale 2” in all directions of joint

Wire Feed Flux Contact Travel Electrode

Material Tandem Electrode
Weld Sequence Speed Depth Amps Volts Tip to Speed Spacing
Thickness Process Size
Plate

In. Wire Side Layer Pass In’s ipm In. A V In. ipm In.

Lead 1 1 1 5/32 150 1/2 950 30 3/4

45 7/8
Trail 1 1 1 5/32 125 1 1/2 600 35 1-1/4
1
Lead 2 1 2 5/32 140-145 1/2 950 30 3/4
45 7/8
Trail 2 1 2 5/32 140-145 1 1/2 600 35 1-1/2

Procedure Qualification Record No.: Procedure Notes: Approval:

Flux shall be baked and held in a holding oven
Date: at temperatures within manufacturer’s specified
range.
FTL:

Qualification of SAW Consumables and Procedures to ABS Rules F-7

BMT Fleet Technology Limited 6134C.FR

WPS No.:
Welding Procedure Data __________________________

Sheet WPDS No.:

36-OSW-1

Welding Process: SAW Electrode Type: Metal Cored Flux: Lincoln MIL-800H

Filler Metal Identification: AWS A5.23 ECM3

Material Specification: EH36

Preheat Temperature (°C): Ambient

Interpass Temperature (°C): N/A

Preheat Method: N/A

Position of Welding: Flat

Travel Direction Lead Wire: 15°Drag Travel Direction Trail Wire: 0°Angle

Current: CV Polarity: AC (66% DCEP 34%DCEN)

Manual, Semi-Auto, Auto,Machine: Machine

Single or Multiple Arc: Multiple (Tandem Arc)

Single or Multipass: Single

Cleaning Method: Grind to remove scale 2” in all directions of joint

Ө = 50° Included Angle Rg = 0 Rf = 1/8

Wire Feed Flux Contact Travel Electrode

Material Tandem Electrode
Weld Sequence Speed Depth Amps Volts Tip to Speed Spacing
Thickness Process Size
Plate

In. Wire Side Layer Pass In’s ipm In. A V In. ipm In.

Lead 1 1 1 5/32 200-215 1 1150 32.5 1/2

1 17 4
Trail 1 1 1 5/32 250-265 1 3/4 950 42.5 2

Procedure Qualification Record No.: Procedure Notes: Approval:

Fill groove in copper backing bar flush with flux.
Date: Copper backing bar shall fit tight to back of
plate.
FTL:
Flux shall be baked and held in a holding oven
at temperatures within manufacturer’s specified
range.

Qualification of SAW Consumables and Procedures to ABS Rules F-8

BMT Fleet Technology Limited 6134C.FR

WPS No.:
Welding Procedure Data __________________________

Sheet WPDS No.:

36-DS-1

Welding Process: SAW Electrode Type: Metal Cored Flux: Lincoln MIL-800H

Filler Metal Identification: AWS A5.23 ECM3

Material Specification: EH36

Preheat Temperature (°C): 66

Interpass Temperature (°C): 66

Preheat Method: Torch

Position of Welding: Flat

Travel Direction Lead Wire: 0°Drag Travel Direction Trail Wire: 15°Push Angle

Current: CV Polarity: AC (66% DCEP 34%DCEN)

Manual, Semi-Auto, Auto,Machine: Machine

Single or Multiple Arc: Multiple (Tandem Arc) Ө1=70° Included Angle, Ө2=90° Included Angle, Rg = 0, Rf = 5/16,
E1=7/16, E2=1/4
Single or Multipass: Single

Cleaning Method: Grind to remove scale 2” in all directions of joint

Wire Feed Flux Contact Travel Electrode

Material Tandem Electrode
Weld Sequence Speed Depth Amps Volts Tip to Speed Spacing
Thickness Process Size
Plate

In. Wire Side Layer Pass In’s ipm In. A V In. ipm In.

