Department of mech. Design and prod.
Academic year: 2024/2025
First term
Second year mechanical
WELDING PROCEDURE SPECIFICATION
(WPS)
WELDING PROJECT
No. NAME SEC. B.N.
1 Ekwan Ehab Ishaak 2 1
2 Andrew Ashraf Shawky 2 4
3 Anas Osama Ashmawy 2 5
4 Anas Sherif Mohsen 2 6
5 Khaled Raafat Mohamed 2 16
6 Khaled Shaaban Mohamed 2 17
WELDING PROCEDURE SPECIFICATION No. 5
Reporting PQR No. 5
Date: 9/11/2024
Welding process: GMAW
BASE METALS (QW-403)
P No. 8
Group: 1
Grades: 304, 316, 317, and 347
Specification Type and Grade: AISI 4140
Thickness range: Up to 6.35 mm
Pipe diameter: N/A
range Groove: N/A
FILLER METALS (QW-404)
F. No. 6
A. No. 1
Specific Number AWS.SF: ER - 148S - 3
Wire Diameter: 1.2 mm
Electrode flux: Rutile Coated Electrode.
Joint Design (QW-402)
Joint Type: Square Butt Joint
Backing: None
Type: N/A
POSITION (QW-405)
Position or Groove: Horizontal.
Welding Progression: Forward.
Posotion of Fillet: All Positions.
PREHEAT (QW-406)
Preheat Temp. min. : 400 C
Interpass Temp. : 260 C
Preheat maintenance: N/A
SHIELDING GAS (QW-408)
Shielding Gas(es): CO2
% Compositin: 0.06
Flow Rate:15 L/min
Gas Backing: N/A
POST WELD HEAT TREATMENT (QW-407):
N/A
WELD TECHNIQUE (QW-409)
String or Weave Root: String
Fill/Cap: Weave Max. Weave Width 3 Times
Electrode Diameter.
Initial and Interpass Cleaning: Brushing.
Method of backing gouging: N/A
Oscillation: N/A
Contact Tube to Work Distances: N/A
Multiple or Single Pass (Per Side): Single.
Multiple or Single Electrodes: Single.
Feed: 2 mm/sec
Peening: N/A
Other: N/A
ELECTRICAL CHARACTERISTICS (QW-410)
Current: AC.
AMPS (range): 50 - 400 Amps.
Volt (range): 15-34 Volts.
Mode for Metal Transfer for GMAW: Spray.
Electrode wire feed speed (range): 1 - 3 mm/sec.
DEFECTS:
Misalignment: N/A
Undercut: N/A
Lack of Fusion: N/A
Lack of Penetration: N/A
Overlap: N/A
Concavity or Convexity: N/A
Improper Reinforcement: N/A
Weld Profiles: N/A
Spatter: Exists
EXPERIMENTS:
Tension Test: 17.4 KN.
Bending Test: 1.2 KN.
Zero Error: 200 N.
DATA SHEET
Types of Welded Joints for Sheets and Pipes:
Joint type Thickness
Square butt joint Up to 1⁄4 in (6.35 mm)
Single-bevel joint 3⁄16–3⁄8 in (4.76–9.53 mm)
Double-bevel joint Over 3⁄8 in (9.53 mm)
Single-V butt joint Up to 3⁄8 in (9.53 mm)
Double-V butt joint Over 3⁄8 in (9.53 mm)
Single-J joint 1⁄2–3⁄4 in (12.70–19.05 mm)
Double-J joint Over 3⁄4 in (19.05 mm)
Single-U joint Up to 3⁄4 in (19.05 mm)
Double-U joint Over 3⁄4 in (19.05 mm)
Pipe Joint Positions:
In the 1G welding position, the pipe is in the
horizontal position and can be rotated along the
horizontal (X) axis. The welder's position remains
stationary. Welding is performed on the top of the
pipe. This is the most basic welding position that can
be performed.
In the 2G welding position, the pipe is in the
vertical position and can be rotated along the
vertical (Y) axis. The welder's position remains
stationary. Welding is performed on the side of the
pipe in a horizontal direction.
In the 5G welding position, the pipe is in the
horizontal position. Unlike the 1G position, the
pipe is in a fixed position and it cannot be rotated.
The welder moves around the pipe in the vertical
direction to perform the welding.
In the 6G welding position, the pipe slopes at
approximately 45° from the horizontal (X) axis or
45° from the vertical (Y) axis. The pipe is in a
fixed position, so the welder must move around
the pipe to perform the welding. This is an
advanced welding position that requires a great
deal of experience and technical expertise.
