1. D10 COMMITTEE ON PIPE AND TUBE WELDING INFORMATION ON-HAND, PROBLEMS SOLVED, QUESTIONS ANSWERED

2. NO MATTER WHAT LEVEL OF THE INDUSTRY YOU WORK …
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

3. MATERIALS & METHODS COVERED
AUSTENITIC STAINLESS STEEL
TITANIUM
ALUMINUM
CHROME-MOLY
LOCAL HEAT TREATING
ROOT PASS WELDING
MILD STEEL
COPPER TUBE

4. GTAW SMAW FCAW GMAW BRAZING
WELDING PROCESS
GTAW
SMAW
FCAW
GMAW
BRAZING

5. William F. Newell, Jr. PE, IWE, Chair D10C
RECOMMENDED PRACTICES FOR WELDING AUSTENITIC CHROMIUM-NICKEL STAINLESS STEEL PIPE AND TUBING

6. 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. …”

7. AWS D10.4 - Uses Often overlooked…… Excellent resource for:
Developing Corporate Procedures & Specifications
Training Engineers, Supervision and Welders
General Reference Guide

8. AWS D 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 D T
AWS D T was revised in 1966

9. AWS D History
In 1979, a major updating of the document was completed and published as AWS D , 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.

10. AWS D History
In 1986, the document was expanded and given an Annex which gives recommendations for welding high-carbon stainless steel castings.
In 1992 and 1999, the document was reaffirmed.

11. AWS D 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.

12. AWS D10.4 - Content Base Metals & Weld Filler Metals Ferrite
Welding Processes, Technique & Problems
Dissimilar Joining
Inspection
Safety

13. AWS D10.4 – Base Metals Austenitic Super Austenitic High Carbon
300-series
Super Austenitic
4% & 6% Mo
High Carbon
“HX” Grades

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

15. Don Connell Welding Engineer Detroit Edison Company
RECOMMENDED PRACTICES FOR GAS TUNGSTEN ARC WELDING OF TITANIUM PIPING AND TUBING

16. 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

17. Process-GTAW
Other processes may be used to weld Ti but are not covered in this recommended practice

18. 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

19. 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

20. Quality Control
Simple tests to check the process before welding & the finished weldment
Describes how weld color is an indication of weld quality

23. 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

24. Tony Anderson ESAB Welding & Cutting
RECOMMENDED PRACTICES FOR GAS SHIELDED ARC WELDING OF ALUMINUN AND ALUMINUM ALLOY PIPE

