D10 COMMITTEE ON PIPE AND TUBE

WELDING

INFORMATION ON-HAND, PROBLEMS

SOLVED, QUESTIONS ANSWERED
 KNOWLEDGE IS
POWER
NO MATTER WHAT LEVEL OF THE
INDUSTRY YOU WORK …

THE D10 DOCUMENT COLLECTION

HAS THE INFORMATION YOU
SHOULD HAVE AT YOUR FINGERTIPS
 MATERIALS & METHODS
COVERED
•AUSTENITIC STAINLESS STEEL
•TITANIUM
•ALUMINUM
•CHROME-MOLY
•LOCAL HEAT TREATING
•ROOT PASS WELDING
•MILD STEEL
•COPPER TUBE
WELDING PROCESS

•GTAW
•SMAW
•FCAW
•GMAW
•BRAZING
William F. Newell, Jr.
PE, IWE, Chair D10C

D10.4
RECOMMENDED
PRACTICES FOR WELDING
AUSTENITIC CHROMIUM-
NICKEL STAINLESS STEEL
PIPE AND TUBING
 AWS D10.4

• “…to provide information which may

be used to avoid, or at least minimize,
difficulties in welding austenitic
stainless steel piping and tubing. …”
 AWS D10.4 - Uses
• Often overlooked……
• Excellent resource for:
– Developing Corporate Procedures & Specifications
– Training Engineers, Supervision and Welders
– General Reference Guide
 AWS D10.4 - History
• First published in August 1955 under
the title, The Welding of Austenitic
Chromium-Nickel Steel Piping and
Tubing. A Committee Report and
published as AWS D10.4-55T
• AWS D10.4-55T was revised in 1966
 AWS D10.4 - History
• In 1979, a major updating of the document was
completed and published as AWS D10.4-79,
Recommended Practices for Welding Austenitic
Chromium-Nickel Stainless Steel Piping and
Tubing. This version presented a detailed
discussion of the role of delta ferrite in
austenitic chromium-nickel steel welds.
 AWS D10.4 - History
• In 1986, the document was expanded
and given an Annex which gives
recommendations for welding high-
carbon stainless steel castings.
• In 1992 and 1999, the document was
reaffirmed.
 AWS D10.4 - History
• The current document, ANSI/AWS D10.4M/D10.4:199X,
Guide for Welding Austenitic Chromium-Nickel Stainless
Steel Piping and Tubing has extended safety and health
information and provides information on super
austenitic stainless steels and flux cored arc welding.

• Tables listing specific chemical composition ranges for

base metal and weld metal that fall under the jurisdiction
of other codes or documents have been omitted from this
revision. Where helpful, however, comparison data is
presented.
 AWS D10.4 - Content
• Base Metals & Weld Filler Metals
• Ferrite
• Welding Processes, Technique &
Problems
• Dissimilar Joining
• Inspection
• Safety
 AWS D10.4 – Base Metals
• Austenitic
– 300-series
• Super Austenitic
– 4% & 6% Mo
• High Carbon
– “HX” Grades
 Coming !
• D10.18 (DRAFT)
• “Guide for Welding
Ferritic/Austenitic Duplex Stainless
Steel Piping and Tubing”
 Don Connell
Welding Engineer
Detroit Edison Company

D10.6
RECOMMENDED
PRACTICES FOR GAS
TUNGSTEN ARC WELDING
OF TITANIUM PIPING AND
TUBING
Applications for Ti Pipe & Tube

Where Ti is selected for its corrosion resistance

rather than its high strength to weight ratio
• Chemical processing
• Petrochemical
• Desalination
• Power generation plants
• Navy to replace Cu-Ni in seawater piping
 Process-GTAW

• Other processes may be used to weld Ti but

are not covered in this recommended
practice
 Base Metals

• 6 grades commonly used for piping, all

single phase alpha
• Ref: ASTM B337 (seamless & welded
pipe) & B338 (seamless & welded tubing)
• Replaced by ASTM B861 and B862
 Critical Factors in Welding
• Cleanliness-proper means of mechanical
and chemical cleaning using acids and
solvents
• Protection from contaminants at elevated
temperatures
– Trailing shields
– Root shielding
– Chamber welding
 Quality Control

