The Welding Handbook

Julián Méndez Torres

The Welding Handbook

Julián Méndez Torres

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Abstract

Notice: All welding is carried out on the welder's own risk and account. Welding should be executed by a qualified and experienced welder and adequate safety measures should always be adhered to. The information and guidelines in this Welding Handbook are based on general information and knowledge at hand and are believed to be accurate and reliable, but the information and guidelines are not to be taken as a guarantee or warranty for a special purpose. The information and guidelines are provided to the welder solely for his own consideration, and Wilhelmsen Ships Service AS assumes no legal responsibility or liability for eventual damages and/or losses should the information and/or guidelines turn out to be incorrect or un-suitable. Wilhelmsen Ships Service AS is not liable for any loss or damages whatsoever and howsoever arising which is due to force majeure, other events beyond the reasonable control of Wilhelmsen Ships Service AS or events that could not reasonably be foreseen by Wilhelmsen Ships Service AS when this Welding Handbook was made. Wilhelmsen Ships Service AS is in no event liable for indirect, incidental or consequential damages or losses, including damages for loss of profits, resulting from lack of conformity, including but not limited to loss resulting from goods or software not working when connected to other goods/software or for any related cause thereto. Wilhelmsen Ships Service AS's liability shall in any event not exceed the total purchase price of theWilhelmsen Ships Service AS goods used during the welding operations. These conditions are automatically accepted by anybody using the information and guidelines in this Welding Handbook.

Figures (554)

towards gas and arc welding techniques when these were developed to useful production and repair methods through the 1930es. Wilhelmsen Ships Service AS enjoys close co-operation with its customers and would like to thank the many who have taken the effort to contribute with examples of successful solutions to real life maintenance situations. In 1943 the company name was changed to UNITOR. Mergers and increasing activity in the department for sales to ships led to the establishment of this department as a separate company; Unitor Ships Service AS in 1968.

that a smoke extractor unit is used. If this is not possible, the welder must be equipped with, and must use a face shield with fresh air connection.

Return clamp must be fastened directly on the work piece.

Keep cables and hoses clear of passage ways.

Quick reference for rebuilding, hardfacing and coating

This indicates an Austenitic stainless steel. Manganese steel, stainless steel: good weldability, but remember: no pre-heating.

Another simple test to find out whether the component is of alumin- ium, magnesium-alloyed aluminium or magnesium is as follows:

Higher strength filler materials must be used for welding low alloy steel. Use: SPECIAL, LH, LHV, LHT, LHL, LHR, ICROMO, TENSILE, GPS.

The example on solutions for “problem” steel that are given here are all based on using the electrode:

* Single values denote maximum percentage unless otherwise stated Unless otherwise stated, other elements of all alloys listed include maximum contents of 2,0 % Mn, 1,0 % Si, 0,045 P and 0,03 % S. Balance Fe. with a few exceptions exceeds 7%. Austenitic grades are non-magnetic. Autenitic stainless steel has the highest corrosion resistance of all the stainless steel. Most materials for chemical carriers are selected from this group of materials, and AISI 316 L is the most commonly used. The highest tonnage of weldable stainless steel produced are of the austenitic grades. These are the chromium nickel steel of the AISI 200 and 300 series in which chromium vernal awwrrnnle: TI aneel wich!

* Single values denote maximum percentage unless otherwise noted. Unless otherwise noted, other elements of all alloys listed include maximum contents of 2.0 % Mn, 1.0 % Si, 0,045 % | and 0,030 % S. Balance is Fe

Storing and handling of stainless steel onboard Stainless steel wire brush

The presence of the graphite flakes promotes ready machinability, useful damping properties and resistance to wear. However, the flakes also serve as crack-indicators, and gray cast iron cannot be bent or forged to shape, neither in cold nor in red-hot condition.

In addition magnesium not in excess of 0,08%, or

If the damage is in the form of a crack in the material, it may be difficult to determine where the crack actually

Place the patch in the hole and secure it in position but do not tackweld it. As this will prevent the patch from expanding to heat. Now weld the patch to the casting, using the backstep technique as indicated in the sketch. Be careful to let each bead of 2 - 3cm cool off before proceeding with the next bead. Use Unitor NIFE-334N for the build-up.

Wrap reinforcement tape around the pipe and patch totally encapsulating it. Make sure the product is impregnating the tape so that the final surface consists of product that can be smoothed out and blending in with the pipe surface.

