SAW (Submerged Arc Welding) Essential Variables
Submerged Arc Welding (SAW) Essential Variables for WPS
The Essential Variables for Submerged Arc Welding (SAW) are parameters that, when changed,
require the Welding Procedure Specification (WPS) to be requalified.
These variables ensure the quality and integrity of the weld when subject to different welding
conditions.
Here is a summary of the **Essential Variables for SAW WPS** as per **ASME Section IX**:
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**Essential Variables for SAW WPS**:
1. **Base Metal**:
- Change in **P-Number** or **Group Number** requires requalification.
2. **Filler Metal**:
- Change in **F-Number** or **A-Number** of the filler material requires requalification.
3. **Welding Process**:
- Change from **SAW** to any other welding process (e.g., GMAW, GTAW) requires
requalification.
4. **Welding Position**:
- A change in **welding position** (e.g., from **1G** to **3G**) requires requalification.
5. **Joint Design**:
- A change in **joint design** (e.g., from **V-groove** to **butt joint**) can impact the weld
properties.
6. **Backing**:
- Changes in **backing** (use of backing material or ceramic backing) require requalification.
7. **Pipe Diameter**:
- A change in **pipe diameter** for pipe welding requires requalification.
8. **Base Metal Thickness**:
- A change in **base metal thickness** that exceeds the qualified thickness range requires
requalification.
9. **Shielding Flux**:
- A change in the **shielding flux type** or flux composition can affect the weld quality and
necessitate requalification.
10. **Current Type and Polarity**:
- Change in **current type** (DC to AC or DCEN to DCEP) or **polarity** requires requalification.
11. **Electrode Size**:
- Change in **electrode size** impacts heat input and welding performance, requiring
requalification.
12. **Travel Speed**:
- Change in **travel speed** that falls outside the qualified range requires requalification.
13. **Preheat & PWHT**:
- A change in **preheat temperature** or **Post Weld Heat Treatment (PWHT)** requires
requalification.
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**Explanation of Essential Variables**:
1. **Base Metal**:
- The **P-Number** of the base metal determines the qualification range for weld procedures. If a
change in the base metal's P-Number or Group Number occurs, the WPS must be requalified.
2. **Filler Metal**:
- The **F-Number** of the filler metal dictates the alloy and chemical composition. Any changes to
the F-Number or A-Number require requalification.
3. **Welding Process**:
- Changing the welding process (e.g., from SAW to another process) impacts the heat input and
deposition rate.
4. **Welding Position**:
- The welding position can significantly affect the bead shape, penetration, and overall quality of
the weld. Different positions require different welding techniques.
5. **Joint Design**:
- A change in the joint design can affect the mechanical properties of the weld, requiring
requalification.
6. **Backing**:
- The use of a backing material or backing bar affects heat distribution and weld pool formation,
requiring requalification.
7. **Pipe Diameter**:
- A change in the pipe diameter (e.g., small diameter to large diameter) can impact the welding
conditions and heat input.
8. **Base Metal Thickness**:
- The **thickness** of the base metal determines heat input and cooling rates. A change in
thickness outside the qualified range requires requalification.
9. **Shielding Flux**:
- The type of **shielding flux** used can change the arc characteristics, heat input, and final weld
quality, requiring requalification if modified.
10. **Current Type and Polarity**:
- Switching between **DC** (Direct Current) or **AC** (Alternating Current) or altering the
**polarity** affects the arc stability and penetration, requiring requalification.
11. **Electrode Size**:
- The **size of the electrode** impacts the weld bead geometry, heat input, and deposition rate.
12. **Travel Speed**:
- Changing the **travel speed** alters the heat input and weld bead formation, requiring
requalification if it is outside the qualified range.
13. **Preheat & PWHT**:
- **Preheat** and **Post Weld Heat Treatment (PWHT)** are critical for avoiding weld cracking,
especially in high-strength materials. Changes in these parameters require requalification.
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This document summarizes the **Essential Variables** that affect the **SAW (Submerged Arc
Welding)** procedure. It is crucial to ensure all variables remain within the qualified range for the
WPS to maintain weld integrity.