Lead 1 1 1 5/32 160-180 1/2 1000 32.5 1-1/4

38 7/8
Trail 1 1 1 5/32 210-220 1 1/2 850 36 1-1/2
1
Lead 2 1 2 5/32 140-145 1/2 950 32.5 1-1/4
45 7/8
Trail 2 1 2 5/32 150-155 1 1/2 725 35 1-1/2

Procedure Qualification Record No.: Procedure Notes: Approval:

Flux shall be baked and held in a holding oven
Date: at temperatures within manufacturer’s specified
range.
FTL:

Qualification of SAW Consumables and Procedures to ABS Rules F-9

BMT Fleet Technology Limited 6134C.FR

WPS No.:
Welding Procedure Data __________________________

Sheet WPDS No.:

65-OSW-0.5

Welding Process: SAW Electrode Type: Metal Cored Flux: Lincoln MIL-800H

Filler Metal Identification: AWS A5.23 ECM3

Material Specification: HSLA-65

Preheat Temperature (°C): 66

Interpass Temperature (°C): N/A

Preheat Method: Torch

Position of Welding: Flat

Travel Direction Lead Wire: 0°Drag Travel Direction Trail Wire: 15°Push Angle

Current: CV Polarity: AC (66% DCEP 34%DCEN)

Manual, Semi-Auto, Auto,Machine: Machine

Single or Multiple Arc: Multiple (Tandem Arc)

Single or Multipass: Single

Cleaning Method: Grind to remove scale 2” in all directions of joint

Ө = 50° Included Angle Rg = 0 Rf = 1/8

Wire Feed Flux Contact Travel Electrode

Material Tandem Electrode
Weld Sequence Speed Depth Amps Volts Tip to Speed Spacing
Thickness Process Size
Plate

In. Wire Side Layer Pass In’s ipm In. A V In. ipm In.

Lead 1 1 1 5/32 150-160 1 925 29.5 1-1/4

1 30 7/8
Trail 1 1 1 5/32 125-140 1 1/2 660 35 1-1/2

Procedure Qualification Record No.: Procedure Notes: Approval:

Fill groove in copper backing bar flush with flux.
Date: Copper backing bar shall fit tight to back of
plate.
FTL:
Flux shall be baked and held in a holding oven
at temperatures within manufacturer’s specified
range.

Qualification of SAW Consumables and Procedures to ABS Rules F-10

BMT Fleet Technology Limited 6134C.FR

WPS No.:
Welding Procedure Data __________________________

Sheet WPDS No.:

65-DS-0.5

Welding Process: SAW Electrode Type: Metal Cored Flux: Lincoln MIL-800H

Filler Metal Identification: AWS A5.23 ECM3

Material Specification: HSLA-65

Preheat Temperature (°C): 66

Interpass Temperature (°C): 66

Preheat Method: Torch

Position of Welding: Flat

Travel Direction Lead Wire: 0°Drag Travel Direction Trail Wire: 15°Push Angle

Current: CV Polarity: AC (66% DCEP 34%DCEN)

Manual, Semi-Auto, Auto,Machine: Machine

Single or Multiple Arc: Multiple (Tandem Arc) Weld first side of joint, flip plate and weld side 2.
Rg = 0
Single or Multipass: Single

Cleaning Method: Grind to remove scale 2” in all directions of joint

Wire Feed Flux Contact Travel Electrode

Material Tandem Electrode
Weld Sequence Speed Depth Amps Volts Tip to Speed Spacing
Thickness Process Size
Plate

In. Wire Side Layer Pass In’s ipm In. A V In. ipm In.

