An Introduction To ASME Section IX

An Introduction to ASME Section IX
ASME IX
For the benefit of business and people

- Copyright Bureau Veritas
Bureau Veritas Presentation _ Date
Welding Technology: Welding, Fabrication and

Inspection (AWS, ASME and API Codes)
Applied Welding Technology
Why Weld?
Metal Structures can be made in several ways
Cast
Fabricate
Castings can weigh 3 to 4 times as much as a fabrication - economics and limited by scale
Why Weld?
Metal Structures can be made in several ways
Forgings - can also be large and heavy but size is limited by the
capacity of the forging press.

Extrusions tend to be of a specific shape. Tool wear limits the
materials that can be extruded.
Sintered Components tend to be small and of high value.
Prototyping uses Lasers and metal powders to build a component.
Limited to high value items.
Fabrication
We can fabricate using rivetting, bolting or welding
Compare:
Rivetting
Bolting
Or We Can WELD
What is a WELD?
Definition:
A localised coalescence of metals or non-metals produced either by

heating the material to the welding temperature with or without the
application of pressure or by the application of pressure alone and with or
without the use of a filler metal.
Welding
It is therefore a special process
It brings together the disciplines of design, metallurgy, process and inspection
It is probably one of the most governed activities in the world
Governed by National and International Codes and Client/Customer Specifications
Metal Joining and Cutting Processes
Three Basic Groups:
Welding
Cutting
Brazing
Well over 100 different processes with new process being developed - especially
hybrids.
10
Coverage of Processes
For the more common processes we will discuss:
Advantages
Limitations
Techniques and filler metals will be discussed later
11
Welding Processes to be Discussed

Shielded Metal Arc Welding - SMAW (or MMAW)
Gas Tungsten Arc Welding - GTAW (or TIG)
Gas Metal Arc Welding - GMAW (or MIG/MAG)
Flux Cored Arc Welding - FCAW
Submerged Arc Welding SAW
Special Welding Processes
12
Shielded Metal Arc Welding
13
SMAW Equipment
Simple Circuit Diagram for SMAW

14
SMAW Equipment
15
SMAW Advantages
Simple equipment smaller diameter electrodes can use single phase
240 V AC power.
Inexpensive and long lasting equipment
Very portable Modern Inverters weigh only a few kilograms
A large range of alloys is available, including alloy steels, stainless
steels, cast irons, hard-facing alloys, etc.
High quality welds
16
SMAW Limitations
Requires a degree of welder skill, especially for positional work
Relatively slow i.e. low deposit rate due to low duty cycle (Arc running
time as a % age of total time)

Can require strict control on electrode storage and preparation for
welding
A degree of fume is produced
The slag must be removed
17
SMAW - Effect of Current

Can use:
AC current, DC electrode +ve and DC electrode -ve
DC Straight or DC Reversed Polarity are not recommended - can mean
different things and very confusing.
Welding with AC transformers :
Cheapest for equipment and is very robust
Suffers less from arc blow
Good heat balance between electrode and workpiece
Generally operates on higher open circuit voltage
18

Welding with DC transformer-rectifier or converters (engine driven):
Unbalanced heat between electrode and workpiece
Suffers more from arc blow
Generally operates on lower open circuit voltage
For DC Electrode -ve :

More heat developed at electrode, increases melt-off
rate
Less arc penetration into workpiece

Less dilution of base metal
Good for surfacing
19

For DC Electrode +ve:
More heat developed at workpiece, decreased melt-off rate
More arc penetration into workpiece
More dilution of base metal
DC Electrode +ve is probably the most common method of welding with

covered electrodes.
20
Gas Tungsten Arc Welding
21
GTAW Equipment
22
GTAW Equipment
Equipment can be simple and cost effective or expensive, it depends upon the
application!
23
GTAW - DC Heat Balance
DC electrode -ve is common method for ferrous alloys

24
GTAW Electrodes
25
GTAW Electrodes
Pure Tungsten - General Purpose AC electrode primarily used for Al,
Mg, Ni and their alloys.

Thoriated - Standard DC electrode for TIG and plasma welding.
Thorium is a radioactive element.
Ceriated - Similar to thoriated in performance but thoria-free. For DC
TIG or plasma welding Ni, Mo, Ti, Cu, Ta and their alloys. A good
replacement for Thoriated.
Lanthanated - An AC/DC electrode for plasma cutting, welding and
spray applications.
Zirconiated - Very similar to the pure tungsten but with better overall
performance.
26
GTAW Electrodes
Point shape - Usually ground to a point but in AC and DC + ve the electrode will ball up.
Point shape - For thoriated, use a purpose - built grinder to collect dust particles.
27
GTAW Advantages
High quality welds in almost all metals and alloys
Good control of current - good for thin materials
Very little, if any, post weld cleaning is required
Arc and weld pool clearly visible to the welder
No filler metal carried across the arc therefore little or no spatter
No slag produced that might be trapped in the weld.
All positional
Mechanisation Can be used with automatic hot or cold wire feed or
fusion only
28
GTAW Limitations
Very low deposition rate - slow process
Two handed operation
Skill level is high, especially root runs and in position.
Needs protection from the environment
Low tolerance for contamination
Equipment is similar but more expensive than SMAW
29
GTAW
Be careful to avoid tungsten inclusions in weld
Avoid using scratch start power sources, especially for aluminium
Consider using lift start or HF start
30
Gas Metal Arc Welding
31
GMAW Equipment
Equipment becomes more complex
32
GMAW Transfer Modes
Factors affecting transfer mode includes shielding gas, current, voltage and power
supply
33
GMAW - Spray Transfer
High current - good penetration and high

deposition.
Droplet size << than wire diameter.
Droplets pinched and forced through arc.
Positional for aluminium (with pulse.)
Flat of H/V for other metals.
34
GMAW - Spray Transfer
35
GMAW - Globular Transfer
High current with CO2
Droplet size than wire diameter
36
GMAW - Globular Transfer
37
GMAW - Dip Transfer
Low current, dilution and penetration

Droplet size > than wire diameter
Wire contacts workpiece and resistance heating at

A to DM
Droplet transferred across arc at D to F
Arc extinguished at H and wire moves to re-contact workpiece at I.

All positional but metal must have high electrical resistance.
38
GMAW - Dip Transfer
39
GMAW - Pulsed Transfer
1 droplet transferred at each pulse
Spray transfer achieved at low currents - thin

materials
Low heat input
Suitable for most metals
40
GMAW Transfer Modes
Typical operating ranges for Spray,

Dip and Pulse transfer with 1.2 mm
diameter wire
41
GMAW Advantages
High productivity
No slag to remove
Clean process
Welds most alloys
Lowest hydrogen potential of all processes
Continuous wire feed - semi automatic
42
GMAW Limitations
Unsuitable for windy conditions
Usually limited to shop welding
Little tolerance for contamination
Equipment more complex
Suffers from inherent weld defects

(Welder training issue - discussed later)
43
GMAW Wire Feed Units
Many types of feed systems, chose one that is

appropriate to the work intended.
Spool mounted on gun or push-pull

system
2 or 4 roll drives
44
Flux Cored Arc Welding
2 main types of FCAW
Self shielded or gas shielded
Equipment similar/same as GMAW
45
FCAW Advantages
High Productivity
Tolerates contamination
High current density, deep penetration especially with DC electrode
+ve.
Suitable for field work, especially self shielded.
Sometimes the only method of obtaining semi-automatic welding with
high alloys, especially surfacing materials.
Combines advantages of GMAW and SMAW without inherent defects.
46
FCAW Limitations
Slag to be removed
Fumes are produced
Higher cost of consumables
Equipment can be more complex
47
Metal Cored Arc Welding
A derivative of Flux Cored Arc welding
No flux used - core filled with metal powders
Does not suffer from GMAW inherent defects with same penetration properties as
FCAW.
48
Submerged Arc Welding
49
Sub-arc Equipment
50
Sub-arc Advantages
High deposition rate
Deep penetration
Automatic process
Good for surfacing
Can use alloy fluxes - but critical voltage dependency
51
Sub-arc Deposition Rates
Welding deposition rates for SAW
52
Sub-arc Limitations
Mainly Flat but horizontal has been used
High set-up time
Needs positioning/rotating equipment
Arc is not visible
High heat input - not suitable for thin materials, aluminium, single phase
and quenched and tempered steels.

