Section 1 F Welding of Hull Structures Chapter 3 Page 1 5

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1 II - Prt 3 Section 1 F Welding of Hull Structures Chpter 3 Pge For welding of ustenitic stinless steels to one nother nd to hull structurl steels, welding consumbles nd uxiliry mterils shll be selected in ccordnce with Tbles 5.21 to 5.23 in Chpter 1, Section 5 nd the mnufcturers' recommendtions, tking the corrosion resistnce nd strength requirements nd the welding metllurgy (including resistnce to hot crcking) into ccount, nd specified in welding schedule, which is to be submitted for pprovl. 9. For welding luminium lloys, the welding consumbles nd uxiliry mterils shll be selected ccording to the type nd condition of the mteril (cf. Rules for Mterils, II/1/3) in ccordnce with Tble 5.28 in Section 5 of Chpter 1 tking the required mechnicl properties of the welded joints into ccount (cf. Rules for Construction I, Prt 1, Chpter 1, Section 19, C.2.8) nd shll be indicted in the production documents to be submitted for pprovl. 10. Welding consumbles nd uxiliry mterils specified in welding shop or procedure pprovl (cf. F.) my only be replced by equivlent consumbles pproved by the Society with n pproprite qulity grde if this is explicitly stted in the respective pprovl document. Filing this, the Society's greement shll be obtined. 11. The welding consumbles nd uxiliry mterils my only be used in the pproved welding positions. The mnufcturer's recommendtions nd instructions for welding (e.g. type of current nd polrity) shll be followed. 12. The welding consumbles nd uxiliry mterils (especilly hydrogen-controlled, bsic covered electrodes nd bsic welding fluxes) shll be re-dried before use in ccordnce with the mnufcturer's instructions (observe mximum drying time!) nd stored in dry plce (in heted continers or the like) t the workplce. Note: The guideline DVS 0504 "Hndling, storge nd redrying of covered electrodes" nd guideline DVS 0914 "Use nd storge of welding fluxes for submerged-rc nd electro-slg welding" issued by the Germn Welding Society (Deutscher Verbnd für Schweißtechnik e.v) contin detiled instructions for this. F. Welding procedure, procedure qulifiction tests 1. Generl 1.1 Beneth the requirements for qulifiction tests of welding procedure intended for hull constructions re stted. Procedure qulifiction tests intended for other use like pipeline systems, pressure vessel nd stem boiler, mchinery structures but lso for the industril sector, e.g. Offshore or steel constructions, re not included in this Section. After GL s greement, the following requirements cn be pplied in corresponding mnner. 1.2 The procedure qulifiction tests concerning specil hull construction e.g. for liquid gs tnks re settled in the GL Rules I Ship Technology, Prt 1 Segoing Ships, Chpter 6 Liquefied Gs Crriers, Section Only those welding procedures re llowed to be pplied, which qulifiction is proved by qulifiction test nd by the following requirements. 1.4 The following requirements re vlid for the welding processes commonly used in shipbuilding like mnul metl rc welding, gs metl rc welding, flux cored rc welding, metl inert gs welding, submerged rc welding, tungsten inert gs welding nd electrogs welding. 1.5 Procedure qulifiction test progrms concerning specil welding processes nd procedures respectively like e.g. lser welding, stud welding, friction welding, robotic welding hve to be greed with GL. 1.6 GL my dditionlly require welding procedure tests for specific (difficult) component shpes or combintions of mterils, environmentl conditions (e.g. underwter welding), prticulr weld shpes, process vrints or combintions, nd lso for prticulr welding consumbles nd uxiliry mterils. This is nlogously vlid for other joining processes or (surfce) finishing techniques such s therml cutting or flme strightening. 1.7 The informtion in the preceding nd following prgrphs, especilly the informtion on test pieces, form of specimens, tests nd requirements, pplies to the norml mterils, welding processes nd weld shpes in current use in shipbuilding, which properties re proved under operting conditions nd hs been verified by test results. In cse of doubt, GL cn require supplementry nd/or other test pieces, forms of specimen nd qulifiction tests showing tht the properties of ppliction re sufficient. 1.8 In the cse of welding processes whose chrcteristics result in weld shpes other thn those verified by test results (e.g. those with considerble notch effect), the influence of the weld shpe on the ftigue strength behviour of the welded joints my be investigted in ddition to crrying out the prescribed tests. The sme pplies in nlogous mnner to other chrcteristics of the welded joints, e.g. corrosion resistnce.

