SECTION IX

Qualifying A Welding Procedures

Essential Variables
All Referenced Section IX Pages are from
the 2001 Edition with Addenda through 03

SECTION IX

When qualifying a welding procedure you must

first determine the important properties of the
planned weldment which then become the
essential variables. The basic ones are;
Base metal to be welded and thickness (T)
required.
Process (es) to be used including filler metal (s).
Preheat.
Postweld heat treatment or the lack of.
Various others based on welding process used.

For this instruction we will use the SMAW Process.

The a brief of Essential, Supplementary Essential
and Non-Essential Variables for the SMAW process
are listed in table QW-253. However this part of the
course will only cover Essential Variables not the
supplementary or non-essentials. Those will be
covered latter. A definition of these variables follows.

Essential Variable A variable that if changed

requires requalification of the procedure by the
welding and testing of a new coupon or support from
a previously qualified Procedure Qualification Record
(PQR), i.e. a change in the base metal thickness (T)
qualified.
Supplementary Essential An essential variable that
is used only when impact testing of a base metal is
required by a construction code, i.e. a change from
one P-No. Group to another such as P1 Gr.1 to Gr.2.
Non-Essential A variable that can be changed as
needed to suit production requirements without
requalification.

QW-253 SMAW Brief of Variables Page 21

We will start our discussion with the top half of the
SMAW brief of variables, beginning with the first
two Essential Variables, Base Metal and Filler
Metal.

Defining Each Essential Variable

Base Metals QW-403.7 Pages 21,58 &159
T/t Limits > 8 inches - this rule only applies at
thickness greater than 8 inches (203 mm) .
Unless you will be welding something over 8
inches this is of little concern. The rule for most
welding procedures is the maximum that can be
welded is 2 times T (the coupon). If you are
welding a coupon over 8 inches you are restricted
to 1.33T or 1.33t, as applicable. 1.33t is the weld
metal thickness, it matters when mixing welding
processes and/or filler metal F-Numbers.

Defining Each Essential Variable

Quiz
1. An 8-1/2 T coupon was welded to produce a
PQR to support welding of a reactor shell course.
The maximum T qualified with this coupon is ___.

Defining Each Essential Variable

Quiz
1. An 8.5 T coupon was welded to produce a PQR
to support welding of a reactor shell course. The
maximum T qualified with this coupon is 11.305.
8.5 X 1.33 = 11.305

Defining Each Essential Variable

Base Metals Pgs. 21, 58,159, &16
Change in Thickness (T) qualified.
QW-403.8 A change in base metal thickness beyond the
range qualified in QW-451, except as otherwise permitted
by QW-202.4(b) (different thickness at joint)
Of concern is the thickness range qualified by the
supporting PQR (s) for the WPS, from less than a 1/16 to
less than 1-1/2 it is 2 x T. To weld a thickness outside the
range supported by the PQR the WPS production welding
changes must be supported by providing an additional
PQR from file or by welding a new PQR test coupon.

Defining Each Essential Variable

Base Metals

Quiz
1. A 1 to 1 P-No.1 coupon was welded
entirely by the SMAW process. The
minimum thickness qualified is ___ and the
maximum is ___

Defining Each Essential Variable

Base Metals

Quiz
1. A 1 to 1 P-No.1 coupon was welded
entirely by the SMAW process. The
minimum thickness qualified is 3/16 and
the maximum is 2.

Defining Each Essential Variable

Base Metals
t (weld metal) pass greater than 1/2 Pages 21 & 58
QW-403.9 For single-pass or multi-pass welding in
which any pass (means layer of weld metal) is
greater than 1/2 in. (13 mm) thick, an increase in
base metal thickness beyond 1.1 times that of the
qualification test coupon.
The thickness range is affected. It will be
restricted to 1.1 T as given above if you deposit
more than 1/2 of weld metal in a single pass
(layer). This has to do with heat input.

Defining Each Essential Variable

A single pass refers to the number of weld
beads required to fill up a layer of weld metal in
the joint. If the single layer/pass, t (deposited
weld metal), exceeds 1/2 in thickness the WPS
will be restricted to 1.1 x T in production
welding.

