D10 COMMITTEE ON PIPE AND TUBE WELDING INFORMATION ON-HAND, PROBLEMS SOLVED, QUESTIONS ANSWERED.

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.


• 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


• 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. . .


Torch

Blast the arc force through the root opening and melt the edges of the metal, then fill the opening with filler metal


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


Gravity



Surface Cohesion (wetting) between the

weld pool and the solid metal



The arc must melt both edges of the root face

and the weld pool must fill the gap without

becoming too large



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

• 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.


Consumable Inserts

Class 3 Insert, formerly the “Grinnell” or flat insert.


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 [email protected] YOU FOR ATTENDING AND ENJOY THE AWS SHOW

D10 COMMITTEE ON PIPE AND TUBE WELDING INFORMATION ON-HAND, PROBLEMS SOLVED, QUESTIONS ANSWERED.

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Transcript of D10 COMMITTEE ON PIPE AND TUBE WELDING INFORMATION ON-HAND, PROBLEMS SOLVED, QUESTIONS ANSWERED.