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AS/NZS 2980:2007
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AS/NZS 2980:2007
Australian/New Zealand Standard™
Qualification of welders for fusion
welding of steels
AS/NZS 2980:2007
This Joint Australian/New Zealand Standard was prepared by Joint Technical
Committee WD-003, Welding of Structures. It was approved on behalf of the
Council of Standards Australia on 19 February 2007 and on behalf of the Council of
Standards New Zealand on 16 February 2007.
This Standard was published on 2 May 2007.
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The following are represented on Committee WD-003:
AUSTROADS
Australian Chamber of Commerce and Industry
Australian Industry Group
Bureau of Steel Manufacturers of Australia
Engineers Australia
New Zealand Heavy Engineering Research Association
New Zealand Non-Destructive Testing Association
Steel Reinforcement Institute of Australia
University of Sydney
Welding Technology Institute of Australia
Keeping Standards up-to-date
Standards are living documents which reflect progress in science, technology and
systems. To maintain their currency, all Standards are periodically reviewed, and
new editions are published. Between editions, amendments may be issued.
Standards may also be withdrawn. It is important that readers assure themselves
they are using a current Standard, which should include any amendments which
may have been published since the Standard was purchased.
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visiting the Standards Web Shop at www.standards.com.au or Standards New
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This Standard was issued in draft form for comment as DR 06262.
AS/NZS 2980:2007
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Australian/New Zealand Standard™
Qualification of welders for fusion
welding of steels
Originated as AS 2980—1987.
Second edition 2004.
Revised and redesignated AS/NZS 2980:2007.
COPYRIGHT
© Standards Australia/Standards New Zealand
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.
Jointly published by Standards Australia, GPO Box 476, Sydney, NSW 2001 and Standards
New Zealand, Private Bag 2439, Wellington 6020
ISBN 0 7337 8178 0
AS/NZS 2980:2007
2
PREFACE
This Standard was prepared by the Australia/New Zealand Committee WD-003, Welding of
Structures, to supersede AS 2980—2004.
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Consistent with the 2004 edition of AS 2980, this edition continues to give cognizance to
the ISO welder qualifications Standard for steels ISO 9606-1:1994, Approval testing of
Welders—Fusion Welding, Part 1: Steels, by adopting largely its principles and
methodologies; however, due to incompatibilities between the European-based approach of
the ISO Standard and the North American basis for many of the Australian and
New Zealand welding Standards, it could not be adopted in its entirety with the methods of
testing and criteria of acceptance continuing to be based on current Australian and
New Zealand Standards.
Changes made to this edition were primarily to accommodate New Zealand specific
requirements to enable jointing to take place, and at the same time opportunity was taken to
clarify acceptance criteria and correct a number of typographic errors. The differences with
the 2004 edition of AS 2980 are as follows:
(a)
Clarification of the Scope: Clauses 1.1.
(b)
Jointing requirements: Clauses 1.4.2, 1.6, 3.3, 3.4, and Appendix F.
(c)
Clarification of requirements for multi-process joints: Clause 2.2 and Table 2.2.
(d)
Amendments to Clause 2.6 and Tables 2.6(A) and 2.6(B) to include recent changes to
welding consumable classification Standards.
(e)
Clarifying requirements for welders qualifying for multiple welding positions
(Clause 2.8) and test requirements (Clause 3.3).
(f)
Clarification of acceptance criteria: Clauses 4.1, 4.2, 4.3, and Table 4.3.5.3.
(g)
Correction of typographical errors: Clauses 3.5.2, 4.3.5.2, and Table 4.3.1.
(h)
Minor amendments to Clauses 5.1.2, 5.2, Paragraph E2.10, and Tables 2.6A and B2.
Readers should note that whilst this Standard provides the welder with a broad range of
approvals, application Standards may offer the welder a limited approval option, which in
some cases may be of some economic benefit to the fabricator.
As drawings in this Standard are complete only to the extent necessary for illustration,
reference is to be made to the requirements specified in the text.
The terms ‘normative’ and ‘informative’ have been used in this Standard to define the
application of the appendix to which they apply. A ‘normative’ appendix is an integral part
of a Standard, whereas an ‘informative’ appendix is only for information and guidance.
Statements expressed in mandatory terms in notes to tables and figures are deemed to be
requirements of this Standard.
3
AS/NZS 2980:2007
CONTENTS
Page
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FOREWORD.............................................................................................................................. 4
SECTION 1 SCOPE AND GENERAL
1.1 SCOPE ........................................................................................................................ 5
1.2 APPLICATION ........................................................................................................... 5
1.3 REFERENCED DOCUMENTS .................................................................................. 5
1.4 DEFINITIONS ............................................................................................................ 6
1.5 NOTATIONS .............................................................................................................. 6
1.6 QUALIFICATIONS OF EXAMINERS....................................................................... 7
SECTION 2 ESSENTIAL VARIABLES AND RANGE OF QUALIFICATION
2.1 GENERAL .................................................................................................................. 9
2.2 WELDING PROCESSES ............................................................................................ 9
2.3 PRODUCT TYPE...................................................................................................... 11
2.4 TYPE OF WELD....................................................................................................... 11
2.5 MATERIAL GROUPS .............................................................................................. 12
2.6 WELDING CONSUMABLES................................................................................... 13
2.7 DIMENSIONS........................................................................................................... 15
2.8 WELDING POSITIONS............................................................................................ 16
2.9 WELD DETAILS ...................................................................................................... 18
SECTION 3 EXAMINATION AND TESTING
3.1 SUPERVISION ......................................................................................................... 20
3.2 SHAPES, DIMENSIONS AND NUMBER OF TEST PIECES ................................. 20
3.3 WELDING CONDITIONS........................................................................................ 23
3.4 TEST METHODS...................................................................................................... 24
3.5 TEST PIECE AND TEST SPECIMEN...................................................................... 25
SECTION 4 CRITERIA OF ACCEPTANCE
4.1 GENERAL ................................................................................................................ 32
4.2 TEST ACCEPTANCE REQUIREMENTS ................................................................ 32
4.3 MINIMUM ACCEPTANCE REQUIREMENTS....................................................... 32
4.4 RE-TESTS................................................................................................................. 38
SECTION 5 VALIDATION AND CERTIFICATION
5.1 PERIOD OF VALIDITY ........................................................................................... 39
5.2 CERTIFICATE.......................................................................................................... 40
APPENDICES
A
LIST OF REFERENCED DOCUMENTS ................................................................. 41
B
MATERIAL GROUPS .............................................................................................. 44
C
INFORMATION TO BE INLCUDED IN WELDER’S QUALIFICATION TEST
CERTIFICATE.......................................................................................................... 48
D
JOB KNOWLEDGE.................................................................................................. 49
E
COMPARISON WITH ISO 9606-1........................................................................... 50
F
WELDER QUALIFICATION TEST FOR STAINLESS STEEL TUBE FOR THE
NEW ZEALAND DAIRY INDUSTRY..................................................................... 53
AS/NZS 2980:2007
4
FOREWORD
The ability of a welder to follow verbal or written instructions and verification of a person’s
skills are important factors in ensuring the quality of the welded product.
The testing of a welder’s skill in accordance with this Standard depends on welding
techniques and conditions used in which uniform rules are complied with, and standard test
pieces are used.
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The principle of this Standard is that a qualification test qualifies the welder not only for
the conditions used in the test, but also for all joints that are considered easier to weld
provided the welder has received appropriate training and/or has industrial practice within
the range of qualification.
The qualification test may be used to qualify a welding procedure and a welder provided all
the relevant requirements, e.g., test piece dimensions, are satisfied. Where a test is intended
as both a procedure qualification and a welder qualification, the welder qualification is not
achieved unless the requirements for procedure qualification are also met.
Qualifications in accordance with AS 2980 existing at the date of publication of this
Standard are to be interpreted in accordance with the requirements of the Standard.
5
AS/NZS 2980:2007
STANDARDS AUSTRALIA/STANDARDS NEW ZEALAND
Australian/New Zealand Standard
Qualification of welders for fusion welding of steels
SECT ION
1
SCOPE
AND
GENERA L
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1.1 SCOPE
This Standard defines the qualification test of welders for the welding of steels to the
requirements of a welding procedure specification. It provides a set of technical rules for a
systematic qualification test of the welder, and enables such qualifications to be uniformly
accepted independently of the type of product, location and examiner/examining body.
When qualifying manual welders, the emphasis is placed on the welder’s ability to
manually manipulate the electrode/welding torch and thereby to produce a weld of
acceptable quality.
The principle of this Standard is that a qualification test that qualifies the welder not only
for the conditions used in the test, but also for all joints that are considered to weld easily,
on the presumption that the welder has received particular training and/or has industrial
practice within the range of qualification.
This Standard is intended to complement existing Standards such as AS 1796 and
AS/NZS 3992 whilst enhancing the requirements for the qualification of welders from the
previous edition of AS 2980 in accordance with international expectations. It does not deal
with the certification of welders.
NOTES:
1
Certification of welders is covered by AS 1796.
2
Qualification of welders for pressure applications is addressed by AS/NZS 3992.
3
Appendix E provides a comparison between this Standard and ISO 9606-1.
1.2 APPLICATION
The qualification tests prescribed in this Standard are intended to provide a method to
qualify welders for the welding of steel structures; however, they may also be suitable for
the qualification of welders for other applications, by agreement between the principal and
the fabricator. These tests are not intended to be used as a guide for welding during actual
construction. The latter should be performed in accordance with the requirements of a
welding procedure specification (WPS) produced for the purpose.
This Standard deals specifically with qualifications for welders using manual or semiautomatic welding equipment and includes requirements for welders using mechanized or
fully automatic equipment.
NOTE: Where a welder fails the specified tests, the performance may be used as a basis for
measuring the value of further training.
1.3 REFERENCED DOCUMENTS
The documents referred to in this Standard are listed in Appendix A.
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AS/NZS 2980:2007
6
1.4 DEFINITIONS
For the purpose of this Standard, the definitions given in AS 2812 and those below apply.
1.4.1 Examiner
Person who has been appointed by the examining body to verify compliance with the
applicable Standard.
NOTE: In certain cases, an external independent examiner may be required.
1.4.2 Examining body
Organization that has been appointed to verify compliance with the applicable Standard.
NOTE: In certain cases, an external independent examining body may be required.
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1.4.3 Process
Any fusion welding process other than resistance welding, e.g., gas welding, MMAW,
SAW, GMAW, FCAW, GTAW, and ESW processes.
1.4.4 Weld metal thickness
Thickness of the weld metal excluding any reinforcement.
1.5 NOTATIONS
1.5.1 For test pieces
The following apply:
a
= design throat thickness
BW
= butt weld
D
= outside pipe diameter
FW
= fillet weld
l1
= length of test piece
l2
= half width of test piece
lf
= examination length
P
= plate
PW
= plug weld
s1
= weld metal thickness for welding process 1
s2
= weld metal thickness for welding process 2
t
= material thickness of test piece (plate or wall thickness)
t1
= material thickness of test piece for welding process 1
t2
= material thickness of test piece for welding process 2
T
= pipe
z
= leg length of fillet weld
The word ‘plate’ alone, or in combination, is used to mean ‘plate’, ‘rolled structural shapes’
or ‘welded structural shapes’ (see AS/NZS 3679.1 and AS/NZS 3679.2).