25. Presented By: Tony Anderson, ESAB North America
© 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
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26. 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.
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27. Filler Alloy Selection Primary Characteristics*
Filler Alloy Selection Primary Characteristics W
Weldability Or Freedom From Cracking
Strength Of Weld - Tensile Or Shear
Ductility Of Weld
Corrosion Resistance
Temperature Service
Match in color after anodizing S D C T M *
Post Weld Heat Treatment
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28. Hot Weld Cracking
Hot Cracking On Base Alloy Plate Adjacent To A Gas Tungsten Arc (GTA) Welded Alloy Fillet
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29. Avoid Critical Chemistry Ranges
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: % ( Electrode )
% ( Base )
Avoid Welding 5xxx Esp.. ( 5086, 5083, )
With Or 4xxx. Mgsi Eutectic Problems
Avoid Mg Range Up To 3.0% In Weld
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30. Alloy Content vs. Crack Sensitivity
RELATIVE CRACK SENSITIVITY
COMPOSITION OF WELD - PERCENT ALLOYING ELEMENT
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31. Dilution Effect On Weld Composition
Base Plate 6061
Filler Metal 5356
20% Filler Metal
80% Base Metal
1.7% Mg
60% Filler Metal
40% Base Metal
3.2% Mg
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32. 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
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33. Heat Affected Zone Non Heat Treatable 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
E - Unaffected
A - Weld Zone
B - Fusion Zone
C - Solid Solution Zone
Where Alloy Elements
Are Solutioned & Cooled
To Retain Solid Solution
D - Partially Annealed
Overaged Zone
Where Heat Has Caused
Precipitation And/or
Coalescence Of Particles
Of Soluable Constituents
E - Unaffected
WHAT WOULD YOU EXPECT THE STRUCTURE TO LOOK LIKE. IN EACH OF THE AREAS?
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34. Distance From Weld Interface
Hardness Profiles of 6061-T6
Made At Three Heat Inputs
Hardness RE
WHICH WOULD BE BETTER. ONE PASS WITH LARGER DIAMETER WIRE OR MULTI PASS WITH SMALL DIAMETER WIRE
-DEPENDS UPON WHAT IS EXPECTEC OF WELD
Distance From Weld Interface
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35. 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
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36. TRANSVERSE Fillet Size (Inch)
Shear Strength
LBS. Per Linear Inch
Shear Strength
TRANSVERSE Fillet Size (Inch)
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37. Typical Shear Strengths Of Fillet Welds
Longitudinal
Shear
Strength
( Ksi )
7.5
16.0
11.5
13.5
18.5
17.0
15.0
20.0
12.0
Transverse
Shear
Strength
( Ksi )
7.5
16.0
15.0
20.0
28.0
26.0
23.0
30.0
18.0
Filler
Alloy
1100
2319
4043
4643
5183
5356
5554
5556
5654
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38. Fracture Characteristics
Heat - Treatable Alloys
Notch Tensile Strength
Tensile Yield Strength
Tear Resistance
Unit Propagation
Energy In.-lb. / In3
Ratio =
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39. Alloy 7075-T6 Welded With 5356 Filler Post Weld Heat Treated and Aged
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
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40. 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.
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41. Color Match After Clear Anodize
Base Metal: 6061
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42. 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.
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43. Filler Alloy Selection For Aluminum
© 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
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44. William F. Newell, Jr. PE, IWE, Chair D10I
RECOMMENDED PRACTICES FOR WELDING OF CHROMIUM-MOLYBDENUM STEEL PIPING AND TUBING

45. 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. …”

46. AWS D10.8 - Uses Often overlooked…… Excellent resource for:
Developing Corporate Procedures & Specifications
Training Engineers, Supervision and Welders
General Reference Guide

47. AWS D 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

48. 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

49. AWS D10.8 – Base Metals C-Steel C-Mo 1-1/4Cr-Mo 2-1/4Cr-Mo 5Cr-Mo
9Cr-Mo (Standard Grade Only)

50. AWS D10.8 – Filler Metal Recommendations Process
AWS Classification Options [C, CrMo & Ni-base]
Similar v. Dissimilar

51. AWS D10.8 – Priorities ! Preaheat w/recommendations Interpass
Post Weld Heat Treat w/recommendations

52. Pending ! D10.08 (DRAFT) Removing information on 9CrMoV (P91)
Removing References to Standard Welding Procedures

53. Coming !
D10.21 (DRAFT)
“Guideline for Welding Advanced Chromium-Molybdenum Steel Piping and Tubing”
P91, P911, P92, P122, T23…

54. Dan Ciarlariello Mannings USA
RECOMMENDED PRACTICES FOR LOCAL HEATING OF WELDS IN PIPING AND TUBING

55. 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

56. Methods Of Localized Heat Treating
Electrical Resistance
Induction
Combustion / Flame
Quartz Lamps
Exothermic Kits.

57. Electrical Resistance

58. Inductive Heating

59. Combustion / Flame

60. Quartz Lamps

61. Reasons for Localized Heat Treating
Bake Out
Preheating and Inter-pass Temperatures
Post Heating
Post-weld Heat Treatment

62. Comparison of Heating Processes
Induction - Resistance
Yes Yes
Attribute
Applicability to bake-out
Applicability to preheat/inter-pass
Applicability to postheating
Applicability to PWHT

63. 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.

64. 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

65. 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

66. 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.

67. Typical Preheat Set-up

68. Boiler Tube Welds

69. Wireless Thermocouple Transmission

73. AWS D10.11 Walter J. Sperko, P.E. Sperko Engineering Services, Inc.
Guide for
Root Pass Welding
of Pipe Without Backing

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

75. 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.

