TOOLS FOR REVIEWING WELDING PROCEDURES Analytical aids based on documented welding procedures are offered to engineers for evaluating WPSs BY DUANE K. MILLER AND R. SCOTT FUNDERBURK or tractus tel projects, AWS DI.! Scrat eldang Code Sie pay the governing coe, apd eling procedure speciation (WBS) ae conta te conaling wad [oaly inthe appcntine Although comiatorwetesthe EPss forthe pinay panpos of rstucting tne webct Eo inser of Recnd maybe Fguied wo review them or cme {Entapprov This paper cons some ool bel the eng ter ths proven It notte author ntnton to prosde 4 eroprenense issn on fw to review WPS but ater ode incre fow new analyica ook for ue by te reviewer, While thaed on AWS DIL! principe, these tol” are appcable ‘ther alaing situation These anc! toni re Soe om aprons 270 at ferent docuented welding proces (Refs 3 3), Talued sree procedures for ailded meal are welding (&MAW), ma ‘etal ate weling (GMAW), else fax cored are wel Ing FCAWS), go sete fv cored are welding FAW) ‘snasbmergeie wang (SAW wisn, parle and mul {le kesrodes. Tis Gtaban genealyvepresentaive of > Jeulstrstrs sel abrietionproesares a was ned 10 de ‘lop the eget and general chs presente hee Heat Input ‘When reviewing welding procedes, perhaps tbe moet cultanput hctermining wich combination! amperage volt grand tanclspoed wil be acepable ora gen appa Those tne armies diy alet heat inp, wtih 8 te sure ofthe amount of enexgy transfered ding the welding rots. Heat input scat oe oll soe 70005 o seers, = ate voltage, I= curren, = wel pee ina ino Hs beat np bn om). cut eput usual motes withcocing tex the weld andeatatteced zone (HAZ), Hower, hea inp aoc ‘ety props to the Indvalweld Beas sre sco ig 1 — ils oi fein of hea ip. sire. Figure I shows the se of le ld incre he est Input increas ‘Tool No. |: Fillet Weld Size ase onthe claims bstwcen Rea inp and wel it spon to pedi the suo let wld the et np ‘sksown. The flowing eelatonahip piel secure che rnd let weld si ¥5o00 e-ssit US. castomary metic a hee — ke. am) and H = heating, inn “Went aleiated dota value sonnei oe nent sete we seston eres pally (0 ‘predicted loge pal eal 0 he ace el nese etn sam be esd 9 pred heat apt ee for arin it weld ae (DUANE K, MILLER (dvsne_milerlincolnelectric com) s Manager, Welding Techwology Center and R, SCOTT FUNDERBURK {cot fanserbur inclines cn i lig Design Enger The incon Plc Co. Cleland Oi, 40 ju1y 2001ze Heggy mete @ ‘Ts allows for a quick predistion ofthe heat inp thal wll be achined tase upon the requisite weld sue I fr example ein. (127mm) flet weld made na single pass, the Rost Sapa mond be aprosimaiely 125 kin. (3 Elio), Following isan cxample of how one would check propesed procedure to determine i he electrical vals ould proce fhe expected filet weld ie Example t contractor propose tose submerged acto make in ‘et wed using the following parameters: let daetey, ‘ins polar, BC-seurrent $75 Aivolags 34¥; rvel peed Binimin, Te this sable combination of variables for this of filet. coe _ 601341575) fe = S0801829 537m [A (533 cas26in or 52 on Gin [igo Oren w ‘Terefore, the proposed procedute should be capable of producing ain filet wel. Tool No. 2: Square Groove Welds tn ode o minimize joint preparation css, square groove wes may be employe. This complete ot penetration (CIP) Meza aot prequalified according to AWS DIL. To success: fay achieve complete fusion through the cross scion, a ale ne us be achieved 10 blan adequate penetration and yet ‘woidmeitahrough. If mo backing sapiie fo the ont, seen ally iit told melt throug the level penetration {ceeds approximately 60% of the cross section, partial, ‘wen welding om the fst side The second ke wel Is re Tentant to methrough: the lt factor ela gon Tu of ‘tam Obviously les than Se penetration i acloved from ‘achside, «CIP wed cannot be achieve. With 0% fom each Siete willbe an approximate 20% overlap between he wo doqute to provide repeatbily. The musa heat laput that canbe applied by a first-pass wel without melt ‘Brough un be estimated fom the following lot = 1301-15 US.eustomary 4, 234-060 meine 6) ere H = heat input, ii.) and = plate thickness, in (am) Wi the scondsideweldcan tolerate het inputs up tothe US. customary =060 merc © When reviewing WPS ne can simply us the following en Sots ctermine the sbeolte msm heat np prevent seh Vas 150 US.evstomary Fig 2— Plo of #2 submerged are welding procedures la = 0231 metic o “The preceding lationship 2 hased upoa SAW with DC> polarity the process pial employed when deep penetration Fccessry for achicing CIP welds in aque ede but joint. Potted in Pig 2 are 42 sobmerged are wedng procedures and Joins from Ref. rand blow ae thee spplcble equations This rows Some msg no the xi eat Us that can be tolerated tr avoldmelt-trough, but in ocd ‘chive adequate penetration, the heat input should hea east {0% of the amximum value, Below san example, Example 2 A proposed WPS involies a CIP neld on asquar-cge ut fein ivoling in. tcl. Submerged arc welding iso Be used ‘wth he folowing proposed parameters electrode dlmer, in polarity, DO, caren side 1 — 750 Aske 2830 A: ‘oly do 135 V side 23 Vravel speed 32-38 in/min, “The range ol teivelspecd would bewithin a= 10% range of ‘nominal 35 ian. Will mele chrough occur? The heat input oF he irs sie Clelated wit he lowest ropescl trv! spced that wl ge the highest eat input Aa =n soln “hath tae wih ee tae "Asia erie f cautions show the maximum scond ‘sae heat inp oe 7.8 in. 0) “Tis would predic that mel through might be a posit. An increase to" jin decreases the heat input to 54 Min. ‘Sn secepabl level. Tha proponed WPS could not be pega fied due wth hassel thickness, 0 procedure qualics- WELDING JOURNAL | 41Pig 9 Jon dei or Example tion cord (POR) shold accompany te proposed WPS. ‘iw ote stl travel speed ed would be avi Tobe best to cnt the nu wel speed to prevent net toh ‘Tool No. 3: Minimum Heat Input Levels for Multiple Pass Welds ‘The AWS DL. Sractral ein Coe — Sw! presrbes vinnie! wel seta a fancion of mater thes. “Thin ot for dein enor But ene the Rea In of “feline tm propos 0 matt tke rer 9 Troi protlems nach on incomplete sion and wnccepable Fuardeing ofthe Hewat zone. As as bees preosty ‘demons tsp to estima he eating eg fomatea ghenflctwel sz. Thi frapven plat eke, Ir iponie fo esate the rian hes imput esesry 8 ‘ide to ache the requhie mnimam ile weld ae “The cost stalghforeardupprouch ithe method inthe ‘ode that st ope the min let wel ire. However, {Ele ae e y t it for enh gen wel pase sain gs to {nee son and aid the etelopment of wns had feat steed ropes The fellow relationship has bee Se ‘hag imorer teint minim evel ot heat pt ee ‘Souysbused apn the fines of el Ding ined Hy 30 HSC US. customary o aw were. = bea input Lin, in) ana = pate bikes ‘n(n. Stee this an eqution to check the Ret ipa a ie the concern ber the inant el het eps he eg thon hordcen based up ke west veto eat Input esa $e with te snl ps filet wel Tat cine should be neces to erase the eat np beyond he tee SOI nm). providing ano ‘Setrades and presses are empge, Tis 8 eosin wih fpecode manasting no resto has 3 in (Se) et Wel ‘Rparlesropat ficktes, when ow hyrogen lotro and proceed we ‘Tool No. 4: Number of Weld Passes Required 42 yutr 2001 When avn it deta hasbeen sable tsps nih rea cae ani pos ne Spied wo complete he weld jon maya dee the te umber of psy he following equa eased a eho, WE = weight of weld metal per length of weld, Ht (gia) sha = est np An (mm) Example 3 ‘A proposed WFS utiles a best Input of 2 Kn. (95 in) asopgain a Sei, 44m file weldcan ere intpmes iste Suhel nld regu approsamaely So Batwed metal pot oo owt aos Ty240 71 pases (ob) “3 ‘Tool No. 5: Root Pass Thickness The oot ps groove wo al the mo iia past mak and mi be the most cia pat ofthe wel Fening the jot appeton, Eases ek a pes ‘ic contin sng ines an nsomplee peneraon. The ‘ow pans tackows mre wel hae pn the hea pat {elated from he wc parameters ean estimated fro ‘he following eelaon sip Th cron seal a a 8 wal deposited in one pas equ ae ‘ooo “4 ‘The cone sectional ara for grove weld (0 enforceme) sna toil ora V prove veld floss Hag 2 “9 where = oot pas thik (Sot not inde any poe Tron): R= rocopeinginsa= velangie Na = Ree tng No. rand = het inp “Combining the to relatamipe eal Hig bitoni yoo DT ie Mane, «a ‘Once impli the rt pos hicks hisetinated rom la oon + 2004 fara) reo fana sang) in Noise ns dened