D10 COMMITTEE ON PIPE AND TUBE WELDING

D10 COMMITTEE ON PIPE AND TUBE WELDING

INFORMATION ON-HAND, PROBLEMS SOLVED, QUESTIONS ANSWERED

KNOWLEDGE IS POWERNO MATTER WHAT LEVEL OF THE INDUSTRY YOU WORK

THE D10 DOCUMENT COLLECTION HAS THE INFORMATION YOU SHOULD HAVE AT YOUR FINGERTIPS

MATERIALS & METHODS COVEREDAUSTENITIC STAINLESS STEELTITANIUMALUMINUMCHROME-MOLYLOCAL HEAT TREATINGROOT PASS WELDINGMILD STEELCOPPER TUBE

WELDING PROCESSGTAWSMAWFCAWGMAWBRAZING

William F. Newell, Jr. PE, IWE, Chair D10C

D10.4 RECOMMENDED PRACTICES FOR WELDING AUSTENITIC CHROMIUM-NICKEL STAINLESS STEEL PIPE AND TUBING

AWS D10.4to provide information which may be used to avoid, or at least minimize, difficulties in welding austenitic stainless steel piping and tubing.

AWS D10.4 - UsesOften overlookedExcellent resource for:Developing Corporate Procedures & SpecificationsTraining Engineers, Supervision and WeldersGeneral Reference Guide

AWS D10.4 - HistoryFirst 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 - HistoryIn 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 - HistoryIn 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 - HistoryThe 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 - ContentBase Metals & Weld Filler MetalsFerriteWelding Processes, Technique & ProblemsDissimilar JoiningInspectionSafety

AWS D10.4 Base MetalsAustenitic300-seriesSuper Austenitic4% & 6% MoHigh CarbonHX Grades

Coming !D10.18 (DRAFT)Guide for Welding Ferritic/Austenitic Duplex Stainless Steel Piping and Tubing

Don ConnellWelding EngineerDetroit Edison CompanyD10.6 RECOMMENDED PRACTICES FOR GAS TUNGSTEN ARC WELDING OF TITANIUM PIPING AND TUBING

Applications for Ti Pipe & TubeWhere Ti is selected for its corrosion resistance rather than its high strength to weight ratioChemical processingPetrochemicalDesalinationPower generation plantsNavy to replace Cu-Ni in seawater piping

Process-GTAWOther processes may be used to weld Ti but are not covered in this recommended practice

Base Metals6 grades commonly used for piping, all single phase alphaRef: ASTM B337 (seamless & welded pipe) & B338 (seamless & welded tubing)Replaced by ASTM B861 and B862

Critical Factors in WeldingCleanliness-proper means of mechanical and chemical cleaning using acids and solventsProtection from contaminants at elevated temperaturesTrailing shieldsRoot shieldingChamber welding

Quality ControlSimple tests to check the process before welding & the finished weldmentDescribes how weld color is an indication of weld quality

Other ReferencesAWS G2.4 to be published this yearAddresses CP and Ti alloys, such as Ti-6Al-4VHelpful guide in base metal selectionOther welding processes includedTables of reference documents

Tony Anderson ESAB Welding & CuttingD10.7 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 AlloysOnly one filler alloy may be optimum for a specific applicationWhen 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 anodizingPost Weld Heat TreatmentFiller Alloy Selection Primary Characteristics WSDCTM**

Hot Weld CrackingHot Cracking On 2014 Base Alloy Plate Adjacent To A Gas Tungsten Arc (GTA) Welded 4043 Alloy Fillet

Weld Cracking - HOTChoice Of Filler Metal

Lower Melting & Solidification Point - MoltenDuring Maximum Contraction Stresses

Smaller Freezing ZoneAvoid 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

COMPOSITION OF WELD - PERCENT ALLOYING ELEMENTRELATIVE CRACK SENSITIVITY

Dilution Effect On Weld Composition

60% Filler Metal40% Base Metal20% Filler Metal80% Base Metal1.7% Mg3.2% MgBase Plate 6061Filler Metal 5356

Weld Strength - Groove WeldsThe Heat Of Welding Softens theAluminum Base Alloy Adjacent To The WeldIn Most Groove Weldsthe H.A.Z. of the Base Alloy Will Controlthe As-welded Tensile Strength of the Joint