2 Chpter 3 Pge 1 6 Section 1 F Welding of Hull Structures II - Prt GL my pprove certin welding procedures such s verticl-down welding, build-up welding on rudderstocks or underwter welding (cf. H.13.3), but mke their ppliction depending on n pprovl of every single cse, e.g. fter exmintion of the lod conditions the use of which is, however, dependent upon uthoriztion, for exmple following n exmintion of the lod conditions, in ech individul cse. For welding processes or pplictions of this nture, GL my lso stipulte restrictions in the opertion of the vessel (e.g. in the operting re) In generl welding procedure tests re to reflect fbriction conditions in respect to welding equipment, inside or outside fbriction, weld preprtion, preheting nd ny post-weld het tretment. It is to be the mnufcturer s responsibility to estblish nd document whether procedure is suitble for the prticulr ppliction For the welding procedure pprovl the welding procedure qulifiction test is to be crried out with stisfctory results. Welding procedure specifictions re to refer to the test results chieved during welding procedure qulifiction testing Welding procedure pprovls re generlly non-trnsferble. Exceptions re only possible fter the cceptnce by GL nd this only for workshops under the sme technicl nd qulity mngement. GL my, however, require proof s to whether the welding processes re being pplied correctly nd the mechnicl properties re dequte by mens of nondestructive tests nd/or production tests with mechnicl-technologicl test specimens Welding procedure tests performed ccording to other rules under the supervision of other independent testing bodies cn be ccepted on demnd nd fter exmintion by GL. For this purpose, test reports indicting the results, the welding procedure specifiction nd the pprovl certificte of the other testing body hve to be submitted to GL. 2. Test schedule nd welding procedure specifictions 2.1 Preliminry welding procedure specifiction (pwps) nd welding procedure specifiction (WPS) The shipyrd or the mnufcturer hs to prepre welding procedure specifiction intended for the welding procedure qulifiction test. This welding procedure specifiction is lso clled preliminry welding procedure specifiction (pwps). In the pwps, ll relevnt welding nd procedure vribles hve to be specified. If deemed necessry, the pwps cn be djusted nd completed during the welding procedure test. 2.2 The scope of welding procedure tests shll be lid down in n ppliction nd submitted for pprovl prior to the tests. Before strting the procedure test, pwps s well s copies of the bse mteril certifictes hve to be submitted together with the ppliction to GL. The ppliction for pprovl nd for the performnce of procedure test bsed upon the pwps hs to be sent to GL Hed Office, with simultneous notifiction of the locl Surveyor, giving the following detils: Rnge of ppliction (components, mterils, plte / wll thickness, dimeter of pipe) Welding process Welding positions Welding equipment, welding prmeters Weld shpes, weld building up Welding consumbles nd uxiliry mterils Joint preprtion Cold- or hot-forming opertions prior to welding Overweldble shop primer Welding jigs, wether protection Preheting nd het input during welding Post-weld het tretment, other fter-tretment Welder Dte of the testing Loction of the testing. If possible, proposl of test schedule including sketch nd dimension of the test pieces nd scheduled test specimens nd testing hs to ccompny the ppliction. In cse tht the bove required detils nd dt re bsing upon workshop stndrds or other (welding) specifictions, these documents hve to be lso enclosed to the ppliction. 2.3 If the test pieces, which re welded under the supervision of GL ccording to the pwps, show insufficient results, the shipyrd or the mnufcturer hs to djust nd modify the pwps considering the improvements. A new revised pwps shll be prepred nd the test pieces shll be welded gin under the supervision of GL nd ccording to the new pwps. 2.4 The finl welding procedure specifiction (WPS) is the bsis for the mnufcturers welding production. If the test results of the test pieces welded in ccordnce with the pwps comply with the requirements, GL cn pprove the welding procedure specifiction (WPS) within the scope of welding procedure pprovl for the shipyrd or the welding workshop respectively. 3. Qulifiction of the welding procedures 3.1 Generl The preprtion nd welding of the test pieces hve to be crried out in ccordnce with the

3 II - Prt 3 Section 1 F Welding of Hull Structures Chpter 3 Pge 1 7 preliminry welding procedure specifiction (pwps) nd under the generl condition of production welding which it represent Welding of the test ssemblies nd testing of the test specimens re to be witnessed by the GL Surveyor If tck welds nd/or strt nd stop points re production condition of the weld they re to be fused into the joint nd re to be included in the test ssemblies If butt nd fillet welding is pplicble during production relevnt welding procedure test pieces of butt nd fillet weld hve to be welded. Only in cse of ppliction nd overwelding of shop primer, test pieces of fillet weld re to be qulified seprtely from butt welds. 3.2 Bse mterils, welding consumbles nd uxiliries The bse mterils used for welding procedures hve to be identified by mens of mteril mrking nd certifictes In cse of welding procedure tests for high het input welding, the weldbility of the bse mteril hs to be proved to GL concerning the mximum pplied het input by the steel mnufcturer The welding consumbles nd uxiliry mterils shll if possible hve lredy been tested nd pproved by GL; however, they my be tested nd pproved t the sme time s the welding procedure. Approvls of this type re generlly restricted to the user's works nd re vlid for mximum of one yer, unless repet tests re performed s required for the welding consumbles Welding consumbles nd uxiliry mterils used in the welding procedure tests my only be replced in the subsequent fbriction work by others of the sme kind which ber the GL pprovl if this is expressly stted in welding procedure pprovl certificte. 4. Welding procedure qulifiction tests for norml nd higher strength hull structurl steels, forgings nd steel cstings with minimum specified yield strength of R eh 400 N/mm The following requirements re vlid for norml nd higher strength hull structurl steels, forgings nd steel cstings ccording to the GL Mteril Rules. Other comprble steels nd mterils respectively cn only be used with previous consent of GL. 4.2 Butt welds The following provisions refer to butt welds on pltes. For butt welds on pipelines, plese refer to Section Assembly nd dimension of test pieces The test ssembly hs to be gret enough in order to ensure resonble het distribution. The dimension of the test piece hs to be djusted to the welding procedure nd to the number of test specimens. Following minimum dimensions of test piece re required: mnul or semi-utomtic welding: width = 2, = 3 x t, min. 150 mm length b = 6 x t, min. 350 mm utomtic welding: width = 2, = 4 x t, min. 200 mm length b = 1000 mm The test ssembly is represented in Fig. 1.1: Where, in order to estblish the mechnicl nd technologicl chrcteristics of the welded joints, especilly in fully mechnized nd/or utomtic welding processes, test piece lengths re selected which re considerbly smller thn the weld lengths to be lid down during lter fbriction, the first fbriction welds shll be included s prt of the welding procedure tests nd, s minimum requirement, shll be subjected to visul inspection nd non-destructive testing to ensure trouble-free welding procedure nd to detect ny imperfections in the weld. For hull structurl steel pltes impct tested in the longitudinl direction (CVN-L), the butt weld of the test piece is perpendiculr to the rolling direction of the two pltes Scope of testing nd test specimens The butt weld test ssemblies re to be exmined nondestructively nd destructively in ccordnce with the following requirements nd with Fig. 1.2: Visul testing 100 % Surfce crck detection 100 % (dye penetrnt testing or mgnetic prticle testing) Rdiogrphic or ultrsonic testing 100 % Trnsverse tensile test two specimens (see section ) Longitudinl tensile test one specimen (see section ) Trnsverse bend test four specimens (see section ) Chrpy V-notch impct test required (see section ) Mcro exmintion one specimen (see section ) Hrdness test required (see section )

