How to Qualify a Welding Procedure
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The document outlines the five step process to qualify a welding procedure according to ASME Section IX. It provides details on developing a draft procedure using 0.75" A36 steel plate welded in the flat position using GTAW and GMAW. Variables such as joint design, base metal and thickness, filler metal type and size, welding position, and electrical parameters are documented. The qualification weld was tested to verify it results in an acceptable weld with proper mechanical properties before the welding procedure specification can be used in construction.
How to Qualify a Welding Procedure
- 1. ASME Section IX Welding Procedure Qualification Antonius P. Bramono
- 3. Primary purpose for procedure qualification: To verify compatibility of materials and techniques to result in a sound weld with acceptable mechanical properties • WPS qualified by mechanical testing • PQR is documentation to prove that a weld can be made using the procedure and have acceptable mechanical properties Welding Procedure Qualification
- 4. How To Qualify A Welding Procedure?
- 5. Five Step Process to Qualify a Welding Procedure 1. Understand the intended application for which the WPS will be used 2. Develop a draft procedure 3. Make a qualification weld 4. Test the qualification weld 5. Write up the WPS
- 6. 1. Understand the Intended Application for Which the WPS Will Be Used Things to know prior to qualifying a welding procedure Know the application for the welding procedure What welding process(es) are going to be used during construction What materials are going to be used during construction • The types and grades • The thicknesses of each material • Are there dissimilar welds including welds between different P-No.?
- 7. 1. Understand the Intended Application for Which the WPS Will Be Used Know the design requirements for the application Does the design require specific material toughness requirements?
- 8. 2. Example Develop a Draft Procedure Qualification GTAW/GMAW qualification weld • 0.75” A 36 plate material • Flat position • ER70S-6 electrode was used for GMAW • ER80S-D2 electrode was used for GTAW • No preheat or PWHT Procedure Qualification Record (PQR) needs to address the welding variables of each welding process
- 9. GTAW Weld Procedure Variables
- 10. GMAW Weld Procedure Variables
- 11. Procedure Qualification Record (PQR)
- 12. 3. Procedure Qualification – Joint Variables • Joint variables are the same for GTAW and GMAW • QW-402.1 – Groove design was a V-groove with a 45° included angle • QW-402.4 – There was a backing bar used • QW-402.10 – The root spacing was 1/8-in. • QW-402.11 – Nonmetallic or non-fusing retainers were not used
- 13. Company Name: XYZ, Co. Ltd. PQR No.: NRC-PQR-1 WPS No.: NRC-WPS-1 Date: June 18 and 19, 2015 Welding Process: GTAW and GMAW Types (Manual, Automatic, Semi-Automatic): Manual Joints (QW-402): Note: The weld was both GTAW and GMAW with 1/4-in. deposited with GTAW and 1/2-in. deposited with GMAW 3. Procedure Qualification – Joint Variables
- 14. 3. Procedure Qualification – Base Metal Variables • Relevance of base metal variables depend on process • QW-403.5 and QW-403.11 – Material was A36 plate which is P-No. 1 and Group 1 Material Table QW-422 Paragraph Brief of Variables Essential Supplementary Essential Non-essential QW-403 Base Materials .5 ϕ Group No. X .11 ϕ P-No. Qualified X Spec No. Type/Grade UNS No. P-No. Group No. Nominal Composition Product Form SA-36 - K02600 1 1 C-Mn-Si Plate, Bar & Shapes
- 15. 3. Procedure Qualification – Base Metal Variables • QW-403.6, QW-403.8 and QW-403.10 – Material thickness was 0.75-in. • QW-403.9 – No single weld pass in the qualification weld was greater than 1/2-in. • GMAW only Paragraph Brief of Variables Essential Supplementary Essential Non-essential QW-403 Base Materials .6 T Limits X .8 ϕ T Qualified X .9 t pass > 1/2-in. X .10 T Limits (S. Cir. Arc) X
