BUTT JOINTS

Butt joints consist of placing two plates side by side and

joining to create a single piece. When plate thickness
increases, or full penetration is desired, the plates are beveled.
These are referred to as groove welds. Beveling increases the
amount of filler metal needed but insures higher strength and
proper penetration.

Butt Joints

TEE JOINTS (FILLET WELDS)

The tee joint has variations when a one of the pieces is
beveled. As with butt welds, the bevel is used to achieved
deeper or full penetration. It also requires less weld for equal
strength on heavier sections.
CORNER WELDS
Corner welds are used to joint plates at 90 degree angles.
Depending on material thickness it can be a straight butt
weld, a lap weld, a fillet weld, or a groove weld.

Corner Joints

LAP WELDS
Lap welds are similar to fillet welds but the the size of the
fillet typically reaches the top of one of the pieces.

Lap Joint

EDGE WELDS
 Edge Joint

ASME Definitions, Consumables, Welding Positions

ASME has adopted their own designation for welding

processes, which are very different from the ISO definitions
adopted by EN24063.

Designation Description
OFW Oxyfuel Gas Welding
SMAW Shielded Metal Arc Welding (MMA)
SAW Submerged Arc Welding
GMAW Gas Metal Arc Welding (MIG/MAG)
FCAW Flux Cored Wire
GTAW Gas Tungsten Arc Welding (TIG)
PAW Plasma Arc Welding

Straight polarity = Electrode -ve

Reverse polarity = Electrode +ve

ASME Welding Positions
Note the welding progression, (vertically upwards or
downwards), must always be stated and it is an essential
variable for both procedures and performance qualifications.

Welding Positions For Groove welds:-

Welding Position Test Position ISO and EN

Flat 1G PA
Horizontal 2G PC
Vertical Upwards Progression 3G PF
Vertical Downwards
3G PG
Progression
Overhead 4G PE
Pipe Fixed Horizontal 5G PF
Pipe Fixed @ 45 degrees
6G HL045
Upwards
Pipe Fixed @ 45 degrees
6G JL045
Downwards

Welding Positions For Fillet welds:-

Welding Position Test Position ISO and EN

Flat (Weld flat joint at 45
1F PA
degrees)
Horizontal 2F PB
Horizontal Rotated 2FR PB
Vertical Upwards Progression 3F PF
Vertical Downwards
3F PG
Progression
Overhead 4F PD
Pipe Fixed Horizontal 5F PF

Welding Positions QW431.1 and QW461.2

Basically there are three inclinations involved.

Flat, which includes from 0 to 15 degrees inclination

15 - 80 degrees inclination

Vertical, 80 - 90 degrees

For each of these inclinations the weld can be rotated from the
flat position to Horizontal to overhead.
Procedure Qualification Record (PQR)

PQR's are not required if Standard Welding Procedures are

used, see below for details.
This document contains details of the welding test, it must
include details of all the parameters listed as variables in
tables QW250 to QW265 for each process involved and all the
destructive test results.

The relevant variables for each type of welding process are

clearly defined in tables QW250 to QW265. The left hand
column of each table defines the section and paragraph where
each variable and its application to the table is explained in
the code.

Welding Variables

Variables used in a welding procedure test are divided into 3

categories :-

Essential Variables Are variables that have a significant

affect on the mechanical properties of a joint. They must
not be changed except within the limits specified by this
code. e.g. Material thickness range, Material Group etc.

Non-Essential Variables Are variables that have no

significant affect on mechanical properties. They can be
changed without re qualification of the PQR.

Supplementary Variables Are variables that have an

affect on the impact properties of a joint. They are classed
as Non-Essential if impact testing is not required
All variables listed as essential, non-essential or
supplementary should be addressed on both the WPS and the
PQR. If any of the variables do not apply to the particular
application then they should be specified as not applicable.

Joint Configuration
Either plate or pipe can be used for the test piece (plate
approves pipe and vice versa ref. QW211), any welding
position approves all positions providing no impact tests are
required ref. tables QW250 to QW265 and any joint geometry
approves all geometry's, e.g. single V, double V, U prep,
backed or unbacked.

A butt or groove weld approves branch and fillet welds but

not the converse, ref. QW202. Non pressure retaining fillet
welds in pipe or plate can be tested but they must be double
sided if plate and at least the dimensions illustrated in
QW462.4a, ref. QW202.2c. Pressure retaining branch welds
must be qualified by groove (butt) welds.

Material Grouping
Materials are assigned P numbers in QW420; a test in one P
number approves all materials listed under that P number,
except where impact tests are required then approval is
restricted to materials listed in the group number within the P
number. Other P number groupings are permissible ref.
QW424.1 for details. Ref QW 424.1 for further details.
It is normally permissible if the material is not listed in
QW422 to assign it to a P number which lists materials with
the same metallurgical and mechanical properties although
this is not in strict conformance with the code. Typically
BS1501 151 430A low carbon steel could be regarded as P1
and stainless steels such as 316, 304 as P8.

