ASME 9 - Introduction

These articles are intended as a very general guide to ASME 9. They are a collection of my own
personal notes which were written to aid my understanding of the code. Their are certain
exceptions in the code that are not covered in these articles, therefore you are urged to study the
code carefully before using its rules to carry out any welding qualifications.

Brief Introduction

Download ASME suggested forms

Procedure Qualification Record (PQR)

Welding Performance Qualification (WPQ)

ASME definitions for welding processes, consumables and welding positions

ASME Approval Range Calculator

ASME P Material Numbers

Graphic Representation of Welding Positions

Multi Process Welding Procedures QW200.4 and QW451.1

Brief Introduction
Welding qualifications to ASME 9 are for use with the ASME boiler and pressure vessel code or
the ASME pipework codes. For use with any other code or standard agreement between all
contracting parties should be obtained.
The ASME boiler and pressure vessel code embraces its own QA system which revolves around
satisfying the rules of the code. This demonstrates that an accredited fabricator has some degree of
competence permitting them to perform a large amount of their own inspection without the
involvement of an Independent Inspection Body, which would be required by other standards for
similar inspections.
This is why welding qualifications carried out under the ASME code do not require Independent
Inspection, a fabricator can qualify his own procedures and welders using the ASME code rules.
However this may not be acceptable to the European Pressure Equipment Directive which requires
all welding qualifications in inspection categories two and above to be approved by a Notified
Body.
However there is nothing stopping anybody using any of the rules of the ASME code without
being ASME approved, but to prove your competence in welding an Independent Inspection Body
is recommended to approve your welding tests.
The advantage of ASME 9 is that its very workable and very comprehensive, if you have a
question you will almost certainly find an answer somewhere in the code, which is more than can
be said for its European equivalent EN ISO 15614-1 (formerly EN288-3).

The ASME code may at first glance appear complex and very legalistic but once you understand
the basic rules they are very easy to apply in practice. Its main advantage is that it requires very
few welding procedures unlike EN ISO 15614-1 which requires a ridiculous number if it is applied
correctly.
The main advantages of ASME welding procedures are: All joint types approve each other. i.e. A double sided weld approves a single sided weld and
vice versa.
No limits on diameter approval for pipe. A plate procedures can be used to weld any diameter
of pipe
Materials and welding consumables are listed in groups, unfortunately only American grades
are included!
Any butt weld will qualify all fillet weld sizes on any parent metal thickness.
A welding procedure qualified in one position approves all positions unless impact tests are
required then only a vertical up approves all positions.
The code covers wide range of welding processes and applications such as hard facing, stud
welding, brazing etc.
If you have difficulty in appreciating the above advantages you need to understand the basic
philosophy behind welding procedure tests described in the Basic Guide.
The main advantages of ASME welder approval tests are: There is no minimum parent thickness, only maximums, and they are applied to the deposited
thickness of the weld not the parent metal thickness.
There is no upper limit on diameter approval, only a lower limit.
Any butt weld approval will qualify all fillet weld sizes on any parent metal thickness.
{Unfortunately unlike EN287 a butt weld carried out in the flat position will not qualify a fillet
weld in the conventional horizontal position, to qualify this your butt weld approval must
include the horizontal position}.
The main problem with the ASME code is that it treats all welding processes separately and
imposes separate restrictions for each on both procedures and approvals. It is therefore prudent to
check what the code says about the welding process you intend to use before you carry out any
welding tests.
The ASME code covers a very wide range of welding processes and applications such as hard
facing, stud welding, brazing etc.
Application standards such as the B31 pipework code may impose additional requirements and
limitations in some cases.

The code is divided into 4 parts as follows:

QW100 General introduction to testing requirements etc.
QW200 Procedure Qualification details.
QW300 Performance Qualifications (Welder Approvals) details.
QW400 Welding Data. This is the biggest section of the code and covers data for
both procedure and performance qualifications. It includes :

Material and consumable data

Test requirements.

