Back gouging:

The main purpose of back gouging is to ensure full penetration of the weld, especially when welding
thick materials where the front-side weld might not fully reach the back side. It removes contaminants
or slag from the back of the weld joint.

Backing:

The primary purpose of backing is to support the molten weld metal to prevent defects like undercuts or
burn-through, especially when welding joints from one side. OR

The concept of backing in welding refers to using a material placed at the root (or bottom) of a weld
joint to provide support for the molten weld metal during the welding process. This support helps
ensure that the weld metal doesn't sag or fall through the joint.

Backing gas:

A gas, such as argon, helium, nitrogen, or reactive gas, which is employed to exclude oxygen from the
root side (opposite from the welding side) of weld joints.

Brazing:

Brazing is a metal joining process that involves the use of a filler metal to join two or more base metals
together. Unlike welding, where the base metals themselves melt, brazing occurs at a lower
temperature, typically above 450°C (about 840°F), but below the melting point of the base metals. The
filler metal, which has a lower melting point than the base metals, flows into the joint by capillary action
and forms a strong bond when it solidifies.

Types of Brazing:

1) Torch Brazing 2) Furnace Brazing 3) Induction Brazing 4) Dip Brazing

Buttering:

The concept of buttering in welding involves applying a layer of weld material to a surface before making
the final weld. This technique is used when:

1) Dissimilar Materials 2) Surface Preparation 3) Strength and Durability

Cladding:

cladding is about adding a protective layer to improve the surface performance of a base material.

Purpose:

 Improve corrosion resistance.

 Enhance wear resistance.
 Protect against high temperatures or chemical exposure.
 Reduce costs by using an expensive material only on the surface while keeping a cheaper
material as the base.
Difference b/w Buttering and Cladding:

Difference b/w Groove and Fillet Weld:

Header:

Manifold for other piping runs

QW-120 TEST POSITIONS:

Test position of groove and fillet weld are same but rotation of degree is different.

TEST POSITIONS FOR GROOVE WELDS

QW-121 PLATE POSITIONS

1. Flat Position 1G:

Plate in a horizontal plane

2. Horizontal Position 2G:

Plate in a vertical plane

3. Vertical Position 3G:

Plate in a vertical plane

4. Overhead Position 4G:

Plate in a horizontal plane

QW-122 PIPE POSITIONS

1. Flat Position 1G:

Pipe with its axis horizontal and rolled

2. Horizontal Position 2G:

Pipe with its axis vertical and the axis of the weld in a horizontal plane.

3. Multiple Position 5G:

Pipe with its axis horizontal and with the welding groove in a vertical plane.

4. Multiple Position 6G:

Pipe with its axis inclined at 45 deg to horizontal.

QW-130 TEST POSITIONS FOR FILLET WELDS

QW-131 PLATE POSITIONS

1. Flat Position 1F
2. Horizontal Position 2F
3. Vertical Position 3F
4. Overhead Position 4F
QW-132 PIPE POSITIONS

1. Flat Position 1F

Pipe with its axis inclined at 45 deg to horizontal and rotated during welding

2. Horizontal Positions 2F and 2FR

Position 2F. Pipe with its axis vertical and axis of the weld will be horizontal.

Position 2FR. Pipe with its axis horizontal and the axis of the deposited weld in the vertical plane.

3. Overhead Position 4F

Pipe with its axis vertical and axis of the weld will be horizontal.

4. Multiple Position 5F

Pipe with its axis horizontal and the axis of the deposited weld in the vertical plane.

Percent outer fiber elongation:

100t
percent outer fiber elongation:
A+t
The following equation is provided for convenience in calculating the bend specimen thickness:

QW-141 MECHANICAL TESTS

1. Tension Tests (QW 150)

2. Guided Bend Tests (QW 160)
3. Fillet-Weld Tests (QW 180)
4. Toughness Tests (QW 171 and QW 172)
5. Stud-Weld Test

QW 150: Tension test (Tensile test):

The purpose of this test is to determine the ultimate strength of groove-weld joints.
The tensile strength shall be calculated by using the following formula;
Ultimate total load/least cross‐sectional area

QW 153: Acceptance criteria for Tension test:

 If the specimen reaches the minimum tensile strength before rupture, then it shall be
considered as accepted.
 If the specimen breaks in the base metal outside of the weld or weld interface, the test
shall be accepted as meeting the requirements, provided the strength is not more than
5% below the minimum specified tensile strength of the base metal.
QW 160: Guided-Bend Test:

Guided bend test is carried out to determine the degree of soundness and ductility of groove-weld
joints.
The specimen for the guided bend test is approximately rectangular in shape and is prepared by cutting
the test plate or pipe. Three terms are frequently used during the bend test, these are side, face, and
root. The cut surfaces are termed as sides. The other two surfaces are the face and root surface, surface
with greater width of weld is known as face surface and the surface opposite to face is known as root
surface.
Guided-Bend tests are of following types:
 Side bend test – Transverse
 Face bend test – Longitudinal and Transverse
 Root bend test – Longitudinal and Transverse

QW 163: Acceptance criteria for Guided-bend test:

1. The weld and heat‐affected zone of a transverse weld bend specimen shall be
completely within the bent portion of the specimen after testing.
2. There shall be no any open discontinuity in the weld or heat ‐affected zone exceeding 3
mm (1/8 inch), measured in any direction on the convex surface of the specimen after
bending.

QW 170: Toughness test:

The purpose of this test is to determine the toughness of weldment. This test shall be carried out
whenever required by any referencing codes.
In absence of any referencing code, the test procedures and apparatus shall conform to the
requirements of SA-370.

