ASME BPVC.
IX-2021
QW-290.5 Test Coupon Preparation and Testing.
(a) The test coupon may be any geometry that is suit-
able for removal of the required specimens. It shall con-
sist of a groove weld, a cavity in a plate, overlay, or
other suitable geometry. The distance from each edge of
the weld preparation to the edge of the test coupon shall
be at least 3 in. measured transverse to the direction of
welding. The depth of preparation shall be such that at
least two layers of weld metal are deposited, one of which
may be the surface temper bead layer and deep enough to
remove the required test specimens.
(b) Only bend tests in accordance with QW-451 are re-
quired for the additional temper bead qualification when
either hardness or toughness testing is also required. No
qualified limitations or process essential or supplemen-
tary essential variables, if applicable, per QW-250 may
be affected. Where neither maximum hardness nor tough-
ness testing is specified by the referencing code, standard,
or specification, all of the test requirements of QW-451
apply.
(c) When hardness testing is specified by a Construc-
tion Code or Design Specification, measurements shall
be taken across the weld metal, heat‐affected zone, and
base metal using the Vickers method with a 10-kg load.
Increments between measurements shall be as specified
in ASTM E384. As an alternative to the Vickers method,
Instrumented Indentation Testing in accordance with
ASTM E2546 may be used with test forces in the macro
range of 2.2 lbf to 265 lbf (1 kgf to 120 kgf) and incre-
ments between measurements as determined in accor-
dance with ASTM E2546.
(1) Measurements shall be taken along a line at ap-
proximately mid-plane of the thickness of the test coupon
weld metal. Along this line, there shall be
(-a) a minimum of two measurements in the weld
metal fill layers.
(-b) at least one measurement on each: the weld
beads against base metal, first-layer tempering beads,
and the second-layer tempering beads.
(-c) a minimum of three measurements in the
heat-affected zone. These measurements may be taken
in a line approximately parallel to the HAZ when spacing
between impressions does not allow for three measure-
ments to be taken in a single line transverse to the HAZ.
(-d) a minimum of two measurements in the unaf-
fected base metal.
(2) Additional measurements shall be taken along a
line approximately 0.04 in. (1 mm) below the original
base metal surface. Along this line, there shall be
(-a) a minimum of two measurements in the weld
metal fill layers
(-b) at least one measurement on each: the weld
beads against base metal, first-layer tempering beads,
and the second-layer tempering beads
(-c) one measurement located immediately below
the toe of the weld bead and at least one measurement on
each side of that impression
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(3) When the coupon is a full-penetration groove
weld made from one side, additional measurements shall
be taken along a line approximately 0.04 in. (1 mm) above
the root side surface. Along this line, there shall be a mini-
mum of two measurements in the weld metal, two in the
heat-affected zone, and two in the unaffected base metal.
Full‐penetration groove weld test coupons qualify full
and partial penetration groove welds, fillet welds, and
weld build‐up. Partial penetration groove weld test cou-
pons only qualify partial penetration groove welds, fillet
welds, and build‐up. Overlay test coupons only qualify
overlay welds.
Hardness readings shall not exceed the hardness
limits specified by the Construction Code or Design
Specification.
(d) When toughness testing is specified by the applica-
ble Construction Code or Design Specification, the test
coupon shall be tested for toughness. The extent of testing
(i.e., weld metal, HAZ, unaffected base metal), the testing
temperature, and the acceptance criteria shall be as pro-
vided in the applicable Construction Code or Design
Specification.
QW-290.6 In-Process Repair Welding.
(a) In‐process repairs to welds made using temper
bead welding are permitted. In‐process repairs are de-
fined as repairs in which a flaw is mechanically removed
and a repair weld is made before welding of a joint is pre-
sented for final visual inspection. Examples of such re-
pairs are areas of removal of porosity, incomplete
fusion, etc., where sufficient metal has been mechanically
removed that localized addition of weld metal is neces-
sary in order to make the surface geometry suitable for
continuation of normal welding.
(b) Surfaces to be repaired shall be prepared by me-
chanical removal of flaws and preparation of the surface
to a suitable geometry.
(c) For processes other than manual and semiauto-
matic GTAW and PAW, repairs shall be made using the
parameters given in the WPS for production temper bead
welding. The approximate location of beads to be depos-
ited relative to the original base metal surface shall be
identified, and the applicable parameters shall be used
for the layers to be deposited as specified by the WPS.
(d) When it is necessary to make repairs using manual
or semiautomatic GTAW or PAW, a WPS shall be prepared
based on PQRs developed for temper bead welding using
machine or automatic GTAW or PAW, respectively. This
WPS shall describe the size of the beads to be deposited
and the volts, amps, and travel speed to be used for the
beads against the base metal, for each temper bead layer
and for the fill and surface temper bead layers corre-
sponding to the locations where repair welding is to be
done. These shall be within the equivalent power ratio
for machine or automatic welding for the respective
layers given in QW-409.29.