WELDING DESIGN,
WELDING PROCEDURE
AND PERFORMANCE
QUALIFICATION
Created By:
Mr. V. Menchavez
Founding Chairman President / CEO
Industrial Welders & Fitters Association of the
Philippines
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Edge Preparation - Need
Poor penetration
Poor access at root
Poor strength
Good penetration
Good access at root
Good joint strength
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Basic Joint Types
butt
lap
tee
corner
edge
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Applicable Welds for Butt
joint
Square Groove weld
Bevel Groove weld
V Groove weld
U Groove weld
J Groove weld
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Applicable Welds for Butt
joint
Double V Groove
weld
Double Bevel Groove
weld
Double U Groove
weld
Double J Groove
weld
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Applicable Welds for Tee
joint
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Applicable Welds for Lap
joint
Fillet weld
Plug / slot weld
Spot / seam weld
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Applicable Welds for Corner
Joint
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Butt joint
Single V
Groove weld
Groove angle
Root face
Root gap
Double V
Groove weld
Groove angle
Single U
Groove weld
Root radius
Root gap
Root face
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Weld Reinforcement
Correct
reinforcement
Excess
reinforcement
Minimum cost
High cost
Good joint
strength
Poor joint
strength
Under
reinforcement
Poor joint
strength
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Butt joint Complete Joint
penetration
Weld from face side
Backing weld from root side
Back gouging
Back gouging from face side
Back weld
Weld from face side
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Tee Joint
leg
throat
leg
Flat profile
throat
leg
leg
Convex
profile
leg
throat
leg
Concave
profile
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Tee Joint Full penetration joint
Groove
angle
leg = throat
leg = throat
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Welding Position Groove
1G
3G
2G
4G
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Welding Position Groove
1G
2G
5G
6G
45
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Welding Position Fillet
1F
2F
3F
4F
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Welding Position Fillet
1F
2F
5F
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Area A
Dilution
Area B
Dilution is the amount of base metal present in the
weld metal and given by (Area B / (Area A + Area B))
Dilution depends on the welding process and heat
input.
High dilution alters the chemical composition of weld
metal
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Weld Metal Requirements
Matching strength with the parent metal
Good notch toughness at the operating
temperature
Corrosion resistance
Creep resistance for elevated temperature
application
Resistance to wear, erosion etc
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Filler Metal Selection
Mechanical / chemical properties required
Welding process
Type of electrode, current, power range
Metal to be joined and its thickness
Weld joint design and welding position
Shop or Field weld / surface condition
Number of passes / amount of weld metal
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Welding Procedure
Specification
It is a written document that provides
direction to the welder for making production
welds in accordance with code
requirements.
Any WPS must be qualified by the
manufacturer.
WPS specifies the condition (ranges) under
which welding must be performed called
variables.
WPS addresses essential, supplementary
essential and non essential variables
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Purpose of WPS Qualification
To determine that the weldment is capable
of providing the required properties for the
intended application.
WPS establishes the properties of the
weldment and not the skill of the welder.
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Procedure Qualification
PQR is a record of welding data to weld a test
coupon. It also contains test results.
Completed PQR shall document all essential
variables including ranges.
PQR to be certified accurate and shall not be
subcontracted.
If more than one process is employed then
weld deposit thickness for each process and
filler metal to be recorded.
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Base Metal Classification
Base metals classified into various P Nos
depending on composition, weldability &
mechanical properties.
P1 - P11
P21 - P25
Steel
Al alloys etc.
Group nos within P nos classify metals for
procedure qualification where notch
toughness requirements are specified.
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Filler Metal Classification
F Numbers are based on usability
characteristics i.e ability of welders to make
satisfactory welds with given filler
e.g. F1 - E XX20, F2 - E XX12,
F3 - E XX10, F4 - E XX18 etc.
A Numbers are based on chemical
composition
e.g. A1 - Mild steel A2 - C - Mo steel etc.
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WPS for SMAW
Essential variables
Change in qualified Thickness
Change in P no
Change in F no of filler metal
Change in A no of filler metal
Change in deposited metal thickness
Decrease of more than 100 F in preheat
Change in PWHT
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WPS for SMAW
Welded
Qualified
Px Px
Px Px
Px Py
Px Py
P3 P3
P3 (P3 / P1)
P4 P4
P4 (P4 / P3 / P1)
P5A P5A
P5A (P5A / P4 / P3 / P1)
P5A (P4 / P3 / P1)
P5A (P4 / P3 / P1)
P4 (P3 / P1)
P4 (P3 / P1)
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Procedure Qualification
Thickness limits
T (mm)
Range of T
<1.6
1.6 10
10 - 19
19 - 38
T - 2T
1.6 - 2T
4.8 - 2T
4.8 - 2T
>38
4.8 - 203
max t
Tests
2t
2T, 2 FB, 2 RB
2t
-do2t
-do2t if t<19
2T, 4 SB
2T if t>19
2t if t<19
-do203 if t>19
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Welding Performance
Qualification
The performance qualification tests are
intended to determine the ability of welders to
make sound welds
A welder is qualified by radiography of a test
coupon or by radiography of initial production
welding or by bend tests taken from a test
coupon
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Welding Performance
Qualification
Variables for SMAW
Removal of backing
Change in Pipe diameter
Change in P number
Change in F Number
Change in thickness of weld deposit
Change in welding position
Change in vertical welding
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Welding Performance
Qualification
Thk (mm) Max tk of dep. Metal
<13
2t
>13
Max to be welded
Test
1FB, 1RB
2SB
OD of test coupon Range of OD qualified
<25
Size welded - unlimited
25 - 71
25 - unlimited
> 71
71 - unlimited
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Welding Performance
Qualification
Welded
Without Backing
Fx
With Backing
F1
F2
F3
F4
F5
Qualified
Fx
F1
F2, F1
F3, F2, F1
F4, F3, F2, F1
F5, F1
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Welding Performance
Qualification
Weld
Plate 1G
Plate 2G
Plate 3G
Plate 4G
Pipe 1G
Pipe 2G
Pipe 5G
Pipe 6G
Plate & pipe
>610 mm OD
F
F, H
F, V
F, O
F
F, H
F, V, O
All
Pipe of OD
71- 610 mm
F
F, H
F
F
F
F, H
F, V, O
All
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Thank you
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