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SECTION IX

Qualifying A Welding Procedure’s

Essential Variables All Referenced Section IX Pages are from

the 2001 Edition with Addenda through 03



SECTION IX

When qualifying a welding procedure you mustfirst determine the important properties of the

planned weldment which then become the

essential variables. The basic ones are;

• Base metal to be welded and thickness (T)required.

• Process (es) to be used including filler metal (s).

• Preheat.• Postweld heat treatment or the lack of.

• Various others based on welding process used.



For this instruction we will use the SMAW Process.

The a brief of Essential, Supplementary Essential

and Non-Essential Variables for the SMAW process

are listed in table QW-253. However this part of thecourse will only cover Essential Variables not the

supplementary or non-essentials. Those will be

covered latter. A definition of these variables follows.



Essential Variable – A variable that if changed

requires requalification of the procedure by the

welding and testing of a new coupon or support froma previously qualified Procedure Qualification Record

(PQR), i.e. a change in the base metal thickness (T)

qualified.

Supplementary Essential – An essential variable that

is used only when impact testing of a base metal is

required by a construction code, i.e. a change from

one P-No. Group to another such as P1 Gr.1 to Gr.2.Non-Essential – A variable that can be changed as

needed to suit production requirements without

requalification.



QW-253 SMAW Brief of Variables Page 21

We will start our discussion with the top half of the

SMAW brief of variables, beginning with the first

two Essential Variables, Base Metal and Filler Metal.



Defining Each Essential Variable

Base Metals QW-403.7 Pages 21,58 &159• T/t Limits > 8 inches - this rule only applies at

thickness greater than 8 inches (203 mm) .

• Unless you will be welding something over 8inches this is of little concern. The rule for mostwelding procedures is the maximum that can bewelded is 2 times T (the coupon). If you arewelding a coupon over 8 inches you are restricted

to 1.33T or 1.33t , as applicable. 1.33t is the weldmetal thickness, it matters when mixing weldingprocesses and/or filler metal F-Numbers.




Quiz 1. An 8-1/2” T coupon was welded to produce a

PQR to support welding of a reactor shell course.

The maximum T qualified with this coupon is ___”.




Quiz 1. An 8.5” T coupon was welded to produce a PQR

to support welding of a reactor shell course. The

maximum T qualified with this coupon is 11.305”.

8.5 X 1.33 = 11.305




Base Metals Pgs. 21, 58,159, &16

• Change in Thickness (T) qualified.

• QW-403.8 A change in base metal thickness beyond

the range qualified in QW-451, except as otherwisepermitted by QW-202.4(b) (different thickness at joint)

• Of concern is the thickness range qualified by the

supporting PQR (s) for the WPS, from less than a 1/16” to

less than 1-1/2” it is 2 x T. To weld a thickness outside the

range supported by the PQR the WPS production welding

changes must be supported by providing an additional

PQR from file or by welding a new PQR test coupon.




Base Metals Quiz

1. A 1” to 1” P-No.1 coupon was welded

entirely by the SMAW process. Theminimum thickness qualified is ___ and the

maximum is ___”




Base Metals Quiz

1. A 1” to 1” P-No.1 coupon was welded

entirely by the SMAW process. Theminimum thickness qualified is 3/16 ” and

the maximum is 2”.




Base Metals t (weld metal) pass greater than 1/2” Pages 21 & 58

• QW-403.9 For single-pass or multi-pass welding in

which any pass (means layer of weld metal) isgreater than 1/2 in. (13 mm) thick, an increase in

base metal thickness beyond 1.1 times that of the

qualification test coupon.

• The thickness range is affected. It will berestricted to 1.1 T as given above if you deposit

more than 1/2” of weld metal in a single pass

(layer). This has to do with heat input.




A single pass refers to the number of weldbeads required to fill up a layer of weld metal in

the joint. If the single layer/pass, t (deposited

weld metal), exceeds 1/2” in thickness the WPS

will be restricted to 1.1 x T in productionwelding.




Quiz

A PQR coupon is 1-1/4”(1.250) thick (T). The weld

will be made in two passes, the root pass/layer will

be 1/4” (.250) thick and second and thirdlayers/passes will be each be 1/2”(.500) thick. The

maximum range of thickness for this qualification

will be ________”.




