AUSTRALIAN STEEL INSTITUTE TABNVACN (4) 000873 B98 contents, Desig ud . . Welding in structural steel connections Page Pog stot fg v7 weLowe RoceoURES x onah ©2067 by AUSTRALIAN STEEL INSTITUTE storie wT Pitot ot wating rte . pecans 2 oot te maior 412 Pregl wating oceans 32 taut canting aborandedtor 3. ualflestan tent 2 ‘etnonedgoner Si 7. Ruano of wen procosuen x“ Pubes by: AUSTRALIAN STEEL NSTIUTE concerror besionounes...1 » wort, * ‘ght rosored. hi book or any pat thee mst nt be reeds in any frm without Beckum +o BP Eage renmaion rd tho wionpomiovon ot estan Sel sist Assn = [Note to commercial software developers: Copyright of the information contained within this publication is 2 INTRODUCTION, 2 83 Preheat 36 ‘i by Ris iat wt pra mua be cea fom A eos fo 4 Tocwats ” Cee ee eae cop tamcenaty mans sire pasate 3 Tresor WELD 3 ES Deen ndreatalstess 38 FIRST EDITION 2007 (LIMIT STATES) 32 flew 58 Cemnnmansdeing wus 38 nonlin Atl Caloocan wets 9 WELD MPERFECTIONS, “0 Hogan. T J * 34 Edge preparations B 9.1 Weld categories 40 1 ule 2 Woking ice! sel comes 35 Prenatiteptoocerions gS iekamoren, i a 36 Sonia sybou Ho 82 Lavell spacer iB 88 wsanocs e Bayo ‘ uy : ISBN 975 0 909945902 ‘This publication originated as part of WELDABILITY OF STEEL. 7 95 Weld repairs ar Deietseenea nc 1 te Shit Atala Dene 5 WeLo PROCESSES. 1 toweuoivsrecrion “a 3 Sch Suet Speatstn Amt ee Sf inodicton je joweomsrect a 3 Soc Stuca- aan, scneaieal 2 Fuson long process 112 foster e 1 ee fe’ Staetaue 83 Termnolngy 2 — Woe Si rented oe 89 Tera 22103 Magna par oa % 1, Aalan Sttte, rely lied weld {04 Ugopatarnterommaion St ‘ie $32 Pataty mscdacets| —2205 Racbgapic xannaton 32 ‘usion (boundary) fine 2 10.6 Uttrasonic examination 4 [Sa Srvc ste comacion es) $2 Fulon ountan) 2 B35 Multiun welds 20 14 PRACTICAL CONSIDERATIONS. 55 Aten ics 84 Manotel wenidng (ie cles snc se Vane: Sig comin open sions 11 Gerrea or wet 5 Tn Des os se seco - 55 Germetlarweidngand 12 Stewoting 5 owen ing wooo ae scene 13 Eeommicd design and detotog 58 Despre: eblecad ic oman ciwaaegpoomes 24 S2REFERENCES. ro Best age: Age cat cme 87 Wag pone Es BIS a: ee comets appenane 6 VIELOING CONSUMABLES 2X NSStoaign cue 2 81" Monust metal ac welting 38 comneat rm Disclamer Te maton peti by the Alan ie lee me pba Ns bot 82 Gesell wldng B cones tina ny a ora, ot he nts enters Si semescaeg Bert Sewn cay of nen osea mie Sn al easnais owe uen fee re 64 Prowatfedwngcontuablos 29 [Scrawl entation sone te ceston eee stl a bu ooo ies {ar ey et pittcn wih! vetgaon ard votes ot corny, saat me Beale ys compen peso pcs apa ie hunni, as Sencar leer oe cater cl na nos gay eaten Sr mae ay clare Scat be eran ponte the a grad by ew) ‘ea ane oononade nay war an) erence ey ny ear Syloa aos oe pts” han ana wn ten yay poe, eer Tsou ietetncche’ fe pokton oor wast maou aero Sonbe coe Sete end Set eat eigen he unos, ens pers The fomaton tnt pbs sd mtb Yoad pon ab 8 sbeuls raepedet due ents petal tse ata sgh aves ca compu pero boasa orf tose srt Sd wots ce ates, mater wo e pee eee la teen a — a eeFue 1 Figure 2 Figure 3 Pague 5 Faure 6 Fue 7 Figure 8 Figue Figure 10 Fue 11 Figue 13 gure 14 Figure 15 Fiore 16 Figue 17 Table 2 Tables LisT OF FIGURES Met yds 9h en Weld use by joint type “ in steelwork connections. e Fillet weld size and details. 7 “Types of butt welds. s in steshwork connections: ° penetration butt welds | Construction of a welding symbol. 15 Basic welding symbols. 16 Z 2 areweling Page Figure 18 Schematic agar fx coved se wading 2 Figure 19 Welding positon fer pat but ‘wei, 2 Figure 20 Welding positions fo plo itis 25, Figure 21 mpertestons in But weld... 4 Figure 22 imperocions let welds 45 Figure 25 Solaiicaton cracks a Floure 2¢ Schematic clagram of magnetic garele examination 0 Figure 25 Schematic agra fig penetant examination 5 Figure 26 Principles ofradonrephe Figure 27 Examples of perfection detaction ‘sing rome examination «4 Figure 28 Angular hts fr jolt prepara forvarous welding techniques. 55 Figure 29 Clearance on an ange leat welded oa beam web 8s Figure 30 Examples of ba accessibiiy 58 LisT OF TABLES Pose Page Piru se egg mes, TaD Le hnosanue wel examination (NOE 2 hareciersics ot welding Table Types of imperfecton condoned procasees Py imSINZs 15541 43 Proquaiod welding fonsomatee 29 sin ote: wD. PREFACE This new serles of connection publications by the Austialian Insitute of Ste! (AS) covering Capacity table, theory and design of individual simple connections will be Known as the Structural Steel Connections Series, Part: 1" ed. 2007 ("Connection Series, Part) TNS Connecion Serie, Part 1 detals the method of design and provides eapaciy tables and ‘etaling parameters for a range of simple connections commonly Uses fr structural saeiwork InAvsttla Connections havea major engineering and economic mporlanca in ste! srucures Inuencing design, dealing, ftricaton and erection coat. Standarisation of dosign approach Integrated with industry Stating isthe Key fo minimum costs at each stage. Ths Connections Sones, Par in conkneton with the fulure Connection Sores, Part 2 for rigid connections (Collec te Stuctural Steal Connactons Sens or "Connection Sovies") replaces. and femances an ASI fagehip publication fst released in 1978 al which time connection design theories ware daveloped for the purpose of generating and releasing connection capacty lables. The fret thre ediions wore rleaced in permissible avess formal. The fourth oditon DBosign of Structoral Gonnectons (olen fetered to a the Green Book) wae released in 1094 in limit state format but there was no subsequent release of limit state companion document Containing conection design capac tates. Design Guide 2 Welaing in stuctual steel connections has been introduced into the AS! ‘Connections Manual asa complementary document to Dasign Guide 1 Bolling in structural tee! ‘Sonrections. The intention cf Deegn Guide 2 is {0 act as a basie prmer on ell aspects of ‘neldng 2 eppiled fo steelwork connections Extensive reference is made to sources which can Supply more dotaled Information many of these roerancea are more general and apply © fabricating In general using welding, Design Guide 2 addresses the matters covered in Australian Standares wih tho exception of ‘weld design which is deat wih nthe Handbnok 1-The Handbook aiacussos welding pracestes, Consumables and procedures in suffisent deal for the stuctral engiear to understand the basis of what occurs in a fabrcaton shop when connections are being fabricaed. Welling In the fabretion shop and Boing on ste remain the Key to economical seucluralseeivork, Design Guide 2 also discusses the issues of workmanship, imperfections in welds, when Imperfections become defecs, now welds can be inepected an repair of welds ‘An appendix Yo each publication in the series ao contains an ASI commont form. Users of this Connections Series are encourages to photocopy this one page form and forward any Suggested improvements which may be incorporated int ule eations 1 Hosen SA. Maio @ ings 0) Sn, tt eaton wo.ABOUT THE AUTHOR ‘Tim Hogan is Diteclor of SCP Consulting Ply Lid. Hie academic achievements Include & Bachelor af Enginoaing from the University of NSW with 1 Class Honours and the Unwareity Medal. Post graduate qualifications Include a Master of Engingering Seance and a Master of Business Aaminstraton, Tim & a Member ofthe insiition of Enginoere Austaa wilh CPENg fand PIE Aust status, His early experience was on bridge design and construction with the NSW Pubic Works Deparment and subsequently as Development Engineor ane then Engineering Manager with the Australian Ineitte of Steel Construction unt 4980. Consufing experience. with’ SCP Consulting since 1980 has induded design and supervision of large sical framed buldngs, indasial buildings, mil buildings, retail developments, defence Inastucture and composite Sleel-conerete bullngs. His published works. deal primaly with the areas of composite Gonstructon, steel connections, labrieaton and efeeion of steel stuctres and he was @ major ontrbuior and editor of the Commentary fo AS 4100. He ks a member of a nunber of Standards Austria Commies dealing with steel and composite siuctures.and is currently Chairman of Commitos BO-001 Steel Stuctutes and BD-032 Composite Consicton. Ho Fecsived an award rom Standards Australia for Ns conbutine to wing. ot Austin Standards, ABOUT THE CONTRIBUTING AUTHOR AND EDITOR Scott Munter is now the National Structural Decking Manager for BlueScope Lysaght He was formerly the Natonal Manager—Engineering & Construction forthe Austin Steel Instiuto IASI) ané worked in this role om 2000 to 2007. Ths key role involved selling the Lechical leadership of ASI in supper of dosign and constuction to enable the effisont specifeation and tse of sieel In constuction. Rospensmilies Included ASI technical publicatons, advice on Indust best pracice, AS and Cad commitees, presentations and lecturing Scotts Member of the Institution of Enginoers Australia wih CP Eng & NPER (Structural) Status. He folds a Bachelor of Siruciural Engineering from the Universi of Technology, Sydney with 1" Class Honours and the University Medal. He professional career includes 15 years In consuting chil and structural engineering working fr Tim Hogan at SCP Consulting His consulting experience Incl a song steel focus wih majr ifrasvucture, indus and ‘commercial developmenis plus domestic constuction. e en sce test aon ms | ACKNOWLEDGEMENTS: ‘The authors woul ke to extond special thanks io: ‘The ASI Connections steering commitse consisting of Richard Cons (Engineering Systems), ‘Anthony Ng (GneStes Marset Mil) Arun Syam (Smorgon Sloet Tube Mil) fr thei recpoctive Contrbuons with tha development and review of the Technical and edtoral contont of the revised ASI Connection Publication. ‘Signiicant contributions were made by + Welding Technology Insitute of Austraia(WTIA) for tei expert review and comments. ‘+ Standards Austrafia for providing thei technical iypessting exparise + Whizzead Ply Lid with dating and graphics for pushing + ASI Slate Engineering & Construction Special Sub-Committees for progressive ‘ginsering and industry review of manuserits. Topethor with suppor of + All focots of the ASI membership incuding design engineers, stechvork detalers and fabricators i contnbutng ndusty best practi and standards tough ASI surveys and ‘roc conaitaton fo establish the theory and geometry in this new ASL Connection Pubicaton e@ es ie 2 oe1 CONCEPT OFDESIGN GUIDES 1.1. Background ‘The ASI was formed in 2002 through the merger of Australian Insiule of Steel Construction (AISC) and Steet Insitute of Australia (SIA). The former AISC published a design manual ving ‘guidance onthe design of stvctura connections i steolwork (Ret 2), ASI is updating Reference 2 by way of the Connection Series inctuding design guides, dealing with connection pals and individual connection types. The overall ries of ‘connections publications wil be know asthe Connections Series. The former AISC also publishes a manual containing standardised detaiing for simple ‘connections, accompanied by load ables (Re. 3) ‘Wherever possible each design guide for indviual connection ypes contains standardaed ‘etaling and design capaci lables for the connection type covered by that design guide ‘derived using the design model in at design