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PART QW
WELDING
ARTICLE I
WELDING GENERAL REQUIREMENTS
14
2013 SECTION IX
QW-121.4 Overhead Position 4G. Plate in a horizontal QW-131.4 Overhead Position 4F. Plates so placed
plane with the weld metal deposited from underneath. Re- that the weld is deposited with its axis horizontal on the
fer to Figure QW-461.3, illustration (d). underside of the horizontal surface and against the verti-
cal surface. Refer to Figure QW-461.5, illustration (d).
QW-122 PIPE POSITIONS
QW-122.1 Flat Position 1G. Pipe with its axis horizon- QW-132 PIPE POSITIONS
tal and rolled during welding so that the weld metal is de- QW-132.1 Flat Position 1F. Pipe with its axis inclined
posited from above. Refer to Figure QW-461.4, illustration at 45 deg to horizontal and rotated during welding so that
(a). the weld metal is deposited from above and at the point of
deposition the axis of the weld is horizontal and the throat
QW-122.2 Horizontal Position 2G. Pipe with its axis
vertical. Refer to Figure QW-461.6, illustration (a).
vertical and the axis of the weld in a horizontal plane.
Pipe shall not be rotated during welding. Refer to QW-132.2 Horizontal Positions 2F and 2FR.
Figure QW-461.4, illustration (b). (a) Position 2F. Pipe with its axis vertical so that the
weld is deposited on the upper side of the horizontal sur-
QW-122.3 Multiple Position 5G. Pipe with its axis
face and against the vertical surface. The axis of the weld
horizontal and with the welding groove in a vertical plane.
will be horizontal and the pipe is not to be rotated during
Welding shall be done without rotating the pipe. Refer to
welding. Refer to Figure QW-461.6, illustration (b).
Figure QW-461.4, illustration (c).
(b) Position 2FR. Pipe with its axis horizontal and the
QW-122.4 Multiple Position 6G. Pipe with its axis in- axis of the deposited weld in the vertical plane. The pipe
clined at 45 deg to horizontal. Welding shall be done with- is rotated during welding. Refer to Figure QW-461.6, illus-
out rotating the pipe. Refer to Figure QW-461.4, tration (c).
illustration (d).
QW-132.3 Overhead Position 4F. Pipe with its axis
vertical so that the weld is deposited on the underside
QW-123 TEST POSITIONS FOR STUD WELDS of the horizontal surface and against the vertical
QW-123.1 Stud Welding. Stud welds may be made in surface. The axis of the weld will be horizontal and the
test coupons oriented in any of the positions as described pipe is not to be rotated during welding. Refer to
in QW-121 for plate and QW-122 for pipe (excluding Figure QW-461.6, illustration (d).
QW-122.1). In all cases, the stud shall be perpendicular QW-132.4 Multiple Position 5F. Pipe with its axis
to the surface of the plate or pipe. See Figures QW-461.7 horizontal and the axis of the deposited weld in the verti-
and QW-461.8. cal plane. The pipe is not to be rotated during welding. Re-
fer to Figure QW-461.6, illustration (e).
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2013 SECTION IX
ð13Þ QW-191.2.2 Personnel Qualifications and Certifica- Every other welding stud (five joints) shall be tested
tions. either by hammering over until one‐fourth of its length
(a) All personnel performing ultrasonic examinations is flat on the test piece, or by bending the stud to an angle
for welder and welding operator qualifications shall be of at least 15 deg and returning it to its original position
qualified and certified in accordance with their employer’s using a test jig and an adapter location dimension that
written practice. are in accordance with Figure QW-466.4.
(b) The employer’s written practice for qualification The remaining five welded stud joints shall be tested in
and certification of examination personnel shall meet all torque using a torque testing arrangement that is substan-
applicable requirements of SNT-TC-1A1 for the examina- tially in accordance with Figure QW-466.5. Alternatively,
tion method and technique. where torquing is not feasible, tensile testing may be used,
(c) Alternatively, the ASNT Central Certification Pro- and the fixture for tensile testing shall be similar to that
gram (ACCP) or CP-1891 may be used to fulfill the exam- shown in Figure QW-466.6, except that studs without
ination and demonstration requirements of SNT-TC-1A heads may be gripped on the unwelded end in the jaws
and the employer’s written practice. of the tensile testing machine.
