411024 structual welding

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ENCLOSURE C.5 Special Workmanship Categories Incorrect Filler Material ................ 41

ENCLOSURE D Workmanship Inspection Methods & Inspection Tools ................................ 42

ENCLOSURE E Welding Attribute Terms & Definitions ........................................................ 54

ENCLOSURE F Weld Joint Designs for Structural Applications............................................. 62

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ENCLOSURE F Figure 1 Permanent Backing Strap ......................................................... 63 ENCLOSURE F Figure 2 B2S.1, B1S.2 BUTT JOINTS, SQUARE ................................. 64

ENCLOSURE F Figure 3 B1V.1, B1V.2, B1V.3, B1V.5, B1V.6, B1V.7 BUTT JOINTS, WELDED ON PERMANENT METAL BACKING ............................................................... 65

ENCLOSURE F Figure 4 B2V.1, B2(S)V.2 BUTT JOINTS, SINGLE-V AND SINGLEBEVEL ...................................................................................................................................... 66

ENCLOSURE F Figure 5 B2V.3, B2(S)V.4 BUTT JOINTS, DOUBLE-V AND DOUBLE- BEVEL ................................................................................................................... 67

ENCLOSURE F Figure 6 B2U.1, B2U.2, B2U.3, B2J.1, B2J.2 BUTT JOINTS, SINGLEU AND SINGLE-J .................................................................................................................... 68

ENCLOSURE F Figure 7 B2U.4, B2U.5, B2J.3, B2J.4 BUTT JOINTS, DOUBLE-U AND DOUBLE-J ............................................................................................................................... 69 ENCLOSURE F Figure 8 C2S.1 CORNER JOINT, OPEN SQUARE .............................. 70 ENCLOSURE F Figure 9 C2V.1 CORNER JOINT, OUTSIDE SINGLE-V .................... 70 ENCLOSURE F Figure 10 C2V.2, C2V.3 CORNER JOINTS, FILLET-REINFORCED, OUTSIDE SINGLE-BEVEL .................................................................................................... 71

ENCLOSURE F Figure 11 C2V.4 CORNER JOINT, FILLET-REINFORCED, INSIDE SINGLE-BEVEL ...................................................................................................................... 72 ENCLOSURE F Figure 12 C2S.2 CORNER JOINT, FILLET-REINFORCED, OUTSIDE SQUARE................................................................................................................................... 72

ENCLOSURE F Figure13 C2V.5, C2V.6 CORNER JOINTS, FILLET-REINFORCED, DOUBLE-BEVEL .................................................................................................................... 73

ENCLOSURE F Figure 14 C2U.1 CORNER JOINT, SINGLE-U .................................... 74 ENCLOSURE F Figure 15 C2J.1, C2J.2, C2J.3, C2J.4 CORNER JOINTS, FILLETREINFORCED, WELDED BOTH SIDES, OUTSIDE SINGLE-J ......................................... 75

ENCLOSURE F Figure 16 C1V.5, C1V.6, C1V.7, C1V.8 C1V.9, C1V.10, C1V.11, C1V.12 CORNER JOINTS, WELDED ONE SIDE, SINGLE-BEVEL .................................. 76

ENCLOSURE F Figure 17 C2J.5 CORNER JOINT, WELDED BOTH SIDES, INSIDE SINGLE-J ................................................................................................................................. 77

ENCLOSURE F Figure 18 C2J.6 CORNER JOINT, FILLET-REINFORCED, DOUBLE-J 77

ENCLOSURE F Figure 19 PT1S.1 TEE JOINT, PARTIAL PENETRATION................. 78 ENCLOSURE F Figure 20 PT2S.1, PT2S.2, PT2S.3 TEE JOINTS, PARTIAL PENETRATION ....................................................................................................................... 79

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ENCLOSURE F Figure 21 PT2J.1, PT2V.1 TEE JOINTS, (HIGH EFFICIENCY) FILLET- REINFORCED, DOUBLE-BEVEL PARTIAL PENETRATION ........................... 80

ENCLOSURE F Figure 22 PT2J.2, PT2V.2 TEE JOINTS, FILLET-REINFORCED, DOUBLE- BEVEL PARTIAL PENETRATION ..................................................................... 81

ENCLOSURE F Figure 23 PT2V.3, PT2V.4, PT2V.5 TEE JOINTS, FILLETREINFORCED, PARTIAL PENETRATION, NO BACKGOUGING REQUIRED .............. 82 ENCLOSURE F Figure 24 T2V.1 TEE JOINT, FILLET-REINFORCED, SINGLEBEVEL ...................................................................................................................................... 83

ENCLOSURE F Figure 25 T2V.2, T1V.1, T1V.2 TEE JOINT, FILLET-REINFORCED 84 ENCLOSURE F Figure 26 T2J.1 TEE JOINT, FILLET-REINFORCED, SINGLE-J ...... 85 ENCLOSURE F Figure 27 T2J.2 TEE JOINT, FILLET-REINFORCED, DOUBLE-J .... 86 ENCLOSURE F Figure 28 L2S.1 LAP JOINT, DOUBLE FILLET ................................. 87

ENCLOSURE F Figure 29 L1V.1, L1S.1, L1S.2, L1V.2 LAP JOINTS ........................... 88 ENCLOSURE F Figure 30 E1S.1, E1V.1, E1U.1, E1U.2 EDGE JOINTS ........................ 89

ENCLOSURE F Figure 31 INSERTS, PATCHES, AND SMALL ACCESS PLATES ... 90 ENCLOSURE F Figure 32 INSERTS, PATCHES, AND SMALL ACCESS PLATES IN RELATION TO EXISTING BUTT WELDS........................................................................... 91

ENCLOSURE F Figure 33 SHRINKAGE ALLOWANCE ............................................... 92 ENCLOSURE F Figure 34 PERMISSIBLE UNFAIRNESS IN STEEL WELDED STRUCTURE ENTIRE SHELL............................................................................................ 93 ENCLOSURE F Figure 35 PERMISSIBLE UNFAIRNESS IN STEEL WELDED STRUCTURE BOUNDARIES & WEATHERDECKS ........................................................ 94

ENCLOSURE F Figure 36 PERMISSIBLE UNFAIRNESS IN ALUMINUM WELDED STRUCTURE ENTIRE SHELL............................................................................................ 95

ENCLOSURE F Figure 37 PERMISSIBLE UNFAIRNESS IN ALUMINUM WELDED STRUCTURE BOUNDARIES & WEATHERDECKS ........................................................ 96 ENCLOSURE F Figure 38 CUTBACK REQUIREMENTS ............................................. 97

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1.0 PURPOSE

This work instruction (WI) provides workmanship inspection requirements and acceptance criteria for the welding at job sites and utilized when performing workmanship inspections of base materials, welds, and welded joint fit-ups of surface ship structures and submarines.

2.0 SCOPE

2.1 This instruction specifies the equipment, procedures, and acceptance standards for the workmanship inspection of base materials, welds, and welded joint fit-ups of surface ship structures and submarines.

2.2 This WI is for workmanship inspection only and should not be mistaken for VT inspections.

2.3 This WI provides detailed welding guidance/requirements that meet the requirements of NAVSEA Tech Pub S9074-AQ-GIB-010/248, MIL-STD 1698, MIL-STD 1688 (where specified), MILSTD-22D and Standard Item 009-12. In the event there is a conflict within this work instruction and the listed fabrication documents the fabrication documents will take precedence.

3.0

RESPONSIBILITIES

3.1 Trade Supervisor:

3.1.1 Train Welders to the requirements of welding workmanship.

3.1.2 Review work item, drawings, and correct weld procedure to identify correct material and welding process.

3.1.3 Provide the Fitter and Welder with the required technical documentation to perform their assigned work, such as work item, weld procedure specification, weld joint design sheet from Reference C, and drawings.

3.2 Production Welder:

3.2.1 Shall adhere to the requirements contained in and be familiar with the requirements within this WI.

3.2.2 Validate the provided technical documentation is applicable for the work assigned.

3.3 QA Welding and NDT Division:

3.3.1 Perform periodic surveillance for conformance to this WI. Surveillances shall be conducted semi-annually (6) months at a minimum. Surveillances can and shall be performed at any time by management or QA personnel.

3.3.2 Provide technical support to production when needed.

4.0 DEFINITIONS

4.1 Standard terms and definitions are based on References A and B.

4.2 See Enclosure E for list of welding attribute terms and definitions applicable to the WI.

5.1 Prerequisites

5.1.1 Training and Qualification Requirements

a. All Welders and Fitters conducting tack welding and welding procedure qualifications shall be qualified IAW S9074-AQ-GIB-010/248.

b. Personnel performing fit-up or welder workmanship inspections shall be qualified by successfully completing structural workmanship inspection IAW this WI.

5.1.2 All welding shall be accomplished IAW S9074-AR-GIB-0101/278. All NDT shall be accomplished using procedures qualified to T9074-AS-GIB-010/271 and evaluated to MIL-STD 1689 or 1688 for submarines and/or MIL-STD-2035 when specifically required.

5.1.3 Production shops conducting structural fitting and welding operations will ensure they have a defined work scope based on the contracted work specification item for the contract they are working. If the scope of work or any aspect of the fitting/welding process is not able to be performed as defined in the work specification item and NAVSEA Standard Item 00912 they are to stop work and initiate the CFR process. Prior to initiating the CFR it is recommended the production shop contact the QA Department to validate the constraint cannot be addressed through some other process.

5.1.4 Production shop Foreman/Supervisor will:

a. Ensure the Production Fitter or Welder is provided the appropriate weld procedure specification (WPS) joint design technical data sheet from MIL-STD 22D Reference C.

b. Ensure the production personnel being assigned are qualified to conduct the assigned welding and understand the critical elements of the WPS and the joint design technical data sheets from Reference C.

c. Provide the Production Fitters/Welders with the appropriate drawings as applicable for work being done.

d. If work is covered by a 009-09 PCP requirement they will ensure the craftsman involved with the work understands the requirements of the PCP. Ensure the PCP is being maintained at the job site while conducting fitting or welding.

e. Ensure weld joint history records are assigned to the welder as needed to support the work being conducted. NASSCO-Norfolk and NASSCO-Bremerton have different weld joint history record form requirements based on local contract requirements. Forms are listed in Section 6. Fitters and Welding Foremen are required to complete the workmanship inspections for their respective areas of responsibility and fill out the appropriate workmanship inspection form.

5.1.5 Maintaining this WI on the job site It is required that the Production Fitter and Welder carry this WI with them to the job site (onboard ship or away from NASSCO production shops) along with the items discussed in the previous paragraph to ensure workmanship requirements are being met. Workers in production shops at NASSCO must have readily

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available access to this WI to ensure workmanship requirements are being met. Foremen and Supervisors must be well versed in the workmanship requirements.

5.1.6 The Production Structural Fitters and Welders will document specific inspection attributes for each weld joint while conducting structural welding.