Lead 1 1 1 5/32 150 1/2 950 30 3/4

45 7/8
Trail 1 1 1 5/32 125 1 1/2 600 35 1-1/4
1
Lead 2 1 2 5/32 140-145 1/2 950 30 3/4
45 7/8
Trail 2 1 2 5/32 140-145 1 1/2 600 35 1-1/2

Procedure Qualification Record No.: Procedure Notes: Approval:

Flux shall be baked and held in a holding oven
Date: at temperatures within manufacturer’s specified
range.
FTL:

Qualification of SAW Consumables and Procedures to ABS Rules F-11

BMT Fleet Technology Limited 6134C.FR

WPS No.:
Welding Procedure Data __________________________

Sheet WPDS No.:

65-OSW-1

Welding Process: SAW Electrode Type: Metal Cored Flux: Lincoln MIL-800H

Filler Metal Identification: AWS A5.23 ECM3

Material Specification: HSLA-65

Preheat Temperature (°C): Ambient

Interpass Temperature (°C): N/A

Preheat Method: N/A

Position of Welding: Flat

Travel Direction Lead Wire: 15°Drag Travel Direction Trail Wire: 0°Angle

Current: CV Polarity: AC (66% DCEP 34%DCEN)

Manual, Semi-Auto, Auto,Machine: Machine

Single or Multiple Arc: Multiple (Tandem Arc)

Single or Multipass: Single

Cleaning Method: Grind to remove scale 2” in all directions of joint

Ө = 50° Included Angle Rg = 0 Rf = 1/8

Wire Feed Flux Contact Travel Electrode

Material Tandem Electrode
Weld Sequence Speed Depth Amps Volts Tip to Speed Spacing
Thickness Process Size
Plate

In. Wire Side Layer Pass In’s ipm In. A V In. ipm In.

Lead 1 1 1 5/32 200-230 1 1150 32.5 1/2

1 17 4
Trail 1 1 1 5/32 280-300 1 3/4 950 42.5 2

Procedure Qualification Record No.: Procedure Notes: Approval:

Fill groove in copper backing bar flush with flux.
Date: Copper backing bar shall fit tight to back of
plate.
FTL:
Flux shall be baked and held in a holding oven
at temperatures within manufacturer’s specified
range.

Qualification of SAW Consumables and Procedures to ABS Rules F-12

BMT Fleet Technology Limited 6134C.FR

WPS No.:
Welding Procedure Data __________________________

Sheet WPDS No.:

65-DS-1

Welding Process: SAW Electrode Type: Metal Cored Flux: Lincoln MIL-800H

Filler Metal Identification: AWS A5.23 ECM3

Material Specification: HSLA-65

Preheat Temperature (°C): 66

Interpass Temperature (°C): 66

Preheat Method: Torch

Position of Welding: Flat

Travel Direction Lead Wire: 0°Drag Travel Direction Trail Wire: 15°Push Angle

Current: CV Polarity: AC (66% DCEP 34%DCEN)

Manual, Semi-Auto, Auto,Machine: Machine

Single or Multiple Arc: Multiple (Tandem Arc) Ө1=70° Included Angle, Ө2=90° Included Angle, Rg = 0, Rf = 5/16,
E1=7/16, E2=1/4
Single or Multipass: Single

Cleaning Method: Grind to remove scale 2” in all directions of joint

Wire Feed Flux Contact Travel Electrode

Material Tandem Electrode
Weld Sequence Speed Depth Amps Volts Tip to Speed Spacing
Thickness Process Size
Plate

In. Wire Side Layer Pass In’s ipm In. A V In. ipm In.

Lead 1 1 1 5/32 160-180 1/2 1000 32.5 1-1/4

38 7/8
Trail 1 1 1 5/32 210-220 1 1/2 850 36 1-1/2
1
Lead 2 1 2 5/32 140-145 1/2 950 32.5 1-1/4
45 7/8
Trail 2 1 2 5/32 150-155 1 1/2 725 35 1-1/2

Procedure Qualification Record No.: Procedure Notes: Approval:

Flux shall be baked and held in a holding oven
Date: at temperatures within manufacturer’s specified
range.
FTL:

Qualification of SAW Consumables and Procedures to ABS Rules F-13

BMT Fleet Technology Limited 6134C.FR

APPENDIX G

UT REPORTS

Qualification of SAW Consumables and Procedures to ABS Rules G-1

BMT Fleet Technology Limited 6134C.FR

Ultrasonic Examination of Welds Transducer: AWS0256 2.25 MHz 70o July 24 2008
Project: ____6134______________________________ 70o Side 1
Weld Identification: 36-DS-1______________________
Material & Thickness: ____1 inch__________________
Weld Joint Identification:_________________________
680 mm long
Weld Process: ___SAW__________________________ o
Quality Requirements: Section # ABS Guide for NDT_ 60
Side 2
Remarks: Calibration on DSC block, inspected as
AWS D1.1 cyclically loaded non-tubular structural weld. Scanned at +20 dB from both sides of weld, only rejectable reflectors
reported.

