Welding

ASME IX

Forward
The Code does not fully address tolerances...
Only the Boiler and Pressure Vessel Committee has the authority
to provide official interpretations of this Code.

Introduction
Qualification in accordance with Section IX is not a guarantee
that procedures and performance qualifications will be acceptable
to a particular construction code.
If a change is made in any essential variable, requalification of the
procedure is required. If a change is made in a nonessential variable,
the procedure need only be revised or amended to address the
nonessential variable change. When notch toughness is required by
the construction code, the supplementary essential variables become
additional essential variables, and a change requires requalification of
the procedure.

QW-100.1
The purpose of the WPS and PQR is to provide direction for
making production welds to code requirements.
Any WPS used by an organization that will have responsible
control of production welding must be a WPS that was qualified
by the organization, or be an AWS Standard Welding Procedure
listed in Appendix E.
QW-100.2
..., the basic criterion established for welder qualification is to
determine the welder's ability...
Operators are tested to determine their mechanical ability to
operate welding equipment.

QW-100.3
... Qualification made in accordance with the requirements of the
1962 or later Edition...

Welding Procedure Specifications and Welder Qualifications

meeting the above requirements do not need to be amended to
include any variables required by later Editions and Addenda.

Qualification of new Welding Procedure Specifications or

Welders and requalification of existing Welding Procedure
Specifications or Welders shall be in accordance with the current
Edition and Addenda of Section IX.

QW-103 Responsibility
Each manufacturer is responsible for welding done and must
conduct tests to qualify procedures and welder/operators.
Each manufacturer must maintain certified records of results
obtained for WPS and performance qualifications.
QW-120 Test Positions for Groove Welds

QW-140 Types and Purposes of Tests and Examinations

Mechanical tests used in procedure or performance
qualification are as follows:
1. QW-141.1 Tension Tests
are used to determine the ultimate strength of groove-weld joint
QW-153 Acceptance Criteria
Minimum values for procedure qualification are provided under the
column heading "Minimum Specified Tensile, ksi" of table QW/QB-422.
In order to pass the tension test, the specimen shall have a tensile
strength that is not less than:
a. The minimum specified tensile strength of the base metal; or,
b. The minimum specified tensile strength of the weaker of the
two, if base metals of different minimum tensile strengths are
used; or

c. The minimum specified tensile strength of the weld metal when

the applicable Section provides for the use of weld metal having
lower room temperature strength than the base metal;
d. If the specimen breaks in the base metal outside of the weld or
weld interface, the test shall be accepted as meeting the
requirements, provided the strength is not more than 5% below the
minimum specified tensile strength of the base metal.
2. QW-141.2 Guided-Bend Tests.
are used to determine the degree of soundness and ductility of
groove-weld joints.
QW-163 Acceptance Criteria - Bend Tests
The weld and heat-affected zone of a transverse weld-bend specimen
shall be completely within the bent portion of the specimen after
testing.

The guided-bend specimens shall have no open discontinuity in the

weld or heat-affected zone exceeding 1/8 in. (3 mm), measured in
any direction on the convex surface of the specimen after bending.
Open discontinuities occurring on the corners of the specimen during
testing shall not be considered unless there is definite evidence that
they result from lack of fusion, slag inclusions, or other internal
discontinuities. For corrosion-resistant weld overlay cladding, no open
discontinuity exceeding 1/16 in. (1.5 mm), measured in any direction,
shall be permitted in the cladding, and no open discontinuity
exceeding 1/8 in. (3 mm) shall be permitted along the approximate
weld interface.
3. QW-141.4 Notch-Toughness Tests.
Charpy V-notch impact tests shall be made when required by
other Sections. Test procedures and apparatus shall conform to
the requirements of SA-370.

 171.3 Location and Orientation of Test Specimen. The impact test

specimen and notch location and orientation shall be as given in the
Section requiring such tests.
When qualifying pipe in the 5G or 6G position, the notch-toughness
specimens shall be removed from the shaded portion of figure QW463.1(f).
4. QW 190 Other Tests and Examinations
QW-191 Radiographic Examination
QW-191.1 Method. The radiographic examination in QW-142 for
welders and in QW-143 for welding operators shall meet the
requirements of Article 2, Section V, except as follows:
a. A written radiographic examination procedure is not required.
Demonstration of density and penetrameter image requirements
on production or technique radio graphs shall be considered
satisfactory evidence of compliance with Article 2 of Section V.