5.2 Workmanship

There are 6 enclosures attached to this WI that provide workmanship requirements as required in References A F. Production Structural Welders and Structural Fitters will use these enclosures to ensure workmanship requirements are met IAW Reference A C. These enclosure are:

5.2.1 Enclosure A Fit-Up Workmanship The enclosure contains fit-up workmanship information: joint design, end preparation, material cleanliness, material acceptance, and fit-up requirements. This section is divided into three areas based on when the inspections are done, as follows:

a. Section A.1 is Prior to Fit-up

b. Section A.2 is Prior to Tacking

c. Section A.3 is Recheck A.1 and A.2 requirements After Tacking

5.2.2 Enclosure B Welder Workmanship This enclosure contains part of the welder workmanship information that a welder needs to verify the weld has been made to requirements of the technical publication. It is divided into three sections, as follows:

a. Section B.1 is Tack Welds and In-Process Welds

b. Section B.2 is Excavations (Back Gouge and Repairs)

c. Section B.3 is Completed Weld and addresses the inspection and acceptance criteria for the following defect attributes: Burn Through Cracks Incomplete Fusion Incomplete Penetration Slag Overlap Sharp Irregularities Oxidation

Crater Pits

Porosity (1689 and 1688)

Weld Spatter (1689 and 1688)

Cleanliness (Including prep for 1689 and 1688)

Melt Through

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Arc Strike Removal Sites, Nicks, Gouges, Fabrication Scars, Grind Marks and Surface Roughness (1689 and 1688)

Corner Melt End Melt

Undercut

Butt Weld Reinforcement Fillet Weld Size

Seal-Off and Wrap-Around Welding Intermittent Fillet Welds

5.2.3 Enclosure C Special Workmanship Categories This enclosure contains information regarding special workmanship categories or guidance to address special situations. It contains the following:

a. Section C.1 is Temporary Snipes

b. Section C.2 is Permanent & Temporary Attachments

c. Section C.3 is Welding Repair of Holes

d. Section C.4 is Peening

e. Section C.5 is Incorrect Filler Material Removal

5.2.4 Enclosure D Workmanship Inspection Methods & Inspection Tools This enclosure contains information regarding inspection methods and recommended tools to be used for these inspections. It provides pictures that illustrate the proper use of the inspection and measurement tools to conduct the following types of inspection of welding/fitting attributes:

a. Bottom Radius b. Corner Melt c. End Melt d. Fabrication Scars

e. Plating Misalignment (or Offset) f. Re-Entrant Angle g. Undercut h. Weld Size (Reinforcement or underfill Butt Welds) i. Weld Size (Fillet) j. Root Opening k. Sharp Irregularities l. Keyholing

5.3

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m. Weld Inspection Tools

5.2.5 Enclosure E Welding Attribute Terms & Definitions This enclosure contains terms and definitions of welding terms.

5.2.6 Enclosure F Weld Joint Designs for Ships Structures This enclosure contains information regarding fit-up requirements related to various joint details as shown in Reference C (MIL-STD-22D) and all related notes.

Applicable Materials

5.3.1

Base Materials

a. New base materials shall meet the requirements of the applicable material specification listed in Table I of S9074-AQ-GIB-010/248.

b. New material conforming to equivalent specifications may be used when authorized by the work specification authorization documents or the specified applicable drawing.

5.3.2 Filler Materials Filler material shall be as specified on the applicable WPS and verified it is applicable for the base materials being used.

5.4 Cleanliness

5.4.1 Cleaning Tools Grinding, polishing, filing, deburring, and brushing tools shall be clean and shall not have been used on aluminum, lead, or materials containing lead or lead compounds, or other low melting point materials. To prevent contamination of corrosion resistant alloys by free iron, tools to be used on corrosion resistant alloys shall have been used on carbon steel or low alloy steels.

a. Grinding and polishing shall be performed with aluminum oxide or silicon carbide grinding wheels or discs that will assure a cleanly cut surface.

b. Brushing shall be performed with clean, corrosion resistant steel brushes. (Carbon steel brushes may be used on carbon steel materials only). Power driven wire brushes shall not be used on surfaces that are to be liquid penetrant inspected (PT) unless the resulting surface is removed using an approved abrasive material prior to performing the inspection. Requirements for wire brushes shall be as follows for the specified base material:

BASE MATERIALS

Carbon steel (S-1, S-2)

WIRE BRUSH MATERIAL

Steel or stainless steel (See Note 1)

Low alloy and high alloy steels (S-3 through S-11) Stainless steel (See Notes 1 &2)

Nonferrous materials (all other S- numbers) Stainless steel (See Notes 1 & 2)

Notes:

1. Wire brushes previously used on aluminum or low melting temperature materia ls shall not be used.

2. Wire brushes previously used on low alloy steels or low melting point temperature materials shall not be used.

c. Filing or deburring shall be performed with carbide or tool steel tools.

d. Stainless or tool steel slag picks may be used for removal of slag or scale.

5.4.2 Base Material The weld area and a minimum of one (1) inch on each side of all joint surfaces shall be free of scale, metallic oxides, paint, oil, grease, and other impurities.

5.4.3 Filler Material All bare rod and insert material shall be free of metallic oxides, oil, grease, or other foreign materials. Cleaning may be accomplished using a suitable abrasive material followed by wiping down with acetone or ethanol (alcohol).

5.4.4 Interbead Cleaning SMAW and FCAW processes shall have slag or scale on each weld bead removed prior to depositing the next bead. Cleaning may be accomplished using slag picks followed by wire brushing. Visible surface defects and sharp bead valleys shall be removed by grinding or burring.

5.5 Welding Equipment

5.5.1 Shielded Metal Arc Welding (SMAW)

a. Power Source A D.C. power source capable of sustaining a stable arc for the current range and electrode size specified.

b. Equipment Use suitable electrode holders, leads, ground connections, work handling equipment, etc.; all of which shall be kept in good condition and maintained within acceptable safety standards.

5.5.2 Gas Metal Arc Welding (GMAW)

a. Power Source A D.C. power source capable of maintaining a stable arc over the current range specified. It should have externally controllable relays to give remote contactor control for semi-automatic and mechanized welding.

b. Wire Feeders and Control A portable unit capable of feeding the listed sizes and types of spooled wire at the specified wire feed rate and having a control for preflow and postflow of shielding gases.

c. Torch The torch shall be designed to operate as a unit capable of handling the specified wire sizes at the required amperage ranges and wire feed rates.

d. Flow Meter Flow meter and gauges shall be capable of registering and sustaining the specified flow rate on the applicable technique sheet. The flow meter inlet supply pressure shall match the pressure rating specified by the flow meter manufacturer.

5.5.3

Gas Tungsten Arc Welding (GTAW)

a. Power Source A D.C. power source capable of maintaining a stable arc over the current range specified, equipped with high frequency or equivalent capabilities for arc initiation and remote operated current controls for starts and stops. Current controls for arc initiation and arc decay shall be capable of being set for a minimum of five seconds.

b. Torch The torch used shall be an air-cooled or water-cooled type, capable of efficient operation within the current range specified and when possible, should be equipped with a gas lens.

c. Flowmeter Flow meter and gauges shall be capable of registering and sustaining the specified flow rate on the applicable technique sheet. The flow meter inlet supply pressure shall match the pressure rating specified by the flow meter manufacturer.

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d. Electrode Unless otherwise specified on applicable technique sheet, 2% thoriated tungsten, shaped to a taper equal to 1.5 to 4 times the electrode diameter with a 1/32" approx. spherical radius or flat tip on the end. Tungsten shall conform to the requirements of AWS A5.12.

5.5.4 Other Equipment

a. Ground The grounding device shall be attached as close as possible to the workpiece. The grounding device shall be of a design that ensures good contact with the base material and shall not exhibit any raised metal or deformation that interferes with the contact surface. Reducing the contact area to a small spot may result in localized melting or arcing between the ground attachment and the base material. Grounding or equipment for shipboard use shall be IAW NAVSEA Standard Item 009-12.

b. Ammeters Calibrated ammeters shall be used to set and check welding current values specified in the WPS. Ammeters should be connected to the electrode lead only and should be connected at a point less than 25 feet from the welding torch or rod holder.

c. Contact Pyrometer Contact type pyrometers and digital type thermometers shall be calibrated and have a range of at least 0° to 500°F. Contact type pyrometers shall have a scale reading in at least 10°F increments.

d. Temperature indicating crayons that contain lead, sulfur, zinc, cadmium or mercury shall not be used.

5.6 Joint Design & Fit-Up

5.6.1 Joint design and fit-up dimensions shall be IAW Enclosure F. Enclosure F shows the applicable joint design sketches (Figure 1 through 30) of this WI.

5.6.2 Weld parameters on the weld data sheet may be used for other than the designated joint designs used for running the PQR when specified by the welding program manager as identified in the application index.

5.6.3 When permanent backing straps authorized for use they may be tacked, welded on one side, or welded on both sides as necessary to suit service conditions.

5.6.4 When a backing strap is used and removed after welding, the joint shall be considered to have an efficiency of 100% provided the weld exposed by removal of the backing passed all required non-destructive tests.

5.6.5 Groove joints within the same group may be interchanged provided joint efficiencies are not reduced.

5.6.6 Full penetration joint designs may be used where partial penetration joints are specified. Where this is done, the inspection requirements for the partial penetration joint may be applied.

5.6.7 Group B Joints Group B joints are butt joints shown in Figures 2 through 7. They may be used subject to the limitations listed below:

a. Unless specifically approved by the government technical design, butt type permanent backing strap joints welded from one side shall not be used in bilge, shear, and stringer

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strakes within the 3/5 midship length of displacement type vessels and as specified for other type vessels and for protective plating.

b. Butt welding of strength members, including inserts, of unequal thicknesses shall require chamfering of the thicker member to the thickness of the thinner member. This requirement applies to all transverse and vertical butt-welded joints in longitudinal strength structure within the 3/5 midship length, butt-welded joints located in normally highly stressed transverse structure such as flight deck bends, and all butt-welded joints in foundation structure designed for shock. Periphery welds of insert plates and other connections not required to be chamfered or tapered and may be designed as corner or tee joints.

5.6.8 Group T Joints Group T joints are full penetration groove tee joints shown in Figures 24 through 27. They may be used subject to the requirement of Enclosure F.

5.6.9 Group PT Joints Group PT joints are partial penetration groove and fillet tee joints shown in Figures 19 through 23.

5.6.10 Group C Joints Group C joints are corner joints as shown in Figures 8 through 18. Corner welded joints may be used subject to the requirements of Enclosure F.

5.6.11 Group L Joints Group L joints are plug and slot welds and fillet-welded lap joints as shown in Figures 28 and 29.

a. Fillet-welded lap joints The strength and efficiency of these fillet welds shall be determined in the same manner as for group PT joints.

b. Plug and slot welds These welds shall be used only upon RMC design approval when applied to primary hull structure.

5.6.12 Group E Joints When Group G joints are edge joints as shown in Figure 30, edge joints shall only be used in secondary structure such as joiner bulkheads and partitions, and for purposes of joint sealing.

5.6.13 Special Joints When Group E joint configurations other than those shown herein are used, the joint(s) shall be detailed on the drawing and be approved for the ship involved, or the special joint(s) shall be specifically approved by RMC as an acceptable alternative.

5.6.14 Canted Tee Joints Where tee joints are formed by structural elements at an angle other than 90 degrees, to one another, the joint(s) shall be designed as follows: For all full penetration Group T joints and all double-beveled or double J-grooved joints, the angle of the bevel or J on the closed side of the joint shall be corrected to provide at least the minimum angle for each joint type as specified in MIL-STD-22.

5.6.15 Inserts, Patches, & Small Access Plates The minimum dimension of an insert, patch, or small access plate in secondary structure shall be 4T or 3-inches, whichever is larger, where T is the thickness of the member penetrated. Corners of inserts, patches, and small access plates shall have a minimum radius as shown in Figure 31, except where those inserts, patches, or small access plates land on full penetration butt welds.

a. Inserts, patches, or small access plates in primary structure shall not intersect any other full penetration butt welds unless they land on these welds or cross them at a 90 +/- 15 degree angle as shown in Figure 32.

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b. When insert, patch, or small access plate welds in primary structure terminate on longitudinal butt welds, the existing weld shall be cut back a minimum distance of 3 inches from the point of intersection, except for longitudinal welds (see Figure 32).

c. When inserts, patches, or small access plates in primary structure terminate on longitudinal butt welds, these latter existing welds shall be cut back to a minimum of 3 inches, except where such cut-back would result in less than 2 inches of existing longitudinal weld remaining between the end of the cut-back and adjacent frame web or bulkhead surface. In such cases, the minimum cut-back shall be terminated not less than 2 inches from the adjacent frame or bulkhead surface, but in no case shall the cutback be less than 2 inches long. When it is anticipated that this latter situation will occur, the weld toes of insert, patch, or smaller access plate welds shall be limited to a minimum of 4 inches from the weld toes of the adjacent frame web or bulkhead surfaces.

