Section 07 WIC7 Codes and StandardsA code of practice js generally a tegally binding document containing the rules and laws required to design, and test a specific product, whereas a standard will generally contain, oF refer to all the relevant optional and mandatory manulavtusing, esting and measuning data. The definitions given in the English dictionary state: A code of practice: A set of law's, or rules that shall be followed when providing a service or product. ‘An applied standard: A level of quality, or specification tou which something must be tested. We use codes and stanelards 19 manufacturo many things that have been bullt many times before. The lessons of failures, ot under-design are generally incorporated into the next tevised edition. Typical design/construction codes and standards used in industry include: Pipe lines carrying tow, and high-pressure fluids Oil storage tanks. Pressure vessels. Offshore structures. Nuclear installations. Composite concrete and steel bridge construction. Vehicle manutacture, Nuclear power station pipe work Submarine hull construction, Earth moving equipment. Building consinierion ote, Generally; the higher the level of quality required then the more epecifie is the codeistandard in terms of the manufacturing, method, materials, workmanship, testing and acceptable imperfection levels. The application code/standard gives important information to the welding inspector as it determines the inspection points aud slages, and other relevant criteria that must be followed, or achieved by the contractor during the fabrication process. Most major application codes and standards contain 3 major sections, which are dedicated to: i 1) Design. 2) Manufacture, 3) Testing. WTC 7 Welding inspection ~ Codes and Standards a Rev 09.09.02 Copyright © 2002 TWI LtdTWI LTT EE Application codes/standards may not contain all the relevant data required for manufacture, but may 1efer (0 other applicable standards for special elements. Examples of these are given below: 1) Materials specifications. 2) Welding consumable specifications. 3) Welding procedure and welder approvals, 4) Personnel qualifications for NDT operators. 5) NDT Methoas, On many occasions the application code/standard will contain it own levels of acceptance, which are drawn up hy » hoaed of profeccional senior engineers, who operate in that specific industrial area, Codes and standards are revised periodically to take into account new data, new manufacturing methods, or processes that may come into being. If no local legal obligations exist deen it is the year of the application code/standard within the contract documents, which becomes the legally binding version. The main areas of responsibility within an application standard is genecally divided into: 1b The client, or customer, 2) ‘The contractor, or manufacturer. 3) The third party inspection authority, or client's representative. The applied code/standatd will form hub of the contract documents lence any deviation, or non-conformance from the code/standard must be applied for by application from the Contractor to the client as a concession, Onee a concession lus been agrecd, it must then become a signed and written document, which is then filed with the fabrication quality documents. i WTC 7 Welding Inspection ~ Codes and Standards 12 Rey 09-09.02 Copyright © 2002 TWI Ltdee Questions aut Qu2, Qua, Qua, aus, Codes and Standards What is the difference between a cades and a standard? |n a code/standard, what is the difference between shall and should What do you understand by the terms: National standard and Harmonized standard ‘As a welding inspector what important information can be obtained form an pplication code/standard? 