- 16. 3. Procedure Qualification – Base Metal Variables Base Metals (QW-403) Material Spec.: SA-36 Type or Grade: N/A P- No.: P-No.1 To P-No.: P-No. 1 Thickness of Test Coupon: 3/4-in. Diameter of Test Coupon: N/A Other: 1. SA-36 does not come in different grades 2. The weld was made on plate so diameter does not apply. 3. All passes were less than 1/2-in. thick
- 17. 3. Procedure Qualification – Filler Metal Variables QW-404.3 – The GTAW wire diameter was 1/8-in. • GTAW only QW-404.6 – The GMAW electrode diameter was 0.035-in. • GMAW only QW-404.23 – Solid wire was used Paragraph Brief of Variables Essential Supplementary Essential Non-essential QW-404 Filler Metals .3 ϕ Size X .6 ϕ Diameter X .23 ϕ Filler Metal Product Form X
- 18. 3. Procedure Qualification – Filler Metal Variables QW-404.4 – The welding wire was ER80S-D2 for GTAW and ER70S-6 for GMAW • ASME Section II, SFA 5.28 specifies low-alloy steel electrodes for gas shielded arc welding • ASME Section II, SFA 5.18 specifies carbon steel electrodes for gas shielded arc welding • Table QW-432 Paragraph Brief of Variables Essential Supplementary Essential Non-essential QW-404 Filler Metals .4 ϕ F-No. X F-No. ASME Specification AWS Classification 6 SFA-5.28 All Classifications 6 SFA-5.18 All Classifications
- 19. 3. Procedure Qualification – Filler Metal Variables QW-404.5 – The welding wire was ER80S-D2 for GTAW and ER70S-6 for GMAW • SAME ASME Section II specifications apply to determine chemistry • Table QW-442 Paragraph Brief of Variables Essential Supplementary Essential Non-essential QW-404 Filler Metals .5 ϕ A-No. X A-No. Weld Deposit Analysis, % C Cr Mo Ni Mn Si 11 Mn – Mo 0.17 - 0.25 – 0.75 0.85 1.25 – 2.25 1.00 ER80S-D2 (SFA 5.18) 0.07 – 0.12 - 0.4-0.6 0.15 1.60 – 2.10 0.5 – 0.8 1 Mild Steel 0.20 - - - 1.60 1.00 ER70S-6 (SFA 5.18) 0.06 – 0.15 0.15 0.15 0.15 1.40 – 1.85 0.80 – 1.15
- 20. 3. Procedure Qualification – Filler Metal Variables QW-404.12 and QW-404.33 – The wire classification was ER80S-D2 for GTAW and ER70S-6 GMAW QW-404.14 – Filler metal was used • GTAW only QW-404.50 – No flux was used • GTAW only Paragraph Brief of Variables Essential Supplementary Essential Non-essential QW-404 Filler Metals .12 ϕ Classification X .14 ± Filler X .33 ϕ Classification X .50 ± Flux X
- 21. 3. Procedure Qualification – Filler Metal Variables QW-404.22 – No consumable insert was used • GTAW only QW-404.24 and QW-404.27 – No Supplemental filler metal was used so variable does not apply • GMAW only QW-404.30 and QW-404.32 – Weld thickness was 1/4-in. for GTAW and 1/2-in. for GMAW Paragraph Brief of Variables Essential Supplementary Essential Non-essential QW-404 Filler Metals .22 ± Consumable Insert X .24 ± or ϕ Supplemental X .27 ϕ Alloy Elements X .30 ϕ t X .32 t limits (S.C. Arc) X
- 22. 3. Procedure Qualification – Filler Metal Variables Filler Metals (QW-404) SFA Specification: SFA 5.28 for GTAW SFA 5.18 for GMAW AWS Classification: ER80S-D2 for GTAW ER70S-6 for GMAW Filler Metal F-No. 6 for GTAW and GMAW Weld Metal Analysis A-No.: 11 for GTAW 1 for GMAW Size of Filler Metal 1/8-in. for GTAW 0.035-in. for GMAW Weld Metal Thickness: 1/4-in. for GTAW 1/2-in. for GMAW Other: -
- 23. 3. Procedure Qualification – Position Variables Positions variables are the same for GTAW and GMAW QW-405.1, QW-405.2 and QW-405.3 – The weld was made in the flat position Paragraph Brief of Variables Essential Supplementary Essential Non-essential QW-405 Positions .1 + Position X .2 ϕ Position X .3 ϕ ↑↓ Ver cal Welding X Position (QW-405) Position of Groove: Flat Weld Progression: N/A Other: -
