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Skill for welding procedure development and qualification per AWS and ASME codes
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SOC 職業分類に基づく
SKILL.md を表示中
| name | welding-qualification |
| description | Skill for welding procedure development and qualification per AWS and ASME codes |
| allowed-tools | ["Read","Write","Glob","Grep","Bash"] |
| metadata | {"specialization":"mechanical-engineering","domain":"science","category":"manufacturing","priority":"high","phase":3,"tools-libraries":["AWS D1.1","ASME Section IX","Welding calculators"]} |
| graph | {"domains":["domain:mechanical-engineering"],"skillAreas":["skill-area:physics-simulation","skill-area:mathematical-reasoning","skill-area:motion-planning"],"roles":["role:systems-integration-engineer","role:research-engineer"]} |
The Welding Procedure Qualification skill provides capabilities for developing and qualifying welding procedures per AWS and ASME codes, enabling compliant welding documentation and welder certification.
| Process | Designation | Applications | Advantages |
|---|---|---|---|
| SMAW | Shielded Metal Arc | Structural, maintenance | Portable, versatile |
| GMAW | Gas Metal Arc (MIG) | Production, sheet metal | High deposition |
| GTAW | Gas Tungsten Arc (TIG) | Precision, root passes | High quality |
| FCAW | Flux Cored Arc | Structural, shipbuilding | High deposition |
| SAW | Submerged Arc | Heavy plate, pipe | Very high deposition |
Consider:
- Base metal type and thickness
- Joint configuration
- Position requirements
- Production volume
- Quality requirements
- Welder skill availability
- Equipment availability
| Variable | Effect | Requalification |
|---|---|---|
| Base metal P-number | Change requires new PQR | Yes |
| Filler metal F-number | Change requires new PQR | Yes |
| Thickness range | Outside qualified range | Yes |
| Position | Change from qualified | Yes |
| Preheat | Decrease below minimum | Yes |
| PWHT | Change in requirements | Yes |
| Electrical characteristics | Change in polarity | Yes |
1. Identification
- WPS number
- Revision
- Supporting PQR(s)
2. Joint Design
- Type (butt, fillet, etc.)
- Groove angle
- Root opening
- Root face
- Backing (if used)
3. Base Metal
- Specification
- P-number/Group
- Thickness range
4. Filler Metal
- Specification
- F-number
- A-number
- Size range
5. Position
- Qualified positions
- Progression (vertical)
6. Preheat/Interpass
- Minimum preheat
- Maximum interpass
7. Welding Parameters
- Current type/polarity
- Amperage range
- Voltage range
- Travel speed range
8. Technique
- String vs weave
- Single vs multi-pass
- Cleaning method
9. PWHT
- Temperature range
- Time at temperature
- Heating/cooling rates
| Test | Code Reference | Acceptance Criteria |
|---|---|---|
| Tensile | ASME IX QW-150 | >= Base metal minimum |
| Bend | ASME IX QW-160 | No cracks > 3mm |
| Impact | ASME IX QW-170 | Per design code |
| Macro | ASME IX QW-183 | Fusion, no defects |
Groove Welds:
- 2 tensile specimens
- 4 bend specimens (2 face, 2 root or 4 side)
- Impact specimens (if required)
Fillet Welds:
- Macro examination
- Fillet weld break test
Welder Performance Qualification:
- Based on qualified WPS
- Position-specific
- Thickness range qualified
- Process-specific
- Maintenance requirements (typically 6 months)
| Test Position | Qualifies Positions |
|---|---|
| 1G (flat) | 1G only |
| 2G (horizontal) | 1G, 2G |
| 3G (vertical) | 1G, 2G, 3G |
| 4G (overhead) | 1G, 4G |
| 3G + 4G | All groove positions |
| 6G (pipe, 45 degree) | All positions |
E70XX (SMAW):
E = Electrode
70 = Tensile strength (70 ksi)
XX = Position and coating type
ER70S-X (GMAW/GTAW):
E = Electrode
R = Rod
70 = Tensile strength
S = Solid wire
X = Specific chemistry
| Base Metal | SMAW | GMAW | GTAW |
|---|---|---|---|
| Carbon steel | E7018 | ER70S-6 | ER70S-2 |
| Low alloy | E8018-B2 | ER80S-B2 | ER80S-B2 |
| Stainless 304 | E308L-16 | ER308L | ER308L |
| Stainless 316 | E316L-16 | ER316L | ER316L |
| Aluminum | - | ER4043 | ER4043 |
Factors affecting preheat:
- Carbon equivalent
- Base metal thickness
- Hydrogen content
- Restraint level
- Ambient temperature
Carbon Equivalent (IIW):
CE = C + Mn/6 + (Cr+Mo+V)/5 + (Ni+Cu)/15
CE > 0.45: Preheat required
| Code | When Required | Typical Range |
|---|---|---|
| AWS D1.1 | Thick sections, certain alloys | 1100-1200 F |
| ASME VIII | Per UCS-56 | Material dependent |
| ASME B31.3 | Per Table 331.1.1 | Material dependent |
{
"base_metal": {
"specification": "string",
"p_number": "number",
"thickness": "number (mm)"
},
"joint_design": {
"type": "butt|fillet|corner|tee",
"groove_type": "V|U|J|bevel",
"position": "1G|2G|3G|4G|5G|6G"
},
"applicable_code": "AWS_D1.1|ASME_IX|ASME_B31.3",
"quality_requirements": {
"ndt_required": "array",
"impact_required": "boolean",
"design_temperature": "number (C)"
}
}
{
"wps_draft": {
"wps_number": "string",
"process": "string",
"joint_design": "object",
"filler_metal": "object",
"parameters": "object",
"preheat": "object",
"pwht": "object"
},
"pqr_requirements": {
"test_specimens": "array",
"acceptance_criteria": "object",
"test_laboratory": "string"
},
"welder_qualification": {
"wpq_required": "boolean",
"positions": "array",
"essential_skills": "array"
},
"code_references": "array"
}