TWI

CSWIP 3.2
WIS 10
SENIOR WELDING
INSPECTION
CALIBRATION
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Calibration/Validation
BS 7570: 1992 Covers the calibration
and validation of welding equipment.
Grade 1 (general purpose equipment)
all parameters should be +/- 10%.
Grade 2 (Automatic or automated
equipment) parameters should be +/2.5% for current and +/- 5% for all
other parameters.
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Calibration/Validation
Calibration can only be done on equipment
with meters or gauges as theses can be
adjusted.
Validation can be done on equipment with
and *without meters or gauges.
Oil fill transformers etc.
All equipment can be Validated but not all
equipment can be Calibrated.

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Measuring in welding
The
purposes of
measuring
Demonstration of
Welding
conformance to
process
specified
control
requirements
Parameters to be measured:
welding current
preheat/interpa
arc voltage
ss temperature
travel speed
force/pressure
shielding gas flow rate
humidity
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Welding current
measurement
Definition: the current delivered by a
welding power source during welding

measured with an ammeter

measured in A
the ammeter may be connected at any point
in the circuit
in case of AC, either the root mean square
value (=0,707 peak value) or the mean value
of the rectified waveform is measured
due to its sensitivity, a shunt is needed
indirect measurement: tachogenerator and
tongue tester
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The
tachogenerator
directly coupled to the
feed motor spindle
the output is an analogue
DC voltage which is a
precise function of rotation
speed
this voltage is used to
provide a speed feedback
signal for the DC Power
Drive powering the main
motor

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The tongue tester

used for AC current
special types can be used
also for DC (Hall-effect device)
no need to insert the meter
into the circuit

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Arc voltage measurement

Definition: the potential difference
across the welding arc

varies with the arc length

measured with a voltmeter
measured in V
the voltmeter may be connected only across
the circuit (to the workpiece and as close as
possible to the electrode!)
if the voltmeter is connected at the welding
power source, a higher voltage will be
recorded (due to potential drops across
cables)
usually not required for MMA and TIG
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Travel speed
measurement
Definition: the rate of weld progression

measured in case of mechanised and

automatic welding processes
in case of MMA can be determined
using ROL and arc time

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Gas flow rate

measurement
Definition: the rate at which gas is
caused to flow
set with a gas
regulator
can be checked
with a flowmeter

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Welding temperaturesdefinitions
is the temperature of the workpiece in the
Preheat
temperature weld zone immediately before any welding
operation (including tack welding!)
normally expressed as a minimum

is the temperature in a multirun weld

Interpass
and adjacent parent metal immediately
temperature
prior to the application of the next run
normally expressed as a maximum

Minimum interpass temperature = Preheat

temperature
is the minimum temperature in the
Preheat
maintenance weld zone which shall be maintained if
welding is interrupted
temperature
shall be monitored during interruption

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Welding temperaturesWHERE?
Point of measurement see BS EN ISO 13916
if t 50 mm A = 4 x t
but max. 50 mm
the temperature shall be
measured on the surface
of the workpiece facing
the welder

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Welding temperaturesWHERE?
Point of measurement see BS EN ISO 13916
if t > 50 mm A = min. 75
mm
where practicable, the
temperature shall be
measured on the face
opposite to that being
heated
allow 2 min per every 25
mm of parent metal
thickness for temperature
equalisation
interpass temperature
shall be measured on the
weld metal or immediately
adjacent parent metal
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Welding temperaturesHOW?
Test equipment
Thermocoupl
e (TE)
Temperatur
e sensitive
materials
(TS)
Contact
thermomet
er (CT)
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Thermistor
(CT)
Optical/electric
al devices for
contactless
measurement
(TB)
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Temperature test
equipment
Temperature
sensitive materials:
crayons, paints and
pills
cheap

easy the
to
convenient,
doesnt measure
use
actual temperature!

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Temperature test
equipment
Contact thermometer
use bimetallic strips steel + INVAR (36% Ni 64% Fe alloy)
accurate
easy to use
gives the actual
temperature
need calibration
suitable for moderate
temperatures
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Temperature test
equipment
Thermocouple
based on measuring the thermoelectric
potential difference between a hot junction
(on weld) and a cold junction
accurate method
measures over a wide range of
temperatures
gives the actual temperature
need calibration

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Temperature test
equipment
Thermistors
are temperaturesensitive resistors whose
resistance varies
inversely with
temperature
used when high
sensitivity is required
gives the actual
temperature
need calibration
can be used up to 320C
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Temperature test
equipment
Devices for
contactless
measurement
IR radiation and
optical pyrometer
measure the
radiant energy
emitted by the hot
body
contactless
method can be
used for remote
measurements
very complex
for measuring
high
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PAMS (Portable Arc Monitor

System)

