:

:
-

:
-

:
:
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.

.

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.
50% .
( )
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.
50-300A 10Kw .
DC AC ) (Polarity
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.

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"
. "

SMAW .
. .
.

. 1.5-10 mm

400-2000A DC AC 440 v
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MIG/MAG

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.
MIG/MAG 1950
.

.
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SMAW .

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. "
1.5-2.5 mm . 20Kw .
. MIG
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.
)(GTAW
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( )Argon

.
(Tungsten Inert Gas) TIG

GMAW
.

GTAW
.
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()

Fe3O4

AL2O3 .
:
3/4 Fe3O4 + 2AL --- > 9/4 Fe + AL2O3 + Heat
3Feo + 2AL --- > 3Fe + AL2O3 + Heat
Fe2 O3 + 2AL --- > 2Fe + AL2O3 + Heat

3200C
2200-2400C .
.

 -1
Symbol

Welding Process

SMAW

Shielded Metal Arc Welding

GMAW

Gas Metal Arc Welding (MIG)

FCAW

Flux Cored Arc Welding

SAW

Submerged Arc Welding

EBW

Electron Beam Welding

ESW

Electric Slag Welding

TIC

Tungesten Inert Gas Arc

Welding

GTAW

Gas Tungesten Arc Welding

(TIG)

PAW

Plasma Arc Welding

OFW

Oxy Fuel Welding

MIG

Metal Inert Gas Arc Welding

MAG

Metal active Gas Welding

EGW

Electric Gas Welding



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AWS .

( )10 ( )11

 ( )2

 ( -)3 Fillet

 ( -)4 Fillet

 (-)5

( -)6 Fillet

 ( -)7 Groove Weld

 ( -)8

 ( -)9 Fillet Butt

 ( )10 AWS

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3-4 mm
12 mm
2-3 mm

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1
2
3
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1000 (
1000
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= + -

= + -

= + -

= -

= -

=+

= + -

= -

= + -

E6010 :
60 ( )4280 Kg/cm2 . . AWS

Exx10

DC+

EXX11

AC
DC+

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DCAC

.
.

.

.

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.
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EXX14

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x .

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DC+

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.

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.
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%50

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DCAC

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DCAC

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.

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DCAC

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EXX20 .

EXX20.

.
F
10000 ( " 6
60000 7 70000 )
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17-15

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150-100

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200

160

150

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.
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24 15
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50 100 .
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WPS .

.
ASME IX Boiler and Pressure Vessels Code .

. " WPS .
ASME.IX .

ISO 9000 EN-729

.
.
ASME IX

AWS D.1.1 .
EN729 BS4870 .
API650 API1101 .

 : WPS
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. ASME Sec. IX
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WPS PQR
.
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" WPS
PQR .
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PQR WPS
PQR .
SMAW, SAW ( )4 .
WPS :
- 1 )(Welding Procedure Specification No.
- 2 (Date) WPS
- 3 )(Revisions

- 4
- 5 )(Supporting PQR No.
- 6 ))(Welding process (es

.
)(Type

 ) (Manual
:
.
Manual . FCAW

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WPS.
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WPS .
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.
WPS
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-
-
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(Base Metals)

WPS .


.
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PNo.

WPS PQR P .

Group

No.
. P Gr.

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( )3 PNo. .
Gr-No. . QW-424
QW-422 P-No. ) (Specification & (Type

) Grade ) (Chemical Analysis )(Mechanical Properties

WPS .
)(Thickness Range

ASME
WPS :
1/16

>3/8 - < 1/16

> 3/4 - < 3/8

> 1,1/2 - < 3/4

- 1,1/2
)(Filler Metals

. "
. AWS A5.1 "
.

230-260 C .
AWS A5.5

370-430 C .
120 .

A ( )1 .
B ( )1
AWSA5.5 .
( )1 .
.

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 ( -)1
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Over 4 to 10 max.

4 max

Over 4 to 10 max
Over 2 to 10 max
Over 1 to 5 max
Over 1/2 to 4 max
Over 1/2 to 4 max

4 max
2 max
1 max
1/2 max
1/2 max

Electrode
A5.1
E70XX
A5.5
E70XX
E80XX
E90XX
E100XX
E110XX

FNo

FNo. QW-432 ASME

.
WPS, PQR .
( )2 F-No. .
( F-No. )2

F-No.
1-6

QW
432.1

A1

21-24

432.2

Cu

31-37

432.3

Ni

41-45

432.4

Ti

51

432.5

Zr

61

432.6

71-72

432.7

ANo.

