----------------------

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SUII(Cl

Chap. 2 - General Requiremeots (Artide 1)

Section IX

37.

SECTION 1t0

!MICINAl !SSIH

CPIX

1983

li[VISION OATt

711196

Read gw- 152.

Each of the above test spectmens was tenslon tested by pulllng on elther end until they
fractured. The tensUe strength (sometimes called ultimate tenslle strength or UfS) for the test
speclmen was calculated by d~dlng the maxlmum measured load of 12,000 lb. at fracture by the
cross sectional area bef()re testing of the test speclmen.

A= 1tr2 = 3.14 x (0.5/2) 2 = 0.196 sq. In.

UfS = 12,000/0.196 = 61,224 PSI

Be sure you understand this as lt wl1l determine whether or not you can properly judge the
acceptablllty of a test coupon ora WPS/PQR.

38.

Read QW-153.1
QW-153.1 addresses the tensUe strength of base metals and correlates that to the acceptance of
the tenslle tests. In general the tensUe test must break In the base material or the test falls. For
example, the tenslon test passes lf the test spectmen breaks ln-the weld below the tensUe
strength of the base matedhl but only when the appllcable reference Code provldes for 1ower
tenslle strength, at room temperature, of the we1d metal. (QW-153.l(e)J Thls usually onlycO<:Curs
when the destgner bases hls desgn on the 1ower strength ftller material. In sorne cases there are
few, lf any, ftller materials made that are a strong as the base materials that are jolned. The
deslgners should be aware of this.
A tenston test was performed and evaluated asfollows:
A test coupon was we1ded ustng base mater!als of dlfferent speclftc ultimate tensUe strengths.
The test coupon was sectloned lnto test spectmens, and those test spectmens were placed in the _.
tensUe test machlne. Of the two base metals (60.000 psi and 65,000 psi tenslle strength
respectlvely), the tnslle test speclmen broke tn-the 60;000psl-base metal. The ultimate tenslle
strength was calculated and found to be 56,000 psi. Wlth only that lnformation gtven, does the
tenslon test results meet the Section IX acceptance standard of QW-53.1 ?_ _ _ _ _ _ _ __

Answer: No. The tenslon test would not pass. QW-153.l{d) allows a fallure no more that 5%

below the tensUe strength of the weaker base material. (95% X 60,000 =57,000 psi.
mlnlmum.)

() 1996 Hartford Stcam Boiler lnspcction and lnsurancc Company

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26

...........)
/1<1\fl

Chap. 2 - General Requirements (Art. 1)

~ection IX

&

,...."'

~"'DJ!'(!\J"~

39.

SECliOH NO

SUBJECT

CPIX

ORIGIIW.JSSUE

1983

RE'IISION OATf

1992

"'"27

Read QW-161.4 through 162.

For baste gulded-bend testlng. see Chapter One.
Note:
Also retar to OW-462.2; 462.3(a) and (b); and the bend jigs of QW-466
at this time. Pay particular attention to note #2 of OW-462.3(a) which
gives guidance lor aubsizad apeclmena you wish to perform tests on
these types of specimens.

The longitudinal bend test may not be used except 1n those cases where the two matertals. belng
joined. cUffer ..;gnlfic$ntly In ducUltty. For example, sorne heat treated steels welded to
aluminum.
Referto QW-466.1. QW-466.2 and QW-466.3 forsome acceptable bend testjlgs.
In QW-466.1 what 1s the lower radlus dlmenslon (D) for testlng a 1/4" thick face bend speclmen
for P-ll material? For a 3/8" thlck P-1 material slde bend?

Answer: IAI

55

48' for.P~ll.
(4-1/3t+

1/16=52/48+3/48=~)

(B) 1-3/16" forP:l.

lO.

A bend test plunger (mandrel) as 1n QW-466.115 1-l/2" wlde.. May.thlstestjlgbeu5ed to tesL ..... '
a slde bend speclmen 1-5/8" wlde? (Yes or No?)

Answer: No. The mandrel, 1n thls case. must be at least 1-7/8" wlde or 1-5/8" + 1/4".

u. Read QW"163.
A quallflcatlon bend test performed on a 3/8" thlck test speclmen allows cracks 1/8" or less In
length on the convex or outer radll of the bend. Thls could mean that the concave or tnner 1/4"
can be consldered as irrelevant. and the manufacturer need only look at the 1/8" cracks on the
outer radll. However. thls 1s not true. It just happens that most dlscontlnultles wll1 appear on
the convex surface. Sltghtly rounded comers on bend test spectmens wUl reduce susceptibUity to
comer or edge craclctng dueto bendtng. In QW-462.2(a) and (b) and 1n QW-462.3(a). the maxlmum
radJJ at the edges of the test speclmens are for the benefit of the manufacturer. These mlnlmum

C 1992 Hartford Sle- 8oiler irupc<:lion ond lnsurance Comp..

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.

