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As 2980-2007 Qualification of Welders For Fusion Welding of Steels
As 2980-2007 Qualification of Welders For Fusion Welding of Steels
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AS/NZS 2980:2007 Qualification of welders for fusion welding of steels
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AS/NZS 2980:2007
welding of steels
Qualification of welders for fusion
Australian/New Zealand Standard™
AS/NZS 2980:2007
AS/NZS 2980:2007
This Joint Australian/New Zealand Standard was prepared by Joint Technical
Committee WD-003, Welding of Structures. It was approved on behalf of the
Council of Standards Australia on 19 February 2007 and on behalf of the Council of
Standards New Zealand on 16 February 2007.
This Standard was published on 2 May 2007.
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AUSTROADS
Australian Chamber of Commerce and Industry
Australian Industry Group
Bureau of Steel Manufacturers of Australia
Engineers Australia
New Zealand Heavy Engineering Research Association
New Zealand Non-Destructive Testing Association
Steel Reinforcement Institute of Australia
University of Sydney
Welding Technology Institute of Australia
Originated as AS 2980—1987.
Second edition 2004.
Revised and redesignated AS/NZS 2980:2007.
COPYRIGHT
© Standards Australia/Standards New Zealand
All rights are reserved. No part of this work may be reproduced or copied in any form or by
any means, electronic or mechanical, including photocopying, without the written
permission of the publisher.
Jointly published by Standards Australia, GPO Box 476, Sydney, NSW 2001 and Standards
New Zealand, Private Bag 2439, Wellington 6020
ISBN 0 7337 8178 0
AS/NZS 2980:2007 2
PREFACE
This Standard was prepared by the Australia/New Zealand Committee WD-003, Welding of
Structures, to supersede AS 2980—2004.
Consistent with the 2004 edition of AS 2980, this edition continues to give cognizance to
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the ISO welder qualifications Standard for steels ISO 9606-1:1994, Approval testing of
Welders—Fusion Welding, Part 1: Steels, by adopting largely its principles and
methodologies; however, due to incompatibilities between the European-based approach of
the ISO Standard and the North American basis for many of the Australian and
New Zealand welding Standards, it could not be adopted in its entirety with the methods of
testing and criteria of acceptance continuing to be based on current Australian and
New Zealand Standards.
Changes made to this edition were primarily to accommodate New Zealand specific
requirements to enable jointing to take place, and at the same time opportunity was taken to
clarify acceptance criteria and correct a number of typographic errors. The differences with
the 2004 edition of AS 2980 are as follows:
(a) Clarification of the Scope: Clauses 1.1.
(b) Jointing requirements: Clauses 1.4.2, 1.6, 3.3, 3.4, and Appendix F.
(c) Clarification of requirements for multi-process joints: Clause 2.2 and Table 2.2.
(d) Amendments to Clause 2.6 and Tables 2.6(A) and 2.6(B) to include recent changes to
welding consumable classification Standards.
(e) Clarifying requirements for welders qualifying for multiple welding positions
(Clause 2.8) and test requirements (Clause 3.3).
(f) Clarification of acceptance criteria: Clauses 4.1, 4.2, 4.3, and Table 4.3.5.3.
(g) Correction of typographical errors: Clauses 3.5.2, 4.3.5.2, and Table 4.3.1.
(h) Minor amendments to Clauses 5.1.2, 5.2, Paragraph E2.10, and Tables 2.6A and B2.
Readers should note that whilst this Standard provides the welder with a broad range of
approvals, application Standards may offer the welder a limited approval option, which in
some cases may be of some economic benefit to the fabricator.
As drawings in this Standard are complete only to the extent necessary for illustration,
reference is to be made to the requirements specified in the text.
The terms ‘normative’ and ‘informative’ have been used in this Standard to define the
application of the appendix to which they apply. A ‘normative’ appendix is an integral part
of a Standard, whereas an ‘informative’ appendix is only for information and guidance.
Statements expressed in mandatory terms in notes to tables and figures are deemed to be
requirements of this Standard.
3 AS/NZS 2980:2007
CONTENTS
Page
FOREWORD.............................................................................................................................. 4
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APPENDICES
A LIST OF REFERENCED DOCUMENTS ................................................................. 41
B MATERIAL GROUPS .............................................................................................. 44
C INFORMATION TO BE INLCUDED IN WELDER’S QUALIFICATION TEST
CERTIFICATE.......................................................................................................... 48
D JOB KNOWLEDGE.................................................................................................. 49
E COMPARISON WITH ISO 9606-1........................................................................... 50
F WELDER QUALIFICATION TEST FOR STAINLESS STEEL TUBE FOR THE
NEW ZEALAND DAIRY INDUSTRY..................................................................... 53
AS/NZS 2980:2007 4
FOREWORD
The ability of a welder to follow verbal or written instructions and verification of a person’s
skills are important factors in ensuring the quality of the welded product.
The testing of a welder’s skill in accordance with this Standard depends on welding
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techniques and conditions used in which uniform rules are complied with, and standard test
pieces are used.
The principle of this Standard is that a qualification test qualifies the welder not only for
the conditions used in the test, but also for all joints that are considered easier to weld
provided the welder has received appropriate training and/or has industrial practice within
the range of qualification.
The qualification test may be used to qualify a welding procedure and a welder provided all
the relevant requirements, e.g., test piece dimensions, are satisfied. Where a test is intended
as both a procedure qualification and a welder qualification, the welder qualification is not
achieved unless the requirements for procedure qualification are also met.
Qualifications in accordance with AS 2980 existing at the date of publication of this
Standard are to be interpreted in accordance with the requirements of the Standard.
5 AS/NZS 2980:2007
1.1 SCOPE
This Standard defines the qualification test of welders for the welding of steels to the
requirements of a welding procedure specification. It provides a set of technical rules for a
systematic qualification test of the welder, and enables such qualifications to be uniformly
accepted independently of the type of product, location and examiner/examining body.
When qualifying manual welders, the emphasis is placed on the welder’s ability to
manually manipulate the electrode/welding torch and thereby to produce a weld of
acceptable quality.
