Universiti ITM

40000 Shah Alam

REPORT NO
SUBJECT Lab 2: Preparation of WPS for carbon steel by GMAW
PROJECT 4th year Mechanical Engineering WELDER NAME
CONTRACTOR N/A I/C NO
CLIENT UITM
REF. STANDARD AWSD1.1 I/C NO
WPS NO. UITM-WPS-13-03 POSITION
PQR NO. UITM-PQR-13-03 WELDING DATE
WQT NO. UITM-WQT-13-03
MATERIAL A B WELDING
BASE METAL TYPE Plate Plate PROCESS
MATERIAL C. Steel C. Steel POLARITY
SPECIFICATIONS A36 A36 CONSUMABLE
SIZE ( IN or mm ) 180 X 40 180 X 40 TYPE
HEAT NO. N/A N/A FLUX
THICKNESS (mm) 6.0 6.0 Flux code
DIAMETER (mm) N/A N/A SPECIFICATIONS
SFA
Tensile strength psi 42000 42000
Weld Joint V Butt SIZE (mm)
Groove angle 60 TRADE NAME
Root face 2.0 BRAND
Root gap 2.0 SHIELDING GAS
Weld Pass 2 FLOWRATE (l/min)
Preheat N/A N/A
Interpass N/A N/A
PWHT N/A N/A
Stress Relief N/A N/A
 Write the name
and IC

ZAINI RUKAINI BIN ROSLI

890126-04-5245 ?

If the thickness
is 6mm
1G Flat TYPE 6 here
DON’T PRINT THIS PAGE
A B
GMAW GMAW
DCRP DCRP

Solid Wire Solid Wire

-- --
-- --
ER70S ER70S
A5.18 A5.18 Write the
correct name of
consumable
0.8 0.8 wire
MG1 MG1
Southern Southern
CO2 CO2
25.0 25.0
E
 Universiti ITM
40000 Shah Alam

PROPOSED WELDING PROCEDURE SPECIFICATIONS

PWPS No: UITM - 3 - 08
PQR No: N/A
Applicable Code AWSD1.1
1 Process Process 1 GMAW Process 2 GMAW
2 Material Side 1 C. Steel Spec A36
Side 2 C. Steel Spec A36
Specified Min. Tensile Strength 42,000 psi
3 Size Side 1 Diameter N/A Thickness 6.0 mm
Side 2 Diameter N/A Thickness 6.0 mm
4 Joint Design V Butt
5 Pass (Single / Multiple) Multiple
6 Position 1G Fixed
7 Direction of Welding Root Pass Flat
Other Pass Flat
8 Time lapse between pass Maximum 10 min
9 Type of Line up clamp N/A
10 Removal of Line-up Clamp N/A
11 Cleaning Power brush
13 Heat Treatment Preheat Type N/A Temperature N/A deg C
Interpass Type N/A Temperature N/A deg C
PWHT Type N/A Temperature N/A deg C
Stress Relief Type N/A Temperature N/A deg C
14 Shielding Gas Root Pass CO2 Flowrate 25 (l/min)
Other pass CO2 Flowrate 25 (l/min)
15 Shielding Flux Root Pass -- Code no --
Other pass -- Code no --
16 Consumable type Root Pass Solid Wire Code no ER70S Diameter 0.8 mm
Other Pass Solid Wire Code no ER70S Diameter 0.8 mm
17 Range of Travel Speed Root Pass 2-8 cm/min
Other Pass 2-8 cm/min

Welding location

60 deg

cap

t=8 root
100mm
2.0mm 1.0mm
300mm

Pass No: 1 2
Root Cap
Welding Process GMAW GMAW
Electrode Type Solid Wire Solid Wire
Filler Metal AWS No ER70S ER70S
SFA No A5.18 A5.18
Dia. (mm) 0.8 0.8
Current Polarity DCRP DCRP
Amp. (A) 130-150 130-150
Arc Voltage Volt (V) 15-28 15-28
Speed (mm/sec) 2-8 2-8
Direction Flat Flat
Temperature N/A N/A
Heat input N/A N/A
Contractor Third Party Owner

Date 30-4-13
 Universiti ITM
40000 Shah Alam

WELDING PROCEDURE QUALIFICATION RECORD

WPS No:
PQR No:
Applicable Code
1 Process Process 1 Process 2
2 Material Side 1 Spec
Side 2 Spec
Specified Min. Tensile Strength psi
3 Size Side 1 Diameter Thickness mm
Side 2 Diameter Thickness mm
4 Joint Design
5 Pass (Single / Multiple)
6 Position
7 Direction of Welding Root Pass
Other Pass
8 Time lapse between pass Maximum 10 min
9 Type of Line up clamp
10 Removal of Line-up Clamp
11 Cleaning Power brush
13 Heat Treatment Preheat Type Temperature deg C
Interpass Type Temperature deg C
PWHT Type Temperature deg C
Stress Relief Type Temperature deg C
14 Shielding Gas Root Pass Flowrate (l/min)
Other pass Flowrate (l/min)
15 Shielding Flux Root Pass Code no
Other pass Code no
16 Consumable type Root Pass Code no Diameter mm
Other Pass Code no Diameter mm
17 Range of Travel Speed Root Pass cm/min
Other Pass cm/min

Welding location

Pass No:

Welding Process
Electrode Type
Filler Metal AWS No
SFA No
Dia. (mm)
Current Polarity
Amp. (A)
Arc Voltage Volt (V)
Speed (cm/min)
Direction
Temperature
Heat input
Contractor Third Party Owner

Date
 Universiti ITM
40000 Shah Alam

WELDING RECORD
WPS No: UITM-WPS-13-03
PQR No: UITM-PQR-13-03
Applicable Code AWSD1.1
1 Process Process 1 GMAW Process 2 GMAW
2 Material Side 1 C. Steel Spec A36
Side 2 C. Steel Spec A36
Specified Min. Tensile Strength 42,000 psi
3 Size Side 1 Diameter N/A Thickness 6.0 mm
Side 2 Diameter N/A Thickness 6.0 mm
4 Joint Design V Butt
5 Pass (Single / Multiple) Multiple
6 Position 1G Fixed
7 Direction of Welding Root Pass Flat
Other Pass Flat
8 Time lapse between pass Maximum 10 min
9 Type of Line up clamp N/A
10 Removal of Line-up Clamp N/A
11 Cleaning Power brush
13 Heat Treatment Preheat Type N/A Temperature N/A deg C
Interpass Type N/A Temperature N/A deg C
PWHT Type N/A Temperature N/A deg C
Stress Relief Type N/A Temperature N/A deg C
14 Shielding Gas Root Pass CO2 Flowrate 25 (l/min)
Other pass CO2 Flowrate 25 (l/min)
15 Shielding Flux Root Pass -- Code no --
Other pass -- Code no --
16 Consumable type Root Pass Solid Wire Code no ER70S Diameter 0.8 mm
Other Pass Solid Wire Code no ER70S Diameter 0.8 mm
17 Range of Travel Speed Root Pass cm/min
Other Pass cm/min

Welding location

60 deg

cap
t=8 root
100mm
2,0mm 1.0mm
300mm

Pass No: 1 2
Root Cap
Welding Process GMAW GMAW
Electrode Type Solid Wire Solid Wire
Filler Metal AWS No ER70S ER70S
SFA No A5.18 A5.18 Write the
0.8 0.8 welding data
Dia. (mm)
here
Current Polarity DCRP DCRP
Amp. (A)
Arc Voltage Volt (V)
Length mm
Calculate the
Time sec
speed
Speed (mm/sec)
Direction
Weight gm
Deposit gm
Temperature Calculate the
Heat input HI here
Contractor Third Party Owner

