I need some info on an aluminum pipe cert. using tig process in 2" sch 40. Is there a prequalified procedure? If not, what is prequalified in aluminum pipe? Also, I need the details of what I should look for in running the test for welder qualification. Is it the same as 2" sch 40 steel? I've done steel and stainless steel qualification tests but never aluminum. Is it done in 6G? Need help!
Bennet,
Even if there IS a "pre-qualified" procedure to give you, it wouldn't be any good to you or your company unless you had someone qualify it.
If you have experience with other procedures than you can make up your own, by using the wps as a guide line which you'd have to fill in the blanks, but you don't make it clear as to what this prodedure is for.
If you have experience welding aluminum then you can determine the parameters(on your own) but knowing the application is critical (is this for structural or otherwise) because there is a specific code you need to go by.
You need to tell us what material is being used and for what purpose. You might get away with a plate test as opposed to a pipe test.....who can tell??? Find out the details of what the certification is for(application), develop a procedure(WPS) and then qualify it and then you can use it to test(certify) anyone you want to.
Be well.
Hawk
Maybe AWS D1.2 "Structural Welding Code - Aluminum" might help you out.
Use ASME IX. You will probably use a chill ring instead of open root. It is a very hot process. Make sure all of the oxides are off before welding. It can cause porosity and you will fail your xray, it would probably be much easier to take it on a larger diameter pipe. Use 5356 wire from alcotec. Generally a better wire to weld with. Do not weld it like carbon make sure you dip the wire and not feed the wire. Do not use a grinder to clean welds, can cause particles to become inbedded in the aluminum as well. Make sure everthing is clean before welding. Use a SS wire brush to clean the smutt off. That is about all I can tell you, also use an argon-helium mixture. At one time I certified welders on 6" sch. 80 aluminum pipe 6061T-6 with 5356 wire and the pipes were x-rayed when done. It was done in the 6g position. It is definitely not as easy as it looks.
Review your purchase order and project specifications. Make sure you know what welding standard or code you are working to. ASME piping code requirements are different from AWS structural aluminum requirements and they are different from aerospace welding requirements.
For the most part, aluminum is not considered prequalified by any welding standard, thus you need to qualify the procedure. Each welding standard has their own specific requirements for the types of tests required and the variables that need to be addressed by the PQR and WPS, as well as the welder's performance tests.
Techniques may also be addressed by the particular welding standard referenced by the purchase order or other contract documents. Approved base metal and filler metal combinations may be specified by the welding standard as well as applicable joint details and/or limitations.
Know what you are getting into before spending money unwisely. Make sure your laboratory is familar with the testing requirements. Remember, one size fits all is a mistake when performing guided bend tests. The bend radius is a function of the base metal, filler metal, and thickness of the test sample. Some welding standards require all samples to be machined to 1/8 inch thick before bend testing.
Contact me if you have a specific question and let me know what standards you are welding to.
Best regards - Al Moore