d10 committee on pipe and tube welding information on-hand, problems solved, questions answered
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D10 COMMITTEE ON PIPE AND TUBE WELDING
INFORMATION ON-HAND, PROBLEMS SOLVED, QUESTIONS ANSWERED
KNOWLEDGE IS POWER
NO MATTER WHAT LEVEL OF THE INDUSTRY YOU WORK …
THE D10 DOCUMENT COLLECTION HAS THE INFORMATION YOU
SHOULD HAVE AT YOUR FINGERTIPS
MATERIALS & METHODS COVERED
•AUSTENITIC STAINLESS STEEL
•TITANIUM
•ALUMINUM
•CHROME-MOLY
•LOCAL HEAT TREATING
•ROOT PASS WELDING
•MILD STEEL
•COPPER TUBE
WELDING PROCESS
•GTAW•SMAW•FCAW•GMAW
•BRAZING
William F. Newell, Jr. PE, IWE, Chair D10C
D10.4 RECOMMENDED
PRACTICES FOR WELDING AUSTENITIC CHROMIUM-NICKEL STAINLESS STEEL
PIPE AND TUBING
AWS D10.4
• “…to provide information which may be used to avoid, or at least minimize, difficulties in welding austenitic stainless steel piping and tubing. …”
AWS D10.4 - Uses
• Often overlooked……
• Excellent resource for:– Developing Corporate Procedures &
Specifications– Training Engineers, Supervision and Welders– General Reference Guide
AWS D10.4 - History
• First published in August 1955 under the title, The Welding of Austenitic Chromium-Nickel Steel Piping and Tubing. A Committee Report and published as AWS D10.4-55T
• AWS D10.4-55T was revised in 1966
AWS D10.4 - History
• In 1979, a major updating of the document was completed and published as AWS D10.4-79, Recommended Practices for Welding Austenitic Chromium-Nickel Stainless Steel Piping and Tubing. This version presented a detailed discussion of the role of delta ferrite in austenitic chromium-nickel steel welds.
AWS D10.4 - History
• In 1986, the document was expanded and given an Annex which gives recommendations for welding high-carbon stainless steel castings.
• In 1992 and 1999, the document was reaffirmed.
AWS D10.4 - History• The current document, ANSI/AWS D10.4M/D10.4:199X,
Guide for Welding Austenitic Chromium-Nickel Stainless Steel Piping and Tubing has extended safety and health information and provides information on super austenitic stainless steels and flux cored arc welding.
• Tables listing specific chemical composition ranges for base metal and weld metal that fall under the jurisdiction of other codes or documents have been omitted from this revision. Where helpful, however, comparison data is presented.
AWS D10.4 - Content
• Base Metals & Weld Filler Metals
• Ferrite
• Welding Processes, Technique & Problems
• Dissimilar Joining
• Inspection
• Safety
AWS D10.4 – Base Metals
• Austenitic– 300-series
• Super Austenitic– 4% & 6% Mo
• High Carbon– “HX” Grades
Coming !
