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A-1 Page 1 WELDING PROCEDURE Procedure No.: A-1 SHIELDED METAL ARC WELDING (SMAW) Revision: 03-2000 Electrode: 1/8" AWS E7018 Applicable Code: AWS D1.1, D1.5 Approved by: _ 1.0 WELDING PROCESS 1.1 Welding shall be done by the Shielded Metal Arc Welding process. 2.0 BASE METAL 2.1 Base Metal shall be limited to the metal listed in the procedure specification. 3.0 FILLER METAL 3.1 All Filler Metal shall conform to the requirements of Table 3.1 of AWS D1.1. 3.2 All Filler Metal shall be stored in accordance with the applicable paragraphs of ..r---.. Section 5 of AWS D1.1. 4.0 POSITION 4.1 Position of Welding shall be as noted in "Permitted Welding Position" of Figure 4.3 of AWS D1.1. 5.0 PREHEAT AND INTERPASS TEMPERATURE 5.1 Preheat and Interpass Temperature requirements shall be 50°F minimum preheat and 550°F maximum interpass. 6.0 STRESS RELIEF HEAT TREATMENT 6.1 Stress Relief Heat Treatment is not required. 7.0 JOINT DESIGN 7.1 Weld Joint Design shall be in accordance with Figure 3.4 of AWS D1.1. 8.0 PREPARATION OF BASE METAL 8.1 Material may be cut to size and prepared for welding by shearing, torch cutting or machining and be free of loose scale, slag, rust, or any other foreign material that would prevent proper welding.

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Page 1: Welding Procedure A1

A-1Page 1

WELDING PROCEDURE

Procedure No.: A-1 SHIELDED METAL ARC WELDING (SMAW)

Revision: 03-2000 Electrode: 1/8" AWS E7018

Applicable Code: AWS D1.1, D1.5 Approved by: _

1.0 WELDING PROCESS

1.1 Welding shall be done by the Shielded Metal Arc Welding process.

2.0 BASE METAL

2.1 Base Metal shall be limited to the metal listed in the procedure specification.

3.0 FILLER METAL

3.1 All Filler Metal shall conform to the requirements of Table 3.1 of AWS D1.1.

3.2 All Filler Metal shall be stored in accordance with the applicable paragraphs of..r---.. Section 5 of AWS D1.1.

4.0 POSITION

4.1 Position of Welding shall be as noted in "Permitted Welding Position" of Figure 4.3of AWS D1.1.

5.0 PREHEAT AND INTERPASS TEMPERATURE

5.1 Preheat and Interpass Temperature requirements shall be 50°F minimum preheatand 550°F maximum interpass.

6.0 STRESS RELIEF HEAT TREATMENT

6.1 Stress Relief Heat Treatment is not required.

7.0 JOINT DESIGN

7.1 Weld Joint Design shall be in accordance with Figure 3.4 of AWS D1.1.

8.0 PREPARATION OF BASE METAL

8.1 Material may be cut to size and prepared for welding by shearing, torch cutting ormachining and be free of loose scale, slag, rust, or any other foreign material thatwould prevent proper welding.

Page 2: Welding Procedure A1

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9.0 JOINT WELDING TECHNIQUE

9.1 The Welding Technique, such as electrode size, voltage and current shall be asshown on the attached Procedure Specification sheet.

10.0 CLEANING

10.1 All slag or flux remaining on any bead of welding shall be removed before layingdown the next successive bead of welding.

11.0 DEFECTS

11.1 Any defect that shows on the surface of any bead of welding > 3/32" shall beremoved prior to depositing the next bead of welding.

12.0 PEENING

12.1 No peening of root or surface layer will be permitted.

13.0 TREATMENT OF UNDERSIDE OF GROOVE

13.1 To prevent melt through, root of groove shall be backed by a Carbon steel back upbar.

Page 3: Welding Procedure A1

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......--..... ..• PROCEDURE SPECIFICATION

Material Specification: 1" ASTM A-36 Plate Single or Multiple Pass: MultipleEqual to: M270/A-709 Gr. 36

Welding Process: SMAW Single or Multiple Arc: Single

Manual or Machine: Manual Welding Current: DC(+), AC

Position of Welding: 3G,4G Polarity: Reverse

Filler Metal Spec.: AWS-A5.1, A5.5 Welding Progression: Vertical Up

Filler Metal Class.: AWS E7018 Root Treatment: Back Up Bar

F#: 4 Preheat &Interpass Temp.: 50°F min. I 550°F max.