5.6.16 Access & Closure Plates Corners of access and closure plates shall have a minimum radius of 6 inches, except when a boundary lands on an existing hull longitudinal or transverse butt weld. In the latter instances, the corners shall intersect the butt weld at an angle of 90 +/- 15 degrees (see Figure 32). The cut-back requirements for inserts, patches, and small access plates apply.

a. Boundaries of access and closure plates shall be located between principal ship framing and bulkheads, and shall be at least 3 inches from any of these members. When variance from this 3-inch minimum is required by special circumstances, approval of the variance must be obtained from design.

b. Boundaries of access and closure plates should land on existing butts or seams wherever practicable.

c. No cuts shall be made in the shear, stringer, or bilge strakes or in the flat keel unless approved by RMC design.

d. Welding closer than 6 inches to a mechanically fastened joint shall be avoided.

e. Closure plate weld joints shall be full penetration, 100% efficient welds.

5.7 Weld Requirements (General)

5.7.1 General Information Protect surrounding area beyond weld prep from arc strikes and weld spatter by covering with heat resistant cloth. The protective material should extend within one inch of each edge of the joint preparation. Inspect the area for preexisting damage IAW NSI 009-06 and report any preexisting damage via the CFR system. Ensure the requirements of NSI 009-06 are followed to protect the area.

5.7.2 Area of Inspection

a. Prior to welding, the area of inspection shall include a minimum of 1” of base metal from the expected toes of the weld.

b. During welding (i.e., after tacks and between weld beads/layers), the area of inspection shall include a minimum of ½” of base metal from the expected toes of the weld.

5.7.3 Repair Authorization Repair is authorized to remove unacceptable indications within the area of inspection by metal removal and/or welding, unless there is a section for

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“Authorization for Repair” listed for the attribute. Unacceptable indications found outside the area of inspection on structure may be repaired by metal removal. All unacceptable indications that require weld repair outside the area of inspection shall be reported to the Quality Assurance Department. Each nonconformity that requires correcting is addressed in Enclosures A-C.

5.7.4 Minimum Lighting Requirements Inspections shall be performed with adequate lighting. Adequate lighting is defined as a minimum of 50 foot candles on the surface being inspected. A standard 2-cell flashlight with good batteries provides approximately 100 foot candles at a distance of one foot.

5.7.5 Tolerances Minimum and maximum dimensions, including dimensions with a tolerance, (such as 1” + 1/8” where 7/8” is the minimum and 1 1/8” is the maximum) shall be considered absolute. No dimension shall be accepted that is less than the minimum or greater than the maximum value specified (i.e., as-measured or calculated dimensions exceeding specification allowances may not be rounded up or down to meet the specification). Any deviation, however small, beyond the limit shall be rejected.

5.7.6 Calibration Not Required Weld gauges and measuring devices used to ensure specified dimensions are not precision measuring instruments and therefore will not require calibration.

5.7.7 For the SMAW process, use either stringer bead or weave bead technique with the bead width not to exceed 6 times the electrode core diameter on carbon steel, 4 times core diameter on stainless steel and CuNi, and 3 times core diameter on NiCu and inconel.

5.7.8 For the GTAW process the stringer bead technique is preferred for all weld beads. When weave bead is used it shall not exceed the width of the cup diameter.

5.7.9 All surface defects and blemishes such as weld spatter, slag, porosity, overlap, etc., shall be removed by grinding or filing. All start and stop craters shall be ground and visually inspected and any defects removed. See Enclosures A C for specific workmanship requirements.

5.7.10 When welding within 4 inches of a brazed joint, precautions shall be taken to prevent melting of braze filler material as a minimum. Interpass temperature can be reduced to a lower level which does not violate minimum preheat temperature and the brazed joint can be wrapped with wetted heat resistant material during the welding operations.

5.7.11 Number of weld passes Unless otherwise approved, no less than two layers shall be used for all pressure containing weld joints with the second layer completely covering the first layer.

5.7.12 Tack Welds

a. Joint alignment shall be established prior to tack welding. Tack welds shall be made by a welder qualified for the process, filler material, operational data, and technique specified for the welding joint. They shall be of sufficient number to maintain joint alignment and be deposited and mechanically contoured. If necessary, to facilitate incorporation into the final weld. Tack welds shall not be made without the specified preheat. See Enclosure A C for specific workmanship requirements.

b. Cracked or broken tack welds or those of poor quality, shall be removed and not incorporated into the final weld. See Enclosure A for specific workmanship requirements for cracked or broken tack welds.

5.7.13 Preheat & Interpass Temperatures

a. Methods Preheat temperature is the temperature of the base metal immediately before welding is performed. In multipass operations, it is also the temperature in the area immediately before the second and subsequent passes are started (See Figure 5-1). Preheat may be applied by any of the following methods used by itself or in combination:

Resistance heaters

Radiant and infrared heaters

Electrical induction

Oxy-fuel torch

Electric hot air blowers

Other approved methods

b. Uniform Heating The heating shall be of the uniform soaking type, applied preferably by means of electric heaters (resistance or induction) uniformly distributed on or around the area being welded. The spacing and wattage of heaters shall be such as to ensure that the entire welding area is maintained within the required temperature range.

c. Maintain Uniform Temperature Shielding for protection from wind and inclement weather shall be employed during welding and maintained until the weldment has cooled to within ambient temperature plus 50°F, unless post weld stress relieving is required and is to be performed immediately upon completion of welding. Control of the required temperature range during welding may be accomplished by distribution of welders or by the use of welding sequence. Cyclic heating and the occurrence of temperature differentials greater than 100°F along the joint during welding should be avoided to maintain thermal expansion and contraction stresses at a uniform level.

d. Preheat and interpass temperature limits for each weld joint shall be listed on the WPS to be used in production.

e. Contact type pyrometers or lead-free temperature or infrared pyrometers may be used if they are calibrated. This equipment will be used for measuring preheat and interpass temperatures except that actual measurement of preheat temperatures less than 125°F is not required provided the material is warm to the touch or is allowed to reach and

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ambient temperature greater than the specified preheat temperature, and there is no evidence of moisture in the material. Recorders attached to induction equipment may also be used.

f. Contact type pyrometers are preferred for measuring preheat and interpass temperatures. Infrared pyrometers may be used if they are calibrated. When used, they shall be held horizontally and with the contact point applied to the location where welding will proceed. Temperature indicating crayons when used shall be applied at least one inch from the expected toe of the weld. The use of low melting metallic alloys for temperature measurement is prohibited.

g. Temperature Checks Preheat temperature shall be checked prior to welding, and for multipass operations, before the second and subsequent passes are started. Interpass temperature shall be checked between weld passes. Temperatures of 125°F and above shall be checked using temperature indicating crayons or other temperature measuring devices. When the ambient temperature is below the required 60°F or there is evidence of moisture on the material surface, preheat shall be applied until the area is dry and warm to the touch. Otherwise, no check of material temperature is required. Temperature indicating crayons shall be located approximately 1 inch away from the weld area to avoid contaminating the weld. Prior to welding over areas where crayons have been used, residue shall be removed.

h. Preheat Temperature Measurements Preheat temperature shall be measured on the surface of the base material on the side from which welding will be performed and within 3 inches of the area to be welded. See Figure 5-1.

i. Interpass Temperature Measurements Interpass temperature in a multiple pass weld is the temperature of the metal at the site of operations before the next pass is started, and shall be measured on the surface of the base material on the side from which welding will be performed, approximately 1 inch maximum from the weld joint edge and along the joint within 3 inches of the start of the next weld pass. See Figure 5-1. Prior to starting another pass, if the base metal temperature is found to be above the maximum interpass temperature, the weld area shall be allowed to cool to within the required temperature range prior to any subsequent welding.

j. When preheating the weld joint and an area 6 inches beyond, the weld site shall be preheated to the temperature specified on the WPS. Take preheat temperature measurement within 3 inches of the area to be welded. See Figure 5-1.

k. When using oxy-acetylene torches for preheating, preheat shall be applied in a gradual and uniform manner avoiding any “spot heating” effect. Application of preheat shall be interrupted by “soaking” periods to allow the heat to travel uniformly through the material.

l. Low Temperature Preheat When torches are used for low temperature (60°F to 125°F) preheating, moisture condensate caused by the flame may occur in the weld joint. This moisture should be removed by maintaining metal temperature above ambient temperature until the surface is warm and dry to the touch.

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Figure 5-1 Preheat and Interpass Temperatures

REVISIONS

Rev. Date Summary of Change

7/7/2016 Initial document.

REVISION RECORD

N/A 12/20/2017 Updated document number and reference document numbers. These changes fall within the scope of the General Manager’s transition memo (2/20/2017), so they do not require additional review and signature.

2/9/2018 Renumbered Bremerton work instruction WI-PNW-5006 to also be applicable to NASSCO-Norfolk.

2/7/2019

Added Ref E Fabrication, Welding, and Inspection of Submarine Structure to reference section. Added James Kea NDT III NASSCO Bremerton as author, changed Jesse Dukes NDT III NASSCO-Norfolk to review. Added 1689/1688 attributes to 2.3 of Enclosure C to show requirements are the same. Added 1.1e Plate edge laminations 1688 requirements. Added undercut, end melt and corner melt chart for 1688. 2.3e added 1688 intermittent fillet weld criteria.

N/A 3/18/2019 Fixed image glitches, protected images, and added missing submarine language to 1.1 and 2.1 based on 2/7/2019 revision.

4/14/2020

Clarified specific differences between 1688 and 1689 requirements. Added general guidance for welders and fitters to enhance this workmanship document. Deleted the original Enclosure A because it was repeated in Enclosure B. Added joint design information from MIL-22D to ensure the Fitter and Welder would have the information on the deck plate when needed. Added weld equipment general information and pre-heat and interpass temperature information.

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ENCLOSURE A Fit-Up Workmanship ENCLOSURE A.1 Fit-Up Workmanship Prior to Fit-Up ENCLOSURE A.1 Fit-Up Workmanship Prior to Fit-Up

A.1.1 Area of Inspection Surfaces to be covered by weld and adjacent base metal surfaces within 1” of expected toes of weld.

A.1.2 Joint Design Prepare bevel angle, bevel depth, J-prep radius, root face and check the material thickness as detailed in MIL-STD 22D for the joint design called out in the work item. Prep only first side. Unless otherwise specified in the technique sheet, all full penetration joints welded without a backing bar require backgouging after sufficient metal is deposited on the first side. Because of this, double bevel weld joint designs (double groove joints) may be prepared by beveling only the first side. The root face and bevel details of the second side need not be prepared or inspected prior to welding.

Notes:

1. B2V.3 and T2V.2 examples are shown. Other joint designs which can be prepped this way include: B2(S)V.4, B2U.4, B2U.5, B2J.3, B2J.4, C2V.5, C2V.6, C2J.6, AND T2J.2.

A.1.3 Full Penetration without Backgouge In special cases where a full penetration weld is made without a backing bar and without backgouging, such as punch punch submerged arc welding, the root face and bevel angles shall be as detailed in the technique sheet.

Thickness

Bevel Angle

Details

Bevel Depth J-Prep Radius if applicable Root Face (Land) if applicable

Notes:

Acceptance Criteria

Verify material thickness is as specified in the work item.

Per joint design from MIL-STD-22D, welding technique sheet, or the work item.

1. Repair bevel angles, bevel depths and insufficient root face by welding and grinding.

A.1.4 End Prep Surfaces Ensure the quality of cut surfaces. The joint edges shall be prepared for welding by any one of the following methods:

Machining (planning, shearing, etc.)

Oxy-fuel cutting

Carbon air arc gouging

Chipping

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Grinding or burring Plasma arc cutting Laser cutting Water jet

A.1.5 Acceptance Criteria All flame or arc cut surfaces shall meet AWS C4.1 (Most rod issue stations have a sample roughness gauge board.) oxygen cutting surface roughness gauge, Sample 2 or better.

A.1.6 Repair End prepared surfaces to be covered by welds: Surface defects up to 1/8” deep, fair in by grinding with a 6 times the depth taper. Surface defects over 1/8” deep, repair by welding.

A.1.7 Material Type, Material Quality Level Check to ensure the material type is as required in the work item.

A.1.8 Material Cleanliness Remove all paint, rust, scale, zinc coating, moisture, galvanizing, grease, oil, thermal sprayed aluminum etc. that can contaminate the weld from surfaces to be covered by weld and adjacent base metal surfaces within 1” of expected toes of the weld. All weld joint surfaces shall be cleaned and visually inspected prior to welding.