The use of Yorcalbro piping allows a higher flow rate in the pipe than possible with copper piping. A flow rate up to 3.5m/s is permitted in Yorcalbro pipes compared to 1.52 m/s in copper pipes. Copper sea water piping on board ships has increasingly been replaced by Yorcalbro pipes. Yorcalbro (aluminium brass) is an alloy with the following chemical composition and mechanical specification: Some years ago, numerous welding tests were carried out on Yorcalbro pipes using the TIG (GTAW) process. The results were very satisfactory. Both small and large size pipes were welded in these tests, and the conclusions were as follows:

Inspection prior to welding also includes verification of correct process and procedures are to be employed — that the electrode type and size and the equipment settings for voltage and amperage are as specified — and that provisions are made for required preheat or post heat.

All Unitor electrodes have an imprint with name, and if applicable, AWS number.

The Heating Cabinet — 85 have 100 mm mineral wool in the bottoom and 50 mm in the top and side walls.

* SDS available on request. ** 90% of max. amperage Re-drying temperature: Normally no need.

Suitable for tack welding and welding on clamp fitments.

* SDS available on request. ** 90% of max. amperage Welding data

Packaging data Re-drying temperature: Normally no need.

Packaging data Re-drying temperature: 350 °C (662 °F) for two hours.

Re-drying temperature: 350 °C (662 °F) for two hours.

The A measurement should be 7/10 of material thickness.

The electrode must be protected against humidity and no attempt should be made to weld with damp electrodes. See the section on after- drying of basic electrodes.

Re-drying temperature: 350 °C (662 °F) for two hours. Can also be used for welding CorTen steel and Mayari R steels.

SDS available on request. ** 90% of max. amperage

General applications: Wear resistant non-magnetic surface layers on most weldable steel surfaces, including cast steel, alloy steels and stainless steels, where following properties are required even at high working temperatures, up to 900°C:

* SDS available on request. Welding data

Re-drying temperature: 250 °C (482 °F) for one hour. Trawler equipment subject to metal to earth wear and metal to metal wear. Suitable for both joining and making wear resistant overlays. Worn winch wheels and anchor windlass wheels on anchoring systems. Cargo handling equipment and dredger equipment, T1-steel, N-A-Xtra steel, OXAR steel, Fine grain steel, Cr Mo steel, Manganese steel, Shear blades.

Re-drying temperature: 350 °C (662 °F) for two hours. SDS available on request. ** 90% of max. amperage

Can also be used for welding dissimilar materials: Unalloyed and low alloyed steels to Duplex stainless steel. Stainless steel to Duplex steels. All weld metal composition

Do not contain chloride containing agents such as hydrochloric acid (HCL) NB. Do not pickle in direct sunlight.

Caution: Storage temperatures higher than 45°C must be avoided since they accelerate the ageing process and destroy the product. Pickling chemicals give best result when they are fresh. Stir the gel to a smooth consistency. Spread a thick layer on to the work surface using the brush supplied. Allow the gel to remain for 50-90 minutes. Rinse off the reminding gel using fresh water. The waste water, after rinsing, contains acids and heavy metals, and must hence be treated according to local wastewater requirements before discharge. This can be done with neutralising agent or slaked lime. The waste water treatment should adjust the pH value of the clear water, pH 6,5-10, and precipi heavy metals into a sludge which should be sent for waste disposal. Recommended temperature limits for application: 10°C - 40°C. Application

Start welding at the end of the crack and work inwards.

Re-drying temperature: 200 °C (392 °F) for one hour.

Small parts should be brazed with AG- 60 and AG-60/45 Flux-252 PF. Larger dimensions should be TIG welded with Icuni 30 329.

Unitor ALBRONZE-344 is not recom- mended for welding Yorcalbro and Cunifer pipes.

Re-drying temperature: 80 °C for 1 hour.

Joining a cast aluminium cover. Such parts should be pre-heated to approx. 300°C if possible

Note: The copper coating will oxidize during the process, but this will not influence the performance of the product.

Stainless surface appearance. Imprint: ER 316LSi / RW 1.4430 Identification:

Whenever possible, welding should take place in the workshop, in the horizontal position.

