SAMI CMI

PROJECT

Welding qualification
SAMI CMI
AWS D1.2

Prepared by ACHREF OUNI

Date 07/02/2023

Saudi Advanced Technologies Company 1

 Summary

1- General 3

1- WPS Variable selection 7

2- Process Qualification “PQR” 12

3- Welders qualification “WPQ” 16

4- Quality & inspection 20

4- Conclusion 24

2
0- General

3
 0- General

0.1 Scope : This document cover the welding process qualification as per AWS D1.2 and welding
requirements for project SAMI-CMI

0.2 General :For Welding qualification we require 3 essential Records

( Procedure then Process and personnel qualification ) :

Qualify the Process :

1- WPS : Procedure Describe the parameter that we are

going to qualify Require preparing specimens
2- PQR : is the qualification of the procedure and tests ,See section 2

Qualify the welders following the PQR

Require preparing specimens
3- WPQ : welders qualification and tests ,See section 3
4
 0.3 CMI Welding
requirements
0 - General

In CMI Project Batch 3 ,

the drawing call for
welding
spec 017884-113

welding spec 017884-113 Requirements

regarding qualification :
=> only written WPS required without supporting
qualification .

Wahaj Can choose to go through the

qualification as per AWS D1.2 that will gain
us other project .
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 0.4 – AWS
material Group 0- General

Base material Group

Filler Group

Material to be used as per DRW :

❑ Main : 5083-H32 OR 5086-H32

➢ Group M25

❑ Alternative : 6061-T6/T651
➢ Group M23

Qualification of one material from one group shall qualify for all the material in that group .
e.g. if we qualify 6061 , we will be qualified to weld M23 group . 6
1- WPS Variable
selection

7
 1.1 WPS Writing
2- Qualification “PQR”

In our case , for qualification we

only require is a writing WPS as
per “Annex E” of AWS D14.3
(Pages158-159) .

For electrical & gas parameters,

travel speed ,preheat and pass
nbrs, please refer to filler TDS
and consult TCR for validation
after sharing the drawings

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 1.2 Filler
Selection
1- WPS Variable selection

Material to be choose (SCM + ME ) :

❑ Main : 5083-H32 OR 5086-H32
❑ Alternative : 6061-T6/T651

Filler to be used :
According to the choosing base material
❑ Alu 5083 => Filler 5183
❑ Alu 5086 => Filler 5356 or 5183 or
5556
❑ Alu 6061 => Filler 4043 or 5356 or
5183 or 5556 or 4047

➢ 5183 can weld all the above

9
 1.3 Gas & Position
Selection
1- WPS Variable selection

Gas Selection :

For aluminium :
=> use Ar , He or Ar-He Gases

After the filler selection , refer to the filler

technical data sheet to know the
recommended gas mixture ratio .

Welding Position :
Position to be qualified is 2G

Position 2G shall qualify :

❑ All groove weld position F,H
❑ All fillet weld Position F,H
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 1.4 fill pass
thickness
2- Qualification “PQR”

Maximum fill pass thickness is 6 mm

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 2- Process
Qualification
“PQR”
12
 2.1 Required
specimens PQR 2- Qualification “PQR”

For SAMI-CMI Project we have See Table 3.4 for the requirements for qualifying a WPS of a
only fillet welding , however by complete penetration (CJP) Groove weld
qualifying groove it will qualify
both groove and fillet

Select thickness between 3 and 10 ,

it shall qualify from 3 mm to 2 times
the thickness
e.g. test piece 8 mm
=>qualify 3 to 16

13
See Next page for test pieces
 2.2 Tests
required for 2- Qualification “PQR”
PQR

Required
1. Prepare 2 plates (each 18 x 50”min” cm) , then create
chamfer 45 degree
2. groove weld
3. cut into 6 sections as shown in the figure :
2 tests face bend + 2 root bend + 2 reduced section tension

TCR to witness & provide :

• 1 PQR for aluminium - groove 2G
• Supporting records of the following tests :
❖ Visual inspection as per clause 3.6
❖ Macro etch test as per clause 3.6.1.2
❖ 4 root & face bend
❖ 2 Tension test
14
 2.2 Tests
required for 2- Qualification “PQR”
PQR
Face and Root Bend Side Bend Reduced-Section Tension
Specimens Specimens Specimens (as per 4.8.3.4 in D1.1)

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 3- Welders
qualification
“WPQ”
16
 3.1 Required
specimens WPQ 3- Weldres qualification “WPQ”

Other then PQR , other different tests & specimens must be conducted for
Welder qualification WPQ

Position to be qualified is 2G

Select thickness between 3 and 10 ,

it shall qualify from 3 mm to 2 times
the thickness
e.g. test piece 8 mm
=>qualify 3 to 16

17
 3.2 Tests
required for 3- Weldres qualification “WPQ”
WPQ
Required
1. Prepare 2 plates (each 18 x 70 cm) , then create
chamfer 60 degree
2. Use backing and separate weld pieces by 10 mm ,
3. groove weld
4. finally cut as shown in figure 3.26 to obtain 2
specimens :
1 face bend + 1 root bend (can be replaced by Radio-grph)

Note : backing width to be 75 mm , if we choose Radio-grph (RT)

shall be 25 mm
TCR to witness & provide for each selected welder
(Mr. Anwar shall provide the number of welders to be selected :

❑ WPQ for aluminium - groove 2G

❑ Supporting records of the tests :
❖ Visual inspection
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❖ 2 root & face bend test or Radio Test See Next page for test piece
 3.2 Tests
required for 3- Weldres qualification “WPQ”
WPQ
Face and Root Bend Specimens Alternative : Radiographic examination

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4- Quality &
inspection
20
 4.1 SAMI
requirements 4- Quality & inspection

SAMI inspection Requirements :

Prior to welding production parts, the following welding inspections are necessary, under SAMI-CMI
Requirements (weld standard 017884-113):

❑ Weld size measurement

❑ Visual inspection
❑ Workmanship and weld quality section 4 & 5

NDT Requirements :
AWS D1.2 state that NDT can only apply if it is
demanded by customer documents , which in our
case is not required .

However can be used for First batches , if we will

use NDT-PT it should be as per ASTM E165 and
acceptance criteria as per table next page .
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 4.2 Visual
inspection 4- Quality & inspection

Please refer to this table , for

acceptance criteria of Visual
inspection

22
 4.3 Workmanship
and weld quality 4- Quality & inspection

Workmanship and weld

quality :

Refer to 5.5 clauses for

additional inspection
requirements

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5- Conclusion

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 4- Conclusion

Conclusion :

❑ SAMI-CMI Requirement doesn’t required qualification ( PQR & WPQ ), only writing WPS is required .
 We don’t need EQN .

❑ However I recommend to do the qualification to ensure the welding as per requirements , also to have qualified welders in
aluminum as per AWS D1.2 in case t is required in the future .
❑ The drawing call for 3 alternative material , for each there is different filler to be used , SCM shall choose the material to be
ordered and also see the availability of filler determined in page 9
• For base metal Alu 5083 => Filler 5183
• For base metal 5086 => Filler 5356 or 5183 or 5556
• For base metal 6061 => Filler 4043 or 5356 or 5183 or 5556 or 4047
=> ER 5183 is common

❑ In this document the all required data and variables are extracted to build our WPS , After Filler selection , Dear Anwar please extract
the recommended variables as per filler data sheet and consult TCR for the remaining variables .
❑ NDT is not required by customer drawing or D1.2 , However it is recommended for the first batches , we require Qc personel who is
qualified in visual inspection or we outsource it .
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~Thank you~

Prepared by

Achref Ouni
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