Welding procedure qualification tests of steels for hull construction and marine structures

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1 (June 2005) (Rev.1 Nov 2006) (Rev.2 Mr 2012) Welding procedure qulifiction tests of steels for hull construction nd mrine structures 1. Scope 1.1 This document gives requirements for qulifiction tests of welding procedures intended for the use of weldble steels s specified in UR W7, UR W8, UR W11 nd UR W16 for hull construction nd mrine structures. 1.2 This document specificlly excludes the welding procedure specified in UR W All new welding procedure qulifiction tests re to be crried out in ccordnce with this document from 1 July This document does not invlidte welding procedure qulifiction tests mde nd ccepted by the Clssifiction Society before 1 July 2007 provided the welding procedure qulifiction tests re considered by the Clssifiction Society to meet the technicl intent of this UR or hve been qulified in ccordnce with the recognized stndrds such s ISO, EN, AWS, JIS or ASME. 2. Generl 2.1 Welding procedure qulifiction tests re intended to verify tht mnufcturer is dequtely qulified to perform welding opertions using prticulr procedure. 2.2 In generl welding procedure tests re to reflect fbriction conditions in respect to welding equipment, inside or outside fbriction, weld preprtion, preheting nd ny postweld het tretment. It is to be the mnufcturer s responsibility to estblish nd document whether procedure is suitble for the prticulr ppliction. 2.3 For the welding procedure pprovl the welding procedure qulifiction test is to be crried out with stisfctory results. Welding procedure specifictions re to refer to the test results chieved during welding procedure qulifiction testing. 2.4 Welding procedures qulified t mnufcturer re vlid for welding in workshops under the sme technicl nd qulity mngement. Note: 1. This UR is to be uniformly implemented by IACS Societies on ships contrcted for construction from 1 Jnury 2007 s well s the mnufcturing of which is commenced on or fter 1 Jnury The contrcted for construction dte mens the dte on which the contrct to build the vessel is signed between the prospective owner nd the shipbuilder. For further detils regrding the dte of contrct for construction, refer to IACS Procedurl Requirement (PR) No Rev.2 of this UR is to be uniformly implemented by IACS Societies on ships contrcted for construction on or fter 1 Jnury Pge 1 of 25 IACS Req. 2005/Rev

2 3 Welding procedure specifiction 3.1 Preliminry welding procedure specifiction nd welding procedure specifiction A welding procedure specifiction (WPS) is to be prepred by the shipyrd or mnufcturer which intends to perform the welding procedure qulifiction test. This document is lso referred to s preliminry welding procedure specifiction (pwps). The pwps cn be modified nd mended during procedure tests s deemed necessry however it is to define ll relevnt vribles s mentioned in the WPS (refer to ISO or other recognized stndrds) The shipyrd or mnufcturer is to submit to the Society pwps for review prior to the tests. In cse tht the test pieces welded ccording to the pwps show uncceptble results the pwps is to be djusted by the shipyrd or mnufcturer. The new pwps is to be prepred nd the test pieces welded in ccordnce with the new pwps The WPS is to be used s bsis for the production welds, nd upon stisfctory completion of the tests bsed on the pwps, the Society my pprove it s WPS. In cse tht WPS is pproved by the Society the pprovl rnge is to be in complince with section Qulifiction of welding procedures 4.1 Generl Preprtion nd welding of test pieces re to be crried out in ccordnce with the pwps nd under the generl condition of production welding which it represents Welding of the test ssemblies nd testing of test specimens re to be witnessed by the Surveyor If tck welds nd/or strt nd stop points re condition of the weld process they re to be fused into the joint nd re to be included in the test ssemblies. 4.2 Butt weld Assembly of test pieces The test ssembly is to be of size sufficient to ensure resonble het distribution nd ccording to Fig. 1 with the minimum dimensions: - mnul or semi-utomtic welding: width = 2, = 3 x t, min 150 mm length b = 6 x t, min 350 mm - utomtic welding: width = 2, = 4 x t, min 200 mm length b = 1000 mm Pge 2 of 25 IACS Req. 2005/Rev