76. 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

77. 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

78. AWS D10.11 What is “Root Pass Welding?”
Let’s look at some “root passes”

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

80. AWS D10.11
Root pass on a Socket Weld

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

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

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

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

85. 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

86. 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

87. 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.

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

89. Full Root Penetration
Continuous metal surface from one member across the weld to the other member

90. Longitudinal Section of a pipe joint
Forces on the weld pool?
Longitudinal Section of a pipe joint

91. Longitudinal Section of a pipe joint
Forces on the weld pool
Gravity
Longitudinal Section of a pipe joint

92. Surface Cohesion (wetting) between the weld pool and the solid metal
Forces on the weld pool
Surface Cohesion (wetting) between the
weld pool and the solid metal
Longitudinal Section of a pipe joint

93. Longitudinal Section of a pipe joint
Forces on the weld pool
The arc must melt both edges of the root face and the weld pool must fill the gap without becoming too large
Longitudinal Section of a pipe joint

94. 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 drop-through.
Longitudinal Section of a pipe joint

95. Parts of a Groove Weld Joint Design
Root Face (“Land”)

96. Parts of a Groove Weld Joint Design
Root Opening (“Root Gap”)

97. 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

98. Root opening - Root face thickness relationship
1/8”
3/32”
Root Face Thickness
1/16”
1/16”
3/32”
1/8”
Root Opening

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

104. Purging

106. 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

110. 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)

111. Purging Welding technique for Open Root
Welding Technique for Consumable Insert
Maintaining purge during welding

112. 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

113. GTAW
Tungsten size, shape of end
Grinding methods

114. GTAW Joint design and fit up

115. GTAW Purge containment Arc initiation Keyhole technique
Wire feed techniques
Orientation of torch and filler

116. GTAW

117. GTAW

118. GTAW
Walking the Cup
Welding with zero root opening (autogenous welding)
Welding in different positions
Using consumable inserts

119. Consumable Inserts 1/32” maximum mismatch
Class 1 Insert, formerly the EB (Electric Boat) or “A” type insert.

121. Class 2 Insert, formerly the “J” type insert.
Consumable Inserts
1/16” maximum mismatch
Class 2 Insert, formerly the “J” type insert.

122. Class 3 Insert, formerly the “Grinnell” or flat insert.
Consumable Inserts
1/16” maximum mismatch
Class 3 Insert, formerly the “Grinnell” or flat insert.

127. Consumable Inserts

128. SMAW Cellulosic Electrodes (EXX10, EXX11)
Low Hydrogen Electrodes (EXX15, EXX16, EXX18)
Rutile electrodes (E6013)

129. GMAW
Joint design
Fit-up
Welding parameters

130. Fill Passes
Use any suitable process
Don’t melt through the root

131. Aluminum Tungsten type, shape of tip Shielding gas cups, lenses
Power supplies
Techniques
Recommended joint design

132. Aluminum

133. Machine and Automatic
Not much said

134. 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

135. D10.12 RECOMMENDED PRACTICES FOR WELDING MILD STEEL PIPE
Alan Beckett
D10.12 RECOMMENDED PRACTICES FOR WELDING
MILD STEEL PIPE

136. 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.

137. Covered Processes
SMAW
GTAW
GMAW
FCAW

138. 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.

139. MICHAEL LANG AWS/CWI/CWE United Association of Plumbers & Pipefitters
RECOMMENDED PRACTICES FOR BRAZING OF COPPER PIPE AND TUBING FOR MEDICAL GAS SYSTEMS

140. 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

141. 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

142. 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

143. Needed Equipment Use and Care Torch Selection Tube Cutting
Purge Monitoring

144. Consumables Pre Braze Joint Cleaning Pre Braze Chemical Cleaning
Post Braze Cleaning
BCuP Brazing Alloys
Bag Brazing Alloys

145. 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.

146. 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.

147. Proven Success You Can Trust
D10.13
RECOMMENDED PRACTICES FOR BRAZING OF COPPER PIPE AND TUBING FOR MEDICAL GAS SYSTEMS

148. THANK YOU FOR ATTENDING
BECOME A COMMITTEE MEMBER FOR DETAILS CONTACT Brian McGrath at
THANK YOU FOR ATTENDING
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