guide. ‘The Connection Series is a speciaks series devoled fo the design of connections in structural stool in accordance with curtent Avsvaian Standard AS 4100 (Ret 1.) reflecting the curont ‘te of knawlodge of connection behaviour ftom lest resule. In some instances, the fost ‘icence i spars and in atherinstancea the evidence fs cntradctny or eouded. Each design ‘guide in the Conracton Saree has been writen by weighing the evidence to provide {ecommendas design procedures based in pal on the design procedures used In equivalent ‘manuals andor pubtshed papers. Each design guide is intended to provide a design model which gives a reasonable astimote of ‘connection design capeciy and efor: has boon expended in osearching and developing Gesign ‘madels which can be justified on the basis of the avallabie research ané current design Drache, It's 1 be emphasised that fer the comestons model presented, the design model fs ‘ot the only possible mada fx therefore not intended to suggest that other models may not result in adequate connection capacity and further reference le made to the Disclaimer on page i of tis publication as tothe required investigation and veriiction bby 8 competent professional person or persons in regards tothe accuracy, sultability and pplicabilty of the materials provided in tis Connections Series. “The connections dealt with are thse present in common use in Australia and reflect he ype ‘of connections covered wihin be eae AISC Standardized Siuctutal Connections (Rel. 3} ‘This design guide doals withthe welding in stoolwork connections and draws on other AISC publications (Refs 5 and 6) e etna scl telco 2. INTRODUCTION Wilds ave widely used for making connections in stuctural steelwork connections, being tecuted predominantly nthe fabrication shop but aeeasonally on site. An understancing of al the aspects of welding that relate (0 stuclral slosivork connections fs vial to desgning, {etoing, fabricating and erecting each type of conechon that involve welding. “This Design Gouide is intend to provide a slato-othe-art summary ofthe felling toms a ‘ney relat fo the use of welds im steel connections + ‘ypes of welds thal ave commonly used in stockwork connections (Section 3) + weldabity of soe (Secon 4 + wolding processes used (Section 5} + woldng consumables (Section 6); + welding procedures (Section 7); + workmanship (Section 8); + wold imperoctione (Section 9) + wols inspection (Secton 10), “+ practical considerations (Section 11) “The scope ofthe publication is ite to: + weld types in commen usein soolwork connections in Australia + wong processes in common use in fabricating steel connections in Australia ‘The decign of welded connections and the design capacities of welds ate discussed in detain Hantook 1 ‘The use of welds and ther design in Indvicuat connections is discussed in ine Design Guide Felovant to each connection e en gute 2 we3 TYPES OF WELD 3A Weld types ‘Six types of welds are mentioned in AS 4100 (Ref. 1) a8 follows: 1. Compete penetration but weld—a weld where fusion exists between weld metal an the paront metal throughout tne entre depth ofthe joint. A Blt weld is one in which the weld Nes substantaly within tho extension of the planes ofthe surfaces ef one oF mote of the pas joined. 2. Incomplete penetration but weld—a but! weld where, by design, fuslon does nol extend ‘thoughout the fll depth of the jin, 3. File! weld—a weld of approximately triangular cross-section which formed in the corner between the surtaces of two components, 4. Plug weld—a weld mace by completly oF partial fing a cular hoe in one campanent wt iter meta, with the filer mata using tothe conuguous component exposed through the hole 5. Sit wold—a wold made by depositing a filet wols around the periphery of an elongated hole in one component so as to jon it the surface ofa contiguous component exposed ‘trough ihe note ©. Compouns weld—a weld comprising a filet weld superimposed on a but weld AS 4100 restricts the use of slug and slot welds to applcaions where these wekis ether Transmit shear in lap joints er where they prevent buckling of lapped pats or where they join Component pars of boikwup members. Such welds are not normaly weed in structural Stoel onnectons and wal not be considered further. Almost al the welds used In structural steel {oanectons re ator but wes o let welds ae shown in Figure ov = (6) Complete perce bat wis (Shortn nf Tontorcomes st (0) Compote poooeatn but wos Patpn ar ama ot CZ} ‘Size: ml vonenewnn Abs. ae — FIGURE + WELD TYPES IN AS 4100, e sin gue 2 oe: \oldingin seat te Sonnets fe etion “The four weld types (1,2, 8 and 6) can be used in fe jlnt typos (but, tee, comer, lap and ‘hagel as shone in Figuie 2, Most stactral seal connactons involve either button welded splices) tap joint (splices using spice plates) joint {many connections) > — (0) Ba pet using et wld (2) Lap let esing le woos (e) Fontan but wot (8 Toit unig tht wide FIGURE 2 WELD USE BY JOINT TYPE tng ru Coots st eton m+3 TYPES OF WELD 32. Filletwolds Features of filet welds ar: + economic ta produce + ease of fabsicaton; + adapabiiy: + ess precision in ting up: + minimum preparation if euting of edges complies with AS 4100 (Ret. 1) “Typical applications in stucural ste! connections ace shown in Figure 3. AASINZS 1554.1 (Ret. 7) contains the following provisions fr filet welds in Cause 3.3. Size + Detned by tg engin (Figure 4) ‘+ Proterodsizas tht are useain structural steel connections are 6,8, 10.and 12 mm, ‘+ Minimum size (Table 1). Minimum sizes are specie in ordor to avoid intemal stresses ‘ue to rapid cooling, such stresses may Tea fo cracking. Effective length + Overall length of fullsize et including end returns. No reduction required for ether the ar or nd ofthe wold + Any sogment of intormittent filet walt shall have an efactive longth of ot fs than 440 mm or tes the filet weld size whichever the gr Effective area + Product of ettectiv langth and design thoat thickness (Figue 4). Maximum sizeof filet slong edges ‘+ Since structural steelwork connections where a filet weld is used along an edge would involve material of not tas than 6 mm in thickoess, the maximum sizo of fet wold ks ‘qual fo the thickness ofthe material (Figure 4) for steel connections ‘Design tnroat thickness i discussed in Handbook 1 TABLE 4 MINIMUM SIZE (LEG LENGTH) OF FILLET WELDS. Thicknoss of thickest par (9) Vinimam ase of Filet weld ‘nite ‘nits os a vest 2 Pinsts ‘ e tng st tate, on o ~ NS (ma (Fens nto (Webs ote (6) Boats enon in rut pod Baso ple 19305 pte (@Sitere FIGURE 9 TYPICAL APPLICATIONS OF FILLET WELDS IN STEELWORK CONNECTIONS e Sesion ie 2: we i oa‘le = Lea erg DPF = Batgn on cn FIGURE 4 FILLET WELD SIZE AND DETAILS FIGURE § FILLET WELD SIZE IN LAPPED PLATES ‘The economics of Met welding should be Kept in mind at all tes. In the horizontal fet postions, cingle fun filet welds are usually limited to\a.6 or 8 mm lo size for most processes ‘16 welding), although with ther processes under cetan condtons, 8 ‘un filet fs possible. If more than single run woling i requlred, the ost ‘ofthe wel ncreacos significantly (Section 11.3). ‘Advantage may be taken of the increased penetration achievable with fully automatic welding process fo reduce the size (but not the design tvoat tnckness) of Hilal weld—85% ofthe Penetration being considered as part ofthe design throat thicknoss. The viably ofthe welding Provedure must be demonsraled by means of a macro test Such automatic processes are however not usually used i fabricating see! connections (generally beng used to fabricate {ections) co the benef of ths llowancs ie nat usualy realise In conection tira nce actor, tt soten a’ 2 TYPES OF WELD 33° Buttwolds ‘butt weld is one in which the weld metal ios within the outine in cross section ofthe part Connected. But welds can have a varity of preparations which reflec the shape fo which the late or element edge Is propared in order 10 accommodate the weld. Weld preparations Showed by ASMIZS 1564.1 (Rot 7) are shown in Figure 8. Bult welds can be made from one ie [aingle) or ath sides (double). t 5+ 4 oo Z POSER SE 1A 5 (@) Single bevel) Double bevel (0) SgleV (0 Doutie v theta they TS i Al, Dt 0 — Sa FIGURE € TYPES OF BUTT WELOS (attr Ref. 9) ‘Typical apollations in structural steel connections are shown in Figure 7. e eon oie 2: weAy Beaton = = 1 - / wa SYST WY Nae {tr Oss Gude secon 22) (nodwadmorrtcmesin-wih (Sheps aimon, ec ecu ae 2a ice once (Go tes wee Seto) ~~ Se 2 4 oN nn HH ir lig A i ot |e Sb tt a tenons — i (Oatatinm pin. in ctr kn Seine NNT, [N= — ——— SS q (weston nomentensptecrmecton (9) gb boa eran en ple onrcton FIGURE 7 TYPICAL APPLICATIONS OF BUTT WELOS IN STRUCTURAL STEEL CONNECTIONS ¢ eltg ns tr, ton gue? ms ‘But welds canbe ther: () complete penetration which has weld motal over the fll dopth of the element being Connected Such welds usualy require accass om bolh sides that weld metal can be ‘lsced the backside ofthe joint whieh fuses with weld metal epoctd from tho ron Sie of hein or |) incomplete penetration which has weld metal over only pat ofthe depin of tho cloment being connocted Most butt welds a sirvlural steel connoctons are complete penetration but welds. [ASINZS 1554-4 (Ref. 7} contains the following provisions for but wolds in Clause 32 Size Completa penstation, bust jet — thickness of hiner part Complete penetration ee joint — thickness of part that buts adjacent face of he other part Incomplete penetration — Minimum depth to which the weld extends fom its face Inta the ont, exclsive of reifercoment Effective length Defined as the length of continuous fullsize weld, exclusng any weld on ‘runon’ and ‘wunoff {abs ori tabs ara not present any length of weld which isnot ful ze. Extension (‘un-oniun- fof) bars are often provided 1 order to ensure sound weld at the ends ofthe foal length of Effective area Defined as the product of effective length and design th Design throat hckness Is defined in Handbook 1. Figure 8 iusrates the use of extansion (runonirunof) bars and becking bars in a wolded {plcs or welded moment connection Such bars are wevally removed one weling Is Completed Figures 9 and 10 show the terminology commonly used for bt welds e lng suc aon, tt eon oeere onion ae FIGURE 6 EXAMPLES OF USE OF RUN-OFF PLATE, BACKING BAR, EXTENSION PLATE (attr Ret. 11) FIGURE 0. TERNS APPLICABLE TO FULL PENETRATION BUTT WELDS Ince wigs] [Rose tas oot gap FIGURE 10 TERMS APPLICABLE TO PARTIAL PENETRATION BUTT WELDS, e sion ue 2 oe vidig nat st comactns, tet elon 3 TYPES OF WELD 34 Edge preparations Filet welds do not requira any edge preparation cther than thatthe cul material complies wih Glause 14.3:9 of AS 4100 (Re. 7). ‘The reason fr having to ape or prepare the plate edge in a butt welds to onable the welding ire to access the wald though the thickness of the joint The doplh of plate preparation ‘depend on the weld used in the int ‘kn ideal edge preparaton has the following features: (Ref. 9) 1. It provies acosee throughout the depth ofthe wald 10 ensure the deposition of sound ‘wold meal that wil Be prope fused fo the parent metal and tothe oreviousy deposited wold meal Haleo allows cleaning ofthe wold Between passes 2. Itminiises the volime of deposited weld metal so a5 to achieve economy and reduee the subsequent joint dstorion caused by shankage ofthe cooling metal 3. ik minimises the cost of edge preparation. Bevel and V edge preparations are ‘consequenlyproferred (Figure 6). 