Welding Inspector

Calibration
Section 24
Calibration, validation and monitoring
Definitions:
Measurement = set of operations for determining a value of a
quantity
Repeatability = closeness between successive measuring results
of the same instrument carried out under the same conditions
Accuracy class = class of measuring instruments that are intended
to keep the errors within specified limits
Calibration = checking the errors in a meter or measuring device
Validation = checking the control knobs and switches provide the
same level of accuracy when returned to a pre-determined point
Monitoring = checking the welding parameters (and other items)
are in accordance with the procedure or specification
 Calibration and validation
Frequency - When it is required?
once a year unless otherwise specified
whenever there are indications that the instrument
does not register properly
whenever the equipment has been damaged,
misused or subject to severe stress
whenever the equipment has been rebuild or
repaired

See BS EN ISO 17662 for details!

Welding parameter calibration/validation
Which parameters need calibration/validation?
How accurate?
depends on the application
welding current - ±2,5%
arc voltage - ±5%
wire feed speed - ±2,5%
gas flow rate - ±20% (±25% for backing gas flow rate)
temperature (thermocouple) - ±5%
depends on the welding process
see BS EN ISO 17662 and BS 7570 for details
 PAMS (Portable Arc Monitor System)
What does a PAMS measure?
Gas flow
Welding rate
current (Hall (heating
effect element
device) sensor)

Arc voltage
(connection Wire feed
leads) speed
Temperature (tachometer)
(thermocouple)
 PAMS (Portable Arc Monitor System)
The purposes of
a PAMS

For measuring For calibrating

and recording and validating
the welding the welding
parameters equipment
 Use of PAMS
Wire feed speed
monitoring

Incorporated pair of
rolls connected to a
tachogenerator
 Use of PAMS
Shielding gas flow
rate monitoring

Heating element
sensor
 Summary
a welding power source can only be calibrated if it has
meters fitted

the inspector should check for calibration stickers, dates etc.

a welding power source without meters can only be validated

that the control knobs provide repeatability

the main role is to carryout “in process monitoring” to ensure

that the welding requirements are met during production