WPS QW-404 Filler Metals
ASME Section IX WPS : QW-404 Filler Metals Example
ASME Section IX Welding Variables for a WPS : QW-404 Filler Metals
QW-404.3 - Change in Filler Metal Size
Only applies to GTAW
A change in the size of the filler metal
Non-Essential variable, so a change must be documented on WPS, but it can be changed without the need for requalification
QW-404.4 - Change in Filler Metal F-Number
A change from one F-Number to any other F-Number as detailed in Table QW-432
Based on the PQR F-Number the WPS can only use F-Numbers listed as permitted in Table QW-432
QW-404.5 - Change in Filler Metal A-Number
The A-Number represents the weld deposit chemistry
A change in the chemical composition of the weld deposit from one A-Number to any other A-Number as detailed in Table QW-442
A-No. 1 shall qualify for A-No. 2 and vice versa
This section lists acceptable methods for determining the A-Number
It should be noted that ER70S-6 does not automatically comply with the A-No. 1 limits unless specified to do so at the time of purchase. SFA 5.18 has also included an optional supplementary designator of “A” which can be used to signify that the ER70S-6 complies with the A-No. 1 deposit chemistry, it is listed as ER70S-6A. See more detail in the following article: ER70S-6A Optional Supplementary Designator.
QW-404.6 - Change in Filler Metal Diameter
A change in the nominal size of the electrode specified on the WPS
Does not apply to GTAW. GTAW uses QW-404.3 to address “size” of the filler metal
QW-404.9 - Change in Filler Metal Flux Wire Classification (SAW)
Only applies to Submerged Arc Welding
Provides details on the un-permissible variations of the SAW flux wire classification
QW-404.10 - Change in Filler Metal Alloy Flux (SAW)
Only applies to Submerged Arc Welding
Provides details for applications where the weld metal is largely dependent upon the composition of the flux used.
QW-404.12 - Change in Filler Metal Classification (Toughness)
Details the permissible and un-permissible variations allowed in the filler metal classification when toughness testing or supplementary essential variables apply.
QW-404.14 - Addition or Deletion of Filler Metal (Autogenous)
Only applies to GTAW
The addition or deletion of filler metal
When no filler metal is used the term “autogenous” is used
QW-404.22 - Addition or Deletion of Consumable Insert
Only applies to GTAW
The addition or omission of consumable inserts
QW-404.23 - Change in Filler Metal Product Form
A change from one of the following filler metal product forms to another
Bare (solid or metal cored)
Flux Cored
Flux Coated (solid or metal cored)
Powder
QW-404.24 - Addition, Deletion, or Change of Supplemental Filler Metal
The addition, deletion, or change of more than 10% in the volume of supplemental filler metal
QW-404.27 - Change in Filler Metal Alloy Elements
Any change where the alloy content of the weld metal is largely dependent upon the composition of the supplemental filler metal
QW-404.29 - Change in Flux Designation (SAW)
Only applies to submerged arc welding
A change in the flux trade name and designation
QW-404.30 - Change in Filler Metal Thickness (t)
Lower case “t” represents Filler Metal thickness (Base Metal is capitol “T”)
A change in the filler metal deposited thickness beyond that qualified or permitted in accordance with Table QW-451
QW-404.33 - Change in Filler Metal Classification
Permits changes between filler metal classifications as long as they are still within the SFA specification
Includes other details in relation to manufacturer’s trade name when that is applicable
QW-404.34 - Change in Filler Metal Flux Type (SAW)
Only applies to submerged arc welding
A change in flux type for multilayer deposits in P-No. 1 materials
Neutral to Active and vice versa
QW-404.35 - Change in Filler Metal Flux Wire Classification (SAW)
Only applies to submerged arc welding
A change in the flux wire classification or a change in either the electrode or flux trade name when the flux wire combination is not classified to an SFA specification.
Other details in this section should be referenced for a full understanding of the requirement
QW-404.36 - Re-crushed Slag (SAW)
Only applies to submerged arc welding
If re-crushed slag is used it is an essential variable, and it must follow the requirements of this reference
QW-404.50 - Addition or Deletion of Filler Metal Flux (GTAW)
Only applies to GTAW
The addition or deletion of flux to the face of a weld joint for the purpose of affecting weld penetration
This is also commonly referred to as “Activated” or “Activating” flux
This activated flux constricts the arc which focuses the current density and amplifies weld puddle penetration. The penetration profile becomes much narrower, and deeper
Essential Variable: Variables for which a change is considered to affect the mechanical properties (other than notch toughness) of the joint. Essential variable changes that fall outside their qualified range requires re-qualification.
Supplementary Essential Variable: Variables for which a change is considered to affect the toughness properties of the joint, heat-affected zone (HAZ), or base material.
Supplementary essential variables become additional essential variables in situations where toughness testing is required. When toughness testing is not required supplementary essential variables are not applicable.
Non-Essential Variable: Variables for which a change is considered to not affect the mechanical properties of the joint. This allows for editorial revisions to procedures within that permitted by Section IX without the need to requalify the procedure. Nonessential variables shall be documented on the procedure.