• Simple tests to check the process before

welding & the finished weldment
• Describes how weld color is an indication
of weld quality
 Other References

• AWS G2.4 to be published this year

• Addresses CP and Ti alloys, such as
Ti-6Al-4V
• Helpful guide in base metal selection
• Other welding processes included
• Tables of reference documents
Tony Anderson
ESAB Welding &
Cutting

D10.7
RECOMMENDED
PRACTICES FOR GAS
SHIELDED ARC WELDING
OF ALUMINUN AND
ALUMINUM ALLOY PIPE
 © Copyright 2005 ESAB Welding & Cutting

Presented By: Tony Anderson, ESAB North America

The Number One Issue

Filler Alloy Selection

For Aluminum Welding

A Need To Up Date
This Information

< >
Many Base Alloys And Base Alloy
Combinations Can Be Joined Using Several
Different Filler Alloys

Only one filler alloy may be optimum for

a specific application

When Choosing The Optimum Filler Alloy, the

End Use Of The Weldment And Its Desired
Performance Must Be The Prime Consideration.

< >
* Filler Alloy Selection Primary Characteristics

W Weldability Or Freedom From Cracking

S Strength Of Weld - Tensile Or Shear

D Ductility Of Weld

C Corrosion Resistance

T Temperature Service

M Match in color after anodizing

* Post Weld Heat Treatment

< >
 Hot Weld Cracking

Hot Cracking On 2014 Base Alloy Plate

Adjacent To A Gas Tungsten Arc (GTA)
Welded 4043 Alloy Fillet

< >
 Weld Cracking - HOT

Choice Of Filler Metal

Lower Melting & Solidification Point - Molten
During Maximum Contraction Stresses

Smaller Freezing Zone

Avoid Critical Chemistry Ranges

Si 0.5% To 2.0%
Example: 4043 20% ( Electrode )
1100 80% ( Base )

Avoid Welding 5xxx Esp.. ( 5086, 5083, 5456 )

With 4043 Or 4xxx. Mgsi Eutectic Problems

Avoid Mg Range Up To 3.0% In Weld

< >
 Alloy Content vs. Crack Sensitivity

0
RELATIVE CRACK SENSITIVITY

A l - C u

A l - M g

A l - M
2 g S i

1 2 3 4 5 6 7
COMPOSITION OF WELD - PERCENT ALLOYING ELEMENT

< >
 Dilution Effect On Weld Composition

Base Plate 6061 Filler Metal 5356

20% Filler Metal

80% Base Metal
1.7% Mg

60% Filler Metal

3.2% Mg
40% Base Metal

< >
 Weld Strength - Groove Welds

The Heat Of Welding Softens the

Aluminum Base Alloy Adjacent To The Weld

In Most Groove Welds

the H.A.Z. of the Base Alloy Will Control
the As-welded Tensile Strength of the Joint

< >
 Heat Affected Zone

A B C D
Non Heat Treatable Heat Treatable
A 1- 2 0- A0
A - Weld Metal 1 1 0 0 A - Weld Zone
As Cast Structure Of Base &
Filler Metal B 1- 0 0- B0 B - Fusion Zone
9 0 0
B - Fusion Zone - C C - Solid Solution Zone
Where Partial Melting 8 0 0 Where Alloy Elements
C -
Of Base Metal Occurs 7 0 0 Are Solutioned & Cooled
6 0 To Retain Solid Solution
C - Anneal Zone -0D
Where Base Metal Is Fully 5 0 0 D - Partially Annealed
Recrystallized - Full Soft D -4 0 0 Overaged Zone
3 0 0 Where Heat Has Caused
D - Partial Anneal Zone E - - E Precipitation And/or
Where Base Alloy Is 2 0 0 Coalescence Of Particles
Recovered And Partially 1 0 0 Of Soluable Constituents
Softened
R T E - Unaffected
E - Unaffected