General Purpose Self-Shielded Electrode wire for the welding of mild steel and ships steel. All position welding, including vertical do

Wire identification: Flux cored wire for welding of stainless steel and welding mild steel to stainless steel. Also welding of clad steel.

Alumag-235 may be used for TIG-welding using AC welding machine. Shielding gas: Argon, 6—9 I/min.

Remember that fluxes can be contaminated. Therefore, always replace the lid after use.

* SDS available on request. Packaging data

Without the flux to suspend water vapour, grease and oxides, a film will prevent the brazing alloy from bonding

Typical Capillary/Silver brazing joints. Note that they all utilise capillary action.

Unitor FC-Wearbro 262 is specially suitable for building up damaged machine parts which have been subjected to impact, wear or bending strain, e.g. gear wheels, cams of all types, valve seats, bearing surfaces and shaft journals. Due to its low bonding temperature, high strength and toughness, it is also suitable for braze welding cast iron.

Gas weld Leftward. Note that the weld pool must not be stirred with the filler rod

Bare cadmium free silver rod for joining of all types of steel, stainless steel, copper, copper alloys, nickel and nickel alloys, cast iron and hard metals. This brazing rod gives a very good joint and can be used for brazing nipples, sleeves and unions to copper pipes.

Use additional flux AG-60/45 Flux 252 PF For Yorkalbro use Albro flux 263 PF

Packaging data If swallowed, seek medical advice immediatly and show this container or label

Unitor Cold Repair System for High Performance Repairs

Before proceeding, please read the following information application carefully to ensure that proper procedures are fully understood.

* Leak Stop III should be used in multiple roll applications 1 pe. 4" x 12' (100 mm x 3,6 m) black repair tape in a pouch. For use on pipe diameter 2'-4" (50-100 mm). If used outside this diameter area:

1 pc. 2" x 4' (50 mm x 1,2 m) black repair tape in a poucl For use on pipe diameter 0-1" (0-25 mm). If used outside this diameter area: 1 pe. 2" x 12' (50 mm x 3,6 m) black repair tape in a pouch. For use on pipe diameter 1'—2" (25-50 mm).

Product specification sheet — Metalgrade Ready-Stick

As long as good practise is observed MetalGrade Ready-Stick can be safely used. Wearing of rubber gloves is advisable during use. Prior to using this product please consult the Safety Data Shee provided with each packaged product.

Cut off equal length of Base & Activator sticks

Thoroughly mix by hand kneading until streak free

Chemical resistance Suitable for permanent immersion at 20 °C (68 °F) in a limited range of chemicals. For a more detailec description refer to the Chemical Resistance Chart. Manufactured under a quality program certified to ISO 9002 As long as good practice is observed MetalGrade Express can be safely used. Wearing of rubber gloves is advisable during use. Prior to using this product please consult the Safety Data Sheet provided with each packaged product.

grease and dirt) with a cleaner. B) Remove all loose rust and surface coatings. Prepared Surfaces should be dry. Using the Spatula provided the mixed material should be pressed firmly

Recommended Temperature Limits For Application: 5 °C TO 40 °C Chemical resistance Manufactured under a quality program certified to ISO 9002 As long as good practice is observed MetalGrade Rebuild can be safely used. Wearing of rubber gloves is advisable during use. Prior to using this product please consult the Safety Data Sheet provided with each packaged product.

If Reinforcement Bandage is used to strengthen the repair, the bandage should be impregnated with MetalGrade Rebuild, or the bandage should be laid over the surface of the MetalGrade Rebuild and pressed into the surface. Additional MetalGrade Rebuild should then be applied over the surface.

As long as good practice is observed MetalGrade Hi- Temp can be safely used. Wearing of rubber gloves is advisable during use. Prior to using this product please consult the Safety Data Sheet provided with each packaged product. Health and Safety With all kits comes 5 x pair of Gloves, 1 pc. Working data sheet, 1 pc. Safety Data Sheet

Repairs pin holes, cracks and warped sur- faces on high temperature, low pressure systems including incinerators, manifolds, stacks, heat exchangers and turbines.

