Sui Northern Gas Pipelines Limited

What is Welding? What is Welding?

Process of joining metal parts together by heating
surfaces to melting point
By means of blow pipe, electric arc or other methods
Process of joining metals or thermoplastics by
causing coalescence.
This joining of metals may be achieved with or
without a filler metal
The fusion may be achieved by the application of
pressure and temperature
Process of joining metal parts together by heating
surfaces to melting point
By means of blow pipe, electric arc or other methods
Process of joining metals or thermoplastics by
causing coalescence.
This joining of metals may be achieved with or
without a filler metal
The fusion may be achieved by the application of
pressure and temperature
Welding objectives Welding objectives
Metallurgical capacity
The parent metal and weld metal should join without formation
of deleterious constituents or alloys
Mechanical soundness
The weld should be free defects/ discontinuities, gas porosity,
shrinkage, slag or crack etc and the weld should exhibit the
mechanical properties of the base metal or better
Serviceability
The weld should be able to perform in the service conditions,
which may be extreme temperatures, corrosive environment,
fatigue or high pressures
We will study how to achieve these objective, but first a few terms
and concepts
Metallurgical capacity
The parent metal and weld metal should join without formation
of deleterious constituents or alloys
Mechanical soundness
The weld should be free defects/ discontinuities, gas porosity,
shrinkage, slag or crack etc and the weld should exhibit the
mechanical properties of the base metal or better
Serviceability
The weld should be able to perform in the service conditions,
which may be extreme temperatures, corrosive environment,
fatigue or high pressures
We will study how to achieve these objective, but first a few terms
and concepts
Welding Glossary Welding Glossary
WELD
A complete weld joining two piece of metal or plastic,
pipes, section of pipe to fittings or two fitting
WELDER
A person who make the weld (Man or machine)
POSITION WELDING
Welding in which work piece, pipe or assembly is not
rotating while the weld is being deposited
ROLL WELDING
Welding in which pipe or assembly is rotated while the
welding is being deposited
WELD
A complete weld joining two piece of metal or plastic,
pipes, section of pipe to fittings or two fitting
WELDER
A person who make the weld (Man or machine)
POSITION WELDING
Welding in which work piece, pipe or assembly is not
rotating while the weld is being deposited
ROLL WELDING
Welding in which pipe or assembly is rotated while the
welding is being deposited
Welding Glossary Welding Glossary
DEFECT
Any discontinuity of sufficient magnitude to warrant
rejection of the weld
QUALIFIED WELDER
A welder, man or machine, who has demonstrated the
ability of produce sound welds
QUALIFIED WELDING PROCEDURE
A tested and proven detailed method by which sound
welds can be produced with the required mechanical
properties
DEFECT
Any discontinuity of sufficient magnitude to warrant
rejection of the weld
QUALIFIED WELDER
A welder, man or machine, who has demonstrated the
ability of produce sound welds
QUALIFIED WELDING PROCEDURE
A tested and proven detailed method by which sound
welds can be produced with the required mechanical
properties
Welding Glossary Welding Glossary
MECHANIZED WELDING
A process where parameters and torch guidance are
controlled mechanically or electronically but may be
manually varied during welding to maintain specified
welding conditions and the welding gun is held by a
manipulator
SEMI AUTOMATIC WELDING
Arc welding with equipment which controls the filler metal
feed while the welding advance is controlled manually
AUTOMATIC WELDING
Arc welding with equipment which performs the entire
welding without any manual manipulation of the arc or
electrode other than guiding or tracking or without skill
MECHANIZED WELDING
A process where parameters and torch guidance are
controlled mechanically or electronically but may be
manually varied during welding to maintain specified
welding conditions and the welding gun is held by a
manipulator
SEMI AUTOMATIC WELDING
Arc welding with equipment which controls the filler metal
feed while the welding advance is controlled manually
AUTOMATIC WELDING
Arc welding with equipment which performs the entire
welding without any manual manipulation of the arc or
electrode other than guiding or tracking or without skill
Welding Glossary Welding Glossary
VOLTAGE
Voltage, also called EMF, is potential difference between
two points in an electrical field
DIRECT VOLTAGE
Maintains the polarity at all times
ALTERNATING VOLTAGE
The polarity reverses direction periodically
ARC
The area in which the current jumps from electrode to the
work piece. The heat generated by the arc melts the
electrode and the base metal
VOLTAGE
Voltage, also called EMF, is potential difference between
two points in an electrical field
DIRECT VOLTAGE
Maintains the polarity at all times
ALTERNATING VOLTAGE
The polarity reverses direction periodically
ARC
The area in which the current jumps from electrode to the
work piece. The heat generated by the arc melts the
electrode and the base metal
Welding Glossary Welding Glossary
ARC LENGTH
The distance the arc stretches from electrode to the base
metal. The greater the distance, the greater the voltage
required to maintain the arc
ARC BLOW
A condition where the arc does not follow its intended
path between electrode and work piece. It results in weld
beads in unwanted positions
BASE METAL
Metals to be welded together to form a joint
ARC LENGTH
The distance the arc stretches from electrode to the base
metal. The greater the distance, the greater the voltage
required to maintain the arc
ARC BLOW
A condition where the arc does not follow its intended
path between electrode and work piece. It results in weld
beads in unwanted positions
BASE METAL
Metals to be welded together to form a joint
Welding Glossary Welding Glossary
FILLER METAL
The metal rod, wire used to prevent the weld from
starvation in fusion welding.
FLUX
A non metallic material used to protect the weld puddle
from atmospheric contaminants
CONSTANT CURRENT
Welding using current that varies only slightly with the
change in voltage. It is commonly used in SMAW and
GTAW
FILLER METAL
The metal rod, wire used to prevent the weld from
starvation in fusion welding.
FLUX
A non metallic material used to protect the weld puddle
from atmospheric contaminants
CONSTANT CURRENT
Welding using current that varies only slightly with the
change in voltage. It is commonly used in SMAW and
GTAW
Welding Glossary Welding Glossary
CONSTANT VOLTAGE
Welding using voltage that varies only slightly with the
change in current. It is commonly used in GMAW and
FCAW
CONSUMEABLE ELECTRODE
An electrode that conducts electricity to the arc but also
melts in the process to provide filler metal.
DUTY CYCLE
The amount to time in a 10 minute period that a welder
can continuously weld without over heating
CONSTANT VOLTAGE
Welding using voltage that varies only slightly with the
change in current. It is commonly used in GMAW and
FCAW
CONSUMEABLE ELECTRODE
An electrode that conducts electricity to the arc but also
melts in the process to provide filler metal.
DUTY CYCLE
The amount to time in a 10 minute period that a welder
can continuously weld without over heating
Welding Glossary Welding Glossary
PENETRATION
The distance below the surface of the base metal that an
arc heat can melt in a joint. It is directly related to the
current
RESISTANCE
The opposition to flow of current. This is what cause the
current to produce the heat.
POLARITY
The direction of current flow in a DC Circuit
PENETRATION
The distance below the surface of the base metal that an
arc heat can melt in a joint. It is directly related to the
current
RESISTANCE
The opposition to flow of current. This is what cause the
current to produce the heat.