< >
 Hardness Profiles of 6061-T6

Made At Three Heat Inputs

1 0 0

9 0
5 8 0 J /c m
7 5 6 J /c m
Hardness RE

8 0

7 0

6 0 1 1 2 8 J /c m
A W S D 1 . 2 M I N T E N S I L E

- O T E M P E R
5 0

4 0
Distance From Weld Interface

< >
 Weld Strength - Fillet Welds

The Shear Strength Of Fillet

Welds Is The Significant Factor And
Is Controlled By The Shear Strength
Through The Weld Metal

5356 Produces Greater Fillet

Weld Strength In The As Welded
Condition Compared To 4043

< >
 Shear Strength

2 5 0 0 0
5 5 5 6

2 0 0 0 0
5 3 5 6
LBS. Per Linear Inch

4 6 4 3
Shear Strength

1 5 0 0 0 5 5 5 4
5 6 5 4
4 0 4 3
1 0 0 0 0

1 1 0 0
5 0 0 0

0
0 1 / 8 1 / 4 3 / 8 1

TRANSVERSE Fillet Size (Inch)

< >
 Shear Strength

Typical Shear Strengths Of Fillet Welds

Longitudinal Transverse
Shear Shear
Filler Strength Strength
Alloy ( Ksi ) ( Ksi )

1100 7.5 7.5

2319 16.0 16.0
4043 11.5 15.0
4643 13.5 20.0
5183 18.5 28.0
5356 17.0 26.0
5554 15.0 23.0
5556 20.0 30.0
5654 12.0 18.0

< >
 Fracture Characteristics

Heat - Treatable Alloys

Notch Tensile Strength Tear Unit Propagation
Ratio = Resistance
Tensile Yield Strength Energy In.-lb. / In3

2 . 0

T te a r R e s is ta n c e
1 . 6 1 6 0 0
R a tio

1 . 2 1 2 0 0

0 . 8 8 0 0

0 . 4 4 0 0

B a s e M 2 e 2 t 1a 9 l 2 2 1 9 6 0 6 1 6 0 6 1 6 0 6
F i l l e r A 2 l 3l o 1 2 y9 3 1 9 44 00 44 3 3 5 3 5 6 5 3 5 6 5
A g e d

< >
 Corrosion Facts – As Welded

Alloy 7075-T6 Welded With 5356 Filler

-849mv -876mv -900mv -810mv

Post Weld Heat Treated and Aged

-810mv -810mv -840mv -806mv

Note: Fusion Zone Mechanical Properties Not Restored to PreWeld Properties

< >
M Color Match After Anodize

Rating Scale: A - B

Ratings Scale Measures Uniformity Of Color

Comparing Base Alloy And Weld Metal
After Anodizing.

Either There Is A Good Or Reasonable Match

Or There Is Not.
A Blank Space Indicates No Reasonable Match.

< >
 Color Match After Clear Anodize

Base Metal: 6061

6 0 6 1 6 0 6 1

6 0 6 1 6 0 6 1

W E L D E D W I WT HE L 5 D3 5E 6 D W I T H 4 0 4 3

< >
 Post Weld Heat Treatment

Filler Alloys Have Been Developed

Which Will Respond To Postweld
Heat Treatment.

4643 Was Developed For Welding

The 6xxx Base Alloys, Has Additions
Of Mg And Is Less Dependant On
Dilution Of The Base Alloy To
Achieve Desired Composition.

Filler Alloys For Welding Castings

Have Been Developed With Chemistries
Which Will Respond To Post Weld
Heat Treatment.

< >
 © Copyright 2005 ESAB Welding & Cutting

Conclusion

Filler Alloy Selection For Aluminum

Can only be made after a full analysis of a

welded components performance
requirements

Should involve the consideration of

metallurgical effects (changes in crack
sensitively) when combining base alloy
chemistry with filler alloy chemistry

