THE WELDING PROCEDURE

SPECIFICATION WRITERS
GUIDE

Michael E. Parsons
June 24, 2004
 INTRODUCTION

In developing the Welding Procedure Specification Writers Guide, I have collected

articles and excerpted material from a wide variety of sources. Amongst these sources
are the following: The American Welding Society, Machinery’s Handbook by the
Industrial Press, Welding Innovation Magazine by The Lincoln Electric Company,
Welding Engineering by Rossi, Welding’s Engineering data Sheets by Ted B. Jefferson,
Welding Essentials by Galvery and Marlow as well as other sources.

This guide written with structural fabrication in mind and is therefore confined to carbon
and low alloy steels.

The material is organized in a natural sequence, such that we proceed from the general to
the specific and we proceed in the same order that the writer is likely to need the material
while preparing the welding procedure specification (WPS).

Additional material is presented about issues that are closely related to the WPS creation
process. For instance the subject of welder certification is briefly addressed, as is non
destructive testing (NDT), and general welding shop procedure.

The appendix contains several time-tested welding procedures that will serve as examples
for practice and study.

The following is presented for use as a reference and guide only. Ultimately, an
engineering writer or welding engineer must accept responsibility for the procedures he
develops.

Michael Parsons
June 24, 2004
 TABLE OF CONTENTS

INTRODUCTION i
ACKNOWLEDGEMENTS ii

CHAPTER 1 WHAT EVERY ENGINEER SHOULD

KNOW ABOUT WELDING PROCEDURES 1
CHAPTER 2 WELDING 11
CHAPTER 3 OUTLINE OF PROCEDURE 36
CHAPTER 4 PROCESS SELECTION 38
CHAPTER 5 JOINT GEOMETRY 46
CHAPTER 6 WELDABILITY OF STEELS 62
CHAPTER 7 HEAT TREATMENTS 75
CHAPTER 8 FILLER METALS 82
CHAPTER 9 PROCEDURE FORMAT 94
CHAPTER 10 WELDER CERTIFICATION 98
CHAPTER 11 WELDING TESTING 99

APPENDIX A TABLES AND ARTICLES

 MEP 06/18/2004
GENERAL OUTLINE PROCEDURE
FOR SHIELDED, ELECTRIC-ARC WELDING OF STEEL

1. Safety procedures:
a) Hazard: electric shock can be fatal. Don’t touch surfaces that are
electrically live.
b) Hazard: Fumes and gases are toxic. Ventilate, avoid plume, don’t breath
gases.
c) Hazard: arc rays can injure eyes and burn skin. Wear protective eyewear,
gloves, hood and other protective gear.
d) Hazard: lifting injury. Use appropriate lifting technique to safely handle
heavy objects.
2. Select joint design and fit up.
a) Butt joint
b) Corner joint
c) Edge joint
d) Lap joint
e) Tee joint
3. Choose the welding process.
a) SMAW (ARC)
b) GTAW (TIG)
c) GMAW (MIG)
d) FCAW (Flux Core)
e) SAW (Submerged Arc)
4. Select the applicable filler metal for base metal(s) and process
a) Material specification
b) Coating, if applicable
c) Wire size
5. Select shielding method(s):
a) Coated electrode (ARC)
 b) Gas (TIG, MIG, and sometimes Flux Core)
c) Granulated flux (SAW)

6. Set the parameters.

a) Direct or Alternating current flow (if alternating, frequency must be
specified)
b) Polarity (direct or reverse)
c) Current (Amps)
d) EMF (Volts)
e) Wire feed rate (not applicable to ARC)
f) Cup size (gas shielding only)
g) Shielding parameters:
1) Gas composition and flow rate.
2) Granular flux composition and flow rate.
7. Clean the base metal.
a) Solvent clean
b) Wire brush
c) Shot blast
8. Preheating and intermediate pass heating if applicable.
a) Flame
b) Other
9. Welding technique.
a) Angle of electrode
b) Arc gap
c) Weld orientation (vertical, horizontal etc.)
d) Travel direction and speed
e) Bead lay: straight or weave pattern.
10. Cooling and post weld heat treatment.
a) Controlled cooling (packing or insulation)
b) Stress Relief
c) Normalize, quench, and temper (NQT)
 Deposition rates: principles and data
by J. J. K. Stekly

Deposition rate data was obtained at various current loadings for different wire
diameters and including tubular welding wires. A method is outlined to optimise
selection of the welding parameters and consumables to obtain maximum deposition
rates.
The object of the investigation was to determine the deposition rate (kg/hr); under
conventional welding conditions, of wires of different cross-sections, and to explain the results
with fundamental energy dissipation theory.
Introduction