4. Ithas suficient tolerance fo aecommedate the variations in ft that aro Wkly to occur in race. 5, does nat aad to notches or cieconinties inthe resulting wal ‘The selection ofthe edge preparations is made by the fabricator lo sil he welding equipment, Imoieras handing methods, access, and welding procedures tha! are avalabla. The ‘mensions of tha edge preparation ae selected to mest the welding paramolers tobe used (electrode, amperage, speed), “The choice between singls oF double edge preparation depends on + ease of turing the structural eloments ‘+ plato or element thickness; ‘+ datonion control methed employed. ‘Bevel and V edge preparations can be flame cut, plasma cul or (rarely) machined. J ond U reparations aa required fo ba machined But have the aevantage of redclng wele volumo and {hus reducing distoruon. Tors used for a weld edge oeeparation are shown in Figure "1 ery td | “eve Zz L_NZ rote aL pete FIGURE 11 WELD EDGE PREPARATION TERMS ¢ ing scr Cmts, Son ou”2 TYPES OF WELD 35 Prequalified joint preparations ASINZS 1554.1 (Ref. 7) requires that the welding procodure, which Includes the joint Preparations, be qualified before any welding commances, (see Section 71 of this Design Guice), Joint preparations may be deemed 10 be prequaliiad—moaning that 90 testing of the joint Dreparation i required. ASINZS 1556.1 allows. certain joint preparations to be deemed Drequalfied proved that te welding process and wolding consumables used comply wit the Feconmendations ofthe consumables manufacirer. Prequaifie jolt preparations are species in ASINZS 1554.1 a follows: “+ compote penetration butt wads, Clause 4 5.2 and Table Et + rcomplete penetration butt welds, Clause 45.9 and Table 2: + filet welds, Clause 45.4 ond Toblo ES + wos in otlow section members, Clause 4.8 6 and Table EA, nce 8 notes that + prequalified joint preparations can produce sasactory weldod conestions even for Comparatively poor workmanship, + prequalified joint preparatons do not represent the best ha individual welsing processos fan achiove. Substantial savings in terms of productivity can be achieved By varying fom {he dimensions nominated forthe prequalified Join preparations + 2 fabricator may wel elect to use a non-prequalified joint preparation and qualify the ‘rovedure ae siscuseed in Section 71 ofthis Design Gude. e sin ou 2 ms “TYPES OF WELD 36 Standard weld symbols ‘Slandard symbols re used to denote a number of dolals about a weld on drawings. Such Symol are described in detain AS 1701.3 (Rel. 13). The constructon of the welding sybels [ie summarised in Figure "2. “Tne following points should be noted in connection with the construction and use of welding symbole: (Ret. 9) “The feference line is drawn in the horizontal direction, Le. parallel to the horizontal axis of Ihe erowing. “The arrow pon 0 the welds) or welded joint boing described, “The file wold symbole @ small sosceles triangle based on the referance line an having ie vera! sige fo the let “The singlo-bovel wold eymbel isa 45* V with its pax to the reerenos line and its vertical fag tthe ft “The double-bevel and double-V weld symbols have thelr legs at 60" to each othr. Symbols and notations seerring 10 the artow sige of the Joint are placed below the feterence ln; those refering to the ater side of tho jn are placod above. Arow side ie meant to daserbe the sige ofthe onto which the arow paints In te case of but welds where only the one plate edge is prepared and the other is let Souare. th symbol arrow i eranked Snide made to point towards the plato that has the bevel aslo weld symbols are given in Figue 13, and supplomentary welcing symbols ar given in Figure 4 Examples ofthe use of weld symbols are given in Reference 9. Weld symbols rarely appear on sirucural engineering drawings these days but they should ‘ppear on shop Goal drawings (Ref 8). e ‘king sr ns Stine eon wooot op death fing Fish ym a pscrgy ow ‘to wold ey weston ) sr ue = é ao T — = =I ; Sozaton ens. ae ey eke 0] ese eld st ‘® Some [accents Sestasete sat gtr Eras rrber ria [ee Sten aman ara rare a show KS Note {te wt nt ta ote aro nda cnte pratt Ba we LK >| cea CF Lai esieses Nelo ide ara Se a whieh aon pois FIGURE 13 BASIC WELDING SYMBOLS (ater Ret. 9) awa] wotcat| sto [oat round’ | weit [Bec ear Bares conou| Fah Fian | Gawex | Goneave| Naina] Gres | China] Peon Lota] —|—|~| mM} e] cc] P (e)amaon egating aber Se fan tora et wld nee). {Bhltrmatonepesng arew ode fr ese bevel nc ponarafon bt wel hs nar) FIGURE 12 CONSTRUCTION OF & WELDING SYMBOL (aftr Ret. 9} FIGURE 14 SUPPLEMENTARY WELDING SYMBOLS (after Re. 9) ¢ ‘eli in structural coer, tt eon me ¢ wean rau Se comacbons, oon aee 3 TYPES OF WELD 3.5 Prequlifled joint preparations ASINZS 1554.1 (Ref, 7) requires thal the welding procedure, which includes the joint preparations, be qualifed before any welding commences. (see Socton 7-1 of this Design Guise) Joint preparations may be doomed to be prequaliled—meaning that no tasting of the joint preparation Is. required. ASINZS 1558.1 allows cerain joint preparations. 10. be doomed Drequalifed provid that ine welaing process and weling consumables used Comply wih the econmendations ofthe coneumabloe manutactirer, requaiied jin preparations are specified in ASINZS 1554.1 2 follows: ‘+ complete penetration but wots, Clause 48.2 and Table Et ‘+ incomplete penetration but welds, Clause 4.5.3 and Table E2: + tilt wo, Clause 45.4 and Tablo ES; ‘+ wolasn nolow section members, Clause 4.5.8 and Table E& Reference 8 note that “+ proqualifed joint preparations can produce satisfactory welded connections even for ‘comparatively poor workmanship “+ prequalified joint preparations do not roprosent the best that individual welding processes ‘can achiave, Substantial savings interme of producti can be achieved by varying fom the dimensione nominated forthe prequalified jot preparation; 1+ a fabricator may well eect to use a non-poqualfied joint prepa rocedure ae cizousseg in Secon 7.1 of this Design Guse tion and qualify the e slang i sei octets, odton oe 3 TYPES oF WELD 3.6 Standard weld symbols ‘standard symbols are used to denote a number of deals about a weld on drawings. Such ‘Symbols are descibes in etal in AS 1101.3 (Rel, 18). The consrution of the welding symbols is summarised in igure 12. ‘The folowing points should be noted in connection withthe construction and use of welding symbols: et. 8) 1. The reference line drawn inthe horizontal section, Le. paral tothe horizontal ans of the erawing 2. The arrow pont othe wells) or welded joint boing deserted 3. The filet wold symbol i a small sosceles angle based on the relerence line and having ‘is verial sige fo the ot. 4. The singe-bevel wed symbol ¢ 45° V with its apex tothe referonce line and its vertical eg to the let 5. The double bevel and dovble:Y weld symbols have thoi loge at 60" to each oer. 6. Symbols and notations refering to the arrow side of the joint are placed below the Feforence tne nove roforring tothe oer aig ofthe Joint ae paced above. Aow sia ls mean te describe the side of te joint to which th erow poms 17. nthe case of butt welds where only the one plate edge Is propared and the othe lft “auore, the symbol arow fe erarked snd ta mada to poin towards the plate shat has the bevel, ‘Basic wold symbols are given in Figure 19, and eupplomentary wolding symbols are given in Figure 18 Examples of he use of weld symbols are given in Reference 8 \Wold symbols rately appear on stuctral engineering srawings these days but they shouts ‘pear on shop Get drawings (Ret 8) e een itn 2 wo lengua sl Srmoton, tat eonoct gap depot feg Fetch ynbot ranean a \ \ Y* ee me 4 ee REESE pun ll d vse omens LEAD SAFE 9 PF Sherrer (2s Ap ~ id —_ ve vie || AL KIS fe IGDG Tall » oe Se tow / aati ef -eale-ali-osmeal [IC] IC a o | sme acrry ora oe same = ee ee ws ea mene ZZ SIZE AS aa omen PN PS LFS | woe | —|—P [4 fes|—| | cal Lee jesiesi "trom 2 ar ia ia whch avo pats FIGURE 13 BASIC WELDING SYMBOLS (ater Ref. 8) worn] on re oni rn snd | wot [Barro [Faas [ conex] cxnene] Meco] cies | chraa] Pong Let Laf—|—|— | M| GEC] P (a) norman oar ater si’ ott an trent ft wl nt) {@}ineratonopacng orow age’ (eagle bevel angi eran tut wun sina) FIGURE 12 CONSTRUCTION OF AWELDING SYMBOL (aftor Ref. 9) FIGURE 14 SUPPLEMENTARY WELDING SYMBOLS (alter Rot 9) @ ‘olin in scar comacons st eon a e ots srr sis somodios st eiton or4 WELDABILITY oF STEEL ‘Tho weldabiliy ofa ste! is 6 measure ofthe ease of producing a crackfae and sound welded connoction. The selection of a electrode fo use in welding shoulé be matched to the chomstry ofthe stool ‘Stoel tobe used in welded construction must be abe o tolerate the rapié heating and cooling whien accompanies are welding, witout undergong sigiieant changes in the metallurgical Proper and without allowing cracking fo occur AAs a weld cools, it develops residual shrinkage stains that can approach the yield strain. Chemical composition, grain az, and thickness of the steel fect botn cucity ane notch “Te major infuences on weldabaty are: () Chemical compositon—measured though the calculation of a carbon equivalent since ‘he most important element effecting weldabiy Is carbon. Weldabity ' enhanced 38 the tentbon equivalent decreases. (©) Grain sizo—weldabittys enhanced by finer grain size (©) Thickness—weldabilty is enhanced as thickness decreases because thicker plats fenract neat ana quench the weld more rally. ‘Stee! weldablty ie discussed in detail Reference 14 ‘Ausraian standards for srvturl stele that are weldabe specify + chomistry + srengt + notch toughness + ovcurrence of inelusonslaminations + resistance to amar tearing + corosion resistance (weather-ressting ste!) ‘Steels used in connections and members at connections in Australia are weldable if they comply iin the folowing Australian Stanaarss: as 1163 (Ret, 15) “asinzs 3678 (Ret. 16) ASINZS 3679.1 (Ref. 17) ASINZS 3879.2 (Ref. 18) ‘These re the standards epected in AS 4100 (Rf. 1) and are among the standards specified in ASINZS 1554.1 (Ret. 7). Chemical analysis of a heat of ste! is mace during th processing and after th hoat has been tapped into a late. The heat analysis is used fo comple a mil test report which canbe supplied to'a customer upon raquest by way of @ mill cetfeate, The mil cerfeate should inet Compliance with the elvan Standar e evn use 2 ae ‘ling in stractur e! nnactons, tt eon 5 WELDING PROCESSES. 54 Introduction Welding in structural steel connections is underakan mostly by the fusion welding proces, the nos common of which are the arc welding processes: “+ manual metal arc welding (MMAW) + gas metal ore wolsing ccmawy tx cored are welding (caw) common tion welding pronsees sed forgone abcalon are submeraed are oe vlan. acto gas welang, swcrosog wating, fash butt woldmg, eri ela ‘fusion wed ison in wich the hat of te ress aoduzes ming n tho fot Filer mea een we ot bo sted The proper of he weld are conta by the motairgied eck ecu sr toiicaten of tw med etal and Ging the Rating cathe Setanta het afected zoe. Dota ivomaton o usion wong and oe weling maybe found in References 5, 10 an % e aig ue 2 oe5 WELDING PROCESSES 52 Fusion welding proves: Fusion welding procosses have the following features in common (Ret. 18). 