The principle of this Standard is that a qualification test that qualifies the welder not only
for the conditions used in the test, but also for all joints that are considered to weld easily,
on the presumption that the welder has received particular training and/or has industrial
practice within the range of qualification.
This Standard is intended to complement existing Standards such as AS 1796 and
AS/NZS 3992 whilst enhancing the requirements for the qualification of welders from the
previous edition of AS 2980 in accordance with international expectations. It does not deal
with the certification of welders.
NOTES:
1 Certification of welders is covered by AS 1796.
2 Qualification of welders for pressure applications is addressed by AS/NZS 3992.
3 Appendix E provides a comparison between this Standard and ISO 9606-1.
1.2 APPLICATION
The qualification tests prescribed in this Standard are intended to provide a method to
qualify welders for the welding of steel structures; however, they may also be suitable for
the qualification of welders for other applications, by agreement between the principal and
the fabricator. These tests are not intended to be used as a guide for welding during actual
construction. The latter should be performed in accordance with the requirements of a
welding procedure specification (WPS) produced for the purpose.
This Standard deals specifically with qualifications for welders using manual or semi-
automatic welding equipment and includes requirements for welders using mechanized or
fully automatic equipment.
NOTE: Where a welder fails the specified tests, the performance may be used as a basis for
measuring the value of further training.
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AS/NZS 2980:2007 6
1.4 DEFINITIONS
For the purpose of this Standard, the definitions given in AS 2812 and those below apply.
1.4.1 Examiner
Person who has been appointed by the examining body to verify compliance with the
applicable Standard.
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1.5 NOTATIONS
1.5.1 For test pieces
The following apply:
a = design throat thickness
BW = butt weld
D = outside pipe diameter
FW = fillet weld
l1 = length of test piece
l2 = half width of test piece
lf = examination length
P = plate
PW = plug weld
s1 = weld metal thickness for welding process 1
s2 = weld metal thickness for welding process 2
t = material thickness of test piece (plate or wall thickness)
t1 = material thickness of test piece for welding process 1
t2 = material thickness of test piece for welding process 2
T = pipe
z = leg length of fillet weld
The word ‘plate’ alone, or in combination, is used to mean ‘plate’, ‘rolled structural shapes’
or ‘welded structural shapes’ (see AS/NZS 3679.1 and AS/NZS 3679.2).
The word ‘pipe’ alone or in combination, is used to mean ‘pipe’, ‘tube’ or ‘hollow section’
(see AS 1163 and AS 1450).
All welding positions described in this Standard are defined in AS 3545.
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7 AS/NZS 2980:2007
C = cellulosic covering
M = electrode core-metal powder
P = electrode core-rutile, fast freezing slag
R = rutile covering or electrode core-rutile, slow freezing slag
S = solid wire/rod
Z = electrode core-other types
1.5.3 For other weld details
The following apply:
bs = welding from both sides
lw = leftward welding (a gas welding term also referred to as ‘pushing’ the torch)
mb = welding with backing
ml = multi-layer
nb = welding without backing
rw = rightward welding (a gas welding term also referred to as ‘dragging’ the torch)
sl = single-layer
ss single-side welding
1.5.4 For bend tests
The following apply:
A = minimum tensile elongation required by the material specification
d = diameter of the former or the inner roller
ts = thickness of the bend test specimen
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AS/NZS 2980:2007 8
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9 AS/NZS 2980:2007
2.1 GENERAL
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The qualification of welders is based on essential variables as applied to the conditions used
to weld the test piece. For each essential variable a range of qualification is defined. If the
welder has to weld outside the range of qualification a new qualification test is required.
The essential variables are the following:
(a) Welding process.
(b) Product type (plate and pipe).
(c) Type of weld (butt and fillet).
(d) Material group.
(e) Welding consumable.
(f) Arc and metal transfer characteristics (e.g., a change between short-arc and spray-arc
in the GMAW process).
(g) Dimension (material thickness and outside pipe diameter).
(h) Welding position.
(i) Weld detail (backing, single side welding, both side welding, single layer, multi-
layer, leftward welding, rightward welding (see also Clause 2.9).
however, when applied to the welding of carbon and many alloy steels, inert shielding gases
such as pure argon are not normally used. Such steels utilize reactive shielding gases based
normally on argon containing minor additions of oxygen (O 2) and/or carbon dioxide (CO 2).
Refer also to AS 4882.
3 Australia and New Zealand do not normally differentiate between the FCAWgs and FCAWss
processes other than where specifically required. The term FCAW is therefore used in this
document to describe both processes, unless otherwise indicated.
4 The principles of this Standard may be applied to other arc and fusion welding processes not
specifically listed above.
For other than electroslag or electrogas welding, a welder qualified to weld with multiple
electrodes shall be qualified to weld with a single electrode, but not vice versa.
Welders qualified for hand-held continuous electrode arc welding shall be considered
properly qualified for single electrode mechanized welding in the same process(es) subject
to the limitations of this Clause (Clause 2.2), provided the welders demonstrate properly
their ability to control the welding equipment.
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11 AS/NZS 2980:2007
TABLE 2.2
THICKNESS RANGE FOR SINGLE- AND MULTI-PROCESS JOINTS
FOR BUTT WELDS
Thickness range
Welding process used for the test piece Multi-process
Single-process joint
joint
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2
According to Table 2.7(A)
S2 1 – welding process without According to
backing t = s1 Table 2.7(A) with
S1 2 – welding process with t = s 1 + s2
1 backing t = s2
1 Welding without backing (nb)
2 Welding with backing (mb)
2 2
t2 t2
According to
3 4 According to Table 2.7(A)
Table 2.7(A)
1 – welding process without
2 Welding process with t = t1 + t2
3 Welding with backing (mb) backing t = t 1
Welding process 1
4 Welding without backing (nb) 2 – welding process with
only for welding
backing t = t 2
of the root area
t1
t1 3 mm 1
1 Welding without backing (nb)
NOTE: The term ‘single process joint’ allows a welder to qualify a process without backing
(welding process 1) and with backing (welding process 2) at the same time within the one joint as
permitted within Clause 2.2.
