AS 3992:2020
AS 3992:2020
p26 - EV
p55 - PQR testing
p90 - welders
p101 - PTP tests
Pressure equipment—Welding and
brazing qualification
AS 3992:2020
Australian Standard®
Pressure equipment—Welding and
brazing qualification
Originated as AS 3992—1992.
Previous edition AS/NZS 3992:2015.
Revised and redesignated as AS 3992:2020.
COPYRIGHT
© Standards Australia Limited
All rights are reserved. No part of this work may be reproduced or copied in any form or by
any means, electronic or mechanical, including photocopying, without the written
permission of the publisher, unless otherwise permitted under the Copyright Act 1968.
ISBN 978 1 76072 883 0
AS 3992:2020
2
PREFACE
This Standard was prepared by the Australian members of Joint Standards
Australia/Standards New Zealand Committee ME-001, Pressure Equipment, to supersede
AS/NZS 3992:2015, Boilers and pressure vessels—Welding and brazing qualification.
After consultation with stakeholders in both countries, Standards Australia and Standards
New Zealand decided to develop this Standard as an Australian Standard rather than an
Australian/New Zealand Standard.
The objective of this Standard is to reduce misunderstanding, costs and delays in qualifying
welding, avoid unnecessary duplication of testing, promote greater confidence in reciprocal
acceptance of approved procedures, and improve safety. It also aims for greater alignment
with ASME and ISO Standards, and to be consistent with the current work health and safety
laws.
The inclusion of roles and responsibilities in AS 3992:2020, was approved by the Standards
Development and Accreditation Committee on 2 May 2019, as a one-off exemption to the
directives of Standardisation Guide 009: Preparation of Standards for Legislative Adoption.
This Standard unifies and revises the requirements for the qualification of welding and
brazing procedures, welding and brazing personnel, and production test plates and welds,
specified in AS 1210, Pressure vessels, AS 1228, Pressure equipment—Boilers, and
AS 4041, Pressure piping.
This Standard is a major revision of AS/NZS 3992:2015, with due allowance for latest
practices or requirements of AS 1210, AS 1228 and AS 4041.
Requirements have been formulated with a view to maximize compatibility with recognized
leading International Standards including ISO 9606 (all parts) and ISO 15614 (all parts).
The main changes in this revision are as follows:
(a)
The roles and responsibilities in this revision have been changed (reduced); however
some level of roles and responsibilities have been retained. The inclusion of roles and
responsibilities in this Standard was approved by the Standards Development and
Accreditation Committee (SDAC).
(b)
Revision and addition of new requirements to Sections 1, 5, 6, 7, 8 and 9 including
revision of figures and tables within.
(c)
Clarification of testing requirements particularly those requiring impact testing.
(d)
Revision of Appendices B and D, and new Appendix G.
(e)
Addition of a new Appendix I to provide guidance on oxidation colours for stainless
steels and titanium.
(f)
Correction of identified errors and ambiguities throughout the Standard.
(g)
Revision of procedure qualification requirements for special welds and welding of
service exposed materials (Section 8).
(h)
Updating of referenced documents and alignment.
It is not intended that the publication of this edition will invalidate welding tests that were
accepted in respect of other Standards referenced in AS/NZS 1200, Pressure equipment.
Statements expressed in mandatory terms in notes to tables and figures are deemed to be
requirements of this Standard.
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AS 3992:2020
CONTENTS
Page
SECTION 1 SCOPE AND GENERAL
1.1 SCOPE AND APPLICATION ..................................................................................... 7
1.2 REFERENCED DOCUMENTS ................................................................................... 9
1.3 TERMS AND DEFINITIONS ..................................................................................... 9
1.4 OTHER PROCESSES ............................................................................................... 12
1.5 OTHER MATERIALS ............................................................................................... 12
1.6 WELDING AND BRAZING—SUPERVISION ........................................................ 12
SECTION 2 PREQUALIFIED WELDING PROCEDURES
2.1 GENERAL ................................................................................................................. 13
2.2 PREQUALIFIED GASES .......................................................................................... 15
SECTION 3 QUALIFICATION OF WELDING PROCEDURES FOR BUTT, BRANCH
AND FILLET WELDS
3.1 GENERAL ................................................................................................................. 17
3.2 METHODS OF QUALIFICATION OF WELDING PROCEDURE .......................... 17
3.3 RECORDING OF WELDING PROCEDURE DATA ............................................... 17
3.4 TESTING OF WELDING PROCEDURE TEST WELDS ......................................... 17
3.5 REQUALIFICATION OF A WELDING PROCEDURE ........................................... 18
3.6 PORTABILITY OF QUALIFIED WELDING PROCEDURES ................................ 18
3.7 WELDING PROCEDURE SPECIFICATION FOR NEW PRESSURE
EQUIPMENT ............................................................................................................ 18
3.8 WELDING PROCEDURES FOR REPAIR WELDING OF NEW PRESSURE
EQUIPMENT ............................................................................................................ 18
3.9 REPAIRS, REPLACEMENT OR ALTERATION TO IN-SERVICE PRESSURE
EQUIPMENT ............................................................................................................ 19
SECTION 4 ITEMS TO BE RECORDED FOR WELDING PROCEDURE TEST WELDS
4.1 GENERAL ................................................................................................................. 20
4.2 ITEMS SPECIFIC TO NOMINATED WELDING PROCESSES ............................. 20
4.3 RECORDING OF WELDING PROCEDURE TEST WELDS................................... 20
SECTION 5 ESSENTIAL VARIABLES FOR WELDING PROCEDURE QUALIFICATION
5.1 GENERAL ................................................................................................................. 22
5.2 MATERIAL GROUPING .......................................................................................... 22
5.3 WELDING ENERGY INPUT.................................................................................... 23
5.4 PREHEAT AND POST WELD HEAT TREATMENT.............................................. 23
SECTION 6 WELD TEST PIECES
6.1 TEST PIECES ........................................................................................................... 51
6.2 VISUAL EXAMINATION ........................................................................................ 52
6.3 NON-DESTRUCTIVE EXAMINATION OF TEST PIECES .................................... 52
6.4 POSTWELD HEAT TREATMENT .......................................................................... 54
SECTION 7 MECHANICAL TESTING OF WELDS FOR PROCEDURE QUALIFICATION
7.1 GENERAL ................................................................................................................. 59
7.2 TEST SPECIMENS ................................................................................................... 59
7.3 TRANSVERSE TENSILE TEST ............................................................................... 59
7.4 ALL-WELD-METAL TENSILE TEST ..................................................................... 60
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7.5
7.6
7.7
7.8
7.9
7.10
7.11
7.12
BEND TEST .............................................................................................................. 60
CHARPY V-NOTCH IMPACT TEST ....................................................................... 62
MACRO EXAMINATION ........................................................................................ 69
WELD JOINT HARDNESS TEST ............................................................................ 69
FRACTURE TEST—FILLET WELDS ..................................................................... 70
FRACTURE TEST—BUTT WELDS ........................................................................ 71
ADDITIONAL TESTS BEFORE REJECTION ......................................................... 71
REPORTING OF RESULTS ..................................................................................... 71
SECTION 8 PROCEDURE QUALIFICATION FOR SPECIAL WELDS
8.1 GENERAL ................................................................................................................. 73
8.2 SPECIAL WELDS NOT REPRESENTED BY A BUTT, BRANCH OR FILLET
WELD........................................................................................................................ 73
8.3 TEMPER BEAD WELDING DURING MANUFACTURE ...................................... 81
8.4 WELD REPAIRS TO SERVICE EXPOSED PRESSURE EQUIPMENT ................. 85
8.5 TUBE TO TUBE PLATE WELDING ....................................................................... 87
SECTION 9 WELDER QUALIFICATION
9.1 GENERAL ................................................................................................................. 88
9.2 METHODS OF QUALIFICATION ........................................................................... 88
9.3 EXTENT OF APPROVAL OF WELDER QUALIFICATION .................................. 88
9.4 INFORMATION FOR WELDER FOR QUALIFICATION TEST WELDS .............. 89
9.5 EXAMINATION AND TESTING OF WELDER QUALIFICATION
TEST WELDS ........................................................................................................... 89
9.6 RECORDING OF WELDER QUALIFICATION TESTS ......................................... 90
9.7 RETESTS .................................................................................................................. 90
9.8 RENEWAL OF WELDER QUALIFICATION.......................................................... 95
SECTION 10 WELD PRODUCTION TESTS
10.1 PRODUCTION TEST PLATES ................................................................................ 96
10.2 EQUIPMENT REQUIREMENTS OF PRODUCTION TEST PLATES .................... 96
10.3 NUMBER OF PRODUCTION TEST PLATES ......................................................... 97
10.4 PREPARATION OF PRODUCTION TEST PLATES ............................................... 97
10.5 PRELIMINARY EXAMINATION OF TEST PLATES ............................................ 98
10.6 TREATMENT OF TEST PLATES ............................................................................ 98
10.7 TESTING OF TEST PLATES ................................................................................... 98
10.8 ADDITIONAL TESTS BEFORE REJECTION ......................................................... 98
10.9 RECORDS ................................................................................................................. 98
SECTION 11 BRAZING QUALIFICATION
11.1 GENERAL ............................................................................................................... 100
11.2 QUALIFICATION REQUIRED .............................................................................. 100
11.3 GROUPING OF MATERIALS FOR BRAZING QUALIFICATION ...................... 100
11.4 GROUPING OF BRAZING FILLER METALS ...................................................... 101
11.5 BRAZING FLOW POSITIONS ............................................................................... 102
11.6 RECORDS ............................................................................................................... 102
SECTION 12 QUALIFICATION OF BRAZING PROCEDURE
12.1 GENERAL ............................................................................................................... 104
12.2 REQUALIFICATION OF A BRAZING PROCEDURE .......................................... 104
12.3 PORTABILITY OF QUALIFIED BRAZING PROCEDURE ................................. 104
12.4 PREQUALIFIED BRAZING PROCEDURE ........................................................... 104
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12.5 ITEMS TO BE RECORDED FOR BRAZING PROCEDURE QUALIFICATION
TEST BRAZES ........................................................................................................ 105
12.6 ESSENTIAL VARIABLES FOR BRAZING PROCEDURE QUALIFICATION ... 105
12.7 TEST PIECES FOR BRAZING PROCEDURE QUALIFICATION ........................ 105
12.8 VISUAL EXAMINATION ...................................................................................... 105
SECTION 13 EXAMINATION AND TESTING OF BRAZED JOINTS
13.1 REMOVAL OF TEST SPECIMENS ....................................................................... 111
13.2 TRANSVERSE TENSILE TEST ............................................................................. 111
13.3 BEND TEST ............................................................................................................ 112
13.4 PEEL TEST ............................................................................................................. 112
13.5 SECTIONING TEST ............................................................................................... 113
13.6 WORKMANSHIP SPECIMEN TEST ..................................................................... 113
13.7 RETESTS ................................................................................................................ 114
SECTION 14 BRAZER AND BRAZING OPERATOR QUALIFICATION
14.1 METHODS OF QUALIFICATION ......................................................................... 115
14.2 ESSENTIAL VARIABLES FOR QUALIFICATION OF BRAZING
PERSONNEL .......................................................................................................... 115
14.3 EXTENT OF APPROVAL OF BRAZING QUALIFICATION ............................... 115
14.4 INFORMATION TO BE GIVEN TO BRAZER OR BRAZING OPERATOR
FOR QUALIFICATION TEST JOINT .................................................................... 115
14.5 QUALIFICATION TEST JOINTS AND TESTING ................................................ 115
14.6 RECORDING OF BRAZER AND BRAZING OPERATOR
QUALIFICATION TESTS ...................................................................................... 116
14.7 RETESTS ................................................................................................................ 116
14.8 RENEWAL OF BRAZER QUALIFICATION ........................................................ 116
SECTION 15 ALUMINOTHERMIC WELDING OF ELECTRICAL CONDUCTORS
15.1 PREQUALIFIED WELDING PROCEDURE .......................................................... 117
15.2 PROCEDURE QUALIFICATION........................................................................... 117
15.3 PRODUCTION TEST ............................................................................................. 117
SECTION 16 THERMOCOUPLE ATTACHMENT JOINTS
16.1 GENERAL .............................................................................................................. 118
16.2 PREQUALIFICATION PROCEDURES ................................................................. 118
16.3 TEST JOINT ............................................................................................................ 118
16.4 PROCEDURE QUALIFICATION TESTS .............................................................. 118
16.5 QUALIFICATION OF OPERATOR ....................................................................... 119
SECTION 17 WELDING QUALIFICATION OF NON-METALLIC MATERIALS
17.1 SCOPE ..................................................................................................................... 120
17.2 GENERAL REQUIREMENTS ................................................................................ 120
SECTION 18 SPECIAL TREATMENT OF WELDS
18.1 SCOPE ..................................................................................................................... 121
18.2 PROCEDURE QUALIFICATION........................................................................... 121
APPENDICES
A
LIST OF REFERENCED DOCUMENTS................................................................ 122
B
WELDING PROCEDURE SPECIFICATION (WPS) ............................................. 127
C
WELDING PROCEDURE QUALIFICATION RECORD (PQR) ............................ 131
AS 3992:2020
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D
E
F
G
H
I
COMPARISON OF SA/SNZ TR ISO 15608 AND AS 3992
MATERIAL GROUPS ............................................................................................ 134
MACRO-ETCHING OF WELDED JOINTS ........................................................... 141
BRAZING PROCEDURE QUALIFICATION RECORD ........................................ 142
BASIS FOR WELD POSITIONS ............................................................................ 144
EXAMPLES OF THE APPLICATION OF THIS STANDARD
TO PRESSURE VESSEL AND PIPING MANUFACTURER ................................ 146
COLOUR SCALES ................................................................................................. 150
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AS 3992:2020
STANDARDS AUSTRALIA
Australian Standard
Pressure equipment—Welding and brazing qualification
S E CTI ON
1
S COP E
AND
GE NE R AL
1.1 SCOPE AND APPLICATION
1.1.1 Scope
This Standard specifies requirements for the qualification of welding and brazing
procedures, welders and brazers, and requirements for production weld testing other than
non-destructive examination, when used in the manufacture, alteration and repair of boilers,
pressure vessels, pressure piping and their components as specified in AS/NZS 1200,
AS 1210, AS 1228 and AS 4041. See Figure 1 for a summary of the welding and brazing
qualification process.
This Standard is intended for use by designers, manufacturers, welders, brazers, inspection
bodies, inspectors, testing authorities and all persons concerned with the welding and
brazing of pressure equipment.
This Standard may apply to automotive LP Gas fuel vessels (covered by AS/NZS 3509),
serially produced pressure vessels (covered by AS 2971) or welded gas cylinders (covered
by AS 2030.1), where specified by these Standards. This Standard does not apply to
pipelines in accordance with AS/NZS 2885.2, except where referenced.
The Standard provides specific details for the following:
(a)
Manual metal-arc welding, flux cored arc welding, gas metal-arc welding, gas
tungsten-arc welding, submerged arc welding, plasma arc welding, electroslag
welding and oxy-acetylene welding.
(b)
Torch brazing, furnace brazing, induction brazing, resistance brazing and dip brazing.
(c)
The welding and brazing of carbon, carbon-manganese, and low and high alloy steels;
and copper, aluminium, nickel, titanium, zirconium and alloys of these materials.
(d)
Welding procedure qualification.
(e)
Welder qualification.
Specific details for stud welding, electron-beam welding, explosion welding, laser beam
welding, electro-gas welding, fusion welding of plastics and friction welding processes are
not covered by this Standard. For these, see ASME BPVC-IX or equivalent.
The principles established in this Standard may be used in the qualification of processes,
materials and applications not covered by the scope outlined above (see also Clause 1.5 and
Clause 1.6).
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Standards Australia
AS 3992:2020
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FIGURE 1.1 SUMMARY OF WELDING AND BRAZING QUALIFICATION PROCESS
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AS 3992:2020
1.1.2 Application
Where there are differences between this Standard and AS 1210, AS 1228 or AS 4041, the
requirements of this Standard apply.
Where this Standard makes reference to other Standards, these referenced Standards are not
intended to be limiting or exclusive and other equivalent national standards acceptable to
the parties concerned may be substituted for the referenced Standards. AS/NZS 1200
provides a list of pressure equipment Standards used in Australia and New Zealand.
Conformance to ASME BPVC-IX, ISO 15607, or ISO 15614-1 is deemed to be an
acceptable alternative to the requirements of this Standard where agreed between
manufacturer and purchaser. Where this Standard (AS 3992) requires tests not already
completed under these ASME and ISO Standards, then this can be covered by those
additional tests only, rather than repeating the full set of tests; for example, as part of a
production test plate.
Users of this Standard are reminded that it has no legal authority in its own right, but may
acquire legal standing in one or more of the following circumstances:
(a)
Adoption by a government or other authority having jurisdiction.
(b)
Adoption by a purchaser as the required standard of manufacture when placing a
contract.
(c)
Adoption where a manufacturer states that pressure equipment is in accordance with
an application Standard which mandates conformance to this Standard.
1.2 REFERENCED DOCUMENTS
The documents referred to in this Standard are listed in Appendix A.
Where reference is made to a Standard by its number only, the reference applies to the
current edition of the Standard. Where reference is made to a Standard by number, year and,
where relevant, an amendment number, the reference applies to that specific document.
1.3 TERMS AND DEFINITIONS
For the purpose of this Standard, the definitions in AS 2812 and those below apply.
Weld positions are defined within AS/NZS 3545.
1.3.1 Backing gas
Backing using gas primarily for the purpose of preventing atmospheric reaction on the
reverse side of a joint preparation.
1.3.2 Brazer
Person who performs a manual brazing operation.
1.3.3 Brazing operator
Person who operates furnaces or other automatically controlled or timed brazing equipment.
1.3.4 Build-up
Overlay welding to restore required dimensions.
1.3.5 Buttering
Surfacing variation in which one or more layers of weld metal are deposited on the weld
face of one member (e.g. a high alloy weld deposit on steel base metal that is to be welded
to a dissimilar base metal). The buttering provides a suitable transition weld deposit for
subsequent completion of the butt joint.
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1.3.6 Cladding
Material deposited on the parent material in order to produce a clad material.
1.3.7 Cladding process
Surfacing (see Clause 1.3.28) used for cladding (see Clause 1.3.6).
1.3.8 Competent person
A person who has acquired, through education, training, qualification or experience, or a
combination of these, the knowledge and skill enabling that person to perform the required
task correctly and safely.
1.3.9 Essential variables (for a welder qualification)
Those variables in the welding procedure in which
this Standard is considered to reduce the ability
required mechanical properties and soundness,
technique, or the omission of a backing strip, bar or
a change outside the limits specified in
of a welder to make a weld with the
(e.g. change in welding process or
ring).
1.3.10 Essential variables (for a welding or brazing procedure)
Those variables in the welding or brazing procedure in which a change outside the limits
specified in this Standard is considered to affect the mechanical properties of the weld,
(e.g. change in welding process, consumables, or heat treatment).
1.3.11 In-service welding
Welding onto pipe or vessel containing a process fluid or residue that may be pressurized
and/or flowing.
NOTE: In-service welding is also referred to as ‘hot-tapping’.
1.3.12 Inspection body
A body corporate or firm that performs inspection, which may be any one or more of design
verification, manufacture inspection and in-service inspection.
NOTES:
1
The manufacturer may be the inspection body when permitted by AS 3920.
2
See also AS/NZS ISO/IEC 17020 and the Standards Australia/Standards New Zealand
Miscellaneous Publication, SAA/SNZ MP76, for more information on inspection bodies.
1.3.13 Inspector
A competent person employed by, or acceptable to, the inspection body for the purpose of
inspecting pressure equipment in accordance with this Standard.
1.3.14 Manufacturer
The person or organization responsible for the manufacture, welding and testing of pressure
equipment in accordance with this Standard. A manufacturer may also be the designer.
NOTE: In this Standard, ‘manufacturer’ includes ‘fabricator’, ‘constructor’, ‘assembler’,
‘installer’, ‘erector’ and ‘repairer’. The term ‘manufacturer’ is used to embrace all or some of
these terms and is applicable to all locations, on or off site, where pressure equipment is welded
or brazed. It also includes a manufacturer’s authorized representative.
1.3.15 Metallurgical properties
Metallurgical properties are the material properties, such as tensile strength, yield strength,
impact toughness and metallurgical structure.
1.3.16 Overlay
Surfacing by means of welding.
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AS 3992:2020
1.3.17 Owner
A body corporate, company or person who has the right of title to, or management of, or
control over the pressure equipment and includes a person exercising such management or
control as an agent of the owner.
NOTE: In Australia, the owner is also a ‘Person Conducting a Business or Undertaking’ (PCBU).
1.3.18 Preliminary welding procedure specification (pWPS)
Document containing the required variables of the welding procedure which is intended to
be qualified.
1.3.19 Prequalified welding procedure
A documented welding procedure satisfying the requirements of Section 2. It has the same
standing as a qualified welding procedure when used within the limits specified in
Section 2.
1.3.20 Pressure equipment
Boilers, pressure vessels, pressure piping and their components covered by AS/NZS 1200.
1.3.21 Procedure qualification record (PQR)
A document recording test variables and test results to establish a welding procedure.
1.3.22 Purging gas
Gas used for the purpose of replacing the atmosphere in a hollow section and subsequently
for gas backing.
1.3.23 Qualified welding procedure
A welding procedure which has been conducted, tested, assessed, documented and verified
as conforming to the requirements of this Standard.
NOTE: This definition is intended to include the use of prequalified welding procedures as
detailed in Section 2.
1.3.24 Service-exposed welding
Welding on material degraded by service.
1.3.25 Shall
Indicates a requirement.
1.3.26 Should
Indicates a recommendation.
1.3.27 Sound or soundness
A weld or braze that is free from unacceptable imperfections (defects).
1.3.28 Surfacing
Deposition of filler metal over an area of a metal surface for building up, wear or corrosion
resistance.
1.3.29 Temper-bead welding
The welding of a bead at a specific location on a weld for the purpose of improving the
metallurgical properties of the heat-affected zone of the previously deposited weld metal.
1.3.30 Test piece
Components welded together in accordance with a specified welding procedure, or a portion
of a welded joint detached from a structure, for test (see Clause 1.3.23).
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1.3.31 Test specimen
A portion detached from a test piece and prepared, as required, for testing.
1.3.32 Welder qualification test
A documented test, carried out by a welder, working to an approved welding procedure, to
determine the welder’s ability to deposit sound weld metal using the manufacturer’s
available equipment.
1.3.33 Welding procedure specification (WPS)
A documented qualified welding procedure prepared to provide direction for making
production welds to the requirements of this Standard (see also Clause 1.3.23).
1.3.34 Welding procedure test
The making and testing of a welded joint representative of that to be used in production in
order to prove the weldment is capable of providing the required properties for its intended
application.
1.3.35 Weld production test
The making and testing of a representative sample of production welds to check the quality
of welds during the manufacture of pressure equipment.
1.4 OTHER PROCESSES
This Standard does not prohibit the use of processes not specifically listed in Clause 1.1.
Where another process is to be used, it shall give a result at least equal to that set by this
Standard.
1.5 OTHER MATERIALS
Materials not specified in Clause 1.1(c) may be welded in accordance with this Standard
provided the welding method gives a result at least equal to this Standard.
1.6 WELDING AND BRAZING—SUPERVISION
Welding for assessment of welding or brazing procedure and welder and brazer
qualification shall be supervised by a competent person.
Personnel with a minimum of three year’s experience in the welding and fabrication of
pressure equipment and holding a AS 1796 Certificate 10, or equivalent or higher
conforming to the requirements of AS/NZS ISO 14731, are deemed to conform.
NOTE: See Clause 1.3.8 for definition of competent person.
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SEC TI ON
2
AS 3992:2020
PR E QU ALI FIED
PR OC E DUR E S
WE L DI NG
2.1 GENERAL
Welding procedure qualification testing is not required for welding procedures classified as
‘prequalified’ in accordance with this Clause 2.1.
Welding procedures which conform to Table 2.1 shall be deemed to be prequalified and do
not require further qualification in accordance with Sections 3 to 7, provided that—
(a)
each procedure is documented in accordance with the applicable requirements of
Appendix B;
(b)
each procedure has a signed endorsement by the manufacturer (see Appendix B);
(c)
each procedure is only applicable within the limits of the essential variables listed in
Table 5.1 but not Table 5.4 which does not apply to prequalified procedures; and
(d)
each procedure has been used by a welder (named) employed by the manufacturer and
who has met the requirements of a welder qualification test (date given) in
accordance with Clause 9.2.
The use of prequalified welding procedures does not relieve the manufacturer of any
responsibilities, in respect of the provisions of this Standard, for welder qualification and
weld production testing.
NOTE: ‘Prequalified welding procedures’
specifications’ in ASME BPVC.
are
known
as
‘Standard
welding
procedure
The following also apply:
(i)
Carbon equivalent = C +
Mn Cr + Mo + V Cu + Ni
+
+
percent.
6
5
15
Where heat analysis of all of these elements is not quoted, the value of
Mn
C
0.42 percent maximum applies.
6
These equations do not apply where B
(ii)
Runout ratio =
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0.0008%.
length of weld run
.
length of electrode consumed
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TABLE 2.1
CONDITIONS FOR PREQUALIFIED WELDING PROCEDURES
Item
Range of application
Pipe diameter
All diameters
Plate or pipe thickness (nominal)
3 mm to 40 mm thickness (see also Weld preparation below)
Parent metal group
A1 and A2 as welded or with PWHT, K1 as welded
Carbon equivalent [see Clause 2.1(i)]
0.45% maximum based on actual or specified values
Welding processes
Manual metal-arc, submerged arc, gas tungsten-arc welding,
flux cored arc welding, gas metal arc (spray transfer) or
combination of these processes
Design minimum temperature
Equal to and above 0°C
Welding consumables
Table 2.2 and Clause 2.2
Weld preparation
Table 2.3
Welding position
Figure 5.1
Welding current, voltage and polarity
In accordance with consumable supplier’s requirements and
recommendations
Preheat temperature
Above 0°C and in accordance with the pressure equipment
Standard (see Note)
Travel speed
Runout length for manual electrodes 1 [see Clause 2.1(ii)].
Submerged arc welding between 200 mm/min and
600 mm/min
Initial and interrun cleaning
Free from any materials which may impair the weld quality
Storage and handling of welding consumables
In accordance with the pressure equipment Standard and the
consumable supplier’s requirements and recommendations
Post weld heat treatment
In accordance with AS 4458
NOTE: Preheat should also conform to AS 4458, EN 1011-2 or Weld Australia TN 01.
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AS 3992:2020
TABLE 2.2
PREQUALIFIED WELDING CONSUMABLES (see Notes 1 and 2)
1
Material
group
(see Table 5.2)
2
3
Manual metal-arc
(AS/NZS 4855)
A1
A-E35 3
A-E38 3
A-E42 3
A2
(see Note 3)
A-E35 3
A-E38 3
A-E42 3
B-E43X6
B-E43X8
B-E49X5
B-E49X6
B-E49X8
U
U
U
U
U
K1
4
5
6
7
Submerged
arc
(AS/NZS
ISO 14171,
AS/NZS
ISO 14174)
Flux-cored
arc
(AS/NZS
ISO 17632)
Gas metal arc
(AS/NZS 14341,
AS/NZS 21952,
AS/NZS 16834)
(ISO 14341)
Gas tungsten arc
(AS/NZS 1167.2)
(ISO 636)
A-S35 3
A-S38 3
A-S42 3
B-S43 3U
B-S49 3U
A-T35 3
A-T38 3
A-T42 3
B-T43 3U
B-T49 3U
A-G35 3
A-G38 3
A-G42 3
B-G43 3U
B-G49 3U
A-W35 3
A-W38 3
A-W42 3
B-W43 3U
B-W49 3U
See Note 4
NOTES:
1
Consumables for material Group A2 are suitable for Group A1 materials.
2
Consumables with a higher impact grading than that shown or equivalent in accordance with
ASME BPVC-IIC are acceptable.
3
For material Group A2, consumables of the A-E35, B-E43XX, A-S35, B-S43, A-T35, B-T43, A-G35 or
B-G43, A-W35 or B-W43 type will equal or exceed the specified minimum yield strength of the material
and will usually give a tensile strength of not less than 95% of the specified minimum tensile strength of
the parent material.
4
Equivalent or alternative consumables complying with ASME BPVC-IIC and listed in Table 5.5.
2.2 PREQUALIFIED GASES
For GTAW, argon gas of ‘welding quality’ only shall be used for a prequalified welding
procedure. The maximum impurity content shall not exceed 1 part in 2000 by volume (i.e.
the gas shall be at least 99.95% pure).
For FCAW, shielding gases shall be in accordance with the specifications and qualification
of the consumable manufacturer.
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Standards Australia
AS 3992:2020
16
TABLE 2.3
ACCEPTABLE WELD PREPARATIONS FOR PREQUALIFIED
WELD PROCEDURES (see Notes 1 to 5)
Dimensions of joint
Item
Joint type
Joint form
(sectional view)
Thickness
(t), (max.)
mm
Gap
(g)
mm
Bevel angle
(a)
degrees
Root face
(f)
mm
1
Single-welded
single-V butt
joint—complete
penetration
20
1.5–3
60–90
0–3
2
Single-welded
single-V butt joint
with backing
strip—complete
penetration
20
5–10
15–45
0–3
3
Single-welded
single-U butt
joint—complete
penetration
20
0–3
20–40
0–3
4
Double-welded
single-V joint back
gouged—complete
penetration
20
0–3
60–90
0–3
5
Double-welded
double-V joint—
complete
penetration
40
0–3
60–90
0–3
6
Single or double
welded fillet joint
40
0–2
80–120
on each side
—
NOTES:
1 All weld preparations are applicable to one of the welding processes (or combinations) permitted in
Table 2.1.
2 Branch welds are qualified by butt welds using maximum parent metal thickness nominated for t above.
3 The use of minimum angle should be associated with maximum radius or gap and conversely the minimum
radius or gap should be associated with the maximum angle.
4 Indicate in welding procedure specification whether backing strip has intermittent or continuous welds.
5 See AS 1210, AS 1228 and AS 4041 for other acceptable weld preparations.
Standards Australia
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17
AS 3992:2020
S E CTI ON 3
Q UALIFI CAT I ON OF WE L D ING
PR OC EDUR ES F OR BUT T, BR ANC H AND
F ILLE T WE LDS
3.1 GENERAL
With the exception of prequalified welding procedures (see Section 2), each welding
procedure that is used in the manufacture of pressure equipment shall be qualified in
accordance with this Standard. Qualification is intended to demonstrate—
(a)
the suitability of the welding procedure for the material used in the construction;
(b)
that the weld can be made without unacceptable imperfections (defects) in the weld
deposit and heat affected zone;
(c)
that the mechanical properties, such as strength, and if applicable fracture toughness
and hardness, satisfy specified requirements; and
(d)
the manufacturer’s organization and equipment is capable of successfully using this
procedure.
Requirements to satisfy other parameters such as microstructure, corrosion resistance,
fatigue or erosion for specific service requirements may be specified by the purchaser. Such
requirements are outside of the scope of this Standard.
Only qualified welding procedures shall be used in the manufacture of pressure equipment.
NOTES:
1
The welding procedure qualification test may also be used to qualify a welder (see Section 9).
2
AS 3920 provides guidance for inspection bodies in relation to welding procedures.
3.2 METHODS OF QUALIFICATION OF WELDING PROCEDURE
A preliminary weld procedure (pWPS) should be drafted prior to qualification of the
welding procedure. Qualification of a welding procedure shall be carried out by one of the
following methods:
(a)
The making and testing of a procedure test weld in accordance with the requirements
of Sections 6 and 7.
(b)
Simultaneously with the welding and testing of a production test plate or pipe
provided that testing is carried out in accordance with Section 7.
(c)
Using a prequalified welding procedure in accordance with Section 2.
Where option (b) above is used, production welds carried out in conjunction with the
proving of a welding procedure which fails to meet the requirements of this Standard shall
be rejected.
3.3 RECORDING OF WELDING PROCEDURE DATA
Each procedure shall be recorded in detail, with the results of qualification tests. These
records shall be accessible to the inspector (and purchaser where required). Appendix C
specifies the required information for a welding procedure qualification record (PQR).
3.4 TESTING OF WELDING PROCEDURE TEST WELDS
The type, number, and methods of tests required to prove the suitability of the welding
procedure for the welding of joints in the components shall be in accordance with this
Standard. Where necessary, additional tests may be required to assess corrosion resistance
or other properties of a weld joint.
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AS 3992:2020
18
3.5 REQUALIFICATION OF A WELDING PROCEDURE
Provided that there are no changes in the essential variables (as listed in Section 5), a
qualified welding procedure shall remain in force indefinitely. Requalification of a welding
procedure is only required where there is any change in the essential variables as specified
in Section 5.
Where additional tests have to be carried out to make the approval technically equivalent, it
is only necessary to do the additional tests on a test piece which should be made in
accordance with this Standard. Welding procedures for manufacturing and fabrication shall
be in accordance with the current version of this Standard, or as nominated by contract.
This Standard does not invalidate previous welding procedure approvals made to former
national standards or specifications provided that the intent of the technical requirements
are satisfied, refer to Clause 3.9 and Clause 8.4.
3.6 PORTABILITY OF QUALIFIED WELDING PROCEDURES
A welding procedure qualified by one manufacturer shall be valid for use by a second
manufacturer, provided that—
(a)
the original qualification tests were carried out in accordance with this Standard, and
were fully documented;
(b)
the second manufacturer has adequate equipment and facilities and demonstrates
successful welding of welder qualification tests or production tests using the
procedure;
(c)
the application of the welding procedure is acceptable to both manufacturers and the
purchaser; and
(d)
the welding procedure specification identifies the original and second manufacturer.
NOTE: ISO 15612 gives information on weld procedures qualified by other manufacturers.
3.7 WELDING
EQUIPMENT
PROCEDURE
SPECIFICATION
FOR
NEW
PRESSURE
For production welding, a welding procedure specification shall be prepared listing all
necessary information for production welds to be made to the requirements of this Standard.
This specification shall include essential variables together with any acceptable ranges for
such variables, and any other variables which may affect the properties and soundness of
the welded joint.
An example of the requirements for a welding procedure specification is given in
Appendix B. Other methods of presentation of a welding procedure specification are
acceptable provided that they contain all relevant information to satisfy the requirements of
this Clause for production welds.
