Professional Documents
Culture Documents
Originated/Compiled by
Kenneth W. Coryell, P.E.
Welding Quality Consultant, Cleveland, Ohio
NOTE: Although care was taken in choosing and presenting the data in this guide, AWS cannot guarantee that it is error free. Further, this
guide is not intended to be an exhaustive treatment of the topic; therefore, it may not include all available information, particularly with respect
to safety and health issues. By publishing this guide, AWS does not insure anyone using the information contained herein against any liability or
injury to property or persons arising from such use.
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Table of Contents
Chapter 1—Introduction ......................................................................................................1
Chapter 2—Welding Procedure Specifications (WPSs)......................................................3
Chapter 3—Forms................................................................................................................7
AWS B2.1-1-004:2002 ....................................................................................................8
AWS B2.1:2005.............................................................................................................12
AWS D1.1/D1.1M:2004 ................................................................................................16
AASHTO/AWS D1.5M/D1.5:2002...............................................................................22
2001 ASME IX with 2003 Addenda..............................................................................26
API 1104 Twentieth Edition, 2005 ................................................................................34
Chapter 4—Procedure Qualification Variables—SAW ....................................................39
Chapter 5—Procedure Qualification Variables—SMAW.................................................49
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Chapter 6—Procedure Qualification Variables—GMAW ................................................59
Chapter 7—Procedure Qualification Variables—FCAW..................................................71
Chapter 8—Procedure Qualification Variables—GTAW .................................................83
Chapter 9—Terms and Definitions....................................................................................93
Annex I—Observations ...................................................................................................123
Annex II—Standard Welding Procedure Specifications .................................................127
Kent Baucher Vice President, Technicon Engineering Services, Inc., Fresno, CA; Member, Product Development Reviewer, General
Committee; Member, AWS Board of Directors
Harvey H. Castner Chair, Product Development Committee; AWS Director-at-Large; Past Chair, AWS Welding Reviewer, General
Handbook Committee; Member, AWS Board of Directors
Leonard P. Connor Consultant, Hollywood, FL; Managing Director, AWS Technical Services (Retired); Member, AWS Reviewer, Primary
Board of Directors
David Landon Corporate Welding Engineer, Vermeer Manufacturing Company, Pella, IA; Chair, AWS Technical Reviewer, General
Activities Committee
David L. McQuaid President, D. L. McQuaid & Associates, Bethel Park, PA; Vice Chair, D1 Subcommittee 10 Reviewer, D1.5 (2002)
ASSHTO/AWS Bridge Welding
Ronald C. Pierce Chair, Welding Engineering Supply Company, Prichard, AL; Advisor, AWS Product Development Reviewer, General
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Committee; AWS Past President
Allen W. Sindel President, Sindel and Associates, Whitehouse, TX; Past Chair, D1 Subcommittee 2 Qualification Reviewer, D1.1 (2004)
Walter J. Sperko President, Sperko Engineering Services, Greensboro, NC; AWS Technical Representative to Reviewer, ASME, IX
ASME (2001/2003)
Debrah C. Weir Secretary, AWS Product Development Committee General Editor
Mat Wisbrock QA Materials/QE Test Supervisor, Lockheed Martin Missiles, Dallas, TX; Chair, B2 Committee on Reviewer, B2.1 (2005)
Procedure and Performance Qualification
Robert R. Wright President, Moody International, Inc. (Retired), Knoxville, TN; AWS Technical Representative to API 1104, 20th Edition
API
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Chapter 1—Introduction
This Professional’s Advisor is intended to provide insight and guidance (2) AWS D1.1/D1.1M:2004, Structural Welding Code—Steel
to the welding professional in the preparation of welding procedure specifi- (3) AASHTO/AWS D1.5M/D1.5:2002, Bridge Welding Code
cations and procedure qualification records. In no way is this a substitute
nor should it be used in lieu of a code or other standards document. (4) Section IX, Welding and Brazing Qualifications, ASME Boiler and
Standards, whether codes or specifications, provide the authoritative and Pressure Vessel Code 2001 with 2003 Addenda
comprehensive requirements for the WPS and PQR. (5) API 1104 2005, Welding and of Pipelines and Related Facilities
This Advisor has concentrated on the common arc welding processes,
including SAW, SMAW, GMAW, FCAW, and GTAW. Documentation The American Welding Society and the Welding Research Council have
and qualification requirements differ somewhat among the various qualifi- joined in a cooperative effort to generate standard welding procedures for
cation standards. This Advisor is not intended to be comprehensive for all industry. The need for pretested welding procedures that are supported by
applications, but rather is focused on five common standards: adequate test data and that satisfy the technical requirements for the com-
monly used construction codes and specification has been expressed by many
(1) AWS B2.1:2005, Specification for Welding Procedure and Perfor- individuals and organizations. The purpose of a welding procedure qualifica-
mance Qualification tion is to provide test data for assessing the properties of a weld joint.
NOTE: The documentation and qualification requirements from the codes or specifications cited in this Advisor are those listed in the specific edition of the
code or specification referenced. Documentation and qualification requirements are subject to change in later editions of the reference codes or specifications.
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Chapter 2—Welding Procedure Specifications (WPSs)
Qualification of WPSs
Test of Procedure Qualification Welds
The purpose of the procedure qualification is to determine, by prepara-
tion and testing of standard specimens, that welding in accordance with the Test specimens are usually removed from the sample joints for exami-
WPS will produce sound welds and adequate mechanical properties. The nation to determine certain properties. The type and number of specimens
type and number of tests required are designated in the standard. The tests removed and test details depend on the particular application, code, or
are selected to provide sufficient information on strength, ductility, tough- specification. Usually, the tests included tensile and guided bend speci-
ness, or other properties of the joint. The qualification variables are speci- mens to determine strength, ductility, and soundness. Additional tests may
fied to maintain desired properties. When significant changes are made to be specified:
the WPS qualification variables, the properties of the weld joint may be • Fracture tests to determine the notch toughness of the weld and the
affected, and requalification or a new WPS is required. heat-affected zone. Fracture tests are usually conducted at a speci-
Qualification tests may or may not simulate the actual conditions antici- fied temperature to minimize the risk of brittle fracture above that
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pated for a given project. Usually, such tests involve conventional butt temperature. Charpy V-notch specimens are most commonly used
joints on pipes or plates, or fillet welds between two plates. Base metals, for such tests, but many other tests, including drop weight and crack-
welding consumables, and thermal treatments must follow production opening-displacement (COD) tests, are sometimes employed.
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• Nick-break tests to determine weld soundness at selected locations. when the qualifier signs the PQR. If the results meet the requirements of a
• Free bend tests to determine the ductility of weld metal. job, code, or specification, then the WPS may be finalized and issued for
• Shear tests to determine the shear strength of fillet welds or clad production welding. Since the PQR is a certified record of a qualification
bonding. test, it should not be revised. If information needs to be added later, it can
• Hardness tests to determine adequacy of heat treatment, preheat, be in the form of a supplement or attachment; records should not be
postheat, and suitability for certain service conditions. Such tests changed by revision. A PQR may support several WPSs. Similarly, several
may be performed on surfaces or on cross sections of welds. PQRs may support a single WPS.
• All-weld metal tension tests to determine the mechanical properties
of the weld metal in the diluted condition.
• Elevated temperature tests to determine mechanical properties at Changes in a Qualified Procedure
temperatures resembling service conditions. If a fabricator has qualified a welding procedure and desires at some
• Restraint tests to determine crack susceptibility and the ability to later date to make changes in that procedure, it may be necessary to con-
achieve sound welds under restrained conditions. duct additional qualifying tests. Those tests should establish that the
• Corrosion tests to determine the properties needed to withstand changed welding procedure will produce satisfactory results.
aggressive environments. Such requalification tests are not usually required when only minor
• Nondestructive examination and macroetch or microetch tests to details of the original procedure are changed. They are required, however,
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determine the soundness of the weld. if the changes might alter properties of the resulting welds. Reference
• Delayed cracking tests to detect resistance to hydrogen cracking in should always be made to the governing code or specification to determine
high strength, low alloy steels, and some other alloys. whether an essential variable has been changed. Typical procedure vari-
• Others ables that may require requalification of the WPS are presented in the
tables that follow. Variables identified with a “Q” require requalification.
Variables identified with a “T” require requalification when toughness test-
Recording Test Results ing is required. Variables identified with an “A” require requalification for
The details of the welding of the test weld, the tests, and the results of automatic welding processes.
all tests and examinations are entered on a Procedure Qualification Record The tables present the variables for the SAW, SMAW, GMAW,
(PQR). Typical record formats follow the sample WPSs provided. FCAW, and GTAW processes for five common standards: B2.1, D1.1,
(Remember: The data shown is illustrative only.) When the qualifier is D1.5, ASME IX, and API 1104. The tables should be regarded as illustra-
satisfied that the records and results are accurate, they become certified tive only, since the various standards are revised periodically.
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Chapter 3—Forms
The sample forms in this chapter (WPSs and PQRs) were taken from of these 8-1/2" × 11" forms have been split in half for the purposes of this
the following publications: AWS B2.1, AWS D1.1, AASHTO/AWS D1.5, Professional’s Advisor, so that the top and bottom half of the forms are
ASME Boiler and Pressure Vessel Code (Section IX), and API 1104. Each viewable as visual spreads, beginning with pages 12 and 13.
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Provisions of AWS B2.1 (Page 1 of 2) ......................................................................................... 12
AWS B2.1 Suggested Procedure Qualification Record (PQR) Format to Accommodate
Provisions of AWS B2.1 (Page 2 of 2) ......................................................................................... 14
E-1 (Front) AWS D1.1 D1.1-Approved Welding Procedure Specification (WPS) (Qualified by Testing) ........................... 16
E-1 (Front) AWS D1.1 D1.1-Approved Welding Procedure Specification (WPS)................................................................ 18
E-1 (Back) AWS D1.1 D1.1-Approved Procedure Qualification Record (PQR) Test Results.............................................. 20
III-2 AASHTO/AWS D1.5 D1.5-Approved Welding Procedure Specification............................................................................ 22
III-1 AASHTO/AWS D1.5 D1.5-Approved Procedure Qualification Record (PQR) for Qualification,
Pretest, and Verification Results ................................................................................................... 24
E00006 (Front) ASME IX QW-482 Suggested Format for Welding Procedure Specification (WPS) ....................................... 26
E00006 (Back) ASME IX QW-482 Suggested Format for Welding Procedure Specification (WPS) ....................................... 28
E00007 (Front) ASME IX QW-483 Suggested Format for Procedure Qualification Records (PQR) ........................................ 30
E00007 (Back) ASME IX QW-483 Suggested Format for Procedure Qualification Records (PQR) ........................................ 32
— API 1104 Sample Procedure Specification Form .................................................................................. 34 and 35
— API 1104 Sample Coupon Test Report Form........................................................................................ 36 and 37
LIMITATIONS
This procedure is not qualified for Notch Toughness or PWHT applications.
WELDING PROCESSES
Welding Process: GMAW-S (Gas Metal Arc Welding)
Method of Application: Semiautomatic
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BASE METALS
Base Metal:2 Carbon Steel, M-1, Group 1 to M-1, Group 1
Thickness Range:3 Groove Weld: 18 ga. (0.0478 in.) through 10 ga (0.1345 in.)
Fillet Weld: 18 ga. (0.0478 in.) through 10 ga. (0.1345 in.)
Coating: Uncoated
FILLER METALS
Filler Metal Specification:2 AWS A5.18
A-Number or Chemical Composition: A Number None, ER70S-6
F-Number: F Number 6
Classification: ER70S-6
Supplementary Filler Metal: Not permitted
Supplementary Powder: Not permitted
Deposit Thickness Range: Groove Weld: Sheet metal thickness plus reinforcement, maximum
Fillet Weld Leg: Sheet metal thickness, minimum
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Maximum Bead Thickness: Sheet metal thickness plus reinforcement
JOINT DESIGNS
Joint Designs: See Figure 1
Backing: Optional
Backing Material: Carbon Steel, M-1. Nonmetallic or nonfusing metal retainers are not permitted.
POSITIONS
Welding Positions: All
Vertical Progression: Uphill or Downhill
GAS
Torch Shielding Gas: 75% Argon, 25% Carbon Dioxide or AWS A5.32, Class SG-AC-25
Flow Rate: 20 to 40 ft3/h
Gas Nozzle Size: 1/2 in. diameter minimum (I.D.)