POLARITY
The direction of current flow in a DC Circuit
WELDING TEST POSITIONS WELDING TEST POSITIONS
1G (Flat Position)
The axis of pipe is
horizontal
Pipe is rotated
Weld is made from
above
In case of plate weld,
the 1G position refers
to a flat weld with weld
made from above
1G (Flat Position)
The axis of pipe is
horizontal
Pipe is rotated
Weld is made from
above
In case of plate weld,
the 1G position refers
to a flat weld with weld
made from above
WELDING TEST POSITIONS WELDING TEST POSITIONS
2G (Horizontal
Position)
The axis of pipe is
Vertical
Pipe is fixed, does not
rotate
Weld is made in
horizontal plane with
axis of welding in
horizontal plane
Same is true for plate
2G (Horizontal
Position)
The axis of pipe is
Vertical
Pipe is fixed, does not
rotate
Weld is made in
horizontal plane with
axis of welding in
horizontal plane
Same is true for plate
WELDING TEST POSITIONS WELDING TEST POSITIONS
3G / 5G (Vertical
Position)
Plate in vertical plane/
Pipe in horizontal plane
Weld deposited with out
pipe rotation
Axis of weld in vertical
plane for both plate and
pipe
3G / 5G (Vertical
Position)
Plate in vertical plane/
Pipe in horizontal plane
Weld deposited with out
pipe rotation
Axis of weld in vertical
plane for both plate and
pipe
WELDING TEST POSITIONS WELDING TEST POSITIONS
4G (Over Head)
Plate is in horizontal
plane
Weld is deposited from
beneath
4G (Over Head)
Plate is in horizontal
plane
Weld is deposited from
beneath
WELDING TEST POSITIONS WELDING TEST POSITIONS
6G (Multiple Position)
The axis of pipe is at 45
deg to horizontal
Pipe is fixed, does not
rotate
6G (Multiple Position)
The axis of pipe is at 45
deg to horizontal
Pipe is fixed, does not
rotate
Welding Polarity Welding Polarity
Polarity is defined as the direction of current flow in
a DC Circuit
In case of AC, the direction of current reverses every
half cycle, usually 120 times in a second in a 60 Hz
power supply system
In case of DC system, the current flows in one
direction
This direction is either straight or reverse depending
upon the welding circuit
Polarity is defined as the direction of current flow in
a DC Circuit
In case of AC, the direction of current reverses every
half cycle, usually 120 times in a second in a 60 Hz
power supply system
In case of DC system, the current flows in one
direction
This direction is either straight or reverse depending
upon the welding circuit
Welding Polarity Welding Polarity
The flow of current in an electrical circuit is from
negative terminal of the power source, say battery,
to the positive terminal.
Electrons being negatively charged particles available
freely in metals/ conductors flow towards the
positive terminal, constituting the flow of current
The flow of current in an electrical circuit is from
negative terminal of the power source, say battery,
to the positive terminal.
Electrons being negatively charged particles available
freely in metals/ conductors flow towards the
positive terminal, constituting the flow of current
Welding Polarity Welding Polarity
Based on this flow of
current, two
configurations are
possible
Electrode is connected
to negative terminal,
work piece to positive
Electrode is connected
to positive terminal,
work piece to negative
terminal
When Electrode is
connected to negative
terminal, it is called
straight polarity, or
DCSP, DCEN
When connections are
reversed, it is called
Reverse Polarity, or
DCRP or DCEP
Based on this flow of
current, two
configurations are
possible
Electrode is connected
to negative terminal,
work piece to positive
Electrode is connected
to positive terminal,
work piece to negative
terminal
When Electrode is
connected to negative
terminal, it is called
straight polarity, or
DCSP, DCEN
When connections are
reversed, it is called
Reverse Polarity, or
DCRP or DCEP
Welding Polarity Welding Polarity
Straight Polarity DCEN
Electrode is connected
to Negative Terminal of
the power source and
work piece is connected
to the positive terminal.
The current flows from
the electrode into the
work piece
Straight Polarity DCEN
Electrode is connected
to Negative Terminal of
the power source and
work piece is connected
to the positive terminal.
The current flows from
the electrode into the
work piece
Welding Polarity Welding Polarity
Straight Polarity
In this case 2/3 heat is
produced at the electrode
and 1/3 is produced at the
work piece
With DCSP, the electrode
melts quickly and deposits
filler metal at a faster rate
Penetration is low and
therefore used for welding
thin metals and sheet
fabrication
Straight Polarity
In this case 2/3 heat is
produced at the electrode
and 1/3 is produced at the
work piece
With DCSP, the electrode
melts quickly and deposits
filler metal at a faster rate
Penetration is low and
therefore used for welding
thin metals and sheet
fabrication
Welding Polarity Welding Polarity
Reverse Polarity DCEP
Electrode is connected
to the positive terminal
of the power source and
the work piece to the
negative
Current flows from the
work piece into the
electrode
Reverse Polarity DCEP
Electrode is connected
to the positive terminal
of the power source and
the work piece to the
negative
Current flows from the
work piece into the
electrode
Welding Polarity Welding Polarity
Reverse Polarity DCEP
In this case 2/3 heat is
produced at work piece
while 1/3 is produced at
electrode
This results in a lower
deposition rate but a
deeper penetration
Most stick weld
electrode are designed
to work with DCEN
Reverse Polarity DCEP
In this case 2/3 heat is
produced at work piece
while 1/3 is produced at
electrode
This results in a lower
deposition rate but a
deeper penetration
Most stick weld
electrode are designed
to work with DCEN
JOINT TYPES JOINT TYPES
AWS defines joint as the
way in which materials
fit together
Butt Joints
T Joint
Lap Joint
Corner Joint
Edge Joint
AWS defines joint as the
way in which materials
fit together
Butt Joints
T Joint
Lap Joint
Corner Joint
Edge Joint
TYPE OF BUTT JOINTS TYPE OF BUTT JOINTS
There are several types
of butt joints:
Square Groove
Bevel Groove
V Groove
J Groove &
U Groove
There are several types
of butt joints:
Square Groove
Bevel Groove
V Groove
J Groove &
U Groove
Butt Joint Butt Joint
A joint between two
members aligned
approximately in the
same plane
LAP Joint LAP Joint
A joint between two
overlapping members
T Joint T Joint
A joint between two
members located
approximately at right
angles to each other
Corner Joint Corner Joint
A joint between two
members located at
right angles to each
other
Basic Components of welding symbol Basic Components of welding symbol
Reference Line (Required element)
Tail
Reference Line must always be horizontal,
Arrow points to the line or lines on drawing which clearly
identify the proposed joint or weld area.
Welding Symbol terminology Welding Symbol terminology
ARROW SIDE
OTHER SIDE
Fillet Weld (Both sides)
Fillet Weld (Arrow Side Only)
Welding Structure/ Joint Design Welding Structure/ Joint Design
Joint Preparation
The source of joint design
is from API 1104
Follows the penny land
& penny gap situation
Penny Land refers to
thickness of root face
Gap refers to the root gap
A 60 Deg included angle is
used
Joint Preparation
The source of joint design
is from API 1104
Follows the penny land
& penny gap situation
Penny Land refers to
thickness of root face
Gap refers to the root gap
A 60 Deg included angle is
used
Welding Joint Cleaning Welding Joint Cleaning
Weld joint preparation is one of the most important
areas associated with welding
The pipe is rarely received in a condition ready for
welding
Usually, it will contain contaminants like dirt, grease,
paint, primer, epoxy or other organic substances
from days of holding in possible open atmosphere
Cleanliness is critical to prevent defects leading to
weld repairs which are often costly and cumbersome
Weld joint preparation is one of the most important
areas associated with welding
The pipe is rarely received in a condition ready for
welding
Usually, it will contain contaminants like dirt, grease,
paint, primer, epoxy or other organic substances
from days of holding in possible open atmosphere
Cleanliness is critical to prevent defects leading to
weld repairs which are often costly and cumbersome
Welding Joint Cleaning Welding Joint Cleaning
In order to prevent defects during welding, the
following should be taken care of:
Remove moisture and condensation, usually done by
heating with a torch
Both ends must be cleaned on inside and outside
surfaces. At least 1 beyond edge of bevel
One method of cleaning the pipe is with an angle
grinder with an abrasive grinding disc or with the a
power brush or by using a half round file
For multi pass welding, ensure that the weld is free
of slag after each pass by using a power brush to
remove slag, spatter etc.
In order to prevent defects during welding, the
following should be taken care of:
Remove moisture and condensation, usually done by
heating with a torch
Both ends must be cleaned on inside and outside
surfaces. At least 1 beyond edge of bevel
One method of cleaning the pipe is with an angle
grinder with an abrasive grinding disc or with the a
power brush or by using a half round file
For multi pass welding, ensure that the weld is free
of slag after each pass by using a power brush to
remove slag, spatter etc.