3.8 WELDING PROCEDURES FOR REPAIR WELDING OF NEW PRESSURE
EQUIPMENT
For new equipment, visual or non-destructive examination which reveals unacceptable
imperfections in the equipment that has not been subject to service environment shall be
repaired. Such repair welding shall be carried out to the original welding procedure or,
where this is not practicable, to a repair procedure approved to this Standard.
Standards Australia
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19
AS 3992:2020
3.9 REPAIRS, REPLACEMENT OR ALTERATION TO IN-SERVICE PRESSURE
EQUIPMENT
Where repairs, replacement, modifications or alterations are made by welding to pressure
equipment that is or has been in service, the welding shall conform to requirements of
Clause 8.4, AS/NZS 3788 and AS 3873 (when applicable) and the following:
(a)
For material, which has not been damaged [see Item (b)] or deteriorated in service,
the welding procedure shall be qualified in accordance with this Standard.
(b)
For material that has been damaged or deteriorated in service (e.g. by creep, hydrogen
embrittlement, temper embrittlement, fatigue, erosion, or other forms of deterioration
as referenced in AS/NZS 3788, API 570 or API 571, etc.), a repair welding procedure
(see Clause 8.4) shall only be effected after the cause of the deterioration has been
ascertained and taken into account to ensure a satisfactory repair procedure. Such a
welding procedure shall be capable of producing welds acceptable to the owner.
(c)
For in-service weld repair procedures, a similar approach to Item (b) shall be
undertaken. In addition, all precautions shall be taken during the in-service weld
repair procedures to ensure the safety of the welding personnel and the repair
procedures have been adequately reviewed.
NOTES:
1
For Item (c) above, AS/NZS 2885.2, AS 4041, AS 5601 and API RP2201 provide processes
that may be suitable.
2
When weld metal is to be deposited over a previously welded surface, all slag and
contamination should be removed, the surface suitably shaped for a restart, and the specified
minimum preheat applied, refer to AS 4458 and AS ISO 13916.
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AS 3992:2020
20
S E CTI ON 4
I TEMS T O B E RE C OR DE D F OR
WEL DING P ROC EDUR E TE ST WE L D S
4.1 GENERAL
The following items shall be recorded for each welding procedure test:
(a)
Welding process or processes when more than one is used, in making a complete
joint.
NOTE: Parent metal specification and group number, thickness, and for pipe, the outside
diameter or outside dimensions.
(b)
Weld joint detail, including sketch and weld deposit thickness for welding processes
used.
NOTE: See Table 5.1, Clause 5.1 and Appendix C for more information.
(c)
Initial and interrun method for cleaning, degreasing, etc.
(d)
Welding position and direction of weld travel.
(e)
Classification of welding consumables (filler metal material specification and size,
flux and gas).
(f)
Preheating and interrun temperature ranges, including method and control.
(g)
Approximate number and arrangement of runs and welding sequence, including
sketch and string or weave technique, as applicable.
(h)
Back gouging or reverse side treatment, when applicable.
(i)
Postweld heat treatment, temperature and holding time.
(j)
Special features applicable to a specific welding procedure not covered in Table 4.1.
NOTE: See Section 18.
(k)
Name of manufacturer responsible for carrying out the procedure test.
(l)
Name of welder performing the test weld.
4.2 ITEMS SPECIFIC TO NOMINATED WELDING PROCESSES
The items listed in Table 4.1, in relation to a specific welding process, shall be recorded for
each welding procedure test in addition to those items in Clause 4.1.
4.3 RECORDING OF WELDING PROCEDURE TEST WELDS
A record of the welding procedure and test results shall be retained.
Appendix C lists the required details of the procedure qualification record (PQR) for the
recording of welding procedure test welds.
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21
AS 3992:2020
TABLE 4.1
ITEMS SPECIFIC TO NOMINATED WELDING PROCESSES
Item to be recorded
Welding process (see Note)
MMAW GTAW GMAW SAW ESW GW FCAW
PAW
Amperage
X
X
X
X
X
X
X
Arc voltage
X
X
X
X
X
X
X
X
X
X
X
X
Wire feed speed
Travel speed or runout length of electrode
X
X
X
X
X
X
X
Current type and polarity
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Welding flux
Shielding gas and flow rate
Arc energy (when applicable)
X
X
X
X
X
X
X
X
Electrode stick out
Purging gas and flow rate
X
Tungsten electrode (diameter and type)
X
Nozzle diameter
X
X
X
X
X
Gas type and pressure
X
Flame characteristic
X
Number of electrodes and configuration
X
X
Oscillation width and dwell periods
X
Slag depth
X
Special baking temperature of electrodes
X
Special baking temperature of flux
LEGEND:
MMAW =
GTAW =
GMAW =
SAW
=
ESW
=
GW
=
FCAW =
PAW
=
X
=
X
X
X
manual metal-arc welding
gas tungsten-arc welding
gas metal-arc welding
submerged arc welding
electroslag welding
oxy-acetylene (gas) welding
flux cored arc welding
plasma transferred arc welding
item to be recorded when applicable
NOTE: For multi-wire arc processes, record details for each wire.
For runout length, see Clause 2.1(ii).
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AS 3992:2020
22
S ECT I ON 5
ES S ENT IAL VAR IA BL E S F OR
WEL DING P ROC EDUR E QUAL I FI CAT ION
5.1 GENERAL
Essential variables in qualifying a welding procedure shall be as specified in this Section
and Table 5.1.
When changes are made to a qualified welding procedure, the welding procedure shall be
requalified when any of the changes to the essential variables, as listed in Table 5.1, are
applicable. Changes to other items of Table 4.1 that are not classified as essential variables
by Table 5.1 may be made to a qualified welding procedure without requalification.
The following also apply:
(a)
For multi-process procedures, each welding process may be approved separately or in
combination with other processes. Similarly, one or more processes may be added or
deleted from an approved welding procedure provided the joint thickness is within the
thickness range of the remaining process or processes.
(b)
Single or double V, J, U or bevel or a square butt may be changed without
requalification provided the form of the weld preparation is in agreement with
recommended joint detail as listed in the pressure equipment Standards. See
Clause 6.1 for changes between butt, branch and fillet welds.
(c)
For GMAW, this includes a change from spray arc, globular arc or waveformcontrolled arc to short-circuiting arc or vice versa.
A change from flat to tubular form of product or vice versa is not an essential variable.
For essential variables for special welding processes, see Section 8.
5.2 MATERIAL GROUPING
5.2.1 General
The material grouping system, referred to in Table 5.2 and throughout this Standard, is
applied throughout the Australian pressure equipment Standards. Table 5.2 provides an
outline of the classification of material groups.
Table 5.2 gives a basis for the grouping of materials for the purpose of specifying
requirements for manufacture, postweld heat treatment, welding procedure and welder
qualification, fabrication and non-destructive examination. It is presented to assist in
grouping steels, including those not covered by Australian Standards but it is not to be
considered the only basis of material specifications, as other factors, not listed may need to
be taken into account, particularly with borderline compositions.
For Group K and M materials, requalification of a welding procedure is required when
specific corrosion resistance tests are required or where parent metal impact tests are
required by the pressure equipment Standard for cryogenic service. In such instances the
procedure is only applicable to the stainless steel grade of material used in the procedure
test. Appendix D provides comparisons between AS 3992 group materials and
SA/SNZ TR ISO 15608 material numbers.
NOTE: Some examples of the application of essential variables to welding procedures for
pressure equipment construction are given in Appendix H.
5.2.2 Extension of qualification
To minimize the number of procedure qualification tests, grouping of parent materials as
per Tables 5.3(A), 5.3(B) and 5.3(C) may be used to extend the range of qualification.
Standards Australia
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23
AS 3992:2020
Permanent backing bars or rings shall be considered as a parent material within the
approval sub-group.
For Table 5.3(A), qualification of a welding procedure using A1 to A1 (or A1 to A2) as the
steel group originally qualified is only permitted for A2 materials if—
(a)
the test values of transverse tensile test, all weld metal tensile test, and notch bar
impact tests, when required, exceed the minimum properties required for A2 group
materials; and
(b)
weld preheat temperatures are applied in accordance with the requirement of
AS 4458, EN 1011-2 or Weld Australia TN 01, (where a production test plate is
required, other pre-heat temperatures are permitted).
5.3 WELDING ENERGY INPUT
Welding energy input is determined from the following equation:
Q
60 EI
v 103
where
Q = welding energy input, in kJ/mm
E = arc voltage, in volts (RMS value for a.c.)
I = welding current, in amperes (RMS value for a.c.) per electrode
v = welding speed, in mm/min
This equation only applies to MMAW, SAW, GMAW, GTAW, FCAW and for nonwaveform-controlled welding.
For waveform-controlled welding, an increase in energy input may be determined by—
(a)
an increase in bead size (width
thickness); or
(b)
total energy as reported on the power source for the weld run; or
(c)
direct measurement, see ISO/TR 18491.
Additional consideration for preheat and energy input is required for any C-Mn steel with
B 0.0008% (see Weld Australia TN 01, SA TS 103 and EN 1011-2).
5.4 PREHEAT AND POST WELD HEAT TREATMENT
Unless otherwise specified, the preheat and post weld heat treatment shall conform to the
requirements of AS 4458. In addition, the following applies:
(a)
Where the parent metal thickness of the production weld differs from that used in the
test weld adjustment shall be made to achieve a satisfactory cooling rate by
conforming to the preheats listed in the pressure equipment Standard, Weld Australia
TN 01 or EN 1011-2.
(b)
Group B1 reflects Group B materials in the previous edition of this Standard and
other Australian Standards.
(c)
Material Groups B2, B3, B4, D3 and D4, are yet to be incorporated into other
Australian Standards including AS 4458. These materials shall be considered on a
case by case basis until incorporation; this includes, but not limited to, requirements
in regard to preheat, PWHT and NDE. Specialist advice should be sought from the
original equipment manufacturer, material manufacturer or competent persons.
NOTE: Group B5 materials in this Standard were previously classed as ‘D1 materials’ within
AS/NZS 3992:2015.
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Standards Australia
AS 3992:2020
(d)
24
When welding Group A1, A2 or B1 material to Group D2 or D3, the postweld heat
treatment temperature shall not exceed 700°C.
TABLE 5.1
ESSENTIAL VARIABLES FOR WELDING PROCEDURE QUALIFICATION
Item
Essential variable
1
Parent material specification
(see Clause 5.2)
A change from a material group to any other material group or for a
combination of material groups, as listed in Table 5.2, except as
permitted in Tables 5.3(A), 5.3(B) and 5.3(C)
2
Parent material and weld deposit Parent material and weld deposit thicknesses outside the limits given in
thickness and form (for mixed
Table 5.4, where ‘t’ is dependent on joint details as given in Table 5.6
processes see Item 6 below)
3
Weld joint detail
(see Clause 5.1)
Omission of backing strip or consumable backing ring in a butt joint. For
fillet welds, see Clause 6.1.2
4
Welding position and weld
direction (see Note 1)
The following are essential variables:
(a) When impact tests are not required, change to or from vertical down.
(b) When impact tests are required, any change in fundamental welding
position (flat, horizontal, vertical and overhead), or change in weld
direction (see Figures 5.1 and 5.2). Testing in the maximum heat
input position, i.e. vertical up in plate or 5G or 6G positions in pipe
shall qualify for all positions.
5
Welding consumables
The following are essential variables:
(a) For all welding processes, a change in the numerical grouping
(F number) of an electrode or filler rod as shown in Table 5.5.
(b) For ferrous metals only, an increase or decrease in the weld metal
specified minimum strength outside the parent metal specified tensile
strength range.
(c) For ferrous metals only, a variation of the alloy content of the weld
metal outside of the specified range of the welding consumables used
in the procedure test, except that for—
(i)
carbon and carbon manganese steels the addition or deletion of
0.5% molybdenum from the weld metal composition shall not
require requalification; and
(ii)
3xx series austenitic Cr-Ni steels (K1 group) a change in weld
metal composition shall not require requalification.
(d) For flux cored arc welding, any change in flux formulations
(e.g. rutile, basic or metal core) other than that which varies iron
powder content only (see Note 2).
(e) For submerged arc welding—
(i)
a change in flux classification as listed in AS/NZS ISO 14171,
AS/NZS ISO 14174 or other International Standard; or
(ii)
a change from a flux recommended for one to three weld runs
to a multi-pass flux or vice versa.
(f) A change in the nominal composition of a shielding or backing gas
outside the range specified in AS 4882 or ISO 14175.
(g) A decrease in gas flow rate of the shielding gas by more than 10%.
(h) Deletion of a backing gas.
(i) For GTAW a change from solid wire to flux cored wire or vice versa.
(j) For all consumables—outside the limits of the applicable weld
consumable Standard and manufacturer’s requirements.
(continued)
Standards Australia
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25
AS 3992:2020
TABLE 5.1 (continued)
Item
6
Welding process
(see Clause 5.1)
Essential variable
A change in welding processes or combination of welding processes
For mixed processes, see
Clause 5.1(a), Appendix C,
Paragraph C2(h) and (m) and
Figure C1
7
Welding energy input
(see Clause 5.3)
The following are essential variables for each weld run:
(a) For Groups F and G steels, an increase or decrease in arc energy
greater than 15%.
(b) For low temperature operation requiring impact testing of weld
metal, an increase in arc energy greater than 15%.
(c) For materials operating in their creep range and Group M materials,
arc energy outside the range 1 to 3 kJ/mm, or for GTAW welding,
the range is 0.7 to 3.0 kJ/mm. Refer to API 579-1/ASME FFS-1 for
creep ranges.
(d) For conditions other than Items (a), (b) or (c), an increase in arc
energy greater than 30% or decrease in arc energy greater than 25%
(see Note 4).
8
Welding current and polarity
(see Clause 5.1)
For all processes, any change in the type of welding current and polarity
9
Preheat and interrun temperature The following are essential variables:
(a) An increase in the maximum of more than 50°C—
(i)
for Groups F and G steels; or
(ii)
when impact tests are required on the weld or heat affected
zone.
(b) An increase of more than 100°C in preheat or interrun temperature
for all other ferrous materials.
(c) A decrease of more than 50°C in preheat or interrun temperature
recorded on the PQR for all ferrous materials provided that the
temperature is not less than that defined in Clause 5.4(a) and that
specified in the welding procedure specification (see also Clauses 5.3
and 5.4).
10 Delayed cooling
Any change in the control of cooling rate after welding when specified in
the qualified welding procedure (see also Clause 5.4).
11 Postweld heat treatment
A change in postweld heat treatment which requires the deletion of
postweld heat treatment; or the addition of postweld heat treatment within
a temperature range (see also Clause 5.4).
NOTES:
1
For the limits of deviation from fundamental welding positions, see AS/NZS 3545.
2
‘All-positional’ coating or flux core formulations do not require requalification for single position welds
provided there is no designated increase in the deposited weld metal hydrogen content.
3
For multi-process procedures, each welding process may be approved separately or in combination with
other processes. Similarly, one or more processes may be deleted from an approved welding procedure
provided the joint thickness is within the thickness range of the remaining process or processes. See also
Item 8, Table 9.1.
4
Consideration should be given to the appropriate service application, e.g. sour service.
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AS 3992:2020
Standards Australia
TABLE 5.2
PARENT MATERIAL GROUPING
AS
material
group
(Note 3)
Material type
Ferrous materials (Fe
Nominal composition
Rm
MPa
Form
ASME BPVC-IX
classification
Typical specification
(grade and alloy or UNS number)
Welding
Brazing
SA/SNZ
TR ISO 15608
P. No.
Group No.
P. No.
Group No.
50%)
Carbon and carbon manganese steel
A1
A3
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C-Mn
C-Mn-Si
430
460
PS
PS
AS 1548 (PT430)
AS 1548 (PT460)
1
1
1
1
101
101
1.1
1.1
C-Mn-Si
415
PT
ASTM A106B (K03006)
1
1
101
11.1
C-Mn
414–
455
PT
API 5L X42, X52
API 5L X42M, X52M
1
1
101
11.1
1.2
C
330
PT
ASTM A106A (K02501)
1
1
101
11.1
Carbon and carbon
manganese
Medium strength steel
CE max 0.55
C 0.33
Mn 1.7
R e 400
460 < Rm 520
C-Mn-Si
490
PS
AS 1548 PT 490
1
2
101
1.2
C-Mn-Si
485
PT
ASTM A106C (K03501)
1
2
101
11.1
Carbon and carbon
manganese high yield
strength steel
CE max 0.40
C 0.15
Mn 1.7
400 < Re 530
520 < Rm 620
C-Mn
570
PS
AS/NZS 1594 (XF 500)
1
3
101
2.2
C-Mn
565
PT
API 5L X70
API 5L X70M
1
3
101
11.1
2.2
Inc. LF6 (515MPa)
(continued)
26
A2
Carbon and carbon
manganese low strength
steel
CE max 0.45
C 0.30
Si 0.60
Mn 1.7
R e 360
R m 460
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TABLE 5.2 (continued)
AS
material
group
(Note 3)
A4
Material type
Carbon and carbon
manganese steel
(quenched and tempered
or equivalent)
CE max 0.40
C 0.25
Mn 1.7
360 < Re 550
460 < Rm 660
Nominal composition
Rm
MPa
Form
ASME BPVC-IX
classification
Typical specification
(grade and alloy or UNS number)
Welding
Brazing
SA/SNZ
TR ISO 15608
P. No.
Group No.
P. No.
Group No.
C-Mn-Si-V-Nb
450
PS
ASTM A656 T3-80
1
4
101
2.2
C-Mn-Si-V-Nb
550
PS
ASTM A656 T4-80
1
4
101
—
C-Mn-Si
620
PS
ASTM A714 A (K11831)
1
4
101
1.3
C-Mn-Si
655
PS
ASTM A714 B (K12031)
1
4
101
1.3
C-Mn-Si
620
PS
ASTM A714 C (K12037)
1
4
101
1.3
C-Mn
620
PT
API 5L X80M, X80MO
1
4
101
2.2
C-Mn-(B)
490
PS
JIS G3115 SPV 490
1
4
101
2.2
101
1.2
3.1
Low alloy steel
Low alloy steel
(alloy < 0.7)
R m 485
CE max 0.48%
Max alloy content of any of
Cr, Mo, Ni is 0.7%
485
EN 10216-2 16Mo3 (Mn-0.5Mo)
Mn-0.5Mo-0.25 Ni
C-0.5Mo
3
1, 2
B2
Low alloy steel
(alloy <1½)
R m 650
Max combined alloy content
Mn, Cr, Mo, Ni, Cu 1.5%
650
0.5Cr-0.5Mo SA213 T2
(no V added)
3
3
B3
Low alloy steel
(alloy <1½ & V
0.1)
4.1
1.5Ni 0.6Cu 0.35Mo 0.3Nb
V 0.1% Mo 0.7%
440
B5
Low alloy steel
(alloy <1½ & V
0.5Cr-0.5Mo-0.25V
610
1Cr-0.5Mo
300
610
WB 36, EN 10216-2
15NiCuMoNb5-6-4 (1.6368)
—
—
EN 10216-2 14MoV6-3
BS 3604 HF660
—
—
PS
ASTM A387 12-1 (K11757)
4
1
100
5.1
450
PS
ASTM A387 12-2 (K11757)
4
1
102
5.1
415
PS
ASTM A387 11-1 (K11789)
4
1
102
5.1
515
PS
ASTM A387 11-2 (K11789)
4
1
102
5.1
0.35)
1.25Cr-0.5Mo
—
4.2
6.1
(continued)
AS 3992:2020
Standards Australia
Low alloy steel, Ni-CuMo (WB36)
Low alloy steel
(1½ total alloy < 3)
R e 430
R m 550
4.2
Max combined alloy content
Mn, Cr, Mo, Ni, Cu
1.5% + V 0.1
B4
C
27
B1
AS
material
group
(Note 3)
D1
D2
D3
E1
www.standards.org.au
E2
Low alloy steel
[Vanadium type]
(V 0.35, Cr 3.5)
Nominal composition
Form
Typical specification
(grade and alloy or UNS number)
Welding
Brazing
SA/SNZ
TR ISO 15608
P. No.
Group No.
P. No.
Group No.
3Cr-1Mo-V-Ti-B
585
F
ASTM A182 F3V (K31830)
5C
1
102
6.2
2.25Cr-1Mo-V
585
PS
ASTM A832 F22V (K31835)
5C
1
102
6.2
3Cr-1Mo-25V-Nb-Ca
585
F
ASTM A182 F3VCb (K31390)
5C
1
102
6.2
3Cr-1Mo-V-Ti-B
585
F
ASTM A182 F3V (K31830)
5C
1
102
6.2
415
PS
ASTM A387 22-1 (K21590)
5A
1
102
5.2
515
PS
ASTM A387 22-2 (K21590)
5A
1
102
5.2
3Cr-1Mo
515
PS
ASTM A387 21-2 (K31545)
5A
1
102
5.2
Cr-Mo steel
Cr 10.0
R e 430
R m 550
5Cr-½Mo
515
PS
ASTM A387 5-2 (K41545)
5B
1
102
5.3
9Cr-1Mo .......................... (F9)
515
ASTM A182 F9 (K90941)
5B
1
102
5.4
Alloy steel Cr > 7%
(Vanadium or tungsten
type)
R e 430
R m 650
9Cr-1Mo-V .................... (F91)
585
F
ASTM A182 (K90901)
15E
1
102
6.4
9Cr-1Mo-V .................... (F91)
585
PS
ASTM A387 (K91560)
15E
1
102
6.4
9Cr-1Mo-V ......... (T91 & P91)
585
PT
ASTM A213 & A335 (K90901)
15E
1
102
6.4
9Cr-1Mo-V
630
PT
EN 10216-2 X10CrMoVNb9-1
15E
1
102
6.4
9Cr-2W .......................... (P92)
620
PS
ASTM A335 (K92460)
15E
1
102
6.4
1.5Ni
415
F
ASTM A350 LF5-1 (K13050)
9A
1
101
9.1
2Ni-1Cu
435
PT
ASTM A333 (K22035)
9A
1
101
9.1
2.5Ni
450
PS
ASTM A203A (K21703)
9A
1
101
9.1
3.5Ni
450
PS
ASTM A203D (K31718)
9B
1
101
9.2
4.5Ni
485
C
ASTM A352 (J41500)
9C
1
101
9.2
Low Mo alloy steel
2.25Cr-1Mo
(Cr 3.5, total alloy < 5)
2.25Cr-1Mo
Nickel steel
(1.0 < Ni 3)
Nickel steel
(3 < Ni < 8)
(continued)
28
D4
Material type
Rm
MPa
ASME BPVC-IX
classification
AS 3992:2020
Standards Australia
TABLE 5.2 (continued)
www.standards.org.au
TABLE 5.2 (continued)
AS
material
group
(Note 3)
F
G1
8 and 9 Nickel steel
Quenched and tempered
low alloy steel
(Re > 360
R m 750)
Quenched and tempered
low alloy steel
(Re 550
R m 750)
Nominal composition
Form
Typical specification
(grade and alloy or UNS number)
Welding
Brazing
SA/SNZ
TR ISO 15608
P. No.
Group No.
P. No.
Group No.
ASTM A553-II (K71340)
11A
1
101
9.3
8Ni
690
S
9Ni
690
PS
ASTM 353 (K81340)
11A
1
101
9.3
9Ni
690
PT
ASTM A333-8 (K81340)
11A
1
101
9.3
690
F
ASTM A522-1 (K81340)
11A
1
101
9.3
Mn-0.5Mo
690
PS
ASTM A533-A3 (K12521)
11A
4
101
3.1
Mn-0.5Mo-0.25Ni
690
PS
ASTM A533-D3 (K12529)
11A
4
101
3.1
3.5Ni-1.75Cr-0.5Mo-V
725
F
ASTM A508-4Ni (K22315)
11A
5
102
3.1
3Ni-1.75Cr-5Mo
725
PS
ASTM A543-B1 (K42399)
11A
5
102
3.1
2.75Ni-1.5Cr-0.5Mo
725
PS
ASTM A543-C1
11A
5
102
3.1
3.5Ni-1.75Cr-5Mo
795
PS
ASTM A543-82 (K42339)
11B
10
102
3.2
Ni-Cr-Mo-B
790
PS
AS 3597 700PV
11B
10
102
3.2
0.75Ni-0.5Cr-0.5Mo-V
760
PS
ASTM A514–F (K11576)
11B
3
101
3.2
0.5Cr-0.25Mo-V
760
690
PS
Other ASTM A514 grades—
A, B, E, P, Q
11B
1, 2, 4, 8, 9
101
3.2
0.5Cr-0.25Mo-Si
795
F
ASTM A517—A (K11856)
11B
2, 3, 4, 8
102
3.2
795
725
F
Other ASTM A517 grades—B, E, F, P
11
13Cr; 13Cr-5Mo
450
PS
ASTM A240 F6a class 3 (S41000)
6
1
102
7.2
13Cr-4.5Ni-Mo
795
PT
ASTM A268 F6Mn (S41500)
6
4
102
7.2
15Cr
415
PT
ASTM A268 F429 (S42900)
6
2
102
7.2
29
G2
Material type
Rm
MPa
ASME BPVC-IX
classification
High alloy steel
H
(continued)
AS 3992:2020
Standards Australia
Martensitic chromium
steel
(Cr 10.5)
AS
material
group
(Note 3)
J
Ferritic high chromium
steel
(10.5 Cr < 19)
Austenitic Cr-Ni steel
(Cr < 19%)
Nominal composition
Form
Typical specification
(grade and alloy or UNS number)
12Cr (403)
Welding
Brazing
SA/SNZ
TR ISO 15608
P. No.
Group No.
P. No.
Group No.
7
1
102
7.1
www.standards.org.au
12Cr-1Al (405)
415
PS
ASTM A240 (S40500)
7
1
102
7.1
12Cr-Ti (408)
380
PT
ASTM A268 (S40800)
7
1
102
7.1
11Cr-Ti (409)
380
PS
ASTM A240 (S40920)
7
1
102
7.1
12Cr-1Ni (401)
455
PS
ASTM A1010 (S41000)
7
1
102
—
13Cr (401)
450
PS
ASTM A240 (S41000)
7
1
102
7.2
17Cr (430)
415
TS
ASTM A268 (S43000)
7
2
102
7.1
18Cr-Ti (439)
415
T
ASTM A268 (S43035)
7
2
102
7.1
18Cr-Ti (439)
415
PT
ASTM A731 (S43035)
7
2
102
7.1
18Cr-2Mo
415
PT
ASTM A731 (S44400)
7
2
102
7.1
17Cr-7Ni (301)
515
PS
ASTM A240 (S30100)
8
1
102
8.1
18Cr-8Ni (302)
515
PS
ASTM A240 (S30200)
8
1
102
8.1
18Cr-8Ni (304)
515
PS
ASTM A240 (S30400)
8
1
102
8.1
18Cr-8Ni
520
PS
EN 10028-7 (X5Cr-Ni-Mo17-12-2)
8
1
102
8.1
18Cr-8Ni (304L)
485
S
ASTM A240 (S30403)
8
1
102
8.1
18Cr-8Ni (304N)
550
S
ASTM A240 (S30451)
8
1
102
8.1
18Cr-8Ni (304LN)
515
S
ASTM A240 (S30453)
8
1
102
8.1
18Cr-11Ni (305)
515
PS
ASTM A240 (S30500)
8
1
102
8.1
16Cr-12Ni-2Mo
(316, 316N, 316LN)
515
PS
ASTM A240 (S31600)
8
1
102
8.1
18Cr-13Ni-3Mo (317)
515
PS
ASTM A240 (S31700)
8
1
102
8.1
(continued)
30
K1
Material type
Rm
MPa
ASME BPVC-IX
classification
AS 3992:2020
Standards Australia
TABLE 5.2 (continued)
www.standards.org.au
TABLE 5.2 (continued)
AS
material
group
(Note 3)
K2
K4
Austenitic Cr-Ni steel
(Cr 19)
Austenitic Cr-Ni-Mn
steel
(4 Mn 12)
Form
Welding
Brazing
SA/SNZ
TR ISO 15608
P. No.
Group No.
P. No.
Group No.
18Cr-10Ni-Ti (321)
515
PS
ASTM A240 (S32100)
8
1
102
8.1
18Cr-10Ni-Nb (347)
515
PS
ASTM A240 (S34700)
8
1
102
8.1
18Cr-10Ni-Nb (348)
515
PS
ASTM A240 (S34800)
8
1
102
8.1
18Cr-10Ni-2Si (XM-15)
515
PS
ASTM A240 (S38100)
8
1
102
8.1
25Cr-20Ni (308)
ASTM A308
8
2
102
8.2
23Cr-12Ni (309)
(also with Nb)
ASTM A309 (also with Nb)
ASTM A310 (also with Nb)
8
8
2
2
102
102
8.2
8.2
25Cr-20Ni (310 S)
515
PS
ASTM A240 (S31008)
8
2
102
8.2
25Cr-20Ni (310 H)
515
PS
ASTM A240 (S31009)
8
2
102
8.2
25Cr-20Ni-Nb (310 Nb)
515
PS
ASTM A240 (S31040)
8
2
102
8.2
25Cr-22Ni-2Mo-N
550
PS
ASTM A240 (S31050)
8
2
102
8.2
20Ni-8Cr (331)
550
F
ASTM A182 F10 (S33100)
8
2
102
8.1
17Cr-4Ni-6Mn (201)
515
PS
ASTM A240 (S20100)
8
3
102
8.3
18Cr-5Ni-9Mn
620
PS
ASTM A240 (S20200)
8
3
102
8.3
22Cr-13Ni-5Mn (209)
690
PS
ASTM A240 (S20910)
8
3
102
8.3
19Cr-8Mn-6Ni-Mo-N (216)
620
PS
ASTM A240 (S21600)
8
3
102
8.3
21Cr-6Ni-9Mn (219)
620
PT
ASTM A321 (S21900)
8
3
102
8.3
18Cr-3Ni-12Mn (240)
690
PT
ASTM A249 (S24000)
8
3
102
8.3
20Cr-18Ni-6Mo (312)
650
PS
ASTM A240 (S31254)
8
4
102
8.2
19Cr-15Ni-4Mo (317)
515
PS
ASTM A240 (S31725)
8
4
102
8.1
19Cr-15.5Ni-4Mo (317)
515
PS
ASTM A240 (S31726)
8
4
102
8.1
24Cr-17Ni-6Mn-4.5Mo-N
795
PS
ASTM A240 (S34565)
8
4
102
8.3
(continued)
AS 3992:2020
Standards Australia
Austenitic Cr-Ni-Mo
steel
(Mo 4%)
(Alloy 38%)
Nominal composition
Typical specification
(grade and alloy or UNS number)
31
K3
Material type
Rm
MPa
ASME BPVC-IX
classification
AS
material
group
(Note 3)
L
M1
High Cr steel
(Ferritic stainless)
(Cr 20; Ni < 5)
Austenitic-ferritic Cr-Ni
steel (Duplex)
(Cr 24)
Cr > 24
Nominal composition
Form
Typical specification
(grade and alloy or UNS number)
Welding
Brazing
SA/SNZ
TR ISO 15608
P. No.
Group No.
P. No.
Group No.
27Cr
450
PT
ASTM A268 TP446-2(S44600)
10I
1
102
7.1
27Cr-1Mo-Ti
470
PS
ASTM A240 XM-33 (S44626)
10I
1
102
7.1
27Cr-1Mo
450
PS
ASTM A240 XM-27 (S44627)
10I
1
102
7.1
25Cr-4Ni-4Mo-Ti
620
PS
ASTM A268 (S44635)
10I
1
102
7.1
29Cr-4Mo
550
PS
ASTM A240 (S44700)
10I
1
102
7.1
26Cr-3Ni-3Mo
585
PT
ASTM A268 (S44660)
10K
1
102
7.1
29Cr-4Mo-2Ni
550
PT
ASTM A731 (S44800)
10K
1
102
7.1
18Cr-5Ni-3Mo-N
625
PT
ASTM A789 315 (S31500)
10H
1
102
10.1
21Cr-5Mo-1.5Ni-Cu-N
650
PS
ASTM A240 320 (S32001)
10H
1
102
10.1
22Cr-5Ni-3Mo-N
655
PS
ASTM A240 2205 (S32205)
10H
1
102
10.1
22Cr-4Ni-3Mo-N
620
PS
ASTM A240 318 (S31803)
10H
1
102
10.1
23Cr-4Ni-Mo-Cu-N
690
PT
ASTM A789 323 (S32304)
10H
1
102
10.1
25Cr-6Ni-Mo-N
690
PS
ASTM A240 312 (S31200)
10H
1
102
10.2
25Cr-5Ni-3Mo-2Cu
760
PS
ASTM A240 325 (S32550)
10H
1
102
10.2
25Cr-8Ni-3Mo-W-Cu-N
745
PS
ASTM A240 327 (S32760)
10H
1
102
10.2
26Cr-4Ni-Mo
620
PS
ASTM A240 329 (S32900)
10H
1
102
10.2
25Cr-7Ni-3Mo-2W-Cu-N
800
PT
ASTM A790 392 (S39274)
10H
1
102
10.2
(continued)
32
M2
Material type
Rm
MPa
ASME BPVC-IX
classification
AS 3992:2020
Standards Australia
TABLE 5.2 (continued)
www.standards.org.au
www.standards.org.au
TABLE 5.2 (continued)
AS
material
group
(Note 3)
Material type
Nominal composition
Rm
MPa
Form
ASME BPVC-IX
classification
Typical specification
(grade and alloy or UNS number)
Welding
Brazing
SA/SNZ
TR ISO 15608
P. No.
Group No.
P. No.
Group No.