Suitable for permanent immersion at 20 °C (68 °F) in a limited range of chemicals. For a more detailed description refer to the Chemical Resistance Chart. Chemical resistance Vianufactured under a quality program certified to ISO 9002 As long as good practice is observed AquaGrade Rebuild can be safely used. Wearing of rubber gloves is advisable during use. Prior to using this product please consult the Safety Data Sheet provided with each packaged product. Health and Safety

Recommended Temperature Limits For Application: 5 °C TO 40 °C Chemical resistance Suitable for permanent immersion at 20 °C (68 °F) in a limited range of chemicals. For a more detailed description refer to the Chemical Resistance Chart. Vianufactured under a quality program certified to ISO 9002 As long as good practice is observed CeramiGrade Rebuild can be safely used. Wearing of rubber gloves is advisable during use. Prior to using this product please consult the Safety Data Sheet provided with each packaged product. Health and Safety

C) Roughen the surface, preferably with abrasive blasting to SAZ2. Alternatively a die grinder, needle scaler or angle grinder may be used. If grinding make sure the surface is roughened, not polished. Where grinding or needle gunning is used, the surface should be cross scored to improve adhesion.

lanufactured under a quality program certified to ISO 9002 As long as good practice is observed CeramiGrade Liner can be safely used. Wearing of rubber gloves is advisable during use. Prior to using this product please consult the Safety Data Sheet provided with each packaged product. Health and Safety

Heavy contamination due to oil or grease must be removed using a cleaner. Where possible, abrasive blasting is the preferred surface preparation, especially in fluid flow repairs.

Below - 20 °C impact resistance will be considerably reduced. The product will become brittle. Recommended Temperature Limits For Application: 5 °C to 40 °C Excellent against water, oil, grease, detergents, diluted acids and alkaline. Resistant to solvents, aliphatic alcohols and aromatics. Against esters, ketones and chlorinated hydrocarbons, tests are recommended. Manufactured under a quality program certified to ISO 9002 As long as good practice is observed Ceramigrade Abrashield can be safely used. Wearing of rubber gloves is advisable during use. Prior to using this product please consult the Safety Data Sheet provided with each packaged product.

As long as normal good practices are observed Ceramigrade Abrashield can be safely used. A fully detailed

Ceramigrade Abrashield can also be used in combina- tion with the hard surfacing electrode Abratech-330 to fill in between runs. The welding runs give the polymer side support and stability.

Product specification sheet — Rubbergrade 6 Rebuild

Chemical resistance Manufactured under a quality program certified to ISO 9002 As long as good practice is observed Rubbergrade 6 Rebuild can be safely used. Wearing of rubber gloves is advisable during use. Prior to using this product please consult the Safety Data Sheet provided with each packaged product.

Using the spatula provided the mixed material should be spread evenly onto the prepared area, working the material into any cracks and surface

Heavy contamination due to oil or grease must be removed using a cleaner. Any areas of frayed or fragmented rubber should be cut away to provide a sound repair area.

Product specification sheet — Rubbergrade 6 Remould

Chemical resistance Manufactured under a quality program certified to ISO 9002 As long as good practice is observed Rubbergrade 6 Remould can be safely used. Wearing of rubber gloves is advisable during use. Prior to using this product please consult the Safety Data Sheet provided with each packaged product.

Arc processes require a complete electric circuit. Always remember proper connection of the return clamp.

Open circuit voltage below 67V provides conformance with the British DOT: CODE OF SAFE WORKING PRACTICE FOR MERCHANT SEAMEN

Application set-up for TIG welding Argon for TIG shielding is available in 10 | cylinders (E-10) and 50 | cylinders (E-50)

Application set-up for Stick Electrode welding TIG welding Accessories for UWI-320 TP Argon for TIG shielding is available in 10 | cylinders (E-10) and 50 | cylinders (E-50)

UWI-500 TP as a manual stick electrode welding unit with a remote control unit and welding cables.

TIG welding accessories (Based on having Stick electrode accessories) Argon for TIG shielding gas is available in 10 | cylinders (E-10) and 50 | cylinders (E-50).

UWI-500 TP Application set-up for TIG welding UWI-500 TP as TIG welding unit with a remote control unit, TIG torch set and return cable

Argon or Argon CO, for Wire Welding shielding gas available in 10 | cylinders (E-10/M-10) and 50 | cylinders (E-50(M-50)

WI-500 TP Application set-up for Wire welding UWI-500 TP with UWF-102 wire feeder, wire welding torch and return cable.