1) The electrode and workplace are connect to opposite sides ofthe power supply: an ae Js sbuck botweon the elacrode and the work pace, releasing heat energy 2) This heat energy metis the surtace of the workpiece, the tip of the electrode i itis consumable and any fux that may be used. The mai components of thesa motion ‘lomonts form a weld poo, which ls held together by olectomagnetc and surlace tension forces, 12) The edges of thi molten weld pol are on the pint of saliiication. As the electrode is ‘moved it aws the ae conte and weld pool with l. Sem-soid metal onthe Boundary of the wold poo! remains behing using withthe parent metal and forming a weld bead 4) The arc, welé pool and hot wolé ead must bo protected from the atmosphere to prevent ‘oviation of tne weld mola. In some processes thal Is achieves by provigng an Inet ‘ase0us almosphere;n ters a fxs Used, and ths is & mature of compounds tat has {5 il eaveral futons, Whon heales, pals a form 2 gaseous envelope to protect the ‘0 nd wela pool, seme pars may be drawn into the Weld pool lo provide necessary ‘Sloying adcitans and the reminder of the melted components wil form a slag over the ‘oposted wold bead. This serves bath to protect the Bead and contol is shape “Tne fusion welding process must supply sufcont heat to effect fusion of the parts tobe joined, rust bo efficient and able to be used ina varity of welding posiions if posible and be abe to ‘tect a wold such that tho properties of the weld are adequate in terms of design sirengtn ang Fracture toughness (afer Ret 10). rs senpute2 om welding stat sta sont, tet elon 5 WELDING PROCESSES 53. Terminology 5.34. Wold metal (eased on Re! 5) ‘Weld mot! i materia that has fused and solid during the welding process. consists of Tintiee of sed base material and filer metal suppl by the electrode. wil have an as-cast ‘ruetite unless. subsaquedlly reheated. lls mechanial properties wil vary in diferent fietions due fo the solidestion process, ‘53.2 Parlay med wold metal (based on Ret. §) “The mising of filer and fused base material may be incom) cour api, Tha usualy oceurs close to tne fusion boundary 153.3 Fusion (boundary) tne ‘Boundary of the weld pool 54 Heatsffected zone (based on Re. 5) “The heat-atfected zone (HAZ) I base material whichis afected metalurgiealy by the heat of the welding process but bayond the fusion boundary. The size ang propertes ofthe HAZ are elated tothe iz o! ho Wold pool, higher arc energy leading to wider HAZ. “The metallurgical changes that occur inthe HAZ dopend onthe mater, the pesk temperate and the cooing fata. The HAZ is usualy harder and less ductle than tne base mates in Src steel. Cracking Inthe HAZ s possible, Material beyoae the HAZ is unafecied by welding although ican contain resicua 53.5 Mut-un wots (based on Ref. 5) Subsequent weld runs modiy the HAZ fiom previously deposited weld cuns. Muit-ran weld Iretal has significantly beter foughnass and dutty compared to ingl-fun weld metal, due 0 tho extra heating cytes rtring and tempering the grain structure i the previously deposited Weld metal and HAZ zones, were melting and solsication / waane Para aid ae FIGURE 15 STRUCTURE OF A SINGLE PASS WELD (Rel. 5) ry eg pe we wig suc onnecors, test edion5 WELDING PROCESSES 54 Manual metal are welding Basic features ofthe Manual Metal Are Wilding process are (Figure 16) 1. being @ manval process quai s very dependent upon the ski of the operstor: 2. oldest welding process and slowest 8. widely used by fabreator for welding conection elements: 4. electrode consists of a core wire surounded by fx; 5 the arc is stuck by scraping the end of the electrode on the earthed work plooe and withdrawing the vp sighly unl steady are conditions of curent and are volage are §ehleved. The electrode needs to be held at iis gap while the wad is completed, 6, electrodes are typieaty 200 mm 10 450 mm long $0 new clctrades must be fited at regular intervals, 7. flexible welding process able to be used in ail welding posons and also used extensvaly for folé welding because of ts low sensitiv f0 wind. FIGURE 16 MANUAL METAL ARC WELDING (MMA) (Ref. 20) “This process may also be rferred to as stick welding (ue fo the use of slick electrodes) or hie metal are welding (USA term), Elacirodes for manual metal arc welding are covered by ASINZS 1553.1 (Ref, 20) and are lscussed in dota in Sacion 6.1 of this Design Guido. Electiode cameters can vary from ‘8mm to 10 mm, athough 2.4 mm to 6 mm are the most common (Rel. 5). “The ux coating can have a varity of constituents (soe Ret. 5. and performs several functions nen iis melon in tho ae 2 follows after Ref. 10} stablises the ar provides the arc and motion weld pool with a gascous envelope to proven the pickup of bxygen and nitrogen from the aimosphere (0) protuces a slag over the ht deposited wold bead o protect trom the atmesphere: (2) protic a gto frm he weld bead shape Inthe welding postion (tt, orzo er ovemesc) wh edogut slay Gatos (0) ats ays whore necessary othe wed ett (9 prove th neconary slaved mela racns (6) canoe th depontion rt. @ ng in sinc nets, eon ms 55 Gas motal arc wo WELDING PROCESSES ‘cored are welding oth Gas Mata Are and Flux Cored Are WelHing use a simdar principle and equipment but are (Belay sonscared fo be Separate procasses, In bath processes, continuously fed wie Is meled Snare stuck between the tp ofthe wire and te workpiece (Ret 5), ‘in Gas Metal Arc Welding (GMAW) the weld pools protected from oxidation by a shielding ides wich fs delivered tothe weld Hough tne welding gun which feods the wire. The wie Is Bs and uncoated and sfx om a all te the gun (Figure 17), Fix Cored Ars Welding (FCAWY) uses a hollow wie witha flux inthe central core tht provises protection to tne malian weld mal (Figure 1) - FCAW may or may nol use a sheting gas {gas shielded ors shielded respectively), Sof shielded would be Used for site welding ‘These two processes are usually n sem-auiomatic mode when used to weld connection ‘laments whereby tho gis Ned by welder and moved along the wel, Figures 17 and 18 (Kor Ref, 25 lusteate the principles of the two methods. FIGURE 18 SCHEMATIC DIAGRAM FLUX CORED ARG WELDING (Ref. 23) e sign uit 2 we5 WeLDIc Processes 56 Summary of charactristics of welding processes GMAW! i ago termed metal inert gas welding (MIG) where on inet ges such fand CO, welding where carbon dioxide is used as the sheng gos. Both processes elimina the slopistart problem wity MMAW due to the use of @ continuous Slactradehenes productsiy is higher ang’ potential source of weld dlecontnultios Is TABLE 2 cesvees (CHARACTERISTICS OF WELDING PROCESSES (after Ret. 23) Electrode for GMAW oro covered by ASINZS 2717.1 (Ref, 21) and are dlecuseed in Section 52 Fa] cherectortice ‘averages Disadvantages Electades for FOAW ar covered by AS 22004 (Re. 22) and are elcussed in Section 6.3. We oa ua [16 |o Soldwro ecveda, |» rent roses [a wanualprcare Equipment and process varables for these processes are discussed in more deta in ee Semieae: | eis [foes Reference 6. welsra | |. axcoatng on im aut speca ocedeteauet code eines tpn chan + Deponion ata I Sa fr ete Sac ‘our Opting |* Sula | Low deposi ate fact 2% High ron amps oer owaereectados can |« Simpicy of ecuipmert | processes, ngrove deposition ate |. syaste tora wide [+ ighes Rethaod of ‘ange ot maleate rior detects + Ponca of equipment J» Requires more silos weldor Tay ormay note aos |» Wich depostion rate [> Dicoty nace sti + Opanare easy guise |e shiny gos used) + osowmeteiube | Srraryeston leving sensive| Seat + morovee penavation + Contruous eecrode feeding + Astomatiem Suomi avanble + Atapabo woo wide + Gases process sted ‘Gee | a7 |p Sona wre oncroae |= Suhatie for waitnga |» Suoing gas wd Shida nuestra widevaseyofsies |" sonsve Stiied | |. shied oro ele + Hon deposton ato |e itentyinaccoss proved penetration [+ Linas in contr of + Ga ase tor + Samiauimate nana utente or oat + fate o weld ight meta (cp vanster made) J Noea9 + Can be wed on our prt ois e ein oie 2 oa lng src ancl tt eon e wing src AS Sao, ten a ™5 WELDING PROCESSES 57 Welding postions | WELDINGCONSUMABLES —6:1__‘Manusl metal are welding CGoverod sleciodos for NMAW ae solid or tubular rods 200 mm t0 450 mm long with on ‘rire or aipped tux coating (Ret. 5). Thoy should comply with ASINZS 1564.1 (Ref 20} ‘uch electodes are designatod as follows in ASINZS 1853.1 (Ref. 20). KKK were € — indeates elctrode ft two digits XX — indicates approximately one tonth of the minimum weld met nile strength, a flows: a0 41-410 MPa 48-280 MPa (ora (oer (Vera (e)ovemeos 55-550 MPa thid gt X —-— Indleates suitable welding positon (Seaton 5.7) FIGURE 19 WELDING POSITIONS FOR PLATE BUTT WELDS (Re. 5) ‘al postions 2—Hat ad horizon positions ‘4 -verieal down positon four digi x — — ux covering type 0,1 —valuosic ype 2.3 nite ype 4” Cron pomder type 6, 8 hydrogen contliod Detailed coverage ofthe properties of te various hypes of Nuxes may be found in Reference. ‘The design engineer only needs to specily E41XX, E4BXX or EB5XX for connection dels on Htucural drawings, thus loaving the solocton of the specific lecvode 10 sult the peaforred ‘welding potion andthe fx covering othe fatriator ore (ey Hexen (9 Vera (@ ovens FIGURE 20. WELDING POSITIONS FOR PLATE FILLETS (Rel. 5) rs ean mie? ws e dosan gute 2: ws lang strstr sel comet, et oton6 WELDING CONSUMABLES «6.2 Gas metal are welding ‘Solid wires for GMAW are availabe in dlameters from 0.6 mn to 1.6 mm (Re. 5). For carbon- ‘manganese steels, the wice ls often copper coated in order to provide caresion protection 19 {he wire and to improve curren pick-up. Copperiree wire Is eso available. Wires can have a ‘atietyof chemical compostion according to the compestion ofthe st! to be welded and the Shing gas to bo used (Re. 5), GMAW wire clasication fo ASINZS 2717 1, 8 9 olows (Ref. 21) ESX_GCIM — W20Xx (shortened version) where ES — electrode soit X —— wire composition term GoM — torch gas, C= carbon dioxide, M= mixed W —— seposited welt metal XX — one enh af he minimum weld metal tensile strength 40-400 MPa 5-500 MPa X = chatpy impact value ‘The design engineer only needs to spect tha WX number required for connection details on iructurel crawings, tus leaving the selocion of the remainder of the parameters to the fabricator. ‘Shielding gases may be ‘inert (argon, neti) ‘acive (oxygen, carbon doxide) risturo (usually argon based) jg gue 2 os e wong in sacl el omacors, rt edton WELDING CONSUMABLES 6.3._Flux cored arc wolding “Cored wire ts manufactured from metal stp of ube and filed with cry powder ingredients Diameters are 12,16, 24 and 8.2 mm (Ref). ‘fhe core material coiains alloying elements, deoxdsers, slag formers and shiling ges “og Saipan els) No Ta-cored wee sso rogue 3 sing gam ahoug se Ehekoe wees have major bdvorages (Re). ‘There are two main classes of wie (Ref). + nto + asle fx Electrodes for FCAW ae designated as flows in AS 2208.1 (Re. 22) (shortened version. ETX — GxpIn—Wo00K vere: ET — electrode, tubular X either P all postonal B fiat and filet only § single pass onty GX — 98s GC carbon dioxide GH no gas (Gk mises ga pin — Pelenyno polarity XX —one tenth of tho minimum wold metal tensile stengn 40-400 MPa 50-500 MPa X _— charpy impact valve ‘The dean engineer only needs to specify the WXXX number required