Notes:

1. Cleaning Aluminum In addition, on aluminum alloys the oxide film shall be removed from the surface to be welded, adjacent surfaces within ½ inch from the expected toe of the weld joint by means of a clean stainless steel wire brush, or by approved chemical or mechanical means. Welding shall take place within 16 hours after oxide film removal or the joint shall be cleaned again and the oxide film removed again.

A.1.9

Plate Edge Laminations

Not Covered by Weld

Covered by Weld

Acceptance Criteria

Unacceptable:

Any lamination found on exposed plate edges, which will not be covered by welding.

Acceptable: Continuous laminations 8” and less in a 24” length.

Discontinuous laminations in a straight line whose total length is 12” or less in a 24” length (with no single continuous lamination greater than 6”) T-9074-AD-GIB-010-1688

Edge laminations visually detected on submarine plating shall be MT inspected (see 8.3.3 of MIL STD 1689A). Rejectable laminations shall be excavated to a depth of approximately 3/4" or 1/2 material thickness, whichever is less from the plate edge and welded over.

A.1.10 Authorized for Repair Report all laminations to the Quality Assurance Department before making repairs as detailed below.

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A.1.11 Repair Excavate until lamination is removed up to approximately 3/8” or ½ the material thickness whichever is less from plate edge. Laminations remaining at the bottom of the excavation are acceptable (See figure below.) Weld the excavation.

A.1.12

Arc Strikes, Nicks, Gouges, and other Fabrication

Base Material Thickness

Scars

Acceptance Criteria

Less than ½” 1/32” maximum depth ½” and greater 1/16” maximum depth (indications greater than 1/32” shall be faired in smoothly)

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ENCLOSURE A.2 Fit-Up Workmanship Prior to Tacking ENCLOSURE A.2 Fit-Up Workmanship Prior to Tacking

A.2.1 Area of Inspection Surfaces to be covered by weld and adjacent base metal surfaces within 1” of expected toes of the weld.

A.2.2 Misalignment Tacking may be performed to correct misalignment.

Base Material Thickness (T(Thin))

Acceptance Criteria

Less than 3/8” 1/6” max. 3/8” to 3/4” 1/8” max. Over 3/4" through 1-1/2” 3/16” max. Over 1-1/2” 1/4" max. A.2.3 Orientation Verify the structure is installed properly as specified by the work item.

A.2.4 Root Opening Acceptance Criteria As specified in MIL-STD-22D for joint designs called out in the work item. See figure below for fillet welds.

A.2.5 Root Opening Repair Unacceptable root openings may be repaired by welding or grinding. Where buildup by welding on the joint surface to correct oversized root opening or errors in joint preparation is accomplished, it should be done prior to fitting. The buildup of the joint edge shall not exceed T or ½” (whichever is less) on each joint edge, unless allowed by the work item. Where one joint edge is inaccessible, the total buildup (that is, 2T or 1”, whichever is less) may be deposited on one member.

A.2.6 Welding to Correct Excessive Root Opening The joint edges shall not be joined until the oversize root opening is corrected to within the requirements specified on the applicable drawing or technical work document, unless specifically approved by welding engineering.

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Notes:

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*Root Opening Fillet Weld Leg Size (S) *Nominal condition along joint. 0 to 1/16" Equals the specified minimum leg size (from drawing, TGI, etc.) Greater than 1/16" to 3/16”

Equals specified minimum leg size plus the root opening minus 1/16" Greater than 3/16"

STOP Report condition to Welding Engineering

1. Increased fillet weld size applies to the whole length of a joint, not just in areas where the root opening is larger than 1/16”.

ENCLOSURE A.3 Fit-Up Workmanship After Tacking (Recheck)

ENCLOSURE

A.3 Fit-Up Workmanship After Tacking (Recheck)

A.3.1 Area of Inspection Surfaces to be covered by weld and adjacent base metal surfaces within ½” of expected toes of the weld.

A.3.2 Recheck the joint fit-up attributes to assure the base material did not move.

A.3.3 Acceptance Criteria Same as for “prior to tacking” section.

A.3.4 Orientation Verify the structure is located and installed properly as specified by the work item.

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ENCLOSURE B Welder Workmanship

ENCLOSURE B.1 Welder Workmanship Tack Welds & In-Process Welds

ENCLOSURE B.1 Welder Workmanship Tack Welds & In-Process Welds

B.1.1 Area of Inspection Surfaces to be covered by weld and adjacent base metal surfaces within 1/2” of expected toes of the weld.

B.1.2 Tack Welding Technique & Acceptance Criteria

Cracked or poor quality single-pass tacks must be removed and replaced (can be removed during backgouging). Cracked or poor quality multiple pass tacks must be removed. Block tacks are at least 1/4 joint thickness but not more than 18” long.

Unacceptable. Shall be removed prior to subsequent welding.

* This condition is not normally visible except on the end of the root pass or when the weld has been cut.

** In areas shown in sketch (next page) entrapped slag that cannot be removed with a pick or brush, and does not interfere with welding or inspection of the weld is acceptable.

All weld spatters greater than 1/8” shall be removed prior to subsequent welding. l.

Weld and adjacent base metal shall be cleaned and continuously checked during welding. Remove all foreign material including slag, excessive smoke or oxide buildup for a minimum of ½” from the weld edge.

B.1.3 Fillet “T” joints, when welded, sometimes have areas that are inaccessible for cleaning (such as under the ends of tack welds and in the gap between joint members behind the tacks or root). In these areas, slag

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which cannot be removed by normal methods (such as a slag pick or brush) is acceptable as long as it does not interfere with welding or inspection of the weld (i.e., is not on the surface of the weld).

Notes:

1. Inaccessible areas with tightly adherent slag is allowable.

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ENCLOSURE B.2 Welder Workmanship Excavations

ENCLOSURE B.2 Welder Workmanship Excavations

B.2.1 Area of Inspection Surfaces to be covered by weld and adjacent base metal surfaces within 1/2” of expected toes of the weld.

Attribute

a. Bottom Radius

b. Excavation Depth

c. Included Angle

Acceptance Criteria

Approximately 1/8” minimum.

FCAW, GMAW When gouge is deeper than ½” the bottom radius shall be great enough to allow torch manipulation, approximately ¼” minimum.

Gouged to clean sound metal.

Approximately 30 minimum for backgouges, and approximately 20 minimum for repairs.

FCAW, GMAW When gouge is deeper than ½” the included angle shall be great enough to allow torch manipulation, approximately 40 minimum.

d. Keyholing

Unacceptable

Sides and bottom fully visible: Sloping side walls: No sharp breaks. e. Cracks f. Incomplete Fusion g. Incomplete Penetration h. Porosity i. Slag

j. Cleanliness

Weld and adjacent base metal shall be cleaned to remove foreign material for a minimum of ½" from the weld edge.

Process Owner QA

ENCLOSURE B.3 Welder Workmanship Completed Weld ENCLOSURE B.3 Welder Workmanship Completed Weld

B.3.1 Area of Inspection Surfaces to be covered by weld and adjacent base metal surfaces within ½" of expected toes of the weld.

Attribute Acceptance Criteria

a. Burn Through

b. Cracks

Unacceptable.

Unacceptable.

Authorization for Repair. Contact Quality Assurance prior to repair of cracks longer than 12”.

Repair. Info PT/MT is recommended to ensure removal.

c. Incomplete Fusion Unacceptable.

d. Incomplete Penetration

e. Slag

f. Overlap

g. Sharp Irregularities

h. Oxidation

i. Crater Pits

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Unacceptable.

This condition is not normally visible except when the weld has been cut exposing the cross section of the root layer.

Authorization for repair. Contact Quality Assurance when this condition is found.

Unacceptable. Tightly adherent slag that cannot be removed by slag pick or wire brush is permissible for VT. Slag shall not interfere with evaluation of other visual attributes.

If MT, UT, or RT is required then slag 1/8 inch in or less in diameter or length is allowed.

If PT is required then no slag is permitted.

Tightly adhering iridescent temper films are acceptable. Wrinkled or crystalline oxide scale is unacceptable.

Acceptable provided there are no cracks, minimum weld thickness is maintained, and the root concavity and convexity limits are not exceeded.

j. Porosity (1689 and 1688)

k. Weld Spatter (1689 and 1688)

l. Cleanliness (Including prep for NDT) (1689 and 1688)

Disregard pores less than or equal to 1/32”. “Wormhole” porosity is always unacceptable. Single pores larger than 3/32” are unacceptable.

MIL-STD-1689 The sum of pore diameters or lengths shall not exceed 3/16” in any 2” length of weld.

T9074-AD-GIB-010/1688 The sum of pore diameters or lengths shall not exceed 1/8” in any 2” length of weld.

Weld spatter remaining after wire brushing shall be evaluated as follows:

For VT or MT surface shall be free of tightly adherent spatter greater than 1/8” in diameter or length.

For ET, PT, RT or UT, spatter is unacceptable.

The area of inspection shall be free of paint, grease, dirt, and other foreign material. See details for surface requirements for NDT. The general guidelines for the minimum area to be inspected are as follows:

For VT the inspection area is the weld face and ½” of adjacent base material.

For MT (yoke), ET, PT or RT, the inspection area is the weld face and 1” of adjacent base material. For PT, the surface SHALL NOT be prepared by power wire brush, peening, tumbling, or shot, sand, grit or vapor blasting.

For MT (prod), the inspection area is the weld face and 3” of adjacent base material.

For RT (with expansion areas), when new welds intersect existing welds, 6” minimum of the existing weld beyond the intersection. For the repair of HY80/100 hard tank full penetration welds, the repaired area plus 6” on each end of the repair.

For UT the inspection area is the sum of 4X plate thickness plus 2” from the weld toe on each side of the weld, or as specified by the inspection code.

For all NDT methods, no evidence of peening.

m. MeltThrough Acceptable provided the areas do not contain cracks, crevices, globules, or unacceptable oxidation, and provided the root concavity and convexity limits are not exceeded.

n. Arc Strikes, Nicks, Gouges, & Fabrication Scars (1689 and 1688)

Material Thickness Max Depth Length Restriction Welds in base metals less than 1/2" 1/32” (See Note 1)

Limited to 12” and bottom of depression shall be visible and rounded or free of notches Welds in base metals 1/2" and greater 1/16” (See Note 2)

B.3.2 Authorization for Repair of Base Material If repair instructions were not included in the Work Item, contact the Quality Assurance Department if greater than 1/32” deep outside the area of inspection.

Notes:

1. If 1/32” or less acceptable without repair.

2. If over 1/32” but not over 1/16” repair by grinding to fair smoothly into adjacent material.

3. If over 1/16” repair by welding.

Attribute

o. Corner Melt Primary Hull

Acceptance Criteria

As welded 1/16” max depth Only at corners After grinding 3/32” max. depth Only at corners

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Structure (1689) Other Structures (1689)

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As-welded 3/32” max. depth Only at corners After grinding 1/8” max depth Only at corners

Attribute Acceptance Criteria

p. End Melt * Primary Hull Structure (1689)

As-welded 1/16” max. depth Only at ends After grinding 3/32” max. depth Only at ends Other Structures (1689)

As-welded 3/32” max depth Only at ends After grinding 1/8” max. depth Only at ends

* End melt criteria applies for material thicknesses ¼" and under. For material thicknesses greater than ¼", undercut requirements apply.

Attribute

q. Undercut Primary Hull Structure (1689)

Notes:

Acceptance Criteria

As-Welded Depth Material Thickness

Action (See Note 1) 1/32” or less All Acceptable

Greater than 1/32” Less than ½” Weld Repair ½” and greater

1/16” or less All Acceptable

Grind to 1/16” max. depth and/or weld repair. (See Note 2) Other Structures (1689)

Greater than 1/16”

Less than ½” Weld repair ½” and greater Grind to 3/32”max. depth and/or weld repair. (See Note 2)

1. The repair of undercut and other weld-edge defects (including ground areas) by welding shall be accomplished by depositing a bead or beads in the undercut or ground area which will fair smoothly into the surrounding material.

