CEMP-E
TI 809-26
1 March 2000
tack welds are likely to propagate into the main weld. Slag that has not been removed will likely result in
slag inclusions in the completed weld.
d. During Welding. Observation of welding techniques and performance for each welder should be
done periodically during welding operations to verify that the applicable requirements of the WPS and
the AWS D1.1 Code are met. Each pass should be visually inspected by the welder for conformance to
AWS D1.1 Table 6.1 provisions for cracks, fusion and porosity prior to placement of subsequent passes.
To avoid trapped slag, penetration and fusion discontinuities, each weld bead profile should be in
substantial conformance with the requirements of Table 6.1.
(1) WPS compliance. The inspector should verify that the welding is performed following the
appropriate Welding Procedure Specification (WPS). If desired, proper current (amperage) and voltage
for the welding operation may be verified using a hand held calibrated amp and volt meter. Because of
welding lead losses, measurement should as near the arc as practical. Welds not executed in
conformance with the WPS may be considered rejectable, and should be referred to a knowledgeable
welding consultant and the Engineer for review.
(2) Interpass temperatures. Interpass temperatures as specified in the WPS must be provided and
checked with compliance with AWS D1.1 Table 3.2 if a prequalified groove weld joint. Higher preheat
temperatures may be specified. It may also be necessary to verify that the interpass temperature does
not exceed any maximum values specified in the WPS, sometimes specified for quenched and
tempered, TMCP, or other special steels, or when toughness requirements apply. Verification of
interpass temperature should be taken 75 mm (3 in.) from the joint, provided the thickest material joined
is 75 mm (3 in.) or less in thickness. Temperatures may be checked with surface temperature
thermometers, close-range focused infrared devices, or with temperature-indicating crayons.
(3) Consumables control. Exposure of SMAW electrodes and SAW fluxes must meet the time
limitations of AWS D1.1 Section 5.3. See AWS D1.1 Table 5.1 for SMAW electrode exposure limits.
SAW fluxes may require drying, special handling, recycling, and removal of exposed flux from opened
packages. Although not limited by AWS D1.1, research indicates that some FCAW electrodes may
absorb moisture in the order of 50% of the "as-manufactured" moisture content. When extra-low
hydrogen welding electrodes are required for critical welding applications, and FCAW wires removed
from the manufacturer's packaging will not be consumed within a few days, special storage conditions
limiting exposure times, repackaging unused FCAW wire in closed moisture-resistant packing overnight,
or the use of storage ovens, may be appropriate. AWS D1.5 Bridge Welding Code, Section 12 provisions
for Fracture Critical Nonredundant Members should be considered for guidance in special cases.
(4) Cleaning. Completed weld passes must be cleaned of all slag prior to placement of the next
pass. Removal of debris by brushing is required. Wire brushing of the completed weld is recommended,
but not required. Slag that has not been removed will likely result in slag inclusions in the completed
weld. See AWS D1.1 Section 5.30.
e. After Welding. After completion of the weld, full compliance with the AWS D1.1 provisions should
be verified. If required or specified, NDT is to be performed. Upon completion of inspection of the weld,
piece, or project, as appropriate, proper documentation of the acceptance of the welding should be
prepared and submitted to the designated parties.
(1) Measurement. The work should be visually inspected for conformance with the Visual
Inspection Acceptance Criteria prescribed in AWS D1.1 Table 6.1. These provisions prohibit cracks and
lack of fusion, and permit limited amounts of undercut, porosity, and weld size underrun. Weld profile
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