Weld inspection before you weld

Using procedure qualification testing to standardize welding processes

By: Zainal. MSc
April 24, 2006
Although it takes effort and time, procedure qualification testing can help you standardize your
welding procedures and know what to expect when it comes to the quality of your manufactured
parts.
While patrolling a shop floor playing "parameter police," a welding inspector may commonly hear
questions like "Why can't I run my machine above XXX wire feed speed?" or "XX volts?"
Welding parameters aren't guidelines merely plucked out of thin air; they are developed and determined
after much trial and error. By standardizing the welding procedures you use to manufacture your
products, you'll have a model that everyone can turn to for quality assurance.
Procedure Qualification Options
Procedure qualification can be performed in one of three main ways:
1. Prequalified Joint Procedures. As the name suggests, prequalified procedures have been
tested in advance. Although they're convenient to follow, requirements still must be met. For
example, one requirement that often is overlooked or misunderstood is that the procedure must
be written. Just pointing to the "good book" isn't nearly enough. Written requirements are laid
out clearly in the applicable code or specification.

For this type of procedure qualification, the American Welding Society (AWS) has determined
that, within a given set of circumstances, additional testing is not required.

2. Prototype Testing. Although initially economical, prototype testing can be limiting because only
those conditions that are tested can be qualified. Any changes require additional testing, which
can change the economics of prototype testing significantly.

For example, off-road, agriculture, and construction equipment manufacturers often qualify a
process through "push" testing—building a structure, documenting the entire fabrication process
(joint by joint), and submitting the structure to several destructive tests. When the structure
survives the test requirements, the procedure is qualified. As the component goes into
production, all conditions used in the initial test must be maintained during fabrication.
Significant changes in production can require additional testing.

3. Procedure Qualification Testing. Procedure qualification testing initially can be costly and time-
consuming, but it can be used to develop standard weld procedures that cover all joints,
consumables, and positions (conditions) used in production.

Procedure qualification testing is a test or series of tests that are performed, documented on a
procedure qualification report (PQR), and then turned into a weld procedure specification
(WPS) or a series of them.
Procedure Qualification Testing: The Basics
In procedure qualification testing, you may find it helpful to try to complete all testing using readily
available resources. Completing testing on one groove weld typically qualifies all groove types and fillets.
Changes in essential variables, however, often require additional testing. For example, in the off-road,
agriculture, and construction equipment manufacturing industry, customers often require fillet welds to
obtain penetration beyond the root, typically 1.5 millimeters. Many codes and standards require
penetration to the root, "... but not necessarily beyond ...." These same books also may say something
like "... joint penetration ... beyond the root ... determined from a significant number of cross-sectioned
samples ...." With an additional customer requirement such as this, you may need to complete both
groove and fillet weld testing when creating a standard WPS.
Standard weld procedure testing requires the following samples:
  One test plate for each position
 One test plate for each process
 One test plate per wire type and diameter
But if your customer requires additional fillet weld testing, you must complete the following:
 One test plate per position (as per standard weld procedure)
 Two test plates per fillet size (one single pass, one multipass)
More Customer Requirements: An Example
A cab and canopy manufacturer, supplies to off-road, agriculture, and construction equipment
manufacturers. The company welds grooves in the flat (1G) and horizontal (2G) positions, and fillets in
the flat (1F), horizontal (2F), and overhead (4F) positions. The shop runs on a bulk 90 percent argon/10
percent CO2 mixture and typically uses a 0.035-inch-diameter ER70S-6 filler metal. After consulting a
wire manufacturer and other industry professionals, the engineers determined that a 550-in.-per-minute
(IPM) wire feed speed (WFS) and 27 volts should yield the best results.
Let's say you want to develop a weld procedure for gas metal arc welding (GMAW) high-strength, low-
alloy (HSLA) carbon steel. You need to develop this procedure for both groove and fillet welds.
First you should know what a test sample will look like and how many samples you're going to need.

Figure 1
For the groove welds, use one test sample for the flat (1G) position and one for the horizontal (2G)
position (see Figure 1).