NB In this location the remote control extension cables can be mounted

The Unitor power sources are delivered with a 2 or 3 meter primary cable. If a longer primary cable is needed this is our recommendation for length and dimension. Note that dimensioning of the cable does not only depend on cable length but also the voltage on the mains.

x) Bring machine to work site and use short electrode/ground cables only The following table shows the theoretical cable lengths relevant tc Length ~ voltage drop/current - conductivity of copper (58) - cable cross section.

Cable drum for up to 100 m cable, order no. The conductor is built up from 0.2 mm diameter tinned copper strands to ensure flexibility. HO1N2-D means that the cable is produced to an international harmonized standard. Welding cables used on board, on deck or in an engine room, are exposed to both rough weather, oil and mechanical wear. The welding_. cable supplied by Unitor has wear, flame and oil-resistant insulation on a polychloroprene rubber basis. It is recognized by its marking at regular intervals with the text “Unitor oil resistant welding cable”, size of cable, and the standard for welding cable HO1N2-D. The cable drum with crank and floor stand is used for storage of up to 100 m cable. The crank may be disengaged to avoid accidents when unwinding cable. Cable drum It may also be ordered in other lengths, without connectors mounted.

Place return clamp in direct contact with work piece. Use of the ships hull as return con- ductor is against regulations. Make sure to grind the connection surface free from paint and rust before connecting the return clamp.

Return clamp 400 A. Grind off rust and paint before connecting return clamp in order to ensure optimal contact with the workpiece

Tech sheets for all products under section Consumables.

Electrode holder for air carbon arc gouging

Torch for Air Carbon Arc Gouging with safety cable connector and air connector

UWI-161 TP with trolly and a 101 Argon cylinder is an excellent mobile solution for TIG welding needs on board. It will in addition do stick electrode welding of up to 3,2mm electrodes and wire welding with or without shielding gas and up to 1mm wire.

All Unitor welding machines are supplied with characteristics especially suited for TIG.

R510 regulator with flow meter in order to adjust gas flow in I/min.

Correct Grinding of Tungsten electrodes for DC welding

TIG Equipment & Accessories for Unitor Welding Machine Range

Connect the equipment and purge the gas system. Check electrode and electrode stick-out.

The most common gas to use is Argon or Formier gas (90% N? and 10% H?) The ideal concentration of oxygen is below 25 ppm, as this is insufficient t oxidize stainless steel.

The guns and welding heads for semiautomatic and full-automatic welding with the gas-shielded processes are out of necessity more complex than those used in self- shielded flux-cored welding. Space

The Unitor Wire Welder UWW-161 TP includes polarity selection possibility. The unit is therefore also able to use self-shielding flux cored wires, and covers all thin plate and light construction welding applications.

Application set-up for Stick Electrode welding

Thread the wire through the ingoing guide tube (8), over the drive roll (3), and into the outgoing guide tube.

These drive rolls are specially developed for flux-cored wires and provides excellent grip on the hard surface of these wires without requiring a pressure that will deform these tubular wires.

T-400 torch for gas shielded wire welding, complete with contact tip 1.0—-1.2 mm and Teflon liner. Order nmber 193-607451 The torch has adjustable neck and is delivered complete with tools for neck adjustment and contact tip change. It is delivered with 3 m cable, complete with liner and contact tips for 0.8-1.2 mm wire. The teflon liner allows for all wire types including aluminium.

Steel, Position welding, 80% Ar, 20% Co, Shielding gas H: Horizontal, VD: Vertical down, VU: Vertical up

Steel, Position welding, 80% Ar, 20% CO, Shielding gas

Stainless steel, Position welding, 80% Ar, 20% CO, Shielding gas

Stainless steel, Horizontal welding, 80% Ar, 20% CO, Shielding gas

Aluminium, Horizontal welding, Argon Shielding gas

luminium, Position welding, Argon Shielding ga:

Copper alloys, Horizontal, Argon Shielding gas NB: When welding Cunifer backing gas must be used

Plasma, the fourth state of matter The process utilizes the electrically One common description of plasma is that it is the fourth state of matter. We normally think of the three states (At a temperature of between 2000°C (3600°F) and 10000°C (18000°F) a process of ionization and dissociation of the gas molecules take place. The molecules are split in molecular and atomic ions and free electrons. When this happens, the gas, which has now become plasma, is electrtrically conductive because free electrons are available to carry current).