Date
 VISUAL INSPECTION REPORT

REPORT NO UITM -V-13-03

SUBJECT Lab 2: Preparation of WPS for carbon steel by GMAW
PROJECT 4th year Mechanical Engineering WELDER NAME ZAINI RUKAINI BIN ROSLI
CONTRACTOR N/A I/C NO 890126-04-5245
CLIENT UITM
REF. STANDARD AWSD1.1
WPS NO. UITM-WPS-13-03 POSITION 1G
UITM-PQR-13-03 WELDING DATE
UITM-WQT-13-03
MATERIAL A B WELDING A B
BASE METAL TYPE Plate Plate PROCESS GMAW GMAW
MATERIAL C. Steel C. Steel POLARITY DCRP DCRP
SPECIFICATIONS A36 A36 CONSUMABLE
SIZE ( IN or mm ) 180 X 40 180 X 40 TYPE Solid Wire Solid Wire
HEAT NO. N/A N/A FLUX -- --
THICKNESS (mm) 6.0 6.0 SPECIFICATIONS ER70S ER70S
DIAMETER (mm) N/A N/A SFA A5.18 A5.18

Material Tensile strength psi 42000 SIZE (mm) 0.8 0.8

TRADE NAME MG1 MG1
BRAND Southern Southern
SHIELDING GAS CO2 CO2
FLOWRATE 25 25
Number 1
Joint Type V Butt
JOINT Pass

DESIGN Position 1G
Direction Flat
Groove angle 60
100mm
Root gap 2
Root face 2
300mm

STANDARD REQUIREMENT RESULT

Coupon No. A-B REMARKS
ROOT FULL FULL Accepted
VISUAL LEG size (V) (mm) N/A N/A
INSPECTION Leg size (H) (mm) N/A N/A
THROAT (mm) Thickness Full thickness Accepted
REPORT SURFACE Contour Even Even Accepted
Crack NIL NIL Accepted
Undercut (mm) 0.8mm max Not Significant Accepted
Convexity (mm) 2.5mm max 2mm Accepted
Inclusion / Cavities 1.6mm Not significant Accepted
Surface defects 1.6mm Not significant Accepted

RESULT Evaluation PASSED

Remarks Complied to the quality requirement of AWSD1.1
INSPECTOR

DATE
 DYE PENETRATION TEST REPORT

REPORT NO UITM -DP-10-03

SUBJECT Lab 2: Preparation of WPS for carbon steel by GMAW
PROJECT 4th year Mechanical Engineering WELDER NAME
CONTRACTOR N/A I/C NO
CLIENT UITM
REF. STANDARD AWSD1.1
WPS NO. UITM-WPS-13-03 POSITION
UITM-PQR-13-03 WELDING DATE
UITM-WQT-13-03
MATERIAL A B WELDING
BASE METAL TYPE Plate Plate PROCESS
MATERIAL C. Steel C. Steel POLARITY
SPECIFICATIONS A36 A36 CONSUMABLE
SIZE ( IN or mm ) 180 X 40 180 X 40 TYPE
HEAT NO. N/A N/A FLUX
THICKNESS (mm) 6.0 6.0 SPECIFICATIONS
DIAMETER (mm) N/A N/A SFA

Material Tensile strength psi 42000 SIZE (mm)

TRADE NAME
BRAND
SHIELDING GAS
FLOWRATE

Number 1
Joint Type V Butt
JOINT Pass

DESIGN Position 1G
Direction Flat
Groove angle 60
Root gap 2
Root face 2

STANDARD REQUIREMENT RESULT

Coupon No. A-B REMARKS
 DYE PENETRATION SPEC
DYE PENT.
INSPECTION

REPORT SURFACE Quality

Crack
Undercut (mm)
Surface Porosity
Inclusion / Cavities
Surface flaw
ROOT Quality
Crack
Surface flaw

RESULT Evaluation
Remarks
INSPECTOR

DATE
TEST REPORT

el by GMAW
ZAINI RUKAINI BIN ROSLI
890126-04-5245

1G

A B
GMAW GMAW
DCRP DCRP

Solid Wire Solid Wire

-- --
ER70S ER70S
A5.18 A5.18

0.8 0.8
MG1 MG1
Southern Southern
CO2 CO2
25 25
 RADIOGRAPHY TEST REPORT

REPORT NO UITM-X-13-03
SUBJECT Lab 2: Preparation of WPS for carbon steel by GMAW
PROJECT 4th year Mechanical Engineering WELDER NAME ZAINI RUKAINI BIN ROSLI
CONTRACTOR N/A I/C NO 890126-04-5245
CLIENT UITM
REF. STANDARD AWSD1.1
WPS NO. UITM-WPS-13-03 POSITION 1G
UITM-PQR-13-03 WELDING DATE
UITM-WQT-13-03
MATERIAL A B WELDING A B
BASE METAL TYPE Plate Plate PROCESS GMAW GMAW
MATERIAL C. Steel C. Steel POLARITY DCRP DCRP
SPECIFICATIONS A36 A36 CONSUMABLE
SIZE ( IN or mm ) 180 X 40 180 X 40 TYPE Solid Wire Solid Wire
HEAT NO. N/A N/A FLUX -- --
THICKNESS (mm) 6.0 6.0 SPECIFICATIONS ER70S ER70S
DIAMETER (mm) N/A N/A SFA A5.18 A5.18

SIZE (mm) 0.8 0.8

TRADE NAME MG1 MG1
BRAND Southern Southern
SHIELDING GAS CO2 CO2
FLOWRATE 24-Jan-00 24-Jan-00
RADIOGRAPHY INSPECTION
X-ray Equipment -- Tube Voltage (kV)
Radiation source X-RAY Tube Current (mA)
Focal spot size -- Exposure time (Min)
Source size 1.6 X 3.0 mm Source distance (mm)
Film type and size D7 IQI Position Film side
Exposure technique DWSI IQI Type 10FEDIN
Screen material LEAD Sensitivity Wire no 12
Screen thickness (mm) Front: 0.125 mm Source type Ir 192
Back: 0.125 mm Source strenght (Ci) 17.4
Density 2.0 to 3.5
PART FILM
NO. Identification TYPE OF DEFECTS EVALUATION REMARKS

1 Aa 1.0 mm Accepted
2 Ba 2 mm max Accepted

CONCLUSION Accepted

Legend Radiographer Inspector

Aa: Gas pore

Ab: Worm hole
Ba: Slag incl.
C: Lack of fusion
D: Lack of penetration
E: Crack
F: Undercut
H: Inclusion
K: Shrinkage cavity
NAD: No apperent defect Date
 BENDING
TEST REPORT

REPORT NO UITM-B-13-03
SUBJECT Lab 2: Preparation of WPS for carbon steel by GMAW
PROJECT 4th year Mechanical Engineering WELDER NAME ZAINI RUKAINI BIN ROSLI
CONTRACTOR N/A I/C NO 890126-04-5245
CLIENT UITM
REF. STANDARD AWSD1.1
WPS NO. UITM-WPS-13-03 POSITION 1G
UITM-PQR-13-03 WELDING DATE
UITM-WQT-13-03
MATERIAL A B WELDING A B
BASE METAL TYPE Plate Plate PROCESS GMAW GMAW
MATERIAL C. Steel C. Steel POLARITY DCRP DCRP
SPECIFICATIONS A36 A36 CONSUMABLE
SIZE ( IN or mm ) 180 X 40 180 X 40 TYPE Solid Wire Solid Wire
HEAT NO. N/A N/A FLUX -- --
THICKNESS (mm) 6.0 6.0 SPECIFICATIONS ER70S ER70S
DIAMETER (mm) N/A N/A SFA A5.18 A5.18

SIZE (mm) 0.8 0.8

TRADE NAME MG1 MG1
BRAND Southern Southern
SHIELDING GAS CO2 CO2
FLOWRATE 25 25
Coupon No FB-01 RB-01
Root/Face/Side FACE ROOT
Width mm 40.0 40.0
Thickness mm 6.0 6.0
Bending Former dia. mm 50 50
Test Bending angle 180 180
Inspection report < 3.0 mm < 3.0 mm
Result PASS PASS

Remarks Complied to the quality rquirement of AWS D1.1

Coupon No
Root/Face/Side
Width mm
Bending Thickness mm
Test Former dia. mm
Bending angle
Inspection report
Result
Remarks

