CEMP-E
TI 809-26
1 March 2000
fillet weld size in AWS Table 5.8. "Matching" filler metals must be used, per AWS Table 3.1, and
minimum preheat and interpass temperatures must be provided per AWS Table 3.2.
e. WPS Qualification Requirements. When WPSs, joints, filler metal selection, or other details do not
meet the prequalification requirements of AWS D1.1 Section 3, the WPS to be used for the joint must be
qualified by testing prescribed in AWS D1.1 Section 4. Documentation of the WPS used and test results
must be documented in the form of Procedure Qualification Records (PQRs). Qualified WPSs must be
referenced to the applicable PQR. PQRs must be in writing, and made available for inspection by the
inspector.
f. Guidance for Engineering Review of Procedures Submitted by Contractors. For review of WPSs,
the contractor should submit all applicable manufacturer data sheets and operating recommendations for
the filler material to be used. It may also be necessary to consult the AWS A5.XX filler metal
specifications for information regarding the use and limitations of the filler metal.
(1) Generally, manufacturer's operating recommendations provide a range of welding parameters
such as voltage and current (amperage) or wire feed speed, and specify polarity, but do not provide
specific travel speeds or adjustments necessary to achieve a particular weld size. The middle of the
provided ranges are often good starting points, but contractors often tend to work near the high end of
the ranges provided to maximize deposition rates and reduce welding time.
(2) Calculations such as heat input and deposition rates are helpful in determining if WPSs should
produce a reasonable quality weld of the size specified. However, it is often difficult to verify FCAW
procedures through calculation because of the variations between specific electrode types. Calculation
should not be used to determine optimum operating characteristics for welding, as these final
adjustments are made by experience. See references in Appendix B.
(3) Caution should be used when reviewing WPSs for thick materials and highly restrained joints.
The 25 mm (1 in.) test plate thicknesses specified in AWS D1.1 Section 4, do not adequately represent
the heat sink capabilities of thicker sections (affecting cooling rates), nor is restraint developed in the
welding of standard WPS test specimens. The use of thicker plates and NDT, and the use of restraint
devices, should be specified as appropriate for critical welding. Alternately, other WPS testing methods
may be used as appropriate.
(4) A checklist should be prepared to verify that all welded joints on the project have written WPSs.
Critical joints should be reviewed to verify that the proper welding materials have been designated for the
joint, particularly when CVN toughness is required.
(5) Approval of the WPS should be taken as review only, and that the responsibility for the
suitability of the WPS, and the resultant weld quality and properties, remains with the contractor.
3. WELDING PERSONNEL QUALIFICATION.
a. Personnel Classification. Welding personnel are classified into three categories: welders, welding
operators, and tack welders. Welders manipulate the electrode by hand, manipulating and controlling the
arc, for manual or semi-automatic welding. Welding operators set up automatic welding equipment with
wire-fed welding processes, such as mechanized SAW, to travel at selected speeds. Tack welders may
only place tack welds to assemble pieces, with the finish welds to be performed by qualified welders or
welding operators.
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