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1 Table of Contents Page No. Personnel... iii Foreword...v List of Tables...xii List of Figures... xiii 1. General Requirements Scope Approval Definitions Welding Symbols Safety Precautions Standard Units of Measure Reference Documents Design of Welded Connections Scope Structural Design Drawings Groove Welds Fillet Welds Plug and Slot Welds Filler Plates Qualification...9 Part A General Requirements General Qualification of WPSs Qualification of Welders, Welding Operators, and Tack Welders Position of Test Welds...9 Part B Types of Tests, Test Methods, and Acceptance Criteria Types and Purposes of Tests Visual Examination Tension Tests Groove Welds Bend Tests Groove Welds Plate and Pipe Soundness Tests Groove Welds in Castings Soundness Tests Fillet Welds RT...14 Part C WPS Qualification General Limits of Qualified Positions for WPSs Limitation of Essential Variables WPS Qualification Tests WPS Qualification Retests...16 Part D Performance Qualification General Limits of Qualified Positions for Performance...16 vii

2 3.19 Preparation of Test Weldments Performance Qualification Essential Variables Tests Performance Qualification Retests Period of Effectiveness Fabrication Scope Processes Base Metal Filler Metal Tungsten Electrodes Shielding Gas Welding and Cutting Equipment Backing Preheat and Interpass Temperatures Welding Environment Compliance with Design Preparation of Base Metal Assembly Technique Tack and Temporary Welds Dimensional Tolerances for Welded Members Arc Strikes Weld Termination Control of Distortion and Shrinkage Weld Profiles Repairs Copper Inclusions Cleaning of Completed Welds Anti-Spatter Compound Postweld Heat Treatment Inspection...77 Part A General Requirements General Inspection of Materials Inspection of WPS Qualification and Equipment Inspection of Welder, Welding Operator, and Tack Welder Qualifications Inspection of Work and Records Obligations of the Contractor Nondestructive Testing Extent of Testing...79 Part B Radiographic Testing (RT) of Groove Welds in Butt Joints General RT Procedures Acceptability of Welds Examination, Report, and Disposition of Radiographs...82 Part C Ultrasonic Testing (UT) of Groove Welds General...82 Part D Acceptance Criteria Visual Inspection...83 viii

3 5.15 RT UT PT Stud Welding...97 Part A General Requirements General Material Requirements Workmanship Qualification Requirements Operator and Preproduction Qualification Acceptance Criteria Production Welds Mislocated Studs Repair of Misapplied Studs...99 Part B Arc Stud Welding General Requirements Material Requirements Workmanship Technique...99 Part C Capacitor Discharge Stud Welding General Requirements Material Requirements Technique Strengthening and Repair of Existing Structures General Base Metal Design Repair Procedure Inspection Nonmandatory Annexes Annex A Reference Documents Annex B Recommended Groove Welded Joints Annex C Examples of Tubular Connections Annex D Effective Throat Annex E Sample Welding Forms Annex F Sample NDT Forms Annex G Solutions for Macroetching Aluminum Weldments Annex H Guide for Specification Writers Annex I Safe Practices Annex J Tungsten Electrodes Annex K Guidelines for Preparation of Technical Inquiries for AWS Technical Committees Annex L Reorganization Commentary Foreword C1. General Requirements C1.1 Scope C2. Design of Welded Connections C2.0 Scope C2.1 Structural Design C2.2 Drawings ix

4 C2.3 Groove Welds C2.5 Plug and Slot Welds C3. Qualification Part A General Requirements C3.1 General C3.3 Qualification of Welders, Welding Operators, and Tack Welders Part B Types of Tests, Test Methods, and Acceptance Criteria C3.5 Types and Purposes of Tests C3.8 Bend Tests Groove Welds Plate and Pipe Part C WPS Qualification C3.13 Limits of Qualified Positions for WPSs C3.14 Limitation of Essential Variables WPS Qualification C3.15 Tests WPS Qualifications Part D Performance Qualification C3.17 General C3.20 Essential Variables C3.22 Retests C4. Fabrication C4.1 Processes C4.2 Base Metal C4.3 Filler Metal C4.8 Preheat and Interpass Temperatures C4.9 Welding Environment C4.11 Preparation of Base Material C4.12 Assembly C4.13 Technique C4.14 Tack and Temporary Welds C4.15 Dimensional Tolerances for Welded Members C4.16 Arc Strikes C4.17 Weld Termination C4.18 Control of Distortion and Shrinkage C4.19 Weld Profiles C4.20 Repairs C4.24 Postweld Heat Treatment C5. Inspection Part A General Requirements C5.1 General C5.2 Inspection of Materials C5.3 Inspection of WPS Qualification and Equipment C5.4 Inspection of Welder, Welding Operator, and Tack Welder Qualifications C5.5 Inspection of Work and Records C5.6 Obligations of the Contractor C5.7 NDT C5.8 Extent of Testing Part B RT of Groove Welds in Butt Joints C5.9 General C5.10 RT Procedures C5.12 Examination, Report, and Disposition of Radiographs x

5 Part C UT of Groove Welds C5.13 General C6. Stud Welding Part A General Requirements C6.2 Material Requirements C6.3 Workmanship C6.4 Qualification Requirements C6.5 Operator Preproduction Qualification C6.6 Acceptance Criteria Production Welds C6.7 Mislocated Studs C6.8 Repair of Misapplied Studs Part B Arc Stud Welding C6.12 Technique C7. Strengthening and Repair of Existing Structures C7.1 General C7.2 Base Metal C7.3 Design Index List of AWS Documents on Structural Welding xi