Non-ferrous materials
Aluminium and aluminium alloys
21
22
25
26
99.6Al (1060)
55
PS
AS/NZS 1734, ASTM B209 (A91060)
21
—
104
21
99Al-Cu (1100)
76
PS
ASTM B209 (A91100)
21
—
104
22.1
Al-Mn-Cu (3003)
97
PS
ASTM B209 (A93003)
21
—
104
22.1
Al-1.5Mg
125
PS
ASTM B209 (A95050)
21
—
104
22.1
Al-Mn-Mg (3004)
150
PS
ASTM B209 (A93004)
22
—
104
22.2
Al-2.5Mg (5050)
170
PT
ASTM B209 (A95052)
22
—
105
22.3
Al-2.5Mg (5052)
170
PS
AS/NZS 1867, ASTM B210 (A95052)
22
—
105
22.3
Al-2.7Mg-Mn (5454)
215
PS
ASTM B209 (A95454)
22
—
105
22.3
Al-3.5Mg (5154)
205
PS
ASTM B209 (A95154)
22
—
105
22.4
Al-Mg-Si alloys
(heat treatable)
Al-Mg-Si-Cu (6061)
165
PS
ASTM B209 (A96061)
23
—
105
23.1
Al-Mg-Si (6063)
115
PT
ASTM B210 (A96063)
23
—
105
23.1
Al-Mg alloys
(Mg > 3.5)
(Rm 230)
(non-heat treatable)
Al-4.4Mg-Mn (5083)
275
PS
ASTM A5058
25
—
105
22.4
Al-4Mg-Mn
235
PS
ASTM A5086
25
—
105
22.4
Al-5.1Mg-Mn
290
PS
ASTM A5456
25
—
105
22.1
Al-Si castings
(Si > 5, Cu 1)
Al-Si
170
C
ASTM B26 T71 (A03560)
26
—
104
24.1
Al-10Si-Mg
150
C
EN 1706 (AC 43000)
26
—
104
24.2
Al alloys (Mg 3.5)
(5000 series)
(Rm < 230)
(non-heat treatable)
33
23
Al alloys
Alloy 1
(Rm < 150)
AS 3992:2020
Standards Australia
(continued)
AS
material
group
(Note 3)
Material type
Nominal composition
Rm
MPa
Form
ASME BPVC-IX
classification
Typical specification
(grade and alloy or UNS number)
Welding
Brazing
SA/SNZ
TR ISO 15608
P. No.
Group No.
P. No.
Group No.
AS 3992:2020
Standards Australia
TABLE 5.2 (continued)
Copper and copper alloys
31
32
Copper (min 99.0Cu)
Cu-Zn alloys
205
PS
ASTM B152 (C11000)
31
—
107
31
99.95Cu-P
205
PT
ASTM B68 (C10200)
31
—
107
31
99.95Cu + Ag
205
PS
ASTM B152 (C10400)
31
—
107
31
99.9Cu-P
205
PT
ASTM B68 (C12000)
31
—
107
31
99.4Cu-As-P
205
PS
ASTM B152 (C14200)
31
—
107
31
60Cu-39Zn-Pb
275
PS
ASTM B71 (C36500)
32
—
107
32.2
60Cu-39Zn-Pb
345
PS
ASTM B171 (C36400)
32
—
107
32.2
85Cu-15Zn
275
PT
ASTM B395 (C23000)
32
—
107
32.2
71Cu-28Zn-1Sn-0.6As
310
PS
ASTM B171 (C44300)
32
—
107
32.2
78Cu-20Zn-2Al
345
PT
ASTM B171 (C68700)
32
—
107
32.2
60Cu-40Zn
345
PT
ASTM B111 (C28000)
32
—
107
32.1
71Cu-28Zn-1Sn-0.6Sb
310
PS
ASTM B171 (C44400)
32
—
107
32.2
71Cu-28Zn-1Sn-0.06P
310
PS
ASTM B171 (C44500)
32
—
107
32.2
76Cu-20Zn-2Al
345
PT
ASTM B543 (C68700)
32
—
107
32.2
www.standards.org.au
33
Cu-Si alloys
97Cu-3Si
345
PS
ASTM B96 (C65500)
33
—
107
37
34
Cu-Ni alloys
90Cu-10Ni (<64 mm)
275
PS
ASTM B171 (C70600)
34
—
107
34
80Cu-20Ni
310
PT
ASTM B359 (C71000)
34
—
109
34
70Cu-30Ni (<64 mm)
315
PS
ASTM B171 (C71500)
34
—
107
34
(continued)
34
99.9Cu
www.standards.org.au
TABLE 5.2 (continued)
AS
material
group
(Note 3)
35
Material type
Nominal composition
Aluminium bronze alloys 88Cu-9Al-3Fe
(>5Al)
90Cu-7Al-3Fe
Rm
MPa
Form
ASME BPVC-IX
classification
Typical specification
(grade and alloy or UNS number)
Welding
Brazing
SA/SNZ
TR ISO 15608
P. No.
Group No.
P. No.
Group No.
450
C
ASTM B271 (C95200)
35
—
108
35
485
PS
ASTM B171 (C61400)
35
—
108
35
95Cu-5Al
345
PT
ASTM B111 (C60800)
35
—
108
35
81Cu-10Al-5Ni-3Fe
550
PS
ASTM B171 (C63000)
—
—
—
—
Cu-Ni-Zn alloys
Note 2
—
—
36
37
Copper alloys,
low-alloyed
(<5% other elements not
in 31 to 36)
Note 2
—
—
37
38
Other copper alloys
( 5% other elements not
in 31 to 36)
Note 2
—
—
38
35
36
Nickel and nickel alloys
41
42
43
Nickel and low carbon
nickel
99.0Ni (200)
380
PS
ASTM B162 (N02200)
41
—
110
41
99.0Ni-low C (201)
345
PS
ASTM B162 (N02201)
41
—
110
41
Ni-Cu alloy
(Ni 45, Cu
67Ni-30Cu (400)
485
PS
ASTM B127 (N04400)
42
—
110
42
67N-30Cu
485
PT
ASTM B165, B168 (N04400)
42
—
110
42
72Ni-15Cr-8Fe (600)
550
PP
ASTM B168 (N06600)
43
—
111
43
58Ni-29Cr-9Fe
585
PT
ASTM B163 (N06690)
43
—
111
43
55Ni-21Cr-13Mo
690
PS
ASTM B575 (N06622)
43
—
111
44
Ni-Cr alloy
(Ni > 45)
10)
AS 3992:2020
Standards Australia
(continued)
AS
material
group
(Note 3)
44
45
www.standards.org.au
47
Ni-Mo alloy
(Ni 45, Mo
32)
Ni-Fe-Cr alloy
(Ni > 20)
Ni-Cr-Si alloy
(Ni > 45)
Ni-Fe-Cr-Cu alloy
(Ni > 45)
Nominal composition
Form
Typical specification
(grade and alloy or UNS number)
Welding
Brazing
SA/SNZ
TR ISO 15608
P. No.
Group No.
P. No.
Group No.
65Ni-28Mo-2Fe
795
PS
ASTM B333 (N10601)
44
—
112
44
62Ni-25Mo-8Cr-2Fe
725
PS
ASTM B434 (N10242)
44
—
112
44
65Ni-28Mo-5Fe
690
PT
ASTM B622 (N10001)
44
—
112
44
65Ni-28Mo-2Fe
760
PT
ASTM B622 (N10065)
44
—
112
44
66Ni-28Mo-3Fe-1.3Cr-0.25Al
760
PS
ASTM B333 (N10629)
44
—
112
44
65Ni-29.5Mo-2Fe-23Cr
760
PS
ASTM B333 (N10675)
44
—
112
44
70Ni-16Mo-7Cr-5Fe
690
PS
ASTM B434 (N10003)
44
—
112
44
25Ni-20Cr-6Mo-Co-N
650
PS
ASTM B625 (N08926)
45
—
111
8.2
25Ni-47Fe-21Cr-5Mo
550
PS
ASTM B599 (N08100)
45
—
111
8.2
35Ni-35Fe-20Cr-Nb
550
PT
ASTM B729 (N08020)
45
—
111
45
44Fe-25Ni-21Cr-Mo
490
PT
ASTM B677 (N08904)
45
—
111
8.2
27Ni-22Cr-7Mo-Co
770
PS
ASTM A240 (S31277)
45
—
111
8.2
42Ni-21.5Cr-3Mo-2.5Co
585
PS
ASTM B424 (N08825)
45
—
111
45
33Ni-42Fe-21Cr
450
PT
ASTM B163 (N08800)
45
—
111
45
32Ni-45Fe-20.5Cr-Ti
585
PT
ASTM B163 (N08800)
45
—
111
45
42Ni-21.5Cr-3Mo-2.5Cu
585
PS
ASTM B424 (N08825)
45
—
111
45
35Ni-19Cr-1.25Si
485
PS
ASTM B536 (N08330)
46
—
111
45
37Ni-30C-28Cr-2.7Si
620
PS
ASTM B435 (N12160)
46
—
111
45
46Ni-27Cr-23Fe-2.8Si
620
B
ASTM B166 (N06045)
46
—
111
45
37Ni-30C-28Cr-2.7Si
620
PT
ASTM B622 (N12160)
46
—
111
45
—
—
Note 2
—
—
47
—
—
(continued)
36
46
Material type
Rm
MPa
ASME BPVC-IX
classification
AS 3992:2020
Standards Australia
TABLE 5.2 (continued)
www.standards.org.au
TABLE 5.2 (continued)
AS
material
group
(Note 3)
48
Material type
Nominal composition
Ni-Fe-Co-Cr-Mo-Cu
alloy (25 Ni 45),
(Fe 20)
—
Rm
MPa
Form
—
—
ASME BPVC-IX
classification
Typical specification
(grade and alloy or UNS number)
Welding
Brazing
SA/SNZ
TR ISO 15608
P. No.
Group No.
P. No.
Group No.
Note 2
—
—
48
ASTM B381 (R50250)
51
—
115
51
—
Titanium and titanium alloys
51
53
54
240
F
240
PS
ASTM B265-1 (R50250)
51
—
115
51
Ti (2)
345
PS
ASTM B265-2 (R50400)
51
—
115
51
Ti (2H)
400
PS
ASTM B265-2H (R50400)
51
—
115
51
Ti-Ru
345
PT
ASTM B338-26 (R52404)
51
—
115
51
Ti-Pd
345
PT
ASTM B861-7 (R52400)
51
—
115
51
Ti-0.3Mo-0.8Ni (12)
485
PT
ASTM B338-12 (R53400)
52
—
115
52
Ti (3)
450
PT
ASTM B338-3 (R50550)
52
—
115
52
Ti (3)
450
PS
ASTM B265-3 (R50550)
52
—
115
52
Ti (12)
485
PS
ASTM B265-12 (R53400)
52
—
115
52
Ti-3Al-2.5V (9)
620
PS
ASTM B265-9 (R56320)
53
—
115
53
Ti-3Al-2.5V-0.1Ru (28)
620
PT
ASTM B861-28 (R56323)
53
—
115
53
Ti-3Al-6V-2Sn (9)
620
PT
ASTM B862-9 (R56320)
53
—
115
53
Ti-3Al-2.5V-0.1Ru (28)
620
PT
ASTM B862-28 (R56323)
53
—
115
53
Note 2
—
—
54
Ti alpha alloys
R m > 420 MPa
Ti alpha-beta alloys
Ti-10V-2Fe-3Al and higher
alloys
—
(continued)
AS 3992:2020
Standards Australia
Ti near-beta and betaalloys
37
52
Unalloyed and alloyed Ti Ti
(Rm 420 MPa)
Ti (1)
AS
material
group
(Note 3)
Material type
Nominal composition
Rm
MPa
Form
ASME BPVC-IX
classification
Typical specification
(grade and alloy or UNS number)
Welding
Brazing
SA/SNZ
TR ISO 15608
P. No.
Group No.
P. No.
ASTM B651-702 (R60702)
61
—
117
61
AS 3992:2020
Standards Australia
TABLE 5.2 (continued)
Group No.
Zirconium and zirconium alloys
61
62
Unalloyed Zr
Alloyed Zr
99.2Zr (702)
95.5Zr-2.5Nb (705)
380
PS
380
F
ASTM B493 (R60702)
61
—
117
61
380
T
ASTM B523 (R60702)
61
—
117
61
550
PS
ASTM B551-705 (R60705)
62
—
117
62
485
F
ASTM B493-705 (R60705)
62
—
117
62
550
T
ASTM B523-705 (R60705)
62
—
117
62
Cast irons
38
NOTE: Not normally welded to pressure equipment.
www.standards.org.au
71
Grey cast irons with
R m or HB
—
—
—
AS 1830, ISO 185
(JL/100 to JL/350)
Note 2
—
—
71
72
Spheroidal-graphite cast
irons with specified
mechanical properties
—
—
—
SA/SNZ TR ISO 15608
ISO 1831 (370-17)
(400-12)
(500-7)
Note 2
—
—
72
73
Malleable cast irons
—
—
AS 1832, ISO 5922
Note 2
—
—
73
74
Austempered ductile
cast irons
—
—
—
—
Note 2
—
—
74
75
Austenitic cast irons
—
—
—
—
Note 2
—
—
75
76
Cast irons excepting
71–75
—
—
—
—
Note 2
—
—
76
White heart and black heart
LEGEND:
Rm = specified minimum tensile strength
Re = specified minimum yield or 0.2% proof strength
A = % elongation
Cv = Charpy V
HB = Hardness Brinell
B
C
F
PS
PT
= bar or section
= casting
= forging
= plate, sheet or strip
= pipe or tube
39
AS 3992:2020
NOTES TO TABLE 5.2:
1
This Table lists material groups according to composition and lists representative standards, primarily
plate and pipe and Rm values only for the thinnest plate when Rm varies with the thickness.
2
SA/SNZ TR ISO 15608 for these alloys is not adopted in ASME BPVC-IX.
3
Where reference is made only to the group letter, all groups with the letter are referenced unless noted.
Group B5 materials in this Standard were previously classed as ‘D1 materials’ within
AS/NZS 3992:2015, see also Clause 5.4.
4
Document titles for the typical specifications may not appear in the referenced documents list. If this
information is required please refer to the website of the relevant Standards organization.
5
See ISO/TR 20172, ISO/TR 20173 and/or ISO/TR 20174 (as appropriate) for SA/SNZ TR ISO 15608
material group numbers. These Standards also list the ASME/AWS P/M numbers and groups, including
those of superseded material designations.
6
SA/SNZ TR ISO 15608 grouping numbers may vary with the product manufacturing route. API 5L grades
are particularly affected with chemistry only and microalloyed group numbers being shown in the Table.
7
The basis for the material groups utilized within AS 3992 are defined within column 2 of this Table
(see also Appendix D). Carbon equivalent (CE) is defined in Clause 2.1.
TABLE 5.3(A)
PROCEDURE QUALIFICATION OF OTHER MATERIAL GROUPS
Material group(s) of original
qualified welding procedure
Other material groups or combinations
of steel groups (see Note 1)
A1 to A1
A1 to A2
A2 to A2
A3 to A1, A2 or A3
A1 to A2 (see Note 2), A2 to A2 (see Note 2)
A1 to A1, A2 to A2 (see Note 2)
A1 to A1, A1 to A2
Nil
B1 to B1
B1 to A2 or A1
B2 to B2
B2 to B1 or A2 or A1
B2 to B1, A2 or A1
B5 to B5
B5 to D2 (see Note 3), B5 to C
C to C
C to B1, A2 or A1
C to B1, A2 or A1
D1 to D1
D1 to D2 (Note 3)
D2 or D3 to D2 or D3
D2 to C, B1, A2
D2 or D3 to C, B1, A2 or A1 (Note 3)
K to A1, A2, B1, C, D2 or D3
K (see Note 5) to any lower ferritic steel group provided
nickel-based alloy welding consumables are used
(see Table 5.5)
NOTES:
1
Conformance to Item 5(b) of Table 5.1 is required.
2
See Clause 5.2.2.
3
See Clause 5.4.
4
For other materials, refer to Table 5.3(B) and Table 5.3(C).
5
K applies to K1 to K4 materials. See also Note 3 of Table 5.2.
www.standards.org.au
Standards Australia
AS 3992:2020
40
TABLE 5.3(B)
RANGE OF QUALIFICATION OF MATERIAL GROUPS IN SA/SNZ TR ISO 15608
SA/SNZ TR
ISO 15608
number
Test piece B (see Notes)
1 and 11
2
3
4
5
6
7
8
9
10
1 and 11
11-11
11-1
1-1
11-1
11-2
11-1
11-2
11-3
11-4
11-5
11-6
11-7
11-8
11-9
11-10
2
1-1
1-2
1-1
2-1
2-2
—
—
—
—
—
—
—
—
1-1
2-1
3-1
1-1
2-1
2-2
3-1
3-2
1-1
2-1
2-2
3-1
3-2
3-3
—
—
—
—
—
—
—
4-1
4-1
4-2
4-1
4-2
4-3
4-1
4-2
4-3
4-4
—
—
—
—
—
—
5-2
5-3
5-4
5-1
5-2
5-5
—
—
—
—
—
—
—
—
—
—
—
—
—
—
3
4
5
6
7
8
9
10
5-1
6-1
7-1
8-1
9-1
10-1
6-1
6-2
6-1
6-2
6-3
6-1
6-2
6-3
6-4
6-1
6-2
6-3
6-4
6-5
6-1
6-2
6-3
6-4
6-5
6-6
7-1
7-2
7-1
7-2
7-3
7-4
7-5
7-5
7-6
7-7
8-1
8-2
8-1
8-2
8-3
8-4
8-1
8-2
8-4
8-5
8-6
8-1
8-2
8-4
8-5
8-6
8-7
9-1
9-2
9-1
9-2
9-3
9-4
9-5
9-6
9-7
10-1
10-2
10-1
10-2
10-3
10-4
8-8
9-8
9-9
—
10-1
10-2
10-3
10-4
10-5
10-6
10-1
10-2
10-4
10-6
10-7
10-8
10-9
10-10
NOTES:
1
Refer to Appendix D for equivalent AS 3992 and ISO material groups.
2
SA/SNZ TR ISO 15608 groups 1, 2, 3 and 11 qualify the equal or lower specified minimum yield strength
steels.
3
Test pieces of SA/SNZ TR ISO 15608 groups 4, 5, 6, 8 and 9 qualify steels in the same sub-group and any
lower sub-group within the same group.
4
Test pieces of SA/SNZ TR ISO 15608 groups 7 and 10 qualify steels in the same sub-group.
Standards Australia
www.standards.org.au
41
AS 3992:2020
TABLE 5.3(C)
RANGE OF QUALIFICATION OF MATERIAL FOR NICKEL ALLOY
AND NICKEL ALLOY/STEEL GROUPS
Test piece material B
Test piece
material A
41
42
43
44
45
46
47
48
41
41c –41
—
—
—
—
—
—
—
42
42c –41
42c –42
—
—
—
—
—
—
—
—
—
—
—
44 c –44
—
—
—
—
—
—
—
46 c –46
—
—
43 c–43
43
43c –41
43c –42
45 c–45
47 c–47
44
44c –41
44c –42
44 c–43
45
45c –41
45c –42
45 c–43
45 c –44
46
46c –41
46c –42
46 c–43
46 c –44
45 c–45
43 c–43
46 c–45
47 c–47
47
47c –41
47c –42
47 c–43
47 c –44
47 c–45
47 c –46
43 c–43
—
45 c–45
48
48c –41
48c –42
48 c–43
48 c –44
48 c–45
48 c –46
48 c–47
48 c –48
1
41c –1
42c –1
43 c–1
44 c –1
45 c–1
46 c –1
47 c–1
48 c –1
41 c–2 a
42 c–2 a
43 c –2 a
44 c–2 a
45 c –2 a
46 c–2 a
47 c –2 a
48 c–2 a
41c –1
42c –1
43 c–1
44 c –1
45 c–1
46 c –1
47 c–1
48 c –1
41 c–3 a
42 c–3 a
43 c –3 a
44 c–3 a
45 c –3 a
46 c–3 a
47 c –3 a
48 c–3 a
41c –2
42c –2
43 c–2
44 c –2
45 c–2
46 c –2
47 c–2
48 c –2
41c –1
42c –1
43 c–1
44 c –1
45 c–1
46 c –1
47 c–1
48 c –1
41 c–5 b
42c –5 b
43c –5 b
44 c–5 b
45 c –5 b
46 c–5 b
47 c –5 b
48 c–5 b
41c –6
42 c –6
43 c–6
44 c –6
45 c–6
46 c –6
47 c–6
48 c –6
41c –4
42c –4
43 c–4
44 c –4
45 c–4
46 c –4
47 c–4
48 c –4
41c –2
42c –2
43 c–2
44 c –2
45 c–2
46 c –2
47 c–2
48 c –2
41c –1
42c –1
43 c–1
44 c –1
45 c–1
46 c –1
47 c–1
48 c –1
41 c–6 b
42c –6 b
43c –6 b
44 c–6 b
45 c –6 b
46 c–6 b
47 c –6 b
48 c–6 b
41c –4
42c –4
43 c–4
44 c –4
45 c–4
46 c –4
47 c–4
48 c –4
41c –2
42c –2
43 c–2
44 c –2
45 c–2
46 c –2
47 c–2
48 c –2
41c –1
42c –1
43 c–1
44 c –1
45 c–1
46 c –1
47 c–1
48 c –1
8
41 c–8 b
42c –8 b
43c –8 b
44 c–8 b
45 c –8 b
46 c–8 b
47 c –8 b
48 c–8 b
11
41c –11
42c –11
43 c–11
44 c –11
45 c–11
46 c –11
47 c–11
48 c –11
2
3
5
6
a
Covers the equal or lower specified yield strength steels of the same group.
b
Covers steels in the same sub-group and any lower sub-group within the same group.
c
For groups 41 to 48, a procedure test carried out with a solid solution or precipitation
hardening alloy in a group covers all solid solution or precipitation hardening alloys,
respectively, in the same group.
www.standards.org.au
Standards Australia
AS 3992:2020
42
TABLE 5.4
RANGE OF PARENT MATERIAL
AND WELD DEPOSIT THICKNESS QUALIFIED
Item
Range of parent material thickness qualified
(see Notes)
Welding process
1
Gas welding
t
2
Single-run or multi-run welding where any run is
greater than 13 mm throat (not applicable to GTAW)
1.1t
3
Gas metal-arc welding and flux cored arc welding both
with short circuiting arc transfer with t 13 mm
1.1t
4
Except for above Items 2 and 3, single or multi-run
t to 2t ...................... for
manual metal-arc, submerged arc, gas tungsten-arc, gas 1.5 mm to 2t ............ for
metal-arc and flux cored-arc welding
5 mm to 2t .............. for
5 mm to 200 mm ..... for
5 mm to 1.33t .......... for
5
Electroslag welding
t < 1.5 mm
t 10 mm
t > 10 mm < 40 mm
t 40 mm and 150 mm
t > 150 mm
1.1t
NOTES:
1
t = thickness of test plate or pipe.
2
The maximum weld deposit throat thickness of each run qualified is—
(a)
2tr when tr < 20 mm; and
(b)
the maximum parent material thickness qualified, when t r
20 mm,
where
tr
= maximum throat thickness of any run in the test weld.
TABLE 5.5
FILLER METAL GROUP CLASSIFICATION
F
Welding
number process
Welding consumable
description
(see Note 1)
Australian
Standard
(see Note 2)
ASME BPVC-IIC
Spec. No.
Classification
Ferrous materials
F1
MMAW High iron powder or iron oxide
electrode for carbon and
carbon manganese and low
alloy steels
AS/NZS 4855
SFA 5.1 and 5.5 EXX20, EXX22,
EXX24, EXX27,
EXX28
F2
MMAW High titania (rutile) electrode
for carbon and carbon
manganese and low alloy steels
AS/NZS 4855
SFA 5.1 and 5.5 EXX12, EXX13,
EXX14, EXX19
F3
MMAW High cellulose electrode for
carbon and carbon manganese
and low alloy steels
AS/NZS 4855
SFA 5.1 and 5.5 EXX10, EXX11
F4
MMAW Hydrogen controlled basic
electrode for carbon and
carbon manganese and low
alloy steels
AS/NZS 4855
AS/NZS 4857
SFA 5.1 and 5.5 EXX15, EXX16,
EXX18, EXX48
MMAW Hydrogen controlled basic
electrode for high chromium
other than austenitic and
duplex steels
AS/NZS 4856
SFA 5.4
EXX15, EXX16,
EXX17
MMAW Hydrogen controlled basic
electrode for high alloy
austenitic and duplex steels
AS/NZS 4854
SFA 5.4
EXX15, EXX16,
EXX17
F5
(continued)
Standards Australia
www.standards.org.au
43
AS 3992:2020
TABLE 5.5 (continued)
F
Welding
number process
F6
Welding consumable
description
(see Note 1)
Oxy
Filler metal rods for carbon
acetylene and low alloy steels
welding
Australian
Standard
(see Note 2)
ASME BPVC-IIC
Spec. No.
AS/NZS 1167.2
SFA 5.2
RX
Classification
SAW
Electrodes for carbon and
carbon manganese steels
AS/NZS ISO 14171
AS/NZS ISO 14174
SFA 5.17
FXX-EXX
SAW
Electrodes for low alloy steels
AS/NZS ISO 14174
SFA 5.23
FX-EXXX-X
SAW
Electrodes for high alloy
austenitic steels
AS/NZS ISO 14343
SFA 5.9
ERXX
GTAW Electrodes for high alloy
GMAW austenitic steels
AS/NZS 1167.2
ISO 14343
SFA 5.9
ERXX
GTAW Electrodes for carbon and
GMAW carbon manganese steels
AS/NZS 1167.2
AS/NZS 14341
ISO 636
SFA 5.18
ERXXS-X
GTAW Electrodes for low alloy steels
GMAW
AS/NZS 1167.2
AS/NZS 14341
AS/NZS 21952
AS/NZS 16834
SFA 5.28
ERXXX-X
ERXXX-X
FCAW
Electrodes for carbon and
carbon manganese steels
AS/NZS ISO 17632
(see Note 3)
SFA 5.20
EXXT-X
FCAW
Electrodes for low alloy steels
AS/NZS ISO 17634
AS/NZS ISO 18276
(see Note 3)
SFA 5.29
EXXTX-X
FCAW
Electrodes for high alloy steels
AS/NZS ISO 17633
SFA 5.22
EXXXT-X
Aluminium alloys
F21
GTAW Aluminium welding rod
GMAW (99% aluminium)
AS/NZS 1167.2
AS/NZS ISO 18273
SFA 5.10
ER 1100
F22
GTAW Aluminium alloy welding rod
GMAW (magnesium chromium alloy)
AS/NZS 1167.2
AS/NZS ISO 18273
SFA 5.10
ER
ER
ER
ER
ER
5183
5356
5554
5556
5654
F23
GTAW Aluminium alloy welding rod
GMAW (silicon 4.5–6%)
AS/NZS 1167.2
AS/NZS ISO 18273
SFA 5.10
ER
ER
ER
ER
ER
4043
4009
4047
4010
4145
F24
GTAW Aluminium alloy
GMAW
AS/NZS 1167.2
AS/NZS ISO 18273
SFA 5.10
R 356.0
F25
GTAW Aluminium alloy electrode and
GMAW rod
AS/NZS ISO 18273
SFA 5.10
ER 2319
R 2319
Copper and copper alloys
F31
GTAW Copper rod
GMAW (Copper 98% minimum)
AS/NZS 1167.2
SFA 5.7
ER Cu
F32
GTAW Copper silicon rod
GMAW (silicon bronze)
AS/NZS 1167.2
SFA 5.7
ER Cu Si-A
F33
GTAW Copper tin rod
GMAW (phosphor bronze)
AS/NZS 1167.2
SFA 5.7
ER Cu Sn-A
(continued)
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TABLE 5.5 (continued)
F
Welding
number process
F34
F35
Welding consumable
description
(see Note 1)
GTAW Copper nickel rod
GMAW
GW
Copper alloy rod (copper zinc)
Australian
Standard
(see Note 2)
ASME BPVC-IIC
Spec. No.
AS/NZS 1167.2
SFA 5.7
ER Cu Ni
AS/NZS 1167.2
SFA 5.27
RB Cu
RB Cu
RB Cu
RB Cu
Classification
Zn-A
Zn-B
Zn-C
Zn-D
F36
GTAW Copper aluminium rod
GMAW (aluminium bronze)
AS/NZS 1167.2
SFA 5.7
ER Cu Al-A1
ER Cu Al-A2
ER Cu Al-A3
F37
GTAW Copper alloy gas welding rods
GMAW (copper-nickel-aluminium)
AS/NZS 1167.2
SFA 5.7
ER Cu Ni Al
ER Cu Mn Ni Al
—
SFA 5.11
E Ni-1
AS/NZS 1167.2
SFA 5.14
ER Ni-1
—
SFA 5.11
E Ni Cu-7
AS/NZS 1167.2
SFA 5.14
ER Ni Cu-7
—
SFA 5.11
E
E
E
E
E
E
E
AS/NZS 1167.2
SFA 5.14
ER
ER
ER
ER
ER
MMAW Nickel molybdenum and nickel
chromium molybdenum
electrodes
—
SFA 5.11
E
E
E
E
E
E
GMAW Nickel molybdenum and nickel
GTAW chromium molybdenum
welding rod
AS/NZS 1167.2
SFA 5.14
ER
ER
ER
ER
ER
ER
MMAW Nickel chromium molybdenum
electrode
—
SFA 5.11
E Ni Cr Mo-1
E Ni Cr Mo-9
GMAW Nickel chromium molybdenum
GTAW and nickel iron chromium
AS/NZS 1167.2
SFA 5.14
ER
ER
ER
ER
Nickel and nickel based alloys
F41
MMAW Nickel welding electrode
(nickel 92% minimum)
GMAW Nickel welding rod
GTAW
F42
MMAW Nickel copper welding
electrode (monel metal)
GMAW Nickel copper welding rod
GTAW (monel metal)
SAW
F43
MMAW Nickel chromium iron and
nickel chromium molybdenum
electrode
GMAW Nickel chromium, nickel
GTAW chromium iron and nickel
SAW
chromium molybdenum
welding rod
F44
F45
Ni
Ni
Ni
Ni
Ni
Ni
Ni
Cr
Cr
Cr
Cr
Cr
Cr
Cr
Ni
Ni
Ni
Ni
Ni
Ni
Ni
Ni
Ni
Ni
Ni
Fe-1
Fe-2
Fe-3
Fe-4
Mo-2
Mo-3
Mo-6
Cr-3
Cr Fe-5
Cr Fe-6
Cr Mo-2
Cr Mo-3
Mo-1
Mo-3
Mo-7
Cr Mo-4
Cr Mo-5
Cr Mo-7
Ni
Ni
Ni
Ni
Ni
Ni
Ni
Ni
Ni
Ni
Mo-1
Mo-2
Mo-7
Cr Mo-4
Cr Mo-5
Cr Mo-7
Cr
Fe
Cr
Cr
Mo-1
Cr-1
Mo-8
Mo-9
(continued)
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AS 3992:2020
TABLE 5.5 (continued)
Australian
Standard
(see Note 2)
Spec. No.
Classification
MMAW Nickel chromium iron
electrode
—
SFA 5.11
E Ni Cr Fe Si-1
GMAW Nickel chromium iron rod
GTAW
Nickel cobalt chromium iron
welding rod
—
SFA 5.14
ER Ni Cr Fe Si-1
—
SFA 5.14
ER Ni Cr Fe Si-1
F
Welding
number process
F46
Welding consumable
description
(see Note 1)
ASME BPVC-IIC
Titanium and titanium alloys
F51
GTAW Titanium alloy welding rod
GMAW
—
SFA 5.16
ER
ER
ER
ER
Ti-1
Ti-2
Ti-3
Ti-4
F52
GTAW Titanium alloy welding rod
GMAW
—
SFA 5.16
ER Ti-4
F53
GTAW Titanium alloy welding rod
GMAW
—
SFA 5.16
ER Ti-9
GLEI-18
GLEI-22
F54
GTAW Titanium alloy welding rod
GMAW
—
SFA 5.16
ER Ti-12
F55
GTAW Titanium alloy welding rod
GMAW
—
SFA 5.16
ER
ER
ER
ER
ER
F56
GTAW Titanium alloy welding rod
GMAW
—
SFA 5.16
ER Ti-32
Ti-5
Ti-23
Ti-24
Ti-25
Ti-29
Zirconium and zirconium alloys
F61
GMAW Zirconium alloy welding rod
—
SFA 5.24
ER Zr2
F61
GMAW Zirconium alloy welding rod
—
SFA 5.24
ER Zr3
F61
GMAW Zirconium alloy welding rod
—
SFA 5.24
ER Zr4
Hard facing weld metal overlay
F71
MMAW Hard facing electrode
—
SFA 5.13
Various
F72
GTAW Hard facing rod
GMAW
SAW
—
SFA 5.21
Various
NOTES:
1
F-number grouping of consumables is based primarily on their useability characteristics, which largely
determine the ability of welders to make satisfactory welds with a given filler metal. The grouping is made
to reduce the number of welding procedure and performance qualifications, where this can logically be
done.
Grouping is not to imply the parent metals or filler metals within a group may be indiscriminately
substituted for a metal which was used in the qualification test without consideration of the compatibility
of the parent and filler metals in respect of metallurgical properties, postweld heat treatment, design and
service requirements, and mechanical properties. See also Table 5.1, Item 5.
2
For welder qualification, each row within a F-number category requires separate qualification. For
classification of the consumable, use the equivalent of the ASME classification in the right hand column.
Other standards and consumables which are equivalent to those listed for ASME BPV Code may be used.
3
It is recommended to determine, based on alloy content(s) and yield/tensile strengths, which of the three
AS/NZS ISO Standards (17632, 17634 or 18276) is applicable.
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TABLE 5.6
EQUIVALENT PARENT MATERIAL THICKNESS
FOR VARIOUS JOINT CONFIGURATIONS
Type of weld
Typical weld preparation
Equivalent parent material
thickness (t) for Item 2 of
Table 5.1 (see Notes)
1
Shell butt welds
1.1
Double welded butt
½ [t s2 + t s1]
see Note 2
1.2
Single welded butt
½ [t s1 + t s2]
1.3
Single welded butt with
retaining backing strip
½ [t s1 + t s2]
2
Nozzle and branch welds
2.1
Butt or fillet welds, full or
partial penetration in set-on
nozzle
½ [ts + t b]
2.2
Set-on butt or fillet welds,
complete penetration
½ [tb + ts ]
2.3
Joint with compensating
plate
Weld A: ½ [t s + t b]
Weld B: ½ [t s + tb + tr ]
Weld C: ½ [2t s + t r ]
(continued)
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AS 3992:2020
TABLE 5.6 (continued)
Type of weld
Typical weld preparation
Equivalent parent material
thickness (t) for Item 2 of
Table 5.1 (see Notes)
3
Flange welds
3.1
Weld neck flange
3.2
Face and back weld on
flange
4
Studded connections welds
4.1
Butt weld to shell
½ [t s + smaller of tp1 and t p2 ]
4.2
Fillet weld to shell
Weld A: ½ [ts + smaller of
t p1 and t p2 ]
Weld B: ½ [2ts + smaller of
t p1 and t p2 ]
5
Attachments to shell welds
5.1
Fillet or butt weld to shell,
full or partial penetration
ts
Weld A: ½ [t s + t f ]
Weld B: ½ [2t s + t f ]
½ [2t s + ta ]
(continued)
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TABLE 5.6 (continued)
Type of weld
5.2
Typical weld preparation
Fillet weld to doubling plate
and shell
Equivalent parent material
thickness (t) for Item 2 of
Table 5.1 (see Notes)
Weld A: ½ [2t s + t p]
Weld B: ½ [2t p + ta ]
NOTES:
1
This table is used to calculate the equivalent parent metal thickness from the joint combined thickness
based on a butt weld with equal thickness plates. AS 4458 uses plate thickness for the determination of
preheat in lieu of combined thickness.