Defining Each Essential Variable

Quiz
A PQR coupon is 1-1/4(1.250) thick (T). The weld
will be made in two passes, the root pass/layer will
be 1/4 (.250) thick and second and third
layers/passes will be each be 1/2(.500) thick. The
maximum range of thickness for this qualification
will be ________.

Defining Each Essential Variable

Quiz
A PQR coupon is 1-1/4(1.250) thick (T). The weld
will be made in three passes, the root pass/layer
will be 1/4 (.250) thick and second and third
layers/passes will be each be 1/2(.500) thick. The
maximum range of thickness for this qualification
will be 2-1/2 (2.500).
Read closely, the rule states it must exceed 1/2
to be limited to 1.1 x T.

Defining Each Essential Variable

Alternate Base Metals for Procedures
QW-403.11 Pages 21 & 58

Base metals specified in the WPS shall be

qualified by a procedure qualification test
which was made using base metals in
accordance with QW-424.

QW 424 Turn to Page 131

Base Metal (s) Used for Procedure
Qualification Test Coupon Versus
Base Metal Qualified for production

Lets examine some of the items on the table.

One Metal From A P-No. To Any

Metal From The Same P-No.
Such as P1 to P1

One metal from a P-No. To any

metal from any Other P-No. We will Use P
No.1 to P No.8 as an example. Other
combinations are possible, P Nos. 1 to 3, P
Nos.3 to 4 etc.

One metal from P-No. 3 To any

other metal from P-No. 3

One metal from P No. 3 to any

other metal from P No. 3
Also qualifies P No. 3 to P No. 1

However one metal from P No. 3 to any

metal from P No. 3 does not qualify P No. 1
to P No. 1

One metal from P-No. 4 to any

other metal from P-No. 4

One metal from P No.4 to any other metal

from P No.4 also qualifies P No.4 to 4, 3
and, 1

It qualifies one metal from P No. 4 to any

metal from P No. 4, 3 or 1. but does not
qualify P No. 3 to P No. 3 or P No. 1 to P
No.1

Quiz

Using the table list the base metals qualified if

we successfully weld a procedure coupon
joining P No. 5A to No. P 5A

Quiz # 1 - P No. 5A to P No. 5A Qualifies?

P No. 5A to __, __,__, or __. It does
not qualify __, __, or __ to each other
or to their selves.

P- No. 5A to P- No. 5A Qualifies?

P- No. 5A to 5A, 4, 3, or 1. It does not
qualify 4 , 3, or 1 to each other or to
their selves.

Quiz # 2 - P No. 5A to P No. 4, 3, or 1

Qualifies?
P No. 5A to any metal assigned __,__,
or __. It does not qualify __, __, or __
to each other or to their selves.

Quiz # 2 - P No. 5A to P No. 4, 3, or 1

Qualifies?
P No. 5A to any metal assigned 4,3, or
1. It does not qualify 4, 3, or 1 to each
other or to their selves.

Defining Each Essential Variable

Base Metals Pages 21 & 58
Change of P-No. 5/9/10
QW-403.13 A change from one P No. 5 to any
other P-No. 5 (P No. 5A to P No. 5B or P No. 5C or
vice versa). A change from P No. 9A to P No. 9B
but, not vice versa. A change from one P No.10 to
any other P No.10 (P No.10A to P No.10B or P
No.10C, etc., or vice versa).
Simple, P-No. 5/9/10 - A,B,C.., are different PNumbers and require individual qualifications,
(with the exception of 9B to 9A)

Defining Each Essential Variable

Filler Metals
Change of F-Number Pages 21 & 59
QW-404.4 A change from one F-Number in QW432 to any other F-Number or to any other filler
metal not listed in QW-432.
Changing the F-Number to one other than that
used for the procedure test coupon, during the
creation the of the Procedure Qualification Record
(PQR). Such as changing from F-No. 1 to F-No. 3.
This rule also applies to a welders qualification
test by the way.

