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EMERGING STANDARDS
ISO-3834 Quality requirements for fusion welding of metallic materials. EN -15085- Welding of railway vehicles and components. IRIS- International Railway Industry Standard
Welding personnel(Men)
Welders and welding operators Welding co-ordination personnel Inspection & testing personnel Welding inspection personnel Non-destructive testing personnel
What is the main reason for carrying out a Welding Procedure Qualification Test ?
To show that following a given set of parameters will produce a welded joint that has the properties that satisfy the design requirements
Welder Qualification
What is the main reason for carrying out a Welder Qualification Test? To test the ability of a welder to follow verbal or written instructions and verification that the weld produced meets the required standard
Terminology
WPS - Weld Procedure Specification: Qualified instructions on how to complete the weld PQR - Procedure Qualification Record (ASME) & WPAR - Weld Procedure Approval Record: Record of the welding parameters and test results Welders Qualification Test Certificate & Welders Performance Qualification (ASME) Record of Welder test results and ranges of approval
Terminology
Essential Variable: A parameter that when changed outside its permitted range requires requalification Non Essential Variable
A parameter that when changed does not require requalification Supplementary Essential Variable Is an essential variable only when impact testing is required
Parent material
Type of process (MMA, MAG, TIG, SAW etc) Equipment parameters Amps, Volts, Travel spee
Welding Consumables
Edge preparation Root gap, root face Jigging and tacking Type of baking
Welding Position
Location, shop or site Welding position e.g. 1G,2G, 3G etc Any weather precaution
EN 287-Part-1 -2011
QUALIFICATION TEST OF WELDERS FUSION WELDING PART-1- STEEL
Validity Of Approval
Valid for 2years, providing that the welders supervisor can confirm that at every six month period the welder has been working within his range of qualification.
Visual Testing
Each test piece shall be subjected to visual testing (VT): after the root run of the butt weld has been performed in the test piece, after completion of the test piece. Visual testing and its recording shall comply with the guidelines contained in EN ISO 17637. The quality level of the test pieces, based on type and size of imperfections, shall be assessed in accordance with EN ISO 5817 for steel test pieces and EN ISO 10042 for the test pieces of aluminium or its alloys. Surface imperfections of the test piece shall be within quality level B. Only the following types of imperfections in quality level C are permitted: excess butt weld metal (502), excess fillet weld metal (503), excess throat of the fillet weld (5214), excessive penetration (504), incorrect weld toe (505), undercuts (501). The reference numbers given in brackets are in accordance with EN ISO 6520-1. In the assessment of the root run of the butt weld test piece welded from both sides, weld root removed, surface imperfections shall not exceed limits for imper fections within quality level D.
WELDER DESIGNATION
EN287-1-135-P-BW-1.1-S-t16-PA-ss nb.
EN 287 111 -1
BW
1.1
10 mm
D 60
PA
ss nb
1-Steel
SMAW
PLATE
Butt Weld
plate thickness
down hand
Applicable above 0.5 mm parent metal thickness. Covers fully penetrated butt welded and all fillet welds. Principles of this standards can also be applied for partial penetration butt weld.
BS EN ISO 4063-2009
WELDING AND ALLIED PROCESSES NOMENCLATURE OF PROCESSES AND REFRENCE NUMBERS.
ISO 4063
Process number 1 arc 23- gas welding resistan weldin ce g welding 5 beam weldin g 8cutting &goug ing
4063 classification
1 arc welding 111- SMAW/MMAW 12- Sub merged welding.(SAW) 121- sub merged arc welding with solid wire electrode. 13- GMAW 131- MIG welding with solid wire 135-MAG welding with solid wire 136- MAG welding with flux core wire.
14- GTAW. 141- TIG welding with solid filler material. 142- Autogenous welding. 15-PLASMA ARC WELDING
Resistance Welding
2- Resistance welding 21- resistance spot welding. 211- indirect spot welding 212- DIrect Spot Welding. 22 Resistance seam welding 225- foil butt seam welding
Beam welding
5- beam welding 52- laser beam welding 521- solid state laser welding 522-gas laser welding 523- diode laser welding
Welding processes
Each qualification test qualifies only one welding process. Change in welding process requires a new qualification. Exceptions. Change from solid wire electrode 135 to metal cored wire 138 does not require requalification.
Type of weld
But welds do not qualify fillet weld and vice versa.
What does not get measured What does not get Recorded What does not get monitored What does not get controlled
Equipment(machine)
Production and testing equipment
Description of equipment Suitability of equipment New equipment Equipment maintenance
Production planning(method)
Welding procedure specifications (WPS) Qualification of the welding procedures Work instructions Procedures for preparation and control of documents
Welding Consumables(material)
Batch testing Storage and handling
Materials
Storage of parent materials Post-weld heat treatment
OTHER REQUIREMENTS
Non-conformance and corrective actions Calibration and validation of measuring, inspection and testing equipment Identification & traceability Quality records
Any questions