2
The thickness of a part (ts , etc.) is the average thickness over a distance of 75 mm from the weld root.
3
The value in brackets is the ‘combined thickness’ which provides paths for heat flow from the weld and
influences cooling rate. It equals the combined thickness of two butt welded test plates each of thickness
‘t’.
4
Alternatively to above figures, for production welds—
5
(a)
the thickness of the thinner part shall be within the range of parent metal thickness as specified in
Table 5.4; and
(b)
the thickness of thicker part(s) shall be—
(i)
unlimited for material groups K, 40–46, 51–53, 61 and 62 provided the thickness of the base
plate is 6 mm; and
(ii)
for other material groups, within the range permitted by Table 5.4, except there will be no
limitation on the maximum thickness when qualification is made with test plate 40 mm
thick.
The parent metal thickness (t) from the above figures ensures cooling rate and properties of production
welds are equivalent to the test plate. The thickness in Note 3 above is based on wide experience, but
cooling rate and properties will vary unless preheat is adjusted in accordance with Note 3 of Table 5.1.
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AS 3992:2020
NOTES:
1
The direction of making a weld is not pertinent to a fundamental welding position. See Item 4, Table 5.1
and Item 4, Table 9.1 for welding direction as an essential variable.
2
Electrode angle shown is nominal and may be varied in practice.
3
PF refers to vertical up welding direction, and PG refers to welding vertical down.
4
Refer to Figure 5.2 for the fundamental welding positions in pipe.
5
Refer Appendix G for further information on fundamental plate welding positions.
FIGURE 5.1 WELDING POSITIONS
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(a) Fundamental welding positions in pipe
(b) Inclined welding position in pipe
NOTES:
1
Pipe positions PA shown with a rotating specimen. Other welds are performed with the workpiece in the
fixed position.
2
For convenience, only round pipe is illustrated.
3
PH (formerly PF) refers to vertical up welding direction and PJ (formerly PG) refers to welding vertical
down in pipe.
4
H-L045 refers to vertical up welding of a pipe inclined at 45° and J-L045 refers to vertical down welding
of a pipe inclined at 45°.
5
Refer Appendix G for further information on fundamental pipe welding positions.
FIGURE 5.2 WELDING POSITIONS IN PIPE
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S E CT I ON
6
WE L D
AS 3992:2020
T E S T
PI E CE S
6.1 TEST PIECES
6.1.1 When required
When a welding procedure, welder qualification or production weld test is required, an
appropriate test piece shall be prepared to assess the mechanical properties or soundness of
the joint.
For procedure qualification tests of special welds, see Section 8.
6.1.2 Form
A test piece shall consist of one of the following:
(a)
A butt joint (plate or pipe).
NOTE: Recommended test pieces are shown in Figure 6.1, Figure 6.2 and Figure 6.4.
(b)
A fillet weld (plate).
NOTE: A recommended test piece is shown in Figure 6.3.
Tests on butt welds qualify welding procedures for use on branch welds and fillet welds,
except that for fillet welds, tests, such as the example shown in Figure 6.3, are required
where doubt exists as to whether butt welds adequately assess the properties of fillet welds,
for example joints under high restraint.
Fillet welds qualified by a fillet weld or butt weld test may be used in all fillet weld sizes in
all base metal thicknesses and in all diameters, provided all other essential variables are
conformed to.
6.1.3 Dimensions
The dimensions and number of test pieces shall be such as to provide for the appropriate
test specimens given in Table 6.1 for qualification of welding procedures, Table 9.3 for
welder qualifications and Table 10.1 for production welds.
Figures 6.4 and 6.5 show locations for taking test specimens from plates and pipes
respectively.
Additional test specimens may be required to fully assess a welding procedure when any of
the following conditions apply:
(a)
Soundness in joints with restrictive access for welding.
(b)
Severe restraint, from loading including mechanical and/or thermal.
(c)
Joints which may produce lamellar tearing.
(d)
Special fillet shapes or fillet welds between dissimilar metals especially when service
requirements are in corrosive environments.
6.1.4 Preparation
Test pieces shall be prepared using the appropriate welding procedure and considering the
service conditions (see also Section 8).
Test pieces shall be suitably identified.
Surface imperfections or defects in completed test welds shall not be repaired or dressed
prior to visual examination.
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6.1.5 Assessment
Test pieces shall be assessed in the following manner and sequence:
(a)
Visual examination.
(b)
Non-destructive examination using the same methods as those proposed for the
assessment of production welds.
(c)
Destructive tests.
The assessment may be stopped at any stage when the results are unsatisfactory.
Final non-destructive examination shall not be carried out until 24 h after the weld has been
completed for crack sensitive materials as defined in AS 4037.
6.2 VISUAL EXAMINATION
Prior to carrying out non-destructive examination as required by Clause 6.3, all completed
test pieces shall be subjected to visual examination and shall conform to the requirements of
AS 4458.
NOTE: For guidance on surface colours when welding stainless steels, or titanium and its alloys,
see Appendix I.
6.3 NON-DESTRUCTIVE EXAMINATION OF TEST PIECES
Non-destructive examination shall be carried out for welding procedure qualification, and
for combined welding procedure and welder qualification test pieces, in accordance with
the pressure equipment Standard. The purpose of the examination is to ensure that only
sound weld metal is subjected to the destructive tests. Weld metal or parent metal cracking
of any type shall be cause for rejection of the test piece.
When non-destructive examination reveals defects outside the acceptance limits of the
pressure equipment Standard, the test piece is not acceptable as a welder qualification test
weld, nor as a procedure qualification test weld where the defects are not attributed to the
welder.
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AS 3992:2020
TABLE 6.1
NUMBER OF TEST SPECIMENS REQUIRED FOR WELDING PROCEDURE
QUALIFICATION (see Notes)
Butt joint in plate and pipe
Test specimen
Fillet weld
Fillet weld
in plate
in pipe
(Note 2)
Thickness
Thickness
<10 mm
10 mm
Macro-examination (Note 1)
1
1
2
4
Hardness survey (Note 3)
1
1
1
—
Transverse tensile (Notes 4, 5 and 6)
2
2
—
—
All-weld-metal tensile (Notes 7 and 12)
—
1
—
—
Root bend (Notes 5, 8 and 9)
2
—
—
—
2
(Note 14)
—
—
—
Face bend (Notes 5 and 8)
Side bend (Notes 5 and 8)
—
4
—
—
Fillet weld fracture (for test piece with
only single side weld)
—
—
3
—
Impact test (Charpy V) weld and HAZ
Chemical analysis
For requirements see Notes 10 and 11
See Note 13
NOTES:
1 One specimen for macro-examination shall be taken from that part of the joint considered to have been
welded in the most difficult welding position or from a stop/start position.
2 Fillet tests are only required to assess the properties of fillet welded joints not reasonably assessed by a
butt joint (see Clause 6.1).
3 The hardness survey is not required unless specified in the application standard. Typical maximum
hardness values for material groups are provided in Table 7.4.
4 For material over 30 mm thickness additional test specimens may be required to ensure that the full
weld thickness is subject to test.
5 For aluminium alloys, parent metal in tempered (thermally treated) condition test pieces shall be
naturally aged at 15°C to 25°C for three days prior to testing.
6 Where postweld heat treatment is to be applied to Group Al 23 alloys, the value obtained in the tensile
test shall equal or exceed that used for design purposes specified in the pressure equipment Standard.
7 An additional test piece for elevated temperature testing may be required when specified by the pressure
equipment Standard, or the designer, purchaser, or owner.
8 For a butt joint in plate when the weld metal and parent metal differ markedly in bending properties,
either between dissimilar parent metals or between weld metal and parent metal, two longitudinal bend
test specimens may be used instead of root and face or side bend tests, in which case the side to be
placed in tension shall be recorded.
9 Required only for a butt joint made from one side only in plate or of pipe.
10 Impact tests on weld metal and HAZ are only required when specified in Clause 7.6.
11 Refer to Figure 7.1 for location, size and number of test specimens.
12 Required only for Group A3 and A4 carbon and carbon manganese steels and for alloy steel butt welds
in material over 10 mm thickness used for—
(a)
(b)
Class 1 boilers to AS 1228; or Classes 1, 1H and 2H vessels (AS 1210) and Class 1 piping
(AS 4041).
Where the weld metal strength may undermatch the parent metal strength, the weld metal
strength may be R m, R e or Ret, whichever determines the design strength ‘f’. See Clause 7.4.2 for
acceptance criteria.
Examples are as follows:
(i)
The welds in Groups F and G steels or some high strength aluminium alloys.
(ii)
The use of consumables with specified minimum strength, equal to or less than the
specified minimum strength of the parent material.
(iii)
The use of consumables with strength specified or not proven.
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13 Chemical analysis of weld deposit is only required by agreement and only on ferritic steel weld deposits
of material groups B to E inclusive for principal alloy elements only. The alloy content shall conform to
the analysis limits of the welding consumables.
14 Single-sided welds require one face bend test and double-sided welds require one bend test for each
side.
15 See Section 8 for bend test for overlay.
16 Where fillet welds are load bearing (e.g. lifting lugs), a butt weld qualification shall be required.
6.4 POSTWELD HEAT TREATMENT
6.4.1 Test piece
The welding procedure qualification test piece shall be subjected to any postweld heat
treatment applied to the finished component.
6.4.2 Heat treatment parameters
Heat treatment parameters shall conform to AS 4458 and the welding procedure.
6.4.3 Operation
The postweld heat treatment operation, when required by the pressure equipment Standard,
shall be carried out before final non-destructive examination for Groups B4, B5, D1, D2,
D3, D4, F, G, H, J, K1, K2, L and M materials.
DIMENSIONS IN MILLIMETRES
FIGURE 6.1 RECOMMENDED TEST PIECE FOR BUTT WELD IN PLATE
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AS 3992:2020
DIMENSIONS IN MILLIMETRES
FIGURE 6.2 RECOMMENDED TEST PIECE FOR BUTT WELD IN PIPE
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DIMENSIONS IN MILLIMETRES
FIGURE 6.3 RECOMMENDED TEST PIECE FOR FILLET WELD IN PLATE
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AS 3992:2020
NOTES:
1
For plates over 30 mm thick, additional specimens may be required, see Clauses 7.3.1, 7.4.1 and 7.6.1.
2
For type of bend test required, see Clause 7.5.1.
3
Impact tests are only required when specified by Table 7.2.
4
Not required when test plate is radiographed.
5
The fracture specimen is not referenced in Table 6.1 for use in the testing of welding procedure test pieces.
It is referenced in this Figure and Clause 7.10 for convenience when production weld testing is required
(see Section 10).
FIGURE 6.4 TEST SPECIMENS TAKEN FROM WELDED PLATE TEST PIECES
(a) Pipes—1.5 mm to less than 10 mm thickness, see Notes 1 and 2
FIGURE 6.5 (in part) TEST SPECIMENS TAKEN FROM PIPE TEST PIECES
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(b) Pipes—10 mm and greater thickness, see Notes 1 and 2
(c) Pipes—Shaded area shows the location for removal of impact test specimens
on 5G and 6G pipes, see Note 4
NOTES:
1
Where pipe diameter does not permit the removal of sufficient specimens, an additional test piece shall be
provided.
2
The location of macro specimens is indicated. Such specimens should be taken in accordance with Note 1
to Table 6.1.
3
Transverse tensile test shall be taken from pipe section at 180 degree intervals. For 5G and 6G positions,
they shall be taken from 0 degree and 180 degree locations.
4
Where impact testing is a requirement, test specimens shall be taken from the test piece location with the
highest heat input.
FIGURE 6.5 (in part) TEST SPECIMENS TAKEN FROM PIPE TEST PIECES
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AS 3992:2020
S ECT I ON 7
MEC HANI CAL T E S T ING OF
WEL DS FOR P ROC E D UR E QUAL IF ICAT I ON
7.1 GENERAL
Although this Section (7) applies directly to testing requirements for welding procedure
qualifications, the test methods and requirements are also used for the qualification of
welders and production weld test plates.
7.2 TEST SPECIMENS
7.2.1 Types of tests and number of test specimens
The types of tests and number of test specimens required shall be as shown in Table 6.1.
7.2.2 Removal of test specimens
Test specimens shall be taken from the locations shown in Figures 6.4 and 6.5.
Test specimens may be cut from the test piece by any method which does not affect the
properties of the finished test specimen.
For procedure test pieces, the test specimens shall be taken from part of the test piece free
from any non-conforming defects revealed by non-destructive examination.
Where plates of different thickness are used, the thicker plate may be machined to the
thickness of the thinner plate.
7.2.3 Identification of specimens
Test specimens shall be suitably identified and traceable.
7.3 TRANSVERSE TENSILE TEST
7.3.1 Method
A transverse tensile test shall be carried out at room temperature in accordance with either
AS 2205.2.1 for transverse butt tensile test or AS 2205.2.3 for transverse joggle butt tensile
test, subject to the following conditions:
(a)
Weld reinforcement shall be dressed flush.
(b)
The test specimen shall be machined to the reduced form except that—
(i)
for pipe of DN 32 or smaller, a full section transverse tensile test specimen
shall be used; and
(ii)
for pipe of nominal size greater than DN 32 up to and including DN 100, the
minimum specimen width ‘b’ (see AS 2205.2.1) requirement in the reduced
section parallel portion may be decreased to 20 mm.
7.3.2 Requirements
The weld strength shall be greater than or equal to the specified minimum tensile strength
of the material (or the weaker material in the combination).
If the specimen breaks in the parent metal outside of the weld, the test shall be accepted as
meeting the requirements provided that the tensile strength is not less than 95% of the
specified minimum for the parent material (see Note 6 to Table 6.1 for requirements of
A1 23 alloys).
Where the transverse tensile test uses multiple test specimens to represent the full test piece
and one test specimen fails, the test may be repeated with a full thickness test piece.
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The report of results shall indicate whether fracture occurred in the weld, at the edge of the
weld, or in the parent metal, and whether weld defects are present on the fractured surfaces.
7.4 ALL-WELD-METAL TENSILE TEST
7.4.1 Method
The all-weld-metal tensile test shall be carried out in accordance with AS 2205.2.2, with the
following conditions:
(a)
The diameter of the parallel tested portion of the test specimen shall be the maximum
possible consistent with the cross-section of the weld but need not be more than
20 mm.
(b)
Where the weld metal has a tensile strength (as determined from the transverse tensile
test) less than the specified minimum tensile strength of the parent metal or where
there may be serious doubt concerning the yield strength of the weld metal at elevated
temperatures, the yield strength also shall be measured.
(c)
The yield strength (or 0.2% proof stress) and elongation shall be determined at room
temperature.
(d)
When serious doubt exists for the proof stress of the weld metal at elevated
temperature, this value shall also be determined by test at the relevant temperature.
7.4.2 Requirements
The tensile strength shall not be less than 95% of the specified minimum tensile strength of
the parent metal. The yield strength shall exceed the specified minimum yield strength of
the parent metal or the yield strength required by the design calculation, whichever is less.
The elongation measured on a gauge length of 5.65 cross-sectional area shall be not less
than 10%, or not less than 80% of the equivalent specified minimum elongation of the
parent material, whichever is the greater.
Where two plates of different specified minimum tensile strength, yield strength, and
elongation are welded, the lower values shall be used.
When elevated temperature proof stress is relevant [see Clause 7.4.1(d)], the proof stress
shall not be less than the value for the parent material at the relevant temperature required
by design.
7.5 BEND TEST
7.5.1 Method
A bend test shall be carried out in accordance with the appropriate test method, as follows:
(a)
For transverse (guided) bend test, AS/NZS 2205.3.1.
(b)
For transverse free bend test, AS 2205.3.2.
(c)
For longitudinal (guided) bend test, AS/NZS 2205.3.1.
(d)
For transverse joggle butt wrap-around bend test, AS 2205.3.4.
(e)
For tongue bend test, AS 2205.3.5.
The following conditions apply:
(i)
Where a combination of welding consumables or processes is used in the joint, each
separate part of the joint shall be tested for ductility by bend testing.
(ii)
Where the thickness of the test piece exceeds 10 mm, side bend test specimens shall
be substituted for transverse bend specimens, except for single-sided butt joints with
plate or pipe thickness exceeding 10 mm (see Note 9 to Table 6.1).
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AS 3992:2020
For side bend specimens, the thickness of the specimen (dimension ‘t’) shall be not
less than 10 mm, and shall be such that the maximum width of the weld will be
always contained within the limits of the former used during the test.
NOTE: Normally the former diameter will first be selected to suit the weld width and the
thickness made a proportion of the former diameter in accordance with Table 7.1.
(iii) The specimen shall be formed around a former having the diameter specified in
Table 7.1 so that the specimen is bent through 180 degrees.
(iv)
For transverse face and root bend tests, the width of plate specimens shall be 1.5t
with a 45 mm maximum and 30 mm minimum limit.
(v)
Longitudinal face and root bend tests should be used instead of transverse side or
transverse face and root bend tests for testing weld metal or parent metal
combinations including HAZ which differ markedly in the yield strength between the
two parent metals or between the weld metal and parent metal.
(vi)
For welded joints with large variation in ductility in different parts of the joint, the
fully guided bend test or wrap-around guided bend test is preferred.
7.5.2 Requirements
On completion of the test, no crack or defect on the outer surface of the specimen shall be
greater than 3 mm in any direction.
In root bend test specimens, for single sided welds, flaws due to incomplete root penetration
or lack of root fusion shall not be considered as a cause for rejection, provided that the flaw
after bending of the test specimen does not exceed 3 mm measured in any direction along
the test specimen, and that the flaw has sound metal at the back and on each side.
For corrosion-resistant weld overlay cladding, the flaw shall not exceed 1.5 mm into the
cladding or overlay.
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TABLE 7.1
BEND TEST DIMENSIONS
Material group
A1, A2, A3, A4
Material type
Carbon and carbon manganese steels
Diameter of former
(see Notes 1, 2 and 6)
4t
B, C, D1, D2, D3, D4 and E Low alloy steels (see Note 3)
4t
F
9% Ni steel
6.7t
G
Quenched and tempered low alloy steels
6.7t
H, J, K1 , K 2, K 3 , K4 , L
and M
High alloy steels
4t
Al 21 and 22
Aluminium and aluminium alloy
(see Note 4)
4t
Al 23
Aluminium alloy (see Notes 5 and 4)
16.5t
Al 23
Al 23 welded to other aluminium alloys
16.5t
Al 25
Aluminium alloy (see Note 5)
6.7t
Al 25
A1 25 welded to Al 21 or Al 22
6.7t
Cu 31, 32, 33 and 34
Copper and copper alloys
4t
Cu 35
Aluminium bronze
16.5t
Ni 41, 42, 43, 44, 45 and 46 Nickel and nickel alloys
4t
Ti 51
Titanium alloy (low strength)
8t
Ti 52
Titanium alloy (higher strength)
10t
Zr 61
Unalloyed Zr
10t
Zr 62
Alloyed Zr
10t
NOTES:
1
t = nominal thickness of specimen, in millimetres.
2
For dissimilar metal joints, use larger former diameter required for the materials under
test.
3
For steels with a specified minimum tensile strength >650 MPa, use former diameters for
Group F and G steels.
4
For any aluminium (Al 21–Al 25) welded with 4000 series aluminium weld metal, use
former diameter 16.5t.
5
Parent metal in other than the annealed condition before welding should be annealed after
welding and prior to testing.
6
The diameter here aims to give an outer fibre strain approximating to the specified
minimum
percentage
elongation
of
the
parent
metal.
The
percentage
strain = 100 [t/(D + t)].
7.6 CHARPY V-NOTCH IMPACT TEST
7.6.1 Method
Impact tests for qualification of welding procedures shall be carried out as required in
Table 7.2, except as modified by the pressure equipment Standard.
Charpy V-notch impact test shall be carried out in accordance with the requirements of
AS 2205.7.1, with the following conditions:
(a)
The number and location of the test specimens shall be as shown in Figure 7.1 and in
accordance with the requirements listed in Table 7.2.
(b)
Each location required shall consist of one set of three (3) specimens.
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AS 3992:2020
(c)
Each specimen shall be tested at no more than 2°C above the required test
temperature (see Table 7.2 for test temperature requirements).
(d)
Where impact testing is required for a pressure component which is to be
pneumatically tested, the impact tests shall be conducted at a temperature to meet the
requirements of the pressure equipment Standard.
(e)
Where applicable, specimens shall be taken from the weld and heat affected zone of
each different parent material, welding process and consumable (weld only) used
(see Figure 7.1). The following also applies:
(i)
For weld metal impact specimens, the base of the notch shall be located
approximately on the centreline of the weld.
(ii)
For HAZ impact specimens, the base of the notch shall be located within 1 mm
to 2 mm of the fusion boundary.
(iii) Specimen height shall be the greatest possible of 2.5, 5, 7.5 and 10 mm (10 mm
is shown Figure 7.1).
(iv)
(f)
Near surface specimens shall be within 2 mm of surface, mid wall specimens
for T 40 mm to be either mid wall or root location.
Where lateral expansion values are required, they shall be determined and reported in
accordance with ASTM A370.
7.6.2 Requirements
The Charpy V-notch impact energy values or lateral expansion values obtained in the tests
shall conform to the relevant requirements set out in Table 7.2 for 10 mm 10 mm
specimens. For specimens less than 10 mm 10 mm, the energy shall be not less than the
required value multiplied by the appropriate energy factor given in Table 7.3.
7.6.3 Retests
According to the nature of failure of a test, retests may be performed as follows:
(a)
Failure of one specimen If the average of the three Charpy impact tests exceeds the
specified minimum average energy value specified in Table 7.2, but one specimen
fails to give the specified minimum individual value, three more impact specimens
shall be cut from the same test piece and retested. If all three specimens give not less
than the specified minimum average value, the test piece represented shall be deemed
to conform to this Standard.
(b)
Failure of average of tests If the average of the three impact tests fails to attain the
specified minimum average energy value or if two of the test results fall below the
specified minimum individual value, the test piece represented shall be deemed not to
conform to this Standard.
(c)
Failure due to specimen defect or procedure error Where failure is the result of a
weld defect in the specimen or to an error in the mechanical test procedure, the result
shall be discarded and a further specimen substituted.
(d)
Failure in lateral expansion test for all specimen sizes If the value of the lateral
expansion for one specimen is below 0.38 mm but not below 0.25 mm, and the
average value for the three specimens equals or exceeds 0.38 mm, then a retest of
three additional specimens may be made, each of which shall attain values equal to or
exceeding 0.38 mm. If the required values are not obtained in the retest or if the
values in the initial test are below the minimum required for retest, the material shall
be either rejected or submitted to a further heat treatment. After such reheat
treatment, three specimens shall be tested and the lateral expansion for each shall
equal or exceed 0.38 mm.
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NOTES:
1
See Clause 7.6.1(e)(i).
2
See Clause 7.6.1(e)(ii).
3
Additional locations may be required—see Clause 7.6.1(e).
DIMENSIONS IN MILLIMETRES
FIGURE 7.1 CHARPY V-NOTCH IMPACT SPECIMENS—LOCATION, SIZE
AND NUMBER OF SPECIMENS IN RELATION TO MATERIAL THICKNESS
AND WELD CROSS-SECTION
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TABLE 7.2
PROCEDURE WELD IMPACT TESTS
Parent metal (see Table 5.2)
Material group
Minimum impact values at impact test
temperatures (Notes 2, 3, 5 and 13)
When weld impact tests are required (see Note 1)
Type (Note 13)
On weld metal
On HAZ
Weld metal
HAZ
Carbon and carbon-manganese steels
A1
A2
A3
A4
C, C-Mn steels
Where parent metal requires impact As for weld metal where the
testing from AS 1210
heat input exceeds 5 kJ/mm,
or where H/t (Note 4)
exceeds—0.1 for preheat or
interrun temperatures 100°C,
or 0.08 for preheat or interrun
temperatures >100°C, but heat
input limits do not apply for
normalized weld zones
When tested at required impact test
temperature for parent metal—
(a)
27 J for R e
310 MPa;
(b)
31 J for 310 < R e
(c)
40 J for 360 < R e < 450 MPa.
360 MPa;
65
Low alloy steels (see Note 13)
B
Alloy steel (alloy <1½)
C
Alloy steel (1½
D1
Alloy steel (Vanadium type)
D2
Alloy steel (3
D3
Cr-Mo steel (Cr > 3.5)
total alloy < 3)
total alloy < 5)
D4
Alloy steel (Cr > 7%)
(Vanadium or tungsten type)
E
Nickel steel 1 < Ni
3
3 < Ni < 8
F
Pressure vessels and piping where
the required MDMT for parent
metal is colder than 30°C, or curve
20°C (see Figure 7.2)
As for Groups B, C, D1 to D4 steels
except below curve 0°C
9 Ni steel (Note 9)
Quenched and tempered low
alloy steel (Note 9)
(d)
As for weld metal
0.38 mm lateral expansion for
Rm > 650 MPa.
18 J at required MDMT
20 J at required MDMT
20 J at required MDMT
All
0.38 mm minimum lateral
expansion at required MDMT
(continued)
AS 3992:2020
Standards Australia
G1
G2
When tested at required impact test As for parent
metal, or where
temperature for parent metal—
there is no data
(a) 27 J for R e 310 MPa;
for parent metal
(b) 31 J for 310 < R e 360 MPa; use value for
(c) 40 J for 360 < R e < 450 MPa; weld metal
Parent metal (see Table 5.2)
Material group
When weld impact tests are required (see Note 1)
Type (Note 13)
On weld metal
On HAZ
Minimum impact values at impact test
temperatures (Notes 2, 3, 5 and 13)
Weld metal
AS 3992:2020
Standards Australia
TABLE 7.2 (continued)
HAZ
High alloy steels
H
Martensitic Cr steel
J
Ferritic high-Cr steel (Note 10)
K1
K2
K3
K4
Austenitic Cr-Ni
C > 0.1
steel; (except steels
to Note 6)
C 0.1
When the required MDMT < 30°C
(see Note 8)
Austenitic Cr-Ni steel (Note 6)
All
High chromium steel (Note 10)
M
Ferritic-austenitic Cr-Ni steel
(Note 11)
When the required MDMT < 30°C
(see Notes 7 and 8)
As for Groups B to D2 steels
As for weld metal
Where parent metal requires
impact testing
0.38 mm minimum lateral
expansion at required MDMT
or
Cv > 27 J where Re < 310 MPa
Cv > 40 J where Re > 310 MPa
As for weld metal
As for parent
metal, or where
there is no data
for parent metal
use value for
weld metal
Non-ferrous metal
Al 21–25
Aluminium and its alloyswrought
For required MDMT < 270°C
AL 21–26
Aluminium and its alloys-cast
For required MDMT < 200°C
Cu 31–38
Copper and its alloys
Ni 41–48
Nickel and its alloys
Ti 51–54
Titanium and its alloys
For required MDMT < 60°C
20 J at required MDMT
Zr 61, 62
Zirconium and its alloys
For required MDMT < 60°C
By agreement
Dissimilar metals
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LEGEND:
MDMT =
HAZ
=
Rm
=
Re
=
By agreement
As for weld metal
As for both parent metals above
As for both HAZs above
material design minimum temperature (TR in AS 1210)
heat-affected zone
specified minimum tensile strength of parent metal
specified minimum yield or proof strength
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As for weld metal having less
stringent requirements for parent
metals
66
L
As for Groups B to D4 steels
67
AS 3992:2020
NOTES TO TABLE 7.2:
1
Impact tests are not required for material thicknesses below 3 mm or where it is impracticable to obtain a
10 mm 2.5 mm specimen. Straightening away from the welds zone is permitted.
2
Charpy V-notch impact values in joules, average of three 10 mm 10 mm specimens. See Clause 7.6.2
for impact values and energy factors for smaller specimens. The minimum individual value shall not be
less than 70% of the specified minimum average value. Lateral expansion values are the minimum for
each specimen (see Clause 7.6.3 for retests).
3
Where the required test temperature exceeds 20°C, the impact tests shall be carried out at room
temperature.
4
H /t
5
The increase in test temperature as a function of the maximum thickness at the weld shall be as follows:
heat input in kilojoules per millimetre
.
sum of parent metal thickness at weld (in millimetres )
Maximum throat thickness at weld (or thickness
of thicker component) whichever is less,
mm
>60
>40
>30
>20
Increase in
temperature,
°C
60
40
0
10
20
30
20
30
50
However, the test temperature need not be lower than that for a non-postweld heat treated weld of the
same thickness.
6
Where austenitic chromium-nickel stainless steel has been heat-treated between 480°C and 900°C, impact
testing of the weld metal and HAZ is required.
7
Impact tests are not required for austenitic chromium nickel stainless steel weld metal at minimum
operating temperatures above 105°C when—
(a)
the deposited weld metal is of Type 308, 308L, 309, 310 or 316L with carbon <0.10% or welds
without filler metal are made between 304, 304L, 316, 316L, 321 and 347 materials; and
(b)
welding processes are limited to gas metal-arc, gas tungsten-arc and submerged arc.
8
Where the general membrane stress does not exceed 50 MPa, impact testing is not required.
9
Welds made with high nickel-alloy filler metal conforming to ANSI/AWS A5.11 EniCrFe-2;
ANSI/AWS A5.11 EniCrFe-3; ANSI/ASTM A5.14 ERNiCrFe-6 and ANSI/AWS A5.14 ERNiCr-3, are
exempt from impact tests of the weld metal under the following conditions:
(a)
Impact tests of the heat-affected zone are performed in accordance with Clause 7.6.
(b)
The welding processes are limited to gas metal-arc, manual metal-arc, gas tungsten-arc and
submerged arc welding.
(c)
The minimum operating temperature of the vessel is not lower than 200°C.
CAUTION: THE PROPERTIES OF THE BASE METAL MAY BE ADVERSELY
AFFECTED BY EXCESSIVE LOCAL HEAT INPUTS.
10 Where ferritic-chromium stainless steels have been thermally treated between 430°C and 730°C, impact
testing of the weld metal and heat-affected zone is required.
11 Where ferritic-austenitic steels have been thermally treated between 320°C and 955°C, impact testing of
the weld metal and heat-affected zone is required.
12 Where Type 309, 310, 316, 309Cb, 310Cb or 316Cb stainless steel has been postweld heat treated at
temperatures below 900°C, impact testing of the weld metal and heat affected zone is required.
Chemical analysis of weld deposit is only required by agreement, and only on ferritic steel weld deposits
of material groups B to E inclusive, for principal alloy elements only. The alloy content shall conform to
the analysis limits of the welding consumables.
13 In creep applications on new construction of pressure equipment, for low alloy steels, toughness testing
may be required, see AS 1210 and Figure 7.2. For welding on service exposed equipment, refer to
Section 8.
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NOTE: Impact testing is required for steels below the thickness curves. Table 7.2 specifies additional requirements.
FIGURE 7.2 TEMPERATURE AND THICKNESS LIMIT FOR IMPACT TESTING
LOW ALLOY STEEL GROUPS B-E
TABLE 7.3
EQUIVALENT ENERGY FACTORS
FOR SUBSIDIARY TEST SPECIMENS
Width of test specimen, mm
10 (standard)
Standards Australia
Equivalent energy factor
1.0
7.5
0.8
5.0
0.7
2.5
0.35
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AS 3992:2020
7.7 MACRO EXAMINATION
7.7.1 Method
A macro cross-section examination shall be carried out in accordance with
AS/NZS 2205.5.1, using a magnification of approximately five times and with the
following conditions:
(a)
The specimen for macro examination shall be taken from the test piece transverse to
the weld. It shall be the full thickness of the material at the welded joint and of
sufficient length to include the weld, heat-affected zone and parent metal, on both
sides of the weld.
(b)
The surface transverse to the weld shall be prepared by machining to ensure removal
of all material affected by flame or other cutting methods.
(c)
Additional etching techniques for nickel, nickel alloys and titanium shall be as given
in Appendix E.
7.7.2 Requirements
On examination, the weld and parent metal shall be free from—
(a)
cracks, lack of fusion, or incomplete penetration unless the procedure is based on a
joint with incomplete penetration; and
(b)
porosity, slag inclusions or surface cavities, the size and distribution of which
exceeds the acceptance limits in AS 4037.
Excess weld reinforcement or penetration shall not be cause for rejection of a welding
procedure test but shall be reported.
The macro test report shall include a full-size sketch or photograph of a representative
macro showing the outline of the fusion boundary, and in addition the approximate number
of runs shall be reported.
A sketch or photograph of the macro specimen shall be retained by the manufacturer to
allow cross-checking of production test plates or production welding with the qualified
welding procedure.
See Section 8 for special welds.
7.8 WELD JOINT HARDNESS TEST
7.8.1 Method
Vickers hardness testing shall be carried out with a 5 kg or 10 kg load in accordance with
AS 2205.6.1.
Where more than one welding process is used, each process shall be tested by at least one
row of indents. Each row of indents will be three individual indentations for each of the
weld, HAZs and both parent materials.
The first indent in the HAZ shall be as close as possible to the fusion zone.
For Materials Groups A3, A4, D4, H and J and for any dissimilar metal welds, hardness
requirements are the subject of agreement between the manufacturer and the purchaser
before testing.
7.8.2 Requirements
When hardness testing is required, unless otherwise specified by the application standard or
by the purchaser prior to testing, hardness values shall conform to Table 7.4. The following
also applies:
(a)
Minimum hardness values are also applicable when specified.
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70
(b)
For steels with minimum R eH > 890 MPa, special values shall be specified.
(c)
For certain materials, higher values may be accepted, if specified prior to the
commencement of the welding procedure test.