The word ‘pipe’ alone or in combination, is used to mean ‘pipe’, ‘tube’ or ‘hollow section’
(see AS 1163 and AS 1450).
All welding positions described in this Standard are defined in AS 3545.
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7
AS/NZS 2980:2007
1.5.2 For consumables
The following notations for welding consumables are those used in the ISO welding
consumable classification Standards:
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nm = no filler metal
B
= basic covering or electrode core-basic
C
= cellulosic covering
M
= electrode core-metal powder
P
= electrode core-rutile, fast freezing slag
R
= rutile covering or electrode core-rutile, slow freezing slag
S
= solid wire/rod
Z
= electrode core-other types
1.5.3 For other weld details
The following apply:
bs
= welding from both sides
lw = leftward welding (a gas welding term also referred to as ‘pushing’ the torch)
mb = welding with backing
ml = multi-layer
nb = welding without backing
rw = rightward welding (a gas welding term also referred to as ‘dragging’ the torch)
sl
ss
= single-layer
single-side welding
1.5.4 For bend tests
The following apply:
A
= minimum tensile elongation required by the material specification
d
= diameter of the former or the inner roller
ts
= thickness of the bend test specimen
1.6 QUALIFICATIONS OF EXAMINERS
Examiners shall have sufficient technical knowledge and experience and be able to satisfy
the ‘examining body’ of suitability for the work required by this Standard.
Examiners complying with the following are deemed to satisfy the technical knowledge
requirements:
(a)
For visual and destructive tests Examiners assessing test plates and test pieces in
accordance with Clauses 4.3.1 to 4.3.4 holding a formal qualification as a welding
supervisor (or higher) or welding inspector. Suitable qualifications are given in
AS/NZS 1554 (all parts).
(b)
For radiographic and ultrasonic examination Examiners undertaking assessments in
accordance with Clauses 4.3.5 or 4.3.6 holding an appropriate qualification at NDT
Level 2 or higher, issued in accordance with AS 3998 (ISO 9712), or CBIP
requirements.
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AS/NZS 2980:2007
8
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In New Zealand, persons issuing reports on destructive and/or non-destructive tests in
accordance with AS 2205 (all parts), AS 2207 or AS 2177 shall be an authorized signatory
of an organization accredited by International Accreditation New Zealand (IANZ) to
conduct the assessment of these tests in accordance with this Standard.
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9
SECT ION 2
ESSENT IA L V AR I AB L E S
RANGE OF Q UA L I F IC AT I ON
AS/NZS 2980:2007
AND
2.1 GENERAL
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The qualification of welders is based on essential variables as applied to the conditions used
to weld the test piece. For each essential variable a range of qualification is defined. If the
welder has to weld outside the range of qualification a new qualification test is required.
The essential variables are the following:
(a)
Welding process.
(b)
Product type (plate and pipe).
(c)
Type of weld (butt and fillet).
(d)
Material group.
(e)
Welding consumable.
(f)
Arc and metal transfer characteristics (e.g., a change between short-arc and spray-arc
in the GMAW process).
(g)
Dimension (material thickness and outside pipe diameter).
(h)
Welding position.
(i)
Weld detail (backing, single side welding, both side welding, single layer, multilayer, leftward welding, rightward welding (see also Clause 2.9).
2.2 WELDING PROCESSES
Each test normally qualifies only one welding process. A change of welding process
requires a new qualification test. Exceptions are the changes of solid wire (welding process
135) to metal flux core wire (welding process 136) or vice versa, which do not require a
new qualification test (see Table 2.6(A)).
It is also permitted for a welder to be qualified for two or more welding processes by
welding a single test piece (multi-process joint) or by two or more separate qualification
tests. The ranges of qualification for each welding process used and for the multi-process
joint for butt welds are given in Table 2.2 (see also Table 2.7(A)).
Welding processes are as follows:
(a)
111
Manual metal arc welding (MMAW).
(b)
114
Flux cored arc welding–self-shielded (FCAWss).
(c)
121
Submerged arc welding with one wire electrode.
(d)
123
Submerged arc welding with multiple electrodes.
(e)
125
Submerged arc welding with tubular cored electrode.
(f)
131
Gas metal arc welding with an inert gas shield (GMAW or ISO MIG process).
(g)
135
Gas metal arc welding with a reactive (active) gas shield (GMAW or ISO MAG
process).
(h)
136
Flux cored arc welding with a reactive gas shield (FCAWgs).
(i)
141
Gas tungsten arc welding (GTAW or TIG welding).
(j)
15
Plasma arc welding (PAW).
(k)
311
Oxy-acetylene welding or gas welding.
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AS/NZS 2980:2007
10
(l)
72
Electroslag (including consumable guide) welding (ESW).
(m)
73
Electrogas welding (EGW).
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NOTES:
1
ISO welding processes numbers used are defined in ISO 857-1 and ISO 4063.
2
The GMAW process is commonly referred to as MIG welding in Australia and New Zealand;
however, when applied to the welding of carbon and many alloy steels, inert shielding gases
such as pure argon are not normally used. Such steels utilize reactive shielding gases based
normally on argon containing minor additions of oxygen (O 2) and/or carbon dioxide (CO 2).
Refer also to AS 4882.
3
Australia and New Zealand do not normally differentiate between the FCAWgs and FCAWss
processes other than where specifically required. The term FCAW is therefore used in this
document to describe both processes, unless otherwise indicated.
4
The principles of this Standard may be applied to other arc and fusion welding processes not
specifically listed above.
For other than electroslag or electrogas welding, a welder qualified to weld with multiple
electrodes shall be qualified to weld with a single electrode, but not vice versa.
Welders qualified for hand-held continuous electrode arc welding shall be considered
properly qualified for single electrode mechanized welding in the same process(es) subject
to the limitations of this Clause (Clause 2.2), provided the welders demonstrate properly
their ability to control the welding equipment.
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11
AS/NZS 2980:2007
TABLE 2.2
THICKNESS RANGE FOR SINGLE- AND MULTI-PROCESS JOINTS
FOR BUTT WELDS
Thickness range
Welding process used for the test piece
Single-process joint
Multi-process
joint
According to Table 2.7(A)
1 – welding process without
backing t = s1
2 – welding process with
backing t = s2
According to
Table 2.7(A) with
t = s 1 + s2
According to Table 2.7(A)
1 – welding process without
backing t = t 1
2 – welding process with
backing t = t 2
According to
Table 2.7(A)
with t = t1 + t2
Welding process 1
only for welding
of the root area
2
S2
S1
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1
1
2
Welding without backing (nb)
Welding with backing (mb)
2
2
t2
t2
3
2
3
4
4
Welding process
Welding with backing (mb)
Welding without backing (nb)
t1
t1
1
3 mm
1
Welding without backing (nb)
NOTE: The term ‘single process joint’ allows a welder to qualify a process without backing
(welding process 1) and with backing (welding process 2) at the same time within the one joint as
permitted within Clause 2.2.
2.3 PRODUCT TYPE
The qualification test shall be carried out on plate or pipe. The following criteria are
applicable:
(a)
Welds in pipes, outside pipe diameter (D) >25 mm, qualify welds in plates.
(b)
Welds in plates qualify welds in pipe—
(i)
of outside pipe diameter (D) ≥150 mm, for welding positions flat (PA),
horizontal-vertical (PB) and horizontal (PC); and
(ii)
of outside pipe diameter (D) 500 mm, for all welding positions.
2.4 TYPE OF WELD
The qualification test shall be carried out as butt or fillet weld. The following criteria shall
apply:
(a)
Butt welds qualify butt welds in any type of joint except branch connections.
(b)
Butt welds also qualify the welder for fillet welds, but fillet welds only qualify fillet
welds.
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AS/NZS 2980:2007
12
(c)
Butt welds in pipes without backing qualify branch connections with an angle ≥60°
and the same range of qualification as in Clauses 2.2 and 2.5 to 2.9. For a branch
weld the range of qualification is based on the outside pipe diameter of the branch.
(d)
For applications where the type of weld cannot be qualified by means of either a butt
or fillet weld test then a specific test piece to be used to qualify the welder, e.g.,
branch connections other than Item (c) above, plug welds (see Clause 3.5.5).
2.5 MATERIAL GROUPS
2.5.1 Steel groups of parent material
In order to reduce the number of qualification tests, materials with similar welding
characteristics shall be grouped in accordance with Appendix B.
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NOTE: The tabulations are grouped according to ISO/TR 15608.
2.5.2 Range of qualification
2.5.2.1 General
The welding of any one metal in a group confers qualification on the welder for the welding
of all other metal within the same group as well as other groups according to Table 2.5.2.
When welding parent materials outside the grouping system, a separate test is required.
2.5.2.2 Qualification of dissimilar metal joints
When using filler metals from group 8 or 10 (see Table 2.5.2), all combinations with
group 8 or 10 to other groups are covered.
A qualification test made on wrought material groups gives qualification for cast material
and a mixture of cast and wrought material in the same material group.
TABLE 2.5.2
RANGE OF QUALIFICATION FOR PARENT METAL
Range of qualification
Material group
of the test
piece
1
1
X
X
—
—
—
—
—
2
X
X
X
—
—
—
3
X
X
X
—
—
4
X
X
X
X
5
X
X
X
6
X
X
7
X
8
9
10
11
—
—
—
X
—
—
X
—
X
—
—
X
X
—
X
—
—
X
X
X
—
X
—
—
X
X
X
X
—
X
—
—
X
X
X
X
X
—
X
—
—
X
—
—
—
—
—
X
X
X
—
X
X
—
—
—
—
—
—
—
X
X
—
—
—
—
—
—
—
X
X
X
10
—
—
—
—
—
—
—
X
—
X
X
—
11
X
—
—
—
—
—
—
—
—
—
—
X
9
2
3
4
5
6
7
8
9.1
9.2 + 9.3
—
—
—
—
—
—
X
X
X
X
X
X
X
X
—
—
9.1
X
9.2 + 9.3
X
LEGEND:
X Indicates those material groups for, which the welder is qualified.
— Indicates those material groups for which the welder is not qualified.
NOTE: Refer to Appendix B for details of material groups. Material is grouped according to ISO/TR 15608.
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AS/NZS 2980:2007
2.6 WELDING CONSUMABLES
Qualification with filler metal (e.g., with the GTAW (141), PAW (15) and gas welding
(311) processes,) qualifies for welding without filler metal but not vice versa.
The ranges of qualification for welding consumables (other than those for SAW, electroslag
and electrogas welding) are given in Tables 2.6(A) and 2.6(B).