Can substantially influence the strength

and performance of a welded component

< >
William F. Newell, Jr.
PE, IWE, Chair D10I
D10.8
RECOMMENDED
PRACTICES FOR WELDING
OF CHROMIUM-
MOLYBDENUM STEEL
PIPING AND TUBING
 AWS D10.8
“… provide recommendations for welding
chromium-molybdenum steel pipe and
tubing to itself and to various other
materials. Subjects covered in detail are
filler metal selection, joint design,
preheating, and postheating. …”
 AWS D10.8 - Uses
• Often overlooked……
• Excellent resource for:
– Developing Corporate Procedures & Specifications
– Training Engineers, Supervision and Welders
– General Reference Guide
 AWS D10.8 - History
• First presented in 1961 as a Committee Report
by the AWS Committee on Piping and
Tubing.
• Revised in 1978 and became a
“Recommended Practice”
• Subsequent revisions/reaffirmations in 1986
and 1996
 AWS D10.8 - Content
• Base Metals
• Weld Filler Metals
• Joint Design & Preparation (purging)
• Preheating
• Post Weld Heat Treatment
• Repair/Maintenance of Service Exposed
Material
• Safety
 AWS D10.8 – Base Metals
• C-Steel
• C-Mo
• 1-1/4Cr-Mo
• 2-1/4Cr-Mo
• 5Cr-Mo
• 7Cr-Mo
• 9Cr-Mo (Standard Grade Only)
AWS D10.8 – Filler Metal

• Recommendations
– Process
– AWS Classification Options [C, CrMo
& Ni-base]
– Similar v. Dissimilar
 AWS D10.8 – Priorities !

• Preaheat w/recommendations
• Interpass
• Post Weld Heat Treat
w/recommendations
 Pending !
• D10.08 (DRAFT)
• Removing information on 9CrMoV (P91)
• Removing References to Standard Welding
Procedures
 Coming !
• D10.21 (DRAFT)
• “Guideline for Welding Advanced
Chromium-Molybdenum Steel
Piping and Tubing”
– P91, P911, P92, P122, T23…
Dan Ciarlariello
Mannings USA
D10.10
RECOMMENDED
PRACTICES FOR LOCAL
HEATING OF WELDS IN
PIPING AND TUBING
 Definition of Heat
Treatment
• Heat Treatment is generally defined as
heating to a suitable temperature then
cooling at a suitable rate of a solid
metal or alloy in a way so as to obtain
specific conditions and/or properties by
changing the physical, chemical and/or
mechanical properties of the steel,
metal or alloy
Methods Of Localized
Heat Treating
• Electrical Resistance

• Induction

• Combustion / Flame

• Quartz Lamps

• Exothermic Kits.
Electrical Resistance
Inductive Heating
Combustion / Flame
Quartz Lamps
Reasons for Localized
Heat Treating
• Bake Out

• Preheating and Inter-pass

Temperatures

• Post Heating

• Post-weld Heat Treatment

Comparison of Heating
Processes
Attribute Induction - Resistance
• Yes Yes
• Applicability to
bake-out
• Applicability to • Yes Yes
preheat/inter-pass
• Applicability to
postheating • Yes Yes
• Applicability to
PWHT • Yes Yes
 Advantages and
disadvantages of heating
processes
Induction Heating
Advantages
 High heating rates
 Ability to heat a narrow band adjacent to a region which
has
temperature restrictions

Disadvantages
 High initial equipment cost.
 Equipment large and less portable.
 Limited ability to create control zones around the
circumference.
 Advantages and
disadvantages of heating
processes

Electrical Resistance
Advantages
 Ability to continuously maintain heat from
welding
operation to PWHT
 Good ability to vary heat around the
circumference

Disadvantages
 Elements may be damaged during welding
 Quantity of heaters required on thicker
components
 High Frequency
Induction heating
• Uniform product quality
• Increased surface wear-proof
characteristics
• Increased material fatigue strength
• Minimum strain due to local surface
hardening
• Very localized heating
 Why Preheat?
• Reduce the level of thermal stress.
• Compensate for high heat losses.
• Minimize the rate of weld
hardening.
• Reduce porosity.
• Reduce hydrogen cracking.
• Improve the microstructure.
Typical Preheat Set-up
Boiler Tube Welds
Wireless Thermocouple
Transmission
 AWS D10.11
Walter J. Sperko, P.E.
Sperko Engineering
Services, Inc.
Guide for
Root Pass Welding
of Pipe Without Backing
 AWS D10.11
Keywords
• Root pass welding, pipe, gas
purging, consumable insert,
gas
tungsten arc welding, gas
metal arc welding, shielded
metal arc welding
 AWS D10.11
Introduction
• This publication was intended
to be a “how to” guide in the
use of open root and
consumable insert welding
techniques for root pass
welding of groove welds
joining metal pipe.
 AWS D10.11
Introduction
• Joint designs, fitting techniques,
consumable insert configurations,
filler and base metal combinations,
purging, and welding processes are
discussed. This publication made
no provision for joints which
include backing rings
 AWS D10.11
Introduction
• This standard is a “best practices”
guide to making high-quality pipe
butt welds where backing cannot
be used
• Welders should have excellent
reasons for deviating from what
this standard recommends
 AWS D10.11