A basic question which arises in any production situation is `what welding para-
meters; process and consumables need to be used, to deposit the maximum amount of weld
metal in the shortest time?'
Comparing processes is only of interest if the deposition rates are to be compared at the
same energy dissipation. Throughout this report, when two systems are considered these will
always be at the same power consumption, and the comments made will apply in these
circumstances. Little is gained by comparing plasma MIG at 1000A (600A MIG + 400A
plasma) with, for example, a 500A MIG weld. At the same power dissipation the MIG process
with correctly chosen materials exceeds, in deposition rate, the plasma-MIG.
Addressing the question of process selection, the first split is the division into directly
heated consumable, e.g., MIG, sub arc, etc and the indirectly heated proces ses such as TIG;
plasma-powder, etc. It will not be shown here, only stated that all the directly heated
processes should be considered when maximisation of deposition rate is to be obtained - only
the situation where the electrode is both the source of power and weld metal.
The other major process variables are: the metal used, (usually predetermined by the
application); the polarity (negative polarity gives a higher burn-off rate, but this factor is
usually determined by the manufacturer of the consumable) and finally the gas or flux used,
both of which have a minor role.
The choice, therefore, is largely res tricted to the wire diameter, solid or tubular wire and
current used. The latter is often limited by available equipment and single- or multiple-arc
systems.
The mechanism of transfer and additional details on burn-off has been covered in a review
where the physics of the arc is discussed.
Welding energy dissipation
The energy consumed when welding a wire or a stick electrode can be divided into the
voltage drop across the arc (Va) and the voltage drop along the wire (Vr). These voltage
drops correspond to the power necessary to maintain the arc and heat the electrode at a
given welding current (I). Figure l illustrates the situation for wires and stick electrodes.

Energy dissipated, E, = (Va + Vr) I

In general Vr is small compared to Va. However, resistance heating is considerably more

efficient than arc heating, and as current increases a larger portion of the energy is
transferred to resistance from arc heating, making the process more effi cient.
Considering only the arc energy it has been shown elsewhere ² that:

Burn-off = Constant (K1) x I

 Arc energy consists of ions, electrons and other forms of energy released at the wire end,
and it will be argued that this energy release will be more effective as the area over which- it
occurs becomes smaller. As a simplification it shall be assumed that:
Kg / hr (arc) = Constant (K2) x I / Area of electrode = K3 x I / mm²

Considering the resistance heated portion, it is clear that the hotter the metal is upon
reaching the arc, the faster the burn off will be.

It has been shown elsewhere ² that:

kg / hr (resistance) = K4 x Energy = K4 x I² R = K8 x I² L / mm²

The stick-out or electrode extension L is, for experimental purposes, constant; hence:

Kg/hr = K6 x I² / mm²

Fig 1. Energy distribution during welding (top, wire and bottom, electrode).
Fig 2. Effect of current increase on deposition rate for left effect
of arc only and right effect of resistance only.

Fig 4. Deposition rate comparison

with diameter variation for open arc'
welding. Chromium carbide type wire
Welding Alloys HC-0, oscillation
25mm, sick out 30mm.

Adding both portions:

Kg / hr = I3 x I / mm² + K6 x I² / mm²

On reviewing the above equation, it can be seen that a plot of deposition rate (kg/hr) against
current would generate, on the first term, a straight line, and, on the second term, a typical
geometric curve, fig 2. .
Measured deposition rates
The results obtained on submerged arc welding are plotted in fig 3, and cover kg/ hr of
weld metal, measured as wire burnt off, with all wires containing only metals, with estimated
deposit efficiency above 95% in all cases. Precise measurement instrumentation was used,
with current measured as total charge over a given welding period.
The results for open arc welding on identical composition tubular wires are plotted in fig 4. It
is clear that any other consumable directly-heated welding elec trode would produce similar
curves.

Discussion of results
The lines for 3.2mm and, 4.Omm diameter solid wires are virtually straight, suggesting that
the resistance portion is not signifi cant when compared to the current density element. As the
cross section of the wire decreases, and this can be accelerated by using a tubular wire, the
curve is seen -to rise geometrically until close to the vertical. In effect the wire, at this stage, is
reaching the arc in a molten state and virtually no more current can be passed through the
wire even with continuously increasing wire feed speed. The limiting condition is that the total
available energy is consumed in resistance heating and no energy remains to support an arc -
conditions under which it is impossible to obtain a satisfactory bead and no bonding can take
place to the base metal.
Fig 3. Deposition rate. Comparison of tubular with solid wire with variation of wire diameter
conditions: electrode positive; voltage at mean of usable range; 30mm wire stick out, WAF
350 sub arc flux; oscillated bead; low alloy steels.

Locating the ideal point on the curve

Aside from commercial considerations and availability of product, the major consideration is
bead shape and penetration.
Two plates to be butt welded with no preparation require maximum penetration with
minimum material deposited. Deposition rate is secondary to energy dissipation at the arc,
which causes the base metal to. melt, increasing the weld depth.
A hardfacing deposit requires the minimum of penetration, hence the maximum energy
should be consumed in resistance heating and the least possible at the arc. The bead shape
alters with these changing, conditions, illustrated in fig 5.
 Single or multiple wires

A single wire is always preferable due to the simplicity, of the operation, and an ideal area
for initial trials on maximising deposition rates is the section about half way through the
usable range of currents. Wire feed speed can be increased thereafter to the suitable
conditions for the combination wire type, item to be welded, pre-heat parameters, etc.

