CSWIP 3.

1: Noted points –
Part 2
1) WPS:

 To come out a WPS we need follow these below steps – 5 steps:

 Five Step Process to Qualify a Welding Procedure:

1. Understand the intended application for which the WPS will be used
2. Develop a draft procedure ( pWPS )
3. Make a qualification weld ( PQR )
4. Test the qualification weld ( PQR )
5. Write up the WPS ( WPS )

 Step No. 2: we can understand it is pWPS ( prequalified WPS )

 Step No. 3: it is PQR

So, between WPS & PQR: PQR have first.

Note:

+ Various WPS can derive from one pWPS.

+ Re-approval of a welding procedure is necessary if there is a change of any of the

essential variables or considerable defect re-occurrence.

2) Welder: Types of Approval Tests.

Tests that are prescribed by most codes and standards are in the main similar.
Common tests are:
a. Plate and structural members.
b. Pipe welding.
c. Positions of welding.
d. Testing of approval test pieces.
e. Re-tests

Notes:

+ As general rule welders who qualify for certain joints on pipe need not qualify for
plate work, but qualifications on plate do not apply to pipe work.

+ The tests should be carried out without interruption but with sufficient supervision
to ensure that the requirements are being complied with. Where welder approval is
carried out in accordance with ASME section IX it states that the person supervising
the test may, if in his opinion he considers that the welder will not meet the required
standard, terminate the test at any time. If it is necessary to apply this ruling, it is
suggested that full reasons for termination be recorded. It is further recommended
that the test piece should also be kept for a short period as a means of backing up
written statement.

+ If the test is to be supervised by a representative of an independent authority he

should be given all the relevant details of the testing required.

+ Where British standards are involved, they generally state that if the welder is of
the opinion that his first attempt may not pass any subsequent testing, he may
withhold it and weld a second. In this case it is the second test piece that is submitted
for examination and the first one must be scrapped.
3) DESTRUCTIVE TESTING

Commonly used destructive tests are:

+ Bend
+ Tensile
+ Charpy
+ Fracture tests
+ Macro section

Ex:

+ TRANSVERSE TENSILE TEST:

– The reduced section tensile test normally fails in the parent metal and so it is
not
designed to give the tensile strength of the weld.
– The radius reduced tensile test is a test of the as deposited diluted weld metal.
The all weld tensile test, using a longitudinal section from the weld only, is used to
check the as deposited undiluted weld metal. (Usually used by consumable
manufacturers.)

 Tensile strength, in Newton’s per mm squared, is calculated from maximum load

and original cross sectional area. When excess weld metal is not removed, the
cross sectional area shall be the product of the parent metal thickness and
the width of the specimen .

Pls take note:

+ Elastic & plastic:

+ Offset 0.2%:
+ Yield strength & tensile strength:
Ductile / Brittle Transition Curve:

Pls note for Carbon steel & Stainless steel: it is difference at low temperature.
+ MACRO SECTION: To examine a cross section of a weld for internal defects and
soundness.
– A transverse section of the weld is cut out. The cross section is then visually
inspected. The section is filed down from rough to smooth, then emery or wet/dry
papered down to a surface finish of 600 grit. The surface is then etched in NITAL (5%
– 10% nitric acid in alcohol), washed off, rinsed and dried. (Possibly a final clean with
acetone and mount in Bakelite.) The specimen is then inspected at up to 10-x
magnification.

Comparison of macro section and micro section:

MACRO MICRO
Magnification X 10 X 1000
Finish 600 grit 1 micron (high level polish)
Features/defects cracks, slag, LOF, etc. intergranular structure
Uses procedure/welder qualification research/failure analysis

Note: We divide tests into Qualitative & Quantitative methods:

for easy remember: it is divided by 2 group and identify via “unit”. Group
Quantitative have Units and Group Qualitative don’t have Units.