PRESSURE VESSEL CODE

ASME SECTION IX

Mohamed Zaki
Welding processes
Welding Process Knowledge -
A Benefit to Inspectors

• Helps spot problems

• Leads to better inspection
• Gains respect of welders
• Gains cooperation
2 Basic ‘Process’ Groups
• Welding
• Brazing
 Common Features of Welding
Processes
• Source of energy
• Source of shielding
• Filler metal (optional)
Shielded Metal
Arc Welding
(SMAW)
SMAW
What are the functions of flux ?
 Flux Function
• To promote the ignition of the arc.
• To facilitate the electric conduction of the
arc and its stability.
• To provide a gaseous atmosphere
protecting the arc and welding pool from
oxygen and nitrogen of the air.
• To contribute with the elements those
balance the physical and chemical
processes of the arc.
 Flux Function

• To provide slag for protection of the welding

metal, to refine it and to contribute to their
control during welding.
• To contribute alloy elements to the melted
weld pool.
Page 148
Welding positions
 EXXXX
SMAW Electrode Identification System
Electrode
 EXXXX
SMAW Electrode Identification System
Strength
 EXXXX
SMAW Electrode Identification System
Position
Position Description
• 1 - used in all positions
• 2 - used in flat or horizontal fillets only
• 3 - not used at present time
• 4 - used for ‘downhill’ progression
 EXXXX
SMAW Electrode Identification System
Coating/Operating Characteristics
Low alloy steel electrodes
Electrode Suffixes - 1 of 2

- A1 0.5% Mo
- B1 0.5% Mo 0.5% Cr
- B2 0.5% Mo 1.25% Cr
- B3 1.0% Mo 2.25% Cr
- B4 0.5% Mo 2.0% Cr
-W Weathering
Electrode Suffixes - 2 of 2
- C1 2.5% Ni
- C2 3.5% Ni
- C3 1.0% Ni
- D1 0.3% Mo 1.5% Mn
- D2 0.3% Mo 1.75% Mn
-G 0.2% Mo 0.3% Cr 0.5% Ni
1% Mn 0.1% V
 Electrode Coating Classification
F #s
• F1 - EXX20, EXX24, EXX27
• F2 - EXXX2, EXXX3, EXXX4
• F3 - EXX10, EXXX1
• F4 - EXXX5, EXXX6, EXXX8
Low Hydrogen Electrodes
• Types end in a ‘5’, ‘6’, or ‘8’
• Purchase in sealed, metal containers
• Store after opening in heated, vented
oven
• Limit atmospheric exposure
Stainless Steel Electrodes
• E308, E308L - Weld 304 and 304L
• E316, E316L - Weld 316 and 316L
• E309 - Weld Stainless to Carbon Steel
SMAW Equipment
Gas Metal Arc Welding (GMAW)
 GMAW
Equipment
GMAW Schematic
GMAW Nomenclature
 ERXXS-X
E – Electrode
R – Rod
XX – Strength
S – Solid
X- Chemical comp.
Short-Circuiting Mode

For thin section and large gap

DCEP or DCEN
Punch force effected by
Current
Electrode diameter
Globular Mode

Low current than spray

Not directed large drops
More spatter than spray
Flat position
 Spray mode

High current
DCEP
High heat capacity
Suitable for thick
section
Suitable for any
position
 Spray Mode

Shielding for reactive metal welding AL , Ti, Mg

Helium and Argon mixing
Shielding for Carbon steel welding add O2 or Co2 to :
1- Arc stability
2- prevent undercut
3- prevent irregular weld bead
 Transition current

• What is the transition current ?

• What are the factors effect on the
transition current ?
Transition Current Depend on
• Electrode diameter
• Shielding gas type
• Filler metal melting point
• Surface tension of molten metal
 Pulsed Arc
mode