• D10.18 (DRAFT)
• “Guide for Welding Ferritic/Austenitic Duplex Stainless Steel Piping and Tubing”
Don ConnellWelding Engineer
Detroit Edison Company
D10.6 RECOMMENDED
PRACTICES FOR GAS TUNGSTEN ARC WELDING OF TITANIUM PIPING AND
TUBING
Applications for Ti Pipe & Tube
Where Ti is selected for its corrosion resistance rather than its high strength to weight ratio
• Chemical processing• Petrochemical• Desalination• Power generation plants• Navy to replace Cu-Ni in seawater piping
Process-GTAW
• Other processes may be used to weld Ti but are not covered in this recommended practice
Base Metals
• 6 grades commonly used for piping, all single phase alpha
• Ref: ASTM B337 (seamless & welded pipe) & B338 (seamless & welded tubing)
• Replaced by ASTM B861 and B862
Critical Factors in Welding
• Cleanliness-proper means of mechanical and chemical cleaning using acids and solvents
• Protection from contaminants at elevated temperatures– Trailing shields– Root shielding– Chamber welding
Quality Control
• Simple tests to check the process before welding & the finished weldment
• Describes how weld color is an indication of weld quality
Other References
• AWS G2.4 to be published this year
• Addresses CP and Ti alloys, such as Ti-6Al-4V
• Helpful guide in base metal selection
• Other welding processes included
• Tables of reference documents
Tony Anderson ESAB Welding &
Cutting
D10.7 RECOMMENDED
PRACTICES FOR GAS SHIELDED ARC WELDING
OF ALUMINUN AND ALUMINUM ALLOY PIPE
Presented By: Tony Anderson, ESAB North America
< >
The Number One Issue
Filler Alloy SelectionFor Aluminum Welding
A Need To Up DateThis Information
© Copyright 2005 ESAB Welding & Cutting
< >
Many Base Alloys And Base Alloy Combinations Can Be Joined Using Several Different Filler Alloys
Only one filler alloy may be optimum for a specific application
When Choosing The Optimum Filler Alloy, the End Use Of The Weldment And Its Desired Performance Must Be The Prime Consideration.
< >
Weldability Or Freedom From Cracking
Strength Of Weld - Tensile Or Shear
Ductility Of Weld
Corrosion Resistance
Temperature Service
Match in color after anodizing
Post Weld Heat Treatment
Filler Alloy Selection Primary Characteristics
W
S
D
C
T
M
*
*
< >
Hot Weld Cracking
Hot Cracking On 2014 Base Alloy Plate Adjacent To A Gas Tungsten Arc (GTA)
Welded 4043 Alloy Fillet
< >
Weld Cracking - HOT
Choice Of Filler Metal
Lower Melting & Solidification Point - MoltenDuring Maximum Contraction Stresses
Smaller Freezing Zone
Avoid Critical Chemistry Ranges
Si 0.5% To 2.0%Example: 4043 20% ( Electrode )1100 80% ( Base )
Avoid Welding 5xxx Esp.. ( 5086, 5083, 5456 )With 4043 Or 4xxx. Mgsi Eutectic Problems
Avoid Mg Range Up To 3.0% In Weld
Alloy Content vs. Crack Sensitivity
< >
0
0
0
0
1 2 3 4 5 6 7
A l - Cu
A l - M g
A l - M g S i2
COMPOSITION OF WELD - PERCENT ALLOYING ELEMENT
RE
LA
TIV
E
CR
AC
K
SE
NS
ITIV
ITY
Dilution Effect On Weld Composition
< >
60% Filler Metal
40% Base Metal
20% Filler Metal
80% Base Metal1.7% Mg
3.2% Mg
Base Plate 6061 Filler Metal 5356
< >
Weld Strength - Groove Welds
The Heat Of Welding Softens theAluminum Base Alloy Adjacent To The Weld
In Most Groove Weldsthe H.A.Z. of the Base Alloy Will Control
the As-welded Tensile Strength of the Joint
Heat Affected Zone
< >
A B C D E
1 2 0 01 1 0 01 0 0 0 9 0 0 8 0 0 7 0 0 6 0 0 5 0 0 4 0 0 3 0 0 2 0 0 1 0 0 R T
A -
B -
- A
- B
C -- C
D -
- D
- EE -
Non Heat TreatableA - Weld MetalAs Cast Structure Of Base & Filler Metal
B - Fusion ZoneWhere Partial MeltingOf Base Metal Occurs
C - Anneal ZoneWhere Base Metal Is Fully Recrystallized - Full Soft
D - Partial Anneal ZoneWhere Base Alloy Is Recovered And Partially Softened
E - Unaffected
Heat TreatableA - Weld Zone
B - Fusion Zone
C - Solid Solution ZoneWhere Alloy ElementsAre Solutioned & CooledTo Retain Solid Solution
D - Partially Annealed Overaged ZoneWhere Heat Has CausedPrecipitation And/orCoalescence Of ParticlesOf Soluable Constituents
E - Unaffected
1 0 0
9 0
8 0
7 0
6 0
5 0
4 0
580 J /c m
756 J /c m
1128 J /c mAW S D1.2 MIN TENSILE
-O TEMPER
Hardness Profiles of 6061-T6
< >
Distance From Weld Interface
Har
dn
ess
RE
Made At Three Heat Inputs
< >
Weld Strength - Fillet Welds
The Shear Strength Of FilletWelds Is The Significant Factor AndIs Controlled By The Shear Strength
Through The Weld Metal
5356 Produces Greater FilletWeld Strength In The As Welded
Condition Compared To 4043
Shear Strength
< >
TRANSVERSE Fillet Size (Inch)
2 5 0 0 0
2 0 0 0 0
1 5 0 0 0
1 0 0 0 0
5 0 0 0
0
0 1 / 8 1 / 4 3 / 8 1 / 2 5 / 8 3 / 4
5556
5356464355545654
4043
1100
Sh
ear
Str
eng
th
LB
S.