(d)
Hardness values other than those on Table 7.4 may be applicable for special corrosion
applications, such as caustic or sour service.
TABLE 7.4
MAXIMUM INDIVIDUAL HARDNESS VALUES
FOR HV OF DEPOSITED METAL, HEAT AFFECTED
ZONES AND PARENT MATERIALS
AS 3992 steel groups
SA/SNZ
TR ISO 15608
steel groups
Non PWHT
PWHT
A1, A2, A3, B1
1, 2
350
320
A4, B2, G1
3
450
380
4, 5
380a
320
6
—
350
E1
9.1
350
300
E2
9.2
450
350
F
9.3
450
350
B3, B4, C, D2, D3
B5, D1,
D4 b
a
See Clause 7.8.2(c).
b
Specific D4 alloys (e.g. P91) may have specific maximum hardness
limits significantly lower than that shown in this Table
(see Clause 7.8.1).
7.9 FRACTURE TEST—FILLET WELDS
7.9.1 Method
A fracture test shall be carried out in accordance with AS/NZS 2205.4.1.
The load shall be applied with the root of the weld in tension and until the test specimen
bends flat upon itself or it breaks along the weld, whichever occurs first.
NOTE: The fillet weld fracture test is also referred to as the fillet-break test.
7.9.2 Requirements
The weld shall be deemed to be satisfactory where the test specimen bends flat upon itself,
or where all of the following occur:
(a)
The test specimen breaks along the weld.
(b)
The weld metal and heat-affected zones are free of prior cracks.
(c)
The exposed surfaces show penetration to and fusion at the root of the weld for a sum
total of at least 80% of the weld length (penetration may not necessarily extend
beyond the root position).
(d)
The sum of the areas of incomplete penetration, inclusions, porosity, wormholes, lack
of fusion and any other weld discontinuities does not exceed a value equal to 5% of
the longitudinal cross-section through the plane of the weld at the effective throat
thickness position.
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AS 3992:2020
7.10 FRACTURE TEST—BUTT WELDS
7.10.1 Method
When required by Table 10.2, a fracture test shall be carried out in accordance with the
requirements of AS/NZS 2205.4.1, with the following optional alternative.
Radiographic examination of the test piece may be substituted for the fracture test. Where
this option is exercised, requirements for retesting under Table 7.5 prevail and no
alternative exists to revert to the fracture test.
NOTE: The butt weld fracture test is also referred to as the nick-break test.
7.10.2 Requirements
The weld shall be deemed to be satisfactory where the fracture surface shows—
(a)
the weld metal and heat-affected zones are free of prior cracks;
(b)
no evidence of lack of fusion and, in the case of complete penetration welds, lack of
penetration; and
(c)
freedom of porosity, inclusions and other weld discontinuities exceeding 3 mm in
maximum dimension. The sum of the maximum dimension of all discontinuities in
any 650 mm 2 area on the fracture face of the weld shall not exceed 10 mm total.
7.11 ADDITIONAL TESTS BEFORE REJECTION
7.11.1 Number of retests
If any of the test specimens taken from the test piece fails to meet the specified
requirements, additional tests in accordance with Table 7.5 shall be allowed on the spare
portion of the original test piece or on an additional test piece prepared using the same weld
procedure.
7.11.2 Requirement
If the results of any of the retests do not meet the specified requirements, the procedure
shall be regarded as not conforming to this Standard.
7.12 REPORTING OF RESULTS
A report shall be prepared in accordance with the requirements of the relevant parts of
AS(/NZS) 2205. The report shall indicate the following additional information:
(a)
Name of laboratory and date of testing.
(b)
Description of the test piece.
(c)
Traceable test piece reference number or identity.
(d)
Any additional information that ensures traceability of test piece to the relevant
production test plate, procedure or welder qualification test weld documentation.
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TABLE 7.5
RETESTS
Test failed
Transverse tensile
Initial test result
as percentage
of required result
Minimum number of
specimens for retests
Notes
95 (parent metal fracture)
0
Conforms
<100 and 95 (weld metal
fracture)
1
—
<95 and 90 (weld or parent
metal fracture)
2
—
<90
0
Test plate fails to conform
All-weld tensile:
(a) Tensile and yield strength
(b) Elongation and reductions
of area
As for transverse tensile
1
2
0
—
—
Test plate fails to conform
—
2
For each original
specimen which failed
Impact test
See Clause 7.6
See Clause 7.6
—
Macro test
—
2
—
Fracture test
—
2
—
Bend
90
<90
<90
—
80
NOTE: If the unsatisfactory results of the tests are shown to be caused by local or accidental mechanical defects
in the test specimen preparation and these would not exist in the component, the test affected may be repeated.
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S ECT I ON
8
AS 3992:2020
P R OCEDU RE QU AL IFI CAT I ON
F OR SP EC IAL WE L D S
8.1 GENERAL
This Section provides the requirements to qualify weld procedures for special welds,
specifically—
(a)
welds during manufacture with geometries not represented by either a butt weld,
branch weld or fillet weld, or a combination thereof (e.g. clad or overlay, see
Clause 8.2); or
(b)
localized build-up, buttering or temper-bead welding during fabrication or
manufacture (see Clauses 1.3.29 and 8.3); or
(c)
welding for repair of service-exposed pressure equipment (see Clauses 3.9 and 8.4,
and AS/NZS 3788); or
(d)
tube-to-tube sheet welding (see Clause 8.5); or
(e)
aluminothermic welding (see Section 15); or
(f)
requirements for thermocouple attachment (see Section 16).
The requirements for the qualification of weld procedures for special welds shall conform
to the requirements of Section 3 and the applicable requirements of this Section 8.
NOTE: These procedures require additional consideration regarding distortion prevention and
control.
The requirements for the qualification of welders for special welds shall conform to the
requirements of Section 9 (see Table 9.3).
8.2 SPECIAL WELDS NOT REPRESENTED BY A BUTT, BRANCH OR FILLET
WELD
8.2.1 Build-up, buttering overlays and clad materials
8.2.1.1 General
Qualification of butt and fillet welds shall be by welding and testing of a representative butt
weld. A butt weld procedure qualification may also be used to qualify welding with
buttering or cladding, and temper bead welding may be in a single test coupon.
Buttering, build-up overlays and cladding, where used on pressure boundaries, shall be
qualified using butt welds. Bend testing of the overlay/build-up/cladding shall be performed
in addition to the butt weld qualification.
For build-up/overlay/cladding welds, the number of layers shall be in accordance with the
draft weld procedure (pWPS—see Clause 1.3.18) or the required thickness of the overlay
deposit, as required by the hardness or chemistry required for the application, according to
the qualification range of Clause 8.2.4.2.
Test pieces for bend testing of build-up/overlay/cladding shall be prepared in accordance
with Section 7, with the exception that test pieces and the location of test specimens shall
conform to Figure 8.1 and Figure 8.2 and tested in accordance with Table 8.1. For guidance
on bead placement, see Figure 8.3.
8.2.1.2 Hardness traverse
Vickers hardness testing with a load of HV10 or HV5 shall be carried out in accordance
with AS 2205.6.1 and AS 1817.1. Hardness indentations shall be made as shown in
Figure 8.4 unless otherwise specified and shall be recorded.
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In all cases, a hardness traverse shall be made at an angle of 15° to the surface including the
overlay, heat affected zone (HAZ) and the parent metal.
For hardfacing, a minimum of five indentations shall be made on the machined surface of
the test piece.
8.2.1.3 Acceptance criteria
Acceptance criteria shall conform to Section 7.
The results from the hardness testing (including any traverse) for the parent metal, HAZ and
for the overlay welding shall conform to Clause 7.8.2 and Table 7.4 unless otherwise
specified, or provided for information when requested by the owner.
8.2.2 Corrosion or heat-resistant weld metal overlay
8.2.2.1 Items to be recorded for welding procedure testing
The items to be recorded for corrosion or heat-resistant overlays in procedure test welds
shall be in accordance with the applicable requirements of Section 4.
8.2.2.2 Essential variables
Welding procedures shall require requalification when changes are made to essential
variables of a qualified welding procedure in accordance with Section 5, or if there is a
reduction in the number of layers of weld metal.
8.2.2.3 Test piece
The overlay test weld shall be completed in accordance with Figure 8.1. Recommended
bead overlap is shown in Figure 8.3.
Weld overlay testing shall be carried out on material of the group letter corresponding to
the requirement of the material specification. Parent material thickness of 25 mm or greater
qualifies for all material thicknesses over 25 mm. Base material thickness below 25 mm
qualifies only for that thickness and all thicknesses up to 25 mm.
8.2.2.4 Non-destructive examination
The weld overlay surface shall be examined by the liquid penetrant method in accordance
with the methods and procedures in AS ISO 3452 (all parts).
The examination shall show that the test piece is free from cracks, porosity or other defects
which penetrate the outer surface of the weld overlay.
8.2.2.5 Test specimen
Bend test specimens in accordance with Table 6.1 shall be machined from each test piece
and subjected to bend tests in accordance with Section 7.
The bend test pieces after bending shall conform to Clause 7.5.2.
NOTE: Where the overlay or interface material is of low ductility, consideration should be given
that the requirements of Clause 7.5 might not apply. Agreement between the parties should be
obtained.
8.2.2.6 Chemical analysis
A chemical analysis shall be taken from the overlay surface within 2 mm of the outer
surface. The analysis shall conform to the analysis limits of the welding consumables used
in the final layer or as specified by the purchaser.
8.2.2.7 Qualification range
Parent material qualification range is given in Table 8.2.
Weld consumable qualification range us given in Clause 8.2.4.2.
Thickness qualification range is provided in Table 8.3.
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8.2.2.8 Acceptance criteria
The surfacing test pieces (see Table 8.1) shall meet the acceptance criteria of the relevant
tests (see Clauses 6.2 and 6.3 for visual examination and NDT, and Section 7 for
mechanical testing).
The owner may require additional corrosion tests to validate the overlay for the corrosion
application.
8.2.3 Hard surfacing (wear resistant) weld metal overlay
8.2.3.1 Items to be recorded for welding procedure testing
The items to be recorded for hard surfacing (hard facing) weld metal overlay test welds
shall be in accordance with the applicable requirements of Section 4.
8.2.3.2 Essential variables
Welding procedures shall require qualification when being established for the first time or
requalification when changes are made to a qualified procedure in accordance with
Section 5.
8.2.3.3 Test piece
Weld overlay testing shall be carried out on material of the group letter corresponding to
the requirements of the material specification. Bend tests are not required.
The overlay weld shall be completed on a test piece in accordance with Figure 8.1.
Recommended bead overlap is shown in Figure 8.3.
Parent metal thickness of 25 mm or greater qualifies for all material thickness over 25 mm.
Parent metal thickness below 25 mm qualifies only for the thickness used and thicknesses
up to 25 mm.
The test piece shall conform to Clause 8.2.4. Alternatively, qualification may be made on a
test sample that suitably represents the production part.
8.2.3.4 Non-destructive examination
The completed weld overlay shall be examined by the penetrant test method in accordance
with the methods and procedures in AS ISO 3452 (all parts).
Other than when specified in Clause 8.2.3.8, the examined surface shall be free of cracks,
porosity, lack of fusion and other defects which penetrate the surface, except where
otherwise specified in the welding procedure specification.
NOTE: Some hard facing materials and processes result in surface relief checking and minor
porosity, which may be acceptable to the parties concerned for some service conditions (e.g. parts
subject to low tensile stress or using ductile parent metal), where unacceptable leakage will not
result from the surface defects and suitable tests or experience show any feasible crack
propagation by fatigue, corrosion or brittle fracture will not be a safety issue. For high pressure
valve seats, such defects are not permitted.
8.2.3.5 Test specimen
The test piece shall be sectioned transverse (at any angle) to the weld overlay.
Both faces exposed by the sectioning shall be polished and etched with a suitable etchant
(see Appendix E) and be visually examined at 5 magnification—one for the macro and
hardness traverse and the second for chemical analyses. The weld overlay, heat-affected
zone and adjacent parent metal shall conform to the thickness and sequence of runs
specified in the welding procedure and defect acceptance specified in Clause 8.2.3.4.
Hardness testing shall be carried out in accordance with Clause 7.8 for parent materials and
for overlay welds, and unless otherwise specified, shall conform to Table 7.4.
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Hardness measurements shall be made in accordance with AS 1817 series of Standards
(i.e. HV—Vickers hardness) or other method specified in the welding procedure, in at least
three positions in the heat-affected zone, in each overlay layer, and on the external surface
representing the wear surface. All readings shall meet the hardness requirements of the
range specified in the welding procedure specification or as otherwise specified by the
purchaser or manufacturer.
External surface readings are intended to provide guidance for any quality control tests
required for production welds.
8.2.3.6 Chemical analysis
A chemical analysis shall be made on the weld overlay within the outer 0.5 mm thick
surface layer, or if the overlay thickness is over 25 mm, within a 0.5 mm thick layer at the
minimum thickness qualified. The analysis shall conform to the analysis limits of the
welding consumables used in the final layer or as specified in welding procedure
specification.
Dilution may affect the analysis, the amount depending mainly on the number of layers
used.
8.2.3.7 Qualification range
Parent material grouping qualification range is given in Table 8.2 and thickness
qualification range is given in Table 8.3.
Weld consumable qualification range is given in Clause 8.2.4.2.
8.2.3.8 Acceptance criteria
The surfacing test pieces shall meet the acceptance criteria of the relevant tests in Table 8.1
(see Clauses 6.2 and 6.3 for visual examination and NDT, and Section 7 for mechanical
testing).
Unless otherwise agreed between the manufacturer and owner prior to testing, surface crack
detection in hardfacing is for information only.
The owner may require additional wear resistance tests to validate the overlay for the wear
application.
8.2.4 Surfacing procedure qualification
8.2.4.1 Testing
Welding procedure test pieces for surfacing applications shall welded to the dimensions
provided in Figure 8.1, sectioned to the requirements in Figure 8.2(a) and (b) and tested to
the requirements in Table 8.1.
Guidance is provided to assist with the required overlap of weld beads in Figure 8.3.
NOTE: Build-up and buttering may have additional requirements, see Clause 8.2.1.
8.2.4.2 Qualification range
The parent material qualification range is given in Table 8.2, and the thickness qualification
ranges is provided in Table 8.3.
For the qualification related to the filler material/overlay, the following applies:
(a)
Filler material designation The filler materials used covers other filler materials
with the same designation in accordance with the appropriate standard for the filler
materials or with the same nominal composition.
(b)
Thickness of overlay:
(i)
Standards Australia
For hardfacing, hardness testing to Figure 8.4 and conforming to Table 7.4,
shall be used to determine the minimum overlay thickness of the deposit.
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(ii)
AS 3992:2020
For corrosion resistant overlays, the minimum thickness qualified shall be
determined by the required chemical composition as specified by the owner.
TABLE 8.1
EXAMINATION AND TESTING OF TEST PIECES
Test piece
Type of test
Overlay welding
(see Clause 8.2.2
and Note)
Hardfacing
(see Clause 8.2.3
and Note)
a
b
c
d
Extent of testing
Footnote
Visual examination (VT)
100%
—
Surface NDE (e.g. MT/PT)
100%
a
Side bend test transverse to the first layer
2 specimens
b
Macroscopic examination
1 specimen
—
Chemical analysis
1 specimen
—
Delta ferrite content/ferrite number (FN)
1 specimen
c
Hardness testing
2 traverses
d
Visual examination (VT)
100%
—
Surface NDE (e.g. MT/PT)
100%
a
Macroscopic examination
1 specimen
—
Hardness testing
2 traverses
d
Penetrant examination (PT) or Magnetic Particle examination (MT). For non-magnetic
materials, penetrant examination.
Side bend tests may be replaced by two additional macroscopic examinations.
If required in accordance with the application standard.
See Clause 8.2.1.
NOTE: Ultrasonic examination (UT) may be used to check for disbonding when specified.
TABLE 8.2
QUALIFICATION RANGE FOR PARENT
MATERIAL GROUPS FOR OVERLAY
WELDING
a
SA/SNZ TR ISO 15608
Grouping
Range of qualification
of parent metal
1, 11
1 a , 11a
2
2 a, 1
3
3 a , 1, 2
4
4a , 1, 2, 3
5
5 a, 1, 2, 3, 4
6
6 a, 1, 2, 3, 4, 5
7
7a
8
8a
9
9
10
10
Covers steels in the same sub-group and any lower
sub-group within the same group.
NOTE: Refer to Table D1 (Appendix D) for AS 3992
groupings.
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TABLE 8.3
QUALIFICATION RANGE AS PER
THICKNESS OF TEST PIECE
Thickness of the test piece
t
Range of qualificationa
t < 25 mma
0.5 t to 2 tb
t
Standards Australia
25 mm a
25 mm to unlimited
a
For laser beam welding, 12 mm instead of 25 mm.
b
Unless specified differently in application standard.
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AS 3992:2020
DIMENSIONS IN MILLIMETRES
FIGURE 8.1 TEST PIECES FOR OVERLAY WELDING QUALIFICATION
PROVIDING DIMENSIONS
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Key
1 Discard 25 mm of deposited metal
2 Area for 1 side bend test specimen
3 Area for—
—
1 macro test specimen
—
chemical analysis, ferrite number if called up by the application standard
—
1 hardness test specimen
—
re-test
4 Area for 1 side bend test specimen
5 Welding direction
FIGURE 8.2 LOCATION OF TEST SPECIMENS FOR WELD OVERLAY
DESTRUCTIVE TESTING
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NOTES:
1
This figure shows a typical surface overlay weld and the requirements for overlap.
2
If practical, keep the included angle of Vee between beads (or runs) >135° to reduce risk of slag inclusion,
if necessary, grind or dress.
3
Any sequence of all runs should provide the correct overlap with minimum restraint on material with
lowest ductility, for example, dissimilar metal joint.
FIGURE 8.3 SUGGESTED BEAD PLACEMENT FOR OVERLAY WELDING
NOTE: Distance between the measuring points along the 15° line approximately 1 mm.
FIGURE 8.4 HARDNESS TRAVERSE REQUIREMENTS FOR OVERLAY
8.3 TEMPER BEAD WELDING DURING MANUFACTURE
8.3.1 General
Where temper bead welding is specified for pressure equipment manufacture, the procedure
shall be qualified in accordance with this Clause (8.3) or ASME BPVC-IX.
Temper bead welding is the welding of a bead at a specific location in, or at the surface of a
weld for the purpose of affecting the metallurgical properties of the heat-affected zone or
previously deposited weld metal.
NOTE: The bead may be above, flush with, or below the surrounding base parent surface, and if
above, may cover all or only part of the weld deposit and may or may not be removed following
welding.
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Temper bead welding is limited to MMAW, SAW, and GMAW (including FCAW). Manual
and semiautomatic GTAW and PAW are prohibited, except for the root runs of butt welds
made from one side and for repairs to temper bead welds in Clause 8.3.8 or in accordance
with Clause 8.4.
Qualification of butt and fillet welds shall be by welding and testing of a representative butt
weld. Qualification for butt welding, welding with buttering or cladding, and temper bead
welding may also be done in a single test piece.
Surface temper reinforcing welds may cover the entire weld surface, or may only be placed
at the toe of the weld. They may or may not be mechanically removed. Beads near the
finished surface may be both tempering beads and surface temper reinforcing beads.
A suggestion for bead placement is shown in Figure 8.3.
NOTE: The aim for each run is to temper the HAZ of the previous run, thereby reduce hardness,
improve ductility and slightly lower residual stress. If practical, keep the included angle of Vee
between beads (or runs) >135° to reduce risk of slag inclusion, if necessary, grind or dress.
The sequence of all runs should provide the correct overlap whilst achieving minimum
restraint.
8.3.2 Items to be recorded for welding procedure testing
Items to be recorded in the PQR for temper bead welding shall be in accordance with the
applicable requirements of Section 4, Clause 8.2 for overlay, and additional items in
Clause 8.3.
8.3.3 Essential variables
Welding procedures shall require qualification when being established for the first time or
requalification when changes are made to a qualified procedure in accordance with
Section 5, or when any of the following conditions apply:
(a)
Welding procedure qualifications shall be made using parent metal of the same
material group as the parent metal to be temper bead welded. When joints are to be
made between parent metals with two different material groups, a temper bead
procedure qualification shall be made for each parent metal to be used in production.
Separate test pieces or a combination on a single test piece may be used. When parent
metals of different Group, ISO Group or P-number/group numbers are tested in the
same test piece, the welding variables utilized and test results on each side of the test
piece shall be documented independently, but may be reported on the same
qualification record. Where temper bead welding is to be applied to only one side of a
joint, or where cladding is being applied or repaired using temper bead techniques,
qualification in accordance with Clause 8.3 is required only for the portion of the
WPS that applies to welding on the material to be temper bead welded.
(b)
An increase in the maximum interpass temperature of more than 50°C from that
achieved on the test piece and recorded on the PQR. This is required only where weld
metal requires impact testing.
A decrease in the preheat temperature from that achieved on the test piece and
recorded on the PQR. The preheat and interpass temperatures shall be measured and
recorded separately for each tempering weld bead layer and, if any, for the surface
weld bead layers(s). The WPS shall specify the minimum preheat and the maximum
interpass temperature limits for each tempering bead layer separately and for the
surface weld bead layers(s).
(c)
A change in heat input beyond the following:
(i)
Standards Australia
An increase or decrease in the ratio of heat input between the first tempering
bead layer and the weld beads deposited against the parent metal of more than
20% for material groups A and B and 10% for all other groups.
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(ii)
AS 3992:2020
An increase or decrease in the ratio of heat input between the second tempering
bead layer and the first tempering bead layer of more than 20% for material
groups A and B, and 10% for all other groups.
(iii) The ratio of heat input between subsequent layers shall be maintained until a
minimum of 5 mm of weld has been deposited over the parent metal.
(iv)
For qualifications where the basis for acceptance is hardness testing, a decrease
of more than 20% in heat input for the remainder of the fill passes.
Heat input shall be determined using the following methods:
(A)
For machine or automatic GTAW or PAW, an increase or decrease of 10% in
the power ratio measured as—
Power ratio = [amperage
voltage] / [(WFS/TS)
Af]
where
Af
= cross-section area of the filler metal wire, mm2
TS
= welding travel speed, mm/s
WFS = filler metal wire feed speed, mm/s
(B)
For processes other than machine or automatic GTAW or PAW, heat input shall
be determined by the method of Table 5.1.
(d)
A change from single electrode to multiple electrodes, or vice versa, for machine or
automatic welding only. This variable does not apply when a WPS is qualified with a
PWHT above the upper transformation temperature or when an austenitic or material
Group M is solution annealed after welding.
(e)
The deletion of surface temper beads or a change from surface temper beads that
cover the weld surface to beads that are only deposited along the toes of the weld.
(f)
A change from machine or automatic welding to manual or semiautomatic welding.
(g)
The addition of thermal methods (e.g. air-carbon arc gouging, flame gouging, plasma
gouging, flame/plasma/laser cutting, etc.) to prepare the surface to be welded unless
the WPS requires that the metal be ground to bright metal before welding.
(h)
The distance (S) from the toe of the weld to the edge of any tempering bead shall be
limited to the distance measured on the test piece 1.5 mm (see Figure 8.3).
Alternatively, a range for (S) may be established by locating temper beads at various
distances from the toe of the weld followed by hardness traverses or impact testing, as
applicable. Temper reinforcing beads shall not be permitted to touch the toe of the
weld. In addition, the ratios of heat input described in Item (c) above shall apply to
temper beads.
(i)
For weld beads on parent metal and for each tempering bead layer, the range of bead
width (b) relative to overlap of the previous bead width (a), as shown in Figure 8.3,
shall be specified on the WPS. Overlap between 25% and 75% does not require
qualification and shall conform to the following:
(i)
Overlap greater than 75% shall be qualified by welding a test piece using the
desired overlap. The overlap qualified shall be the maximum overlap permitted
and the minimum overlap shall be 50%.
(ii)
Overlap less than 25% shall be qualified by welding a test piece using the
desired overlap. The overlap qualified shall be the minimum overlap permitted
and the maximum overlap shall be 50%.
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(j)
Bead length and time to deposit shall be monitored and recorded for each bead. Heat
input conditions (amps, volts, and travel speed) shall also be recorded. Timing shall
be within 3% of the PQR, and heat input shall be within 10%.
(k)
The addition or deletion of grinding beyond that required to clean the surface or
remove minor surface flaws (i.e. use or non-use of half-bead technique or similar
technique).
When these variables conflict with or provide more stringent limitations than those of
Section 5, these variables shall govern.
8.3.4 Test pieces
The test piece may be any geometry that is suitable for removal of the required specimens.
It shall consist of a butt weld or a cavity in a plate or overlay or other suitable geometry.
The distance from each edge of the weld preparation to the edge of the test piece shall be at
least 75 mm measured transverse to the direction of welding. The depth of preparation shall
be such that at least two layers of weld metal are deposited, one of which may be the
surface temper bead layer and deep enough to remove the required test specimens.
Preparation shall conform to Clauses 6.1.4 and 8.2.1.1.
The preheat and interpass temperatures shall be measured and recorded separately for each
tempering weld bead layer and, if any, for the surface weld bead layers(s). The WPS shall
specify the minimum preheat and the maximum interpass temperature limits for each
tempering bead layer separately and for the surface weld bead layers(s).
8.3.5 Non-destructive examinations
The completed test specimen shall be visually examined and where required be subjected to
other non-destructive testing (see Section 6 and Clause 8.2.3.4).
The examination shall show that the test piece is free from cracks, porosity or other defects
and that the sequence, overlap and to distance (s) conform to requirements.
8.3.6 Test specimens
Test specimens shall be removed from the test piece as necessary by any method which
does not affect the properties of the finished test specimen required for the tests as
described in Clause 8.3.7.
8.3.7 Mechanical test
The following tests shall be made:
(a)
Bend test in accordance with Clause 7.5.
(b)
Hardness test using Vickers method in accordance with AS 1817 (series) on an
appropriately prepared surface or equivalent. Indents shall be HV5 unless observed
readings are in excess of 350HV, in which the entire traverse should be re-examined
using HV10. Distance between centres of adjacent indentations shall be 3 times the
mean diagonal length of the larger of the two indentations.
Measurements shall be taken across the weld metal, heat-affected zone and unaffected
base metal in appropriate locations (refer to AS 2205.6.1), and shall include—
(i)
a minimum of two measurements in the weld metal fill layers;
(ii)
measurements across all weld metal temper bead layers;
(iii) measurements across the heat-affected zone; and
(iv)
a minimum of two measurements in the unaffected base metal.
Hardness of the weld metal shall not be more than 100HV greater the parent metal.
Hardness of the HAZ shall conform to Table 7.4.
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(c)
AS 3992:2020
Charpy impact tests, in accordance with AS 2205.7.1 or equivalent, when specified by
the pressure equipment Standard or design specification. The extent of testing
(i.e. weld metal, HAZ, unaffected base metal), the testing temperature and the
acceptance criteria shall be as provided in the applicable pressure equipment Standard
or design specification. Impact test specimens shall be removed from the coupon in
the weld metal and HAZ as near as practical to a depth of one-half the thickness of
the weld metal for each process. For HAZ specimens, the specimen shall be oriented
so as to include as much of the HAZ as possible at the notch. Specimens shall be the
largest size that can be removed from the test coupon with the notch cut
approximately normal to the test piece surface. More than one set of impact test
specimens shall be removed and tested when weld metal and heat-affected zone
material from each process or set of variables cannot be included in a single set of
test specimens.
8.3.8 Repair welding during manufacture
Repair to welds made using temper bead welding to correct welding flaws or bead shape
shall be made in accordance with the following:
(a)
Surfaces to be repaired shall be prepared by mechanical removal of flaws and
preparation of the surface to a suitable geometry.
(b)
For processes other than manual and semiautomatic GTAW and PAW, repairs shall
be made using the parameters given in the WPS for production temper bead welding.
The approximate location of beads to be deposited relative to the original parent
metal surface shall be identified, and the applicable parameters shall be used for the
layers to be deposited as specified by the WPS.
(c)
This WPS shall describe the size of the beads to be deposited and the volts, amp, and
travel speed to be used for the beads against the base metal, for each temper bead
layer and for the fill and surface temper bead layers corresponding to the locations
where repair welding is to be done.
(d)
Each welder shall complete a proficiency demonstration (see Table 9.3). For this
demonstration, each welder shall deposit two or more weld beads using WPS
parameters for each deposit layer. The test coupon size shall be sufficiently large to
make the required weld bead runs. The minimum run length shall be 100 mm. The
heat input used by the welder shall be measured for each run, and the size of each
weld bead shall be measured for each run, and they shall be as required by the WPS.
The following essential variables shall apply for this demonstration:
(i)
A change from one welding procedure to another.
(ii)
A change from manual to semiautomatic welding and vice versa.
(iii) A change in position based on a groove weld in either plate or pipe as shown in
Table 9.2.
(iv)
Continuity of qualification in accordance with Clause 9.8.
8.4 WELD REPAIRS TO SERVICE EXPOSED PRESSURE EQUIPMENT
8.4.1 General
For welds to repair defects on plant that has been in service, the requirements of Clause 3.9
of this Standard and AS/NZS 3788 shall apply.
Where temper bead welding is specified for repair of service-exposed pressure equipment,
the considerations of this Clause 8.4 shall be incorporated into a risk assessment and the
repair procedure. Specific qualification requirements as identified in this Clause shall
apply.
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Repairs, and repair procedures shall be subject to approval by competent persons with
knowledge of—
(a)
plant service conditions, history and condition;
(b)
welding technology or welding engineering;
(c)
materials and failure modes and causes; and
(d)
other expertise necessary to understand, identify and assess the impact of proposed
repairs on the plant and material.
NOTE: Examples of competent persons typically include plant engineers, owner, welding
engineers, welding technologists, metallurgists and materials engineers, process engineer, and
other specialists.
8.4.2 Repair procedure
A repair procedure shall be developed that considers any degradation or contamination due
to service operation., as well as plant support, and any other potential affects to the plant
throughout the stages of repair including preparation, welding, heat treatment and
inspection and testing.
The repair procedure shall include details of the following:
(a)
Any health and safety issues specific to the repair.
(b)
Support of plant and connected or adjacent piping (including allowance for cold pull).
(c)
The means of removing the defect, including extent of surrounding metal to be
removed.
(d)
Cleaning of weld preparation and surrounding metal, including bore if applicable.
(Capture or mitigation of debris to avoid contamination.)
(e)
Welding procedure methodology and sequencing (to minimize residual stresses and
distortion).
(f)
Consideration of weld toe peening or dressing.
(g)
Any heat treatment requirements throughout the repair, including preheat, interpass
and post weld heat treatments.
(h)
The method, application and timing of heat treatment, including cool-down intervals
throughout the repair.
(i)
Acceptance criteria, and the non-destructive testing methods used to confirm the
repair meets the defect acceptance criteria.
(j)
The method and the timing of non-destructive testing of the completed repaired weld.
(k)
Qualification of welding procedure and welders.
(l)
Expected life of repair weld, if not the same as expected plant life (e.g. a temporary
repair), and recommended reinspection interval.
(m)
The measurement and recording of parameters.
Where the original material/weld properties have degraded in-service (i.e. due to creep,
and/or fatigue), the repair procedure shall include methodology to address these properties
and acceptance criteria.
A welding procedure shall be qualified that demonstrates the repair welds are made in
accordance with the following:
(i)
Have required mechanical properties, such as strength, toughness, ductility and
hardness.
(ii)
Produce sound result, i.e. free from cracks or other unacceptable defects.
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(iii) Results in a weld that has the desired metallurgical structure throughout the weld, its
HAZ and base metal, i.e. that temper bead welding has refined the weld HAZ and/or
previous weld deposit (testing may include macro, hardness and impact toughness
testing).
Qualification of all welders shall be carried out to demonstrate capability to achieve these
additional requirements.
8.4.3 Weld procedure qualification
Procedure qualification (PQR) shall meet the requirements for ‘as-new’ or non-deteriorated
material, plus supplementary tests that demonstrate that desired microstructural and
mechanical property refinements are achieved in the weld deposit, HAZ and parent
materials. Qualification testing shall include macro and hardness testing in the positions to
be welded to confirm refinement of the weld HAZ. Each welder shall be qualified to
demonstrate ability to achieve the required properties.
NOTE: Where available, qualification should be conducted on ex-service material. Where
ex-service material is not available, qualifications should be carried out using similar grade new
material (see Clause 8.4.2).
8.5 TUBE TO TUBE PLATE WELDING
When the qualification of welding procedures for tube to tube plate welds is specified,
qualification tests shall conform to ASME BPVC-IX or equivalent. For proving strength
weld requirements to meet minimum tube tensile requirements, push out testing shall be
carried out in accordance with ISO 15614-8 or ASME BPVC VIII-I.
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SEC TI ON
9
WE L DE R
QU ALI FIC AT IO N
9.1 GENERAL
Where required by the pressure equipment Standard or AS 4458, welder qualification shall
be carried out in accordance with this Section (9).
9.2 METHODS OF QUALIFICATION
The methods of qualifications shall be as one of the following:
(a)
Welding a test piece which simulates the production weld or conforms to Section 6
(examining and testing). The test piece shall be in accordance with Clause 9.5 or
Section 8 as appropriate.
Where the option in Table 9.3 Note 1 is taken to approve a welder by non-destructive
examination methods, the parent material for the test piece may be from Group A1
or A2 materials welded using the preheat and consumables of the required welding
procedure. This option is only permitted for the parent material groups A through G
(see also Appendix I).
(b)
Welding a test piece in accordance with AS/NZS ISO 9606-1 or ISO 9606 Parts 2
to 5, as appropriate.
(c)
Welding a test piece in accordance with ASME BPVC-IX, provided that welder has
made production welds in accordance with this Standard within the previous six
months.
(d)
Presentation of documentary evidence of having satisfactorily welded a production
joint that has conformed to the appropriate requirements of the pressure equipment
Standard for radiographic or ultrasonic testing within the previous six months. See
Note 1 of Table 9.3 for exclusions from this method of qualification.
(e)
Presentation of documentary evidence of having welded the test piece of a qualified
welding procedure to this Standard within the last six months.
(f)
Holding an appropriate certificate specified in AS 1796, which shall qualify the
welder within the range covered by that certificate, provided that the welder has made
production welds in accordance with this Standard within the previous six months.