Defining Each Essential Variable

Filler Metals
QW- 404.5 Change of A-Number Pages 21,59 &
138
A-Nos. are the chemical analysis of the ferrous
weld metal deposits produced by a given filler
metal. Changing A numbers can change the
chemistry and possibly the mechanical properties
of the weld metal. This occurs by changing filler
metals. It also changes the weld add mixture, that
part that contains both base metal and weld metal.
Changing the A No. to one other than that used to
qualify requires a new test or additional PQR (s)
from a file (with one exception).

The below indicates trace amounts

,single values are maximums. i.e. C = 0.20
% max.

Filler Metals
Consider the following filler metals for the SMAW
process.
1. E-7018 which has an A-Number of 1.
2. E-7018 A1 which has an A-Number of 2
Lets compare the chemistry tables from Section II
Part C Filler Metals for these two AWS
Classification SMAW Electrodes/Filler Metals to
the A Numbers of Section IX.

From Section IX QW-442 A No. 1 contains by %

C 0.20/ Cr --/ Mo --/ Ni --/ Mn 1.60/ Si 1.00
From Section II Part C / E-7018 SFA 5.1

From the Section IX QW-442 A No. 2 contains by %

C 0.15 / Cr 0.50/ Mo 0.40 0.65/ Ni --/ Mn 1.60/ Si 1.00
From Section II Part C / E-7018-A1 SFA 5.5

A note on the API Exams

If you are taking any of the three API Exams
you will be required to review a WPS and
PQR. Part of that review might be a
question about the A-Number listed for the
filler metal on the documents. This is a
protest question. You would need ASME
Section II Part C to answer that question.
Sect. II Part C is listed as required for the
exam. You have no way of answering!

For our example we find the following rule,

proving you must read Section IX carefully!
QW-404.5 (Applicable only to ferrous
metals.) A change in the chemical
composition of the weld deposit from one ANumber to any other A-Number in QW- 442.
Qualification with A-No. 1 shall qualify for
A-No. 2 and vice versa. (Note: all other ANo. changes will force re-qualification).

Defining Each Essential Variable

Filler Metals
Change t deposited Pages 21 & 61
QW-404.30 A change in deposited weld metal
thickness beyond the range qualified in QW-451
for procedure qualification.
Example: In a SMAW procedure 1/4 of E-6010
was qualified on the PQR by depositing 1/8 in the
coupon (2t), the balance of the coupon was filled
with E 7018. The need arises to increase the E6010 t to 3/8 in production. This would require a
new coupon or an existing PQR.

Defining Each Essential Variable

Preheat - Turn to Page 21

Defining Each Essential Variable

Preheat - Pages 21 & 62
A decrease in preheat greater than 100 o F
QW-406.1 A decrease of more than 100F (56C)
in the preheat temperature qualified. The minimum
temperature for welding shall be as specified in
the WPS.
Example: A PQR coupon was welded using a
preheat of 250 F but the WPS requires a preheat
of only 100 F. This is a 150 F decrease below
that qualified and will require a new PQR or one
from your files to support the lower temperature.

Defining Each Essential Variable

PWHT

Change in PWHT Pages 21 & 62

QW-407.1 This long paragraph specifies what is

considered a change in post weld heat
treatments.
The changes are P-Number specific with 5
different conditions of PWHT for P Nos. 1,3, 4, 5,
6, 9,10 and, 11.
For all other materials there are two conditions
1. NO PHWT
2. The specified PWHT for the P No. used

Defining Each Essential Variable

PWHT
T Limits (Thickness Limits) Pages 21 & 63
QW-407.4 For a procedure qualification test
coupon receiving a post weld heat treatment in
which the upper transformation temperature is
exceeded, the maximum qualified thickness for
production welds is 1.1 times the thickness of the
test coupon.
This rule only applies when a production weld will undergo
heat treatment at temperature that will alter the base
metals physical properties, such as tempering, etc.

Producing The PQR

We have looked at all of the essential
variables for the SMAW process. Lets put it
all together by filling out a SMAW PQR to
support a Welding Procedure Specification
(WPS). To do this it will be necessary to
specify a list of the essential variables for
the welding we have planned.