Per
Lin
ear
In
ch
< >
Shear Strength
Typical Shear Strengths Of Fillet Welds
Filler Alloy
1100
2319
4043
4643
5183
5356
5554
5556
5654
LongitudinalShear
Strength( Ksi )
7.5
16.0
11.5
13.5
18.5
17.0
15.0
20.0
12.0
Transverse Shear
Strength( Ksi )
7.5
16.0
15.0
20.0
28.0
26.0
23.0
30.0
18.0
< >
Fracture Characteristics
2 .0
1 .6
1 .2
0 .8
0 .4
Ra
tio
1 6 0 0
1 2 0 0
8 0 0
4 0 0
T
tea
r R
es
ista
nc
e
Heat - Treatable Alloys
Ratio = Tear Resistance
Unit Propagation
Energy In.-lb. / In3
Notch Tensile Strength
Tensile Yield Strength
2 2 1 9 2 2 1 9 6 0 6 1 6 0 6 1 6 0 6 1 7 0 0 5 7 0 3 9
2 3 1 9 4 0 4 3 2 3 1 9 4 0 4 3 5 3 5 6 5 3 5 6 5 1 8 0
B a s e M e ta l
F i l le r A l lo y
Aged
< >
Corrosion Facts – As Welded
Alloy 7075-T6 Welded With 5356 Filler
-849mv -876mv -900mv -810mv
Post Weld Heat Treated and Aged
-810mv -810mv -840mv -806mv
Note: Fusion Zone Mechanical Properties Not Restored to PreWeld Properties
< >
Color Match After AnodizeM
Rating Scale: A - B
Ratings Scale Measures Uniformity Of ColorComparing Base Alloy And Weld Metal
After Anodizing.
Either There Is A Good Or Reasonable MatchOr There Is Not.
A Blank Space Indicates No Reasonable Match.
< >
Color Match After Clear Anodize
Base Metal: 6061
6061 6061
6061 6061
W ELDED W ITH 5356 W ELDED W ITH 4043
< >
Post Weld Heat Treatment
Filler Alloys Have Been DevelopedWhich Will Respond To PostweldHeat Treatment.
4643 Was Developed For Welding The 6xxx Base Alloys, Has Additions Of Mg And Is Less Dependant On Dilution Of The Base Alloy To Achieve Desired Composition.
Filler Alloys For Welding Castings Have Been Developed With Chemistries Which Will Respond To Post Weld Heat Treatment.