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AS/NZS 2980:2007 12
(c) Butt welds in pipes without backing qualify branch connections with an angle ≥60°
and the same range of qualification as in Clauses 2.2 and 2.5 to 2.9. For a branch
weld the range of qualification is based on the outside pipe diameter of the branch.
(d) For applications where the type of weld cannot be qualified by means of either a butt
or fillet weld test then a specific test piece to be used to qualify the welder, e.g.,
branch connections other than Item (c) above, plug welds (see Clause 3.5.5).
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TABLE 2.5.2
RANGE OF QUALIFICATION FOR PARENT METAL
Range of qualification
Material group
of the test 9
piece 1 2 3 4 5 6 7 8 10 11
9.1 9.2 + 9.3
1 X X — — — — — — — — — —
2 X X X — — — — — X — — X
3 X X X — — — — — X — — X
4 X X X X X X X — X — — X
5 X X X X X X X — X — — X
6 X X X X X X X — X — — X
7 X X X X X X X — X — — X
8 — — — — — — — X X X —
9 9.1 X X X — — — — — X — — X
9.2 + 9.3 X — — — — — — — X X X
10 — — — — — — — X — X X —
11 X — — — — — — — — — — X
LEGEND:
X Indicates those material groups for, which the welder is qualified.
— Indicates those material groups for which the welder is not qualified.
NOTE: Refer to Appendix B for details of material groups. Material is grouped according to ISO/TR 15608.
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13 AS/NZS 2980:2007
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AS/NZS 2980:2007 14
TABLE 2.6(A)
RANGE OF QUALIFICATION FOR WELDING CONSUMABLES (see Notes)
P, R, F1, F2 B, F4, F5 C, F3
MMAW (111) P, R, F1, F2 X — —
B, F4, F5 X X —
C, F3 — — X
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15 AS/NZS 2980:2007
TABLE 2.6(B)
GROUP DESIGNATION OF WELDING CONSUMABLES (See Notes)
Abbreviation Group designation to Electrode classification
(Clause 1.5.2) AS/NZS 3992 to AS/NZS 4855, AS/NZS 4856,
AS/NZS 4857
B F4 EXX15, EXX16, EXX18, EXX46, EXX48
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C F3 EXX10, EXX11
R F2 EXX12, EXX13, EXX14, EXX19
— F1 EXX20, EXX24, EXX27, EXX28
NOTES:
1 The letters ‘XX’ used in the classification designation stand for the various tensile
strength levels of deposited weld metal.
2 Group B is deemed to include consumables classified to AS/NZS 4854.
3 Group F4 includes electrodes for high chromium steels other than austenitic and duplex
steels. Electrodes for high alloy austenitic and duplex steels are designated group F5 in
AS/NZS 3992.
2.7 DIMENSIONS
The welder qualification test of butt welds is based on the material thickness and outside
pipe diameters. The ranges of qualification shall be as specified in Tables 2.7(A) and
2.7(B).
NOTE: It is not intended that material thickness or outside pipe diameters be as measured
precisely but rather the general philosophy behind the values given in Tables 2.7(A) and 2.7(B)
should be applied.
For fillet welds, the range of qualification for material thickness shall be as specified in
Table 2.7(C).
For branch welding, the material thickness criteria to which Table 2.7(A) applies and the
outside pipe diameter criteria to which Table 2.7(B) applies are as follows:
(a) Set on The material thickness and outside pipe diameter of the branch.
(b) Set in or set through The material thickness of the main pipe or shell and the outside
pipe diameter of the branch.
For test pieces of different outside pipe diameters and material thicknesses, the welder is
qualified for—
(i) the thinnest and thickest material thickness qualified in accordance with
Table 2.7(A); and
(ii) the smallest and largest outside pipe diameter qualified in accordance with
Table 2.7(B).
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AS/NZS 2980:2007 16
TABLE 2.7(A)
RANGE OF QUALIFICATION OF MATERIAL THICKNESS
AND WELD METAL THICKNESS (MULTI-PROCESS)
OF TEST PIECE FOR BUTT WELDS
millimetres
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TABLE 2.7(B)
RANGE OF QUALIFICATION FOR OUTSIDE
PIPE DIAMETER (See Note)
millimetres
Outside pipe diameter of test piece
Range of qualification
D
≤25 D to 2D
>25 ≥0.5 × D (25 mm min.)
NOTE: For structural hollow sections, D is the dimension of the smaller side.
TABLE 2.7(C)
RANGE OF QUALIFICATION OF MATERIAL THICKNESS
OF TEST PIECE FOR FILLET WELDS (See Note)
millimetres
Material thickness of test piece
Range of qualification
t
≤3 to3
>3 ≥3
NOTE: See also Table 2.9(B).
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TABLE 2.8
RANGE OF QUALIFICATION FOR WELDING POSITION (see Note 1)
Range of approval
Plates Pipes
Welding position of approval test Butt welds Fillet welds
piece Butt welds Fillet welds Rotating Fixed Rotating Fixed
(Note 2)
0° 90° 45° 0° 90°
F H VD VU OH F HV VD VU OH F VD VU H 6G-VU 6G-VD F HV VD VU (Note 3)
F — — — — X X — — — X — — — — — X X — — —
H X — — — X X — — — X — — X — — X X — — —
Butt welds VD — — — — — — X — — — — — — — — — — — — —
VU X — — — X X — X — X — — — — — X X — X —
OH X X — X X X — X X X — — — — — X X — X X
Plates
F — — — — — — — — — — — — — — — X — — — —
HV — — — — — X — — — — — — — — — X X — — —
Fillet welds VD — — — — — — — — — — — — — — — — — — — —
17
VU — — — — — X X — — — — — — — — X X — — —
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OH — — — — — X X — X — — — — — — X X — — X
Rotating F X — — — — X X — — — — — — — — X X — — —
VD — — X — — — — X — — — — — — — — — X — —
But VU X — — X X X X — X X X — — — — — — — X —
welds Fixed 90° H X X — — — X X — — — X — — — — X X — — —
6G-VU X X — X X X X — X X X — X X — X X — X X
Pipes
45° 6G-VD — — X — — — — X — — — X — — — — — X — —
Rotating F — — — — — X — — — — — — — — — — — — — —
Fillet (Note 2) HV — — — — — X X — — — — — — — — — X — — —
welds VD — — — — — — — X — — — — — — — — — — — —
Fixed 0°
VU — — — — — X X — X X — — — — — — X X — X
LEGEND:
Indicates the welding position for which the welder is approved in the approval list.