HOW DOES THE WELDING PROCESS HOW DOES THE WELDING PROCESS
START START
The welding process takes a start when a detailed
process of welding is created taking into
consideration the details of materials to welded, the
condition for which these welds will be made in, the
requirement of filler metals, the design of joints, the
speed of welding required etc.
This detailed procedure is called Proposed Welding
Procedure Specification or SWPS
The welding process takes a start when a detailed
process of welding is created taking into
consideration the details of materials to welded, the
condition for which these welds will be made in, the
requirement of filler metals, the design of joints, the
speed of welding required etc.
This detailed procedure is called Proposed Welding
Procedure Specification or SWPS
PWPS QUALIFICATION PWPS QUALIFICATION
Before production welding can be started, this PWPS
needs to be qualified to demonstrate that weld of
suitable mechanical properties and soundness can be
made by the procedure
The quality of welds is determined by destructive
testing of joint made using the procedure
The results of testing are recorded in the form of
PQR Procedure Qualification Record
These PQR shall be retained as long as the procedure
is in use with in the company
Before production welding can be started, this PWPS
needs to be qualified to demonstrate that weld of
suitable mechanical properties and soundness can be
made by the procedure
The quality of welds is determined by destructive
testing of joint made using the procedure
The results of testing are recorded in the form of
PQR Procedure Qualification Record
These PQR shall be retained as long as the procedure
is in use with in the company
What information Should a PWPS What information Should a PWPS
include? include?
Process, Manual, Semi Automatic, Mechanized or
Automatic
Materials
Grouping of materials is allowed provided the test is made
on the materials with highest SMYS in the group
Diameters and Wall thicknesses
Joint Design
Size and classification of filler metal and minimum
number and sequence of beads
Process, Manual, Semi Automatic, Mechanized or
Automatic
Materials
Grouping of materials is allowed provided the test is made
on the materials with highest SMYS in the group
Diameters and Wall thicknesses
Joint Design
Size and classification of filler metal and minimum
number and sequence of beads
What information Should a PWPS What information Should a PWPS
include? (Continued) include? (Continued)
Electrical characteristics
Current and Polarity should be specified along with range
of voltage and amperage for each electrode rod or wire
shall be specified
Flame Characteristics
Neutral, carburizing, oxidizing
Position
Direction of welding, Uphill or down
Time between passes, between root and next and
time between passes
Electrical characteristics
Current and Polarity should be specified along with range
of voltage and amperage for each electrode rod or wire
shall be specified
Flame Characteristics
Neutral, carburizing, oxidizing
Position
Direction of welding, Uphill or down
Time between passes, between root and next and
time between passes
What information Should a PWPS What information Should a PWPS
include? (Continued) include? (Continued)
Type and Removal of Line Up Clamp
Cleaning and/ or Grinding (Choice between power
and hand tools)
Heat Treatment (Pre/ Post)
Shielding Gas and its flow rate
Shielding Flux
Speed or Travel (IPM)
Type and Removal of Line Up Clamp
Cleaning and/ or Grinding (Choice between power
and hand tools)
Heat Treatment (Pre/ Post)
Shielding Gas and its flow rate
Shielding Flux
Speed or Travel (IPM)
Essential Variables Essential Variables
Welding procedure must be reestablished as a new
procedure specification and must be completely
prequalified when any of the essential variable
undergo a change
Changes in variable other than the essential variables
may be made in the procedure without the need for
requalification provided the welding procedure
specification is modified to reflect these changes
Welding procedure must be reestablished as a new
procedure specification and must be completely
prequalified when any of the essential variable
undergo a change
Changes in variable other than the essential variables
may be made in the procedure without the need for
requalification provided the welding procedure
specification is modified to reflect these changes
Essential Variables Essential Variables
Welding process and the method of application
Base material
Any change in base metal requires requalification of the
welding procedure
Case in Point: An equal Tee WPHY 56 is to be Welded
to Run Pipe with API 5L X 70 specifications??????
WHAT WELDING PROCEDURE WOULD YOU USE?
Welding process and the method of application
Base material
Any change in base metal requires requalification of the
welding procedure
Case in Point: An equal Tee WPHY 56 is to be Welded
to Run Pipe with API 5L X 70 specifications??????
WHAT WELDING PROCEDURE WOULD YOU USE?
Essential Variables Essential Variables
In case two different metals are being welded together, the
procedure for higher strength group shall be used.
Within the scope of API 1104, grouping of materials is
allowed as follows
SMYS <= 42 Ksi
42 Ksi < SMYS < 65 Ksi
For materials with SMYS > 65 Ksi, each material should receive a
separate qualification test
Joint Design
A change from, say V Groove to U Groove requires a
requalification, change in bevel angle of from, say 30 to 35
deg does not.
In case two different metals are being welded together, the
procedure for higher strength group shall be used.
Within the scope of API 1104, grouping of materials is
allowed as follows
SMYS <= 42 Ksi
42 Ksi < SMYS < 65 Ksi
For materials with SMYS > 65 Ksi, each material should receive a
separate qualification test
Joint Design
A change from, say V Groove to U Groove requires a
requalification, change in bevel angle of from, say 30 to 35
deg does not.
Essential Variables Essential Variables
Position
Change from roll to fixed or vise versa
Wall thickness
Change of group constitutes an essential variable
CASE IN POINT: our equal tee WPHY 56 has a wall
thickness of 0.812, while the pipe run of X 70 grade
has a wall thickness of 0.625. Which welding
procedure is to be used? If both were of same grade,
would the same procedure be applicable on both
wall thicknesses?
Position
Change from roll to fixed or vise versa
Wall thickness
Change of group constitutes an essential variable
CASE IN POINT: our equal tee WPHY 56 has a wall
thickness of 0.812, while the pipe run of X 70 grade
has a wall thickness of 0.625. Which welding
procedure is to be used? If both were of same grade,
would the same procedure be applicable on both
wall thicknesses?
Essential Variables Essential Variables
API 1104 allows grouping of wall thicknesses as
follows:
WT < 0.188
0.188 < WT < 0.750
WT > 0.750
Any change of WT group requires requalification of the welding
procedure.
API 1104 allows grouping of wall thicknesses as
follows:
WT < 0.188
0.188 < WT < 0.750
WT > 0.750
Any change of WT group requires requalification of the welding
procedure.
Essential Variables Essential Variables
Filler Metal
A change in filler metal
group
For pipes with SMYS >=
65 Ksi, change in AWS
classification of filler
metal requires
requalification
Changes in filler metal within group
are allowed. However mechanical
properties of base metal should
be kept in mind.
Filler Metal
A change in filler metal
group
For pipes with SMYS >=
65 Ksi, change in AWS
classification of filler
metal requires
requalification
Changes in filler metal within group
are allowed. However mechanical
properties of base metal should
be kept in mind.
Essential Variables Essential Variables
Electrical Characteristics
Change in polarity or change of current from AC DC or
vise versa requires requalification
Time Between Passes
The increase in time between root bead and 2
nd
bead
requires requalification
Direction of welding
Uphill to down hill or vice versa requires requalification
Shielding Gas and Flow Rate
The change of shielding gas or composition of mixture and
change in flow rate requires requalification
Electrical Characteristics
Change in polarity or change of current from AC DC or
vise versa requires requalification
Time Between Passes
The increase in time between root bead and 2
nd
bead
requires requalification
Direction of welding
Uphill to down hill or vice versa requires requalification
Shielding Gas and Flow Rate
The change of shielding gas or composition of mixture and
change in flow rate requires requalification
Essential Variables Essential Variables
Shielding Flux
Change in Flux that causes a change in AWS designation
requires requalification.
Speed of Travel
Change of range of speed of travel is an essential variable
PWHT
Addition of PWHT or changes from ranges specified in
procedure
Shielding Flux
Change in Flux that causes a change in AWS designation
requires requalification.