(g)
Part of the first production weld or a complete pipe weld carried out by a welder to an
approved welding procedure, which shall be shown by either radiographic or
ultrasonic examination to conform to the pressure equipment Standard. See Note 1 of
Table 9.3 for exclusions from this method of qualification.
The length of weld examined in a production weld or test piece shall be at least 300 mm or
the circumference of a pipe weld, whichever is less.
Welders qualified in accordance with the above are permitted to undertake production
welding within the limits of the essential variables listed in Table 9.1 or in the applicable
welder qualification standard, using welding procedures documented in accordance with the
requirements of this Standard.
Additional testing shall be conducted for special welds in accordance with Section 8.
9.3 EXTENT OF APPROVAL OF WELDER QUALIFICATION
A welder qualified for individual welding processes is qualified for those processes used in
combination, and vice versa.
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A welder qualified to an approved welding procedure in accordance with any method as laid
down in Clause 9.2 shall be requalified when required to weld outside the range of their
qualification, or when the essential variables of additional production welds exceed the
requirements laid down in Table 9.1(A) for the items as listed or Section 8.
Welders qualified in accordance with Clause 9.2(b) or (c) shall be requalified when
required to weld outside the range of their qualification, or the validity of the qualification
ceases.
9.4 INFORMATION FOR WELDER FOR QUALIFICATION TEST WELDS
When welding a test piece for qualification purposes in accordance with Clause 9.2(a), the
welder shall be provided with full details of the approved welding procedure.
9.5 EXAMINATION AND TESTING OF WELDER QUALIFICATION TEST
WELDS
9.5.1 Methods of examination and testing
All test pieces shall be examined visually (see Clause 6.2). If they are in accordance with
the pressure equipment Standard, they shall then be examined and tested in accordance with
Table 9.3. Unless otherwise specified, the first and last 25 mm of the length of a butt joint
in plate shall be ignored in both non-destructive and destructive testing.
9.5.2 Preparation and testing of specimens for destructive testing
9.5.2.1 General
When destructive tests are required, test specimens, using the tests specified in Table 9.3,
shall be removed from the locations indicated in Figures 6.4 and 6.5, or as specified in
Section 8, as appropriate.
It is permissible to take the test specimens from locations that avoid areas showing visual
imperfections.
9.5.2.2 Butt, branch and fillet welds
For other than special welds (e.g. butt joints, fillet joints, branch joints, see Section 3),
specimens shall be tested in accordance with Clauses 7.6, 7.8 and 7.10.
Bend tests (see Table 9.3) shall include—
(a)
one root and one face bend (for butt joints <10 mm thick); or
(b)
two side bends (butt joints 10 mm thick and all overlays requiring bend testing);
(c)
for all welds made from one side only, one root bend, and either—
(i)
one face bend; or
(ii)
two side bends (based on thickness).
Macro examination of tube to tubeplate welds shall consist of one tube to tube plate weld
sectioned through the centre of the tube and all four exposed weld faces to be examined.
9.5.2.3 Special welds
For special welds (see Section 8), weld test coupons shall conform to Section 8, or when
agreed, on a test sample which suitably represents the production part.
Surface NDE shall be conducted prior to mechanical testing in accordance with the relevant
clause in Section 8.
Each welder shall complete a proficiency demonstration including macro and hardness
testing in the positions to be welded to confirm that the resultant weld has the desired
metallurgical structure throughout the weld, its HAZ and/or base metal.
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For temper bead welding, welders who will use manual and semiautomatic GTAW or PAW,
shall be qualified to use the welding process (see Clause 9.1). In addition, each welder shall
deposit two or more weld beads using WPS parameters for each deposit layer on a test piece
sufficiently large to make the required weld beads. The minimum bead length shall be
100 mm. The heat input and the size of each weld bead shall be measured and shall be as
required by the WPS. The following essential variables shall apply for this qualification:
(a)
A change from one welding procedure to another.
(b)
A change from manual to semiautomatic welding and vice versa.
(c)
A change in position based on a butt weld in either plate or pipe as shown in
Table 9.2.
(d)
Continuity of qualification in accordance with Clause 9.8.
9.6 RECORDING OF WELDER QUALIFICATION TESTS
A statement of the results of assessing each test piece, including repeat tests, shall be made
for each welder. In addition, the weld procedure used for the qualification shall be recorded
with the test results. The items required by Clause 9.5 shall be included together with
details of any features that do not conform. If no unacceptable features are found, a
statement that the test piece made by the particular welder satisfied the requirements of this
Standard in respect of that type of test piece shall be signed by the person conducting the
test.
Records of all approval tests for each welder shall be held, regularly maintained and be
accessible to the inspecting body.
Welder approval tests carried out in accordance with this Standard and witnessed and
signed by an inspection body should be accepted by other inspecting agencies.
9.7 RETESTS
If any test specimen fails to satisfy the relevant requirements given in Clause 9.5, two
further test specimens for each failed specimen shall be obtained, either from the same test
piece if there is sufficient material available, or from a new test piece, and subjected to the
same test. If either of these additional test specimens does not meet the required standard,
the cause of failure shall be established. If this failure is established as being the result of
metallurgical or extraneous causes and is not attributable to the welder’s workmanship, then
a further repeat test shall be taken. If the failure is established as being attributable to the
welder’s workmanship, then the welder is permitted to repeat the test weld which shall be
subjected to the same test procedure.
Where the failure of a welder qualification is determined by radiographic or ultrasonic
examination of a test piece or production weld, an additional test piece or production weld
shall be made and examined in accordance with the requirements of Clause 9.5.
If the additional test specimens, test piece or production weld pass the required tests, then
the welder shall be accepted as qualified to weld production welds within the limits of the
essential variables.
If the additional test specimens, test piece or production weld do not pass the required tests,
then the welder shall not be regarded as capable of meeting the requirements of this
Standard without further training and examination.
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TABLE 9.1(A)
ESSENTIAL VARIABLES FOR QUALIFICATION OF WELDERS
Item
1 Parent material specification
Essential variables
A change in material group number (see Table 5.2) requires welder
requalification, except qualification on any material group within—
(a) A–M ............................ qualifies for all material groups within this
range;
(See Item 2, Change in consumable classification)
(b) 21–26 ........................... qualifies for all material groups within this
range;
(c) 31–38 ........................... qualifies for all material groups within this
range;
(d) 41–48 ........................... qualifies for all material groups within this
range;
(e) 51–54 ........................... qualifies for all material groups within this
range; and
(f)
2 Welding consumables
F numbers
61–62 ........................... qualifies for all material groups within this
range.
A change in electrode or filler metal classification (see Column 4 of
Table 5.5) requires welder requalification except qualification as
provided in Table 9.1(B).
A change from a stainless steel consumable to any other type, or vice
versa, requires requalification.
3 Welding position
(see Figures 5.1 and 5.2)
Refer to Table 9.2 for essential variables for welding position.
4 Direction of welding
Qualification in the 3G position only qualifies for the 1G position when
direction of welding is vertical up. Vertical down welding qualifies for
welding only in the vertical down direction for position 3G.
5 Weld deposit thickness
Qualification with a weld deposit thickness (t) qualifies a welder for all
thickness up to 2t, except—
(a) if t 12 mm with minimum of 3 layers—qualifies for the maximum
to be welded; and
(b) for gas welding—qualifies for t.
6 Range of diameter
Requalification is required when the pipe outside diameter is smaller than
the following values:
(a) D where D < 25 mm.
(b) 25 mm where 25
(c) 73 mm where D
D < 73 mm.
73 mm.
D = outside diameter of the welder’s test pipe
Requalification is not required for pipe diameters greater than the
welder’s test pipe.
7 Weld joint detail
Omission of backing strip or consumable backing ring detail or backing
gas (see Clauses 9.3 and Note).
8 Welding process
A change in welding process or combination of welding processes.
9 Metal transfer
For GMAW and FCAW, a change from spray arc, globular arc or pulse
arc to short circuiting (dip transfer) arc or vice versa.
NOTE: For narrow joint preparations in thick ( 20 mm) sections, (e.g. J or double-angle-V) welded from
one-side only where the included angle of preparation is <45°, consideration should be given to assess the
welder’s skill (for root and fill runs) by specific welder qualifications where access into the joint is limited.
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F31–F33, F35–F37 with backing
F34, F41–F46 with backing
F51–F56 with backing
F61 with backing
Any F31–F33, F35–F37 with or without backing
Any F34, F41–F46 with or without backing
Any F51–F56 with or without backing
Any F61 with or without backing
F71–F72 with backing
F21–F25 with backing
Any F21–F25 with or without backing
Any F71–F72 with or without backing
F6 with backing
X
F4 without
backing
F6 with backing
X
X
X
X
F3 with
backing
F6 with or without backing
X
X
F3 without
backing
F6 without backing
X
X
X
X
X
X
F2 with
backing
Qualified for
X
X
X
X
F2 without
backing
Qualified for
Qualify with
F5 with backing
F5 without backing
F4 with backing
F4 without backing
F3 with backing
F3 without backing
F2 with backing
X
X
F2 without backing
X
F1 with
backing
X
X
F1 without
backing
F1 with backing
F1 without backing
Qualify with
X
X
F4 with
backing
X
F5 without
backing
ESSENTIAL VARIABLES FOR QUALIFICATION OF WELDERS—WELDING CONSUMABLES
TABLE 9.1(B)
X
X
F5 with
backing
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TABLE 9.2
QUALIFICATION OF WELDING POSITIONS
Qualification test
Weld type
performed
Plate butt
Plate fillet
Pipe butt
Weld type and position qualified (see Notes)
Weld position
Plate butt
Plate fillet
Pipe butt
DN 500
Pipe butt
>DN 500
PA
1G
PA
1G
PA
1F
PA
1G
See Note 1
PA
1F
PC
2G
PA PC
1G 2G
PA PB
1F 2F
PA PC
1G 2G
See Note 1
PA PB
1F 2F 2FR
PF
3G
PA PF
1G 3G
PA PB PF
1F 2F 3F
PA
1G
—
PA PB PF
1F 2FR
PG
3G
PG
3G
—
—
—
—
PE
4G
PA PC PE
1G 2G 4G
PA PB PD
1F 2F 4F
PA
1G
—
PA PB PD
1F 2FR 4F
PF + PE
3G + 4G
PA PC PF PE
1G 2G 3G 4G
Any ( )
PA
1G
—
Any ( )
PC + PF + PE
2G + 3G + 4G
Any ( )
Any ( )
Any ( )
—
Any ( )
PA
1F
—
PA
1F
—
—
PA
1F
PB
2F
—
PA PB
1F 2F
—
—
PA PB
1F 2F 2FR
PF
3F
—
PA PB PF
1F 2F 3F
—
—
PA PB PF
1F 2F 2FR
PD
4F
—
PA PB PC PD
1F 2F 4F
—
—
PA PB PD
1F 2F 2FR 4F
PG
3F
—
PG
3F
—
—
—
PD PF
3F + 4F
—
Any ( )
—
—
Any ( )
PA
1G
PA
1G
PA
1F
PA
1G
PA
1G
PA
1F
PC
2G
PA PC
1G 2G
PA PB
1F 2F
PA PC
1G 2G
PA PC
1G 2G
PA PB
1F 2F 2FR
PH
5G
PA PE PF
1G 3G 4G
PA PB PD PF
1F 2F 3F 4F
PA PH
1G 5G
PA PH
1G 5G
Any ( )
PJ
5G
PA PE PG
1G 3G 4G
PA PB PD PF
1F 2F 3F 4F
PA PJ
1G 5G
PA PJ
1G 5G
Any ( )
H-L045
6G
Any ( )
Any ( )
Any ( )
Any ( )
Any ( )
J-L045
6G
Any( )
Any( )
Any( )
Any( )
Any( )
PC + PH
2G + 5G
Any ( )
Any ( )
Any ( )
Any ( )
Any ( )
PC + PJ
2G + 5G
—
PA PB PG
1G 2G 3G 4G
Any( )
Any( )
PA PB PD PG PJ
1G 2G 4G 5G
Pipe fillet
(continued)
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TABLE 9.2 (continued)
Qualification test
Weld type
performed
Weld type and position qualified (see Notes)
Pipe butt
DN 500
Pipe butt
>DN 500
PA
1F
—
—
PA
1F
—
PA PB
1F 2F
—
—
PA PB
1F 2F 2FR
PB
2FR
—
PA PB
1F 2F
—
—
PA PB
1F 2FR
PD
4F
—
PA PB PC PD
1F 2F 4F
—
—
PA PB PD
1F 2F 2FR 4F
PH
5F
—
Any ( )
—
—
Any ( )
PJ
5F
—
Any ( )
—
—
Any ( )
Weld position
Plate butt
Plate fillet
PA
1F
—
PB
2F
Pipe fillet
Pipe fillet
NOTES:
1
Qualification on plate butt welds welded in the PA (1G) and PC (2G) positions includes approval for
butt joints in pipes of outside diameter 150 mm welded in the same position.
2
Position 2FR—welded similarly to position 2F with the pipe held vertical and rotated about its vertical
axis.
3
Position 2F qualifies welders for position 2FR.
4
Separate qualification is required for a change in direction from up ( ) to down ( ) for vertical welding.
TABLE 9.3
NUMBER OF TEST SPECIMENS REQUIRED
Test specimen
Butt joint
(see Note 1) Fillet
weld
Branch
in
connection
Plate Pipe plate
Tube to
tubeplate
welds
Special welds (see Note 2)
Corrosion Hard
resistant
facing
overlay
overlay
Weld buildup/Temper
bead
Macro examination
1
2
2
4
See
Clause 9.5.2.2
1
1
1
(see Note 4)
Bend test
(see Clause 9.5.2.2)
2
2
—
—
—
1
—
1
Fracture test
(for single side weld
only) (see Note 5)
—
—
1
—
—
—
—
—
NOTES:
1
With the exception of welds using GMAW or FCAW, mechanical testing on butt welds may be replaced
by volumetric NDE (radiography or ultrasonic examination) at the fabricator’s discretion.
2
See Clause 9.5.2.3.
3
Single sided fillet welds only.
4
Hardness testing may be required as appropriate (see Clause 9.5.2.3 and Section 8).
5
Fracture test may be substituted by completing an additional macro examination.
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9.8 RENEWAL OF WELDER QUALIFICATION
A welder’s qualification to weld to a specified welding procedure shall remain valid
provided that records show that the welder has been employed using the relevant welding
processes, and has continued to produce welds that are verified by the non-destructive
examination, and workmanship and pressure testing requirements of the relevant pressure
equipment Standard.
Reapproval shall be required if any of the following conditions apply:
(a)
Six months or more have elapsed since the welder was employed on the relevant
welding processes.
(b)
The welder changes employment. Under such circumstances the employer shall
qualify the welder who has changed employment.
(c)
There is some specific reason to question the welder’s ability.
(d)
Temper bead welding welders, who will use manual and semiautomatic GTAW or
PAW, shall be qualified to use these welding processes. In addition, each welder shall
complete a proficiency demonstration. For this demonstration, two or more weld
beads using WPS parameters shall be deposited for each deposit layer. The test
coupon size shall be sufficiently large to make the required weld bead runs. The
minimum run length shall be 100 mm. The heat input used by the welder shall be
measured for each run, and the size of each weld bead shall be measured for each run,
and they shall be as required by the WPS. The following essential variables shall
apply for this demonstration:
(i)
A change from one welding procedure to another.
(ii)
A change from manual to semiautomatic welding and vice versa.
(iii) A change in position based on a groove weld in either plate or pipe as shown in
Table 9.2.
NOTES:
1
Manufacturing records should be maintained to establish continuity of welder qualification.
2
See also Section 8 for special welds.
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SEC T I ON
10
WE L D
PR OD UC T ION
T E S T S
10.1 PRODUCTION TEST PLATES
Unless otherwise modified by the pressure equipment Standard, weld production test plates
representative of the completed pressure equipment shall be—
(a)
produced as required in Clause 10.2;
(b)
prepared in accordance with Clauses 10.4 and 10.6; and
(c)
subjected to the examination in Clause 10.5 and the tests in Clause 10.6.
Such test plates are required as a further control of quality of welded manufacture to
primarily assess mechanical properties, and only apply to main longitudinal (type A) and
circumferential (type B) welds.
The conditions and welding procedures for the welding of test plates shall be as close as
practicable to those for the production welding.
10.2 EQUIPMENT REQUIREMENTS OF PRODUCTION TEST PLATES
Welded production test plates are required for all boilers and pressure vessels except as
exempted in Table 10.1.
Where piping and special tests (see Clause 6.1) are specified by the purchaser, weld
production test plates may be required.
TABLE 10.1
EXEMPTION FROM WELD PRODUCTION TEST PLATES
Boiler and pressure
vessel class
1, 2, 2A
Material group
Shell thickness
(maximum)
(Note 3)
mm
A1 and A2
A3
A4
K1, K2
100
50
25
50
2B
Other provision
No
No
No
No
Cv
Cv
Cv
Cv
(Note 1)
(Note 1)
and no PWHT (Notes 1 and 2)
and no PWHT (Notes 1 and 2)
No exemption applies
3
1H, 2H
Any
Any
A1 and A2
A3
A4
K1, K2
50
30
15
30
No Cv (Note 1)
No
No
No
No
Cv
Cv
Cv
Cv
(Note 1)
(Note 1)
and no PWHT (Notes 1 and 2)
and no PWHT (Notes 1 and 2)
NOTES:
1
Only exempted if Cv impact tests are not required by Clause 7.6.
2
Only exempted if PWHT is not required for the pressure equipment.
3
Maximum thickness is also limited by boiler or pressure vessel class, e.g. Class 3 pressure vessels
in A1 material is limited to 12 mm maximum.
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10.3 NUMBER OF PRODUCTION TEST PLATES
10.3.1 For single boiler or pressure vessel
For each boiler or pressure vessel as required by Clause 10.2, one production test plate
welded as a continuation of a longitudinal joint shall be provided to represent each type of
longitudinal weld within the limits of the essential variables of the welding procedure. This
plate shall also represent circumferential joints in the same shell or ends, provided that the
welding procedure is within the limits of the essential variables of the qualified welding
procedure.
If required by the manufacturer, a test plate may be provided from each end of a joint and
the required test specimens may be cut from one test plate and, if necessary, retested from
the other test plate.
Where there are only circumferential joints, or the welding of the circumferential joints is
different from that of the longitudinal joints, a test plate shall be welded separately, in
accordance with the procedure for the circumferential joints, and shall be welded
immediately before or immediately after the production welded joint, using the same
welding.
Where one test plate represents more than one welded joint, the welding of such joints shall
be carried out in a reasonably continuous operation and preferably within a 3-month period.
An additional test plate shall be provided to represent welding where—
(a)
another welding procedure outside the limits of essential variables of the first
production test plate weld is used for longitudinal or circumferential type joints in the
main shell or ends;
(b)
the length of weld represented is evaluated for longitudinal joints only (unless a
different weld procedure is used for the circumferential joint) and exceeds 200 m for
automatic welding or 100 m for manual or semi-automatic welding for ferrous metals,
and 50 m and 25 m respectively for non-ferrous metals; or
(c)
the welding is not done in a reasonably continuous operation using the same welding
procedure.
10.3.2 For multiple boilers and pressure vessels
Where a number of boilers and pressure vessels are welded in succession, one test plate
may represent each 200 m or fraction of automatically welded joints or each 100 m or
fraction of manually or semi-automatically welded joints in ferrous metals, provided that—
(a)
such test plate represents the welds within the limits of the essential variables of the
welding procedure; and
(b)
all welding represented by the test plate is done in a reasonably continuous operation
using the same welding procedure.
10.4 PREPARATION OF PRODUCTION TEST PLATES
The form, dimensions and preparation of test plates shall conform to Clause 6.1.
The material of the weld production test plate shall be of the same specification and same
nominal thickness as that of the production represented, and may be taken from the offcuts
of plates used in the manufacture of the pressure equipment.
The preparation, welding, and treatment of test plates shall be as for the production.
Test plates attached to the shell plates as a continuation of the longitudinal joint shall be
supported so that distortion does not exceed 5°C. The plate may be straightened before any
post weld heat treatment.
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10.5 PRELIMINARY EXAMINATION OF TEST PLATES
On completion of welding, test plates shall be subjected to—
(a)
visual examination in accordance with Clause 6.2; and
(b)
where required by Table 10.2, non-destructive examination, using the same nondestructive examination method as required for the pressure equipment represented by
the test plate (refer to ‘extent of non-destructive examination of welded joints’ in
AS 4037).
The location of any imperfections revealed in the above examinations shall be clearly
marked on the test plate and test specimens shall be selected from those parts of the test
plate which do not contain weld imperfections.
Test plates which contain imperfections of sufficient magnitude so as to not permit the
selection of test specimens from acceptable weld metal shall be rejected. Such test plates
shall not be repaired by welding but shall be re-made using the same welding procedure. In
the event that the test plates again fail to give sufficient length of sound weld metal for the
required test plate specimens, the welding procedure used for the test plate shall be rejected.
When production test plates, representative of pressure equipment requiring spot
examination by non-destructive examination methods, show imperfections in excess of the
limitations permitted by AS 4037, and give sufficient sound weld metal to prepare the
required test specimens, then a spot examination shall be carried out on each weld using the
welding procedure of the production test plate. Such welds shall be treated in accordance
with AS 4037.
10.6 TREATMENT OF TEST PLATES
Test plates in accordance with the acceptance criteria in Clause 10.5 shall then be subject
to—
(a)
postweld heat treatment, when specified for the pressure equipment in the relevant
Standard, in accordance with Clause 6.4; and
(b)
special conditioning when specified by the pressure equipment Standard.
10.7 TESTING OF TEST PLATES
The type and number of test specimens required for the various classes of pressure
equipment are given in Table 10.2.
Such specimens shall be prepared and tested in accordance with the requirements of
Section 7 and shall meet the test requirements listed therein.
10.8 ADDITIONAL TESTS BEFORE REJECTION
If any test specimen taken from a production test plate fails to meet the requirements of
Section 7, additional test specimen(s) shall be taken from the spare portion of the test plate
in accordance with Table 7.5.
If the additional test specimens do not meet the requirements of Section 7, the production
test plate shall be regarded as not conforming to the requirements of the pressure equipment
Standard.
10.9 RECORDS
The results of production weld tests shall be recorded and identified in accordance with the
test plate welding procedure and equipment represented. Refer to AS 4458 for reporting.
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TABLE 10.2
TYPE OF TEST SPECIMENS
Transverse
tensile
Bend
tests
(Note 1)
Impact tests
(Note 2)
Macro
Chemical
analysis
(Note 3)
Fracture
test
Nondestructive
examination
(Note 5)
X
X
X
X
—
X
AS 1210 Class 2A
—
X
X
—
—
—
X
AS 1210 Class 2B
—
X
X
—
—
X (Note 4)
X (Note 4)
AS 1210 Class 3
—
—
X
—
—
—
—
AS 1210 Class 1H
and 1S
X
X
X
X
X
—
X
AS 1210 Class 2H
and 2S
X
X
X
X
—
—
X
AS 1228 Class 1
X
X
—
X
X
—
X
AS 1228 Class 2
—
X
—
—
—
X (Note 4)
X (Note 4)
Class of
construction
AS 1210 Class 1
LEGEND:
X = test specimen required
— = test specimen not required
NOTES:
1
The type and number of bend tests shall be in accordance with Table 6.1 for shell thickness as
nominated.
2
Impact tests are only required as follows:
3
(a)
When specified for the parent metal by the pressure equipment Standard and in the welding
procedure in Clause 7.6. The test shall be at a temperature as specified in Clause 7.6.
(b)
When the shell thickness exceeds twice the thickness requiring postweld heat treatment by the
pressure equipment Standard. The required impact value shall be as required by Clause 2.6 of
AS 1210 for the material of construction when tested at 10°C.
Chemical analysis of weld deposit is only required by agreement and only on ferritic steel weld deposits
of material groups B to E inclusive, for principal alloy elements only. The alloy content shall conform
to the analysis limits of the welding consumables.
Chemical analysis of weld deposit is required for clad plate construction in accordance with
Clause 8.1.6 and for corrosion-resistant welded metal overlay in accordance with Clause 8.2.6 and for
hard facing weld overlay in accordance with Clause 8.3.6.
4
Fracture test is not required when test plate is examined by either radiographic or ultrasonic methods.
5
Only required for welds in Groups F and G materials.
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S ECTI ON
11
B R AZ IN G
QUAL IFI CAT I ON
11.1 GENERAL
This Section, together with Sections 1, 12, 13 and 14, specifies requirements for the
qualification of brazing procedures and brazing personnel (i.e. brazers and brazing
operators) for all brazing processes.
Brazing is the joining of metals using filler metals—
(a)
with a melting point greater than 450°C which is less than the melting point of the
metals joined; and
(b)
distributed by capillary action.
Braze welding is a form of brazing where filler metal is not distributed by capillary action.
In this Standard, brazing includes braze welding.
It is intended that brazing be permitted for the following conditions:
(i)
All joints other than those consisting of fillets only or those subject to severe cyclic
service.
(ii)
Containers for all fluids other than those which are lethal or will cause serious
corrosion of the joint materials.
(iii) Containers for fluids which are flammable, toxic or damaging to human tissue only
where safety precautions are provided for (e.g. by limiting the location or site the, or
conditions where a feasible amount of fluid release will not severely impair safety).
(iv)
Use in areas of possible exposure to fire or elevated temperatures only where the low
melting point of brazing alloys is considered acceptable.
11.2 QUALIFICATION REQUIRED
Procedures and personnel employed in brazing in the manufacture of pressure equipment
shall be qualified and subject to production tests in accordance with Sections 11 to 14 when
specified in the pressure equipment Standard (AS 1210, AS 1228 and AS 4041).
The manufacturer is responsible for brazing and for brazing qualifications.
11.3 GROUPING OF MATERIALS FOR BRAZING QUALIFICATION
To reduce the number of brazing qualifications required, parent metals which are to be
brazed have been grouped as shown in Table 11.1.
The grouping is based on comparable parent metal characteristics, such as compositions,
brazability and mechanical properties, so that generally a procedure qualified for one metal
in a group can be used for other metals in the same group. However, in doing this,
suitability of metallurgical properties, post-braze heat treatment, design, mechanical
properties and service conditions shall be taken into account.
NOTE: ISO/TR 24471 gives information on the ISO braze grouping.
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TABLE 11.1
GROUPING OF PARENT METALS FOR BRAZING
Material group
ASME BPVC-IX
P number for brazing
Type of parent metal
Specified minimum
tensile strength,
MPa
A, B
101
Carbon, carbon manganese and low
alloy steels—Chromium <0.90%
(excludes quenched and tempered
boron-treated steels—Group G)
<625
C (selected) D2, E, F,
H, J, K
102
Ferrous alloys—chromium >0.90%
and 9% nickel steel
<700
Iron castings
103
Malleable, grey and nodular iron
castings
<420
A1 21
104
Aluminium and aluminium alloys
(1000 series and 3004)
<160
A1 23
105
Aluminium and aluminium alloys
(6000 series)
<125
Cu 31, Cu 32, Cu 33,
Cu 34
107
Copper and copper alloys—
aluminium <0.5%
<360
Cu 35
108
Copper and copper alloys—
aluminium >0.5%
<690
Ni 41 and Ni 42
110
Nickel and nickel alloys—chromium
<1%
<490
Ni 43, 45 and 46
111
Nickel and nickel alloys—chromium
>1%
<830
Ni 44
112
Nickel and nickel alloys—
molybdenum >10%
<800
Ti 51 and 52 (selected)
115
Titanium—unalloyed only
<450
11.4 GROUPING OF BRAZING FILLER METALS
To reduce the number of brazing qualifications required, brazing filler metals are grouped
as shown in Table 11.2.
The grouping is based on filler metal useability characteristics, which determine the ability
of brazers and brazing operators to make brazed joints with a given filler metal.
The grouping does not imply that filler metals within a group may be substituted for a filler
metal used in the qualification test without consideration of the suitability of metallurgical
properties, post-braze heat treatment, design, mechanical properties and service conditions.
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TABLE 11.2
GROUPING OF BRAZING FILLER METALS
ASME BPVC-IX
F number
AWS classification
AS/NZS 1167.1 classification
101
BAg-1, -1a, -8, -8a, -22, -23
BVAg-0, -8, -8b, -30
A1, A4, A6
102
BAg-other than above
BVAg-other than above
103
BCuP-1 to 7
104
BA1 Si-2 to 11
105
BCu-1, -1a, -2; BVCu-1x
106
RBCuZn-A, -C, -D
BCuZn-E, -F, -G, -H
107
BNi-1 to 8
—
108
BAu-1 to 6
BVAu-2, -4, -7, -8
—
109
BMg-1
—
110
BCo-1
—
111
BVPd-1
—
Ag2, Ag3, Ag5, Ag8, Ag10, Ag12
Ag4
B1-B4
R4073, R4043, R4342
—
RcuZn-A, -C, -D
11.5 BRAZING FLOW POSITIONS
Basic positions for brazing are classified by—
(a)
the orientation of the brazed surface (i.e. lap or mating surfaces); and
(b)
the direction of flow of brazing filler metal in the joint.
These positions are specified in Figure 11.1.
11.6 RECORDS
A record of the test results and dates in qualifying brazing procedures, brazers and the
brazing operators employed shall be maintained and endorsed by the manufacturer. These
records shall be accessible to the inspector.
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NOTE: The positions shall be suitable for applying brazing filler metal in rod, strip or other suitable form to permit the
flow shown.
FIGURE 11.1 BRAZING FLOW POSITIONS
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S E CTI ON
12
QU ALIFI CAT IO N
PR OC E DUR E
OF
B R AZ I NG
12.1 GENERAL
With the exception of prequalified brazing procedures (see Clause 12.4), each brazing
procedure which is to be used in the manufacture of pressure equipment shall be qualified
in accordance with this Standard. The objectives are to prove the suitability of the brazing
procedure for the material used in the manufacture and demonstrate that the procedure is
carried out in accordance with this Standard. Only qualified brazing procedures shall be
used in the manufacture of components.
Qualification of a brazing procedure may be carried out simultaneously with the brazing
and testing of a production component or test plate provided that the risk of rejection is
accepted. Such circumstances are recognized as being most representative of production
brazing and should be documented.
Each procedure shall be recorded in detail with the results of qualification tests, and these
records shall be accessible to the inspector. The inspection body may require that it witness
qualification brazing and tests.
The type, number and methods of tests required to prove the suitability of the procedure for
the brazing of joints in the components shall be in accordance with this Standard. Where
necessary, additional tests may be required to assess corrosion resistance or other properties
of a brazed joint.
12.2 REQUALIFICATION OF A BRAZING PROCEDURE
Provided that there are no changes in the essential variables (in accordance with
Clause 12.6), a qualified brazing procedure shall remain in force indefinitely.
Requalification of a brazing procedure is only required where there is any change in the
essential variables.
12.3 PORTABILITY OF QUALIFIED BRAZING PROCEDURE
A brazing procedure qualified by one manufacturer is valid for use by another manufacturer
provided that—
(a)
the original qualification tests were carried out in accordance with this Standard, were
witnessed by an inspection body, and were fully documented;
(b)
the second manufacturer demonstrates successful brazing or brazing operator
qualification or production tests using the qualified procedure; and
(c)
the application of the brazing procedure is acceptable to both the manufacturers and
the purchaser.
12.4 PREQUALIFIED BRAZING PROCEDURE
A brazing procedure which has been widely and successfully used in the manufacture of
pressure equipment is recognized as a prequalified brazing procedure.
The use of a prequalified brazing procedure does not relieve the manufacturer of
responsibilities in respect of the brazer qualification provisions of this Standard.
The prequalified procedure used shall be documented and shall have a signed endorsement
that the procedure has been successfully carried out by a (named) brazer who is employed
by the manufacturer and who has passed a brazer qualification test (with the date of the test
given).
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12.5 ITEMS TO BE RECORDED FOR BRAZING PROCEDURE QUALIFICATION
TEST BRAZES
The applicable items listed in Figure F1 of Appendix F shall be recorded for each brazing
welding procedure required to be qualified.
12.6 ESSENTIAL VARIABLES FOR BRAZING PROCEDURE QUALIFICATION
Essential variables in a brazing procedure are listed in Table 12.1. When any of the changes
to the essential variables are made, the brazing procedure shall be requalified.
12.7 TEST PIECES FOR BRAZING PROCEDURE QUALIFICATION
Test pieces for brazing procedure qualification shall be made in accordance with the
specified procedure.
The dimensions and number of the test pieces shall be such as to provide the appropriate
test specimens given in Table 12.2.
Parent metals should be of a form which represents the production brazing, but if this is not
practicable plate, pipe, or other product form may be used. Test positions shall be as shown
in Figure 11.1.
Figure 12.1 shows typical layout of test pieces.
For service temperatures above 95°C, additional test pieces shall be carried out at
temperatures of 50°C increments up to and including the design temperature and shall
conform to the following:
(a)
Tensile tests of the joint, the resulting tensile and yield strength of which shall be not
less than the minimum tensile or yield strength of the weaker of the parent materials
at the test temperature.
(b)
When the design stress of one of the parent materials is based on creep rupture
properties at the design temperature, creep or rupture tests shall be performed to
ensure that the creep or rupture strength of the joint is not less than that of the weaker
of the parent materials.
12.8 VISUAL EXAMINATION
Prior to carrying out any mechanical testing, all test pieces shall be examined visually to
estimate soundness by external appearance (e.g. adequacy of fit up, continuity of brazing
filler metal, size, contour and wetting of filler along the joint), and where appropriate, that
the filler metal flowed completely through the joint.
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TABLE 12.1
ESSENTIAL BRAZING VARIABLES
Item
Essential variable
Applicable
processes
(see Note 1)
1
Parent material
specification
A change from one material group to any other group listed in
Table 11.1 or any material not listed. The brazing of dissimilar
metal joints need not be requalified if each parent metal
involved is qualified individually for the same filler metal,
flux, atmosphere and process. Similarly, the brazing of a
dissimilar metal joint qualified the individual parent metal
brazed to itself and for the same filler metal. See Item 8(d)
TB, FB, IB, RB, DB
2
Parent material
thickness
A change in parent metal thickness beyond the range qualified
in Table 12.2
All
3
Brazing filler
metal
Any of the following are an essential variable:
(a) A change from one F number in Table 11.2 to any other
F number, or to any other filler metal of a type not listed.
All
(b) A change in filler metal from one product form to another
(e.g. from reformed ring to paste).