Should the deposition rate required under these conditions not suffice, a twinwire system
will be required; which will normally yield precisely double the optimum values previously
determined. It would theoretically be possible to load a 3.2mm tubular wire to deposit 20
kg/hr with sufficiently high current. In practice this is undesirable due to the need to transfer
a very large current into the wire; and the surface area on which current transfer depends is
not doubled by doubling the cross-section. Two 2.Omm or 2.4mm tubular wires can deposit
the required 20 kg/hr without necessarily overloading any component of the system.

Fig 5. Effect of welding conditions on bead shape.

Conclusions
To optimise deposition rate, the effective wire diameter should be decreased, possibly by the
use of tubular wires, and current increased, ensuring at all times that bead shape is adequate.
Energy considerations are a reasonable approximation to experimental data and should be
considered when evaluating deposition rate.

References

1 The Physics of Welding; IIW Publication; Pergamon Press: 1984:

2 Tichelaar, G W et al. 'Droplet Temp. Meas. Arc. Weld.', IIW document 212411-77.
3 Mori, N. et al. 'Molten pool phenomena in sub arc weld.' IIW document 212-188-70.
4 Lesnewich, A. Control of melting rate and metal transfer in MIG welding. Weld. J., 34 (12), .1167-1178.

240 WELDING REVIEW, NOVEMBER 1989

 STERLING STRUCTURAL ENGINEERING
AND DESIGN GROUP LTD

Client: Job Number:

Calculation No: Rev: 0 Prep. by: MEP Chk'd by: Date:6/24/2004
_______________________________________________________________________________________________

Carbon Equivalency Calculation for Steels

_______________________________________________________________________________________________

Objectives:
To claculate a Carbon Equivalency (CE) for the base metals being considered for joining by welding.
Method:
we wll use a standard formula to calculate CE from the chemical composition of the base metal. This composition
may be taken from the ASTM or other standard for the steel being considered. The weldability of steel is indicated
by the CE, with higher values being associated with greated welding difficulty.
Steel Specification and Composition:
Specification of steel to be investigated: ASTM, A572 Grade 50

Cmax := 0.23% ...Maximum percentage of carbon allowed

Mnmax := 1.35% ...Maximum percentage of manganese allowed

Momax := 0% ...Maximum percentage of molybednum allowed

Crmax := 0% ...Maximum percentage of chromium allowed

Nimax := 0% ...Maximum percentage of nickel allowed

Cumax := 0% ...Maximum percentage of copper allowed

Pmax := 0.035% ...Maximum percentage of phosphorus allowed

Calculations:

Mnmax Momax Crmax Nimax Cumax Pmax

CE := Cmax + + + + + + CE = 0.467 %
6 4 5 15 15 3

Recommendations:

If the CE is less than 0.40% then there are no special requirements.

If the CE is 0.40% to 0.60% then use low hydrogen electrode.

If the CE is 0.60% or greater then use low hydrogen electrodes, increase welding heat inputs, pre-heating,
post heating and/or slow cooling rates.

Values of CE greater than 0.80% indicates steels that may not be readily weldable, that may exhibit inferior
weld properties, or may crack when welded.

CarbonEquivalency.mcd 1 of 1 6/28/04
 QW-482 SUGGESTED FORMAT FOR WELDING PROCEDURE SPECIFICATIONS (WPS)
(See QW-200.1, Section IX, ASME Boiler and Pressure Co d e )

Company Name: By:

Welding Procedure Specification No: Date: Supporting PQR No.(s)

Revision No: Date:

Types Manual Auto Machine Semi-A

Welding Process(es):

*JOINTS(QW-402) Details

Joint Design See Detail Drawing

Backing Yes No

Backing Material NA
Metal Nonfusing Metal

Nonmetallic Other

Sketches, Production Drawings, Weld Symbols or Written Description

should show the general arrangment of the parts to be welded. Where
applicable, the root spacing and the details of weld groove may be
specified.

(At the option of the Mfgr., sketeches may be attached to illustrate joint
design, weld layers and bead sequence, e.g. for notch toughness
procedures, for multiple process procedures, etc.
*BASE METALS (QW-403)

P-No. Group No. to P-No. Group No.

OR
Specification type and grade
to specification type and grade
OR
Chem. Analysis and Mech. Prop.
Thickness Range:
Base Metal: Groove: Fillet:

Pipe Diameter Range: Groove: Fillet:

Other:

*FILLER METALS (QW-404)

Spec. No.: (SFA)

AWS No. (Class)

F-No.

A-No.
Size of Filler Materials
Weld Metal:
Thickness Range:
Groove:
Fillet:
Electrode Flux (Class)
Flux Trade Name
Consumable Insert
Other
 QW-482 (Back)
WPS No. DATE:

POSITIONS (QW-405) POSTWELD HEAT TREATMENT (QW-407)

Position(s) of Groove Temperature Range
Welding Progression Up Down Time Range

Position(s) of Fillet
GAS (QW-408)
PREHEAT (QW-406) Percent Composition
Preheat Temp. Min. Shielding
Interpass Temp. Max
Trailiing
Preheat Maintenance
Backing

ELECTRICAL CHARACTERISTICS (QW-409)

Current AC or DC Polarity
Amps (Range) Volts (Range)

Amps and volts range should be recorded for each electrode size, position, and thickness, etc. This information may be listed
in a tabular form similar to that shown below.