QW-190 Other Tests and Examinations

QW-191.2.2 Acceptance Standards.
Welder and welding operator performance tests by radiography of
welds in test assemblies shall be judged unacceptable when the
radiograph exhibits any imperfections in excess of the limits specified
below.
a. Linear Indications
1) Any type of crack or zone of incomplete fusion or penetration
2) Any elongated slag inclusion which has a length greater than
a) 1/8 in. (3 mm) for t up to 3/8 in. (10 mm), inclusive
b) l/3t for t over 3/8 in. (10 mm) to 2 1/4 in. (57 mm), inclusive
c) 3/4 in. (19 mm) for t over 2 1/4 in. (57 mm)
3)
Any group of slag inclusions in line that have an aggregate
length greater than t in a length of 12t, except when the distance
between the successive imperfections exceeds 6L where L is the
length of the longest imperfection in the group

QW-194 Visual Examination Performance

Performance test coupons shall show complete joint penetration
with complete fusion of weld metal and base metal.
QW-195 Liquid Penetrant Examination
QW-195.1
The liquid penetrant examination in QW-214 for corrosion-resistant
weld metal overlay shall meet the requirements of Section V, Article
6. The acceptance standards of QW-195.2 shall be met.

QW-200 General
Each manufacturer or contractor shall prepare written Welding
Procedure Specifications which are defined as follows:

WPS
QW-200.1
Written qualified welding procedure prepared to provide direction
for making production welds to Code requirements.
Contents
Shall describe all of the essential, nonessential, and when
required, supplementary essential variables. It shall reference the
supporting PQR.
Changes
Can be made in the nonessential variables of a WPS to suit
production requirements without requalification provided such
changes are documented with respect to the essential, nonessential,
and when required, supplementary essential variables.. .This may be
by amendment to the WPS or by use of a new WPS.

 Format
a The information may be in any format, written or tabular, to fit
the needs of each manufacturer or contractor, as long as every
essential, nonessential, and when required, supplementary
essential variable is included or referenced.
Availability
a The WPS shall be available for reference and review by the
Authorized Inspector at the fabrication site.

PQR
QW-200.2
Each manufacturer or contractor shall be required to prepare a
PQR which is defined as follows:
PQR - A record of the welding data used to weld a test coupon.
Records variables recorded during the welding of the test coupons.
It also contains the test results of the tested specimens. Recorded
variables normally fall within a small range of the actual variables
that will be used in production.

 Contents
Shall document all essential and when required,
supplementary essential variables. Nonessential or other variables
used during the welding of the test coupon may be recorded at the
manufacturer's or contractor's option. All variables, if recorded shall
be the actual variables (including ranges) used during the welding of
the test coupon. It is not intended that the full range or the extreme
of a given range of variables to be used in production be used
during qualification unless required due to a specific essential or,
when required, supplementary essential variable.
The PQR shall be certified accurate by the manufacturer or
contractor. The manufacturer or contractor may not subcontract the
certification function.
When more than one welding process or filler metal is used to
weld a
test coupon, the approximate deposited weld metal
thickness of each welding process and filler metal shall be recorded.

 Changes
Not permitted except:
Editorial corrections
Addenda
Additional information can be incorporated into a PQR at a
later date provided the information is substantiated as having
been part of the original qualification condition by lab record or
similar data.
Format
Any that suits the needs of the manufacturer or contractor
as long as every essential and, when required,
supplementary essential variable is included.
Availability
Must be available to the AI upon request. (Doesn't have to
be on site).

P-Numbers
QW-200.3
To reduce the number of welding procedure qualifications required, PNumbers are assigned to base metals dependent on characteristics
such as composition, weldability, and mechanical properties, where
this can logically be done; and for steel and steel alloys (table
QW/QB-422) Group Numbers are assigned additionally to PNumbers. These Group Numbers classify the metals within PNumbers for the purpose of procedure qualification where notchtoughness requirements are specified. The assignments do not imply
that base metals may be indiscriminately substituted for a base metal
which was used in the qualification test without consideration of the
compatibility from the standpoint of metallurgical properties, postweld
heat treatment, design, mechanical properties, and service
requirements. Where notch toughness is a consideration, it is
presupposed that the base metals meet the specific requirements.

QW-202
Type of Tests Required
QW-202.1 Mechanical
The type and number of specimens for groove welds
specified in QW 451.

