Course: Welding of Mild Steel: Module 4

2009.08.
16
Course:WELDINGOFMILDSTEEL
Module4
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2009.08.16
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List of content
MODULE4..........................................................................................................................................3
Weldingproceduresandinstructions...............................................................................................3
MODULE4
Welding procedures and instructions.

TheManufacturershallpreparetheWeldingProcedureSpecification(s)(WPS)andshallensurethat
theseareusedcorrectlyinproduction.
Theweldingproceduresappliedduringproductionshallbeasspecificaspossible,inorderto
clearlyidentifyactionsandparameterstobeusedfortherequiredjoint.However,iftherelevant
WPScontainsdatatoodetailedandnotusefulforthewelder,dedicatedworkinstructionsmaybe
useddirectlyderivedfromsuchaWPScontainingonlythenecessarydata.Theseinstructionshave
toreferdirectlytotheweldingprocedurespecificationtheyderivedfrom,e.g.byreferringtothe
relevantWPSnumber.
Consideringthatweldingisaspecialprocessandthatthequalityoftheweldedjointcannotbe
properlycontrolledonlybyfinaltests,theweldingproceduressignificantforthefinalproduct
qualityshallbequalifiedpreciselypriortoproduction.Asaconsequence,thoseWeldingProcedure
SpecificationsshouldbepreparedinaccordancewithaWeldingProcedureQualificationRecord
(WPQR).Normativereferencestothespecificationandtothequalificationofweldingprocedures
aregiveninthetable.
Weldingprocess
Standard
Material
ISO15607
Scope
WPS,
WPQR
ISO15610
Allfusionwelding
processes
ISO15611
ISO15612
All
WPQR
ISO15613
GasWelding
ISO 15609-2
ISO156141
ISO 15614 - 6
ISO 15614 7
Allapplicable
WPQR
ISO 15614 8
Allapplicable
WPQR
ISO 15609 3
ISO1561411
All
Allapplicable
WPS
WPQR
ISO 15614 - 1
ISO 15614 - 2
ISO 15614 - 3
ISO 15614 - 4
ISO 15614 - 5
Electronbeam
welding
WPQR
All
SteelsandNickel
alloys
Aluminium,
Magnesium
Steelcastings
Aluminium
castings
Titaniumand
zirconium
Copper
ISO 15609-1
Arcwelding
WPS
Steels
WPS
Fieldofapplication
GeneralRules
Qualificationbasedontestedweldingconsumables
Qualificationbasedonpreviouswelding
experience
Qualificationbyadoptionofastandardwelding
procedure
Qualificationbasedonpreproductionweldingtest
Compiling
Qualificationbasedonweldingproceduretest
Steels
Compiling
WPQR
WPQR
WPQR
WPQR
WPQR
WPQR
corrosionresistanceoverlay,claddingrestoreand
hardfacing
Weldingoftubestotubeplatejoints
Compiling
LaserWelding
UnderwaterArc
WeldingWet
Hyperbaric
UnderwaterArc
WeldingDry
Hyperbaric
ISO 15609 4
ISO1561411
All
Allapplicable
WPS
WPQR
Compiling
ISO156149
Allapplicable
WPQR
ISO1561410
Allapplicable
WPQR
Standards for the qualification of welding procedures
Differentmethodsforthequalificationofweldingproceduresareavailable:
-
weldingproceduretestthismethodconsistsinweldingastandardisedtestpieceonwhich
destructiveandnondestructivetestsarecarriedoutinordertoverifytheachievementof
requiredproperties;
- useofapprovedweldingconsumablesthismethodofapprovalmaybeusedifthewelding
consumablesandthebasematerialarenotparticularlyaffectingtheweldingquality,provided
thatheatinputsarekeptwithinspecifiedlimits;
- previousweldingexperienceaweldingproceduremaybequalifiedbyreferringtoprevious
experiencesinweldingiftheManufacturerisabletoprove,byappropriateauthentic
documentationofanindependentnature,thathehaspreviouslysatisfactorilyweldedthesame
jointwithreliableresults;
- useofastandardweldingprocedureaprocedureisqualifiedifitisissuedasaspecificationin
theformatofaWPSorWPQRbasedonappropriatequalification(e.gbasedontherelevantpart
ofENISO15614),notrelatedtotheManufacturerandqualifiedbyanexaminerorexamining
body;
- PreproductionTestthismethodistheonlyreliablemethodofqualificationforthosewelding
proceduresinwhichtheresultingpropertiesoftheweldstronglydependoncertainconditions
suchas:components,specialrestraintconditions,heatsinksetc.,whichcannotbereproduced
bystandardisedtestpieces;itismostlyusedwhentheshapeanddimensionsofstandardised
piecesdonotadequatelyrepresentthejointtobewelded.
Evenifdifferentqualificationmethodsareconsidered,themostcommonlyusedarequalificationby
weldingproceduretestandpreproductiontest;howevertheapplicablemethodofqualificationis
generallyspecifiedineithermanufacturingcodes,standardsorcontracts.
Inordertodemonstratetheachievedqualityoftheweldedproduct,alltheweldingrelated
documents(e.g.WPS,WPQR,WeldersQualificationrecord,etc)shallbeproperlycontrolled.
Thisinvolvesthepreparationandmaintenanceofaprocedureforthemanagementofsuch
documents,inordertoidentifyissuanceresponsibilities,distributionmethods,availability,and
methodforwithdrawingobsoletedocuments.Evenifitisnotanormativerequirement,acommonly
adoptedmethodtocontroldocumentationistheproductionofawrittenprocedure,producedor
approvedbytheweldingcoordinator,tobekeptbytheManufacturerqualityassurancedepartment
ordirectlybytheweldingcoordinatorhimself.
InthenextpageatypicalWPSformisreported,producedaccordingtoENISO156091.
COMPANY NAME OR LOGO
Welding process(es)
a)
WELDING PROCEDURE
SPECIFICATION (WPS)
b)
WPS n
Rev.
Supp. WPQR
Date
c)
Type(s)
a)
b)
c)
JOINTS
Joint Type
Backing
Backing material
Weld preparation
Method of preparation & Cleaning
PARENT METAL
Group n
To group n
Spec. Type & grade