X Indicates those welding positions for which the welder is also approved.
— Indicates those welding positions for which the welder is not approved.
AS/NZS 2980:2007
AS/NZS 2980:2007 18
TABLE 2.9(A)
RANGE OF QUALIFICATION FOR WELD DETAILS ON BUTT WELDS
Range of qualification
Weld details of test piece Single-sided welding/ Single-sided welding/ Welding from
welding without backing welding with backing both sides
(ss nb) (ss mb) (bs)
Single-sided welding/
welding without backing X X X
(ss nb)
Single-sided welding/
welding with backing — X X
(ss mb)
Welding from both sides
— X X
(bs)
LEGEND:
X Indicates those welds for which the welder is qualified.
— Indicates those welds for which the welder is not qualified.
NOTE: A consumable insert may be used in lieu of backing material; however, separate qualification is
required for the use of consumable inserts.
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19 AS/NZS 2980:2007
TABLE 2.9(B)
RANGE OF QUALIFICATION OF LAYER TECHNIQUE
FOR FILLET WELDS
Single-layer (sl) X —
Multi-layer (ml) X X
LEGEND:
X Indicates the layer technique for which the welder is qualified.
— Indicates the layer technique for which the welder is not qualified.
NOTE: Throat thickness shall be in the range of 0.5 × t ≤ a ≤ 0.7 × t (see Clause 1.5.1).
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AS/NZS 2980:2007 20
3.1 SUPERVISION
The welding of test pieces shall be witnessed by the examiner or examining body. The
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125 125
300
t
LEGEND:
t = material thickness of test piece
DIMENSIONS IN MILLIMETRES
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21 AS/NZS 2980:2007
Z = a 2
t Z
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125
a
0
t 20
125
LEGEND:
0.5 x t5 a 0.7 x t
a = design throat thickness
t = material thickness of test piece
z = leg length of fillet weld
DIMENSIONS IN MILLLIMETRES
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AS/NZS 2980:2007 22
5
12
5
12
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LEGEND:
D = outside pipe diameter
t = material thickness of test piece (wall thickness)
DIMENSIONS IN MILLLIMETRES
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23 AS/NZS 2980:2007
Z = a 2
Z
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a
t
50
125
l1
50
t
l1
LEGEND:
0.5 x t a 0.7 x t
a = design throat thickness
D = outside pipe diameter
l 1 = length of test piece
t = material thickness of test piece
z = leg length of fillet weld
DIMENSIONS IN MILLLIMETRES
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AS/NZS 2980:2007 24
TABLE 3.4
TEST METHODS
Visual Radiographic Fracture test to Macroscopic
Bend test
Weld type examination examination AS 22.5.4.1 or examination
to AS 2205.3.1
to AS 3978 to AS 2177 AS 2205.4.2 to AS 2205.5.1
Butt weld (in plate Mandatory Mandatory Mandatory Not applicable
Mandatory
or pipe) (Notes 1, 2, 4) (Notes 1, 2, 6) (Notes 1, 2, 6) (Note 7)
Fillet weld and Mandatory Mandatory
Mandatory Not mandatory Not applicable
branch connection (Notes 3, 5) (Notes 3, 5, 7)
Plug weld Mandatory Not applicable Not applicable Not applicable Mandatory
NOTES:
1 Either radiographic testing or bend or fracture tests shall be used.
2 When radiographic testing is used, then additional bend or fracture tests are mandatory for the GMAW,
FCAW (only metal cored wire) and gas welding processes (see Clauses 3.4 and 3.5.2).
3 The fracture tests may be replaced by a macroscopic examination, according to AS 2205.5.1, of at least
two sections.
4 The radiographic testing may be replaced by ultrasonic testing according to AS 2207 for thickness
≥8 mm on ferritic steels only.
5 The fracture tests on pipes may be replaced by radiographic testing.
6 For outside pipe diameter (D) ≤25 mm, the bend or fracture tests may be replaced by a notched tensile
test (see ISO 9017) of the complete test piece (example is given in Figure 3.4).
7 A macroscopic examination may be required by the application Standard where the welder and
procedure are being qualified at the same time.
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25 AS/NZS 2980:2007
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300 25
DIMENSIONS IN MILLIMETRES
FIGURE 3.4 EXAMPLE FOR NOTCH TENSILE TEST FOR PIPE PIECE OUTSIDE
DIAMETER ≤25 mm
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AS/NZS 2980:2007 26
For thickness (t) >12 mm, the transverse bend tests may be substituted by side bend tests.
For pipes, the number of the additional fracture or transverse bend test specimens for the
GMAW, FCAW (only metal cored wire) and gas welding processes, using the radiographic
testing, depends on the welding position. For the flat (PA) or horizontal (PC) welding
position one root and one face bend test specimen shall be tested (see Figure 3.5.2(B)(a)).
For all other welding positions, two root and two face bend test specimens shall be tested
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27 AS/NZS 2980:2007
l2
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l2
25 lf
l1 25
LEGEND:
l 1 = length of test piece
l 2 = half width of test piece
l f = examination length
2 2
5 5
40
DIMENSIONS IN MILLIMETRES
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AS/NZS 2980:2007 28
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lf
2
LEGEND:
l f = examination length
1 = location for one root fracture or one root transverse bend or one side bend test specimen
2 = location for one face fracture or one face transverse bend or one side bend test specimen
(a) Sectioning of additional fracture or bend test specimens for the flat (PA)
and horizontal (PC) welding positions
1
2
lf
4 3
LEGEND:
l f = examination length
1 = location for one root fracture or one root transverse bend or one side bend test specimen
2 = location for one face fracture or one face transverse bend or one side bend test specimen
3 = location for one root fracture or one root transverse bend or one side bend test specimen
4 = location for one face fracture or one face transverse bend or one side bend test specimen
(b) Sectioning of additional fracture or bend test specimens for the vertical up (PF), vertical down
(PG), 6G vertical up (H-L045) and 6G vertical down (J-L045) welding positions
DIMENSIONS IN MILLIMETRES
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40
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2 2
5 5
DIMENSIONS IN MILLIMETRES
25
lf
25
LEGEND:
l f = examination length
DIMENSIONS IN MILLIMETRES
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31 AS/NZS 2980:2007
75 min.
