Processes – WELDING ANSWERS

Hadfield steel is a unique, impact-resistant material that thrives under abuse, becoming tougher with every blow. This post explores its properties, why it's so durable, and its common applications in demanding environments like crusher jaws and rail crossings. Learn essential welding techniques to ensure its longevity and prevent costly failures, from selecting the right electrodes to managing heat input.

ASTM A514 (T-1) is a high-strength, quenched and tempered steel known for its exceptional yield strength and use in heavy-duty structural applications like cranes and bridges. Its martensitic microstructure, while providing strength, makes it susceptible to cracking if not welded correctly, particularly in the heat-affected zone. Successful welding requires careful selection of high-strength, low-hydrogen electrodes, precise adherence to preheat and interpass temperature guidelines, and diligent control of hydrogen sources. Unlike many steels, AWS D1.1 requires qualification by testing for A514, emphasizing the need for rigorous procedures to achieve sound and reliable welds.

Welding in out-of-position scenarios like vertical up or overhead presents challenges due to gravity, often forcing welders to use colder, slower techniques that can compromise fusion. To combat this, the ideal solution is to reposition the part for flat or horizontal welding whenever possible, significantly increasing quality and speed. If repositioning isn't feasible, using welding processes that produce slag, such as FCAW or SMAW, provides a "shelf" to support the molten puddle, allowing for higher deposition rates and better quality. Alternatively, employing pulsed welding machines enables higher wire feed speeds and even spray transfer out of position by rapidly alternating between high and low amperage for penetration and quick solidification.

This post provides answers to frequently asked questions regarding the "280 Prequalified Welding Procedures for Stainless Steel" product. It addresses common inquiries from customers about the digital format, permissible uses for CWIs, distinctions between qualified and prequalified procedures, and the rationale behind the product's affordability. Additionally, it clarifies compliance with AWS D1.6, modification flexibility, and how included guides facilitate proper use and customization of these welding procedures.

We're thrilled to announce the release of our new collection: 280 Prequalified Welding Procedure Specifications for Stainless Steel. Developed in accordance with AWS D1.6/D1.6M, this comprehensive package is designed to bring consistency and compliance to welding operations. It includes procedures for GMAW, FCAW-G, GTAW, and SMAW, covering 14 common weld joint configurations and widely used 304, 304L, 316, and 316L stainless steel base metals. This resource is perfect for business owners, fabricators, CWIs, and schools seeking to enhance quality and productivity.

Selecting the correct filler metal is paramount when welding dissimilar metals, as it dictates the strength, ductility, and corrosion resistance of the new joint. Choosing the wrong filler can lead to severe issues like cracking, reduced strength, accelerated corrosion, and ultimately, premature failure of the welded assembly. This post explains why filler metal compatibility is crucial, especially concerning thermal expansion differences and preventing brittle phases. It provides examples of dissimilar metal welding scenarios, like stainless steel to carbon steel, highlighting how specific filler metals like ER309LSi are engineered to bridge metallurgical gaps and ensure long-term integrity under various service conditions.

AWS D1.6, the Structural Welding Code for Stainless Steel, focuses on the structural integrity of welds on stainless steel alloys. It allows for cost-saving prequalified welding procedure specifications (WPSs), similar to AWS D1.1 for carbon steel. Using prequalified WPSs involves adhering to guidelines for welding process, base and filler metals, temperature, and joint type. While advantageous, users must own the code and ensure their applications align with its structural focus, as engineers are responsible for additional requirements like corrosion resistance.

Thinking about using prequalified welding procedures to save time and money? This post uncovers the eight most common mistakes fabricators make when developing and using AWS D1.1 prequalified welding procedure specifications—and how to avoid them. You’ll learn about code restrictions, filler metal requirements, joint tolerances, and other critical factors that ensure code compliance and weld quality. If you're serious about preventing costly rework and audit issues, this is a must-read.

The AWS D1.1 Structural Welding Code for Steel allows fabricators to use prequalified welding procedures (WPSs), saving significant time and money by exempting them from testing. This post outlines an 8-step guide to writing a prequalified WPS, covering selecting approved base metals, weld joints, welding processes, filler metals, shielding gases, and determining preheat, interpass, and post-weld heat treatment. It emphasizes that anyone who understands the code can create these essential documents for quality and productivity.

Want to boost welding productivity? Increasing your deposition rate is one of the most effective ways—but only if done right. This post explains the difference between melt-off and deposition rate, how higher deposition leads to faster travel speeds (and real time savings), and the common mistakes that sabotage these gains. Learn how to avoid costly errors, why simply turning up the amps isn’t enough, and how training and proper welding procedures can unlock major efficiency improvements in your shop.

Get your FREE guide on what every welding engineer must know

Get your FREE guide on what every welding engineer must know