Tungsten Electrode Size and Type

(Pure Tungsten, 2% Thoriated, etc.)
Mode of Metal Transfer for GMAW
(Spray arc, short circuiting arc., etc.)
Electrode Wire feed speed range

TECHNIQUE (QW-410)
String or Weave Bead
Orifice or Gas Cup Size
Initial and Interpass Cleaning (Brushing, Grinding, etc.
Method of Back Gouging
Oscillation

Contact Tube to work Distance

Multiple of Single Pass (per side)

Multiple or single Electrodes
Travel speed (Range)
Peening
Other

Filler Material Current Travel

Weld Layer (s) Process Volt Range Speed Range Other
Class Dia. Type Polar Amp. Range
 METALS INSPECTION SERVICES, INC.
P.O. BOX 87486
HOUSTON TEXAS 77287
713-641-0436 FAX 713-649-1304

QW - 482 SUGGESTED FORMAT FOR WELDING PROCEDURE SPECIFICATION ( WPS )

( See QW - 200.1(d), Section IX, ASME Boiler and Pressure Vessel Code)

Company Name: Dooley Tackaberry By

Welding Procedure Specification No. GMAW - SMAW - P1 Date 2/16/2001
Revision Number Date Supporting PQR No.(s) GMAW - SMAW - P1
Welding Process (es) Gas Metal Arc Welding; Shielded Metal Arc Welding Type(s) Semi - Auto, Manual
(Automatic, Manual, Machine, or Semi-Auto)
JOINTS (QW - 402)
Details
Joint Design: Single - V - Groove
Backing: Yes X No Material 37 1/2 deg.+- 5 deg.
Root Opening: 5/32" +- 1/32" Retainers: Yes No X
Sketches, Production Drawing, welding Symbols or Written Description
should show the general arrangement of the part to be welded. Where
applicable, the root spacing and details of the weld groove may be
specified. (At the option of the Mfg., sketches may be attached to illustrate
joint design, weld layers and bead sequence, e.g. for notch toughness
procedures, for multiple process procedures, etc. 5/32" 1/16"+- 1/32"

BASE METALS (QW - 403)

Specification No. SA 106 Grade B P-No. 1 Group No. 1
To Specification No. SA 106 Grade B P-No. 1 Group No. 1
Or Other Materials of P- No. 1
Chemical Analysis and Mechanical Properties
To Chemical Analysis and Mechanical Properties
Thickness Range: .438" Deposited weld Metal Range:
Base Metal: Groove .187" - .864" Process: GMAW Maximum .250"
Fillet All Sizes and Diameters Process: SMAW Maximum .614"
Pipe Diameter Range Groove: Procedure Unlimited Process: Maximum
Other: Diameter Range & Thickness Range established by attached PQR's
No pass Greater than 1/2" in Thickness.

FILLER METALS (QW - 404)

Process (es) GMAW SMAW

F - No. 6 4
A - No. 1 1
Spec. No.(SFA) 5. 18 5.1
AWS No. (class) ER70S-6 E 7018
Dia. of filler metals .035" 3/32"- 1/8"
Tungsten Size: N/A Type: N/A Class: SFA No.
Electrode - Flux (class) Flux Trade Name:
Impact Specimens: Test Temperature Average Ft /Lb. Min. Ft/Lb.
Consumable Insert GTAW: Addition of Filler Yes No
Other:
Contractor's Specification

(Electrode, Code Wire, Hot Wire, etc.)

Each base metal-filler combination should be recorded individually. This form modified for information and typing purposes.(QW-200.1(d)
QW - 482 (Back)
POSITION (QW - 405) POSTWELD HEAT TREATMENT (QW - 407)
ANSI B31.3 Table 331.1.1
Position of Test Groove: 6G
Weld Progression (UP, Down, Flat) Root Down Temperature None Required
Hotpass Up Filler Up Cap Up Time
Other: Other:

PREHEAT (QW - 406) GAS (QW - 408)

ANSI B31.3 Table 330.1.1 Process(es) GMAW SMAW

P1 Materials 1" and Less Shielding 75% Argon 25% Co2 None
Preheat Temperature 50 degree F. Flow Rate 20 - 35 CFH N/A
Interpass Temp. Min. 50 deg. F. Max. 350 deg F. Purge None None
Other: Flow Rate N/A N/A
Other:
Contractor's Specification
ELECTRICAL CHARACTERISTICS (QW - 409)
Amp and Volt ranges should be recorded for each electrode Process(es) GMAW SMAW
size, position, and thickness, etc. This information may Current AC or DC Direct Direct
be listed in a tabular form similar to that shown below. Polarity Reverse Reverse
Amp Range 60 - 150 90 - 150
Volt Range 16 - 20 18 - 25

