ASME BPVC.
IX-2023
NONMANDATORY APPENDIX H
WAVEFORM CONTROLLED WELDING
H-100 BACKGROUND
Advances in microprocessor controls and welding
power source technology have resulted in the ability to
develop waveforms for welding that improve the
control of droplet shape, penetration, bead shape and
wetting. Some welding characteristics that were
previously controlled by the welder or welding operator
are controlled by software or firmware internal to the
power source. It is recognized that the use of controlled
waveforms in welding can result in improvements in
productivity and quality. The intention of this Code is
to enable their use with both new and existing procedure
qualifications.
The ASME Section IX heat input measurement methods
in QW-409.1(a) and QW-409.1(b), were developed at a
time when welding power source output was relatively
constant. The heat input of welds made using waveform
controlled power sources is not accurately represented by
QW-409.1(a) due to the rapidly-changing outputs, phase
shifts, and synergic changes, but is correctly represented
by QW-409.1(b) or QW-409.1(c). During waveform
controlled welding, current and voltage and values
observed on the equipment meters no longer are valid
for heat input determination, and must be replaced by
instantaneous energy (joules) or power (joules/second
or watts) to correctly calculate heat input.
QW-409.1(c) more accurately reflects heat input
changes when performing waveform controlled
welding, but is also suitable for nonwaveform controlled
(conventional) welding.
H-200 WAVEFORM CONTROLLED WELDING
AND HEAT INPUT DETERMINATION
Power sources that support rapidly pulsing processes
(e.g., GMAW-P) are the most common waveform
controlled power sources. Power sources that are
marketed as synergic, programmable, or microprocessor
controlled are generally capable of waveform controlled
welding. In these cases, heat input is calculated by the
methods outlined in either QW-409.1(b) or
QW-409.1(c) when performing procedure qualification
or to determine compliance with a qualified procedure.
If any doubt exists on whether waveform controlled
welding is being performed, the welding equipment
manufacturer should be consulted. It is recognized that
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waveform controls may not be active for all of the
welding processes or equipment settings for a particular
power source. When the waveform control features of the
equipment are not used, the heat input determination
methods of either QW-409.1(a), QW-409.1(b), or
QW-409.1(c) are used.
When the welding equipment does not display instan-
taneous energy or power, an external meter with high
frequency sampling capable of displaying instantaneous
energy or power is typically used, or the welding equip-
ment is upgraded or modified to display instantaneous
energy or power.
Welding power sources or external meters typically
display instantaneous energy as cumulative measure-
ments of instantaneous energy, i.e., the sum of instanta-
neous energy measurements made during a time period
such as trigger-on to trigger-off. The units of measurement
may be joules (J). Other conveniently obtained units of
energy, such as calories or British thermal units (Btu),
may be used with the appropriate conversion factors.
The other measurement that is needed to use the calcula-
tions given in QW-409.1(c)(1) is weld length.
Welding power sources or external meters typically
display instantaneous power as average measurements,
i.e., the average value of instantaneous power measure-
ments made during a time period such as trigger-on to
trigger-off. The unit of measurement may be watts
(W). One watt is equal to 1 joule/second (J/s). Other
conveniently obtained units of power such as horsepower
(hp) or kilowatts (kW) may be used with the appropriate
conversion factors. Because power must be multiplied by
time to obtain energy, the arc-on time needs to be
recorded, and the distance traveled during that time
needs to be measured; with these data, the calculation
in QW-409.1(c)(2) can be made. Either of the equations
in QW-409.1(c)(1) and QW-409.1(c)(2) may be used,
depending on whether total instantaneous energy (IE)
or average instantaneous power (IP) is displayed.
H-300 NEW PROCEDURES QUALIFICATIONS
When qualifying a new procedure using waveform
controlled welding, the instantaneous energy or power
range is used in lieu of the current (amperage) and
voltage ranges to determine the heat input per
QW-409.1(c).
 ASME BPVC.IX-2023
When qualifying a new procedure using nonwaveform
controlled welding, either the current and voltage is
recorded and heat input determined using the methods
of QW-409.1(a) or QW-409.1(b), as previously required,
or the instantaneous energy or power is recorded and the
heat input determined by the method in QW-409.1(c).
H-400 EXISTING QUALIFIED PROCEDURES
Welding procedures previously qualified using nonwa-
veform controlled welding and heat input determined by
QW-409.1(a) may continue to be used for waveform
controlled welding, provided they are amended to
require heat input determination for production welds
using the methods of QW-409.1(c). Welding procedures
previously qualified using nonwaveform controlled
welding and heat input determined by QW-409.1(b)
continue to be applicable for waveform controlled
welding without changes to the heat input determination
method.
(a) To determine if the heat input of a waveform
controlled production weld meets the heat input range
of a welding procedure qualified with nonwaveform
controlled welding with heat input determined using
QW-409.1(a)
(1) the heat input of the production weld is deter-
mined using instantaneous power or energy per the
method of QW-409.1(c)
(2) the heat input of the production weld is
compared to the heat input range of the welding proce-
dure specification
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(b) to determine if the heat input of a nonwaveform
controlled production weld meets the heat input range
of a welding procedure qualified with waveform
controlled welding with heat input determined using
QW-409.1(c)
(1) the heat input of the production weld is deter-
mined using QW-409.1(a) or QW-409.1(c)
(2) the heat input of the production weld is
compared to the heat input range of the welding proce-
dure specification
H-500 PERFORMANCE QUALIFICATIONS
Separate performance qualifications are not required
for waveform controlled welding. However, it is recog-
nized that a welder or welding operator may require
instruction on proper use of the equipment. The extent
of such instruction is best determined by the organization,
as needed to understand how to properly set up and adjust
the equipment for welding and conformance to the WPS
requirements.
Power sources capable of waveform controlled welding
often have additional operator settings that are typically
not used during nonwaveform controlled welding. It is
important for a welder to be familiar with other equip-
ment parameters that can influence the overall
welding performance. These can include the mode, arc
control, program, cable length, wire feed speed, trim,
and other machine and software settings.