2. The accumulated length after grinding shall not exceed 15% of the joint length or 12 inches in any 36 inch length of weld, whichever is less.

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Undercut, End-Melt and Corner Melt IAW NSTP 1688

Primary Hull

Condition Base metal thickness (inches)

Maximum Depth/Length After Grinding

Maximum depth as-welded condition (inches) Depth (inches) Length Restriction

Undercut < than 1/2 1/2 and > 1/32 1/32 1/32 1/32 1/16

None None (See Note 1) End-melt (See Note 2) 1/4 and less only 1/32 1/16 Only at ends of a member

Corner-melt Any thickness 1/32 1/16 Only at the corners of a member

Notes:

1. The accumulated length does not exceed either 15 percent of the joint length or 12 inches in any 36-inch length of welding, whichever is less.

2. For base material greater than 1/4 inch, undercut requirements apply.

B.3.3 Butt Weld Reinforcement Acceptance Criteria Shall not be below adjacent base metal surface, except undercut at weld toes that do not exceed allowed undercut limits is acceptable.

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B.3.4 Plate Thickness Mismatch For welds on plates of unequal thickness, the weld shall taper gradually (approx. 4 to 1 minimum) between plate edges.

B.3.5 Taper length can combine weld taper plus plate taper. Weld reinforcement may be extended over onto the thinner plate to achieve a 4 to 1 taper.

B.3.6 Contour shall not be below a straight line between edges of weld joint.

B.3.7 Repair Grind or add filler metal until weld meets the requirements.

B.3.8 Fillet Weld Size Acceptance Criteria Fillet weld leg length shall be equal to or greater than the minimum specified size. Weld shall be essentially flat between the two legs. Essentially flat is defined as concavity up to and including 1/16”. Concavity in excess of 1/16” is acceptable provided minimum throat thickness is maintained (0.7 X S where S is the fillet leg size) (See figure on next page) Convexity shall not exceed 3/16”. For partial penetration fillet welds with root opening between members greater than 1/16” but less than 3/16”, the fillet size shall be larger than the specified size by an amount equal to the amount of root opening over 1/16”

B.3.9 No maximum fillet size applies for partial of full penetration joints. Avoid over-welding to prevent unnecessary distortion of assemblies and to prevent situations where oversized welds interfere with locating other items. Intermittent fillets require continuous fillet on ends for 1/8 length of member. Fillet welds ¼” and greater, and fillet reinforced partial penetration welds, may be undersized by no more than 1/16” provided the undersized length does not exceed 6” in any single location; or the accumulated length does not exceed 15% of the joint length, whichever is less.

B.3.10 Repair Add filler metal until leg length and face of the weld meet the requirements.

B.3.12 Acceptance Criteria Fillet and fillet reinforced partial penetration welds shall be sealed off with weld at the end(s) of members (flat bars, angles, channels, and tees) being joined to form a closed loop where surfaces are to be wetted. Members which will not be wetted shall be sealed off when practical. When specified by a weld all-around symbol, the minimum weld reinforcement shall be maintained (wrap-around) at the end(s) of the attached members, except as noted below. When the member is located per tolerances and the full size fillet (wrap-around) is not obtainable, the maximum size obtainable shall be considered acceptable provided the seal-off requirement in the wetted areas is maintained.

B.3.13 Intermittent Fillet Welds Inspection Area Start and stop ends outside the effective length of each increment shall be evaluated for cracks only.

B.3.14 (T9074-AD-GIB-010/1688) Intermittent fillet weld sizes shall be determined by increasing the continuous double fillet size required by this document in proportion to the unwelded length of the joint. That is, if the unwelded length of the joint is half the total length, the intermittent fillet size shall be twice the double continuous fillet size. Calculated intermittent weld sizes shall not be based on weld load capacity greater than base material load capacity. In such cases, the size of the intermittent fillet welds shall be reevaluated using a reduced weld spacing or an increased weld length. Additional restrictions applicable to intermittent welds are found in MIL-STD-22 and MIL-STD-1628.

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ENCLOSURE C Special Workmanship Categories

ENCLOSURE C.1 Special Workmanship Categories Temporary Snipes

ENCLOSURE C.1 Special Workmanship Categories Temporary Snipes

C.1.1 Where continuous welds in systems of intersecting structures are required, temporary snipes shall be provided as necessary to assure the deposition of sound metal at such intersections. Temporary snipe locations shall be governed by the details of the welding sequence. Bevels shall be provided on temporary snipes to allow proper closure after completion of the joint that passes through.

C.1.2 Acceptance Criteria The dimensions shall be the minimum required allowing satisfactory completion of welding and proper closure of welding in the through joint. Snipes shall be beveled to allow proper closure when welding and such welding shall be in accordance with the applicable technique sheet for the metal being welded. For Tee welds, the snipes shall be cut back a minimum of ¼” from the anticipated weld toe location. For Butt welds, snipes shall be a minimum of ¼” beyond the weld toes of the butt weld and a minimum of 3/16” above plate or weld reinforcement. The maximum buildup for welding snipes shall be 1 1/2”.

C.1.3 Authorization for Repair If the snipe openings are larger than the limits shown, contact Quality Assurance Department for instructions.

ENCLOSURE C.2 Special Workmanship Categories Permanent & Temporary Attachments

ENCLOSURE C.2 Special Workmanship Categories Permanent & Temporary Attachments

C.2.1 Location of Temporary Attachments Welded temporary attachments, such as erection clips, fairing bolts, staging braces, and brackets should be kept to a minimum. Attachments which do not require welding should be used when possible. Typical welded attachments such as clips and other temporary items should be located on weld joints edges to maximum extent possible.

C.2.2 Removal of Welded Attachments Welded attachments on all materials should be removed a minimum of 1/16” away from permanent member to which they are attached. HY/HSLA-80/100 attachments shall be removed a minimum of 1/16” away from the permanent member. Removal may be accomplished by any one or combination of the following: oxy fuel cutting, plasma arc cutting, carbon arc gouging, sawzall, or chipping followed by grinding or by grinding alone. The final surface shall be ground smooth and flush to within 1/16” of the adjacent surface. Arc welded studs and spot welds shall not be removed by bending or hammering. When attachments welded with austenitic or nonferrous filler materials (i.e. 300 CRES or other than steel) are removed and will be welded over using ferrous filler materials, complete removal of the austenitic or nonferrous weld metal shall be verified with an etchant. Surface defects shall be faired out by grinding, not to exceed the undercut limits of Enclosure B para. B.3.2.q. All removal sites requiring NDT other than final visual shall be circled to identify area for removal site inspections.

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ENCLOSURE C.3 Special Workmanship Categories Welding Repair of Holes ENCLOSURE C.3 Special Workmanship Categories Welding Repair of Holes

C.3.1 General Holes cut into or through a member may be welded provided the original hole does not exceed 2-1/2 inches. Holes less than 1/2" in diameter shall be opened to greater than 1/2" diameter. Except that holes in members ¼” thick or less need only be opened to a diameter (d) equal the thickness (t) of the member (e.g. d=t). Holes shall be beveled to 20 degrees minimum included angle as shown below. Ensure removal of all internal threads in holes when present. Holes greater than 2 1/2” in original diameter shall be reported to the Quality Assurance Department.

C.3.2 Partial Penetration Holes Partial penetration holes shall have 3/16 minimum material remaining prior to welding or shall be drilled through and prepared as a full penetration repair, unless the joint is visually inspected on the backside. Partial penetration holes greater than 2-1/2 inches diameter may be welded closed to the above requirements provided the depth of the hole does not exceed 20 percent of the member.

C.3.3 Full Penetration Holes Full penetration holes shall be repaired, as shown below, using a 3/16” minimum backing plate of compatible ferrous or nonferrous material, or approved non-metallic material. Backing plate shall be removed if accessible and backside visually inspected. Permanent backing may be used to repair holes when authorized by the Quality Assurance Department. In cases where c oncentric expansion of the hole would lead to cutting through an existing butt weld or cutting across existing structural member, the hole can be egg-shaped to meet the requirements above. Non-metallic material shall only be used when specified in the work item and when the back side is accessible for grinding to remove any residual non metallic material and 1/8” of base material. Contact the Quality Assurance Department for guidance when the back side is not accessible.

ENCLOSURE C.4 Special Workmanship Categories Peening ENCLOSURE C.4 Special Workmanship Categories Peening

C.4.1 The mechanical working of metals using impact blows. Power driven round or blunt nosed tools (See figure below) should be used for peening.

C.4.2 Peening may be accomplished on welds to correct distortion or to minimize residual stresses, except that peening shall not be allowed on the first layer of multiple layer welds.

C.4.3 Final weld layer peening, if required, shall be followed by grinding or burring to remove all evidence of peening prior to final NDT.

C.4.4 Welds shall not be over peened, causing flaking and laps or reducing the cross section thickness of the adjacent base metal.

C.4.5 Surface slag, slag inclusions, cracks, porosity and other weld defects shall be removed prior to peening.

C.4.6 Lightly grind or burr the peened surface sufficient to remove visual indications of flaking or laps on the finished contour prior to MT and/or RT inspection.

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ENCLOSURE C.5 Special Workmanship Categories Incorrect Filler Material

ENCLOSURE C.5 Special Workmanship Categories Incorrect Filler Material

C.5.1 Authorization for Repair for Non-Critical Welds Contact Quality Assurance Dept of incorrect filler material usage prior to any removal or repair work.

C.5.2 Authorization for Repair for Critical Welds Stop work and initiate an IDR for technical direction. Notify Quality Assurance Department of incorrect filler material usage prior to any removal or repair work. Incorrect filler material removal site requirement: The following requirements are provided for all classes and weld joint types. For butt welds, remove the entire weld length and depth as shown below (if it is known that only a portion of the weld was made with incorrect filler metal, contact the Quality Assurance Department for case-by-case instructions for partial weld removal). In all cases, use scribe line measurements as shown in the figures below.

Table for Surfacing & Fillet Type Welds

GTAW 1/16” 1/16” 3/16” SMAW 3/32” 3/32” 3/16”

FCAW 1/8” 1/8” 1/4" GMAW 3/16” 3/16” 3/8” SAW 1/2" 1/2" Contact Quality Assurance

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ENCLOSURE D Workmanship Inspection Methods & Inspection Tools

ENCLOSURE D Workmanship Inspection Methods & Inspection Tools

Inspections and Methods This section lists methods for evaluating various workmanship attributes to the applicable requirements using approved tools. Alternate methods are acceptable if required accuracy is maintained.

D.1 Bottom Radius

D.1.1 Required Tools None. If questionable, a radius gauge should be used.

D.1.2 Press 1/8” radius gauge into excavation. If a gap exists between the gauge and the bottom of the excavation, the radius is less than 1/8”. See Figures D.1 and D.2.

Figure D.1

D.2 Corner Melt (as-welded or after grinding)

D.2.1 Required Tools 6” scale, or 4-in-1 gauge with 6” scale.

Figure D.2

D.2.2 Press a 6” scale into deepest indication (or pointer of 4-in-1 gauge). Measure the amount of corner melt with the scale. As an alternate, use two 6” scales, one held on the corner and one into the deepest indication, then read the distance. Use smallest increment necessary on 6” scale to get the most accurate measurement. See Figure D.3.

Figure D.3

D.3 End Melt (as-welded or after grinding)

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Figure D.4

D.4 Fabrication Scars (Nicks, Gouges, Cavities, etc.)

D.4.1 Required Tools 4-in-1 gauge and 6” scale.

D.4.2 Press pointer of 4-in-1 into deepest indication. Measure the amount indicated on the 4-in-1 using the 6” scale. Use smallest increment necessary on the 6” scale to get the most accurate measurement. See Figure D.5.

Figure D.5

D.5 Plating Misalignment (or Offset)

D.5.1 Required Tools Gauge block, 4-in-1 gauge, and 6” scale.

D.5.2 Place gauge block on base material adjacent to weld. Place 4-in-1 on gauge block. Press pointer of 4in-1 down to opposite base material. As an alternate, use two 6,” scales one held on the gauge block and one to the surface of the plate, then read the distance. Use smallest increment necessary on the 6” scale to get the most accurate measurement. Subtract the thickness of the gauge block from 4-in-1 reading. See Figure D.6.