Needs slag removal
Needs flux drying, delivery and recovery systems
Defects can be large i.e. lack of fusion or slag lines
53
Special Welding Process
There are variations of the processes discussed
Many hybrid process being developed
Many other special welding process
There are too many to cover in this course but some can be mentioned
54
Plasma Arc Welding

Equipment can be complex but low cost units are now available which run on compressed
air.
55
Electroslag Welding
56
Electrogas Welding
57
High Energy Processes
Electron Beam
High Vacuum Electron Beam
58
Laser Processing
A LASER is a device that amplifies light
Light
Amplification by
Stimulated
Emission of
Radiation
Lasers come in a great variety of forms, using many different materials, many different
systems and many different excitation mechanisms.
59
Laser Processing
60
Power Sources for Arc Welding
Will limit discussion to three most common types:

Transformer
Transformer /rectifier
Inverter - solid state
61
Main Components of a Power Source
Transformer
Rectifier
Inductor
High Frequency unit or Capacitor Discharge (GTAW)
Protection System for overheating and over current
Burn-back
Cooling fan or oil
Enclosure
62
Transformer
Simple operation
V1/V2 = A2/A1
Many types including movable shunt, centre tap,
single phase and 3 phase etc.
Cost increases with complexity
AC current only
63
Transformer Rectifier
64
Arc Characteristics
Constant current
Constant voltage
CC/CV inverters
65
Constant Current
66
Constant Current
Manual welding has poor control of arc length
When arc length is increased or decreased, the arc energy remains fairly constant and
therefore electrode melt-off rate remains constant as does the heat of the arc
Especially true when using equipment with high open circuit voltage
SMAW and GTAW typically use constant current arc control
67
Constant Voltage
68
Constant Voltage
Typical arc control for semi automatic and automatic processes.
These process could use CC but would need voltage sensing device to control wire
feed rate to keep arc length constant.
Prior to electronic control, sensing was limited to supply frequency and feed motor
could not react fast enough.
Controls arc length by adjusting melt-off rate
Current and heat are not constant
69
Inverters
70
Inverters
Solid state units
Compact, portable and large weight saving
High frequency of operation
Combines best features of CC and CV units
71
Duty Cycle
The permissible temperature rises in a transformer

without harming the insulation.
72
Arc Blow
The result of magnetic disturbances (including residual) which forcibly directs the arc
away from the point of welding
Ends of ferromagnetic
workpiece
Location of lead
Edge of steel plate

73
Arc Blow
Cannot always be elimimated, but may be controlled or reduced
Change from DC to AC
Use short arc technique
Reduce welding current or voltage
Use heavy tack welds at either end and intermittent tacks along length
Angle electrode in the direction opposite to the arc blow
Weld towards heavy tack or completed weld
74
Arc Blow
Use backstep technique

Attach work cable to both ends of the joint to be welded
Extend end of joint by attaching run-off plates
Bridge joint in piping
Wrap cable round workpiece and pass current through it - try winding both ways - aim
to neutralise the residual magnetism
Can try magnetic particle yoke
75
Cutting Processes
Oxy-Fuel Gas Cutting
Plasma Cutting
Carbon Arc Cutting
(more often for gouging)
Laser Beam Cutting
Water Jet Cutting
Mechanical
76
Oxy-Fuel Gas Cutting
Uses same basic set-up as Oxyfuel welding

Can be used for gouging
Generally limited to carbon steels in a wide range of
thicknesses
Can be mechanised
Needs fluxing or abrasive powder additions to cut other
metals
DO NOT USE CUTTING HEAD TO PREHEAT WELD JOINTS
77
Plasma Arc Cutting
More expensive than Oxy-Fuel

Small systems using compressed air as plasma
gas are available
Cuts most metals
Can inject water to supplement superheat or
shroud to minimise noise, fume etc.
Can submerge workpiece in water to minimise width of the HAZ and distortion.
78
Carbon Arc Cutting
Uses same equipment as SMAW but needs

higher power i.e. 600 - 800A power sources are
better
Can cut most metals
Can be automated
High fume and noise
Carburises cut surfaces
*Fire Hazard*
79
Laser Cutting
High speed cutting
Can cut most materials
Equipment is expensive
80
X* = Process applicable with special techniques

This table should be used only as a very general guide
81
Water Jet Cutting
High velocity water jet - large

expensive installations.
Can cut range of non
metallics up to about 9 mm.
Can cut metals but limited.
Better with Garnet feed.
No thermal distortion of cut
material
Relatively slow
Noise problem
82
Mechanical Cutting
Grinding
Sawing
As with Water Jet cutting there is no heat from an arc
Ideal when there is a need to preserve the metallurgical structure or for cutting nonmetals.
83
THANK
YOU
84

ASME IX
Welding and Brazing Qualifications

ASME IX
Qualification standard for Welding and Brazing

Produced by ASME subcommittee on welding
Applicable to any section of the ASME Boiler and
Pressure Vessel code
Also applicable to ASME B31: code for Pressure Piping
ASME IX
There are 3 principal documents in the ASME System:1. WPS Welding Procedure Specification
2. PQR Procedure Qualification Record
3. Welder Qualification Record
ASME IX
Welding Procedure Specification

The Code user must describe on a WPS the details to
guide the welder on how each weld is to be made.
The WPS shall specify an allowable range for each
variable.
The WPS shall be used to provide direction for the
welder and to control each of the variables for each
welding process used.
ASME IX
Procedure Qualification Record
The PQR documents the actual parameters used
during the test.
The Code user may perform the required mechanical
tests, or testing may be subcontracted to a testing
lab. The PQR is intended to prove weld ability of the
base metal, filler metal, and welding process
combinations.
The Code user in each case must certify the PQR
thereby accepting responsibility for the results.
ASME IX
A WPS must address all VARIABLES
What is a Variable? It is any change that may affect the
properties of the welded joint. The ASME System
identifies 3 types of variable:
Essential
Non-Essential
Supplementary
ASME IX

Essential Variables are those that if changed outside
specific limits, affect the mechanical properties of a
joint to such an extent that re-qualification of the
procedure becomes necessary.
Non-essential Variables are those that can be changed
without affecting the mechanical properties. A new or
revised WPS needs to be established but not a new PQR.
ASME IX

Supplementary essential variables are invoked when
notch toughness is specified and impact tests are
required as part of the procedure qualification test.
ASME IX
Each Manufacturer (Code user) shall prepare
written WPS
QW - 200.1(a) A WPS is a written, qualified, document
prepared to provide direction for making
production welds to code requirements
QW - 200.1(b) The completed WPS shall describe all of
the essential, nonessential and
supplementary essential variables
for each process used in the WPS. The
WPS shall reference the supporting
Procedure Qualification Record(s) PQR.
QW - 200.1
ASME IX

How do you know what are Essential, Non-essential and
Supplementary variables?
If you start with QW 400, Variables, and start reading, it
will not make much sense. You need to start with QW 250
through to QW 290. these detail the variables per process,
and you only need to read those sections in QW 400 that
are applicable.
10
ASME IX
QW 402
Joints
QW 402.1 A change in the type of groove (veeGroove, U-groove, single-bevel, double-bevel, etc.).
QW 402.2 The addition or deletion of a backing.
QW 402.3 a change in the nominal composition of the
backing
QW - 402.4 The deletion of the backing in single-welded
groove welds Double-welded groove welds
are considered welding with backing.
QW 402.5 The addition of a backing or a change in its
nominal composition.
11
ASME IX
12
ASME IX
QW 403.6 The minimum base metal thickness qualified

is the thickness of the test coupon T or 5/8 in (16 mm),
whichever is less. However, where T is less than in (6
mm), the minimum thickness qualified is T. This
limitation dose not apply when a WPS is qualified with a
PWHT above the upper transformation temperature or
when an austenitic material is solution annealed after
welding.
13
ASME IX
QW 403.8 A change in base metal thickness beyond the

range qualified in QW-451, except as otherwise permitted
by QW-202.4(b)
QW-403.9 For single-pass or multipass welding in which
any pass is greater than in. (13 mm) thick, an increase
in base metal thickness beyond 1.1 times that of the
qualification test coupon.
14
ASME IX
Qw-403.10 For the short-circuiting transfer mode of the
gas metal-arc process, when the qualification test coupon
thickness is less than in. (13 mm), an increase in
thickness beyond 1.1 times that of the qualification test
coupon. For thicknesses of in. (13mm) and greater, use
table QW-451.1 or table QW-451.2, as applicable.
QW-403.11 Base metal specified in the WPS shall be
qualified by a procedure qualification test that was made
using base metals in accordance with QW-424.
15
ASME IX

QW - 200.2(c)
Changes to the PQR are not

permitted, except editorial
corrections or an addendum to
reflect Code changes. If
substantiated as having been part of
the original qualification by
laboratory record or similar data,
additional information may be added
to the PQR.
16
ASME IX
QW - 200.2(d)
The information required to be in a

PQR may be in any format, provided
every essential and, when required
supplementary essential variable,
specified by QW- 250 through QW
280 (Table 3.3, QW - 253 for SMAW)
is included. The type, number, and
results of the tests shall also be
recorded in the PQR
17
ASME IX

It is presupposed that the welder or welding operator
performing the welding procedure qualification test is a
skilled workman.
That is, the welding procedure qualification test
establishes the properties of the weld and HAZ, not the
skill of the welder or welding operator.
18
ASME IX
Welder Performance Qualification