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An SAW, electroslag or electrogas welder qualified with an electrode and shielding medium
combination shall be considered qualified to weld with an equivalent electrode and
shielding medium combination for the process used in the qualification test. For this
purpose, all appropriate solid electrodes including those complying with and classified to
AS 1858.1, AS 1858.2, AS/NZS ISO 14343, ISO 14341 or ISO 16834 shall be regarded as
equivalent to each other, as are all appropriate cored electrodes complying with
AS/NZS ISO 17632, AS/NZS ISO 17634 or AS/NZS ISO 18276.
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AS/NZS 2980:2007
14
TABLE 2.6(A)
RANGE OF QUALIFICATION FOR WELDING CONSUMABLES (see Notes)
Welding process
P, R, F1, F2
B, F4, F5
C, F3
P, R, F1, F2
X
—
—
B, F4, F5
X
X
—
C, F3
—
—
X
Solid wire
(S)
Electrode core
(M)
Electrode core
(B)
Electrode core
(P, R, Z)
Solid wire
(S)
X
X
—
—
Electrode core
(M)
X
X
—
—
FCAWgs (136)
Electrode core
(B)
—
—
X
X
FCAW (114 &136)
Electrode core
(P, R, Z)
—
—
—
X
MMAW (111)
—
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Range of qualification
Welding consumables use
in the test
GMAW (131 & 135)
FCAWgs (136)
GTAW (141)
—
LEGEND
X
Indicates those welding consumables for which the welder is qualified.
—
Indicates those welding consumables for which the welder is not qualified.
NOTES:
1
Abbreviations are defined in Clause 1.5.2 and Table 2.6(B).
2
Solid wire (S) consumables includes welding consumables classified and complying with AS/NZS 1167.2,
AS 1858.1, AS 1858.2, AS/NZS 2717.1, AS/NZS ISO 14343, ISO 14341 and ISO 16834.
3
Other than where specified by the consumable manufacturer, FCAW consumables classified and
complying with AS/NZS ISO 17632, AS/NZS ISO 17634 or AS/NZS ISO 18276 shall be deemed to be
equivalent to the following ISO designations in Table 2.6(A) for welder qualification purposes:
(a)
Electrode core type M consumables includes metal cored FCAWgs consumable (e.g., usability type
T15)
(b)
Electrode core type B consumables includes FCAW consumables containing basic fluxes (e.g.,
usability type T4 and T5)
(c)
Electrode core type P consumables includes rutile type FCAW consumables described by the
manufacturer as being suitable for out of position welding, (e.g., vertical up, overhead, etc.)
(d)
Electrode core type R consumables include rutile type FCAW consumables described as being
suitable for downhand and/or horizonal only
(e)
All other FCAW consumables classified and complying with AS/NZS ISO 17632, AS/NZS ISO
17634 or AS/NZS ISO 18276 are deemed to be type Z unless otherwise specified by the
consumable manufacturer.
4
Flux cored wires suitable for alloy steels including high chromium, austenitic and duplex steels complying
with AS/NZS ISO 17633 are deemed to be equivalent to group B in Table 2.6(A).
5
Consumables without the relevant Australian or New Zealand classification as specified in Notes 2, 3 and
4 above may be used, provided they have a Ship Classification Society’s classification complying with
AS/NZS 1554.1.
6
A welder qualified with an electrode and shielding medium given in Table 2.6(A) shall be considered
qualified to weld or tack weld with other electrode and shielding medium combinations with similar arc
and metal transfer characteristics within the limits of the Table. Therefore, separate qualification is
required; for example, for a change from spray transfer to short arc mode and vice versa.
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AS/NZS 2980:2007
TABLE 2.6(B)
GROUP DESIGNATION OF WELDING CONSUMABLES (See Notes)
Abbreviation
(Clause 1.5.2)
Group designation to
AS/NZS 3992
Electrode classification
to AS/NZS 4855, AS/NZS 4856,
AS/NZS 4857
B
F4
EXX15, EXX16, EXX18, EXX46, EXX48
C
F3
EXX10, EXX11
R
F2
EXX12, EXX13, EXX14, EXX19
—
F1
EXX20, EXX24, EXX27, EXX28
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NOTES:
1
The letters ‘XX’ used in the classification designation stand for the various tensile
strength levels of deposited weld metal.
2
Group B is deemed to include consumables classified to AS/NZS 4854.
3
Group F4 includes electrodes for high chromium steels other than austenitic and duplex
steels. Electrodes for high alloy austenitic and duplex steels are designated group F5 in
AS/NZS 3992.
2.7 DIMENSIONS
The welder qualification test of butt welds is based on the material thickness and outside
pipe diameters. The ranges of qualification shall be as specified in Tables 2.7(A) and
2.7(B).
NOTE: It is not intended that material thickness or outside pipe diameters be as measured
precisely but rather the general philosophy behind the values given in Tables 2.7(A) and 2.7(B)
should be applied.
For fillet welds, the range of qualification for material thickness shall be as specified in
Table 2.7(C).
For branch welding, the material thickness criteria to which Table 2.7(A) applies and the
outside pipe diameter criteria to which Table 2.7(B) applies are as follows:
(a)
Set on The material thickness and outside pipe diameter of the branch.
(b)
Set in or set through The material thickness of the main pipe or shell and the outside
pipe diameter of the branch.
For test pieces of different outside pipe diameters and material thicknesses, the welder is
qualified for—
(i)
the thinnest and thickest material thickness qualified in accordance with
Table 2.7(A); and
(ii)
the smallest and largest outside pipe diameter qualified in accordance with
Table 2.7(B).
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AS/NZS 2980:2007
16
TABLE 2.7(A)
RANGE OF QUALIFICATION OF MATERIAL THICKNESS
AND WELD METAL THICKNESS (MULTI-PROCESS)
OF TEST PIECE FOR BUTT WELDS
millimetres
Thickness (see Note)
t
Range of qualification
<3
t to 2t
3 to ≤12
3 to 2t
>12
≥5
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NOTE: For multi-processes, s1 and s 2 of Table 2.2 apply.
TABLE 2.7(B)
RANGE OF QUALIFICATION FOR OUTSIDE
PIPE DIAMETER (See Note)
millimetres
Outside pipe diameter of test piece
D
Range of qualification
≤25
D to 2D
>25
≥0.5 × D (25 mm min.)
NOTE: For structural hollow sections, D is the dimension of the smaller side.
TABLE 2.7(C)
RANGE OF QUALIFICATION OF MATERIAL THICKNESS
OF TEST PIECE FOR FILLET WELDS (See Note)
millimetres
Material thickness of test piece
t
Range of qualification
≤3
to3
>3
≥3
NOTE: See also Table 2.9(B).
2.8 WELDING POSITIONS
The range of qualification for each welding position is given in Table 2.8.
NOTES:
1
The specified welding positions and symbols refer to AS 3545 and ISO 6947.
2
Welders undertaking tests to qualify in all positions (i.e., testing in the overhead position)
should have had suitable training and experience in the welding of all other positions
qualified by the test including vertical-up welding (see Clause 1.1).
The test pieces shall be welded in accordance with the nominal angles of the welding
positions according to AS 3545.
The welding positions 6G welded vertical down (J-L045) and 6G welded vertical up (HL045) for pipes qualify for all pipe angles.
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—
X
—
—
—
—
—
—
HV
VD
VU
—
—
—
—
—
X
—
X
—
—
—
X
—
X
X
—
X
X
X
—
X
X
X
—
X
—
X
—
—
X
X
X
—
X
X
X
—
—
X
—
—
X
—
—
—
X
—
—
—
— Indicates those welding positions for which the welder is not approved.
Indicates those welding positions for which the welder is also approved.
—
—
—
—
—
X
—
X
—
—
—
—
—
X
—
—
—
—
X
—
—
—
X
—
—
—
—
Indicates the welding position for which the welder is approved in the approval list.
—
—
—
—
—
X
X
—
—
—
—
—
—
—
—
X
6G-VD
X
H
X
VU
6G-VU
X
—
F
VD
Fillet (Note 2)
welds
Fixed
0°
—
—
—
—
X
—
—
—
—
—
—
—
OH
F
45°
90°
—
—
—
—
—
—
—
—
X
X
—
—
—
—
X
—
X
—
—
X
—
—
X
—
—
—
—
X
—
X
—
—
—
—
—
—
—
—
X
X
X
—
—
—
—
X
—
—
—
—
X
—
—
—
—
—
—
—
—
—
—
—
—
—
X
—
—
—
—
—
—
—
—
—
—
—
—
—
X
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
X
—
X
X
—
—
X
X
X
—
X
X
X
X
—
X
X
—
X
X
—
—
X
X
X
—
X
—
X
X
—
X
—
X
—
—
—
X
—
—
—
—
—
—
—
—
—
—
—
—
X
—
X
—
—
—
—
—
—
—
X
X
—
—
—
—
—
X
—
—
—
—
X
—
—
—
—
X
—
—
—
—
(Note 3)
—
—
VU
—
—
X
—
—
—
—
—
VU
—
—
VD
—
—
X
—
—
—
—
VD
—
—
—
—
X
—
X
X
—
HV
—
F
X
—
—
X
—
—
—
—
6G-VD
—
—
—
F
HV
—
X
—
—
—
6G-VU
X
X
X
—
X
H
—
X
X
OH
X
—
—
—
VU
X
—
—
—
VD
—
—
F
X
—
—
X
—
—
—
X
—
—
X
VU
—
—
—
VD
Rotating
Fixed
Rotating
Fillet welds
But
welds
LEGEND:
Pipes
Plates
Butt welds
OH
90°
—
X
VU
Fixed
—
X
VD
0°
—
HV
(Note 2)
X
F
Rotating
H
OH
45°
—
VU
Fixed
—
VD
90°
H
0°
Rotating
Fillet welds
—
Fillet welds
Pipes
F
Butt welds
Butt welds
Range of approval
F
Welding position of approval test
piece
Plates
TABLE 2.8
RANGE OF QUALIFICATION FOR WELDING POSITION (see Note 1)
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AS/NZS 2980:2007
AS/NZS 2980:2007
18
NOTES TO TABLE 2.8:
1
The letters in the Table refer to welding positions as defined in AS 3545, except that for
vertical welding directions D = down and U = up.
2
Horizontal for pipes may be welded in two versions, as follows:
3
(a)
Pipe: rotating; axis: horizontal; welds: vertical.
(b)
Pipe: fixed; axis: vertical; weld: horizontal vertical.
OH—this is an approved position and is covered by the other related tests.
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Welding two pipes with the same outside pipe diameter, one welded vertical up (position
PF) and one weld in the horizontal position (position PC), also covers the range of
qualification of a pipe welded in welding position H-L045.
Welding two pipes with the same outside pipe diameter, one welded vertical down (position
PG) and one in welding position PC, also covers the range of qualification of a pipe welded
in welding position J-L045.
Outside pipe diameters (D) ≥150 mm may be welded in two welding positions (PF or PG
2/3 of circumference, PC 1/3 of circumference) using only one test piece.
