D10 COMMITTEE ON PIPE AND TUBE
WELDING
INFORMATION ON-HAND, PROBLEMS
SOLVED, QUESTIONS ANSWERED
KNOWLEDGE IS POWER
NO MATTER WHAT LEVEL OF THE
INDUSTRY YOU WORK …
THE D10 DOCUMENT COLLECTION HAS
THE INFORMATION YOU SHOULD HAVE
AT YOUR FINGERTIPS
MATERIALS & METHODS
COVERED
•AUSTENITIC STAINLESS STEEL
•TITANIUM
•ALUMINUM
•CHROME-MOLY
•LOCAL HEAT TREATING
•ROOT PASS WELDING
•MILD STEEL
•COPPER TUBE
WELDING PROCESS
•GTAW
•SMAW
•FCAW
•GMAW
•BRAZING
William F. Newell, Jr.
PE, IWE, Chair D10C
D10.4
RECOMMENDED PRACTICES
FOR WELDING AUSTENITIC
CHROMIUM-NICKEL
STAINLESS STEEL PIPE AND
TUBING
AWS D10.4
• “…to provide information which may
be used to avoid, or at least minimize,
difficulties in welding austenitic
stainless steel piping and tubing. …”
AWS D10.4 - Uses
• Often overlooked……
• Excellent resource for:
– Developing Corporate Procedures &
Specifications
– Training Engineers, Supervision and Welders
– General Reference Guide
AWS D10.4 - History
• First published in August 1955 under
the title, The Welding of Austenitic
Chromium-Nickel Steel Piping and
Tubing. A Committee Report and
published as AWS D10.4-55T
• AWS D10.4-55T was revised in 1966
AWS D10.4 - History
• In 1979, a major updating of the
document was completed and published
as AWS D10.4-79, Recommended
Practices for Welding Austenitic
Chromium-Nickel Stainless Steel Piping
and Tubing. This version presented a
detailed discussion of the role of delta
ferrite in austenitic chromium-nickel
steel welds.
AWS D10.4 - History
• In 1986, the document was expanded
and given an Annex which gives
recommendations for welding highcarbon stainless steel castings.
• In 1992 and 1999, the document was
reaffirmed.
AWS D10.4 - History
• The current document, ANSI/AWS D10.4M/D10.4:199X,
Guide for Welding Austenitic Chromium-Nickel Stainless
Steel Piping and Tubing has extended safety and health
information and provides information on super
austenitic stainless steels and flux cored arc welding.
• Tables listing specific chemical composition ranges for
base metal and weld metal that fall under the jurisdiction
of other codes or documents have been omitted from this
revision. Where helpful, however, comparison data is
presented.
AWS D10.4 - Content
• Base Metals & Weld Filler Metals
• Ferrite
• Welding Processes, Technique &
Problems
• Dissimilar Joining
• Inspection
• Safety
AWS D10.4 – Base Metals
• Austenitic
– 300-series
• Super Austenitic
– 4% & 6% Mo
• High Carbon
– “HX” Grades
Coming !