4 Chpter 3 Pge 1 8 Section 1 F Welding of Hull Structures II - Prt 3 Discrd Plte rolling direction (Steel pltes with CVN-L) Plte rolling direction (Steel pltes with CVN-T) b Discrd Fig. 1.1 Test ssembly for butt weld

5 II - Prt 3 Section 1 F Welding of Hull Structures Chpter 3 Pge Chrpy V-notch impct test (notch in weld metl) (notch in HAZ) t (notch on fusion line) Discrd T1 Trnsverse tensile test P1 Fce bend test or 2 side bend test P2 Root bend test Longitudinl tensile test M Mcro exmintion & Hrdness test P3 Fce bend test or 2 side bend test P4 Root bend test T2 Trnsverse tensile test Discrd weld Fig. 1.2 Test smpling Non-destructive testing Trnsverse tensile test Test ssemblies hve to be exmined by visul nd non-destructive testing prior to the cutting of test specimens. In cse tht ny post-weld het tretment is required or specified, the non-destructive testing hs to be performed fter the het tretment. GL my require specific testing intervls to be dhered to between completion of the welding work nd performnce of the crck tests, unless het tretment hs been executed. Imperfections detected by visul or non-destructive testing hve to be ssessed in ccordnce with ISO 5817, qulity level B (except for excess weld metl nd excess of penetrtion for which the qulity level C pplies). The testing hs to be crried out in ccordnce with EN 895 / ISO In cse of gret plte thicknesses more test specimens hve to be intended for testing in order to cover the whole cross section. If not stted otherwise prior to the testing, the tensile strength recorded for ech specimen hs not to be less thn the minimum required for the bse mteril. The welding procedure minimum tensile test requirements for hull structurl steels re shown in Tble 1.2. When butt welds re mde between pltes of different grdes, the tensile strength to be obtined on the welded ssembly is to be in ccordnce with the requirements relting to the steel grde hving lower strength.

6 Chpter 3 Pge 1 10 Section 1 F Welding of Hull Structures II - Prt Longitudinl tensile test The testing hs to be crried out in ccordnce with Chpter 2 Design, Fbriction nd Inspection of Welded Joints, Section 5, C.2. Longitudinl tensile test of deposited weld metl tken lengthwise from the weld is required for cses where the welding consumble or uxiliries is not GL pproved or tht greter influence on the weld metl is expected due to the chrcter of the procedure. Tensile strength, yield strength nd elongtion of the specimen hs not to be less thn the minimum tensile strength, minimum yield strength nd minimum elongtion of the required qulity/strength grde of the welding consumble. Tble 1.2 shows the requirements for the minimum tensile strength, yield strength nd elongtion of the weld metl. Where more thn one welding process or type of consumble hs been used to mke the test weld, test specimens re to be tken from the re of the weld where ech ws used with the exception of those processes or consumbles used to mke the first weld run or root deposit Bend test Trnsverse bend tests hve to be crried out in ccordnce with EN 910 / ISO Two of the four test specimens hve to be bent with finl pss in tension nd the other two hve to be bent with the root pss in tension. In cse of specimen thicknesses 12 mm, four side bend test specimens cn be lterntively tested. For butt joints in heterogeneous steel pltes, fce nd root longitudinl bend test specimens my be used insted of the trnsverse bend test specimens. The bending tests re to be performed using mndrel with dimeter equl to 4 times the thickness of the specimen. The required bending ngle of 180 under the test conditions specified in EN 910 / ISO 5173 is deemed to hve been ttined when the specimen hs been thrust between the supporting rolls to the minimum distnce indicted in this stndrd. The required bending elongtion shll be ttined before the first incipient crck ppers. Minor pore exposures or the like up to mximum length of 3 mm my be tolerted. The frcture surfces of ruptured test specimens shll be evluted Impct tests The specimen position, the test temperture nd the requirements of the notched-br impct tests hve to be in line with the following requirements. The dimensions of the specimens nd the tests hve to follow EN 875 / ISO Chrpy V-specimens with the notch perpendiculr to the surfce of the plte in ccordnce with EN 875 / ISO 9016 trnsversl to the weld re required. The notched br impct test specimens shll be tken from the lst side welded nd this 1-2 mm below the surfce of the bse mteril, in cse of lrger plte thicknesses they hve to be tken from both sides. In cse of very gret plte thicknesses or welding procedure tending to centre segregtion, dditionl notched-br impct specimens hve to be tken from the middle of the plte thickness. Figure 1.3 nd Figure 1.4 show the position of specimen depending on het input, plte thickness nd weld preprtion. Tble 1.2 presents the impct requirements. For the impct tests the verge vlue out of three impct test specimens (for ech notch loction, weld metl, fusion line, HAZ) pplies. When butt welds re mde between different steel grdes/types, the test specimens re to be tken from the side of the joint with lower toughness of steel. Temperture nd bsorbed energy results re to be in ccordnce with the requirements for the lower toughness steel.

7 II - Prt 3 Section 1 F Welding of Hull Structures Chpter 3 Pge 1 11 ) t 50 mm (1) 1-2mm 2nd side b c 1-2mm b c 1st side Note: (1) For one side welding with thickness over 20 mm notch loctions is to be dded on root side. b) t > 50 mm 1-2mm b c 1-2mm 2nd side b c b 1st side Notch loctions: : center of weld WM b : on fusion line FL c : in HAZ, 2mm from fusion line Fig. 1.3 Loctions of V-notch for butt weld of norml het input (het input 50 KJ/cm)

8 Chpter 3 Pge 1 12 Section 1 F Welding of Hull Structures II - Prt 3 ) t 50mm (1) 1-2 mm b c d e 1-2mm 2nd side b c d e 1st side Note: (1) For one side welding with thickness over 20 mm notch loctions, b nd c re to be dded on root side. b) t>50mm 1-2 mm b c d e 1-2mm 2nd side b c d e c b c 1st side Notch loctions: : center of weld WM b : on fusion line FL c : in HAZ, 2mm from fusion line d : in HAZ, 5mm from fusion line e : in HAZ, 10mm from fusion line in cse of het input > 200kJ/cm Fig. 1.4 Loctions of V-notch for butt weld of high het input (het input > 50 KJ/cm)

