WIXLIB

SummaryModule 7

Module 7 – SummaryModule 7 – Summary 7A – ASME Section IX Weld Procedure Qualification 7B – ASME Section IX Welder Qualification7-2

Module 7 – SummaryModule 7 Learning Objectives Understand how to qualify welding procedures in accordanceto ASME Section IX Understand how to qualify welders accordance to Section IX7-3

Weld Procedure QualificationModule 7A

Module 7 – SummaryWeld Procedure QualificationWeld Procedure Qualification Primary purpose for procedure qualification To verify compatibility of materials and techniques to result in asound weld with acceptable mechanical properties WPS qualified by mechanical testing PQR is documentation to prove that a weld can be made using theprocedure and have acceptable mechanical properties How do you qualify a welding procedure? Five step process1.2.2.3.4.Understand the intended application for which the WPS will be usedDevelop a draft procedureMake a qualification weldTest the qualification weldWrite up the WPS7-5

Module 7 – SummaryWeld Procedure QualificationWeld Procedure Qualification Understand the intended application for which the WPS willbe 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 constructionWhat 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. Know the design requirements for the application Does the design require specific material toughness requirements7-6

Module 7 – SummaryWeld Procedure QualificationExample Procedure Qualification GTAW/GMAW qualification weld 0.75” A 36 plate materialFlat positionER70S-6 electrode was used for GMAWER80S-D2 electrode was used for GTAWNo preheat or PWHT Procedure Qualification Record (PQR) needs to address thewelding variables of each welding process7-7

Module 7 – SummaryWeld Procedure QualificationGTAW Weld Procedure Variables7-8

Module 7 – SummaryWeld Procedure QualificationGMAW Weld Procedure Variables7-9

Module 7 – SummaryWeld Procedure QualificationProcedure Qualification Record (PQR)7-10

Module 7 – SummaryWeld Procedure QualificationProcedure Qualification – Joint Variables Joint variables are the same for GTAW and GMAWParagraphQW-402JointsBrief of al.1φ Groove DesignX.4- BackingX.10φ Root SpacingX.11 RetainersX QW-402.1 – Groove design was a V-groove with a 45ºincluded 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 nonfusing retainers were notused7-11

Module 7 – SummaryWeld Procedure QualificationProcedure Qualification – Joint VariablesCompany Name: Nuclear ConstructionPQR No.:NRC-PQR-1WPS No.:NRC-WPS-1Date: June 8 and 9, 2010Welding Process: GTAW and GMAWTypes (Manual, Automatic, Semi-Automatic): ManualJoints (QW-402):Note: The weld was both GTAW and GMAW with 1/4-in. deposited withGTAW and 1/2-in. deposited with GMAW7-12

Module 7 – SummaryWeld Procedure QualificationProcedure Qualification – Base Metal Variables Relevance of base metal variables depend on processParagraphQW-403BaseMaterialsBrief of Variables.5φ Group No.11φ P-No. alXX QW-403.5 and QW-403.11 – Material was A36 plate which isP-No. 1 and Group 1 Material Table QW-422Spec. No.Type/GradeUNS oduct FormC-Mn-SiPlate, Bar & Shapes7-13

Module 7 – SummaryWeld Procedure QualificationProcedure Qualification – Base Metal VariablesParagraphQW-403BaseMaterialsBrief of VariablesEssential.6T Limits.8φ T QualifiedX.9t pass 1/2-in.X.10T Limits (S. Cir. Arc)XSupplementaryEssentialNonessentialX QW-403.6, QW-403.8 and QW-403.10 – Material thicknesswas 0.75-in. QW-403.9 – No single weld pass in the qualification weld wasgreater than 1/2-in. GMAW only7-14

Module 7 – SummaryWeld Procedure QualificationProcedure Qualification – Base Metal VariablesBase Metals (QW-403)Material Spec.:SA-36Type or Grade:N/AP- No.:P-No.1To P-No.: P-No. 1Thickness of Test Coupon: 3/4-in.Diameter of Test Coupon:N/AOther:1. SA-36 does not come in different grades2. The weld was made on plate so diameter does not apply.3. All passes were less than 1/2-in. thick7-15