• D10.18 (DRAFT)
• “Guide for Welding
Ferritic/Austenitic Duplex Stainless
Steel Piping and Tubing”
Don Connell
Welding Engineer
Detroit Edison Company
D10.6
RECOMMENDED PRACTICES
FOR GAS TUNGSTEN ARC
WELDING OF TITANIUM PIPING
AND TUBING
Applications for Ti Pipe & Tube
Where Ti is selected for its corrosion
resistance rather than its high strength to
weight ratio
• Chemical processing
• Petrochemical
• Desalination
• Power generation plants
• Navy to replace Cu-Ni in seawater piping
Process-GTAW
• Other processes may be used to weld Ti but
are not covered in this recommended
practice
Base Metals
• 6 grades commonly used for piping, all
single phase alpha
• Ref: ASTM B337 (seamless & welded pipe)
& B338 (seamless & welded tubing)
• Replaced by ASTM B861 and B862
Critical Factors in Welding
• Cleanliness-proper means of mechanical
and chemical cleaning using acids and
solvents
• Protection from contaminants at elevated
temperatures
– Trailing shields
– Root shielding
– Chamber welding
Quality Control
• Simple tests to check the process before
welding & the finished weldment
• Describes how weld color is an indication
of weld quality
Other References
• AWS G2.4 to be published this year
• Addresses CP and Ti alloys, such as
Ti-6Al-4V
• Helpful guide in base metal selection
• Other welding processes included
• Tables of reference documents
Tony Anderson
ESAB Welding & Cutting
D10.7
RECOMMENDED PRACTICES
FOR GAS SHIELDED ARC
WELDING OF ALUMINUN AND
ALUMINUM ALLOY PIPE
© Copyright 2005 ESAB Welding & Cutting
Presented By: Tony Anderson, ESAB North America
The Number One Issue
Filler Alloy Selection
For Aluminum Welding
A Need To Up Date
This Information
<
>
Many Base Alloys And Base Alloy
Combinations Can Be Joined Using Several
Different Filler Alloys
Only one filler alloy may be optimum for a
specific application
When Choosing The Optimum Filler Alloy, the
End Use Of The Weldment And Its Desired
Performance Must Be The Prime Consideration.
<
>
*
Filler Alloy Selection Primary Characteristics
W
Weldability Or Freedom From Cracking
S
Strength Of Weld - Tensile Or Shear
D
Ductility Of Weld
C
Corrosion Resistance
T
Temperature Service
M
Match in color after anodizing
*
Post Weld Heat Treatment
<
>
Hot Weld Cracking
Hot Cracking On 2014 Base Alloy Plate
Adjacent To A Gas Tungsten Arc (GTA)
Welded 4043 Alloy Fillet
<
>
Weld Cracking - HOT
Choice Of Filler Metal
Lower Melting & Solidification Point - Molten
During Maximum Contraction Stresses
Smaller Freezing Zone
Avoid Critical Chemistry Ranges
Si 0.5% To 2.0%
Example: 4043 20% ( Electrode )
1100
80% ( Base )
Avoid Welding 5xxx Esp.. ( 5086, 5083, 5456 )
With 4043 Or 4xxx. Mgsi Eutectic Problems
Avoid Mg Range Up To 3.0% In Weld
<
>
Alloy Content vs. Crack Sensitivity
RELATIVE CRACK SENSITIVITY
0
Al - Cu
0
Al - Mg
0
Al - Mg2 Si
0
1
2
3
4
5
6
7
COMPOSITION OF WELD - PERCENT ALLOYING ELEMENT
<
>
Dilution Effect On Weld Composition
Base Plate 6061
Filler Metal 5356
20% Filler Metal
1.7% Mg
80% Base Metal
60% Filler Metal
3.2% Mg
40% Base Metal
<
>
Weld Strength - Groove Welds
The Heat Of Welding Softens the
Aluminum Base Alloy Adjacent To The Weld
In Most Groove Welds
the H.A.Z. of the Base Alloy Will Control
the As-welded Tensile Strength of the Joint
<
>
Heat Affected Zone
A
Non Heat Treatable
A - Weld Metal
As Cast Structure Of Base &
Filler Metal
B - Fusion Zone
Where Partial Melting
Of Base Metal Occurs
C - Anneal Zone
Where Base Metal Is Fully
Recrystallized - Full Soft
D - Partial Anneal Zone
Where Base Alloy Is
Recovered And Partially
Softened
B
A- 1200
11 0 0
B- 1000
900
800
C700
600