3 Discrd Plte rolling direction (Steel pltes with CVN-L) Plte rolling direction (Steel pltes with CVN-T) b Discrd Fig.1 Test ssembly for butt weld For hull structurl steel pltes impct tested in the longitudinl direction (CVN-L) in UR W11, the butt weld of the test piece is perpendiculr to the rolling direction of the two pltes. For high strength quenched nd tempered steel pltes impct tested in the trnsverse direction (CVN-T) in UR W16, the butt weld of the test piece is prllel to the rolling direction of the two pltes Exmintions nd tests Test ssemblies re to be exmined non-destructively nd destructively in ccordnce with the following nd Fig 2: - Visul testing 100 % - Surfce crck detection 100 % (dye penetrnt testing or mgnetic prticle testing) - Rdiogrphic or Ultrsonic testing 100 % - Trnsverse tensile test two specimens s per Longitudinl tensile test required s per Trnsverse bend test four specimens s per Chrpy V-notch impct test required s per Mcro exmintion one specimen s per Hrdness test required s per Pge 3 of 25 IACS Req. 2005/Rev

4 50 50 Chrpy V-notch impct test (notch in weld metl) (notch on fusion line) (notch in HAZ) Discrd T1 Trnsverse tensile test P1 Fce bend test or 2 side bend test P2 Root bend test Longitudinl tensile test M Mcro exmintion & Hrdness test P3 Fce bend test or 2 side bend test P4 Root bend test T2 Trnsverse tensile test Discrd weld Fig.2 Test smpling Pge 4 of 25 IACS Req. 2005/Rev

5 Non-destructive testing Test ssemblies re to be exmined by visul nd by non-destructive testing prior to the cutting of test specimen. In cse tht ny post-weld het tretment is required or specified, non-destructive testing is to be performed fter het tretment. For steels ccording to UR W16 with specified minimum yield strength of 420 N/mm 2 nd bove the non-destructive testing is to be delyed for minimum of 48 hrs, unless het tretment hs been crried out. NDT procedures re to be greed with the Society. Imperfections detected by visul or non-destructive testing re to be ssessed in ccordnce with ISO 5817, clss B, except for excess weld metl nd excess of penetrtion for which the level C pplies Trnsverse tensile test The testing is to be crried out in ccordnce with UR W2.4. The tensile strength recorded for ech specimen is not to be less thn the minimum required for the bse metl. When butt welds re mde between pltes of different grdes, the tensile strength to be obtined on the welded ssembly is to be in ccordnce with the requirements relting to the steel grde hving lower strength Longitudinl tensile test Longitudinl tensile test of deposited weld metl tken lengthwys from the weld is required for cses where the welding consumble is not pproved by the Society. The testing is to be crried out in ccordnce with UR W2.4. The tensile properties recorded for ech specimen re not to be less thn the minimum required for the pprovl of the pproprite grde of consumble. Where more thn one welding process or type of consumble hs been used to mke the test weld, test specimens re to be tken from the re of the weld where ech ws used with the exception of those processes or consumbles used to mke the first weld run or root deposit Bend test Trnsverse bend tests for butt joints re to be in ccordnce with UR W2.6. The mndrel dimeter to thickness rtio (i.e. D/t) is to be tht specified for the welding consumble (UR W17, UR W23) pprovls + 1. The bending ngle is to be 180. After testing, the test specimens re not to revel ny open defects in ny direction greter thn 3 mm. Defects ppering t the corners of test specimen during testing re to be investigted cse by cse. Two root nd two fce bend specimens re to be tested. For thickness 12 mm nd over, four side bend specimens my lterntively be tested. For butt joints in heterogeneous steel pltes, fce nd root longitudinl bend test specimens my be used insted of the trnsverse bend test specimens. Pge 5 of 25 IACS Req. 2005/Rev