Conclusion
Can only be made after a full analysis of a welded components performance requirements
Should involve the consideration of metallurgical effects (changes in crack sensitively) when combining base alloy chemistry with filler alloy chemistry
Can substantially influence the strength and performance of a welded component
Filler Alloy Selection For Aluminum
< >
© Copyright 2005 ESAB Welding & Cutting
William F. Newell, Jr. PE, IWE, Chair D10I
D10.8 RECOMMENDED
PRACTICES FOR WELDING OF CHROMIUM-
MOLYBDENUM STEEL PIPING AND TUBING
AWS D10.8
“… provide recommendations for welding chromium-molybdenum steel pipe and
tubing to itself and to various other materials. Subjects covered in detail are
filler metal selection, joint design, preheating, and postheating. …”
AWS D10.8 - Uses
• Often overlooked……
• Excellent resource for:– Developing Corporate Procedures & Specifications
– Training Engineers, Supervision and Welders
– General Reference Guide
AWS D10.8 - History• First presented in 1961 as a Committee Report
by the AWS Committee on Piping and Tubing.
• Revised in 1978 and became a “Recommended Practice”
• Subsequent revisions/reaffirmations in 1986 and 1996
AWS D10.8 - Content• Base Metals • Weld Filler Metals• Joint Design & Preparation (purging)
• Preheating• Post Weld Heat Treatment• Repair/Maintenance of Service Exposed
Material• Safety
AWS D10.8 – Base Metals
• C-Steel• C-Mo• 1-1/4Cr-Mo• 2-1/4Cr-Mo• 5Cr-Mo• 7Cr-Mo• 9Cr-Mo (Standard Grade Only)
AWS D10.8 – Filler Metal
• Recommendations – Process– AWS Classification Options [C, CrMo
& Ni-base]– Similar v. Dissimilar
AWS D10.8 – Priorities !
• Preaheat w/recommendations
• Interpass • Post Weld Heat Treat
w/recommendations
Pending !
• D10.08 (DRAFT)
• Removing information on 9CrMoV (P91)
• Removing References to Standard Welding Procedures
Coming !
• D10.21 (DRAFT)
• “Guideline for Welding Advanced Chromium-Molybdenum Steel Piping and Tubing” – P91, P911, P92, P122, T23…
Dan CiarlarielloMannings USA
D10.10RECOMMENDED
PRACTICES FOR LOCAL HEATING OF WELDS IN
PIPING AND TUBING
Definition of Heat Treatment
• Heat Treatment is generally defined as heating to a suitable temperature then cooling at a suitable rate of a solid metal or alloy in a way so as to obtain specific conditions and/or properties by changing the physical, chemical and/or mechanical properties of the steel, metal or alloy
Methods Of Localized Heat Treating
• Electrical Resistance
• Induction
• Combustion / Flame
• Quartz Lamps
• Exothermic Kits.
Electrical Resistance
Inductive Heating
Combustion / Flame
Quartz Lamps
Reasons for Localized Heat Treating
• Bake Out
• Preheating and Inter-pass Temperatures
• Post Heating
• Post-weld Heat Treatment
Comparison of Heating Processes
Attribute• Applicability to
bake-out• Applicability to
preheat/inter-pass• Applicability to
postheating• Applicability to
PWHT
Induction - Resistance• Yes Yes
• Yes Yes
• Yes Yes
• Yes Yes
Advantages and disadvantages of heating
processesInduction Heating
Advantages High heating rates Ability to heat a narrow band adjacent to a region
which has temperature restrictions
Disadvantages High initial equipment cost. Equipment large and less portable. Limited ability to create control zones around the
circumference.
Advantages and disadvantages of heating
processes
Electrical ResistanceAdvantages
Ability to continuously maintain heat from welding
operation to PWHT Good ability to vary heat around the
circumference
Disadvantages Elements may be damaged during welding Quantity of heaters required on thicker
components
High Frequency Induction heating
• Uniform product quality• Increased surface wear-proof
characteristics• Increased material fatigue strength• Minimum strain due to local surface
hardening• Very localized heating
Why Preheat?
• Reduce the level of thermal stress.• Compensate for high heat losses.• Minimize the rate of weld
hardening.• Reduce porosity.• Reduce hydrogen cracking.• Improve the microstructure.
Typical Preheat Set-up
Boiler Tube Welds
Wireless Thermocouple Transmission
AWS D10.11Walter J. Sperko, P.E. Sperko Engineering
Services, Inc.
