Focus On Proper Weld Size When Developing Wps Parameter Ranges

FOCUS ON PROPER WELD SIZE WHEN DEVELOPING WPS PARA...
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FOCUS ON PROPER WELD SIZE WHEN DEVELOPING WPS PARAMETER RANGES

By Regis Geisler About the Author: Regis Geisler III is a registered The fabricator and the erector must determine the Professional Engineer, most appropriate range of travel speeds for a Specials Certification particular application, rather than relying blindly on Engineer and AWS If a welder or welding operator wished (or published product certs. However, following the Certified Welding Inspector who has was incented) to maximize his methodology presented here provides another productivity, he may want to decrease his worked the last eleven years at The possible blueprint on how this may be achieved. Lincoln Electric Company, 22800 Saint travel speed. This would be logical from A structural steel fabrication company is preparing for a project that Clair Avenue, Cleveland, OH the welders perspective as it would is to be welded in accordance with the American Welding Society decrease the number of passes required 44117-8542, 216-481-8100, Fax: D1.8 Seismic Supplement and would like to use a .045 in E71T-1 to fill up the joint. 216-486-1751, www.lincolnelectric.com. gas-shielded flux-cored (FCAW-G) wire. This fabricator has the luxury of being able to position the steel so that they can weld in the For questions or comments on this column, contact Regis at downhand position. regis_geisler@lincolnelectric.com. They would like to use a particular manufacturers wire, but the travel speed at which the high/low heat input envelope testing was
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conducted is not listed on their D1.8 certs. They need this to show a travel speed range on their Welding Procedure Specification (WPS). Is there a reason that the travel speeds are not listed?
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Regina says: Although it would be much easier to transfer these travel speeds 1. directly to the WPS, it will be shown shortly that this may not be such November 13, 2012 at 12:22 pm a good idea. Granted, a few straightforward and systematic When you are calculating the weld calculations are required, but there is no reason to be intimidated by penetration do you take the whole numbers or equations in the welding field. diameter of the material thickness or The most recent D1.8 cert for the E71T-1 electrode is shown below half? Thank you. in Table 1. Although not displayed here, both the high heat input and Reply low heat input deposits met the mechanical property requirements of AWS D1.8, including tensile strength, yield strength, elongation and Regis Geisler says: Charpy V-notch impact toughness at 70 deg F. If so desired, the travel speed could be easily determined by rearranging the welding November 19, 2012 at 8:34 pm heat input formula presented in Figure 1. For illustration purposes, the resulting travel speeds for both the high heat input and low heat I assume that you intend to calculate the percent penetration of a weld deposit in input tests are shown in Figure 2. order to determine the strength of a butt joint. This would be applicable for Based on the question posed above, one would assume that it is now appropriate to use the calculations from Figure 2, and hence complete-joint-penetration (CJP) and partial-joint-penetration (PJP) groove display the travel speed range on their WPS as 2.9 ipm to 10.8 ipm. Furthermore, a fabricator or erector may also want to derive a welds and you would use the entire current range of 160 amps to 215 amps from the D1.8 cert. We will through-thickness of the plate rather than half of the thickness. now discuss why caution must be used here.
Table 1. The most recent D1.8 cert for the E71T-1 electrode.
If a welder or welding operator wished (or was incented) to maximize By definition, all CJP joints by definition are supposed to have 100 percent his productivity, he may want to decrease his travel speed. This would be logical from the welders perspective as it would decrease penetration, while PJP joints have less Regis Geisler the number of passes required to fill up the joint. And therefore, he than 100 percent penetration. Lincoln Electric assumes, it would save the company money (or make him more Please keep in mind that this concept is It is quite difficult to deposit a single money) as cleaning and set up time would be reduced. So, according to the travel speed range listed on his WPS, he can use a different than what I talked about in my pass fillet weld in the downhand position June-July 2011 Welding Tips column, greater than 5/16 in with a single travel speed as low as 2.9 ipm. where I discussed the 105 percent vs. electrode without encountering defects Finally, as long as he stayed within the current range of 160 amps to 115 percent penetration of an individual such as trapped slag, overlap, or lack of 215 amps and the voltage range of 24V to 26V listed on the WPS, heroot pass weld bead through the mid-line penetration and/or fusion, because the of a double V-groove CJP weld. Here I arc is riding on the puddle. would then appear to have some justification for using this travel did use the half-thickness of the plate as speed. However, a problem arises with this logic when the my basis to calculate the percent uppermost values of 215 amps and 26 volts are used. Again, a higher wire feed speed would result in higher productivity. penetration of that one particular weld pass into the weld bead on the opposite Figure 3 shows the resulting welding heat input in this scenario. side of the plate. Obviously 116 kJ/in is far too high of a heat input to be used with a cored wire. Some problems that may arise by using a 116 kJ/in heat To illustrate, for 1.50 in plate (with a 0.75 in half-thickness), if the root pass on the input include reduction of the Charpy V-notch impact properties in the weld, softening of the base material in the heat-affected zone second side had 105 percent (HAZ), or lack of penetration and/or fusion (because the arc is riding penetration, the bottom of the weld bead on the puddle). Also, this heat input exceeds the maximum heat input profile would extend approximately .04 in (0.75 in x .05) into the first side of the of the envelope established on the D1.8 cert. Figure 1. Welding heat input formula joint. At 115 percent penetration, the converted to calculate the travel speed Consider the opposite situation. What if the