Speed of Travel
Change of range of speed of travel is an essential variable
PWHT
Addition of PWHT or changes from ranges specified in
procedure
Test Requirements for Procedure Test Requirements for Procedure
Qualification Qualification
Tensile Test
Requirements
Tensile strength of the welding including the fusion zone of each
specimen shall be greater than the SMYS of the pipe, but may not
be greater than the actual tensile strength of the pipe
If the specimen breaks outside the weld (i.e. in the parent pipe
metal) and meets the minimum tensile strength requirements of
the specifications, the weld shall be accepted.
If the specimen breaks in the weld or fusion zone, and the
observed strength is greater than or equal to SMYS of the Pipe
(Parent metal), the weld shall be accepted.
In case, the observed strength is less than the SMYS, the weld shall
be rejected and new test weld shall be made
Tensile Test
Requirements
Tensile strength of the welding including the fusion zone of each
specimen shall be greater than the SMYS of the pipe, but may not
be greater than the actual tensile strength of the pipe
If the specimen breaks outside the weld (i.e. in the parent pipe
metal) and meets the minimum tensile strength requirements of
the specifications, the weld shall be accepted.
If the specimen breaks in the weld or fusion zone, and the
observed strength is greater than or equal to SMYS of the Pipe
(Parent metal), the weld shall be accepted.
In case, the observed strength is less than the SMYS, the weld shall
be rejected and new test weld shall be made
Pipe Strengths Vs Electrode Tensile Pipe Strengths Vs Electrode Tensile
Strength Strength
Test Requirements for Procedure Test Requirements for Procedure
Qualification Qualification
Nick Break Test
Requirements
Exposed surface shall show complete fusion and penetration
Gas pockets, if any, shall not exceed 1/16 in dimension
All gas pockets shall not exceed 2% of exposed surface area
Slag inclusions shall not be more than 1/32 in depth and the
length shall not be more than 1/8 or the nominal wall
thickness, whichever is smaller
Slag inclusion shall be separated by 1/2
Nick Break Test
Requirements
Exposed surface shall show complete fusion and penetration
Gas pockets, if any, shall not exceed 1/16 in dimension
All gas pockets shall not exceed 2% of exposed surface area
Slag inclusions shall not be more than 1/32 in depth and the
length shall not be more than 1/8 or the nominal wall
thickness, whichever is smaller
Slag inclusion shall be separated by 1/2
Test Requirements for Procedure Test Requirements for Procedure
Qualification Qualification
Root Bend and Face Bend Test
Requirements
No crack or imperfection exceeding 1/8 or of the nominal wall
thickness, which ever is smaller, in any direction is allowed
between the weld and the fusion zone after bending
Cracks that may originate on the outer radius of the bend along
the edges of the specimen during test and are less than
measured in any direction shall not be considered unless an
obvious imperfection is noted
Each specimen subjected to bend test shall meet these
requirements
Root Bend and Face Bend Test
Requirements
No crack or imperfection exceeding 1/8 or of the nominal wall
thickness, which ever is smaller, in any direction is allowed
between the weld and the fusion zone after bending
Cracks that may originate on the outer radius of the bend along
the edges of the specimen during test and are less than
measured in any direction shall not be considered unless an
obvious imperfection is noted
Each specimen subjected to bend test shall meet these
requirements
Test Requirements for Procedure Test Requirements for Procedure
Qualification Qualification
Side Bend Test
Requirements
Each side bend test shall meet the requirements of the face bend
and root bend test
Typical WPS Typical WPS
Welding Types Welding Types
Homogeneous
Gas Welding
Electro Slag
High Energy
Beam
MIG
Fusion Welding
High Energy
Beam
Arc Welding TIG
Stick
Heterogeneous
Soldering
Brazing
Pressure
Welding
Friction
Welding
Fusion Welding Types Fusion Welding Types
Submerged Arc Welding (SAW)
Flux Cored Arc Welding (FCAW)
Electron Beam Welding
Oxy Fuel Gas welding (OFW)
Gas Metal Arc Welding (GMAW) (MIG)
Gas Tungsten Arc Welding (GTAW) (TIG)
Shielded Metal Arc Welding (SMAW) or Stick Welding
Submerged Arc Welding (SAW)
Flux Cored Arc Welding (FCAW)
Electron Beam Welding
Oxy Fuel Gas welding (OFW)
Gas Metal Arc Welding (GMAW) (MIG)
Gas Tungsten Arc Welding (GTAW) (TIG)
Shielded Metal Arc Welding (SMAW) or Stick Welding
Submerged Arc Welding (SAW) Submerged Arc Welding (SAW)
consumable electrode
Arc is struck by high resistance
conducting material like steel
wool or carbon
The weld area is covered with
granulated slag
When melted, the slag
becomes conductive allowing
current flow between
electrode and work piece
Usually used in flat and
horizontal position
consumable electrode
Arc is struck by high resistance
conducting material like steel
wool or carbon
The weld area is covered with
granulated slag
When melted, the slag
becomes conductive allowing
current flow between
electrode and work piece
Usually used in flat and
horizontal position
SAW Advantages and Limitations SAW Advantages and Limitations
Advantages
Ease of welding thin plates
with little edge prep
Very good quality welds in
toughness, ductility and
uniformity
High welding speeds due to
use of very high currents and
multiple wires (up to 5 m/
min)
High deposition rates (up to
45 kg/ hr)
No smoke or visible arc or
spatter
Limitations
Limited to steel or stainless
steel and some nickel based
alloys
Use of powder/ granulated
flux limits the welding to flat
or horizontal welds
Min thickness of plate is
limited to 1.8 mm due to
high penetration
Advantages
Ease of welding thin plates
with little edge prep
Very good quality welds in
toughness, ductility and
uniformity
High welding speeds due to
use of very high currents and
multiple wires (up to 5 m/
min)
High deposition rates (up to
45 kg/ hr)
No smoke or visible arc or
spatter
Limitations
Limited to steel or stainless
steel and some nickel based
alloys
Use of powder/ granulated
flux limits the welding to flat
or horizontal welds
Min thickness of plate is
limited to 1.8 mm due to
high penetration
SAW Typical Application Areas SAW Typical Application Areas
Pipe mills
Pressure vessels
Structural steels
Pipeline Double jointing, Yard fabrication
Ship building
Storage tanks
Pipe mills
Pressure vessels
Structural steels
Pipeline Double jointing, Yard fabrication
Ship building
Storage tanks
Flux Cored Arc Welding (FCAW) Flux Cored Arc Welding (FCAW)
FCAW requires a continuously fed tubular electrode containing
a flux and a constant voltage power supply
The cored flux produces both the liquid slag and gaseous
protection for the molten weld metal pool from the
atmospheric contaminants
The process is a variation of MIG
FCAW Advantages/ Limitations FCAW Advantages/ Limitations
Advantages
All position process
No shielding gas
required
High deposition/ High
Speed
Less skill requirement in
comparison to GTAW
and SMAW
Limitations
Melted contact tip
Gas porosity specially
from flux cored, as gases
dont escape before the
metals hardens
Generates smoke
Filler metal change
requires changing spool
Filler wire is quite
expensive
Advantages
All position process
No shielding gas
required
High deposition/ High
Speed
Less skill requirement in
comparison to GTAW
and SMAW
Limitations
Melted contact tip
Gas porosity specially
from flux cored, as gases
dont escape before the
metals hardens
Generates smoke
Filler metal change
requires changing spool
Filler wire is quite
expensive
Electron Beam Welding Electron Beam Welding
A beam of high velocity
electrons is applied to the
work pieces
Works piece melt and flow
together as kinetic energy
of electrons is converted to
heat
Welding is carried out in
vacuum to prevent
dissipation of electron
beam
Produce very high quality
welds
Has use in aircraft and
automotive industry
A beam of high velocity
electrons is applied to the
work pieces
Works piece melt and flow
together as kinetic energy
of electrons is converted to
heat
Welding is carried out in
vacuum to prevent
dissipation of electron
beam
Produce very high quality
welds
Has use in aircraft and
automotive industry
Oxy Fuel Welding Oxy Fuel Welding
Oxy acetylene welding
Uses pure oxygen instead
of air to increase the flame
temperature
Propane and acetylene are
both used as fuel gases,
acetylene produces flame
temperature of about 3500
Deg C
Used for both welding
as well as cutting
The heat produced by
burning fuel gas in pure
oxygen environment
melts the base metals,
which flow to fuse
together.