Heat Affected Zone

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 - UnaffectedHeat 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

Hardness Profiles of 6061-T6

Distance From Weld InterfaceHardness REMade At Three Heat Inputs

Weld Strength - Fillet WeldsThe Shear Strength Of FilletWelds Is The Significant Factor AndIs Controlled By The Shear StrengthThrough The Weld Metal5356 Produces Greater FilletWeld Strength In The As WeldedCondition Compared To 4043

Shear Strength

TRANSVERSE Fillet Size (Inch)Shear StrengthLBS. Per Linear Inch

Shear StrengthTypical Shear Strengths Of Fillet WeldsFiller Alloy

110023194043464351835356555455565654LongitudinalShearStrength( Ksi )

7.516.011.513.518.517.015.020.012.0Transverse Shear Strength( Ksi )

7.516.015.020.028.026.023.030.018.0

Fracture CharacteristicsHeat - Treatable AlloysRatio =Tear ResistanceUnit PropagationEnergy In.-lb. / In3Notch Tensile StrengthTensile Yield Strength

Corrosion Facts As WeldedAlloy 7075-T6 Welded With 5356 Filler-849mv-876mv-900mv-810mvPost Weld Heat Treated and Aged-810mv-810mv-840mv-806mvNote: Fusion Zone Mechanical Properties Not Restored to PreWeld Properties

Color Match After AnodizeMRating Scale: A - BRatings Scale Measures Uniformity Of ColorComparing Base Alloy And Weld MetalAfter Anodizing.Either There Is A Good Or Reasonable MatchOr There Is Not.A Blank Space Indicates No Reasonable Match.

Color Match After Clear AnodizeBase Metal: 6061

Post Weld Heat TreatmentFiller 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.

ConclusionCan 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 componentFiller 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 - UsesOften overlookedExcellent resource for:Developing Corporate Procedures & SpecificationsTraining Engineers, Supervision and WeldersGeneral Reference Guide

AWS D10.8 - HistoryFirst presented in 1961 as a Committee Report by the AWS Committee on Piping and Tubing. Revised in 1978 and became a Recommended PracticeSubsequent revisions/reaffirmations in 1986 and 1996

AWS D10.8 - ContentBase Metals Weld Filler MetalsJoint Design & Preparation (purging)PreheatingPost Weld Heat TreatmentRepair/Maintenance of Service Exposed MaterialSafety

AWS D10.8 Base MetalsC-SteelC-Mo1-1/4Cr-Mo2-1/4Cr-Mo5Cr-Mo7Cr-Mo9Cr-Mo (Standard Grade Only)

AWS D10.8 Filler MetalRecommendations ProcessAWS Classification Options [C, CrMo & Ni-base]Similar v. Dissimilar

AWS D10.8 Priorities !Preaheat w/recommendationsInterpass 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 USAD10.10RECOMMENDED PRACTICES FOR LOCAL HEATING OF WELDS IN PIPING AND TUBING

Definition of Heat TreatmentHeat 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 TreatingElectrical Resistance

Induction

Combustion / Flame

Quartz Lamps

Exothermic Kits.

Electrical Resistance

Inductive Heating

Combustion / Flame

Quartz Lamps

Reasons for Localized Heat TreatingBake Out

Preheating and Inter-pass Temperatures

Post Heating

Post-weld Heat Treatment

Comparison of Heating ProcessesAttributeApplicability to bake-outApplicability to preheat/inter-passApplicability to postheatingApplicability to PWHT

Induction - Resistance Yes Yes

Yes Yes

Yes Yes

Yes Yes

Advantages and disadvantages of heating processesInduction HeatingAdvantages 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 processesElectrical 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 heatingUniform product qualityIncreased surface wear-proof characteristicsIncreased material fatigue strengthMinimum strain due to local surface hardeningVery 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 forRoot Pass Weldingof Pipe Without Backing

AWS D10.11 KeywordsRoot pass welding, pipe, gas purging, consumable insert, gas tungsten arc welding, gas metal arc welding, shielded metal arc welding

AWS D10.11 IntroductionThis 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 IntroductionJoint 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 IntroductionThis standard is a best practices guide to making high-quality pipe butt welds where backing cannot be usedWelders should have excellent reasons for deviating from what this standard recommends

AWS D10.11What is Root Pass Welding?Lets look at some root passes. . . .