Guide for
Root Pass Welding
of Pipe Without Backing
AWS D10.11 Keywords
• Root pass welding, pipe, gaspurging, consumable insert, gastungsten arc welding, gas metal arc welding, shielded metal arc welding
AWS D10.11 Introduction
• This publication was intended to be a “how to” guide in the use of open root and consumable insert welding techniques for root pass welding of groove welds joining metal pipe.
AWS D10.11 Introduction
• Joint designs, fitting techniques, consumable insert configurations, filler and base metal combinations, purging, and welding processes are discussed. This publication made no provision for joints which include backing rings
AWS D10.11 Introduction
• This standard is a “best practices” guide to making high-quality pipe butt welds where backing cannot be used
• Welders should have excellent reasons for deviating from what this standard recommends
AWS D10.11
• What is “Root Pass Welding?”• Let’s look at some “root
passes”. . . .
AWS D10.11
• A single-vee Butt weld between two pipes
AWS D10.11
• Root pass on a Socket Weld
AWS D10.11
• Root pass on a Double Vee-Groove Weld
AWS D10.11
• All of these “Root Passes” are on backing
AWS D10.11
• Take away the Backing Strip and you have a weld without backing. . . .
Welding without Backing
You now have a pool of liquid metal hanging in space
suspended between the ends of two pipes. . .
Welding without Backing
Torch
Blast the arc force through the root opening and melt the edges of the metal, then fill the opening with filler metal
Welding without Backing
Electrode
Blast the arc force through the root opening and melt the edges of the metal, then fill the opening with filler metal
Effect of Included Angle
LARGE included angle makes it easy to get the electrode close to the root and easy to direct the arc into the root.
Effect of Included Angle
SMALL included angle holds the electrode away from the root and makes it difficult to direct the arc into the root.
Full Root Penetration
Continuous metal surface from one
member across the weld to the other
member
Forces on the weld pool?
Longitudinal Section of a pipe joint
Forces on the weld pool
Longitudinal Section of a pipe joint
Gravity
Forces on the weld pool
Longitudinal Section of a pipe joint
Surface Cohesion (wetting) between the
weld pool and the solid metal
Forces on the weld pool
Longitudinal Section of a pipe joint
The arc must melt both edges of the root face
and the weld pool must fill the gap without
becoming too large
Forces on the weld pool
Longitudinal Section of a pipe joint
If the weld pool becomes too large, the surface
cohesion forces are overcome. The result is
root concavity or drop-through.
Parts of a Groove Weld Joint Design
Root Face (“Land”)
Parts of a Groove Weld Joint Design
Root Opening (“Root Gap”)
Root Opening vs. Root FaceThick Root Face
Thin Root Face
Small Root opening Incomplete Penetration
Proportional Root opening Complete Penetration
Excessive Root opening Root concavity or burn-through
Root
Face
Th
ickn
ess
Root Opening
1/8”
3/32”
1/16”
1/8”3/32”1/16”
Root opening - Root face thickness relationship
Cleaning
• Cleanliness is important in all welding, but it is especially important in root pass welding.
• Contamination affects wetting which affects bead shape.
Purging
Purging
• A purge is required for stainless and nonferrous piping systems (except aluminum) if a smooth root surface is to be obtained.
• Standard describes how to set up for purging
• Purging time
Purging
• The following oxygen limits are recommended:
• For carbon and low alloy steels: 2%(20,000 ppm)
• For stainless steels: 1/2% (5000 ppm)• For nickel alloys: 1/2% (5000 ppm)• For titanium and zirconium alloys:
1/4% (2500 ppm)
Purging
• Welding technique for Open Root
• Welding Technique for Consumable Insert
• Maintaining purge during welding
Fitting and tack welding
• Size, spacing, feathering ends• Root spacing depends on
process to be used.• Inspection after fit-up. This is
the most important step in pipe welding
GTAW
• Tungsten size, shape of end• Grinding methods
GTAW Joint design and fit up
GTAW
• Purge containment• Arc initiation• Keyhole technique• Wire feed techniques• Orientation of torch and filler
GTAW
GTAW
GTAW
• Walking the Cup• Welding with zero root
opening (autogenous welding)• Welding in different positions• Using consumable inserts
Consumable Inserts
Class 1 Insert, formerly the EB (Electric Boat) or “A” type insert.
