Welding Engineering basic and concepts .pptx

Welding enginnering

1. welding Engineering By: Welding Technology division

2. Development of New Welding procedures as per production requirement. Welder Qualification in different PROCESSES / Positions as per shop requirement . Main work area of Welding Engineering

3. Welding processes used in HEEP/Hardwar Shielded metal arc welding Gas metal arc welding gas tungsten arc welding submerged arc welding Plasma transferred arc welding Spot welding

4. Essential Variable : Essential variable are those in which a change, as described in the specific variables ,is considered to effect the mechanical properties of weldment, and shall require requalification of the WPS. Supplementary Variables: Supplementary Variables are required for metals for which other sections specify notch-toughness tests and are in addition to the essential variables for each welding process . Nonessential Variables: may be made in the WPS without requalification. Nonessential variables are those in which a change, as described in the specific variable. Welding Variables

5. Joint design (Groove angle, root preparation) Welding process. Type of current. Pre and post weld heat treatment. Base material (P No: & Group No : ) or Grade. Base metal thickness range. Filler metal ‘F No’. Preheating temperature and inter-pass temperature. Voltage & ampere range. Supporting Procedure Qualification Report (PQR) Important Parameter

6. Welding Variables For Procedure Qualification

7. Welding Variables For Procedure Qualification

8. Welding Variables For Performance Qualification

9. P-Numbers are assigned to base metals for the purpose of reducing the number of welding procedure qualification required. Base Metal Grouping BASE METAL GROUPING Steel and steel alloys P No 1 through P No 15F Incl. P No. 5A,5B and 5C Aluminum and aluminum alloys P No 21 through P No 25 Copper and copper alloys P No 31 through P No 35 Nickel and nickel base alloys P No 41 through P No 49 Titanium and titanium base alloys P No 51 through P No 53

10. P No. EN288 Base Metal Example 1 1 C- Mn Steels AA10119, AA10104, AA10108 3 4 Typically half chrome & half moly HW19578 4 5 Typically one and a quarter chrome, half moly 5A 5 two and a quarter chrome one moly(Forging) HW19576 5B 5 Typically five chrome half moly and nine chrome one moly HW19688 5C 6 Chrome moly vanadium &Two quarter chrome one moly(Casting) HW19581 6 8 Martensitic Stainless Steels Typically Grade 410 HW10767 7 8 Ferritic Stainless Steels Typically Grade 409 ------ 8 9 Austenitic Stainless Steels AA10740, AA10788 15E Nine Chrome one Moly- Vanadium HW 19462 ASME P-Numbers

11. Designation for maual electrode

12. Base metal Thickness range for procedure qualification

13. Test required in procedure qualfiacation

14. Welding Procedure Specification

15. Welding Procedure Specification

16. Procedure Qualification Record

17. Procedure Qualification Record

18. Guided-bend test specimens

19. Welder performance qualification (WPQ)

20. Welding Positions in welder Qualification F: Fillet , G: Groove Flat - 1F or 1G Horizontal - 2F or 2G Vertical - 3F or 3G overhead - 4F or 4G Pipe - 5G (Flat+ vertical) Pipe - 6G(9all position)

21. Welding Positions in welder Qualification

22. Welding Positions in welder Qualification

23. Alternate Base Material for Welder Qualification Welder Qualified with Base Metals Welder Qualified to weld Base Metals P No 1 through P No 15F,P No 34 and P No 41 through P No 49 P No 1 through P No 15F,P No 34 and P No 41 through P No 49 P No 21 through P No 25 P No 21 through P No 25 P No 51 through P No 53 P No 51 through P No 53

24. Welder Qualified With F-No.1 With Backing F-No.1 Without Backing F-No.2 With Backing F-No.2 Without Backing F-No.3 With Backing F-No.3 Without Backing F-No.4 With Backing F-No.4 Without Backing F-No.5 With Backing F-No.5 Without Backing Welder Qualified to Weld F-No.1 With Backing √ √ √ √ √ √ √ √ √ √ F-No.1 Without Backing √ F-No.2 With Backing √ √ √ √ √ √ F-No.2 Without Backing √ F-No.3 With Backing √ √ √ √ F-No.3 Without Backing √ F-No.4 With Backing √ √ F-No.4 Without Backing √ F-No.5 With Backing √ √ F-No.5 Without Backing √ Alternate F- Number for Welder Qualification

25. Welder Qualified With Welder Qualified to Weld Any F-No. 6 All F-No. 6 Any F-No.21 through F-No. 25 All F-No.21 through F-No. 25 Any F-No. 31, 32, 33, 35, 36 or 37 Only the same F-Number as was used during the qualification test F-No.34 or any F-No. 41 through F-No. 46 F-No.34 and all F-No. 41 through F-No. 46 Any F-No.51 through F-No. 55 All F-No.51 through F-No. 55 Any F-No.61 All F-No.61 Any F-No.71 through F-No.72 Only the same F-Number as was used during the qualification test Alternate F- Number for Welder Qualification

26. F Number General Description 1 Heavy rutile coated iron powder electrodes :- A5.1 : E7024 2 Most rutile consumables such as :- A5.1 : E6013 3 Cellulosic electrodes such as :- A5.1 : E6011 4 Basic coated electrodes such as : A5.1 : E7016 and E7018 5 High alloy austenitic stainless steel and duplex :- A5.4 : E316L-16 6 Any steel solid or cored wire (with flux or metal) ASME Filler Code

27. Performance Qualification -Performance & diameter Limitation( QW-303)

28. Base metal thickness requirement for welder qualification

29. Performance qualification in case of pipe

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