Approval ranges for thickness, diameter, joint configuration and welding

positions

Definitions used in the code.

Procedure Qualification Record (PQR)

PQR's are not required if Standard Welding Procedures are used, see below for details.
This document contains details of the welding test, it must include details of all the
parameters listed as variables in tables QW250 to QW265 for each process involved and all
the destructive test results.
The relevant variables for each type of welding process are clearly defined in tables QW250
to QW265. The left hand column of each table defines the section and paragraph where each
variable and its application to the table is explained in the code.
Welding Variables
Variables used in a welding procedure test are divided into 3 categories :

Essential Variables Are variables that have a significant affect on the mechanical
properties of a joint. They must not be changed except within the limits specified by
this code. e.g. Material thickness range, Material Group etc.

Non-Essential Variables Are variables that have no significant affect on mechanical

properties. They can be changed without re qualification of the PQR.

Supplementary Variables Are variables that have an affect on the impact properties
of a joint. They are classed as Non-Essential if impact testing is not required

All variables listed as essential, non-essential or supplementary should be addressed on both

the WPS and the PQR. If any of the variables do not apply to the particular application then
they should be specified as not applicable.
Joint Configuration
Either plate or pipe can be used for the test piece (plate approves pipe and vice versa ref.
QW211), any welding position approves all positions providing no impact tests are required
ref. tables QW250 to QW265 and any joint geometry approves all geometry's, e.g. single V,
double V, U prep, backed or unbacked.
A butt or groove weld approves branch and fillet welds but not the converse, ref. QW202.
Non pressure retaining fillet welds in pipe or plate can be tested but they must be double
sided if plate and at least the dimensions illustrated in QW462.4a, ref. QW202.2c. Pressure
retaining branch welds must be qualified by groove (butt) welds.
Material Grouping
Materials are assigned P numbers in QW420; a test in one P number approves all materials
listed under that P number, except where impact tests are required then approval is restricted
to materials listed in the group number within the P number. Other P number groupings are
permissible ref. QW424.1 for details. Ref QW 424.1 for further details.
It is normally permissible if the material is not listed in QW422 to assign it to a P number
which lists materials with the same metallurgical and mechanical properties although this is
not in strict conformance with the code. Typically BS1501 151 430A low carbon steel could
be regarded as P1 and stainless steels such as 316, 304 as P8.
Note P5, 9 & 10 are divided into sub groups eg 5A,5B etc., Treat each sub group like a
separate P Number
Dissimilar materials are acceptable providing they are compatible. For example P1 to P8, but
this does not cover P1 to P1 or P8 to P8.
Note S numbers are for pipework to B31, a P number covers an S number but not the
converse
Consumables
The ASME code uses its own specifications for consumables SFA. which is almost identical
to the AWS specification.
NOTE A change in consumable is only permissible providing it has the same F number
and A number (if applicable) as the P.Q.R..
Thickness Limits
Thickness limits Groove welds. See QW451 for precise details.

When Impact tests are required the minimum thickness approved is restricted. See
QW403.6

More than one PQR may be required to qualify dissimilar thickness

The thickness little 't' of deposited weld metal for each process involved is approved from 0
to 2xt except:

MIG/MAG (GMAW/FCAW) dip transfer weld of deposited thickness less than "
approves maximum thickness of 1.1 x t only Ref: QW255 (QW403.10)

If any Pass in a single or multipass weld > " then the thickness approval equals
1.1xT

Dissimilar Thickness QW202.4:- The thicker and thinner part must be qualified, Except P8
and P4X the thinner part can be qualified if no Impacts and test coupon > 6mm thick.
Thickness limits for fillet welds as per QW462.4a or QW462.4d qualify all fillet weld sizes
on all base material thicknesses and all diameters in one test.
Testing Requirements (Ref QW 463 for location of specimens)
Unlike EN288 there is no requirement for any non-destructive testing such as radiography or
MPI/DPI, although I would recommend radiography for butt welds.
The testing requirement for groove welds are as follows:

Two Transverse tensile tests (QW150).