(d) Provisions for the training, experience, qualification, QW-192.1.2 Acceptance Criteria — Bend and
and certification of NDE personnel shall be described in Hammer Tests. In order to pass the test(s), each of the five
the Manufacturer’s Quality Control System. stud welds and heat‐affected zones shall be free of visible
QW-191.2.3 Acceptance Criteria for Qualification separation or fracture after bending and return bending or
Test Welds. Indications shall be sized using the applicable after hammering.
technique(s) provided in the written procedure for the ex- QW-192.1.3 Acceptance Criteria — Torque Tests.
amination method. Indications shall be evaluated for ac- In order to pass the test(s), each of the five stud welds
ceptance as follows: shall be subjected to the required torque shown in the fol-
(a) All indications characterized as cracks, lack of fu- lowing table before failure occurs.
sion, or incomplete penetration are unacceptable regard-
less of length. Required Torque for Testing Threaded Carbon Steel Studs
(b) Indications exceeding 1/8 in. (3 mm) in length are Nominal Diameter Threads/in. and Testing Torque,
considered relevant, and are unacceptable when their of Studs, in. (mm) Series Designated ft‐lb (J)
lengths exceed 1
/4 (6.4) 28 UNF 5.0 (6.8)
(1) 1/8 in. (3 mm) for t up to 3/8 in. (10 mm). 1
/4 (6.4) 20 UNC 4.2 (5.7)
(2) 1/3t for t from 3/8 in. to 21/4 in. (10 mm to 57 mm). 5
/16 (7.9) 24 UNF 9.5 (12.9)
(3) 3/4 in. (19 mm) for t over 21/4 in. (57 mm), where t 5
/16 (7.9) 18 UNC 8.6 (11.7)
is the thickness of the weld excluding any allowable rein-
3
forcement. For a butt weld joining two members having /8 (9.5) 24 UNF 17 (23.0)
3
different thicknesses at the weld, t is the thinner of these /8 (9.5) 16 UNC 15 (20.3)
two thicknesses. If a full penetration weld includes a fillet 7
/16 (11.1) 20 UNF 27 (36.6)
weld, the thickness of the throat of the fillet shall be in- 7
/16 (11.1) 14 UNC 24 (32.5)
cluded in t . 1
/2 (12.7) 20 UNF 42 (57.0)
QW-191.2.4 Acceptance Criteria for Production 1
/2 (12.7) 13 UNC 37 (50.2)
Welds. The acceptance criteria for welders or welding op- 9
/16 (14.3) 18 UNF 60 (81.4)
erators who qualify on production welds by ultrasonic ex- 9
/16 (14.3) 12 UNC 54 (73.2)
amination as permitted in QW-304.1 or QW-305.1 shall be
5
per QW-191.2.3. /8 (15.9) 18 UNF 84 (114.0)
5
/8 (15.9) 11 UNC 74 (100.0)
QW-191.3 Record of Tests. The results of welder and
3
welding operator performance tests evaluated by volu- /4 (19.0) 16 UNF 147 (200.0)
3
/4 (19.0) 10 UNC 132 (180.0)
metric NDE shall be recorded in accordance with
QW-301.4. 7
/8 (22.2) 14 UNF 234 (320.0)
7
/8 (22.2) 9 UNC 212 (285.0)
QW-192 STUD‐WELD TESTS
1 (25.4) 12 UNF 348 (470.0)
QW-192.1 Procedure Qualification Specimens. 1 (25.4) 8 UNC 318 (430.0)
QW-192.1.1 Required Tests. Ten stud‐weld tests
are required to qualify each procedure. The equipment
used for stud welding shall be completely automatic ex-
cept for manual starting.