Note P5, 9 & 10 are divided into sub groups eg 5A,5B etc.,
Treat each sub group like a separate P Number

Dissimilar materials are acceptable providing they are

compatible. For example P1 to P8, but this does not cover P1
to P1 or P8 to P8.

Note S numbers are for pipework to B31, a P number covers

an S number but not the converse

Consumables
The ASME code uses its own specifications for
consumables SFA. which is almost identical to the AWS
specification.

NOTE A change in consumable is only permissible providing

it has the same F number and A number (if applicable) as the
P.Q.R..

Thickness Limits
Thickness limits Groove welds. See QW451 for precise
details.
 When Impact tests are required the minimum thickness
approved is restricted. See QW403.6

More than one PQR may be required to qualify

dissimilar thickness

The thickness little 't' of deposited weld metal for each process
involved is approved from 0 to 2xt except:-

MIG/MAG (GMAW/FCAW) dip transfer weld of

deposited thickness less than " approves maximum
thickness of 1.1 x t only Ref: QW255 (QW403.10)

If any Pass in a single or multipass weld > " then the

thickness approval equals 1.1xT

Dissimilar Thickness QW202.4:- The thicker and thinner part

must be qualified, Except P8 and P4X the thinner part can be
qualified if no Impacts and test coupon > 6mm thick.

Thickness limits for fillet welds as per QW462.4a or QW462.4d

qualify all fillet weld sizes on all base material thicknesses
and all diameters in one test.

Testing Requirements (Ref QW 463 for location of specimens)

Unlike EN288 there is no requirement for any non-destructive

testing such as radiography or MPI/DPI, although I would
recommend radiography for butt welds.
The testing requirement for groove welds are as follows:-

Two Transverse tensile tests (QW150).

Two Root bends and Two face bends unless the plate
thickness exceeds 3/8" then 4 side bends are required.
All bend tests should be done to QW160 using the correct
former ref. QW466 to an angle of 180 degrees.
Longitudinal (all weld) bend tests are not recommended
unless the base/weld materials differ markedly in
bending properties. See QW 466 for exceptions and
precise details.

The testing requirement for fillet welds on plate is 5 macro

sections only, for Pipe fillet welds 4 macro sections. No
fracture test required.

Welding Procedure Specifications (WPS)

This document details the practical application of the

Procedure Qualification Record (PQR). It should contain
enough information to give direction to the welder and
should address all variables associated with the welding
process defined in QW250 including non essential and
supplementary.
A WPS can combine welding processes from other PQR's but
all the relevant variables must be addressed including parent
metal thickness. There is an exception to this rule for root runs
from PQR's that are greater than 1.5 inches thick (38.1mm),
see code for details.

Standard Welding Procedures Specifications (SWP's)

Standard welding procedures listed in annex E of ASME IX
can be purchased from the 'American Welding Society' and
used without qualifying a PQR. Section V of ASME IX gives
details of essential variables and restrictions. A successful
welder performance qualification must be carried out to
demonstrate the SWP's before a manufacturer can use it.
Welder Performance Qualification (WPQ)

Materials
The purpose of this test is to determine the welders ability to
deposit a sound weld therefore the base material is not
considered as critical as it is in the PQR. Hence a performance
test on any material in P groups 1 to 11 approves all those
groups and sub groups, also P34 and P4X (P40-P49).
Providing a compatible consumable exists with the same F
number used in the qualification test. (QW423.1)
Note a single sided weld is classed as a weld without backing
and a double sided weld or weld with sealing run is classed
as a weld with backing

Consumables
The F number cannot be changed without re qualification of
the welder except that for performance qualification only
using SMAW (MMA) F numbers up to and including 4
approve all lesser F numbers for double sided or welds with
backing only. One Consumable from F41 To F45 approves any
of these consumables, except SAW. Ref. QW404.11.

Note 'A' numbers do not apply to welder approval tests.

Variables
For each welding process there is a list of essential variables in
QW352 to QW357 and QW360 for welding operators, these
are not necessarily the same as the ones for the PQR. Essential
variables cannot be changed. Explanations of all these
variables is given in section IV of the code.

Diameter and Thickness Ranges

Diameter limits for all circular welds including groove welds,
branch welds and fillet welds is given in QW452.3. there are
no upper limits on diameters approved and pipe covers plate

Note for branch welds the diameter considered for the above
limits is the one containing the weld preparation.
Thickness limits, groove welds.
The thickness limit only applies to the deposited weld metal
thickness not the plate thickness and any groove weld
approves all fillet weld sizes.
For t greater than 12.5mm there is no restriction on the size
that can be welded (Providing the test weld deposit contains
at least 3 layers of weld).