The basic criterion established for welder
qualification is to determine the welders ability to
deposit sound weld metal.
The purpose of the performance qualification test for
the welding operator is to determine the welding
operators ability to operate mechanical welding
equipment.
19
ASME IX
Revisions
Qualification of new Welding Procedure Specifications or
Welders/Welding Operators and re-qualification of
existing
Welding
Procedure
Specifications
or
Welders/Welding Operators shall be in accordance with
the current Edition (see Foreword) and Addenda of
Section IX.
WPSs and PQRs to older editions are still valid!
20
ASME IX
Revisions
It is recommended that the Code user review each
Edition and Addenda of the Code as they are issued.
Code users should address all technically sound new
requirements.
Code users should consider re-qualification of PQRs and
WQRs as variables are revised or added, although Section
IX does not require this.
21
ASME IX
Materials
In order to prevent duplication of essentially similar
tests, Base metals are grouped according to P numbers
for the purposes of qualification.
These P numbers are listed in QW/QB 422
Materials are listed under ASTM numbers
ASTM A 516 Gr 70
ASME adopts ASTM numbers and adds an S
SA 516 Gr 70
22
ASME IX
P Numbers
If base metals have specific impact properties, a Group
number is assigned within the P number SA 182 Gr F12
= P no. 4 Group no. 1
QW/QB 422 also lists material UNS Numbers
All materials with same UNS Number are considered to
be same P No. even if not listed in QW/QB 422
Procedures qualified to 1971 edition are valid to 1974
and later editions where P and Group nos may have
changed
23
ASME IX
S Numbers
S- Numbers are non mandatory
S numbers are listed for materials acceptable to ASME

B31 Pressure Piping or selected Boiler and pressure
Vessel Code Cases.
S numbers are also combined with Group numbers

A211 Gr A570-30 = S no. 1, Group no. 1
24
ASME IX
P Numbers
Material grouped under one P number or P number plus
Group no qualifies all other materials under same P
number (and Group number) or S no. and Group no.
Material grouped under one S number or S no plus
Group no qualifies all other materials under same S no
(and Group no.)
Material qualified under S numbers do not qualify P
number materials.
25
ASME IX
26
ASME IX
27
ASME IX
F Numbers
F - Numbers group electrodes and welding rods
according to usability characteristics.
Determines the welders ability to make satisfactory
welds with a given filler metal.
Used to reduce the number of welding procedure and
qualification tests.
Does not imply indiscriminate substitution. Metallurgical
properties, design, post weld heat treatment and
mechanical properties must be considered.
28
ASME IX
29
ASME IX
30
ASME IX
A Numbers
QW 440 Weld metal chemical composition
Applies only to ferrous metals
Needs to be designated on WPS and PQR (as per QW 404.5)
31
ASME IX
32
ASME IX
Post Weld Heat Treatment
QW-407.1 A separate procedure qualification is required
for each of the following conditions.
a. For P-No. 1, P-No. 3, P-No. 4, P-No. 5, P-No. 6, P- No.
9, P-No. 10, and P-No. 11 materials, the following post
weld heat treatment conditions apply:
1. No PWHT
2. PWHT below the lower transformation temperature
3. PWHT above the upper transformation temperature
(e.g., normalizing)
33
ASME IX
4. PWHT above the upper transformation temperature
followed by heat treatment below the lower
transformation temperature (e.g., normalizing or
quenching followed by tempering);
5. PWHT between the upper and lower transformation
temperatures.
b. For all other materials, the following post weld heat
treatment conditions apply:
1. No PWHT
2. PWHT within a specified temperature range
34
ASME IX
ASME IX specifies minimum holding temperature and
minimum holding time.
When using application Codes such as ASME VIII Division 1,
also need to consider:
Heating rate
Cooling rate
Method (local or furnace, resistance or induction if
local)
Control
Insulation
Thermocouple number and position
35
ASME IX
Preheat
Preheat temperature depends on:
Welding process and heat input
Chemical composition
Degree of restraint
Material thickness
Elevated temperature properties
Low temperature properties
36
ASME IX
Preheat Variables - QW 406
QW-406.1 A decrease of more than 56C in the preheat
temperature qualified. The minimum temperature for
welding shall be specified in the WPS.
QW-406.2 A change in the maintenance or reduction of
preheat upon completion of welding prior to any required
post weld heat treatment.
QW-406.3 An increase of more than 56C in the maximum
interpass temperature recorded on the PQR.
37
THANK
YOU
38
SECTION IX
Welders Qualifications / Essential Variables
We will discuss all of the welders essential

variables listed in QW-353 for the SMAW
process. So here goes, turn to page 52 of
Section IX.
QW-353
Shielded Metal-Arc Welding (SMAW)
Essential Variables
Brief of Variables
Paragraph
QW 402
Joints
QW 403
Base Metals
QW 404
Filler Metals
QW 405
Positions
.4
Deletion of Backing
.16
.18
Change Pipe Diameter

Change in P Number
.15
.30
Change in F Number
Change in weld t deposited
.1
.3
Addition of a position
Change from vertical Up to Down
or Down to UP progression
QW-353
Welder Essential Variables
The first essential variable listed is Backing (Removal of).
If a welder is qualified using any type of backing, and asked
to perform an open root weld he must retest without backing
to be qualified to perform the welding.
The Code definition of backing is welding with a backing bar
or retainer, welding double sided welds where the weld metal
of the first pass is used after gouging/grinding as weld metal
backing for the balance of the weld.
Fillet and partial penetration welds are also considered
welding with backing.
QW-353
The next inline is change in Pipe Diameter
qualified. As pipe diameters become smaller the
difficulty for a welder is increased resulting in a
higher skill level requirement.
So this translates to a change in diameter to one
smaller than qualified by the welders pipe
coupon on a previous test with this process.
The ranges of pipe diameters qualified are given
in Section IX, turn to page 143 in Section IX.
QW-452.3 GROOVE-WELD DIAMETER LIMITS

As we can see:
1. Under 1 inch (25mm) qualifies the diameter
down to the size welded to unlimited
diameter, because it is only easier for the
welder as the diameter of the Pipe welded
increases.
2. From 1 inch (25mm) to 2-7/8 inch (73mm)
qualifies 1 inch to unlimited.
3. Over 2-7/8 inch (73mm) qualifies 2-7/8 inch
to unlimited.
Quiz
1. If a welder qualified on a NPS 6 inch pipe
coupon the range of diameter qualifications
in production with the WPS he tested to will
be _________.
2. If tested with a NPS 2 inch coupon what is
his minimum and maximum diameter range
is ________
Quiz
1. If a welder qualified on a NPS 6 inch pipe
coupon the range of diameter qualifications
in production with the WPS he tested to will
be 2-7/8 to unlimited.
2. If tested with a NPS 2 inch coupon what is
his minimum and maximum diameter range
is 1 to unlimited.
QW-353
P-Numbers. P-Numbers serve to group metals
by mechanical and chemical properties. So it is
reasonable to think that not all metals can be
welded using the same technique, or have the
same level of difficulty for welders.
There are three basic P-No. groupings for
welder qualifications. If a welder changes to a PNo. group that he/she has not qualified for then a
retest is required. We will have a more
thorough lesson on Alternate Base Metals later
in this course.
QW-432
F Numbers
We have now arrived at the Filler Metal Number
or F Number. F Numbers are a grouping of
electrodes and filler metals that weld in a
similar way and in general present more or less
difficulty for a welder. In other words some FNumber filler metals require different skills than
others.
Turn now to Page 132 of Section IX
QW-433 Alternate F-Numbers for Welder

Performance Qualifications
Changing the F Number for a welder may affect
his ability to weld and require re-qualification.
There are some provisions for using lower FNumbers when qualifying with numbers 2 to 4
but, there are restrictions on those qualifications.
Turn now to Page 137 of Section IX

Examples
1. Using the table QW-433, if a welder qualifies
with or without backing with a filler metal or
electrode assigned to F-Number 4. What FNumbers can he use with backing in a
production weld?
2. What F Numbers can he weld without
backing?

Solution
1. He can weld F-Numbers 1 through 4 with
backing. Going right across the row titled
Qualified With to F-Number 4 without
backing then down to each x in the boxes, then
left to read the Qualified For Column we find
F Numbers 1, 2, 3 and 4 with backing.
2. Also the Qualified For F Number 4 without
backing is included which makes sense as he
performed that weld for his test.

Notice that the large table only addresses FNumbers 1 through 5. The rest of the F-Numbers
are in a small table along with notes beneath
the large table. Lets have a look at those.
QW-433 Alternate F-Numbers for Welders
QW-452.1 (b)
Thickness Of Weld Metal Deposit
The fifth essential variable listed is change in
thickness of Weld deposit.
A welder is restricted by the amount of weld
metal he deposits during his performance
qualification test with a particular, welding
process, electrode/filler metal F-number in a
P-Number base metal combination. We will now
have a look at those rules.
Turn to Page 142 of Section IX
QW-452.1 (b)
The column Thickness t, of weld metal in the

coupon refers to the amount of weld metal from
a process or a filler metal. Perhaps a bit of E6010 and the rest E-7018 or GTAW root and
SMAW fill and cap.
QW-452.1 (b)
Example
Assume one welding process, SMAW and one
electrode E-7018 using a P-No.1 pipe.
A coupon thickness of 3/8 inch was welded
using E-7018. In the column on the right titled
Thickness of weld metal qualified we see 2t,
so 2 x 3/8 = 3/4 this is the maximum amount
of E-7018 (F-No. 4) , that the welder can
deposit in production.
QW-452.1 (b)
Suppose now the coupon is 1/2 thick and a