• What is “Root Pass Welding?”

• Let’s look at some “root
passes”. . . .
 AWS D10.11

• A single-vee Butt weld

between two pipes
 AWS D10.11

• Root pass on a Socket Weld

 AWS D10.11

• Root pass on a Double Vee-

Groove Weld
 AWS D10.11
• All of these “Root Passes” are on
backing
 AWS D10.11

• Take away the Backing Strip

and you have a weld without
backing. . . .
 Welding without
Backing

You now have a pool of liquid

metal hanging in space
suspended between the ends of
two pipes. . .
 Welding without
Backing
Torch

Blast the arc force through the root

opening and melt the edges of the
metal, then fill the opening with filler
metal
 Welding without
Backing
Electrode

Blast the arc force through the root

opening and melt the edges of the
metal, then fill the opening with filler
metal
Effect of Included Angle

LARGE included angle makes it

easy to get the electrode close
to the root and easy to direct
the arc into the root.
Effect of Included Angle

SMALL included angle holds the

electrode away from the root
and makes it difficult to direct
the arc into the root.
Full Root Penetration

Continuous metal
surface from one
member across the
weld to the other
Forces on the weld pool?

Longitudinal Section of a
pipe joint
Forces on the weld pool

Gravi
ty

Longitudinal Section of a
pipe joint
Forces on the weld pool

Surface Cohesion (wetting) between the

weld pool and the solid metal

Longitudinal Section of a
pipe joint
 Forces on the weld pool

The arc must melt both edges of the root face

and the weld pool must fill the gap without

becoming too large

Longitudinal Section of a
pipe joint
 Forces on the weld pool

If the weld pool becomes too large, the surface

cohesion forces are overcome. The result is
root concavity or drop-through.

Longitudinal Section of a
Parts of a Groove Weld
Joint Design

Root Face
(“Land”)
Parts of a Groove Weld
Joint Design

Root Opening (“Root

Gap”)
Root Opening vs. Root Face
Thick Root Thin Root
Face Face

Small Root opening ➾ Incomplete Penetration

Proportional Root opening ➾ Complete

Penetration

Excessive Root opening ➾ Root concavity or

 Root opening - Root face thickness
relationship

1/8”

3/32”
Root Face
Thickness

1/16”

1/16” 3/32” 1/8”

Root Opening
 Cleaning

• Cleanliness is important in all

welding, but it is especially
important in root pass
welding.
• Contamination affects wetting
which affects bead shape.
Purging
 Purging

• A purge is required for stainless

and nonferrous piping systems
(except aluminum) if a smooth
root surface is to be obtained.
• Standard describes how to set
up for purging
• Purging time
 Purging

• The following oxygen limits are

recommended:
• For carbon and low alloy steels:
2%(20,000 ppm)
• For stainless steels: 1/2% (5000 ppm)
• For nickel alloys: 1/2% (5000 ppm)
• For titanium and zirconium alloys:
1/4% (2500 ppm)
 Purging

• Welding technique for Open

Root
• Welding Technique for
Consumable Insert
• Maintaining purge during
welding
 Fitting and tack
welding

• Size, spacing, feathering ends

• Root spacing depends on
process to be used.
• Inspection after fit-up. This is
the most important step in
pipe welding
 GTAW

• Tungsten size, shape of end

• Grinding methods
GTAW Joint design and fit
up
 GTAW

• Purge containment
• Arc initiation
• Keyhole technique
• Wire feed techniques
• Orientation of torch and filler
GTAW
GTAW
 GTAW