Quiz

A PQR coupon is 1-1/4”(1.250) thick (T). The weld

will be made in three passes, the root pass/layer

will be 1/4” (.250) thick and second and thirdlayers/passes will be each be 1/2”(.500) thick. The

maximum range of thickness for this qualification

will be 2-1/2 (2.500)”.

Read closely, the rule states it must exceed 1/2”

to be limited to 1.1 x T.




Alternate Base Metals for Procedures

• QW-403.11 Pages 21 & 58

• Base metals specified in the WPS shall bequalified by a procedure qualification test

which was made using base metals in

accordance with QW-424.



QW 424 – Turn to Page 131

Base Metal (s) Used for Procedure

Qualification Test Coupon VersusBase Metal Qualified for production



Let’s examine some of the items on the table.



One Metal From A P-No. To Any

Metal From The Same P-No.Such as P1 to P1



One metal from a P-No. To any

metal from any Other P-No. We will Use P

No.1 to P No.8 as an example. Other

combinations are possible, P Nos. 1 to 3, P

Nos.3 to 4 etc.



One metal from P-No. 3 To any

other metal from P-No. 3



One metal from P No. 3 to any

other metal from P No. 3 Also qualifies P No. 3 to P No. 1



However one metal from P No. 3 to any

metal from P No. 3 does not qualify P No. 1to P No. 1



One metal from P-No. 4 to any

other metal from P-No. 4



One metal from P No.4 to any other metal

from P No.4 also qualifies P No.4 to 4, 3

and, 1



It qualifies one metal from P No. 4 to any

metal from P No. 4, 3 or 1. but does not

qualify P No. 3 to P No. 3 or P No. 1 to PNo.1



Quiz

Using the table list the base metals qualified if

we successfully weld a procedure coupon

joining P No. 5A to No. P 5A



Quiz # 1 - P No. 5A to P No. 5A

Qualifies?

P No. 5A to __, __,__, or __. It does

not qualify __, __, or __ to each other or to their selves.



P- No. 5A to P- No. 5A Qualifies?

P- No. 5A to 5A, 4, 3, or 1. It does not

qualify 4 , 3, or 1 to each other or to

their selves.



Quiz # 2 - P No. 5A to P No. 4, 3, or 1

Qualifies?

P No. 5A to any metal assigned __,__,

or __. It does not qualify __, __, or __

to each other or to their selves.



Quiz # 2 - P No. 5A to P No. 4, 3, or 1

Qualifies?

P No. 5A to any metal assigned 4,3, or

1. It does not qualify 4, 3, or 1 to each

other or to their selves.




Base Metals Pages 21 & 58• Change of P-No. 5/9/10

• QW-403.13 A change from one P No. 5 to any

other P-No. 5 (P No. 5A to P No. 5B or P No. 5C

or vice versa). A change from P No. 9A to P No.9B but, not vice versa. A change from one P

No.10 to any other P No.10 (P No.10A to P

No.10B or P No.10C, etc., or vice versa).

• Simple, P-No. 5/9/10 - A,B,C.., are different P-

Numbers and require individual qualifications,

(with the exception of 9B to 9A)




Filler Metals• Change of F-Number Pages 21 & 59

• QW-404.4 A change from one F-Number in QW-

432 to any other F-Number or to any other filler

metal not listed in QW-432.

• Changing the F-Number to one other than that

used for the procedure test coupon, during the

creation the of the Procedure Qualification Record(PQR). Such as changing from F-No. 1 to F-No. 3.

• This rule also applies to a welder’s qualification

test by the way.



Defining Each Essential Variable Filler Metals

• QW- 404.5 Change of A-Number Pages 21,59 &138

• A-Nos. are the chemical analysis’ of the ferrousweld metal deposits produced by a given filler metal. Changing A numbers can change thechemistry and possibly the mechanical propertiesof the weld metal. This occurs by changing filler metals. It also changes the weld add mixture, that

part that contains both base metal and weld metal.Changing the A No. to one other than that used toqualify requires a new test or additional PQR (s)from a file (with one exception).