Filler metals are
commonly used
Oxy acetylene welding
Uses pure oxygen instead
of air to increase the flame
temperature
Propane and acetylene are
both used as fuel gases,
acetylene produces flame
temperature of about 3500
Deg C
Used for both welding
as well as cutting
The heat produced by
burning fuel gas in pure
oxygen environment
melts the base metals,
which flow to fuse
together.
Filler metals are
commonly used
Oxy Fuel Welding Oxy Fuel Welding
Gas Metal Gas Metal Arc Welding (GMAW) Arc Welding (GMAW)
Metal Inert Gas (MIG)
Metals are melted by heating with electric arc
Arc is established between continuous consumable
electrode and the metal being welded
Shielding is provided against the atmospheric
contaminants by shielding gas
Semi automatic, machine and automatic welding is
possible with GMAW
Produces high quality welds
Yields high productivity
Metal Inert Gas (MIG)
Metals are melted by heating with electric arc
Arc is established between continuous consumable
electrode and the metal being welded
Shielding is provided against the atmospheric
contaminants by shielding gas
Semi automatic, machine and automatic welding is
possible with GMAW
Produces high quality welds
Yields high productivity
Typical GMAW Equipment Typical GMAW Equipment
Typical GMAW Equipment Typical GMAW Equipment
GMAW torch
1 Handle
2 Dielectric and threaded
metal nut
3 shielding gas diffuser
4 contact tip
5 nozzle output face
GMAW torch
1 Handle
2 Dielectric and threaded
metal nut
3 shielding gas diffuser
4 contact tip
5 nozzle output face
GMAW Typical Equipment GMAW Typical Equipment
Wire Feeder
Supplies electrode to the work piece
Wire is fed a constant feed rate
Advanced machines can vary feed rate with voltage and arc
length
Typical feed rate is 2 10 m/ min, some reach 30 m/ min
Voltage source
Constant voltage power supply
Arc length change results in changes in heat input
Shorter arc lengths cause greater heat input, faster melting of
wire and restoration of arc length
Rarely, constant current source and arc voltage controlled wire
feeders are used, which change wire feed rate to maintain
constant arc length
Wire Feeder
Supplies electrode to the work piece
Wire is fed a constant feed rate
Advanced machines can vary feed rate with voltage and arc
length
Typical feed rate is 2 10 m/ min, some reach 30 m/ min
Voltage source
Constant voltage power supply
Arc length change results in changes in heat input
Shorter arc lengths cause greater heat input, faster melting of
wire and restoration of arc length
Rarely, constant current source and arc voltage controlled wire
feeders are used, which change wire feed rate to maintain
constant arc length
GMAW Process GMAW Process
Process involves heating metals to melting point
using an electric arc
Arc is created between a continuous consumable
electrode and the base metal
Arc is shielded from atmospheric contaminants using
a shielding gas
Process involves heating metals to melting point
using an electric arc
Arc is created between a continuous consumable
electrode and the base metal
Arc is shielded from atmospheric contaminants using
a shielding gas
GMAW Process GMAW Process
ER70S-X
Electrode
Rod
70,000 psi Min. Tensile Strength
Solid
Chemistry, Amount of Deoxidizers (Silicon, Manganese
and/or Aluminum, Zirconium and Titanium)
X=2,3,4,6,7 or G
AWS Classification of AWS Classification of
GMAW Electrodes GMAW Electrodes
71
Electrode
Rod
70,000 psi Min. Tensile Strength
Solid
Chemistry, Amount of Deoxidizers (Silicon, Manganese
and/or Aluminum, Zirconium and Titanium)
X=2,3,4,6,7 or G
GMAW Process GMAW Process
Hand Held or semi automatic
Only the wire is controlled by the equipment, welding is
carried out by hand
mechanized welding
Gun is connected to a manipulator which is continuously
controlled by the operator
Automatic
Completely automatic, no intervention from operator is
required
Hand Held or semi automatic
Only the wire is controlled by the equipment, welding is
carried out by hand
mechanized welding
Gun is connected to a manipulator which is continuously
controlled by the operator
Automatic
Completely automatic, no intervention from operator is
required
Metal Transfer Metal Transfer Modes in GMAW Modes in GMAW
There are three variations of metal transfer in GMAW
which depend upon the
Shielding gas type
Arc voltage
Arc current
Electrode Dia
Wire feed speed
Short Circuit Transfer
Globular transfer
Spray Arc Transfer
There are three variations of metal transfer in GMAW
which depend upon the
Shielding gas type
Arc voltage
Arc current
Electrode Dia
Wire feed speed
Short Circuit Transfer
Globular transfer
Spray Arc Transfer
Short Circuit Transfer Short Circuit Transfer
This refers to the welding wire actually short
circuiting (touching) the base metal between 90
200 times/ second
With short circuit transfer, the voltage, wire feed
speed and deposition rates are usually lower than
other forms of metal transfer like spray transfer
This allows the welder more control over the process
and allows welding of thin and thick plates alike.
This refers to the welding wire actually short
circuiting (touching) the base metal between 90
200 times/ second
With short circuit transfer, the voltage, wire feed
speed and deposition rates are usually lower than
other forms of metal transfer like spray transfer
This allows the welder more control over the process
and allows welding of thin and thick plates alike.
Short Circuit Transfer Short Circuit Transfer
Electrode is short circuited with
base metal, no arc exists, but
current flows
The resistance of welding wire to
high current flow causes it to heat,
melt and neck down
Electrode breaks and arc is struck.
The portion of electrode left at
base metal forms the weld puddle
Arc length and voltage reach
maximum
Wire feed cause the electrode to
short circuit with base metal and
arc is extinguished starting the
cycle all over again
Electrode is short circuited with
base metal, no arc exists, but
current flows
The resistance of welding wire to
high current flow causes it to heat,
melt and neck down
Electrode breaks and arc is struck.