Root Shielding Gas: None
Trailing Gas: None
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Preheat Temperature: 50°F minimum, 120°F maximum
Interpass Temperature: No maximum
Preheat Maintenance: Continuous or special heating not required
TECHNIQUE
Weave or Stringer Beads: Stringer or weave
Peening: No
Initial Cleaning: Mechanical or chemical, joint shall be dry prior to welding
Interpass Cleaning: Mechanical only
Single or Multiple Electrodes: Single
Single or Multiple Pass: Either
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Backgouging: Not required, mechanical or thermal if used
Repair: Defects in welds shall be removed by mechanical or thermal methods. The repair cavity may dif-
fer in contour and dimension from a normal joint preparation and may present different restraint
conditions.
In the name of the Company stated above, I accept full responsibility for the application of this SWPS for use with:
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6 NPS
Diameter (Pipe) __________________________________ ELECTRICAL CHARACTERISTICS
None
Surfacing: Material ___________ N.A.
Thickness ________ 1/2 in.
Electrode Extension ______________________________
N.A.
Chemical Composition ____________________________ 9/16 in.
Standoff Distance ________________________________
N.A.
Other __________________________________________ Short Circuiting
Transfer Mode (GMAW) ___________________________
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FILLER METALS N.A.
Electrode Diameter Tungsten _______________________
1
Weld Metal Analysis A No. _________________________ N.A.
Type Tungsten Electrode __________________________
6
Filler Metal F No. _________________________________ Current: AC DCEP X DCEN Pulsed
5.18
AWS Specification________________________________ 6720-12075 J/in.
Heat Input ______________________________________
ER70S-3
AWS Classification _______________________________ EBW: Beam Focus Current ______N.A. Pulse Freq. ______
N.A.
None
Flux Class _____________ N.A.
Flux Brand _____________ N.A.
Filament Type _______ N.A.
Shape _______ N.A.
Size________
None
Consumable Insert: Spec. __________ N.A.
Class. _______ N.A.
Other__________________________________________
Supplemental Filler Metal Spec. None N.A.
_______ Class._______ TECHNIQUE
None
Nonclassified Filler Metals _________________________ N.A.
Oscillation Frequency ________ N.A.
Weave Width ________
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Note: Those items that are not applicable should be marked N.A. Page 1 of 2
Specimen No. Width, in. Thickness, in. Area, in.2 Max Load, lbs UTS, psi Typical Failure and Location
1 0.752 0.432 0.325 23,200 71,400 Base Metal-Ductile
2 0.754 0.432 0.326 23,500 72,100 Base Metal-Ductile
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N.A.
Test Temperature ________________________________
Specimen Location: WM = Weld Metal; BM = Base Metal; HAZ = Heat-Affected Zone
Test Results:
IF APPLICABLE RESULTS
Hardness Tests: Values __________________________________________ Acceptable Unacceptable
Visual (Special Weldments) X Acceptable X Unacceptable
Torque psi Acceptable Unacceptable
Proof Test Method ____________________________________________ Acceptable Unacceptable
Chemical Analysis Acceptable Unacceptable
Radiography
Nondestructive Exam X Process_____________________________________ Acceptable X Unacceptable
Other ____________________________________________________________ Acceptable Unacceptable
Weld Test Lab, USA
Mechanical Testing by (Company) _________________________________________________ Q225
Lab No. _________
We certify that the statements in this Record are correct and that the test welds were prepared, welded, and tested in
accordance with the requirements of the American Welding Society Specification for Welding Procedure and Performance
Qualification (AWS B2.1).
Joseph Plunkett
Qualifier________________________________________ 02-15-05
Date __________________________________________
Page 2 of 2
Data included in this suggested PQR format is illustrative only.
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—
Electrode Spacing None Longitudinal ____________
—
Lateral_________________
SHIELDING Angle _________________
—
—
Flux ___________________ CO2
Gas _________________
100% CO2
Composition __________ 1/2-1"
Contact Tube to Work Distance ____________________
45-55 cfh
Electrode-Flux (Class)_____ Flow Rate ____________ None
Peening ______________________________________
#4
______________________ Gas Cup Size _________ Wire Brush
Interpass Cleaning: _____________________________
WELDING PROCEDURE
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All FCAW E71T-1 .045" DC+ 180-220 25-26 8-12
ipm
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A
Type or Grade _________________________________ Size: ______________
1"
Thickness: Groove ____________ —
Fillet __________ Type: ______________
—
Diameter (Pipe) ________________________________
TECHNIQUE
FILLER METALS Stringer
Stringer or Weave Bead: _________________________
A5.20
AWS Specification______________________________ Multipass
Multipass or Single Pass (per side) _________________
E71T-1
AWS Classification _____________________________ 1
Number of Electrodes ___________________________
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Electrode Spacing —
Longitudinal ____________
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—
Lateral_________________
SHIELDING —
Angle _________________
—
Flux ___________________ CO2
Gas _________________
100% CO2
Composition __________ 3/4-1"
Contact Tube to Work Distance ____________________
45 cfh
Electrode-Flux (Class)_____ Flow Rate ____________ None
Peening ______________________________________
#4
______________________ Gas Cup Size _________ Wire Brush
Interpass Cleaning: _____________________________
WELDING PROCEDURE
20
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Dennis McSweny
Welder’s Name ________________________________ 261
Clock No. ______________ Stamp No. ____________
RED Inc. & ABC Testing
Tests Conducted by_________________________________________________________ Laboratory
PQR 231
Test Number ___________________________________
D. Miller
Per __________________________________________
We, the undersigned, certify that the statements in this record are correct and that the test welds were prepared, welded, and
2004 ) Structural Welding Code—Steel.
tested in accordance with the requirements of Section 4 of AWS D1.1, ( __________
(year)
RED Inc.
Signed _______________________________________
Manufacturer or Contractor
Sean McBride
By ___________________________________________
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Q.C. Mgr.
Title _________________________________________
02-15-05
Date _________________________________________
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180-220 amps
Welding Current __________________________________________________________________________________
DCEP
Polarity _________________________________________________________________________________________
N.A.
Welding Progression _______________________________________________________________________________
Backing Removed
Root Treatment ___________________________________________________________________________________
80°C min 230°C max
200°C
Preheat and Interpass Temperature ___________________________________________________________________
None
Postheat Temperature ______________________________________________________________________________
Heat Input 0.9 kJ/mm
Min _______________ 1.5 kJ/mm
Max _______________
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WELDING PROCEDURE
Pass Electrode
No. Size Amperes Volts Travel Speed Joint Detail
1 .045 180 26 200
2-8 .045 200 27 250
9-11 .045 220 28 280
12-15 .045 200 27 250
16 .045 220 28 280
This procedure may vary due to fabrication sequence, fit-up, pass size, etc., within the limitation of variables given in
Section 5.
W44
Procedure No. _________________________________ Any Welding Company
Contractor ____________________________________
0
Revision No. __________________________________ James Connolly
Authorized By __________________________________
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All-Weld-Metal Tension (AWMT) 810 MPa
Tensile Strength (MPa) __________________________________________
700 MPa
Yield Strength (MPa) ____________________________________________
20%
Elongation in 50 mm (%) _________________________________________
40%
Reduction in Area % ____________________________________________
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Side Bends Accept
1. ____________ Accept
2. ____________ Accept
3. ____________ Accept
4. ____________
REMARKS Acceptable
Visual ________________________ Acceptable
Radiographic Test ________________
*Wire feed may be used in lieu of current when a correlation curve is provided for the same electrode diameter and same
electrode extension.
Jean McDermott
Test Witness:__________________________________ Independent Lab, Inc.
Agency: ______________________________________
Michael Collins
Results Reviewed:______________________________ Eamon Kent
State Acceptance: ______________________________
Single-V
X
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N.A.
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N.A.
N.A.
N.A.
N.A.
SFA 5.18
ER70S-3
6
1
.035 in.
1-1/4 in.
N.A.
None
N.A.
N.A.
70°F Min
250°F Max
70°F Min
CO2 Welding Gr. 25 cfh
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None — —
None — —
Electrode
DC Positive
140-175 20-23
None
Short Circuiting
225-305 ipm
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String and Weave
1/2 in.
Wire Brushing
None
Manually Controlled as Necessary to Fill Groove
1/2 in.
Multiple
Single
5-20 ipm
None
N.A.
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Q211 02-15-05
100
GMAW-S
Semi-Automatic
None
ASME SA53 N.A.
A N.A.
1 1 N.A.
0.562 in.
24 in.
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N.A.
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5G 22-23 ipm
Downhill root pass Both-As Required
N.A. Balance uphill N.A.
Multiple
Single
Short Circuiting Metal Transfer
70°F
250°F max
N.A.
This form (E0007) may be obtained from the Order Dept., ASME, 222 Law Drive, Box 2300, Fairfield, NJ 07007-2300, (800) 843-2763.
None
Required
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N.A.
Visual Examination
N.A.
N.A.
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02-15-05 Patrick Pearse
Sample
Downhill
One
Unlimited
None
Grinding/Wire Brush to Remove Slag
None
External—Must complete 70% of weld before removal
N.A.
Plasma Gas Composition _______________ Plasma Gas Orifice Size _______________ Plasma Gas Flow Rate ________________
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5.2
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1 2 3 4 5 6 7
Coupon Stenciled A B
0.945 x 1.022 x
Original Specimen Dimensions
0.203 0.203
Original Specimen Area 0.192 0.207
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X Procedure X Qualifying Test X Qualified
Welder Line Test Disqualified
80,000
Maximum Tensile ___________________ 79,500
Minimum Tensile_____________________ 79,500
Average Tensile __________________
Remarks on Tensile-Strength Tests ______________________________________________________________________________
Failed in Base Metal 1 in. from Weld Toe
1. ________________________________________________________________________________________________________
Failed "n"Base "etal 1-1/2 in. frr"
2. ________________________________________________________________________________________________________
3. ________________________________________________________________________________________________________
4. ________________________________________________________________________________________________________
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Joseph Dolan
Tested by ___________________________________________ Michael Brandon
Supervised by ________________________________________
Note: Use back for additional remarks. This form can be used to report either a procedure qualification test or a welder qualification test.
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Chapter 4—SAW Procedure Qualification Variables
The tables in this chapter illustrate submerged arc welding procedure The following legend applies to the five standards (AWS B2.1:2005,
qualification variables for the following criteria: AWS D1.1/D1.1M:2004, AASHTO/AWS D1.5M/D1.5:2002, 2001ASME
(1) Joint Design IX with 2003 Addenda, and API 1104 Twentieth Edition, 2005) used for
(2) Base Metal comparison in the tables:
(3) Filler Metal
(4) Position Q = Variable requires requalification
(5) Preheat and Interpass Temperature T = Variable requires requalification when toughness testing is required
(6) Postweld Heat Treatment A = Variable requires requalification for automatic welding
(7) Electrode
(8) Electrical Characteristics The tables should be regarded as illustrative only, since the various
(9) Other standards are revised periodically.
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Table 4-1—Joint Design
SAW PQR Variables B2.1 D1.1 D1.5 ASME IX API 1104
Q
detail complying with the requirements of 3.12 or 3.13 of D1.1.
A change in the type of groove to a square groove and vice versa. Q Q
A major change in joint design (for example, from V groove to U groove). Minor changes in the angle of bevel or the
Q
land of the welding groove are not essential variables.
Any change beyond the range established in the procedure specification for such factors as spacing, root face, and
Q
angle of bevel.
A change exceeding the tolerances of 3.12, 3.13, 3.13.4, 5.22.4.1, or 5.22.4.2 of D1.1 involving:
(1) A decrease in the groove angle,
Q
(2) A decrease in the root opening,
(3) An increase in the root face.
A change exceeding the tolerances of 2.9, 2,10, or 3.3.4 of D1.5 in the shape of any type of groove involving:
(1) A decrease in the groove angle,
Q
(2) A decrease in the root opening,
(3) An increase in the root face which will not be subsequently removed by backgouging.
The omission, but not inclusion, of backing or backgouging. Q Q
A change from U-groove to a V-groove (but not vice versa). Q
Q = Variable requires requalification. T = Variable requires requalification when toughness testing is required. A = Variable requires requalification for automatic welding.
40
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Table 4-2—Base Metal
SAW PQR Variables B2.1 D1.1 D1.5 ASME IX API 1104
A change from one M-Number to another M-Number or to an unlisted base metal, except as 2.3 of B2.1 permits. Q
A change from one P-Number to another P-Number or to an unassigned base metal, except as QW-424 of ASME IX
Q
permits.