9 II - Prt 3 Section 1 F Welding of Hull Structures Chpter 3 Pge 1 13 Tble 1.2 Requirements pplicble to welded hull structurl steel in the scope of welding procedure tests Grde Yield strength (weld metl) [N/mm 2 ] Tensile strength [N/mm 2 ] Elongtion (weld metl L O = 5 d o ) [%] mnul nd semimechnised Temperture [ C] A B 5, D ± 0 E 20 A D 32 ± 0 E F A D 36 ± 0 E F A D 40 ± 0 E F (1), (3), (4) Impct energy (J) PA, PC, PE PF, PG Full mechnised Bending ngle (D = 4 t) Bending elongtion guge length 2 L s (2) [%] (1) (2) (3) (4) (5) Chrpy-V-notch specimen, verge vlue of three specimens. The guge length (L 0 ) = weld width (L S ) + hlf of the plte thickness on ech side djcent to the weld; see EN 910/ISO 5173 In the cse of plte thickness > 50 mm, the requirements of the impct energy hve to be greed with GL prior to testing The impct requirements re vlid for test pieces with weld perpendiculr to the rolling direction of the pltes. For grde A / B, the minimum vlue of impct energy is 27 J in the fusion line (FL) nd in the het ffected zone (HAZ). Where the plte thickness is less thn 10 mm, notched br impct test specimens with width corresponding to the plte thickness, nd wherever possible 7,5 mm or 5 mm, my be used. In such cses the impct energy vlues specified in Tble 1.2 shll be reduced in ccordnce with Tble 1.3. The notched br impct test is generlly dispensed with for pltes less thn 5 mm thick. However, other tests of resistnce to brittle frcture my be stipulted. Tble 1.3 Cross section of specimen [mm x mm] Required impct energy vlues with specimens of reduced width Frction of the required minimum impct 10 x 7,5 5/6 10 x 5,0 2/3

10 Chpter 3 Pge 1 14 Section 1 F Welding of Hull Structures II - Prt Mcro exmintion The exmintion of the mcro-structure hs to be executed on minimum one polished section. The polished surfce of the section hs to be tken perpendiculr to the weld xis. The mcro specimen shll be of such size nd treted by grinding nd etching in such wy s to revel the nture nd structure of the crystlliztion of the weld metl nd the het-ffected zone s well s the texture of the bse metl. For the mcro exmintion, minimum 10 mm out off the het ffected zone from the bse mteril hs to be considered. The polished sections shll be photogrphed nd the photos ppended to the inspection report. Mcrogrphs shll normlly be to scle of 1:1 to 1:3; if the cross-sectionl re of the weld is smll, they my be mgnified. The specimen hve to be ssessed in ccordnce with ISO 5817, qulity level B, except for excess weld metl nd excess of penetrtion for which the qulity level C pplies Hrdness test The hrdness test is required for steels with specified minimum yield strength of R eh 355 N/mm 2 nd in generl for steel cst nd forgings. The Vickers method with test strength of 98N (HV10) hs normlly to be used. The hrdness hs to be verified on ground nd etched specimens, with test surfce perpendiculr to the weld xis. Other test methods hve to be greed with GL prior to testing. Two test rows re necessry in ccordnce with Figure 1.5. At lest three individul indenttions in the weld metl, the het ffected zones (both sides of the weld) nd the bse metl (both sides of the weld) re required in ccordnce with Figure 1.6. The distnce between the indenttions is 1 mm in cse of Vickers HV10. Fig. 1.5 Exmples of hrdness test with rows of indenttions in butt welds

11 II - Prt 3 Section 1 F Welding of Hull Structures Chpter 3 Pge 1 15 Fig. 1.6 Exmple of hrdness indenttions in butt welds More exmples concerning hrdness indenttions re presented in EN / ISO The results from the hrdness test hve not to exceed hrdness of 350 HV10 in cse of higher strength steel, steel csting nd forgings with specified minimum yield strength of ReH 400 N/mm Fillet welds The following requirements refer to fillet welds on pltes nd sections. Concerning fillet weld on pipelines, see Section 4. In cse tht fillet welding procedure shll be used for pltes nd sections, coted with n overweldble shop primer, similrly coted pltes hve to be used during the procedure test for fillet welds in the sme mnner. The kind of the shop primer nd dry-film thickness hve to be indicted in the report. Fillet weld test pieces (T- joint nd/or double T-joint (cruciform) test pieces) hve to be welded with root gps not greter thn 0.5 mm. Depending on the subsequent prctice, tcks shll lso be included in the test (nd overwelded where pplicble). The throt thickness of the fillet shll correspond to those used in subsequent fbriction, but shll not be greter thn 0.5 times the plte thickness Test ssembly nd dimension Depending on the welding position to be qulified, Tjoint nd/or double T-joint (cruciform) test pieces re necessry. In cse of verticl down welding (PG) double T-joint (cruciform) test pieces re lwys required for pltes coted with shop primer nd lso for pltes without shop primer. In cse of the other welding positions (PA, PB, PD, PF) T-joint test pieces re sufficient but only for pltes coted with shop primer. The evlution of fillet welds on pltes without shop primer coting in welding positions (PA, PB, PD, PF) cn tke plce in the scope of butt weld procedure test fter GL s greement T-joint test pieces The test ssembly hs to be gret enough in order to ensure resonble het distribution. The dimension of the test piece hs to be djusted to the welding procedure nd to the number of test specimens. Following minimum dimensions of test piece re required: mnul nd semi-utomtic welding: width = 3 x t, min. 150 mm length b = 6 x t, min. 350 mm utomtic welding: width = 3 x t, min. 150 mm length b = 1000 mm The test ssembly is represented in Figure 1.7.

