WELDING DOCUMENTATION

(BBX 10504)
C1 : INTRODUCTION
By
MR. MOHD HAFIZ BIN GHAZALI
Faculty of Technical and Vocational Education
Welding Equipment
Protective And Safety Equipment
• Head shield
• Gloves
• Long sleeves jacket
• Work shoes
• Chipping hammer
• Wire brush
• Safety glass
• Rod ovens
• Welding machine
Welding Process
Welding is a fabrication process whereby two or more parts are fused together
by means of heat, pressure or both forming a join. Welding is usually used on
metals and thermoplastics

Possible energy sources

 Ultrasonic
 Electron beam

 Friction

 Electric resistance

 Electric arc
Welding is regarded as a joining process in which the work
pieces are in atomic contact

Solid state processes Fusion welding processes

 Forge welding  Oxy-acetylene

 Friction welding  MMA (SMAW)

 MIG/MAG (GMAW)
 TIG/TAG (GTAW)
 Sub-arc (SAW)
 Electro-slag (ESW)
 Fusion Welding Factors

The four essential factors for fusion welding

1. Fusion is achieved by melting using a high intensity heat source

2. The welding process must be capable of removing any oxide and
contamination from the joint
3. Atmosphere contamination must be avoided
4. The welded joint must possess the mechanical properties required
by the specification being adapted
Welding Consumables
Welding consumables types include:

• Stick electrodes.
• Solid wires.
• Flux-cored wires.
• SAW wires.
• Fluxes.
• Others
Pairing Consumables to Welding Processes

• The American Welding Society has designated filler material

specifications and listed which welding processes each material can be
used for. As you can see from the chart, some of the filler materials
should only be used in one welding process, such as iron and steel gas
welding rods for Oxy-Acetylene (OA) welding. Below are a few different
types of electrodes used for some of the most common
• Shielded metal arc welding uses a powder-coated electrode (flux). When
it burns off, the coating shields the weld from oxygen. Filler metal is
often added to the coating to speed up the process.
• Gas tungsten arc welding uses a non-consumable tungsten rod to heat
the metal and filler metal. The rod just heats the metal and doesn’t add
to the filler material.
• Gas metal arc welding is a process that uses a wire consumable with a
wire spool feeding the wire into the weld joint.

Choose the Right Consumable/current/process

Welding Position

Fillet
Groove
Fillet Weld
Groove Weld
Essential Variable in Welding Procedure
The ASME Code Section IX provides a table for each welding process
and identifies essential, nonessential and supplementary essential
variables. So if you have a WPS, and you need to use this WPS in another
job with the implication of some changes, then you need to refer these
tables to see if these changes fall among of essential variables. If they fall,
then you need to re-qualify your WPS.
In most of welding process, The P number, F number, A number PWHT,
thickness (out of specified range) are essential variable. Based on
requirements of ASME Code Section IX all essential variable,
nonessential variable and supplementary essential variable (such
as Group Number) must be indicated in the welding procedure
specification.
• When you have a change in the essential variable, you need to write a
new welding procedure specification and qualify that with a
new procedure qualification record (PQR). To have a PQR you have to
prepare a new test specimen that welded based on this new WPS and
make two tension test, two root bend test and two face bend test.

• This PQR number should be indicated in this new WPS. You need to
refer to ASME Code Section IX to find correct size and number of test
specimens, test specimen preparation, testing equipment requirements
and related acceptance criteria.
ASME Boiler and pressure vessel code (BPVC) has assigned certain
numbers to base metals as well as to filler metals (electrodes)

For base metals, ASME has assigned two number system, these are :
• P Numbers
• Group Numbers

For filler metals, the number system which is assigned, are as follows :
• F Number
• A Number
ASME BPVC Section IX
PROCEDURE QUALIFICATION RECORDS (PQR)

• The American Welding Society states that before a Welding Procedure

Specification (WPS) can be drafted, a preliminary set of procedures and
materials must be established.
• This initial procedure is used to create a series of welds, which are then
tested to ensure they meet applicable requirements.
• The procedures for creating and testing the sample welds, as well as the
final results, are documented on a Procedure Qualification Record, or
PQR. If the test results are acceptable, the PQR is approved and can
then serve as the foundation on which one or more WPS's are drafted.
• In short, a PQR serves as evidence that a given WPS can, in fact, be
used to produce an acceptable weld.
WELDING PROCEDURE SPECIFICATIONS (WPS)

• WPS is essentially a welder’s guide that includes applicable code

requirements and production standards. It controls the welding process.
• It includes details on what you will need and the welding processes to
follow that will create a sound weld
• The WPS is a proven process of welding and is important to ensure
welding operators in the field are maintaining the same, required
standards across the board. The mechanical properties of a weld cannot
be verified in production welds after welding so control of the welding
process using a WPS is critical.
• A WPS always has ranges to allow for joint and operator technique
variation, it is unlikely every joint is the same or every welder uses the
same technique. These ranges are different for every standard. The
ranges are based on what is known as essential variables. Things which
if changed require you to requalify the WPS.
Thank You