Welding - Introduction

Menas Wibowo – Aug 2021

Content
• What is welding ?
• Basic weld configuration and weld terminologies
• Common types of welding in construction
• WPS and PQR
 What is Welding ?
• Welding – joining method by melting base materials (with or without filler)
• Brazing – joining method by melting a filler that bonds the base material
• Soldering – similar to brazing but temp < 450 ºC
Configuration of weld
• Two common geometries: groove or butt weld and fillet weld
• Zones : parent / unaffected material (BM), heat affected zone (HAZ),
weld metal (WM)
Some weld terminologies

Double sided welds

 Common types of welding in construction
Most common welding in construction is arc welding; and the
• GTAW / TIG – Gast Tungsten Arc Welding / Tungsten Inert Gas
• GMAW / MIG / MAG – Gas Metal Arc Welding / Metal Inert Gas / Metal Active Gas
• FCAW – Flux Cored Arc Welding
• SMAW/MMAW – Shielded Metal Arc Welding / Manual Metal Arc Welding

Less common:
• SAW (Submerged Arc Welding)
• PAW (Plasma Arc welding)
 GTAW / TIG
• Stable and clean process
• Low heat input
• Used for root pass
• Non-melting electrode (tungsten)
 GMAW / MIG/MAG
• High deposition rate
• Few stop/starts
• Not all position
• Spatter
 SMAW / MMA
• Most common and basic welding process
• Simple, cheap and robust process
• Slag removal, requires highly skilled welders, start/stop and grinding
FCAW
Welding proses apakah ini ?
A B

D
What is WPS and WPQR
• WPS stands for Welding Procedure Specification
• (W)PQR stands for (Welding) Procedure Qualification Records

• WQT = Welder qualification test

• WPQ = Welder performance qualifications
Typical Testing for PQR
• Visual – incl weld dimensions
• NDT
• Mechanical testing (tensile, bend, hardness, impact)
• Corrosion testing (optional – for SS)
Process of creating WPS
Process starts with Preliminary WPS (pWPS) - then performing the test (PQR), and if all pass –
pWPS becomes WPS

pWPS PQR WPS

To review WPS – you need to have the supporting PQR

Checklist:
- Who is going to weld it ? Contractor (matching with PQR submitted)
- What are the reference / governing codes ? ASME, AWS, ISO, API
- What items/equipments and what is the size ? Piping / pipeline / tank /
- What materials do they want to weld ? CS, SS, strength and grade – material group
- Which welding process ? And welding parameters ? Welding direction, bevel configuration,
consumable, preheat, etc
PQR Testing
• Tensile
• Hardness
• Impact