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Welding Machine Pre Start Checklist

Welding procedures must be qualified through inspection and testing of weld samples to ensure acceptable welds. The qualification involves documenting welding variables and testing samples to verify they meet standards. For fillet welds, samples undergo visual inspection, macro etching of two samples, and a fillet weld break test. For groove welds, samples undergo visual inspection and mechanical testing including two tensile tests, two root bends, and two face bends. Qualification demonstrates welding can meet a recognized standard through inspection and testing of samples.

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204 views2 pages

Welding Machine Pre Start Checklist

Welding procedures must be qualified through inspection and testing of weld samples to ensure acceptable welds. The qualification involves documenting welding variables and testing samples to verify they meet standards. For fillet welds, samples undergo visual inspection, macro etching of two samples, and a fillet weld break test. For groove welds, samples undergo visual inspection and mechanical testing including two tensile tests, two root bends, and two face bends. Qualification demonstrates welding can meet a recognized standard through inspection and testing of samples.

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yesp1976
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Inspection and Testing for Welding Procedure

Qualification

17

Welding Procedures are the guidelines used to perform a weld. They are designed to provide
a record of the welding variables used and the inspection results obtained during the
procedure qualification test. They can also provide the instructions for the welder to use in
production in order to produce acceptable welds. Usually welding procedures are developed
in accordance with a welding code or standard, and with few exceptions*, require that
physical weld samples be produced, inspected, and tested to establish qualification. Welding
procedures are usually divided into two categories, the Procedure Qualification Record
(PQR) and the Welding Procedure Specification (WPS).

Procedure Qualification Records are the documented values used during the actual welding
test and all the inspection and test results obtained from the actual test samples.

Welding Procedure Specifications are usually documented work instructions that can be used
by the welder to conduct welding operations, and are based on, but not necessarily the same
as, the parameters used for the Procedure Qualification Record.

We will consider the Procedure Qualification Record and the inspection and testing
performed during its qualification.

Qualification testing of a welding procedure normally requires documentation to show all the
variables used during the welding test and the documented inspection and test results. The
variables required to be documented are typically such items as: welding process used, size,
type and classification of filler alloy, type and thickness of base material welded, type and
polarity of welding current, amps and volts recorded, travel speed during welding, welding
position, type and dimensions of joint design, preheating temperature, interpass temperature,
post weld heat treatment details, and others. In addition to the recording of all the welding
variables used during the test, in order to qualify a welding procedure, details of the
inspection and test results must also be recorded. These records must show that the inspection
and testing has proven that the weld samples have met or exceeded the specified standard
requirement. The typical types of inspection and testing for each sample for Welding
Procedure Qualification are:

Inspection and Testing for Fillet Welds (Tee Joints) - This involves visual inspection of
the completed weld, followed by two macro etches, and one fillet weld break test. The
welded sample is first inspected for any visual discontinuities and then sectioned, and two
small samples removed at predetermined locations. These small samples are polished across
their cross-section and then etched using some type of mild acid mixture, dependent on the
base material used. The remaining welded sample is used as the fillet weld break test and is
broken against the weld to reveal the internal structure of the weld for inspection.

Inspection and Testing for Groove welds (Butt Joints) – This involves visual inspection,
followed by two transverse tensile tests, two root bend test and two face bend tests. (These
tests are typical but may differ dependent on material thickness, type and standard
requirements. Different and/or additional testing, such as side bends, all weld tensile tests,
impact testing or other testing may be required.) The completed weld coupon, after visual
inspection, is divided into predetermined small sections. Each section is prepared, usually by
machining, to specific dimensions as prescribed by the standard. Each small sample is then
tested mechanically to determine its characteristics. These samples are then inspected to
determine their acceptability, against specified acceptance criteria, as laid down by the
applicable code or standard. Typically the standard will provide the maximum size and
location of various weld discontinuities and/or, as relevant, values such as minimum tensile
strengths or minimum desired impact properties.

Samples that are found not to have discontinuities that exceed these specified limits, and that
meet or exceed the minimum values as specified in the standard, will be acceptable, and the
welding procedure will be qualified.

The welding procedure is an important part of the overall welding quality system, as it
provides documented evidence that inspection and testing has been performed to ensure that
welding can be conducted to meet a recognized standard.

* One exception to welding procedure qualification is the D1.1 Structural Welding Code for
Steel, which will, under some circumstances, allow the use of pre-qualified welding
procedures, however these procedures are still required to be documented and meet all of the
relevant code requirements.

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