The welding current is variable; it is pulsed

between high and low current cycles set by
the welder
GMAW Advantages
• Semiautomatic process
• High productivity
• No slag to remove
• Clean process
• Continuous filler metal feed
• Welds most alloys
GMAW Limitations
• Unsuitable for windy conditions
• Little tolerance for contamination
• Usually limited to shop welding
• Equipment is more complex
• Consumables - liners, contact tips
 Flux Cored
Arc Welding (FCAW)
Gas-shielded
FCAW
Equipment
Self-shielded
FCAW
Equipment
Self-shielded FCAW
FCAW Guns - Gas & Self-shielded
 EXXT-X
E – Electrode
X – Strength
X – Position ( 0 flat 1 overall )
T – Tubular
X _ Chemical Composition & Operating Characteristics
1,2,3,4,6,9,12 DCEP
7,8,10,11,13,14 DCEN
5 DCEP or DCEN
Gas Tungsten
Arc Welding
(GTAW)
GTAW Nomenclature
Gas Tungsten Arc
Welding Equipment
GTAW Shielding gases
• Argon ( 7-16 L / min )
- High density
- weld all metals except reactive and
refractory
Helium ( 14 – 24 L / min )
- Light gas ( suitable for overhead )
- Good penetration
Argon + helium or Argon + hydrogen
15 % H2 increase welding speed by 50 %
 GTAW Advantages
• Good for thin materials ( .005 inch )
• High quality welds
• Good appearance
• High quality for weld root by using current remote
control
• No arc striking with high frequency start current
• No slag
• No spatter
• Autogeneous & heterogeneous
• Mechanization potential
GTAW Limitations
• Relatively slow
• Low tolerance for contamination
• Shielding gas expensive
• Purging gas expensive
Causes of Tungsten Inclusions
• Contact between:
– Tungsten and base metal
– Tungsten and filler metal
• Excess current
• Excess tungsten extension
• Improper tungsten tip grinding
Submerged
Arc Welding
(SAW)
SAW Equipment
SAW
SAW Advantages
• High deposition rate
• Deep penetration
• Mechanized process
• Hand-held process
• Good for overlay of large areas
• High operator appeal
SAW Limitations
• Flat or horizontal fillets only
• Extensive setup time
• Needs positioning equipment
• Arc not visible to operator
• Slag removal
Plasma Arc Welding
(PAW)
Plasma Arc Welding

Bare
Rod
 PAW Advantages
• Intense arc ( faster welding speed & less distortion
• Changing in stand off without change in melting
capacity
• Good arc visibility because long stand off
• Reduction of tungsten inclusion
• Deep penetration
• Clean process
• Keyhole welding
Keyhole Welding
Technique
Brazing
Brazing vs Welding vs Soldering
• Base metal not melted in brazing or
soldering
• Brazing filler metals melt above 8400 F
(4500 C)
• Soldering filler metals melt below 8400 F
• Strong joints possible with all processes
if designed properly
Brazing Aspects
• Large surface area
• Very small clearance
• Clean surfaces
• Flux often used
• Capillary action
Braze Joint Configurations
Brazing Filler Metals
• Wire
• Strip
• Foil
• Paste
• Preforms
ASME Section IX
Overview
 Article I
Welding General Requirements
 QW – 100 General

Section IX relates to the qualification of

welders, welding operators, brazers, and
brazing operators, and the procedures
It is divided into two parts: Part QW gives
requirements for welding and Part QB contains
requirements for brazing
 Welding Procedure Specification
• (WPS) is a written document that provides direction
to the welder or welding operator for making
production welds in accordance with Code
requirements.

• When a WPS is to be prepared by the manufacturer

or contractor, it must address, as a minimum, the
specific variables, both essential and nonessential, as
provided in Article II for each process to be used in
production welding.

• As a minimum, the PQR shall document the essential

variables and other specific information identified in
Article II for each process used during welding the test
coupon and the results of the required testing.
 QW – 141 Mechanical Tests
Mechanical tests used in procedure or performance
qualification are as follows:
QW – 141.1 Tension QW – 141.2 Guided-
Tests Bend Tests
…as described in QW- …as described in QW-
150 are used to 160 are used to
determine the ultimate determine the degree of
strength of groove-weld soundness and ductility
joints. of groove-weld joints.
QW – 153 Acceptance Criteria
Tension Tests
Minimum values for procedure qualification are
provided under the column heading “Minimum
Specified Tensile, ksi” of QW/QB- 422. In order to
pass the tension test, the specimen shall have a
tensile strength that is not less than:

(a)the minimum specified tensile strength of the

base metal; or…

(b) the minimum specified tensile strength of the

weaker of the two, if base metals of different
minimum tensile strengths are used; or…
 QW – 163 Acceptance Criteria – Bend
Tests
The weld and heat-affected zone of a transverse
weld-bend specimen shall be completely within the
bent portion of the specimen after testing.
 
