WELDERS TESTED AT AWTI ACCORDING TO THE

FOLLOWING PROCEDURE: Preparation of weld test pieces according to BS EN ISO 15614-1:2004.

Butt and fillet test pieces should be prepared according to the standard size
mentioned in
ISO 15614-1.
Selection of welding process, consumables and position of weld accordance
with the PWPS.
Welding and testing of the test pieces shall be witnessed by an examiner or
an examining body.
After completion of weld test coupon evaluated for weld defects as per ISO
5817:2014.

S.N
O
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20

Description
Crack
Crater crack
Surface pore
End crater pipe1
LSF/m LF
IP root
C/I undercut C
Shrinkage groove
E W M C
Ex Convexity C
Ex penetration
Incorrect Weld Toe
Overlap
Sagging/ IFW
Burn Through
Ass. Leg Length
Root Concavity
Root Porosity
Poor Restart
Insufficient Throat

S.N
O

Description

21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40

Excess Throat C
Stay Arc
Spatter
Cracks
Micro cracks
Gas Pore { u d }
Clustered pore
Linear Pore
Worm holes
Shrinkage cavity
Crater pipe
Inclusions
Metallic inclusions
Copper inclusion
LF/LSF/LIF/LRF
Lack of Penetration
Linear misalign
Incorrect root gap
Multiple imperfection
Projected or cross section area

Further Weld test sample examined in accordance with as follows.

Visual Examination as per ISO 17637/2003.

Dye reentrant test as per ISO 3452-1.
Hardness survey as per ISO 9015-1.
Macro etch test as per ISO 17639/2003.

Attached one test result copy of Weld sample done by N.RADHAKRISHNA

/Tech-1/6101/H.COR/CRS/TPTY, AWTI LABORATORY.

GROUPING OF
WELDERS
The system of grouping the welders into three categories namely A, B and C, based on the
tensile testing of weld samples already prevails. Definite targets are being set to train and
develop the welders from the lower category to higher category and are being periodically
reviewed, on monthly basis, at Headquarters level. For ensuring sound welding in a coach
undergoing POH, this practice is considered to be inadequate and the necessity to improve
the skills and to enrich the expertise has been felt. Hence, an attempt made in CRS / Tirupati
to impart practical on job training for the welders, area-wise, duly adopted by the Instructors of
BTC such that (i) welders are made aware of the significance of their job and thus develop a
sense of pride (ii) gain expertise and (iii) acquire skills.
To validate the proposed methodology, weld samples were compared before and after the
training and the results were encouraging. The same methodology is now being extended to the
entire workshop for obtaining real field advantage there of. Experience of CRS/TPTY is being
shared in this article.

GROUPING
Once in two years, Samples are welded in down-hand position with manual metal arc welding
process. Samples are prepared out of 8mm thick, IRS-M41 material with `V edge preparation.
3.15mm electrode is used for root run. 4mm A2 class Electrodes are being used for
subsequent passes.
The samples prepared are tested in CMT Laboratory as per IS 7310 (part I)-1974 (re-affirmed
2006). Depending upon the tensile strength of the weld joint welders are classified into any one
of the following groups.
Group

Tensile strength

A
B
C

Kg/mm2
46 and above
42 46
38-42

This system do not measure the skills of the welders in real field application. Skills acquired in
welding of 8mm thick plate may not help a welder to perform better quality side body panel
welding of 2mm thick. Similarly, skills required for CO 2 welding is different from that of arc
welding. Cent percent of the welding applications during POH are not carried out in down hand
welding.

To address the above challenges, it is proposed to focus on individual work area by grouping
the welders, working in that area, duly adopted by a Supervisor. Supervisor will study and
impart practical on the job training during the course of welding itself such that the training will
be focused on that particular application e.g. welding of protective tube, welding of sole bar with
outer headstock beam, side panel welding, welding of SS trough-floor with sole bar etc.
Welding parameters arrived by verifying NIMI(National Instructional media Instructions)
CHENNAI and by observing various workshop practices of parent workshops.

CO2 Welding Parameters

Plate
Thickne
ss in
mm
2
3
5
8

Wire
diamet
er in
mm
0.8
1.2
1.2
1.2

Arc
Voltage
in Volts

Current in
Amps

19-20
20-22
24-26
26-28

80-100
150-160
160-180
200-225

Shield gas
flow LPM

Root
gap in
mm

10-15
10-15
10-15
10-15

Nil
1
2
3

Wire feed
rate
Mtrs/min
5.5
3.10
3.30
3.50

Manual Arc Welding Parameters

Plate
Welder Control Parameters
Electrode dia in
Root gap in
Thickness
mm
mm
in mm
2
2.5
Nil
3
3.15
1
5
4
2.5
8
4
3
Summary: YEAR -2016

Voltage
in volts

Current in
Amps

80
80
80
80

60-80
90-120
120-160
120-160

Grade - A

Grade - B

Grade - C

Total

34

55

35

124

A-GRADE - WELDERS WHO QUALIFIED AT AWTI/ICF/CHENNI

B-GRADE - WELDERS WHO ARE NOT- QUALIFIED AT AWTI/ICF/CHENNI