50 min.
Macroetch
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test specimen
(etch interior face)
75 min.
50 min.
Cutine
See Note
See Note
10
10 min.
DIMENSIONS IN MILLIMETRES
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SECT I ON 4 C R I T E R I A O F A CCE PT A N CE
4.1 GENERAL
Test pieces shall be evaluated according to the acceptance requirements specified for
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33 AS/NZS 2980:2007
A fillet weld shall be permitted to underrun the nominal fillet weld size
specified by 1.5 mm without correction, provided the undersize portion of the
weld does not exceed 10% of the length of the weld.
(b) Pipe For acceptance qualification, the welded pipes, when examined visually, shall
comply with the following requirements:
(i) The weld shall be free of cracks.
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(ii) All craters shall be filled to the full cross-section of the weld.
(iii) The face of the weld shall be at least flush with the outside surface of the pipe,
and the weld shall merge smoothly with the parent metal. Undercut shall not
exceed 5% of the pipe wall thickness, or 0.5 mm in depth, whichever is less.
Weld reinforcement shall not exceed the values given in Table 4.3.1.
(iv) The root of the weld shall be examined, and there shall be no evidence of
cracks, incomplete fusion, or lack of root penetration. A concave root surface is
permitted, within the limits of Item (v) below, provided the total weld thickness
is equal to or greater than that of the parent metal.
(v) The maximum root surface concavity shall be 1.5 mm, and the maximum
penetration shall be 3 mm.
(c) Plug welds For acceptance qualification, the plug welds, when examined visually,
shall be filled.
TABLE 4.3.1
PERMISSIBLE WELD REINFORCEMENT FOR PIPE
millimetres
Pipe wall thickness Maximum reinforcement
≤10 2.5
10 to ≤20 3.0
>20 5.0
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AS/NZS 2980:2007 34
5 mm 2 .
(c) The total area of all internal imperfections shall not exceed 24 mm2 over the length of
the weld (see Clause 3.5.3), or 5% of the fractured surface area, whichever is the
lesser.
4.3.4 Macroetch examination
The specimen shall be prepared and examined in accordance with AS 2205.5.1.
For acceptable qualification, the specimen, when inspected visually, shall comply with the
following requirements:
(a) Fillet welds shall have fusion to the root of the joint but not necessarily beyond.
(b) Minimum leg size shall comply with the specified fillet weld size.
(c) Fillet welds shall—
(i) have no cracks;
(ii) have thorough fusion between adjacent layers of weld metal and between weld
metal and parent metal;
(iii) have weld profiles conforming to AS/NZS 1554.1;
(iv) have no undercut exceeding the values permitted by Clause 4.3.1(a)(iv);
(v) for porosity larger than 1mm, have accumulated porosity not exceeding 6 mm;
and
(vi) have no accumulated slag, the sum of the greatest dimensions of which shall not
exceed 3 mm.
(d) Plug welds shall—
(i) have no cracks;
(ii) have thorough fusion to the backing plate and to the sides of the hole; and
(iii) no visible slag in excess of 6 mm total accumulated length.
4.3.5 Radiography
4.3.5.1 Preparation of test piece
If radiographic examination is used in lieu of the prescribed bend or fracture tests, the test
piece shall be prepared in accordance with the following:
(a) The backing bar (when used) shall not be removed.
(b) Following visual examination to Clause 4.3.1, weld ripples or weld surface
irregularities on the test piece shall be removed by any suitable mechanical process to
the degree necessary to ensure that resulting radiographic images due to surface
irregularities cannot mask, or be confused with, the image of any discontinuity. A
witness of weld metal shall remain.
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Where materials of different thicknesses are examined, the thinner plate shall determine the
technique selection.
Image quality indicator (IQI) sensitivity for each technique shall be as required by
Table 4.3.5.2. The IQI sensitivity shall be measured through the weld using wire type IQI in
accordance with AS 2177. At least one IQI should be used with each radiograph.
TABLE 4.3.5.2
SMALLEST DISCERNIBLE WIRE
Wire number (see AS 2177)
Method
Weld metal thickness, mm
(see Note 1)
≤6 >6 ≤10 >10 ≤12 >12 ≤18 >18 ≤25 >25 ≤35 >35 ≤50 >50
XR2/z 13 12 11 10 9 8 7 See Note 2
GR1/z OR
12 11 11 10 9 8 7 See Note 2
GR2/z
NOTES:
1 As designated by AS 2177, for which ‘z’ is ‘S’, ‘DWS’ or ‘DWD’, as appropriate.
2 For thicknesses greater than 50 mm, an IQI sensitivity of 2.0% is required.
4.3.5.3 Criteria
For acceptance qualification, the weld, as revealed by the radiograph, shall comply with the
following requirements:
(a) The permissible level of imperfections shall not exceed the levels given in
Table 4.3.5.3.
(b) Adjacent imperfections:
(i) Aligned Where adjacent imperfections are aligned, they shall be assessed as
shown in Figure 4.3.5.3(a).
(ii) Overlapping Where there is a horizontal displacement between adjacent
imperfections, the effective length (l) shall be as shown in Figure 4.3.5.3(b).
(iii) Overlapping vertical displacement Where imperfections occur above one
another in the vertical plane of the weld, they shall be assessed as shown in
Figure 4.3.5.3(c).
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AS/NZS 2980:2007 36
TABLE 4.3.5.3
PERMISSIBLE LEVELS OF IMPERFECTION AS DETERMINED BY
RADIOGRAPHIC OR ULTRASONIC EXAMINATION
Type of imperfection Maximum allowable dimensions or number of
imperfections (see Notes 1 and 2)
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37 AS/NZS 2980:2007
L1
L1
ΣL
L2
L1
h1
h2
L2
h1
d
h
h2
L
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essentially square or circular transducer in the size range 15 mm to 22 mm. For plate
thicknesses of less than 15 mm, the transducer size may be reduced to 8 mm and
frequencies increased to 5 MHz. Compression probes shall have a dominant frequency in
the range 4 MHz to 5 MHz, and an essentially square or circular transducer in the size range
10 mm to 20 mm.