All
4
Brazing
temperature
A change in brazing temperature to a value outside the range
specified in the procedure
FB, IB, RB, DB
(i.e. not applicable
to TB)
5
Brazing process
A change from one process to another process or to another
combination of processes
All
6
Brazing flux, gas, Any of the following are an essential variable:
or atmosphere
(a) A change in the nominal chemical composition of brazing
flux, fuel gas or atmosphere.
(b) A change in furnace atmosphere from one type to another,
for example—
(i)
All
All
reducing to inert;
(ii) carbonizing to decarbonizing; and
(iii) hydrogen to dissociated hydrogen.
7
Flow position
A change from one basic flow position to another as shown in
Figure 11.1.
All
NOTE: Requalification may be required for change of location
of filler metal application to conform to Figure 11.1.
Qualification in the flat, vertical up and horizontal flow
positions qualifies for the vertical down flow position.
8
Joint design
Any of the following are an essential variable:
(a) A change in joint type (i.e. from a butt to a lap or socket).
All
(b) A change in lap length of lap or socket joints of 25% or
more.
All
(c) A change in clearance outside specified range.
All
(d) Use in areas of possible exposure to fire or elevated
temperatures, only where the low melting point of brazing
alloy is considered acceptable.
All
(continued)
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TABLE 12.1 (continued)
Item
9
Post-braze heat
treatment
Essential variable
Applicable
processes
(see Note 1)
Any of the following are an essential variable:
(a) A change in the specified post-braze heat treatment
temperature range, where—
(i)
All
no post-braze heat treatment is used;
(ii) post-braze heat treatment is used (i.e. defined as
below the critical range); or
(iii) the brazement is heat treated above the critical range
with or without additional post-braze heat treatment.
10
Technique
(b) A change in the specified post-braze heat treatment
temperature and time where notch toughness is a
requirement.
All
(c) The addition or deletion of a solution or stabilizing heat
treatment from Group K (austenitic) steels.
All
(d) An increase of more than 10% in the thickness tested
where the post-braze heat treatment temperature exceed
the lower critical temperature.
All
This is not an essential variable but will affect the soundness of
the joint. Therefore, see Clause 14.2 for brazer qualification
essential variables
—
LEGEND:
DB = dip braze
FB = furnace braze
IB = induction braze
RB = resistance braze
TB = torch braze
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TABLE 12.2
BRAZING PROCEDURE QUALIFICATION NUMBER OF TEST SPECIMENS AND TESTS REQUIRED
Type and number of test specimens and test required
Thickness of test
specimens as brazed
(t)
Range of thickness of materials
qualified by test plate or pipe
Butt and scarf joints
Lap joints
Transverse
tensile
First surface
bend
Second
surface bend
Max.
(see Note 4)
(see Note 1)
(see Note 1)
Transverse
tensile
Rabbet joints
Peel
Sectioning
mm
Min.
<3
0.5t
2t
2
2
2
2
2
2
2
2
1.5 mm
2t
2
2
2
2
2
2
2
2
5 mm
2t
2
2
2
2
2
2
2
2
3 <10
10
(see Note 2)
Transverse
Sectioning
tensile
Workmanship
joints
(see Note 3)
NOTES:
Longitudinal bend tests shall replace these transverse bend tests where braze metal or parent metal combinations differ markedly in bending properties.
First surface specimens are those which have the first surface (i.e. the side from which brazing filler metal is applied and fed by capillary action into the joint) located on the
convex (outer) sides of the bent specimens.
Second surface specimens are those which have the second surface (i.e. opposite to the first surface) located on the convex (outer) sides of the bent specimens.
Transverse specimens are those with the axis (length) of the joint transverse to the longitudinal axis of the specimen.
Longitudinal specimens are those with the axis (length) of the joint parallel to the longitudinal axis of the specimen.
2
Sectioning tests in accordance with Clause 13.5 shall replace these peel tests where the filler metal has a tensile strength equal to greater than either metal being joined.
3
This test in itself does not constitute a procedure qualification, which shall be validated by tests on butt or lap joints as appropriate, as follows:
4
(a)
For joints connecting tension members such as stays—use a butt joint.
(b)
For joints connecting members in shear such as saddle or spud joints—use a lap joint.
See Clause 12.7 for additional tests at elevated temperatures when service temperature is above 95°C.
b 108
1
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FIGURE 12.1 (in part) TEST PIECES
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NOTE: For test pieces 80 mm OD or less, two test pieces are required for peel or section tests. One specimen is to be
removed from each test piece. For pieces <25 mm OD, the specimen width shall be one half-section of the test piece.
FIGURE 12.1 (in part) TEST PIECES
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S E CT I ON
1 3
OF
EXAM INATION AND
BR AZ E D JOI NT S
AS 3992:2020
T E S T ING
13.1 REMOVAL OF TEST SPECIMENS
The required test specimens shall be cut from the test piece by any method which does not
affect the properties of the finished test specimen and taken from parts of the test piece free
from any defects revealed by non-destructive examination.
13.2 TRANSVERSE TENSILE TEST
13.2.1 Preparation
Test specimens shall be prepared in accordance with Figure 13.1 or for pipe less than
80 mm outside diameter a full section pipe may be used.
13.2.2 Test method
Test specimens shall be tested for tensile strength in accordance with AS 1391. Additional
test specimens are required when service temperature exceeds 95°C (see Clause 12.7).
13.2.3 Requirements
The joint strength shall be greater than or equal to the specified minimum tensile strength of
the weaker component in the annealed condition.
If the specimen breaks in the parent metal outside the joint, the tensile strength shall be at
least 95% of the above value.
The report of results shall indicate the joint strength, where the joint failed and any defects
on the fractured surface. Additionally, for specimens tested at elevated temperatures in
accordance with Clause 12.7, the test temperature shall be recorded.
NOTES:
1
Width of lap shall be at least four times the thickness of specimen or as specified by design.
2
For pipe, machine the minimum amount needed to obtain plain parallel faces over a 15 mm wide reduced
section.
DIMENSIONS IN MILLIMETRES
FIGURE 13.1 TRANSVERSE TENSILE SPECIMEN
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13.3 BEND TEST
13.3.1 Preparation
The specimens shall be prepared in accordance with Figure 13.2.
13.3.2 Method
Specimens shall be bent in a guided bend jig that ensures reasonably uniform bending of the
specimen through 180° over a former with diameter of 4t, where t is specimen thickness.
13.3.3 Requirements
Bent specimens shall have no open defect exceeding 3 mm, measured in any direction on
the convex surface. Cracks at the corners may be ignored unless there is clear evidence they
result from flux inclusions, voids or other defects.
Material thickness
mm
1.5
>10
10
Specimen thickness
(t)
mm
Width (b)
(see Note 1)
mm
Material thickness
30–40
10 (Note 2)
30–40
NOTES:
1
Where is not practicable to achieve this width, each standard specimen may
be replaced by three specimens with width = 4t or 10 mm, whichever is
lesser.
2
Machine opposite side to test side.
DIMENSIONS IN MILLIMETRES
FIGURE 13.2 BEND SPECIMENS
13.4 PEEL TEST
13.4.1 Preparation
Test specimens shall be prepared in accordance with Figure 13.3.
13.4.2 Method
The two components shall be separated or peeled by clamping Section A and striking
Section B (Figure 13.3) with a tool such that bending occurs at the fulcrum point, or by
clamping Sections A and B and separating by tension.
13.4.3 Requirements
The specimen shall show evidence of brazing filler metal along each edge of the joint.
After separation, the faying surfaces shall have—
(a)
total area of defects (e.g. unbrazed areas or flux inclusions) equal to or less than 30%
of the total area of any individual faying surface;
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(b)
total length of defects measured on any one line in the direction of the lap equal to or
less than 25% of the lap width; and
(c)
no defect extending continuously from one edge of the joint to the other edge.
NOTES:
1
The length may vary to fit testing machine.
2
X = 4t min. or as required by design.
3
The flange may be omitted from Section B when peeling is accomplished in a tension machine.
4
The specimen shall be brazed from this side.
DIMENSIONS IN MILLIMETRES
FIGURE 13.3 LAP JOINT PEEL SPECIMEN
13.5 SECTIONING TEST
13.5.1 Preparation
The test specimen shall be cut transverse to the lap or rabbet joint and polished on each
section to permit accurate viewing.
13.5.2 Method
The sectioned surfaces shall be examined with a four power magnifying glass, as a
minimum magnification.
13.5.3 Requirements
The total length of unbrazed areas on either side, considered individually, shall not exceed
20% of the length of the joint overlap.
13.6 WORKMANSHIP SPECIMEN TEST
13.6.1 Preparation
The dimensions and configuration of the test piece shall approximate as closely as possible
the finished product.
The test piece shall be sectioned as specified in Clause 13.5.1.
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13.6.2 Method
The sectioned surfaces shall be examined with a four power magnifying glass, as a
minimum magnification.
13.6.3 Requirements
Test specimens shall conform to Clause 13.5.3.
13.7 RETESTS
If any specimen fails to satisfy the specified requirements, two further test specimens for
each one that failed shall be obtained, either from the same test piece (if there is sufficient
material available) or from a new test piece, and subjected to the same test.
If either of these additional test specimens does not meet the required standard, the cause of
failure shall be established.
If this failure is established as being the result of metallurgical or extraneous causes and is
not attributable to the brazer’s workmanship, then a further repeat test shall be taken.
If the failure is established as being attributable to the brazer’s workmanship, then the
brazer shall not be regarded as capable of meeting the requirements of this Standard without
further training.
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SEC TI ON 14
B R AZ ER AND B R AZ ING
OP ER ATOR QUAL I FIC AT I ON
14.1 METHODS OF QUALIFICATION
Each brazer (see Clause 1.3.2) or brazing operator (see Clause 1.3.3) employed in the
manufacture of pressure components shall be qualified in accordance with this Standard by
one of the following methods:
(a)
Brazing a test piece which simulates the production joint and examining and testing
the test piece in accordance with Clause 14.5.
(b)
Presentation of documentary evidence of having successfully brazed the test piece of
a qualified brazing procedure.
Such qualification tests shall only qualify the brazer or brazing operator within the limits of
essential variables specified in Clause 14.2.
14.2 ESSENTIAL
PERSONNEL
VARIABLES
FOR
QUALIFICATION
OF
BRAZING
The essential variables for the qualification of brazing personnel are the same as those for
qualifying the brazing procedure (see Table 12.1) except for the following:
(a)
Qualification in pipe qualifies for plate brazing but not vice versa.
(b)
Items 4, 6 and 9 of Table 12.1 do not apply.
(c)
Item 10, Table 12.1 applies to torch brazing.
(d)
Item 7, Table 12.1 is modified to permit the following:
(i)
For plate, qualification in the flat flow, vertical up flow, or horizontal flow
positions shall qualify for the vertical down flow position.
(ii)
For pipe, qualification in either the flat flow or vertical up flow position shall
qualify for the vertical down flow position.
14.3 EXTENT OF APPROVAL OF BRAZING QUALIFICATION
A brazer or brazing operator qualified to a qualified brazing procedure in accordance with
any method as laid down in Clause 14.1 shall be requalified when the essential variables of
additional production welds exceed the requirements laid down in Clause 14.2.
14.4 INFORMATION TO BE GIVEN TO BRAZER OR BRAZING OPERATOR
FOR QUALIFICATION TEST JOINT
A brazer or brazing operator undertaking a test joint for qualification purposes in
accordance with Clause 14.1(a) shall be provided with full details of the qualified brazing
procedure.
14.5 QUALIFICATION TEST JOINTS AND TESTING
14.5.1 Test joint
The brazer or brazing operator shall produce a test joint or joints in accordance with the
qualified brazing procedure, and within the essential variables in Clause 14.2, sufficient to
provide the required test specimens.
14.5.2 Test specimens
The number of test specimens shall be in accordance with Table 14.1.
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14.5.3 Testing, examination and acceptance requirements
These shall be in accordance with the tests specified in Table 14.1.
TABLE 14.1
BRAZER AND BRAZING OPERATOR QUALIFICATION TESTS
Thickness (t) of test
piece as brazed
Range of thickness of material
qualified by test piece
mm
Butt, scarf, lap
or rabbet joints
Workmanship
specimen joints
2t
2 peel tests
(see Note 1)
1 section test
(see Note 2)
1.5
2t
2 peel tests
1 section test
5
2t
2 peel tests
1 section test
mm
Min.
Max.
<3
0.5t
3
10
>10
Type and number of test
specimens required
NOTES:
1
Tests shall conform to Clause 13.4, except that where the filler metal tensile strength is less
than or equal to that of the metal joined, the specimens shall be sectioned and shall conform to
Clause 13.5.
2
Tests shall conform to Clause 13.6.
14.6 RECORDING OF BRAZER AND BRAZING OPERATOR QUALIFICATION
TESTS
A statement of the results of assessing each test piece, including repeat tests, shall be made
for each brazer or brazing operator. In addition, the brazing procedure used for the
qualification shall be recorded with the test results. The items required under Clause 14.4
shall be included together with details of any features that would be rejectable. If no
rejectable features are found, a statement that the test piece made by the particular brazer
satisfied the requirements of this Standard in respect of that type of test piece shall be
signed by the person conducting the test. The form shown in Appendix F lists the
information that shall be provided.
Records of all qualification tests for each brazer shall be held and maintained.
Brazer and brazing operator qualification tests carried out in accordance with this Standard
and witnessed by an inspection body representative should be accepted by other inspecting
agencies, unless otherwise agreed.
14.7 RETESTS
Retest requirements shall be in accordance with Clause 13.7.
14.8 RENEWAL OF BRAZER QUALIFICATION
A brazer or brazing operator’s approval to braze to a specified brazing procedure shall
remain valid provided that it can be shown from records conforming to Clause 14.6 that the
brazer has been employed with reasonable continuity using the relevant brazing processes
and has continued to produce satisfactory brazed joints as verified by non-destructive
examination.
Requalification shall be required if any of the following conditions apply:
(a)
Six months or more have elapsed since the brazer was employed on the relevant
brazing processes.
(b)
The brazer changes employment.
(c)
There is some specific reason to question the brazer’s ability.
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AS 3992:2020
SEC TI ON 15
ALU MI NOT HER M IC W E L D ING
OF ELEC TRI C AL C ONDUC T OR S
15.1 PREQUALIFIED WELDING PROCEDURE
Aluminothermic welding of electrical conductors to carbon and carbon-manganese steel
pipes by use of aluminium powder and copper oxide may be used without prior
qualification where the following limitations apply:
(a)
The size of the aluminium powder and copper oxide cartridge for aluminothermic
welding shall not exceed 15 g.
(b)
The cross-sectional area of the cable conductor for each weld nugget shall be not
greater than 10.5 mm2 .
(c)
The depth of insertion of the conductor shall not be more than one half of the mould
chamber diameter.
(d)
The pipe surface shall be cleaned by filing or grinding to remove all surface markings
from an area not less than 50 mm2 .
15.2 PROCEDURE QUALIFICATION
Where required, other aluminothermic welds shall be qualified and tested as follows:
(a)
The welds shall be qualified separately for each material composition, conductor size,
cartridge size, and surface preparation.
(b)
Procedure tests shall be conducted on three nuggets, each of which shall pass a test of
one firm side blow from a hammer having a mass of approximately 1 kg, after which
each nugget shall be visually examined for adequate bonding and the absence of
lifting.
(c)
One of the test nuggets shall then be sectioned and examined for copper penetration,
which shall not exceed 0.4 mm.
15.3 PRODUCTION TEST
Each production aluminothermic weld shall be subjected to the hammer test specified in
Clause 15.2, Item (b).
Unsatisfactory welds shall be removed and remade in a new location, not less than 75 mm
distant.
Qualification of welders for production aluminothermic welds is the subject of agreement
between the manufacturer and the purchaser.
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118
SE C TI ON
16
THER M OC OUPL E
J OINTS
AT T AC HM E N T
16.1 GENERAL
This Section provides the methods of qualifying—
(a)
procedures for joints attaching thermocouple leads to pressure equipment when
specified; and
(b)
the method for qualifying operators for these joints.
It applies to welded, brazed and soldered joints for either temporary or permanent use.
16.2 PREQUALIFICATION PROCEDURES
Procedures which have been proven successful in industry by experience are exempt.
Capacitor discharge or electric resistance welding procedures are prequalified where—
(a)
the procedure is documented and includes equipment and materials;
(b)
the energy output for welding is limited to a maximum of 125 J;
(c)
the weld is to bare wire thermocouple;
(d)
parent material thickness is not less than 5 mm;
(e)
there is no subsequent postweld heat treatment; and
(f)
group B, C, D2, D3 and D4 steels have carbon not exceeding 0.15%.
16.3 TEST JOINT
A test joint shall be made on the pressure equipment or on a separate representative test
piece using the proposed joining procedure. The test piece material and thickness shall be
the same as in the pressure equipment within the limits of essential variables in Table 16.1.
16.4 PROCEDURE QUALIFICATION TESTS
The following tests shall be performed and criteria met:
(a)
Visual test.
Criteria—No apparent damage to parent metal or leads.
(b)
Electrical resistance between the test piece and each lead.
Criteria— 0.01
(c)
.
Strength for tensile load of 5N in the direction of service loading.
Criteria—No breakage or resistance >0.01
(d)
.
Hardness test of the parent metal surface (see Clause 7.9) where stress corrosion
cracking (SCC), hard spot-local corrosion, hydrogen assisted cold cracking (HACC)
are credible and specified.
Criteria—As specified for the pressure equipment, e.g. user may require max.
240 HV10 for carbon and carbon manganese steels in sour gas or caustic service.
(e)
Macro examination (see Clause 7.8) of the equipment surface after grinding to
remove the joint to a depth of 0.5 mm and etching, a section of a separate test piece.
Criteria—No cracks, lack of fusion or detrimental penetration.
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AS 3992:2020
Temperature of the above tests shall be nominally 20°C.
The hardness test and macro examination shall be repeated after postweld heat treatment or
exposure to the design maximum service temperature as appropriate.
TABLE 16.1
ESSENTIAL VARIABLES FOR PROCEDURES
Variables
Essential variable
Parent material
A change outside material groups A to G, or H to M, or from aluminium, copper,
nickel, titanium or zirconium groups
Material thickness
A change outside 0.5t to t for t < 3 mm, where t = test plate thickness
Joining process
A change from the process qualified
Consumables
A change outside the range qualified for welding, brazing and soldering process
Preheat temperature
A change outside 50°C of the test procedure temperature
Heat input
A change outside 30%
Initial surface
A change from clean, dry smooth surface
16.5 QUALIFICATION OF OPERATOR
Where required, the operator shall be qualified by—
(a)
making a test joint as in Clause 16.3, which meets the criteria of visual and macro
examination in Clause 16.4; or
(b)
providing documentary evidence of having successfully made such production or test
joints with the process.
Such qualification shall remain valid for 12 months.
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120
S ECT I ON 17
WE L DING QUALI FIC AT ION
NON- M ETALL IC M AT E RIAL S
OF
17.1 SCOPE
Previous sections of this Standard deal specifically with metallic vessels. This Section
applies to the welding qualification (and other joining methods) of pressure equipment
made from plastics, fibre-reinforced plastics, glass and other non-metallic materials.
17.2 GENERAL REQUIREMENTS
The qualification of procedures and personnel for the welding and joining of non-metallic
materials shall be in accordance with—
(a)
the qualification principles of this Standard as provided for Clause 1.1; and
(b)
National Standards and Practices that apply to the particular type of materials and
pressure equipment, and are acceptable to the manufacturer and purchaser
(e.g. ASME Section-IX for hot plate welding of thermoplastics).
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121
S ECT I ON
18
SP E CI AL T R E AT M E NT
WE L DS
AS 3992:2020
OF
18.1 SCOPE
This Section provides for special treatment of welds sometimes required (see AS 1210), and
which may affect the welded joint properties, soundness and performance.
Examples are weld or weld toe—
(a)
grinding or burring;
(b)
hammer or needle gun peening (see AS 4458);
(c)
ultrasonic impact treatment (UIT);
(d)
GTAW weld toe dressing; and
(e)
planishing of welds as in expansion bellows.
18.2 PROCEDURE QUALIFICATION
Where such treatments are required, the procedure shall be documented, qualified to
conform to specified requirements and, where necessary, agreed by the manufacturer and
purchaser/owner.
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122
APPENDIX A
LIST OF REFERENCED DOCUMENTS
(Normative)
AS
1210
Pressure vessels
1228
Pressure equipment—Boilers
1391
Metallic materials—Tensile testing—Method of test at room temperature
1548
Fine grained, weldable steel plates for pressure equipment
1796
Certification of welders and welding supervisors
1817
Metallic materials—Vickers hardness test (series)
1830
Grey cast iron
2030
2030.1
Gas cylinders
Part 1: General requirements
2205
2205.2.1
2205.2.2
2205.2.3
2205.3.2
2205.3.4
2205.3.5
2205.7.1
Methods of destructive testing of welds in metal
Method 2.1: Transverse butt tensile test
Method 2.2: All-weld-metal tensile test
Method 2.3: Transverse joggle-butt tensile test
Method 3.2: Transverse free bend test
Method 3.4: Transverse joggle-butt wrap-around bend test
Method 3.5: Tongue bend test
Method 7.1: Charpy V-notch impact fracture toughness test
2243
2243.1
2243.2
Safety in laboratories
Part 1: Planning and operational aspects
Part 2: Chemical aspects
2812
Welding, brazing and cutting of metals—Glossary of terms
2971
Serially produced pressure vessels
3597
Structural and pressure vessel steel—Quenched and tempered plate
3873
Pressure equipment—Operation and maintenance
3920
Pressure equipment—Conformity assessment
4037
Pressure equipment—Examination and testing
4041
Pressure piping
4458
Pressure equipment—Manufacture
4882
Shielding gases for welding
AS ISO
3452
Non-destructive testing—Penetrant testing (all parts)
13916
AS/NZS
1167
1167.1
1167.2
Standards Australia
Welding—Measurement of preheating temperature, interpass temperature
and preheat maintenance temperature
Welding and brazing—Filler metals
Part 1: Filler metal for brazing and braze welding
Part 2: Filler metal for welding
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AS 3992:2020
AS/NZS
1200
Pressure equipment
1554
1554.6
Structural steel welding
Part 6: Welding stainless steels for structural purposes
1594
Hot-rolled steel flat products
1867
Aluminium and aluminium alloys—Drawn tubes
2205
2205.3.1
2205.4.1
2205.5.1
Methods of destructive testing of welds in metal
Method 3.1: Bend tests
Method 4.1: Fracture test
Method 5.1: Macroscopic and microscopic examination of welds
2885
2885.2
Pipelines—Gas and liquid petroleum
Part 2: Welding
3509
LP Gas fuel vessels for automotive use
3545
Welding and allied processes—Welding positions
3788
Pressure equipment—In-service inspection
4854
Welding consumables—Covered electrodes for manual metal arc welding of
stainless and heat-resistant steels—Classification
4855
Welding consumables—Covered electrodes for manual metal arc welding of
non-alloy and fine grain steels—Classification
4856
Welding consumables—Covered electrodes for manual metal arc welding of
creep-resisting steels—Classification
4857
Welding consumables—Covered electrodes for manual metal arc welding of
high-strength steels—Classification
14341
Welding consumables—Wire electrodes and weld deposits for gas shielded
metal arc welding of non alloy and fine grain steels—Classification
(ISO 14341:2010, MOD)
16834
Welding consumables—Wire electrodes, wires, rods and deposits for gas
shielded
arc
welding
of
high
strength
steels—Classification
(ISO 16834:2012, MOD)
21952
Welding consumables—Wire electrodes, wires, rods and deposits for gas
shielded
arc
welding
of
creep-resisting
steels—Classification
(ISO 21952:2012, MOD)
AS/NZS ISO
9606
Qualification testing of welders—Fusion welding
9606.1
Part 1: Steels
14171
Welding consumables—Solid wire electrodes, tubular cored electrodes and
electrode/flux combinations for submerged arc welding of non-alloy and
fine grain steels—Classification
14174
Welding consumables—Fluxes for submerged arc welding and electroslag
welding—Classification
14343
Welding consumables—Wire electrodes, wires and rods for arc welding of
stainless and heat-resisting steels—Classification
14731
Welding coordination—Tasks and responsibilities
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AS/NZS ISO
17632
Welding consumables—Tubular cored electrodes for gas shielded and nongas shielded metal arc welding of non-alloy and fine grain steels—
Classification (ISO 17632:2004, MOD)
17634
Welding consumables—Tubular cored electrodes for gas shielded metal arc
welding of creep-resisting steels—Classification (ISO 17634:2004, MOD)
18273
Welding consumables—Wire electrodes, wires and rods for welding of
aluminium and aluminium alloys—Classification
18276
Welding consumables—Tubular cored electrodes for gas shielded and nongas shielded metal arc welding of high-strength steels—Classification
(ISO 18276:2005, MOD)
AS/NZS ISO/IEC
17020
Conformity assessment—Requirements for the operation of various types of
bodies performing inspection
SA/SNZ TR ISO
15608
Welding—Guidelines for a metallic materials grouping system
ISO
185
Grey cast irons—Classification
5922
Malleable cast iron
9606
9606-2
9606-3
9606-4
9606-5
Qualification test of welders—Fusion welding
Part 2: Aluminium and aluminium alloys
Part 3: Copper and copper alloys
Part 4: Nickel and nickel alloys
Part 5: Titanium and titanium alloys
14175
Welding consumables—Gases and gas mixtures for fusion welding and
allied processes
15607
Specification and qualification of welding procedures for metallic
materials—General rules
15614
15614-8
Specification and qualification of welding procedures for metallic
materials—Welding procedure test
Part 1: Arc and gas welding of steels and arc welding of nickel and nickel
alloys
Part 8: Welding of tubes to tube-plate joints
SA/TS
103
Structural steel welding—Limits on boron in parent materials
SAA/SNZ
MP76
Pressure equipment—Inspection bodies and personnel
ISO/TR
24471
Brazing—Grouping systems for materials—American materials
15614-1
ASME
BPVC-IIC
ASME Boiler and Pressure Vessel Code (BPVC), Section 2: Materials—
Part C: Specifications for Welding Rods, Electrodes and Filler Metals
BPVC-VIII-1 ASME Boiler and Pressure Vessel Code (BPVC), Section 8,
Division 1: Rules for Construction of Pressure Vessels
BPVC-IX
Standards Australia
ASME Boiler and Pressure Vessel Code (BPVC), Section 9: Welding,
Brazing and Fusing Qualifications
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ANSI/AWS
A5.11
AS 3992:2020
Specification for nickel and nickel alloy welding electrodes for shielded
metal arc welding
A5.14
Specification for nickel and nickel alloy bare welding electrodes and rods
D18.2
Guide to weld discoloration levels on inside of austenitic stainless steel tube
API
5L
Specification for line pipe
570
Pipe inspection code: In-service inspection, rating, repair, and alteration of
piping systems
571
Damage mechanisms affecting fixed equipment in the refining industry
571-1/
Fitness-For-Service
ASME FFS-1
ASTM
A105
Specification for forgings, carbon steel forgings for piping components
A106
Specification for seamless carbon steel pipe for high-temperature service
A182
Specification for forged or rolled alloy and stainless steel pipe flanges,
forged fittings, and valves and parts for high-temperature service
A203
Specification for pressure vessel plates, alloy steel, nickel
A213
Specification for seamless ferritic and austenitic alloy-steel boiler,
superheater, and heat-exchanger tubes
A240
Specification for chromium and chromium-nickel stainless steel plate, sheet
and strip for pressure vessels and for general applications
A266
Specification for carbon steel forgings for pressure vessel components
A333
Specification for seamless and welded steel pipe for low-temperature service
and other applications with required notch toughness
A335
Specification for seamless ferritic alloy-steel pipe for high-temperature
service
A350
Specification for forgings, carbon and low-alloy steel requiring notch
toughness testing for piping components
A352
Specification for steel castings, ferritic and martensitic for pressurecontaining parts suitable for low-temperature service
A355
Specification for steel bars, alloys, for nitriding
A370
Test methods and definitions for mechanical testing of steel products
A387
Specification for pressure vessel plates, alloy steel, chromium-molybdenum
A514
Specification for high-yield-strength, quenched and tempered alloy steel
plate, suitable for welding
A517
Specification for pressure vessel plates, alloy steel, high-strength, quenched
and tempered
A522
Specification for forged or rolled 8 and 9% nickel alloy steel flanges,
fittings, valves, and parts for low-temperature service
A533
Specification for pressure vessel plates, alloy steel, quenched-and-tempered,
manganese-molybdenum and manganese-molybdenum-nickel
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ASTM
A542
126
Specification for pressure vessel plates, alloy steel, quenched-and-tempered,
chromium-molybdenum, and chromium-molybdenum-vanadium
A553
Specification for pressure vessel plates, alloy steel, quenched and tempered
7, 8 and 9% nickel
A714
Specification for high-strength low-allow welded and seamless steel pipe
A790
Specification for seamless and welded ferritic/austenitic stainless steel pipe
A832
Specification for pressure vessel plates, alloy steel, chromium-molybdenunvanadium
DIN
17740
Wrought nickel—Chemical composition
EN
1011
1011-2
Welding—Recommendations for welding of metallic materials
Part 2: Arc welding of ferritic steels
10028
10028-7
Flat products made of steels for pressure purposes
Part 7: Stainless steels
10216
10216-2
Seamless steel tubes for pressure purposes—Technical delivery conditions
Part 2: Non-alloy and alloy steel tubes with specified elevated temperature
properties
JIS
G3115
Steel plates for pressure vessels for intermediate temperature service
Weld Australia
TN 01
The weldability of steels
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AS 3992:2020
APPENDIX B
WELDING PROCEDURE SPECIFICATION (WPS)
(Normative)
B1 GENERAL
This Appendix specifies information which shall be recorded, as appropriate, for a welding
procedure specification (WPS) for the more commonly used welding processes. Typical
form for recording these details are given in Figures B1 and B2. Both may be freely copied;
Standards Australia waives copyright for both Figures only.
Other formats of these forms, inclusive of simplified work instructions may be used
provided that such formats contain all necessary information for the manufacture of
production welds.
B2 INFORMATION TO BE RECORDED
The WPS shall include the information presented on the form in Figure B1. The following
list of items shall be recorded.
(a)
Welding process—Use appropriate term, e.g. MMAW and SAW, from those in
Table 4.1.
(b)
Material group number—Nominate material group number on both sides of joint.
(c)
Thickness range qualified—Nominate pipe or plate thickness range qualified for
relevant welding process (see Table 5.4).
(d)
Joint types—Nominate type(s) of joint(s) qualified (butt, branch, etc.) by placing ‘x’
in applicable box and nominate drawing or standard sketch number if known.
(e)
Welding position—Nominate welding position in accordance with Figure 5.1 or
Figure 5.2. Nominate weld direction when specific to weld procedure (e.g. vertical up
or down).
(f)
Preheat and interrun temperature (as applicable)—Nominate minimum preheat
temperature and maximum interrun temperature.
(g)
Welding details:
(i)
Run or pass location—Nominate as base run, root run or fill pass(es) as
applicable to welding process.
(ii)
Wire/electrode diameter.
(iii) Current polarity.
(iv)
Amps/voltage/speed—Nominate range for each process and electrode size.
Electrode run out ratio may be used for MMAW.
(v)
Arc energy—Determine average arc energy for each process and set of welding
conditions.
(h)
Gas—Nominate any shielding and purging gas when used together with flow rate.
(i)
Flux—Nominate flux used in submerged arc welding by trade name or specification.
(j)
Interrun cleaning—Use terms brush, de-slag, grind as applicable.
(k)
Back gouging—Nominate method of back gouging and any subsequent treatment,
e.g. arc/air grind.
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128
(l)
Heat treatment—Nominate any details of intermediate or postweld heat treatment
when applicable.
(m)
NDE requirements—Nominate requirements in accordance with pressure equipment
Standard or client specification.
(n)
Remarks—Nominate any specific requirements or testing for production welding not
covered in the above, e.g. if weld run sequence is important such as may be required
in dissimilar metal joints, nominate requirements at this location or weld metal
hardness range when specified for production welds (see also Section 18).
(o)
WPQ Record—Nominate manufacturer’s weld procedure qualification record (PQR)
number and parent material specification and thickness used in procedure. Where a
welding procedure is prequalified, insert ‘prequalified’ for the welding procedure
number in the last paragraph of Figure B1.
Do not leave any entry on the form blank. If a nominated entry is inapplicable to the
welding specification, write ‘not applicable’ or ‘N/A’.
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AS 3992:2020
WELDING PROCEDURE SPECIFICATION (WPS)
WPS No .............
Company name: ...............................................................................................................................
Address: ...........................................................................................................................................
Welding process(es) .............................................. Type(s) ...............................................................
Material group No. ................................................. to material group No. ..........................................
Pipe diameter range qualified ............................................. mm OD to ................................... mm OD
Pipe and plate thickness range qualified .............................................. mm to .............................. mm
Joint design:
Joint sketch
(welding details)
Double Vee butt
Single Vee butt
Branch
Set in
Set on
Fillet weld
Other ............................................................................................................................................
Applicable drawing Nos. ..................................................................................................................
Standard sketch Nos.........................................................................................................................
Welding position ..........................................
Weld direction ...........................................................
Welding preheat temp. min. .......................°C
Interrun temp. max. .......... °C Maintained ............... h
Welding details
Layer
Run
number
Welding
process
Filler metal
Diameter
Classification
mm
Current
range
A
Voltage
range
V
Speed
range
mm/min
Arc energy
range
kJ/mm
For submerged arc welding flux name ...............................................................................................
Gas shielding type ................................................. Flow rate ................................................. L/min
Gas backing type ................................................... Flow rate .................................................. L/min
Interrun cleaning method ....................................... Back gouging ................................................. °C
Heat treatment intermediate:
Postweld heat treatment:
Heating rate ..................... °C/h
Temp. range ................... °C
Time ..................................... h
Cooling rate .................. °C/h
Heating rate ..................... °C/h
Temp. range ................... °C
Time ..................................... h
Cooling rate .................. °C/h
NDE requirements as appropriate
Remarks ...........................................................................................................................................
This welding procedure specification is supported by PQR .......................................... (No. and date)
in which parent material used was to specification ....................................................... of
thickness
..................................................................... mm.
Manufacturer (name or signature) .....................................................................................................