welder welds it with 100% E-7018 using 3 weld
layers, we see that welders limit of deposited
weld metal with an F-No.4 is the maximum to be
welded.
QW-452.1 (b)
Another combination in the 1/2 coupon.
1/8 of E-6010 (F-No.3) and 3/8 of E-7018. By
the first column 2 x 1/8 = 1/4 of E-6010 (FNo.3) and 2 x 3/8 = 3/4 of 7018 (F-No.4). The
welder can deposit up to 1/4 of any F-No.3 and
3/4 of any F-No.4 with any production WPS he
is otherwise fully qualified for, meaning position,
diameter, P-No., backing, progression etc.
QW-452.1 (b)
Quiz
How can we qualify a welder for unlimited
thickness with both F-No.3 and 4 in a single
coupon?
If he or she welds a coupon that is at least ___
thick and deposits at least___ of E-6010 and at
least ___ of E-7018 using a minimum of ____
layers of each filler metal.
* Hint See Note 1 of table QW-452.1(b)
QW-452.1 (b)
Solution
If he or she welds a coupon that is at least 1
thick and deposits at least 1/2 of E-6010 and at
least 1/2 of E-7018 using a minimum of three
weld layers for each filler metal.
The welder can deposit unlimited t with any FNo.3 and/or F-No.4 with any production WPS he
is otherwise fully qualified for such as, position,
P-No., backing, diameter, progression etc.
QW-353
The next essential variable listed is Position.
Consider the welding positions versus the welder
test positions for a moment. We will use pipe test
coupons. Positions for pipe tests are designated
such as 1G, 1 designates the coupon orientation, in
this example the pipe is on the horizontal and is
rotated/rolled beneath the welder and is considered
to be flat welding. The G means a groove butt
weld. The others are 2G, 5G and, 6G.
Turn to Page 148 QW-461.4 in Section IX.
QW-461.4
Groove Welds in Pipe Test Positions
The more difficult the test position, the more
positions a welder can apply. The four positions
for welding are Flat, Horizontal, Vertical and
Overhead.
These are referred to as:
F,H,V,O
QW-461.4
There are corresponding pipe and plate test
positions that qualify a welder for F,V,H, and O.
We will use pipe in the examples.
1G qualifies F (Rotated)
2G qualifies H
5G qualifies F, V, and O
6G qualifies F, V, H and, O (this yields all
positions)
QW-461.4
Section IX allows combing test positions to
produce an all position welder. Therefore if a
welder tests in 2G and 5G he/she was tested for
all positions.
2G covers H and 5G covers F, V, and O
Which is equal to 6G that qualifies F, V, H and,
O. Either of these two yields an all positions
welder.
QW-469.1
Performance Qualifications - Position and
Diameter Limitations
All of this information is compiled into one table.
In this way you can go straight to a one page
table and review a Welder Performance
Qualification (WPQ) for position and diameter
qualifications.
Turn to Page 151 Section IX
Notice the entry on the top row right

Position and Type Weld Qualified. [Note (1) ]
Below that Groove
Below Groove exists two sub-headings
Plate and Pipe Over 24 inches and Pipe less than or
equal to 24 inches. Ignoring Fillets because any welder
qualified for groove 1G is qualified for the same fillet 1F.
To the left we have Qualification Test

Which has the sub-headings Weld and Position
We will use the Pipe-Groove [ Note (3)] row. Starting at

the top of the table in the Qualification Test column
move down and stop at the 1G entry below. To the right
we see the entries F
F
F ignore fillets.
Move up at the first F and find Plate and Pipe Over 24 in.
O.D. is qualified
Move up from the second F and find Pipe less than or
equal to 24 in. O.D. is qualified. See [ Note (3)]
Pipe less than or equal to 24 in. O.D. is

qualified. See [ Note (3)]
Note (3) See diameter restrictions in QW-452.3, QW452.4, and QW-452.6
Notice that while the welder can weld on pipe in

the FLAT position he or she is still restricted by
the diameters given in the table below on,
Pipe less than or equal to 24 in. O.D..
QW-353
The last essential variable listed is Progression.
This as simple as it gets.

If a welder welds Vertically Up (Uphill) during a
particular test he is only qualified for Vertically Up.
Should the welder be required to weld Vertically Down
(Downhill) it is required to test a coupon (keeping other
variables the same) welding Vertically Down.
The reverse is also true, qualify Downhill and you must
weld another coupon to qualify Uphill.
QW-353
(SMAW) Welder Essential Variables
Quiz
A welder performs a test on a NPS 4 (4.5) pipe
coupon in the 6G position. The coupon is Schedule
160 and has a wall T of 0.531. The welder will use
SMAW with E-6010 for the root pass for a total weld
deposit t of .125 (1/8). The balance of the weld
deposit t (.401) will be performed using 3 weld
layers of E-7018 filler metal. No backing will be
used. All welding will be uphill during the test. What
are his qualifications as listed in table QW-353?

Continued
The test qualifies ___ positions with a minimum
diameter of ______ and a maximum of _______.
The test also qualifies the welder to deposit ___
inches of F- No. 3 and ____inches of F-No.4.
The welder will also be qualified to weld _____or
_______backing. The thickest weld he can make
using this combination in production is__________.
The welders production welds must made using
_______ progression.

Solutions
The test qualifies all positions with a minimum
diameter of 2-7/8 and a maximum of unlimited.
The test also qualifies the welder to deposit .250
inches of F- No. 3 and .812 inches of F-No.4.
The welder will also be qualified to weld with or
without backing. The thickest weld he can make
using this combination in production is .250 +.812
or 1.062. The welders production welds must be
made using uphill progression.
QW-353
The next series of slides address the alternate
base materials for welder qualifications. As you
will see a welder can test for example on a P-No.
1 base material with a selected F-No. filler metal
and, under the rules of Section IX he can weld
many other P-Numbers using the F-No. selected
for the test, maintaining all the other essential
variables for the welder, position, diameter, etc.

ASME IX

SECTION IX
QW 423
Alternate Base Materials for Welder
Qualification
Versus
Base Metal Qualified
QW-423 Alternate Base Metals for Welder Qualification

Base metals used for welder qualification may be
substituted for the metal specified in the WPS in

accordance with the following in-text table.
When a base metal in the left column is used for
welder qualification, the welder is qualified to

weld all combinations of base metals in the
right column. Including unassigned metals of
similar composition to these metals.
Base Metal (s) Used for

Welder Qualification
Base Metal (s) for

which the Welder is Qualified
P-No. 1 through P-No. 11, PNo. 34, or P-No. 41 through

P-No. 47
P-No. 1 through P-No. 11, PNo. 34, or P-No. 41 through

P-No. 47
P-No. 21 through P-No. 25
P-No. 21 through P-No. 25
P-No. 51 through P-No. 53 or PNo. 61 through P-No. 62
P-No. 51 through P-No. 53 or PNo. 61 through P-No. 62

So, all we need to do is qualify a welder to weld any P-No. from the list
and he can weld all of the others. This would be great!

There is however a problem with this theory. Welders are also limited by
the Filler Metal Number (F-No.) used during a test.
If a welder qualifies on any P number from

P 1 through P 11, P 34 or P 41 through
P47 he/she is qualified to weld any of
those metals together. Be warned this is
further limited by the F-number (s)!
If a welder qualifies on P 21 to P 25 he/she

is qualified to weld any of these metals
together or any combination of these
aluminum alloys together!
If a welder qualifies on P 51 to P 53 or P 61 to 62
he/she is qualified to weld any of these
metals together or in any combination of
Titanium or Zirconium alloy!
In theory a welder could be qualified for all the

listed base materials by welding just three (3)
coupons. Remember our lesson on Filler
Metal Numbers (F-Numbers). This is where
the welders limitations become very
important.
One of the essential variables for a welder is
the F- Number of the electrode he qualifies
with during a given test.
Suppose a welder qualifies with SMAW using an

F-No.4 electrode the test coupon is a P-No.1
base material.
The welder has qualified to weld P No. 1 to
11, 34 or 41 through 47. So lets have him
weld one of the nickels, a P-No.41. Assume it
will be required to make the weld with a filler
metal that is designated as a F-No.41 in
Section IX. There is a problem , he has not
qualified any of those metals with a F-No.41
filler metal. He would have to prove his skill
with the F-No.41 filler metal.
10
He is qualified for SMAW using a F-No.4

electrode not F-No.41. The welder will have
to test again on any of those metals using a
SMAW electrode designated as a F-No.41,
why because the F-Numbers 4 and 41 are
considered to require different skill levels to
weld. The F-Number is a welders essential
variable as well as a procedures.
Welders are limited by all of the following
essential variables (skill issues), which are
in Section IX for the welding processes
listed QW 350.
11
QW-353
Essential Variables
Paragraph
QW 402
Joints
QW 403
Base Metals
QW 404
Filler Metals
QW 405
Positions
.4
Brief of Variables
Deletion of Backing
.16
.18
Change Pipe Diameter

Change in P Number
.15
.30
.1
.3
Change in F Number
Change in weld metal t deposited
Addition of a position
Change from vertical Up to Down
or Down to UP progression
12
Simply put the welder must qualify all of

his/her essential variables, not just be
qualified to weld a particular P Number. In
our example he/she is disqualified for the
nickel alloy weld because of the required F Number qualification being F-No.41 as listed
on the WPS/PQR.
13
A welder is limited by, process, pipe

diameter, P- Number, F- Number, weld metal
thickness, position, backing and
progression.
All of these Essential Variables must meet
the requirements of the WPS to be used in
the production weld.
14
THANK
YOU
15