For plug welds in plate (see Clause 3.5.5), the range of qualification applicable for plate to
plate welds (without extension to fillet or pipe welds) given in Table 2.8 shall apply.
2.9 WELD DETAILS
Depending on the weld details, the range of qualification shall be as shown in Tables 2.9(A)
and 2.9(B).
When welding with the gas welding process (311) a change from rightward to leftward
welding and vice versa requires a new qualification test.
TABLE 2.9(A)
RANGE OF QUALIFICATION FOR WELD DETAILS ON BUTT WELDS
Range of qualification
Single-sided welding/
welding without backing
(ss nb)
Single-sided welding/
welding with backing
(ss mb)
Welding from
both sides
(bs)
Single-sided welding/
welding without backing
(ss nb)
X
X
X
Single-sided welding/
welding with backing
(ss mb)
—
X
X
Welding from both sides
(bs)
—
X
X
Weld details of test piece
LEGEND:
X
Indicates those welds for which the welder is qualified.
—
Indicates those welds for which the welder is not qualified.
NOTE: A consumable insert may be used in lieu of backing material; however, separate qualification is
required for the use of consumable inserts.
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AS/NZS 2980:2007
TABLE 2.9(B)
RANGE OF QUALIFICATION OF LAYER TECHNIQUE
FOR FILLET WELDS
Test piece
(see Note)
Range of qualification
Single-layer (sl)
Multi-layer (ml)
Single-layer (sl)
X
—
Multi-layer (ml)
X
X
LEGEND:
X
Indicates the layer technique for which the welder is qualified.
—
Indicates the layer technique for which the welder is not qualified.
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NOTE: Throat thickness shall be in the range of 0.5 × t ≤ a ≤ 0.7 × t (see Clause 1.5.1).
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AS/NZS 2980:2007
20
SECT ION
3
EXAM I NA T I ON
AN D
T E ST IN G
3.1 SUPERVISION
The welding of test pieces shall be witnessed by the examiner or examining body. The
testing shall be verified by the examiner or examining body.
The test pieces shall be marked with the identification of the examiner and the welder
before welding starts. Additionally welding positions for all test pieces shall be marked on
the test piece. For fixed pipe welds, the 12 o’clock welding position shall also be marked.
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The examiner or examining body may stop the test if the welding conditions are not correct
or if it appears that the welder does not have the skill to fulfil the requirements, e.g., where
there are excessive and/or systematic repairs.
3.2 SHAPES, DIMENSIONS AND NUMBER OF TEST PIECES
The shape and dimension of test pieces (see Clause 2.7) required for butt and fillet welds
are shown in Figures 3.2(A) to 3.2(D).
For electroslag and electrogas welding, the minimum length of sound weld required for
testing is 430 mm in addition to any length extension for process run-on and run-off
purposes.
For pipes, a minimum examination length of 150 mm is required; however, if the
circumference of pipes is less than 150 mm, additional test pieces will be required with a
maximum of three test pieces.
For plug welds, the preparation of the test plate shall be in accordance with Clause 3.5.5.
125
125
300
t
LEGEND:
t = material thickness of test piece
DIMENSIONS IN MILLIMETRES
FIGURE 3.2(A) DIMENSIONS OF TEST PIECE—BUTT WELD IN PLATE
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21
AS/NZS 2980:2007
Z = a 2
t
Z
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a
125
20
t
0
125
LEGEND:
0.5 x t5 a 0.7 x t
a = design throat thickness
t = material thickness of test piece
z = leg length of fillet weld
DIMENSIONS IN MILLLIMETRES
FIGURE 3.2(B) DIMENSIONS OF TEST PIECE—FILLET WELD ON PLATE
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22
12
5
12
5
AS/NZS 2980:2007
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t
D
LEGEND:
D = outside pipe diameter
t = material thickness of test piece (wall thickness)
DIMENSIONS IN MILLLIMETRES
FIGURE 3.2(C) DIMENSIONS OF TEST PIECE—BUTT WELD IN PLATE
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23
AS/NZS 2980:2007
Z = a 2
Z
a
D
t
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50
125
l1
50
t
l1
t corresponds to the thinner part
LEGEND:
0.5 x t a 0.7 x t
a = design throat thickness
D = outside pipe diameter
l 1 = length of test piece
t = material thickness of test piece
z = leg length of fillet weld
DIMENSIONS IN MILLLIMETRES
FIGURE 3.2(D) DIMENSIONS OF TEST PIECE—FILLET WELD ON PIPE
3.3 WELDING CONDITIONS
The qualification test of welders shall follow either a draft (preliminary welding procedure
specification or PWPS) or qualified welding procedure prepared in accordance with the
application Standard that the welder is being tested to (e.g., AS/NZS 1554.1 category SP,
AS 2885.2, etc.)
The following welding conditions shall apply:
(a)
The welding time for the test piece shall correspond to the working time under usual
production conditions.
NOTE: The working time should be agreed between the welder and examiner prior to the
commencement of the test.
(b)
Butt and fillet weld test pieces shall have at least one stop and one re-start in the root
run and in the capping run and be identified in the examination length to be examined
This provision does not apply to electroslag and electrogas welding.
NOTE: Any post-weld heat treatment required in the welding procedure may be omitted
unless bend tests are required.
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AS/NZS 2980:2007
24
(c)
The test piece shall be suitably identified.
(d)
The welder shall be allowed to remove minor imperfections by grinding, except on
the surfaces after finishing the weld. Back grinding of the weld root is permitted only
where the welder is required to weld from both sides and when specified on the weld
procedure. The permission of the examiner or examining body shall be obtained.
(e)
Welders qualifying to weld stainless steel tube for the New Zealand dairy industry
shall also comply with the additional requirements of Appendix F.
3.4 TEST METHODS
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Each completed weld shall be visually examined in the as-welded condition and tested
according to Table 3.4 (and when appropriate, Appendix F).
If the weld is accepted by visual testing, the additional test(s) according to Table 3.4 shall
be carried out. Where permanent backing is used in the qualification test, it shall be
removed prior to destructive testing.
The test specimen for macroscopic examination shall be prepared and etched on one side in
accordance with AS 2205.5.1 to clearly reveal the weld. Polishing is not required.
When radiographic testing of butt welds in plate made by the GMAW, FCAW (only metal
cored wires) and gas welding processes is undertaken, it shall be supplemented by either
two additional bend tests (one face and one root or two side bends), or two nick-break tests
(one face and one root).
For outside pipe diameter (D) ≤25 mm, the bend or fracture tests may be replaced by a
notched tensile test (see ISO 9017) of the complete test piece.
NOTE: For example, see Figure 3.4.
TABLE 3.4
TEST METHODS
Weld type
Visual
examination
to AS 3978
Radiographic
examination
to AS 2177
Bend test
to AS 2205.3.1
Fracture test to
AS 22.5.4.1 or
AS 2205.4.2
Macroscopic
examination
to AS 2205.5.1
Butt weld (in plate
or pipe)
Mandatory
Mandatory
(Notes 1, 2, 4)
Mandatory
(Notes 1, 2, 6)
Mandatory
(Notes 1, 2, 6)
Not applicable
(Note 7)
Fillet weld and
branch connection
Mandatory
Not mandatory
Not applicable
Mandatory
(Notes 3, 5)
Mandatory
(Notes 3, 5, 7)
Plug weld
Mandatory
Not applicable
Not applicable
Not applicable
Mandatory
NOTES:
1
Either radiographic testing or bend or fracture tests shall be used.
2
When radiographic testing is used, then additional bend or fracture tests are mandatory for the GMAW,
FCAW (only metal cored wire) and gas welding processes (see Clauses 3.4 and 3.5.2).
3
The fracture tests may be replaced by a macroscopic examination, according to AS 2205.5.1, of at least
two sections.
4
The radiographic testing may be replaced by ultrasonic testing according to AS 2207 for thickness
≥8 mm on ferritic steels only.
5
The fracture tests on pipes may be replaced by radiographic testing.
6
For outside pipe diameter (D) ≤25 mm, the bend or fracture tests may be replaced by a notched tensile
test (see ISO 9017) of the complete test piece (example is given in Figure 3.4).
7
A macroscopic examination may be required by the application Standard where the welder and
procedure are being qualified at the same time.
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25
AS/NZS 2980:2007
d
300
25
Holes are not allowed in start and stop areas
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For t
For t
1.8 mm: d = 4.5
1.8 mm: d = 3.5
NOTE: Notch profiles s and q are also permitted in circumferential direction according to ISO 9017.
DIMENSIONS IN MILLIMETRES
FIGURE 3.4 EXAMPLE FOR NOTCH TENSILE TEST FOR PIPE PIECE OUTSIDE
DIAMETER ≤25 mm
3.5 TEST PIECE AND TEST SPECIMEN
3.5.1 General
Clauses 3.5.2 to 3.5.5 provide details of the type, dimensions and preparation of the test
pieces and test specimens, and the requirements for destructive tests.
3.5.2 Butt weld in plate and pipe
When radiographic testing is used, the examination length of the weld (see
Figures 3.5.2(A)(a), 3.5.2(B)(a) and (b)) in the test piece shall be radiographed in the
as-welded condition. Removal of excess weld metal is not permitted.
When fracture testing is used, the test piece examination length shall be cut into the test
specimens of equal width and all of them tested in accordance with AS 2205.4.1 in such a
manner that the fracture will be reached. The examination length of each test specimen shall
be ≥40 mm.
Where transverse bend testing or side bend testing is used, the diameter for the former or
the inner roller shall be 4t and the bending angle 180° for parent metal with elongation
(A) ≥20%. For parent metal with elongation (A) <20%, the following equation shall apply:
d=
100 × t s
− ts
A
where
d = diameter of the former or the inner roller, in millimetres
ts = thickness of the bend test specimen, in millimetres
A = minimum tensile elongation required by the material specification
When only transverse bend testing is carried out, the examination length shall be cut into
test specimens of equal width and all specimens shall be tested. When only side bend tests
are used, a minimum of four test specimens shall be taken equally spaced along the
examination length. One of these side bend tests shall be taken from the start and stop area
in the examination length. Bend tests shall be performed in accordance with AS 2205.3.1.
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AS/NZS 2980:2007
26
For thickness (t) >12 mm, the transverse bend tests may be substituted by side bend tests.
For pipes, the number of the additional fracture or transverse bend test specimens for the
GMAW, FCAW (only metal cored wire) and gas welding processes, using the radiographic
testing, depends on the welding position. For the flat (PA) or horizontal (PC) welding
position one root and one face bend test specimen shall be tested (see Figure 3.5.2(B)(a)).
For all other welding positions, two root and two face bend test specimens shall be tested
(see Figure 3.5.2(B)(b)).
3.5.3 Fillet weld on plate
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For fracture tests (see Figure 3.5.3) the test piece may be cut, if necessary, into several test
specimens. Each test specimen shall be positioned for breaking in accordance with
AS 2205.4.2 and examined after fracture.