The… below indicates trace amounts ,single

values are maximums. i.e. C = 0.20 % max.



Filler Metals

Consider the following filler metals for the SMAWprocess.

1. E-7018 which has an A-Number of 1.

2. E-7018 A1 which has an A-Number of 2

Let’s compare the chemistry tables from Section II

Part C Filler Metals for these two AWS

Classification SMAW Electrodes/Filler Metals tothe A – Numbers of Section IX.



From Section IX QW-442 A No. 1 contains by %

C 0.20/ Cr --/ Mo --/ Ni --/ Mn 1.60/ Si 1.00

From Section II Part C / E-7018 SFA 5.1



From the Section IX QW-442 A No. 2 contains by %

C 0.15 / Cr 0.50/ Mo 0.40 – 0.65/ Ni --/ Mn 1.60/ Si 1.00

From Section II Part C / E-7018-A1 SFA 5.5



A note on the API Exams

• If you are taking any of the three API Examsyou will be required to review a WPS and

PQR. Part of that review might be a

question about the A-Number listed for thefiller metal on the documents. This is a

protest question. You would need ASME

Section II Part C to answer that question.Sect. II Part C is listed as required for the

exam. You have no way of answering!



For our example we find the following rule,

proving you must read Section IX carefully!

• QW-404.5 (Applicable only to ferrous

metals.) A change in the chemicalcomposition of the weld deposit from one A-

Number to any other A-Number in QW- 442.

Qualification with A-No. 1 shall qualify for

A-No. 2 and vice versa. (Note: all other A-

No. changes will force re-qualification).




Filler Metals

• Change t deposited Pages 21 & 61

• QW-404.30 A change in deposited weld metal

thickness beyond the range qualified in QW-451

for procedure qualification.• Example: In a SMAW procedure 1/4” of E-6010

was qualified on the PQR by depositing 1/8” in the

coupon (2t), the balance of the coupon was filled

with E 7018. The need arises to increase the E-

6010 t to 3/8” in production. This would require a

new coupon or an existing PQR.




Preheat - Turn to Page 21



Defining Each Essential Variable Preheat - Pages 21 & 62

• A decrease in preheat greater than 100 o F

• QW-406.1 A decrease of more than 100°F (56°C)

in the preheat temperature qualified. The minimum

temperature for welding shall be as specified inthe WPS.

• Example: A PQR coupon was welded using a

preheat of 250 °F but the WPS requires a preheat

of only 100 °F. This is a 150 °F decrease below

that qualified and will require a new PQR or one

from your files to support the lower temperature.




PWHT

• Change in PWHT Pages 21 & 62

• QW-407.1 This long paragraph specifies what is

considered a change in post weld heat

treatments.

The changes are P-Number specific with 5

different conditions of PWHT for P Nos. 1,3, 4, 5,

6, 9,10 and, 11.For all other materials there are two conditions

1. NO PHWT

2. The specified PWHT for the P No. used




PWHT

• T Limits (Thickness Limits) Pages 21 & 63

• QW-407.4 For a procedure qualification test

coupon receiving a post weld heat treatment in

which the upper transformation temperature isexceeded, the maximum qualified thickness for

production welds is 1.1 times the thickness of the

test coupon.

• This rule only applies when a production weld will undergo

heat treatment at temperature that will alter the base

metal’s physical properties, such as tempering, etc.



Producing The PQR

We have looked at all of the essential

variables for the SMAW process. Let’s put it

all together by filling out a SMAW PQR to

support a Welding Procedure Specification(WPS). To do this it will be necessary to

specify a list of the essential variables for

the welding we have planned.



Producing The PQR

From QW-253 we need to address the basic

essential variables and they will be:

1. Base Metal (s) – 2” SA-516 Gr. 70 Norm. P-No. 12. Filler Metal (s) – E-7018 Only

3. Preheat – 175 o F for P-No.1 (from Sect. VIII Div. 1

non-mandatory Appendix R)4. PWHT – 1100 o F Minimum per inch of thickness

for P-No. 1 (from Sect. VIII Div. 1 UCS-56)



Producing The PQR

Next we define the ranges of the variables:

Base Metal – SA-516 Gr.70 Normalized (2”max.)