6 Impct test ) Norml nd higher strength hull structurl steels ccording to UR W11 The positions of specimens re to be in ccordnce with these requirements. Dimensions nd testing re to be in ccordnce with the requirements of UR W2.7. Test specimen with Chrpy-V-notch re to be used nd smpled from 1 to 2 mm below the surfce of the bse metl, trnsverse to the weld nd on the side contining the lst weld run. V-notch specimens re locted in the butt-welded joint s indicted in Fig. 1 nd 2 of Annex A nd the V-notch is to be cut perpendiculr to the surfce of the weld. Test temperture nd bsorbed energy re to be in ccordnce with Tble 1. Tble 1 Impct test requirements for butt joints (t 50 mm) (1),(2) Grde of steel Testing Temperture (C o ) A (3) 20 B (3), D 0 E -20 A32, A36 20 D32, D36 0 E32, E36-20 F32, F36-40 A40 20 D40 0 E40-20 F40-40 Vlue of minimum verge bsorbed energy (J) For mnully or semi-utomticlly welded joints Downhnd, Verticl upwrd, Horizontl, Verticl downwrd Overhed 47 For utomticlly welded joints Note: (1) For thickness bove 50 mm impct test requirements re to be greed by the Society. (2) These requirements re to pply to test piece of which butt weld is perpendiculr to the rolling direction of the pltes. (3) For Grde A nd B steels verge bsorbed energy on fusion line nd in het ffected zone is to be minimum 27 J. When butt welds re mde between different steel grdes/types, the test specimens re to be tken from the side of the joint with lower toughness of steel. Temperture nd bsorbed energy results re to be in ccordnce with the requirements for the lower toughness steel. Where more thn one welding process or consumble hs been used to mke the test weld, impct test specimens re to be tken from the respective res where ech ws employed. This is not to pply to the process or consumbles used solely to mke the first weld run or root deposit. Pge 6 of 25 IACS Req. 2005/Rev

7 The testing of sub - size specimen is to be in ccordnce with UR W2.7.2 b) High strength quenched nd tempered steels ccording to UR W16 Impct test is to be performed s described in the bove ). V-notch specimens re locted in the butt welded joint s indicted in Fig. 1 nd 2 of Annex A nd the V-notch is to be cut perpendiculr to the surfce of the weld. Test temperture nd bsorbed energy re to be in ccordnce with the requirements of bse metl s specified in UR W16. c) Weldble C nd C-Mn hull steel cstings nd forgings ccording to UR W7 nd UR W8 For bse metl with specified impct vlues test temperture nd bsorbed energy re to be in ccordnce with the requirements of the bse metl to be welded Mcro exmintion The test specimens re to be prepred nd etched on one side to clerly revel the weld metl, the fusion line nd the het ffected zone. Mcro exmintion is to include bout 10 mm unffected bse metl. The exmintion is to revel regulr weld profile, through fusion between djcent lyers of weld nd bse metl nd the bsence of defects such s crcks, lck of fusion etc Hrdness test Hrdness test is required for steels with specified minimum yield strength of R eh 355 N/mm 2. The Vickers method HV 10 is normlly to be used. The indenttions re to be mde in the weld metl, the het ffected zone nd the bse metl mesuring nd recording the hrdness vlues. At lest two rows of indenttions re to be crried out in ccordnce with Fig. 1 nd 2 of Annex B. For ech row of indenttions there is to be minimum of 3 individul indenttions in the weld metl, the het ffected zones (both sides) nd the bse metl (both sides). A typicl exmple is shown in Annex B. The results from the hrdness test re not to exceed the following: - Steel with specified minimum yield strength R eh 420 N/mm 2 ; 350 HV10 - Steel with specified minimum yield strength 420 N/mm 2 < R eh 690 N/mm 2 ; 420 HV Fillet welds Assembly of test pieces The test ssembly is to be of size sufficient to ensure resonble het distribution nd ccording to Fig. 3 with the minimum dimensions: - mnul nd semi-utomtic welding: width = 3 x t, min. 150 mm length b = 6 x t, min. 350 mm Pge 7 of 25 IACS Req. 2005/Rev

8 - utomtic welding: width = 3 x t, min. 150 mm length b = 1000 mm t 1, t 2 = plte thickness of test pieces t 2 t 1 Fig.3 Test ssembly for fillet weld Welding of test pieces The test ssembly is welded on one side only. For single run mnul nd semi-utomtic welding, stop/restrt is to be included in the test length nd its position is to be clerly mrked for subsequent exmintion Exmintions nd tests Test ssemblies re to be exmined non-destructively nd destructively in ccordnce with the following: - Visul testing 100 % - Surfce crck detection 100 % (dye penetrnt testing or mgnetic prticle testing) - Mcro exmintion two specimen s per Hrdness test required s per Frcture test required s per Pge 8 of 25 IACS Req. 2005/Rev

