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Technical Articles
Note: Items 1 through 6 were included in the article Basic Weld Inspection Part 1.
A pressure vessel manufacturer is manufacturing a lethal service vessel. ASME Section VIII, Div. 1, paragraph
UW-2 (a)(1)(d) states that all Category D joints shall be full penetration welds. That means the weld metal must
extend completely from one face of the joint to the opposing face of the joint. Without watching the entire welding
process, how does the inspector ensure the manufacturer has complied with Code requirements? A review of the
welding procedure and any supplementary instructions combined with a verification of the joint preparation will
tell the inspector much of the story. If the full penetration weld is to be accomplished by welding from both sides,
the inspector should make a point of observing how the root of the first weld is prepared for incorporating the
weld on the opposing face. This is usually done by mechanical means (such as grinding or chipping) or thermal
gouging.
When welding in areas with limited access to move, welders will sometimes shorten SMAW welding rods and
GTAW filler wire. To shorten the SMAW rod, the welder will grip the rod in the electrode holder a few inches from
the bare end and crumble the flux until he or she is able to grip a bare portion of the rod. When this is done, the
rod identification is usually destroyed since it is normally printed on the flux close to the bare end. GTAW filler
wire normally comes in 36-inch lengths with identification on one or both ends of the wire in the form of a
flag-type label or embossing. A welder will seldom attempt to use a full length of wire because the free end may
hit an obstruction or in some way impede the welders manipulation of the wire in the weld puddle. A welder may
cut the length of filler wire in two or more pieces to make it easier to handle. Depending upon how the filler wire
is marked, there could be one or more pieces without identification. If the certificate holder is using only one type
and size of SMAW rod or GTAW wire (such as 3/32 in. E7018 or ER70S-6), the inspector may feel more
comfortable if rods or wire with missing identification are found at the welders station. However, most certificate
holders use more than one type and size of rod or wire, and the inspector must always ensure there are
adequate controls in place to maintain rod or wire identification.
SMAW welding rod storage seems to always stir up a lively debate. The rod manufacturers recommendations
should always be followed or, at the very least, the rods should be stored in compliance with the information
found in ASME Section II, Part C. As an example, SFA-5.1, Annex 6.11 and SFA-5.5, Annex 6.12 discuss
moisture content and conditioning for carbon steel and low-alloy steel electrodes (rods). One interesting point
found in these references deals with rods such as E6010 with cellulosic coverings (flux). They actually need a
moisture level of approximately 3 to 7 percent to operate properly. That means if these rods are stored in a
heated oven, they may be too dry to use. I have personally seen E6010 rods taken from an oven, and the flux
crumbles and falls off with the slightest touch. To the other extreme, I have seen a welder quickly dip an E6010
rod in a bucket of water immediately before striking an arc. This was on plate steel in a non-pressure boundary
application so there were no ASME or NBIC violation concerns, but I am sure it exceeded the rod manufacturers
recommended moisture content. This is definitely not condoned or recommended.
Holding ovens for welding rods are commercially available in many sizes. Human resourcefulness has also
converted derelict refrigerators into makeshift holding ovens by installing light bulbs as the heat source. Is that
permitted? As far as I know, it is not prohibited. The key, in my opinion, is the ability to achieve and maintain the
recommended temperature. For example, SFA-5.1, Annex Table A3 shows a temperature range of 50F 250F
above ambient temperature for E7018 rods. It should not be difficult to obtain 50F above ambient temperature
during the winter in a shop where the temperature is 60F. But, go to a shop in Louisiana or Florida in the
summer, and the ambient temperature may easily be over 100F. Can a simple light bulb in an old refrigerator
achieve the necessary temperature in those conditions? There are variables such as the wattage and number of
light bulbs in addition to how well the old refrigerator is insulated and sealed. As part of their normal monitoring
duties, inspectors should be verifying the rod storage conditions no matter if a commercial oven is used or if a
homemade alternative is in place.
While we are on the subject of welding rod storage, it seems that there are always a few people who mistake
holding ovens with drying or rebaking. Looking at the table below, we find E7018 should be held or stored at
50F 250F above ambient temperature. If the rod flux may have absorbed excess moisture, then it may be
reconditioned by drying or rebaking. That requires a temperature of 500F 800F for 1-2 hours for E7018.
Looking at the specifications for one manufacturer of electrode ovens, their holding ovens are capable of 550F
plus or minus 25. That would just barely meet the minimum rebaking temperature specified in Table A3. The
same manufacturer offers another purpose-built oven capable of reaching 800F. The two big differences in their
construction are the electric heating elements and the insulation thickness.
As you can see, weld inspection includes much more than just looking at the finished product. The best advice for an
inspector is to stop for a moment and think about every element which goes into making a weld. That can become the
inspectors checklist for review, inspection, and verification.
TABLE A3
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yp
y g
Storage Conditions(1,2)
AWS Classification
Drying Conditions(3)
A5.1
A5.1M
Ambient Air
Holding Ovens
E6010, E6011
E4310, E4311
Ambient temperature
Not recommended
Not recommended
E6012, E6013
E6019, E6020,
E6022, E6027,
E7014, E7024,
E7027
E4312, E4313
E4319, E4320,
E4322, E4327,
E4914, E4924,
E4927
80F 20F
[30C 10C]
50% max.
relative humidity
20F to 40F
[10C to 20C]
above ambient
temperature
275F 25F
[135C 15C]
1 hr at temperature
E6018, E7015
E7016, E7018,
E7028, E7018M,
E7048
E4318, E4915
E4916, E4918,
E4928, E4918M,
E4948
Not recommended
50F to 250F
[30C to 140C]
above ambient
temperature
500F to 800F
[260C to 425C]
1-2 hr at
temperature
Notes:
(1) After removal from manufacturer's packaging.
(2) Some of these electrode classifications may be designated as meeting low moisture absorbing requirements.
(3) Because of inherent differences in covering composition, the manufacturers should be consulted for the exact drying
conditions.
Table and Notes reprinted from ASME 2007 BPVC, Section II-Part C, by permission of the American Society of
Mechanical Engineers. All rights reserved.
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