Approval

Test Date
 FRACTURE & NICK BREAK
TEST REPORT

REPORT NO UITM-N-13-03
SUBJECT Lab 2: Preparation of WPS for carbon steel by GMAW
PROJECT 4th year Mechanical Engineering WELDER NAME ZAINI RUKAINI BIN ROSLI
CONTRACTOR N/A I/C NO 890126-04-5245
CLIENT UITM
REF. STANDARD AWSD1.1
WPS NO. UITM-WPS-13-03 POSITION 1G
UITM-PQR-13-03 WELDING DATE
UITM-WQT-13-03
MATERIAL A B WELDING A B
BASE METAL TYPE Plate Plate PROCESS GMAW GMAW
MATERIAL C. Steel C. Steel POLARITY DCRP DCRP
SPECIFICATIONS A36 A36 CONSUMABLE
SIZE ( IN or mm ) 180 X 40 180 X 40 TYPE Solid Wire Solid Wire
HEAT NO. N/A N/A FLUX -- --
THICKNESS (mm) 6.0 6.0 SPECIFICATIONS ER70S ER70S
DIAMETER (mm) N/A N/A SFA A5.18 A5.18

SIZE (mm) 0.8 0.8

TRADE NAME MG1 MG1
BRAND Southern Southern
SHIELDING GAS CO2 CO2
FLOWRATE 25 25
Coupon No

Type
Thickness mm
Fracture Width mm
Test Fracture Location
Inspection report
Result
Remarks

Coupon No. NB-01 NB-02

Type NICK NICK

Thickness mm
Nick-break Width mm
Test Fracture Location
Inspection report

Result
Remarks

Approval

Test Date
 TENSILE TEST REPORT

REPORT NO UITM-T-13-03
SUBJECT Lab 2: Preparation of WPS for carbon steel by GMAW
PROJECT 4th year Mechanical Engineering WELDER NAME ZAINI RUKAINI BIN ROSLI
CONTRACTOR N/A I/C NO 890126-04-5245
CLIENT UITM
REF. STANDARD AWSD1.1
WPS NO. UITM-WPS-13-03 POSITION 1G
UITM-PQR-13-03 WELDING DATE
UITM-WQT-13-03
MATERIAL A B WELDING A B
BASE METAL TYPE Plate Plate PROCESS GMAW GMAW
MATERIAL C. Steel C. Steel POLARITY DCRP DCRP
SPECIFICATIONS A36 A36 CONSUMABLE
SIZE ( IN or mm ) 180 X 40 180 X 40 TYPE Solid Wire Solid Wire
HEAT NO. N/A N/A FLUX -- --
THICKNESS (mm) 6.0 6.0 SPECIFICATIONS ER70S ER70S
DIAMETER (mm) N/A N/A SFA A5.18 A5.18

SIZE (mm) 0.8 0.8

TRADE NAME MG1 MG1
BRAND Southern Southern
SHIELDING GAS CO2 CO2
FLOWRATE 25 25
Coupon No. T-01 T-02
Diameter mm N/A N/A
Thickness mm 6 6
Width mm 12.17 12.2
Tensile Area mm2 73.0 73.0
Test Gauge mm 60 60
Elongated length mm N/A N/A
Yield Load kg 2200
Strength kg/mm2 30.1 0.0
Mean kg/mm2 30.1
Standard kg/mm2 28.0
Tensile Load kg 2500
Strength kg/mm2 34.2 0.0
Mean kg/mm2 34.2
Standard kg/mm2 40.0
Elongation % N/A N/A
Mean % N/A
Standard % 25.0
Fracture location WM --
Report WELD STRENGTH IS BETTER THAN BASE METAL

Result FAILED
REMARKS Rejected according to the requirement of AWS D1.1
Approval

Test Date
 MACRO ETCHING TEST REPORT

REPORT NO UITM-M-13-03
SUBJECT Lab 2: Preparation of WPS for carbon steel by GMAW
PROJECT 4th year Mechanical Engineering WELDER NAME ZAINI RUKAINI BIN ROSLI
CONTRACTOR N/A I/C NO 890126-04-5245
CLIENT UITM
REF. STANDARD AWSD1.1
WPS NO. UITM-WPS-13-03 POSITION 1G
UITM-PQR-13-03 WELDING DATE
UITM-WQT-13-03
MATERIAL A B WELDING A B
BASE METAL TYPE Plate Plate PROCESS GMAW GMAW
MATERIAL C. Steel C. Steel POLARITY DCRP DCRP
SPECIFICATIONS A36 A36 CONSUMABLE
SIZE ( IN or mm ) 180 X 40 180 X 40 TYPE Solid Wire Solid Wire
HEAT NO. N/A N/A FLUX -- --
THICKNESS (mm) 6.0 6.0 SPECIFICATIONS ER70S ER70S
DIAMETER (mm) N/A N/A SFA A5.18 A5.18

SIZE (mm) 0.8 0.8

JOINT Joint Type V Butt TRADE NAME MG1 MG1
DESIGN Position Flat BRAND Southern Southern
SHIELDING GAS CO2 CO2
FLOWRATE 25 25

cap
Photo
root

Coupon No. 1
STANDARD REQUIREMENT MEASURE REPORT RESULT
AWSD1.1 (mm)
ROOT Full fusion FULL
MACROGRAPH LEG size (V)(mm) N/A
INSPECTION Leg siz (mm) N/A
THROAT (mm) > Thickness YES
REPORT SURFACE ContourEVEN YES
Crack (mm) NIL NIL
Undercu (mm) Max 0.8mm NIL
Convexi (mm) Max 2.4 mm YES
Inclusion / Cavit Max 2.4 mm NIL
Surface defects Max 1.6 mm --

RESULT Evaluation PASSED

Remarks Acceptable according to the requirement of AWS D1.1
INSPECTOR

DATE
 MATERIAL COMPOSITION REPORT

REPORT NO UITM-C-13-03
SUBJECT Lab 2: Preparation of WPS for carbon steel by GMAW
PROJECT 4th year Mechanical Engineering WELDER NAME ZAINI RUKAINI BIN ROSLI
CONTRACTOR N/A I/C NO 890126-04-5245
CLIENT UITM
REF. STANDARD AWSD1.1
WPS NO. UITM-WPS-13-03 POSITION 1G
UITM-PQR-13-03 WELDING DATE
UITM-WQT-13-03
MATERIAL A B WELDING A B
BASE METAL TYPE Plate Plate PROCESS GMAW GMAW
MATERIAL C. Steel C. Steel POLARITY DCRP DCRP
SPECIFICATIONS A36 A36 CONSUMABLE
SIZE ( IN or mm ) 180 X 40 180 X 40 TYPE Solid Wire Solid Wire
HEAT NO. N/A N/A FLUX -- --
THICKNESS (mm) 6.0 6.0 SPECIFICATIONS ER70S ER70S
DIAMETER (mm) N/A N/A SFA A5.18 A5.18

SIZE (mm) 0.8 0.8

JOINT Joint Type V Butt TRADE NAME MG1 MG1
DESIGN Position Flat BRAND Southern Southern
SHIELDING GAS CO2 CO2
FLOWRATE 25 25

PROCESS: ARC SPECTOMETRY

Coupon No. 1
ELEMENT % % ELEMENT % %
SPOT 1 (Weld) SPOT 2 (Base) SPOT 1 (Weld) SPOT 2 (Base)
C 0.103 V 0.027
Si 0.540 W
MATERIAL Mn 0.850 Pb
P 0.004 Mg
COMPOSITION S 0.013 B
Cr 0.067 Sn 0.006
Ni 0.063 Zn
Mo 0.071 As
Al 0.026 Bi
Cu 0.218 Ca
Co 0.007 Ce
Ti Zr
Nb 0.003 Fe 98.100
RESULT Evaluation
Remarks Accepted according to the requirement of AWSD1.1
INSPECTOR

DATE
 HARDNESS TEST REPORT

REPORT NO UITM-H-13-03
SUBJECT Lab 2: Preparation of WPS for carbon steel by GMAW
PROJECT 4th year Mechanical Engineering WELDER NAME ZAINI RUKAINI BIN ROSLI
CONTRACTOR N/A I/C NO 890126-04-5245
CLIENT UITM
REF. STANDARD AWSD1.1
WPS NO. UITM-WPS-13-03 POSITION 1G
UITM-PQR-13-03 WELDING DATE
UITM-WQT-13-03
MATERIAL A B WELDING A B
BASE METAL TYPE Plate Plate PROCESS GMAW GMAW
MATERIAL C. Steel C. Steel POLARITY DCRP DCRP
SPECIFICATIONS A36 A36 CONSUMABLE
SIZE ( IN or mm ) 180 X 40 180 X 40 TYPE Solid Wire Solid Wire
HEAT NO. N/A N/A FLUX -- --
THICKNESS (mm) 6.0 6.0 SPECIFICATIONS ER70S ER70S
DIAMETER (mm) N/A N/A SFA A5.18 A5.18