fo eannection details on rica coins, oving the sears of he vemaner ofthe panel tthe fabrcaor.6 WELDING CONSUMABLES 64 Proqualified welding ‘consumables Prequalified welsing consumables. are nominated in ASINZS 1554.1 (Ref. 7). They are Considered prequlined because they ga deposited weld metal ihat has mechanical properties ‘squivalet to those of the parent material when ing any a tho welding procedures permed by ASINZS 1564.1 (Rel 7) Mechanical properties matched by prequalified electrodes are + tsi svongth eld strengths = ductay + hardness + notch toughness (Ret. 8) Table 4.61 (B) of ASINZS 1554.1 (Ret. 7) groups stels complying with Australian Standards Into types fo 8 depending upon thew mechanical properties. Table &.6,1(A) of ASINZS 1554.4 ists he welding consumables to Australian Standards thal af tbe used for each steel type ‘order tobe considered prequaliioa Table 2 summarses the prequalifled welding consumables for the tee common welding provesses used in steelwork connections for sleol grades to ASINZS 8678 (Rel. 10) and ISINZS 3079 (Ret. 17 nd 18), TABLE 3 PREQUALIFIED WELDING CONSUMABLES. Stet grade in Wold metal classification ‘asmizs 97 ‘Wanval Maal Are ASINZS 1585.1 | Flux cored—AS 2208.1 ‘at 1) (oh 20) ‘eh.22) Asis 3679 a (ar i7 10) ee ed ere 200,250,300 Ea evox Omar | WAOK, ws0x 2s010 ADK, 400K 2 soa, ws 260118, 300015 atx, E4050 3 eos, ws0 ‘350, R30, 400 40, 400% sox, wanx 200, WRas0L0 EtOH. 4X 2 502, W402 seocrs.coours_| 6 | €4bon. cern 2 509, 03 NOTE: See expanged version of i tabla ASINZS T8641 (Ral. Ty ‘hore base mateias or welding consumables are not to the Austalian Standards listed, then proqvaltiaton fs net posable and special welding procedures qualiicaton tests ae requited 10 be undertaken using the methods epociied in ASINZS 1554.1 (Ref 7}—soe Section 7.9 ofthis Design Guide Reference § (Section 1.25) deals at length withthe aificultes encountered when imported gels sed or substiuion of grades is envisaged. ‘More deals on this issue may be found in Reference 8 7 WELDING PROCEDURES TA Quatifeation of a welding procedure “A-matding prosedure encompasses the following variables: + Process + Elocrote speifiation 1+ Glocrode classitation + Elecroge ciameter = Elpccal characterises (ac, de, do-) + Base metal specification “+ Minimum preneat an inespass temperature ‘+ Welding curent (amperage) irefeed speed + evoliane +Travel epoes + Poston of welsing 1+ Postwald neal reatment + Shieaing cas type and ow rate + Joint eoniguration + Wels preparation dtats + Sequones of weld passes Since all these variables can affect the soundness of the resulting wold and is mechanical proper ls cal that all the values actualy used fora specific weld ave approprate [ASINZS 1654.1 (Rel. 7) requtes that the welding procedue be qualiied before welding ommences (Clause 4.11). This Clause also requires that the fabricator establish a welding Procedure and lst the appicable parameters on a welding procedure qualification record wear) wien shal be held and shal be avalble for examination, A suitable form e given IS ‘Appendix © of ASINZS 1554.1 (Rel 7). ‘A wolding procedure speciation (WPS) is developed from the WPOR and made available 10 the weldor during fabrication. "A suitable form for» WPS Is givon in Appendix Cf |ASINZS 1854.1 (Re. 7). Such a form would also be issued to the welding supervisor Inthe fabrication shop and to anyone inspecting the weld ‘The WPS isthe primary means of communicating to all the partes involved how the welding I {0 be performed ‘Tho quaificaton of welding procedre in conformity with ASINZS 1554. (Re. 7) involves the folowing steps (0) quatteation of to joint preparation )quatcaion of te materia: {l8)qualication of te consumables; {W)qualication of he welding parameters. ‘ASINZS 1554.1 (Ref. 7) also raquies that the welding supervisor and the welder both be ‘ualfiod (Clause 4.12). The fabricator remains responsible for ensuring that the correct Procedure f followed and ensuring compliance wih ASINS 1854.1 ¢ olga ir, ttn o*Methods of quaiying weking procedure are epecifed in Clause 4.2 of ASINZS 1554.1 i @ o © © 7). Those are 9 lows: 4 prequalified proceduce(dscussed in Section 7.2 ofthis Design Guide) ‘documentary evidence of relevant prior experince by the fabricator. This would be ‘expected to include a WPOR, recorss of procedure Qualification, records of testing, records of macro specimens production of a test place which 1s tested In accordance with Clause 4.7. of ASIN2S 1554 1, the welding of the test piace having involved tne same parameters th ft Be uso forthe welding in he project preparation ofa special lest pisce which simulates the weld to be made and which is feslod in accordance with Clause 4.7 of ASINZS 1554.1 Aesiryetve testing ofa prototype joint or component ‘acoption of a welding procedure already qualified by another fabricator, subject to ‘estntions specified in Cause 4.4 of ASINZS. 1558-1 design sie 2 os wolang instal a concn, tet eton 7.2. Prequalified welding procedure _ WELDING PROCEDURES “Aprauaifes wen pocode in tors of ASINZS 1554.1 vale: “ {@)__ se of prequaiios joint preparation (see Section 3 5 ofthis Design Guide) {e) ye of reqtties mates, comping ) puronmaanal to specitod Ausalan Standards © Rn vase: | ()_bakog mtoral comping win Cause 2.2 of ASINZS 154.1 i) losodes lor wires, fx, shina, g2s comping with nominates Aus Slants ove Cisse 2 of ASN ToB8 1) 10) censumatis compbjna wih Clause 46 of ASNZS 19.1 and matched 10 parent ‘floral os ducosay in Seton 8 ofthis Doon Gove {@)_woreantio and welsng etnies complying wih ASINZS 15541 1H) osumeriacyevktonce of a mcr lst ofthe completed walt, usualy cane’ fo & tavanar tf poce “aon: eta pocecure canbe proquid by sng a nurber of proqusifed pret by king et wed andy examining mac spacmen oth esting wes ‘The macro test volves taking a tensvecse slice through the weld and then grinding and palshing K 20 that no damage is caused to th sample. Th tost pace fs thon aed olched to Feveal the gain srsture. The intnton fs to detonmine i tho wold contains dofects but the aero test wl also show up the wold rs used, Macharil testing of welds produced by a prequalified welding procedure is not required because there very iil sk that ho procedure wil not produce a satisfactory wel. | prequalified wolding procedure may not be the mast productive procedure fora particular ‘pplcalion, in which case a fabricator may elac to qualy a more prosuetve procedure ‘Some portability of qualified welding procedures between fabricators is permite by Clause 44 SfASINZS 1954.1 (Rel 7) (s00 Clause 2.1. of on we e eta se Seine, een7 WELDING pRoceDURES 73. Qualification by testing ‘A welding procedure canbe qualified in lorms of ASINZS 1554.1 (Ref, 7) by producing a special tect piace ane subjecing the welded test plece fo nominated tests, The welding procedure becomes qualified Ht compias wih al the requirements of Clause 4.7 of ASINZS 1654.1 (Ret7), “Tho tosis tat might be required ae: + transverse but ensl est + bend test + charpy impact test + hardness comparison test + hardness test for welded heat-affcted zone [Al these tests are covered by parte of AS 2205 (Rel. 24). They are described britly in References 6 and 8 “Table 47.1 of ASINZS 1854.1 (Rel. 7) nominates which teste ace required according to the following parameters + wold catogory (soe Section 8.1 ofthis Design Guide) + proqualiiedinotproqualiied consumables ‘+ prequaliiesinat prequalified preparations “whore a welting procedure fs qualified by testing there i no necessiy to employ proqualifes Consumables of prequalified materiis or progualled preparations. Thus, a fabricator may ‘ually'a weldng procedure whicn Is ditty sued to particular application in order 0 ‘maximise producti. ‘Te testing is intondad to (Ref. 8): (2) ensure adequate penetraion and freedom from defects when using non-prequaliied Dreperaons and consumables; (6) ensure. adequate weld metal strength and ductly when using nongrequalifed ‘consumables (©) ensure freedom rom excessive HAZ hardness when the heat Inut/preheat requirements ‘OLASINZS 1564.1 (Ret. Tharo net observes () Affirm thatthe notch toughness ofthe weld metal fom aon-quaiied consumables when fabricating noten oughness tested pat fs satisfactory ‘A fll record of the testing should be retanad by the fabricator so that it can be retarted tof requires: AWPOR should be used fr this pupose (Section 7.1), e long ns feta, fe oaton os 74 Requaliteation of welding : procedures “une 441 1 ASNz8 15541 el. 7) corr o seman fr chrge a stent Gie'olo nating procedure in acesang what tang Is Tequres In over to roqualy & tang procedure. "se he Sug rinoe—an doings by Table 411 (©) of ASNZS 1584 1—ony a aco tas Resta Ra conten thatthe revood welding procaduf Wil su produce a satay wold “wore the change is molor—as dofined by Table 4.11 (A) oF (B) of ASINZS 1554.1— ‘Fajazaton one welding procedure lo vecured - A-comparatvely wide variation in welding parameters is permitted without requalfication being Aigner rer 8)by jsicous selection ef the parameters which aroused for quaifeaton of & ‘lding procedure a fobicator can qual tat procedure for a wide range of operations “A deed decussion of Tables 4.11 (A) a (C) is contained in Reference 8. ¢ woting soc A Sti, tt eon o*84 Edge preparation 82 Assombly © WORKMANSH! 8.4 Ege preparation Edge preparation is covered by Clause 5.1 of ASINZS 1964.1 (Ref. 7) “Thermaly cul surfaces which ae to be incorporated into a weld are require to have a surface Toughness no worse than that given by Clase 9 in Reference 25, (Gaus 5.1.1 of ASINZS 1554.1 requires as follows: “uraces and edges to be welded shall be uniform and ree from fins, tears, racks and ‘other efocts tht would adversely fact the Guay oF strength ofthe weld. Surfaces to fi welsed and surfaces adjacent to a weld shall also be fee from loose oF thick scale, Sag, Tost, grease, pain or ater forlgn mattor thal coulé prevent proper welding, i Miate inet withstands vigorous we brushing. rustinhbiing. coatings. antspater Compound’ and weld-tvough primers tat do not terre wih welt quality or the welding ‘operation may main” 82 Assombly [Assembly is covered by Clause 5:2 of ASINZS 1864.1 (Re. 7), whorsin requirements fr the ‘Stonment of parts te be joined by welding ae species. Alignment requyements may aso be found in Section 44 of AS 4100 (Ret 1) oon the strvtural drawings. 