Where macroscopic examination is used, at least two test specimens shall be taken. One
macroscopic specimen shall be taken at the stop/start location.
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AS/NZS 2980:2007
l2
l2
25
lf
25
l1
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LEGEND:
l 1 = length of test piece
l 2 = half width of test piece
l f = examination length
(a) Sectioning into an even-numbered quantity of test specimens
2
2
5
5
40
(b) Examination length of the test specimen
NOTE: In addition, the test specimen may be longitudinally notched in the centre of the weld of the tension side in
order to achieve a fracture in the weld on the test specimen.
DIMENSIONS IN MILLIMETRES
FIGURE 3.5.2(A) PREPARATION AND FRACTURE TESTING OF TEST SPECIMENS
FOR A BUTT WELD IN PLATE
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1
lf
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2
LEGEND:
l f = examination length
1 = location for one root fracture or one root transverse bend or one side bend test specimen
2 = location for one face fracture or one face transverse bend or one side bend test specimen
(a) Sectioning of additional fracture or bend test specimens for the flat (PA)
and horizontal (PC) welding positions
1
2
lf
4
3
LEGEND:
l f = examination length
1 = location for one root fracture or one root transverse bend or one side bend test specimen
2 = location for one face fracture or one face transverse bend or one side bend test specimen
3 = location for one root fracture or one root transverse bend or one side bend test specimen
4 = location for one face fracture or one face transverse bend or one side bend test specimen
(b) Sectioning of additional fracture or bend test specimens for the vertical up (PF), vertical down
(PG), 6G vertical up (H-L045) and 6G vertical down (J-L045) welding positions
DIMENSIONS IN MILLIMETRES
FIGURE 3.5.2(B) (in part) PREPARATION AND LOCATIONS OF TEST SPECIMENS
FOR A BUTT WELD IN PIPE
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AS/NZS 2980:2007
40
2
2
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5
5
(c) Examination length of the fracture test specimen
NOTE: In addition, the test specimen may be longitudinally notched in the centre of the weld of the tension side in
order to achieve a fracture in the weld of the test specimen.
DIMENSIONS IN MILLIMETRES
FIGURE 3.5.2(B) (in part) PREPARATION AND LOCATIONS OF TEST SPECIMENS
FOR A BUTT WELD IN PIPE
25
lf
25
LEGEND:
l f = examination length
DIMENSIONS IN MILLIMETRES
FIGURE 3.5.3 EXAMINATION LENGTH FOR FRACTURE TESTING FOR A FILLET
WELD ON PLATE
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3.5.4 Fillet weld on pipe
For fracture tests, the test piece shall be cut into four or more test specimens and fractured
(one possibility is shown in Figure 3.5.4).
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When macroscopic examination is used, at least two test specimens shall be taken. One
macroscopic specimen shall be taken at the stop/start location.
FIGURE 3.5.4 PREPARATION AND FRACTURE TESTING OF TEST SPECIMENS
FOR A FILLET WELD ON PIPE
3.5.5 Plug welds only
The preparation of the test plate for plug weld qualification test shall be in accordance with
Figure 3.5.5. Plug welds shall be visually examined in accordance with AS 3978. If
satisfactory, two macroscopic test pieces shall then be prepared and examined in
accordance with AS 2205.5.1.
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AS/NZS 2980:2007
75 min.
50 min.
Macroetch
test specimen
(etch interior face)
75 min.
50 min.
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Cutine
See Note
(a) Plug weld test plate–Macroetch both cut (internal) faces
See Note
10
10 min.
(b) Macroetch test specimen
NOTE: Unless otherwise specified by the welding procedure specification (WPS), the hole shall be 30 mm diameter,
and shall be filled.
DIMENSIONS IN MILLIMETRES
FIGURE 3.5.5 TEST PIECE FOR PLUG WELD QUALIFICATION
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SECT I ON
4
C R IT E R I A
O F
A CCE PT A N CE
4.1 GENERAL
Test pieces shall be evaluated according to the acceptance requirements specified for
relevant types of imperfections.
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Prior to any testing the following shall be checked:
(a)
All slag and spatter is removed.
(b)
No grinding on the root and the face side of the weld except as permitted in
Clause 3.3.
(c)
Stop and restart in the root run and in the capping run are identified (see Clause 3.3).
(d)
Weld profile and dimensions.
4.2 TEST ACCEPTANCE REQUIREMENTS
The acceptance requirements for imperfections found by test methods according to this
Standard shall, unless otherwise specified, be assessed in accordance with the application
Standard the welder is required to work within, and the requirements of Clause 4.3.
For welders qualifying to weld stainless steel tube for the New Zealand dairy industry, test
methods and the imperfections found shall comply with the requirements of Appendix F.
4.3 MINIMUM ACCEPTANCE REQUIREMENTS
4.3.1 Visual Examination
Each weld test piece shall be examined visually in accordance with the requirements of
AS 3978. Aids to visual examination may be used wherever necessary to facilitate the
assessment of an imperfection. Inspection aids and measuring devices shall be sufficient to
enable the examiner to detect imperfections that could occur on welds and test pieces.
The test welds shall also comply with the following:
(a)
Plate For acceptance qualification, the welded test plates, when examined visually,
shall conform to the following requirements:
(i)
The weld shall be free of cracks.
(ii)
Complete fusion shall exist between adjacent layers of weld metal, and between
weld metal and parent metal.
(iii) All craters shall be filled to the full cross-section of the weld.
(iv)
The face of the weld shall be at least flush with the outside surface of the plate,
and the weld shall merge smoothly with the parent metal. Undercut shall not
exceed 5% of the plate thickness, or 0.5 mm, whichever is less. Weld
reinforcement shall not exceed 3 mm. The root of the weld may be concave
provided the maximum surface concavity does not exceed 1 mm and the total
weld thickness is equal to or greater than that of the base metal. The maximum
melt-through shall be 3 mm.
(v)
The frequency of worm-holes in fillet welds shall not exceed one in each
100 mm of weld length and the maximum diameter shall not exceed the lesser
of t/3 or 2.5 mm.
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AS/NZS 2980:2007
A fillet weld shall be permitted to underrun the nominal fillet weld size
specified by 1.5 mm without correction, provided the undersize portion of the
weld does not exceed 10% of the length of the weld.
(b)
Pipe For acceptance qualification, the welded pipes, when examined visually, shall
comply with the following requirements:
(i)
The weld shall be free of cracks.
(ii)
All craters shall be filled to the full cross-section of the weld.
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(iii) The face of the weld shall be at least flush with the outside surface of the pipe,
and the weld shall merge smoothly with the parent metal. Undercut shall not
exceed 5% of the pipe wall thickness, or 0.5 mm in depth, whichever is less.
Weld reinforcement shall not exceed the values given in Table 4.3.1.
(c)
(iv)
The root of the weld shall be examined, and there shall be no evidence of
cracks, incomplete fusion, or lack of root penetration. A concave root surface is
permitted, within the limits of Item (v) below, provided the total weld thickness
is equal to or greater than that of the parent metal.
(v)
The maximum root surface concavity shall be 1.5 mm, and the maximum
penetration shall be 3 mm.
Plug welds For acceptance qualification, the plug welds, when examined visually,
shall be filled.
TABLE 4.3.1
PERMISSIBLE WELD REINFORCEMENT FOR PIPE
millimetres
Pipe wall thickness
Maximum reinforcement
≤10
10 to ≤20
>20
2.5
3.0
5.0
4.3.2 Transverse guided bend tests
Bend test specimens shall be tested in accordance with the requirements of AS 2205.3.1
using a former with a diameter as specified in Clause 3.5.2.
The test pieces shall not reveal any one single flaw ≥3 mm in any direction. Flaws
appearing at the edges of a test specimen during testing shall be ignored in the evaluation
unless there is evidence that cracking is due to incomplete penetration, slag or other flaw.
If the imperfections in the welder’s test piece exceed the permitted maximum specified, the
welder is deemed to have failed the test.
4.3.3 Fracture tests
4.3.3.1 Nick break test
Specimens for the nick break test shall be tested in accordance with AS 2205.4.1.
The fractured surface of the weld shall comply with the following requirements:
(a)
The weld shall be free of cracks and incomplete fusion.
(b)
The weld shall be free from individual pores or inclusions, the areas of which exceed
5 mm 2 .
(c)
The total area of all internal imperfections shall not exceed 24 mm2 over the length of
the weld (see Clause 3.5.2), or 5% of the fractured weld surface area, whichever is the
lesser.
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4.3.3.2 Fillet break test
Specimens for fillet break test shall be tested in accordance with AS 2205.4.2.
The fractured surface of the weld shall comply with the following requirements:
(a)
The weld shall be free of cracks and incomplete fusion.
(b)
The weld shall be free from individual pores or inclusions, the areas of which exceed
5 mm 2 .
(c)
The total area of all internal imperfections shall not exceed 24 mm2 over the length of
the weld (see Clause 3.5.3), or 5% of the fractured surface area, whichever is the
lesser.
4.3.4 Macroetch examination
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The specimen shall be prepared and examined in accordance with AS 2205.5.1.
For acceptable qualification, the specimen, when inspected visually, shall comply with the
following requirements:
(a)
Fillet welds shall have fusion to the root of the joint but not necessarily beyond.
(b)
Minimum leg size shall comply with the specified fillet weld size.
(c)
Fillet welds shall—
(i)
have no cracks;
(ii)
have thorough fusion between adjacent layers of weld metal and between weld
metal and parent metal;
(iii) have weld profiles conforming to AS/NZS 1554.1;
(d)
(iv)
have no undercut exceeding the values permitted by Clause 4.3.1(a)(iv);
(v)
for porosity larger than 1mm, have accumulated porosity not exceeding 6 mm;
and
(vi)
have no accumulated slag, the sum of the greatest dimensions of which shall not
exceed 3 mm.
Plug welds shall—
(i)
have no cracks;
(ii)
have thorough fusion to the backing plate and to the sides of the hole; and
(iii) no visible slag in excess of 6 mm total accumulated length.
4.3.5 Radiography
4.3.5.1 Preparation of test piece
If radiographic examination is used in lieu of the prescribed bend or fracture tests, the test
piece shall be prepared in accordance with the following:
(a)
The backing bar (when used) shall not be removed.
(b)
Following visual examination to Clause 4.3.1, weld ripples or weld surface
irregularities on the test piece shall be removed by any suitable mechanical process to
the degree necessary to ensure that resulting radiographic images due to surface
irregularities cannot mask, or be confused with, the image of any discontinuity. A
witness of weld metal shall remain.
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AS/NZS 2980:2007
4.3.5.2 Radiographic examination
Radiography shall be carried out in accordance with AS 2177 using the following test
methods as designated by AS 2177, for which ‘z’ is ‘S’, ‘DWS’ or ‘DWD’ as appropriate:
(a)
For thickness ≤12 mm..................................................................................... XR2/z.