A change of a Group Number within an M-Number. T
A change of a Group Number within a P-Number. T
A change from a joint between the same M-Numbers, to a joint between different M-Numbers or vice versa except as
permitted; or for M-Numbers 1, 3, 4, and 5A (of 3% max nom chromium), a procedure test with one M-Number shall Q
also qualify for that metal welded to each of the lower M-Number metals.
A change from M5A to M5B or M5C, and vice versa.
A change from M9A to M9B, but not vice versa. Q
A change from M10A to M10B, M10C, M10F, M10H, M10I, M10J, or M10K, and vice versa.
A change from P5A to P5B or P5C, and vice versa.
A change from P9A to P9B, but not vice versa. Q
A change from P10A to P10B, P10C, P10F, P10H, P10I, P10J, or P10K, and vice versa.
A change in base metals as specified in 4.7.3 of D1.1. Q
A change in base metal or combination of base metals not listed on the PQR or qualified by Table 4.7 of D1.1. Q
A change in base metal specification and grade as specified in 5.4 of D1.5. Q
A change in pipe material as specified in 12.5.2.2 of API 1104. Q
A change in wall-thickness group as specified in 12.5.2.4 of API 1104. Q
A change in base metal thickness beyond the range permitted in 2.5 of B2.1. Q
Q = Variable requires requalification. T = Variable requires requalification when toughness testing is required. A = Variable requires requalification for automatic welding.
--`,,```,,,,````-`-`,,`,,`,`,,`---
--`,,```,,,,````-`-`,,`,,`,`,,`---
The minimum thickness qualified is T or 5/8 in., whichever is less. However, where T is less than 1/4 in. the minimum is
1/2T. This limitation does not apply when a WPS is qualified with a PWHT above the upper transformation temperature T
or when an austenitic material is solution annealed after welding.
The minimum thickness qualified for thicknesses 5/8 in. or less is the thickness of the procedure qualification test plate. T
The minimum thickness qualified is T or 5/8 in., whichever is less, except that if T is less than 1/4 in., the minimum
T
thickness is 1/8 in.
Q = Variable requires requalification. T = Variable requires requalification when toughness testing is required. A = Variable requires requalification for automatic welding.
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Table 4-3 —Filler Metals
SAW PQR Variables B2.1 D1.1 D1.5 ASME IX API 1104
A change from one F-Number to any other F-Number or to any filler metal not listed in Annex III of B2.1. Q
A change from one F-Number in QW-432 of ASME IX to any other F-Number or to any other filler metal not listed
Q
in QW-432.
For ferrous materials, a change from one A-Number to any other A-Number or to a filler metal analysis not listed in
Annex III of B2.1 or QW-432 of ASME IX (the PQR and WPS shall state the nominal chemical composition or
Q Q
manufacturer’s designation for filler metals which do not fall into an A-Number group). Qualification with A-1 shall
qualify for A-2 and vice versa.
A change in AWS filler metal classification. T T Q
A change from one filler-metal group to another as specified in Table 1 of API 1104. Q
For pipe materials with a specified minimum yield strength greater than or equal to 65,000 pounds per square inch
Q
(448.16 megapascals), a change in the AWS classification of the filler metal.
Change to an electrode or flux-electrode combination not covered in AWS A5.17 or A5.23. Q
A change in the filler metal classification strength designator exceeding 10,000 psi, or to a filler metal classification
Q
strength designator less than the base metal tensile strength.
A change in manufacturer’s brand and type of cored electrode. Q
A change in manufacturer’s brand and type of flux. Q
A change in the indicator for minimum tensile strength (e.g., the 7 in F7A2-EM12K) when the flux wire combination
is classified in ASME II, Part C. A change in either the flux trade name or wire trade name when neither the flux nor the
Q
wire is classified in ASME II, Part C. A change in the flux trade name when the wire is classified in ASME II, Part C,
but the flux is not. A change in wire classification within the requirements of QW-404.5 does not require requalification.
A change in either the flux trade name or wire trade name when neither the flux nor the wire is classified in ASME II,
Q
Part C.
A change in the flux trade name or when the wire is classified in ASME II, Part C but the flux is not classified. A
Q
change in the wire classification within the requirements of QW-404.5 of ASME IX does not require requalification.
A change in the flux trade name for A-No. 8 deposits. Q
An increase in filler metal classification strength. Q
Q = Variable requires requalification. T = Variable requires requalification when toughness testing is required. A = Variable requires requalification for automatic welding.
--`,,```,,,,````-`-`,,`,,`,`,,`---
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Table 4-4—Position
SAW PQR Variables B2.1 D1.1 D1.5 ASME IX API 1104
Q = Variable requires requalification. T = Variable requires requalification when toughness testing is required. A = Variable requires requalification for automatic welding.
--`,,```,,,,````-`-`,,`,,`,`,,`---
Table 4-7—Electrode
SAW PQR Variables B2.1 D1.1 D1.5 ASME IX API 1104
Change in nominal electrode diameter by any increase. For WPSs using alloy flux, any increase or decrease in the
Q
electrode diameter shall require WPS requalification.
Increase or decrease in electrode diameter by more than one standard size. Q
Change in number of electrodes. Q Q Q
A change from single electrode to multiples electrodes in the same weld pool, and vice versa. For ASME IX
applications, this limitation does not apply when a WPS is qualified with a PWHT above the upper transformation T T T
temperature or when an austenitic material is solution annealed after welding.
Change in electrode classification. T Q
Change in electrode/flux combination. Q
Q = Variable requires requalification. T = Variable requires requalification when toughness testing is required. A = Variable requires requalification for automatic welding.
--`,,```,,,,````-`-`,,`,,`,`,,`--- 46
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Table 4-8—Electrical Characteristics
SAW PQR Variables B2.1 D1.1 D1.5 ASME IX API 1104
An increase of heat input or volume of weld metal deposited per unit length of weld, over that qualified, except when
a grain refining austenitizing heat treatment is applied after welding. The increase may be measured by either of the
following:
Volts × Amps × 60 T T T
(1) Heat Input (J/in.) = ------------------------------------------------------
Travel Speed (in./min)
(2) Weld Metal Volume—An increase in bead size, or a decrease in the length of weld bead per unit length of
electrode.
--`,,```,,,,````-`-`,,`,,`,`,,`---
A change in the amperage for each diameter used by >10% increase or decrease. Q Q
A change in type of current (ac or dc) or polarity. Q T Q
A change in type of current (ac or dc) or polarity, only when using an alloy flux or quenched and tempered material. Q
A change in the voltage for each diameter used by >7% increase or decrease. Q Q
For WPSs using alloy or active fluxes, any increase in the maximum voltage. Q
An increase or decrease in the wire feed speed for each electrode diameter (if not amperage controlled) by >10%. Q
A change in the travel speed (unless heat input control is required) by >15% increase or decrease. Q
A change in the travel speed by >15% increase or decrease. Q
A change in the range for speed of travel. Q
An increase in heat input by >10%. This essential variable applies only when heat input control is a contract document
requirement. Heat input in joules per inch shall be calculated as 60EI/V where: E = PQR voltage, I = PQR amperage, Q
and V = PQR travel speed.
An increase in heat input by more than 10% or decrease of more than 30%. For M270M, (A 709M) Gr. 690, 690W,
Q
allowable heat input increase or decrease shall be limited to 10%.
A change in electrical characteristics. Q
Q = Variable requires requalification. T = Variable requires requalification when toughness testing is required. A = Variable requires requalification for automatic welding.
--`,,```,,,,````-`-`,,`,,`,`,,`---
48
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Chapter 5—SMAW Procedure Qualification Variables
The tables in this chapter illustrate shielded metal arc welding procedure The following legend applies to the five standards (AWS B2.1:2005,
qualification variables for the following criteria: AWS D1.1/D1.1M:2004, AASHTO/AWS D1.5M/D1.5:2002, 2001ASME
(1) Joint Design IX with 2003 Addenda, and API 1104 Twentieth Edition, 2005) used for
(2) Base Metal comparison in the tables:
(3) Filler Metal
(4) Position Q = Variable requires requalification
(5) Preheat and Interpass Temperature T = Variable requires requalification when toughness testing is required
(6) Postweld Heat Treatment A = Variable requires requalification for automatic welding
(7) Electrode
(8) Electrical Characteristics The tables should be regarded as illustrative only, since the various
(9) Other standards are revised periodically.
--`,,```,,,,````-`-`,,`,,`,`,,`---
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Table 5-1—Joint Design
SMAW PQR Variables B2.1 D1.1 D1.5 ASME IX API 1104
--`,,```,,,,````-`-`,,`,,`,`,,`---
A change exceeding the tolerances of 2.9, 2,10, or 3.3.4 of D1.5 in the shape of any type of groove involving:
(1) A decrease in the groove angle,
Q
(2) A decrease in the root opening,
(3) An increase in the root face which will not be subsequently removed by backgouging.
The omission, but not inclusion, of backing or backgouging. Q Q
A change from U-groove to a V-groove (but not vice versa). Q
Q = Variable requires requalification. T = Variable requires requalification when toughness testing is required. A = Variable requires requalification for automatic welding.
50
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Table 5-2—Base Metal
SMAW PQR Variables B2.1 D1.1 D1.5 ASME IX API 1104
A change from one M-Number to another M-Number or to an unlisted base metal, except as 2.3 of B2.1 permits. Q
A change from one P-Number to another P-Number or to an unassigned base metal, except as QW-424 of ASME IX
Q
permits.
A change of a Group Number within an M-Number. T
A change of a Group Number within a P-Number. T
A change from a joint between the same M-Numbers, to a joint between different M-Numbers or vice versa except as
permitted, or for M-Numbers 1, 3, 4, and 5 (of 3% max nom chromium); a procedure test with one M-Number shall Q
also qualify for that metal welded to each of the lower M-Number metals.
A change from M5A to M5B or M5C, and vice versa.
A change from M9A to M9B, but not vice versa.
Q
A change from M10A to M10B, M10C, M10F, M10H, M10I, M10J, or M10K, and vice versa.
A change from M11A to M11 B, and vice versa.
A change from P5A to P5B or P5C, and vice versa.
A change from P9A to P9B, but not vice versa. Q
A change from P10A to P10B, P10C, P10F, P10H, P10I, P10J, or P10K, and vice versa.
A change in base metals as specified in 4.7.3 of D1.1. Q
A change in base metal or combination of base metals not listed on the PQR or qualified by Table 4.7 of D1.1. Q
--`,,```,,,,````-`-`,,`,,`,`,,`---
A change in base metal specification and grade as specified in 5.4 of D1.5. Q
A change in pipe material as specified in 5.4.2.2 of API 1104. Q
A change in wall-thickness group as specified in 5.4.2.5 of API 1104. Q
Q = Variable requires requalification. T = Variable requires requalification when toughness testing is required. A = Variable requires requalification for automatic welding.
A change in base metal thickness beyond the range permitted in 2.5 of B2.1. Q
A change in diameter, or thickness, or both not qualified by Table 4.2 of D1.1. Q
A change in base metal thickness beyond the range permitted in Table 5.2 of D1.5. Q
For M270M (A 709M) Gr. 690, 690W, increase in plate thickness greater than 12 mm or decrease of 25 mm or more. Q
A change in base metal thickness beyond the range qualified in QW-451 of ASME IX. Q
A change from an uncoated metal to a coated (such as painted or galvanized) metal unless the coating is removed from
Q
the weld area prior to welding, but not vice versa.
Each grade of base metal with a specified minimum yield strength of 65,000 psi requires a separate qualification test. Q
The minimum thickness qualified is T or 5/8 in., whichever is less. However, where T is less than 1/4 in. the minimum is
--`,,```,,,,````-`-`,,`,,`,`,,`---
1/2T. This limitation does not apply when a WPS is qualified with a PWHT above the upper transformation temperature T
or when an austenitic material is solution annealed after welding.
The minimum thickness qualified for thicknesses 5/8 in. or less is the thickness of the procedure qualification test plate. T
The minimum thickness qualified is T or 5/8 in., whichever is less, except that if T is less than 1/4 in., the minimum
T
thickness is 1/8 in.
Q = Variable requires requalification. T = Variable requires requalification when toughness testing is required. A = Variable requires requalification for automatic welding.
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Table 5-3—Filler Metals
SMAW PQR Variables B2.1 D1.1 D1.5 ASME IX API 1104
A change from one F-Number to any other F-Number or to any filler metal not listed in Annex III of B2.1. Q
A change from one F-Number in QW-432 of ASME IX to any other F-Number or to any other filler metal not listed
--`,,```,,,,````-`-`,,`,,`,`,,`---
Q
in QW-432.