Flux: N/A Shielding Gas: N/A

Post-heat Treatment: None Flow Rate: N/ASingle-V-groove weld (2)

IITolerances

Butt joint (B)As Detailed As Fit-Up

~

/"'- (see 3.13.1) (see 3.13.1)R;+1116,-o +1/4, -1116a = +10·,-<l· +10·, -5.fI

~ lRBase Metal Thickness

(U = unlimited) Groove Preparation Permitted GasWelding Joint Welding ShieldingProcess Designation Tl T2 Root Opening Groove Angle Positions for FCAW Notes

R = 1/4 a= 45· All - D,NSMAW 8-U2a U - R =318 a= 30· F,V,OH - D,N

R -1/2 a= 20· F, V, OH - D,NR = 3116 0.= 30· F,V,OH Required A,N

GMAW 8-U2a-GF U - R =318 IX - 30° F, V,OH Not req. A,NFCAW

R = 1/4 a. - 45· F,V OH Not reo. AN

Electrode Size Current Amperes Volts Travel Speed

1/8" DC(+) 90-150 19-24 6-81PM

Page 4: Welding Procedure A1

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IRONWORKERS NATIONAL WELDER QUALIFICATION TEST

WORKSHEET

Welding Procedure No.: A - 1 Process: SMAW

Base Metal:Equal to:

1" ASTM A-36 PlateM270 / A-709 Gr. 36

Filler Metal: 1/8" AWS E7018

TEST PLATE FIT UP: The parts to be joined by welding shall be fit within tolerances outlined for agroove preparation of 1/4" root opening and a 45-degree groove angle. (AWS B-U2a) .

.Single-V-groove weld (2) TolerancesButt joint (6) I As Detailed As Fit-Upa:s:I /"- (see 3.13.1) (see 3.13.1)

R= +1/16,...() +1/4, -1/16a = +10·,-0· +10·, -50

~

- ~R

Base Metal Thickness(U = unlimited) Groove Preparation Permitted Gas

Welding Joint Welding ShieldingProcess Designation Tl T2 Root Opening Groove Angle Positions for FCAW Notes

R= 1/4 a=45° All - D,NSMAW B-U2a U - R=318 a=30· F. V.OH - D,N

R= 1/2 a=20· F. V,OH - D,NR = 3/16 a=30· F, V.OH Required A.N

GMAW B-U2a-GF U - R=3/8 a=30· F. V.OH Notreq. A.NFCAWR= 1/4 a=45· FV.OH Not rea. A,N

POSITION: 3G. 4G

HEAT TREATMENT: None needed

JOINT WELDING TECHNIQUE: Weld metal shall be deposited by the use of the stringer beadtechnique (vertical Up).

HOLD POINTS: Request an approval to continue the welding operation from your test supervisorafter:

1. Fit up of coupon.2. Stamping coupon with weld test number and position.3. Positioning coupon for welding.4. Completion of root pass.5. Completion of welding operation prior to removing coupon from welding

position.

-- - -- ._-------------------

Page 5: Welding Procedure A1

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CLEANING: All cleaning of weld and base metal after the start of welding shall be done withoutthe use of power tools or mechanical methods. Caulking or masking of surface discontinuities isnot allowed and will invalidate the test.

VISUAL INSPECTION: Inspect welds for their size, as well as for their qualities such as beadshape, reinforcement, and undercut. Weld reinforcement shall not exceed 1/8".

BUTT JOINT-EQUAL THICKNESS PLATE

BUTT JOINT (TRANSITION)-UNEQUAL THICKNESS PLATE

NOTE: REINFORCEMENT R SHALL NOT EXCEED 1/8 in. (3 mm). SeE 5.24.4.

(D) ACCEPTABLE GROOVE WELD PROALE IN BUTT JOINT

EXCESSIVECONVEXITY

INSUFFICIENTTHROAT

EXCESSIVEUNDERCUT

OVERLAP

(E) UNACCEPTABLE GROOVE WELD PROFILES IN BUTT JOINTS

POSITION OF SPECIMENS: Test specimens shall be removed from the following locationson the weld coupons.

SIDE 8ENDSPECIMEN SIDE8END X

SPECIMEN /

DIRECTION OFROLLING OpnONAL----

in. mm

1/4 6

3/8 10

1 25

3 75

5 125

6 150

AT THE COMPLETION OF YOUR WELDER QUALIFICATION TEST NOTIFY YOUR TESTSUPERVISOR PRIOR TO MOVING THE TEST COUPON FROM THE TEST POSITION.

PLEASE RETURN UNUSED WELDING ELECTRODES TO THE PROPER STORAGERECEPTACLE. RETURN ALL TOOLS AND EQUIPMENT TO THEIR PROPER LOCATION.CLEAN YOUR WELDING AREA.

.~.