SIZE (mm) 0.8 0.8

TRADE NAME MG1 MG1
BRAND Southern Southern
SHIELDING GAS CO2 CO2
FLOWRATE 25 25
Joint Type V Butt
JOINT Pass 2
DESIGN Position 1G
Direction Flat
Groove angle 60
Root gap 2
Root face 2

VICKERS HARDNESS VALUES

LOCATION BASE METAL HAZ WELD METAL HAZ BASE METAL

LOCATION

A-B 146.3 159.1 171 162.6 145.5

HIGHEST VALUE 171

LOCATION WELD METAL
REMARKS ACCEPTED

CONCLUSION Acceptable according to the requirement of AWS D1.1

INSPECTOR

DATE
 IMPACT TEST REPORT

REPORT NO UITM-I-13-03
SUBJECT Lab 2: Preparation of WPS for carbon steel by GMAW
PROJECT 4th year Mechanical Engineering WELDER NAME
CONTRACTOR N/A I/C NO
CLIENT UITM
REF. STANDARD AWSD1.1
WPS NO. UITM-WPS-13-03 POSITION
UITM-PQR-13-03 WELDING DATE
UITM-WQT-13-03
MATERIAL A B WELDING
BASE METAL TYPE Plate Plate PROCESS
MATERIAL C. Steel C. Steel POLARITY
SPECIFICATIONS A36 A36 CONSUMABLE
SIZE ( IN or mm ) 180 X 40 180 X 40 TYPE
HEAT NO. N/A N/A FLUX
THICKNESS (mm) 6.0 6.0 SPECIFICATIONS
DIAMETER (mm) N/A N/A SFA

SIZE (mm)
TRADE NAME
BRAND
SHIELDING GAS
FLOWRATE
Joint Type V Butt
JOINT Pass 2
DESIGN Position 1G
Direction Flat
Groove angle 60
Root gap 2
Root face 2

CHARPY IMPACT VALUES

LOCATION BASE METAL HAZ WELD METAL

 LOCATION

A-B 51 JOULES 24 JOULES

HIGHEST VALUE 51
LOCATION BM
REMARKS

CONCLUSION Acceptable according to the requirement of AWS D1.1

INSPECTOR

DATE
by GMAW
ZAINI RUKAINI BIN ROSLI
890126-04-5245

1G

A B
GMAW GMAW
DCRP DCRP

Solid Wire Solid Wire

-- --
ER70S ER70S
A5.18 A5.18

0.8 0.8
MG1 MG1
Southern Southern
CO2 CO2
25 25

HAZ BASE METAL

ment of AWS D1.1
 Universiti ITM
40000 Shah Alam

WELDING PROCEDURE QUALIFICATION RECORDS

WPS No: UITM-WPS-13-03 PAGE
WPQR No: UITM-PQR-13-03 1 of 2
Applicable Code AWSD1.1
1 Process Process 1 GMAW Process 2 GMAW
Side Material Spec Type Heat No
2 Material Side 1 C. Steel A36 Plate N/A
Side 2 C. Steel A36 Plate N/A
Specified Min. Tensile Strength 42,000 psi
3 Size Side 1 Diameter N/A Tthickness 6.0 mm
Side 2 Diameter N/A Tthickness 6.0 mm
4 Joint Design V Butt
5 Pass (Single / Multiple) Multiple
6 Position 1G Fixed
7 Direction of Welding Root Pass Flat
Other Pass Flat
8 Time lapse between pass Maximum 10 min
9 Type of Line up clamp N/A
10 Removal of Line-up Clamp N/A
11 Cleaning Power brush
13 Heat Treatment Preheat Type N/A Temperature N/A deg C
Interpass Type N/A Temperature N/A deg C
PWHT Type N/A Temperature N/A deg C
Stress Relief Type N/A Temperature N/A deg C
14 Shielding Gas Root Pass CO2 Flowrate 25 (l/min)
Other pass CO2 Flowrate 25 (l/min)
15 Shielding Flux Root Pass -- Code no --
Other pass -- Code no --
16 Consumable type Root Pass Solid Wire Code no ER70S Diameter 0.8 mm
Other Pass Solid Wire Code no ER70S Diameter 0.8 mm
17 Range of Travel Speed Root Pass 2-8 cm/min
Other Pass 2-8 cm/min

Welding location

Pass No: 1 2
Root Cap
Welding Process GMAW GMAW
Electrode Type Solid Wire Solid Wire
Filler Metal AWS No ER70S ER70S
SFA No A5.18 A5.18
Dia. (mm) 0.8 0.8
Current Polarity DCRP DCRP
Amp. (A) 140 140
Arc Voltage Volt (V) 20 20
Speed (mm/sec) 2.7 2.7
Direction Flat Flat
Temperature N/A N/A
Heat input 1.04 1.04
Contractor Inspector Witness

Date
 Universiti ITM
40000 Shah Alam

WELDING PROCEDURE QUALIFICATION RECORDS

WPS No: UITM-WPS-13-03 PAGE
WPQR No: UITM-PQR-13-03 1 of 2

REFERENCE REMARKS

1 Guided Bend Test Report No. UITM-B-13-03 PASSED

2 Nick Break Test report No. UITM-N-13-03 --

3 Tensile Test Report No. UITM-T-13-03 FAILED

4 Macro Etching Report No. UITM-M-13-03 PASSED

5 Fracture Test report No. N/A N/A

6 Radiographic Inspection Report No. UITM-X-13-03 PASSED

7 Dye Penetrant Test Report No. N/A N/A

8 Other Test HARDNESS UITM-H-13-03 PASSED

Name I/C No Stamp No

Welder 1 ZAINI RUKAINI BIN ROSLI 890126-04-5245 N/A
Welder 2

Test conducted by: UITM Test Date

We certify that the statement in this record are correct and that the welds were prepared, welded
and tested in accordance with the requirrement of AWSD1.1

CONTRACTOR THIRD PARTY

ON HOLD- prepare for retest

WITNESS APPROVED BY
 Universiti ITM
40000 Shah Alam

WELDER QUALIFICATION RECORDS

WQT No: UITM-WQT-13-03 PHOTO
WPS No: UITM-WPS-13-03 (if any)
PQR No: UITM-PQR-13-03
X-ray Report
Welder Name ZAINI RUKAINI BIN ROSLI Test date 12/30/1899
I/C No 890126-04-5245 Expiry date 6/30/1900 RANGE OF APPROVAL
Applicable Code
1 Process Process 1 GMAW Process 2 GMAW
2 Material Side 1 C. Steel Spec A36 Type Plate
Side 2 C. Steel Spec A36 Type Plate
Specified Min. Tensile Strength 42,000 psi
3 Size Side 1 Diameter N/A Tthickness 6.0 mm
Side 2 Diameter N/A Tthickness 6.0
4 Joint Design V Butt
5 Pass (Single / Multiple) Multiple
6 Position 1G Fixed
7 Direction of Welding Root Pass Flat
Other Pass Flat
8 Time lapse between pass Maximum 10 min
9 Type of Line up clamp N/A
10 Removal of Line-up Clamp N/A
11 Cleaning Power brush
13 Heat Treatment Preheat Type N/A Temperature N/A deg C
Interpass Type N/A Temperature N/A deg C
PWHT Type N/A Temperature N/A deg C
Stress Relief Type N/A Temperature N/A deg C
14 Shielding Gas Root Pass CO2 Flowrate 25 (l/min)
Other pass CO2 Flowrate 25 (l/min)
15 Shielding Flux Root Pass -- Code no --
Other pass -- Code no --
16 Consumable type Root Pass Solid Wire Code no ER70S Diameter 0.8 mm
Other Pass Solid Wire Code no ER70S Diameter 0.8 mm
17 Range of Travel Speed Root Pass 2-8 cm/min
Other Pass 2-8 cm/min

