1. Poor attitude toward any of the other students, instructors, or judges. 2. Failure to use personal protective equipment (PPE).

Transcription

1 Welding Contest Rules and Score Sheet G Rules: 1. Be Safe & Have Fun 2. Can tack in any position but groove welding must be in accordance with your WPS. 3. Can use wire brush, chipping hammer, and grinder. 4. Cannot use new pieces (only the material given to you). 5. Direct any questions to the closest proctor. 6. Coupon must be in specified position while welding (except tacking). If you have questions about the correct position, refer to the WPS in your package. Disqualification: 1. Poor attitude toward any of the other students, instructors, or judges. 2. Failure to use personal protective equipment (PPE). Zero Score: 1. Welding in the wrong position or wrong technique. 2. Any crack shall be unacceptable, regardless of size or location. 3. Incomplete fusion A copy of the welding procedure specification (WPS) has been provided in your packet. Be sure to read it thoroughly to be certain you comply with the welding instructions given in the WPS.

2 Welding Procedure Specification (WPS) In Accordance with AWS Structural Steel Welding Code D WPS Name: CHA-D G Rev 0 December 9, 2013 SMAW-MA JOINT DESIGN POSITION Type: Single V Butt Position of Groove 4G Backing: No Root Opening: 1/8 Root Face: 1/8 Groove Angle: 75º Included ELECTRICAL CHARACTERISTICS Back Gouging: No Current: DCEP Amps Root: BASE METAL Amps Fill & Cap: Material Spec: ASTM A36 TECHNIQUE Thickness: 3/8 Stringer or Weave: Either Multi or Single Pass: Multipass FILLER METAL Number of Electrodes: One Peening: None AWS Spec: A5.1 Interpass Cleaning: Grinder AWS Class: E6010 / E7018 Wire Brush Diameter: 1/8 or 3/32 Chipping PREHEAT POSTWELD HEAT TREATMENT Preheat Temp: Ambient >32ºF Max Interpass Temp: 350ºF Temperature: None Pass or Weld Layer(s) Process Filler Metal Class Root SMAW E6010 Fill & Cap SMAW E7018 Dia. 3/32 or 1/8 3/32 or 1/8 Current Type & Amps Polarity DCEP DCEP Joint Details See Contest Drawing THIS PROCEDURE WAS QUALIFIED IN ACCORDANCE WITH D FOR THE SOLE PUROPOSE OF PROVIDING A QUALIFIED PROCEDURE TO THE STUDENTS PARTICIPATING IN THE CHATTANOOGA AWS WELDING CONTEST. THIS DOCUMENT SHALL NOT BE DISTRIBUTED OUTSIDE OF THE AWS DISTRICT 08 CHATTANOOGA SECTION AND SHALL NOT BE USED FOR ACTUAL PRODUCTION OR CONSTRUCTION.

3 Procedure Qualification Record (PQR) In Accordance with AWS Structural Steel Welding Code D WPS Name: CHA H Revision 0 March 15, 2010 SMAW-MA PQR Name: CHA G Rev 0 January 9, 2014 SMAW-MA JOINT DESIGN POSITION Type: Single V Butt Position of Groove 4G Backing: None Root Opening: 1/8 Root Face: 1/8 Groove Angle: 37.5º (75º Included) ELECTRICAL CHARACTERISTICS Back Gouging: No Current: DCEP Amps Root: 78 BASE METAL Amps Fill & Cap: 83 Material Spec: ASTM A36 TECHNIQUE Thickness: 3/8 Group No.: 1 Stringer or Weave: Weave Multi or Single Pass: Multipass FILLER METAL Number of Electrodes: One Peening: None AWS Spec: A5.1 Interpass Cleaning: Grinder and/or AWS Class: E6010 / E7018 Wire Brush Diameter: 1/8 / 3/32 Chipping PREHEAT POSTWELD HEAT TREATMENT Preheat Temp: Ambient >32ºF Max Interpass Temp: 350ºF Temperature: None Nondestructive Tension Test Examination Failure VT RT Stress (KSI) Location Base Metal acceptable acceptable Base Metal Bend Test Type Number Result Side 4 acceptable We certify that the statements in this record are correct and that the test welds were prepared, welded, and tested in accordance with the requirements of AWS D Date: 1/27/14 Jason M. West AWS CWI THIS PROCEDURE WAS QUALIFIED IN ACCORDANCE WITH D FOR THE SOLE PUROPOSE OF PROVIDING A QUALIFIED PROCEDURE TO THE STUDENTS PARTICIPATING IN THE CHATTANOOGA AWS WELDING CONTEST. THIS DOCUMENT SHALL NOT BE DISTRIBUTED OUTSIDE OF THE AWS DISTRICT 08 CHATTANOOGA SECTION AND SHALL NOT BE USED FOR ACTUAL PRODUCTION OR CONSTRUCTION.