6 Table List of Tables Page No. 2.1 Minimum Diameter of Hole for Plug Welds or Width of Slot for Slot Welds Limitations of Essential Variables of a WPS Tensile Strength of Welded Aluminum Alloys (GTAW or GMAW with No Postweld Heat Treatment) WPS Qualification Type of Weld and Position Limitations Number and Type of Test Specimens and Range of Thickness Qualified WPS Qualification CJP Groove Welds Number and Type of Test Specimens and Range of Thickness Qualified WPS Qualification PJP Groove Welds Number and Type of Test Specimens and Range of Thickness Qualified WPS Qualification Fillet Welds Welder Performance Qualification Type of Weld and Position Limitations Number and Type of Test Specimens and Range of Thickness Qualified Welder and Welding Operator Qualification Welding Personnel Performance Essential Variable Changes Requiring Requalification Aluminum Alloy Products Available for Structural Applications Recommended Aluminum Alloy Filler Metals for Structural Welding of Various Base Aluminum Alloys Limit of Acceptability and Repair of Cut Edge Discontinuities in Plate Technique Maximum Heat Exposure Time at Temperature Hole-Type IQI Requirements Wire IQI Requirements Acceptable Undercut Values (Cyclically Loaded Nontubular Structures) Maximum Acceptable Porosity in Radiographs for Any 3 in. [75 mm] Length of Weld (Cyclically Loaded Nontubular) Acceptance Criteria Class I Structures Acceptance Criteria Class II Structures Maximum Acceptable Porosity in Radiographs for Any 3 in. [75 mm] Length of Weld (Tubular) Minimum Required Torque Values and Tension Loads for Welding F-22 Aluminum-Alloy Studs Stud Alloys for Arc Stud Welding of Various Base Alloys Stud Alloys for Capacitor Discharge Stud Welding of Various Base Alloys J-1 Typical Current Ranges for Tungsten Electrodes J-2 Typical Chemical Composition of Tungsten Electrodes xii

7 Figure List of Figures Page No. 2.1 Details of Skewed T-Joints Filler Plates Less Than 1/4 in. [6 mm] in Thickness Filler Plates 1/4 in. [6 mm] or More in Thickness Positions of Groove Welds Positions of Fillet Welds Position of Test Plates for Groove Welds Position of Test Pipes for Groove Welds Position of Test Plates for Fillet Welds Position of Test Pipes for Fillet Welds Reduced Section Tension Specimens Plate and Pipe Alternate Reduced Section Tension Specimen for Pipe (3 in. [75 mm] Diameter or Less) Full Section Tension Specimens Small Diameter Pipe (3 in. [75 mm] Diameter or Less) Transverse Side Bend Specimens Longitudinal Face and Root Bend Specimens Transverse Face and Root Bend Specimens Wraparound Guided Bend Jig Plunger-Type Guided Bend Jig Roller-Type Guided Bend Jig Fracture Test Specimen for WPS Qualification of Cast to Cast or Cast to Wrought Alloys Fillet Weld Soundness Test for WPS Qualification Option 1 Plate Fillet Weld Soundness Test for WPS Qualification Pipe Fillet Weld Soundness Test for WPS Qualification Option 2 Root Bend Test Plate Location of Test Specimens for WPS Qualification Plate Location of Test Specimens for WPS Qualification Pipe Location of Test Specimens for WPS Qualification Box Tubing Location of Test Specimens for WPS Qualification Job Size Pipe or Tubing 1/16 in. [2 mm] through 3/8 in. [10 mm] Wall Thickness Location of Test Specimens for WPS Qualification Job Size Pipe or Tubing over 3/8 in. [10 mm] Wall Thickness Performance Qualification in All Positions Plate Thickness T 1/8 in. [3 mm] Performance Qualification in All Positions Plate Thickness T > 1/8 in. [3 mm] Performance Qualification in the Horizontal Position Plate Thickness T > 1/8 in. [3 mm] Alternative Groove Weld Qualification Test Plate: All Thicknesses Tubular Groove Weld Performance Qualification Without Backing Tubular Groove Weld Performance Qualification Without Backing (Alternative to Figure 3.29) Tubular Groove Weld Performance Qualification With Backing Fillet Weld or Tack Welder Performance Qualification Plate Fillet Weld or Tack Welder Performance Qualification Pipe or Tubing Location of Test Specimens on Welded Test Pipe and Box Tubing Performance Qualification Edge Discontinuities in Cut Plate Acceptable and Unacceptable Weld Profiles Radiographic Identification and Hole-Type or Wire IQI Locations on Approximately Equal Thickness Joints 10 in. [250 mm] and Greater in Length Radiographic Identification and Hole-Type or Wire IQI Locations on Approximately Equal Thickness Joints Less than 10 in. [250 mm] in Length...89 xiii

8 5.3 Radiographic Identification and Hole-Type or Wire IQI Locations on Transition Joints 10 in. [250 mm] and Greater in Length Radiographic Identification and Hole-Type or Wire IQI Locations on Transition Joints Less Than 10 in. [250 mm] in Length Hole-Type IQI Design Wire IQI RT Edge Blocks Acceptable Undercut for Nontubular Statically Loaded Structures Acceptable Undercut for Total Length of Joint Class I Tubular Structures Stud Weld Bend Jig Torque Testing Arrangement for Stud Welds Annexes B1 Recommended CJP Groove Welded Joints B2 PJP Box Connections B3 PJP Circular Tubular Joints for T-, Y-, and K-Connections Made by GTAW and GMAW C1 Examples of Tubular Connections D1 Effective Throats of PJP Groove Welds Reinforced with Fillet Welds Commentary C4.1 Examples of Unacceptable Cutting Beyond the Point of Tangency C4.2 Permissible Offset in Abutting Members C4.3 Correction of Misaligned Members C4.4 Measurement of Flange Warpage and Tilt xiv