'sita requirement for the application code/standard to contain all relevant data required for manutacturing a product? And if nat give details of what clements may be missing, WIC 7 Welding Inspection -QU Codes & Standants See‘? Copyright © 2003 TW1 LidSection 08 WIC7 Welding Symbols on DrawingsA Weld Symbols on Drawings: We se weld symbols to transfer information from the design office to the workshop. {tis essentin! that a welding inopector can interpret weld symbols, as a lange proportion of the welding inspectors time will be spent checking that the welder is correctly, completing the weld in accordance with the approved fabrication drawing, Therefore itvout a good knowledge of weld symbols, a welding inspector is unable f0 carry out his full scope of work. Standards for weld symbols do not follow logic, hum are based on simple conventions ‘There are many different standads for weld symbols, as most major manufacturing countries have their own. Basically a weld symbol is made of § different components; and the following is common to all major otandards, 1) ‘The arrow lin ‘rhe arrow line is always a straight and unbroken line, (With the exception of instances in AWS A2.4) and has only 1 of 2 points on the joint where it must touch, as shown below: Fither/or 2) The reference line: The reference line must touch the arrow line, and is generally parallel to the bottoms of ihe crawing page. ‘here is therefore always an angle between the arrow Tine and reference line, The point ofthe joint ofthe 2 lines is referred to as the knuckle PAM ai INNA 3) The symbol: ‘The orientation of the symbol on the line is generally the came in most standatds, however the concept of arrow side and other side is shown differently in some Standards. This convention is explained within the following text for UK. European, and 150 staudatds. (AWS A2.4 convention for arrow and other side follows that of BS 499) 4) The dimensions: Basically, all cross sectional dimensions are given to the left, and all linear dimensions are given (o the right hand side of the symbols in most standards, 5) _ Supplementary infgrmation Supplementary information, such as welding process, weld profile, NDT, and any special instructions may differ from standard to standard The following scetion gives a guide to the standards used in UK and Europe. WTC 7 Welding Inspection - Weld Symbols on Drawings 1 Rev 09-09-02 Copyright © 2002 TWI Lid,TWI Cee LRAT instiute 1) Convention of BS 499 (UK): The Arrow Line: 2) Shall touch the joint intersection, b) Shall not be parallel to the drawing ©) Shull point towards a single plate preparation The Reference Line: a) Shall join the arrow line, b)_ Shall he parallel to the bottom of die drawing, The Weld Symbol: 3) Welds done from this side (Arrow side) of joint, go underneath the reference line ©) Welds done from the other side ofthe joint, goon top of the reference line ©) Symbols with a vertical Hine component must be drawn with the vertical line drawn t0 the loft side of the symbol @) _Alleross sectional dimensions are shown tothe lft ofthe symbol ‘The throat thickness is preceded by the letter a and the leg length by the lttea b ‘When only leg length is shown the reference letter (b) is optional. ©) Alllinear dimensions are shown on the right of the symbol 42. Number of welds, length of welds, length of any spaces Example: a, Throat, b, Leg Number X Length (Space) Example: 2.7 b.10 50 WTC 7 Welding inspection — Weld Symbols on Drawings 2 7 Rev 09-09-02 Copyright © 2002 TWI Liaem Examples of BS 499 ISO 2553 and BSEn 22553 Double-sided butt weld symbols Double bevel DoubleV — DoubleS_ ~—-Nouble U Supplementary & further weld symbols to BS 499: Square butt weld ail Profile of fillet ee Sl) 11 (Welding process to ISO 4063 mH Spot weid Weld all around Weld on site Me a.10 a7 b. Vv Compound weld (Single bevel and double fillet) Staggered Intermittent welds in BS 499 and BSEn 22553 are pitched to the start welds 3.No’s 20mm length 50mm gap pel il e 10 10 Staggered WTC 7 Welding Inspection ~ Weld Symbols on Drawings §.3, Rey 09-09-02 Copyright © 2002 TWI Ltd,TWI CLM. THE WF ning instiTure (eee 2) Convention of ISO 2553 and BSEn 22553: (Has now replaced BS 499 in UK) The Arrow Line: (As per BS 499) 2) Shall touch the joint intersection b) Shall not be parallel to the drawing ©) Shall point towards a single plato preparation The Reference Line: a) Shall join the arrow line ce Sasa) ¥) Shall be parallel to the botiom of the drawing, a ase ©) Shall have a broken line placed above, or beneath the reference line. —, The Symbol: As per BS 499 with the following exceptions: The other side of the joint is represented by the broken line, which shall be shown Shere: oF below tle reference line, except in the case where the welds are iolally symmetrical about the central axis of the joint. Fillet weld leg length shall always be preceded by the letter z, Nominal fillet weld throat thickness shall always be preceded by the letter