Two Root bends and Two face bends unless the plate thickness exceeds 3/8" then 4
side bends are required. All bend tests should be done to QW160 using the correct
former ref. QW466 to an angle of 180 degrees. Longitudinal (all weld) bend tests are
not recommended unless the base/weld materials differ markedly in bending
properties. See QW 466 for exceptions and precise details.

The testing requirement for fillet welds on plate is 5 macro sections only, for Pipe fillet welds
4 macro sections. No fracture test required.

Welding Procedure Specifications (WPS)

This document details the practical application of the Procedure Qualification Record (PQR).
It should contain enough information to give direction to the welder and should address all
variables associated with the welding process defined in QW250 including non essential and
supplementary.
A WPS can combine welding processes from other PQR's but all the relevant variables must
be addressed including parent metal thickness. There is an exception to this rule for root runs
from PQR's that are greater than 1.5 inches thick (38.1mm), see code for details.

Standard Welding Procedures Specifications (SWP's)

Standard welding procedures listed in annex E of ASME IX can be purchased from the
'American Welding Society' and used without qualifying a PQR. Section V of ASME IX
gives details of essential variables and restrictions. A successful welder performance
qualification must be carried out to demonstrate the SWP's before a manufacturer can use it.

Welder Performance Qualification (WPQ)

Materials
The purpose of this test is to determine the welders ability to deposit a sound weld therefore the
base material is not considered as critical as it is in the PQR. Hence a performance test on any
material in P groups 1 to 11 approves all those groups and sub groups, also P34 and P4X (P40P49). Providing a compatible consumable exists with the same F number used in the qualification
test. (QW423.1)
Note a single sided weld is classed as a weld without backing and a double sided weld or weld
with sealing run is classed as a weld with backing
Consumables
The F number cannot be changed without re qualification of the welder except that for
performance qualification only using SMAW (MMA) F numbers up to and including 4 approve all
lesser F numbers for double sided or welds with backing only. One Consumable from F41 To F45
approves any of these consumables, except SAW. Ref.QW404.11.
Note 'A' numbers do not apply to welder approval tests.
Variables
For each welding process there is a list of essential variables in QW352 to QW357 and QW360 for
welding operators, these are not necessarily the same as the ones for the PQR. Essential variables
cannot be changed. Explanations of all these variables is given in section IV of the code.
Diameter and Thickness Ranges
Diameter limits for all circular welds including groove welds, branch welds and fillet welds is
given in QW452.3. there are no upper limits on diameters approved and pipe covers plate
Note for branch welds the diameter considered for the above limits is the one containing the weld
preparation.
Thickness limits, groove welds.
The thickness limit only applies to the deposited weld metal thickness not the plate thickness and
any groove weld approves all fillet weld sizes.
For t greater than 12.5mm there is no restriction on the size that can be welded (Providing the test
weld deposit contains at least 3 layers of weld).
Thickness limits, fillet welds.