Figure 2
For fillet welds, you'll need samples in the flat (1F), horizontal (2F), and overhead (4F) positions. You'll
also need a sample for each weld size, and on that sample you'll weld a single-pass fillet on one side and
a multipass fillet (if applicable) on the other. In this case, you'll want to qualify 5- through 13-mm fillets
(see Figure 2).
So that's a total of two grooves and 24 fillets—26 tests. What if you want to qualify higher WPS?
According to most codes and standards, 550 IPM qualifies in the range between 495 and 605 IPM. If you
want to run a WPS at 650 IPM or more, you'll need to do another 26 test samples. The same applies if
you want to use a 0.045-in.-dia. wire, a cored wire, or change another variable
Standard weld procedures are fairly labor-intensive, but the finished WPS will be out of the way and ready
to be applied across the board whenever you encounter similar essential variables.
Performing Qualifications
In procedure qualification testing, you'll encounter two main types of qualifications: fillet weld and groove
weld.
Fillet Weld Qualification. Fillet weld qualification is pretty straightforward (see Figure 3). For each weld
size, make a single-pass fillet weld on one side of the test plate and a multi-pass fillet on the opposite side
(see lead photo).
Then simply cut and etch the sample as required in your code or standard and document the results with
a digital camera. Use caution when dealing with etching solutions. Strictly follow the instructions and
safety requirements laid out by your code or standard.
Groove Weld Qualification. As previously mentioned, it may be beneficial to use materials readily
available in your shop for your testing. For example, if your shop uses a lot of tubing, you can use
sections of 4-in. by 4-in. by 3/8-in. tubing for your groove testing (see Figure 4). The tubes, laid side by
side, can create a good flare V groove, and you won't need to bevel the plates or fabricate separate
backing (see Figure 5).
If you use tubing, watch where you place the tubing's welded seam. You don't want it to be located in
such a way that it will influence your bend and pull tests. If you place the seams face-to-face, you'll be
sure of their location and know that you'll cut them out later.
After you've tacked your samples together, always, always, always mark each coupon with a steel
stamp. For example, you can use a two-digit number for the sample and 1 through 6 for the individual
coupon, increasing in number in the direction of the weld (23-1, 23-2, 23-3, and so on) (see Figure 6).
These will be cut from the finished weld later.
Next collect and log all required data per pass, by sample: preheat and interpass temperatures, WFS,
voltage, travel speed, electrode stick-out, everything. This system will help you if you're left with a pile of
bent and broken coupons and have to figure out what went wrong. That's no time to wonder if you have
the right coupon.
Once you finish welding, perform the first required test: visual examination. All test samples must meet
visual acceptance criteria first. If any test sample (fillet or groove) is not visually acceptable, you must
discard it. Figure out why it wasn't visually acceptable, correct your process, and make another test
sample. Never continue testing on a sample that isn't considered visually acceptable.
Your code or standard may require radiographic evaluation. If so, perform this next. Remove all portions
of the tube that don't make up the test sample, clean them up, and ship them off (see Figure 7). If you
use tubing, this can require a lot of whittling — hopefully you're good with an oxyfuel torch. As with visual
evaluation, if your test samples don't pass radiographic evaluation, don't take additional action on the test
sample. Figure out what went wrong and make a new test plate.

Figure 6 Figure 7
Mark each test sample's coupons with a This test sample has been removed from the
steel stamp so you can trace each tubing and is ready to be cut with a saw.
coupon back to its corresponding test.
After you successfully complete these tests, you'll need to start cutting your individual coupons. Your
code or specification will dictate exact coupon size and location. Typically, you'll need four coupons for
bending and two for tensile testing. Next, move on to etch testing.
Bend and tensile testing comes next. Bend testing equipment is fairly inexpensive and often can be
fabricated in-house; documentation is on the market for the equipment's dimensional requirements.
Tensile testing equipment isn't as economical, but many companies can perform this type of testing.
Finally, collect and document all test data on a procedure qualification report (PQR) and develop your
WPS per your code or standard. Educate your inspectors, supervisors, and welders about the allowed
parameters and the need to stay within them.
Although many steps are necessary to complete procedure qualification testing, this process will help
ensure that the WPS meets the requirements of the codes and standards you create product to and will
serve your company and customers for years to come
Weld Discontinuities - Part 2 - Unacceptable Weld Profiles
The profile of a completed weld may have considerable affect on the performance of that weld in service.  It is the welding
inspector’s function to identify these discontinuities through visual inspection and often to evaluate their acceptance, or
rejection, through the use of the applicable welding code or standard acceptance criteria.  Unacceptable weld profiles can
cause problems associated with a reduction in base material thickness, a reduction in the affective weld size, or provide
stress concentrations on the weld or plate surface.  These types of weld discontinuities can often seriously detract from the
overall performance of a welded component in service.  We will consider some of the discontinuities associated with weld
profiles: Undercut, Overlap, Insufficient Throat, and Excessive Convexity.
Undercut – This discontinuity is defined as a groove melted into the base metal adjacent to the weld toe, or weld root, and
left unfilled by weld metal.  The term undercut is used to describe either of two conditions.  The first is the melting away of
the base material at the side wall of a groove weld at the edge of a bead, thereby producing a sharp recess in the side wall
in the area where the next bead is to be deposited.  This type of undercut can facilitate the entrapment of inclusions that the
recess which may be covered by a subsequent weld bead.  This condition, if necessary, can be corrected, usually by
grinding the recess away prior to depositing the next bead.  If the undercut is slight, however, an experienced welder, who
knows how deep the arc will penetrate, may not need to remove the undercut.  Undercut of the side wall of a groove weld
will in no way affect the completed weld if the condition is corrected before the next bead is deposited.  The second
condition is the reduction in thickness of the base metal at the line where the weld bead on the final layer of weld metal ties
into the surface of the base metal.  This position is known as the toe of the weld.  This condition can occur on a fillet weld or
a butt joint.  The amount of undercut permitted at the surface of the completed weld is usually specified within the welding
code or standard being used.  The maximum permissible undercut requirements for completed welds should be followed
stringently because excessive undercut can seriously affect the performance of a weld, particularly in services subjected to
fatigue loading.  Both types of undercut are usually caused by the welding technique used during welding, incorrect
electrode positioning and/or incorrect travel speed.  High currents and a long arc length can increase the probability for
undercut.
Overlap – This discontinuity is defined as the protrusion of weld metal beyond the weld toe or weld root.  This condition can
occur in fillet welds and butt joints and can produce notches at the toe of the weld that are undesirable due to their resultant
stress concentration under load.  This discontinuity can be caused by incorrect welding techniques or insufficient current
settings.
Insufficient Throat – This condition describes a weld profile that is usually concave in shape, and due to its concavity,
provides an inadequate throat thickness.  Excess concavity, that can produce an unintentional reduction in throat thickness,
can occur in fillet welds and butt joints.  The problem associated with this discontinuity is its ability to considerably reduce
that part of the weld that controls the weld’s strength, namely the throat thickness.  This condition is usually caused by
excessive welding current or arc lengths.
Excessive Convexity –This discontinuity can produce a notch effect in the welded area and, consequently, stress
concentration under load.  For this reason, some codes and standards will specify the maximum convexity of a weld profile. 
This condition is usually caused by insufficient current or incorrect welding techniques.
Conclusion – A number of discontinuities are associated with the exterior profile or shape of the completed weld.   These
discontinuities are generally detected through visual inspection of the weld, however, some are detectable through other
inspection methods such as radiography, liquid penetrant, and magnetic particle inspection.  The maximum acceptable
limitations associated with these discontinuities is dependent on the performance requirements of the welded component
and is usually specified in the appropriate welding code, standard or specification.  The welding inspector is often required to
determine the extent of these discontinuities and to establish their acceptance, or rejection, based on the relevant
acceptance criteria