fastest travel speed weld bead extended about .11 in (0.75 in from the welding procedures listed in (10.8 ipm) and the lowest current (160 amps) and voltage (24V) x .15) into the second side. Table 1. settings are used during fabrication or erection? Obviously this will result in a lower welding heat input than the 30 kJ/in value shown on With all of that said, for T-Joint fillet welds the thickness of the base material the D1.8 cert. But why is this important? is generally not a consideration when it The answer to this question boils down to ensuring that the weld comes to determining the strength of the size is large enough (and hence the welding heat input is high joint. As described in the attached enough) relative to the thickness of the plate being welded. Welds document published by the James F. that are too small can contribute to HAZ or underbead cracking. It Lincoln Foundation (which can be found would then be a worthwhile exercise to see just exactly how large at http://www.jflf.org/pdfs/papers Figure 2. Travel speeds calculated from the welds would be with these ultra-low heat input procedures. /design_file3.pdf), any distance that the the welding procedures listed in Table 1. weld bead extends beyond the root is The process of analyzing the weld size begins with determining the added to the theoretical throat. This deposition rate. A quick peek at the literature on this E71T-1 wire distance is termed the effective throat reveals that at a wire feed speed of 275 ipm, a deposition rate of 5.5 and is used to calculate the load carrying lb per hour is yielded. This, combined with the 10.8 ipm travel speed, capacity of the joint. Regards. yields a weld nugget of 0.102 lb per foot as demonstrated in Figure 4. Regis Figure 3. Welding heat input resulting from using the lowest travel speed and It behooves us at this point to harken back to an earlier column Reply the highest current and voltage settings (Pre-Calculating Wire-Feed Speed, Travel Speed and Voltage, from the ranges that one might Welding Tips, November-December 2010) where my colleague Leave a Reply mistakenly extract from the D1.8 cert. Kevin Beardsley discussed pre-calculating a travel speed when the
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deposition rate and desired weld size are known. It can be seen from Name (required) Table 2 (excerpted from that column) that a weld that weighs 0.102 lb per foot is equivalent to a fillet weld with less than a in leg size. Moreover, lets assume that you are welding on mild steel plate with a thickness of in. According to Table 5.8 in the AWS D1.1-2010 Structural Welding Code Steel , the minimum fillet weld leg size required is in. Even if you are not making fillet welds, but rather complete-joint penetration (CJP) groove welds, the concept is still the same the weld nugget should be equivalent to that of a in fillet weld in order to ensure a cooling rate that is sufficiently slow to prevent underbead cracking or other weld defects such as lack of fusion. Therefore, according to Table 2, a in fillet weld with a flat face (and 10 percent overwelded as is customary in shop practice) will have a weld nugget of 0.128 lb per foot. So, if we decide that we actually like how the E71T-1 electrode performs at 275 ipm wire feed speed, 160 amps and 24V, what is the limit on how fast we can travel and still have a weld pass larger than an equivalent in fillet? This is a matter of simply re-arranging the formula shown in Figure 4. In order to ensure that the equivalent of a minimum in fillet weld is deposited, the travel speed can be no faster than the 8.6 ipm as shown in Figure 5. Compare this result with the 10.8 ipm that was extracted from the D1.8 certification testing. Now that we have determined an upper limit on travel speed, what is the thought process for the lower limit on travel speed? How slow is too slow? Mentioned above was the unacceptable scenario where a heat input of 116 kJ/in was obtained when the highest current and voltage settings and the slowest travel speed were utilized based on the ranges extracted directly from the D1.8 certs. For guidance on the largest weld that can be made, one may look to the AWS D1.1 code, which never requires a single pass fillet weld leg size greater than 5/16 in. From a practical standpoint, it is quite difficult to deposit (with a single electrode) a single pass fillet weld in the downhand position greater than 5/16 in without encountering defects such as trapped slag, overlap, or lack of penetration and/or fusion (because the arc is riding on the puddle). Based on this, we will begin the minimum travel speed calculation with a 5/16 in fillet weld as the target. Once again referring to Table 2 above, a flat 5/16 in fillet weld will require a weld nugget of 0.201 lb per foot. Also, a welder may prefer to weld it hot using the 325 ipm wire feed speed (which translates to a deposition rate of 6.5 lb per hour) and 26V setting listed on the D1.8 cert. In order to ensure that the equivalent of a maximum 5/16 in fillet weld is deposited, the travel speed can be no slower than the 6.5 ipm as shown in Figure 6. Compare this result with the 2.9 ipm that was extracted from the D1.8 certification testing. We have achieved our ultimate goal of constructing a conservative travel speed range of 6.5 ipm to 8.6 ipm that increases the chances of depositing a sound weld. The range of 2.9 ipm to 10.8 ipm that could be extracted from the D1.8 certs may misapplied in a worst case scenario. This is the primary reason that the travel speeds are not listed on this manufacturers D1.8 certs. In the end, it is up to the fabricator and the erector to determine the most appropriate range of travel speeds for a particular application, rather than relying blindly on published product certs. Following the methodology presented above provides one possible blueprint on how this may be achieved. Email (required) (will not be published) Figure 5. Calculation of the recommended travel speed with a wire feed speed of 275 ipm and and a voltage of 24V if a minimum in weld size is to be obtained.
Figure 4. Pounds per linear foot of weld determined from the lowest travel speed and the highest current and voltage settings from ranges that one might mistakenly extract from the D1.8 cert.
Table 2. Bartonian Conversion Factor
Figure 6. Calculation of the recommended travel speed with a wire feed speed of 325 ipm and voltage of 26V if a maximum 5/16 in weld size is to be obtained.
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