1/32” maximum mismatch
Consumable Inserts
Class 2 Insert, formerly the “J” type insert.
1/16” maximum mismatch
Consumable Inserts
Class 3 Insert, formerly the “Grinnell” or flat insert.
1/16” maximum mismatch
Consumable Inserts
SMAW
• Cellulosic Electrodes (EXX10, EXX11)
• Low Hydrogen Electrodes (EXX15, EXX16, EXX18)
• Rutile electrodes (E6013)
GMAW
• Joint design• Fit-up• Welding parameters
Fill Passes
• Use any suitable process• Don’t melt through the root
Aluminum
• Tungsten type, shape of tip• Shielding gas cups, lenses• Power supplies• Techniques• Recommended joint design
Aluminum
Machine and Automatic
• Not much said
Summary
• AWS D10.11 gives very specific recommendations about techniques that have proven successful in making pipe welds without backing
• Recommendations should be familiar to welder’s supervision
• Recommendations should not be take lightly
Alan Beckett
D10.12RECOMMENDED
PRACTICES FOR WELDING MILD STEEL PIPE
D10.12 Welding Mild Steel Pipe
This document provides recommendations for the welding of mild steel pipe such as A106 type. This material is found in many scopes of work, and extensively in commercial building construction.
A106 material is often used as a starting point for welder training.
Covered Processes
• SMAW
• GTAW
• GMAW
• FCAW
D10.12 A Document for All Reasons
As with other D10 documents, you will find excellent attention to detail presented in a manner for all to understand.
For these reasons D10.12 is a welcome addition to your library or a valuable resource for training.
MICHAEL LANG AWS/CWI/CWEUnited Association
of Plumbers & Pipefitters
D10.13RECOMMENDED
PRACTICES FOR BRAZING OF COPPER PIPE AND
TUBING FOR MEDICAL GAS SYSTEMS
What is Medical Gas Piping?
There are many perceptions of Medical Gas Piping but the facts are:
• Cleanliness is entirely dependant on installation practices
• Poor installation can produces conditions that harbor bacteria and diseases
• These systems are not cleanable• These are life critical systems
Purpose
The governing document for all Medical Gas Piping is NPFA Code 99C which dictates the methods and installation practices that shall be used in system construction…
However this document does not cover actual brazed joint construction or the tools and practices needed for system construction
Important Notes
• D10.13 is a Recommended Practice developed to work with NFPA 99C.
• All recommendations have been used in actual jobsite conditions with a 100% success rate
• The use of these practices have produced consistent profitable results
Needed Equipment
• Use and Care
• Torch Selection
• Tube Cutting
• Purge Monitoring
Consumables
• Pre Braze Joint Cleaning
• Pre Braze Chemical Cleaning
• Post Braze Cleaning
• BCuP Brazing Alloys
• Bag Brazing Alloys
Something you will only find in D10.13
• The only document that provides joint heating and filler metal application methods.
• These methods continually produce a 99% acceptance rate in accordance with ASME Boiler & Pressure Vessel Code Section XI.
And… Purging Methods
• Purging is possibly the most important component to internal cleanliness. This document provides methods and parameters for the use of oxygen analyzers.
• We also provide purge timing matrix charts for estimating purge times for long runs of piping. These charts should be used in conjunction with an O2 analyzer.
D10.13RECOMMENDED PRACTICES FOR
BRAZING OF COPPER PIPE AND TUBING FOR MEDICAL GAS
SYSTEMS
Proven Success You Can Trust
BECOME A COMMITTEE MEMBER FOR DETAILS CONTACT Brian
McGrath at bmcgrath@aws.orgTHANK YOU FOR ATTENDING AND ENJOY THE AWS SHOW
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