AWS D10.11A single-vee Butt weld between two pipes

AWS D10.11Root pass on a Socket Weld

AWS D10.11Root pass on a Double Vee-Groove Weld

AWS D10.11All of these Root Passes are on backing

AWS D10.11Take away the Backing Strip and you have a weld without backing. . . .

Welding without BackingYou now have a pool of liquid metal hanging in space suspended between the ends of two pipes. . .

Welding without BackingTorchBlast the arc force through the root opening and melt the edges of the metal, then fill the opening with filler metal

Welding without BackingElectrodeBlast the arc force through the root opening and melt the edges of the metal, then fill the opening with filler metal

Effect of Included AngleLARGE 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 AngleSMALL included angle holds the electrode away from the root and makes it difficult to direct the arc into the root.

Full Root PenetrationContinuous 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 poolLongitudinal Section of a pipe jointGravity

Forces on the weld poolLongitudinal Section of a pipe jointSurface Cohesion (wetting) between the weld pool and the solid metal

Forces on the weld poolLongitudinal Section of a pipe jointThe 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 poolLongitudinal Section of a pipe jointIf 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 DesignRoot Face (Land)

Parts of a Groove Weld Joint DesignRoot Opening (Root Gap)

Root Opening vs. Root FaceThick Root FaceThin Root FaceSmall Root opening Incomplete PenetrationProportional Root opening Complete PenetrationExcessive Root opening Root concavity or burn-through

Root Face ThicknessRoot Opening1/83/321/161/83/321/16Root opening - Root face thickness relationship

CleaningCleanliness is important in all welding, but it is especially important in root pass welding.Contamination affects wetting which affects bead shape.

Purging

PurgingA 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 purgingPurging time

PurgingThe 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 RootWelding Technique for Consumable InsertMaintaining purge during welding

Fitting and tack weldingSize, spacing, feathering endsRoot 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 endGrinding methods

GTAW Joint design and fit up

GTAW Purge containmentArc initiationKeyhole techniqueWire feed techniquesOrientation of torch and filler

GTAW

GTAW

GTAWWalking the CupWelding with zero root opening (autogenous welding)Welding in different positionsUsing consumable inserts

Consumable InsertsClass 1 Insert, formerly the EB (Electric Boat) or A type insert.1/32 maximum mismatch

Consumable InsertsClass 2 Insert, formerly the J type insert.1/16 maximum mismatch

Consumable InsertsClass 3 Insert, formerly the Grinnell or flat insert.1/16 maximum mismatch

Consumable Inserts

SMAWCellulosic Electrodes (EXX10, EXX11)Low Hydrogen Electrodes (EXX15, EXX16, EXX18)Rutile electrodes (E6013)

GMAWJoint designFit-upWelding parameters

Fill PassesUse any suitable processDont melt through the root

AluminumTungsten type, shape of tipShielding gas cups, lensesPower suppliesTechniquesRecommended joint design

Aluminum

Machine and AutomaticNot much said

Summary AWS D10.11 gives very specific recommendations about techniques that have proven successful in making pipe welds without backingRecommendations should be familiar to welders supervisionRecommendations should not be take lightly

Alan BeckettD10.12 RECOMMENDED 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 ProcessesSMAWGTAWGMAWFCAW

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 Associationof Plumbers & PipefittersD10.13RECOMMENDED 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 cleanableThese 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 NotesD10.13 is a Recommended Practice developed to work with NFPA 99C. All recommendations have been used in actual jobsite conditions with a 100% success rateThe use of these practices have produced consistent profitable results

Needed EquipmentUse and CareTorch SelectionTube CuttingPurge Monitoring

ConsumablesPre Braze Joint Cleaning Pre Braze Chemical CleaningPost Braze CleaningBCuP Brazing AlloysBag 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 MethodsPurging 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

*WHAT WOULD YOU EXPECT THE STRUCTURE TO LOOK LIKE. IN EACH OF THE AREAS?

*WHICH WOULD BE BETTER. ONE PASS WITH LARGER DIAMETER WIRE OR MULTI PASS WITH SMALL DIAMETER WIRE

-DEPENDS UPON WHAT IS EXPECTEC OF WELD