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Think of a WPS as a recipe for welders. This includes information such as base metal grade, filler metal classification, amperage range, shielding gas composition, and pre-heat and interpass temperatures. The idea is that if a group of welders adhere to all the details on a WPS, they should each be able to produce welds with reasonably similar mechanical properties.
To answer this question, we need to take a step back. You see, before a WPS can be drafted, a preliminary set of procedures and materials must be established. This initial procedure is used to create a series of welds which are then mechanically tested to ensure they meet all applicable requirements. The procedures for creating and testing the sample welds, as well as the final results, are documented on a Procedure Qualification Record, or PQR. If the test results are acceptable, the PQR is approved and can then serve as the foundation on which one or more WPSs are drafted.
This document offers an approximate breakdown of the topics that are covered in each part of the test. No I am not upstairs, my office is on the production floor. AWS D1. Blah blah blah. I do believe this trumps 4. I do all my own testing for the company I am with. I produce the drawings and keep them in my database for future use I conduct the test and observe the welder. I do all the testing except the tensiles which I have done for about I would say someone needs to look at the waste in your system and see what can be eliminated.
Taking into account everything at my plant our cost, depending on material and other factors, ranges between Having said that, if you were to go outside for your testing you would only eliminate the actual test cost. All the cost associated with QC, welder qualification etc. From a liability standpoint may be cheap compared to a lawsuit stemming form a failure due to no testing. One other option may be to purchase the coupons outside or just have a vendor make them.
Thats what I do to save time and not have to worry about routers and all the crap that goes with them. By Date Due consideration must be given to the requirements of the applicable welding standard. The cost of qualifying a WPS is nothing compared to going to court and explaining why you didn't qualify your WPSs to verify they produce acceptable results.
A real bargain to anyone that doesn't fully appreciate what is involved in qualifying a welding procedure. The cost of ordering the proper materials with supporting CMTRs, electrode with the proper certifications especially for military work , preparing the coupons, welding, performing the requisite NDT, cutting, machining samples, and performing the required destructive tests can easily cost more than the numbers you quoted.
Now let's consider the actual cost of writing a good WPS. There are numerous "lessons to be learned" by qualifying welding procedures in-house. Simply purchasing WPSs from AWS or other sources is a lost opportunity for the welders and management to gain an appreciation of how important proper cleaning and technique are in achieving the desired results. Best regards - Al. By GRoberts Date The SWPS issue being seperate. If you capture all of them, it may surprise you.
I realize that for basic commercial D1. And that is no lie, you probably would be happy to stop!! GRoberts, Very well said and so true. It must be done. Now on to the other true part of your statement that some of us have been pointing out.
And I would agree with handing them the applicable code, specifications, and customer contract, and ask them thier own question. By jon Date If I were only working to D1.
Do NOT re-write, rather make an "informational" copy. I might be fringing on copyright here but believe a copy can be made for review purposes but would stamp it in some way to identify it as a copy for review only.
Be cautious too that I don't think SWPS' are currently offered with impacts although B2 Committee folks inform me that they are no reviewing PQR's with impacts for future consideration. No impacts? Any certification required? Labor cost in the Northeast Metro area is high - very high. So here I am again justifying my own costs and you know what? I think I may have arrived at the answer I was looking for.
Thanks all. Also, it was stated that this was a typical price. I perform almost all work myself. I am not ignorant of the costs.
I am not trying to criticize you tom. It's just hard for me to see that much overhead. By Bill M Date By Date Edited Hello Hogan; I guess you work for free. Not many of us are willing to work for no pay considering there is no one willing to pay my mortgage, medical insurance, buy my food, save for retirement, etc. If I remember correctly, you said you are working with a welding supplier and do CWI work on the side. There's a major difference in doing it as a part time job and doing it as a means of earning a living.
I would place you in the same category as welding instructors that do CWI work as a side line business using the equipment, materials, etc. Don't misconstrue what I'm saying, there's nothing wrong with doing what you are doing, but it doesn't reflect the true cost of doing business.
I noticed you didn't say anything about witnessing the actual welding of the coupon. God bless you if you are working for free, because I have a couple of jobs to send you on. I assume you are willing to cover your own airfare and you'll rent the car on your own nickel. If you do not witness the actual welding of the test coupon How do you know what the test conditions were if you were not there? Are you "pencil whipping" the information such as test position, voltage, amperage, travel speed, the welder's name, etc.?
Surely you don't believe the client is actually watching and recording that information. If they were, they wouldn't need you to complete the paperwork. So, are you "certifying" the information is correct when you sign the welding documents? There have been several posts relating to CWIs that basically say, "Send me your test plates and I'll do the rest.
I had to come back to this post and edit it or at least add to it. I don't fault anyone for starting their career as a part time CWI, but please don't sell yourselves cheap. You have the training and the credentials that set you above the rest. A Welding Procedure Specification is essential for every welding company to have because it maintains quality standards across every weld.
Under various Australian and international standards eg. Under the Work Health and Safety Act of , business owners have an obligation and duty of care to construct and operate a safe plant.
For compliance to the Act, welders need to ensure they are following correctly designed WPS. In Australia, Standards Australia is the peak non-governmental agency in charge of the approval of welding standards.
Their 73 member group has created basic WPS for some of the most common welding types, including welding of carbon steels, stud welding, and welding stainless steels for structural purposes. Because every company has different welds to complete, Standards Australia has not created WPS for every type of weld. If your company uses a weld that does not have a WPS, it is your obligation to create one. Gather the base materials and welding consumables you need, including metal types, grades, and tools.
You should also go through the weld, step by step, to ensure anyone with the proper welder qualification can follow your lead. During this stage, you will essentially build the weld based on the tools and procedures you wrote down in the pWPS. If there are any mistakes or if you skipped over any part of the process, you will adjust the pWPS. Once you have created a procedure test and proven your initial pWPS creates the desired weld, you will have the information to create the final WPS.
This will have all the correct information about building the weld, including the tools you need, the process you need to go through, and the final, desired outcome. This final WPS will once again be tested again to ensure there are no errors. A PQR is used to test a weld and is a record of what actually took place at the time of welding it.
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