Introduction to Materials Joining

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Codes Standards
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Codes and Standards

• Learning Activities
• Read Handbook 412-464
• View Slides
• Read Notes,
• Listen to lecture
• Do on-line workbook
• Do homework

• Lesson Objectives
• When you finish this lesson you will understand
• Codes and Standards and Standards Writing Bodies
• Welding Procedure Development and Qualifications

Keywords Codes, Specifications, Recommended
Practices, Guides, Classifications, Methods,
ANSI, ISO, Welding Procedure Specification (WPS),
Procedure Qualification Record (PQR), Welder
Performance Qualification
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Types of Standards
Introduction

• Codes are generally applicable to processes and
  indicate the mandatory use of materials or
  actions
• Specifications are generally associated with a
  product and indicate the mandatory use of
  materials or actions
• Recommended practices and guides are offered
  primarily as aids to the user
• Classifications and methods provide lists of
  established practices or categories for processes
  or products

Shall/will Shall/will Should/may
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Code Writing Agencies
This Table is in the Welding Handbook
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What is Covered by Standards
Introduction

• Products
• Piping - American Petroleum Institute
• Filler metals - American Welding Society
• Ships - American Bureau of Shipping
• Pressure vessels and boilers - American Society
  of Mechanical Engineers
• Bridges - American Institute of Steel
  Construction
• Health Safety
• Terminology
• Testing Procedures

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American National Standards Institute (ANSI)
Introduction

• Coordinating organization for the U.S. voluntary
  standards system
• There are approximately 10,000 American National
  Standards, which encompass nearly every field and
  discipline
• ANSI standards are developed and used
  voluntarily they become mandatory when adopted
  or referenced by a governmental body

International Organization for Standardization
(ISO)

• Establishment of Uniform Standards for
  International Trade

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International Organization for Standards (ISO)
Professional Society Standards

• 80 countries, 4000 standards, ANSI is the U.S.
  representative
• ISO 9000-9004 (ANSI/ASQC Q90) is a series of
  quality management and assurance standards in
  manufacturing
• Designed for manufacturing sector
• EC has adopted ISO 9000 and prefers US suppliers
  that are ISO 9000 certified
• DoD, DuPont, 3M, ATT are asking suppliers to
  comply with ISO 9000
• ISO 3834 - Factors to be Considered When
  Assessing Firms Using Welding as a Prime Means of
  Fabrication

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Health Safety
Health and Safety

• ANSI/ASC Z49.1-1988 Safety in Welding and
  Cutting
• Included in the General Industry Standards of
  OSHA
• Specifically covers arc, oxyfuel gas, resistance
  welding
• Health and Safety in Welding and Allied Processes
  4th edition, ed. N.C. Balchin and H. R. Castner,
  McGraw-Hill Inc. 1993

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American Welding Society (AWS) Standards
Professional Society Standards

• Definitions and Symbols (A)
• Filler Metals (A5)
• Qualification and Testing (B, C, and D)
• Welding Processes (C)
• Welding Applications (D)

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Definitions and Symbols
Professional Society Standards

• ANSI/AWS A2.4 Symbols for Welding, Brazing, and
  Nondestructive Examination
• Communication between designers and fabricators
• Joint geometry, weld contour, surface finish
• ANSI/AWS A3.0 Standard Welding Terms and
  Definitions
• Standard terms for use in written and oral
  communication conveying materials joining
  information
• Non-standard terms

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ANSI/AWS D1.1 Structural Welding Code Steel
Professional Society Standards

• Guidelines for design of welded joints as well as
  prequalified joint geometries
• Statically loaded structures
• Dynamically loaded structures
• Tubular sections
• Details the processes used with particular joints
• How to qualify welding procedures and personnel
• Outlines quality and inspection in welded
  construction
• Filler metal recommendations

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AWS D1.1 Prequalified Joint Design
Professional Society Standards
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ASTM (American Society for Testing and Materials)
Professional Society Standards

