Welding and Brazing Standards Overview

Focus of S9074-AR-GIB-010/278

Welding requirements for fabrication of pressure vessels and piping.

/278 standard governance

Materials, fabrication, inspection, testing, and documentation of welds.

Welding procedure approval

NAVSEA or an authorized representative.

Welding documentation requirements

WPS, PQR, welder qualifications, and inspection reports.

Level I systems

Systems critical to ship safety or nuclear components.

Controlled Material (CM)

Material with documented traceability and certification.

Material Identification and Control (MIC) program

A program to ensure correct materials are used with full traceability.

Joining Level I systems requirements

Strict adherence to qualified procedures and materials.

Pre-welding requirements for controlled systems

Obtain QA approval and verify procedure, material, and personnel.

Welder's responsibility

Follow approved procedures and ensure proper joint preparation.

Repair welding requirements

Written approval and documented repair procedure.

Monitoring welding conditions

Heat input, interpass temperature, and preheat temperature controls.

Recorded information during weld fabrication

Welding parameters, material lot numbers, welder IDs, and inspection results.

Purpose of visual weld inspection

To identify surface defects and verify weld quality.

NDT methods referenced in /278

VT, PT, MT, UT, and RT.

'Hold point' in QA

A required stop in the process until inspection or approval is obtained.

Weld repair tracking

Using a nonconformance report and repair log.

Welder training requirements

Formal training and certification under controlled procedures.

Action if a welder fails visual inspection

Stop work and requalification may be required.

Heat input

The amount of energy introduced into the material during welding.

Post-weld cleaning

Removing slag, spatter, and contaminants from the weld area.

Key factors of joint preparation

Alignment, fit-up, root gap, bevel angle.

Weld map

A diagram identifying weld locations and details.

Importance of filler metal control

To ensure proper chemistry and performance of the weld.

Documentation for Level I welds

Material certs, weld maps, NDT reports, and QA records.

Causes of undercut in a weld

Excessive current, incorrect technique, or poor travel speed.

Role of the QA Inspector

Ensure compliance with standards and verify required documentation.

Importance of traceability in /278

To ensure materials and processes meet safety and quality requirements.

NAVSEA 248

Requirements for welding and brazing procedure and performance qualification.

Welding Procedure Specification (WPS)

A written document detailing how welding is to be performed.

Procedure Qualification Record (PQR)

A document showing results of tests conducted to qualify a WPS.

PQR necessity

To verify that the WPS produces acceptable welds.

Performance qualification

A welder's ability to make sound welds under specified conditions.

Welder requalification

If they haven't welded for 6 months or fail an inspection.

Brazer qualification

That the individual can produce acceptable brazed joints.

Visual weld inspection code

NAVSEA-approved standards and acceptance criteria.

Requirements before welding production joints

Approved WPS and welder/brazer qualification.

Essential variables

Changes that require requalification if altered (e.g., process, base metal).

Nonessential variable

Changes allowed without requalification (e.g., joint design).

Filler metal

Material added to facilitate the weld or braze.

Backing

To support and protect molten weld metal during welding.

Acceptable discontinuity

A flaw that does not affect the structural integrity.

Defect

A flaw that makes a weld unacceptable under the standard.

Weld qualification testing types

Visual, radiographic, bend, and macroetch tests.

Weld coupons usage

For testing weld procedures and welder qualifications.

Interpass temperature

The temperature between welding passes.

Welding consumables control

To ensure quality and traceability.

Continuity log

A record of welding activity to maintain qualification.

Base metal grouping

Classification of materials for ease of qualification.

Group I base metals

Common steels used in naval fabrication.

Overmatching filler metal

Filler stronger than base metal to ensure joint strength.

Minimum bend radius for testing

Usually dictated by procedure; often 2x thickness.

Macroetch test

A test where a cross-section of a weld is etched to reveal structure.

Test specimens marking

With traceable identifiers and orientation marks.

Weld bead profile

The shape of the weld on the surface.

Lack of fusion causes

Insufficient heat or incorrect technique.

Porosity

Gas pockets trapped in the solidifying weld.

RT in testing

Radiographic Testing.

PT in testing

Penetrant Testing, used for detecting surface cracks.

Welder ID

A unique number assigned to track qualification and work.

Documenting welding tests

For traceability and to meet QA and safety standards.

Welder position or process change

They must requalify.

Test failure handling

Root cause is determined and retesting is done after corrective action.