Module 7 – SummaryWeld Procedure QualificationProcedure Qualification – Filler Metal Variables Relevance of filler metal variables depend on processParagraphQW-404FillerMetalsBrief of al.3φ SizeX.6φ DiameterX.23φ Filler Metal Product FormX 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 used7-16

Module 7 – SummaryWeld Procedure QualificationProcedure Qualification – Filler Metal VariablesParagraphQW-404FillerMetalsBrief of Variables.4Essentialφ F-No.SupplementaryEssentialNonessentialX QW-404.4 – The welding wire was ER80S-D2 for GTAW andER70S-6 for GMAW ASME Section II, SFA 5.28 specifies low-alloy steel electrodes for gasshielded arc weldingASME Section II, SFA 5.18 specifies carbon steel electrodes for gasshielded arc weldingTable QW-432F-No.ASME SpecificationAWS Classification6SFA-5.28All Classifications6SFA-5.18All Classifications7-17

Module 7 – SummaryWeld Procedure QualificationProcedure Qualification – Filler Metal VariablesParagraphQW-404FillerMetalsBrief of Variables.5Essentialφ A-No.SupplementaryEssentialNonessentialX QW-404.5 – The welding wire was ER80S-D2 for GTAW andER70S-6 for GMAW SAME ASME Section II specifications apply to determine chemistryTable QW-442Analysis, %A-No.Weld DepositCCrMoNiMnSi11Mn – Mo0.17-0.25 – 0.750.851.25 – 2.251.000.07 – 0.12-0.4-0.60.151.60 – 2.100.5 – 0.80.20---1.601.000.06 – 0.150.150.150.151.40 – 1.850.80 – 1.15ER80S-D2 (SFA 5.18)1Mild SteelER70S-6 (SFA 5.18)7-18

Module 7 – SummaryWeld Procedure QualificationProcedure Qualification – Filler Metal VariablesParagraphQW-404FillerMetalsBrief of al.12φ ClassificationX.14 Filler.33φ ClassificationX.50 FluxXX QW-404.12 and QW-404.33 – The wire classification wasER80S-D2 for GTAW and ER70S-6 GMAW QW-404.14 – Filler metal was used GTAW only QW-404.50 – No flux was used GTAW only7-19

Module 7 – SummaryWeld Procedure QualificationProcedure Qualification – Filler Metal VariablesParagraphQW-404FillerMetalBrief of VariablesEssential.22 Consumable Insert.24 or φ SupplementalX.27φ Alloy ElementsX.30φtX.32t limits (S.C. Arc)SupplementaryEssentialNonessentialXX QW-404.22 – No consumable insert was used GTAW only QW-404.24 and QW-404.27 – No Supplemental filler metalwas used so variable does not apply GMAW only QW-404.30 and QW-404.32 – Weld thickness was 1/4-in. forGTAW and 1/2-in. for GMAW7-20

Module 7 – SummaryWeld Procedure QualificationProcedure Qualification – Filler Metal VariablesFiller Metals (QW-404)SFA Specification:AWS Classification:Filler Metal F-No.Weld Metal Analysis A-No.:Size of Filler MetalWeld Metal Thickness:SFA 5.28 for GTAWSFA 5.18 for GMAWER80S-D2 for GTAWER70S-6 for GMAW6 for GTAW and GMAW11 for GTAW1 for GMAW1/8-in. for GTAW0.035-in. for GMAW1/4-in. for GTAW1/2-in. for GMAWOther:7-21

Module 7 – SummaryWeld Procedure QualificationProcedure Qualification – Position Variables Positions variables are the same for GTAW and GMAWParagraphQW-405PositionsBrief of Variables.1 Position.2φ Position.3φ Vertical XXX QW-405.1, QW-405.2 and QW-405.3 – The weld was madein the flat position7-22

Module 7 – SummaryWeld Procedure QualificationProcedure Qualification – Position VariablesPosition (QW-405)Position of Groove:Weld Progression:Other:FlatN/A7-23

Module 7 – SummaryWeld Procedure QualificationProcedure Qualification – Preheat Variables Relevance of preheat variables depend on the processParagraphQW-406PreheatBrief of Variables.1Decrease 100ºF.2φ Preheat Maintenance.3Increase XX QW-406.1 and QW-406.2 – No preheating was used duringqualification QW-406.3 – Maximum interpass temperature was 450ºF7-24