Change from low hydrogen to non-low hydrogen SMAW electrode. Q
For ferrous materials, a change from one A-Number to any other A-Number or to a filler metal analysis not listed in
Annex III of B2.1 or QW-432 of ASME IX (the PQR and WPS shall state the nominal chemical composition or
Q Q
manufacturer’s designation for filler metals which do not fall into an A-Number group). Qualification with A-1 shall
qualify for A-2 and vice versa.
A change in AWS filler metal classification. T Q T
A change from one filler-metal group to another as specified in Table 1 of API 1104. Q
For pipe materials with a specified minimum yield strength greater than or equal to 65,000 pounds per square inch
Q
(448.16 megapascals), a change in the AWS classification of the filler metal.
A change to an electrode or flux-electrode combination not covered in AWS A5.1 OR A5.5. Q
A change in the filler metal classification strength designator exceeding 10,000 psi, or to a filler metal classification
Q
strength designator less than the base metal tensile strength.
An increase in filler metal classification strength. Q Q
An addition or deletion of supplementary filler metal (powder or wire), or a change of 10% in the amount. T
A change in the weld metal thickness beyond that permitted in 2.5 of B2.1 or QW-451 of ASME IX as applicable. Q Q
Q = Variable requires requalification. T = Variable requires requalification when toughness testing is required. A = Variable requires requalification for automatic welding.
A change in the filler metal classification within an SFA specification or to a filler metal not covered by an SFA
specification, or from one filler metal not covered by an SFA specification to another filler metal that is not covered by
an SFA specification.
When a filler metal conforms to a filler metal classification within an SFA specification, requalification is not required
if a change is made in any of the following:
(1) from a filler metal that is designated as moisture-resistant to one that is not designated as moisture-resistant and vice
versa (i.e., from E7018R to E7018)
(2) from one diffusible hydrogen level to another (i.e., from E7018-H8 to E7018-H16)
(3) for carbon, low alloy, and stainless steel filler metals having the same minimum tensile strength and the same nom-
inal chemical composition, a change from one low hydrogen coating type to another low hydrogen coating type (i.e., a T
change among EXX15, 16, or 18 or EXXX15, 16, or 17 classifications
(4) from one position-usability designation to another for flux-cored electrodes (i.e., a change from E70T-1 to
E71T-1 or vice versa
(5) from a classification that requires impact testing to the same classification which has a suffix which indicates that
impact testing was performed at a lower temperature or exhibited greater toughness at the required temperature or both,
as compared to the classification which was used during procedure qualification (i.e., a change from E7018 to E7018-1)
(6) from the classification qualified to another filler metal within the same SFA specification when the weld metal is
exempt from Impact Testing by other sections
This exemption does not apply to hard-facing and corrosion-resistant overlays.
Q = Variable requires requalification. T = Variable requires requalification when toughness testing is required. A = Variable requires requalification for automatic welding.
54 --`,,```,,,,````-`-`,,`,,`,`,,`---
For the following M -Numbers 1, 3, 4, 5, 6, 9, 10,11, and 13, and for P-Numbers 1, 3, 4, 5, 6, 9, 10, and 11, a change
from any one condition to any other requires requalification:
(1) No PWHT,
(2) PWHT below the lower transformation temperature,
Q Q
(3) PWHT within the transformation temperature range,
(4) PWHT above the upper transformation temperature,
(5) PWHT above the upper transformation temperature followed by treatment below the lower transformation
temperature.
Addition or deletion of PWHT. Q Q
The qualification test weldment shall be subjected to heat treatment essentially equivalent to that of the production
T T T
weldment, including at least 80% of the aggregate time at temperature.
The addition of PWHT or a change in the specified ranges of PWHT. Q
Table 5-7—Electrode
SMAW PQR Variables B2.1 D1.1 D1.5 ASME IX API 1104
--`,,```,,,,````-`-`,,`,,`,`,,`---
56
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Table 5-8—Electrical Characteristics
SMAW PQR Variables B2.1 D1.1 D1.5 ASME IX API 1104
An increase of heat input or volume of weld metal deposited per unit length of weld, over that qualified, except when
a grain-refining austenitizing heat treatment is applied after welding. The increase may be measured by either of the
following:
Volts × Amps × 60 - T T T
(1) Heat Input (J/in.) = -----------------------------------------------------
Travel Speed (in./min)
(2) Weld metal volume—an increase in bead size, or a decrease in the length of weld bead per unit length of electrode.
A change in the amperage for each diameter used to a value not recommended by manufacturer. Q Q
A change in type of current (ac or dc) or polarity. Q T Q
A change in the voltage for each diameter used to a value not recommended by the electrode manufacturer. Q
A change in the range for speed of travel. Q
An increase in heat input by >10%. This essential variable applies only when heat input control is a contract document
requirement. Heat input in joules per inch shall be calculated as 60EI/V where: E = PQR voltage, I = PQR amperage, Q
and V = PQR travel speed.
--`,,```,,,,````-`-`,,`,,`,`,,`---
An increase in heat input by more than 10% or decrease of more than 30%. For M270M, (A 709M) Gr. 690, 690W,
Q
allowable heat input increase or decrease shall be limited to 10%.
Q = Variable requires requalification. T = Variable requires requalification when toughness testing is required. A = Variable requires requalification for automatic welding.
Q = Variable requires requalification. T = Variable requires requalification when toughness testing is required. A = Variable requires requalification for automatic welding.
--`,,```,,,,````-`-`,,`,,`,`,,`---
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Chapter 6—GMAW Procedure Qualification Variables
The tables in this chapter illustrate gas metal arc welding procedure The following legend applies to the five standards (AWS B2.1:2005,
qualification variables for the following criteria: AWS D1.1/D1.1M:2004, AASHTO/AWS D1.5M/D1.5:2002, 2001ASME
(1) Joint Design IX with 2003 Addenda, and API 1104 Twentieth Edition, 2005) used for
(2) Base Metal comparison in the tables:
(3) Filler Metal
(4) Position Q = Variable requires requalification
(5) Preheat and Interpass Temperature T = Variable requires requalification when toughness testing is required
(6) Postweld Heat Treatment A = Variable requires requalification for automatic welding
(7) Electrode
--`,,```,,,,````-`-`,,`,,`,`,,`---
(8) Electrical Characteristics The tables should be regarded as illustrative only, since the various
(9) Other standards are revised periodically.
--`,,```,,,,````-`-`,,`,,`,`,,`---
angle of bevel.
A change exceeding the tolerances of 3.12, 3.13, 3.13.4, 5.22.4.1, or 5.22.4.2 of D1.1 involving:
(1) A decrease in the groove angle,
Q
(2) A decrease in the root opening,
(3) An increase in the root face.
A change exceeding the tolerances of 2.9, 2,10, or 3.3.4 of D1.5 in the shape of any type of groove involving:
(1) A decrease in the groove angle,
Q
(2) A decrease in the root opening,
(3) An increase in the root face which will not be subsequently removed by backgouging.
The omission, but not inclusion, of backing or backgouging. Q Q
A change from U-groove to a V-groove (but not vice versa). Q
Q = Variable requires requalification. T = Variable requires requalification when toughness testing is required. A = Variable requires requalification for automatic welding.
60
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Table 6-2—Base Metal
GMAW PQR Variables B2.1 D1.1 D1.5 ASME IX API 1104
A change from one M-Number to another M-Number or to an unlisted base metal, except as 2.3 of B2.1 permits. Q
A change from one P-Number to another P-Number or to an unassigned base metal, except as QW-424 of ASME IX
Q
permits.
A change of a Group Number within an M-Number. T
A change of a Group Number within a P-Number. T
A change from a joint between the same M-Numbers, to a joint between different M-Numbers or vice versa except as
permitted, or for M-Numbers 1, 3, 4, and 5 (of 3% max nom chromium); a procedure test with one M-Number shall Q
also qualify for that metal welded to each of the lower M-Number metals.
A change from M5A to M5B or M5C, and vice versa.
--`,,```,,,,````-`-`,,`,,`,`,,`---
A change from M9A to M9B, but not vice versa.
Q
A change from M10A to M10B, M10C, M10F, M10H, M10I, M10J, or M10K, and vice versa.
A change from M11A to M11 B, and vice versa.
A change from P5A to P5B or P5C, and vice versa.
A change from P9A to P9B, but not vice versa. Q
A change from P10A to P10B, P10C, P10F, P10H, P10I, P10J, or P10K, and vice versa.
A change in base metals as specified in 4.7.3 of D1.1. Q
A change in base metal or combination of base metals not listed on the PQR or qualified by Table 4.7 of D1.1. Q
A change in base metal specification and grade as specified in 5.4 of D1.5. Q
A change in pipe material as specified in 12.5.2.2 of API 1104. Q
A change in wall-thickness group as specified in 12.5.2.4 of API 1104. Q
A change in base metal thickness beyond the range permitted in 2.5 of B2.1. Q
Q = Variable requires requalification. T = Variable requires requalification when toughness testing is required. A = Variable requires requalification for automatic welding.
Q = Variable requires requalification. T = Variable requires requalification when toughness testing is required. A = Variable requires requalification for automatic welding.
--`,,```,,,,````-`-`,,`,,`,`,,`---
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Table 6-3—Filler Metals
GMAW PQR Variables B2.1 D1.1 D1.5 ASME IX API 1104
A change from one F-Number to any other F-Number or to any filler metal not listed in Annex III of B2.1. Q
--`,,```,,,,````-`-`,,`,,`,`,,`---
A change from one F-Number in QW-432 of ASME IX to any other F-Number or to any other filler metal not listed
Q
in QW-432.
For ferrous materials, a change from one A-Number to any other A-Number or to a filler metal analysis not listed in
Annex III of B2.1 or QW-432 of ASME IX (the PQR and WPS shall state the nominal chemical composition or
Q Q
manufacturer’s designation for filler metals which do not fall into an A-Number group). Qualification with A-1 shall
qualify for A-2 and vice versa.
A change in AWS filler metal classification. T T Q
A change from one filler-metal group to another as specified in Table 1 of API 1104. Q
For pipe materials with a specified minimum yield strength greater than or equal to 65,000 pounds per square inch
Q
(448.16 megapascals), a change in the AWS classification of the filler metal.
A change to an electrode or flux-electrode combination not covered in AWS A5.18 or A5.28. Q
A change in the filler metal classification strength designator exceeding 10,000 psi, or to a filler metal classification
Q
strength designator less than the base metal tensile strength.
An increase in filler metal classification strength. Q Q
An addition or deletion of supplementary filler metal (powder or wire), or a change of 10% in the amount. Q Q
A change in the weld metal thickness beyond that permitted in 2.5 of B2.1 or QW-451 of ASME IX as applicable. Q Q
Q = Variable requires requalification. T = Variable requires requalification when toughness testing is required. A = Variable requires requalification for automatic welding.
A change in the filler metal classification within an SFA specification or to a filler metal not covered by an SFA
specification, or from one filler metal not covered by an SFA specification to another filler metal that is not covered by
an SFA specification.
When a filler metal conforms to a filler metal classification within an SFA specification, requalification is not required
if a change is made in any of the following:
(1) from a filler metal that is designated as moisture-resistant to one that is not designated as moisture-resistant and vice
versa (i.e., from E7018R to E7018)
(2) from one diffusible hydrogen level to another (i.e., from E7018-H8 to E7018-H16)
(3) for carbon, low alloy, and stainless steel filler metals having the same minimum tensile strength and the same nom-
inal chemical composition, a change from one low hydrogen coating type to another low hydrogen coating type (i.e., a T
change among EXX15, 16, or 18 or EXXX15, 16, or 17 classifications
(4) from one position-usability designation to another for flux-cored electrodes (i.e., a change from E70T-1 to
E71T-1 or vice versa
(5) from a classification that requires impact testing to the same classification which has a suffix which indicates that
impact testing was performed at a lower temperature or exhibited greater toughness at the required temperature or both,
as compared to the classification which was used during procedure qualification (i.e., a change from E7018 to E7018-1)
(6) from the classification qualified to another filler metal within the same SFA specification when the weld metal is
exempt from Impact Testing by other sections
This exemption does not apply to hard-facing and corrosion-resistant overlays.
A change from one of the following filler metal product forms to another:
(1) Flux cored,
Q
(2) Bare (solid) or metal cored,
(3) Powder.
A change in the size of filler metal wire. A
Q = Variable requires requalification. T = Variable requires requalification when toughness testing is required. A = Variable requires requalification for automatic welding.
