QUALIFICATION TESTS FOR SHOP WELDING

 

QUALIFICATION OF WELD PROCEDURES

 

Acceptability of welding procedures is based on the qualification requirements outlined in Section 5 of Bridge Welding Code AASHTO/AWS D1.5/D1.5M-2002. Welding procedures are required to be approved on an individual project basis.  Each submitted weld procedure shall include job number, project number, design number, county, and contractor’s name.

 

WELDER QUALIFICATION

 

All welders, welding operators and tackers are required to be qualified before they will be permitted to weld on any bridge structure being built by the Iowa Department of Transportation. These qualification tests shall conform to the Bridge Welding Code AWS (American Welding Society) D1.5 as modified by the Iowa Department of Transportation Standard Specification as explained in these instructions.

 

The qualification herein specified for the welder, welding operator and the tacker shall be considered as remaining in effect from the end of the month in which the tests were taken, for a period of one year. The welding qualifications may be extended annually, based on a letter from the fabricator, which certifies that the welder has been engaged in the processes for which they qualify without interruption of more than six months during the preceding twelve months, or by requalification. Requalification will not be required every five years as previously required.

 

TEST PLATES

 

The fabricator shall furnish all test plates used in the qualification tests of the fabricator’s personnel or procedure tests, regardless of the type or thickness.

 

QUALIFICATION TESTS REQUIRED

 

The tests described herein are to determine the welder’s ability to produce sound welds. The contracting authority, independent testing laboratories, or other governmental agencies shall witness the welding and conduct the tests required by the Bridge Welding Code to qualify the welding procedures and the welders, welding operators, and tackers who will apply these procedures. The name of the agency employee who witnessed the testing shall be included on the documents submitted to the Central Laboratory for approval.

 

Qualification tests for welders, welding operators and tackers shall be as follows:

 

1.    Qualification Test for Unlimited Thickness

 

2.    Qualification Test for Limited Thickness

 

3.    Qualification Test for Fillet Welds Only

 

4.    Qualification Test for Tackers

 

QUALIFICATION TEST FOR UNLIMITED THICKNESS

 

Joint detail as follows:

 

1.    For manual and semi-automatic welders, 1 in. (25 mm) thick plate, single V groove, 45 degree included groove angle, 1/4 in. (6 mm) root opening with backing. Minimum length of welding groove shall be 5¼ in. (130 mm). Figure 5.17 of AWS D1.5. There is an optional test plate for horizontal position unlimited thickness, Figure 5.18.

 

2.    For welding operators, 1 in. (25 mm) thick plate, single V groove, 20 degree included groove angle, 5/8 in. (16 mm) root opening with backing. Minimum length of welding groove shall be 15 in. (400 mm). Figure 5.24 of AWS D1.5.

 

      Test Specimens – Two side bend tests.

 

This test will qualify the welder or welding operator for groove and fillet welds in material of unlimited thickness for the test position shown in the paragraph, Position of Test Welds.

 

WELDER QUALIFICATION TEST FOR LIMITED THICKNESS

 

Joint detail as follows:

 

3/8 in. (10 mm) plate, single V groove, 45 degree included angle, 1/4 in. (6 mm) root opening with backing. Minimum length of welding shall be 7 in. (180 mm). Figure 5.19 of AWS D1.5. There is an optional test plate for horizontal limited thickness. Figure 5.20.

 

Test Specimens – One face and one root bend specimen.

 

This test will qualify the welder for groove welds in material not over 3/4 in. (20 mm) in thickness, and fillet welds on material of unlimited thickness for the test positions shown in the paragraph entitled Position of Test Welds.

 

ALTERNATE RADIOGRAPHIC TESTING

 

Radiographic examination of welder and welding operator qualification test plates may be made in lieu of bend test. Radiography procedure and test results shall comply with AWS D1.5 Sections 5.26 and 5.27 of the Bridge Welding Code.

 

QUALIFICATION TEST FOR FILLET WELDS ONLY

 

Welders:

 

Joint details as shown in Figure 5.21 or 5.22 (of AWS Code D1.5):

 

1/2 in. (12 mm) plate, T, minimum length of welding shall be 8 in. (200 mm).

 

Test Specimen – Fillet-Weld Break Specimen and Macroetch Specimen

 

OR:

 

3/8 in. (10 mm) plate, square butt, 15/16 in. (25 mm) root opening with backing. Minimum length of welding shall be 7 in. (180 mm).

 

Test Specimens – Two guided root bend specimens.

 

Welding Operators:

 

Joint details as shown in Figure 5.26 or 5.27:

 

1/2 in. (12 mm) plate, T, minimum length of welding shall be 15 in. (400 mm)

 

Test Specimen-Fillet-weld Break Specimen and Macroetch Specimen

 

OR:

 

3/8 in (10 mm) plate, square butt 5/16 in. (8 mm) root opening with backing.