Module 7 – SummaryWeld Procedure QualificationProcedure Qualification – Preheat VariablesPreheat (QW-406)Preheat Temperature:Interpass Temperature:Other:Ambient (70ºF)450ºF7-25

Module 7 – SummaryWeld Procedure QualificationProcedure Qualification – PWHT Variables PWHT variables are the same for GTAW and GMAWParagraphQW-407PWHTBrief of Variables.1φ PWHT.2φ PWHT (T & T range).4T XX QW-407.1, QW-407.2 and QW-407.4 – No PWHT was usedduring qualification7-26

Module 7 – SummaryWeld Procedure QualificationProcedure Qualification – Preheat VariablesPWHT (QW-407)Temperature: NoneTime:NoneOther:1. No PWHT was used during qualification7-27

Module 7 – SummaryWeld Procedure QualificationProcedure Qualification – Gas Variables Gas variables are the same for GTAW and GMAWParagraphQW-408GasBrief of al.1 Trail or φ CompositionX.5 or φ Backing GasX.9- Backing or φ CompositionX.10φ Shielding or TrailingX 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 used7-28

Module 7 – SummaryWeld Procedure QualificationProcedure Qualification – Gas VariablesParagraphQW-408GasBrief of Variables.2φ Single, Mixture or %.3φ Flow RateEssentialSupplementaryEssentialNonessentialXX QW-408.2 – 100% Argon shielding gas was used for GTAWand 75% Argon/25% CO2 was used for GMAW QW-408.3 – 15 – 25 cfh shielding gas flow rate was used forGTAW and 25 – 35 cfh shielding gas flow rate was used forGMAW7-29

Module 7 – SummaryWeld Procedure QualificationProcedure Qualification – Gas VariablesGas (QW-408)ShieldingTrailingBackingPercent CompositionGas(es)MixtureGTAW - Argon100%GMAW - Argon/CO275%/25%N/AN/AN/AN/AFlow Rate15 – 25 cfh25 – 35 cfhN/AN/A7-30

Module 7 – SummaryWeld Procedure QualificationProcedure Qualification –Electrical Characteristics Variables Relevance of electrical characteristics variables depend onthe processParagraphBrief of Variables.1QW-409.2ElectricalCharacteristics .3Essential Heat Inputφ Transfer ModeSupplementaryEssentialNonessentialXX Pulsing IX 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 only7-31

Module 7 – SummaryWeld Procedure QualificationProcedure Qualification –Electrical Characteristics VariablesParagraphBrief of Variables.4φ Current or PolarityQW-409.8φ I or E RangeElectricalCharacteristics .12 φ Tungsten alXXXX QW-409.4 – GTAW weld was made using direct current withelectrode positive polarity and the GMAW weld was madeusing direct current and electrode negative polarity QW-409.8 – GTAW weld was made using a 175 -200 ampsand 10 - 14 volts and the GMAW weld was made using 170200 amps and 24-28 volts QW-409.12 – The tungsten was 2% ceriated with a 1/8-in.diameter GTAW only7-32

Module 7 – SummaryWeld Procedure QualificationProcedure Qualification –Electrical Characteristics VariablesElectrical Characteristics (QW-409)Current: Direct CurrentPolarity: EP for GTAW and EN for GMAWAmps:175 – 200 for GTAW and 170 – 200 for GMAWVolts:10 – 14 for GTAW and 24 – 28 for GMAWTungsten Electrode Size: 1/8-in. diameterOther:1. Maximum heat input was 45 kJ/in.2. 2% Ceriated Tungsten was used7-33

Module 7 – SummaryWeld Procedure QualificationProcedure Qualification –Technique Variables Relevance of technique variables depend on the processParagraphQW-410TechniqueBrief of al.1φ Stringer/WeaveX.3φ Orifice, Cup or Nozzle SizeX.5φ Method of cleaningX.6φ Method of Back GougingX QW-410.1 – GTAW and GMAW weld was made usingstringer beads QW-410.3 – GTAW weld was made with a 5/8-in. cup sizeand 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 performed7-34