Preheat – 175 o F

Then PWHT based on 2” per UCS-56 shall be 1

hour per inch, which in this example = 2 hours.

The next step is to start filling out a Procedure

Qualification Record as if we had actually weldedthe coupon. Here is the front of a blank PQR form.



First we will fill out the top half of the

PQR from the company name to the

base metal information on the left side

and include a graphic of the joint

design used to weld the coupon.



Next we will fill out the bottom half of

the PQR with the filler metal and

preheat on the left side. While not

required on the PQR by Section IX

the Non-Essential variables will be

entered as well.



Now we will fill out the upper half of

the PQR with the PWHT metal on the

right side. Making the comment Not

Applicable in the box for Gas, since

the SMAW process does not use

shielding gasses.



Finally the bottom right which consists

of all non-essential variables. Once

again these are not required by

Section IX, but may be helpful for meeting a construction code

requirement, i.e. Section VIII Div. 1 or

B31.3.



Now we start completing the back of

the PQR. To do so we need some

test results for our required tension

and bend tests. The tension testspecimens are fabricated as given in

Section IX QW-462.1(a). Page 152 .



The required number of tension test

specimens are 2 as shown in Section

IX QW-451.1 Page 139. The required

number of tension specimens arealways two, unless your coupon

exceeds 1”, then you are allowed

divide the two specimens into multiple

pieces. (see QW-151.1 (c) and (d) )



The ultimate strength of the tension

specimens must be computed as

described in below in QW-152.

• QW-152 Tension Test Procedure

The tension test specimen shall be

ruptured under tensile load. The tensilestrength shall be computed by dividing

the ultimate total load by the least cross

sectional area of the specimen as

calculated from actual measurementsmade before the load is applied.

We must measure each specimen’s



We must measure each specimen s

width and thickness after machining as

shown in QW-462.1(a). Section IX

requires two specimens be tested.The data for our specimens was;

TS1 - width = .750” thickness = .453”

TS2 - width = .753” thickness = .456”

Area for each specimen.

TS1= .750 x.453 = .340 in.2

TS2= .753 x.456 = .343 in.2

We put the specimens in a tensile tester

like this and pull each one apart;



The specimens were broke in the



The specimens were broke in the

tensile tester and the breaking forces as

read from the gage on the machine

were recorded as follows ;TS1 = 25,010 Lbs.

TS2 = 24,050 Lbs.

Computing the ultimate strength for 1square inch for each specimen;

‘Load divided by Area’

25,010/.340 = 73,558 PSI24,050/.343 = 70,116 PSI

We now evaluate the specimens;

‘Load divided by Area’



Load divided by Area

25,010/.340 = 73,558 PSI

24,050/.343 = 70,116 PSI

Observing the character and location of

the specimen failures, it was noted that

both failed in the base metal outside of the weld heat affected zones and in a

ductile manner.

We can now record this information onthe back side of the our Procedure

Qualification Record.

‘But First’



But First

We must determine the required

minimum specified strength from

Section IX in the P-Number listings.

Turn to Page 96 of Section IX

We find that SA-516 Grade 70 has a

Minimum Specified Tensile Strength of:

70 KSI = 70,000 Pounds Per Square Inch.



Our tensile specimens exceeded the



Our tensile specimens exceeded the

minimum. Now we have one more task to

complete. We must do 4 side bend tests.

This requirement is found in Section IX

along with the accept/reject values for all

bend tests. Turn now to Page 139 again.

The required type and number of bend tests

based on a 1” thick coupon are 4 Side Bend

tests. Remember side bends are

mandatory after the coupon thicknessreaches 3/4” or larger.



We must evaluate the bend specimens to

section IX QW-163. Turn now to Page 6.

QW-163 - The guided-bend specimens shall

have no open discontinuity in the weld or

heat-affected zone exceeding 1/8 in. (3.2

mm), measured in any direction on the

convex surface of the specimen after

bending. Open discontinuities….etc.

To see the details for making the bendspecimens look at QW-462.2 Page 156.