- 24. • Relevance of preheat variables depend on the process • QW-406.1 and QW-406.2 – No preheating was used during qualification • QW-406.3 – Maximum interpass temperature was 450°F 3. Procedure Qualification – Preheat Variables Paragraph Brief of Variables Essential Supplementary Essential Non- essential QW-406 Preheat .1 Decrease > 100°F X .2 ϕ Preheat Maintenance X .3 Increase >100°F X
- 25. 3. Procedure Qualification – Preheat Variables Preheat (QW-406) Preheat Temperature: Ambient (70°F) Interpass Temperature: 450°F Other:
- 26. • PWHT variables are the same for GTAW and GMAW • QW-407.1, QW-407.2 and QW-407.4 – No PWHT was used during qualification 3. Procedure Qualification – PWHT Variables Paragraph Brief of Variables Essential Supplementary Essential Non-essential QW-407 PWHT .1 ϕ PWHT X .2 ϕ PWHT (T & T range) X .3 T Limits X
- 27. 3. Procedure Qualification – Preheat Variables PWHT (QW-407) Temperature: None Time None Other: 1. No PWHT was used during qualification
- 28. • Gas variables are the same for GTAW and GMAW • QW-408.1 and QW-408.10 – No trail shield gas was used • QW-408.5 and QW-408.9 – No backing shield gas was used 3. Procedure Qualification – Gas Variables Paragraph Brief of Variables Essential Supplementary Essential Non-essential QW-408 Gas .1 ± Trail or ϕ Composition X .5 ± or ϕ Backing Gas X .9 - Backing or ϕ Composition X .10 ϕ Shielding or Trailing X
- 29. • QW-408.2 – 100% Argon shielding gas was used for GTAW and 75% Argon/25% CO2 was used for GMAW • QW-408.3 – 15 – 25 cfh shielding gas flow rate was used for GTAW and 25 – 35 cfh shielding gas flow rate was used for GMAW 3. Procedure Qualification – Gas Variables Paragraph Brief of Variables Essential Supplementary Essential Non-essential QW-408 Gas .2 ϕ Single, Mixture or % X .3 ϕ Flow Rate X
- 30. Gas (QW-408) Percent Composition Gas(es) Mixture Flow Rate Shielding GTAW - Argon GMAW - Argon/CO2 100% 75% / 25% 15 – 25 cfh 25 – 35 cfh Trailing N/A N/A N/A Backing N/A N/A N/A 3. Procedure Qualification – Gas Variables
- 31. • Relevance of electrical characteristics variables depend on the process • QW-409.1 – The maximum heat input was 45 kJ/in. HI (kJ/in.) = I * V /T.S. * 60 / 1000 • QW-409.2 – The GMAW transfer mode was globular GMAW only • QW-409.3 – Pulse mode GTAW was not used GTAW only 3. Procedure Qualification – Electrical Characteristics Variables Paragraph Brief of Variables Essential Supplementary Essential Non-essential QW-409 Electrical Characteristics .1 > Heat Input X .2 ϕ Transfer Mode X .3 ± Pulsing I X
- 32. • QW-409.4 – GTAW weld was made using direct current with electrode positive polarity and the GMAW weld was made using direct current and electrode negative polarity • QW-409.8 – GTAW weld was made using a 175 -200 amps and 10 - 14 volts and the GMAW weld was made using 170-200 amps and 24-28 volts • QW-409.12 – The tungsten was 2% ceriated with a 1/8-in. diameter GTAW only 3. Procedure Qualification – Electrical Characteristics Variables Paragraph Brief of Variables Essential Supplementary Essential Non-essential QW-409 Electrical Characteristics .4 ϕ Current or Polarity X X .8 ϕ I or E Range X .12 ϕ Tungsten Electrode X
- 33. 3. Procedure Qualification – Electrical Characteristics Variables Electrical Characteristics (QW-409) Current: Direct Current Polarity: EP for GTAW and EN for GMAW Amps: 175 – 200 for GTAW and 170 – 200 for GMAW Volts: 10 – 14 for GTAW and 24 – 28 for GMAW Tungsten Electrode Size: 1/8-in. diameter Other: 1. Maximum heat input was 45 kJ/in. 2. 2% Ceriated Tungsten was used