UNITOR UPC-310 TP Plasma Cutter Technical Data:

UPC-1041 is supplied complete with Unitor Plasma Cutter UPC-1041 Technical Data

Air supply precaution: Use only oil-free dry compressed air. Normally the control air on board will have the best quality.

In order to ensure oil and water free air for plasma cutting, Unitor recommend the following set up:

Arc Welding Current Distribution System socket is a 10 pole amphenol type, female for both inlet and outlet stations. The socket is equipped with a screw cover. The remote control connection is done with a special connection cable and/or adaptor, see ordering information. A red diode 130 V AC is placed between the welding terminals to warn when outlet is live. The housing is mounted to the bulkhead by use of brackets that are incliudad with the inlete / qiutlate

The energy (kJ/cm?e S) from the core flame of acetylene compared to propane at various mixing rates with oxygen. Hydrogen molecules dissociate on the surface of the core flame and recombine on the surface of the workpiece.

Temperature variation through a neutral acetylene/oxygen flame. Combustion velocity of acetylene com- pared to propane.

Dimensions: 600 x 600 x 300mm Free distance above cabinet 310 mm. Weight complete 56 kg. The Unitor workshop cabinet for Gas Cutting, Welding, Heating and Brazing.

mark on the surface to be heated. When the stick mark goes from solid to liquid the temperature have been reached

NB: Gas hoses are measured on their internal diameter.

Twist-Lock Quick Couplings for Oxygen, Acetylene and Shielding gases

It is important to adjust welding flame correctly for the material to be welded. Flame types are given under the descriptions of the various filler materials.

Braze welding may be used to join a wide range of metals, and is also used for rebuilding wear surfaces. As with capillary brazing the surfaces must be cleaned and correct flux should be applied where required.

Metric and Decimal Equivalents of Fractions of an Inch

Juan Velasquez Serna

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Safety in Welding, Cutting, and Allied Processes

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Standard Welding Terms and Definitions

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This standard is a glossary of the technical terms used in the welding industry. Its purpose is to establish standard terms to aid in the communication of welding information. Since it is intended be a comprehensive compilation of welding terminology, nonstandard terms used in the welding industry are also included. All terms are either standard or nonstandard. They are arranged in the conventional dictionary letter-by-letter alphabetical sequence.

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PART QW WELDING ARTICLE I WELDING GENERAL REQUIREMENTS QW-100 GENERAL