A test on plate greater than 3/16" approves all base metal thicknesses and fillet weld sizes ref.
QW452.5. (Note the above diameter limits apply unless the fillet weld is qualified by a groove
weld)
Joint Configuration
Joint geometry, a double V (or U) is considered the same as a joint with backing and does not
qualify a single V (or U) without backing, but a single full penetration joint without backing
qualifies all joint configurations.
Approval Range
Extent of approval is very well explained in QW461.9. Take particular note of welding positions
which are also explained in QW461, for example to qualify a fillet weld in the normal horizontalvertical position with a groove weld, the groove weld must be qualified in at least the 2G position.
The welding positions defined in QW461.1.& QW461.2 should be referred to in the WPS. The
position designations: 1G ,2G ,3G ,4G ,5G ,6G (Groove Welds) and 1F ,2F ,3F ,4F (Fillet Welds)
are test positions
Period of Validity/Renewal of Qualifications (QW 322.2)
Providing the welder uses the process for which he is qualified and there is no reason to question
his ability then his qualification lasts indefinitely.
If the welder does not use the welding process for which he is qualified for a period of 6 months or
more then he must perform a new test in pipe or plate, any parent material, thickness and position,
if successful all the welder approvals for that welding process are renewed in one test.
Testing Requirements
Test requirements for groove welds QW452 consists of either: One face bend and one root bend except for welding positions 5G & 6G which require 4
bends (Ref QW452.1 Note 4). If the plate exceeds 3/8" side bends may be used. See QW
466 for precise details and exceptions.
Note:- Bend Tests can in most cases be replaced by Radiography {See Below}.
Radiography is optional and must be supplemented by bend tests when using GMAW
(MIG/MAG) with dip transfer (Short Circuiting Arc) or when welding some special
materials. Ref. QW304.
Note:- Ultrasonic Examination in lieu of Radiography is not permitted
Test requirements for fillet welds in plate ref. QW452.5: One macro section (QW 184) and One fracture test (QW182).
The location where each specimen has to be taken is defined in QW463
Radiography Ref QW 191

 A length of at least 6" must be examined for plate or the entire circumference for pipe.
If the pipe circumference is less than 6" then more samples must be welded up to a
maximum of 4. Ref QW 302.2.
Visual Examination Ref QW 302.2 & QW 190
Performance test coupons must show complete joint penetration with full fusion of the weld metal
and base metal.
The welder performance test must follow a properly qualified W.P.S. Once qualified the welder
must always work within the extent of approval of any properly qualified W.P.S. and his W.P.Q.
The welder who qualifies the P.Q.R. is automatically approved within the limits specified in
QW304, QW305 and QW303. Ref QW301.2.
Specialist Processes
Such as corrosion resistant overlay or hard facing are covered in QW 453.
Procedure variables are defined with all procedure variables in QW252 and in QW380 for welder
approval.
Min base thickness approved = size welded or 1", QW 453
Min Deposit Size Approved:- Point Where Chemical analysis taken No upper limit QW402.16
(462.5a) Welding Positions QW405.4 Performance Qualification approves all deposit thickness
No min.QW381

ASME Definitions, Consumables, Welding Positions

ASME P Material Numbers Explained

ASME has adopted their own designation for welding processes, which are very different
from the ISO definitions adopted by EN24063.
Designation
Description
OFW
Oxyfuel Gas Welding
SMAW
Shielded Metal Arc Welding (MMA)
SAW
Submerged Arc Welding
GMAW
Gas Metal Arc Welding (MIG/MAG)
FCAW
Flux Cored Wire
GTAW
Gas Tungsten Arc Welding (TIG)
PAW
Plasma Arc Welding
Straight polarity = Electrode -ve

Reverse polarity = Electrode +ve

ASME F Numbers
F
Number
1
2
3
4
5
6
2X
3X
4X
5X
6X
7X

General Description
Heavy rutile coated iron powder electrodes :- A5.1 : E7024
Most Rutile consumables such as :- A5.1 : E6013
Cellulosic electrodes such as :- A5.1 : E6011
Basic coated electrodes such as : A5.1 : E7016 and E7018
High alloy austenitic stainless steel and duplex :- A5.4 : E316L-16
Any steel solid or cored wire (with flux or metal)
Aluminium and its alloys
Copper and its alloys
Nickel alloys
Titanium
Zirconium
Hard Facing Overlay