Welding location

Pass No: 1 2 3
Root Cap
Welding process GMAW GMAW
Electrode Type Solid Wire Solid Wire
Filler Metal AWS No ER70S ER70S
SFA No A5.18 A5.18
Dia. (mm) 0.8 0.8
Current Polarity DCRP DCRP
Amp. (A) 130-150 130-150
Arc Voltage Volt (V) 15-28 15-28
Travel Speed (mm/sec) 2- 6 2- 6
Direction Flat Flat
Contractor Third Party Witness

ON HOLD- prepare for retest

Date
 Universiti ITM
40000 Shah Alam

WELDING PROCEDURE SPECIFICATIONS

WPS No: UITM-WPS-13-03 PAGE
WPQR No: UITM-PQR-13-03 1 of 1
Applicable Code
1 Process Process 1 GMAW Process 2 GMAW
2 Material Side 1 C. Steel Spec A36 Type Plate
Side 2 C. Steel Spec A36 Type Plate
Specified Min. Tensile Strength 42,000 psi
3 Size Side 1 Diameter N/A Thickness 6.0 mm
Side 2 Diameter N/A Thickness 6.0 mm
4 Joint Design V Butt
5 Pass (Single / Multiple) Multiple
6 Position 1G Fixed
7 Direction of Welding Root Pass Flat
Other Pass Flat
8 Time lapse between pass Maximum 10 min
9 Type of Line up clamp N/A
10 Removal of Line-up Clamp N/A
11 Cleaning Power brush
13 Heat Treatment Preheat Type N/A Temperature N/A deg C
Interpass Type N/A Temperature N/A deg C
PWHT Type N/A Temperature N/A deg C
Stress Relief Type N/A Temperature N/A deg C
14 Shielding Gas Root Pass CO2 Flowrate 25 (l/min)
Other pass CO2 Flowrate 25 (l/min)
15 Shielding Flux Root Pass -- Code no --
Other pass -- Code no --
16 Consumable type Root Pass Solid Wire Code no ER70S Diameter 0.8 mm
Other Pass Solid Wire Code no ER70S Diameter 0.8 mm
17 Range of Travel Speed Root Pass 2-8 cm/min
Other Pass 2-8 cm/min

Welding location

Pass No: 1 2
Root Cap
Welding Process GMAW GMAW
Electrode Type Solid Wire Solid Wire
Filler Metal AWS No ER70S ER70S
SFA No A5.18 A5.18
Dia. (mm) 0.8 0.8
Current Polarity DCRP DCRP
Amp. (A) 130-150 130-150
Arc Voltage Volt (V) 15-28 15-28
Speed (mm/sec) 2- 6 2- 6
Direction Flat Flat
Temperature N/A N/A
Heat input N/A N/A
Contractor Third Party Owner

ON HOLD- prepare for retest

Date
CONTENT OF PROJECT REPORT

a) Content of report
b) List of figures, photos, diagram, tables

1.0 Title: Development of Welding Procedure Specifications -

Pipe fillet welding in 2F position by SAW

1.1 Introduction
1.1.1 Procedure of developing a WPS
Process of development:
PWPS, selection, preparation, training, welding, VI, NDT, DT= (FF,M,H), PQR, WQTR, WPS

1.1.2 Develop the PWPS

Justify the selection of process, material, consumable, choice of welding conditions,
acceptable range of heat input

1.1.3 Before welding

o PWPS + review / justify the selection
o Study the requirements of code / standard
o Select and prepare material, + arc spectometry of material & consumable
o arc spectometry to confirm material & consumable
o Select and prepare welding process
o Select and prepare welding consumable
o Select and prepare measuring instrument
o Joint design - preparation, cutting, machining
o Welder training / welding operator training
o Prepare the welding conditions instruction table
o Prepare the welding jig, flux container, clamping system, toolings
o Safety preparation, protection from wind etc

1.1.4 During welding

o Monitor the compliance of welding conditions
o Record data of actual welding condition
o Inspection during welding
o Monitor quality of root pass, hot pass, cap-pass etc

1.1.5 After welding

o Inspection of finished welding
o NDT, evaluation and reporting
o Marking of location for DT
o Prepare DT
o DT, evaluation and reporting

1.1.6 Documentation
o Documentation of PWPS, Material test report, Weld records, VI, NDT, DT (FF, M, H)
o Documentation of PQR, WQTR, WPS.
1.2 Required information
1.2.1 The importance of PWPS
Reduce risk of trial and error
Starting the development of WPS based on the advice from expert

1.2.2 The importance of WPS

Evidence of technology and know-how,
Knowledge to produce quality welding, tested and approved procedure
Fulfilled the requirements of Code and Standard,
Fulfilled the requirement of quality assurance procedure, client, insurance and statutory by-laws

1.2.3 The importance of PQR

PQR show the record of actual welding condition
Record of all test reports

1.2.4 The inmportance of WQT

Company can undertake project only when Welder has valid qualification and skill

1.3 Welding process:

1.3.1 Process diagram ( SMAW / SAW / GMAW / FCAW / GTAW )

1.3.2 Principle of welding process:
Describe the process, advantages, disadvantages, application, , + diagram

System drawing Photo Diagram

All extracts must have the correct reference

1.3.3 Estimation of welding deposition by calculation

Place this in
Calculate the weld deposition and compare it with the actual measurement Lab report
1.3.4 Significance of HI Range: 0.7 - 3.5 KJ mm sec
Low HI = poor fusion and penetration = describe _____
High HI = poor toughness, low ductility = describe _____
Place this in
Lab report

1.3.5 Significance of electrode orientation

Leading angle
Electrode arc lead ahead of the molten pool
Shallow penetration, lower reinforcement profile

90 deg angle
Electrode arc directly above the molten pool
Medium penetration, medium reinforcement

Trailing angle
Electrode arc pushes molten pool against the weld deposit
Deeper penetration, higher reinforcement profile

1.3.6 Significance of electrode polarity

DCEP

Place this in
Lab report
DCEN

AC

DCEP AC DCEN

1.3.7 Significance of welding current

Increase in welding current causes
Deeper penetration
Wider bead
More weld metal deposit
Low A High A
1.3.8 Significance of welding speed
Increase in welding speed causes
Shallower penetration
Narrower bead
Lower weld metal deposit
Low S High S
1.3.9 Significance of arc voltage / arc length
Low voltage cause shallow penetration, small width, high reinforcement
High voltage causes shallow penetration, wide bead, low penetration
Medium voltage causes normal penetration, width and reinforcement
 Low V High V
1.3.10 Simulation of the butt welding by SYSWELD

Step by step details, show the heat transfer, distortion profile etc

1.3.11 Program to operate the robot

Step by step details, wirte the program

1.4 Cutting process

1.4.1 Principle of cutting process 1
Describe the process, advantages, disadvantages, application, , + diagram
Diagram Photo

1.4.2 Principle of cutting process 2

Describe the process, advantages, disadvantages, application, , + diagram
Diagram Photo
2.0 Methodology in development of WPS
2.1 BEFORE WELDING

2.1.1 PWPS Photo of PWPS

List the information given in PWPS

2.1.2 Welding process:

Process ( SMAW / SAW / MAG / FCAW / GTAW )
List specifications of welding process Photo of welding
Set-up, polarity, earthing condition etc process

2.1.3 Welding material: (Selection and preparation)

Type of material_______
Specification of base metal _____________
Characteristic / properties of material

2.1.4 Material composition test (report from arc spectrometry test)

Preparation of arc spectro coupon
Test procedure
Display spectometry report (photo)
Discussion and conclusion

Photo of machine Photo of coupons Table of element Table of element Material Report
(Base metal ) (weld metal) (Mini)

2.1.5 Material preparation

Photo of material prep

Preparation: Sawing, milling, grinding etc

Size: 150mm X 300mm X 2 no Thickness ( 6 - 12 mm) ________
2.1.6 Joint design

Joint design

Joint design:
Size: Length of weld
Groove angle _____, ___ bevel angle_____,
Root Gap_N/A____ Root Face__n/a_
Fillet angle__N/A___ Desired leg size__N/A___