83. Proheat | Most crucura see! i hemaly cut without preheat, which i usualy only used to avd | Meron easing i te foot alee zone when ternal cling hey Secon of oh -Fasaetanity sets ra.) Preet procedures fr cuting we contd nReeronce 2, “Preheaing before welding i requ n oder o avoid heat affect zone racking by slowing feeling sale, t's ony requrd for catan combinations of steel grade, mater tikes | We fecluyparemetors. Cause 5.3 of ASINZS 15941 (Re. 7) contains te eleven provisions mic ae Mich are dees tom Reoronce 16 Generally, he procodore required of ne fabreator isa follows (ater Ref. 8) “{a)_nily tne stcts being welded and the Weldabilty Group Number rom Table 8.9.4 (8) (9 GenShs test. Te hare the carton eau the more the soe! I pone 10 « SLASiyand te higher he grou number iiet tine than one group number FeeTe tal enoes tw Nghe number i ateratve cate the ean PE ot bse ona chum! aay of he tal bang onset 8) (0) Caelte ve conbined iikoos of thao. The ihc the quench seventy ofthe on ‘fur ty racing wi cect, ond the ugh i combines sess 10) Uaing Hg 64 (A, of ABINZS 15581, determine te Joint alsa Inx fo the (SEE CBsce tothe inicecton of tw conned theknes. and Wedaty Gro Mimbo (8) Dotarine wheter the welng paces is Low hyoge oF net. Chaose he relat Propet Seeminaon agra 9.3.8 (8) or 534 (C) fom ASINZS 18561 (©) Deter the lowest noo input wach any ase wil be welded at, Preheat tompertre Exnve detenine tom he ovat ont wean cure Some HAZ caching may sil cco undor conions of extrem resin (Rot 8). Mata Ryioaensrckng nba wed may rc onl presenting Ret 8) ‘oor evel fest han ht cls canbe ured canbe demons {he radar ssn hw owe a of reen Re8) "Examples of metnod of calculating reheat are gion in Reference 8 td by qualying widngstretura sil eamectons, Rat eonWORKMANSHI BA Tack welds “Tock welds are used to temporary hold stl slemonts in place so that they can be welded in Accordance wih the quaifed procedure. Bath fomporary and permanent tack welds must be of the same quality 2s the tinal welds Inthe structure. Unforunatly thee have Deed instances fre weld facture has cea fom racks onginaing attack wed locations (Ret. 8) Limitations on tack weld minimum lengths are epecied in ASINZS 1554.1 in order to avold tne ‘Sluaton whore the welder merely apples @ Job of weld metal fo hold componenis Together ‘uring seven, These date are Invariably apalied wtheut preheat and are offen already ‘cracked before Belg incorporates inthe nal weld (Ret. 8) long iste ste anactns fest eon 185 Distortion and residual stress "nce a wuld bead has been deposited and stars to col, it soldiles and contracts both along | eicngatna ents and wanoverse to thet ans, Tis conracion induces resicua svesses ar ada ~ Laaplinlaneinkge con cause slender elements 10 bustle and can cause bowing of the maa ere “Tronsersesvinkace cn produce both angular ans outa lstrions. | Distertion can be of considerable significance in general fabrication—parteuary in the | fabvcaton of buitup sections or spicing of momber lengths t's generally of ess sgiicance [Brihe tabication of connections, This ie because the weld runs are generally short and “onitdina shrinkage i rarely a problem, Distortion in connections can have the following effects: 1+ fun between ars isnot achieved local Boking strength may be reduced de to tho rosuting out-of traighness: “+ iereased local stvesses can reduce design capac “+ appearance may be atected Tn genera the contol of sisorton sin he hands of the fabcalac who can we a numberof “fecbngies io compensate forthe distortion, These veces etuge rosa relevant restraint ring fabrication (us of strongbacke): + modiving wea sequoncing: = peening: post weld eatment (mechanical, neating). ‘Therm i oo real guidance in Clause 5,7 of ASINZS 1554.1 (Ref. 7} oF AS 4100 (Ref. 1) a8 10 Control of distortion ASNZS 1541 (Ret 7) Clause 57.4 pois te folowing metiods forte conection of istorton sents ‘+ mechanical means (hydraule presses, loca aching, local wedging) ‘+ eat appcation; + controled application of coxectng weld runs + cultng apart and rewelding Resaualsvors and aston are discussed in more deta in Refrences 6 and 10, “The sirutural steel connection design engineer can assist in reducing both disorbon and ‘residual srosses by the following means: + using as few wet possi; + using te smates! weld size required by the design requirements + istibuing welds as equally as possible bout tho connection + use intermittont ot welds in ou of fl length filet welds I possibe, ¢ role scr comodo, fst eon oe8 WORKMANSHIP ASINZS 1654.1 Clause 5.11 roqirs that sig be removed from all compioted welds by wire ‘rushing or oiner suitable means, Tightly adhesng weld spatter can remain unless required 10 be remaved for surace veatment oft alow nonaestructive testing. ASINZS 1554.1 Clause 5.12 requires that bull welds that are required to be crested fish shal be irises so a8 (0! + not raduoe the thickness ofthe thinner bate metal or weld metal by more than 0.8 mm or 5% of tho thicaness, whichever is lesser, + not leave aay reinforcement that exceeds 06 mm, remove any reinforcement on a contact race + blend smoothly with he plate surfaces, Dressing is nermally ony dane for srhitectural reasons in connection rather than for tuctural 86 Cleaning and dressing welds 9.4 Wold categories sits the use of two wold categories 2s fohows: ce ctr purpose pene purpose ference etween (nso wold calegores les i the level of pemissble imperfactons - Manodty ASINES 1654.1 (Ret 7). SP wold category has smaler permed mperfoctons ond Be Sea nar etngsy ob: Secs 'nm pune ova of Inpro i eseded, the imperfections are classed as delects. These categones of wold cannot be | Sialuny Adm 104.1 tee of pemitedimpertecion exon es a Safed by a racure mechanics assessment atthe detect wi tbe mjurious © Pe Garemmence ote sctue (Sncion 9.40 his sgn oe) “Tr slicton cf wol catagory the dscraton ofthe design enaineer "Clouse 1.8 of ASINZS 1554.1 (Ref, 7) contains the following provisions for the two weld fnloporas of ASNZS 1858 1 | (a). GP (general purpose)—GP tobe goneraly selected where: the wold requirement "ly the weld is stressed fo not more than 60% of the relevant maximum permissible ross ae spaced in AS 3090 (Rel 26); or (8) he welding application is other than structural "SP (structural purpose)—SP tobe generally selected where (0) the wold is essentially statically loaded and designed to meet the appropriate Fequrements of AS 4100 (Ret 1 (G) the wold is stressed to more than 80% ofthe relevant maximum permissibe stress 8 specid in AS 3000 (Ret. 26): ce (3) the weld is subject dyname loading, within the limits stipulated in Clause 1.1 of ASINZS 1854. ‘Welds nominated as Category SP, but not complying with the requirements of that category “when Inspected after fabrication, may be considered as Catagory GP wolds, provided the Fequrements of AS 4100 or AS 3000 ae salisted ane the princpal has agreed “Types of wold inpertectons are discussed in Section 9.3 of this Design Guide. Once a Imparfecion excoods a permitod lovel It becomes a defect and this is discussed in Secton 9.4 ofthis Design Guae. Foforence & notes the following In relation to weld categories: (2) the love of permited imperfection f et on the bass that pa Ihave been selected (0 avoid the nok of bile facture, su AS 4100 (Ret 1) andlor AppencixB af ASINZS 1554.1 (Ref 7) (©) the faare mechanism is that of ductile failure in tension: (0) the infuonce of any weld defects approximates toa loss of load-bearing cross-sectional ‘tea the weld ot (5% catagory SF 10% category GP (@) Asmzs 1558.1 depends on certain ovels on inspection of the wold (discussed in Section 9.2 of tis Design Guide), both before and ater welding; materials and weld metal iy using Section 10 of enon oie 2 mo» weg in cle cee, et oon ¢ king scr Sons, ta eton o*(©) ASINZS 1554.1 rales upon acherence to qualiled welding procedures (decussed in g WelpmpenrecTIONS —«92_Levels ofinpecon Setton tative Design Suc) = ost wee senets in scr cnmctons wit recute SP wold algo. The sive) ae ee oe reiemamian agated eons seals of heels see ons wos leoey The smpeted etext rion dsiuctveexancation NDE) x eh wal category cold ‘Gite ease aie, In genera, it is doubt wnethor the than SP catagory welds (Rel 6) ny cot saving Pe Seee ese Anas test (rot 7) A svononed verson of tis Tabla Te contained In in speasiog GP cxopor wos rater TE ee. TABLE 4 LEVELS OF NON-DESTRUCTIVE EXAMINATION (NDE) SS oc ee ae we ‘Visual means: ‘Other means PT ascanning| Masel Moanetc parle | Rastography or : examination ‘rane oe ‘oo 51025 ow? mH oe 100 tows a1010 aw |The structural drawings andlor specification should contain details of the metnods of nan- | Bev exanimaion 10 bo ceed andthe exon ol sing rended (clause 74 of SNES 888") o 6 notes tat there can be cnseable dieenc inthe cat of nondesrucive | Manteo of etegn GP ond SP welse ‘Note that a wlds must be 100% visually scanned but that detailed visual examination should ‘hip invole 5 to 50% of all welds wile thorough examination by a vatety of mears may only "br ced ou for Oto 10% of welds. ASINZS 15561 (Re. ) places a great coal of lance 0% _ ting the welding procedure corect asthe primary means of producing saltactory welds eign gue 2 — . wn tel eet wo9 WELD IMPERFECTIONS: 9. perfection levels ASINZS 1554.1 (Rel, 7) deals with imperoctions—best described as a deviaon com porfocion. The term ‘npertection’ ls not defined In ASINZS 1584.1. An imperfection only ocomes 8 ‘tect I ia mpertction exceeds tne permissible lovels of imperection defined it ‘Table 62.4 and 6.22 of ASINZS 1554.1 [Cause 6) “The types of imperfections considered in Table 6.2.1 and 6.22 of ASINZS 1556.1 are as follows TABLE 5 ‘TYPES OF IMPERFECTION CONSIDERED IN ASINZS 1554.1 ibe imperecion Tyee of weld ® tt woit | rece Inowion Una asian ortnarpots pentatin Unoraut Shantage groves Root crcanty ‘Surtacsporsty an intra porcsy isagnment Filet weld | Height of enorcament Burace mpertecions~as but wlds Coen ro cetnal ated Diagrams itustrating some af these imperfections are shown in Figure 21 and Figure 22. “The pormsible levels of impartecton are given 9 Table 6.22 of ASINZS 1554.1 (Ref 7) and {to discusses in datal In Reference ® They ae no repeated inthis Design Gude, Table 6.2.1 of ASINZS 1554.1 deals wih permissible levels of Imperfections as determined by RRaciographie or Utrasonie Examinations (260 Seclons 10'5 and 10.6 of this Design Guide respectively). Table 6.2.2 of ASINZS 1554.1 deola with pormistibie lvels of Imperfections as determined by ‘Visual (Gecton 10.2), Magnet Particle (Section 10.3) and Liquid Penotrant (Suction 10.4) Examination [ASINZS 1554.1 contained detalles provision fe ona aoa + caeulation of ose of eos + trastmant of aligned impertectons + weatment of overlapping impertoctons |A. commentary on the provisions of ASINZS 1854.1. concerning permissible levels of ‘mmperfections may be feund at Reference & econ pit 2 os @ ng in sc Sac, tet ton (e)Undersize (oy oret (er Roteonenety (B25 ponaaton| (6) Poor apna shape (9 Ovetap \ Vv (@)lackot low ision (Lack ft penataion| N (0 Toe eaceinZ ek \ ©) Shape tows (0 29 incaon| (ry igen (oymsigrnet 4 FIGURE 21 IMPERFECTIONS IN BUTT WELDS _Reference 5 clasifes imperfections into the folowing categories @) Fusion tows | elween weld runs) incomplete fusion sie incomplete penetation —everst —Sicessive filet size —Sxcessive cap height —Sverall indore irisatgnment —spater wotsngsrocwal ise Somodions at eaten(6) Gas and slag enrapment laws —porosty lag inclusions (0) Nestites (©) Cracking—sofitication cracks —tnydrogen induced col cracks lametar tearing ‘Solication crack ypes include (Rel. 5}—Figure 23 ftom Reference 5: 0) erator cracks ()tongtusinal cracks (ti) narrow bead cracking (iv) wide boad cracking ‘Cracking is also dlecussed in References 10, 12 and 27 Lo | “Underout Lover tlh S aia v L \ { Se FIGURE 22 IMPERFECTIONS IN FILLET WELDS (} jG Narowbeadcrecng Wide bead eacna eae) FIGURE 23 SOLIDIFICATION CRACKS (tom Ret. 5) e wan sac el macnn defects 9 WELDINPERFECTIONS: 94 Wal sfecions in excess of the permissible levels specified in Table 62.1 and Table 6:22 of “{9541 consiule defects These tables should be consulteg for deta of te Benes tees of mperecions |The levels of permissible imperfections ate essentially derived from what constitutes