Attenuation Factor

Indication Rating
Indication Level

Depth from Surface

Reference Level
Indication Number

Half Skip Number

Transducer Angle

Angular Distance
Line Number

Discontinuity
Sound Path

Evaluation
Length

“A”
Distance
Remarks
From
(All distances are in millimetres)
a b c d X Y
1 No rejectable reflectors found
2
3
4
5
6
7
8
9
Attenuation Factor “c”: subtract 25.4 mm from the sound path distance and divide the remainder by 12.7

Qualification of SAW Consumables and Procedures to ABS Rules G-2

BMT Fleet Technology Limited 6134C.FR

Ultrasonic Examination of Welds Transducer: AWS0256 2.25 MHz 70o July 24 2008
Project: ____6134______________________________ CJP Side 1
Weld Identification: 36-DS-1/2____________________
Material & Thickness: ____1/2 inch__________________
Weld Joint Identification:_________________________
623 mm long
Weld Process: ___SAW__________________________ Side 2
Quality Requirements: Section # ABS Guide for NDT_
Remarks: Calibration on DSC block, inspected as
AWS D1.1 cyclically loaded non-tubular structural weld. Scanned at +20 dB from both sides of weld, only rejectable reflectors
reported.

Attenuation Factor

Indication Rating
Indication Level

Depth from Surface

Reference Level
Indication Number

Half Skip Number

Transducer Angle

Angular Distance
Line Number

Discontinuity
Sound Path

Evaluation
Length

“A”
Distance
Remarks
From
(All distances are in millimetres)
a b c d X Y
1 No reportable reflectors found
2
3
4
5
6
7
8
9
Attenuation Factor “c”: subtract 25.4 mm from the sound path distance and divide the remainder by 12.7

Qualification of SAW Consumables and Procedures to ABS Rules G-3

BMT Fleet Technology Limited 6134C.FR

Ultrasonic Examination of Welds Transducer: AWS0256 2.25 MHz 70o July 24 2008
Project: ____6134______________________________ 50o Side 1
Weld Identification: 65-OSW-1/2____________________
Material & Thickness: ____1/2 inch__________________
Weld Joint Identification:_________________________ 3 mm
623 mm long
Weld Process: ___SAW__________________________ Welded from Side 1
Quality Requirements: Section # ABS Guide for NDT_
Remarks: Calibration on DSC block, inspected as
AWS D1.1 cyclically loaded non-tubular structural weld. Scanned at +20 dB from both sides of the weld, only rejectable reflectors
reported.

Attenuation Factor

Indication Rating
Indication Level

Depth from Surface

Reference Level
Indication Number

Half Skip Number

Transducer Angle

Angular Distance
Line Number

Discontinuity
Sound Path

Evaluation
Length

“A”
Distance
Remarks
From
(All distances are in millimetres)
a b c d X Y
1 1 70 2 +3.7 57.0 2 +2 28 53 7.3 320 -19 This reflector is 8 mm outside weld
zone in base metal.
2
3
4
5
6
7
8
9

Attenuation Factor “c”: subtract 25.4 mm from the sound path distance and divide the remainder by 12.7

Qualification of SAW Consumables and Procedures to ABS Rules G-4

BMT Fleet Technology Limited 6134C.FR

Ultrasonic Examination of Welds Transducer: AWS0256 2.25 MHz 70o July 24 2008
Project: ____6134______________________________ 70o Side 1
Weld Identification: 65-DS-1______________________
Material & Thickness: ____1 inch__________________
Weld Joint Identification:_________________________
680 mm long
Weld Process: ___SAW__________________________
Quality Requirements: Section # ABS Guide for NDT_ 60o
Side 2
Remarks: Calibration on DSC block, inspected as
AWS D1.1 cyclically loaded non-tubular structural weld. Scanned at +20 dB from both sides of weld, only rejectable reflectors
reported.