9 Non-destructive testing Test ssemblies re to be exmined by visul nd by non-destructive testing prior to the cutting of test specimen. In cse tht ny post-weld het tretment is required or specified non-destructive testing is to be performed fter het tretment. For steels ccording to UR W16 with specified minimum yield strength of 420 N/mm 2 nd bove the non-destructive testing is to be delyed for minimum of 48 hrs, unless het tretment hs been crried out. NDT procedures re to be greed with the Society. Imperfections detected by visul or non-destructive testing re to be ssessed in ccordnce with ISO 5817, clss B except for excess convexity nd excess throt thickness for which the level C pplies Mcro exmintion The test specimens re to be prepred nd etched on one side to clerly revel the weld metl, fusion line, root penetrtion nd the het ffected zone. Mcro exmintion is to include bout 10 mm unffected bse metl. The exmintion is to revel regulr weld profile, through fusion between djcent lyers of weld nd bse metl, sufficient root penetrtion nd the bsence of defects such s crcks, lck of fusion etc Hrdness test Hrdness test is required for steels with specified minimum yield strength of R eh 355 N/mm 2. The Vickers method HV 10 is normlly to be used. The indenttions re to be mde in the weld metl, the het ffected zone nd the bse metl mesuring nd recording the hrdness vlues. At lest two rows of indenttions re to be crried out in ccordnce with Fig. 3, 4 nd 4b of Annex B. For ech row of indenttions there is to be minimum of 3 individul indenttions in the weld metl, the het ffected zone (both sides) nd the bse metl (both sides). A typicl exmple is shown in Annex B. The results from the hrdness test re not to exceed the following: - Steel with specified minimum yield strength R eh 420 N/mm 2 ; 350 HV10 - Steel with specified minimum yield strength 420 N/mm 2 < R eh 690 N/mm 2 ; 420 HV Frcture test The frcture test is to be performed by folding the upright plte onto the through plte. Evlution is to concentrte on crcks, porosity nd pores, inclusions, lck of fusion nd incomplete penetrtion. Imperfection tht re detected is to be ssessed in ccordnce with ISO 5817, clss B. 4.4 Re-testing If the test piece fils to comply with ny of the requirements for visul or non-destructive testing one further test piece is to be welded nd subjected to the sme exmintion. If this dditionl test piece does not comply with the relevnt requirements, the pwps is to be regrded s not cpble of complying with the requirements without modifiction. Pge 9 of 25 IACS Req. 2005/Rev

10 4.4.2 If ny test specimens fil to comply with the relevnt requirements for destructive testing due to weld imperfections only, two further test specimens re to be obtined for ech one tht filed. These specimens cn be tken from the sme test piece if there is sufficient mteril vilble or from new test piece, nd re to be subjected to the sme test. If either of these dditionl test specimens does not comply with the relevnt requirements, the pwps is to be regrded s not cpble of complying with the requirements without modifiction If tensile test specimen fils to meet the requirements, the re-testing is to be in ccordnce with UR W If there is single hrdness vlue bove the mximum vlues llowed, dditionl hrdness tests re to be crried out (on the reverse of the specimen or fter sufficient grinding of the tested surfce). None of the dditionl hrdness vlues is to exceed the mximum hrdness vlues required The re-testing of Chrpy impct specimens re to be crried out in ccordnce with UR W Where there is insufficient welded ssembly remining to provide dditionl test specimens, further ssembly is to be welded using the sme procedure to provide the dditionl specimens. 4.5 Test record Welding conditions for test ssemblies nd test results re to be recorded in welding procedure test record. Forms of welding procedure test records cn be tken from the Society s rules or from relevnt stndrds A sttement of the results of ssessing ech test piece, including repet tests, is to be mde for ech welding procedure test. The relevnt items listed for the WPS of these requirements re to be included A sttement tht the test piece ws mde ccording to the prticulr welding procedure is to be signed by the Surveyor witnessing the test nd is to include the Society s identifiction. 5. Rnge of pprovl 5.1 Generl All the conditions of vlidity stted below re to be met independently of ech other Chnges outside of the rnges specified re to require new welding procedure test Shop primers my hve n influence on the qulity of fillet welds nd is to be considered. Welding procedure qulifiction with shop primer will qulify those without but not vice vers. 5.2 Bse metl Norml nd higher strength hull structurl steels ccording to UR W11 ) For ech strength level, welding procedures re considered pplicble to the sme nd lower toughness grdes s tht tested. Pge 10 of 25 IACS Req. 2005/Rev

