WPS Qualification Test - Material Availablility

[JohnTM]

I need to perform a PQR on a listed base material being welded to an unlisted, forged and heat treated material. I should be using Figure 4.19 from D1.1:2010, the fillet weld soundness test.

The problem is, with the forged material, I cannot make or buy a plate that matches the dimensions shown in Fig 4.19, .5" x 6.00" x 12.00".

The forged material is not pipe, it is solid, round material. That said, I could reproduce Figure 4.20, detail B, the pipe to plate fillet weld soundness test with what I have, except the round material is not 3" tall it is only 1/2" tall. Is that a possible avenue?

Are there ways of producing a qualified WPS when you can't actually weld a Figure 4.19 test?

Thanks in advance for any help.

 

[gtaw]

Since you are welding a prequalified base metal to one that is not prequalified, you must demonstrate the combination will produce the required mechanical properties per clause 4.8.3. That entails qualification using a grooved plate assembly as per figures 4.10 or 4.11. The positions tested must be per table 4.1 and the types and number of tests required is as per table 4.2. Once you have demonstrated the combination of base metals and filler metals produce the required mechanical properties you can qualify the fillet welds per tables 4.1, 4.4 and figure 4.19. If the filler metal is not prequalified the task is made more arduous because you must then qualify the consumables. If notch toughness is an issue, hold on to your hat, because clause 4 Part D must be met.

Do not be misled by table 4.1 Positions, the table does not mean you do not have to meet clause 4.12. It is confusing, but the table only indicates the positions in which the qualified WPS can be used. In other words, you qualify the mechanical properties by welding a CJP test plate in the flat position and you qualify the fillet welds in the horizontal position. The plate qualifies the WPS or grooves and fillets in the flat position. The fillet weld test in the horizontal extends the qualifications to both flat and horizontal fillet welds. Make sure you read the applicable footnotes.

This is not the same as qualifying a WPS to AWS D1.6 (stainless steel). D1.6:2007, clause 4.1.7 states that qualification on a CJP qualifies CJP, PJP, fillets, slot and plug welds. D1.1 does not include the same provisions.

Further note, the base metal you use, whether it is prequalified or unlisted, must have published mechanical properties. In other words, if you select an AISI steel that does not have published mechanical properties, the properties can vary from one heat to another, or they can change depending on whether it is forged, hot rolled, or cold rolled even if the chemistry is the same.

Good luck.


Best regards - Al

 

[Mr168]

This is not the same as qualifying a WPS to AWS D1.6 (stainless steel). D1.6:2007, clause 4.1.7 states that qualification on a CJP qualifies CJP, PJP, fillets, slot and plug welds. D1.1 does not include the same provisions.

That's not an entirely true statement. D1.1 does pick up qualification of PJP's and fillets with a CJP test (position dependent), with the exception that you have to run supplemental PJP macroetch specimens to weld PJP's (this can be derived from Table 4.5, Table 4.1, the notes in Table 4.2, and 4.10.3). In D1.6, it's more restrictive in that you have to run macros on both PJP's and fillets when using a CJP as the basis for qualification. (Referencing D1.1:2000 and D1.6:1999 accordingly). AWS does a remarkably poor job of putting in catch-all statements, and then putting contradictory statements in the body of the Code - something they're working on correcting moving forward.

That aside, and back to the OP's question - if The Engineer has selected a material that cannot be qualified within the provisions of D1.1 as-written, then it is up to The Engineer to specify what the appropriate path for qualification is. We have encountered this on several instances, with course of action being anything from substituting materials for the purpose of qualification to doing macroetch in instances where the only function the weld served was as a temporary seal weld.