4.3.6.2 Evaluation
For welds on material with a thickness not greater than 50 mm, evaluation shall be carried
out at Level 2, in accordance with AS 2207. For welds on material with thickness greater
than 50 mm, evaluation shall be carried out at Level 3. Planar imperfections should be
evaluated at an incident angle of less than 10°. Where this is not possible, additional gain
shall be added in accordance with Table 4.3.6.2. For the purposes of Table 4.3.6.2, planar
imperfections shall be considered to lie along the welding preparation faces. The probe
angle shall be the actual measured angle, not the nominal angle.
TABLE 4.3.6.2
ADDITIONAL GAIN FOR EVALUATION
OF PLANAR IMPERFECTIONS
Angle of incidence, degrees Additional gain, dB
≤10 0
>10 ≤15 6
>15 ≤20 12
>20 Not permitted
4.4 RE-TESTS
If any test fails to comply with the requirements of this Standard, the welder shall be given
the opportunity to repeat the qualification test.
If it is established that failure is due to metallurgical or other extraneous causes that cannot
be directly attributed to the welder’s lack of skill, an additional test is required in order to
assess the quality and integrity of the new test material and/or new test conditions.
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5.2 CERTIFICATE
It shall be verified that the welder has successfully passed the qualification test. All
essential variables shall be recorded on the certificate. Whilst not regarded as an essential
variable for the purposes of this Standard, the classification of any shielding gas and/or
backing gas used (see AS 4882) shall be recorded on the certificate. If the test piece(s)
fail(s) any of the required tests, no certificate shall be issued.
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The certificate shall be issued to the welder under the sole responsibility of the examiner or
examining body and shall contain at least all information detailed in Appendix C.
In general, for each test piece, a separate welder’s qualification test certificate shall be
issued. If more than one test piece is welded, a single welder’s qualification test certificate
may be issued, which shall combine the ranges of qualification of the individual test pieces,
provided doing so does not lead to ambiguity.
The practical test and the examination of job knowledge should be designated by
‘Accepted’ or ‘Not tested’.
NOTES:
1 An outline of job knowledge criteria is given in Appendix D.
2 A new certificate may need to be issued to the welder after prolongation if insufficient space
remains on the certificate to record all details relating to the confirmation of the validity of
the qualification by the employer or welding supervisor for the following two years.
3 The procedure to which the welder has qualified and is used to transfer qualification in
accordance with Clause 5.1.1 should be recorded on the certificate.
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APPENDIX A
LIST OF REFERENCED DOCUMENTS
(Normative)
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AS
1163 Structural steel hollow sections
1450 Steel tubes for mechanical purposes
1548 Steel plates for pressure equipment
1796 Certification of welders and welding supervisors
1858 Electrodes and fluxes for submerged-arc welding
1858.1 Part 1: Carbon steels and carbon-manganese steels
1858.2 Part 2: Low and intermediate alloy steels
2062 Non destructive testing—Penetrant testing of products and components
2177 Non-destructive testing—Radiography of welding butt joints in metal
2205 Methods of destructive testing of welds in metal
2205.2.1 Method 2.1: Transverse butt tensile tests
2205.3.1 Method 3.1: Transverse guided bend test
2205.4.1 Method 4.1: Nick-break test
2205.4.2 Method 4.2: Fillet break test
2205.5.1 Method 5.1: Macro metallographic test for cross-section examination
2207 Non-destructive testing—Ultrasonic testing of fusion welded joints in carbon
and low alloy steel
2812 Welding, brazing and cutting of metals—Glossary of terms
2885 Pipelines—Gas and liquid petroleum
2885.2 Part 2: Welding
3545 Welding positions
3597 Structural and pressure vessel steel—Quenched and tempered plate
3978 Non-destructive testing—Visual inspection of metal products and components
4037 Pressure equipment—Examination and testing
4882 Shielding gases for welding
AS/NZS
1167 Welding and brazing—Filler metals
1167.2 Part 2: Filler metal for welding
1554 Structural steel welding
1554.1 Part 1: Welding of steel structures
1554.2 Part 2: Stud welding (steel studs to steel)
1554.3 Part 3: Welding of reinforcing steel
1554.4 Part 4: Welding of high strength quenched and tempered steels
1554.5 Part 5: Welding of steel structures subject to high levels of fatigue loading
1554.6 Part 6: Welding stainless steels for structural purposes
1594 Hot-rolled steel flat products
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AS/NZS
2717 Welding—Electrodes—Gas metal arc
2717.1 Part 1: Ferritic steel electrodes
3678 Structural Steel—Hot-rolled plates, floorplates and slabs
3679 Structural steel
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43 AS/NZS 2980:2007
ISO
14341 Welding consumables—Wire electrodes and deposits for gas shielded metal
arc welding of non alloy and fine grain steels—Classification
16834 Welding consumables—Wire electrodes, wires, rods and deposits for gas-
shielded arc welding of high strength steels—Classification
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NZS
4703 Welder qualification tests for stainless steel tubes for the dairy industry
TR 15608 Welding—Guidelines for a metallic material grouping system
AWS
D1.1 Structural welding code—Steel
D18.2 Guide to weld discoloration levels on inside of austenitic stainless steel tube
API
Spec 5L Specification for line pipe
ASTM
A517 Standard specification for pressure vessel plates, alloy steel, high strength,
quenched and tempered
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APPENDIX B
MATERIAL GROUPS
(Normative)
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This Appendix tabulates material groups used in this Standard. They are based on those
found in ISO/TR 15608 and are summarized in Table B1. Only those elements that are
specified in material Standards or specifications shall be considered. The figures given in
groups 1 and 11 are referring to the ladle analysis of the materials. The figures given in
groups 4 to 10 are based on the element content used in the designation of the alloys.