Desired passes_________

2.1.7 Joint preparation

Describe the preparation process = list the cutting process and preparation process
Measure, cutting, tacking, preparing
Preparation: Milling bevel 30 deg, Root face 1mm Root gap 2.5mm
Photo of
Photo of assemble and
Photo of cutting Photo of
measuring tools tacking
machining

2.1.8 Welding consumable

Verification of consumable, Size, specification and preparation (electrode, filler, flux, gas)
Type and spec of consumable
Welding consumable used: ___________________
Wire / Electrode code = _____
Size_____
Maker______ Trade Name_______

Gas = ______ , ____ %, (If any)

Flow-rate ____ l/min
 Flux type =______ (If any)
Code no ______
Brand____ Name______

Photo of consumables Photo of Photo of Photo

Photo of gas / flux electrodes / Shielding others
wire / flux gas

Preparation of consumable (if any)

2.1.9 Welding conditions

Proposed Welding conditions: (Refer to PWPS)
Current I = _____ Voltage =_____
Welding length = __________________, welding time __________
Speed = _____ HI = ________
Temperature control (if any)
Table of welding conditions (pass 1- to pass XX)

similar to PWPS table PWPS (photo)

2.1.10 Welder training

Welder = skill training program, Welder photo & training
Skill level required for WPS
Skill training program / schedule

2.1.11 Measurement tools

Prepare measuring instrument to record time, current, voltage, etc
Essential records to be taken during development of WPS
(Current, voltage, time, shielding record, speed, H-Input)
How to measure – Multi -meter, timer, ruler,
Cut material to size (refer to code requirement)

2.1.12 Safety tools

Photo Measurement n Other

instrument accessories
2.2 DURING WELDING
Activities during welding
1 Welding of coupon
2 Monitoring of welding quality at root, inter-pass to final pass
3 Recording of actual welding conditions (Length, time speed, current, voltage, etc)
4 Calculate HI on the spot to estimate the weldability
5 Calculate deposition rate and efficiency on the spot
6 (Weight test piece after welding & take photo)

Photos of Measurement Other Welding Records

welding in instrument accesories record
progress + Speed & HI

2.2.1 Heat input calculation

HI = IxV/S
Current ________ Voltage______ Speed________ HI=________
(Get the value & unit right)

2.2.2 Weld deposition rate

2.2.3. Weld deposition efficiency
Weight before welding Use accurate weighing mchine, 3 decimals
Weight after welding
Weight of weld deposit
No of pass
Deposition rate = Weight of weld deposit / welding time
kg/hr
Wire weight / m
Wire feed rate
Welding time
Weigh of consumable issued

Deposition efficiency = weight of deposit / weight of consumable issued

2.3 AFTER WELDING

Activities after weding
2.3.1 Visual Inspection – and evaluation
The essential observation on weldment and Defect to be recorded

2.3.2 Non Destructive Testing - and evaluation

Radiography / UT - Evaluate the radiographic film, based on code requirements
 2.3.3 Destructive test, preparartion, testing and evaluation
2.3.3.1 Bending test
2.3.3.2 Tensile test
2.3.3.3 Nick break test
2.3.3.4 Macro etching tst
2.3.3.5 Hardness trst
2.3.3.6 Charpy impact test
Information on coupon:
Class: Year, Name
2.3.3.7 Etc Weight (BW) Weight (AW)
Welding onditions (Current, Voltage, Length, weld time, speed)
Consumble info (cons type, trade name, code no, diameter, flux).
2.3.4 Finishing / Repair Shielding gas, flow rate
Welding process
2.3.5 Documentation Materal (thickness

3.0 Evaluation of weldment quality

3.1 Visual inspection

Describe VI Inspect all weld surface for defects; indicate the position and length/ value
o Surface imperfection -under cut, crack, surface slag, lack of fusion
o surface profile- under-fill, reinforcement height, misalignment, surface quality,
spatter, arc strike, tool marks, bead quality, linearity,
uniformity of height
o root quality - root penetration and lack of foot fusion, excess penetration
o leg size and throat (for fillet)
o Arc stop and start, bead profile, crater quality,

Inspection tools Physical viewing in suitable lighting

ruler, welding gauge, caliper, torch light

Evaluation code - AWS D1.1, extract displayed below

Evaluation of welding based on code

No Name of flaw Position of flaw Size Size allowed by Code Result
1 Undercut 50 mm from A 25mm L, 1.0mm D 0.8mm max Failed
2 LOP Eg 100 mm from A 55mm L 25 mm Failed
only
3

Discussion: Welding failed due to deep undercut, LOP exceed 25mm allowed by code
Result : Welding is rejected according to the requirement of AWS D1.1

Prepare visual inspection report

Display copy of VI report (mini)
Photo of VI

Photo of VI report
finished weld
AWS D1.1 – visual
inspection requirements

3.2 NDT test

3.2.1 NDT Process X-ray Digital

Maker = ?, Spec of mc = ?
Describe preparation Setting of NDT: KV = ?, Contrast = ?, Distance = ? Others = ?

Process NDT Inspect all weld defects; indicate the position and length/ value

Evaluation code AWS D1.1, extract displayed below

Evaluate NDT based on code

No Name of flaw Position of flaw Size Size allowed by Code Result
1 Undercut 50 mm from A 25mm L, 1.0mm D 0.8mm max Failed
2 LOP Eg only 100 mm from A 55mm L 25 mm Failed
3

Discussion: Welding failed due to deep undercut, LOP exceed 25mm allowed by code
Result : Welding is rejected according to the requirement of AWS D1.1

Prepare NDT report

Display NDT report (mini)
Photo of NDT
Photo NDT NDT report
AWS D1.1 for NDT - X ray
- X ray
(X-ray)

3.2.2 Repeat for NDT-2 (Dye penetrant rest) if any

DISTORTION records
Compare the distortion at edge of plate with dta from
OMITTED SYSweld
3.3 Destructive tests (fill form in software -& attach with report)

Location of DT (see diagram below)

Marking for DT coupon as follow

Describe DT, preparation, Testing, Code requirement, Result and conclusion of DT

3.3.1 Bending test

Description of DT - Bending test
Root bend, Face bend, tested by pressing a former to form U shape,
Observe the surface of covex side
The preparation of DT coupons
· Number = 2 No,
· Location = one on left and right
· Size = 38 mm width, length >150 mm
Machining of DT Cutting by power saw
if length too short for cutting - Add attachment
Removes reinforcement, grind to base metal surface, transverse to
welding direction
Preparation quality for DT coupons
Polish surface for bending
- rounding all sharp edges
Info. punched on coupon : Date, test type, Joint no, test no, mark centerline,
top/ bottom, W process, W orientation
 Testing of DT
Place on hydraulic press
· Select former – diameter 50mm
· Roof bend - press on face
· Face bend – press on root,
The observation on DT coupon
Code requirement · Code – surface crack > 3.2 mm = failed
· Crack from edge > 6mm = failed
· Undercut, but no crack - OK
Observation: eg; 5 mm crack on surface

Discussion Failed
Result Rejected according to the requirement of --------

Photo of DT coupons in the process of preparing, testing and result

Table Photos
AWS D1.1 Preparation of Coupon - Bending in Result after Bend test
for Bending coupon Before progress bending report (mini)
test bending

3.3.2 Tensile = preparation, size, quality required by code, machine, observation,

photo, test report, remarks & conclusion
Description of DT - Tensile test
Tensile test coupon tested to record the Force vs Elongation, Stress vs
Strain characteristic of the material
Data on yield strength, ultimate strength, elongation and ductility can be observed
The preparation of DT coupons
Cut a sample from the weldment according to the specification in code
AWS requirement: Coupon width = 30mm, waist width 20 mm, gauge 60mm
Quantity: 2 no
Finish the coupon by polishing transverse to the welding direction, all edges
to be rounded finish

Mark the centre-line of weld, root and face, location on the weldment,
gauge and identification
Measure the width, thickness or diameter, gauge length before testing

Testing of DT
Clamp securely on tensile testing machine, pull to fracture
Record the graph of Stress and strain / Force vs elongation

The observation on DT coupon

Record the nature of the fracture
Record the location of the fracture
Record the value of yield, tensile / ultimate and fracture load
 Discussion
The test coupon failed at base metal, yield stress above the standard
UTS more than standard, test result acceptable
Result
Complied to the requirements of AWS D1.1
Photo of DT coupons in the process of preparing, testing and result