ASME IX
Destructive Testing of Welders

Qualification Coupons
There are three items that must be
addressed when performing destructive
testing of a welders test coupon.
1. The type of the specimens required.
2. Where in the test coupon specimens shall
be taken from.
3. How many specimens are required.
These values are listed in Article IV

Welding Data of Section IX in a tabular
form, 452.1(a) and are accompanied by
notes referencing paragraphs found in
Article III, of Section IX .The type and
number a listed in that paragraph.
Turn now to Page 147 of Section IX.
We will now examine the figures referenced in

QW-452.1(a) for removal of Welders
Performance Coupons.
Turn to Page 179
Example - Billy Bob Welders

performance test was made under the
following conditions using Big Welding
Companys WPS CW-1010 :
1. P-Number 1 pipe coupon
2. Pipe diameter NPS 8 (8.625)
3.Thickness 0.500
4. 6G test position
5. Uphill progression
6. F-No.4 (SFA 5.1)
7. 3 layers/passes of weld metal
8. Process SMAW only
Next we fill out the of Welders

Performance Qualification (WPQ)
Form QW-484 for Billy Bob Welder.
Finally an example of the coupons required

for a 2G and 5G test in a single coupon
which will qualify a welder for all four of the
positions, Flat, Horizontal, Vertical and
,Overhead just the same as the single 6G
test.
This coupon requires 6 bend specimens
instead of the usual 4, taken from the
locations indicated in the graphic.
THANK
YOU

ASME IX
SECTION IX
Qualifying A Welding Procedures
Essential Variables
All Referenced Section IX Pages are from
the 2001 Edition with Addenda through 03
SECTION IX
When qualifying a welding procedure you must

first determine the important properties of the
planned weldment which then become the
essential variables. The basic ones are;
Base metal to be welded and thickness (T)
required.
Process (es) to be used including filler metal (s).
Preheat.
Postweld heat treatment or the lack of.
Various others based on welding process used.
For this instruction we will use the SMAW Process.

The a brief of Essential, Supplementary Essential
and Non-Essential Variables for the SMAW process
are listed in table QW-253. However this part of the
course will only cover Essential Variables not the
supplementary or non-essentials. Those will be
covered latter. A definition of these variables follows.
Essential Variable A variable that if changed

requires requalification of the procedure by the
welding and testing of a new coupon or support from
a previously qualified Procedure Qualification Record
(PQR), i.e. a change in the base metal thickness (T)
qualified.
Supplementary Essential An essential variable that
is used only when impact testing of a base metal is
required by a construction code, i.e. a change from
one P-No. Group to another such as P1 Gr.1 to Gr.2.
Non-Essential A variable that can be changed as
needed to suit production requirements without
requalification.
QW-253 SMAW Brief of Variables Page 22

We will start our discussion with the top half of the
SMAW brief of variables, beginning with the first
two Essential Variables, Base Metal and Filler
Metal.
Defining Each Essential Variable

Base Metals QW-403.7
T/t Limits > 8 inches - this rule only applies at
thickness greater than 8 inches (203 mm) .
Unless you will be welding something over 8
inches this is of little concern. The rule for most
welding procedures is the maximum that can be
welded is 2 times T (the coupon). If you are
welding a coupon over 8 inches you are restricted
to 1.33T or 1.33t, as applicable. 1.33t is the weld
metal thickness, it matters when mixing welding
processes and/or filler metal F-Numbers.

Quiz
1. An 8-1/2 T coupon was welded to produce a
PQR to support welding of a reactor shell course.
The maximum T qualified with this coupon is ___.

Quiz
1. An 8.5 T coupon was welded to produce a PQR
to support welding of a reactor shell course. The
maximum T qualified with this coupon is 11.305.
8.5 X 1.33 = 11.305

Base Metals Pgs. 21, 58,159, &16
Change in Thickness (T) qualified.
QW-403.8 A change in base metal thickness beyond
the range qualified in QW-451, except as otherwise
permitted by QW-202.4(b) (different thickness at joint)
Of concern is the thickness range qualified by the
supporting PQR (s) for the WPS, from less than a 1/16 to
less than 1-1/2 it is 2 x T. To weld a thickness outside the
range supported by the PQR the WPS production welding
changes must be supported by providing an additional
PQR from file or by welding a new PQR test coupon.

Base Metals
Quiz
1. A 1 to 1 P-No.1 coupon was welded
entirely by the SMAW process. The
minimum thickness qualified is ___ and the
maximum is ___

Base Metals
Quiz
1. A 1 to 1 P-No.1 coupon was welded
entirely by the SMAW process. The
minimum thickness qualified is 3/16 and
the maximum is 2.

Base Metals
t (weld metal) pass greater than 1/2
QW-403.9 For single-pass or multi-pass welding in
which any pass (means layer of weld metal) is
greater than 1/2 in. (13 mm) thick, an increase in
base metal thickness beyond 1.1 times that of the
qualification test coupon.
The thickness range is affected. It will be
restricted to 1.1 T as given above if you deposit
more than 1/2 of weld metal in a single pass
(layer). This has to do with heat input.

A single pass refers to the number of weld
beads required to fill up a layer of weld metal in
the joint. If the single layer/pass, t (deposited
weld metal), exceeds 1/2 in thickness the WPS
will be restricted to 1.1 x T in production
welding.

Quiz
A PQR coupon is 1-1/4(1.250) thick (T). The weld
will be made in two passes, the root pass/layer will
be 1/4 (.250) thick and second and third
layers/passes will be each be 1/2(.500) thick. The
maximum range of thickness for this qualification
will be ________.

Quiz
A PQR coupon is 1-1/4(1.250) thick (T). The weld
will be made in three passes, the root pass/layer
will be 1/4 (.250) thick and second and third
layers/passes will be each be 1/2(.500) thick. The
maximum range of thickness for this qualification
will be 2-1/2 (2.500).
Read closely, the rule states it must exceed 1/2
to be limited to 1.1 x T.

Alternate Base Metals for Procedures
QW-403.11
Base metals specified in the WPS shall be

qualified by a procedure qualification test
which was made using base metals in
accordance with QW-424.
QW 424
Base Metal (s) Used for Procedure
Qualification Test Coupon Versus
Base Metal Qualified for production
Lets examine some of the items on the table.
One Metal From A P-No. To Any

Metal From The Same P-No.
Such as P1 to P1
One metal from a P-No. To any

metal from any Other P-No. We will Use P
No.1 to P No.8 as an example. Other
combinations are possible, P Nos. 1 to 3, P
Nos.3 to 4 etc.
One metal from P-No. 3 To any

other metal from P-No. 3
One metal from P No. 3 to any

other metal from P No. 3
Also qualifies P No. 3 to P No. 1
However one metal from P No. 3 to any

metal from P No. 3 does not qualify P No. 1
to P No. 1
One metal from P-No. 4 to any

other metal from P-No. 4
One metal from P No.4 to any other metal

from P No.4 also qualifies P No.4 to 4, 3
and, 1
It qualifies one metal from P No. 4 to any

metal from P No. 4, 3 or 1. but does not
qualify P No. 3 to P No. 3 or P No. 1 to P
No.1
Quiz
Using the table list the base metals qualified if

we successfully weld a procedure coupon
joining P No. 5A to No. P 5A
Quiz # 1 - P No. 5A to P No. 5A

Qualifies?
P No. 5A to __, __,__, or __. It does
not qualify __, __, or __ to each other
or to their selves.
P- No. 5A to P- No. 5A Qualifies?

P- No. 5A to 5A, 4, 3, or 1. It does not
qualify 4 , 3, or 1 to each other or to
their selves.
Quiz # 2 - P No. 5A to P No. 4, 3, or 1

Qualifies?
P No. 5A to any metal assigned __,__,
or __. It does not qualify __, __, or __
to each other or to their selves.
Quiz # 2 - P No. 5A to P No. 4, 3, or 1

Qualifies?
P No. 5A to any metal assigned 4,3, or
1. It does not qualify 4, 3, or 1 to each
other or to their selves.

Base Metals Pages 21 & 58
Change of P-No. 5/9/10
QW-403.13 A change from one P No. 5 to any
other P-No. 5 (P No. 5A to P No. 5B or P No. 5C
or vice versa). A change from P No. 9A to P No.
9B but, not vice versa. A change from one P
No.10 to any other P No.10 (P No.10A to P
No.10B or P No.10C, etc., or vice versa).
Simple, P-No. 5/9/10 - A,B,C.., are different PNumbers and require individual qualifications,
(with the exception of 9B to 9A)

Filler Metals
Change of F-Number Pages 21 & 59
QW-404.4 A change from one F-Number in QW432 to any other F-Number or to any other filler
metal not listed in QW-432.
Changing the F-Number to one other than that
used for the procedure test coupon, during the
creation the of the Procedure Qualification Record
(PQR). Such as changing from F-No. 1 to F-No. 3.
This rule also applies to a welders qualification
test by the way.

