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
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.
Type (Grouping)
Thickness
Diameter (Pipes)
Surface condition
Welding process
Type of process
- SMAW,
- GMAW(MIG/MAG)
- GTAW(TIG)
- FCAW
- SAW .etc
Equipment parameters
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
Type of backing
Welding Joint
Tee Butt
Cruciform
Welding Joint
Angle of
bevel
Root
Radius
4/23/2007
Joint Preparation
Angle of bevel Angle of bevel
Root
Radius
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 - J Double - U
Groove Weld Preparation
bevel angle
included angle
root face
root gap
Typical Dimensions
bevel angle 30 to 35
root face ~1.5 to~2.5mm
root gap ~2 to ~ 4mm
4/23/2007
Figure 3.4 (Continued)-Prequalified CJP Groove Welded Joint Details (see 3.13)
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
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
Flat 1G Overhead 4G
Vertical up
3G
PB / 2F
PC / 2G
PE / 4G PG / 3G
PD / 4F
Pipe Welding Positions
PF / 5G PG / 5G
PA / 1G
Weld: Flat Weld: Vertical upwards Weld: Vertical Downwards
Pipe: rotated Pipe: Fixed Pipe: Fixed
Axis: Horizontal Axis: Horizontal Axis: Horizontal
45o 45o
PC / 2G
H-LO 45 / 6G J-LO 45 / 6G
Weld: Horizontal Weld: Upwards Weld: Downwards
Pipe: Fixed Pipe: Fixed Pipe: Fixed
Axis: Vertical Axis: Inclined Axis: Inclined
Position
AWS D1.1, Table 4.1, WPS Qualification
CJP Groove Weld (Plate or Tubular)
SHIELDING
Brand/classification
Tin can
cellulosic 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
TYPES OF ELECTRODES
(for C, C-Mn Steels)
AWS A5.1
Cellulosic EXX10
EXX11
Rutile EXX12
EXX13
Rutile Heavy Coated EXX24
Basic EXX15
EXX16
EXX18
MIG/MAG Welding Consumables
Welding wires:
carbon and low alloy wires may be copper coated
stainless steel wires are not coated
wires must be kept clean and free from oil and dust
flux cored wires does not require baking or drying
MIG/MAG shielding gases
Aluminium Ar
MIG/MAG shielding gases
Ar Ar-He He CO2
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 (CO2):
cheap; deep penetration profile; cannot support spray
transfer; poor wetting; high spatter
MIG/MAG shielding gases
Gases for Short-Circuiting transfer:
CO2: carbon steels only: deep penetration; fast welding speed;
high spatter levels
Ar + up to 25% CO2: carbon and low alloy steels: minimum
spatter; good wetting and bead contour
90% He + 7.5% Ar + 2.5% CO2: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)
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MIG/MAG shielding gases
Gases for spray transfer
Ar + (5-18)% CO2: carbon steels: minimum spatter; good
wetting and bead contour
Ar + 2% O2: low alloy steels: minimise undercut; provides
good toughness
Ar + 2% O2 or CO2: 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)% N2: 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% CO2 for C-Mn & low alloy steels
Ar + 2% O2 for stainless steels
100% CO2 can be used for C - steels
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MIG/MAG - metal transfer modes
Electrode diameter = 1,2 mm
Voltage
WFS = 8,3 m/min
Current = 295 A
Voltage = 28V
Globular Spray
transfer transfer
+ - + - + -
+ - + - + -
+ - + - + -
Heat balance 70% at work 30% 50% at work 50% 35% at work 65%
at electrode at electrode at electrode
Penetration Deep, narrow Medium Shallow, wide
Oxide cleaning action 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
Increase
Vertex
diameter
angle
Decrease
Bead width
increase
Electrode tip prepared for low Electrode tip prepared for high
current welding current welding
Electrode tip for AC
DC -ve AC
Vetex angle
Welding current
Preflow
and
Postflow Preflow Postflow
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Fusible Inserts
Consumable inserts:
used for root runs on pipes
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
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 -