The guided-bend specimens shall have no open
discontinuities in the weld or heat-affected zone
exceeding 1/8 in. (3.2 mm), measured in any
direction on the convex surface of the specimen
after bending. Open discontinuities occurring on the
corners of the specimen during testing shall not be
considered unless there is definite evidence that
they result from lack of fusion, slag inclusions, or
other internal discontinuities.
 QW-171 Notch Toughness Tests Charpy V-Notch
• QW-171.1 General Charpy V-notch impact tests shall
be made when required by other Sections. Test
procedures and apparatus shall conform to the
requirements of SA-370.

• QW-171.2 Acceptance in accordance with the Section

specifying impact requirements.

• QW-171.3 Location and Orientation of Test Specimen.

The impact test specimen and notch location and
orientation shall be as given in the Section requiring
such tests.
 Article II
Welding Procedure Qualifications
 QW – 200.1

Each manufacturer and contractor shall

prepare written Welding Procedure
Specifications which are defined as follows:

(b) Contents of the WPS.

The completed WPS shall describe all of the
essential, nonessential, and, when required,
supplementary essential variables for each
welding process used in the WPS.

See page 21
Page 21
 QW – 200.1
(c) Changes to the WPS. Changes may be
made in the nonessential variables of a WPS
to suit production requirements without
requalification. This may be by amendment to
the WPS or by use of a new WPS.

Changes in essential or supplementary

essential (when required) variables require
requalification of the WPS (new or additional
PQR s to support the change in essential or
supplementary essential variables).
 QW – 200.1
(d) Format of the WPS. The WPS may be in
any format
** The WPS/PQR forms of Section IX are not
mandatory.

(e) Availability of the WPS.

A WPS used for Code production welding
shall be available for reference and review by
the Authorized Inspector (AI) at the
fabrication site.
 QW – 200.2
(a)Procedure Qualification Record (PQR).
The PQR is a record of variables recorded
during the welding of the test coupons.
(b) Contents of the PQR. The completed PQR
shall document all essential and, when
required, supplementary essential variables

Nonessential or other variables used during

the welding of the test coupon may be
recorded at the manufacturer’s or
contractor’s option.
 QW – 200.2
(e) Availability of the PQR. PQR’s used to support
WPS’s shall be available, upon request, for review
by the Authorized Inspector (AI).. (You have the right
to review).

The PQR need not be available to the welder or

welding operator.
(f) Multiple WPS’ s With One PQR/Multiple PQR s
With One WPS. Several WPS’ s may be prepared
from the data on a single PQR
(e.g., a 1G plate PQR may support WPS’s for the F,
V, H, and O positions on plate or pipe within all other
essential variables).
 QW – 200.3
To reduce the number of welding procedure
qualifications required, P-Numbers are assigned
to base metals dependent on characteristics
such as composition, weldability, and
mechanical properties, (QW/QB-422) Page 74

These Group Numbers classify the metals within

P-Numbers for the purpose of procedure
qualification where notch-toughness
requirements are specified. (Group numbers are
required on the PQR only when Charpy testing is
required of the production welds).
Page 74
Quiz
WPS qualified with autogenous gas
tungsten arc welding process and during
production it is needed to weld with filler
metal , what is the correct action
A- welding with filler metal without any action
B- Re qualify a new WPS
Defining Each Essential Variable

Quiz
1. An 20 mm Test coupon was
welded to produce a PQR to
support welding of a reactor
shell course.
The maximum T qualified with this
coupon is ___”.
 Quiz

Using the table list the base metals qualified if

we successfully weld a procedure coupon
joining P No. 5A to No. P 5A
 P- No. 5A to P- No. 5A Qualifies?

P- No. 5A to 5A, 4, 3, or 1.
It does not qualify 4 , 3, or 1 to each other or
to their selves.
Article III
Welding Performance
Qualifications
 QW-300.1
This Article lists the welding processes
separately, with the essential variables that
apply to welder and welding operator
performance qualifications.