Filler Metals
QW- 404.5 Change of A-Number Pages 21,59 &
138
A-Nos. are the chemical analysis of the ferrous
weld metal deposits produced by a given filler
metal. Changing A numbers can change the
chemistry and possibly the mechanical properties
of the weld metal. This occurs by changing filler
metals. It also changes the weld add mixture, that
part that contains both base metal and weld metal.
Changing the A No. to one other than that used to
qualify requires a new test or additional PQR (s)
from a file (with one exception).
The below indicates trace amounts ,single

values are maximums. i.e. C = 0.20 % max.
Filler Metals
Consider the following filler metals for the SMAW
process.
1. E-7018 which has an A-Number of 1.
2. E-7018 A1 which has an A-Number of 2
Lets compare the chemistry tables from Section II
Part C Filler Metals for these two AWS
Classification SMAW Electrodes/Filler Metals to
the A Numbers of Section IX.
From Section IX QW-442 A No. 1 contains by %

C 0.20/ Cr --/ Mo --/ Ni --/ Mn 1.60/ Si 1.00
From Section II Part C / E-7018 SFA 5.1
From the Section IX QW-442 A No. 2 contains by %

C 0.15 / Cr 0.50/ Mo 0.40 0.65/ Ni --/ Mn 1.60/ Si 1.00
From Section II Part C / E-7018-A1 SFA 5.5
A note on the API Exams

If you are taking any of the three API Exams
you will be required to review a WPS and
PQR. Part of that review might be a
question about the A-Number listed for the
filler metal on the documents. This is a
protest question. You would need ASME
Section II Part C to answer that question.
Sect. II Part C is listed as required for the
exam. You have no way of answering!
For our example we find the following rule,

proving you must read Section IX carefully!
QW-404.5 (Applicable only to ferrous
metals.) A change in the chemical
composition of the weld deposit from one ANumber to any other A-Number in QW- 442.
Qualification with A-No. 1 shall qualify for
A-No. 2 and vice versa. (Note: all other ANo. changes will force re-qualification).

Filler Metals
Change t deposited Pages 21 & 61
QW-404.30 A change in deposited weld metal
thickness beyond the range qualified in QW-451
for procedure qualification.
Example: In a SMAW procedure 1/4 of E-6010
was qualified on the PQR by depositing 1/8 in the
coupon (2t), the balance of the coupon was filled
with E 7018. The need arises to increase the E6010 t to 3/8 in production. This would require a
new coupon or an existing PQR.

Preheat - Turn to Page 21

Preheat - Pages 21 & 62
A decrease in preheat greater than 100 o F
QW-406.1 A decrease of more than 100F (56C)
in the preheat temperature qualified. The minimum
temperature for welding shall be as specified in
the WPS.
Example: A PQR coupon was welded using a
preheat of 250 F but the WPS requires a preheat
of only 100 F. This is a 150 F decrease below
that qualified and will require a new PQR or one
from your files to support the lower temperature.

PWHT
Change in PWHT Pages 21 & 62
QW-407.1 This long paragraph specifies what is

considered a change in post weld heat
treatments.
The changes are P-Number specific with 5
different conditions of PWHT for P Nos. 1,3, 4, 5,
6, 9,10 and, 11.
For all other materials there are two conditions
1. NO PHWT
2. The specified PWHT for the P No. used

PWHT
T Limits (Thickness Limits) Pages 21 & 63
QW-407.4 For a procedure qualification test
coupon receiving a post weld heat treatment in
which the upper transformation temperature is
exceeded, the maximum qualified thickness for
production welds is 1.1 times the thickness of the
test coupon.
This rule only applies when a production weld will undergo
heat treatment at temperature that will alter the base
metals physical properties, such as tempering, etc.
Producing The PQR

We have looked at all of the essential
variables for the SMAW process. Lets put it
all together by filling out a SMAW PQR to
support a Welding Procedure Specification
(WPS). To do this it will be necessary to
specify a list of the essential variables for
the welding we have planned.
Producing The PQR

From QW-253 we need to address the basic
essential variables and they will be:
1. Base Metal (s) 2 SA-516 Gr. 70 Norm. P-No. 1
2. Filler Metal (s) E-7018 Only
3. Preheat 175 o F for P-No.1 (from Sect. VIII Div. 1
non-mandatory Appendix R)
4. PWHT 1100 o F Minimum per inch of thickness
for P-No. 1 (from Sect. VIII Div. 1 UCS-56)
Producing The PQR

Next we define the ranges of the variables:
Base Metal SA-516 Gr.70 Normalized (2max.)
Preheat 175 o F
Then PWHT based on 2 per UCS-56 shall be 1
hour per inch, which in this example = 2 hours.
The next step is to start filling out a Procedure
Qualification Record as if we had actually welded
the coupon. Here is the front of a blank PQR form.
First we will fill out the top half of the

PQR from the company name to the
base metal information on the left side
and include a graphic of the joint
design used to weld the coupon.
Next we will fill out the bottom half of

the PQR with the filler metal and
preheat on the left side. While not
required on the PQR by Section IX
the Non-Essential variables will be
entered as well.
Now we will fill out the upper half of

the PQR with the PWHT metal on the
right side. Making the comment Not
Applicable in the box for Gas, since
the SMAW process does not use
shielding gasses.
Finally the bottom right which consists

of all non-essential variables. Once
again these are not required by
Section IX, but may be helpful for
meeting a construction code
requirement, i.e. Section VIII Div. 1 or
B31.3.
Now we start completing the back of

the PQR. To do so we need some
test results for our required tension
and bend tests. The tension test
specimens are fabricated as given in
Section IX QW-462.1(a). Page 152 .
The required number of tension test

specimens are 2 as shown in Section
IX QW-451.1 Page 139. The required
number of tension specimens are
always two, unless your coupon
exceeds 1, then you are allowed
divide the two specimens into multiple
pieces. (see QW-151.1 (c) and (d) )
The ultimate strength of the tension

specimens must be computed as
described in below in QW-152.
QW-152 Tension Test Procedure
The tension test specimen shall be
ruptured under tensile load. The tensile
strength shall be computed by dividing
the ultimate total load by the least cross
sectional area of the specimen as
calculated from actual measurements
made before the load is applied.
We must measure each specimens

width and thickness after machining as
shown in QW-462.1(a). Section IX
requires two specimens be tested.
The data for our specimens was;
TS1 - width = .750 thickness = .453
TS2 - width = .753 thickness = .456
Area for each specimen.
TS1= .750 x.453 = .340 in.2
TS2= .753 x.456 = .343 in.2
We put the specimens in a tensile tester
like this and pull each one apart;
The specimens were broke in the

tensile tester and the breaking forces as
read from the gage on the machine
were recorded as follows ;
TS1 = 25,010 Lbs.
TS2 = 24,050 Lbs.
Computing the ultimate strength for 1
square inch for each specimen;
Load divided by Area
25,010/.340 = 73,558 PSI
24,050/.343 = 70,116 PSI
We now evaluate the specimens;
Load divided by Area

25,010/.340 = 73,558 PSI
24,050/.343 = 70,116 PSI
Observing the character and location of
the specimen failures, it was noted that
both failed in the base metal outside of
the weld heat affected zones and in a
ductile manner.
We can now record this information on
the back side of the our Procedure
Qualification Record.
But First
We must determine the required
minimum specified strength from
Section IX in the P-Number listings.
We find that SA-516 Grade 70 has a
Minimum Specified Tensile Strength of:
70 KSI = 70,000 Pounds Per Square Inch.
Our tensile specimens exceeded the

minimum. Now we have one more task to
complete. We must do 4 side bend tests.
This requirement is found in Section IX
along with the accept/reject values for all
bend tests. Turn now to Page 139 again.
The required type and number of bend tests
based on a 1 thick coupon are 4 Side Bend
tests. Remember side bends are
mandatory after the coupon thickness
reaches 3/4 or larger.
We must evaluate the bend specimens to

section IX QW-163. Turn now to Page 6.
QW-163 - The guided-bend specimens shall
have no open discontinuity in the weld or
heat-affected zone exceeding 1/8 in. (3.2
mm), measured in any direction on the
convex surface of the specimen after
bending. Open discontinuities.etc.
To see the details for making the bend
specimens look at QW-462.2 Page 161.
We evaluated the bend specimens to

section IX and had the following comments.
Side Bend S1. No open defects acceptable
Side Bend S2. 1/32 acceptable
We have the correct type based on the
coupon thickness and the correct number of
acceptable side bend tests.
We can now fill out the top back of the PQR.
All that is left is to fill out the bottom of the

back of the PQR. This will be easy, just a
few housekeeping items to complete.
Here is the front side of the complete