12 Chpter 3 Pge 1 16 Section 1 F Welding of Hull Structures II - Prt 3 t 1, t 2 = plte thickness of test pieces t 2 Fig Test ssembly for fillet weld in welding positions PA, PB, PD, PF Where, in order to estblish the mechnicl nd technologicl chrcteristics of the welded joints, especilly in fully mechnized nd/or utomtic welding processes, test piece lengths re selected which re considerbly smller thn the weld lengths to be lid down during lter fbriction, the first fbriction welds shll be included s prt of the welding procedure tests nd, s minimum requirement, shll be subjected to visul inspection or production tests shll be rrnged to ensure trouble-free welding procedure nd to detect possible imperfections in the weld Double T- joint (cruciform) test pieces The test ssembly hs to be gret enough in order to ensure resonble het distribution. The dimension of the test piece hs to be djusted to the welding procedure nd to the number of test specimens. The minimum dimensions of test piece nd the test ssembly re shown in Figure 1.8 concerning mnul nd semi-utomtic welding procedures nd in Figure 1.9 concerning utomtic welding procedures. Sets of specimens ³ 100 ³ 350 ³ 150 t 1 b Sets of specimens 50 ³ 1000 (³ 3000) ³ 150 ³ 150 Remining fillet welds to be frctured on lternte sides Fig. 1.8 Double T- joint (cruciform) test pieces for mnul nd semi-utomtic welding procedures (welding position PG) ³ 150 ³ Remining fillet welds to be frctured on lternte sides Fig. 1.9 Double T- joint (cruciform) test pieces for utomtic welding procedures

13 II - Prt 3 Section 1 F Welding of Hull Structures Chpter 3 Pge Welding of test pieces For single run mnul nd semi-utomtic fillet welding, stop/restrt hs to be included in the test length nd its position is to be clerly mrked for subsequent exmintion. If tck welds re intended to be overwelded in the subsequent production, they hve to be considered in the test piece s well. T-joint test pieces hve to be welded on one side only. Only one welding position shll be used per test piece. M Z Z Z Reminder for retests M ~ Exmintions nd tests Test ssemblies hve to be exmined nondestructively nd destructively in ccordnce with the following: Exmintions nd tests of T-joint test pieces Visul testing 100 % Surfce crck detection 100 % (dye penetrnt testing or mgnetic prticle testing) Mcro exmintion 2 specimens (see section ) Hrdness test required (see section ) Frcture test required (see section ) Exmintions nd tests of double-t joint (cruciform) test pieces Visul testing 100 % Surfce crck detection 100 % (dye penetrnt testing or mgnetic prticle testing) As shown in Figures 1.8 nd 1.9, one or more sets of test specimens shll be tken from the (cruciform) fillet-welded test pieces in ccordnce with Figure A set of (cruciform) fillet weld test specimens shll include the following specimens. The specimen shpes nd dimensions hve to be in line with Chpter 2 Design, Fbriction nd Inspection of Welded Joints, Section 5. One set of test specimens hs to include the following specimens: Cruciform tensile test specimens (Z) 3 specimen (see section ) Mcrogrphic exmintion (M) 2 specimen (see section ) Hrdness test required (see section ) Frcture test required, from the remining test piece on lternte side (see section ) 50 ~35 ~35 ~35 50 Fig Set of double-t (cruciform) test specimens Non-destructive testing Test ssemblies hve to be exmined by visul nd non-destructive testing prior to the cutting of test specimens. In cse tht ny post-weld het tretment is required or specified, the non-destructive testing hs to be performed fter the het tretment. GL my require specific testing intervls to be dhered to between completion of the welding work nd performnce of the crck tests, unless het tretment hs been executed. Imperfections detected by visul or non-destructive testing hve to be ssessed in ccordnce with ISO 5817, qulity level B (except for excess convexity nd excess throt thickness for which the qulity level C pplies) Mcro exmintion The exmintion of the mcro-structure hs to be executed on minimum two polished section. For single run mnul nd semi-utomtic fillet welds one mcro-section is necessry in the stop/restrt re. The polished surfce of the section hs to be tken perpendiculr to the weld xis. The mcro specimen shll be of such size nd treted by grinding nd etching in such wy s to revel the nture nd structure of the crystlliztion of the weld metl nd the het-ffected zone s well s the texture of the bse metl. For the mcro exmintion, minimum 10 mm out off the het ffected zone from the bse mteril hs to be considered. The polished sections shll be photogrphed nd the photos ppended to the inspection report. Mcrogrphs shll normlly be to scle of 1:1 to 1:3; if the cross-sectionl re of the weld is smll, they my be mgnified. The specimens hve to be ssessed in ccordnce with ISO 5817, qulity level B, except for excess convexity nd excess throt thickness for which the qulity level C pplies Hrdness tests The hrdness test is required for steels with specified minimum yield strength of R eh 355 N/mm 2 nd in generl for steel cst nd forgings. The Vickers method with test strength of 98N (HV10) hs nor-

14 1 4 Chpter 3 Pge 1 18 Section 1 F Welding of Hull Structures II - Prt 3 mlly to be used. The hrdness hs to be verified on ground nd etched specimens, with test surfce perpendiculr to the weld xis. Other test methods hve to be greed with GL prior to testing. Two test rows re necessry in ccordnce with Figure At lest three individul indenttions in the weld metl, the het ffected zones (both sides of the weld) nd the bse metl (both sides of the weld) re required in ccordnce with Figure The distnce between the indenttions is 1 mm in cse of Vickers HV10. Further exmples for hrdness tests with indenttions re given in EN / ISO The results from the hrdness test hve not to exceed hrdness of 350HV10 in cse of higher strength steel, steel csting nd forgings with specified minimum yield strength of R eh 400 N/mm 2. Fig Exmple of hrdness indenttions in fillet weld Cruciform tensile test The cruciform tensile test specimens hve to be evluted in order to determine the tensile-sher strength of the weld metl ccording to Fig. 13. Before the performnce of cruciform tensile tests, the fillet weld throt thicknesses nd the width of the specimens hve to be mesured. The width of the specimen should be bout 35 mm. 3 2 Fig Exmple of hrdness test with row indenttion in fillet welds = frcture section S 1/ = frcture section S 3/4 Breking lod F Tensile-sher strength = [N/mm 2 ] S B width of secimen Frcture test S B = S 1/2 or S 3/4 ccording to position of frcture The frcture test hs to be performed in ccordnce with EN 1320 / ISO Evlution is to concentrte on crcks, porosity nd pores, inclusions, lck of fusion nd incomplete penetrtion (penetrtion of the theoreticl root point), to be ssessed in ccordnce with ISO 5817, qulity level B. Fig Cruciform tensile test specimen (weld cross section) Mesured on cruciform tensile test specimens, the minimum tensile (tensile-sher) strength of the weld section (frcture section in ccordnce with Fig. 1.13) shll meet the requirements stted in Tble 1.4.