Mode of Metal Transfer for GMAW: Low voltage short circuit Wire Feed Speed Range:
(Spray Arc, Short Circuiting Arc, etc.)
Contractor's Specification
TECHNIQUE (QW - 410)
Process(es) GMAW SMAW
String or Weave Bead: Stringer Weave
Orifice or Gas Cup Size: 1/2" - 1.0" N/A
Method of Back Gouging: None None
Oscillation: Minimum Minimum
Contact Tube to Work Distance: 1/4" - 1.0" N/A
Multiple or Single Pass (per side) Single Multiple
Multiple or Single Electrodes: Single Single
Travel Speed (Range) -- --
Peening: N/A N/A
Initial and Interpass Cleaning: Yes Yes
(a) The surfaces of the parts to be welded shall be clean and free of scale, rust, oil, grease, and other deleterious foreign
material for a distance of at least 1/2" from the welding joint preparation for ferrous materials and at least 2" for
Non-ferrous materials. Detrimental oxide shall be removed from the weld metal contact area when weld metal is to
be deposited over a previously welded surface, all slag shall be removed by a roughing tool, chisel, air chipping
hammer, or other suitable means so as to prevent inclusion of impurities in the weld metal.
Other:

Weld Filler Metal Current Travel

Layer (s) Process Class Diameter Type Polarity Amp Range Volt Range Speed Range
1 GMAW ER70S-6 .035" Reverse 60 - 150 16 - 20
2 SMAW E 7018 3/32" Reverse 90 - 120 18 - 24
3 SMAW E 7018 1/8" Reverse 110 - 150 19 - 25
Balance SMAW E 7018 1/8" Reverse 110 - 150 19 - 25
WELDER CERTIFICATION – WHAT IS IT?
By Jim Collins, AWS-CWI
Certification Specialist
Hobart Institute of Welding Technology
Welder certification is the written verification that a welder has produced welds meeting
a prescribed standard of welder performance. Welder performance qualification is the
demonstration of a welder’s or welding operator’s ability to produce welds meeting
prescribed standards. [Standard Welding Terms and Definitions, AWS A3.0:2001].
There are many welder performance qualification codes and procedures in existence.
Each is designed to cover a specific scope of work. For example, ASME Boiler and
Pressure Vessel Code, Section IX deals with welding of pressure vessels and piping;
AWS D1.1 Structural Welding Code – Steel is for the structural welding of steel;
American Petroleum Institute’s API 1104 Standard for Welding Pipelines and Related
Facilities relates to energy transmission lines; and AWS D1.5 is the Bridge Welding
Code. The codes enable contractors and manufacturers to qualify welding procedures for
the type of welding they perform.
In most cases, the qualification procedures are very specific. Stainless steel cannot be
substituted for aluminum or steel, for example. Gas metal arc (MIG) welding would not
qualify if gas tungsten arc (TIG) welding were specified. The welding certifications are
not transferable. Thus, if you are qualified to weld stainless steel pipe while you worked
for Sam’s Welding Company, that certification will not transfer to Fred’s Welding Shop,
even though you may be doing a similar job.
However, the American Welding Society has developed a National Welder Certification
program that allows an individual to carry his or her own certification. To accomplish
this, you must test through an accredited test facility. Your name is then put on a national
registry and you may carry this certification with you to a new employer. It permits the
new employer to know that you have proven a certain level of expertise. Employers may
still require that you qualify to their company’s welding procedure, especially in cases
where the welding performed is considered critical.
To keep your National Certification current, you must weld with the process and send a
maintenance of certification form to the American Welding Society every six months.
The Hobart Institute was one of the first AWS test facilities and has been accredited to
perform qualification of welders (AWS-QC7) since 1989. HIWT also has the unique
ability to test off-site. This means that the test can be taken at the Hobart Institute or we
can travel to your facility and monitor the welding test. Our staff has the expertise and
experience to qualify welders to various structural, pressure piping, production, and
aerospace specifications. HIWT works with all types of ferrous and nonferrous materials
including (but not limited to) steel, titanium, cobalt, nickel, aluminum, and various alloys.
Our organization is fully staffed with AWS Certified Welding Inspectors and American
Society of Nondestructive Testing Level III Technicians that meet most, if not all,
welding specification requirements including ASME Section IX, AWS QC-7, AWS B2.1,
AWS D1.1, AWS D1.2, AMS-STD-1595, MIL-STD-248, MIL-STD-453, MIL-STD-
410, and MIL-STD 2219.
 Positioners
Efficient and precise welding depends on the right positioning.
Preston-Eastin positioners are designed for precision operation while drive positively prevents the load from moving unless the worm gear is

affording as much safety as possible. Drive system mechanisms and elec- revolved, regardless of the load. Preston-Eastin positioners are standard

trical controls are completely enclosed for the operator's protection. with a four-post base for vertical adjustment.