good | workmanship and experience of using ASINZS 1554.1 since fst published in 1975. The levels: ‘himperfecton ore lse related tothe Feskclons discussed in Section 9.1 ofthis Design Guide | {Rel 8) ropardng weld categories. “Reference 6 makes the folowing pertinent points in relation to the acceptance cites of ASINZS 1554.1. | There ate diferences in he acceptance eri for sutace Naws between the two weld talegris, but those aro only significant to the fableator if the structure 2 all Catagory Gp. Where here ls a mitre of SP and GP welds, the fabricator generally works t Iie higher standard. Having twa standards is conusing to welders They have to be qualiiod tomeet the highost standard require forthe work. Welders genoraly try fo work to the highest standard, and donot deliberately iry only to just achieve the minimum standard, “Te diforénces in accaptanc standard between SP and GP welds are miner and of tte practical signiteance. Distinguishing Betweon undercut depths of 1 and 15 mm i fiat practically and seems of ile signieance tom a siucural vewpoi. Catan, 8 of 90 Sgnifeance when making the weld Only one diference hes practi! sigaiicanco tthe “welder ana thal ig the amaunt of excess weld metal (enforcement). Tiss unresticled for GP welde and hao easly achieved limi for category SP walde. Only poor skied \eldrs cannot achiave the standard. From an engineoring viewpoint, excess weld meal Te undosirable only fi cases astrtion, or aterratvely ithe weld bead hosght is such that causes aeute notches atthe bead toes. Why theres such a aference between the two categories of welds la questionable *ull-peetation bu welds have to be backgouges or ground lo ensure treedom trom root, detect Because GP welds are not gubject to intemal inepecton techniques, precede fda ot need to. asaure feadom from infernal detects. In pareuarful-penetration bat welds can be made wioul backgousing or back grinding, and this should allow Considerable savings. However, many fabricators donot fllow this eoncopt and wil back ‘ne the root un of bth SP and GP welds. This avoids the risk ofa SP weld being made {0 GP ‘category There is no aflrence in the procedure Tor making Talet and paral ponetration welds” ‘The designer of a siuctral steel connection will seed to rly upon repens prosuced by 2 Welding inspection ‘Service in order to tnow sf the weld in a coanecion “complion with AASINZS 1554-1. The eves of examination undertaken are generally those nominated in Table 4 ‘ofthis Design Gude, s0 not every connection i examined except that 100% of al welding at al Connections shoul be at laat vaually scanned ry gon ote o« \eldg structural sel enmecns tat on9 WELD IMPERFECTIONS 95 Wold pairs [Avweld with defects excoeding the permissible levels of imperfections shouldbe considered for fccoplance bore a rpalr is underiaken Clause 6.7 of ASINZS 1558.1 (Ref. 7) allows that where a defect is not injurious to the Derformance of @ sirvcture (and by implicalen a connection) then the defect need not be Gepared provided that the principal and fabricator agres. Ths would usually involve the ‘SKictura toot connection design engineer mating an assessment ofthe sign strength of fo ‘told after atowing for imperfections (usualy on the base of an estimate of the loss of cross- ‘SStonat area) andlor canying outa fracture mechanics assessment, using Reference 28 or Simlor Fracture mechanice assessments are best leo specialist n ihe fl ‘items to reps @ weld with a defect can be fraught with ifculy and, in some cases, th end ‘asult'may be n0 bettor than the orginal defective weld. Repair welds can ilroduce local Feaidual evevs which can lead fo datorion and cracking (Ref. §). Backgouging and ropait of rele is covered by Clause 5.8 of AGINZS 1964.1. Under this Clause ether part of allo he Weld is removed, the rewelcing is caries cut m accordance wi ASINZS 1854.1 and tho ‘pated weld respected tothe same level as the orginal (defective) weld ‘Clavse 6.8 of ASINZS 1854.1 allows the following repair methods: + machining + geinding + chipping + gouging (oxygen, are, plasma) ‘Substantial removal (ndofind ato extent) snot permite by Clause 8.8 of ASINZS 1854.1, ’kn altrnative to eeparing a detective welé i to replaca it with new fabricated piece. This fs ‘ten tne Best course when dealing witha detecive weld In a connection as the prabiom is 80 ‘Goatead and lately cheep fo replace, alike e weld ina fabricated member of many meles intonat. e asian guid 2 oe 410 WELD INSPECTION 104 Introduction Depending upon the application andthe weld Depending von te apscaion and he wel category. ald maybe specie ob apace + visual examination (Section 10.2) 1+ magnetic particle examination (Section 10.3) ‘+ quid penetrant examination (Section 10.4) + radiographic examination (Section 10:5) + utrasonic examination Section 10.6) Reference 8 reconmenés that where only visual, andor magnetic pate andor penetantoxaminabon fe undertaken, tal this be augmented By examination of the macro teat Specimen from the procedure quaicaton(Socon ? otis Desan ui) Radiographic and ukrasoie examination ore only “ lon azo only appropiate for wal category SP and can ‘ony be aplod wo butt welds mower to vey intemal ety ota wala Te ee ‘methods can only identify surface imperfections. ee Because te tachigues involved ae specialised. o wel prialced, 0 woking inspection service win qusiiee ‘operators should be employed. Many fabricators rely on their own inter rs carry out any welding inspections required. my intemal gualty orem (@ Sa wan sc A Sn tt etn oe410 WELD INSPECTION 102 Visual examination \ioual examination isthe fist stop ia any weld evaluation process. Such examination 1 0 _ubethuto for proper supervision ofthe welding whe tis cecuring, ‘Visual examination can be used to detec he following (Ref. 10) + see and shape of weld + corect weld preparation + coreot up + oot passes of mutizun welds + surace cracks + undoret + surace porosity + all wolds nominated are actualy in place + rot concavity + overlap + excess penetration + shrinkage grooves + misalignment 1 omovat + spater + dloanlne Ideally, the welding supervisor will make regular visual examination before, during and at the completion of welding. Ether the welding supervsor or the welding inspector or both should \roualy examine the completed wos, ‘There 6 no Australian Standard describing procedures for visual examination. Reliance fs placed on ais such as of weld + magnifying alassos + gauges e rsp ge? oe wlan sutton, fst eon 40 WELDINSPECTION 103. Magnotc particle examination “Magnetic partici examination (MPE) Is covered by Clause 6.5 of ASINZS 1564.1 (Ref. 7) and is equ By that Clause to be carried cut in accordance wilh one ofthe techniques spectted i ASTIT! (Ret-29), ‘The following description i taken fram Reterance 11, Section 8: “For magnetic particle testing,» magnetising curtis introduce into the weldment fo be Inspected 2s shown in Figure 24. The magnetic Weld induced inthe work wil be distorte Dy any cracks, seams, inelusions, ete located oa or within approximately 2mm of the surface. A dry magnetic powder spread ugndy on ‘he suvlace wil gather at such Aiscontnuies, leaving a ditinet mark. Those magnaicly held particles then show the ‘ze locaton. and shape ofthe disconinily. A liqud ink may also be use. Ths method wil detect surface cracks filed with slg oF contaminants hicn dye penetant could not {enler Additonaly, the powder may be picked up and preserved with clear tape, paving Accurate and dealed rocords of inspection resus Howover. this method requites Telatwely smooth surfaces and while Gearup 's easy, demagnotlsaion, whan necessary, may not be FIGURE 24 SCHEMATIC DIAGRAM OF MAGNETIC PARTICLE EXAMINATION (rom Ref. 11) [MBE can only be employed to detect impertetons on the surface of a weld or sub-surface Imperfections very close tothe surtace ‘The surlaces need to be clean and fre of grease. They aro usualy sprayed with a whit, mat {quick-drying paint te give contast so thal he magnetic pattern can be sean, Mathods of magnetisatio are discussed in detlin Reference 6, as well as ts application and limitations. Te teenique is quick and sonetve, and relatively economic. Fly trained technicians are quired to cary out the examination. e ing sect eon, on om40 WELDINSPECTION 104 Liquid penetrant examination Ligue penetrant examination (LPE) is covered by Clause 6.6 of ASINZS 1984.1 (Ret. 7) and is required by that Clause fo be caved out in sccordance with one of he techniques speciied in 1x5 2062 (Re. 20), ‘The following description ie taken frm Relecence 11, Section 6: “in ponetrant testing, ated dye panetrant applied to the work and penetrates any crack tr evevice agen tothe surface, Air removing excess dye, a white developer's applied "where cracks ate present, the red ye seeps through the developer. producing a visible fed image. This process is summarised in Figure 25. “LPE may be used to detect tght cracks as long as they are open to the surface However, only surface cracks are celectable, Furhemore, deep weld ripples and indica won LPE fs used (Geared (e)Penarant—_(o)Excass (4) Deron ace es roves apd FIGURE 25. SCHEMATIC DIAGRAM OF LIQUID PENETRANT EXAMINATION “trom Ref. 11) LPE can only be employed to detect importections onthe surface ofa weld LPE is an economical and quick method of examination that does not reauie Nay techncans. Tho weld surface mut be fee of grease eof whieh should be removed by Seivens ide cracks produc a seopage of spread af th ponerant whist shar cracks often appear as Jers of dots th ne whic in tne may ink vp to gve a continous ne. Rounded sutace ‘etects oe easly recognisable and hay ate clearly observed because of he penevant spread {her 10) Cracks ae smal as 0.2 mm con be deeced (Ret 6). ‘The method is also known as dye penerantingpection More details ofthe method may be foundin Reference & e sgn pe 2 oe ‘len natural steal omens, fs eton 10 WELD INSPECTION 105 Radiographic examination Rasiographic examination (RE) is coverad by Clause 6.3 of ASINZS 1564.1 (Ref. 7) and i= Feajikes by that Clause 1 be carted oul in accordance with AS 2177.1 (Rel. 3). Speci test ‘mothods ate prescribes according to whether the maleral hckness tess than 12 mm o ea {oor grote than 12 mm Ether Xray of Gramma-ray technology may be employed. The method uses a rasioactve source and a lm process which produces © negaive, The negative serves as 9 fecord of the etoct sub-sutacedefocss such a: (alr Ref, 11) + porosity + slag inclusions + cracks + tack of fasion but tobe detected, tha impariacton must be orlaned roughly parallel te the radiation beam and ‘cupy about 15 percent ofthe metal ticknees slong the radiation beam, RE can be dificult to interpret for: + connsetions wih varying thicknesses + it ws + teojoins + camerjoints ‘The principle of the method is thal where there is an imperfection more ratiation passes through Wand affects the photographic fim such tha the area appears dark after being veloped. Tho principle o the metho is showin Figure 26. Interpretation of radiographs requires extensive training, experience, knowledge of welcng and Caroll inerpetation of the fim. Access Is requ to bath sides of @ weld, tne im being placed on one sie and the rasiationsourco onthe ater sie. a ameey source _— aE ry [hn =F hn oe [TT TE] — cay vee FIGURE 26 PRINCIPLES OF RADIOGRAPHIC