BY : MANOOSAK RERGPANEE

Welding Document BY : MANOOSAK RERGPANEE NDT: ISO 9712,EN 473 PT/MT/RT LEVEL III ASNT PT/MT/UT/RT LEVEL II IIW: INTERNATIONAL WELDING ENGINEER (IWE) EUROPIAN WELDING FEDERATION (EWF)

AWS American Welding Society Structural Welding Code Steel มาตรฐานการเช อมเหล กโครงสร าง

AWS D 1.1 AWS D 1.2 AWS D 1.3 AWS D 1.4 AWS D 1.5 AWS D 1.6 Structural welding (steel) Structural welding (aluminum) Structural welding (sheet steel) Structural welding (reinforcing steel) Bridge welding Structural welding (stainless steel)

AWS A2.4 AWS A3.0 AWS A5.1 AWS A5.18 AWS B1.10 AWS B2.1 Standard symbols for welding, brazing, and nondestructive examination Standard welding terms and definitions Specification for carbon steel electrodes for shielded metal arc welding Specification for carbon steel electrodes and rots for gas shielded arc welding Guide for the nondestructive examination of welds Specification for Welding Procedure and Performance Qualification

AWS D8.1 AWS D8.6 AWS D8.7 AWS D8.8 AWS D8.9 AWS D8.14 AWS D9.1 AWS D10.10 AWS D10.11 AWS D10.12 Automotive spot welding Automotive spot welding electrodes supplement Automotive spot welding recommendations supplement Automotive arc welding (steel) Automotive spot weld testing Automotive arc welding (aluminum) Sheet metal welding Heating practices for pipe and tube Root pass welding for pipe Pipe welding (mild steel)

Welding Procedures Producing a welding procedure involves: Planning the tasks Collecting the data Writing a procedure for use of for trial Making a test welds Evaluating the results Approving the procedure Preparing the documentation

Welding Procedures Scope/ITP Basic of Welding Procedures Testing Agenda Processing WPS Tension Spect. Variable PQR Bending Criteria Metallurgical WQT Impact experience Code Standard

Variable Weld ability of the part a) Suitability for welding: - chemical composition - metallurgical properties - physical properties b) Welding safety: - structural design - state of stresses c) Possibility for welding: - preparation for welding - execution of the welding works - post treatment

Welding Variable Parent material Welding process Joint design Welding Position Welding Variables Thermal heat treatments

Welding Procedures WPSs: Prequalification Welding Procedure Specification Before procedure approval. WPS: Welding Procedure Specification After procedure approval PQR: Procedure Qualification Record Welding procedure test record WQT : Welder Qualification Test Record After PQR approval

WPS Welding Procedure Specification

IDENTIFICATION COMPANY NAME WPS No IS-GMAW-001 IS WELDING PROCESS(ES) SUPPORTING PQR No.(S) GMAW Prequalify Revision 0 Date Nov 20,2014 By Mr.Sakon P. Authorized by Mr.Manoosak R. Date Nov 20,2014 Type Manual Semi - Automatic Machine Automatic

Parent material Type (Grouping) Thickness Diameter (Pipes) Surface condition

Welding process Type of process - SMAW, - GMAW(MIG/MAG) - GTAW(TIG) - FCAW - SAW.etc Equipment parameters Amps, Volts, Travel speed

Welding Process

JOINT DESIGN USED Type: Single BUTT WELD Backing : Yes No Backing Material : ASTM A36 Double Weld Root Opening - Root Face - Groove Angle : - Radius(J-U) - Back Gouging : Yes No Method - POSITION Position of Groove: 3G Fillet : - Vertical Progression : Up Down

Base Matals Material Spec: ASTM A36 Type or Grade - Thickness Groove : 10 mm Fillet - Diameter (Pipe): -

Joint design Edge preparation Root gap, root face Jigging and tacking Type of backing

Welding Joint Edge Open & Closed Corner Lap Cruciform Tee Butt

Welding Joint Butt weld Fillet weld Spot weld Edge weld Plug weld Compound weld

Included angle Joint Preparation Angle of bevel Included angle Root Radius Root Gap Single-V Butt Root Face Root Gap Single-U Butt Root Face 4/23/2007