FIGURE B1 TYPICAL FORM FOR THE WELDING PROCEDURE SPECIFICATION (WPS)
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AS 3992:2020
Draft 30/06/2020
MANUFACTURER
Name and/or
Logo
WPS No
Date
PQR No
WELDING PROCEDURE SPECIFICATION
CARBON STEEL – MMAW / SMAW (Low Hydrogen)
With or Without PWHT
1 USE
Welded Joints
Maximum thickness 40mm in C and C-Mn steels in
pressure equipment to Standards AS 1210, AS 1228 and AS 4041, or equivalent.
Weld metal service temperature -30°C to 450°C subject to limits by the above
Standards.
Not qualified for welding on “live” pressure equipment.
Welding Process(s)
Welding Standards
AS 3992
MMAW = SMAW
2 JOINT PREPARATION & WELD QUALIFIED
Tolerance
60°
0-3 mm
0-3mm
T
T1
T1
45°
0-3mm
0-3 mm
T1
T
T1
T
0-3mm
45°
1.5-3mm
T
T
3 PARENT METAL QUALIFIED
Code / Spec.
AS 3992
ASME IX
45°
T
Recommended
sequence to
reduce toe
hardness
0-2mm
Weld Build Up
Parent Metal
3 to 40
3.2 to 38
SIZE (mm)
Deposited Metal
13
19
Diameter (OD)
All
All
Included Angle (°) See fig.
Bevel angle (°)
“
Root face (mm)
“
Gap (mm)
”
Misalignment (mm) 1.6 max.
Backing
Without or metal, parent
metal, non-metallic, or
weld from 2 sides
Preparation
Grind, machine, shear,
flame cut, or gouge
Cleaning Degrease
chip, grind, or brush
Layers as required
THICKNESS (mm)
Group No. CE (%)
A1, A2
0.45
P 1, 2
Not req’d
0-2mm
50% overlap minimum
0-3mm
Weld Repair
T1
T1
0-2mm
T
60°
CM-01 Rev.0
30-06-2020
Prequalified
Fillet Weld
All
All
POSITION QUALIFIED
Position
All
All
Progression
Vertical up
Vertical up
Qualified Grades
AS 1548: PT 430, 460, & 490; AS/NZS 3678 Gr. 250, 300, 350.
AS/NZS 3679.1; AS/NZS 1594 HU300, HA300/1.
ASTM 53; 105; 106: 181 Gr. 60,70; 234 .Gr. WPB, WPC; 266; 283; 285; 299; 216; 333 Gr. 1,6; 334 Gr. 1.6; 350 Gr. LF1,2; 352 Gr. LCB;
420 Gr. WPL 6; 516; 500
API 5L Gr. B, X42, X52, X60, X65. ABS Gr. AH 32/36, DH 32/36, EH 32. MSS SP-75 Equivalents As agreed
Grades listed can be welded to each other or to any other grades listed as per Standard used.
Note Not all grades mentioned above are listed in each Standard used. The relevant Standard sgould be consulted for approved grades.
4 CONSUMABLES
FILLER METALS
Specification
Classification
Filler Metal F & A No
Trade Name
Wire Flux designation
Flux Specification
Australian
AWS
AS/NZS 4855
SFA 5.1
E55 10 H10
E7018(-1)
4,4,1
Any approved supplier
N/A
N/A
N/A
N/A
SHIELDING AND BACKING GAS
ISO
Type
Composition Flow Rate
(%)
(L/min)
Shielding
N/A
N/A
Backing
5 JOINT SUPPORT
N/A
Tungsten Size
Tungsten Type
Gas cup size (ID)
CTWD (mm)
Transfer Mode
Solid/Tubular
Flux Type
N/A
N/A
N/A
N/A
N/A
N/A
N/A
TECHNIQUE
Tack welds Lesser of 4 x T and 50 mm long. Equally spaced. Full
penetration. Tacked with the same procedure as the root
Pipe clamp If used, release external clamp on >60% completion of
root run &>80% of top and bottom quadrants of root completed
Pipe lifting & lowering Nil or normal lifts only.
6 PREHEAT (Note 1) For T
7 WELDING DETAILS
Layer / Run
Process
Roor/Filler/Cap
“
”
N/A
OTHER CONSUM. DATA
MMAW
”
“
12 mm
0°C For T > 12 &
25 mm
FILLER METAL
Classification
Diam
AS
AWS (mm)
E4918 E7018(-1)
2.5
E4918 E7018(-1)
3.2
E4918 E7018(-1)
4.0
Bead Type
Stringer / Weave (max. 3x electrode core diam)
No of Runs/Slide
As required
Oscillation
N/A
No. of Electrodes
Single
Back Gouging Yes
Pulse transfer mode
N/A
Max. Run “t” 5 mm
GTAW with / without filler N/A
Peening
No
25°C For T > 25 mm 50°C
ELECTRICAL
Polarity Current Voltage
(Amps) (Volts)
DCEP(+) 60-90
18-26
“
100-140 20-28
”
140-190 22-30
INTERRUN (max) 280°C
SPEED (mm/min)
ENERGY INPUT
Travel
Wire Feed
(kJ/mm)
90-130
”
“
6 PWHT (if needed) Hold Temp (°C ) 590-620 Hold Time (hrs) 1 / 25 mm T Method, Heating & Cooling Rate
N/A
N/A
N/A
N/A
“
”
As in AS 4458 or equivalent
9 NOTES
1
Preheat may be electrical or flame. Minimum width = lesser of 6 x T
and 75mm both sides of weld centreline. If practical, measure on the
opposite side of the heating source with temperature crayon or other.
2 Interruns shall be free from any materials such as moisture, slag, oil,
which may impair the weld quality. Time between runs as required.
3 Sequence of runs and welds as needed. See T-fillet figure in 2 above
.4 Consumable handling As required by the relevant Standard
and the consumable suppliers’ recommendations.
.5 Tests As required by PE Specification, Standard and Class
.6 Weld repair & build-up Remove defects for their entire length
and depth plus 15 mm at both end. dress smooth, groove to suit
and VT. Probably increase preheat if repair restraint is high
10 APPROVAL This WPS was proven by the above PQR or WPS report .........................(date)
Manufacturer ................................................(name)
FIGURE B2 EXAMPLE PREQUALIFIED WPS
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AS 3992:2020
APPENDIX C
WELDING PROCEDURE QUALIFICATION RECORD (PQR)
(Normative)
C1 GENERAL
This Appendix specifies requirements for recording details of tests for the qualification of
welding procedures for the more common welding processes. In certain cases for the more
unusual welding processes it will be necessary to provide additional details on
supplementary sheets. The form of the PQR illustrated in Figure C1 shows a typical form
for presenting the information.
C2 DETAILS OF TESTS
The welding procedure qualification record (PQR) shall include the information presented
on the form in Figure C1. The following list of items shall be recorded:
(a)
Weld type Give the relevant description, e.g. butt, fillet, branch.
(b)
Material specification Nominate material specification and grade on both sides of
joint.
NOTE: Where reasonably practicable, include material test certificate identification.
(c)
Material thickness and pipe outside diameter Nominate plate or pipe thickness and
pipe outside diameter as applicable.
(d)
Weld position Nominate weld position as shown in Figure 5.1 or Figure 5.2.
(e)
Material group number Nominate group letter from Table 5.3 for material on both
sides of joint.
(f)
Interrun cleaning Use terms, brush, de-slag, grind, as applicable, e.g. at stop/starts.
(g)
Joint sketch Show details of initial joint plus plate number(s), if applicable, and heat
number(s) of material(s) used in test weld for both sides of joint.
(h)
Run sequence Show sequence of each weld run, together with extent of back gouge
and layer numbers as applicable to welding record. Show the deposit thickness for
each process for multiple run process (essential for determining deposit thickness
range qualified limits and temper bead weld bead/layer thickness).
(i)
Thermal treatment Record details of preheat, maximum interrun temperature and
postweld heat treatment, inclusive of time at temperature and heating and cooling
rate.
(j)
Welding details Record the following:
(i)
Welding process Use appropriate term, e.g. MMAW and SAW, from those in
Table 4.1.
(ii)
Electrodes or filler wire The diameter and electrode classification.
(iii) Details Amps, volts, travel speed in mm/min, or run out length of electrode,
and type of current and polarity and arc energy.
(iv)
(k)
Flux or shielding gas The flux classification for submerged arc welding, and
shielding gas for gas tungsten arc, gas metal arc and flux cored arc
(gas shielded) for process utilized.
Additional details Record electrode stick out, shielding gas flow rate and other
details specific to the welding procedure when applicable.
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AS 3992:2020
132
(l)
NDE test details Record type of tests carried out and list NDE certificates covering
same.
(m)
Mechanical test details Record type of tests carried out and list test certificates
covering same.
(n)
Special treatment of welds See Section 18.
Test certificates for both Items (l) and (m) shall be retained by the fabricator and shall be
made available to all purchaser and inspection body representatives when requested.
Do not leave any entry on the form blank. If a nominated entry is inapplicable to the
welding procedure under consideration, write ‘not applicable’ or ‘N/A’.
Standards Australia
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AS 3992:2020
PROCEDURE QUALIFICATION RECORD (PQR)
Company name:
Shop
Welder
Address:
Site
Date of test
Welding procedure No.
Material
specification
Weld type
Weld position
....................... (Material
thickness)
to
....................... Pipe
Material group
No.
Plate
Pipe
OD
Thickness
range
qualified
mm
mm
mm
........................ mm
to
........................ mm
Joint details
Root gap ...........................................
Root face ..........................................
Groove angle ....................................
Interrun cleaning ...............................
Thermal treatment
Heat No. .................................
Plate No. ................................
Joint detail (sketch)
Run sequence (sketch)
Show deposit thickness for each
process used
Preheat ......................................... °C
Max. interrun ................................. °C
PWHT ........................................... °C
Heating rate ......................................
Cooling rate ......................................
Welding details
Layer Runs per
No.
layer
Welding
process
Wire or
electrode
diameter
Electrode
Classification
Amps Volts
NDE tests and test
certificate reference
Additional details
Travel
speed
mm/min
Current
Flux or
type and shielding
polarity
gas
Arc
energy
kJ/mm
Mechanical tests and test certificate
reference
Electrode stickout
............ mm
Shielding gas flow rate
......... L/min
VT .............................
Transverse tensile ........................
Other
.................
RT .............................
(Value ................. MPa)
UT .............................
All-weld tensile ..............................
MT ............................
(Value ................. MPa)
PT .............................
Bends ...........................................
Impacts .........................................
(Mean value and temperature... °C)
Macro ...........................................
Hardness ......................................
(Maximum ........... MPa)
Other ............................................
Notes:
The statements in this record are correct. The test welds were prepared, welded and tested with results in
accordance with the requirements of AS 3992.
Manufacturer ................................................. (Name) Witnessed by ................................................ (signed)
..................................................................(Signature)
Position ....................................................................... Organization ...............................................................
Date ............................................................................ Date ............................................................................
FIGURE C1 TYPICAL FORM FOR THE WELDING PROCEDURE
QUALIFICATION RECORD (PQR)
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AS 3992:2020
134
APPENDIX D
COMPARISON OF SA/SNZ TR ISO 15608 AND AS 3992 MATERIAL GROUPS
(Informative)
Table D1 compares the SA/SNZ TR ISO 15608 ferrous material groups with those used in
this Standard, as a ready guide to the use of the material group classification system.
The following applies to Table D1:
(a)
If a material has different minimum specified yield strengths depending on the
thickness, the highest yield strength shall be used for the determination of the
subgroup.
(b)
ISO material groupings are based on the specified material chemistry and/or yield
strength properties, and are defined within SA/SNZ TR ISO 15608.
Tables D2 to D7 are applicable to the following materials:
(i)
Table D2: Aluminium and its alloys
(ii)
Table D3: Copper and its alloys
(iii) Table D4: Nickel and its alloys
(iv)
Table D5: Titanium and its alloys
(v)
Table D6: Zirconium and its alloys
(vi)
Table D7: Cast iron groupings
Standards Australia
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www.standards.org.au
TABLE D1
COMPARISON OF SA/SNZ TR ISO 15608 AND AS 3992 FERROUS ALLOY GROUPS
SA/SNZ TR ISO 15608 Group
1
Steels with a specified minimum yield
strength ReH 460 MPa
Description
Steel conforming to the chemical
composition specified in
SA/SNZ TR ISO 15608
C
4
1.1
A1 if C < 0.25%
AS 1548 PT430
ASTM A106A
360 MPa
1.2
B1
15Mo3
Normalized fine-grain steels with
Re > 360 MPa
1.3
A1 normalized
API 5L 56N
Steels with improved atmospheric corrosion
resistance
1.4
B1
ASTM A588 A
360 MPa < Re
2.1
460 MPa
Re > 460 MPa
API 5L X56M
2.2
A3
AS/NZS 1594 (XF 500)
API 5L X70 M
3.1
B1
A4
G1
ASTM A514 E
ASTM A714 A
ASTM A533 A Cl 1
3.2
G2
ASTM A533 B Cl 3
Precipitation-hardened fine-grain steels
except stainless steels
3.3
B2
Cr
0.3% and Ni 0.7%
4.1
B3
ASTM A213 T17
Cr
0.7% and Ni
4.2
B4
WB 36,
EN 10216-2
15NiCuMoNb5-6-4
(1.6368)
Quenched and tempered and precipitation 360 MPa < Re 690 MPa
hardened fine-grain steels except stainless
steels with a specified minimum yield
strength ReH > 360 MPa
ReH > 690 N/mm2
Low vanadium alloyed Cr-Mo-(Ni) steels
with Mo 0,7% and V 0,1%
Example
1.5%
135
3
Thermomechanically treated fine-grain
steels and cast steels with a specified
minimum yield strength ReH > 360 MPa
AS 3992 Materials Group
0.25%
275 MPa < Re
2
SA/SNZ TR ISO 15608
Sub Group
AS 3992:2020
Standards Australia
(continued)
SA/SNZ TR ISO 15608
Sub Group
AS 3992 Materials Group
Example
5.1
C
ASTM A355 P11
1.5% < Cr 3.5%; and
0.7% < Mo 1.2%
5.2
D2
ASTM A355 P22
3.5% < Cr 7.0%; and
0.4% < Mo 0.7%
5.3
D3
ASTM A355 P5
7.0% < Cr 10.0%; and
0.7% < Mo 1.2%
5.4
D3
ASTM A355 P9
6.1
B5
EN 10216-2 14MoV6-3
6.2
D1
ASTM A832 F22V
SA/SNZ TR ISO 15608 Group
5
6
Cr-Mo steels free of vanadium with
C 0.35%
Description
0.75% Cr
Mo 0.7%
High vanadium alloyed Cr-Mo-(Ni) steels 0.3% Cr 0.75%;
Mo 0.7%; and
V 0.35%
8
Ferritic, martensitic or precipitationhardened stainless C 0.35% and
10.5% Cr 30%
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Austenitic stainless steels,
Ni 35%
3.5%;
1.2%; and
i 136
0.75% < Cr
0.7% < Mo
V 0.35%
7
1,5%; and
AS 3992:2020
Standards Australia
TABLE D1 (continued)
3.5% < Cr 7.0%;
Mo 0.7%; and
0.45% V 0.55%
6.3
ASTM A542 D, Cl. 4a
7.0% < Cr 12.5%;
0.7% < Mo 1.2%; and
V 0.35%
6.4
D4
ASTM A355 P91
Ferritic stainless steels
7.1
J, L
ASTM A182 F430
Martensitic stainless steels
7.2
H
ASTM A240 405
Precipitation-hardened stainless steels
7.3
—
UNS S17400 14-4 PH
Cr
19%
8.1
K1, K4
Cr > 19%
8.2
K2, K4
Manganese austenitic stainless steels with
4% < Mn 12%
8.3
K3
(continued)
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TABLE D1 (continued)
SA/SNZ TR ISO 15608 Group
9
Nickel alloy steels with Ni
10.0%
Description
Nickel alloy steels with Ni
AS 3992 Materials Group
9.1
E1
3.0% < Ni
8.0%
9.2
E2
8.0% < Ni
10.0%
9.3
F
24%
10.1
M1
Cr > 24%
10.2
M2
Ni
10.3
—
10 Austenitic ferritic stainless steels (duplex) Cr
11 Steels covered by group 1 except
0.25% < C 0.85%
10.0%
SA/SNZ TR ISO 15608
Sub Group
2%
Example
0.25% < C
0.35%
11.1
A2
ASTM A105
ASTM A106 B
0.35% < C
0.5%
11.2
A2
ASTM A266 3
0.5% < C
0.85%
11.3
—
137
AS 3992:2020
Standards Australia
AS 3992:2020
138
TABLE D2
ALMUMINIUM AND ALUMINIUM ALLOYS GROUPING
ACCORDING TO SA/SNZ TR ISO 15608 AND AS 3992
Group
Subgroup
Type of aluminium and aluminium alloy
21
Pure aluminium 1% impurities or alloy content
22
Non heat treatable alloys
22.1
Aluminium-manganese alloys
22.2
Aluminium-manganese alloys with Mg
22.3
Aluminium-manganese alloys with 1.5% < Mg
22.4
Aluminium-manganese alloys with Mg > 3.5%
23
1.5%
3.5%
Heat treatable alloys
23.1
Aluminium-manganese-silicon alloys
23.2
Aluminium-zinc-manganese alloys
24
Aluminium-silicon alloys with Cu
1%
24.1
Aluminium-silicon alloys with Cu
1% and 5% < Si
24.2
Aluminium-silicon-magnesium alloys with Cu
0.1% < Mg 0.80%
1%; 5% < Si
25
Aluminium-silicon-copper alloys with 5% < Si
14%, 1% < Cu
26
Aluminium-copper alloys with 2% < Cu
15%
15% and
5% and Mg
0.8%
6%
NOTE: Groups 21 to 23 are generally for wrought materials and groups 24 to 26 are generally for cast
materials.
TABLE D3
COPPER AND COPPER ALLOYS GROUPING
ACCORDING TO SA/SNZ TR ISO 15608 AND AS 3992
Group
Subgroup
Type of copper and copper alloy
31
Copper with up to 6% Ag and 3% Fe
32
Copper-zinc alloys
32.1
Copper-zinc alloys, binary
32.2
Copper-zinc alloys, complex
33
Copper-tin alloys
34
Copper-nickel alloys
35
Copper-aluminium alloys
36
Copper-nickel-zinc alloys
37
Copper alloys, low alloyed (less than 5% other elements) not covered by groups 31 to 36
38
Other copper alloys (5% or more other elements) not covered by groups 31 to 36
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AS 3992:2020
TABLE D4
NICKEL AND NICKEL ALLOYS GROUPING
ACCORDING TO SA/SNZ TR ISO 15608 AND AS 3992
Group
Type of nickel and nickel alloy
41
Pure nickel
42
Nickel-copper alloys (Ni-Cu) Ni
43
Nickel-chromium alloys (Ni-Cr-Fe-Mo) Ni
44
Nickel-molybdenum alloys (Ni-Mo) Ni
45
Nickel-iron-chromium alloys (Ni-Fe-Cr) Ni
46
Nickel-chromium-cobalt alloys (Ni-Cr-Co) Ni
47
Nickel-iron-chromium-copper alloys (Ni-Fe-Cr-Cu) Ni
48
Nickel-iron-cobalt alloys (Ni-Fe-Co-Cr-Mo-Cu) 31%
45%, Cu
10%
40%
45%, Mo
32%
31%
45%, Co
10%
45%
Ni
45% and Fe
20%
TABLE D5
TITANIUM AND TITANIUM ALLOYS GROUPING
ACCORDING TO SA/SNZ TR ISO 15608 AND AS 3992
Group
Subgroup
51
Type of titanium and titanium alloy
Pure titanium
51.1
Titanium with O2
0.20%
51.2
Titanium with 0.20% < O 2
0.25%
51.3
Titanium with 0.25% < O 2
0.35%
51.4
Titanium with 0.35% < O 2
0.40%
alloysa
52
Alpha
53
Alpha-beta alloysb
54
Near-beta and beta alloysc
a
Alloys covered by group 52 are: Ti-0.2Pd; Ti-2.5Cu; Ti-5A1-2.5Sn;
Ti-8Al-1Mo-1V; Ti-6Al-2Sn-4Zr-2Mo; Ti-6Al-2Nb-1Ta-0.8Mo.
b
Alloys covered by group 53 are: Ti-3Al-2.5V; Ti-6Al-4V; Ti-6Al6V-2Sn; Ti-7Al-4Mo.
c
Alloys covered by group 54 are: Ti-10V-2Fe-3Al; Ti-13V-11Cr3Al; Ti-11.5Mo-6Zr-4.5Sn; Ti-3Al-8V-6Cr-4Zr-4Mo.
TABLE D6
ZIRCONIUM AND ZIRCONIUM ALLOYS GROUPING
ACCORDING TO SA/SNZ TR ISO 15608 AND AS 3992
Group
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Type of zirconium and zirconium alloy
61
Pure zirconium
62
Zirconium with 2.5% Nb
Standards Australia
AS 3992:2020
140
TABLE D7
CAST IRON GROUPING ACCORDING
TO SA/SNZ TR ISO 15608 AND AS 3992
Group
Subgroup
71
Type of cast iron
Grey cast irons with specified tensile strength or Brinell hardness
Spheroidal graphite cast irons with specified mechanical properties
72
72.1
Spheroidal graphite cast irons, ferrite type, with specified tensile strength,
0.2% proof stress, elongation and specified impact resistance values
72.2
Spheroidal graphite cast irons, ferrite type, with specified tensile strength,
0.2% proof stress and elongation or specified Brinell values
72.3
Spheroidal graphite cast irons EN-GJS-500-7 and EN-GJS-450-10 (if >20%
perlite) or specified Brinell hardness
72.4
Spheroidal graphite cast irons, perlite type, with specified tensile strength,
0.2% proof stress and elongation or specified Brinell hardness
73
Malleable cast irons
74
Austempered ductile cast irons
75
Austenitic cast irons
76
Cast irons excepting 71 to 75
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AS 3992:2020
APPENDIX E
MACRO-ETCHING OF WELDED JOINTS
(Normative)
E1 GENERAL
Etchants suitable for preparing steels, coppers and copper alloys, aluminium and aluminium
alloys for macro tests are given in AS/NZS 2205.5.1. Etchants for nickel, nickel alloys and
titanium are given below.
Attention is drawn to the cautionary notes given in AS/NZS 2205.5.1 relating to the
handling, mixing and use of etching solutions.
WARNING: GUIDANCE ON THE SAFE HANDLING OF CHEMICALS IN
LABORATORIES IS GIVEN IN AS 2243.1 AND AS 2243.2.
E2 NICKEL AND NICKEL ALLOYS
E2.1 Preparation of surface
The surface to be etched shall be prepared in accordance with AS/NZS 2205.5.1.
E2.2 Etching solutions
Etching solutions shall be as follows:
(a)
For nickel, low-carbon nickel and nickel-copper (monel)—Nitric acid.
(b)
For nickel-chromium-iron (inconel)—Aqua regia (one part of concentrated nitric acid
and two parts of concentrated hydrochloric acid).
E2.3 Etching procedure
The etching solution shall be applied at room temperature by swabbing or immersion of the
specimen.
E3 TITANIUM
E3.1 Preparation of surface
The surface to be etched shall be prepared in accordance with AS/NZS 2205.5.1.
E3.2 Etching solution
A suitable general purpose etching solution, as defined in Clause E1, shall be used. Kroll’s
etch has been found to be suitable, i.e. 1 mL to 3 mL hydrofluoric acid (48%), 2 mL to
6 mL nitric acid (concentrated) and water to make 100 mL.
E3.3 Etching procedure
The etching solution shall be applied at room temperature by swabbing or immersion of the
specimen.
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142
APPENDIX F
BRAZING PROCEDURE QUALIFICATION RECORD
(Normative)
This Appendix specifies the information that is required when recording details of the
qualification of brazing procedures. The presentation of the form below is recommended.
The form may be used also to record the brazing procedure specification and the
qualification of the brazer. The Record of qualified brazing procedure form may be freely
copied; Standards Australia waives copyright for the form only.
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AS 3992:2020
RECORD OF QUALIFIED BRAZING PROCEDURE FORM
Company name: ...........................................................................
Procedure No. .........................................
......................................................................................................
Date ........................................................
Brazing process(es) .......................................................................
Type(s) ...................................................
Joints
Joint design used (sketch)
Type of joint(s) .........................................................
Joint clearance .........................................................
Length of overlap ......................................................
Other ........................................................................
Parent metals thickness range qualified
P-No. ............................. to P-No. ............................
Material spec. ...........................................................
Type or grade ...........................................................
Thickness range .......................................................
Thickness used .........................................................
Blazing flux or atmosphere
Method of precleaning ..............................................
Flux trade name or company .......................................
Other ........................................................................
Atmosphere for furnace brazing ..................................
Filler metals
Flow position
F-No. ........................................................................
Flow position(s) ..........................................................
Spec. No. .................................................................
Method of applying filler metal ....................................
AWS class No. ..........................................................
...................................................................................
Size ..........................................................................
(Face feeding, preplace rings, shims, spray deposit,
cladding, etc.)
Other ........................................................................
Other ..........................................................................
Brazing temperature
Technique
Temperature range ...................................................
Post-braze heat treatment ...........................................
Other ........................................................................
Type of ageing or stabilizing thermal temperature after
brazing .......................................................................
Brazing process
Post-braze cleaning method ........................................
.................................................................................
Type of flame ..............................................................
Other ........................................................................
Torch tip size ..............................................................
Test results
1 Tensile test
Spec.
No.
2 Bend tests
Spec.
No.
3 Peel, sectioning
or other test
Width
mm
Thickness
mm
Tensile load
N
Type of specimen
Tensile strength
MPa
Type of failure
and location
Result
.......................................................................... Test brazer’s name: .........................
Brazer’s company name I certify that the test brazers, specimens and results conform to AS 3992.
...................................
..................................................................................................................................
................................... Manufacturer (signed) .................................................... ................................. Date
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144
APPENDIX G
BASIS FOR WELD POSITIONS
(Informative)
LEGEND TO FIGURES G1(a) AND (b):
ISO AWS butt AWS fillet
PA
1G
1F
Flat (F) position
PB
—
2F
Horizontal-vertical (HV) position
PV
2G
—
Horizontal (H) position
PD
—
4F
Overhead (OH) position
PE
4G
—
Overhead (OH) position
PF
3G
3F
Vertical up (VU) position
PG
3G
3F
Vertical down (VU) position
NOTE: See also Figure 5.1.
FIGURE G1 PLATE WELD POSITIONS
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AS 3992:2020
LEGEND TO FIGURES G2(a) AND (b):
ISO AWS butt AWS fillet
PA
1G
1F
Flat (F) position (pipe rotated)
PB
—
2F
Horizontal-vertical (HV) position
PC
2G
—
Horizontal (H) position
PD
—
4F
Overhead (OH) position
PH
5G
5F
Vertical up (VU) position
PJ
5G
5F
Vertical down (VU) position
H-L045
6G
—
Vertical up (VU) position
J-L045
6G
—
Vertical down (VU) position
NOTES:
1
Pipe is rotated in PA (1G or 1F) position. Pipe fixed in all other positions.
2
PH (formerly PF) refers to vertical up welding direction and PJ (formerly PG) refers to welding vertical
down in pipe.
3
H-L045 refers to vertical up welding of a pipe inclined at 45° and J-L045 refers to vertical down welding
of a pipe inclined at 45°.
4
See also Figure 5.2.
FIGURE G2 PIPE WELD POSITIONS
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AS 3992:2020
146
APPENDIX H
EXAMPLES OF THE APPLICATION OF THIS STANDARD TO PRESSURE
VESSEL AND PIPING MANUFACTURER
(Informative)
This Appendix gives examples of the application of this Standard to a pressure vessel in
Examples 1 to 7 and for pressure piping in Example 8. The principles applying in
Examples 1 to 7 are equally applicable to boilers and pressure piping. Figure H1 illustrates
a typical pressure vessel to be used in conjunction with the examples below.
FIGURE H1 TYPICAL PRESSURE VESSEL
Standards Australia
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AS 3992:2020
Example 1:
T = 10 mm
T n (max.) = 10 mm
Material Group—A1 (CE 0.45% max.)
TR =10 mm
Design temperature 10°C
PWHT—Nil
Welding processes
Welds, L1 , L2 , C1 , C2 and C 3 ; submerged arc welding
Nozzle to shell joints—manual metal arc
Attachments to shell—manual metal arc
Weld preparation
In accordance with Table 2.3
Welding consumables
In accordance with Table 2.2
Welding procedure
qualification
All procedures prequalified, i.e. no welding procedure
testing required
Welding procedure
specification
Required—see Clause 2.1
Welder qualification
Required—see Clause 2.1
Production weld test
requirements
Required only by construction class—see Clauses 2.1
and 10.1
NOTE: A design temperature of 10°C will not require impact testing of weld metal. If
the design temperature is reduced to a temperature where the construction Standard
requires impact testing, then welding procedures and weld production testing in
accordance with Sections 7 and 10 are required.
Example 2:
T = 20 mm
T n (max.) = 12 mm
Material Group—A2
TR =10 mm
Design temperature 10°C
PWHT—Nil
Welding processes
Welds, L1 , L2 , C1 , C2 and C 3 ; submerged arc
Nozzle to shell joints—gas metal arc
Attachments to shell—gas metal arc
Weld procedure
qualification
Required for both welding processes
Min. thickness for SAW—10 mm (see Table 5.4)
Min. thickness for GMAW—10 mm (see Table 5.4)
All joints qualified by butt welds
Welder qualification
Required in accordance with Clause 9.2 for each
welding process
Production weld test
requirements
When required by construction standard for the class
of construction, testing in accordance with
requirements of Section 10
Other items listed in
Table 5.1
Within the limits stated for essential variables in
Table 5.1
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Example 3:
Assume a pressure vessel with all the conditions covering dimensions and welding
procedure and processes the same as Example 2 except that the design temperature is
reduced to 20°C.
The addition of impact testing of weld metal in accordance with the requirements of
Table 7.2 (40 J at impact test temperature of parent metal) will be required.
Example 4:
Assume a pressure vessel the same as Example 3 except that design temperature is reduced
to 40°C.
In this case the MDMT will be lower than that required for Example 3 and impact testing in
accordance with the requirements of Table 7.2 (40 J at impact test temperature of parent
metal) will be required.
Example 5:
T = 40 mm
T n (max.) = 12 mm
Material Group—A2
TR =30 mm
Design temperature 50°C
PWHT—Nil (Preheat 100°C)
Welding processes Welds, L1 , L2 , C 1, C 2 and C3 ; submerged arc
Nozzle to shell joints—gas metal arc
Attachments to shell—gas metal arc
Weld procedure
qualification
Required for both welding processes
Min. thickness for SAW—20 mm (see Table 5.4 and Notes below)
Min. thickness for GMAW—20 mm (see Table 5.4 and Notes below)
All joints qualified by butt welds
Welder
qualification
Required in accordance with Clause 9.2 for each welding process
Production weld
test requirements
When required by construction standard for the class of
construction, testing in accordance with requirements of Section 10
(see Note 2 for example)
Other items listed
in Table 5.1
Within the limits stated for essential variables in Table 5.1
NOTES:
1
2
The procedure tests carried out for Example 2 would conform to the requirements for the
above example provided the following requirements are met:
(a)
Procedure plate thickness 20 mm.
(b)
Filler metal in accordance with F numbers of Table 5.5. Submerged arc flux in
accordance with Item 5 of Table 5.1 for production welding.
(c)
Weld joint details in accordance with the requirements of Item 3 of Table 5.1.
(d)
Welding energy input in production welding in accordance with the requirements of
Item (7) of Table 5.1.
For a Class 1 Pressure Vessel, the test pieces required are two side bends and one macro. For
a Class 1H Pressure Vessel, the test pieces required are two side bends, one macro and two
transverse tensile tests.
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Example 6:
Assume a pressure vessel with all conditions, dimensions and welding procedure and
processes the same as Example 5 except that vessel is postweld heat treated.
The addition of postweld heat treatment requires that all welding procedures be requalified.
Example 7:
Assume a pressure vessel with all the conditions covering dimensions and welding
procedure and processes the same as Example 5 except that the vessel in constructed in
ASTM A387 Grade 12 Class 1 (Material Group C of Table 5.3) and the vessel is postweld
heat treated.
The addition of postweld heat treatment and construction in a different material group
classification requires that all welding procedures be requalified.
These are no additional requirements for welder qualification.
In addition to the test pieces nominated in Note 2 to Example 5, production test plate weld
metal requires chemical analysis for chromium and molybdenum content.
Example 8:
Assume a welding procedure qualification test carried out in the 1G position on a butt weld,
in pressure piping of size DN 200 16 mm wall thickness.
The procedure qualification test qualifies for all other welding positions in Figures 5.1
and 5.2 provided that the welding variables for other positions are within the limits for
essential variables as listed in Table 5.1.
Welder qualification using this welding procedure is required for welding positions in
production welding as required by Table 9.2.
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APPENDIX I
COLOUR SCALES
(Informative)
I1 STAINLESS STEEL
I1.1 General
Finished welds in stainless steel should be treated for corrosion resistance or appearance as
specified in AS 4458, AS/NZS 1554.6 or by the owner.
I1.2 Heat tint and oxide scale
The weld and heat-affected zone surfaces, including internal surfaces of piping, may be
permitted to have light straw colour oxide (for example, ANSI/AWS D18.2 Samples 1
through 3, as shown in AS/NZS 1554.6, can be used as a guide). For product contact
surface, blue, brown or black oxide heats (Sample 4 and above) may not be acceptable. Any
discoloration should be so tightly adhering to the surface that normal operations will not
remove it. Post-weld conditioning may be specified by the principal to meet discoloration
requirements.
The owner and the manufacturer should agree upon the acceptable degree of weld
discoloration either using the weld discoloration levels of ANSI/AWS D18.2
(see AS/NZS 1554.6) or by sample comparison. Depending on the application, a surface
treatment (e.g. pickling or electro polishing, and passivation) may be required to remove
heat tint unless otherwise specified (see also AS 4458).
I2 TITANIUM
When welding titanium and its alloys, the protective inert shielding should be retained until
the weld area has cooled below its oxidation temperature. When correctly protected from
atmospheric contamination or oxidation, the weld zone should retain its bright silver
colouration.
Any discolouration is an indicator of weld pool contamination and indicates that weld metal
properties are likely to be degraded, and remedial action may be required.
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NOTES
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NOTES