tthe noun of hapten tthe resource Tt des ntl rot pene Ther relaorhips cum as ews to determine te ma ‘mum cept heat ap ve! fore ee tout geomet ‘heron pases held apo lskaes, For example DL Di Table 7, tess the oo pashan fo regal {WPS forte saris processes. Sing forthe at pat{he previous equation yield the following equation: HE= 1000AR + 500K? tana + SOOKE (8) toe maximum allowable bead eight, heals in. (05 ‘(at postion SMAW. GMAW, FCAW por AWS DL.1), then he maximum allowable heat fepat canbe found by ng te perins equation 75R + 7034 + ta) uo (23mm):bom. np or other po “Tis equaton valid ony or equal ver one sould dctermie the aia Sons with varying maim bead heights. a Conse 4 B-U2-GF prequalified joint detail wih a root ‘pening equal Xin and am incl angle ot dry (a=, =0) Themaximum heat inpt forthe oot passto not exceed fhe a amu ticks would be 180 Li, Tool No. 6: Weld Root Details The specific gometry for CIP groove weld that devises ftom preculiied conditions sould be evaluated to deteronine hater the eometty is conde t sound welds thal wil be free ofexesse discontnutes and unaccepable cracks. Ace ‘epube combinations tte root openings and included angles te Imperato ensure hat eeteline cracking does not Se- ‘elsptecame oan inapprocrae wd to-depth ratio. In bene fal the econimendedwih4o-depth ratio oprohintcenter ln cracking varies fom 1019 18. The following equation cen te ued to evaluate any combination of Vgrome or beveled poor welds censure ths prope ais achive TP 0) where, W = head wid = bead depth; R= ret openings ‘bevel angle No.1) = bevel ale No.2: = depot pene Te; and h = bead heh ‘Te rot pass hikes (canbe calculatd fom the pee- ios presented relationship. The bead depth disequal to Deteminingthe depth of penetaton Sore dite, at for [roceduteevew purposes anette of 01251 wil onser ‘abvely identity joins where widthto-depth problems may ft This oto imply, however, that this vel of penetration Baten achved “Ahving the proper oot geomcty wil help pechad cen- tesne cracking ut I does not ensure Ireedom from incom pete fasion org nctoions. Th set scetsined by are ful examinstion of the macroctch specimen that i part Of ‘qulieuion tesng, Acceptable resuit rom the required aon -eeracine examination, swell at wessfl seals fom he ‘pte bend specimens wl poe ance os ond Example s Aonprequsifed joint detail ito he welded with 350,26 Wands rave! speed of 1m mn (heat input equals $4.64) ‘Thedouble Vgrove weld deals an inchided angle ot 3 oy anu root face cmension of 128 fn shown inthe shot ‘alo. Te desin requires compete joint pencrtion groove ela the welds toe made without ackgoaging Ther Is Some concern that tis situation may’ esl in an improper ‘wiilto dept ati, which could lend to centerline easkng Determine the wdtht-depts ea, I the potent fr root cracking an se? “Assuming a penetration of ins achieved the kings cakulate __—o0or + fan) + 208 (naan) 1000 fan a b e dog and = Puthena = 175 100040) + {100040} +2000 (54.6) (2tan17.8) 1000 fan173) 05241, 2 [Note hat this exceeds the code maxinum thickness f 0.575 in. forthe dat poston. Ne, a specie check onthe wih 10 pth rat is made w _R+hana+an8) 0» 0524(t0n175 a7 hep 7 a5zeyor07 w eo ) ‘This rato muh es than helmet recommendation of 10, and centerline cracking concern The gested proces are suspect, and the supporting POR shouldbe earful cite hed ‘Conclusions Welding musthe performed under coritons that canbe e pected to setive hgh quay zest A WPS I the pinay ‘ies by which the proper welding contin are coin fated the wel. ts eset he welder perform the ati ‘welag in eonformance with the WPS, batt equally impor {ant the WHS provide tbe values nectar for achieving ese als, When welding procedures fall ouside the puidelines re Served mre eattu seratiny of the procedure i sified, a, Ine appropriate, the services of an expert welding engines? Should be employed to properly evaluate the multi f the proposed WES. © References 1.45 Simca Wea Cole — Sel (AWS DLL 2000. Nie a! The Ameroan Welling ose 2. Ghat Me Wing Cad 19S Larue ulti # C420, (Cleveland, Ot Tee binela Rec Co, 3. The Powers Han ofc eng. 1994, Cleveland, Odo: ‘The lames Lica Are Webi Foundation. WELDING JOURNAL | 43