EXAMINATION (Ret. 19 and 10) ign gue 2 oe @ ston cl Scions, tet‘i necessary to chock the eons ofthe procedure during operation. This is cari out by placing an image qualty indicator (IA) on te surface of tho weldmont being nspectad. A common type of 1 consists of wires of diferntdlametors mounted side by side ina polythene {ag (Ret. 19). The sensitivity ofthe particular radiograph is defines as ‘Salles lsmater of wie hate visible “Thickss of weldment being radiogsphed ‘The [Al sensitivity must comply with Table 6.8.2 of ASINZS 1554.1 X-rays have the advantage that te intensity of raciaton can be varied, that Wis more sensitive ‘ana that. since the source can be switéed of I's only necessary to take safety precautions ‘during the exposure time ratser han be concemed with continuous Neary shielding ‘Gamma-rays have tho advantage that the equipment is smaller, cheaper and more mobile than the Xray unit and that the rays have greater penetration than X-rays and can be used for thicker sections (Fat #9), 100% Detaled information on radiographic examination may be found in References 6 end 10 e gm pc 2 oes 10 WELD INSPECTION 108 Utwasonie examination Utrasonic examination (UE) is covered by Clause 64 of ASINZS 1554.1 (Ref. 7} and ic raquiced by that Causo te be carried out in aooordance with AS 2207 (Ret. 32) or by an allernatve method o test acceptable to the principal “The following descristonis taken from Re "Usrasonic examination is analogous to radar and operates on a principle called pulse: tecto. A short pulse f high-frequency sound i nroduced into the meta. The reflection of this soune wave fom the far end of the member and Irom any voids encountered along the way may then Be detected, Any reflectone are csplayed ae pips on a case display In shich the horzonial grid roprosonts the distance through the metal andthe vertical Seale represents heaven, and horetore the strangn of ha reflecting surtace. The point ‘or ongin he sound wave can be feay moved around to check many erentalone and ‘an project he wave inte the metal st angles of $0", 70" 60" and 45" LUE can detect favourably oriented flat discontiuites but certain joint configurations tnt the Use of UE andi fs dificult 19 nspect component materia joss than & mm thick. The technique Fs not exact and is highly dependent an the skll'and taming of the operator and frequent calraion ofthe equipment UE is moro versaile, expedient and economical than RE but it does not provide a permanent ‘record except via a writen repor. UE can detec ight cracks thal RE might nol detect and can provide infomation on the depth of on imperection Probes can be either nce 11, Section ‘+ compression wave (employed normal toa surlace) + shear wave (employed at an ang to the surface) Figure 27 (om Reference 19) illustrates examples of ction ofan inpecection Detaled information on ultrasonic examination may be found in References 6,8 ans 10 : | i i i 2 fos oH FIGURE 27 EXAMPLES OF IMPERFECTION DETECTION USING ULTRASONIC EXAMINATION (Ret. 19) ¢ sig scr Sine, ft ton as11 PRACTICAL CONSIDERATIONS 11.1 Clearances for welding In order to deposit a satisfactory weld complying wth ASINZS 1554.1, the woldor must have Suficent rom to manipulate the electrode and must have a Gear view of he entre wed ‘There are configurations where although a welding rod oc gun can be deected a the oi the Angle Between the parts is so small hat the ip ofthe rod or wir fs insuficenly close to the Joint bine 0 allow proper hiion ito the rct ofthe jen (Flgure 28). FIGURE 28 ANGULAR LIMITS FOR JOINT PREPARATIONS FOR VARIOUS WELDING. "TECHNIQUES. Reference 9 contains the following acvee: {a} The pretered position ofthe electrode when welding inthe horizontal poston would be ‘one ta plane forming an angle of 30° wth tha verteal sige ofthe filet being lid down. Nowever ite it any difeulty fs encountred when in oder te proven contact wih some rjecing part of the work, the angle can be increased (b) Asimple rue used by many fatricatars o ensure adequate clearance forthe passage of {he elecirode in horizontal ilt welsing f thatthe root of th weld shall be visible tothe “aeider The welds clear distance from a projecting element whicn might obstruct the ‘essage ofthe electrode, shall be al east one-half th height ofthe projection. (©) One technique used by fabricators might be to cut a component at an angle to improve accoss—as in a welded angle cleat fed toa beam web in Figure 29, are" ete aa ocrade ELEVATION Pu : FIGURE 29. CLEARANCE ON AN ANGLE CLEAT WELDED TO A BEAM WEB (afr Ret. 9) e sign ude 2 os \eldng in stucul dtu comets frat etion —_ ‘The examples of bad acco from Reference 23, iby for stetura steal connections shown in Figure 20 are = — = 7 Mt a AS RAIN | a SEE atm cide Seat pees (omtteseinn ——_ heutnn seperate — | 4 ‘0.88,min. i t =. 2a a lsutelent (e) Ange sation tot aga noes aa sy Not: ito weld stn Prete et + fy | (Colm stener des FIGURE $0 EXAMPLES OF BAD ACCESSIBILITY econ ute 2 msi 41 PRACTICAL CONSIDERATIONS 112 Site welding ‘The following matters need to be borne In mind when consisering using site welding for a Suclra steel connection: 1. labour eharge-out rates are higher; special equipment (chemy pickers, mobile acess platforms, scatfolding) may be required: weather can iohibit when welding can be card ou wold quality may be affected and higher defect rates ae o be expected sa shielded fx cored are welding and manual metal arc welding are the only processes commonty used 6, tk offre and electric shock are increased, 7. towor productivity apples e access forbes! results can be dul to achave; 9. _ site storage of consumables requires a aty warm are: 10, _urless the site has 3-phase power supply, mobile generators ae requis: 11. welding cables may get 00 long from the general tothe weld location rth cotun may have © pa De continuous when can pre trough several components ofthe structure and must * siculbes 42, welding cable can be easly damaged on ast; 44, proheat i required) canbe aii to apply 15, the welding area must be corelly scrooned; 16. ventilation might be requied For tego reasons, shop welding is preorod to ste welding e ein ns a has 11 PRACTICALCONSIDERATIONS 11.3. Economical design and detaling ‘The design and detaing of any structural stel connection shoul be such that he welding can ‘be done as economically az possible, le stl delvering @ weld that complies wih AS 4700 (Ret) and ASINZS 1584.1 (Ref. 7). References @ and 28 discuss economical design ane detailing in considerable deta. Tho baste prine)ples related to economical wolding in srvctural steel connections can be summetised as follow: 1. design and deta wath wolsing in ming, 2. do not specify oversize or unnecessary wold: keep the number of elements tobe welded to 8 minimum: ‘maxoe the extent of shop welding, minimise the extent of ate welding (Section 11.2 of this Design guide): 5. use fit wales in preference to but welds wherever possible Bul remomber th economic Tentations on fit weld siz (Section 8.2 of his Design Guide): 6, ensure adequate access and clearances are available (Section 11.1 of this Design Gude) 7. eave the selection of welding procedure and joint preparation tothe fabricator wherever posaila 8 recognise the value of consultation withthe fatriclor and be receptive to atlornatve ‘proposals cuggertod: 9, standaraise connection details as much a practical: 10. allow the use of sub-assembles whorever practical, “1. do not overspeciy ine extent of weld inspection requested 12, veld dotale which qui turing of components during fabrication, 19, sllow for welds to be deposited inthe Mat positon wherever possible as this is more oduetve than the verlal or overnead position. Bd wang src te comes, eon os EE Es2 10 " 2 3 “ 6 6 7 18 a 2 a REFERENCES [STANDARDS AUSTRALIA, AS 4100-1998 ‘Stee! structures. AUSTRALIAN INSTITUTE OF STEEL CONSTRUCTION, ‘Design of stuctural ‘comectons, 4" edition, Autors Hogan, TJ. and Thomas, LR. Eto Sjam, AA, 1988 AUSTRALIAN INSTITUTE OF STEEL CONSTRUCTION, ‘Siondariized stuctual comectons, 3 eaton, 1985, STANDARDS AUSTRALIA, AS 4100 Supplement 11999 ‘St Commentary AUSTRALIAN INSTITUTE OF STEEL CONSTRUCTION, ‘An enginsers guide to fabricating ste! sirctures, Volume t: Fabrication methods, John Tayler, 200% AUSTRALIAN STEEL INSTITUTE, ‘An onginoors guide to fabricating steal structures, Volume 2: Successful walaing of soe structures, John Tayler, 2008, STANDARDS AUSTRALIA/STANDARDS NEW ZEALAND, ASINZS 1554.1:2004 ‘Structural soo! welding, Pat 1: Woling oF stool structures WELDING TECHNOLOGY INSTITUTE OF AUSTRALIA | AUSTRALIAN STEEL INSTITUTE, WTA Technical Nate No.1, ‘Commentary on the Standars ASINZS 1554 ‘Siuctuat sie! welding, TN11-08, 2008 AUSTRALIAN INSTITUTE OF STEEL CONSTRUCTION, ‘Australian too! defaiors Ihanaboot, 1999 PRATT, J. "troduction othe welding of structural steelwork’, 3 er edn, 1980, AMERICAN INSTITUTE OF STEEL CONSTRUCTION, ‘Manual of ste! construction, lost ‘esletance factor design Valume i Compections, 1995. LINCOLN ELECTRIC COMPANY, "The procedure handbook of are wen, 1973. STANDARDS AUSTRALIA, AS 110%.3—1887 ‘Graphic symbols for general engineering, Part 8 Welding and non-destructive examination [AUSTRALIAN WELDING RESEARCH ASSOCIATION, “The weldabilty of steel’, AWRA ‘Fechneal Note 1, May 1982. STANDARDS AUSTRALIA, AS 11631091, ‘Structural ste! holow sections STANDAROS AUSTRALIAISTANDARDS NEW ZEALAND, ASINZS 36781006 ‘Structural stoel-Hot ole plates, Noor plates and slabs STANDARDS AUSTRALINSTANDARDS NEW ZEALAND, ASINZS 9679.1:1906 ‘Sirtural Stool, Pat Hot raed bars ard sections STANDARDS AUSTRALINSTANDARDS NEW ZEALAND, ASINZS 2679.2:1906 “Sinsctoral stool, Part 2: Walded I sections. ‘Owens, G.W. and Chea, 8.0. “Siructurst Steelwork Connoctons’, Chapter 2 ‘STANDARDS AUSTRALIASTANDAROS NEW ZEALAND, ASINZS 1553.1:1985 ‘Covered scttodes for weaing, Pal 1: Low carbon se! electrodes for manual metal are welding ‘of carbon stools and earbon-mangonese see! NOTE: This rteranco is oxpectas to bo supersede soon, by ASINZS 4858:207. STANDARDS AUSTRALIAISTANDARDS NEW ZEALAND, _ASINZS 2717.1:1906 Wolaing—Electrodes-Gas motal ar, Part Ferrite ste! electrodes STANDARDS AUSTRALIA, AS 2203.1—1990 ‘Cored lecvodes for Arc-wolding, Pant Fert tee lecrodes. AUSTRALIAN INSTITUTE OF STEEL CONSTRUCTION, ‘Economical structural ‘Sleelwor, 4” Eaton, 1995, 1 atvcturoo— woidngin set sal comactons, tat ion a 2 2 a Ey a 0 a STANDARDS AUSTRALIA, AS 2208-2009 ‘Method for dostuctve testing of welds in mata WELDING TECHNOLOGY INSTITUTE OF AUSTRALIA, WTIA Technical Nole 5, ‘Flame euting f stl, 1934 ‘STANDARDS AUSTRALIA, AS 2990-1999 ‘Mechanica! equloment-—Steoivor Handbook of sructural steel connections design and deta’, AR. Tambol—Edtor, Gras 1999, WELDING TECHNOLOGY INSTITUTE OF AUSTRALIA, WTIA Technical Note 10, "Fracture Mecnanies, 2002. [STANDARDS AUSTRALIA, AS 1171—1998 ‘Non-destactve testing~Magnetc particle {esting of feromagnetieprodvets, companents ana structures. [STANDARDS AUSTRALIA, AS 2062-1997 ‘Nom destructive testing—Penatrat testing of produets and components [STANDARDS AUSTRALIA, AS 2177.1—1994 ‘Non-destuctve testngRadography of wold but ints n metal. Part: Methoss of est STANDARDS AUSTRALIA, AS 22071994 "Non destructive festing—Ulrasonle testing 2 fusion-welded joints in carbon and iw alloy ses. voting srt Se comedions fs eion oe