Positive Material Identification (PMI)

Positive Material Identification (PMI) is one of the more specialized non-destructive testing methods. With Positive Material
Identification the alloy composition of materials can be determined. If a material certificate is missing or it is not clear what the
composition of a material is, then PMI offers the solution. PMI is particularly used for high-quality metals like stainless steel and
high alloy metals. Elements that can be identified using PMI include: Ti, V, Cr, Mn, Co, Fe, Cu, Zn, Ni, Se, Nb, Mo.

The purposes of PMI is:

o To verify that all critical materials conform to project requirements,

o To ensure that dangerously inappropriate alloys are not incorporated in the completed process plant, either by accident or well-

meant but misinformed action;

o To provide documentary evidence to authorities or endorsers that reasonable quality control procedures have been used in

building any plant where failure could have serious consequences;

o To identify material other than that specified and to allow for an appropriate body to judge its suitability. This avoids accidental

incorporation of acceptable

o substitutes with inappropriate welding procedures and leaves a record for future plant maintenance.

Ferrite Content
A minimum ferrite content is necessary to avoid hot cracking in stainless steel welds. The amount of ferrite in the weld metal
also control the micro structural evolution during high temperature service. Moreover the amount of ferrite controls the corrosion
and stress corrosion resistance

Duplex solidifies initially as ferrite, then transforms on further cooling to a matrix of ferrite and austenite. In modern raw material
the balance should be 50/50 for optimum corrosion resistance, particularly resistance to stress corrosion cracking. However
the materials strength is not significantly effected by the ferrite / austenite phase balance.

Duplex stainless steels are called “duplex” because they have a two-phase microstructure consisting of grains of ferritic and
austenitic stainless steel. The picture shows the yellow austenitic phase as “islands” surrounded by the blue ferritic
phase. When duplex stainless steel is melted it solidifies from the liquid phase to a completely ferritic structure. As the material
cools to room temperature, about half of the ferritic grains transform to austenitic grains (“islands”). The result is a
microstructure of roughly 50% austenite and 50% ferrite.

Duplex stainless steels have a two-phase microstructure of austenite and ferrite grains.

Low levels of austenite: – Poor toughness and general corrosion resistance.

High levels of austenite: – Some Reduction in strength and reduced resistance to stress corrosion cracking.

The main problem with Duplex is that it very easily forms brittle intermetalic phases, such as Sigma, Chi and Alpha
Prime. These phases can form rapidly, typically 100 seconds at 900°C. However shorter exposure has been known to cause a
drop in toughness, this has been attribute to the formation of sigma on a microscopic scale. Prolonged heating in the range
350 to 550°C can cause 475°C temper embrittlement. For this reason the maximum recommended service temperature for
duplex is about 280°C.

WPS & PQR

Weld procedures specification (WPS) is a written document that provides direction to the welder or welding operator for making
production weld in accordance with code requirements.
The Procedure qualification Record (PQR) is a record what occurred during welding the test coupon and results of testing of
coupon

Welders qualification to ensure a particular welder is capable of welding to a procedure and obtaining a result that meets
specification

The following parameters to be considered during procedure qualification:

o Joint Design

o Parent Metal / Base Metal

o Filler Metal

o Welding Process

o Welding Position

o Electrical characteristics
Material Grouping for the purpose of welding and heat treatment:

o P-Numbers are assigned to base metals depending on characteristics such as composition, weldability and mechanical properties

where this can logically be done.

o Group Number; classify the metals with P-numbers for the purpose of procedure qualification where notch-toughness

requirements are specified

o F-Numbers are assigned to filler metals or welding rods based on essentially on their usability characteristics, which

fundamentally determine the ability of welders to make satisfactory welds with a given filler metal
Welding Variables

o Essential Variables – An essential variable is a variable that will influence or change the mechanical or metallurgical properties of

the welded joint – changes affecting the procedure approval. Any change in an essential variable requires a new welding

procedure specification (WPS).

o Supplementary Essential Variable – A change in a welding condition which will affect the notch-toughness properties of a

weldment

o Non Essential Variable – Non essential variables are those in which a change, as described in the specific variable may be made

in the WPS without re-qualification