The portion of electrode left at
base metal forms the weld puddle
Arc length and voltage reach
maximum
Wire feed cause the electrode to
short circuit with base metal and
arc is extinguished starting the
cycle all over again
Globular Transfer Globular Transfer
Large globs of electrode wire are
expelled from its end and enter the
weld puddle
Globular transfer occurs when welding
parameters like voltage, wire feed
speed and amps are somewhat higher
than short circuit mode
Spatter may be present
Weld appearance is less desirable
Limited to flat position
Min thickness of base metal limited to
1/8 inch
Large globs of electrode wire are
expelled from its end and enter the
weld puddle
Globular transfer occurs when welding
parameters like voltage, wire feed
speed and amps are somewhat higher
than short circuit mode
Spatter may be present
Weld appearance is less desirable
Limited to flat position
Min thickness of base metal limited to
1/8 inch
Spray Arc Transfer Spray Arc Transfer
A stream of molten droplets, which
form at the tip of the electrode, is
sprayed across the arc on base
metal
It is done high voltage, wire feed
speed and current
High deposition rates with good
penetration and fusion
Good appearance
No or fine spatter
Limited to flat & Horizontal
No open root capability
A stream of molten droplets, which
form at the tip of the electrode, is
sprayed across the arc on base
metal
It is done high voltage, wire feed
speed and current
High deposition rates with good
penetration and fusion
Good appearance
No or fine spatter
Limited to flat & Horizontal
No open root capability
Weld Bead Characteristics Weld Bead Characteristics
Poor weld bead
Large spatter
Irregular shape
Noticeable crater
Bead over lap
Poor penetration
Poor weld bead
Large spatter
Irregular shape
Noticeable crater
Bead over lap
Poor penetration
Weld Bead Characteristics Weld Bead Characteristics
Good weld bead
Fine or no spatter
Regular or uniform
bead
Slight or no crater
No overlap
Good penetration
into base metal
Good weld bead
Fine or no spatter
Regular or uniform
bead
Slight or no crater
No overlap
Good penetration
into base metal
GMAW Shielding Gases GMAW Shielding Gases
Welding Defects, Causes & Remedies Welding Defects, Causes & Remedies
Excessive Spatter
Scatter of molten metal
particles that cool to
solid near weld bead
High wire speed
Voltage too high
Electrode extension too
long
Dirty Work piece
Insufficient gas shielding
Dirty welding wire
Excessive Spatter
Scatter of molten metal
particles that cool to
solid near weld bead
High wire speed
Voltage too high
Electrode extension too
long
Dirty Work piece
Insufficient gas shielding
Dirty welding wire
Welding Defects, Causes & Remedies Welding Defects, Causes & Remedies
Porosity
Small pockets or holes resulting
from gas pockets in the weld
metal
Inadequate shielding gas
coverage/shielding gas flow
rate
Spatter in the nozzle
Wrong shielding gas
Dirty wire or work piece
Welding wire stick out too
long (should be between

Porosity
Small pockets or holes resulting
from gas pockets in the weld
metal
Inadequate shielding gas
coverage/shielding gas flow
rate
Spatter in the nozzle
Wrong shielding gas
Dirty wire or work piece
Welding wire stick out too
long (should be between

Welding Defects, Causes & Remedies Welding Defects, Causes & Remedies
Incomplete fusion
Failure of weld metal to fuse with
filler metal
Dirty work piece
Insufficient heat input
Low voltage
High wire feed speed
Improper welding technique
Narrow groove
Gun angle
Improper placement of stringer
bead
Incomplete fusion
Failure of weld metal to fuse with
filler metal
Dirty work piece
Insufficient heat input
Low voltage
High wire feed speed
Improper welding technique
Narrow groove
Gun angle
Improper placement of stringer
bead
Welding Defects, Causes & Remedies Welding Defects, Causes & Remedies
Excessive Penetration
Weld metal melting through the
base metal and hanging
underneath the weld
High heat input
Excessive Penetration
Weld metal melting through the
base metal and hanging
underneath the weld
High heat input
Welding Defects, Causes & Remedies Welding Defects, Causes & Remedies
Lack of Penetration
Shallow fusion between weld
metal and base metal
Improper Joint preparation
Joint Design/ thickness of base
metal
Improper Technique (Gun Angle,
Stick out and Arc positioning on
leading edge of puddle
Insufficient heat input
Lack of Penetration
Shallow fusion between weld
metal and base metal
Improper Joint preparation
Joint Design/ thickness of base
metal
Improper Technique (Gun Angle,
Stick out and Arc positioning on
leading edge of puddle
Insufficient heat input
Welding Defects, Causes & Remedies Welding Defects, Causes & Remedies
Burn Thru
Weld metal burns through
the base metal leaving
holes
Excessive heat input
Waviness of bead
Weld metal does not
cover the joint
Unsteady hands
Burn Thru
Weld metal burns through
the base metal leaving
holes
Excessive heat input
Welding Defects, Causes & Remedies Welding Defects, Causes & Remedies
Distortion of Base metal
Weld metal contracts
during welding forcing
base metal to move
Excessive heat input
Distortion of Base metal
Weld metal contracts
during welding forcing
base metal to move
Excessive heat input
Shielded Metal Arc Welding (SMAW) Shielded Metal Arc Welding (SMAW)
Stick welding, Manual Metal Arc (MMA)
Consumable non Continuous stick electrode
Shielding gas and molten slag provided by flux
coating for protection against the atmospheric
contaminants
Electric current is used for creating the arc for
melting the filler metal and base metal
Current source may be of either AC or DC Type
Stick welding, Manual Metal Arc (MMA)
Consumable non Continuous stick electrode
Shielding gas and molten slag provided by flux
coating for protection against the atmospheric
contaminants
Electric current is used for creating the arc for
melting the filler metal and base metal
Current source may be of either AC or DC Type
How Does SMAW Work How Does SMAW Work
Electric arc is struck by
lightly touching the
electrode with the base
metal and then pulling
away slightly
Heat of the arc melts the
electrode and the work
piece
Droplets of molten metal
form at the tip of the
electrode which pass from
electrode to weld pool
Electric arc is struck by
lightly touching the
electrode with the base
metal and then pulling
away slightly
Heat of the arc melts the
electrode and the work
piece
Droplets of molten metal
form at the tip of the
electrode which pass from
electrode to weld pool
How Does SMAW Work How Does SMAW Work
As electrode melts, the flux
coating disintegrates giving
off shielding gas
Molten slag also cover the
molten metal as it travels
from electrode to the weld
pool
Slag floats to the surface in
the weld pool and protects
the weld pool from
atmospheric contaminants
As electrode melts, the flux
coating disintegrates giving
off shielding gas
Molten slag also cover the
molten metal as it travels
from electrode to the weld
pool
Slag floats to the surface in
the weld pool and protects
the weld pool from
atmospheric contaminants
How Does SMAW Work How Does SMAW Work
When the weld hardens, the
slag layer has to be chipped
away and cleaned with a wire
brush
SMAW is a slow welding process
owning to the fact that the
welder has to stop periodically
for removing the stub and
replacing the electrode.
Chipping of slag between
passes further reduces the time
a welder can use laying the
weld
In general, the percentage of time
laying the weld is approximately
25%
When the weld hardens, the
slag layer has to be chipped
away and cleaned with a wire
brush
SMAW is a slow welding process
owning to the fact that the
welder has to stop periodically
for removing the stub and
replacing the electrode.