Photo of Photo of coupo Graph AWS code Mini tensile test

Photo of
coupon after test Force vs elongation requirement for report
tensile test
Stress vs strain tensile test

3.3.3 Nick break = preparation, size, quality required by code, machine, observation, photo,
test report, remarks & conclusion
Description Creation of fracture in the weld metal by nick break
Observe and evaluate the flaws in weld metal according to code of practice

Preparation od DT Cut 30mm width by power saw

Cut 5mm slot at both sides, centre of weld metal,
as shown in Fig ------, weld metal 20mm
Finishing all sharp corners by chamfering
Write the identification and coupon number, top/ root side
Testing of DT Press on hydraulic press, at the slot to fracture at the weld
Observe the crack surface for weld flaws
Describe any weld flaws and evaluate based on codes of practice
Report Eg: 3mm length flaw, 2mm porosity
Failed
Result / conclusion Rejected according to hthe requirement of code--------

AWS D1.1 Preparation Coupon Testing in View of Mini NB test

code on Nick of coupon before progress fracture report
break testing surface

3.3.4 Macro = preparation, size, quality required by code, machine, observation, photo,
test report, remarks & conclusion
Description of DT - Macrography
Weld macrography reveals the characteristic of weld metal, HAZ and the fusion boundary

The preparation of DT coupons

A cross-section of the weld is cut, polished to mirror finish
Coupon size; 20mm weld length, 30 mm width
Etched with acid / etching reagent to reveal the weld profile structure
Dried and spray with lacquer coating
 Testing of DT
Observe the condition and quality of weld crossection, fusion boundary, toes
and internal defects
Measure the reinforcement height, root penetration
Under higher magnification, the grain profile can be investigated
The observation on DT coupon
Full penetration, full fusion at boundary, no visble defects
Profile dimension acceptable to code

Discussion
Root pass: Full penetration and fusion
Cap pass: Weld reinforcement < 1.6mm, toe no undercut
Result
Acceptable acording to the requirement of AWS D1.1
Photo of DT coupons in the process of preparing, testing and result

Cutting of Polishing of Macrography Macro report AWS D1.1 Macro report

coupon coupon requirement (mini)
Etching

3.3.5 Hardness = preparation, size, quality required by code, machine, observation, photo,
test report, remarks & conclusion
Description of DT -
To determine the hardness profile across weldment
High hardness means poor ductility and crack sensitveness
Best condition is smooth hardness profile, without high hardness peak
The preparation of DT coupons
Same preparation as macro-structure etching

Testing of DT
Apply constant load on region of weldment, hard = small indentation, soft= bigger indentation
Read hardness value from respective table

The observation on DT coupon

Hardness range: 120hv to 175hv
Base metal hardness: 120hv to 150hv
HAZ hardness: 140hv to 175hv
Weld metal hardness: 130hv to 165hv

Discussion
Hardness range acceptable for good fabrication application, absence of high hardness peak
Maximum hardness: 175hv, well below 300hv maximum permitted
 Result
Acceptable acording to the requirement of AWS D1.1

Photo of DT coupons in the process of preparing, testing and result

Photo of Hardness Hardness Hardness chart AWS D1.1 Hardness

coupon test on weld report requirement report (mini)
crossection

3.3.6 Arc spectrometry = Similar to Lab test

preparation, size, quality required by code, machine, observation, photo,
test report, remarks & conclusion
Material composition (report from arc spectrometry test )

Description of DT -
Arc strike on metal will release light frequency for every individual element
By analysing the intensity of the light frequency, it can be proportioned to the composition
ratio of that element

The preparation of DT coupons

Cut a coupon size 50 X 100 mm, grind flat to display the weld metal or base metal portion

Testing of DT
Placed on the machine at the specific window for arc strike, at specific duration
The arc spectometry will be converted to individual elemental composition
Machine will display the elemental content in a simple table
The observation on DT coupon
The unique property of weld metal is the composition of the carbon, silicon and manganese etc
The unique property of base metal is the composition of the carbon, silicon and manganese etc

Discussion
The elemental content of bath sample fall within the acceptable range
Selection is aceptable for fabrication purpose
Result
Electrode composition complied to the requirement of AWS D1.1
Display spectometry report (mini)

Photo Table of element Table of element Charpy Report

(Base metal ) (weld metal) (Mini)

3.3.7 Impact test =

preparation, size, quality required by code, machine, observation, photo,
test report, remarks & conclusion
Description of DT -
When the hammer strikes the coupon, there is a loss of potential energy
The loss in energy measures the energy required to fracture the coupon
 The preparation of DT coupons
Cut coupon to size 10X10 X55, groove 45deg 2mm depth at test location
Size specified in standard

Testing of DT
Impact test at 0 degC and - 20 decC

The observation on DT coupon

Find percentage of brittle fracture
Find strength highest at ?
Lateral expansion vs strength

Discussion
Highest strength at weld metal = XXX (example)

Result
Weld metal is superior in strength than base metal

Photo of DT coupons in the process of preparing, testing and result

Photo Impact test result AWS D1.1 Impact test

requirement Report
(Mini)

4.0 Development of WPS

FORMS TO BE FILLED (All for appendix of Lab report 2)

Summarize the result of ALL tests
1) Proposed WPS for respective process
2) Records of ACTUAL welding for the respective process
3) Visual inspection report
4) NDT report (Xray, MPI etc)
5) Destructive test reports (tensile, bending, nick, macro, hardness, arc spec etc)
6) PQR and WQTR (filled up with detailed reference as required )
7) WPS (signed only if ALL tests had been passed )

Copy of PQR & WQT & WPS

PQR WQT WPS

 5.0 Project performance
The time to perform all activities should be recorded.
Prepare project schedule chart
Data required for work and time study ( )

CPM chart List of improvement to reduce cost of WPS

Project chart CPM New project chart New CPM

 6.0 REMARKS and CONCLUSION
Describe the outcome of every test conducted
Describe the project performance in development of WPS

7.0 Appendix
Display WPS/ PWPS, VI, NDT, DT, X-ray spec,
Reference Plagrism is NOT tolerated

8.0 Reference

Group report = Submit draft for correction, before final hard copy and soft copy
Individual must fill up data in individual report, before proceeding to next activity
All data to be filled while in the laboratory, NO home work

All figures, photos, diagrams, tables = must have a title and fig. no

Note about software

If date appears in a cell, click format, cell, general
If cannot type into a cell – click tools, unprotect
One WPS in a single file, another WPS use another file
Date should be in order: PWPS, welding, record, Visual, NDT, DT, PQR WQT and WPS
Inspection and result should not contradict
Visual inspection should show, sketch/photo of face and root, mark location of imperfection, then fill-in the table
Macro should have the photo + drawing of joint
PQR should have actual welding condition, not range value like in WPS or WQT
Cover page
Marking sheet
Content
List of Figures, Photos, Diagram, Tables
1.0 Title: Development of Welding Procedure Specifications

1.1 Introduction
1.1.1 Procedure of developing a WPS
Develop the PWPS

1.1.2 Preparation before welding

1.1.3 Activities during welding

1.1.4 Inspection after welding

1.1.5 Documentation
1.2 Required information

1.2.1 The importance of PWPS

1.2.2 The importance of WPS

1.2.3 The importance of PQR

1.2.4 The inmportance of WQT

1.3 Welding process:

1.3.1 Process diagram

1.3.2 Principle of welding process:

The welding process

 The advantages

The limitation

The applications

Photo Accessories
System drawing

5
1.3.3 Estimate the weld deposition by calculation

1
Area of 1 2
4
3
Area of 2
Area of 3
Area of 4
Area of 5
Total cross-section area
Length
Total volume
Density of steel
Total weight of deposit
Welding time
Deposition rate
Measured weight of deposit
Weight of wire / electrode
Weight of wire / electrode consumed
Deposition efficiency