Figure D.6

D.6 Re-Entrant Angle

D.6.1 Required Tools 6” scale.

D.6.2 Butt scale up against toe of weld. The 90° corner of the scale will touch the toe of the weld if the reentrant angle is 90° or greater. See Figure D.7.

Figure D.7

D.7 Undercut (as-welded or after grinding)

D.7.1 Required Tools 4-in-1 gauge and 6” scale.

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D.7.2 Press pointer of 4-in-1 into deepest undercut indication. Measure the amount indicated on the 4-in-1 using the 6” scale. Use the smallest increment necessary on a 6” scale to get the most accurate measurement. See Figures D.8 and D.9.

Figure D.8

D.8 Weld Size (reinforcement or underfill butt welds)

D.8.1 Required Tools 4-in-1 and gauge block.

Figure D.9

D.8.2 Place gauge block on base material. Place 4-in-1 on gauge block. Press pointer of 4-in-1 into the lowest point on the weld surface. Move the 4-in-1 point to the base metal using established pointer position. If a gap exists between the 4-in-1 and gauge block, then underfill is present. See Figures D.10 and D.11 for underfill.

Figure D.10

Figure D.11

D.8.3 Measure height of reinforcement as shown using applicable acceptance criteria. See Figures D.12 and D.13.

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Figure D.12

Figure D.13 D.9 Weld Size (Fillet)

D.9.1 Required Tools G.A.L. fillet weld gauge, or two 6” scales (alternative method)

D.9.2 Measure leg length as shown. Measure each leg in enough areas to verify the minimum fillet leg requirements are met for the length of the entire weld. (Gauge must touch toe of weld at or before touching the base material.) See Figures D.14, D.15, and D.16.

Figure D.14 Figure D.15 Figure D.16

D.9.3 Measure throat thickness as shown. Measure in enough areas to verify the minimum throat thickness requirements are met for the length of the entire weld. (Gauge must touch throat of weld at or before touching the base material.)

Notes:

1. It is not required to measure throat thickness on flat or convex fillet welds with satisfactory leg lengths. See Figures D.17, D.18, and D.19.

Figure D.17

Figure D.18

Figure D.19

D.9.4 Fillet welds can have satisfactory leg lengths yet a rejectable throat thickness. See Figure D.20.

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Figure D.20

D.9.5 Fillet welds can have satisfactory throat thickness yet a rejectable leg length. See Figure D.21.

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Figure D.21

D.9.6 Oversized concave fillet welds with satisfactory leg lengths can appear to have a rejectable throat thickness using a G.A.L. fillet weld gauge, however it may still be acceptable if configuration is as shown. Contact the Quality Assurance Department as necessary to assist in evaluating this condition. See Figures D.22, D.23, and D.24.

Figure D.22

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Figure D.23

Figure D.24

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D.9.7 Fillet Welds at Angled Attachments Fillet welds for angled attachments shall be measured as follows:

D.9.7.1 The size of fillet welds for attaching a member that intersects at an angle other than 90 degrees shall be measured using the projected block method where the block dimension is equal to the specified fillet size (see Figure D.25).

Figure D.25

Projected Block Method

D.10 Root Opening Required Tools 6” scale or dial caliper.

D.11 Sharp Irregularities Required Tools 6” scale (or workmanship sample if questionable). See Figure D.26.

Figure D.26

D.12 Keyholing

D.12.1 Required Tools Flashlight.

D.12.2 See Figure D.27 and D.28 for proper use of a flashlight.

Figure D.27

Figure D.28 D.13 Weld Gauge D.14 Bridge Cam Gauge

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ENCLOSURE E Welding Attribute Terms & Definitions Term ENCLOSURE E Welding Attribute Terms & Definitions

Aligned Rounded Indication

Ambient Temperature

Angular Misalignment

Four or more indications in a line, where each is separated from the adjacent indication by less than 1/16 inch or D, whichever is greater, where D is the major diameter of the larger of the adjacent indications.

A work piece is considered to have cooled to ambient temperature when it is cool enough to place a hand on the material (typically less than 125°F).

The amount in degrees that two joint members (pipe or plate) are misaligned from a common plane.

Arc Strikes Any localized heat affected zone or change in the surface contour of a finished weld or adjacent base metal resulting from an arc or heat generated by the passage of electrical energy between a finished surface and a current source.

As-Welded The condition of a weld, after welding, without any surface modifications such as grinding. Back Gouge (back gouging)

Bevel Angle

Back gouge is the preparation of the second side of full penetration welds welded from both sides to the extent necessary to permit proper deposition of weld metal and complete joint penetration.

The angle formed between the prepared edge of a member and a plane perpendicular to the surface of the member. See Figure in Back Gouge.

Block (Weld): An increment of a continuous multiple pass weld that is completely or partially built up in cross-section before adjacent lengths of weld are deposited.

Bottom Radius Dimension representative of the bottom of an excavation.

Burn Through A void or open hole that extends through a backing ring or strip, fused root, or adjacent base metal resulting from fusion completely through a localized region.

Buttering The deposition of surfacing metal on one or more surfaces to provide metallurgically compatible weld metal for the subsequent completion of the weld. Usually associated with dissimilar metal welds.

Cladding The deposition or application of surfacing material usually to improve corrosion or heat resistance.

Term ENCLOSURE E Welding Attribute Terms & Definitions

Completed Weld Completion occurs when all weld metal has been deposited, required weld soaks are completed, preheat is removed, weld has cooled to ambient temperature, and the weld is ready for other nondestructive test (NDT) inspections.

Concavity The maximum distance from the face of a concave fillet weld perpendicular to a line joining the weld toes. For pipe butt welds, concavity is a root contour condition.

Contour See weld contour.

Convexity The maximum distance from the face of a convex fillet weld perpendicular to a line joining the weld toes. For pipe butt welds, convexity is a root contour condition.

Corner Crack A crack occurring in weld metal in way of a temporary access snipe, a drain or vent opening, or at the intersection of three members.

Crack A linear rupture of metal under stress.

Crater A depression in the weld face at the termination of a weld bead.

Crater Pit A sharp conical concavity on the surface at weld stops, extending into the weld in an irregular manner. Crater pits are caused by shrinkage of molten metal during solidification.

Crevice A narrow opening between two pieces of metal in which liquids or particles can be trapped (e.g., backing straps, partial penetration welds, lap joints, etc.).

Defect A discontinuity or discontinuities that by nature or accumulated effect (for example total crack length) render a part or product unable to meet minimum applicable acceptance standards or specifications. The term designates rejectable condition.

Design material Thickness (TM)

The nominal or average thickness of material of the strength member, exclusive of reinforcement or backing rings and strips, as follows:

For groove welds, the TM shall be the groove depth including the root land thickness.

For fillet, partial penetration and socket type welds, the TM shall be the nominal pipe wall thickness.

For weld deposited pads, butter, cladding, hard-surfacing or wear-surfacing, the TM shall be the average height of the deposit thickness measured from the original base metal surface.

For tapered welds, the TM shall be the average weld thickness.

For base metal repairs, the TM shall be the maximum depth of repair exclusive of reinforcement.

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Term ENCLOSURE E Welding Attribute Terms & Definitions

Discontinuity An interruption of the typical structure of a material that affects its mechanical, metallurgical, or physical characteristics (e.g., slag, spatter, porosity, etc.). A discontinuity is not necessarily a defect (rejectable).

Dissimilar Metal Weld Welds between two metals that differ sufficiently in metallurgical and physical properties to require special consideration in welding qualification and inspection. Welds made by either direct joining of the dissimilar metals or by use of weld deposited buttering are considered dissimilar metal welds.

End Melt A form of weld undercut at the end of welded members that are 1/4 inch thick or less.

Face of Weld The exposed surface of a weld on the side from which welding was done.

Fillet Weld A weld of approximately triangular cross section joining two surfaces approximately at right angles to each other in a lap joint, tee joint, or corner joint.

Finished Weld Finished weld is a weld which has received all required final inspections and has been accepted.

Globules Ball or globe shaped metal formations commonly associated with melt through.

Grind Undercut The resultant groove after grinding to fair weld undercut smoothly into the base metal.

Groove Angle The total included angle of the groove between pieces to be welded.

Hardfacing Surfacing metal deposited to reduce wear.

Hydrodynamic Surface A surface that has the potential for generating noise if not smooth because of water flowing across the surface (e.g., ship’s hull).

Incomplete Fusion Lack of complete fusion of some portion of the metal in a weld joint with adjacent metal. The adjacent metal may be either base metal or previously deposited weld metal, or consumable insert.

Incomplete Penetration Lack of penetration through the thickness of the joint, or penetration which is less than specified. A portion of the weld preparation has been left in its original state.

Term ENCLOSURE E Welding Attribute Terms & Definitions

Indication

Visual evidence that indicates a discontinuity may be present. For example, magnetic particles may align to form an indication during performance of magnetic particle inspection.

Keyholing A rejectable condition that exists when the base metal overhangs on the side wall(s) of an excavation preventing accessibility for welding. Keyholing results from grinding or air carbon arc gouging.

Lamination

A type of discontinuity with separation generally aligned parallel to the work surface of a metal.

Lap Folding of metal on the surface of the forging, usually when some of the forging metal is squeezed out between the two dies.

Layer A stratum of weld metal, consisting of one or more weld beads. The thickness of a layer shall not be greater than the thickness of a pass. See also weld layer or root layer.

Leg (fillet weld) The distance from the joint root to the toe of the fillet weld.

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Term ENCLOSURE E Welding Attribute Terms & Definitions

Linear Indication

An indication in which the length is equal to or greater than three times the width.

Melt Through A convex or concave irregularity on the surface of a backing ring or strip, fused root, or adjacent base metal resulting from fusion completely through a localized region, but without development of a void or open hole.

Minimum Allowable Thickness

For fit-up purposes, piping thickness not exceeding 10% below the nominal pipe thickness shall be acceptable. Thickness exceeding 10% below the nominal pipe thickness will have the minimum allowable thickness researched (notify the Welding Engineering Department for assistance) prior to acceptance.

Misalignment The distance two members butted together are misaligned.

Mismatch Differing thickness of two base materials to be butted together.

Nominal Thickness

Indication whose length is less than three times its width.

That thickness specified on plans or drawings without application of any allowed tolerance. Non-linear or Rounded Indication

Overlap The protrusion of weld metal beyond the weld toe or weld root. The weld metal protrusion extends over the base material surface but is not fused to the base material. This condition occurs when the re-entrant angle is less than 90°.

Term ENCLOSURE E Welding Attribute Terms & Definitions

Oxidation A condition resulting from partial or complete lack of inert gas shielding of a surface which is heated during welding, resulting in the formation of oxide on the surface. This condition may range from slight oxidation evidenced by a multicolored or tightly adhering black film to the extreme of a very rough surface having a crystalline appearance. For purposes of this procedure, iridescent temper films and tightly adhering films are not considered oxidation.

Pass A weld bead which extends the entire length of a longitudinal weld or a maximum of 360° of a circumferential or spiral weld. A pass may include several starts and stops.

Peening The mechanical working of metals using impact blows to reduce distortion and stress.

Porosity Gas pockets or voids in a weld or casting.

Re-Entrant Angle The angle formed between the base plate and the toe of the weld.

Root See “Weld Root”.

Root Face (land) The portion of the groove face adjacent to the joint root.

Root Layer The first layer of weld metal placed in a joint required to initially join the base materials. This may consist of one or more passes depending on the width of the root opening.

Root Opening A separation at the joint root between the work pieces.

Sharp Irregularity

A rejectable condition that exists when the angle formed between weld beads or weld ripples on the bead surface are less than 90°.

Slag Non-metallic solid material entrapped between beads of weld metal or between weld metal and base metal or in a casting.

Snipes Snipe is a small temporary or permanent opening in an abutting member to permit the deposition of a sound weld in a joint passing beneath the abutting member. A temporary snipe is closed by welding or a patch plate depending on its size.

Spatter Metal particles expelled during welding which deposit on the surface of the weld or adjacent base metal and which do not form a part of the weld.