64 --`,,```,,,,````-`-`,,`,,`,`,,`---
For the following M-Numbers 1, 3, 4, 5, 6, 9, 10, 11, and 12, and for P-Numbers 1, 3, 4, 5, 6, 9, 10, and 11, a change
from any one condition to any other requires requalification:
(1) No PWHT,
(2) PWHT below the lower transformation temperature,
Q Q
(3) PWHT within the transformation temperature range,
(4) PWHT above the upper transformation temperature,
(5) PWHT above the upper transformation temperature followed by treatment below the lower transformation
temperature.
Addition or deletion of PWHT. Q Q
The qualification test weldment shall be subjected to heat treatment essentially equivalent to that of the production
T T T
weldment, including at least 80% of the aggregate time at temperature.
A change in post-heat treatment requirements. Q
Q = Variable requires requalification. T = Variable requires requalification when toughness testing is required. A = Variable requires requalification for automatic welding.
66
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--`,,```,,,,````-`-`,,`,,`,`,,`---
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Table 6-9—Electrical Characteristics
GMAW PQR Variables B2.1 D1.1 D1.5 ASME IX API 1104
An increase of heat input or volume of weld metal deposited per unit length of weld, over that qualified, except when
a grain refining austenitizing heat treatment is applied after welding. The increase may be measured by either of the
following:
Volts × Amps × 60 - T T T
(1) Heat Input (J/in.) = -----------------------------------------------------
Travel Speed (in./min)
(2)Weld metal volume—an increase in bead size, or a decrease in the length of weld bead per unit length of electrode.
A change in the mode of metal transfer from short circuiting to globular, spray, or pulsed and vice versa. Q Q Q Q
A change in the amperage for each diameter used by >10% increase or decrease. Q Q
A change in type of current (ac or dc) or polarity. Q Q T Q
A change in the voltage for each diameter used by >7% increase or decrease. Q Q
An increase or decrease in the wire feed speed for each electrode diameter (if not amperage controlled) by >10%. Q
A change in the travel speed (unless heat input control is required) by >25% increase or decrease. Travel speed ranges
for all sizes of fillet welds may be determined by the largest single pass fillet weld and the smallest multiple pass fillet Q
weld qualification tests.
--`,,```,,,,````-`-`,,`,,`,`,,`---
A change in the travel speed by >10% increase or decrease. Q
A change in the range for speed of travel. Q
An increase in heat input by >10%. This essential variable applies only when heat input control is a contract document
requirement. Heat input in joules per inch shall be calculated as 60EI/V where: E = PQR voltage, I = PQR amperage, Q
and V = PQR travel speed.
An increase in heat input by more than 10% or decrease of more than 30%. For M270M, (A 709M) Gr. 690, 690W,
Q
allowable heat input increase or decrease shall be limited to 10%.
A change in electrical characteristics. Q
Q = Variable requires requalification. T = Variable requires requalification when toughness testing is required. A = Variable requires requalification for automatic welding.
Q = Variable requires requalification. T = Variable requires requalification when toughness testing is required. A = Variable requires requalification for automatic welding.
70
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--`,,```,,,,````-`-`,,`,,`,`,,`---
--`,,```,,,,````-`-`,,`,,`,`,,`---
(3) An increase in the root face which will not be subsequently removed by backgouging.
The omission, but not inclusion, of backing or backgouging. Q Q
A change from U-groove to a V-groove (but not vice versa). Q
Q = Variable requires requalification. T = Variable requires requalification when toughness testing is required. A = Variable requires requalification for automatic welding.
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Table 7-2—Base Metal
FCAW PQR Variables B2.1 D1.1 D1.5 ASME IX API 1104
A change from one M-Number to another M-Number or to an unlisted base metal, except as 2.3 of B2.1 permits. Q
A change from one P-Number to another P-Number or to an unassigned base metal, except as QW-424 of ASME IX
Q
permits.
A change of a Group Number within an M-Number. T
A change of a Group Number within a P-Number. T
A change from a joint between the same M-Numbers, to a joint between different M-Numbers or vice versa except as
permitted, or for M-Numbers 1, 3, 4, and 5 (of 3% max nom chromium), a procedure test with one M-Number shall Q
also qualify for that metal welded to each of the lower M-Number metals.
A change from M5A to M5B or M5C, and vice versa.
A change from M9A to M9B, but not vice versa.
Q
A change from M10A to M10B, M10C, M10F, M10H, M10I, M10J, or M10K, and vice versa.
A change from M11A to M11 B, and vice versa.
A change from P5A to P5B or P5C, and vice versa.
A change from P9A to P9B, but not vice versa. Q
A change from P10A to P10B, P10C, P10F, P10H, P10I, P10J, or P10K, and vice versa.
A change in base metals as specified in 4.7.3 of D1.1. Q
A change in base metal or combination of base metals not listed on the PQR or qualified by Table 4.7 of D1.1. Q
A change in base metal specification and grade as specified in 5.4 of D1.5. Q
A change in pipe material as specified in 12.5.2.2 of API 1104. Q
A change in wall-thickness group as specified in 12.5.2.4 of API 1104. Q
A change in base metal thickness beyond the range permitted in 2.5 of B2.1. Q
Q = Variable requires requalification. T = Variable requires requalification when toughness testing is required. A = Variable requires requalification for automatic welding.
--`,,```,,,,````-`-`,,`,,`,`,,`---
--`,,```,,,,````-`-`,,`,,`,`,,`---
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Table 7-3—Filler Metals
FCAW PQR Variables B2.1 D1.1 D1.5 ASME IX API 1104
A change from one F-Number to any other F-Number or to any filler metal not listed in Annex III of B2.1. Q
A change from one F-Number in QW-432 of ASME IX to any other F-Number or to any other filler metal not listed
Q
in QW-432.
For ferrous materials, a change from one A-Number to any other A-Number or to a filler metal analysis not listed in
Annex C of B2.1 or QW-432 of ASME IX (the PQR and WPS shall state the nominal chemical composition or
Q Q
manufacturer’s designation for filler metals which do not fall into an A-Number group). Qualification with A-1 shall
qualify for A-2 and vice versa.
A change in AWS filler metal classification. T T Q T
A change from one filler-metal group to another as specified in Table 1 of API 1104. Q
For pipe materials with a specified minimum yield strength greater than or equal to 65,000 pounds per square inch
Q
(448.16 megapascals), a change in the AWS classification of the filler metal.
A change to an electrode or flux-electrode combination not covered in AWS A 5.20 or A5.29. Q
A change in the filler metal classification strength designator exceeding 10,000 psi, or to a filler metal classification
Q
strength designator less than the base metal tensile strength.
A change in manufacturer’s brand and type of cored electrode. T Q
An increase in filler metal classification strength. Q Q
--`,,```,,,,````-`-`,,`,,`,`,,`---
Addition or deletion of supplementary filler metal (powder or wire), or a change of 10% in the amount. T Q
A change from one electrode or flux-electrode classification listed to any other electrode or flux-electrode classification. Q
A change in the weld metal thickness beyond that permitted in 2.5 of B2.1 or QW-451 of ASME IX as applicable. Q Q
Q = Variable requires requalification. T = Variable requires requalification when toughness testing is required. A = Variable requires requalification for automatic welding.
A change in the filler metal classification within an SFA specification or to a filler metal not covered by an SFA
specification, or from one filler metal not covered by an SFA specification to another filler metal that is not covered by
an SFA specification.
When a filler metal conforms to a filler metal classification within an SFA specification, requalification is not required
if a change is made in any of the following:
from one diffusible hydrogen level to another
from one position-usability designation to another for flux-cored electrodes (i.e., a change from E70T-1 to E71T-1 or
T
vice versa
from a classification that requires impact testing to the same classification which has a suffix which indicates that
impact testing was performed at a lower temperature or exhibited greater toughness at the required temperature or both,
as compared to the classification which was used during procedure qualification
from the classification qualified to another filler metal within the same SFA specification when the weld metal is
exempt from Impact Testing by other sections
This exemption does not apply to hard-facing and corrosion-resistant overlays.
A change from one of the following filler metal product forms to another:
(1) Flux cored,
Q
(2) Bare (solid) or metal cored,
(3) Powder.
A change in the size of filler metal wire. Q
Q = Variable requires requalification. T = Variable requires requalification when toughness testing is required. A = Variable requires requalification for automatic welding.
--`,,```,,,,````-`-`,,`,,`,`,,`---
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Table 7-4—Position
FCAW PQR Variables B2.1 D1.1 D1.5 ASME IX API 1104
A change from any position to the vertical position, uphill progression. Vertical uphill progression qualifies all positions. T T T
A change in position not qualified by Table 4.1 of D1.1. Q
A change from any position except that flat positions qualify for flat and horizontal welding. Q
Vertical welding: for any pass from uphill to downhill or vice versa. Q Q
Vertical welding shall be vertical up unless qualified by tests approved by the Engineer. Q
A change in position from roll to fixed, or vice versa. Q
Q = Variable requires requalification. T = Variable requires requalification when toughness testing is required. A = Variable requires requalification for automatic welding.
--`,,```,,,,````-`-`,,`,,`,`,,`---
For the following M or P-Numbers 1, 3, 4, 5, 6, 9, 10, and 11 a change from any one condition to any other requires
requalification:
(1) No PWHT,
(2) PWHT below the lower transformation temperature,
Q Q
(3) PWHT within the transformation temperature range,
(4) PWHT above the upper transformation temperature,
(5) PWHT above the upper transformation temperature followed by treatment below the lower transformation
temperature.
Addition or deletion of PWHT. Q Q
The qualification test weldment shall be subjected to heat treatment essentially equivalent to that of the production
T T T
weldment, including at least 80% of the aggregate time at temperature.
A change in post-heat treatment requirements. Q
--`,,```,,,,````-`-`,,`,,`,`,,`---
Q = Variable requires requalification. T = Variable requires requalification when toughness testing is required. A = Variable requires requalification for automatic welding.
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Table 7-7—Shielding Gas
FCAW PQR Variables B2.1 D1.1 D1.5 ASME IX API 1104
The addition or deletion of shielding gas. Q Q
A change in shielding gas from a single gas to any other shielding gas or mixture of gas, or in the specified nominal
Q Q Q
composition of a gas mixture, or to no gas.
A change in shielding gas from a single gas to any other shielding gas or mixture of gases, or a change of more than
Q
25% in any of the minor elements of the gas mixture, or a change from a gas mixture to a single gas.
A change from one shielding gas to another or from one mixture of gases to another. Q
A change in total gas flow rate by ≥50% increase; ≥10% decrease. Q
A change to a shielding gas not covered in AWS A5.20 or A5.29. Q
A change from external shielding to self shielding. Q
A major increase or decrease in the range of flow rates for the shielding gas. Q
A change in total gas flow rate by ≥25% increase; ≥10% decrease. Q
The addition, deletion, or change in composition, or a decrease of 15% in the flow rate of root shielding gas or single-
sided M-41 through M-46 single-sided groove welds.
Table 7-8—Electrode
FCAW PQR Variables B2.1 D1.1 D1.5 ASME IX API 1104
A change in nominal electrode diameter by any increase. Q
An increase or decrease in electrode diameter by more than one standard size. Q
A change in number of electrodes. Q Q
A change from single electrode to multiples electrodes in the same weld pool, and vice versa. For ASME IX
applications, this limitation does not apply when a WPS is qualified with a PWHT above the upper transformation Q T
temperature or when an austenitic material is solution annealed after welding.
A change in electrode classification. Q Q
A change in electrode-shielding gas combination. Q
Q = Variable requires requalification. T = Variable requires requalification when toughness testing is required. A = Variable requires requalification for automatic welding.
--`,,```,,,,````-`-`,,`,,`,`,,`---
An increase of heat input or volume of weld metal deposited per unit length of weld, over that qualified, except when
a grain refining austenitizing heat treatment is applied after welding. The increase may be measured by either of the
following:
Volts × Amps × 60 - T T T
(1) Heat Input (J/in.) = -----------------------------------------------------
Travel Speed (in./min)
(2) Weld metal volume—an increase in bead size, or a decrease in the length of weld bead per unit length of electrode.