4 1/8" 1/8" 75 1 Once coupon is tacked in position it cannot be removed. 2 All welding must be done in the overhead position. 3 Weld reinforcement and melt-through must be 1/8" max. 4 Welds should be free of undercut. 5 Clean weld area of millscale, rust & ect. 6 Weld cap and bring to inspectors. 7 The root and cap surfaces of the finished plate must be inspected before grinding and bend specimen removal

5 Face Bend Specimen Root Bend Specimen Radius 1/8" max 1 1/2" 1" 1" 1 1/2" 1 All weld reinforcement must be removed flush with surface of the specimen. 2 Edges of the bend samples may have a 1/8" max radius. 3 Identify the root and face side of the test plate before removing any reinforcement Test Plate - Bend Specimen Removal

6 Score Sheet Name: Contestant Number: Scoring is based on a scale: zero is the lowest possible score and 5, 10, or 20 are the highest scores possible depending on category being evaluated. Measurements outside of the code requirements will result in a zero score for that category. Category Weight Score D1.1 Comments / Notes Be sure to get your visual inspection, of the completed plate performed before you grind or remove any bends! Crater Fills Weld Reinforcement < 1/8 if > 1/8 score = 0 Weld Profile (Fig 5.4) Undercut < 1/32 if > 1/32 score = 0 Melt Through Root Concavity 1/16 max allowed Max melt through < 1/8 If outside the limits score = 0 Porosity See details below Weave consistency / stringer bead tie-in Overall Appearance - Uniformity of thickness - Base metal tie-in - Restarts - Overlap (Cold Lap) You will need to come back to the judges table for inspection of your bends. Root & Face Bends Points will be decided based If your bends on the number of open fail, you discontinuities in the bends cannot place Blue Text summarizes the requirements of AWS D1.1 Porosity Details No visible piping porosity. The sum of the porosity 1/32 or greater shall be less than 3/8 total in any linear inch. Not to exceed 3/4" in the length of the plate. Bend Specimen Details No discontinuities greater than 1/8, 3/8 sum of 1/32-1/8, 1/4 corner except slag or fusion then 1/8

7 Judge 2 Category Weight Score D1.1 Comments / Notes Be sure to get your visual inspection, of the completed plate performed before you grind or remove any bends! Crater Fills Weld Reinforcement < 1/8 if > 1/8 score = 0 Weld Profile (Fig 5.4) Undercut < 1/32 if > 1/32 score = 0 Melt Through Root Concavity 1/16 max allowed Max melt through < 1/8 If outside the limits score = 0 Porosity See details below Weave consistency / stringer bead tie-in Overall Appearance - Uniformity of thickness - Base metal tie-in - Restarts - Overlap (Cold Lap) You will need to come back to the judges table for inspection of your bends. Root & Face Bends Points will be decided based If your bends on the number of open fail, you discontinuities in the bends cannot place Blue Text summarizes the requirements of AWS D1.1 Porosity Details No visible piping porosity. The sum of the porosity 1/32 or greater shall be less than 3/8 total in any linear inch. Not to exceed 3/4" in the length of the plate. Bend Specimen Details No discontinuities greater than 1/8, 3/8 sum of 1/32-1/8, 1/4 corner except slag or fusion then 1/8

8 Judge 3 Category Weight Score D1.1 Comments / Notes Be sure to get your visual inspection, of the completed plate performed before you grind or remove any bends! Crater Fills Weld Reinforcement < 1/8 if > 1/8 score = 0 Weld Profile (Fig 5.4) Undercut < 1/32 if > 1/32 score = 0 Melt Through Root Concavity 1/16 max allowed Max melt through < 1/8 If outside the limits score = 0 Porosity See details below Weave consistency / stringer bead tie-in Overall Appearance - Uniformity of thickness - Base metal tie-in - Restarts - Overlap (Cold Lap) You will need to come back to the judges table for inspection of your bends. Root & Face Bends Points will be decided based If your bends on the number of open fail, you discontinuities in the bends cannot place Blue Text summarizes the requirements of AWS D1.1 Porosity Details No visible piping porosity. The sum of the porosity 1/32 or greater shall be less than 3/8 total in any linear inch. Not to exceed 3/4" in the length of the plate. Bend Specimen Details No discontinuities greater than 1/8, 3/8 sum of 1/32-1/8, 1/4 corner except slag or fusion then 1/8