To Spec. Type & grade
Thickness
Outside Diameter
Other
Joint drawiing
WELDING CONSUMABLE
GAS(ES)
a)
b)
c)
Gas(es)
Mixture
Flow Rate
l/min
Specification n
Plasma
Designation
Shielding
a)
l/min
Size
Shielding
b)
l/min
Trade name
Trailing
l/min
Manufacturer
Backing
l/min
Flux design. EN
Other
Flux Trade name
ELECTRICAL CHARACTERISTIC Current
Weld deposit
Position
Polarity
Mode of Metal
Transfer
Tungsten Electrode Type & size
Welding Progression
Electrode wire feed speed range
Other
PREHEAT
Preheat Temperature
Other
TECHNIQUE
String or weave beads
Interpass Temperature
Orifice or gas cup size
Preheat maintenance
Initial & interpass cleaning
Other
Method of back gouging
PWHT and/or AGEING
Oscillation
Temperature Range
Distance contact tube work piece
Time Range (hour)
Multiple, single pass (for side)
Heating rate
Single or multiple electrodes
Cooling rate
Torch angle direction of welding
Other
WELDING POSITION
Other
Welding
process
EN designation or trade
name.
Freq.
Other
Current
Filler metal
Run(s) or
Layer(s)
Amplitude
Size
(mm)
Type &
polarity
Amperage
A
MANUFACTURER
WeldingProcedureSpecification
Voltage
V
Travel
Speed
mm/min
APPROVED BY
Heat input
KJ/mm
Other

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Course: Welding of Mild Steel: Module 4

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2009.08.

Welding procedures and instructions.

Standards for the qualification of welding procedures

Spec. Type & grade

Flux Trade name

ELECTRICAL CHARACTERISTIC Current

Electrode wire feed speed range

Orifice or gas cup size

Initial & interpass cleaning

Method of back gouging

PWHT and/or AGEING

Distance contact tube work piece

Time Range (hour)

Multiple, single pass (for side)

Single or multiple electrodes

Torch angle direction of welding

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