 

Minimum length of welding shall be 15 in. (400 mm).

 

Test Specimens-Two guided root bend specimens.

 

A test will quality the welder or welding operator for fillet welding on material of unlimited thickness for the test position shown in the paragraph entitled Position of Test Welds.

 

QUALIFICATION TEST FOR TACKERS

 

Joint detail as follows:

 

1/2 in. (12 mm) plate 4 in. (100 mm) square placed on second plate of the same size 1/2 in. (12 mm) from edge to form a tee. Weld length 2 in. (50 mm). Figure 5.28 of AWS D1.5.

 

Test Specimen – Fillet-Weld Break Specimen

 

This test will qualify the tacker for fillet and groove tack welding on material of unlimited thickness for the test position below.

 

POSITION OF TEST WELDS

 

Qualification Test

Type of Weld & Position of Welding Qualified* Plate or Pipe

Weld

Plate Position**

Groove

Fillet

Plate-Groove

1G

F

F,H

 

2G

F,H

F,H

 

3G

F,H,V

F,H,V

 

4G

F.OH

F,H,OH

 

3G &4G

All

All

Plate Fillet & Tackers

1F

 

F

 

2F

 

F,H

 

3F

 

F,H,V

 

4F

 

F,H,OH

 

3F & 4F

 

All

*Position of Welding; F = Flat, H = Horizontal, V = Vertical, OH = Overhead

**1G = Flat Groove, 2G = Horizontal Groove, 3G = Vertical Groove, 4G = Overhead Groove;

1F = Flat Fillet, 2F = Horizontal Fillet, 3F = Vertical Fillet, 4F = Overhead Fillet

 

RETESTS

 

In cases of test failures, a retest shall be allowed under the conditions outlined in AWS D1.5, Section 5, for that type of weld test.

 

VISUAL INSPECTION OF WELDER TEST PLATES

 

To pass the visual examination, the fillet weld shall present a reasonably uniform appearance and shall be free of overlaps, cracks and excessive undercut. There shall be no porosity visible on the surface of the weld. Thorough fusion shall exist between adjacent layers of weld metal and between weld metal and base metal. All craters are to be filled to the full cross-section of the weld, except for the ends of intermittent fillet welds outside of their effective length.

 

VERTICAL WELDS

 

All vertical welds for grooves or fillets shall be made with the progression for all passes in the upward direction.

 

FILLER METAL

 

Refer to the Approved Brands Electrode listed in table 4.1 or 4.2 of the AWS D1.5 2002 welding code.  The electrode or electrode flux combination shall have the same strength class shown in the project plans or the approved shop drawings and as indicated.  The filler metal shall be selected from either table 4.1 or table 4.2, consistent with the design requirements.

 

MINIMUM PREHEAT & INTERPASS TEMPERATURE

 

AWS D1.5/D1.5M-2002 - TABLE 4.4 – MINIMUM PREHEAT & INTERPASS TEMPERATURE

°F (°C)(NOTE 1)

(See 4.2)

 

Thickness of Thickest Part at Point of Welding – in (mm).

G

R

O

U - Welding Process

 

 

 

 

P - (Base Metal)

To 3/4”

Over 3/4 to 1½ ”

Over 1½” to 2½”

Over 2½”

 

 

Included

Included

Included

Included

 

 

(20 mm)

(20 to 40 mm)

(40 to 60 mm)

(60 mm)

 

 

°F (°C)

°F (°C)

°F (°C)

°F (°C)

SAW, GMAW, FCAW, SMAW

50 (10)

70 (20)

150 (65)

225 (110)

A709/A709M (M270/M270M)

 

 

 

 

Gr. 36 (250), 50 (345), 50W (345W)

 

 

 

 

 

 

 

 

 

 

SAW, GMAW, FCAW, SMAW

50 (10)

125 (50)

175 (80)

225 (110)

A709/A709M (M270/M270M)

 

 

 

 

Gr. 70W (485W), 100 (690), 100W (690W)

 

 

 

 

 

NOTE 1:   See Appendix VIII and Tables 12.3, 12.4, and 12.5 (of the AWS D1.5) for alternate preheat and interpass temperatures.

 

MAXIMUM PREHEAT & INTERPASS TEMPERATURE LIMITATIONS

 

The maximum preheat and interpass temperature shall be specified in the WPS.

 

NOTE 2:   For A709 (M270) Gr. 70W (485W), 100 (690), 100W (690W), the maximum preheat and interpass temperature shall not exceed 400°F (205°C) for thickness up to 1 1/2 in. (40 mm) inclusive, and 450°F (230°C) for greater thicknesses.