S9074-AQ-GIB-010/248 Rev 1
4-4.8.1 Requirements. Qualification shall consist of welding and testing a mock-up in accordance with the following: a. The mock-up shall consist of six joints welded in this sequence: complete six root welds, then inspect, complete all welds, and then perform final inspection. b. Each joint shall simulate the production weld joint, except: (1) Groove depth shall be 3/16 inch, minimum. (2) Flat plate of the required alloy may be used. Plate thickness shall be at least 1 inch. c. The number of weld passes for each joint shall equal the minimum number of passes allowed for production welding. d. Position of welding shall be in accordance with 4-2.8. e. Root pass welds shall be inspected visually and with dye penetrant or magnetic particle for porosity, cracks, slag, and fusion in accordance with 4-5. Also, the reentrant angle between the weld and sidewall shall be 90 degrees minimum and surface condition shall be in accordance with NAVSEA S9221-C1-GTP-010 and NAVSEA S9221-C1-GTP-020. f. Completed welds shall be inspected visually and with dye penetrant in accordance with 4-5. Final welds shall also be inspected to the requirements of NAVSEA S9221-C1-GTP-010 and NAVSEA S9221-C1-GTP-020 for size, surface condition, and other controlled attributes. g. After completion of the required nondestructive testing, three of the six welds shall be sectioned into quadrants to provide four macro-etch specimens 90 degrees apart. At least one section of each weld shall be taken through a root weld pass start. All macro-etch specimens shall be evaluated in accordance with 4- 5.2.6.b and 4-5.2.6.c. h. The remaining three welds (and tubes) shall be machined down to 1/32 inch +1/32, -0 below the base material surface, examined, then machined to 1/32 inch +0, -1/64 above the original groove bottom and examined again. Examination and preparation of machined surfaces shall be in accordance with 4-5.2.6.b. i. Acceptance criteria for nondestructive testing and macro section examination shall be based on tube wall thickness, except that reinforcement shall be 1/8 inch maximum. j. Failure of either the root pass or final weld by nondestructive testing on more than one joint or by other testing on any joint shall constitute failure of the qualification test. For compliance with 4-2.9.d, repair of a root pass defect shall preclude further repair. k. Test failure shall require retesting of another complete (i.e., six tube joints) mock-up. 4-4.9 LOCK WELDS. Lock welds shall be qualified by one of the following methods: a. Welding a butt or fillet weld test per 4-4.1 for the process, materials, positions, and thicknesses to be qualified. (1) If the production weld involves a pressurized component less than 3/16 inch thick at the weld, qualification shall be performed by a socket or fillet seal weld test per 4-4.6 for the thickness involved, or a mock-up per 4-4.9.b below. b. Welding a mock-up test simulating the process, materials, components, and joint design to be welded in production. Components that are complex or large can be qualified by simplified mock-ups and do not actually have to be welded themselves. Multiple components (e.g., different size nuts) can be qualified by one representative test weld but the test assembly is subject to approval and any desired variances from the test assembly shall be described in the welding procedure. The following requirements shall apply: (1) Qualified positions shall be per table 7-4, footnote 7(a). (2) Table 7-3 shall apply. (3) Qualified thicknesses shall be per table 7-6; where condition 4-4.9.a(1) above applies and a mock-up test is used, the base material thickness representing the pressurized component shall conform to table 7-6, footnote 6 for socket welds.
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