S9074-AQ-GIB-010/248 Rev 1
(3) First article testing shall be re-performed when a procedure is re-qualified per 4-7 for any of the following changes, if applicable to welding of the part involved: (a) Welding process (b) Base material alloy/S-group (c) Filler material A-group (d) Welding position. 4-4.1.10.4 Special Automatic, Mechanized, and Robotic Welds. Qualification requirements shall be as specified in 4-4.7. 4-4.1.11 Fillet Welds – Welding on Bare Surfaces. When this document is specified in the applicable fabrication document, procedures for depositing fillet welds on bare surfaces (except for piping system applications; see 4-4.6) may be qualified in accordance with figure 7-8. The test assembly shall be welded with the type and largest diameter electrode to be used and shall be visually inspected and either dye penetrant or magnetic particle inspected, as appropriate, per 4-5. The fractured weld surface shall be visually examined and free of incomplete root fusion or any other indication exceeding 3/32 inch in length; the sum of the greatest dimensions of all indications over 1/32 inch shall not exceed 3/8 inch in any 4-inch length of weld. Fillet weld qualifications in accordance with figure 7-8 are limited to those base metal/filler metal combinations acknowledged in Appendix B. Butt weld qualification may also qualify for fillet weld joints. For S-10H materials, testing shall also be performed per 4-7.5.f, 4-7.10, and table 7-7, footnote 22. 4-4.1.12 Fillet Welds – Welding Over Primer-Coated Surfaces. When this document is specified in the applicable fabrication document, procedures for welding over primer-coated surfaces of S-1 materials with any process using a previously qualified procedure shall require additional qualification in accordance with figure 7-9. The test assembly shall be welded with the type and the largest diameter electrode to be used and shall be visually inspected and magnetic particle inspected per 4-5. Both pieces of each test assembly shall be coated with the maximum allowable thickness of the paint system to be used in production prior to test welding. Separate test assemblies are required for each manufacturer and for each manufacturer’s specific paint system. Separate test assemblies are also required for each manufacturer and manufacturer’s designation of the electrode used. These details are essential elements and must be added to the weld procedures. Weld quality shall be considered acceptable provided visual examination of the fractured weld surface conforms to the criteria of 4-4.1.11. 4-4.1.13 Heat Input. For materials where toughness testing is required by table 7-7, footnote 2 (including thicknesses less than 1/2 inch), S-10H per 4-7.5.f, and for cladding and hardfacing, the requirements of this section shall apply. 4-4.1.13.1 Test Assembly Welding. Test assemblies shall be welded such that: a. At least 80 percent of all weld beads are 90 percent of the maximum heat input to be qualified or greater (applies only to the first two layers for cladding and hardfacing), and b. The heat input, when averaged for all beads in the completed test assembly, shall not be less than the maximum heat input to be qualified; beads removed by back-gouging, etc., shall be excluded, and c. The same welding process shall be used for repair welding per the conditions in 4-4.1.13.1.a and 4-4.1.13.1.b above, unless the repair area is marked and toughness test specimens are removed away from the repair weld. See 4-2.9.f for repair welding with alternate qualified processes. The requirements of 4-4.1.13.1.a and 4-4.1.13.1.b above are optional for qualification of HY/HSLA-80/100 when the welding procedure restricts maximum heat input to that specified by the fabrication document or 55 kilojoules/inch, whichever is less; instead, the test assembly should be welded such that most weld passes are close to the maximum heat input to be qualified.
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