WELDING DOCUMENTATION

(BBX 10504)
C2 : WELDER QUALIFICATION
By
MR. MOHD HAFIZ BIN GHAZALI
Faculty of Technical and Vocational Education
Welder Qualification

• Welder qualification is a process which evaluates a welder's capability to

create welds to an industry standard following a welding procedure,
this qualification can then lead to welder certification.

• The main part of the welder's test consists of welding one or more test coupons
which are then examined using non-destructive and destructive methods.

• The extent of certification is described by a number of variables, which include the

specific welding process, type of deposited metal, thickness, joint design, position,
backing, and others.
Welder Qualification

• The main certification employers will require is the

basic AWS Certified Welder certification. You will take an exam to earn
this certification, which is offered at many AWS Accredited Testing
Facilities.
Qualification test coupon
Retest and Renewal of Qualification
• Welder certification, also known as welder qualification is a process
which examines and documents a welder's capability to create welds of
acceptable quality following a well defined welding procedure.

• A renewal or recertification application can be received up to 6 months

prior to the expiry of your certificate.

• Welding certifications are usually good for anywhere from six months
to three years.
How do you do the welder qualification test?
How do you do the welder qualification test?

It has some steps as below:

• Code & standard apply for testing: In this case we use: ASME IX.
• Witness for Welder testing: Each performance qualification welder
testing shall be done under full supervise and control by a third party.
• Train The Welder For The Process To Be Qualified.
• Testing procedure.
ASME Section Ix For Quality Retesting/Retraining Of
Welders

Immediate Retest Using Visual Examination

• A welder who fails to satisfy the visual examination criteria for a welded
test coupon is allowed an immediate retest but must make two
consecutive test coupons, for each test position failed, and both must
satisfy the visual examination criteria.
• The examiner may select one of the two test coupons that satisfied the
visual examination for conducting the mechanical testing.
Visual Examination
Visual Examination
Immediate Retest Using Mechanical Testing

• A welder who fails to satisfy the mechanical test criteria for a test
coupon is allowed an immediate retest but must make two consecutive
test coupons, for each test position failed, and both must satisfy the
mechanical test criteria.
Mechanical test
Immediate Retest Using Radiography

• A welder who fails to satisfy the radiographic acceptance criteria for a

welded test coupon is allowed an immediate retest but must make two
consecutive test coupons, for each failed test, and both must satisfy the
radiographic acceptance criteria.
• A welder who fails the production weld alternative test (radiographic
requirements) may be retested by radiography of twice the required
length of production weld (or number of pipe circumferences) of the
same, or consecutively made, production welds. To qualify, he must
satisfy the radiographic requirements for this welding. He is allowed to
repair his defective welds or this may be done by another qualified
welder.
Radiography test
Further Training

• A welder who fails a retest is expected to undergo further training or

practice before attempting a new test but the Code does not give any
details of type or duration of training.
• A new test is required for each welding position that he failed to meet
the acceptance requirements.
Welding Variables For Welders

Welding Variables

1. Essential variables
2. Nonessential variables
3. Supplementary Essential variables

Three types of variables are mentioned in the code. All the necessary parameters viz.
joints, base metals, filler metals, positions, preheat, PWHT, gas etc. (including ranges,
if any) under which the welding process must be performed. These parameters are
known as variables (as per ASME Section IX).
Essentials Variables

• Welding variables that are critical to making acceptable welds are

categorized as essential variables.
• The minimum requirements would include mechanical properties such
as tensile strength, ductility, and soundness.
• There are so many welding variables that influence a weld’s quality; the
variables are amps, volts, travel speed, filler metal, shielding gas, base
material, etc.
Essential Variables (For
WPS – QG-105.1 &
QW-251.2): A change in
essential variable is
considered to affect the
mechanical properties
(other than toughness)
of the welded joint.
Hence the WPS must be
requalified, if the
essential variable is
changed.
Essential variables examples

• Welding position
• Joint configuration
• Electrode type & size
• Base metal type, thickness
• Welding techniques
• Use of backing

Essential variables are those that have a significant influence on the mechanical properties, such as
tensile strength and ductility. Nonessential variables are those that do not have a significant influence
on tensile strength or ductility of the completed weld.
Supplementary essential variables
• Supplementary Essential Variables (QG-105.3 & QW-401.1): A change in the
supplementary essential variable will affect the toughness properties of the joint,
heat-affected zone, or base material. Hence supplementary essential variables
become additional essential variables in situations where procedure qualification
requires toughness testing. When procedure qualification does not require the
addition of toughness testing, supplementary essential variables are not applicable.

• The code defines it as "Supplementary essential variables are conditions in which a

change will affect the toughness properties of the joint, heat-affected zone, or base
material". The supplementary essential variable becomes an essential
variable when welding procedure qualification requires impact testing.
• Normally, base metal group number, thickness out of specified range, filler metal
diameter, filler metal classification, position, etc. are categorized on
the supplementary essential variables.
Supplementary essential variables as per ASME IX
Nonessential Variables

• Nonessential Variables (QG-105.4 & QW-251.3): Nonessential

variables are those in which a change can be made without
requalification of the existing WPS, since it is not considered to affect
the mechanical properties of the joint. Though a change in the
nonessential variable doesn’t require requalification of the WPS but
still it should be properly addressed in the welding procedure
specification (WPS).
Nonessential Variables as per ASME IX
Non Essential variables examples
• Joint design,
• filler metal diameter
• the minor change in the electrical characteristic
• welding positions
• welding technique
Welding Variables for Welding Operators
Main purpose for Welder qualification:

• To verify the skill of an individual to preform a qualified welding procedure

specification ( WPS ) to produce a good weld.
• Welders qualify to specific welding process NOT welding procedures ( need note
this one: welding process & welding procedure )
– Welding process:
• Welder: have SMAW / GTAW / FCAW / GMAW …
• Welding operators : SAW…
– Welding types:
• MANUAL / SEMI-AUTOMATIC – Welders
• MACHINE- welding operators
• AUTOMATIC- welding operators
For welder
For welding operators
ASME & AWS

• The difference between ASME and AWS is that ASME is for welding
procedure and welder qualification. AWS is for both welder and welding
procedure qualification including inspection, erection and fabrication.
Contracts may specific one or the other code
• American Society of Mechanical Engineers (ASME) – This society is
responsible for the development of the Boiler and Pressure Vessel Code,
which contains eleven sections and covers the design, construction, and
inspection of boilers and pressure vessels.
• The American Welding Society (AWS) was founded in 1919, as a nonprofit
organization with a global mission to advance the science, technology and
application of welding and allied joining and cutting processes, including
brazing, soldering and thermal spraying.
Thank You