Precision spur gears, driven by self-locking worm gear In addition to the standard models, Preston-

reducers, provide minimum backlash with maximum Eastin will custom design positioners to

strength and longevity. A self-locking worm meet the customer's needs.

Model PA-10 HD12

POSITIONER MODEL Load Capacity INH. OH. ROTAT. TORQUE TILT TORQUE R.P.M. TABLE SIZE
PA-5 MT 500 Lbs.@ 4.0" 3.81" 2,000 N/A .12-3.7 22 Dia.
PA-15 HD4 1,500 Lbs.@ 4.0" 4.25" 6,000 12,375 .12-3.6 24 Dia.
PA-10 HD12 1,000 Lbs.@ 12" 5.25" 12,000 17,250 .05-2.0 30 x 30
PA-20 HD6 2,000 Lbs.@ 6.0" 5.25" 12,000 22,500 .05-2.0 30 x 30
PA-25 HD6 2,500 Lbs.@ 6.0" 5.56" 15,000 28,750 .05-2.0 30 x 30
PA-30 FB 3,000 Lbs.@ 6.0" 6.06" 18,000 36,000 .05-2.0 36 Dia.
PA-30 HD6 3,000 Lbs.@ 6.0" 6.0" 18,000 36,000 .05-2.0 36 x 36
PA-30 HD12 3,000 Lbs.@ 12" 7.0" 36,000 56,250 .032-1.3 42 x 42
PA-45 HD12 4,500 Lbs.@ 12" 7.0" 54,000 85,500 .032-1.3 42 x 42
PA-60 HD6 6,000 Lbs.@ 6.0" 7.0" 36,000 78,000 .032-1.3 42 x 42
PA-60 HD12 6,000 Lbs.@ 12" 8.75" 72,000 124,500 .032-1.3 54 x 54
PA-100 HD12 10,000 Lbs.@ 12" 9.00" 120,000 207,500 .025-1.0 54 x 54
PA-160 HD12 16,000 Lbs.@ 12" 9.50" 192,000 344,000 .015-.60 60 x 60
PA-240 HD12 24,000 Lbs.@ 12" 9.25" 288,000 510,000 .016-.66 66 x 66
PA-300 HD12 30,000 Lbs.@ 12" 12.0" 360,000 720,000 .012-.48 66 x 66
PA-400 HD12 40,000 Lbs.@ 12" 12.0" 480,000 960,000 .003-.30 84 x 84
PA-500 HD12 50,000 Lbs.@ 12" 12.0" 600,000 1,200,000 .003-.30 84 x 84
Selecting the proper positioner
1. Determine the total weight you will be A B
positioning, including fixtures. Positioner Rotating Capacity Positioner Tilt Capacity
2. Calculate the center of gravity of the work.
A. Distance from rotational center. Load C.G.
B. Distance from face of table.
Table
3. Using the distance found in step 2-A, calculate the Center Distance
Load C.G.
rotational torque required. (Illustration A)
4. Using the distance found in step 2-B, calculate the Distance INH.
tilt torque required. (Illustration B) OH.
5. Compare the required rotational and tilt torque with
the chart below. Select a Positioner with a load
capacity equal to or greater than your requirements.

Head and Tailstock Positioners

Preston-Eastin Headstock and Tailstock Positioners are designed for

many years of maintenance-free operation. They provide powered rotation

in either direction at a constant speed, controlled from a remote pendant

station, and are ideal for welding or flame cutting.

Models TS-20 through TS-240 Tailstock Positioners have the same

specifications as the corresponding Headstock Positioners, except they

are not powered.

Model HS-45
Headstock

POSITIONER MODEL LOAD CAPACITY ROTAT. TORQUE MOTOR H.P. C.S. R.P.M. TABLE SIZE
HS-20 Headstock 2,000 Lbs. @ 6" 12,000 1/2 1.68 30 x 30
TS-20 Tailstock 2,000 Lbs. @ 6" -------- -- ---- 30 x 30
HS-45 Headstock 4,500 Lbs. @ 12" 54,000 2 1.68 42 x 42
TS-45 Tailstock 4,500 Lbs. @ 12" -------- -- ---- 42 x 42
HS-60 Headstock 6,000 Lbs. @ 12" 72,000 2 1.00 54 x 54
TS-60 Tailstock 6,000 Lbs. @ 12" -------- -- ---- 54 x 54
HS-100 Headstock 10,000 Lbs. @ 12" 120,000 3 1.00 54 x 54
TS-100 Tailstock 10,000 Lbs. @ 12" -------- -- ---- 54 x 54
HS-160 Headstock 6,000 Lbs. @ 12" 192,000 3 .50 54 x 54
TS-160 Tailstock 6,000 Lbs. @ 12" -------- -- ---- 54 x 54
HS-240 Headstock 24,000 Lbs. @ 12" 288,000 3 .40 60 x 60
TS-240 Tailstock 24,000 Lbs. @ 12" -------- -- ---- 60 x 60
For larger sizes, please consult your customer service representative.
 Floor Turntables
Preston-Eastin. Your single source for high quality floor turntables.
Preston-Eastin floor turntables provide a high-precision, low-cost method of Pendant controls are labeled FORWARD, STOP, REVERSE, RAPID and

rotating a workpiece around a vertical axis. They provide powered rotation SET (for variable speed control). Table rotation is maintained until

in either direction at adjustable speeds controlled from a remote pendant stopped by the operator.

station, and are ideal for welding, flame cutting, grinding, X-ray, or drill Preston-Eastin floor turntables are rated for maximum work-

press positioning. piece weight and off-set from the axis of rotation. Normal primary

Table rotation is driven by an SCR-controlled DC vari- electrical input is 115/220/440, depending upon the size of

able-speed motor. the turntable.