Angle of bevel Joint Preparation Angle of bevel Root Radius Root Gap Root Face Root Gap Root Face Land Single Bevel Butt Single-J Butt

Single Sided Butt Preparations Single sided preparations are normally made on thinner materials, or when access form both sides is restricted Single Bevel Single Vee Single-J Single-U

Double Sided Butt Preparations Double sided preparations are normally made on thicker materials, or when access form both sides is unrestricted Double -Bevel Double -Vee Double - J Double - U

Groove Weld Preparation bevel angle included angle root face root gap Typical Dimensions bevel angle 30 to 35 root face root gap ~1.5 to~2.5mm ~2 to ~ 4mm 4/23/2007

Figure 3.4 (Continued)-Prequalified CJP Groove Welded Joint Details (see 3.13)

POSITION Position of Groove: 3G Fillet : - Vertical Progression : Up Down Welding Position Location, shop or site Welding position e.g. 1G, 2G, 3G etc.

Welding Positions PA 1G / 1F Flat / Downhand PB 2F Horizontal-Vertical PC 2G Horizontal PD 4F Horizontal-Vertical (Overhead) PE 4G Overhead PF 3G / 5G Vertical-Up PG 3G / 5G Vertical-Down H-L045 6G Inclined Pipe (Upwards) J-L045 6G Inclined Pipe (Downwards)

Butt welds in plate Flat 1G Overhead 4G Vertical up 3G Vertical down 3G Horizontal 2G

Butt welds in pipe Flat 1G axis: horizontal pipe: rotated Vertical up 5G axis: horizontal pipe: fixed Vertical down - 5G axis: horizontal pipe: fixed H-L045-6G axis: inclined at 45 pipe: fixed J-L045-6G axis: inclined at 45 pipe: fixed Horizontal 2G axis: vertical pipe: fixed

Fillet welds on plate Flat 1F Horizontal 2F Overhead 4F Vertical up - 3F Vertical down 3F

Fillet welds on pipe Flat 1F axis: inclined at 45 pipe: rotated Horizontal 2F axis: vertical pipe: fixed Overhead 4F axis: vertical pipe: fixed Horizontal 2FR axis: horizontal pipe: rotated Vertical up - 5F axis: horizontal pipe: fixed Vertical down 5F axis: horizontal pipe: fixed

PA / 1G PA / 1F PF / 3G PB / 2F PC / 2G PD / 4F PE / 4G PG / 3G

Pipe Welding Positions PA / 1G Weld: Flat Pipe: rotated Axis: Horizontal Weld: Vertical upwards Pipe: Fixed Axis: Horizontal 45 o PF / 5G PG / 5G Weld: Vertical Downwards Pipe: Fixed Axis: Horizontal 45 o Weld: Horizontal Pipe: Fixed Axis: Vertical PC / 2G Weld: Upwards Pipe: Fixed Axis: Inclined H-LO 45 / 6G J-LO 45 / 6G Weld: Downwards Pipe: Fixed Axis: Inclined

Position AWS D1.1, Table 4.1, WPS Qualification CJP Groove Weld (Plate or Tubular) Position Tested Position Qualified* 1G, 1G (Rotated) F 2G F, H 3G V 4G OH 5G F, V, OH (2G+5G), 6G, 6GR All

Position AWS D1.1, Table 4.1, WPS Qualification Fillet Weld (Plate or Tubular) Qualification Test: Position Tested Position Qualified 1F, 1F (Rotated) F 2F, 2F (Rotated) F, H 3F V 4F (Plate) OH 4F (Tubular) F, H, OH 5F All

BASE METALS Material Spec. ASTM A36 Type of Grade - Thickness: Groove 10 mm. Fillet - Diameter (Pipe) - - Data from Mill Certificate - Go to AWS D1.1 Table 3.1 Prequalified Base Metal-Filler Metal Combinations for Matching Strength

Parent material Table 3.1 prequalified Base Material Filler Metal Combinations for Matching Strength

Parent material

FILLER METALS AWS Specification A 5.18 AWS Classification ER 70 S-6 SHIELDING Flux - Gas Ar + Co2 Ar84% + Co216% Composition Electrode-Flux (Class) - Flow Rate 10-18 L/min Gas Cup Size 20 mm.