a. Erfective throat thickness shall always be preceded by the letter $ for deep penetration fillet welds and partial penetration butt welds. Unbroken line representing the arrow side of the joint Removable backing strip Welding process to ISO 4633 yi x7 Reference information MR] s.10 131 a8 s.10 2.10 yy + iN Broken line indicating other side of the j Weld toos to be ground smoothly WTC 7 Welding tuspection - Weld Symbols én Drawings §.4 Rev 09.09.02 Copyright © 2002 TWI Ltdea Table 10 * Numerical \dication of process No. Process No. Process 1 Are welding 47 Gas pressure welding, TT Metal-are welding without gos protection 48 Cold welding 111 Metal-are welding with covered olectrode 7 Other welding processes 112 Gravity are welding with covered electrode 71 Thermit welding 113 Bare wire metal-are welding Electroslag welding Nid lux eared metalare welding Blectrogas welding 11S Coated wire metal-are welding, Induction welding M8 Firecracker welding, Light radiation welding 12 Submerged are welding Laser Welding 121 Submerged are welding with wire electrode Are image welding 122 Submerged are welding with strip clectrade 753 Infrared welding 15 Gas shielded metal-are welding 76 Blectron beam welding 131 MIG welding TT Percussion welding, 135 MAG welding: motatare welding with 78 sluc welding nnonsinedt gas shield 136 Flux cored metalare welding 781 Are stud welding 14 Gas ahilded welding with non-consumable 782_—_‘Resistance welding, electrode 141 TIG welding 9 Rrrazing, soldering & braze welding 149 Aromic-hydrogen welding 91 Brazing 15 Plasma are welding 911 Infrared brazing 18 Other are welding processes 912 Flame lnwing 181 Carbon are welding 913 Furnace brazing 185 Rotating are welding 914 Dip brazing 2 Resistance welding 915 Sale bath brazing 21 Spot welding 916 Induction brazing 22 Steam welding 917 Titrenie bracing 221 Lap seam welding DIS Resistance brazing 225° Seam welding with strip 919 Diffusion brazing 23° Projection welding 923 riction brazing 24 Flash welding 924 Vacuum brazing, 25 Resistance buat welding 93 Other brazing processes 29 Other resistance welding processes 9 Soldering 291 HP resistance welding, 941 Infrared soldering 3 Gas welding 967 Flame coldering 31 Oxy-tuel gas welding 943 Furnace soldering. 311 Oxy-aeetylene welding 944 Dip soldering 312 Onyepropane welding 945 Salt bath soldering 313 Onyshydrogen welding 946 Induction soldering 32 Air fuel gas welding, 547 Ultrasonic soldering 321 Aitsacetylone welding 948 Resistance soldering. 322 Air-propane welding 949 Diffusion soldering 4 Solid phase welding: Pressure welding 981 Flow soldering 41 Ulvasonie welding 952 Soldering with soldering iron 42 Friction welding 953 Friction soldering 43. Forge welding Mt 954 Vacuum soldering 44 Welding by high mechanical nergy 96 Other soldering processes 441 Explosive welding 97 Brave welding 45 Diffusion welding 971 Gas braze welding 972 Are brave welding WTC 7 Welding tnspection ~ Welg Symbols on Drawings Copyright © 2002 TW1 Led 85 ble complies with International Standard ISO 4063 Rev 09-09-02eA Complete a symbols drawing for the welded ericiform joint given below: All butt weld are welded with the MIG process and fillet welds with MMA. All fillet weld leg lengths are 19 mm Use the sheets overleaf to transcribe the information shown above into weld symbols complying with the following standards BS 499 Part II BSEn 22553 Use the drawings provided overleaf ‘The course lecturer will present the solutions, after you have completed the exercise. WTC:7 Welding Inspection Weld Symbols on Drawings 8.6 Rev 09-09-02 Copyright © 2002 TWI LtdTWI CM. —————— NNN THE EL DING INSTITUTE BS 499 Part II BSEn 22553 > WTC 7 Welding Inspection - Wold Symbols on Drawings 8,7 Rev 09-09-02 Copyright © 2002 TWI LedTEAL e007 @ dda Ted Gor $a NO ~ 1oN23E60 Suey £ OE S95 s0quss pay 4 “SS@WOILY OILY WLU gO} ‘y}Budy Ba] WLU gy ‘PI9M Jal}4 XeAUOD snonuRUOD Y TPIS 48UIO papjany “wu SZ Piem yore usamieq oLe}SIp ay) ‘UW |. pjam yore JO wiBue| ‘sseuyony you) Ly ‘syyBUE) Ba] LUI Q) SFIOM 184 JUSHILUIE|UI OUY, 1@pIS Moe PEpIOM “p “alls Uo yno pais 94 0} spjem ‘sseuyoryy eos wi > ‘syiBuat 69) I WU 9 “PieM Je\Iy srionunuoD Y ‘sepis oq Papiom ‘¢ “pereBBeys [aT -+s 7+] 94.0} SDI9 NA “WIL OL Pjom YDee Leemieg acuE)SIp But ‘UW CE pjam Yoks Jo YIBUE] oy) ‘sypBUA| Bo) LL ZI SPIOM TOMY JUOTUWAWU! OM, :@PIs J8y;0 