Model FT-25

VARIABLE SPEED CONSTANT SPEED

MODEL LOAD CAPACITY C.G. ROTATIONAL TORQUE H.P. R.P.M. H.P. R.P.M. X Y
FT-25 2,500 12 22,500 3/4 .04-1.7 3/4 1.5 23 60
FT-60 6,000 12 26,200 3/4 .04-1.5 3/4 1.5 23 60
FT-120 12,000 12 30,000 1 .04-1.5 1 1.5 23 60
FT-400 40,000 12 50,000 1-1/2 .04-1.5 1-1/2 1.5 23 72
FT-800 80,000 12 135,000 2 .04-1.5 2 1.5 25 72
FT-1200 120,000 12 236,000 3 .04-1.5 3 1.5 33 60
Manipulators
Increase output while decreasing fatigue.
Preston-Eastin welding head manipulators are versatile tools with many

precision or heavy-duty applications. Among the many benefits are reduced

operator fatigue, precision waver-free welds, and uninterrupted welds of

unlimited duration, at distances far greater than an operator can reach.

Preston-Eastin welding head manipulators are designed for many

years of maintenance-free operation. Smooth operation of vertical and

horizontal movement is assured with heavy-duty roundways and bearing

mounted RC60 hardened rollers.

Limit Switches are installed to prevent overtravel. The remote-con-

trol Pendant is stepped down to 115 volts for operator's safety.

Preston-Eastin manipulators are compatible

with any make head or welding process. They

may be located over a workpiece to perform

manual welds or other operations. Manual or

powered travel cars are available for all Preston-Eastin manipulators.

Model MA 44 LD

MOTOR H.P.
MODEL VERTICAL TRAVEL HORIZONTAL TRAVEL LIFT RAM BOLT CIRCLE BASE X Y TRAVEL CAR
MA 44 LD 4 4 1/4 Manual – 97” 6’-6” STD.
MA 66 LD 6 6 1/4 1/4 or Manual – 121” 8’-6” STD.
MA 66 MD 6 6 1/2 1/2 13” 121” 9’-0” OPT.
MA 88 MD 8 8 1/2 1/2 13” 145” 11’-0” OPT.
MA 99 MD 9 9 1/2 1/2 13” 157” 12’-0” OPT.
MA 1212 HD 12 12 3/4 3/4 22-1/8” 205” 16’-0” OPT.
MA 1414 SHD 14 14 1-1/2 1 33-1/2” 241” 19’-0” OPT.
 Turning Rolls
Preston-Eastin’s turning rolls help turn precision into productivity.
Preston-Eastin turning rolls are designed and constructed to afford the Final drive gearcase is totally enclosed and constructed entirely of steel.

customer many years of safe and dependable operation. Aluminum-Bronze worm gears provide maximum strength and durability to

To ensure precision alignment at any center-distance setting, these the final drive.

products have machined and jig-drilled frames. Rubber-tired rollers absorb Remote pendant with 20’ cord provides the operator with all

shock during loading and cushion the load during welding. A steel over- functions for welding, forward/reverse, start/stop, weld/rapid, and

load disc (Models TDRA-10 and larger) protects the rubber tires from potentiometer for precise speed adjustment.

excessive overloads.

Model TDRA-20

Model TIRA-20
Model TDRA-60

Model TIRA-60

MODEL LOAD CAPACITY DIAMETER RANGE ROLLER SPEED MOTOR H.P. TURNING CAPACITY TRACTIVE PULL
TDRA-5 5,000 6” - 12’ - 0” 1.2-46 IPM 1/2 15,000 2,000
TDRA-10 10,000 6” - 12’ - 0” 1.2-46 IPM 3/4 30,000 2,900
TDRA-15 15,000 6” - 12’ - 0” 1.6-50 IPM 1 45,000 4,000
TDRA-20 20,000 6” - 12’ - 0” 1.4-57 IPM 1-1/2 60,000 5,000
TDRA-30 30,000 8” - 15’ - 0” 1.1-44 IPM 2 90,000 8,300
TDRA-60 60,000 8” - 15’ - 0” 1.1-44 IPM 3 180,000 12,400
TDRA-90 90,000 8” - 15’ - 0” 1.1-44 IPM 3 270,000 12,400
TDRA-120 120,000 8” - 15’ - 0” 1.1-44 IPM 5 360,000 21,250
TDRA-200 200,000 8” - 15’ - 0” 1.0-40 IPM 5 600,000 28,000
TDSA-300 300,000 2’ - 15’ - 0” .64-64 IPM 10 900,000 38,000
Idler Model TIRA available for each model number.
Special Purpose Rolls Friction Drive Rolls
The final drive gearcase is all steel fabricated and totally enclosed, with cast
Model FIR-3
iron worm gears for maximum strength and durability. A remote pendant with

20-foot cord provides the operator with start/stop functions for welding, for-

ward/reverse, foot/hand, and a potentiometer for precise speed adjustment is

located at the motor control enclosure. A variable-speed footswitch is included.