Thickness limits, fillet welds.

A test on plate greater than 3/16" approves all base metal
thicknesses and fillet weld sizes ref. QW452.5. (Note the above
diameter limits apply unless the fillet weld is qualified by a
groove weld)

Joint Configuration
Joint geometry, a double V (or U) is considered the same as a
joint with backing and does not qualify a single V (or U)
without backing, but a single full penetration joint without
backing qualifies all joint configurations.

Approval Range
Extent of approval is very well explained in QW461.9. Take
particular note of welding positions which are also explained
in QW461, for example to qualify a fillet weld in the normal
horizontal-vertical position with a groove weld, the groove
weld must be qualified in at least the 2G position. The
welding positions defined in QW461.1.& QW461.2 should be
referred to in the WPS. The position designations: 1G ,2G ,3G ,
4G ,5G ,6G (Groove Welds) and 1F ,2F ,3F ,4F (Fillet Welds)
are test positions

Period of Validity/Renewal of Qualifications (QW 322.2)

Providing the welder uses the process for which he is
qualified and there is no reason to question his ability then his
qualification lasts indefinitely.

If the welder does not use the welding process for which he is
qualified for a period of 6 months or more then he must
perform a new test in pipe or plate, any parent material,
thickness and position, if successful all the welder approvals
for that welding process are renewed in one test.

Testing Requirements
Test requirements for groove welds QW452 consists of either:-

One face bend and one root bend except for welding
positions 5G & 6G which require 4 bends (Ref QW452.1
Note 4). If the plate exceeds 3/8" side bends may be
used. See QW 466 for precise details and exceptions.

Note:- Bend Tests can in most cases be replaced by

Radiography {See Below}.

Radiography is optional and must be supplemented by

bend tests when using GMAW (MIG/MAG) with dip
 transfer (Short Circuiting Arc) or when welding some
special materials. Ref. QW304.

Note:- Ultrasonic Examination in lieu of Radiography is

not permitted
Test requirements for fillet welds in plate ref. QW452.5:-

One macro section (QW 184) and One fracture test

(QW182).

The location where each specimen has to be taken is defined

in QW463

Radiography Ref QW 191

A length of at least 6" must be examined for plate or the

entire circumference for pipe.

If the pipe circumference is less than 6" then more

samples must be welded up to a maximum of 4. Ref QW
302.2.

Visual Examination Ref QW 302.2 & QW 190

Performance test coupons must show complete joint
penetration with full fusion of the weld metal and base metal.

The welder performance test must follow a properly qualified

W.P.S. Once qualified the welder must always work within the
extent of approval of any properly qualified W.P.S. and his
W.P.Q.

The welder who qualifies the P.Q.R. is automatically approved

within the limits specified in QW304, QW305 and QW303. Ref
QW301.2.

Specialist Processes
Such as corrosion resistant overlay or hard facing are covered
in QW 453.
Procedure variables are defined with all procedure variables
in QW252 and in QW380 for welder approval.

Min base thickness approved = size welded or 1", QW 453

Min Deposit Size Approved:- Point Where Chemical analysis

taken No upper limit QW402.16 (462.5a) Welding Positions
QW405.4 Performance Qualification approves all deposit
thickness No min.QW381

The main Types of welding used in industry and by home engineers

are commonly referred to as Mig welding, Arc welding, Gas
welding and Tig welding.
GMAW or Gas Metal Arc Welding

More commonly called MIG welding this welding type is the most
widely used and perhaps the most easily mastered type of
welding for industry and home use. The GMAW process is
suitable for fusing mild steel, stainless-steel as well as
aluminium.

GTAW or Tungsten Inert Gas

TIG welding is comparable to oxy acetylene gas welding and

needs a lot more expertise from the operator. Employed for
carrying out high-quality work when a superior standard of
finish is needed without making use of excessive clean up by
sanding or grinding.

Arc Welding or SMAW

Generally known as stick or arc welding. Arc welding is the most

basic of all welding types, is easy to master in a home welding
situation.
Stick welding can be used for manufacturing, construction
and repairs, very much well suited for heavy metal size 4
millimetres upwards. Thinner sheet metals and alloys are
usually more suited to the mig welding types.

Gas or Oxy Acetylene Welding And Cutting

Not used as widely for general welding of mild steel. Consists

of mixing oxygen and acetylene gas to greate a flame capable
of melting steels. Mostly used today for maintenance work
and gas metal cutting. Also common for brazing softer metals
such as copper and bronze. Can also be used for welding
delicate aluminium parts such as refrigeration pipes.

Gas Cutting equipment for metal construction and

maintenance. The most accessible of thermal cutting gear is by
qxy-acetylene gas cutting and plasma cutting machines. Other
methods include the use of a thermal cutting electrode for use
with the arc welder machine