Inspection and Testing for Welding Procedure Qualification

Welding Procedures are the guidelines used to perform a weld.  They are designed to provide a record of the welding
variables used and the inspection results obtained during the procedure qualification test.  They can also provide the
instructions for the welder to use in production in order to produce acceptable welds.  Usually welding procedures are
developed in accordance with a welding code or standard, and with few exceptions*, require that physical weld samples be
produced, inspected, and tested to establish qualification.  Welding procedures are usually divided into two categories, the
Procedure Qualification Record (PQR) and the Welding Procedure Specification (WPS).
Procedure Qualification Records are the documented values used during the actual welding test and all the inspection and
test results obtained from the actual test samples.
Welding Procedure Specifications are usually documented work instructions that can be used by the welder to conduct
welding operations, and are based on, but not necessarily the same as, the parameters used for the Procedure Qualification
Record.
We will consider the Procedure Qualification Record and the inspection and testing performed during its qualification.
Qualification testing of a welding procedure normally requires documentation to show all the variables used during the
welding test and the documented inspection and test results.  The variables required to be documented are typically such
items as:  welding process used, size, type and classification of filler alloy, type and thickness of base material welded, type
and polarity of welding current, amps and volts recorded, travel speed during welding, welding position, type and dimensions
of joint design, preheating temperature, interpass temperature, post weld heat treatment details, and others.  In addition to
the recording of all the welding variables used during the test, in order to qualify a welding procedure, details of the
inspection and test results must also be recorded.  These records must show that the inspection and testing has proven that
the weld samples have met or exceeded the specified standard requirement.  The typical types of inspection and testing for
each sample for Welding Procedure Qualification are: 
Inspection and Testing for Fillet Welds (Tee Joints) -  This involves visual inspection of the completed weld, followed by
two macro etches, and one fillet weld break test.  The welded sample is first inspected for any visual discontinuities and then
sectioned, and two small samples removed at predetermined locations.  These small samples are polished across their
cross-section and then etched using some type of mild acid mixture, dependent on the base material used.   The remaining
welded sample is used as the fillet weld break test and is broken against the weld to reveal the internal structure of the weld
for inspection.
Inspection and Testing for Groove welds (Butt Joints) – This involves visual inspection, followed by two transverse
tensile tests, two root bend test and two face bend tests. (These tests are typical but may differ dependent on material
thickness, type and standard requirements.  Different and/or additional testing, such as side bends, all weld tensile tests,
impact testing or other testing may be required.)  The completed weld coupon, after visual inspection, is divided into
predetermined small sections. Each section is prepared, usually by machining, to specific dimensions as prescribed by the
standard.  Each small sample is then tested mechanically to determine its characteristics.  These samples are then
inspected to determine their acceptability, against specified acceptance criteria, as laid down by the applicable code or
standard.  Typically the standard will provide the maximum size and location of various weld discontinuities and/or, as
relevant, values such as minimum tensile strengths or minimum desired impact properties.
Samples that are found not to have discontinuities that exceed these specified limits, and that meet or exceed the minimum
values as specified in the standard, will be acceptable, and the welding procedure will be qualified.
The welding procedure is an important part of the overall welding quality system, as it provides documented evidence that
inspection and testing has been performed to ensure that welding can be conducted to meet a recognized standard.
* One exception to welding procedure qualification is the D1.1 Structural Welding Code for Steel, which will, under some
circumstances, allow the use of pre-qualified welding procedures, however these procedures are still required to be
documented and meet all of the relevant code requirements