15 II - Prt 3 Section 1 F Welding of Hull Structures Chpter 3 Pge 1 19 Tble 1.4 Requirements pplicble to cruciform tensile specimens ssembly hs to be welded using the sme procedure to provide the dditionl specimens. Grdes Tensile-sher strength [N/mm 2 ] A E 350 A 32 F A 40 F Re-testing If the test specimen fils to comply with ny of the requirements for visul or non-destructive testing one further test piece is to be welded nd subjected to the sme exmintion. If this dditionl test piece does not comply with the relevnt requirements, the pwps hs to be regrded s not cpble of complying with the requirements without modifiction. If ny test specimen fils to comply with the relevnt requirements for destructive testing due to weld imperfections only, two further test specimens hve to be obtined for ech one tht filed. These specimens cn be tken from the sme test specimen if there is sufficient mteril vilble or from new test specimen, nd hve to be subjected to the sme test. If one of these dditionl test specimens does not comply with the relevnt requirements, the pwps hs to be regrded s not cpble of complying with the requirements without modifiction. If tensile test specimen fils to meet the requirements, two more tensile tests my be performed. If both dditionl specimens comply with the requirement, the tensile test is pssed. If one or both of the dditionl specimens do not comply with the requirement, the tensile test nd thus the procedure test hs been filed. If there is single hrdness vlue bove the mximum vlues llowed, dditionl hrdness tests re to be crried out (on the reverse of the specimen or fter sufficient grinding of the tested surfce). None of the dditionl hrdness vlues is to exceed the mximum hrdness vlues required. When the verge vlue of the three initil Chrpy V- notch impct specimens fils to meet the stted requirement, or the vlue for more thn one specimen is below the required verge vlue, or when the vlue of ny one specimen is below 70 % of the specified verge vlue, three dditionl specimens from the sme test piece my be tested nd the results dded to those previously obtined to form new verge. However, of the six individul vlues only two my be below the required verge vlue, of which only one individul vlue my be less thn 70 % of the prescribed verge vlue. Otherwise the impct test nd thus the procedure test hs been filed. Where there is insufficient welded ssembly remining to provide dditionl test specimens, further 4.5 Test record Welding conditions for test ssemblies nd test results hve to be recorded in welding procedure test record nd signed by the tester nd the testing supervisor submitted to GL. The relevnt items listed for the WPS of these requirements hve to be included. The welding procedure test record hs to be signed by the Surveyor witnessing the test nd submitted to GL together with the welding procedure specifiction for the finl pprovl of the welding procedure. 5. Welding procedure qulifiction tests for high-strength (quenched nd tempered) fine-grined steels with specified minimum yield strength R eh > 400 N/mm 2 Unless no further sttements to the procedure tests re mde in the following, the requirements given in the previous sections pply. For welding procedure tests on high-strength steels intended for hull structures the GL cceptnce on cse by cse decision is necessry. The requirements will be defined seprtely. 5.1 The following requirements pply for highstrength (quenched nd tempered) fine-grined steels for welded structures ccording to the GL Mteril Rules. Comprble high-strength steels, suitble for welding, cn only be used with GL s greement. 5.2 For high-strength nd quenched nd tempered steels with specified minimum yield strength R eh > 400 N/mm 2, the non-destructive test hs to be crried out t lest 48 hours fter the welding, unless het tretment hs been crried out. 5.3 A round tensile test specimen is to be prepred in every cse where the mechnicl properties of the weld metl re inferior to those of the bse mteril. 5.4 The bending tests hve to be performed, depending of the specified minimum yield strength in the rnge of 420 N/mm 2 up to 500 N/mm 2 using mndrel with dimeter of 5 times the specimen thickness, nd in the rnge bove 500 N/mm 2 up to 690 N/mm 2 using mndrel with dimeter of 6 times the specimen thickness. The required bending ngle is For high-strength nd quenched nd tempered steels, where the impct energy hs been demonstrted in trnsverse direction (CVN-T), the welding sem hs to be rrnged prllel to the rolling direction of both pltes. The requirements for the impct energy nd the test temperture re the sme s for the bse mteril. 5.6 The results of the hrdness test for highstrength nd quenched nd tempered steels of speci-

