American Welding Society Chattanooga Section

Welding Contest Rules and Score Sheet 2012

Rules: 1. Be Safe & Have Fun 2. Can tack in any position but groove welding must be in accordance with your WPS. 3. Can use wire brush, chipping hammer, and grinder. 4. Cannot use new pieces (only the material given to you). 5. Direct any questions to the closest proctor. 6. Coupon must be in specified position while welding (except tacking). If you have questions about the correct position, refer to the WPS in your package. Disqualification: 1. Poor attitude toward any of the other students, instructors, or judges. 2. Failure to use personal protective equipment (PPE). Zero Score: 1. Welding in the wrong position or wrong technique (i.e. stringer vs. weave). 2. Any crack shall be unacceptable, regardless of size or location. 3. Incomplete fusion

A copy of the welding procedure specification (WPS) has been provided in your packet. Be sure to read it thoroughly to be certain you comply with the welding instructions given in the WPS.

AWS CHATTANOOGA SECTION

Welding Procedure Specification (WPS)
In Accordance with AWS Structural Steel Welding Code D1.1-2008

WPS Name: CHA-08-1.1-2G

Rev 0

March 15, 2010

SMAW-MA

___________________________________ JOINT DESIGN Type: Single V Butt Backing: No Root Opening: 1/8 Root Face: 1/8 Groove Angle: 75 Included Back Gouging: No ___________________________________ BASE METAL Material Spec: ASTM A36 Thickness: 3/8 ___________________________________ FILLER METAL AWS Spec: AWS Class: Diameter: A5.1 E6010 / E7018 1/8 and 3/32

________________________________ POSITION Position of Groove 2G

________________________________ ELECTRICAL CHARACTERISTICS Current: DCEP Amps Root: 75 - 95 Amps Fill & Cap: 80 - 100 ________________________________ TECHNIQUE Stringer or Weave: Multi or Single Pass: Number of Electrodes: Peening: Interpass Cleaning: Stringer Multipass One None Grinder Wire Brush Chipping

___________________________________ PREHEAT Preheat Temp: Ambient >32F Max Interpass Temp: 350F

________________________________ POSTWELD HEAT TREATMENT Temperature: None

Pass or Weld Layer(s) Root Fill & Cap

Filler Metal Process SMAW SMAW Class E6010 E7018 Dia. 1/8 3/32

Current Type & Amps Polarity DCEP DCEP 75-95

Joint Details

See Contest Drawing 80-100

THIS PROCEDURE WAS QUALIFIED IN ACCORDANCE WITH D1.1-2008 FOR THE SOLE PUROPOSE OF PROVIDING A QUALIFIED PROCEDURE TO THE STUDENTS PARTICIPATING IN THE CHATTANOOGA AWS WELDING CONTEST. THIS DOCUMENT SHALL NOT BE DISTRIBUTED OUTSIDE OF THE AWS DISTRICT 08 CHATTANOOGA SECTION AND SHALL NOT BE USED FOR ACTUAL PRODUCTION OR CONSTRUCTION.

AWS CHATTANOOGA SECTION

Procedure Qualification Record (PQR)
In Accordance with AWS Structural Steel Welding Code D1.1-2008

WPS Name: CHA-08-1.1H PQR Name: CHA-08-1.1-2G

Revision 0 March 15, 2010 Rev 0 March 15, 2010

SMAW-MA SMAW-MA

___________________________________ JOINT DESIGN Type: Single V Butt Backing: None Root Opening: 1/8 Root Face: 1/8 Groove Angle: 37.5 (75 Included) Back Gouging: No ___________________________________ BASE METAL Material Spec: ASTM A36 Thickness: 3/8 Group No.: I ___________________________________ FILLER METAL AWS Spec: AWS Class: Diameter: A5.1 E6010 / E7018 1/8 / 3/32

________________________________ POSITION Position of Groove 2G

________________________________ ELECTRICAL CHARACTERISTICS Current: DCEP Amps Root: 80 Amps Fill & Cap: 85 ________________________________ TECHNIQUE Stringer or Weave: Multi or Single Pass: Number of Electrodes: Peening: Interpass Cleaning: Stringer Multipass One None Grinder Wire Brush Chipping

___________________________________ PREHEAT Preheat Temp: Max Interpass Temp: Ambient >32F 350F

________________________________ POSTWELD HEAT TREATMENT

Temperature:

None

Tensile Test Stress (KSI)

75.68 78.57

Bend Test Type

Side

Failure Location
Weld Weld

Number
4

Result
Satisfactory

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 AWS D1.1-2008. Date: March 15, 2010

Dusti Jones Chattanooga Section Chair

THIS PROCEDURE WAS QUALIFIED IN ACCORDANCE WITH D1.1-2008 FOR THE SOLE PUROPOSE OF PROVIDING A QUALIFIED PROCEDURE TO THE STUDENTS PARTICIPATING IN THE CHATTANOOGA AWS WELDING CONTEST. THIS DOCUMENT SHALL NOT BE DISTRIBUTED OUTSIDE OF THE AWS DISTRICT 08 CHATTANOOGA SECTION AND SHALL NOT BE USED FOR ACTUAL PRODUCTION OR CONSTRUCTION.