Chipping of slag between
passes further reduces the time
a welder can use laying the
weld
In general, the percentage of time
laying the weld is approximately
25%
Typical SMAW Equipment Typical SMAW Equipment
Consumable Electrodes Theory Consumable Electrodes Theory
(SMAW) (SMAW)
The electrode consist of a solid metal rod of drawn or
cast materials fabricated by encasing metal powders
in a metallic sheath
The core metal rod conducts the current to the arc
and provides the filler metal for the weld
Electrode coating provides stability to the arc and
shields molten metal in the arc from atmospheric
oxygen with gases created by decomposition of the
coating from the heat of arc
Flux also provides the slag coating that protects the
molten metal from atmosphere and allows it to cool
at a controlled rate
The electrode consist of a solid metal rod of drawn or
cast materials fabricated by encasing metal powders
in a metallic sheath
The core metal rod conducts the current to the arc
and provides the filler metal for the weld
Electrode coating provides stability to the arc and
shields molten metal in the arc from atmospheric
oxygen with gases created by decomposition of the
coating from the heat of arc
Flux also provides the slag coating that protects the
molten metal from atmosphere and allows it to cool
at a controlled rate
Consumable Electrodes Theory Consumable Electrodes Theory
(SMAW) (SMAW)
Shielding together with the filler metal determines the
mechanical properties, chemical composition and
metallurgical structure of the weld as well as the arc
characteristics of electrode
Electrode coatings have been designed to work with
alternating current (AC)
The arc goes out every half cycle as the current crosses the
zero potential and is re established when the current reverses
its direction
Arc is basically the flow of current through the air , often
termed as current jump
The current doesnt actually jump through the air, rather the
gases present between the electrode and work piece become
ionized and the current flows due to these ionized gases
Shielding together with the filler metal determines the
mechanical properties, chemical composition and
metallurgical structure of the weld as well as the arc
characteristics of electrode
Electrode coatings have been designed to work with
alternating current (AC)
The arc goes out every half cycle as the current crosses the
zero potential and is re established when the current reverses
its direction
Arc is basically the flow of current through the air , often
termed as current jump
The current doesnt actually jump through the air, rather the
gases present between the electrode and work piece become
ionized and the current flows due to these ionized gases
Consumable Electrodes Theory Consumable Electrodes Theory
(SMAW) (SMAW)
For stability, the ionized gases need to be present in
the arc stream during each current reversal
Presence of ionized gases makes re ignition of the arc
possible
Gases that readily ionize can be obtained from a
compounds that contain Potassium
Incorporation of these compounds in the electrode
covering allow an electrode to operate on AC
For stability, the ionized gases need to be present in
the arc stream during each current reversal
Presence of ionized gases makes re ignition of the arc
possible
Gases that readily ionize can be obtained from a
compounds that contain Potassium
Incorporation of these compounds in the electrode
covering allow an electrode to operate on AC
Consumable Electrodes Theory Consumable Electrodes Theory
(SMAW) (SMAW)
Deposition Rate can also be effected by the coating
Some low alloy and carbon steel electrode contain
iron powder which another source of material
available for deposition other than the core metal of
electrode
Metal powders other than iron are also frequently
used to alter the mechanical properties of the weld
metal
Addition of iron and other metal powder usually
increases the deposition rate and welding speed
Deposition Rate can also be effected by the coating
Some low alloy and carbon steel electrode contain
iron powder which another source of material
available for deposition other than the core metal of
electrode
Metal powders other than iron are also frequently
used to alter the mechanical properties of the weld
metal
Addition of iron and other metal powder usually
increases the deposition rate and welding speed
Consumable Electrodes Theory Consumable Electrodes Theory
(SMAW) (SMAW)
SMAW electrodes are available for welding low alloy
and carbon steels, stainless steels, copper, nickel and
their alloys and some Aluminum alloys
Low melting alloys like lead, tin, zinc and their alloys
are not welded with SMAW as the intense heat of
the arc is too high for them
SMAW is not suitable for reactive metals like
titanium, zirconium, tantalum and columbium
because the shield provided is inadequate for
preventing formation of oxides
SMAW electrodes are available for welding low alloy
and carbon steels, stainless steels, copper, nickel and
their alloys and some Aluminum alloys
Low melting alloys like lead, tin, zinc and their alloys
are not welded with SMAW as the intense heat of
the arc is too high for them
SMAW is not suitable for reactive metals like
titanium, zirconium, tantalum and columbium
because the shield provided is inadequate for
preventing formation of oxides
Electrode Classification System Electrode Classification System
(SMAW (SMAW
Electrode Classification System Electrode Classification System
(SMAW (SMAW
Electrode Classification System Electrode Classification System
(SMAW (SMAW
AWS
CLASSIFICATION
TYPE OF COVERING
CAPABLE OF PRODUCING
SATISFACTORY WELDS IN
POSITION SHOWN
a
TYPE OF CURRENT
b
E60 SERIES ELECTRODES
E6010 High cellulose sodium F, V, OH, H DCEP
E6011 High cellulose potassium F, V, OH, H AC or DCEP
E6012 High titania sodium F, V, OH, H AC or DCEN
E6013 High titania potassium F, V, OH, H AC or DC, either polarity
E6020 High iron oxide H-fillets, F AC or DCEN
E6022
c
High iron oxide F, H AC or DC either polarity
E6027 High iron oxide, iron powder H-fillets, F AC or DCEN
Electrode Classification System Electrode Classification System
(SMAW (SMAW
AWS
CLASSIFICATION
TYPE OF COVERING
CAPABLE OF PRODUCING
SATISFACTORY WELDS IN
POSITION SHOWN
a
TYPE OF CURRENT
b
E70 SERIES ELECTRODES
E7014 Iron powder, titanium F, V, OH, H AC or DC, either polarity
E7015 Low hydrogen sodium F, V, OH, H DCEP
E7016 Low hydrogen potassium F, V, OH, H AC or DCEP
E7018 Low hydrogen potassium,
iron powder
F, V, OH, H AC or DCEP Low hydrogen potassium,
iron powder
E7024 Iron powder, titanium H-fillets, F AC or DC, either polarity
E7027 High iron oxide, iron powder H-fillets, F AC or DCEN
E7028 Low hydrogen potassium,
iron powder
H-fillets, F AC or DCEP
E7048 Low hydrogen potassium,
iron powder
F, OH, H, V-down AC or DCEP
The suffix (Example: EXXXX-A) indicates the approximate alloy in the weld deposit:
-A1 0.5 % Mo
-B1 0.5 % Cr, 0.5 % Mo.
-B2 1.25 % Cr, 0.5 % Mo.
-B3 2.25 % Cr, 1 % Mo.
-B4 2 % Cr, 0.5 % Mo.
-B5 0.5 % Cr, 1 % Mo.
-C1 2.5% Ni
-C2 3.25 % Ni
-C3 1% Ni, 0.35 % Mo, 0.15% Cr
-D1 and D2 0.25 0.45% Mo,1.75%Mn
-G 0.5% min. Ni. Or 0.3%, or 0.3%min. Cr,
or 0.2% min. Mo,
or 0.1%min. V,or 1% min.Mn
(only one element required)
AWSE 10018-M or AWS E 12018-M are a special military grade for welding sub marine hulls and
test turrets.
Electrode Classification System Electrode Classification System
(SMAW (SMAW
The suffix (Example: EXXXX-A) indicates the approximate alloy in the weld deposit:
-A1 0.5 % Mo
-B1 0.5 % Cr, 0.5 % Mo.
-B2 1.25 % Cr, 0.5 % Mo.
-B3 2.25 % Cr, 1 % Mo.
-B4 2 % Cr, 0.5 % Mo.
-B5 0.5 % Cr, 1 % Mo.
-C1 2.5% Ni
-C2 3.25 % Ni
-C3 1% Ni, 0.35 % Mo, 0.15% Cr
-D1 and D2 0.25 0.45% Mo,1.75%Mn
-G 0.5% min. Ni. Or 0.3%, or 0.3%min. Cr,
or 0.2% min. Mo,
or 0.1%min. V,or 1% min.Mn
(only one element required)
AWSE 10018-M or AWS E 12018-M are a special military grade for welding sub marine hulls and
test turrets.