Attenuation Factor

Indication Rating

Depth from Surface

Indication Level

Reference Level
Indication Number

Half Skip Number

Transducer Angle

Angular Distance
Line Number

Discontinuity
Sound Path

Evaluation
Length

“A”
Distance
Remarks
From
(All distances are in millimetres)
a b c d X Y
1 No rejectable reflectors found
2
3
4
5
6
7
8
9
Attenuation Factor “c”: subtract 25.4 mm from the sound path distance and divide the remainder by 12.7

Qualification of SAW Consumables and Procedures to ABS Rules G-5

BMT Fleet Technology Limited 6134C.FR

Ultrasonic Examination of Welds Transducer: AWS0256 2.25 MHz 70o July 24 2008
Project: ____6134______________________________ CJP Side 1
Weld Identification: 65-DS-1/2____________________
Material & Thickness: ____1/2 inch__________________
Weld Joint Identification:_________________________
623 mm long
Weld Process: ___SAW__________________________ Side 2
Quality Requirements: Section # ABS Guide for NDT_
Remarks: Calibration on DSC block, inspected as
AWS D1.1 cyclically loaded non-tubular structural weld. Scanned at +20 dB from both sides of the weld, only rejectable reflectors
reported.

Attenuation Factor

Indication Rating
Indication Level

Depth from Surface

Reference Level
Indication Number

Half Skip Number

Transducer Angle

Angular Distance
Line Number

Discontinuity
Sound Path

Evaluation
Length

“A”
Distance
Remarks
From
(All distances are in millimetres)
a b c d X Y
1 No reportable reflectors found
2
3
4
5
6
7
8
9

Attenuation Factor “c”: subtract 25.4 mm from the sound path distance and divide the remainder by 12.7