16 Chpter 3 Pge 1 20 Section 1 F Welding of Hull Structures II - Prt 3 fied minimum yield strength R eh > 400 N/mm 2 nd R eh 690 N/mm 2 shll not exceed hrdness of 420 HV For fillet welds on high-strength nd quenched nd tempered steels with specified minimum yield strength R eh > 460 N/mm 2 seprtely fillet weld procedure tests re required using double-t joint (cruciform) test specimens. If the frcture occurs in the bse mteril, t lest the minimum tensile strength of the bse mteril is to be chieved. If the frcture occurs in the cross-section of the weld sem, the tensile-sher strength is to be determined, tking into considertion the ctul cross-section of the weld sem. Where necessry, the melting depth hs to be considered which exceeds the theoreticl root point. The men tensile-sher strength determined in the weld sem cross-section shll be t lest 80 % of the tensile strength of the bse mteril used. 5.8 For the rnge of ppliction see Section Austenitic stinless (cld) nd usteniticferritic (duplex) steels If no further sttements re mde regrding welding procedure tests in the following, the Rules Chpter 1 Generl Requirements, Proof of Qulifictions, Approvls, Section 4 or respectively the stndrds of series EN ISO re pplicble. 6.1 For welding procedure tests for ustenitic stinless steels for liquefied nturl gs tnks see GL Rules I Ship Technology, Prt 1 Segoing Ships, Chpter 6 Liquefied Gs Crriers. 6.2 The minimum properties specified in Chpter 1 Generl Requirements, Proof of Qulifictions, Approvls, Section 5, for the testing of welding consumbles nd uxiliry mterils shll be met for butt weld specimens. In the cse of joints between different types of steels, the strength vlues of the bse mteril which hs the lower strength, shll be used. 6.3 Unless otherwise greed in n individul cse, bending mndrel dimeter of three times the specimen thickness my be used for the bending test nd test temperture of minus 30 C for the notched br impct test performed on ustenitic-ferritic (duplex) steels. For ustenitic stinless mterils normlly no notched br impct tests hve to be performed unless the qulifiction of the welding procedures is necessry for low temperture ppliction. Hrdness test for ustenitic stinless mterils hve normlly not to be performed s well. For such mterils, dye penetrtion tests hve to be crried out. 6.4 Depending on the field of ppliction or if required for the bse mteril, dditionl corrosion protection tests hve to be performed within the scope of welding procedure tests, e.g. testing of resistnce ginst intergrnulr corrosion. 6.5 For test specimens of ustenitic-ferritic (duplex) steels determintion of the ferrite content is dditionlly necessry, which should not be less thn 30 % in both the welding mteril nd in the het ffected zone. 7. Aluminium lloys If in the following no sttements re mde for welding procedure tests, the requirements of the Rules in Chpter 1 Generl Requirements, Proof of Qulifictions, Approvls, Section 4 or respectively the stndrds given in EN ISO re pplicble. 7.1 For welding procedure tests nd tests on production specimens relting to luminium lloys, the vlues specified in Tble 1.5 shll be used s stndrd vlues for butt weld specimens tken from 5000 nd 6000 series lloys s stipulted in the GL Rules for Mterils. Alloys of the 5000 nd 6000 series seprtely to be qulified within the scope of welding procedure tests. Welding procedure tests on mterils of higher strength in ech of the 5000 nd 6000 series include mterils of lower strength. In no cse the tensile strength of the specimens shll not be less thn the minimum stipulted vlue for the bse mteril in its "soft" condition. During design nd dimensioning opertions, these differing vlues hve to be considered, where pplicble. The stipulted tensile strength vlues pply to test specimens retining the weld reinforcement. Other luminium lloys shll be clssified in nlogous mnner, nd the requirements for this re specified on cse-by-cse bsis under considertion the chrcteristics of the bse mteril nd the joint efficiency fctors stipulted in EN ISO

17 II - Prt 3 Section 1 F Welding of Hull Structures Chpter 3 Pge 1 21 Tble 1.5 Requirements pplicble to luminium lloys Bse mteril Welded joints 1 Alloy no. Mteril designtion 0,2 %-proof stress 2 [N/mm 2 ] Tensile strength [N/mm 2 ] Bending ngle 3 [degree] Bending elongtion [%] EN AW-5083 AlMg4,5Mn0, EN AW-5086 AlMg EN AW-5383 AlMg4,5Mn0,7mod EN AW-5754 AlMg EN AW-5059 AlMg5,5Mn0,8ZnZr EN AW-6005A AlSiMg(A) EN AW-6061 AlMgSilCu EN AW-6082 AlSilMgMn Using weld consumble of qulity grde in ccordnce with the bse mteril ccording to Chpter 1, Section 5, J. 2 As fr s estblished (on dditionl smples which re to be greed). 3 Bending mndrel- to be selected depending on the mteril group nd condition ccording EN ISO The required bending ngle of 180 under the test conditions specified in EN 910/ISO 5173 is deemed to hve been ttined when the specimen hs been forced between the supporting rolls to the minimum length specified in this stndrd. The required bending elongtion shll be ttined before the first incipient crck ppers. Minor pore exposures or the like, up to mximum length of 3 mm, my be tolerted. The frcture surfces of ruptured test specimens shll be evluted. 7.3 If fillet welding is pplicble during the fbriction, seprtely fillet weld procedure tests re required using double-t joint (cruciform) test specimens. If the rupture occurs in the bse mteril, t lest the minimum tensile strength of the bse mteril in its soft condition hs to be chieved. If the rupture occurs in the cross-section of the weld sem, the tensile-sher strength hs to be determined, tking the ctul cross-section of the weld sem into considertion. Where necessry, the melting depth which exceeds the theoreticl root point hs to be considered. The men tensile-sher strength determined in the weld sem cross-section shll be t lest 60 % of the tensile strength of the used bse mteril. Necessry mrgins (if this vlue is not ttined) hve to be considered for the dimensioning of fillet joints. 7.4 For the welding procedure tests nd tests on production specimens relting to luminium lloys, unless otherwise stipulted in individul cses, the notch impct toughness test my be omitted. The requirements pplicble to low temperture pplictions will be seprtely specified. 8. Other mterils or welding processes The requirements pplicble to other mterils or other test methods will be determined on cse-bycse bsis in mnner nlogous to tht pplied to the mterils covered erlier, on the bsis of their chemicl composition, mechnicl properties nd other chrcteristics of the bse mterils nd with due regrd for the nticipted operting conditions, such s the lowest nticipted service temperture (design). 9. Scope of ppliction 9.1 Generl All the conditions of vlidity stted below hve to be met independently of ech other. 9.2 Chnges outside of the rnges specified nd pproved by GL require new welding procedure test. 9.3 Shop primers my hve n influence on the qulity of fillet welds. Therefore they hve to be tken into ccount for the testing. Welding procedure qulifiction with shop primer will qulify those without shop primer, but not vice vers.