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--

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-.~
~
~

~~~.41'QUJIIY!"'
IM4MI

....

SECTtOft NO

SUBIECT

Chap. 2 - General Requirements (Art. I)

Section IX

CPIX

OIIICilfiAI.ISSlJ[

RfVISION Oo\lt

1983

1992

""28

radli lessen the poss!blllty that cracks will occur when bend testlng. Questlons about poros!ty
may aiso artse tn QW-163 because the acceptance standard 1s vague.
Keep In mtnd that a customer or contractor may requtre a more str!ngent standard. Section IX
has mln!mum requ!rements only. A testtng laboratory cannot evaluate the results for a
manufacturer. The test lab's functlon !s only to perform the test and then describe the results. A
test result descr!bed as "acceptable" may not be an adequate descriptlon for the manufacturer to
state that Sectlon IX has been met on the PQR cerUflcatlon.
Results stated l!ke, "No defects not.ed." can be cons!dered more useful. If the manufacturer does not
know the exact standard used by the test lab, the statements !ssued by that lab can affect the Code
acceptablllty of the results.
A bend test was performe;! as follows:
A s!de bend test spec!men was bent and then examlned. No open defects were found that exceeded
1/8" In length. There were 3/16" long cracks at the test spec!men's comers, but there was no
ev!dence that they were caused by tncluslons such as slag.
Wtth only the tnformatlon gtven, !s th!s test spec!men acceptable under QW-163?
~es/N~-------------------------------------------------------------

Answer: Yes. However, tt would be a good practice to have the test scrutlnlzed to determine
what caused the cracks. It could be that lmproper filler metal was selected.

If the prev!ous test In #41 (see above) was of a face bend spec!men tnstead of a slde bend
spec!men, would tt be acceptable under the Section IX acceptance standards?
~es/No)---------

Answer: Yes. The acceptance crtterta 1s the same In both cases.

A weld test ustng two dlfferent base matertals SA-516, Gr. 70 to SA-234 WPB was g!ven a
postweld heat treatment at 1350F for stx hours to meet the requ!rements of appllcation for ANSI
B31.1, ANSI B31.3, and Section vm. WhUe the tension tests were acceptable wtth this heat
treatment. the stde bends broke In half with a brtttle type fraction at the fuston llne (Interface of
the test plate and weld deposit). No other visible defects were noted. Durtng weldtng. the test
coupons were matntatned at 400-600F between each filler metal pass and allowed to cool slowly
after weldtng.
QW-163 does permtt cracking at the comers. If the cracks were not the results of slag tnclusions
or other tntemal defects, would the above stde bends be acceptable despite the fracture?
~es/No)-----

!992 Hartford Sream Boiler Inspection and Insurance Company

JI!:),

..)

-$

SUBJECT
~

. e

~
~~ 11..1111
*'"
- ~ ...DI~""

Answer:

M.

SECHON NO

Chap. 2 - General Requirements (Article)

R(YISION I)U[

OIGINAliSSUE

CPIX

1983

111196

Section

No. However. Artlcle 11 of Sectlon IX does require a manufacturer to consider items

other than just the Code minlmums when welding. Sorne other welding Codes
such as the AWS D 1.1 Structural Steel Code have more speclfic limits.

ls the total length of the dlscontlnultles allowed on the surface one bend test speclmen equal to
1/8'' or may there be many 1/8" long dlscontlnuitles?_ _ _ _ _ _ _ _ _ _ _ _ _ __

Answer:

There may be any number of dlscontlnultles as long as any one does not exceed
1/8" In length. Agaln. common sense should llmlt these.

15.

Read al! ofQW -171.

-.

See Chapter One. PageI7, for1tnpact lttachtnes and ,sam~ notch toughness infonnatlon. SA 370 from Sectlon II, PartA ofthe ASMK Code.' 11'errous Materiiils Is a testing spectfiC.itian
niferanced by ferrous materlals. Nonferrous materlals do n<!t requlre notch toughness t~sting .
. ;.- .
Notch toughness only applle~
a ~ferenclng Code requlre~ it. Generally thts requlre~entls.
not mandated uless low temerature service ls lnvolved. You would not expect notch toughness
testlng In Sectlon 1 and Sectlon IV for bollers. In sorne classes of nuclear constructlon notch
toughness ls also requlred regardless of deslgn operatlng temeratures. Thls course will not cover
the actual testlng nor the acceptance crlte.rla. Suffice lt to say that each Code is dlfferent. Also
the acceptance crlterla IS dlfferent. Son'1e Codes tstfor "ICiteri: ~iOn. other testfor absorbed
energy. Refer to the appllcable Code for acceptance and do not asaume that a WPS quallfted for
one Code qualiftes for all Codes.
-:-~,_

when

A manufacturer belleves that Sectlon IX requlres a Charpy V -notch test lf the pressure vessel
wlll be In corroslve atmosphere and that the acceptance crlterla must be In accordance with QW
- 171.2.
.
Is the manufacturer correct In the above assumptlon?

Answer: No. Sectlon IX has no such requlrement; however, the referenclng Code may have
such requirements. Usually 1t will depend on the type of metal.