Striking the SMAW ARC Striking the SMAW ARC
Arc Length and Voltage Relationship Arc Length and Voltage Relationship
Constant current power
sources are used for SMAW
process
With a CC power source,
the voltage changes with
change in arc length
Voltage follows the arc
length increasing or
decreasing with it
When striking an arc, the
electrode comes in contact
with base metal and arc
length reduces to zero,
there is tendency for
electrode to stick
Constant current power
sources are used for SMAW
process
With a CC power source,
the voltage changes with
change in arc length
Voltage follows the arc
length increasing or
decreasing with it
When striking an arc, the
electrode comes in contact
with base metal and arc
length reduces to zero,
there is tendency for
electrode to stick
Arc Length and Arc Length and Voltage Relationship Voltage Relationship
In traditional SMAW power, ARC Length and Voltage
have inverse relationship with Current. This allows the
welder control over the heat input into the work piece
Arc Length and Arc Length and Voltage Relationship Voltage Relationship
Arc force control allows more current when the voltage
goes below 20 V. this allows the welder to achieve
penetration control by just varying the arc length
Weld Bead Weld Bead
Weld bead is the resultant of a weld pass
Stringer (drag) (whip)
Weave
Circles
crescent
zig zag
box weave
double J
Stringer (drag) (whip)
Weave
Circles
crescent
zig zag
box weave
double J
Progression Progression
Vertical UP
Deep Penetration
High deposition
Near 90 deg travel angle
or slightly up
Vertical Down
Faster
Less penetration for this
metal
Use steep drag angle
Vertical UP
Deep Penetration
High deposition
Near 90 deg travel angle
or slightly up
Vertical Down
Faster
Less penetration for this
metal
Use steep drag angle
CLAMS CLAMS
Welding parameters that need to be control to
produce great welds
Current Settings
Length of Arc
Angle of Electrode
Manipulation of electrode
Speed of travel
Welding parameters that need to be control to
produce great welds
Current Settings
Length of Arc
Angle of Electrode
Manipulation of electrode
Speed of travel
CLAMS CLAMS Current Settings Current Settings
Amperage requirements
are defined by the
electrode manufacturer
including the polarity and
current type requirement
As a rule of thumb for
determining the current
setting, 1 Ampere for
0.001 of electrode size is
a good starting point
Then adjust the current in
increment of 5 10 Amps
Low amperage would
cause sticking of
electrode
Arc will keep going out or
it will stutter
Amperage requirements
are defined by the
electrode manufacturer
including the polarity and
current type requirement
As a rule of thumb for
determining the current
setting, 1 Ampere for
0.001 of electrode size is
a good starting point
Then adjust the current in
increment of 5 10 Amps
CLAMS CLAMS Current Settings Current Settings
The weld puddle will be
excessively fluid and hard
to control
The electrode chars when
half used
Arc sound is louder than
normal
The amperage may be too
high
Too much heat can negative
effect the properties of
flux
The weld puddle will be
excessively fluid and hard
to control
The electrode chars when
half used
Arc sound is louder than
normal
The amperage may be too
high
Too much heat can negative
effect the properties of
flux
CLAMS CLAMS ARC Length ARC Length
Varies with electrode and
application
Arc should not exceed the
diameter of the metal portion
or core of the electrode, as a
starting point, e.g. 1/8 for a
1/8 electrode
If the arc length is too short
the voltage decrease, and may
extinguish itself and cause the
electrode to stick to the weld
Cause the electrode to freeze
faster and produce weld bead
with a high crown
Varies with electrode and
application
Arc should not exceed the
diameter of the metal portion
or core of the electrode, as a
starting point, e.g. 1/8 for a
1/8 electrode
If the arc length is too short
the voltage decrease, and may
extinguish itself and cause the
electrode to stick to the weld
Cause the electrode to freeze
faster and produce weld bead
with a high crown
CLAMS CLAMS ARC Length ARC Length
Excessively long arcs
mean too much voltage
and too much power/
heat
Too long arcs produce
spatter, low deposition
rate, under cuts and
often porosity
Excessively long arcs
mean too much voltage
and too much power/
heat
Too long arcs produce
spatter, low deposition
rate, under cuts and
often porosity
CLAMS CLAMS Angle of Travel Angle of Travel
Stick welding in Flat,
Overhead and vertical
positions use a Drag
angle of 5 15 degs
For vertical up, use a
push angle of 5 15
degs
Stick welding in Flat,
Overhead and vertical
positions use a Drag
angle of 5 15 degs
For vertical up, use a
push angle of 5 15
degs
CLAMS CLAMS Manipulation of electrode Manipulation of electrode
For thinner materials,
string is best
For thicker materials,
use weave pattern or
split weave pattern
For uphill welding, take
care of the sides by
pausing slightly, the
middle with take care of
itself
For thinner materials,
string is best
For thicker materials,
use weave pattern or
split weave pattern
For uphill welding, take
care of the sides by
pausing slightly, the
middle with take care of
itself
CLAMS CLAMS Speed of Travel Speed of Travel
Stay at the leading edge of the puddle
Weld puddle is molten metal pool produced while the weld is being made.
Can be made from base metal alone or a mix of filler and base metal
Once a good sized pool is created, move at speed
that keeps the arc in about leading 1/3
rd
of the
puddle
Stay at the leading edge of the puddle
Weld puddle is molten metal pool produced while the weld is being made.
Can be made from base metal alone or a mix of filler and base metal
Once a good sized pool is created, move at speed
that keeps the arc in about leading 1/3
rd
of the
puddle
CLAMS CLAMS -- Speed of Travel Speed of Travel
If too slow, the heat will be directed into the puddle and
not into the weld leading to cold lap or poor fusion
Traveling too slow creates a wide convex bead with
shallow penetration and possibility of cold lapping and
weld appears to be just sitting on the surface of the
material
If too slow, the heat will be directed into the puddle and
not into the weld leading to cold lap or poor fusion
Traveling too slow creates a wide convex bead with
shallow penetration and possibility of cold lapping and
weld appears to be just sitting on the surface of the
material
CLAMS CLAMS Speed of Travel Speed of Travel
Excessive travel speeds decrease penetration, create
a narrow, highly crowned bead and under fill or
under cut
Root Pass Hot Pass
Fill Pass Cover Pass
Weld Passes Weld Passes
Root Pass Root Pass
Root Opening
Small root opening would be allow more amperage
welding is smoother, easier
Arc starts are easy
Large root openings allow more penetration
Root Faces
Large root faces allow more current, smoother welding
and easy arc start
Small face allow deeper penetration
Root Opening
Small root opening would be allow more amperage
welding is smoother, easier
Arc starts are easy
Large root openings allow more penetration
Root Faces
Large root faces allow more current, smoother welding
and easy arc start
Small face allow deeper penetration
Open Root Technique Open Root Technique
Use root opening to allow increase in amperage for
smoother welding
Whip backwards for penetration
Whip forwards to reduce penetration
Do Not Weave a root pass.
Maintain a short arc gap
Stay slightly in front of the puddle at all times. Use
the keyholing technique.
Use root opening to allow increase in amperage for
smoother welding
Whip backwards for penetration
Whip forwards to reduce penetration
Do Not Weave a root pass.
Maintain a short arc gap
Stay slightly in front of the puddle at all times. Use
the keyholing technique.
Key Holing Technique Key Holing Technique
Technique for getting
100% penetration on
root weld
Hole is made through
the open root pushing
through the base metal
Weld metal goes
through to the back
side and fuses the back
corner of the of root
opening
Technique for getting
100% penetration on
root weld
Hole is made through
the open root pushing
through the base metal
Weld metal goes
through to the back
side and fuses the back
corner of the of root
opening
Restarts Restarts
Stagger all starts and stops or use runon, runoff tabs
Feather all restarts & start on top, or start in front
and remelt
Also stagger all beads on a single pass.
Use a longer arc length when starting a weld.
Stagger all starts and stops or use runon, runoff tabs
Feather all restarts & start on top, or start in front
and remelt
Also stagger all beads on a single pass.
Use a longer arc length when starting a weld.
Craters Craters
Fill craters by welding into the previous weld start
Use a short arc length to control heat.
WAGON TACKS WAGON TACKS
WAGON TACKS WAGON TACKS
Keep it melted into these spots.
TACKING/ GRINDING OF TACKS TACKING/ GRINDING OF TACKS
3/4 long
feather both ends
clean and flatten tops
start on top, burn through before end
run completely onto tack before stopping
grind lumps off before next pass
stagger all starts and stops between passes
stagger all starts and stops between beads in a single
pass
Dont over grind tacks
3/4 long
feather both ends
clean and flatten tops
start on top, burn through before end
run completely onto tack before stopping
grind lumps off before next pass
stagger all starts and stops between passes
stagger all starts and stops between beads in a single
pass
Dont over grind tacks
Non Destructive Tests Non Destructive Tests
Radiographic tests/ X ray
Ultrasonic testing (UI)
Dye Penetrant Testing / Liquid Penetrant Test
Magnetic Particle inspection (MPI)
Radiographic tests/ X ray
Ultrasonic testing (UI)
Dye Penetrant Testing / Liquid Penetrant Test
Magnetic Particle inspection (MPI)
Welding Defects Welding Defects
Welding Defects Welding Defects Cracks Cracks
Welding Defects Welding Defects Porosity Porosity
Welding Defects Welding Defects Cluster Porosity Cluster Porosity
Welding Defects Welding Defects Surface Under Cut Surface Under Cut
Welding Defects Welding Defects Root Under Cut Root Under Cut
Welding Defects
Inadequate Reinforcement
Welding Defects
Excess Reinforcement
Welding Defects
Lack of Fusion
Welding Defects
Offset / Mismatch / Lack of Penetration due to high
low
Welding Defects Welding Defects Interpass Interpass Cold Lap Cold Lap
Welding Defects Welding Defects Slag Inclusion Slag Inclusion
Thank you!