Producing The PQR

From QW-253 we need to address the basic
essential variables and they will be:
1. Base Metal (s) 2 SA-516 Gr. 70 Norm. P-No. 1
2. Filler Metal (s) E-7018 Only
3. Preheat 175 o F for P-No.1 (from Sect. VIII Div. 1
non-mandatory Appendix R)
4. PWHT 1100 o F Minimum per inch of thickness
for P-No. 1 (from Sect. VIII Div. 1 UCS-56)

Producing The PQR

Next we define the ranges of the variables:
Base Metal SA-516 Gr.70 Normalized (2max.)
Preheat 175 o F
Then PWHT based on 2 per UCS-56 shall be 1
hour per inch, which in this example = 2 hours.
The next step is to start filling out a Procedure
Qualification Record as if we had actually welded
the coupon. Here is the front of a blank PQR form.

First we will fill out the top half of the

PQR from the company name to the
base metal information on the left side
and include a graphic of the joint
design used to weld the coupon.

Next we will fill out the bottom half of

the PQR with the filler metal and
preheat on the left side. While not
required on the PQR by Section IX
the Non-Essential variables will be
entered as well.

Now we will fill out the upper half of

the PQR with the PWHT metal on the
right side. Making the comment Not
Applicable in the box for Gas, since
the SMAW process does not use
shielding gasses.

Finally the bottom right which consists

of all non-essential variables. Once
again these are not required by
Section IX, but may be helpful for
meeting a construction code
requirement, i.e. Section VIII Div. 1 or
B31.3.

Now we start completing the back of

the PQR. To do so we need some
test results for our required tension
and bend tests. The tension test
specimens are fabricated as given in
Section IX QW-462.1(a). Page 152 .

The required number of tension test

specimens are 2 as shown in Section
IX QW-451.1 Page 139. The required
number of tension specimens are
always two, unless your coupon
exceeds 1, then you are allowed
divide the two specimens into multiple
pieces. (see QW-151.1 (c) and (d) )

The ultimate strength of the tension

specimens must be computed as
described in below in QW-152.
QW-152 Tension Test Procedure
The tension test specimen shall be
ruptured under tensile load. The tensile
strength shall be computed by dividing
the ultimate total load by the least cross
sectional area of the specimen as
calculated from actual measurements
made before the load is applied.

We must measure each specimens

width and thickness after machining as
shown in QW-462.1(a). Section IX
requires two specimens be tested.
The data for our specimens was;
TS1 - width = .750 thickness = .453
TS2 - width = .753 thickness = .456
Area for each specimen.
TS1= .750 x.453 = .340 in.2
TS2= .753 x.456 = .343 in.2
We put the specimens in a tensile tester
like this and pull each one apart;

The specimens were broke in the

tensile tester and the breaking forces as
read from the gage on the machine
were recorded as follows ;
TS1 = 25,010 Lbs.
TS2 = 24,050 Lbs.
Computing the ultimate strength for 1
square inch for each specimen;
Load divided by Area
25,010/.340 = 73,558 PSI
24,050/.343 = 70,116 PSI
We now evaluate the specimens;

Load divided by Area

25,010/.340 = 73,558 PSI
24,050/.343 = 70,116 PSI
Observing the character and location of
the specimen failures, it was noted that
both failed in the base metal outside of
the weld heat affected zones and in a
ductile manner.
We can now record this information on
the back side of the our Procedure
Qualification Record.

But First
We must determine the required
minimum specified strength from
Section IX in the P-Number listings.
Turn to Page 96 of Section IX
We find that SA-516 Grade 70 has a
Minimum Specified Tensile Strength of:
70 KSI = 70,000 Pounds Per Square Inch.

Our tensile specimens exceeded the

minimum. Now we have one more task to
complete. We must do 4 side bend tests.
This requirement is found in Section IX
along with the accept/reject values for all
bend tests. Turn now to Page 139 again.
The required type and number of bend tests
based on a 1 thick coupon are 4 Side Bend
tests. Remember side bends are
mandatory after the coupon thickness
reaches 3/4 or larger.

We must evaluate the bend specimens to

section IX QW-163. Turn now to Page 6.
QW-163 - The guided-bend specimens shall
have no open discontinuity in the weld or
heat-affected zone exceeding 1/8 in. (3.2
mm), measured in any direction on the
convex surface of the specimen after
bending. Open discontinuities.etc.
To see the details for making the bend
specimens look at QW-462.2 Page 156.