QW-202.1 Mechanical
Removed in a manner similar to that
shown in QW 463.
If any specimen fails, the coupon shall fail
(new test must be conducted).
QW-202.2 Groove and Fillet Welds
(a) Coupons shall qualify the thickness
ranges for base metal and deposited weld
metal. Qualification limits shall be in
accordance with QW 451. Groove weld
qualifications will be made on groove welds.
(b) Partial penetration groove welds shall be qualified in
accordance with the requirements of QW 451 for both base metal and
deposited weld metal thickness, except there need to be no upper
limit on the base metal thickness provided qualification was made on
base metal having a thickness of 1 1/2 in. or more.

 QW-202.3 Weld Repair and Buildup

Groove weld qualifications are applicable to weld repairs to
groove and fillet welds and for weld buildup provided:

(a) There is no limitation on the thickness of base metal or

deposited weld metal for fillet welds.

(b) For other than fillet welds, the thickness range for base
metal and deposited weld metal for each welding process shall
be in accordance with QW-451, except there need be no upper
limit on the base metal thickness provided qualification was
made on base metal having a thickness of 1-1/2 in. or more.
QW-202.4 Dissimilar Base Metal Thicknesses
Groove weld qualifications are applicable to welds between
dissimilar base metal thicknesses provided:
a) The thinner member thickness is within the range permitted
by QW 451.

 QW 202.4 Dissimilar Base Metal Thicknesses (cont'd)

b) The thickness of the thicker member is:
Within the range permitted by QW-451, except there is no
limitation on the maximum thickness of the thicker production
member provided qualification was made on base metal of 11/2" or greater.
For P-No. 8, 41, 42, 43, 44, 45, 46, 51, 52, 53, 61, and 62,
there is no limitation on the maximum thickness of the thicker
production member in joints of similar P-number materials;
provided, qualification was made on base metal having a
thickness of 1/4" or greater.
Positions
A PROCEDURE qualification run in any position qualifies the
procedure for use in all positions. The welding process and
electrodes must be suitable for use in the positions permitted by
the WPS.

QW-210
Preparation of Test Coupon
QW-211 Base Metal
Can be plate or pipe, or any product form, and the coupon shall
have sufficient dimensions to provide the required specimens.
QW-212 Types and Dimensions of Groove Welds
The type and dimensions of groove welds is a nonessential
variable unless otherwise provided in QW-250.

QW-253

QW-300 General
QW-300.1
This article lists essential variables for welder/welding
operator by process. Welder qualifications are limited by the
variables given for each process in QW 250. Welding Operator
qualifications are limited by the variables given in QW 390 for
each type of weld.
Except as stated in QW 304 and QW- 305, a welder or welding
operator may be qualified by radiography of a test coupon, or
first production weld, or by bend tests taken from a test
coupon.
QW-300.2
Manufacturer is responsible for qualification of welders and
operators. Cannot subcontract this responsibility. In an
organization with more than one company, if effective controls
can be maintained, one company may use the welders from
another company within that organization.

QW-300.3
Multiple Certifications of Welders and Welding Operators
can be accomplished if:
1) The WPS used is identical to that used by the participating
Manufacturer (except for PWHT).
2) The base metal and deposited weld metal thickness are
within the thickness range specified on the participating
manufacturer's qualified WPS.
OR
The participating organizations shall agree upon the use of a
single WPS provided each participating organization has a
PQR(s) to support the WPS covering the range of variables to be
followed in the performance qualification. This single WPS must
be accepted by each participating organization.

QW-300.3
Multiple Certifications of Welders and Welding Operators can be
accomplished if: (cont'd)
3) Each welder or operator shall be positively identified by
each participating organization, and verify the marking on each
weld coupon.
4) Each organization shall visually examine the test
coupons and each test specimen.
OR
After visually examining the coupon, may accept a report from
an independent test lab as basis for accepting or rejecting the
test results.
If coupons are radiographically examined, the report from an
independent lab may be used for acceptance or rejection.

 5) Each organization will complete and sign a qualification record.

6) When a welder changes employers between participating
organizations, the employing organization will verify that the welder's
continuity of qualifications has been maintained as required by QW
322. If qualifications have been withdrawn for specific reasons, the
employing organization shall notify all other participating
organizations that the welder's or operator's qualifications have been
revoked in accordance with QW 322. l(b). The other participating
organizations shall determine that the welder or welding operator can
perform satisfactory work.
7) When the qualifications are renewed in accordance with the
provisions of QW-322.2, each organization shall be represented by an
employee who is responsible for welder qualifications. The testing
procedures shall follow the rules of this paragraph.