QW 171.2: Acceptance criteria for Toughness test:

Acceptance criteria shall be in accordance with job requirements or the applicable specification.
QW 180: Fillet Weld Test:

Purpose of the Fillet weld test is to determine the size, contour, and degree of soundness of fillet welds.
Rules for the preparation of specimen for procedure qualification is given in QW 181.1 and
corresponding figures for test specimen is given in QW 462.4 (a) and QW 462.4 (d). Rules governing the
preparation of specimen for performance qualification of welders can be found in QW 181.2 and the
corresponding figures are given in QW 462.4 (b) and QW 462.4 (c).
Specimen for procedure qualification shall be subjected to macro examination as per the requirements
of QW 183. Whereas for welder performance qualification one of the specimens shall be subjected to
fracture test and the other specimen shall be macro examined.
Requirements for fracture tests of specimens are given in QW 182 and requirements for macro
examination of specimens for procedure qualification can be found in QW 183, whereas the
requirements for macro examination of performance qualification specimen can be found in QW 184.
QW 190: Other tests and examinations:

QW 191: Volumetric NDE: ASME has mentioned two tests under this heading, these are the following;

 Radiographic Examination (QW 191.1)

 Ultrasonic Examination (QW 191.2)

QW 191.1: Radiographic Examination:

The purpose of this examination is to check the soundness of the welding of the performance
qualification test coupon. The method for Radiographic examination shall meet the requirements of
ASME Section V, Article 2. However, a written procedure for radiographic examination is not required
for this purpose. The prescribed image and the image quality indicator (IQI) must be visible.
QW 191.1: Radiographic Examination:

The purpose of this examination is to check the soundness of the welding of the performance
qualification test coupon. The method for Radiographic examination shall meet the requirements of
ASME Section V, Article 2. However, a written procedure for radiographic examination is not required
for this purpose. The prescribed image and the image quality indicator (IQI) must be visible.

QW 191.1.2: Acceptance Criteria for Radiographic Examination:

Two terminologies have been used, based on the dimensions of discontinuities, to define the
acceptance criteria for Radiographic examination, these are the following;

Linear Indications:

If the length of discontinuity is more than three times the width of the discontinuity, then it is called as
Linear discontinuity i.e
L > 3 W;
Where, L – Length of discontinuity
W – Width of discontinuity
Cracks, Lack of penetration, Lack of fusion are common examples of Linear indications.

Rounded Indications:

If the length of discontinuity is less than or equal to three times the width of the discontinuity, then it is
defined as Rounded discontinuity i.e
L ≤ 3 W;
Where, L – Length of discontinuity
W – Width of discontinuity
Porosity and inclusions are common examples of Rounded indications.

Acceptance criteria for Linear Indications:

  Any type of crack, incomplete fusion, and incomplete penetration shall be considered
unacceptable.
 Any elongated slag inclusion shall be considered unacceptable, which has a length
greater than

1. 1∕8in. (3mm) for t up to 3∕8 in.(10mm), inclusive

2. T/3 for T greater than or equal to 10 mm (3/8 in.) and less than or equal to 57 mm (2-1/4 in.)
3. 19 mm (3/4 in.) for T greater than 57 mm (2-1/4 in.)

(Where, ‘T’ – Thickness of deposited weld metal)

 Any group of aligned inclusions (inline) with an aggregate length of more than T (within
a length of 12T) shall be considered unacceptable except when the distance between
the successive discontinuities exceeds 6L.
(where ‘L’ is the length of the longest imperfection in the group).

Acceptance criteria for Rounded Indications:

 The maximum acceptable dimension for rounded indications shall be 20% of T or 3 mm

(1/8 in.), whichever is smaller.
 For a material thickness less than 3 mm (1/8 in.), the number of maximum acceptable
rounded indications are 12 for 150 mm (6 in.) weld length. The number of acceptable
rounded indications shall be decreased proportionately for weld length less than 150
mm (6 in.).
 For a material thickness equal to or more than 3 mm, refer figure QW 191.1.2.2 (b) (4)
for acceptance criteria. Rounded indications less than 0.8 mm (1/32 in.) in maximum
diameter shall not be considered in the radiographic acceptance tests of welder
performance qualification in these ranges of material thicknesses.

QW 191.2: Ultrasonic Examination:

Ultrasonic examination may be conducted for performance qualification test coupons for the material
thickness more than or equal to 6 mm (1/4 in.).
A written procedure shall be required for performing the ultrasonic examination. The test method,
procedure, and qualifications shall meet the requirements of ASME Section V, Article IV.

QW 191.2.3: Acceptance Criteria for Ultrasonic Examination:

 All indications interpreted as cracks, lack of fusion, or lack of penetration are shall be considered
unacceptable regardless of length.
 Any indication shall be considered unacceptable, which has a length greater than
1. 3 mm (1/8 in.) for T up to 10 mm (3/8 in.)
2. T/3 for T greater than or equal to 10 mm (3/8 in.) and less than or equal to 57 mm (2-
1/4 in.) i.e., 10 mm ≤ T ≤ 57 mm.
3. 19 mm (3/4 in.) for T greater than 57 mm (2-1/4 in.)
 (Where, ‘T’ – Thickness of the weld metal excluding any allowable reinforcement)

Other tests which are mentioned in ASME Section IX are the following;

 Stud Weld Test (QW 192)

 Tube to Tube sheet Tests (QW 193)
 Visual Examination – Welder Performance Qualification (QW 194)
 Liquid Penetrant Examination (QW 195)
 Resistance Weld Testing (QW 196)
 Laser Beam Welding (LBW) Lap Joint Tests (QW 197)
 Flash Welding (QW 199)