11 b) For ech toughness grde, welding procedures re considered pplicble to the sme nd two lower strength levels s tht tested. c) For pplying the bove ) nd b) to high het input processes bove 50kJ/cm, e.g. the tworun technique with either submerged rc or gs shielded metl rc welding, electro slg nd electro gs welding, welding procedure is pplicble to tht toughness grde tested nd one strength level below. Where steels used for construction re supplied from different delivery conditions from those tested the Society my require dditionl tests High strength quenched nd tempered steels ccording to UR W16 ) For ech strength level, welding procedures re considered pplicble to the sme nd lower toughness grdes s tht tested. b) For ech toughness grde, welding procedures re considered pplicble to the sme nd one lower strength level s tht tested. c) The pprovl of quenched nd tempered steels does not qulity thermo-mechniclly rolled steels (TMCP steels) nd vice vers Weldble C nd C-Mn hull steel forgings ccording to UR W7 ) Welding procedures re considered pplicble to the sme nd lower strength level s tht tested. b) The pprovl of quenched nd tempered hull steel forgings does not qulity other delivery conditions nd vice vers Weldble C nd C-Mn hull steel cstings ccording to UR W8 ) Welding procedures re considered pplicble to the sme nd lower strength level s tht tested. b) The pprovl of quenched nd tempered hull steel cstings does not qulity other delivery conditions nd vice vers. 5.3 Thickness The qulifiction of WPS crried out on test ssembly of thickness t is vlid for the thickness rnge given in Tble 2. Tble 2 Approvl rnge of thickness for butt nd T-joint welds nd fillet welds Thickness of test piece T (1) (mm) Butt nd T-joint welds with single run or single run from both sides Rnge of pprovl Butt nd T-joint welds with multi-run nd fillet welds (2) 3 < t x t to 1.1 x t 3 to 2 x t 12 < t x t to 1.1 x t (3) 0.5 x t to 2 x t (Mx. 150) Pge 11 of 25 IACS Req. 2005/Rev

12 Note: (1) For multi process procedures, the recorded thickness contribution of ech process is to be used s bsis for the rnge of pprovl for the individul welding process. (2) For fillet welds, the rnge of pprovl is to be pplied to both bse metls. (3) For high het input processes over 50kJ/cm, the upper limit of rnge of pprovl is to be 1.0 x t In ddition to the requirements of Tble 2, the rnge of pprovl of throt thickness for fillet welds is to be s follows: - Single run ; 0.75 x to 1.5 x - Multi-run ; s for butt welds with multi-run (i.e. =t) For the verticl-down welding, the test piece thickness t is lwys tken s the upper limit of the rnge of ppliction For unequl plte thickness of butt welds the lesser thickness is ruling dimension Notwithstnding the bove, the pprovl of mximum thickness of bse metl for ny technique is to be restricted to the thickness of test ssembly if three of the hrdness vlues in the het ffected zone re found to be within 25 HV of the mximum permitted, s stted nd Welding position Approvl for test mde in ny position is restricted to tht position (see Annex C). To qulify rnge of positions, test ssemblies re to be welded for highest het input position nd lowest het input position nd ll pplicble tests re to be mde on those ssemblies. 5.5 Welding process The pprovl is only vlid for the welding process(es) used in the welding procedure test. It is not permitted to chnge from multi-run to single run For multi-process procedures the welding procedure pprovl my be crried out with seprte welding procedure tests for ech welding process. It is lso possible to mke the welding procedure test s multi-process procedure test. The pprovl of such test is only vlid for the process sequence crried out during the multi-process procedure test. 5.6 Welding consumble Except high het input processes over 50kJ/cm, welding consumbles cover other pproved welding consumbles hving the sme grde mrk including ll suffixes specified in UR W17 nd UR W23 with the welding consumble tested. 5.7 Het input The upper limit of het input pproved is 25% greter thn tht used in welding the test piece or 55kJ/cm whichever is smller, except tht the upper limit is 10% greter thn tht for high het input processes over 50kJ/cm. Pge 12 of 25 IACS Req. 2005/Rev