Qualification of SAW Consumables and Procedures to ABS Rules G-6

BMT Fleet Technology Limited 6134C.FR

APPENDIX H

ALL WELD METAL TENSILE TEST REPORTS

Qualification of SAW Consumables and Procedures to ABS Rules H-1

BMT Fleet Technology Limited 6134C.FR

Qualification of SAW Consumables and Procedures to ABS Rules H-2

BMT Fleet Technology Limited 6134C.FR

Qualification of SAW Consumables and Procedures to ABS Rules H-3

BMT Fleet Technology Limited 6134C.FR

Qualification of SAW Consumables and Procedures to ABS Rules H-4

BMT Fleet Technology Limited 6134C.FR

Qualification of SAW Consumables and Procedures to ABS Rules H-5

BMT Fleet Technology Limited 6134C.FR

Qualification of SAW Consumables and Procedures to ABS Rules H-6

BMT Fleet Technology Limited 6134C.FR

Qualification of SAW Consumables and Procedures to ABS Rules H-7

BMT Fleet Technology Limited 6134C.FR

Qualification of SAW Consumables and Procedures to ABS Rules H-8

BMT Fleet Technology Limited 6134C.FR

Qualification of SAW Consumables and Procedures to ABS Rules H-9

BMT Fleet Technology Limited 6134C.FR

APPENDIX I

CROSS WELD TENSILE TEST REPORTS

Qualification of SAW Consumables and Procedures to ABS Rules I-1

BMT Fleet Technology Limited 6134C.FR

Qualification of SAW Consumables and Procedures to ABS Rules I-2

BMT Fleet Technology Limited 6134C.FR

Qualification of SAW Consumables and Procedures to ABS Rules I-3

BMT Fleet Technology Limited 6134C.FR

Qualification of SAW Consumables and Procedures to ABS Rules I-4

BMT Fleet Technology Limited 6134C.FR

Qualification of SAW Consumables and Procedures to ABS Rules I-5

BMT Fleet Technology Limited 6134C.FR

Qualification of SAW Consumables and Procedures to ABS Rules I-6

BMT Fleet Technology Limited 6134C.FR

Qualification of SAW Consumables and Procedures to ABS Rules I-7

BMT Fleet Technology Limited 6134C.FR

Qualification of SAW Consumables and Procedures to ABS Rules I-8

BMT Fleet Technology Limited 6134C.FR

Qualification of SAW Consumables and Procedures to ABS Rules I-9

BMT Fleet Technology Limited 6134C.FR

Qualification of SAW Consumables and Procedures to ABS Rules I-10

BMT Fleet Technology Limited 6134C.FR

Qualification of SAW Consumables and Procedures to ABS Rules I-11

BMT Fleet Technology Limited 6134C.FR

Qualification of SAW Consumables and Procedures to ABS Rules I-12

BMT Fleet Technology Limited 6134C.FR

APPENDIX J

CHARPY IMPACT TEST REPORTS

Qualification of SAW Consumables and Procedures to ABS Rules J-1

BMT Fleet Technology Limited 6134C.FR

Qualification of SAW Consumables and Procedures to ABS Rules J-2

BMT Fleet Technology Limited 6134C.FR

Qualification of SAW Consumables and Procedures to ABS Rules J-3

BMT Fleet Technology Limited 6134C.FR

Qualification of SAW Consumables and Procedures to ABS Rules J-4

BMT Fleet Technology Limited 6134C.FR

Qualification of SAW Consumables and Procedures to ABS Rules J-5

BMT Fleet Technology Limited 6134C.FR

Qualification of SAW Consumables and Procedures to ABS Rules J-6

BMT Fleet Technology Limited 6134C.FR

Qualification of SAW Consumables and Procedures to ABS Rules J-7

BMT Fleet Technology Limited 6134C.FR

Qualification of SAW Consumables and Procedures to ABS Rules J-8

BMT Fleet Technology Limited 6134C.FR

APPENDIX K

HARDNESS RESULTS

Qualification of SAW Consumables and Procedures to ABS Rules K-1

BMT Fleet Technology Limited 6134C.FR

Qualification of SAW Consumables and Procedures to ABS Rules K-2

BMT Fleet Technology Limited 6134C.FR

Qualification of SAW Consumables and Procedures to ABS Rules K-3

BMT Fleet Technology Limited 6134C.FR

Qualification of SAW Consumables and Procedures to ABS Rules K-4

BMT Fleet Technology Limited 6134C.FR

Qualification of SAW Consumables and Procedures to ABS Rules K-5

BMT Fleet Technology Limited 6134C.FR

Qualification of SAW Consumables and Procedures to ABS Rules K-6

BMT Fleet Technology Limited 6134C.FR

Qualification of SAW Consumables and Procedures to ABS Rules K-7

BMT Fleet Technology Limited 6134C.FR

Qualification of SAW Consumables and Procedures to ABS Rules K-8

BMT Fleet Technology Limited 6134C.FR

Qualification of SAW Consumables and Procedures to ABS Rules K-9

BMT Fleet Technology Limited 6134C.FR

APPENDIX L

WELD METAL CHEMICAL ANALSYS RESULTS

Qualification of SAW Consumables and Procedures to ABS Rules L-1

BMT Fleet Technology Limited 6134C.FR

Qualification of SAW Consumables and Procedures to ABS Rules L-2

BMT Fleet Technology Limited 6134C.FR

APPENDIX M

ABS STATEMENT OF FACT

Qualification of SAW Consumables and Procedures to ABS Rules M-1

BMT Fleet Technology Limited 6134C.FR

Qualification of SAW Consumables and Procedures to ABS Rules M-2

BMT Fleet Technology Limited 6134C.FR

Qualification of SAW Consumables and Procedures to ABS Rules M-3