(b)
For thickness >12 mm........................................................... XR2/z, GRI/z or GR2/z.
Where materials of different thicknesses are examined, the thinner plate shall determine the
technique selection.
Image quality indicator (IQI) sensitivity for each technique shall be as required by
Table 4.3.5.2. The IQI sensitivity shall be measured through the weld using wire type IQI in
accordance with AS 2177. At least one IQI should be used with each radiograph.
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TABLE 4.3.5.2
SMALLEST DISCERNIBLE WIRE
Wire number (see AS 2177)
Method
(see Note 1)
Weld metal thickness, mm
≤6
>6 ≤10
>10 ≤12
>12 ≤18
>18 ≤25
>25 ≤35
>35 ≤50
>50
XR2/z
13
12
11
10
9
8
7
See Note 2
GR1/z OR
GR2/z
12
11
11
10
9
8
7
See Note 2
NOTES:
1
As designated by AS 2177, for which ‘z’ is ‘S’, ‘DWS’ or ‘DWD’, as appropriate.
2
For thicknesses greater than 50 mm, an IQI sensitivity of 2.0% is required.
4.3.5.3 Criteria
For acceptance qualification, the weld, as revealed by the radiograph, shall comply with the
following requirements:
(a)
The permissible level of imperfections shall not exceed the levels given in
Table 4.3.5.3.
(b)
Adjacent imperfections:
(i)
Aligned Where adjacent imperfections are aligned, they shall be assessed as
shown in Figure 4.3.5.3(a).
(ii)
Overlapping Where there is a horizontal displacement between adjacent
imperfections, the effective length (l) shall be as shown in Figure 4.3.5.3(b).
(iii) Overlapping vertical displacement Where imperfections occur above one
another in the vertical plane of the weld, they shall be assessed as shown in
Figure 4.3.5.3(c).
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TABLE 4.3.5.3
PERMISSIBLE LEVELS OF IMPERFECTION AS DETERMINED BY
RADIOGRAPHIC OR ULTRASONIC EXAMINATION
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Type of imperfection
Maximum allowable dimensions or number of
imperfections (see Notes 1 and 2)
Cracks
Not permitted
Lack or penetration or incomplete fusion
Not permitted
Incompletely filled groove
Not permitted
Burn-through
Not permitted
Undercut (see Note 3)
5 percent of material thickness (t) or 0.5 mm,
whichever is less
Shrinkage grooves
As for undercut
Slag inclusions
Height: 0.2 t or 2 mm maximum, whichever is less
Length: t or 25 mm maximum, whichever is less
Porosity (see Note 4)
Surface—Not permitted
Linear porosity—Not permitted
Internal—See loss of cross-sectional area
Loss of cross-sectional area (see Note 5)
5% maximum
NOTES:
1
For adjacent imperfections, see Clause 4.3.5.3(b).
2
For the purpose of radiographic and ultrasonic examination, the height of the detected imperfection is to
be taken as 2 mm. If the radiographic or ultrasonic examination indicates that height could be greater than
2 mm, height is to be determined by sectioning or vertical ultrasonic sizing in accordance with AS 2207.
3
Dimensions (length and depth) of undercut shall not exceed that permitted for the qualified WPS.
4
For radiographic inspection, porosity levels representing a loss of projected area not exceeding 2% are
permitted. If required, reference may be made to porosity charts in AS 4037, to assist in assessing the
appearance of this level of porosity on a radiograph. For ultrasonic examination, porosity that interferes
with the examination is not permitted.
5
For calculation of loss of cross-sectional area, all relevant imperfections shall be considered.
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AS/NZS 2980:2007
L1
d
L2
Where d is less than L 1 the smaller
imperfection, ΣL
L1
L2
d
Where d is not less than the L 1
smaller imperfection, ΣL
L2
L1
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(a) Aligned imperfections
L1
ΣL
L2
(b) Overlapping imperfections
L1
h1
d
h2
L2
NOTE: Treat as separate defects.
(i) Cross-section
(ii) Longitudinal section, where
d
5mm
h1
d
h
h2
L
NOTE: Treat as a single defect with dimensions h and L as shown.
(iii) Longitudinal section, where d
5mm
(c) Overlapping vertical displacement
FIGURE 4.3.5.3 ASSESSMENT OF ADJACENT IMPERFECTIONS
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4.3.6 Ultrasonic examination
4.3.6.1 Method
If ultrasonic examination is used in lieu of the radiographic examination for ferritic steels
(see Table 3.4), it shall comply with AS 2207.
Shear probes shall have a dominant frequency in the range 2.0 MHz to 2.5 MHz, and an
essentially square or circular transducer in the size range 15 mm to 22 mm. For plate
thicknesses of less than 15 mm, the transducer size may be reduced to 8 mm and
frequencies increased to 5 MHz. Compression probes shall have a dominant frequency in
the range 4 MHz to 5 MHz, and an essentially square or circular transducer in the size range
10 mm to 20 mm.
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4.3.6.2 Evaluation
For welds on material with a thickness not greater than 50 mm, evaluation shall be carried
out at Level 2, in accordance with AS 2207. For welds on material with thickness greater
than 50 mm, evaluation shall be carried out at Level 3. Planar imperfections should be
evaluated at an incident angle of less than 10°. Where this is not possible, additional gain
shall be added in accordance with Table 4.3.6.2. For the purposes of Table 4.3.6.2, planar
imperfections shall be considered to lie along the welding preparation faces. The probe
angle shall be the actual measured angle, not the nominal angle.
TABLE 4.3.6.2
ADDITIONAL GAIN FOR EVALUATION
OF PLANAR IMPERFECTIONS
Angle of incidence, degrees
Additional gain, dB
≤10
0
>10
≤15
6
>15
≤20
12
>20
Not permitted
4.3.6.3 Acceptance limits
The maximum permissible levels of imperfections shall be as given in Table 4.3.5.3.
4.4 RE-TESTS
If any test fails to comply with the requirements of this Standard, the welder shall be given
the opportunity to repeat the qualification test.
If it is established that failure is due to metallurgical or other extraneous causes that cannot
be directly attributed to the welder’s lack of skill, an additional test is required in order to
assess the quality and integrity of the new test material and/or new test conditions.
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SECT ION 5
VA L I DAT I ON
C E RT I F I C A T I O N
AS/NZS 2980:2007
AND
5.1 PERIOD OF VALIDITY
5.1.1 Initial qualification
The validity of the welder’s qualification begins from the date of welding of the test
piece(s), provided the required testing has been carried out and the test results obtained
were acceptable.
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Welders, qualified to previous editions of this Standard, or to other qualification Standards
(e.g., AS/NZS 3992), may be issued with a qualification test certificate without further
testing provided the requirements of Clause 5.1.3 can be satisfied.
5.1.2 Confirmation of the validity
The welder’s qualification test certificate issued is valid for two years, provided the
welding supervisor or the responsible personnel of the employer can confirm that the
welder has been working within the range of qualification and has been producing welds of
an acceptable quality. This shall be confirmed and recorded on the certificate every six
months.
5.1.3 Prolongation of qualification
An examiner/examining body shall, upon request, prolong the validity of the approval on
the certificate for a further period of two years, within the range of original approval,
provided each of the following conditions are fulfilled:
(a)
All records and evidence used to support prolongation are traceable to the welder and
identify the qualified WPS(s) that have been used in production.
(b)
Evidence used to support prolongation is of a volumetric nature (radiographic testing
or ultrasonic testing) or for destructive testing (fracture or bends) made on two welds
during the previous six months. Evidence relating to prolongation is retained for a
minimum of two years.
(c)
The welds satisfy the acceptance levels for imperfections as specified in Clause 4.2.
(d)
A welder who has changed employer but has not been provided with the
documentation required to satisfy the condition in Item (a) may have his qualification
prolonged by a volumetric examination using a qualified WPS of his new employer,
provided—
(i)
supervision meets the requirements of Clause 3.1;
(ii)
the test piece, plate or pipe, complies with Clause 3.2; and
(iii) the welded test piece meets the requirements of Clause 4.3.1.
NOTES:
1
Welders who have changed employer within the life of certificate, or who are employed by
labour hire companies, or who are self-employed contractors may find it beneficial to have
their certificates prolonged by an independent examiner/examining body.
2
Upon expiry or prior to the expiry of the qualification, the welder may also elect to requalify
by the welding of a test piece in lieu of prolongation.
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5.2 CERTIFICATE
It shall be verified that the welder has successfully passed the qualification test. All
essential variables shall be recorded on the certificate. Whilst not regarded as an essential
variable for the purposes of this Standard, the classification of any shielding gas and/or
backing gas used (see AS 4882) shall be recorded on the certificate. If the test piece(s)
fail(s) any of the required tests, no certificate shall be issued.
The certificate shall be issued to the welder under the sole responsibility of the examiner or
examining body and shall contain at least all information detailed in Appendix C.
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In general, for each test piece, a separate welder’s qualification test certificate shall be
issued. If more than one test piece is welded, a single welder’s qualification test certificate
may be issued, which shall combine the ranges of qualification of the individual test pieces,
provided doing so does not lead to ambiguity.
The practical test and the examination of job knowledge should be designated by
‘Accepted’ or ‘Not tested’.
NOTES:
1
An outline of job knowledge criteria is given in Appendix D.
2
A new certificate may need to be issued to the welder after prolongation if insufficient space
remains on the certificate to record all details relating to the confirmation of the validity of
the qualification by the employer or welding supervisor for the following two years.
3
The procedure to which the welder has qualified and is used to transfer qualification in
accordance with Clause 5.1.1 should be recorded on the certificate.