A change in the mode of metal transfer from short circuiting to globular, spray, or pulsed and vice versa. Q Q
A change in the amperage for each diameter used by >10% increase or decrease. Q Q
A change in type of current (ac or dc) or polarity. Q Q T Q
A change in the voltage for each diameter used by >7% increase or decrease. Q Q
An increase or decrease in the wire feed speed for each electrode diameter (if not amperage controlled) by >10%. Q
A change in the travel speed (unless heat input control is required) by >25% increase or decrease. Travel speed ranges
for all sizes of fillet welds may be determined by the largest single pass fillet weld and the smallest multiple pass fillet Q
--`,,```,,,,````-`-`,,`,,`,`,,`---
weld qualification tests.
A change in the travel speed by >10% increase or decrease. Q
A change in the range for speed of travel. Q
An increase in heat input by >10%. This essential variable applies only when heat input control is a contract document
requirement. Heat input in joules per inch shall be calculated as 60EI/V where: E = PQR voltage, I = PQR amperage, Q
and V = PQR travel speed.
An increase in heat input by more than 10% or decrease of more than 30%. For M270M, (A 709M) Gr. 690, 690W,
Q
allowable heat input increase or decrease shall be limited to 10%.
A change in electrical characteristics. Q
Q = Variable requires requalification. T = Variable requires requalification when toughness testing is required. A = Variable requires requalification for automatic welding.
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Table 7-10—Other
FCAW PQR Variables B2.1 D1.1 D1.5 ASME IX API 1104
--`,,```,,,,````-`-`,,`,,`,`,,`---
austenitic material is solution annealed after welding.
For the PQR groove area, an increase or decrease >25% in the number of passes. For M270M (A 709M) Gr. 690,
690W, passes any change in the number of groove weld passes requires requalification, except proportional changes
Q
to accommodate a change in weld cross-sectional area. For fillet welds in these steels, any change in the number of
passes requires a fillet weld T-test per Figure 5.8 of D1.5 to be performed.
An increase in the maximum time between completion of the root bead and the start of the second bead. Q
A change in the width, frequency, or dwell time of oscillation for machine or automatic welding only. T
Q = Variable requires requalification. T = Variable requires requalification when toughness testing is required. A = Variable requires requalification for automatic welding.
82
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--`,,```,,,,````-`-`,,`,,`,`,,`---
A major change in joint design (for example, from V groove to U groove). Minor changes in the angle of bevel or the
Q
land of the welding groove are not essential variables.
Any change beyond the range established in the procedure specification for such factors as spacing, root face, and
Q
angle of bevel.
A change in the type of groove to a square groove and vice versa. Q
A change exceeding the tolerances of 3.12, 3.13, 3.13.4, 5.22.4.1, or 5.22.4.2 of D1.1 involving:
(1) A decrease in the groove angle,
Q
(2) A decrease in the root opening,
(3) An increase in the root face.
The omission, but not inclusion, of backing or backgouging. Q
Q = Variable requires requalification. T = Variable requires requalification when toughness testing is required. A = Variable requires requalification for automatic welding.
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Table 8-2—Base Metal
GTAW PQR Variables B2.1 D1.1 D1.5 ASME IX API 1104
A change from one M-Number to another M-Number or to an unlisted base metal, except as 2.3 of B2.1 permits. Q
--`,,```,,,,````-`-`,,`,,`,`,,`---
A change from one P-Number to another P-Number or to an unassigned base metal, except as QW-424 of ASME IX
Q
permits.
A change of a Group Number within an M-Number. T
A change of a Group Number within a P-Number. T
A change from a joint between the same M-Numbers, to a joint between different M-Numbers or vice versa except as
permitted, or for M-Numbers 1, 3, 4, and 5 (of 3% max nom chromium), a procedure test with one M-Number shall Q
also qualify for that metal welded to each of the lower M-Number metals.
A change from M5A to M5B or M5C, and vice versa.
A change from M9A to M9B, but not vice versa.
Q
A change from M10A to M10B, M10C, M10F, M10H, M10I, M10J, or M10K, and vice versa.
A change from M11A to M11 B, and vice versa.
A change from P5A to P5B or P5C, and vice versa.
A change from P9A to P9B, but not vice versa. Q
A change from P10A to P10B, P10C, P10F, P10H, P10I, P10J, or P10K, and vice versa.
A change in base metals as specified in 4.7.3 of D1.1. Q
A change in base metal or combination of base metals not listed on the PQR or qualified by Table 4.7 of D1.1. Q
A change in pipe material as specified in 12.5.2.2 of API 1104. Q
A change in wall-thickness group as specified in 12.5.2.4 of API 1104. Q
A change in base metal thickness beyond the range permitted in 2.5 of B2.1. Q
Q = Variable requires requalification. T = Variable requires requalification when toughness testing is required. A = Variable requires requalification for automatic welding.
Q = Variable requires requalification. T = Variable requires requalification when toughness testing is required. A = Variable requires requalification for automatic welding.
--`,,```,,,,````-`-`,,`,,`,`,,`---
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Table 8-3—Filler Metals
GTAW PQR Variables B2.1 D1.1 D1.5 ASME IX API 1104
A change from one F-Number to any other F-Number or to any filler metal not listed in Annex III of B2.1. Q
A change from one F-Number in QW-432 of ASME IX to any other F-Number or to any other filler metal not listed
Q
in QW-432.
For ferrous materials, a change from one A-Number to any other A-Number or to a filler metal analysis not listed in
Annex III of B2.1 or QW-432 of ASME IX (the PQR and WPS shall state the nominal chemical composition or
Q Q
manufacturer’s designation for filler metals which do not fall into an A-Number group). Qualification with A-1 shall
qualify for A-2 and vice versa.
A change from one filler-metal group to another as specified in Table 1 of API 1104. Q
For pipe materials with a specified minimum yield strength greater than or equal to 65,000 pounds per square inch
Q
(448.16 megapascals), a change in the AWS classification of the filler metal.
A change in AWS filler metal classification. T
A change to an electrode or flux-electrode combination not covered in AWS A5.18 or A5.28. Q
A change in the filler metal classification strength designator exceeding 10,000 psi, or to a filler metal classification
Q
strength designator less than the base metal tensile strength.
The addition or deletion of filler material. Q Q Q
The addition or deletion of supplementary filler metal (powder or wire), or a change of 10% in the amount. T
A change from one electrode or flux-electrode classification listed to any other electrode or flux-electrode classification. Q
A change in the weld metal thickness beyond that permitted in 2.5 of B2.1 or QW-408.3 of ASME IX as applicable. Q Q
A change from cold wire feed to hot wire feed or vice versa. Q
A change in the SFA specification filler metal classification or to a filler metal not covered by an SFA specification,
or from one filler metal not covered by an SFA specification to another which is not covered by an SFA specification.
T
When a filler metal conforms to an SFA specification, requalification is not required if a change is made to any of the
conditions listed in QW-404.12 of ASME IX.
A change from one of the following filler metal product forms to another:
(1) Flux cored,
Q
(2) Bare (solid) or metal cored,
(3) Powder.
A change in the size of filler metal wire. A
Q = Variable requires requalification. T = Variable requires requalification when toughness testing is required. A = Variable requires requalification for automatic welding.
--`,,```,,,,````-`-`,,`,,`,`,,`---
A change from any position to the vertical position, uphill progression. Vertical uphill progression qualifies all positions. T T T
A change in position not qualified by Table 4.1 of D1.1. Q
Vertical welding: for any pass from uphill to downhill or vice versa. Q Q
A change in position from roll to fixed, or vice versa. Q
Q = Variable requires requalification. T = Variable requires requalification when toughness testing is required. A = Variable requires requalification for automatic welding.
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--`,,```,,,,````-`-`,,`,,`,`,,`---
Table 8-6—Postweld Heat Treatment
GTAW PQR Variables B2.1 D1.1 D1.5 ASME IX API 1104
For the following M or P-Numbers 1, 3, 4, 5, 6, 9, 10, and 11 a change from any one condition to any other requires
requalification:
(1) No PWHT,
(2) PWHT below the lower transformation temperature,
Q Q
(3) PWHT within the transformation temperature range,
(4) PWHT above the upper transformation temperature,
(5) PWHT above the upper transformation temperature followed by treatment below the lower transformation
temperature.
A separate PQR is required for no PWHT and PWHT. Q Q Q
The qualification test weldment shall be subjected to heat treatment essentially equivalent to that of the production
Q T
weldment, including at least 80% of the aggregate time at temperature.
A change in post-heat treatment requirements. Q
--`,,```,,,,````-`-`,,`,,`,`,,`---
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--`,,```,,,,````-`-`,,`,,`,`,,`---
Table 8-8—Electrode
GTAW PQR Variables B2.1 D1.1 D1.5 ASME IX API 1104
A change in nominal electrode diameter by >1/16 in. increase or decrease. Q
A change from single electrode to multiples electrodes in the same weld pool, and vice versa. For ASME IX
applications, this limitation does not apply when a WPS is qualified with a PWHT above the upper transformation T T
temperature or when an austenitic material is solution annealed after welding.
A change in tungsten electrode type as shown in AWS A5.12. Q
--`,,```,,,,````-`-`,,`,,`,`,,`---
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Chapter 9—Terms and Definitions Related to Welding Procedure Specifications and Procedure Qualifications
These terms and definitions are derived from AWS A3.0:2001, Standard As-welded, adj. Pertaining to the condition of weld metal, welded joints,
Welding Terms and Definitions, Including Terms for Adhesive Bonding, Braz- and weldments after welding, but prior to any subsequent thermal,
ing, Soldering, Thermal Cutting, and Thermal Spraying, unless indicated ( ) mechanical, or chemical treatments.
as AWS (D1.1), Structural Welding Code—Steel, AWS (D1.5), Bridge Weld-
Autogenous weld. A fusion weld made without filler metal.
ing Code, AWS (B2.1), Specification for Welding Procedure and Perfor-
mance Qualification, (API 1104), Welding of Pipelines and Related Facilities, Automatic welding. Welding with equipment that requires only occa-
or ASME Boiler and Pressure Vessel Code (Section IX), Welding and Braz- sional or no observation of the welding, and no manual adjustment of
ing Qualifications. Note: The standards referenced are revised periodically. the welding equipment. See also Manual welding, Mechanized weld-
Active flux, submerged arc welding. A flux formulated to produce a weld ing, and Semiautomatic welding.
metal composition that is dependent on the welding parameters, Automatic welding (API 1104). Arc welding with equipment that per-
especially arc voltage. forms the entire welding operation without manual manipulation of the
Active flux, submerged arc welding (D1.5). A flux which contains small arc or electrode other than guiding or tracking and without a manual
amounts of manganese or silicon, or both, added to improve the weld in welding-skill requirement of the operator.
certain single pass applications. Change in arc voltage or the number of A-Number (B2.1). A designation used to classify ferrous weld metal for
weld passes can significantly change weld metal chemistry and procedure qualification based upon chemical composition.
mechanical properties.
Alloy flux, submerged arc welding (D1.1). A flux upon which the alloy Backgouging. The removal of weld metal and base metal from the weld
content of the weld metal is largely dependent. root side of a welded joint to facilitate fusion and complete joint pene-
tration upon subsequent welding from that side.
Alloy flux, submerged arc welding (D1.5). A flux which contains alloy
ingredients intended to modify the weld metal chemistry. Changes in Backing. A material or device placed against the back side of the joint,
arc voltage can significantly change weld metal chemistry. adjacent to the root or at both sides of a joint in electroslag and electro-
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Alloy. A substance with metallic properties and composed of two or more gas welding, to support and shield molten weld metal. The material may
chemical elements of which at least one is a metal. be partially fused or remain unfused during welding and may be either
metal or nonmetal. See Figure 9-1.
Arc voltage, arc welding. The electrical potential between the electrode
and workpiece. Base material. The material that is welded, brazed, soldered, or cut.
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perpendicular to the surface of the member. See Figure 9-2. Edge preparation. The preparation of the edges of the joint members, by
Consumable electrode. An electrode that provides filler metal. cutting, cleaning, plating, or other means.
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96 --`,,```,,,,````-`-`,,`,,`,`,,`---
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Figure 9-5—Direct Current Electrode POSITIVE
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Tabulation of Positions of Groove Welds
Position Diagram Reference Inclination of Axis Rotation of Face
Flat A 0° to 15° 150° to 210°
80° to 150°
Horizontal B 0° to 15°
210° to 280°
0° to 80°
Overhead C 0° to 80°
280° to 360°
D 15° to 80° 80° to 280°
Vertical
E 80° to 90° 0° to 360°
Notes:
1. The horizontal reference plane is always taken to lie below the weld under
consideration.
2. The inclination of the weld axis is measured from the horizontal reference
plane toward the vertical reference plane.