We evaluated the bend specimens to



We evaluated the bend specimens to

section IX and had the following comments.

Side Bend S1. No open defects acceptable

Side Bend S2. 1/32” acceptable



We have the correct type based on the

coupon thickness and the correct number of acceptable side bend tests.



We can now fill out the top back of the PQR.



All that is left is to fill out the bottom of the

back of the PQR. This will be easy, just afew housekeeping items to complete.



Here is the front side of the complete

Procedure Qualification Record



Here is the back side of the complete

Procedure Qualification Record



The WPS



The WPS

• We have completed the Procedure Qualification

Record, which is a laboratory report of the

welding and testing of a coupon.

• From this we will write a Welding Procedure

Specification. It must be in complete agreementconcerning Essential Variables with the PQR.

Th WPS



The WPS

• The Welding Procedure Specification, must becomplete. You must address all of the essential,

supplementary essential (if Notch toughness

testing is required), and non-essential variables.

The best approach is through the use of the

Brief of Variables found in QW-253 on Page 21

as an item check list.

• We will go line by line and address all of theEssential and Non-Essential variables since our

WPS will not require Notch toughness testing.



Th WPS



The WPS

Starting in box QW-402 we will address each of the non-essential variables.

• Groove Design• Backing

• Root Spacing

• RetainersThe following is how it was completed.



The WPS



The WPS

In box QW-402 we have addressed each of thenon-essential variables as follows;

• Groove Design – Single Vee, Double Vee, J-

Groove and, U-Groove• Backing – The X in both the Yes and No boxes

denotes that this WPS may be used with or

without backing.

• Root Spacing –This is given below Details.

• Retainers – Same as Root Spacing

The WPS



The WPS

Since we have addressed each of the non-

essential variables and thereby giving all the

needed Joint information for making a weldment.It is complete for joint design and no one

should have to ask what is allowed when using

this WPS.

The WPS



The WPS

Next QW-403 Base Metals



The WPS



The WPS

We have addressed each of the essential

variables under Base Metal QW-403.

It is complete for P-No., Thickness range

and the restriction of No t Pass > 1/2” has

been addressed. SupplementaryEssentials need not be addressed, no

impact testing is required of this weldment.

The WPS



The WPS

Next QW-403 Filler Metals



The WPS



The WPS

We have addressed each of the essential

variables under Filler Metal QW-404.

It is complete for AWS Classification,

F-No., A-No., Size of Filler Metals, and

Weld Metal Thickness Range. Again no

impact testing is required so theSupplementary Essentials do not apply.

The WPS



The WPS

Next the back and top of the WPS

We will now complete the Positions,

Preheat, Electrical, and Postweld Heat

Treatment on the WPS.



The WPS



The WPS

1. The Positions for use with this WPS are,Flat, Horizontal, Vertical and, Overhead.

This instructs that this WPS can be used

with all positions.2. The Preheat minimum is set at 100 o F

which is within 100 o F of the PQR actual

value of 175o

F.3. The Preheat Maintenance specified as

none required.

The WPS



The WPS

The Electrical Characteristics are;

1. Direct Current Electrode Positive.

2. Amps are set to a range of 90-190 and

the Volts are set to a range of 15-25,these values are normally obtained from

the filler metal manufacturer’s literature

or from actual experience.3. The rest are not required for SMAW.

The WPS



The WPS

The Postweld Heat Treatment valuesare;

1. 1150 +/- 50 o F Which is in agreement

with the PQR minimum value of 1100 o F2. Time at temperature is 1 hour, also in

agreement with the PQR.

3. Gas variables are not required for SMAW.

The WPS



The WPS

We will now complete the bottom half of

the back of the WPS. Which consists of the Technique box QW-410 only.



The WPS



e S

1. String or Weave, restricted from 2 to 3 core

diameters (core wire exclusive of any coating).

2. Cleaning is limited to Brushing or Grinding.

Back Gouging will be by Air Carbon Arc.

3. Multiple Pass, Manual is entered in theheading and Peening is not allowed.

4. All others are not SMAW variables.



The Complete WPS Front



The Complete WPS Back

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