SMAW
1/8" 75

1/8"

1 Once coupon is tacked in position it cannot be removed. 2 All welding must be done with stringer beads. 3 Weld reinforcement and melt-through must be 1/8" max. 4 Welds should be free of undercut. 5 Clean weld area of millscale, rust & ect. 6 Weld cap and bring to inspectors. 7 The root and cap surfaces must be inspected before bend specimen removal

American Welding Society Chattanooga Section

Radius 1/8" max Face Bend Specimen Root Bend Specimen

1" 1 1/2"

1"

1 1/2"

1 All weld reinforcement must be removed flush with surface of the specimen. 2 Edges of the bend samples may have a 1/8" max radius. 3 Identify the root and face side of the test plate before removing any reinforcement

American Welding Society Chattanooga Section

Test Plate - Bend Specimen Removal

Score Sheet Name: ______________________ Contestant Number: __________

Scoring is based on a scale: zero is the lowest possible score and 5, 10, or 20 are the highest scores possible depending on category being evaluated. Measurements outside of the code requirements will result in a zero score for that category. Category Weight Score D1.1 Comments / Notes

Crater Fills
< 1/8

Be sure to get your visual inspection, of the completed plate performed before you grind or remove any bends!
0 10 0 10 0 10 05 0 10 05

Weld Reinforcement Weld Profile

(Fig 5.4) < 1/32

if > 1/8 score = 0

Undercut

Melt Through

if > 1/32 score = 0

Root Concavity 1/16 max allowed Max melt through < 1/8 If outside the limits score = 0

Porosity

See details below

Weave consistency / 0 10 stringer bead tie-in Overall Appearance - Uniformity of thickness - Base metal tie-in 0 20 - Restarts - Overlap (Cold Lap) You will need to come back to the judges table for inspection of your bends. Root & Face Bends 0 20 Points will be decided based If your bends on the number of open fail, you discontinuities in the bends cannot place

Blue Text summarizes the requirements of AWS D1.1 Porosity Details No visible piping porosity. The sum of the porosity 1/32 or greater shall be less than 3/8 total in any linear inch. Not to exceed 3/4" in the length of the plate.

Judge 2 Category Weight Score D1.1 Comments / Notes

Crater Fills
< 1/8

Be sure to get your visual inspection, of the completed plate performed before you grind or remove any bends!
0 10 0 10 0 10 05 0 10 05

Weld Reinforcement Weld Profile

(Fig 5.4) < 1/32

if > 1/8 score = 0

Undercut

Melt Through

if > 1/32 score = 0

Root Concavity 1/16 max allowed Max melt through < 1/8 If outside the limits score = 0

Porosity

See details below

Weave consistency / 0 10 stringer bead tie-in Overall Appearance - Uniformity of thickness - Base metal tie-in 0 20 - Restarts - Overlap (Cold Lap) You will need to come back to the judges table for inspection of your bends. 0 20 Root & Face Bends Points will be decided based If your bends on the number of open fail, you discontinuities in the bends cannot place

Blue Text summarizes the requirements of AWS D1.1 Porosity Details No visible piping porosity. The sum of the porosity 1/32 or greater shall be less than 3/8 total in any linear inch. Not to exceed 3/4" in the length of the plate.

Judge 3 Category Weight Score D1.1 Comments / Notes

Crater Fills
< 1/8

Be sure to get your visual inspection, of the completed plate performed before you grind or remove any bends!
0 10 0 10 0 10 05 0 10 05

Weld Reinforcement Weld Profile

(Fig 5.4) < 1/32

if > 1/8 score = 0

Undercut

Melt Through

if > 1/32 score = 0

Root Concavity 1/16 max allowed Max melt through < 1/8 If outside the limits score = 0

Porosity

See details below

Weave consistency / 0 10 stringer bead tie-in Overall Appearance - Uniformity of thickness - Base metal tie-in 0 20 - Restarts - Overlap (Cold Lap) You will need to come back to the judges table for inspection of your bends. 0 20 Root & Face Bends Points will be decided based If your bends on the number of open fail, you discontinuities in the bends cannot place

Blue Text summarizes the requirements of AWS D1.1 Porosity Details No visible piping porosity. The sum of the porosity 1/32 or greater shall be less than 3/8 total in any linear inch. Not to exceed 3/4" in the length of the plate.