QW-301
Tests
QW-3 01.1 Intent
To determine the ability of the welder to make a sound weld.
QW-301.2 Qualification Tests
The test coupon will be welded in accordance with a qualified
WPS, except that preheat or PWHT may be omitted. Visual,
mechanical, and radiographic examination requirements are given
in QW 304 and QW 305. Retests and renewals are covered in QW
320. Welders who qualify procedures are qualified within the limits
of QW- 303 and QW 304or QW 305.
QW-301.3 Identification
Each welder will be assigned and an identifying number, letter,
or symbol, which will be used to identify the work of that person.
QW-301.4 Records
The WPQ will include the essential variables, the type of test
and test results, and the ranges qualified in accordance with QW452.

QW-452

GENERAL NOTE: The "Thickness of Weld Metal" is the total weld metal thickness
deposited by all welders and all processes in the test coupon exclusive of the weld
reinforcement.
NOTES:
(1) To qualify using positions 5G or 6G, a total of four bend specimens are required.
To qualify using a combination of 2G and 5G in a single test coupon, a total of six
bend specimens are required. See QW-302.3. The type of bend test shall be based
on weld metal thickness.
(2) Coupons tested by face and root bends shall be limited to weld deposit made by
one welder with one or two processes or two welders with one process each. Weld
deposit by each welder and each process shall be present on the convex surface of
the appropriate bent specimen.
(3) One face and root bend may be substituted for the two side bends.

QW-302
Type of Test Required
QW 302.1 Mechanical Test
Per QW 452. Removed from coupon in a
manner similar to that shown in QW 43.2(a)
through (h). Must meet requirements of QW
160or QW180
QW-302.2 Radiographic Examination
Minimum length of coupon is six inches and
must include entire circumference of pipe weld.
For small diameter pipe, more than one
coupon may be necessary to meet the six inch
criteria, but the number of coupons need not
exceed four consecutively made test coupons.
Acceptance perQW-191.

 QW-302.3 Test Coupons in Pipe

1G or 2G position - Two specimens as shown in QW-463.2(d) or
(e) omitting the specimens in the upper-right and lower-left
quadrants, and replacing the root-bend in the upper-left of QW463.2(d) with a face-bend specimen.
5G or 6G - Specimens per QW-463.2(d) or (e). All four shall
pass the test.
2G and 5G - Specimens per QW-463.2(f) or (g).
QW-302.4 Visual Examination
Plate coupons, except "discard" areas, and entire circumference of
pipe welds, inside and outside will be visually examined per QW-194.

QW-303 Limits of Qualified Positions and

Diameters (See QW-461)
QW-303.1 Groove Welds - See
QW-461.9
Groove weld qualifications also
qualify for fillet welds in any
thickness or diameter.
QW-303.2 Fillet Welds - See
QW-461.9 QW-303.3 Special
Positions
Qualifies for the special
position and the flat position.
Fifteen degree angular and/or
rotation deviation permitted.

QW-304
Welders
Except for special requirements of QW 380, all welders will
pass the mechanical and visual examination of QW 302.1 and
QW 302.4
For welders using SMAW, SAW, GTAW, PAW and GMAW
(except short circuiting mode) radiography may be used for
qualification except for P- Me. 21 thru 25, P nos. 51 thru 53, and
P nos. 61 and 62 materials.
Groove welds made with GTAW in P Ms. 21 thru 25 and P
Nos. 51 thru 53 may also be radiographed.
A welder qualified to weld in accordance with one WPS is
also qualified to weld in accordance with other WPS's, using the
same welding process, within the limits of the essential variables
of QW 350.

QW-304.1
Examination
Test coupon welds may be examined by visual and mechanical
examination or by radiography for the process(es) and mode of metal
transfer specified in QW-304.
OR
A six inch length of the first production weld made by a welder
using the processes(es) and/or mode of metal transfer specified in
QW-304 may be radiographed.
QW-304.2
Failure to Meet Radiographic Standards
If a production weld is used to qualify a welder and it does not meet
the radiographic acceptance standards, the welder has failed and the
entire production weld must be radiographed and repaired by a
qualified welder. Retests are permitted per QW-320.