Note:- X represents any number 0 to 9

ASME A Numbers
These refer to the chemical analysis of the deposited weld and not the parent material. They
only apply to welding procedures in steel materials.
A1
Plain unalloyed carbon manganese steels.
A2 to A4 Low alloy steels containing Moly and Chrome Moly
A8
Austenitic stainless steels such as type 316.
ASME Welding Positions Graphic Representation
Note the welding progression, (vertically upwards or downwards), must always be stated and
it is an essential variable for both procedures and performance qualifications.
Welding Positions For Groove welds:Welding Position
Flat
Horizontal
Vertical Upwards Progression
Vertical Downwards Progression
Overhead
Pipe Fixed Horizontal
Pipe Fixed @ 45 degrees Upwards

Test Position
1G
2G
3G
3G
4G
5G
6G

ISO and EN
PA
PC
PF
PG
PE
PF
HL045

Pipe Fixed @ 45 degrees Downwards

6G

JL045

Test Position
1F
2F
2FR
3F
3F
4F
5F

ISO and EN
PA
PB
PB
PF
PG
PD
PF

Welding Positions For Fillet welds:Welding Position

Flat (Weld flat joint at 45 degrees)
Horizontal
Horizontal Rotated
Vertical Upwards Progression
Vertical Downwards Progression
Overhead
Pipe Fixed Horizontal
Welding Positions QW431.1 and QW461.2
Basically there are three inclinations involved.

Flat, which includes from 0 to 15 degrees inclination

15 - 80 degrees inclination

Vertical, 80 - 90 degrees

For each of these inclinations the weld can be rotated from the flat position to Horizontal to
overhead.

ASME Code Calculator

Information on how to use this page
Test Piece Data
Parent Metal Thickness

All dimensions in mm

Blank Assumes same as

Thickess Of Weld Deposit
Parent Metal
Note the thickness of weld deposit should be checked for each welding process involved and the sum of each
deposit must not exceed the thickness of the parent metal

Blank Assumes Plate

Diameter

Required By ASME QW 403.6

Impact Tests
Welding Position
No data to be entered below this line
Procedure Approval Range Range
Min Thickness Tmin:

Max Thickness Tmax:

Max Thickness Of Weld Deposit t:

No Minimum

Note GMAW In Dip Transfer Mode restricts max deposit size

Position:

Special Requirements:

Diameters: All Diameters and product forms approved Ref QW211

Joint Type: All Joint Types Approved, a double sided weld will approve single sided.
Fillet Welds: All weld sizes and parent metal thickness approved QW451.3
Note Fillet welds must be approved by a groove weld for pressure retention

Welder Qualification Approval Range

Max Thickness Of Weld Deposit t:

Min Diameter:

No Minimum

No Maximum Diameter.

Any Part containing a weld prep is subject to Diameter Limits

Welding Positions QW461

Plate & Pipe > 610mm:

Pipe < 610mm:

Fillet Welds: All weld sizes and parent metal thickness approved QW451.3
Single Sided Welds: Approve double sided welds and welds with backing
Double Sided Welds: Approve welds with backing and vice versa

ASME P Material Numbers

This is a general guide ASME P numbers and their equivalent EN288 groupings. Groups referred
to in the Base Metal column are ASME sub groups. EN288 material groups are included for
comparison only.
P No.

2
3
4
5A
5B
5C
6
7
8

EN288

4
5
5
5
6
8
8
9

Base Metal
Carbon Manganese Steels, 4 Sub Groups

Group 1 up to approx 65 ksi

Group 2 Approx 70ksi

Group 3 Approx 80ksi

Group 4 ?

Not Used
3 Sub Groups:- Typically half moly and half chrome half moly
2 Sub Groups:- Typically one and a quarter chrome half moly
Typically two and a quarter chrome one moly
2 Sub Groups:- Typically five chrome half moly and nine chrome one moly
5 Sub Groups:- Chrome moly vanadium
6 Sub Groups:- Martensitic Stainless Steels Typically Grade 410
Ferritic Stainless Steels Typically Grade 409
Austenitic Stainless Steels, 4 Sub groups

