Lawrence, if the work is to D1.1 then table 3.7 should be helpful, if the WPS is pre-qualified. if the welds are produced per a PQR that has everything in order....than there might not be anything that can be done. as far as optimum, i think that would depend on a few variables like material grade, thickness,etc. i searched through Ed Craig's book GMAW & FCAW welding parameters, with no luck on electrode dia. to optimum fillet weld size sort of info. i'm sure you have already looked in the places i mentioned. tryin to help.
JJ
Yep,
These folks have no code to constrain them at this point (though I expect D1.1 will be comming one day, may that day be soon)
I found one small mention in the "Certified Welding Supervisor Manual for Quality and productivity Improvement"
It suggests 5/8" maximum for a single pass when making groove welds and has an Illustration of both fillets and grooves.(Fig. 4.57) but it's not compelling for fillets.
L,
Have you tried to prove the weld is sound mechanically?(even though you don't like the wide weave) Break test? Macro etch?
Mountainman!
Somehow I overlooked table 3.7 in D1.1..
That is a good perspective to start with... If you consider that a 3/8" horizontal fillet is maximim for even FCAW with a 3/32 electrode than horizontal fillets in excess of 1/2" with 045 and spray transfer appears a bit excessive.
Also look at paragraph 3.7.3.2 in D1.1 for single pass fillets(5/16" for GMAW)
So basically right off the bat they are out of the prequalified ranges of D1.1 and must qualify there single pass weld sizes by testing if and when they abide to D1.1. Bring some plate down there and have them run a few fillets for ya. Put them in a break press and smash them till they break and inspect. Macros are always a crowd pleaser to when it comes to showing someone they're doing something wrong. ;-) 2F fillets are a killer with metal core or spray and trying to run a big single pass fillet. The bottom leg roles on ya almost every time and gives you some nice lack of fusion about an 1/8" in from the toe. I had this prob with my welders and had to show them. They could not run consistent 2F 3/8" fillets so they now have to do 3 passes. .062 metal core wire helped out a bunch, but we're on 1/2" and thicker material. You also have to use some manipulation to keep the multen puddle pushed up where you want it to be. Gravity is a killer on big 2F singlepass welds.
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