The groupings of common steel types used in Australia are shown in Table B2. For
information purposes, the alphanumeric equivalents of the material groups utilized in
AS/NZS 3992 are also shown in Table B3.
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TABLE B1
GROUPING SYSTEM FOR STEELS (see Notes)
Group Subgroup Type of steel
1 Steels with a specified minimum yield strength (ReH) ≤460 N/mm 2 (see Note 1) and
with analysis in %:
C ≤25
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Si ≤0.60
Mn ≤1.70
Mo ≤0.70 (see Note 2)
S ≤0.045
P ≤0.045
Cu ≤0.40 (see Note 2)
Ni ≤0.5 (see Note 2)
Cr ≤0.3 (0.4 for castings) (see Note 2)
Nb ≤0.05
V ≤0.12 (see Note 2)
Ti ≤0.05
2 Thermomechanically treated fine grain steels and cast steels with a specified
minimum yield strength (R eH ) >360 MPa
3 Quenched and tempered steels and precipitation hardened steels except stainless steels
with a specified minimum yield strength (R eH ) >360 MPa
4 Low vanadium alloyed Cr-Mo-(Ni) steels with Mo ≤0.7% and V ≤0.1%
5 Cr-Mo steels free of vanadium with C ≤0.35% (see Note 3)
6 High vanadium alloyed Cr-Mo-(Ni) steels
7 Ferritic, martensitic or precipitation hardened stainless steels with C ≤0.35% and
10.5% ≤Cr ≤30%
8 Austenitic stainless steels
9 Nickel alloy steels with Ni ≤10.0%
9.1 Nickel alloy steels with Ni ≤3.0%
9.2 Nickel alloy steels with 3.0% < Ni ≤8.0%
9.3 Nickel alloy steels with 8.0% < Ni ≤10.0%
10 Austenitic ferritic stainless steels (duplex)
11 Steels covered by group 1 (see Note 4) except 0.25% < C ≤0.5%
NOTES:
1 In accordance with the specification of the steel product standards, ReH may be replaced by Rp0.2 or Rt0.5.
2 A higher value is accepted provided Cr + Mo + Ni + Cu + V ≤0.75%.
3 ‘Free of vanadium’ means not deliberately added to the material.
4 A higher value is accepted provided Cr + Mo + Ni + Cu + V ≤1%.
5 Alphanumeric codes in Column 2 are nearest equivalents from AS/NZS 3992.
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TABLE B2
TYPICAL MATERIAL GROUPS FOR COMMON STEELS
(see notes)
Material group Typical grade or specification
API Spec 5L
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1 X52
2 X60, X65, X70, X80
AS 1163
1 C250, C350
2 C450
AS 1450
1 C200, H200, C250, H250, C350, H350
2 C450
AS 1548
1 7-430, 7-460, 5-490, 7-490
AS/NZS 1594
HA3, HA4N, HA200, HA250, HU250, HA250/1
1 HA300, HU300, HA300/1, XF300, HU300/1,HA350,
HW350
2 HA400, XF400, XF500
AS 3597
3 500, 600, 700, 700PV
AS/NZS 3678 and AS/NZS 3679.2
1 200, 250, 300, 350, WR350
2 400, 450
AS/NZS 3679.1
1 250, 300, 350
2 400
AS/NZS 4671
1 250N, 300E
2 500N, 500E
3 500N
NOTES:
1 Impact tested variants of the above grades are not shown for clarity.
2 AS/NZS 4671 grade 500N is manufactured by both microalloying and quench and
self-tempering (QST) processes.
3 The material groups in Table B2 above are those of ISO/TR 15608 and, therefore,
have no relation to the material groupings contained in AS/NZS 1554.1.
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47 AS/NZS 2980:2007
TABLE B3
AS/NZS 3992 MATERIAL GROUPS
ANSI/ASME BPV-IX
Material Typical nominal conditions
Type P Group
group or specification
number number
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AS/NZS 2980:2007 48
APPENDIX C
INFORMATION TO BE INLCUDED IN WELDER’S QUALIFICATION TEST
CERTIFICATE
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(Normative)
Name of examiner or
Type of tests Performed and accepted Not tested
examining body:
Visual testing: Place, date and signature
Radiographic testing: of examiner or examining
body:
Fracture test:
Bend test:
Date of welding:
Notch tensile test:
Macroscopic examination:
Qualification valid until:
Confirmation of the validity by employer/welding supervisor for the following 6 months (see
Clause 5.1.2)
Date Signature Position or title
Prolongation for qualification by examiner or examining body for the following 2 years (see
Clause 5.1.3)
Date Signature Position of title
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APPENDIX D
JOB KNOWLEDGE
(Informative)
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The test of job knowledge is recommended, but it is not mandatory. When the job
knowledge test is carried out, it should be recorded on the welder’s qualification test
certificate.
This Appendix outlines the job knowledge that a welder should have to ensure that welding
and other procedures are followed and common practices are complied with. The job
knowledge indicated in this Appendix is set at a basic level and exceeds the requirements of
ISO 9606-1. The actual questions used in the job knowledge test are not specified, but
should include questions on areas relevant to the qualification test of the welder with
outcomes showing that the welder is able to follow welding and other procedures, and is
aware of the range of qualification applicable.
The actual tests of a welder’s job knowledge may be given by any of the following methods
or combinations of these methods:
(a) Written objective tests (multiple choice).
(b) Oral questioning following a set of written questions.
(c) Computer testing.
(d) Demonstration/observation testing following a written set of criteria.
Welders who have successfully passed the AS 1796 welder theory examination covering
syllabus topics 1 to 18 inclusive (or an equivalent acceptable to the examining body) are
deemed to comply with the recommendation of this Appendix.
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APPENDIX E
COMPARISON WITH ISO 9606-1
(Informative)
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E1 GENERAL
ISO 9606-1, upon which much of this Standard is based, has its origins in European
welding practices, some of which vary considerably from that used throughout Australia
and New Zealand, and similarly the USA and many Pacific Rim countries who base their
welding practices on North American Standards and practices. This Appendix is designed to
assist the user to identify where the key differences lay, especially for those who may be
required to work with either ISO 9606-1 in its original form or its European equivalent.