Here is the back side of the complete

The WPS
We have completed the Procedure Qualification
Record, which is a laboratory report of the
welding and testing of a coupon.
From this we will write a Welding Procedure
Specification. It must be in complete agreement
concerning Essential Variables with the PQR.
The WPS
The Welding Procedure Specification, must be
complete. You must address all of the essential,
supplementary essential (if Notch toughness
testing is required), and non-essential variables.
The best approach is through the use of the
Brief of Variables found in QW-253 on Page 22
as an item check list.
We will go line by line and address all of the
Essential and Non-Essential variables since our
WPS will not require Notch toughness testing.
The WPS
Starting in box QW-402 we will address each of
the non-essential variables.
Groove Design
Backing
Root Spacing
Retainers
The following is how it was completed.
The WPS
In box QW-402 we have addressed each of the

non-essential variables as follows;
Groove Design Single Vee, Double Vee, JGroove and, U-Groove
Backing The X in both the Yes and No boxes
denotes that this WPS may be used with or
without backing.
Root Spacing This is given below Details.
Retainers Same as Root Spacing
The WPS
Since we have addressed each of the nonessential variables and thereby giving all the
needed Joint information for making a weldment.
It is complete for joint design and no one
should have to ask what is allowed when using
this WPS.
The WPS
Next QW-403 Base Metals
The WPS
We have addressed each of the essential
variables under Base Metal QW-403.
It is complete for P-No., Thickness range
and the restriction of No t Pass > 1/2 has
been addressed. Supplementary
Essentials need not be addressed, no
impact testing is required of this weldment.
The WPS
Next QW-403 Filler Metals
The WPS
We have addressed each of the essential
variables under Filler Metal QW-404.
It is complete for AWS Classification,
F-No., A-No., Size of Filler Metals, and
Weld Metal Thickness Range. Again no
impact testing is required so the
Supplementary Essentials do not apply.
The WPS
Next the back and top of the WPS
We will now complete the Positions,
Preheat, Electrical, and Postweld Heat
Treatment on the WPS.
The WPS
1. The Positions for use with this WPS are,
Flat, Horizontal, Vertical and, Overhead.
This instructs that this WPS can be used
with all positions.
2. The Preheat minimum is set at 100 o F
which is within 100 o F of the PQR actual
value of 175 o F.
3. The Preheat Maintenance specified as
none required.
The WPS
The Electrical Characteristics are;
1. Direct Current Electrode Positive.
2. Amps are set to a range of 90-190 and
the Volts are set to a range of 15-25,
these values are normally obtained from
the filler metal manufacturers literature
or from actual experience.
3. The rest are not required for SMAW.
The WPS
The Postweld Heat Treatment values
are;
1. 1150 +/- 50 o F Which is in agreement
with the PQR minimum value of 1100 o F
2. Time at temperature is 1 hour, also in
agreement with the PQR.
3. Gas variables are not required for
SMAW.
The WPS
We will now complete the bottom half of

the back of the WPS. Which consists of
the Technique box QW-410 only.
The WPS
1. String or Weave, restricted from 2 to 3 core
diameters (core wire exclusive of any coating).
2. Cleaning is limited to Brushing or Grinding.
Back Gouging will be by Air Carbon Arc.
3. Multiple Pass, Manual is entered in the
heading and Peening is not allowed.
4. All others are not SMAW variables.
The Complete WPS Front
The Complete WPS Back
THANK
YOU
ASME IX
Review of WPSs and PQRs
Review of the WPS and PQRs

The API candidate will be given a WPS and a PQR and will
be asked to identify errors or unsupported requirements.
Questions will be asked about individual blocks on the
WPS/PQR. You will not be required to review the entire
document. The exam is in multiple choice format, normally 3
to 6 questions come from the WPS/PQR review.
When answering the questions about the WPS and/or the
PQR, look for omitted information. Every Essential and
Nonessential variable should be addressed. Common
errors, such as filler metal F-Numbers and base metal
thickness ranges are typically found. The PQR test coupon
thickness T can and often does support only part of the
thickness range stated on the WPS etc.
Limitations on the WPS/PQR Review

The API Body of Knowledge has limited the content of the
WPS and PQR in the following key ways.
1. There will be only one welding process, and they have
been limited to SMAW, GTAW, GMAW or SAW.
2. Just one filler metal i.e. all E-7018 with no mixing of
F- Numbers.
3. There will not be different thickness or different base
metals welded to each other.
4. The P-Numbers are limited to P1, P3, P4, P5 and, P8
5. For P1, P3, P4, and, P5 the lower transition temperature
is 1,333 o F and the upper is transformation is 1600 o F
Limitations on the WPS/PQR Review

Limits Continued:
6. Supplemental powdered fillers or consumable inserts will
not be on the WPS/PQR.
7. Special welding processes such as corrosion resistant
weld metal overlay and hard surfacing will not be present.
8. Welds with buttering of the ferritic member or excluded.
In short the WPS/PQR review will be of the most basic type,
and will not require a great deal of expertise in Section IX.
WPS/PQR Mistakes are of Four Types

1. Missing variables, both Essentials and Non-Essentials on
the WPS.
2. Missing Essential variables on the PQR, Non-Essentials
are not required for the PQR.
3. Incorrect Essential Variables, such as the wrong FNumber for a filler metal or electrode. For example:
The electrode E-6010 has an F-Number of 3 and often the
wrong F-Number is assigned to it such as F-Number 4
4. An Essential Variable listed on the WPS that is not
supported by the PQR.
Note: Editorial mistakes such as misspellings of company
names or typing errors are excluded from the exam. i.e.
Brief of Variables
We will use the SMAW QW-253 Brief of
Variables as a check list as we go through
the reviews of two WPS and PQRs.
Confusion Welding and Wee Welders
Turn now to Page 21 of Section IX and
remove it for convenience during the review.
Confusion Welding
Now also turn to the WPS/PQR titled Confusion

Welding in the class textbook. It starts on Page
161 and is four pages total. Remove it from the
textbook for convenience during the review.
We will review it step by step for errors.
Confusion Welding WPS

The first checks are in the title of the WPS.
1. Does our WPS reference our PQR?
2. Has our welding process been listed?
3. Is the Type of welding listed, manual, automatic
etc.?
* Note: The Type of Welding in box QW-410 at the

bottom of QW-253 is out of order in reference to the
box on the WPS, as it appears in the title instead of
box QW-410 on the WPS.

Conclusion:
1. WPS references our PQR.
2. Our welding process is listed.
3. Type of welding is listed as manual.
No mistakes in the title page.

Next we compare the variables in the row QW-402
Joints on QW-253 to the box QW-402 Joints on
the WPS.
1. Groove design, is it addressed?
2. Backing has it been listed?
3. Has root spacing been detailed?
4. Finally have retainers been mentioned?
For definitions see Page 56 of Section IX.

402.1 - A Change in Groove Design
402.4 - Deletion/Removal of Backing
402.10 - A Change in Root Spacing
402.11 Addition or Removal Retainers
We go line by line checking the WPS < ;

Conclusions: Nothing is missing, there are no
mistakes in box QW-402 on the WPS. Note that
Non-Essentials are only wrong if they are missing
i.e. the Code user can choose any groove design,
root spacing etc.
1. Groove Design is addressed as Single Vee.
2. Backing as Flat Bar P-No.1 steel material.
3. Retainers under Details are Not Allowed.
4. Root Spacing is present under Details.

