Welding:joining of two metals by fusion process.

Brazing:

WPS: it is a wriiten document prepare to provide ditection to the the welders to make sound welds to
the code requirements.WPS shall inicate all essential supplementary essentail and non essential
variables.changes in essential varaibles requires requalification of WPS.Wpsa shall indicate reference
PQR NO.

Essential varaiables :

Change in base metal thickness,P-NO,F-NO,A-NO,change in deposited weld metal thickness,change in

shielding gas compsotion from single to mix%,addition or deletion of filler metal.

Supplementary essential variables:

change in base metal group number,change in any position to vertical position,change in filler metal
specification from one SFA to another,change in filler wire dia >6mm.

Non essential variables:

change in Groove design,deletion of backing,change in method of cleaning,change in gas flow

rate,change in gas cup or orifice size.

PQR:it is a record of welding data used during the test of a weld coupon.it shows all the test results of
the tested specimen.it shall desribe all the essenital varaibles.any change in essentaila variable requires
recertification of the PQR (including date).

Mechanical testing for Procedure qualifications:(Quantative test)

tensile test: to determine the strength of weldment,

Guide bend test: to determine the soundness of the weldment and to determine the ductility of
weldment.(WPS and welder qualification)

Root bend test:root of the weld outside upto 12mm(root in tension).

face bend test:face of the weld outside upto 12mm(face in tension).

Side bend test:sides are in tension >12mm.

Longitudnal bend test:boot root and face in tension lass than or equal to 12mm.

Fillet fracture weld test: to determine the soundness of the weldment .

Notch/impact toughness test:to determine the toughness of the weldment (Charpy imapact test)

Hardness testing: to determine the resistance to plastic deformation by measuring the resistance to
indention by an indenter.smaller the indention harder the material.

Vickers hardness test: square base diamond indenter,

rockwell hardness test: cone diamond indenter,

Brinell hardness test: ball indenter.

Welder performance test:WQTR shall desribe all the essential variables and ranges qulaified.

Essential varaibles:

deletion of backing,change inP-NO,F-NO,change in thickness of weld deposited,change in positon.

Any chnage in essential variables required requalification of welder.if welder not performed welding
upto 6 months(Qualification expired) needs welder requalification.

Ranges qualified:Table QW-461.9

Plate positions:(GROOVE)

POSITION PIPE >24 " O.D PIPE < 24"O.D PLATE AND PIPE

1G F F F

2G F,H F,H F,H

3G F,V F F,H,V

4G F,O F F,H,O

2G,3G,4G ALL F,H ALL

Pipe positions:(GROOVE)

POSITION PIPE >24 " O.D PIPE < 24"O.D PLATE AND PIPE

1G F F F

2G F,H F,H F,H

5G F,V,O F,V,O ALL

65 ALL ALL ALL

2G,5G ALL ALL ALL

Diameter limitations: Table QW-452.3

PIPE O.D of test coupon O.D Qualified

 min max

<25mm size welded unlimited

25mm to 73mm 25mm unlimited

>73mm 73mm unlimited

Plate positions:(FILLET)

POSITION PLATE AND PIPE

1F F

2F F,H

3F F,H,V

4F F,H,O

3F & 4F ALL

Pipe positions:(FILLET)

POSITION PLATE AND PIPE

1F F

2F F,H

2FR F,H,

4F F,H,O

5F ALL

Plate positons:

1G:Flat position-Plate will be in horozontal plane and weld metal is deposited from above.

2G:Horizontal position-Plate will be in a verticaal plane with the axis of weld horizontal.

3G:Vertical position-Plate will be in a vertical plane with the axis of weld vertical.

4G Overhead position-Plate will be in horizontal plane and weld metal is deposited from under beneath.

Pipe positons:

1G:Flat position-pipe will be in horozontal plane and rolled during welding so that weld metal is
deposited from above.
2G:Horizontal position-pipewill be in a verticaal plane with the axis of horizontal.

5G:multiple position-pipe will be in a horizontal plane with the axis of weld vertical.

6G Overhead position-pipewill be in 45 deg to horizontal plane and weld metal is deposited without
rotating.

P-NO:Grouping of base metals.

P1 to P15: Steel and its alloys

P21 to P26: Alumimium and its alloys.

P31 to P35: copper and its alloys,

P41 to P49: Nickel and its alloys,

P51 to P53: Titanium and its alloys.

P61 to P62: Zirconium and its alloys.

F-NO: Grouping of filler metals,

SFA-5.1: Carbon steel electrodes for SMAW.(Low Hydrogen Electrode)

F-4: E 7018(E-electrode covering,70-Tensile strength 70,000psi or 482.3 n/mm^2 orMpa,1-Welding

postion F,H,V,O,H8-Diffusible hydrogen content 8ml-100gm of deposited weld metal).

F-2: E6010.

SFA-5.18: Carbon steel electrodes for FCAW.

F-6: E 71T-1M-H8(E-Electrode,7-tensile strength 70,000psi or 482.3 n/mm^2 orMpa,1-welding

position,T-tubular(FLUX CORED),1-usibilty designator*1or G-multipass or GS-single pass,M-Shielding gas
75-80% argon-balance co2 or C-100%co2 or NO designator means self shielded,H8-Diffusible hydrogen
content 8ml-100gm of deposited weld metal).

SFA-5.20: Carbon steel electrodes for GMAW/GTAW.

F-6:ER70S(ER-Electrode Rod,70-Tensile strength 70,000psi or 482.3 n/mm^2 orMpa,S-solid wire or

C-composite wire)

A-NO: chemical compositon of deposted weld metal

Dissimilar welding: welding carbon steel to stainless steel.

SFA-5.4: Stainless steel electrodes for SMAW

F-5-E309(S.S to C.S),E309L(,0.04%C it helps to minimize the damaging effets of croosion resistance of

HAZ),E309H(0.04-0.08%C it provides high tensile strenght at elevated temperatures)

E308-for Austenetic type S.S

SFA-5.22: Stainless steel electrodes for FCAW and Stainless steel rods for GTAW.

F-6:E309T1-1(E-Electrode,309-chemical compostioin of undiluted weld metal,T-flux cored welding rod or

rod,1-weldong positon(0-flat or horizontal and 1-all positions),1-external shielding gas 100%co2 or
100%argon or 75-25%ar reamining co2)