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2013 SECTION IX
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2013 SECTION IX
QW-203 LIMITS OF QUALIFIED POSITIONS FOR QW-216.1 The size of test coupons, limits of qualifica-
PROCEDURES tion, required examinations and tests, and test specimens
shall be as specified in Table QW-453.
Unless specifically required otherwise by the welding
variables (QW-250), a qualification in any position quali- QW-216.2 Welding variables shall be as specified in
fies the procedure for all positions. The welding process QW-250 for the applicable process.
and electrodes must be suitable for use in the positions
QW-216.3 Where Spray Fuse methods of hard‐facing
permitted by the WPS. A welder or welding operator mak-
(e.g., Oxyfuel and Plasma Arc) are to be used, the coupons
ing and passing the WPS qualification test is qualified for
for these methods shall be prepared and welding variables
the position tested. see QW-301.2.
applied in accordance with QW-216.1 and QW-216.2,
respectively.
QW-210 PREPARATION OF TEST COUPON QW-216.4 If a weld deposit is to be used under a
QW-211 BASE METAL hard‐facing weld metal overlay, a base metal with an as-
signed P‐Number and a chemical analysis nominally
The base metals may consist of either plate, pipe, or matching the weld deposit chemical analysis may be sub-
other product forms. Qualification in plate also qualifies stituted to qualify the PQR.
for pipe welding and vice versa. The dimensions of the test
coupon shall be sufficient to provide the required test
specimens. QW-217 JOINING OF COMPOSITE (CLAD METALS)
The WPS for groove welds in clad metal shall be quali-
QW-212 TYPE AND DIMENSIONS OF GROOVE fied as provided in (a) when any part of the cladding thick-
WELDS ness, as permitted by the referencing Code Section, is
Except as otherwise provided in QW-250, the type and included in the design calculations. Either (a) or (b) may
dimensions of the welding groove are not essential be used when the cladding thickness is not included in
variables. the design calculations.
(a) The essential and nonessential variables of QW-250
QW-214 CORROSION‐RESISTANT WELD METAL shall apply for each welding process used in production.
OVERLAY The procedure qualification test coupon shall be made
QW-214.1 The size of test coupons, limits of qualifica- using the same P‐Number base metal, cladding, and
tion, required examinations and tests, and test specimens welding process, and filler metal combination to be used
shall be as specified in Table QW-453. in production welding. For metal not included in
Table QW/QB-422, the metal used in the composite test
QW-214.2 Essential variables shall be as specified in plate shall be within the range of chemical composition
QW-250 for the applicable welding process. of that to be used in production. The qualified thickness
range for the base metal and filler metal(s) shall be based
QW-215 ELECTRON BEAM WELDING AND LASER on the actual test coupon thickness for each as applied to
BEAM WELDING QW-451, except that the minimum thickness of filler metal
QW-215.1 The WPS qualification test coupon shall be joining the cladding portion of the weldment shall be
prepared with the joint geometry duplicating that to be based on a chemical analysis performed in accordance
used in production. If the production weld is to include with Table QW-453. Tensile and bend tests required in
a lap‐over (completing the weld by rewelding over the QW-451 for groove welds shall be made, and they shall
starting area of the weld, as for a girth weld), such lap‐over contain the full thickness of cladding through the reduced
shall be included in the WPS qualification test coupon. section of the specimen. The bond line between the
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2013 SECTION IX
original cladding and the base metal may be disregarded the WPS for two variables, the first variable with a toler-
when evaluating side‐bend tests if the cladding was ap- ance shall be set at the midpoint of its tolerance and two
plied by a process other than fusion welding. test coupons shall be welded with each of the upper and
(b) The essential and nonessential variables of QW-250 lower extremes of the tolerance for the second variable
shall apply for each welding process used in production (i.e., four coupons must be welded). These coupons shall
for joining the base metal portion of the weldment. The be examined and tested in accordance with QW-199.1.3.