• Walking the Cup

• Welding with zero root
opening (autogenous welding)
• Welding in different positions
• Using consumable inserts
 Consumable Inserts

1/32” maximum
mismatch
Class 1 Insert, formerly the EB
(Electric Boat) or “A” type insert.
Consumable Inserts

1/16” maximum
mismatch
Class 2 Insert, formerly the “J” type
insert.
Consumable Inserts

1/16” maximum
mismatch
Class 3 Insert, formerly the
“Grinnell” or flat insert.
Consumable Inserts
 SMAW

• Cellulosic Electrodes (EXX10,

EXX11)
• Low Hydrogen Electrodes
(EXX15, EXX16, EXX18)
• Rutile electrodes (E6013)
 GMAW

• Joint design
• Fit-up
• Welding parameters
 Fill Passes

• Use any suitable process

• Don’t melt through the root
 Aluminum

• Tungsten type, shape of tip

• Shielding gas cups, lenses
• Power supplies
• Techniques
• Recommended joint design
Aluminum
Machine and Automatic

• Not much said

 Summary
• AWS D10.11 gives very specific
recommendations about techniques
that have proven successful in
making pipe welds without backing
• Recommendations should be
familiar to welder’s supervision
• Recommendations should not be
take lightly
 Alan Beckett

D10.12
RECOMMENDED
PRACTICES FOR WELDING
MILD STEEL PIPE
 D10.12
Welding Mild Steel Pipe

This document provides

recommendations for the welding of
mild steel pipe such as A106 type. This
material is found in many scopes of
work, and extensively in commercial
building construction.
A106 material is often used as a
starting point for welder training.
Covered Processes
• SMAW
• GTAW
• GMAW
• FCAW
 D10.12
A Document for All Reasons

As with other D10 documents, you will find

excellent attention to detail presented in a
manner for all to understand.
For these reasons D10.12 is a welcome
addition to your library or a valuable resource
for training.
 MICHAEL LANG
AWS/CWI/CWE
United Association
of Plumbers & Pipefitters
D10.13
RECOMMENDED
PRACTICES FOR BRAZING
OF COPPER PIPE AND
TUBING FOR MEDICAL GAS
SYSTEMS
What is Medical Gas Piping?
There are many perceptions of Medical
Gas Piping but the facts are:
• Cleanliness is entirely dependant on
installation practices
• Poor installation can produces conditions
that harbor bacteria and diseases
• These systems are not cleanable
• These are life critical systems
 Purpose
The governing document for all Medical Gas
Piping is NPFA Code 99C which dictates the
methods and installation practices that shall
be used in system construction…

However this document does not cover actual

brazed joint construction or the tools and
practices needed for system construction
 Important Notes
• D10.13 is a Recommended Practice developed
to work with NFPA 99C.
• All recommendations have been used in actual
jobsite conditions with a 100% success rate
• The use of these practices have produced
consistent profitable results
 Needed Equipment
• Use and Care
• Torch Selection
• Tube Cutting
• Purge Monitoring
 Consumables
• Pre Braze Joint Cleaning
• Pre Braze Chemical Cleaning
• Post Braze Cleaning
• BCuP Brazing Alloys
• Bag Brazing Alloys
Something you will only find in
D10.13

• The only document that provides joint heating

and filler metal application methods.
• These methods continually produce a 99%
acceptance rate in accordance with ASME Boiler
& Pressure Vessel Code Section XI.
 And… Purging Methods
• Purging is possibly the most important
component to internal cleanliness. This
document provides methods and parameters for
the use of oxygen analyzers.
• We also provide purge timing matrix charts for
estimating purge times for long runs of piping.
These charts should be used in conjunction with
an O2 analyzer.
 Proven Success
You Can Trust

D10.13
RECOMMENDED PRACTICES FOR
BRAZING OF COPPER PIPE AND
TUBING FOR MEDICAL GAS
SYSTEMS
BECOME A COMMITTEE MEMBER
FOR DETAILS CONTACT Brian
McGrath at bmcgrath@aws.org
THANK YOU FOR ATTENDING
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