O 1996 Hanford Sleam BoUcr lnspection and

lnsu~c

Company

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29

:~~)
~~!:~~;~..~~

Sl:CTION NO

SUBIECT

Chap. 2 - General Requlrements (Art. 1)

Sectil;m IX

CPIX

ORICINAI.ISSUE

lttvtSION Qa,T[

1983

1992

Read al! of QW-172.

Drop welght testlng procedures are handled the same as lmpact testlng as far as the
Section IX Cede ls concemed. The referenclllg Fabrication Cede provtdes all the details. If
testlllg 1s mandated by a particular ASME Cede they reference E208 from ASTM (American
Soclety for Testlllg and Materials).
An example of a drop welght test ls shown In Flg.6 for your lnformation. The test measures the
"Nll-ductWty temperature" (NDT) of weld metal. The test plece 1s cooled and qulCkly placed

on the testlllg apparatus. The test speclmen must fallln arder to be evaluated properly. The
falllng welght cracks the base plate at the zero or nll-ductllity temperature.
A customer tells a manufacturer that a notch-toughness test 1s mandatory under Sectlon IX, even
1f a Charpy V-notch test 1s not requtred by the appllcable fabrtcation Cede section. ls the
customercorrect? _______________________________________________________________

Answer: No. However, contractual obllgations may overr1de Cede mlnlmums by betng

more
restricttve. The ASME nor the Authorlzed Inspector has any responslbility In thls
area. It 1s outslde the scope of Section IX.

Figure #6
Drop Welght Test
thls coupon 1s cooled
to the deslred test
temperature and
then quickly tested
as In (b)

Weld Bead on P1ate

/)

Notch Ground Down to Base Material

falllllg welght - descends In a controUed
manner for direct hit
~
Test Plate From (a)

"
(a)

Stop

(b)

!992 Hartford Steam Boiler lnspecrion and Insurance Company

:J

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30

SUBJECT

SEcfiON MO

Cbap. 2 -

7.

General Requirements (Art. 1)

Section IX

CPIX

ORtGIHALISSUE

1983

REVISIOfl DATE

,...

1992

31

Read QW-180.
It can be lmmedlately noted from the titles of these paragraphs that the tests required for

procedure and performance quallflcations are fundamentally different. Otherwise one paragraph
would cover all testing generically.
For fillet weld procedure testing, no test 1s required to determine the strength of the weld.
lnstead, all that 1s requ!red are five macro-etch tests for plate-to-plate testlng [See QW-462.4(a)) or
four macro-etch, quarter section, tests for plpe-to-plate testing [See QW-462.4:dll
The performance quallficatlon requires a fracture test and two macro-etch tests [See QW-462.4(b)
and {e)]. When the fillet test coupon 1s made, the welder must start and stop the weld so that both
a starting and stopptng polnt may be fracture tested by bendtng the stem over. 1h1s 1s a polnt
commonly overlooked pecause you must use QW-462.4(b) and notjust QW-182. Remembe:: the
purpose or content of Artlcles 1 and IV (general lnformation and data). Read all referenced
paragraphs and figures. The above discusslon should hfghllght the need to use all Artlcles of
Section IX. Part QW, and not ptck out paragraphs at random wlthout conslderation of the rest of
Part QW.
A plate-to-plate fillet weld test coupon for a weldtng procedure was tested 1n the followtng
manner: The fillet weld coupon was cut transversely (perpendicular) to the weld axis lnto five
sections, each 2-1/8" wlde. The spectmens were macro-etch to the QW-470 requtrements. The.
weld showed good fuslon at the root and small ha1rl1ne cracks 1n the heat aft'ected zone. Are the
results acceptable to the standards 1n Section IX?
:. .
(Yes/No?)-----

Answer: No. The test speclmen does not pass. QW-183 requlres that the heatfrected zone
show no cracks, not even ha1rl1ne.

S.

QW-181.1.
The d1mens1ons of the atem are lndlcated as 3" on the plpe to plate weld of QW-462.4(c) and (d).
1h1s dlmenslon should be used when posslble for the manufactuiers beneftt. However, there are

sorne speclallzed pleces of equlpment that are destgned to make small fillet welds on plpe-to-plate
(!.e. seal welds on tubes) that do not permlt that much extens1on lnto the machlne. Because these
dlmenslons are approxlmate, unless otherwtse tndlcated, you may use less than or greater than a
3" stem to make the test coupon 1f you cn obtafn acceptable results.
A fillet-welded socket-type jolnt [slnl1lar to QW-462.4(cJI that 1S lesa than 3/4" 1n dlameter has
been tested and meets the performance qual1ftcation test coupon requtrements. Wlll the test
spectmen also meet the test requlrements for procedure qual1ficatton?
(Yes/No?) - - - - -

Answer: Maybe. QW-181.1 refers to QW-462.4(d) as the acceptable practice to qualify such
weldtng procedures. QW-462.4(d) 1S identical to QW-462.4(c) except no bend is
lndicated. However, severa! test coupons may be requlred because four macro-etch
tests rnay not be posslble ustng the very srnall 3/4" pipe.

e 1992 H.nfcml Sream Boiler Inspection and lnsurance Company