13 5.7.2 The lower limit of het input pproved is 25% lower thn tht used in welding the test piece. 5.8 Preheting nd interpss temperture The minimum preheting temperture is not to be less thn tht used in the qulifiction test The mximum interpss temperture is not to be higher thn tht used in the qulifiction test. 5.9 Post-weld het tretment The het tretment used in the qulifiction test is to be mintined during mnufcture. Holding time my be djusted s function of thickness Type of joint Rnge of pprovl depending on type of welded joints for test ssembly is to be specified in Tble A qulifiction test performed on butt weld will lso qulify for fillet welding within the thickness rnges specified for fillet welds specified in 5.3 bove. Tble 3 Rnge of pprovl for type of welded joint Type of welded joint for test ssembly Rnge of pprovl Butt welding 5.11 Other vribles One side Both side With bcking A A, C, D Without bcking B A, B, C, D With gouging C C Without gouging D C, D The rnge of pprovl relting to other vribles my be tken ccording to the Society requirements. Pge 13 of 25 IACS Req. 2005/Rev

14 Annex A Loction of Chrpy V-notch impct test Pge 14 of 25 IACS Req. 2005/Rev

15 ) t 50mm (1) 1-2mm b c 1-2mm 2nd side b c 1st side Note: (1) For one side single run welding over 20mm notch loction is to be dded on root side. b) t>50mm 1-2mm b c 1-2mm 2nd side b c b 1st side Notch loctions: : center of weld WM b : on fusion line FL c : in HAZ, 2mm from fusion line Fig. 1 Loctions of V-notch for butt weld of norml het input (het input 50 kj/cm) Pge 15 of 25 IACS Req. 2005/Rev

16 ) t 50mm (1) 1-2mm b c d e 1-2mm 2nd side b c d e 1st side Note: (1) For one side welding with thickness over 20mm notch loctions, b nd c re to be dded on root side. b) t>50mm 1-2mm b c d e 1-2mm 2nd side b c d e c b c 1st side Notch loctions: : center of weld WM b : on fusion line FL c : in HAZ, 2mm from fusion line d : in HAZ, 5mm from fusion line e : in HAZ, 10mm from fusion line in cse of het input > 200kJ/cm Fig. 2 Loctions of V-notch for butt weld of high het input (het input > 50kJ/cm) Pge 16 of 25 IACS Req. 2005/Rev

17 Annex B Hrdness test (Typicl exmples of hrdness test) Pge 17 of 25 IACS Req. 2005/Rev

18 Fig. 1 Exmples of hrdness test with rows of indenttions (R) in butt welds Tble 1 Recommended distnces l between indenttions for hrdness test in the het ffected zone Vickers hrdness Symbol Distnce between indenttions l (mm) HV 10 1 The distnce of ny indenttion from the previous indenttion is not to be less thn the vlue llowed for the previous indenttion by ISO 6507/1. Pge 18 of 25 IACS Req. 2005/Rev

19 l l l Fig. 2 Exmple showing the position of the indenttions for hrdness test in the weld metl, the het ffected zone nd the bse metl of butt weld (dimensions in mm) Pge 19 of 25 IACS Req. 2005/Rev

20 ) Fillet weld b) T-joint weld Fig. 3 Exmples of hrdness test with row indenttion (R) in fillet welds nd in T-joint welds Fig. 4 Exmple showing the position of the indenttions for hrdness test in the weld metl, the het ffected zone nd the bse metl of fillet weld (dimensions in mm) Pge 20 of 25 IACS Req. 2005/Rev

21 Fig. 4b Exmple showing the position of the indenttions for hrdness test on the weld metl, the het ffect zone nd the bse metl of T-joint weld (dimensions in mm) Pge 21 of 25 IACS Req. 2005/Rev

22 Annex C Welding positions Pge 22 of 25 IACS Req. 2005/Rev

23 Annex C.1: Welding positions ccording to ISO Stndrd Pge 23 of 25 IACS Req. 2005/Rev

24 Annex C.2: Welding positions ccording to AWS-Code ) Butt weld for pltes Pge 24 of 25 IACS Req. 2005/Rev

25 b) Fillet welds for pltes End of Document Pge 25 of 25 IACS Req. 2005/Rev

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