 ANo. . ) ASME (QW-404.5

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WPS .
PAW, GTAW, SMAW

.
ESW, GMAW .
.
.
SAW
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ASME .
ASME SF . ( )3
AWS :

 ( -)3

A5.1
A5.3
A5.4
A5.5
A5.6
A5.7
A5.8 )(Brazing

A5.9

A5.10
A5.11
A5.12 TIG

A5.13
A5.14
A5.15

 A5.16
A5.17 SAW
A5.18 GMAW

A5.19
A5.20
A5.21
A5.22
A5.23 SAW

A5.24

"

) (SFA.No.

( )3 . SFA
.
ASM )]:(AWS No. [Class

DIN, BS, JIS, AWS, ISO , :

A5.1 AWS

E E
Ksi ( (E11013G

":
E60XX, E70XX, E80XX, E90XX, E110XX, E120XX,
:
:EXX1X ) (OH,H,V,F .
:EXX2X - ) (H,F .
:EXX3X - ) (F .

 AWS 8 -0
.
A5.4

)(ASTM

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) . E316 L-16 E310 E304
OFW E G G316
ASTM316.

FCAW, GMAW, SAW,

ASME II-Part C .

):(Size of Electrode
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. :
.

.
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3.25 4
. 4 5
.

 . 2.5
3.25 4 .
- V

.
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4 .
-
3.25 4 5 .
)(Position

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: )(Flat
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: )(Vertical
: )(Over head

1 4 .

 )(Groove Weld
1

 -2 (Fillet Weld)

 -3 Groove

 -4 Fillet

 )4(

1G

1G

1F

1F

2G

2G

2F

2F

3G

5G

3F

2FR

4G

6G

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4F

( )

5F

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( )4 .
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.
. "

.
.
) EGW, ESW , (Stud Welding
QW-406 .
( )): (Postweld Heat Treatment
*( )(Temperature

"
:
)590 C (1100 F
- )650 C (1100-1200 F

 - ) 600 F (315 C .
- 315 C 220 C /hr
220/t .
- 4.6m 140 C
.

-
83 C .
- 260 C/hr . 260/t
.


.
*( )(Time Renge

."

.
*( )(Shielding Gas(es

CO2 Argon ) (Ar-CO2

.
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:
.

*( )(Electrical Characteristic

:
V * I * 60
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Heating Pnt

. 44 48 WPS ( )1
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*( )(Current AC or DC

AD, DC . DC
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AC DC .
AC "

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DC
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DCEP=Direct Current Electrode Positive

-
Negative

DCEN= Direct Current Electrode

 DCEN DCEP .
*( (Technique) :

) ASME (QW-410 .
*( )(String or Weave Bead

.

. .
*( )(Orifice or Gas Cup Size

.
*( ( )
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. .

.
"
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*(

:
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. .

*( )(Travel Speed

"
. .
) (L/T .
*( )(Other

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OFW
- OFW Forhand or Backhand

- EBW

- Multi Electrode

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.


.

.

ASME

ANSI

.
( )5 .
WPS
.
( )6
.
( )7
( )8 .
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A.S.M.E
GTAW

GMAW

SAW

SMAW

X
X
X

X
X

X
X
X

X
X
X

- Gas Backing

Transfer Mode

Current or Polarity

X
X

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X
X

)C Pipe Dia (2
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Inserts

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X
X

X
X
X

G T Qualified
+ Position
C Vert Welding
Progress
C Type Fuel Gas

( )

:
: C
()

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: d ()
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: T
:
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.
- 2 .

 ( )6
ASME

()5

()2

()1

()6

2t

3/8

()7

2t

3/8 3/4

3/4

:
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.
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.
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- 5 .
- .
- .
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.

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 ( ) 6
ASME

()2

()1

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1

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3/8

2t

3/8

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3/4
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6
8 .

-5

D.T .

 ( - )6
A.S.M.E

3/4

3/4 2

7/8 2

( -)6
A.S.M.E

3/16 3/8

2 7/8

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A.S.M.E

-16 -16 -16

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( )

3/4

3/4 2

2 7/8 ()2

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2,7/8- 2 2,1/2 .