Mohammad Khalid

Section IX of the ASME Boiler and Pressure Vessel Code relates to the qualification of welders, welding operators, brazers, and brazing operators, and the procedures that they employ in welding and brazing according to the ASME Boiler and Pressure Vessel Code and the ASME B31 Code for Pressure Piping. It is divided into two parts: Part QW gives requirements for welding and Part QB contains requirements for brazing. The purpose of the Welding Procedure Specification (WPS) and Procedure Qualification Record (PQR) is to determine that the weldment proposed for construction is capable of providing the required properties for its intended application. It is presupposed that the welder or welding operator performing the welding procedure qualification test is a skilled workman. That is, the welding procedure qualification test establishes the properties of the weldment, not the skill of the welder or welding operator. In addition to this general requirement, special considerations for notch toughness are required by other Sections of the Code. Briefly, a WPS lists the variables, both essential and nonessential, and the acceptable ranges of these variables when using the WPS. The WPS is intended to provide direction for the welder /welding operator. The PQR lists what was used in qualifying the WPS and the test results. In performance qualification, the basic criterion established for welder qualification is to determine the welder's ability to deposit sound weld metal. The purpose of the performance qualification test for the welding operator is to determine the welding operator's mechanical ability to operate the welding equipment. 1 QW-100.3 Welding Procedure Specifications (WPS) written and qualified in accordance with the rules of this Section, and welders and welding operators of automatic and machine welding equipment also qualified in accordance with these rules may be used in any construction built to the requirements of the ASME Boiler and Pressure Vessel Code or the ASME B31 Code for Pressure Piping. However, other Sections of the Code state the conditions under which Section IX requirements are mandatory, in whole or in part, and give additional requirements. The reader is advised to take these provisions into consideration when using this Section. Welding Procedure Specifications, Procedure Qualification Records, and Welder /Welding Operator Performance Qualification made in accordance with the requirements of the 1962 Edition or any later Edition of Section IX may be used in any construction built to the ASME Boiler and Pressure Vessel Code or the ASME B31 Code for Pressure Piping. Welding Procedure Specifications, Procedure Qualification Records, and Welder /Welding Operator Performance Qualification made in accordance with the requirements of the Editions of Section IX prior to 1962, in which all of the requirements of the 1962 Edition or later Editions are met, may also be used. Welding Procedure Specifications and Welder/Welding Operator Performance Qualification records meeting the above requirements do not need to be amended to include any variables required by later Editions and Addenda. Qualification of new Welding Procedure Specifications or Welders /Welding Operators and requalification of existing Welding Procedure Specifications or Welders /Welding Operators shall be in accordance with the current Edition (see Foreword) and Addenda of Section IX. A99 A99 QW-101 1998 SECTION IX QW-123.1 The rules in this Section apply to the preparation of Welding Procedure Specifications and the qualification of welding procedures, welders, and welding operators for all types of manual and machine welding processes permitted in this Section. These rules may also be applied, insofar as they are applicable, to other manual or machine welding processes permitted in other Sections. Terms and Definitions Some of the more common terms relating to welding and brazing are defined in QW-492. Wherever the word pipe is designated, tube shall also be applicable. Responsibility QW-103.1 Welding. Each manufacturer 1 or contractor 1 is responsible for the welding done by his organization and shall conduct the tests required in this Section to qualify the welding procedures he uses in the construction of the weldments built under this Code, and the performance of welders and welding operators who apply these procedures. Each manufacturer or contractor shall maintain a record of the results obtained in welding procedure and welder and welding operator performance qualifications. These records shall be certified by the manufacturer or contractor and shall be accessible to the Authorized Inspector. Refer to recommended Forms in Nonmandatory Appendix B. The orientations of welds are illustrated in QW-461.1 or QW-461.2. Groove welds may be made in test coupons oriented in any of the positions in QW-461.3 or QW-461.4 and 2 as described in the following paragraphs, except that an angular deviation of Ϯ15 deg. from the specified horizontal and vertical planes, and an angular deviation of Ϯ5 deg. from the specified inclined plane are permitted during welding. Plate Positions QW-121.1 Flat Position 1G. Plate in a horizontal plane with the weld metal deposited from above. Refer to QW-461.3 sketch (a). QW-121.2 Horizontal Position 2G. Plate in a vertical plane with the axis of the weld horizontal. Refer to QW-461.3 sketch (b). QW-121.3 Vertical Position 3G. Plate in a vertical plane with the axis of the weld vertical. Refer to QW-461.3 sketch (c). QW-121.4 Overhead Position 4G. Plate in a horizontal plane with the weld metal deposited from underneath. Refer to QW-461.3 sketch (d). Pipe Positions QW-122.1 Flat Position 1G. Pipe with its axis horizontal and rolled during welding so that the weld metal is deposited from above. Refer to QW-461.4 sketch (a). Position 2G. Pipe with its axis vertical and the axis of the weld in a horizontal plane. Pipe shall not be rotated during welding. Refer to QW-461.4 sketch (b). QW-122.3 Multiple Position 5G. Pipe with its axis horizontal and with the welding groove in a vertical plane. Welding shall be done without rotating the pipe. Refer to QW-461.4 sketch (c). QW-122.4 Multiple Position 6G. Pipe with its axis inclined at 45 deg. to horizontal. Welding shall be done without rotating the pipe. Refer to QW-461.4 sketch (d). Test Positions for Stud Welds QW-123.1 Stud Welding. Stud welds may be made in test coupons oriented in any of the positions as described in QW-121 for plate and QW-122 for pipe (excluding QW-122.1). In all cases, the stud shall be QW-123.1 QW-143 perpendicular to the surface of the plate or pipe. See QW-461.7 and QW-461.8. Fillet welds may be made in test coupons oriented in any of the positions of QW-461.5 or QW-461.6, and as described in the following paragraphs, except that an angular deviation of Ϯ15 deg. from the specified horizontal and vertical planes is permitted during welding. Plate Positions QW-131.1 Flat Position 1F. Plates so placed that the weld is deposited with its axis horizontal and its throat vertical. Refer to QW-461.5 sketch (a). Plates so placed that the weld is deposited with its axis horizontal on the upper side of the horizontal surface and against the vertical surface. Refer to QW-461.5 sketch (b). Plates so placed that the weld is deposited with its axis vertical. Refer to QW-461.5 sketch (c). Plates so placed that the weld is deposited with its axis horizontal on the underside of the horizontal surface and against the vertical surface. Refer to QW-461.5 sketch (d). Pipe Positions QW-132.1 Flat Position 1F. Pipe with its axis inclined at 45 deg. to horizontal and rotated during welding so that the weld metal is deposited from above and at the point of deposition the axis of the weld is horizontal and the throat vertical. Refer to QW-461.6 sketch (a). (a) Position 2F. Pipe with its axis vertical so that the weld is deposited on the upper side of the horizontal surface and against the vertical surface. The axis of the weld will be horizontal and the pipe is not to be rotated during welding. Refer to . (b) Position 2FR. Pipe with its axis horizontal and the axis of the deposited weld in the vertical plane. The pipe is rotated during welding. Refer to QW-461.6 sketch (c). 3 QW-132.3 Overhead Position 4F. Pipe with its axis vertical so that the weld is deposited on the underside of the horizontal surface and against the vertical surface. The axis of the weld will be horizontal and the pipe is not to be rotated during welding. Refer to . QW-132.4 Multiple Position 5F. Pipe with its axis horizontal and the axis of the deposited weld in the vertical plane. The pipe is not to be rotated during welding. Refer to QW-461.6 sketch (e). Mechanical tests used in procedure or performance qualification are as follows. 141.1 Tension Tests. Tension tests as described in QW-150 are used to determine the ultimate strength of groove-weld joints. QW-141.2 Guided-Bend Tests. Guided-bend tests as described in QW-160 are used to determine the degree of soundness and ductility of groove-weld joints. QW-141.3 Fillet-Weld Tests. Tests as described in QW-180 are used to determine the size, contour, and degree of soundness of fillet welds. QW-141.4 Notch-Toughness Tests. Tests as described in QW-171 and QW-172 are used to determine the notch toughness of the weldment. QW-141.5 Stud-Weld Test. Deflection bend, hammering, torque, or tension tests as shown in QW-466.4, , and a macro-examination performed in accordance with QW-202.5, respectively, are used to determine acceptability of stud welds. Radiographic examination may be substituted for mechanical testing of QW-141 for groove-weld performance qualification as permitted in QW-304 to prove the ability of welders to make sound welds. An examination of a weld by radiography may be substituted for mechanical testing of QW-141 for groove weld performance qualification as permitted in QW- 305 to prove the ability of welding operators...