Choose the P Number and S Number for the Base
Metal from
the Table below:
P Number Base Metal
Carbon Manganese Steels (four Group
1
Numbers)
2 Not Used
1/2 Molybdenum or 1/2 Chromium,
3
1/2 Molybdenum (three Group Numbers)
1 1/4 Chromium, 1/2 Molybdenum
4
(two Group Numbers)
5A 2 1/4 Chromium, 1 Molybdenum
5 Chromium, 1/2 Molybdenum or 9
Chromium,
5B
1 Molybdenum (two Group Numbers)
Chromium, Molybdenum, Vanadium
5C
(five Group Numbers)
Martensitic Stainless Steels (Grade 410, 415,
429)
6
(six Group Numbers)
7 Ferritic Stainless Steels (Grade 409, 430)
Austenitic Stainless Steels:
Group 1 - Grades 304, 316, 317, 347
8 Group 2 - Grades 309, 310
Group 3 - High Manganese Grades
Group 4 - High Molybdenum Grades
9A, B, C 2 - 4 Nickel Steels
10A, B, C, F Various Low Alloy Steels
Duplex and Super Duplex Stainless Steel
10H
(Grades 31803, 32750)
10I High Chromium Stainless Steel
High Chromium, Molybdenum Stainless
10J
Steel
High Chromium, Molybdenum,
10K
Nickel Stainless Steel
Various High Strength Low Alloy Steels
11A
(six Group Numbers)
Various High Strength Low Alloy Steels
11B
(ten Group Numbers)
15E 9 Chromium, 1 Molybdenum
16 to 20 Not Used
High Aluminum Content (1000 and 3000
21
series)
22 Aluminum (5000 series - 5052, 5454)
23 Aluminum (6000 series - 6061, 6063)
24 Not Used
25 Aluminum (5000 series - 5083, 5086, 5456)
26 to 30 Not Used
31 High Copper Content
32 Brass
33 Copper Silicon
34 Copper Nickel
35 Copper Aluminum
36 to 40 Not Used
41 High Nickel Content
42 Nickel, Copper - (Monel 500)
Nickel, Chromium, Iron - (Inconel) (C22,
43
C276, X)
44 Nickel, Molybdenum - (Hastelloy B2)
45
Nickel, Chromium, Si
46 Nickel, Chromium, Silicone
47 Nickel, Chromium, Tungsten
47 to 50 Not Used
51, 52, 53 Titanium Alloys
61, 62 Zirconium Alloys
Choose the A Number for the Base Metal from
this Table below:
Table QW - 442
A Numbers
Classification of Ferrous Weld Metal Analysis for Procedure Qualification
Analysis, % [Note (1)] and [Note (2)]
A-No. Type of Weld Deposit C Cr Mo Ni Mn Si
1.0
1 Mild Steel 0.20 0.20 0.30 0.50 1.60
0
1.0
2 Carbon - Molybdenum 0.15 0.50 0.40-0.65 0.50 1.60
0
1.0
3 Chrome (0.4% to 2%) - Molybdenum 0.15 0.40-2.00 0.40-0.65 0.50 1.60
0
2.0
4 Chrome (2% to 4%) - Molybdenum 0.15 2.00-4.00 0.40-1.50 0.50 1.60
0
Chrome (4% to 10.5%) - 4.00- 2.0
5 0.15 0.40-1.50 0.80 1.20
Molybdenum 10.50 0
11.00- 1.0
6 Chrome - Martensitic 0.15 0.70 0.80 2.00
15.00 0
11.00- 3.0
7 Chrome - Ferritic 0.15 1.00 0.80 1.00
30.00 0
14.50- 7.50- 1.0
8 Chromium - Nickel 0.15 4.00 2.50
30.00 15.00 0
19.00- 15.00- 1.0
9 Chromium - Nickel 0.30 6.00 2.50
30.00 37.00 0
0.80- 1.0
10 Nickel to 4% 0.15 0.5 0.55 1.70
4.00 0
1.25- 1.0
11 Manganese - Molybdenum 0.17 0.5 0.25-0.75 0.85
2.25 0
Choose the F Number for Welding Electrode from
the Table below:
F - Numbers Electrodes/Welding Rods
F - No. 1 through F - No. 6 Steel and Steel Alloys
F - No. 21 through F - No. 25 Aluminum and aluminum - base alloys
F - No. 31 through F - No. 37 Copper and Copper Alloys
F - No. 41 through F - No. 46 Nickel and Nickel Alloys
F - No. 51 through F - No. 56 Titanium and Titanium Alloys
F - No. 61 Zirconium and zirconium - base alloys
F - No. 71 through F - No. 72 Hard - Facing Weld Metal Overlay