A welder or welding operator may be

qualified by radiography of a test coupon,
radiography of his initial production welding,
or by bend tests taken from a test coupon
except as stated in QW-304 and QW-305.
 QW-301.2 Qualification Tests
• The performance qualification test shall be
welded in accordance with a qualified (WPS),
except that when performance qualification is
done in accordance with a WPS that requires
a preheat or postweld heat treatment, these
may be omitted.
 QW-304 Welders

A welder qualified to weld in accordance with

one qualified WPS is also qualified to weld in
accordance with other qualified WPSs, using
the same welding process, within the limits of
the essential variables of QW-350.
Go to QW – 350 page 56
QW-305 Welding Operators
QW-305.1 Examination
Welds made in test coupons may be
examined by radiography or by visual and
mechanical examinations Alternatively, a 3 ft
(0.9 m) length of the first production weld
made entirely by the welding operator in
accordance with a qualified WPS may be
examined by radiography.

.
QW-321 Retests
A welder or welding operator who fails one or
more of the tests, may be retested under the
following conditions
QW-321.1 Immediate Retest Visual Exam
•When the qualification coupon has failed the
visual examination ,retesting shall be by
visual examination before conducting the
mechanical testing.
• When an immediate retest is made, the
welder or welding operator shall make two
test coupons for each position which he has
failed, all of which shall pass the visual
examination requirements. (Two for One)
 QW-321.3 Immediate Retest
Radiography
When the qualification coupon has failed the
radiographic examination, the immediate retest shall
be by the radiographic examination method.
 
(a) For welders and welding operators the retest
shall be to radiographically examine two 6 in. plate
coupons; for pipe, to examine two pipes for a
total of 12 in. of weld, which shall include the entire
weld circumference for pipe or pipes (for small
diameter pipe the total number of consecutively
made test coupons need not exceed eight). (Two for
One)
 QW-322.1 Expiration of Qualification
The performance qualification of a welder or welding
operator shall be affected……occurs:
 

(a) When he has not welded with a process during a period of

6 months or more, his qualifications for that process shall
expire; unless, within the six month period, …..
(1) a welder has welded using a manual or semiautomatic
welding process which will maintain his qualification …
(2) a welding operator has welded with a machine or
automatic welding process which will maintain his…..
(b) When there is a specific reason to question his ability to
make welds that meet the specification, the qualifications
shall be revoked. All other qualifications not questioned
remain in effect.
QW-452.3 GROOVE-WELD DIAMETER LIMITS
QW-452.3 GROOVE-WELD DIAMETER
LIMITS
Quiz
1. If a welder qualified on a NPS 6 inch
pipe coupon the range of diameter
qualifications in production with the
WPS he tested to will be _________.
2. If tested with a NPS 2 inch coupon
what is his minimum and maximum
diameter range is ________
 QW-452.3 GROOVE-WELD DIAMETER LIMITS

Quiz
1. If a welder qualified on a NPS 6 inch pipe
coupon the range of diameter qualifications in
production with the WPS he tested to will be
2-7/8” to unlimited.
2. If tested with a NPS 2 inch coupon what is
his minimum and maximum diameter range is
1” to unlimited.
 QW-353
Welder Essential Variables

P-Numbers. P-Numbers serve to group

metals by mechanical and chemical
properties. So it is reasonable to think that
not all metals can be welded using the
same technique, or have the same level
of difficulty for welders.

QW 423 Alternate Base Material for welder

qualification Page 128
Page 128
 QW-432
F Numbers

We have now arrived at the Filler Metal Number

or F Number. F Numbers are a grouping of
electrodes and filler metals that weld in a
similar way and in general present more or less
difficulty for a welder. In other words some F-
Number filler metals require different skills than
others.
Turn now to Page 129 of Section IX
 QW-433 Alternate F-Numbers for Welder Performance
Qualifications

Changing the F Number for a welder may affect

his ability to weld and require re-qualification.
Turn now to Page 137 of Section IX
 QW-433 Alternate F-Numbers for Welder Performance
Qualifications

Examples
1. Using the table QW-433, if a welder qualifies with or without
backing with a filler metal or electrode assigned to F-Number 4.
What F-Numbers can he use with backing in a production weld?

2. What F Numbers can he weld without backing?

 QW-433 Alternate F-Numbers for Welder Performance
Qualifications
Solution

1. He can weld F-Numbers 1 through 4 with

backing. Going right across the row titled
“Qualified With” to F-Number 4 without
backing then down to each x in the boxes, then
left to read the “Qualified For” Column we find
F Numbers 1, 2, 3 and 4 with backing.
2. Also the “Qualified For” F Number 4 without
backing is included which makes sense as he
performed that weld for his test.