Welding Consumables Type /diameter of consumable Brand/classification Heat treatments/ storage

Welding Consumables Each consumable is critical in respect to: Size, (diameter and length) Classification / Supplier Condition Treatments e.g. baking / drying Handling and storage is critical for consumable control Handling and storage of gases is critical for safety

SMAW Welding Consumables Plastic foil sealed cardboard box rutile electrodes general purpose basic electrodes Tin can cellulosic electrodes Vacuum sealed pack extra low hydrogen electrodes

AWS A5.1 Alloyed Electrodes E 60 1 3 Covered Electrode Tensile Strength (p.s.i) Welding Position Flux Covering

AWS A5.5 Alloyed Electrodes E 70 1 8 M G Covered Electrode Tensile Strength (p.s.i) Welding Position Flux Covering Moisture Control Alloy Content

Cellulosic Rutile TYPES OF ELECTRODES Rutile Heavy Coated Basic (for C, C-Mn Steels) AWS A5.1 EXX10 EXX11 EXX12 EXX13 EXX24 EXX15 EXX16 EXX18

MIG/MAG Welding Consumables Welding wires: carbon and low alloy wires may be copper coated stainless steel wires are not coated Courtesy of Lincoln Electric Courtesy of ESAB AB wires must be kept clean and free from oil and dust flux cored wires does not require baking or drying

MIG/MAG shielding gases Type of material Shielding gas Carbon steel CO 2, Ar+(5-20)%CO 2 Stainless steel Ar+2%O 2 Aluminium Ar

MIG/MAG shielding gases Ar Ar-He He CO 2 Argon (Ar): higher density than air; low thermal conductivity the arc has a high energy inner cone; good wetting at the toes; low ionisation potential Helium (He): lower density than air; high thermal conductivity uniformly distributed arc energy; parabolic profile; high ionisation potential Carbon Dioxide (CO 2 ): cheap; deep penetration profile; cannot support spray transfer; poor wetting; high spatter

MIG/MAG shielding gases Gases for Short-Circuiting transfer: CO 2 : carbon steels only: deep penetration; fast welding speed; high spatter levels Ar + up to 25% CO 2 : carbon and low alloy steels: minimum spatter; good wetting and bead contour 90% He + 7.5% Ar + 2.5% CO 2 :stainless steels: minimises undercut; small HAZ Ar: Al, Mg, Cu, Ni and their alloys on thin sections Ar + He mixtures: Al, Mg, Cu, Ni and their alloys on thicker sections (over 3 mm) 75 of 691

MIG/MAG shielding gases Gases for spray transfer Ar + (5-18)% CO 2 : carbon steels: minimum spatter; good wetting and bead contour Ar + 2% O 2 : low alloy steels: minimise undercut; provides good toughness Ar + 2% O 2 or CO 2 : stainless steels: improved arc stability; provides good fusion Ar: Al, Mg, Cu, Ni, Ti and their alloys Ar + He mixtures: Al, Cu, Ni and their alloys: hotter arc than pure Ar to offset heat dissipation Ar + (25-30)% N 2 : Cu alloys: greater heat input 76 of 691

Gas Metal Arc Welding Types of Shielding Gas MAG (Metal Active Gas) Active gases used are Oxygen and Carbon Dioxide Argon with a small % of active gas is required for all steels (including stainless steels) to ensure a stable arc & good droplet wetting into the weld pool Typical active gases are Ar + 20% CO 2 Ar + 2% O 2 for C-Mn & low alloy steels for stainless steels 100% CO 2 can be used for C - steels 77 of 691

MIG/MAG - metal transfer modes Voltage Electrode diameter = 1,2 mm WFS = 8,3 m/min Current = 295 A Voltage = 28V Globular transfer Spray transfer Electrode diameter = 1,2 mm WFS = 3,2 m/min Current = 145 A Short-Circuit Voltage = 18-20V Current Current/voltage conditions 78 of 691

Current type influence + + + - - - + + + - - - + + + - - - Current type & polarity Heat balance Penetration Oxide cleaning action DCEN 70% at work 30% at electrode AC (balanced) 50% at work 50% at electrode DCEP 35% at work 65% at electrode Deep, narrow Medium Shallow, wide No Yes - every half cycle Yes Electrode capacity Excellent (e.g. 3,2 mm/400a) Good (e.g. 3,2 mm/225a) Poor (e.g. 6,4 mm/120a)