The next listings are in box QW-403 Base Metals.
1. Is the P-Number entered?
2. Is Base Metal Thickness present?
3. Has t pass > 1/2 been addressed?
* Note: During the review of the PQR we will
confirm that all Essential Variables are in
agreement between the WPS and the PQR
regarding the specifications and ranges supported.
Confusion Welding
Conclusions:
1. The P-Number is present.
2. Base metal thickness range is present.
3. t pass > 1/2 is missing, not addressed!
This is a mistake, as all essentials variables
must be addressed.
* Remember, all variables that apply to the process
must be addressed on the WPS, both essential
and non-essential.
Confusion Welding
Check the box QW-404 on the WPS for omissions.
1. Is the F-Number present and is it correct?
2. Is the A-Number present?
3. Diameter of electrodes allowed?
4. The range of weld metal t ?
5. AWS Classification how about it?
You may remember from our previous lesson that
A-Numbers cannot be correctly identified without
Section II Part C of the ASME Code. So we can
only check for its presence on the form.
Confusion Welding
Everything on the list is present, but is the Essential
Variable F-Number correct? We cant check the ANumber without Section II Part C.
Turn to Page 132 and look at the F-Numbers.
Check the F-Number for E-7018 which appears
under the title E-XX18.
Confusion Welding
Conclusions:
1. The F-Number is present but wrong!
2. The A-Number is present.
3. Diameter/Size of electrodes are missing!
4. The range of weld metal t is present.
5. AWS Classification is listed.
Confusion Welding
Now to the back of the WPS to the box QW-405
Positions.
1. Are the positions allowed for welding present?
2. Has progression permitted been entered?
Since fillets are not on the list of QW-253 you may
ignore this entry for the purposes of the test.
Confusion Welding
Conclusion:
1. The positions allowed for welding are present?
2. Progression permitted has been entered?
There are no mistakes. However the positions
allowed would have been better stated in actual
practice by using Flat, Horizontal, Vertical and
Overhead (F,H,V,O). 6G is a welders all positions
qualification test.
Confusion Welding
Now Preheat in box QW-406.
1. Has Preheat Temp. been entered?
2. Preheat Maintenance is it there?
Since Interpass Temp. is a Supplementary
Essential you may ignore this entry for the purposes
of the test.
Confusion Welding
Conclusion:
1. Preheat Temp. has been entered.
2. Interpass Temp is present but was not required.
3. Preheat Maintenance Temp. is missing!
There is one mistake. Preheat Maintenance Temp.
is not present, this is an error by omission of a NonEssential Variable.
Confusion Welding
Now Post Weld Heat Treatment in box QW-407.
1. Simple it is addressed as NONE.
We will check it against the PQR during the PQR
review portion of this instruction.
Confusion Welding
Conclusion:
All we need do is to make sure it is in agreement
with what occurred during the making of the
supporting PQR test coupon. We will compare
those during the PQR portion of this review.
Confusion Welding
Next up is the box QW-408 Gases.
This is not applicable to the SMAW Process. We
will ignore it completely on this review.
Confusion Welding
Now for box QW-409 Electrical Characteristics.
1. Has the Current been entered?
2. How about the Polarity?
3. What about the Amps (I) ?
4. Volts (E)?
Confusion Welding
Conclusion:
1. The Current has been entered.
2. Polarity is there.
3. Amps (I) are present.
4. Volts (E) it is there.
No mistakes in block QW-409
Confusion Welding
Finally block QW-410 Technique
1. String or Weave allowed or both?
2. Initial or interpass cleaning, how?
3. Method of Back Gouging?
4. Multiple to Single pass/side permitted?
5. Peening, is it there?
6. Manual or Automatic welding?
Confusion Welding
Conclusion:
1. String or Weave both are allowed.
2. Initial or interpass cleaning, addressed.
3. Method of Back Gouging present.
4. Multiple to Single pass/side, not addressed!
5. Peening addressed as None Allowed.
6. Manual/Automatic appears in the title.
One mistake. Multiple or Single Pass an error by
omission.
Confusion Welding
Now to the Front of the PQR and its title section.
There isnt much to see here. The correct company
name etc., but the API Body of Knowledge specifies
that the WPS will be supported by only one PQR
and it will be the correct one. This leaves the
welding Process which is addressed as SMAW. All
others are non-essential variables and those are
not required to be on the PQR, in fact they could
be missing. Anything else in the title will fall under
Editorial and is not considered on the exam
WPS/PQR review questions.
Confusion Welding
Conclusion:
1. SMAW has been addressed, no mistakes in the
PQR title.
Note: The PQR does not have to reference the
WPS. A single PQR may support multiple WPS
since WPS are often written years after the PQR
was made. How could you know the WPS number
years before it will be written?
Confusion Welding
We start all over using QW-253 and the box QW402 Joints on the PQR, all of those are NonEssential Variables and are not required on the
PQR. Nothing to do here. The box is blank and
that is not a mistake.
Note: In a real world PQR, you would never leave the joint
design information blank, in fact you would detail it, but
Section IX clearly states that Non-Essentials are optional.
However the Construction Code will usually force this
information be present. For the PQR on this examination it
is not required.
Confusion Welding
Using QW-253 in the box QW- 403 Base Metals, we
check the following items:
1. Has the P-Number been addressed and does it
agree with the WPS?
2. Has the thickness of test coupon been entered
and does it support the full range stated on the
WPS for production welding?
Confusion Welding
Conclusion:
1. No P-Numbers listed!
2. The thickness of the test Coupon is stated to be
0.500 but it does not support the full range stated
on the WPS of 1/16 to 1.
There are two mistakes, No P-Numbers and the
thickness range qualified by the coupon is not
adequate for the WPS proposed thickness.
Turn now to QW-451.1 on Page 139.
Confusion Welding
Conclusion continued:
We can see that the range supported by the coupon
is from 3/16 to 2T. Our T is 0.500 so the range
supported is from 3/16 to 1. Look back to the front
of the WPS, it states a range of 1/16 to 1.
The entire range of thickness on the WPS is not
supported by the PQRs test coupon thickness,
since it does not support a thickness below 3/16.
Confusion Welding
One last thing to consider. What is the P-Number of

SA-53 Grade B? What should have been entered
in the P-Number boxes? Turn now to Page 69.
Confusion Welding
Turn your attention to box QW-404 Filler Metals.
1.Has the F-Number been addressed and
correctly?
2. Has the A -Number been entered?
3. AWS Classification, is it present?
Note: Since Supplementary Essentials will not be on the
exam, the AWS Class in this case is a Non-Essential
Variable. By Section IX, it is not required on the PQR!
Strange but true, it could be omitted and only the F-Number
listed. Real world it would be there.
Confusion Welding
Conclusions:
1. The F-No. for E-7018 is correct and is present.
2. The A-No. is present.
3. AWS Class is shown as E-7018.
No Mistakes!
Confusion Welding
Skipping the Non-Essentials of QW-405 Positions
and turning to QW-406 Preheat we ask the
following:
1. Preheat Temp, is it there and if so does it support
the WPS values?
2. Interpass Temp do we need it?
Confusion Welding
Conclusions:
1. Preheat Temp is there but does not support the
WPS, the PQR must be within 100 o F of the WPS
listed preheat for production which is only 60 o F.
The PQR was qualified with a preheat of 175 o F !
To fix this you could revise the WPS to a minimum
preheat of 75 o F (175 100 = 75 o F).
Take a look at the paragraph QW-406.1 on
Page 62 of Section IX.
Confusion Welding
Confusion Welding
Conclusions contd:
2. Interpass Temp is not there, but we do not need it
since it is a Supplementary Essential.
One Mistake Preheat does not support the WPS.
Confusion Welding
Now the Postweld Heat Treatment.
1. Is it present and does it agree with the WPS
Type, Temp and Time?
Confusion Welding
Conclusions:
1. Well since the block is empty, there is only one
conclusion. The Essential Variable PWHT has not
been addressed. The block being empty does not
mean it was not done, it may or may not have been
postweld heat treated. How can anyone know for
sure.
One mistake, PWHT not addressed.
Confusion Welding
All the remaining blocks contain Non-Essential
Variables and are blank.
They are not needed on a PQR so we will just pass
those blocks and turn to the back of the PQR.
Confusion Welding
Next the Tensile Tests listed in the block QW-150.

1. Are the correct number of tension tests present?
2. Is the math correct?
3. Did the specimens fail at or above the Minimum
stated in the rules of QW-153.1 for SA-53 Grade B?
Confusion Welding
Conclusions:
1. The correct number of tension tests are present,
two.
2. The math is correct (using normal rounding).
3. The specimens did meet the Minimum stated by
the rules of QW-153.1 for the SA-53 Grade B pipe.
Now confirm the above statements.
You can see on right that we need two tension tests.
Confusion Welding
By QW-152 area into load = Tensile Strength
Specimen No. 1
.750 x .453: = .340 sq.
25010 lbs/.340 sq. = 73,559 PSI
Specimen No. 2
.753 x .456 = .343 sq.
24,050 lbs/.343 sq. = 70,116 PSI
Turn to page 69 of Section IX. The Minimum

Specified Tensile Strength is 60,000 PSI.
Confusion Welding
Conclusions Continued:
3. The specimens did meet the Minimum stated in
the rules of QW-151.3 for SA-53 Grade B. It has a
minimum specified tensile strength of 60,000 PSI.
According to the requirements of Section IX the
specimens could have failed 5% below that and still
been acceptable. They failed in the base metal
which is also a requirement of QW-153.1
Confusion Welding
Now the Bend Specimens
1. Are the correct number present?
2. Are they the correct types?
3. Where the results reported and acceptable?
Confusion Welding
Conclusions:
1. The correct number is 4 and only three are fully
present.
2. They are not the correct types, it should be all
face and root bends (4 total), or since the coupon is
at least 3/8 (.500) 4 side bends are permitted.
3. The results were reported and are not
acceptable.
There are three mistakes, incorrect number and
types of bend specimens, max size of defect
Confusion Welding
Last, the bottom of the PQR.
1. Has the PQR been signed?
Conclusion: No.
This is a mistake a PQR is not certified without a
signature.
Wee Welders
Now we will do the second WPS/PQR review.
We will go through this box by box and find
the mistakes and do a recap at the end of
this lesson.
Mistakes on the WPS:

Joints (QW-402)
1. Root gap not addressed
2. Retainers not addressed
Technique (QW-410)
3. Multi or single pass not addressed.
Mistakes on the PQR:

Filler Metals (QW-404)
4. E-8018 is not F-No. 3.
5. Weld metal thickness not addressed.
Mistakes on the PQR Contd:

Tensile Tests (QW-150)
6. First tensile specimen was not within the
tolerance. The specimen failed at less than 95 %
of the specified ultimate tensile strength for the
material.
Guided Bend Tests (QW-160)
7. The test coupon is 0.365 and it must be 0.375 or
greater to use side bends. The coupons should
have been subjected to two face and two root
bends.
Thank You

An Introduction To ASME Section IX

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An Introduction to ASME Section IX

For the benefit of business and people

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Welding Technology: Welding, Fabrication and

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Applied Welding Technology

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Metal Structures can be made in several ways

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capacity of the forging press.

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A localised coalescence of metals or non-metals produced either by

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It is therefore a special process

It brings together the disciplines of design, metallurgy, process and inspection

It is probably one of the most governed activities in the world

Governed by National and International Codes and Client/Customer Specifications

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Metal Joining and Cutting Processes

Three Basic Groups:

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Techniques and filler metals will be discussed later

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Welding Processes to be Discussed

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Shielded Metal Arc Welding

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Simple Circuit Diagram for SMAW

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time as a % age of total time)

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SMAW - Effect of Current

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SMAW - Effect of Current

For DC Electrode -ve :

Less arc penetration into workpiece

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SMAW - Effect of Current

DC Electrode +ve is probably the most common method of welding with

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Gas Tungsten Arc Welding