500
D- 400
300
E200
100
RT
E - Unaffected
<
>
-A
C
D
E
Heat Treatable
A - Weld Zone
-B
B - Fusion Zone
-C
C - Solid Solution Zone
Where Alloy Elements
Are Solutioned & Cooled
To Retain Solid Solution
-D
-E
D - Partially Annealed
Overaged Zone
Where Heat Has Caused
Precipitation And/or
Coalescence Of Particles
Of Soluable Constituents
E - Unaffected
Hardness Profiles of 6061-T6
Made At Three Heat Inputs
100
Hardness RE
90
580 J /cm
756 J/cm
80
70
1128 J/cm
60
AWS D1.2 MIN TENSILE
-O TEMPER
50
40
Distance From Weld Interface
<
>
Weld Strength - Fillet Welds
The Shear Strength Of Fillet
Welds Is The Significant Factor And
Is Controlled By The Shear Strength
Through The Weld Metal
5356 Produces Greater Fillet
Weld Strength In The As Welded
Condition Compared To 4043
<
>
Shear Strength
25000
5556
LBS. Per Linear Inch
Shear Strength
20000
5356
4643
5554
5654
15000
4043
10000
1100
5000
0
0
1/8
1/4
3/8
1/2
TRANSVERSE Fillet Size (Inch)
<
>
5/8
3/4
Shear Strength
Typical Shear Strengths Of Fillet Welds
Filler
Alloy
Longitudinal
Shear
Strength
( Ksi )
Transverse
Shear
Strength
( Ksi )
1100
7.5
7.5
2319
16.0
16.0
4043
11.5
15.0
4643
13.5
20.0
5183
18.5
28.0
5356
17.0
26.0
5554
15.0
23.0
5556
20.0
30.0
5654
12.0
18.0
<
>
Fracture Characteristics
Heat - Treatable Alloys
Ratio =
Notch Tensile Strength
Tensile Yield Strength
Tear
Resistance
Unit Propagation
Energy In.-lb. / In3
1.6
1600
1.2
1200
0.8
800
0.4
400
Base Metal
Filler Alloy
2219 2219 6061 6061 6061 7005 7039
2319 2319 4043 4043 5356 5356 5180
Aged
<
>
Ttear Resistance
Ratio
2.0
Corrosion Facts – As Welded
Alloy 7075-T6 Welded With 5356 Filler
-849mv
-876mv
-900mv
-810mv
Post Weld Heat Treated and Aged
-810mv
-810mv
-840mv
-806mv
Note: Fusion Zone Mechanical Properties Not Restored to PreWeld Properties
<
>
M
Color Match After Anodize
Rating Scale: A - B
Ratings Scale Measures Uniformity Of Color
Comparing Base Alloy And Weld Metal
After Anodizing.
Either There Is A Good Or Reasonable Match
Or There Is Not.
A Blank Space Indicates No Reasonable Match.
<
>
Color Match After Clear Anodize
Base Metal: 6061
6061
6061
6061
6061
WELDED WITH 5356
<
WELDED WITH 4043
>
Post Weld Heat Treatment
Filler Alloys Have Been Developed
Which Will Respond To Postweld
Heat Treatment.
4643 Was Developed For Welding The
6xxx Base Alloys, Has Additions Of
Mg And Is Less Dependant On
Dilution Of The Base Alloy To
Achieve Desired Composition.
Filler Alloys For Welding Castings Have
Been Developed With Chemistries
Which Will Respond To Post Weld
Heat Treatment.
<
>
© Copyright 2005 ESAB Welding & Cutting
Conclusion
Filler Alloy Selection For Aluminum
Can only be made after a full analysis of a
welded components performance
requirements
Should involve the consideration of
metallurgical effects (changes in crack
sensitively) when combining base alloy
chemistry with filler alloy chemistry
Can substantially influence the strength
and performance of a welded component
<
>
William F. Newell, Jr.
PE, IWE, Chair D10I
D10.8
RECOMMENDED PRACTICES
FOR WELDING OF CHROMIUMMOLYBDENUM STEEL PIPING
AND TUBING
AWS D10.8
“… provide recommendations for welding
chromium-molybdenum steel pipe and
tubing to itself and to various other
materials. Subjects covered in detail are
filler metal selection, joint design,
preheating, and postheating. …”
AWS D10.8 - Uses
• Often overlooked……
• Excellent resource for:
– Developing Corporate Procedures & Specifications
– Training Engineers, Supervision and Welders
– General Reference Guide
AWS D10.8 - History
• First presented in 1961 as a Committee Report
by the AWS Committee on Piping and
Tubing.