We evaluated the bend specimens to

section IX and had the following comments.
Side Bend S1. No open defects acceptable
Side Bend S2. 1/32 acceptable
Side Bend S3. No open defects acceptable
Side Bend S4. No open defects acceptable
We have the correct type based on the
coupon thickness and the correct number of
acceptable side bend tests.

We can now fill out the top back of the PQR.

All that is left is to fill out the bottom of the

back of the PQR. This will be easy, just a
few housekeeping items to complete.

Here is the front side of the complete

Procedure Qualification Record

Here is the back side of the complete

Procedure Qualification Record

The WPS
We have completed the Procedure Qualification
Record, which is a laboratory report of the
welding and testing of a coupon.
From this we will write a Welding Procedure
Specification. It must be in complete agreement
concerning Essential Variables with the PQR.

The WPS
The Welding Procedure Specification, must be
complete. You must address all of the essential,
supplementary essential (if Notch toughness
testing is required), and non-essential variables.
The best approach is through the use of the
Brief of Variables found in QW-253 on Page 21
as an item check list.
We will go line by line and address all of the
Essential and Non-Essential variables since our
WPS will not require Notch toughness testing.

The WPS
Starting in box QW-402 we will address each of
the non-essential variables.

Groove Design
Backing
Root Spacing
Retainers
The following is how it was completed.

The WPS

In box QW-402 we have addressed each of the

non-essential variables as follows;
Groove Design Single Vee, Double Vee, JGroove and, U-Groove
Backing The X in both the Yes and No boxes
denotes that this WPS may be used with or
without backing.
Root Spacing This is given below Details.
Retainers Same as Root Spacing

The WPS
Since we have addressed each of the nonessential variables and thereby giving all the
needed Joint information for making a weldment.
It is complete for joint design and no one
should have to ask what is allowed when using
this WPS.

The WPS

Next QW-403 Base Metals

The WPS
We have addressed each of the essential
variables under Base Metal QW-403.
It is complete for P-No., Thickness range
and the restriction of No t Pass > 1/2 has
been addressed. Supplementary
Essentials need not be addressed, no
impact testing is required of this weldment.

The WPS

Next QW-403 Filler Metals

The WPS
We have addressed each of the essential
variables under Filler Metal QW-404.
It is complete for AWS Classification,
F-No., A-No., Size of Filler Metals, and
Weld Metal Thickness Range. Again no
impact testing is required so the
Supplementary Essentials do not apply.

The WPS
Next the back and top of the WPS
We will now complete the Positions,
Preheat, Electrical, and Postweld Heat
Treatment on the WPS.

The WPS
1. The Positions for use with this WPS are,
Flat, Horizontal, Vertical and, Overhead.
This instructs that this WPS can be used
with all positions.
2. The Preheat minimum is set at 100 o F
which is within 100 o F of the PQR actual
value of 175 o F.
3. The Preheat Maintenance specified as
none required.

The WPS
The Electrical Characteristics are;
1. Direct Current Electrode Positive.
2. Amps are set to a range of 90-190 and
the Volts are set to a range of 15-25,
these values are normally obtained from
the filler metal manufacturers literature or
from actual experience.
3. The rest are not required for SMAW.

The WPS
The Postweld Heat Treatment values are;
1. 1150 +/- 50 o F Which is in agreement
with the PQR minimum value of 1100 o F
2. Time at temperature is 1 hour, also in
agreement with the PQR.
3. Gas variables are not required for
SMAW.

The WPS

We will now complete the bottom half of

the back of the WPS. Which consists of
the Technique box QW-410 only.

The WPS
1. String or Weave, restricted from 2 to 3 core
diameters (core wire exclusive of any coating).
2. Cleaning is limited to Brushing or Grinding.
Back Gouging will be by Air Carbon Arc.
3. Multiple Pass, Manual is entered in the
heading and Peening is not allowed.
4. All others are not SMAW variables.

The Complete WPS Front

The Complete WPS Back