Group1 Typically Grades 304, 316, 347

9A, B, C
10A,B,C,F,G
10 H
10J
11A Group 1
11 A Groups
2 to 5
11B
12 to 20
21
22
23
24
25
26 to 30
31
32
33
34
35
36 to 40
41
42
43
44
45
46
47
47 to 50
51, 52, 53
61, 62

Group 2 Typically Grades 309, 310

Group 3 High manganese grades

Group 4 Typically 254 SMO type steels

7
?
10
?
7

Typically two to four percent Nickel Steels

Mixed bag of low alloy steels, 10G 36 Nickel Steel
Duplex and Super Duplex Grades 31803, 32750
Typically 26 Chrome one moly
9 Nickel Steels

Mixed bag of high strength low alloy steels.

?
21
22a
23
22b

10 Sub Groups:- Mixed bag of high strength low alloy steels.

Not Used
Pure Aluminium
Aluminium Magnesium Grade 5000
Aluminium Magnesium Silicone Grade 6000
Not Used
Aluminium Magnesium Manganese Typically 5083, 5086
Not used
Pure Copper
Brass
Copper Silicone
Copper Nickel
Copper Aluminium
Not Used
Pure Nickel
Nickel Copper:- Monel 500
Nickel Chrome Ferrite:- Inconel
Nickel Moly:- Hastelloy C22, C276
Nickel Chrome :- Incoloy 800, 825
Nickel Chrome Silicone
Nickel Chrome Tungstone
Not Used
Titanium Alloys
Zirconium Alloys

Multi Process Welding Procedures QW200.4 and QW451.1

Base Metal approval range for the above welded joint is 4.76mm To 52mm Ref QW451.1
If the joint is made of more than one welding process then the maximum deposited
thickness each process in the above example is (2 x Deposited Weld Metal t) :- GTAW
12mm and SMAW 52mm (This is because t = T for this process as t > 19.1mm QW451.1)
If the SMAW deposit in the above qualification was less than 19.1mm, assume 18mm and
GTAW 8mm then to weld a joint 52mm thick with 8mm GTAW and 44mm SMAW is not
permitted as maximum SMAW deposit would be 36mm
You can delete the SMAW and qualify an all GTAW weld 4.76mm To 12mm thick or delete
the GTAW and weld SMAW 4.76mm to 52mm thick, providing all the essential, non
essential and supplementary variables are applied to the WPS. (Note the procedure allows
the SMAW to be used as a root run but not the welder qualification.)
When tested the deposited weld metal of each process must be included in the tension and
bend test specimens and impacts where applicable. Note it is acceptable for the impact
test for the GTAW to contain some SMAW in the test specimen.
PICK and MIX QW200.4 b [Note restrictions in QW451.1 notes (1)]
This applies to test coupons 13mm and thicker and welding processes SMAW, SAW,
GTAW, GMAW. A WPS consisting of several processes can be created from different
PQRs, but the maximum thickness of base metal covered by this WPS cant exceed 2 x
the thickness of the thinnest test coupon used for each PQR and each process cant
exceed 2 x its deposited thickness. This applies even if all the processes used for that
coupon are not required in this WPS. However the base metal thickness of the PQR used
for the root does not have to be considered if the WPS is single sided QW200.4 b

Note test coupons 38mm and above approve deposited weld metal and also base metal
thickness up to 200mm max QW451.1. (QW403.7 Processe GTAW,SMAW,GMAW,SAW)
EXAMPLE

Can the proposed PQR be made from the above example + PQR 2 + PQR 3.
Consider individual deposited thickness 2 x t
GTAW 12mm > 6mm. SMAW 60mm > 39mm. GMAW 66mm > 20mm All OK
Consider Plate thickness 2 x T
SMAW 60mm <65mm Fail. GMAW 66mm > 65mm OK. GTAW not considered.
SMAW procedure cant be used for proposed PQR
WELDER PERFORMANCE QUALIFICATIONS
If you want to weld a 30mm plate and your welder qualifications only go up to 15mm use
two welders. You cant use one welder with two different qualifications for the same
process