- 34. • Relevance of technique variables depend on the process • QW-410.1 – GTAW and GMAW weld was made using stringer beads • QW-410.3 – GTAW weld was made with a 5/8-in. cup size and the GMAW weld was made with a 1-in. nozzle size • QW-410.5 – Cleaning was done using a wire brush • QW-410.6 – No back gouging was performed 3. Procedure Qualification – Technique Variables Paragraph Brief of Variables Essential Supplementary Essential Non-essential QW-410 Technique .1 ϕ Stringer/Weave X .3 ϕ Orifice, Cup or Nozzle Size X .5 ϕ Method of cleaning X .6 ϕ Method of Back Gouging X
- 35. • QW-410.7 – The weld was a manual weld • QW-410.8 – A CTWD of 1/2 to 3/4-in. was used GMAW only • QW-410.9 – Multiple passes per side were deposited • QW-410.10 – A single electrode was used • QW-410.11 – The weld was made outside a chamber GTAW only 3. Procedure Qualification – Technique Variables Paragraph Brief of Variables Essential Supplementary Essential Non-essential QW-410 Technique .7 ϕ Oscillation X .8 ϕ Tube-work Distance X .9 ϕ Multiple to Single Pass/Side X X .10 ϕ Single to Multiple Electrodes X X .11 ϕ Closed to Out Chamber X
- 36. • QW-410.15 – Only a single electrode was used • QW-410.25 – The weld was a manual weld • QW-410.26 – No peening was used • QW-410.64 – No thermal processing was used 3. Procedure Qualification – Technique Variables Paragraph Brief of Variables Essential Supplementary Essential Non-essential QW-410 Technique .15 ϕ Electrode Spacing X .25 ϕ Manual or Automatic X .26 ± Peening X .64 Use of Thermal Processes X
- 37. 3. Procedure Qualification – Electrical Characteristics Variables Technique (QW-410) Travel Speed: 1 to 5 ipm Stringer or Weave Bead: Manual Stringer Bead Oscillation: No Oscillation Multi/Single Pass per Side: Multiply Passes per Side Multi/Single Electrode: Single Electrode Other: 1. No peening was used 2. CTWD was 1/2 – 3/4-in. 3. Cleaning with a wire brush 4. GTAW gas cup was 5/8-in. 5. GMAW nozzle size was 1-in.
- 38. 4. Procedure Qualification – Testing The qualification weld was a groove weld in 0.75-in. thick plate • Table QW-451.1 and QW-451.2 outline the destructive test requirements for procedure qualification Thickness of Test Coupon, T Type and Number of Test Required Tension, QW- 150 Side Bend, QW- 160 Face Bend, QW- 160 Root Bend, QW- 160 1/16-in. to 3/8-in. 2 (5) 2 2 > 3/8-in. but < 3/4- in. 2 (5) 2 2 3/4-in. to < 1 1/2-in. 2 (4) 4 - - 1 1/2-in. to 6-in. 2 (4) 4 - -
- 39. 4. Procedure Qualification – Testing (4) See details on multiple specimens when coupon thickness is over 1-in. (5) Four side bends can replace the face and root bends when coupon thickness is 3/8-in. or greater
- 40. 4. Procedure Qualification – Testing
- 41. 4. Procedure Qualification – Testing QW-150 describes the different types of tensile test samples, machine tolerances and acceptance criteria • The tensile strength must exceed 58 ksi Minimum required strength for A36 QW-422
- 42. 4. Procedure Qualification – Testing QW-160 describes the different types of bend test samples, machine tolerances and acceptance criteria No open discontinuities in the weld or HAZ greater than 1/8-in. Provides some leeway
- 43. 4. Procedure Qualification – Testing QW-162 describes the bend test jig that should be used for qualification
- 44. 4. Procedure Qualification – Testing The diameter of the mandrel is based on the material being tested
- 45. 4. Procedure Qualification – Testing
- 46. 4. Procedure Qualification – Testing Tension Test, QW-150 Specimen No. Width Thickness Area Ultimate Load, lb Ultimate Stress, psi Type of Failure and Location Specimen 1 Specimen 2 The tensile strength must exceed 58 ksi Guided-Bend Test, QW-160 Specimen No. Width Thickness Area Ultimate Load, lb Ultimate Stress, psi Type of Failure and Location Side Bend 1 Side Bend 2 Side Bend 3 Side Bend 4 No open weld or HAZ discontinuity greater than 1/8-in.
- 47. 5. Welding Procedure Specification (WPS)
- 50. Feel free to contact: Antonius P. Bramono E: pbramono@gmail.com