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Term ENCLOSURE E Welding Attribute Terms & Definitions

Stress Riser Changes in contour or discontinuities in structure that cause local increases in stress (stress concentration point).

T Unless otherwise specified herein or by the TWD, “T” (used alone) represents nominal thickness (TNOM). Another term used in conjunction with “T” is TMIN = minimum allowable thickness (min. wall), or minimum drawing or design thickness.

Tack Welds Welds made to hold the parts of a weldment in proper alignment until the final welds are made.

Temporary Attachment Weld

Throat Thickness (fillet weld)

A weld made to attach a piece or pieces to a weldment or temporary use in handling, shipping, or working on a weldment.

The shortest distance from the face of the weld to the joint root of the weld.

Undercut A groove melted into the base metal at the toe of the weld and left unfilled by weld metal. This is an as welded condition which can be removed by grinding. See grind undercut or weld undercut.

Underfill A condition in which the weld face extends below the adjacent surface of the base metal.

Weld Bead An increment of a weld pass with one start and one stop. A weld bead may be a weld pass if it extends for the entire length of the joint or block length.

Weld Buildup The deposition of filler material to restore base material or weld surface dimensions or to deposit a weld layer on the material surface of the joint prior to joining the material members together.

Weld Contour The surface profile of a weld in the as-deposited condition or after mechanical preparation to meet workmanship or NDT requirements.

Weld Contouring The deliberate shaping of weld surfaces for hydrodynamic or fatigue considerations, or as otherwise permitted in this procedure.

Weld Deposited Buttering

Weld Deposited Hard Surfacing

Weld metal deposited on base metal prior to completing the weld to permit the final portion of a dissimilar metal weld to be completed as a similar metal weld.

Weld metal which is deposited for the purpose of providing wear resistance.

Weld Deposited Overlay Cladding Weld metal which is deposited for the purpose of corrosion protection only.

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Term ENCLOSURE E Welding Attribute Terms & Definitions

Weld Distortion Warping of the base material due to welding and the associated heating and cooling.

Weld Face The exposed surface of a weld on the side from which welding was done.

Weld Layer A single stratum (layer) of weld metal consisting of one or more adjacent weld passes. The thickness of a layer shall not be greater than the thickness of a pass.

Weld Pass A weld bead extending the entire length or block of a longitudinal weld or a maximum of 360° of a circumferential or spiral weld. A weld pass may include several starts and stops.

Weld Reinforcement Weld metal in excess of the quantity required to fill a joint.

Weld Root The points, shown in a cross section, at which the root surface intersects the base metal surfaces.

Weld Spatter Material particles which deposit on the surface of the weld or adjacent base metal during welding and which do not form a part of the weld.

Weld Toe The junction of the weld face and the base metal.

Weld Undercut A groove melted into the base material adjacent to the weld toe or weld root and left unfilled by weld metal.

Workmanship Samples Samples (actual or replications), photos, or other visual aids used to evaluate conditions.

Wrap Weld applied to seal-off a fillet weld at the end of a member (flat bar, angle, channel, or tee).

Wrought Material Pipes, bars, plates, forgings and extrusions.

ENCLOSURE F Weld Joint Designs for Structural Applications ENCLOSURE F Weld Joint Designs for Structural Applications

G.1 This enclosure provides weld joint designs for joining materials by manual, semi- automatic and mechanized welding processes as further described in individual welding data sheets. The welded joint designs shown herein comply with all requirements of MIL-STD-22 and represent typical and standard joint designs used in welded fabrication.

G.2 General Requirements

G.2.1 For joints with "u" or "v" bevels, the centerline of the included angle may be shifted from the position shown on the joint designs herein, as follows:

Included Bevel Angle Max Bevel Angle Shift

Less than 30° ± 5° 30° up to 59° ± 10° 60° and greater ± 20°

G.2.1.1 Bevel angle shifts are permitted provided the specified minimum total included angle is maintained.

G.2.2 For material 1½ inches thick and over, the joint bevel angles specified need only be maintained for a minimum thickness of 5/8 inch to provide accessibility for welding the root, after which the included angle may be reduced to 20 degrees minimum for the remainder of the material thickness.

G.2.3 Materials for permanent or temporary backing rings or backing strips, and run-off tabs shall be made from the same s-group as either of the materials being joined. Nonmetallic material may not be used as backing material unless specifically approved by welding engineering.

G.2.3.1 When welding dissimilar types of CRES base metals, the material type for backing material specified for either of the CRES base metal types may be used. Where the joint is in contact with seawater, backing material of type CRES 316L shall be used.

G.2.4 Joints shall be so located, to the maximum extent possible, that the entire weld groove is visible for the welder and that no obstructions impair the accessibility for welding.

G.2.5 Double bevel weld joint designs may be prepared by beveling one side of the joint before welding and by back gouging the root on the second side after sufficient weld metal has been deposited on the first side.

G.2.6 Full penetration joint designs may be used where partial penetration joint designs are specified. Where a full penetration joint design is substituted for a partial penetration joint design, the inspection requirements for the partial penetration joint design may be applied.

G.2.7 The maximum allowable root opening of backing strap or ring type joints, where only the minimum dimension is specified, shall be 1/4 inch above the specified minimum.

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ENCLOSURE F Figure 1 Permanent Backing Strap ENCLOSURE F Figure 1 Permanent Backing Strap (Notes 1 & 2)

Plate Thickness - (t) T1 min. W min.

Up through 1/8” 1/8” 1/2”

Over 1/8” through 5/16” 3/16” 1” Over 5/16” 1/4” 1-1/2”

Notes:

1. When shapes are used in lieu of backing strap, all above dimensions and notes shall apply.

2. Butt joints in permanent backing straps shall be welded, but need not comply with NDT requirements applicable to the welded joint itself.

3. S= 1/2t, but in no case less than 1/8 inch or greater than 1/4 inch. The welds may be on either side of the strap or within the weld groove.

4. Intermittent fillet welds or tack welds may be employed unless otherwise specified.

5. Materials for backing rings or backing strips shall be made from the same s-group as either of the materials being joined. Nonmetallic material may not be used as backing material unless specifically approved by welding engineering.

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ENCLOSURE F Figure 2 B2S.1, B1S.2 BUTT JOINTS, SQUARE ENCLOSURE F Figure 2 B2S.1, B1S.2 BUTT JOINTS, SQUARE B2S.1

WELDED BOTH SIDES B1S.2

WELDED ON BACKING Joint Number Dimension “y” (inch) Dimension “t” max. (inch) B2S.1 0 to t 1/4 B1S.2 T min, t + 1/4 3/16

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ENCLOSURE F Figure 3 B1V.1, B1V.2, B1V.3, B1V.5, B1V.6, B1V.7 BUTT JOINTS, WELDED ON PERMANENT METAL BACKING

ENCLOSURE F Figure 3 B1V.1, B1V.2, B1V.3, B1V.5, B1V.6, B1V.7 BUTT JOINTS, WELDED ON PERMANENT METAL BACKING

Joint Number Angle “X” Min Dim. “Y” (Inch) Dim. “T” (Inch) Welding Position

Notes:

B1V.1 45 3/16 to 7/16 Unlimited

All B1V.2 35 1/4 to 1/2 All B1V.3 20 3/8 to 5/8

Flat, Vert, Over B1V.5 45 1/4 to 1/2 All B1V.6 25 3/8 to 5/8

Flat, Vert, Over B1V.7 35 3/8 to 5/8 All

1. Ceramic or other non-metallic backing may be used subject to prior NAVSEA approval.

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ENCLOSURE F Figure 4 B2V.1, B2(S)V.2 BUTT JOINTS, SINGLE-V AND SINGLE-BEVEL ENCLOSURE F Figure 4 B2V.1, B2(S)V.2 BUTT JOINTS, SINGLE-V AND SINGLE-BEVEL

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Single-V Welded Both Sides

Single- Bevel Welded Both Sides

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ENCLOSURE F Figure 5 B2V.3, B2(S)V.4 BUTT JOINTS, DOUBLE-V AND DOUBLE- BEVEL ENCLOSURE F Figure 5 B2V.3, B2(S)V.4 BUTT JOINTS, DOUBLE-V AND DOUBLE- BEVEL

Double-V Double-Bevel

ENCLOSURE F Figure 6 B2U.1, B2U.2, B2U.3, B2J.1, B2J.2 BUTT JOINTS, SINGLE-U AND SINGLEJ

ENCLOSURE F Figure 6 B2U.1, B2U.2, B2U.3, B2J.1, B2J.2 BUTT JOINTS, SINGLE-U AND SINGLE-J

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ENCLOSURE F Figure 8 C2S.1 CORNER JOINT, OPEN SQUARE ENCLOSURE F Figure 8 C2S.1 CORNER JOINT, OPEN SQUARE C2S.1

Welded Both Sides

ENCLOSURE F Figure 9 C2V.1 CORNER JOINT, OUTSIDE SINGLE-V ENCLOSURE F Figure 9 C2V.1 CORNER JOINT, OUTSIDE SINGLE-V C2V.1

Fillet Reinforced

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ENCLOSURE F Figure 10 C2V.2, C2V.3 CORNER JOINTS, FILLET-REINFORCED, OUTSIDE SINGLE-BEVEL

ENCLOSURE F Figure 10 C2V.2, C2V.3 CORNER JOINTS, FILLET-REINFORCED, OUTSIDE SINGLE-BEVEL

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ENCLOSURE F Figure 11 C2V.4 CORNER JOINT, FILLET-REINFORCED, INSIDE SINGLE-BEVEL ENCLOSURE F Figure 11 C2V.4 CORNER JOINT, FILLET-REINFORCED, INSIDE SINGLEBEVEL

Welded Both Sides

ENCLOSURE F Figure 12 C2S.2 CORNER JOINT, FILLET-REINFORCED, OUTSIDE SQUARE ENCLOSURE F Figure 12 C2S.2 CORNER JOINT, FILLET-REINFORCED, OUTSIDE SQUARE

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NIMS Page 73 of 97 Revision 4/14/2020

STRUCTURAL WELDING WORKMANSHIP & TRAINING GUIDE Process Owner QA WI-Q-3008

ENCLOSURE F Figure13 C2V.5, C2V.6 CORNER JOINTS, FILLET-REINFORCED, DOUBLE-BEVEL ENCLOSURE F Figure 13 C2V.5, C2V.6 CORNER JOINTS, FILLET-REINFORCED, DOUBLE-BEVEL

NIMS Page 74 of 97 Revision 4/14/2020

STRUCTURAL WELDING WORKMANSHIP & TRAINING GUIDE Process Owner QA

ENCLOSURE F Figure 14 C2U.1 CORNER JOINT, SINGLE-U ENCLOSURE F Figure 14 C2U.1 CORNER JOINT, SINGLE-U

ENCLOSURE F Figure 15 C2J.1, C2J.2, C2J.3, C2J.4 CORNER JOINTS, FILLET-REINFORCED, WELDED BOTH SIDES, OUTSIDE SINGLE-J

ENCLOSURE F Figure 15 C2J.1, C2J.2, C2J.3, C2J.4 CORNER JOINTS, FILLETREINFORCED, WELDED BOTH SIDES, OUTSIDE SINGLE-J

NIMS

STRUCTURAL WELDING WORKMANSHIP & TRAINING GUIDE Process Owner QA WI-Q-3008

ENCLOSURE F Figure 16 C1V.5, C1V.6, C1V.7, C1V.8 C1V.9, C1V.10, C1V.11, C1V.12 CORNER JOINTS, WELDED ONE SIDE, SINGLE-BEVEL

ENCLOSURE F Figure 16 C1V.5, C1V.6, C1V.7, C1V.8 C1V.9, C1V.10, C1V.11, C1V.12 CORNER JOINTS, WELDED ONE SIDE, SINGLE-BEVEL

Joint Number

Angle X Min (Deg)

Notes:

Dimension Y (Inch) Welding Position

Dimension T (Inch) C1V.5, C1V.8, C1V.11 45 1/4 to 1/2 All Unlimited C1V.6, C1V.9, C1V.12 35 3/8 to 5/8 All C1V.7, C1V.10 25 3/8 to 5/8 Flat, Vert., Over

1. Backing may be removed and joint welded on both sides.

Page 76 of 97 Revision 4/14/2020

NIMS

STRUCTURAL WELDING WORKMANSHIP & TRAINING GUIDE Process Owner QA WI-Q-3008

ENCLOSURE F Figure 17 C2J.5 CORNER JOINT, WELDED BOTH SIDES, INSIDE SINGLE-J ENCLOSURE F Figure 17 C2J.5 CORNER JOINT, WELDED BOTH SIDES, INSIDE SINGLE-J

ENCLOSURE F Figure 18 C2J.6 CORNER JOINT, FILLET-REINFORCED, DOUBLE-J ENCLOSURE F Figure 18 C2J.6 CORNER JOINT, FILLET-REINFORCED, DOUBLE-J

Page 77 of 97 Revision 4/14/2020

STRUCTURAL WELDING WORKMANSHIP & TRAINING GUIDE Process Owner QA

ENCLOSURE F Figure 19 PT1S.1 TEE JOINT, PARTIAL PENETRATION ENCLOSURE F Figure 19 PT1S.1 TEE JOINT, PARTIAL PENETRATION

Notes:

1. Where Y is greater than 1/16 inch as a nominal condition, S shall be increased by an amount equal to the excess of the opening above 1/16 inch.