• Revised in 1978 and became a
“Recommended Practice”
• Subsequent revisions/reaffirmations in 1986
and 1996
AWS D10.8 - Content
•
•
•
•
•
•
Base Metals
Weld Filler Metals
Joint Design & Preparation (purging)
Preheating
Post Weld Heat Treatment
Repair/Maintenance of Service Exposed
Material
• Safety
AWS D10.8 – Base Metals
•
•
•
•
•
•
•
C-Steel
C-Mo
1-1/4Cr-Mo
2-1/4Cr-Mo
5Cr-Mo
7Cr-Mo
9Cr-Mo (Standard Grade Only)
AWS D10.8 – Filler Metal
• Recommendations
– Process
– AWS Classification Options [C, CrMo
& Ni-base]
– Similar v. Dissimilar
AWS D10.8 – Priorities !
• Preaheat
w/recommendations
• Interpass
• Post Weld Heat Treat
w/recommendations
Pending !
• D10.08 (DRAFT)
• Removing information on 9CrMoV
(P91)
• Removing References to Standard
Welding Procedures
Coming !
• D10.21 (DRAFT)
• “Guideline for Welding Advanced
Chromium-Molybdenum Steel
Piping and Tubing”
– P91, P911, P92, P122, T23…
Dan Ciarlariello
Mannings USA
D10.10
RECOMMENDED PRACTICES
FOR LOCAL HEATING OF
WELDS IN PIPING AND TUBING
Definition of Heat Treatment
• Heat Treatment is generally defined as
heating to a suitable temperature then
cooling at a suitable rate of a solid metal
or alloy in a way so as to obtain specific
conditions and/or properties by changing
the physical, chemical and/or
mechanical properties of the steel, metal
or alloy
Methods Of Localized Heat
Treating
• Electrical Resistance
• Induction
• Combustion / Flame
• Quartz Lamps
• Exothermic Kits.
Electrical Resistance
Inductive Heating
Combustion / Flame
Quartz Lamps
Reasons for Localized Heat
Treating
• Bake Out
• Preheating and Inter-pass Temperatures
• Post Heating
• Post-weld Heat Treatment
Comparison of Heating
Processes
•
•
•
•
Induction - Resistance
Attribute
Yes
Yes
Applicability to bake- •
out
Applicability to
•
Yes
Yes
preheat/inter-pass
Applicability to
postheating
•
Yes
Yes
Applicability to
PWHT
•
Yes
Yes
Advantages and disadvantages of
heating processes
Induction Heating
Advantages
 High heating rates
 Ability to heat a narrow band adjacent to a region
which has
temperature restrictions
Disadvantages
 High initial equipment cost.
 Equipment large and less portable.
 Limited ability to create control zones around the
circumference.
Advantages and disadvantages of
heating processes
Electrical Resistance
Advantages
Ability to continuously maintain heat from welding
operation to PWHT
 Good ability to vary heat around the
circumference

Disadvantages
Elements may be damaged during welding
 Quantity of heaters required on thicker
components

High Frequency Induction
heating
• Uniform product quality
• Increased surface wear-proof
characteristics
• Increased material fatigue strength
• Minimum strain due to local surface
hardening
• Very localized heating
Why Preheat?
•
•
•
•
•
•
Reduce the level of thermal stress.
Compensate for high heat losses.
Minimize the rate of weld hardening.
Reduce porosity.
Reduce hydrogen cracking.
Improve the microstructure.
Typical Preheat Set-up
Boiler Tube Welds
Wireless Thermocouple
Transmission
AWS D10.11
Walter J. Sperko, P.E.
Sperko Engineering
Services, Inc.
Guide for
Root Pass Welding
of Pipe Without Backing
AWS D10.11 Keywords
• Root pass welding, pipe, gas
purging, consumable insert, gas
tungsten arc welding, gas metal arc
welding, shielded metal arc welding
AWS D10.11 Introduction
• This publication was intended to be a
“how to” guide in the use of open root
and consumable insert welding
techniques for root pass welding of
groove welds joining metal pipe.