18 Chpter 3 Pge 1 22 Section 1 F Welding of Hull Structures II - Prt Bse metl Norml- nd higher strength hull structurl steels The strength level (--, 32, 36, 40) nd the toughness grde (A/A, B, D/D, E/E, F ) of the specimen re decisive for the scope of ppliction. ) For ech strength level, welding procedures re considered pplicble to the sme nd lower toughness grdes s the tested one. b) For ech toughness grde, welding procedures re considered pplicble to the sme nd two lower strength levels s the tested one. c) For pplying the bove ) nd b) to high het input processes bove 50 kj/cm, e.g. the two-run technique with either submerged rc or gs shielded metl rc welding, electro slg nd electro gs welding, welding procedure is pplicble to tht toughness grde tested nd one strength level below. If steels used for construction re supplied with different delivery conditions s those tested, GL my require dditionl tests. Welding procedure tests of thermo-mechniclly rolled (TM) steels do not include normlised steels, however vice vers High strength (quenched nd tempered) steels with R eh > 400 N/mm 2 ) For ech strength level, welding procedures re considered pplicble to the sme nd lower toughness grdes s the tested one. b) For ech toughness grde, welding procedures re considered pplicble to the sme nd one lower strength level s the tested one. c) The pprovl of quenched nd tempered steels does not qulify thermo-mechniclly rolled steels (TMCP steels) nd vice vers Weldble C nd C-Mn hull steel forgings ) Welding procedures re considered pplicble to the sme nd lower strength level s the tested one. b) The pprovl of quenched nd tempered hull steel forgings does not qulify other delivery conditions nd vice vers. These hve to be tested nd qulified seprtely Weldble C nd C-Mn hull steel cstings ) Welding procedures re considered pplicble to the sme nd lower strength level s the tested one. b) The pprovl of quenched nd tempered hull steel cstings does not qulify other delivery conditions nd vice vers. These hve to be tested nd qulified seprtely. 9.5 Thickness The qulifiction of WPS crried out on test ssembly of thickness t is vlid for the thickness rnge given in Tble In ddition to the requirements of Tble 1.6, the rnge of pprovl of throt thickness for fillet welds is to be s follows: single run: 0.75 x to 1.5 x multi-run: s for butt welds with multi-run (i.e. = t) For the verticl-down welding, the test piece thickness t is lwys tken s the upper limit of the rnge of ppliction For unequl plte thickness of butt welds, the lesser thickness is the ruling dimension. Tble 1.6 Approvl rnge of thickness for butt nd filled welds Thickness of test piece t (mm) 1 Butt welds with single run or single run from both sides Rnge of pprovl 4 Butt welds with multi-run nd fillet welds 2 3 < t 12 0,7 x t to 1,1 x t 3 to 2 x t < t 100 0,7 x t to 1,1 t 3 0,5 x t to 2 x t (mx. 150 mm) For multi process procedures, the recorded thickness contribution of ech process is to be used s bsis for the rnge of pprovl for the individul welding process. For fillet welds, the rnge of pprovl is to be pplied to both bse metls (web nd flnge thickness) For high het input processes over 50 kj/cm, the upper limit of rnge of pprovl is to be 1.0 x t. T-butt welds re in generl qulified by butt welds. GL my dditionlly require welding procedure tests s T-joint welds, e.g. for prticulr weld shpes.

19 II - Prt 3 Section 1 F Welding of Hull Structures Chpter 3 Pge Notwithstnding the bove, the pprovl of mximum thickness of bse metl for ny technique hs to be restricted to the thickness of test ssembly if three of the hrdness vlues in the het ffected zone re found to be within 25 HV of the mximum permitted, s stted in , nd Welding positions Approvl for test mde in ny position is restricted to tht position. To qulify rnge of positions, test ssemblies hve to be welded for highest het input position (normlly verticl-up position (PF)) nd lowest het input position (normlly horizontl-verticl (PC)). The verticl-down welding position (PG), in generl, hs to be tested seprtely. 9.7 Welding process The pprovl is only vlid for the welding process(es) used in the welding procedure test. A chnge from multi-run to single run is not llowed For multi-process procedures, the welding procedure pprovl my be crried out with seprte welding procedure tests for ech welding process. It is lso possible to mke the welding procedure test s multi-process procedure test. The pprovl of such test is only vlid for the process sequence crried out during the multi-process procedure test In generl, full mechnized nd utomtic (robot) welding procedures hve to be qulified seprtely from the semi-utomtic welding procedures. 9.8 Welding consumbles Welding consumbles nd uxiliry mterils my be replced by other equivlent, suitble, with corresponding qulity grde nd with GL pprovl, if this is explicitly stted in the welding procedure pprovl. 9.9 Het input The upper limit of het input pproved is 25 % greter thn tht used in welding the test piece or 55kJ/cm whichever is smller, except tht the upper limit is 10 % greter thn tht for high het input processes over 50 kj/cm The lower limit of het input pproved is 25 % lower thn tht used when welding the test piece Preheting nd interpss temperture The minimum preheting temperture hs not to be less thn tht used in the beginning of the welding of the test piece. If necessry, for the higher rnge of thicknesses, the specifiction of the preheting temperture my be incresed. For the necessity nd mount of preheting see Chpter 2 Design, Fbriction nd Inspection of Welded Joints, Section The mximum interpss temperture hs not to be higher thn tht used when welding the test piece. The stndrd vlues for the mximum interpss temperture ccording to Chpter 2 Design, Fbriction nd Inspection of Welded Joints, Section 3 hve to be observed Post-weld het tretment The het tretment used in the qulifiction test hs to be mintined during mnufcture. The holding time my be djusted s function of thickness. Further notes with reference to post-weld het tretment see Chpter 2 Design, Fbriction nd Inspection of Welded Joints, Section Type of joint The rnge of pprovl depending on type of welded joints for test ssembly is shown in Tble A qulifiction test performed on butt weld, if no shop primers re overwelded, will lso qulify for fillet welding within the thickness rnges specified for fillet welds specified in bove. Additionl qulifiction tests, e.g. for T-joints, my be required by GL, e.g. if the edge preprtion (root gp, included ngle) hs been chnged nd lck of fusion, insufficient penetrtion or negtive influence on the mechnicl-technologicl properties cnnot be excluded. Tble 1.7 Rnge of pprovl for type of welded joint Type of welded joint for test ssembly Rnge of pprovl Butt welding one side both side with bcking A A, C without bcking B A, B, C, D with gouging C C without gouging D C, D