Model FDR-3

MODEL WEIGHT CAP. TURNING CAP. TRACTIVE PULL DIA. RANGE SPEED RANGE MOTOR SIZE WHEEL DIA. WHEEL FACE
FDR-3 Drive/Idler 3 Tons 9,000 pounds 2,000 pounds 3.5” thru 30” diameter 1.2 to 46 IPM 1/4 H.P. DC 12” Diameter Rubber 3.5” Wide Rubber

Unit Frames
Preston-Eastin UFTR Series Unit Frame Pipe Turning Rolls are designed and con-

structed to afford the customer many years of safe and dependable operation, with

machined and jig-drilled frames to assure precision alignment. Rubber-tired rollers

absorb shock during loading and cushion the load during welding. The final drive

gearcase is all steel fabricated and totally enclosed, with aluminum-bronze worm

gears for maximum strength and durability. A remote pendant with a 15-foot cord
Model UFTR4A-5/36
provides the operator with all functions for welding, forward/reverse, start/stop,
Unit Frame
weld/rapid, and potentiometer for precise speed adjustment.

MODEL WEIGHT CAPACITY DIAMETER RANGE SPEED RANGE MOTOR SIZE WHEEL DIAMETER WHEEL FACE
UFTRA-5/36 Driver 5,000 lbs. 3” thru 36” Diameter 1.6 to 64 IPM 1/2 H.P. DC 12” Diameter Rubber 4.5” Wide Rubber
UFTR4A-5/36 Driver 5,000 lbs. 3” thru 36” Diameter 1.6 to 64 IPM 1/2 H.P. DC 12” Diameter Rubber 4.5” Wide Rubber
UFTIA-Idler 5,000 lbs. 3” thru 36” Diameter 12” Diameter Rubber 4.5” Wide Rubber
UFTR4A-10/36 Driver 5,000 lbs. 3” thru 36” Diameter 1.6 to 64 IPM 1/2 H.P. DC 12” Diameter Rubber 4.5” Wide Rubber
UFTIA-10/36 Idler 5,000 lbs. 3” thru 36” Diameter 12” Diameter Rubber 4.5” Wide Rubber

Welding Head Cross Slides Body of Slide is fabricated from aluminum. Hardened and ground shafts guide the

traveling block on precision ball bushings. The slide can be mounted either vertically

or horizontally, or can be compounded together to give travel in both directions.

Model WCS-100 and WCS-150 are manual versions with a 4-inch handwheel to

control travel. The WCS-100P and WCS-150P are powered by a DC motor, which

is controlled by solid state electronic drive. Direction is controlled with a joystick

and slide comes standard with limit switches for overtravel protection.

MODEL MECHANISM TRAVEL TRAVEL SPEED

WCS-50 Manual 4”
Model WCS-150P WCS-100 Manual 6”
WCS-100P Powered 6” 22 IPM
WCS-150 Manual 12”
WCS-150P Powered 12” 17 IPM
 Accessories
Jack Stands
The Preston-Eastin adjustable pipe dolly has a 2,000 pound weight

capacity, 2” to 36” pipe diameter range, with 8” diameter wheels, 2-1/2”

wide. The rubber roller assembly has an 8” vertical adjustment by means

of an Acme Screw and Nut. These Jack Stands are used as outboard
Jack Stands support with our Positioners for extra-long work.

MODEL DESCRIPTION
RPJS-20 Adjustable Pipe Dolly

Self-Centering
Welding Chuck

MODEL DESCRIPTION CLAMPING RANGE

PC-8 Self-Centering Welding Chuck with Adapter .16” to 7.87”
PC-12 Self-Centering Welding Chuck with Adapter .20” to 9.84”
PC-15 Self-Centering Welding Chuck with Adapter .39” to 15.75”
PC-20 Self-Centering Welding Chuck with Adapter .79” to 19.69”
PC-24 Self-Centering Welding Chuck with Adapter 1.18” to 24.80”

Foot Switches

MODEL DESCRIPTION
VFS-20 Variable Speed Footswitch
RFS-20 Forward/Reverse Footswitch
SFS-20 On/Off Footswitch

Get in Touch with Us Today! P.O.Box 582288

Tulsa, OK 74158
For more information on Preston-Eastin products, call us today at 918-834-5591.
918-834-5591
Or you can visit our website at www.prestoneastin.com Fax: 918-834-5595
www.prestoneastin.com