E2 VARIANCES
E2.1 Welding consumables
ISO 9606-1 does not incorporate allowance for the use of welding consumables whose
properties are based on tensile strength, this being the system of classification in use in
Australia and New Zealand and many other Pacific Rim countries. This variance has been
addressed through the addition of Table 2.6(B).
The hierarchy of qualification is somewhat similar to that used in Australia and New
Zealand with the exception that users of cellulose consumables are required to qualify
specifically with those consumable types. The reason for the variance has more to do with
welder technique than other technical issues. Cellulose consumables find primary use in
pipeline welding principally in the vertical down, welding position, a position that requires
specific qualification in any event.
E2.2 Product type
Weld joints within ISO 9606-1 largely follow similar requirements to the previous edition
of AS 2980 and AWS D1.1, although special allowance is not necessarily required for the
complex K, Y and T pipe connections. Requirements for the qualification of welders for
plug welds has been retained, this joint type not being considered in the ISO document.
E2.3 Welding processes
ISO 9606-1 was written to provide for the qualification of welders using hand-held welding
equipment and does not addresses the additional needs of welders using mechanized or
automatic welding processes, for which no equivalent ISO requirements currently exist.
Requirements for such processes were included in the 1987 edition of AS 2980 and
similarly AWS D1.1 on which it was based, and these requirements have been transposed
into this edition of the Standard. Conversely, whereas the previous edition of AS 2980 did
not cater for the gas welding process, this edition has adopted the requirements for the oxy-
acetylene gas welding process recognized in ISO 9606-1.
Requirements to requalify welders who change the arc or metal transfer characteristics of
the welding process in use have been retained from the previous editions of AS 2980, thus
retaining consistency with most major welding Standards in use in Australia and New
Zealand, but surprisingly absent in ISO 9606-1.
E2.4 Material groups
ISO 9606-1 utilizes a material grouping system somewhat similar to that used in the
previous edition of AS 2980 and AS/NZS 3992. Details and differences are shown in
Appendix B of this Standard.
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51 AS/NZS 2980:2007
to incorporate the ISO 9606-1 requirements. These requirements have also been adopted in
the AS/NZS 1554 series of Standards.
E2.7 Weld details
Requirements for the qualification of welders required to weld single-sided butt welds with
and without backing materials have been carried over from ISO 9606-1. They are similar to
that previously published in AS 2980. Requirements have been included for the use of
consumable inserts, a feature missing in both the previous edition of AS 2980 and
ISO 9606-1.
Requirements for welders who qualify specifically on fillet welds have been adopted from
the latest draft of ISO 9606-1 where restrictions are placed depending on whether the
welder is required to produce single run or multi-run fillet welds. This is similar to the
requirements of the various parts of AS/NZS 1554.
E2.8 Examination and testing
Reference is made throughout this Standard to the Australian AS 2205 weld testing
Standards series. Test methods and requirements are similar to those of the ISO references
in ISO 9606-1. Where equivalents do not exist, reference is retained to the original ISO test.
E2.9 Criteria of acceptance
The criteria of acceptance remains largely consistent with AWS D1.1 and current Australian
and New Zealand Standards, and is consistent to a limited degree with the requirements of
ISO 9606-1. Criteria of acceptance used in ISO 9606-1 mainly calls up category B levels of
imperfections from ISO 5817, which is closer in requirements to that used in
AS/NZS 1554.5 and some critical joints in pressure applications. General imperfection
acceptance levels within AS/NZS 3992 (through AS 4037) and those within AS/NZS 1554.1
category SP are similar to but not identical to category C levels within ISO 5817.
E2.10 Validation and certification
Requirements for welders to demonstrate maintenance of their qualifications (conformation)
have now been included and are consistent with the requirements of the major application
Standards used in Australia and New Zealand. The system utilized is not as extensive as
that of ISO 9606-1 where more extensive validation requirements exist. The system, as
adopted, allows welders to demonstrate a higher level of ongoing conformation and
capability than that previously available.
E2.11 Designation
ISO 9606-1 incorporates an extensive designation system based on the notations given in
Clause 1.5 of this document. It is designed for use in computerized welder qualification
management systems and such designations are, therefore, required to be incorporated into
the welder’s certificate. As such systems are rarely used in Australia and New Zealand,
designations have not been incorporated into this edition of the Standard. For the
information of the user, the designations used in ISO 9606-1 comprise the following items
in the order given;
(a) The number of the Standard.
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AS/NZS 2980:2007 52
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53 AS/NZS 2980:2007
APPENDIX F
WELDER QUALIFICATION TEST FOR STAINLESS STEEL TUBE FOR THE
NEW ZEALAND DAIRY INDUSTRY
(Normative)
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F1 GENERAL
This Appendix provides a specific welder qualification for the welding of stainless steel
tube for applications such as plant and equipment for the food and dairy industries. It
replaces NZS 4703.
The Welders Qualification Test Certificate shall record the Testing Standard as
AS/NZS 2980, Appendix F, New Zealand Welder Qualification Test for Stainless Steel
Tube for the Dairy Industry.
F2 TEST METHOD
Qualification shall be in accordance with this Standard and the following:
(a) Test pieces shall be stainless steel tube of 1.5 mm nominal wall thickness.
(b) Test pieces welded from one side (single sided) shall be welded with backing gas.
(c) Test methods shall be visual examination, bend test and macro examination to
Table 3.4 and penetrate testing to AS 2062.
(d) Test pieces shall be evaluated with the external weld (outside of the tube) cleaned
with a stainless steel wire brush for welder qualification testing unless otherwise
specified on the WPS. The internal weld (inside of the tube) shall be as welded.
(e) For welds made using Ferritic stainless steel the heat affected zone grain size in the
macro section shall not exceed 0.5 mm, for any individual grain.
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AS/NZS 2980:2007 54
TABLE F3
PERMISSIBLE LEVELS OF IMPERFECTIONS IN TEST WELDS
Imperfection Maximum allowable dimension or number of imperfections
Cracks Nil
Reinforcement (height) 1.5 mm max.
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55
NOTES
AS/NZS 2980:2007
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AS/NZS 2980:2007
56
NOTES
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