AWS D10.11 Introduction
• Joint designs, fitting techniques, consumable
insert configurations, filler and base metal
combinations, purging, and welding
processes are discussed. This publication
made no provision for joints which include
backing rings
AWS D10.11 Introduction
• This standard is a “best practices” guide to
making high-quality pipe butt welds where
backing cannot be used
• Welders should have excellent reasons for
deviating from what this standard
recommends
AWS D10.11
• What is “Root Pass Welding?”
• Let’s look at some “root passes”. . . .
AWS D10.11
• A single-vee Butt weld between two
pipes
AWS D10.11
• Root pass on a Socket Weld
AWS D10.11
• Root pass on a Double Vee-Groove
Weld
AWS D10.11
• All of these “Root Passes” are on backing
AWS D10.11
• Take away the Backing Strip and you
have a weld without backing. . . .
Welding without Backing
You now have a pool of liquid metal
hanging in space suspended between
the ends of two pipes. . .
Welding without Backing
Torch
Blast the arc force through the root opening and
melt the edges of the metal, then fill the opening
with filler metal
Welding without Backing
Electrode
Blast the arc force through the root opening and
melt the edges of the metal, then fill the opening
with filler metal
Effect of Included Angle
LARGE included angle makes it easy to
get the electrode close to the root and
easy to direct the arc into the root.
Effect of Included Angle
included angle holds the electrode
away from the root and makes it difficult
to direct the arc into the root.
SMALL
Full Root Penetration
Continuous metal surface from
one member across the weld
to the other member
Forces on the weld pool?
Longitudinal Section of a pipe joint
Forces on the weld pool
Gravity
Longitudinal Section of a pipe joint
Forces on the weld pool
Surface Cohesion (wetting) between the
weld pool and the solid metal
Longitudinal Section of a pipe joint
Forces on the weld pool
weld
pool must fill the gap without becoming too large
The arc must melt both edges of the root face and the
Longitudinal Section of a pipe joint
Forces on the weld pool
If the weld pool becomes too large, the surface cohesion
forces are overcome. The result is root concavity or dropthrough.
Longitudinal Section of a pipe joint
Parts of a Groove Weld Joint
Design
Root Face (“Land”)
Parts of a Groove Weld Joint
Design
Root Opening (“Root Gap”)
Root Opening vs. Root Face
Thick Root Face
Thin Root Face
Small Root opening  Incomplete Penetration
Proportional Root opening  Complete Penetration
Excessive Root opening  Root concavity or burn-through
Root opening - Root face thickness relationship
1/8”
Root Face
Thickness
3/32”
1/16”
1/16”
3/32”
Root Opening
1/8”
Cleaning
• Cleanliness is important in all welding,
but it is especially important in root pass
welding.
• Contamination affects wetting which
affects bead shape.
Purging
Purging
• A purge is required for stainless and
nonferrous piping systems (except
aluminum) if a smooth root surface is to
be obtained.
• Standard describes how to set up for
purging
• Purging time
Purging
• The following oxygen limits are
recommended:
•
•
•
•
For carbon and low alloy steels: 2%(20,000 ppm)
For stainless steels: 1/2% (5000 ppm)
For nickel alloys: 1/2% (5000 ppm)
For titanium and zirconium alloys: 1/4% (2500
ppm)
Purging
• Welding technique for Open Root
• Welding Technique for Consumable
Insert
• Maintaining purge during welding
Fitting and tack welding
• Size, spacing, feathering ends
• Root spacing depends on process to be
used.
• Inspection after fit-up. This is the most
important step in pipe welding
GTAW
• Tungsten size, shape of end
• Grinding methods
GTAW Joint design and fit up
GTAW
•
•
•
•
•
Purge containment
Arc initiation
Keyhole technique
Wire feed techniques
Orientation of torch and filler
GTAW
GTAW
GTAW
• Walking the Cup
• Welding with zero root opening
(autogenous welding)
• Welding in different positions
• Using consumable inserts
Consumable Inserts
1/32” maximum mismatch
Class 1 Insert, formerly the EB (Electric Boat) or
“A” type insert.