1.3.4 Significance of HI Range:

Low heat input

High heat input

Permissible range : 0.7 - 3.5 KJ / mm

1.3.5 Significance of electrode orientation

Leading angle

90 deg angle

Trailing angle

1.3.6 Significance of electrode polarity

DCEP

DCEN

AC
1.3.7 Significance of welding current

1.3.8 Significance of welding speed

1.3.9 Significance of arc voltage / arc length

1.3.10 Simulation of welding by SYSWELD

Detailed step in simulation program

Heat transfer outcome

Video
 Distortion profile outome

Diagram

1.3.11 Robotic welding program

Detailed of programming

The program language

Robotic performance
1.4 CUTTING process

1.4.1 Principle of cutting process

Cutting process 1 Cutting process 2

The cutting process

The advantages

The limitation

The applications

Diagram
Photo Accessories
2.0 METHODOLOGY

2.1 BEFORE WELDING

2.1.1 PWPS
List the information given in PWPS

2.1.2 Welding process:

List the specifications

2.1.3 Material selection

Specifications of material

Characteristic / properties of material

 2.1.4 Material composition (report from arc spectrometry test

COUPON 1 COUPON 2
Preparation of coupon

Same method as in
Test procedure Lab repsrt

Display spectometry report

Table of element
(Base metal )

Discussion and conclusion

Photo Material
Report
(Mini)
2.1.5 Material preparation

Size:

Preparations of coupon

2.1.6 Joint design:

60 deg

1.0mm 2mm

Photo of Photo of cutting Photo of Photo of

measuring machining assemble and
tacking
2.1.7 Joint preparation:
Joint specifications

How joint is prepared

Photo of
Photo of Photo of Photo
machining
measuring tools cutting others

2.1.8 Welding consumable

Photo Photo
electrodes/ Shield gas
wire
2.1.9 Welding conditions: (Refer to PWPS)

similar to PWPS PWPS (mini)

table

2.1.10 Welder training

Identification
Training duration
Process
Material
Consumable
Quality of welding
Quantity of training
 2.1.11 Select instrument and prepare measurement

Measurement n
instrument

Photo

Safetyaccessorie
s

2.1.12 Safety tools, environment and safety attire

 2.2 DURING WELDING

2.2.1 Heat input calculation

2.2.2. Weld deposition rate

2.2.3 Weld deposition efficiency

 2.3 AFTER WELDING
Activities after welding

3.0 Evaluation of weldment quality

3.1 Visual inspection

Description

Inspection tools

Evaluation code
Evaluation of welding based on code
No Name of flaw Position of flaw Size Size allowed by Code
1
2
3

Discussion:

Result :

Photo AWS D1.1 – visual

inspection
requirements

3.2 NDT test - Radiographic test

3.2.x Repeat for NDT-2 (Dye penetrant rest)

Describe preparation Setting of NDT: KV = ?, Contrast = ?, Distance = ? Others = ?

Process NDT Inspect all weld defects; indicate the position and length/ value

Evaluation code AWS D1.1, extract displayed below

Evaluate NDT based on code
No Name of flaw Position of flaw Size Size allowed by Code Result
1
2
3

Discussion:

Result :

Photo NDT NDT report

AWS D1.1 for NDT - X ray
- X ray
(X-ray)
3.3 Destructive tests

Destructive tests location (fill form in software -& attach with report)

Location of DT (see diagram )

Marking for DT coupon as follow

Dimension and Quality of DT coupon required

3.3.1 Bending test

Description

Preparation

Testing

Report

Code
Defect Location Length Result

Result / conclusion

AWS D1.1 Preparation Coupon Testing in

code on Nick of coupon before progress
break testing
3.3.2 Tensile test

Description of DT - Tensile test

The preparation of DT coupons

Testing of DT

The observation on DT coupon

Discussion

Result

Photo of DT coupons in the process of preparing, testing and result

Photo of Photo of coupo Graph Photo of Mini tensile

coupon after test Force vs elongation tensile test test report
Stress vs strain
3.3.3 Nick break test

Preparation od DT

Testing of DT

Report

Result / conclusion

AWS D1.1 Preparation Coupon Testing in View of Mini NB test

code on Nick of coupon before progress fracture report
break testing surface
3.3.4 Macrostructure analysis

Description

Preparation od DT

Testing of DT

Report

Defect Location Length Result

Result / conclusion

Macro report
AWS D1.1 Preparation Coupon Etching (mini)
code on of coupon polishing process
Macro -cuttinf
 3.3.5 Hardness test (use the macro test piece)

Description

The preparation of coupons

Testing

The observation on coupon

Discussion

Result

Photo of Hardness test Hardness chart AWS D1.1 Hardness

Hardness
coupon on weld requirement report (mini)
report
crossection
Hardness profile graph (2 no ) add in new page
3.3.6 Arc spectrometry

Description of DT -

The preparation of DT coupons

Testing of DT

The observation on DT coupon

Discussion

Result

Display spectometry report (mini)

Photo Table of element Table of element

(Base metal ) (weld metal)
3.3.7 Impact test (Take report from FYP group)

Description of DT -

The preparation of DT coupons

Testing of DT

The observation on DT coupon

Discussion

Result

Photo of DT coupons in the process of preparing, testing and result

Charpy Report
(Mini)

Photo Impact test result AWS D1.1 Impact test

requirement Report
(Mini)
4.0 Development of WPS
Describe

Evaluation report

Report no Result
1 PWPS
2 Arc spectrometry test report
3 Viisual inspection report
4 Radiography test report
5 Bend test report
6 Nick break test report
7 Tensile test report
8 Macro etching report
9 Hardness test report
10 Impact test report
11 PQR
12 WQT
13 WPS

WPS
WQT
PQR Mini copy of reports
Charpy
Hardness
Macro
Tensile
Nick break
Bending
Radiography
Visual
Arc spectro
Record
PWPS
5.0 Project performance ORIGINAL PROJECT SCHEDULE
DATE TIME
No ACTIVITIES Start Finish Time
1 Search material, handle and measure
2 Prepare and cutting of weld coupon
3 Machining / milling of bevel
4 Assembly of weld joint
5 Weighing of test coupon (before welding)

6 Training to simulate and operating the robot

7 Set up test coupon for welding

8 Welding of coupon by robot
9 Inspection after welding
10 Marking for NDT and DT
11 Weighing of test coupon (after welding)

12 Preparation before NDT

13 NDT ( radiography test)

14 Cutting DT coupons
15 Preparing for beding test
16 Bending test
17 Preparing for nick break test
18 Nick break test
19 Preparing for tensile test
20 Tensile test
21 Preparing macro test
22 Macro test
23 Hardness test
24 Preparing for charpy coupons
25 Charpy impact test
26 Preparing WQT reoirt
27 Preeparing PQR report
28 Preparing WPS report

29 Final documentation

TOTAL
 The project CHART

The improved project performance

REMARKS and CONCLUSION

List of improvement
6.0 REMARKS and CONCLUSION
Describe the outcome of every test conducted
Describe the project performance in development of WPS

7.0 APPENDIX
Full page copy of PWPS
Arc spectrometry test report
Viisual inspection report
Radiography test report
Bend test report
Nick break test report
Tensile test report
Macro etching report
Hardness test report
Impact test report
PQR
WQT
WPS

8.0 Reference
5.0 Performance evaluation ORIGINAL PROJECT SCHEDULE
DATE TIME
No ACTIVITIES Start Finish Time

1 Search material, handle and measure

2 Prepare and cutting of weld coupon
3 Machining / milling of bevel
4 Assembly of weld joint
5 Weighing of test coupon (before welding)

6 Training to simulate and operating the robot

7 Set up test coupon for welding

8 Welding of coupon by robot
9 Inspection after welding Report
10 Marking for NDT and DT
11 Weighing of test coupon (after welding)

12 Preparation before NDT

13 NDT ( radiography test) Report

14 Cutting DT coupons
15 Preparing for bending test
16 Bending test Report
17 Preparing for nick break test
18 Nick break test Report
19 Preparing for tensile test
20 Tensile test Report
21 Preparing macro test
22 Macro test Report
23 Hardness test Report
24 Preparing for charpy coupons
25 Charpy impact test Report
26 Preparing WQT reoirt Report
27 Preeparing PQR report Report
28 Preparing WPS report Report

29 Final documentation Report

TOTAL
HEDULE

1 2 3 4 5
6 7 8 9 1 0 1 1 1 2
1 3 1 4