PQRs that support this portion of the WPS need not be If it is desired to provide tolerance for a third variable,
based on test coupons made with clad metal. For the the first two variables shall be set at the midpoint of their
corrosion‐resistant overlay portion of the weld, the essen- tolerance, and two test coupons shall be welded with each
tial variables of QW-251.4 shall apply and the test coupon of the upper and lower extremes of the new tolerances for
and testing shall be in accordance with Table QW-453. the third variable (i.e., four coupons must be welded).
The WPS shall limit the depth of the groove, which will re- These coupons shall be examined and tested in accordance
ceive the corrosion‐resistant overlay in order to ensure with QW-199.1.3.
development of the full strength of the underlying weld No more than three essential variables on a WPS may
in the base metal. show tolerances.
Production tests conducted in accordance with the re-
QW-218 APPLIED LININGS quirements of other Sections may be used to satisfy this
QW-218.1 WPSs for attaching applied linings shall be requirement.
qualified in accordance with QW-202.2(a), QW-202.2(b),
or QW-202.2(c).
QW-218.2 As an alternative to the above, each process QW-220 HYBRID LASER-GMAW WELDING ð13Þ
to be used in attaching applied linings to base metal shall
Hybrid laser-GMAW is limited to the combination of
be qualified on a test coupon welded into the form and
automatic LBW and automatic GMAW. The GMAW process
arrangement to be used in construction using materials
shall not be applied using the short-circuiting arc transfer
that are within the range of chemical composition of the
mode.
metal to be used for the base plate, the lining, and the
weld metal. The welding variables of QW-250 shall apply All hybrid laser-GMAW procedures for welding groove
except for those regarding base metal or weld metal thick- and fillet welds shall be qualified in accordance with the
ness. Qualification tests shall be made for each position to rules in QW-202. Table QW-268 lists the essential, supple-
be used in production welding in accordance with mentary essential, and nonessential variables that apply
Table QW-461.9, except that qualification in the vertical for hybrid laser-GMAW qualification.
position, uphill progression shall qualify for all positions.
One cross‐section for each position tested shall be sec- QW-221 HYBRID PLASMA-GMAW ð13Þ
tioned, polished, and etched to clearly show the demarca- When the applicable Code Section specifies the use of
tion between the base metal and the weld metal. In order this paragraph for utilizing the hybrid plasma-GMAW pro-
to be acceptable, each specimen shall exhibit complete fu- cess, QW-221.1 through QW-221.3 shall apply.
sion of the weld metal with the base metal and freedom
from cracks. QW-221.1 Qualification. All hybrid plasma-GMAW
procedures for groove and fillet welds shall be qualified
QW-218.3 When chemical analysis of the weld deposit
in accordance with the rules outlined in QW-202. All hy-
for any elements is required, a chemical analysis shall be
brid plasma-GMAW procedures for corrosion-resistant
performed per Table QW-453, Note 9 for those elements.
overlay shall be qualified in accordance with the rules out-
QW-219 FLASH WELDING lined in QW-214. All hybrid plasma-GMAW procedures for
hard-facing overlay shall be qualified in accordance with
Flash welding shall be limited to automatic electrical re- the rules outlined in QW-216.
sistance flash welding. Procedure qualification tests shall
be conducted in accordance with QW-199.1. QW-221.2 Welding Process Restriction. Hybrid
plasma-GMAW is limited to the combination of PAW and
QW-219.1 Tolerances on Variables . Flash welding
GMAW. The hybrid process is limited to machine welding
variables that may require adjustment during production
only.
welding are synergistically related. Accordingly, even
though the variables shown in Table QW-265 provide tol- QW-221.3 Variables for Hybrid Plasma-GMAW.
erances on many welding variables, the WPS shall specify Table QW-269 lists the essential, supplementary essential,
the same specific variables shown on the PQR with toler- and nonessential variables that apply when hybrid
ance shown for no more than one variable (e.g., if it is de- plasma-GMAW qualification is required for groove and fil-
sired to provide a tolerance on the upset current, all other let welds. Table QW-269.1 lists the special process essen-
variables shown on the WPS must be the same as they are tial and nonessential variables associated with hardfacing
shown on the PQR). If it is desired to provide tolerances in and corrosion resistant overlay (CRO).
31