2. When the bar or tube meets the plate at an angle other than 90° bias cut the end of the bar or tube to maintain the gap between members within the specified limits.

3. All PT1S.1 joints in tank boundaries shall have a minimum of two weld layers.

NIMS

Process Owner QA

ENCLOSURE F Figure 20 PT2S.1, PT2S.2, PT2S.3 TEE JOINTS, PARTIAL PENETRATION ENCLOSURE F Figure 20 PT2S.1, PT2S.2, PT2S.3 TEE JOINTS, PARTIAL PENETRATION

Notes:

1. Where Y is greater than 1/16 inch as a nominal condition, S shall be increased by an amount equal to the excess of the opening above 1/16 inch.

2. The specific length of the fillet shall be the length of the weld at full size. Crater and tapered ends shall not be included when measuring dimension L.

3. Fillet size (S) shall be determined in accordance with the requirements of the applicable fabrication document. Unless two different fillet sizes are specified, “S” specified only on one side shall be understood to mean the same size fillet applies to the other side of the member also.

4. When the two members meet at an angle other than 90°, bias cut the tee member to maintain the gap between members within the specified limits on both sides of the joint.

5. For the PT2S.1 joint design, if the two members meet at an obtuse angle greater than 105°, bevel the tee member on the obtuse angle side to produce an included angle of 45° minimum and a joint similar to PT2V.4.

6. All PT2S.1 joints in tank boundaries shall have a minimum of two weld layers per side.

Process Owner QA

ENCLOSURE F Figure 21 PT2J.1, PT2V.1 TEE JOINTS, (HIGH EFFICIENCY) FILLETREINFORCED, DOUBLE-BEVEL PARTIAL PENETRATION

ENCLOSURE F Figure 21 PT2J.1, PT2V.1 TEE JOINTS, (HIGH EFFICIENCY) FILLETREINFORCED, DOUBLE-BEVEL PARTIAL PENETRATION

Notes:

1. When the calculated land dimension is not greater than 3/16 inch, a full penetration weld shall be used.

2. Alternate methods of determining a depth of bevel “B” and corresponding size of reinforcing fillet “S” may be used provided each such joint is individually sketched or checked to assure that the required effective width of weld “D” will be obtained. However, in no case shall the reinforcing fillet be smaller than 1/2T or 3/8 inch whichever is less. Unless two different fillet sizes are specified, “S” specified only on one side shall be understood to mean the same size fillet applies to the other side of member also.

3. When the two members meet at an angle other than 90°, adjust the bevel angle on the acute angle side of the joint to maintain the minimum included angle (35° or 52°) for welding.

Process Owner QA WI-Q-3008

ENCLOSURE F Figure 22 PT2J.2, PT2V.2 TEE JOINTS, FILLET-REINFORCED, DOUBLE- BEVEL PARTIAL PENETRATION

ENCLOSURE F Figure 22 PT2J.2, PT2V.2 TEE JOINTS, FILLET-REINFORCED, DOUBLEBEVEL PARTIAL PENETRATION

Notes:

1. This joint design is for use when “Z” is 1/2 inch or greater.

2. “S” shall be T/2 or 3/8 inch whichever is less. Unless two different fillet sizes are specified, “S” specified only on one side shall be understood to mean the same size fillet applies to the other side of the member also.

3. When the two members meet at an angle other than 90°, adjust the bevel angle on the acute angle side of the joint to maintain the minimum included angle (35° or 52°) for welding.

STRUCTURAL WELDING WORKMANSHIP & TRAINING GUIDE

Process Owner QA WI-Q-3008

ENCLOSURE F Figure 23 PT2V.3, PT2V.4, PT2V.5 TEE JOINTS, FILLET-REINFORCED, PARTIAL PENETRATION, NO BACKGOUGING REQUIRED

ENCLOSURE F Figure 23 PT2V.3, PT2V.4, PT2V.5 TEE JOINTS, FILLET-REINFORCED, PARTIAL PENETRATION, NO BACKGOUGING REQUIRED

Notes:

1. B1 shall not exceed 2B2

2. SB shall equal 1/2 TB

3. S shall be T/2 or 3/8 inch whichever is less.

4. When the two members meet at an angle other than 90°, adjust the bevel angle on the acute angle side of the joint to maintain the minimum 45° included angle for welding.

5. Unless two different fillet sizes are specified, "S" specified only on one side shall be understood to mean the same size filler applies to the other side of the member also.

NIMS Page 82 of 97 Revision 4/14/2020

STRUCTURAL WELDING WORKMANSHIP & TRAINING GUIDE Process Owner QA WI-Q-3008

ENCLOSURE F Figure 24 T2V.1 TEE JOINT, FILLET-REINFORCED, SINGLE- BEVEL ENCLOSURE F Figure 24 T2V.1 TEE JOINT, FILLET-REINFORCED, SINGLE- BEVEL

Notes:

1. Unless two different fillet sizes are specified, “S” specified only on one side shall be understood to mean the same size fillet applies to the other side of the member also.

2. When the two members meet at an angle other than 90° and the bevel is on the acute angle side of the joint, adjust the bevel angle to maintain the minimum 45° included angle for welding.

NIMS Page 83 of 97 Revision 4/14/2020

ENCLOSURE F Figure 25 T2V.2, T1V.1, T1V.2 TEE JOINT, FILLET-REINFORCED ENCLOSURE F Figure 25 T2V.2, T1V.1, T1V.2 TEE JOINT, FILLET-REINFORCED Joint

Notes:

1. Unless two different fillet sizes are specified, “S” specified only on one side shall be understood to mean the same size fillet applies to the other side of the member.

2. Backing may be removed and joint welded on both sides.

3. When the two members meet at an angle other than 90º, do the following:

a. If the obtuse angle side of the joint is no more than 105º, adjust the bevel angle on the acute angle side of the joint to maintain the minimum 45º minimum included angle for welding.

b. If the obtuse angle side of the joint is more than 105º, single bevel the tee member 45º minimum on the obtuse angle side of the joint to produce a joint similar to T2V.1.

Notes:

STRUCTURAL WELDING WORKMANSHIP & TRAINING GUIDE Process Owner QA WI-Q-3008

ENCLOSURE F Figure 26 T2J.1 TEE JOINT, FILLET-REINFORCED, SINGLE-J ENCLOSURE F Figure 26 T2J.1 TEE JOINT, FILLET-REINFORCED, SINGLE-J

1. Unless two different fillet sizes are specified, “S” specified only on one side shall be understood to mean the same size fillet applies to the other side of the member also.

2. When the two members meet at an angle other than 90° and the bevel is on the acute angle side of the joint, adjust the bevel angle to maintain the minimum 35° included angle for welding.

NIMS Page 85 of 97 Revision 4/14/2020

Process Owner QA

ENCLOSURE F Figure 27 T2J.2 TEE JOINT, FILLET-REINFORCED, DOUBLE-J ENCLOSURE F Figure 27 T2J.2 TEE JOINT, FILLET-REINFORCED, DOUBLE-J

Notes:

1. Unless two different fillet sizes are specified, “S” specified only on one side shall be understood to mean the same size fillet applies to the other side of the member also.

2. When the two members meet at an angle other than 90°, do the following:

a. If the obtuse angle side of the joint is no more than 105°, adjust the bevel angle on the acute angle side of the joint to maintain the minimum 35° included angle for welding.

b. If the obtuse angle side of the joint is more than 105°, single bevel the tee member 45° minimum on the obtuse angle side of the joint to produce a joint similar to T2V.1.

STRUCTURAL WELDING WORKMANSHIP & TRAINING GUIDE Process Owner QA

ENCLOSURE F Figure 28 L2S.1 LAP JOINT, DOUBLE FILLET ENCLOSURE F Figure 28 L2S.1 LAP JOINT, DOUBLE FILLET

Notes:

1. Size of fillet shall be as governed by design requirements.

2. Unless two different fillet sizes are specified, “S” specified only on one side shall be understood to mean the same size fillet applies to the other side of the member also.

Notes:

NIMS Page 88 of 97 Revision 4/14/2020

STRUCTURAL WELDING WORKMANSHIP & TRAINING GUIDE Process Owner QA

ENCLOSURE F Figure 29 L1V.1, L1S.1, L1S.2, L1V.2 LAP JOINTS ENCLOSURE F Figure 29 L1V.1, L1S.1, L1S.2, L1V.2 LAP JOINTS

1. When T is less than 1/2 inch, slot shall be beveled to a 45° included angle.

ENCLOSURE F Figure 30 E1S.1, E1V.1, E1U.1, E1U.2 EDGE JOINTS ENCLOSURE F Figure 30 E1S.1, E1V.1, E1U.1, E1U.2 EDGE JOINTS

NIMS Page 90 of 97 Revision 4/14/2020

STRUCTURAL WELDING WORKMANSHIP & TRAINING GUIDE Process Owner QA WI-Q-3008

ENCLOSURE F Figure 31 INSERTS, PATCHES, AND SMALL ACCESS PLATES ENCLOSURE F Figure 31 INSERTS, PATCHES, AND SMALL ACCESS PLATES

WHEN “W’ = 6” MIN THEN R2=3” OR 2T WHICHEVER IS LARGER

STRUCTURAL WELDING WORKMANSHIP & TRAINING GUIDE Process Owner QA WI-Q-3008

ENCLOSURE F Figure 32 INSERTS, PATCHES, AND SMALL ACCESS PLATES IN RELATION TO EXISTING BUTT WELDS

ENCLOSURE F Figure 32 INSERTS, PATCHES, AND SMALL ACCESS PLATES IN RELATION TO EXISTING BUTT WELDS

NIMS Page 91 of 97 Revision 4/14/2020

INSERTS, PATCHES, OR SMALL ACCESS PLATES WHICH LAND ON EXISTING BUTT WELDS

STRUCTURAL WELDING WORKMANSHIP & TRAINING GUIDE

Process Owner QA

ENCLOSURE F Figure 33 SHRINKAGE ALLOWANCE ENCLOSURE F Figure 33 SHRINKAGE ALLOWANCE (FOR GUIDANCE ONLY)

Butt Welds (Steel)

Transverse

Thickness

Shrinkage Allowance

1/16 to 3/32 inch for all thicknesses

Shrinkage Allowance

1/32 inch in 10 feet 3/8 to ½ inch thick 1/32 to 1/16 inch in 10 feet ¼ to 3/8 inch thick 1/32 to 3/32 inch in 10 feet ¼ inch thick and less 1/16 to 1/8 inch in 10 feet

Over ½ inch thick

Thickness

Fillet Welds

Tucking Allowance

T-over ½ inch thick No allowance 3/8 to ½ inch thick 1/64 inch per stiffener ¼ to 3/8 inch thick 1/32 inch per stiffener 1/4 inch thick and less 1/16 inch per stiffener

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