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AS/NZS 2980:2007
APPENDIX A
LIST OF REFERENCED DOCUMENTS
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(Normative)
AS
1163
Structural steel hollow sections
1450
Steel tubes for mechanical purposes
1548
Steel plates for pressure equipment
1796
Certification of welders and welding supervisors
1858
1858.1
1858.2
Electrodes and fluxes for submerged-arc welding
Part 1: Carbon steels and carbon-manganese steels
Part 2: Low and intermediate alloy steels
2062
Non destructive testing—Penetrant testing of products and components
2177
Non-destructive testing—Radiography of welding butt joints in metal
2205
2205.2.1
2205.3.1
2205.4.1
2205.4.2
2205.5.1
Methods of destructive testing of welds in metal
Method 2.1: Transverse butt tensile tests
Method 3.1: Transverse guided bend test
Method 4.1: Nick-break test
Method 4.2: Fillet break test
Method 5.1: Macro metallographic test for cross-section examination
2207
Non-destructive testing—Ultrasonic testing of fusion welded joints in carbon
and low alloy steel
2812
Welding, brazing and cutting of metals—Glossary of terms
2885
2885.2
Pipelines—Gas and liquid petroleum
Part 2: Welding
3545
Welding positions
3597
Structural and pressure vessel steel—Quenched and tempered plate
3978
Non-destructive testing—Visual inspection of metal products and components
4037
Pressure equipment—Examination and testing
4882
Shielding gases for welding
AS/NZS
1167
1167.2
Welding and brazing—Filler metals
Part 2: Filler metal for welding
1554
1554.1
1554.2
1554.3
1554.4
1554.5
1554.6
Structural steel welding
Part 1: Welding of steel structures
Part 2: Stud welding (steel studs to steel)
Part 3: Welding of reinforcing steel
Part 4: Welding of high strength quenched and tempered steels
Part 5: Welding of steel structures subject to high levels of fatigue loading
Part 6: Welding stainless steels for structural purposes
1594
Hot-rolled steel flat products
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AS/NZS
2717
2717.1
Welding—Electrodes—Gas metal arc
Part 1: Ferritic steel electrodes
3678
Structural Steel—Hot-rolled plates, floorplates and slabs
3679
3679.1
3679.2
Structural steel
Part 1: Hot-rolled bars and sections
Part 2: Welded I sections
3992
Pressure equipment—Welding and brazing qualification
3998
Non-destructive testing—Qualification and certification of personnel
4671
Steel reinforcing materials
4854
Welding consumables—Covered electrodes for manual metal arc welding of
stainless and heat-resisting 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
AS/NZS ISO
14343
Welding consumables—Wire electrodes, wires and rods for arc welding of
stainless and heat-resisting steels—Classification
17632
Welding consumables—Tubular cored electrodes for gas shielded and non-gas
shielded metal arc welding of non-alloy and fine grain steels—Classification
(ISO 17632:2004, MOD)
17633
Welding consumables—Tubular cored electrodes and rods for gas shielded
and non-gas shielded metal arc welding of stainless and heat-resisting steels—
Classification (ISO 17633:2004, MOD)
17634
Welding consumables—Tubular cored electrodes for gas shielded metal arc
welding of creep-resisting steels—Classification (ISO 17634:2004, MOD)
18276
Welding consumables—Tubular cored electrodes for gas shielded and non-gas
shielded metal arc welding of high-strength steels—Classification
(ISO 18276:2005, MOD)
ISO
857
857-1
Welding and allied processes—Vocabulary
Part 1: Metal welding processes
4063
Welding and allied processes—Nomenclature of processes and reference
numbers
5817
Welding—Fusion-welded joints in steel, nickel, titanium and their alloys
(beam welding excluded)—Quality levels of imperfections
6947
Welds—Working positions—Definitions of angles of slope and rotation
9017
Destructive tests on welds in metallic materials—Fracture test
9606
9606-1
Approval testing of welders—Fusion welding
Part 1: Steels
9712
Non-destructive testing—Qualification and certification of personnel
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ISO
14341
Welding consumables—Wire electrodes and deposits for gas shielded metal
arc welding of non alloy and fine grain steels—Classification
16834
Welding consumables—Wire electrodes, wires, rods and deposits for gasshielded arc welding of high strength steels—Classification
NZS
4703
Welder qualification tests for stainless steel tubes for the dairy industry
TR 15608
Welding—Guidelines for a metallic material grouping system
AWS
D1.1
Structural welding code—Steel
D18.2
Guide to weld discoloration levels on inside of austenitic stainless steel tube
API
Spec 5L
Specification for line pipe
ASTM
A517
Standard specification for pressure vessel plates, alloy steel, high strength,
quenched and tempered
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APPENDIX B
MATERIAL GROUPS
(Normative)
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This Appendix tabulates material groups used in this Standard. They are based on those
found in ISO/TR 15608 and are summarized in Table B1. Only those elements that are
specified in material Standards or specifications shall be considered. The figures given in
groups 1 and 11 are referring to the ladle analysis of the materials. The figures given in
groups 4 to 10 are based on the element content used in the designation of the alloys.
The groupings of common steel types used in Australia are shown in Table B2. For
information purposes, the alphanumeric equivalents of the material groups utilized in
AS/NZS 3992 are also shown in Table B3.
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TABLE B1
GROUPING SYSTEM FOR STEELS (see Notes)
Group
Subgroup
Type of steel
Steels with a specified minimum yield strength (ReH) ≤460 N/mm 2 (see Note 1) and
with analysis in %:
1
C ≤25
Si ≤0.60
Mn ≤1.70
Mo ≤0.70 (see Note 2)
S ≤0.045
P ≤0.045
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Cu ≤0.40 (see Note 2)
Ni ≤0.5 (see Note 2)
Cr ≤0.3 (0.4 for castings) (see Note 2)
Nb ≤0.05
V ≤0.12 (see Note 2)
Ti ≤0.05
2
Thermomechanically treated fine grain steels and cast steels with a specified
minimum yield strength (R eH ) >360 MPa
3
Quenched and tempered steels and precipitation hardened steels except stainless steels
with a specified minimum yield strength (R eH ) >360 MPa
4
Low vanadium alloyed Cr-Mo-(Ni) steels with Mo ≤0.7% and V ≤0.1%
5
Cr-Mo steels free of vanadium with C ≤0.35% (see Note 3)
6
High vanadium alloyed Cr-Mo-(Ni) steels
7
Ferritic, martensitic or precipitation hardened stainless steels with C ≤0.35% and
10.5% ≤Cr ≤30%
8
Austenitic stainless steels
9
Nickel alloy steels with Ni ≤10.0%
9.1
Nickel alloy steels with Ni ≤3.0%
9.2
Nickel alloy steels with 3.0% < Ni ≤8.0%
9.3
Nickel alloy steels with 8.0% < Ni ≤10.0%
10
Austenitic ferritic stainless steels (duplex)
11
Steels covered by group 1 (see Note 4) except 0.25% < C ≤0.5%
NOTES:
1
In accordance with the specification of the steel product standards, ReH may be replaced by Rp0.2 or Rt0.5.
2
A higher value is accepted provided Cr + Mo + Ni + Cu + V ≤0.75%.
3
‘Free of vanadium’ means not deliberately added to the material.
4
A higher value is accepted provided Cr + Mo + Ni + Cu + V ≤1%.
5
Alphanumeric codes in Column 2 are nearest equivalents from AS/NZS 3992.
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TABLE B2
TYPICAL MATERIAL GROUPS FOR COMMON STEELS
(see notes)
Material group
Typical grade or specification
API Spec 5L
1
X52
2
X60, X65, X70, X80
AS 1163
1
C250, C350
2
C450
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AS 1450
1
C200, H200, C250, H250, C350, H350
2
C450
AS 1548
1
7-430, 7-460, 5-490, 7-490
AS/NZS 1594


1 


HW350
2
HA400, XF400, XF500
HA3, HA4N, HA200, HA250, HU250, HA250/1
HA300, HU300, HA300/1, XF300, HU300/1,HA350,
AS 3597
3
500, 600, 700, 700PV
AS/NZS 3678 and AS/NZS 3679.2
1
200, 250, 300, 350, WR350
2
400, 450
AS/NZS 3679.1
1
250, 300, 350
2
400
AS/NZS 4671
1
250N, 300E
2
500N, 500E
3
500N
NOTES:
1
Impact tested variants of the above grades are not shown for clarity.
2
AS/NZS 4671 grade 500N is manufactured by both microalloying and quench and
self-tempering (QST) processes.
3
The material groups in Table B2 above are those of ISO/TR 15608 and, therefore,
have no relation to the material groupings contained in AS/NZS 1554.1.
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TABLE B3
AS/NZS 3992 MATERIAL GROUPS
Material
group
A1
Typical nominal conditions
or specification
Type
ANSI/ASME BPV-IX
P
number
Group
number
Carbon and carbon-manganese
steel (low strength)
AS 1548: 7-430, 7-460
1
1
A2
Carbon and carbon-manganese
steel (medium strength)
AS 1548: 5-490, 7-490
1
1
A3
High-yield strength micro
alloyed, C, C-Mn steels
API Spec 5L: X52, X60, X65
and X70 AS/NZS 1594: XF400
and XF500
—
—
B
Alloy steel (alloy >¾)
C-½Mo; ½Cr-½Mo; Mn-2Mo
3
1, 2, 3
C
Alloy steel (¾ ≤ total alloy < 3)
1 Cr-½Mo; 1¼Cr-Mo;
¾Ni-Cu-A1
4
1, 2
D1
Alloy steel (vanadium type)
½Cr-½Mo-¼V; Mn-Cr-Mo-V
—
—
D2
Alloy steel (3 ≤ total alloy < 10)
2¼Cr-1Mo; 5%Cr-½Mo;
7Cr-2Mo; 9Cr-1Mo
5A
5B
1
1
E
3½ nickel steel
3½ Ni
9B
1
F
9 nickel steel
9 Ni
11A
1
G
Quenched and tempered low
alloy steel
ASTM A 517
AS 3597:700PV
11B
1 to 8
Martensitic chromium steel
13Cr (Type 410)
15Cr (Type 429)
12Cr-1 Mo-V(W)
6
—
1, 2
3, 4
—
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Carbon steel
Low-alloy
High-alloy
H
J
Ferritic high chromium steel
(11–13 Cr)
12Cr-AI (Type 405)
13Cr-Low C (Type 410S)
7
1
K
Austenitic chromium-nickel steel
18Cr-8 Ni (Type 304)
18Cr-12 Ni-2.5Mo (Type 316)
18Cr-10 Ni-Ti (Type 321)
8
1
L
High chromium steel (>25 Cr)
27Cr-1Mo (S44627)
101
1
M
Ferritic austenitic chromiumnickel steel
22Cr-5 Ni-3Mo-N (S31803)
10H
1
NOTE: For further information see AS/NZS 3992.
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APPENDIX C
INFORMATION TO BE INLCUDED IN WELDER’S QUALIFICATION TEST
CERTIFICATE
(Normative)
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WPS—Reference:
Examiner or examining body – Reference No.:
Welder’s Name:
Method of identification:
Date and place of birth:
Employer code:
Testing Standard
Job knowledge: Acceptable/ Not tested (Delete as necessary)
Test piece
Photograph
(if required)
Range of qualification
Welding process(es):
Product type (plate or pipe)
Type of weld:
Material group(s):
Welding consumable
Designation):
Shielding gas:
Auxiliaries (e.g., backing gas):
Material thickness (mm):
Outside pipe diameter (mm):
Welding position:
Weld details:
Type of tests
Performed and accepted Not tested
Name of examiner or
examining body:
Place, date and signature
of examiner or examining
body:
Visual testing:
Radiographic testing:
Fracture test:
Bend test:
Date of welding:
Notch tensile test:
Macroscopic examination:
Qualification valid until:
Confirmation of the validity by employer/welding supervisor for the following 6 months (see
Clause 5.1.2)
Date
Signature
Position or title
Prolongation for qualification by examiner or examining body for the following 2 years (see
Clause 5.1.3)
Date
Signature
Position of title
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APPENDIX D
JOB KNOWLEDGE
(Informative)
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The test of job knowledge is recommended, but it is not mandatory. When the job
knowledge test is carried out, it should be recorded on the welder’s qualification test
certificate.