Tungsten Electrodes Old types: (Slightly Radioactive) Thoriated: DC electrode -ve - steels and most metals 1% thoriated + tungsten for higher current values 2% thoriated for lower current values Zirconiated: AC - aluminum alloys and magnesium New types: (Not Radioactive) Cerium: DC electrode -ve - steels and most metals Lanthanum: AC - Aluminum alloys and magnesium

AWS A 5.12

2-2,5 times electrode diameter Electrode tip for DCEN Penetration increase Increase Vertex angle Decrease Electrode tip prepared for low current welding Bead width increase Electrode tip prepared for high current welding

Electrode tip for AC Electrode tip ground Electrode tip ground and then conditioned

Tungsten electrodes TIG Welding Variables The electrode diameter, type and vertex angle are all critical factors considered as essential variables. The vertex angle is as shown DC -ve AC Vetex angle Note: too fine an angle will promote melting of the electrodes tip Note: when welding aluminium with AC current, the tungsten end is chamfered and forms a ball end when welding

Shielding gas requirements Shielding gas flow Preflow and Postflow Preflow Welding current Postflow (6-10 l/min) Flow rate too low Flow rate too high

TIG Welding Consumables Welding consumables for TIG: Filler wires, Shielding gases, tungsten electrodes (non-consumable). Filler wires of different materials composition and variable diameters available in standard lengths, with applicable code stamped for identification Steel Filler wires of very high quality, with copper coating to resist corrosion. shielding gases mainly Argon and Helium, usually of highest purity (99.9%).

Welding rods: supplied in cardboard/plastic tubes must be kept clean and free from oil and dust might require degreasing

Fusible Inserts Pre-placed filler material Before Welding After Welding Other terms used include: EB inserts (Electric Boat Company) Consumable socket rings (CSR) 90 of 691

Consumable inserts: used for root runs on pipes Fusible Inserts used in conjunction with TIG welding available for carbon steel, Cr-Mo steel, austenitic stainless steel, nickel and copper-nickel alloys different shapes to suit application Radius 91 of 691

Fusible Inserts Application of consumable inserts

Shielding gases for TIG welding Argon low cost and greater availability Helium costly and lower availability than Argon lighter than air - requires a higher flow rate compared with argon (2-3 times) Nitrogen not an inert gas high availability - cheap added to argon (up to 5%) - only for back purge for duplex stainless, austenitic stainless steels and copper alloys not used for mild steels (age embritlement)

Shielding gases for TIG welding Hydrogen not an inert gas - not used as a primary shielding gas increase the heat input - faster travel speed and increased penetration better wetting action - improved bead profile produce a cleaner weld bead surface added to argon (up to 5%) - only for austenitic stainless steels and nickel alloys flammable and explosive

Welding Variables Run sequences Back gouging Interpass temperatures

TECHNIQUE Stringer or Weave Bead Multi-pass or Single Pass(per side) Stringer or Weave Bead Multi-pass Number of Electrodes 1 Electrode Spacing Longitudinal - Lateral - Angle - Contact Tube to Work Distance 15-20 mm. Peening - Interpass Cleaning Wire Brush

PREHEAT Preheat Temp.,Min - Interpass Temp.,Min - Max - POST WELD HEAT TREATMENT Temp - Time -

Thermal heat treatments Preheat - Table 3.2 Prequalified Minimum Preheat and Interpass Temperature Post weld heat treatments Chapter 5.8 Stress Relief Heat Treatment pg.196 - Table 5.2 Minimum Holding Time page.208 - Table 5.3 Alternate Stress Relief Heat Treatment page.208

WELDING PROCEDURE Pass or Layer Process Filler Metals Class Dia mm. Current Type/ Polarity Amps/Wire Feed Speed Volts Travel Speed (cm/min) 1 GMAW ER 70 S-6 1.2 DCEP 100-120 18 8 2 GMAW ER 70 S-6 1.2 DCEP 120-160 20 10 3 GMAW ER 70 S-6 1.2 DCEP 120-160 20 10 Joint Details

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