papjam, WU! O€ PiaM YORE Uaanyag couE;sIp aLy ‘will 02 plom yoee Jo yjBuBl aur ‘su6ue) Ba] LLU g ‘SPIOM 19/1 JUS TIUUAYUI Gosy | MOE papjany ‘Z ‘syi6u9 Bo] wg weg peplem “1 Plo 42Ily @AeOUOD snonuUDD Y :s9| 9S1949X9 POM JeI114 Z Wed 66) Sa BLNLUSNI ONIGTS¢ SHL ee WF) IMLEM G002 @ alkoxy sods SUPIM J LN {8995 oauads Buran nna esse Na Sa AD —H Plam 39113 Y6US| 69) ww Z) :ap1s seyJo papjayy “WW G} SSauyoIy: aye Id) “pesoduiuadns pjam joi ww ge Ui UL Z| UOReJedaid 40 Udap ‘pam tng f-2|ulg :epis Mowe pepjey, “py (usu sb ssousjoup eretd) “und Bupjoeg :epis 10430 papionm {uu OL Uonesedesd jo uidep pram yng A-ajBuIg :epls Moe peplom “E S1cud pion 184 ‘Dem ung A-<)BuIs :apis seMo peplom -z “eI Youd pion yey ‘dias Bupoeq IWeUPUHEd YM plom HNg A-2/SuIg :epls Moe paploM *} 8S1D49x3 PIM 3Ng Ess7z NA sq BLTLILSNI ONIOTAM SHL ee MTA IMLSection 09 WIC7 Introduction to Welding ProcessesIntroduction to Welding Processes: A welding process: Special equipment used with method, for producing welds ‘The 4 main requirements of any fusion welding process are: To make sound welds, we need Adequate properties Cleaning Heating: Of high enough intensity to cause melting of base metals and filler metals, Protection: OF tie molten filler metal in transit and base nietal from oxidation, and to protect the heat source and metals from ingress of gases such as hydrogen & oxygen, Cleaning: Of the weld metal to remove oxides and impurities, and refine the grains Adequate: Adding alloying elements to the weld, to produce the desired suechanical Properties properties. WTC 7 Welding Inspection ~ Introduetion to Welding Processes 9:1 Rev 09-09-02 Copyright © 2002 TWI LtdeA Heating: There are many heat sources used for welding. In fusion welding, the main requirement is that the source must be of sufficient temperature to melt die materials being welded. Combustion of gases: Oxygen & acetylene will combust to produce a temperature of 3,200 °C. Other fuel gases may be used for oxy fuel gas cutting. The intensity of the flame is not as high as vuthes heating methods and so longer time has to be spent to bring the material to ite melting point. Electrical resistance: The heat generated by electrical resistance between 2 surfaces is used 10 produce over 95% of all welds made, in the resistance spot welding process. Electrical resistance is also used as a heat source in the Electro Slag welding paces whera the resistance, is f1ven by the molten slag. This process is classed as a resistive heating process High inteusity energy beams: We use 3 types of concentrated high intensity energy beams, which are: 1) Laser. (Light Amplification by Stimulated Emissions of Radiation) 2) Electron Beam. (Concentrated heam af electrons, generally in a vacuum) 3) Plasma. (A gas forced through an electeie arc to create an ionised gas) All ‘hese welding processes use beams of high energy creating extremely high lemperatures. These energy beams also enable very high welding spceds, which reduce the amount of overall distustivu wilh increased productivity, Friction: We can use the heat gencrated by friction (and piessure) to weld components together The joint is made with the materials faces in the plastie state. The Electric Are: Dy far the most common heat source for fusion welding, the electric arc is utilised in Most of the common welding processes, The electric arc can produce heat of > 6000 °C with extreme levels of ultra-violet, infrared and visible light, Heat is derived from the Collision of electrons and ions with the base material and the electrode. An clectric arc may be defined as the passage of current across an ionised gap. All gases are insulators and thus sufficient voltage, or pressure needs to be available to enable an electron to be stripped from an atom into the next. Once this conducting path ar plasma has boon created, a lower voltage can maintain the arc. The voltage required to initiate the are is ermed the open circuit voltage or OCV requirement of the process/consumable, The oltage that maintains thé are Once itis ereated is termed the welding, or are voltage ‘The conducting path produced is termed the plasma column. WTC 7 Welding incpection ~ Introduction tu Welding Processes 9.2. Rev 09-09-02 Copyright © 2002 TWI LtdTE Protection: In MMA welding, the gas shield is produced from the combustion of compounds in the electrode