QW-306
Combination of Welding Processes
A welder may use a separate test coupon for each process.
A welder may use one test coupon for several processes.
Two or more welders may use the same test coupon with the
same or different processes.
For combination, qualifications in a single test coupon, the
limits for thicknesses of deposited weld metal, and bend and fillet
testing, are given in QW-452 and shall be considered individually
for each welder and each welding process or whenever there is a
change in an essential variable.
Combination qualifications in a single test coupon can be used
in production either together or individually, or in any combination.
The production welds must be within the welders limits of
qualification.
Failure of any portion of a combination qualification is failure for
the entire combination.

QW-310
Qualification Test Coupons
QW-310.1
Pipe welds in the 2G and 5G position must be made with
coupons meeting the requirements of QW-463.2(f),or(g).
QW-310.2
Welding with backing must be done with a joint that is listed on a
qualified WPS or per QW-469.1
QW-310.3
Welding without backing must be done with a joint that is listed
on a qualified WPS or per QW-469.2
QW-320
Retests and Renewal of Qualification
QW-321 Welders that fail may be retested under the following: QW321.1
Immediately using visual examination. Must make two
consecutive coupons for each position. All must pass.

QW-321.2
Immediately using mechanical testing. Must make two consecutive
coupons for each position. All must pass.
QW-321.3 Immediately using radiography.
a) For plate, must examine two 6 inch plates. For pipe, must
have two pipes for a total of 12 inches of weld, which shall include
the entire weld circumference. (For small diameter pipe the total
number of consecutively made test coupons need not exceed eight).
b) At the option of the manufacturer, the welder who has failed
the (production weld alternative) test in QW 3)4.1 may be retested
by radiographing an additional 12 inch length of the same production
weld.
If this length of weld passes the test, the welder is qualified and the
area of weld on which he had previously failed the test shall be
repaired by him or another qualified welder. If the 12 inches do not
pass, the welder has failed the retest and all of the production welds
made by this welder shall be radiographed completely and repaired.

QW-321.4 Further Training

When the welder or operator has had further training or
practice, a new test shall be made for each position on which he
failed to meet the requirements.
QW-322
Expiration and Renewal of Qualification
QW-322.1 Performance Qualification is Affected By:
a) He has not welded with a process during period of 6 months
or more
A welder can maintain qualification by using a manual or
semiautomatic process.
An operator can maintain qualification by using a machine or
automatic process.
b) When there is a specific reason to question his ability.
Qualification is revoked only for the welding being done, not for
any other qualification.

QW-322.2
Renewal of Qualification
When qualifications expire under QW-322.1 (a), renewal may
be done by welding a single test coupon of either plate or pipe, of
any material, thickness or diameter, in any position, and by
testing of that coupon as required by QW-301 and QW-302. If
successful, all previous qualification for that process are renewed.
Renewal of qualification may be done on production work.
Qualifications revoked under QW-322.1 (b) require
requalifications under QW-301 and QW-302.

QW-353

QW-500
General
SWPS's listed in Appendix E only
Construction Code take precedence
Not to be used for impact tested construction
QW-510
Adoption of SWPS's
Enter name on SWPS
Sign SWPS
List applicable Code Section (may be added later. SeeQW-511)
Perform groove weld test

QW-510
Groove Weld Test Requirements
Record
Base Metal specification, type and grade
Groove design
Initial cleaning method
With or without backing
ASME/AWS specification and AWS classification and manufacturer's
trade name
Size and classification of tungsten
Size of consumable electrode or filler metal
Shielding gas and flow rate
Preheat temperature
Position and progression (if applicable)
Weld metal deposit thickness for each process or electrode type
Maximum interpass temperature
PWHT including holding time and temperature
Visual inspection and mechanical testing results
Results of RT

QW-520
Changes That Require Demonstration
Change in process
Change in P- or S- Number
Change from as-welded PWHT (not vise-versa)
Change from gas shielded to flux cored
Change from spray, globulas, or pulsed to short circuit (and
vice-versa)
Change in F-Number
Addition of preheat
Change from sheet metal SWPS to one that is not

QW-540
Use of SWPS's
Welding must be done in strict accordance with the SWPS's
Code user may not deviate from conditions specified
SWPS's may not be supplements with Section IX PQR's
Only revision is to add new fabrication document
Only processes shown on SWPS's may be used
Multiple processes must be used in order specified on SWPS
May attach additional instructions to help welder
Additional instruction may not violate ranges on SWPS
Can't use SWPS until demonstrated
Note demonstration number on SWPS
Supporting Demonstration Record must be available to the AI