This Appendix outlines the job knowledge that a welder should have to ensure that welding
and other procedures are followed and common practices are complied with. The job
knowledge indicated in this Appendix is set at a basic level and exceeds the requirements of
ISO 9606-1. The actual questions used in the job knowledge test are not specified, but
should include questions on areas relevant to the qualification test of the welder with
outcomes showing that the welder is able to follow welding and other procedures, and is
aware of the range of qualification applicable.
The actual tests of a welder’s job knowledge may be given by any of the following methods
or combinations of these methods:
(a)
Written objective tests (multiple choice).
(b)
Oral questioning following a set of written questions.
(c)
Computer testing.
(d)
Demonstration/observation testing following a written set of criteria.
Welders who have successfully passed the AS 1796 welder theory examination covering
syllabus topics 1 to 18 inclusive (or an equivalent acceptable to the examining body) are
deemed to comply with the recommendation of this Appendix.
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APPENDIX E
COMPARISON WITH ISO 9606-1
(Informative)
E1 GENERAL
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ISO 9606-1, upon which much of this Standard is based, has its origins in European
welding practices, some of which vary considerably from that used throughout Australia
and New Zealand, and similarly the USA and many Pacific Rim countries who base their
welding practices on North American Standards and practices. This Appendix is designed to
assist the user to identify where the key differences lay, especially for those who may be
required to work with either ISO 9606-1 in its original form or its European equivalent.
E2 VARIANCES
E2.1 Welding consumables
ISO 9606-1 does not incorporate allowance for the use of welding consumables whose
properties are based on tensile strength, this being the system of classification in use in
Australia and New Zealand and many other Pacific Rim countries. This variance has been
addressed through the addition of Table 2.6(B).
The hierarchy of qualification is somewhat similar to that used in Australia and New
Zealand with the exception that users of cellulose consumables are required to qualify
specifically with those consumable types. The reason for the variance has more to do with
welder technique than other technical issues. Cellulose consumables find primary use in
pipeline welding principally in the vertical down, welding position, a position that requires
specific qualification in any event.
E2.2 Product type
Weld joints within ISO 9606-1 largely follow similar requirements to the previous edition
of AS 2980 and AWS D1.1, although special allowance is not necessarily required for the
complex K, Y and T pipe connections. Requirements for the qualification of welders for
plug welds has been retained, this joint type not being considered in the ISO document.
E2.3 Welding processes
ISO 9606-1 was written to provide for the qualification of welders using hand-held welding
equipment and does not addresses the additional needs of welders using mechanized or
automatic welding processes, for which no equivalent ISO requirements currently exist.
Requirements for such processes were included in the 1987 edition of AS 2980 and
similarly AWS D1.1 on which it was based, and these requirements have been transposed
into this edition of the Standard. Conversely, whereas the previous edition of AS 2980 did
not cater for the gas welding process, this edition has adopted the requirements for the oxyacetylene gas welding process recognized in ISO 9606-1.
Requirements to requalify welders who change the arc or metal transfer characteristics of
the welding process in use have been retained from the previous editions of AS 2980, thus
retaining consistency with most major welding Standards in use in Australia and New
Zealand, but surprisingly absent in ISO 9606-1.
E2.4 Material groups
ISO 9606-1 utilizes a material grouping system somewhat similar to that used in the
previous edition of AS 2980 and AS/NZS 3992. Details and differences are shown in
Appendix B of this Standard.
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E2.5 Dimensions and positional
The 1987 edition of AS 2980 had limitations in its extension of qualification, especially for
plate thicknesses below 10 mm. This problem has been addressed using the similar
requirements to those of ISO 9606-1.
E2.6 Welding positions
Extension of welder qualification based on the original position qualified has been extended
to incorporate the ISO 9606-1 requirements. These requirements have also been adopted in
the AS/NZS 1554 series of Standards.
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E2.7 Weld details
Requirements for the qualification of welders required to weld single-sided butt welds with
and without backing materials have been carried over from ISO 9606-1. They are similar to
that previously published in AS 2980. Requirements have been included for the use of
consumable inserts, a feature missing in both the previous edition of AS 2980 and
ISO 9606-1.
Requirements for welders who qualify specifically on fillet welds have been adopted from
the latest draft of ISO 9606-1 where restrictions are placed depending on whether the
welder is required to produce single run or multi-run fillet welds. This is similar to the
requirements of the various parts of AS/NZS 1554.
E2.8 Examination and testing
Reference is made throughout this Standard to the Australian AS 2205 weld testing
Standards series. Test methods and requirements are similar to those of the ISO references
in ISO 9606-1. Where equivalents do not exist, reference is retained to the original ISO test.
E2.9 Criteria of acceptance
The criteria of acceptance remains largely consistent with AWS D1.1 and current Australian
and New Zealand Standards, and is consistent to a limited degree with the requirements of
ISO 9606-1. Criteria of acceptance used in ISO 9606-1 mainly calls up category B levels of
imperfections from ISO 5817, which is closer in requirements to that used in
AS/NZS 1554.5 and some critical joints in pressure applications. General imperfection
acceptance levels within AS/NZS 3992 (through AS 4037) and those within AS/NZS 1554.1
category SP are similar to but not identical to category C levels within ISO 5817.
E2.10 Validation and certification
Requirements for welders to demonstrate maintenance of their qualifications (conformation)
have now been included and are consistent with the requirements of the major application
Standards used in Australia and New Zealand. The system utilized is not as extensive as
that of ISO 9606-1 where more extensive validation requirements exist. The system, as
adopted, allows welders to demonstrate a higher level of ongoing conformation and
capability than that previously available.
E2.11 Designation
ISO 9606-1 incorporates an extensive designation system based on the notations given in
Clause 1.5 of this document. It is designed for use in computerized welder qualification
management systems and such designations are, therefore, required to be incorporated into
the welder’s certificate. As such systems are rarely used in Australia and New Zealand,
designations have not been incorporated into this edition of the Standard. For the
information of the user, the designations used in ISO 9606-1 comprise the following items
in the order given;
(a)
The number of the Standard.
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(b)
52
The essential variables:
(i)
welding processes (see Clause 2.2);
(ii)
product type: plate (P), pipe (T) (see Clause 2.3);
(iii) type of weld: butt weld (BW), fillet weld (FW), plug weld (PW) (see
Clause 2.4);
(iv)
material group (see Clause 2.5);
(v)
welding consumables (see Clause 2.6);
(vi)
arc and metal transfer characteristics (see Clause 2.4);
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(vii) dimensions of test piece; material thickness t and outside pipe diameter D (see
Clause 2.7);
(viii) welding positions (see Clause 2.8 and AS 3545); and
(ix)
weld details (see Clause 2.9).
The type of shielding and backing gas is not incorporated in the designation but is included
in the welder’s qualification test certificate.
E2.12 Job knowledge
The 1987 edition of AS 2980 did not incorporate any technical knowledge requirements.
This edition has carried over the optional requirements of ISO 9606-1. The technical
knowledge attained by welders who have completed the AS 1796 welder knowledge
requirements have been recognized, these being more specific and extensive than that
specified in ISO 9606-1. Compatibility with the existing welder training systems is
therefore assured.
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APPENDIX F
WELDER QUALIFICATION TEST FOR STAINLESS STEEL TUBE FOR THE
NEW ZEALAND DAIRY INDUSTRY
(Normative)
F1 GENERAL
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This Appendix provides a specific welder qualification for the welding of stainless steel
tube for applications such as plant and equipment for the food and dairy industries. It
replaces NZS 4703.
The Welders Qualification Test Certificate shall record the Testing Standard as
AS/NZS 2980, Appendix F, New Zealand Welder Qualification Test for Stainless Steel
Tube for the Dairy Industry.
F2 TEST METHOD
Qualification shall be in accordance with this Standard and the following:
(a)
Test pieces shall be stainless steel tube of 1.5 mm nominal wall thickness.
(b)
Test pieces welded from one side (single sided) shall be welded with backing gas.
(c)
Test methods shall be visual examination, bend test and macro examination to
Table 3.4 and penetrate testing to AS 2062.
(d)
Test pieces shall be evaluated with the external weld (outside of the tube) cleaned
with a stainless steel wire brush for welder qualification testing unless otherwise
specified on the WPS. The internal weld (inside of the tube) shall be as welded.
(e)
For welds made using Ferritic stainless steel the heat affected zone grain size in the
macro section shall not exceed 0.5 mm, for any individual grain.
F3 MINIMUM ACCEPTANCE REQUIREMENTS
In lieu of the acceptance criteria specified in Section 4 of this Standard, the minimum
acceptance requirements shall comply with Table F3.
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TABLE F3
PERMISSIBLE LEVELS OF IMPERFECTIONS IN TEST WELDS
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Imperfection
Maximum allowable dimension or number of imperfections
Cracks
Nil
Reinforcement (height)
1.5 mm max.
Excess penetration
1 mm max.
Overlap
Nil
Lack of fusion
Nil
Undercut
0.5 mm max. 25 mm total length per joint
Surface porosity
Nil
Shrinkage groove
Nil
Root concavity
0.5 mm max. provided—
(a)
thickness of the weld is not less than the wall thickness,
and
(b)
the root concavity merges smoothly with the adjacent
surfaces
Linear misalignment
0.5 mm across any diameter
Crater, solid inclusion, poor restart,
spatter, torn surface, grinding mark,
chipping mark
Nil
Heat tint (oxidation)—Internal weld
(inside of tube)
The maximum permitted heat tint shall be a straw or light blue
colour (see Note)
NOTE: As a guide, the American Welding Society publishes AWS D18.2. This is a colour chart used to
identify the degree of heat tint oxide by a Number. A Number 4 on this chart is the maximum heat tint
permitted.
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NOTES
AS/NZS 2980:2007
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AS/NZS 2980:2007
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NOTES
Standards Australia
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Standards Australia is an independent company, limited by guarantee, which prepares and publishes
most of the voluntary technical and commercial standards used in Australia. These standards are
developed through an open process of consultation and consensus, in which all interested parties are
invited to participate. Through a Memorandum of Understanding with the Commonwealth
government, Standards Australia is recognized as Australia’s peak national standards body.
Standards New Zealand
The first national Standards organization was created in New Zealand in 1932. The Standards
Council of New Zealand is the national authority responsible for the production of Standards.
Standards New Zealand is the trading arm of the Standards Council established under the Standards
Act 1988.
Australian/New Zealand Standards
Under a Memorandum of Understanding between Standards Australia and Standards New Zealand,
Australian/New Zealand Standards are prepared by committees of experts from industry,
governments, consumers and other sectors. The requirements or recommendations contained
in published Standards are a consensus of the views of representative interests and also take
account of comments received from other sources. They reflect the latest scientific and industry
experience. Australian/New Zealand Standards are kept under continuous review after publication
and are updated regularly to take account of changing technology.
International Involvement
Standards Australia and Standards New Zealand are responsible for ensuring that the Australian
and New Zealand viewpoints are considered in the formulation of international Standards and that
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