For
measuring
and
recording
the welding
parameters

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The
purposes of
a PAMS

For
calibrating
and
validating
the welding
equipment

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PAMS (Portable Arc Monitor

System)
What does a PAMS
measure?
Welding
current
(Hall
effect
device)

Gas flow
rate
(heating
element
sensor)

Arc
voltage
(connectio
n leads)

Wire feed
speed
(tachomete
r)

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Temperature
(thermocoupl
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Use of PMAS
Welding current monitoring - the Hall
effect
Magnetic field
(produced by
welding current)
Electron
deviation due to
magnetic field
eElectric
current
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Voltmeter

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Use of PMAS
Wire feed
speed
monitoring

Incorporated pair
of rolls connected
to a
tachogenerator

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Use of PMAS
Shielding gas
flow rate
monitoring
Heatin
g
elemen
t
sensor

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Use of PMAS
Shielding gas flow rate
sensor
Metallic
tube

Increased gas flow

rate
Increased
cooling

Heating
resistance

Drop in
temperature
Thermocoupl
e
Thermocouple

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Potential
difference
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Calibration, validation and

monitoring
Definitions:
Measurement = set of operations for determining a value
of a quantity
Repeatability = closeness between successive measuring
results of the same instrument carried out under the
same conditions
Accuracy class = class of measuring instruments that are
intended to keep the errors within specified limits
Calibration = checking the errors in a meter or measuring
device
Validation = checking the control knobs and switches
provide the same level of accuracy when returned to a
pre-determined point
Monitoring = checking the welding parameters (and other
items) are in accordance with the procedure or
specification
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Calibration and validation

When it is required?
once a year unless otherwise specified
whenever there are indications that the
instrument does not register properly
whenever the equipment has been damaged,
misused or subject to severe stress
whenever the equipment has been rebuild or
repaired
See BS EN ISO 17662 for details!

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Calibration and validation

When it is NOT required?
when verification of the process is not required

in case of small series and single piece

production when all the following conditions
are fulfilled:
- procedures are approved by procedure
testing
- production is carried out by the same
welding machine used during procedure
testing

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Calibration and validation

When it is NOT required?
in case of mass production when all the
following conditions are fulfilled:
- production is controlled by pre-production
testing, followed by testing of samples
from production at regular intervals
- a statistical quality control system is used
- the process is stable between testing of
samples
- pre-production testing and sampling are
performed separately for each production
line (robotic cells)
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Welding parameter
calibration/validation
Which parameters need calibration/validation?

depends on the welding process

see BS EN ISO 17662 and BS 7570 for details

How accurate?

depends on the application

welding current - 2,5%
arc voltage - 5%
wire feed speed - 2,5%
gas flow rate - 20% (25% for backing
gas flow rate)
temperature (thermocouple) - 5%
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Example 1 - MMA elementary

monitoring
IN THEORY any M.M.A. operation could
require monitoring of:
welding current
arc voltage
R.O.L.
preheat/interpass temperature
electrode treatment and storage

IN PRACTICE (depending on the application)

only the welding current could require
monitoring with a tongue test ammeter
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Example 2 - High integrity MMA

operation
IN THEORY, this might require monitoring of all the
activities previously mentioned.

the equipment thus required would be:

ammeter
voltmeter
stop watch
tape measure
thermometer
calculator

OR

a PAMS

all of the above equipment would require

calibration; any meters fitted to the
power source or electrode ovens would
also require calibration.
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Example 3 - MIG/MAG welding with a

robot
IN THEORY, the following would require monitoring:
wire feed speed
amperage
voltage
travel speed
gas flow rate
repeatability of the controls

IN PRACTICE, a data logger would be preferred

to monitor all the parameters; also a PAMS
would be required to check the repeatability
of the control knobs.
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Summary
a welding power source can only be
calibrated if it has meters fitted
the inspector should check for calibration
stickers, dates etc.
a welding power source without meters
can only be validated that the control
knobs provide repeatability
the main role is to carryout in process
monitoring to ensure that the welding
requirements are met during production

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Typical examination
question 1
The measurement of welding parameters is common
in arc welding practice. Comment on the parameters
that can be measured and recorded,including the
different types of equipment that maybe used.

This question by definition is related to monitoring

Introduction: would include monitoring is
dependent on the integrity of the product.
Welding parameters: need to be identified. (with
comments!)
Equipment details: can be established from the
welding parameters identified.
Conclusion: should incorporate
calibration/validation and the need for checking
temperatures (interpass/preheat).
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Typical examination
question 2
Describe how you would ensure that the welding
parameters listed in a WPS are being adhered to
during production welding. Give the advantages
and limitations of the methods used.

This question is related more to the whole

fabrication process: e.g.
QA/QC requirements
Training, experience and qualification of welders
and inspectors
Inspection procedures (during welding)
Auditing to ensure that the above is taking place
Calibration/validation and in process monitoring
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