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SAFETY IN WORK PLACE Safety In Welding & Cutting Operations HAZARDS ASSOCIATED WITH WELDING

ASHOK KUMAR RAMCHANDER

Welding in India has developed to a great extent and has become indispensable tool for fabrication. Besides, oxy-acetylene and electric arc welding, other modes used are submerged arc welding, gas shielded arc welding processes TIG and MIG, plasma arc cutting and gauging etc. All these types of operations are associated with various hazards. In general welding is carried out almost in all factories and workshops and the sites can be broadly divided into four categories. (a) Open workshop (b) Open are (c) Semi-confined spaces (d) Confined spaces. Hazards associated with welding and cutting can be classified as: i. Radiation hazards – which are usually visual hazards ii. Hazards due to dangerous fumes and gases. iii. Burns and eye injuries. iv. Fire & explosion. v. Electric shock. vi. Environment/Atmospheric condition. vii. Postural fatigue viii. Hazards associated with working at height. ix. High noise level during certain operations.

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Welding Journal-January 2012

Dusko Radakovic

2012

An evaluation of the cross-tension test behavior of resistance spot welds in high-strength dual-phase steels was performed with two objectives. The first objective was to examine the variables that affect the load-carrying capacity of spot welds in 780 and 980 MPa dualphase steels. This was accomplished through cross-tension testing of the steels, and finite element modeling (FEM) of the weld crosstension test behavior. The second objective was to determine whether the cross-tension test represents the type of loading and deformation modes that spot welds undergo in a real vehicle crash event. This was done through a detailed examination of a crash-tested vehicle made available for examination by the Auto/Steel Partnership of the American Iron and Steel Institute. The observed weld failure modes and base material deformation in the crash-tested vehicle were compared to those in the cross-tension test. The modeling indicated that the failure load in the cross-tension test is related ...

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Qualification test of welders -Fusion welding -Part 1: Steels

Carlos Oliveros

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