Understanding Welding

What is Welding?
Welding is metallurgical fusion process, where part to be joined by the application of heat and
pressure.
Weldment
Part joined by welding.
Fillet Weld
A close weld, in which base metal is not cut through to accommodate weld metal. No beveling,
just clean surfaces are required.
Groove Weld
Require full weld metal penetration. At least one side is beveled to wide the gap.
Root Pass
The first deposited bead is called root pass
Hot Pass
The second bead is known as hot pass
Filling
After root and hot pass subsequent beads are know as fill passes.
Capping
The last or top most pass is called capping.
Welding Procedure Specifications

 A written document that provides direction to the welder or welding operator for making production welds in
accordance with the code requirements.
 It states conditions/variables under which welding shall be performed. These variables are further classified as
essential and non essential elements.
Essential Variables
A change in a welding condition which will effect the mechanical properties of the weldments and require
requalification of the WPS.
Supplementary variables in addition to essential variables and required for metals for which toughness tests are
required.
Non- Essential Variables
A change in welding conditions/variable can made without the need of WPS requalification.
PQR (Procedure Qualification Record)
Demonstrates that joining process proposed for construction is capable of producing joints having the required
mechanical properties for the intended application.
Welding Processes (Essential)

SMAW (Shielded Metal Arc Welding)

Electric arc is used for the welding purpose.
Flux coated electrode is used for welding
Advantages: Can be used in any position, low cost, simple process

GTAW (Gas Tungsten Arc Welding)

Also known as tungsten inert gas welding (TIG)
Filler wire is used instead of electrode
Inert gas (argon) is used act as shield instead of electrode flux
Advantages: Lesser defects & damage to base metals, slag free
A- Joint Design (Non Essential Variable)

Retainer: Used to hold metal metal, are not Backing: A strip placed at the back side/root of weld to
part of the weld neither fuses with weld prevent molten metal for dripping and ensure complete
penetration (metallic, copper strips)

Groove Design

Root Spacing
B- Base Metals (Essential Variable)
P Number: Base metals have been assigned P numbers for the purpose of reducing welding procedure qualifications.
P numbers are assigned on the basis of comparable base metal characteristics, such as chemical compositions and mechanical
properties

P1 = A36, SA210-C, SA 106C P3 = SA213T12, SA335P12 P5 = SA213T22, A335P22, SA213T91, A335P91 P8 = TP347H,
SATP304H

S number = P number (Materials which are not a part of ASME BPVC Section II but other sections and B31.1)

Base Metal Thickness: ASME defines thickness range against every WPS for which welds can be produced.
Note: IF test coupon thickness ≥ 38mm, there will be no limitation for maximum qualified thickness

Weld strengths vary according to

thickness and distance from the
root.
C- Filler Metals (Essential Variable)
F Number
Electrodes and welding rods have been assigned F numbers for the purpose of reducing welding procedure
qualifications.

Material P number Electrode SFA F Number

A106 1 E7018 A5.1 5

A312-TP316 8 E309 A5.9 6

E 70 1 8 Digit Coating Type

0 High cellulose sodium
Electrode Tensile Strength Position Coating
Shielding, arc 1 High cellulose potassium
stabilization,
2 High Titania sodium
Digit Position deoxidizer, metal
alloying 3 High Titania potassium
1 All Positions
4 Iron powder, Titania
2 F, H 5 Low hydrogen sodium

4 F,H, Overhead 6 Low hydrogen Potassium

7 High Iron Oxide

8 Low Hydrogen Potassium
ER for filler wire
C- Filler Metals (Essential Variable)
A Number:
It refers to the deposited weld metal chemical composition. It gives chemical composition in a “as weld” condition.
It can be determined from chemical analysis of a deposited weld or determined by filler metal manufacturer.

Deposit Metal thickness (t):

Change in deposited weld metal thickness beyond that qualified in accordance to code.
D-Welding Positions (Essential Variable for Welder/non essential for WPS)
Welds positions are critical to welder for producing sound weldment.
ASME Section IX clearly defines weld positions for welding pipes and plates, and correspondingly their qualification
ranges.
Welds are broadly divided into two categories Fillet & Groove
E- Preheat (Essential Variable)

Why?
➢ To remove moisture
➢ Reduce the hardness of the weld
➢ Reduces temperature difference between the welding arc and base metal
➢ Slower cooling rate
A decrease of more than 55 oC in the preheat temperature qualified. Due to change in mechanical properties.

F- Post Weld Heat Treatment (Essential Variable)

In order to remove residual stresses

Whenever post weld heat treatment is required a separate WPS shall be generated
Welding Symbols
Weld All-Around &
Root Gap & Angle Field Symbol

Weld Placement Weld Dimensions