coating, The gas produced is mainly CO? but electrodes are available that Produce hydrogen gas, which give a very high level of penetration, In Submerged Are welding the gas shield is again produced from the combustion of compounds, but these compounds are supplied in a granulated fix, which ie supplied Separately to the wire, MMA clectrodes or SAW fluxes containing high levels of basic compounds are used where hydrogen controlled welding is required In MIG/MAG & TIG welding the as is supplied directly from a cylinder, or bulk feed system and may be stored in a gascous, or liquid state. In TIG & MIG welding we gencrally use the inert gases argon or helium, In MAG welding we generally use CO? or mixtures of CO? or 0" in argon. Cleaning (of surface contaminants): The cleaning, refining and de-oxidation of the weld metal is a major requirement of all vommon fusion welding processes. As a weld can be considered as a casting, it is Possible t0 uso low quality wires in some processes, and yet produce high quality weld metal by adding cleaning agents to the flux. This is especially true in MMA welding, where many cleaning agents and de-oxidants may be added directly to the electrode coating. De-oxidants and cleaning agents are also generally added to FCAW & SAW fluxes. For MIG/MAG & TIG welding wires, de-oxidants, such as silicon, aluminium and manganese must be added to the wire during initial casting. Flectraies am wires for RUG & L1G welding must also be refined to the highest quality prior to casting, as they have no flux to add cleaning agents to the solidifying weld metal Adequate properties (from alloying): As with de-oxidants, we may add alloying elements to the weld metal via a flux in some processes to produce the desired weld metal properties. Its the main reason why there is a wide range of consumables for the MMA process, The chemical composition of the deposited weld metal can he changed easily during manufacture of Uh: Mux coating, This also increases the electrode efficiency. (Electrodes of > 160% are not uncommon). In SAW, elements such as Ferro-manganese may be added to agglomerated fluxes, It is ‘much cheaper to add alloying elements to the weld via the flux as an ore, or compound As with the cleaning requirement described above, wires for MIGIMAG & TIG must be Grawn as cast, thus all the elements required in the deposited weld metal composition must be within the cast and drawn wire. This iy the main reason why the tange of these consumables is very limited. With the developments of flux core wires, the range of consumables for FCAW is now very extensive, as alloying elements may be casily addod to the flux core in the same way as MMA electrodes fluxes, WTC 7 Welding Inspection ~ Introduction to Welding Processes 9.3 Rev 09-09-02 Copyright © 2002 TWI Ltd,TWI Ve Special Terms Related to Welding Safety Duty cycle: A Duty Cyele is the amount of current that can be safely carried by a conductor in a period of time. The time base is normally 10 mimutes and a 60% duty cycle means that the conductor can safely carry this current for 6 minutes in 10 and then must rest and cool for 4 minutes. Ata 100% duty eyele equipment can enmy the current continuously. Generally 60% & 100% duty cycles are given on welding equipment. Example: 350amps at 60% duty cycte and 300amps 100% duty cycle. This should not be confused with the teun Operating Factor, oflen wrongly used for Duty Cycle, as they are both measured as a percentage. Operating Factors are mainly used in economic caleulations to ealcntte the amount of time required fivin a welding, Process to deposit an amount of weld metal. A typical Operating Factor for MMA would be only 30% Occupational, and Maximum Exposure Limit (OEL and MEL): Operational, and Maximum Exposure Limits may be defined as a safe, or maximum working limit of exposure to various fue, gases or compounds during certain time limits, as calculated by the Health and Safety Executive or HSE in the UK. ‘The branch of the executive that holds responsibility for this function is known as COSHH or Control of Substances Hazardous to Health. Examples of levels of some fume and gases that workers may be exposed to, taken from Guidance Nate RH/40 7002, are given in the table below: Fume or gas Exposure Limit | Effect on Health Cadmium, 0.025Mgim Extremely toxie_| | SMgim Low toxicity | SMgim™ Low toxicity ‘Aluminium SMp/m* Low toxicity | Ozone 0.20 PPM Extremely toxic Phosgene 0.02 PRM, Extremely toxic ‘Argon No OEL Value Very low toxicity OF air content to be controlled _| SUP “Note MEL/OEL values given in Guidance Note EH/40 may change annually. ‘The toxicity of these examples can be gauged by the value of exposure limit, Any of the above examples may be present in welding under certain conditions, which will be expanded upon by your course lecturer at the relevant time, though Welding Safety will be discussed fully as a separate subject area WTC 7 Welding Inspection — introduction to Welding Processes 9.4...” Rev 09.09.02 Copyright © 2002 TWI Lid,TWI ae Questions Introduction to Welding Processes aut ‘What are the four essential factors for fusion welding? Qua Name five energy sources for fusion welding, ous ‘At what temperature is Ue electrical arc during an arc welding process qua, Briefly discuss the differences between a friction weld and a fusion weld aus. |n welding, what do you understand by the term Duty Cycle? WIC 7 Welding Inspection ~QU Introduction to Welding Processes See 9 Copyright © 2003 TWr LtdSection 10 WIC7 Manual Metal Arc Welding (MMA SMAW)TWI ne Are Characteristic for MMA & 'TIG In MMA & TIG welding, the are length is controlled by the welder. Whilst an experienced and highly ckilled welder can keep te atc length ata fairly constant length, there will always be some variation. When the arc length is increased, the voltage or pressure required to maintain the are will also need to increase. This would also reduce the current supplied in a normal electrical Circuit, where the supplied voltage is proportional to a drop in current. ‘Thus we need to find a way uf weducing a large drop in current for the variation in are voltage. This is achieved by the use of special electrical components within the equipment that pravuce sets af curvec ac chown below. The graph below shows amperage curve (A) selected @ 100 amps, with the effect of variation in the are gap and voltage. Note how an increase in arc length increases the area under the graph, which appears (o give an tnerease in overall heat input. The extra heat is, however, generally lost in the are and is not transferred to the weld pool. Constant Current (Drooping) Characteristic : Output Curves for current selector settings; A: 100 Amps. B: 140 Amps, C: 180 Amps ocyv 50-90 volts Long are gap Arc Voltage Welding Amperage A BC A large variation in voltage = A smaller variation in amperage WTC 7 Welding Inspection ~ Manual Metal Are Welding 10.1 Rev 09-09-02 Copyright © 2002 TWI Ltd,TWI UM. Manual Metal Arc Welding: THE WELDING INSTITUTE MMA is a welding process that was first developed in the late 19" century using bare wire electrodes, Definitions: MMA: Manual Metal Are Welding. (UK) SMAW: Shiclded Metal Arc Welding, (USA) Introduction: MIMIA is simple process m terms of equipment and consumables, using short flux covered slectrodes. The electrode is secured in the electrode holder and the leads for this, and the Hower return cable are placed in Uke + or ~ electrical ports as required. The’ process demands a high level of skill from the welder to obtain consistent high quality welds, bat is widely used in industry, mainly becauee of the range of available consumables, ils Positional capabilities and adaptability to site work. (Photograph 1) [The electrode core wire is often of very low quality, as refining elements arc easily added ‘o the flux coating, which can produce high quality weld metal relatively cheaply. ‘The arc is struck by striking the electrode onto the surface of the plate and withdrawing it a small distance, as you would strike a match, The afc should be struck in the direct area of the weld preparation avoiding arc strikes, or stray flash on the plate material, Care should also be taken fo maintain a short and constant arc length and specd of travel Photograph 2 shows a traince dressed in the correct safety clothing, whilst photograph 3 indicates the level of proctss-produced fume, and the use of a flexible hose extraction system. Lille has changed with the basic principles of the process since it was developed. but improvements in consumuble technologies occur on a very regular basis, WIC 7 Welding Inspection Manual Metal Are Welding 10.2 Rev 09.09.02 Copyright © 2002 TWI Ltd