• Specifications cover virtually all materials used
  in industry and commerce, but not welding
  consumables
• Annual Book of ASTM Standards, 15 sections (65
  volumes)
• 1 - Iron and Steel
• 2 - Non-ferrous
• 3 - Metal test methods and analytical procedures
• Specification of groups of similar steel (A)
• A36 - general construction steels
• A387 - chromium-molybdenum steel for
  elevated-temperature service in piping and
  pressure vessel systems

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American Society of Mechanical Engineers (ASME)
Professional Society Standards

• Boiler and Pressure Vessel Code has 11 sections
  and is referenced by most states, major cities in
  the U.S., Canadian provinces, a number of federal
  agencies
• Before fabricating a boiler or pressure vessel, a
  company must have a quality control system and a
  manual describing it
• ASME issues a Certificate of Authorization and a
  code symbol stamp
• Unique in that it required 3rd party inspection
  independent of fabricator and user
• Uses same steel designations as ASTM

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Boiler and Pressure Vessel Code
Professional Society Standards

• Section II- Materials Specifications for base
  metals, filler metals, fluxes
• Section V - Nondestructive Examination
• Section IX - Welding and Brazing Qualifications
  for personnel and procedures
• Delineates a P number grouping of steels for the
  purpose of welding qualification
• P1 - carbon-manganese steels with a minimum UTS
  of 45-90 ksi
• P5 - alloy steels with 2.25-9 chromium, lt10
  total alloy
• All steels within a P number can be welded with
  the same procedure

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Other Standards
Professional Society Standards

• American Petroleum Institute (API) Standard 1104
  Welding of Pipelines and Related Facilities
• Qualifications of Welding Procedures and Welders
• Inspection and nondestructive testing
• Repair and removal of defects
• Unified Numbering System (UNS)
• Cross references the numbering systems from
  different countries
• Over 3500 metals, alloys, and filler metals
• Designated SAE HSJ1086 / ASTM DS56

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Questions?

• Turn to the person sitting next to you and
  discuss (1 min.)
• What does being a third party consensus
  standards writing body mean?

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Qualification Certification
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Welding Procedure Specification (WPS)
A document that provides in detail required
welding conditions for a specific application.
Procedure Qualification Record (PQR)
A record of actual welding conditions used to
produce an acceptable test joint and the results
of the qualification tests.
Welder Performance Qualification-Certification
A record of a welders or welding operators
ability to produce welded joints that meet
prescribed standards
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Pre-Qualified Procedures (Some Codes Permit -
Example AWS D1.1 Code) Based on the reliability
of certain proven procedures spelled out by the
applicable code or specification

• Use Written Procedures From Code
• All Essential Variable Specified
• Weld Qualification Tests Not Required
• Employer Accepts Responsibility for Use
• Deviations Negate Prequalified Status

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Basic Steps in Qualification of a Procedure
1. Prepare a preliminary WPS 2. Prepare and weld
a suitable test weldment using WPS 3. Conduct
required NDT and Destructive Tests 4. Evaluate
Results of prep, welding, testing 5. Document
results on PQR 6. Issue approved PQR 7. Issue
approved WPS
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PQR - WPS Variables Considered

• Base Metal
• Welding Process
• Filler Metal
• Type of Current/Range
• Voltage
• Heat Input
• Travel Speed
• Joint Design and Tolerances
• Joint and Surface Prep

• Tack Weld/Grind Off?
• Welding Details
• Electrode Size
• Passes
• Weave
• Position
• Preheat and Interpass
• Peening
• Second Side Prep
• Post Weld Heat Treat
• Records (If Required)

Check Specific Code for List of Essential
Variables (Essential Variable Must Be Included in
the WPS)
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PQR Page 1
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PQR Page 2
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Tests Commonly Used for PQRs
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WPS
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Welder Performance Qualification
Variables

• Welding Process
• Filler Metal
• Position
• Joint Details
• Thickness
• Technique
• (Qualifying in a more difficult position
• may qualify in an easier position)

Duration Of Qualification
Dependent upon Code (Usually inactivity of 3 to
6 months required requalification)
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Performance Qualification Record
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Demonstration
Run the Welding Procedure Specification from
the Demonstration Page of the WE300 Web Page
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Homework
Please do Assignment 14