3. The angle of rotation of the weld face is determined by a line perpendicular
to the weld face at its center which passes through the weld axis. The refer-
ence position (0°) of rotation of the weld face invariably points in the
direction opposite to that in which the axis angle increases. When looking
at point P, the angle of rotation of the weld face is measured in a clockwise
direction from the reference position (0°).
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Figure 9-8—Welding Position Diagram for Groove Welds in Plate
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Tabulation of Positions of Fillet Welds
Position Diagram Reference Inclination of Axis Rotation of Face
Flat A 0° to 15° 150° to 210°
125° to 150°
Horizontal B 0° to 15°
210° to 235°
0° to 125°
Overhead C 0° to 80°
235° to 360°
D 15° to 80° 125° to 235°
Vertical
E 80° to 90° 0° to 360°
Notes:
1. The horizontal reference plane is always taken to lie below the weld under
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consideration.
2. The inclination of the weld axis is measured from the horizontal reference
plane toward the vertical reference plane.
3. The angle of rotation of the weld face is determined by a line perpendicular
to the weld face at its center which passes through the weld axis. The refer-
ence position (0°) of rotation of the weld face invariably points in the
direction opposite to that in which the axis angle increases. When looking
at point P, the angle of rotation of the weld face is measured in a clockwise
direction from the reference position (0°).
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Flux cored arc welding. Abbreviated as FCAW. An arc welding process
that uses an arc between a continuous filler metal electrode and the
weld pool. The process is used with shielding gas from a flux
contained within the tubular electrode, with or without additional
shielding from an externally supplied gas, and without the application
of pressure.
Flux cored arc welding (Section IX). A gas metal arc welding process that
uses an arc between a continuous filler metal electrode and the weld
pool. Shielding is provided by a flux contained within the tubular elec-
trode with or without additional shielding from an externally supplied
gas and without the application of pressure.
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Figure 9-13—Flat Welding Test Position—1G Flux cored electrode. A composite tubular filler metal electrode consist-
ing of a metal sheath and a core of various powdered materials, produc-
ing an extensive slag cover on the face of a weld bead.
4F, plate. A welding test position designation for a linear fillet weld
applied to a joint in which the weld is made in the overhead welding
position. See Figure 9-15.
4G. A welding test position designation for a linear groove weld applied to
a joint in which the weld is made in the overhead welding position. See
Figure 9-14—Flat Welding Test Position—1F Figure 9-17.
Figure 9-15—Overhead Welding Test Position—4F Figure 9-17—Overhead Welding Test Position—4G
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Gas metal arc welding. Abbreviated as GMAW. An arc welding process
that uses an arc between a continuous filler metal electrode and the weld
pool. The process is used with shielding from an externally supplied gas
and without the application of pressure.
Gas metal arc welding (Section IX). An arc welding process that uses an
arc between a continuous filler metal electrode and the weld pool. The
process is used with shielding from an externally supplied gas and with-
out the application of pressure.
Globular transfer, gas metal arc welding. The transfer of molten metal in
large drops from a consumable electrode across the arc. See Figure 9-18. Figure 9-18—Globular Transfer
Groove angle. The included angle between the groove faces of a weld
groove. See Figure 9-2.
Horizontal welding position, fillet weld. The welding position in which
Heat-affected zone. Abbreviated as HAZ. The portion of the base metal the weld is on the upper side of an approximately horizontal surface and
whose mechanical properties or microstructure have been altered by the against an approximately vertical surface. See Figures 9-9 and 9-19
heat of welding, brazing, soldering, or thermal cutting. through 9-21.
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Figure 9-19—Horizontal Welding Test Position—2F Figure 9-21—Horizontal Welding Test Position—2FR
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Horizontal welding position, groove weld. The welding position in which
the weld face lies in an approximately vertical plane and the weld axis
at the point of welding is approximately horizontal. See Figures 9-8,
9-10, 9-22, and 9-23.
Interpass temperature, welding. In a multipass weld, the temperature of
the weld area between weld passes. See also Preheat temperature.
Longitudinal weld test specimen. A weld test specimen with its major
axis parallel to the weld axis.
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Figure 9-22—Horizontal Welding Test Position—2G Figure 9-23—Horizontal Welding Test Position—2G
M-Number (B2.1). A designation used to group base metals for procedure and 9-15 through 9-17.
and performance qualifications consistent with the P-Number and Postheating. The application of heat to an assembly after brazing, solder-
S-Number designations established by the ASME Boiler and Pressure ing, thermal spraying, thermal cutting, or welding,.
Vessel Code, Section IX, but which also incorporate materials not rec-
ognized or used under ASME rules. Position welding (API 1104). Welding in which the pipe or assembly is
held stationary.
Neutral flux, submerged arc welding. A flux formulated to produce a weld
metal composition that is not dependent on the welding parameters, Preheat temperature, welding. The temperature of the base metal in the
especially arc voltage. volume surrounding the point of welding immediately before welding is
started. In a multipass weld, it is also the temperature immediately
Nonconsumable electrode. An electrode that does not provide filler metal. before the second and subsequent passes are started.
1F, pipe. A welding test position designation for a circumferential fillet Prequalified welding procedure specification. A welding procedure
weld applied to a joint in pipe, with its axis approximately 45° from the specification that complies with the stipulated conditions of a particular
horizontal, in which the weld is made in the flat welding position by welding code or specification and is therefore acceptable for use under
rotating the pipe about its axis. See Figure 9-14. that code or specification without a requirement for qualification testing.
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Procedure. The detailed elements of a process or method used to produce Reverse polarity. A nonstandard term for direct current electrode
a specific result. positive.
Procedure qualification. The demonstration that welds made by a specific Roll welding (API 1104). Welding in which the pipe or assembly is rotated
procedure can meet prescribed standards. while the weld metal is deposited at or near the top center.
Procedure Qualification Record (B2.1). Abbreviated as PQR. A written Root bend test. A test in which the weld root is on the convex surface of a
record of welding variables used to produce an acceptable test weld- specified bend radius.
ment and the results of tests conducted on that weldment to qualify a
welding procedure specification. Self-shielded flux cored arc welding. Abbreviated as FCAW-S. A flux
cored arc welding process variation in which shielding gas is obtained
Procedure qualification variable (B2.1). A controllable detail which if exclusively from the flux within the electrode.
changed beyond the limits of 2.14 Procedure Qualification Variables,
requires requalification of the WPS. Semiautomatic welding. Manual welding with equipment that automati-
cally controls one or more of the welding conditions. See also Auto-
Pulsed gas metal arc welding. Abbreviated as GMAW-P. A gas metal arc matic welding, Manual welding, and Mechanized welding.
welding process variation in which the current is pulsed.
Semiautomatic welding (D1.5, API 1104). Arc welding with equipment
Pulsed gas tungsten arc welding. Abbreviated as GTAW-P. A gas tung- that controls only the filler metal feed. The advance of the welding is
sten arc welding process variation in which the current is pulsed. manually controlled.
Pulsed power welding. An arc welding process variation in which the Shielded metal arc welding. Abbreviated as SMAW. An arc welding pro-
welding power source is programmed to cycle between low and high cess with an arc between a covered electrode and the weld pool. The
power levels. process is used with shielding from the decomposition of the electrode
covering, without the application of pressure, and with filler metal from
Pulsed spray welding. An arc welding process variation in which pulsed the electrode.
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spray transfer occurs.
Short circuit gas metal arc welding. Abbreviated as GMAW-S. A gas
Reduced section tension test. A test in which a transverse section of the metal arc welding process variation in which the consumable electrode
weld is located in the center of the reduced section of the specimen. is deposited during repeated short circuits.
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is on the convex surface of a specified bend radius.
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Figure 9-26—Multiple Welding Test Position
with Restriction Ring—6GR
Standoff distance. The distance between a nozzle and the workpiece. See
Figures 9-28 and 9-29.
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Stickout, gas metal arc welding and gas shielded flux cored arc welding.
The length of unmelted electrode extending beyond the end of the gas
nozzle.
Stickout, gas tungsten arc welding. The length of the tungsten electrode
extending beyond the end of the gas nozzle. See Figure 9-29.
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Figure 9-29—Gas Tungsten Arc Welding Torch Nomenclature
including Stickout and Standoff Distance
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3F. A welding test position designation for a linear fillet weld applied to a
joint in which the weld is made in the vertical welding position. See
Figure 9-31.
3G. A welding test position for a linear groove weld applied to a joint in
which the weld is made in the vertical welding position. See Figure
9-32.
Transverse weld test specimen. A weld test specimen with its major axis
perpendicular to the weld axis.
2F, pipe. A welding test position designation for a circumferential fillet
weld applied to a joint in pipe, with its axis approximately vertical, in
Figure 9-30—Stringer Bead which the weld is made in the horizontal welding position. See Figure
9-20.
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T (B2.1). A symbol for base metal thickness, or for identifying a procedure 2F, plate. A welding test position designation for a linear fillet weld
qualification variable for fracture toughness applications, as appropriate. applied to a joint in which the weld is made in the horizontal welding
t (B2.1). A symbol for weld metal thickness, which is equal to groove weld position. See Figure 9-19.
size, or to fillet weld leg size, as appropriate. 2FR. A welding test position designation for a circumferential fillet weld
Tension test. A test in which a specimen is loaded in tension until failure around a joint in a pipe, with its axis approximately horizontal, in which
occurs. the weld is made in the horizontal welding position by rotating the pipe
about its axis. See Figure 9-21.
Test coupon (ASME IX). A weld or braze assembly for procedure or per-
formance qualification testing. The coupon may be any product from 2G, pipe. A welding test position designation for a circumferential groove weld
plate, pipe, tube, etc., and may be a fillet weld, overlay, deposited weld applied to a joint in a pipe, with its axis approximately vertical, in which
metal, etc. the weld is made in the horizontal welding position. See Figure 9-23.
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--`,,```,,,,````-`-`,,`,,`,`,,`---
Figure 9-31—Vertical Welding Test Position—3F Figure 9-32—Vertical Welding Test Position—3G
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Welding schedule. A written statement, usually in tabular form, specifying Welding variable (B2.1). Any controllable detail of a welding procedure
values of parameters and the welding sequence for performing a weld- which is required to be addressed on the WPS.
ing operation. Welding wire. A form of welding filler metal, normally packaged as coils
or spools, that may or may not conduct electrical current depending
Welding technique. The details of a welding procedure that are controlled upon the welding process with which it is used.
by the welder or welding operator.
Whipping. A manual welding technique in which the arc or flame is
Welding test position designation. A symbol representation for a fillet manipulated to alternate backwards and forwards in the direction of
weld or a groove weld, the joint orientation and the welding test posi- travel as it progresses along the weld path.
tion. See 1F, 2F, 2FR, 3F, 4F, 5F, 6F, 1G, 2G, 3G, 4G, 5G, 6G, and Wire feed speed. The rate at which wire is consumed in arc cutting, ther-
6GR. mal spraying, or welding.
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Notes
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Annex I—Observations
This Annex contains observations by Duane K. Miller, Sc.D., P.E., on CC systems, the arc voltage is determined by the arc length, which is
manager, Engineering Services, The Lincoln Electric Company. The obser- manipulated by the welder. As arc lengths are increased with SMAW,
vations are from a paper presented to the AISC National Steel Construction the arc voltage will increase, and the amperage will decrease. Arc volt-
Conference and subsequently published in the Welding Journal. These age also controls the width of the weld bead, with higher voltages gen-
items are contained in this Annex because they are useful opinions of a erating wider beads. Arc voltage has a direct effect on the heat input
credible welding professional. They have been excluded from the body of computation. The voltage in a welding circuit is not constant, but is
this work because all of the content in the body is the result of consensus composed of a series of voltage drops. Consider the following example:
committees rather than single individuals. assume the power source delivers a total system voltage of 40 volts.
Between the power source and the welding head or gun, there is a volt-
Amperage. A measure of the amount of current flowing through the elec- age drop of perhaps 3 volts associated with the input cable resistance.
trode and the work. It is a primary variable in determining heat input.