 A.S.M.E IX ()
.

A.S.M.E IX QW-152 QW-153

QW-162 .

ASME

IX QW-320
.
QW-320

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8 .
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PQR (Procedure Qualification Report) .

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.
WPS .
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.
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 ( )5 PQR

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EGW, ESW

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)8 )(Tensile test

) (Fillet :
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)4 )(All-Weld Metal tension



10 :
: ASME, Sec IX ) (180
(180)

: AWS, D1.1

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(180)

: BS4870 ) (180 180 ()

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- 2
- 3
- 4
- 5

PQR .

Procedure Qualification

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 PQR" . PQR

WPS

. :
... .
PQR
... . ()3
.

PQR .
PQR . PQR"
.
( PQR )

PQR .
PQR , WPS .

WPS

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PQR WPS .
( )
.




)(Heat Affected Zoon

.

.

.

:

.

 ) (HAZ

.
.
.
" " .

.
:
Mn% Cr Mo V % Ni Cu %

6
5
15

CE C

0/38
0/50
.
190
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.

.

300 .


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.
0/40
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100
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.
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Co
Porosity .

.

.
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.
.

.

.

 Preheating

Preheating .
:
- 1
- 2 ( 19)

- 3
- 4
- 5
.
15 ( .
150 mm )

80 c .



.
WPS
.
Widmanstatten

A.de.Widmanstatten .

:
- 1
- 2 )(Overheating

- 3

Wid. Overheating

0.2-0.4
HAZ .

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Overheating
.

 ( )2

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A3 1000
.
L 1

2 1

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.
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.

 ( )3
.
.

+ Cem

Widmanstatten .

 ( ) 4 Widmanstatten
- .
Widmanstatten
.
( -)1 Widmanstatten
Impact value
)(Kgm/ cm 2
Annealed at
850 c
17.8
15.20
14.60

Tempered
Back
6.40
6.0
5.20

Chemical composition
of Metal
Widmanstatten
structure
3.2
2.35
2.8

Si

Mn

Trace
0.36
0.15

0.32
0.74
0.87

0.19
0.37
0.46

Weld Quality
.

) (Economic ) (Safety .

. "

.
:
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)2 )(Preparation

)3 )(Procedure

.
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.
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( ) .

.
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.

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).


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.

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.

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0/30 0/25

0/45 0/30

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1 3

0/20

0/30 0/20

0/40 0/30

0/40

0/18

0/28 0/18

0/28 0/18

0/38

Mn

Si

0/23

0/060

0/07

32 47

18 22

0/06

0/25

0/05

0/055

0/045

32 47

28 33

0/12

0/50

0/09

0/25

0/15

0/50

0/14

0/40

0/22

0/65

0/18

0/40

0/27

0/70

0/28

0/50

0/37

0/80

0/38

0/50

0/49

0/80

0/50

0/55

0/60

0/85

0/07
0/12 0/30
0/12 0/30
0/15 0/35
0/15 0/35
0/15 0/35

0/055
0/055
0/055
0/055
0/055
0/055

0/045
0/045
0/045
0/045
0/045
0/045

34 42
38 47
42 52
50 62
60 72
70 80

26 31
23 27
21 25
17 21

13 15
9 11

"
HAZ .

.

.

 "
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.

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.
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.
0/40
.

.


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.
100 " 5
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.


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.
.
( 75 200
) .

.
.

 Root Pass

Filling Hot Pass

Cap .
Crack
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.

()LACK OF FUSION
:

-12 .

 OVER LAPPING
( )13 :


( )

-13 .

SPATTER
( )14 :
ARC BLOW

 -14 .

MAGNETIC ARC BLOW

:


LACK OF PENTRATION
( )15 :

-15 .

 UNDER CUTTING
( )16 :




ARC BLOW

-16 .

 -17 .Overlap Under Cut

POROSITY
:


TIG MIG-MAG




TIG MIG-MAG

()DISTORTION

 ()18 :


WPS


( )

-18 .

 ( ) Slag noisulcnI
(

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CRT .

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dB

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I1,I0

P1,P0

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I0,I1 P0/P1
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P V2
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- 1

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- 4

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- 6

- 7

- 8

- 9

-10

 V2
V1
V1
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 -3 ( A.I.C ) Aluminium Industies Concil

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Roughness
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