Consumable Inserts
1/16” maximum mismatch
Class 2 Insert, formerly the “J” type insert.
Consumable Inserts
1/16” maximum mismatch
Class 3 Insert, formerly the “Grinnell” or flat
insert.
Consumable Inserts
SMAW
• Cellulosic Electrodes (EXX10, EXX11)
• Low Hydrogen Electrodes (EXX15,
EXX16, EXX18)
• Rutile electrodes (E6013)
GMAW
• Joint design
• Fit-up
• Welding parameters
Fill Passes
• Use any suitable process
• Don’t melt through the root
Aluminum
•
•
•
•
•
Tungsten type, shape of tip
Shielding gas cups, lenses
Power supplies
Techniques
Recommended joint design
Aluminum
Machine and Automatic
• Not much said
Summary
• AWS D10.11 gives very specific
recommendations about techniques
that have proven successful in making
pipe welds without backing
• Recommendations should be familiar to
welder’s supervision
• Recommendations should not be take
lightly
Alan Beckett
D10.12
RECOMMENDED PRACTICES
FOR WELDING
MILD STEEL PIPE
D10.12
Welding Mild Steel Pipe
This document provides
recommendations for the welding of
mild steel pipe such as A106 type. This
material is found in many scopes of
work, and extensively in commercial
building construction.
A106 material is often used as a starting
point for welder training.
Covered Processes
•
•
•
•
SMAW
GTAW
GMAW
FCAW
D10.12
A Document for All Reasons
As with other D10 documents, you will find
excellent attention to detail presented in a
manner for all to understand.
For these reasons D10.12 is a welcome
addition to your library or a valuable resource
for training.
MICHAEL LANG
AWS/CWI/CWE
United Association
of Plumbers & Pipefitters
D10.13
RECOMMENDED PRACTICES
FOR BRAZING OF COPPER
PIPE AND TUBING FOR
MEDICAL GAS SYSTEMS
What is Medical Gas Piping?
There are many perceptions of Medical
Gas Piping but the facts are:
• Cleanliness is entirely dependant on
installation practices
• Poor installation can produces
conditions that harbor bacteria and
diseases
• These systems are not cleanable
• These are life critical systems
Purpose
The governing document for all Medical
Gas Piping is NPFA Code 99C which
dictates the methods and installation
practices that shall be used in system
construction…
However this document does not cover
actual brazed joint construction or
the tools and practices needed for
system construction
Important Notes
• D10.13 is a Recommended Practice
developed to work with NFPA 99C.
• All recommendations have been used in
actual jobsite conditions with a 100%
success rate
• The use of these practices have
produced consistent profitable results
Needed Equipment
• Use and Care
• Torch Selection
• Tube Cutting
• Purge Monitoring
Consumables
•
•
•
•
•
Pre Braze Joint Cleaning
Pre Braze Chemical Cleaning
Post Braze Cleaning
BCuP Brazing Alloys
Bag Brazing Alloys
Something you will only find in
D10.13
• The only document that provides joint
heating and filler metal application
methods.
• These methods continually produce a
99% acceptance rate in accordance
with ASME Boiler & Pressure Vessel
Code Section XI.
And… Purging Methods
• Purging is possibly the most important
component to internal cleanliness. This
document provides methods and
parameters for the use of oxygen
analyzers.
• We also provide purge timing matrix
charts for estimating purge times for
long runs of piping. These charts should
be used in conjunction with an O2
analyzer.
Proven Success
You Can Trust
D10.13
RECOMMENDED PRACTICES FOR
BRAZING OF COPPER PIPE AND
TUBING FOR MEDICAL GAS
SYSTEMS
BECOME A COMMITTEE MEMBER FOR
DETAILS CONTACT Brian McGrath at
bmcgrath@aws.org
THANK YOU FOR ATTENDING
AND ENJOY THE AWS SHOW