Generally, an increase in amperage means higher deposition rates, From the point of attachment of the work lead to the power source
deeper penetration, and more admixture. The amperage flowing through work terminal, there is an additional voltage drop of, say, 7 volts. Sub-
an electrical circuit is the same, regardless of where it is measured. It tracting the 3 volts and the 7 volts from the original 40, this leaves 30
may be measured with a tong meter or with the use of an electrical volts for the arc. This example illustrates how important it is to ensure
shunt. The role of amperage is best understood in the context of heat that the voltages used for monitoring welding procedures properly rec-
input and current density considerations. For constant voltage (CV) ognize any losses in the welding circuit. The most accurate way to
welding, an increase in wire feed speed will directly increase amperage. determine arc voltage is to measure the voltage drop between the con-
For SMAW on constant current (CC) systems, the machine setting tact tip and the workpiece. This may not be practical for semiautomatic
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determines the basic amperage, although changes in the arc length (con- welding, so voltage is typically read from a point on the wire feeder
trolled by the welder) will further change amperage. Longer arc lengths (where the gun and cable connection is made), to the workpiece. For
reduce amperage. SMAW welding, voltage is not usually monitored, since it is constantly
changing and cannot be controlled except by the welder. Skilled weld-
Arc voltage. Arc voltage is directly related to arc length. As the voltage ers hold short arc lengths to deliver the best weld quality.
increases, the arc length increases, as does the demand for arc shielding.
For CV welding, the voltage is determined primarily by the machine Current density. Current density is determined by dividing the welding
setting, so the arc length is relatively fixed in CV welding. For SMAW amperage by the cross sectional area of the electrode. For solid
on current density.
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In constant voltage systems, it is possible to simultaneously increase tion rates with negative polarity than with positive. AC exhibits a mix
both the ESO and the wire feed speed in a balanced manner so that the of both positive and negative polarity characteristics. The magnetic
current remains constant. When this is done, higher deposition rates are field that surrounds any DC conductor can cause a phenomenon known
attained. Other welding variables such as voltage and travel speed must as arc blow, where the arc is physically deflected by the field. The
be adjusted to maintain a stable arc and to ensure quality welding. The strength of the magnetic field is proportional to the square of the current
ESO variable should always be within the range recommended by the value, so this is a more significant potential problem with higher
manufacturer. currents. AC is less prone to arc blow, and can sometimes be used to
overcome this phenomenon.
Heat input. Heat input is proportional to the welding amperage, times the
arc voltage, divided by the travel speed. Higher heat inputs relate to Preheat temperature, welding. Preheat and interpass temperatures are used
larger weld cross sectional areas, and larger heat affected zones, which to control cracking tendencies, typically in the base materials. Regarding
may negatively affect mechanical properties in that region. Higher heat weld metal properties, for most carbon-manganese-silicon systems, a
input generally results in slightly decreased yield and tensile strength in moderate interpass temperature promotes good notch toughness. Preheat
the weld metal, and generally lower notch toughness because of the and interpass temperatures greater than 550°F may negatively affect
interaction of bead size and heat input. notch toughness. When the base metal receives little or no preheat, the
resultant rapid cooling may also lead to a deterioration of notch tough-
Polarity. Polarity is a definition of the direction of current flow. Positive ness. Therefore, careful control of preheat and interpass temperatures is
polarity (“reverse”) is achieved when the electrode lead is connected to critical.
the positive terminal of the direct current (DC) power supply. The work
lead is connected to the negative terminal. Negative polarity Travel speed. Travel speed, measured in inches per minute, is the rate at
(“straight”) occurs when the electrode is connected to the negative ter- which the electrode is moved relative to the joint. All other variables
minal and the work lead to the positive terminal. Alternating current being equal, travel speed has an inverse effect on the size of the weld
(AC) is not a polarity, but a current type. With AC, the electrode is beads. As the travel speed increases, the weld size will decrease.
alternately positive and negative. Submerged arc is the only process that Extremely low travel speeds may result in reduced penetration, as the
commonly uses either electrode positive or electrode negative polarity arc impinges on a thick layer of molten metal and the weld puddle rolls
for the same type of electrode. AC may also be used. ahead of the arc. Travel speed is a key variable used in computing heat
input; reducing travel speed increases heat input.
For a fixed wire feed speed, a submerged arc electrode will require
more amperage on positive polarity than on negative. For a fixed Wire feed speed. Wire feed speed is a measure of the rate at which the
amperage, it is possible to utilize higher wire feed speeds and deposi- electrode is passed through the welding gun and delivered to the arc.
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Annex II—Standard Welding Procedure Specifications
SHEET METAL
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without Backing
Galvanized Steel SMAW 10–18 gauge E6010 or E6013 As-Welded, with or B2.1-1-011:2002
without Backing
(Continued)
PIPE or PLATE
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Carbon Steel SMAW -3/16 in.–7/8 in.0 E7018 As-Welded, with or B2.1.001-90
without Backing
Carbon Steel SMAW - 1/8 in.–1-1/2 in. E7018 As-Welded or PWHT B2.1-1-016-94R
Carbon Steel SMAW - 1/8 in.–1-1/2 in. E6010 As-Welded or PWHT B2.1-1-017-94R
Carbon Steel GTAW followed by - 1/8 in.–1-1/2 in. ER70S-2 and E7018 As-Welded or PWHT B2.1-1-021-94R
SMAW
Carbon Steel SMAW -1/8 in.–1-1/2 in. E6010* and E7018 As Welded or PWHT B2.1-1-026-94R
Carbon Steel SMAW -1/8 in.–1-1/2 in. E6010 and E7018 As-Welded or PWHT B2.1-1-022-94R
Carbon Steel FCAW, self-shielded -1/8 in.–1-1/2 in. E71T-8 As-Welded B2.1-1-018-94R
Carbon Steel FCAW, self-shielded 1/8 in.–1/2 in. E71T-11 As-Welded B2.1-1-027:1998R
Carbon Steel FCAW, CO2 shielded -1/8 in.–1-1/2 in. E70T-1 or E71T-1 As-Welded B2.1-1-019-94R
Carbon Steel FCAW, Ar-CO2 shielded -1/8 in.–1-1/2 in. E70T-1 or E71T-1 As-Welded or PWHT B2.1-1-020-94
(Continued)
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Standard Welding Procedure Specifications (Continued)
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Base Metal Process Thickness Filler Metal Condition Order No.
Carbon Steel GTAW 3/16 in.–7/8 in.- ER70S-2, -3 As-Welded, with or B2.1.002-90
without Backing
Stainless Steel SMAW -1/8 in.–1-1/2 in. E3XX-XX As-Welded B2.1-8-023-94R
Stainless Steel GTAW 1/16 in.–1-1/2 in. ER3XX As-Welded B2.1-8-024:2001
Stainless Steel GTAW followed by 1/8 in.–1-1/2 in. ER3XX and E3XX-XX As-Welded B2.1-8-025:2001
SMAW
PIPE
Carbon Steel SMAW 1/8 in.–3/4 in. E6010 and E7018 As Welded B2.1-1-201-96
Carbon Steel SMAW 1/8 in.–3/4 in. E6010* and E7018 As Welded B2.1-1-202-96
Carbon Steel SMAW 1/8 in.–3/4 in. E6010 As Welded B2.1-1-203-96
Carbon Steel SMAW 1/8 in.–3/4 in. E6010* As Welded B2.1-1-204-96
Carbon Steel SMAW -1/8 in.–1-1/2 in. E6010 and E7018 As Welded or PWHT B2.1-1-205-96
Carbon Steel SMAW -1/8 in.–1-1/2 in. E6010* and E7018 As Welded or PWHT B2.1-1-206-96
Carbon Steel GTAW -1/8 in.–1-1/2 in. ER70S-2 As-Welded or PWHT B2.1-1-207-96
Carbon Steel SMAW -1/8 in.–1-1/2 in. E7018 As-Welded or PWHT B2.1-1-208-96
Carbon Steel GTAW followed by -1/8 in.–1-1/2 in. ER70S-2 and E7018 As-Welded or PWHT B2.1-1-209-96
SMAW
(Continued)
PIPE (Continued)
Carbon Steel GTAW, consumable insert -1/8 in.–1-1/2 in. INMs-1 and ER70S-2 As-Welded or PWHT B2.1-1-210:2001
Carbon Steel GTAW, consumable insert, -1/8 in.–1-1/2 in. INMs-1, E70S-2, As-Welded or PWHT B2.1-1-211:2001
followed by SMAW and E7018
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Carbon Steel GMAW-S followed by -1/8 in.–1-1/2 in. ER70S-3 and E7XT-1 As-Welded or PWHT B2.1-1-232:2005
FCAW-G
Carbon Steel GMAW-S followed by -1/8 in.–1-1/2 in. ER70S-3 As-Welded or PWHT B2.1-1-233:2005
spray transfer
Carbon Steel FCAW-G -1/8 in.–1-1/2 in. E7XT-X As-Welded or PWHT B2.1-1-234:2005
Carbon Steel GMAW spray transfer -1/8 in.–1-1/2 in. ER70S-3 As-Welded or PWHT B2.1-1-235:2005
Carbon to GTAW -1/16 in.–1-1/2 in. ER309(L) As-Welded B2.1-1/8-227:2002
Stainless Steel
Carbon to SMAW - 1/8 in.–1-1/2 in. E309 (L)-15, -16, -17 As-Welded B2.1-1/8-228:2002
Stainless Steel
Carbon to GTAW followed by - 1/8 in.–1-1/2 in. ER309(L) and As-Welded B2.1-1/8-229:2002
Stainless Steel SMAW E309(L)-15, -16, -17
Carbon to GTAW, consumable insert -1/16 in.–1-1/2 in. IN309 and ER309(L) As-Welded B2.1-1/8-230:2002
Stainless Steel
Carbon to GTAW, consumable insert, - 1/8 in.–1-1/2 in. IN309; ER304 and ER304-15, As-Welded B2.1-1/8-231:2002
Stainless Steel followed by SMAW -16, -17; or ER309(L) and
ER309(L)-15, -16, -17
Cr-Mo Steel GTAW 1/8 in.–3/4 in. ER80S-B2 or ER70S-B2L As-Welded or PWHT** B2.1-4-217:1999
(Continued)
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Standard Welding Procedure Specifications (Continued)
Base Metal Process Thickness Filler Metal Condition Order No.
PIPE (Continued)
Cr-Mo Steel SMAW -1/8 in.–1-1/2 in. E8018-B2 or E7018-B2L As-Welded or PWHT** B2.1-4-218:1999
Cr-Mo Steel GTAW followed by SMAW -1/8 in.–1-1/2 in. ER80S-B2 and E8018-B2 As-Welded or PWHT** B2.1-4-219:1999
Cr-Mo Steel GTAW, consumable insert 1/8 in.–3/4 in. IN515 and ER80S-B2 As-Welded or PWHT** B2.1-4-220:1999
Cr-Mo Steel GTAW, consumable insert, -1/8 in.–1-1/2 in. IN515, ER80S-B2, and As-Welded or PWHT** B2.1-4-221:1999
followed by SMAW E8018-B2
Cr-Mo Steel GTAW 1/8 in.–3/4 in. ER90S-B3 or ER80S-B3L As-Welded or PWHT** B2.1-5A-222:1999
Cr-Mo Steel SMAW -1/8 in.–1-1/2 in. E9018-B3 or E8018-B3L As-Welded or PWHT** B2.1-5A-223:1999
Cr-Mo Steel GTAW followed by SMAW -1/8 in.–1-1/2 in. ER90S-B3 and E9018-B3 As-Welded or PWHT** B2.1-5A-224:1999
Cr-Mo Steel GTAW, consumable insert 1/8 in.–3/4 in. IN521 and ER90S-B3 As-Welded or PWHT** B2.1-5A-225:1999
Cr-Mo Steel GTAW, consumable insert -1/8 in.–1-1/2 in. IN521, ER90S-B3, and As-Welded or PWHT** B2.1-5A-226:1999
followed by SMAW E9018-B3
Stainless Steel GTAW -1/16 in.–1-1/2 in. ER3XX As-Welded B2.1-8-212:2001
Stainless Steel SMAW 1/8 in.–1-1/2 in. E3XX-XX As-Welded B2.1-8-213-97
Stainless Steel GTAW followed by SMAW 1/8 in.–1-1/2 in. ER3XXX and E3XX-XX As-Welded B2.1-8-214:2001
Stainless Steel GTAW, consumable insert 1/8 in.–1-1/2 in. IN3XX and ER3XX As-Welded B2.1-8-215:2001
Stainless Steel GTAW, consumable insert, 1/8 in.–1-1/2 in. IN3XX, ER3XX, As-Welded B2.1-8-216:2001
--`,,```,,,,````-`-`,,`,,`,`,,`---
followed by SMAW and E3XX-XX
*Downhill progression on root pass. All other vertical position passes are uphill.
**≤1/2 in. As-Welded or PWHT.
>1/2 in. PWHT.
--`,,```,,,,````-`-`,,`,,`,`,,`---
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