Metal Arc Welding of Carbon & Carbon Manganees Steel(9595-1996)

8/13/2019 Metal Arc Welding of Carbon & Carbon Manganees Steel(9595-1996)

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Welding Applications Sectional Committee, MTD 12

FOREWORDThis Indian Standard ( First Revision ) was adopted by the Bureau of Indian Standards, after thedraft finalized by the Welding Applications Sectional Committee had been approved by theMetallurgical Engineering Division Council.This standard was first published in 1980. While reviewing the standard in the light of experiencesgained during these years, the Committee decided to revise it to bring it in line with the presentpractices being followed by the Indian industry.This standard relates to the welding of particular types of steel regardless of the form in which thesteel is used, for example, plates, sections or tubes. It has been used extensively over a wide fieldof fabrication and has been recognized as a comprehensive welding standard.Annexures are included to give guidance on factors that should be considered in establiihingwelding requirements and procedures for a particular fabrication.,methods of testing and acceptance levels are not specified. Permissible stresses in welds,These requirements should be obtainedfrom the relevant application standard or by agreement between the purchaser and the fabricator.This standard keeps in view the practices being followed in the country in this field. Assistancehas also been derived from BS 5135 : 1984 Specification for process of arc welding of carbon andcarbon Manganese steels, issued by the British Standards Institution.For the purpose of deciding whether a particular requirement of this standard is complied with,the final value, observed or calculated, expressing the result of a test, shall be rounded off inaccordance with IS 2 : 1960 Rules for rounding off numerical values ( r evi sed ). The number ofsignificant places retained in the rounded off value should be the same as that of the specifiedvalue in this standard.

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I ndian St andardMETAL-ARCWELDINGOFCARBONANDCARBONMANGANESESTEELS- RECOMMENDATIONS

( i rst Rev i si on1 SCOPE1 1 This standard recommends generalrequirements for the manual, semi-automaticand automatic metal arc welding of carbon andcarbon manganese steel in all product formsincluding tubes and hollow sections, complyingwith the requirements of 5.1.2 The annexures are intended to assist usersof this Standard by giving guidance on. varioustopics.

IS No4353 : 1967

5760 : 19835419 : 1971

Ti t leRecommendations for sub-merged arc welding of mildsteel and low alloy steelsCompressedr evision ) argon ( firs2Welding rods and bareelectrodes for gas shielded arcwelding of structural steel

7280 : 19742 REFERENCESThe following Indian Standards are necessary 7307adjuncts to this standard: (Part 1) : 1974

I S No..307 : 1,966812 : 1957813 : 1986814 : 1991816 : 1969

822 : 19701024 : 1979

2062 : 1992

8500 : 1992

~3613 : 1974

Ti t leCarbon dioxide ( secondrevision )Glossary of terms relating towelding and cutting of metalsScheme of symbols for weldingCovered electrodes for metalarc welding of structural steelCode of practice for use ofmetal arc welding for generalconstruction in mild steel f i rs trevision )Code of procedure forinspection of weldsCode of practice for use ofwelding on bridges andstructures subject to dynamicloading (first r evision )Steel for general struc-tural purposes - Specificat ion( four th revision )Structural steel-microalloyed( medium and high stren~gthqualities )revision ) - Specification f i rs tAcceptance tests for wire-fluxcombinations for submergedarc welding of structural steels( j i rst~revision )

7310(Part 1): 1974

7318( Part 1) : 1974

10178 : 1982

13851 : 1993

Base wire electrodes forsubmerged -arc welding ofstructural steelsApproval testsprocedures: Part of welding1 Fusionwelding of steelApproval tests for weldersworking to approved weldingprocedures: Part 1 Fusionwelding of steelApproval tests for welders whenwelding procedure approval isnot required : Part 1 Fusionwelding of steelRecommended procedure forCO8 gas shielded metal-arcwelding of structural steelsStorage and redrying ofcovered electrodes before use- Recommendations

3 TERMINOLOGYFor the purpose of this standard, the definitionsgiven in IS 812 : 1957 and the following shallapply.3.1 Auto-Contact WeldingAn automatic metal-arc welding prooess usingcovered electrode the covering of which is keptin contact with the parent metal during welding.3.2 Gravity Welding

Metal-arc welding using a contact electrodesupported by a mechanism which allows the

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IS 9595 : 1996electrodes to descend and move along the jointunder gravity.4 INFORMATION TO BE SUPPLIEDThe information either supplied by thepurchaser or decided between the purchaser orhis representative and the fabricator asappropriate shall include the following:

a) Specification of the parent metal and ofthe required weld metal and weld jointproperties,b) The application standard or code to beapplied together with any supplementaryrequirements;c) Locations, dimensions and details, thatis, form of joint, angle between fusionfaces, gaps between parts, of all welds.Symbols conforming to IS 813 : 1986should be used for standard weld forms,but details shall be given for any non-standard welds;d) Whether the welds are to be made in theshop or elsewhere;e) Surface finish of weld profile;f) Pre-and post-weld heat treatment;g) Whether written welding procedures and/or tests are required;h) Quality control arrangements and testingand inspection requirements;j) Weld acceptance levels; andk) Whether means of identification on welds

to trace back to the welders is requiredand if so means to be used.5 PARENT METAL5.1 The requirements of this standard apply tocarbon and carbon manganese steels both semi-killed and killed having chemical analysisdetermined by ladle analysis and refer to steelsup to a maximum carbon equivalent of 0.53when calculated using the following formula:Carbon Equivalent=c++ + Cr -I- MO+ V + Ni +Cu

5 15NOTE - This carbon equivalent formula may notapply to carbon manganese steels of low carboncontent ( less than 0.10 percent) or boroncontaining steels and therefore the guidance givenin F-3.1 should be followed.5.2 The requirements of this standard may beapplied to steels whose carbon equivalentexceeds 053. but it should be borne in mind

users should consult the steel maker, thewelding consumable supplier or other appro-priate authoritative sources with regard to thewelding procedures ( see 23 ).5.3 Requirements .of these standards may beapplied to the steels in as rolled and normalizedconditions.6 DISSIMILAR STEELSWhile welding joints between dissimilar carbonor carbon manganese steels covered by this.standard, the welding procedure shall be thatrelating to the steel having the higher carbonequivalent unless otherwise required by thedesigner.7 WELDING CONSUMABLES7.1 Manual Metal-Arc WeldingThe electrodes used for manual metal-arcwelding shall comply with the requirements ofIS 814 : 1991 or other appropriate standard.Electrodes should be selected having regard tothe application, that is, joint design, weldingposition, current conditions and the propertiesrequired to meet the service conditions.7.2 Semi-Automatic and Automatic Metal-ArcWelding ( Covered Electrodes )This group of processes embraces gravity andautocontact welding with long straight lengthsof covered electrode and open-arc welding witha continuous covered electrode. The weldmetal produced from electrodes used with theseprocesses shall have mechanical properties notless than the minimum specified for the weldmetal produced by electrodes complying withIS 814 : 1991, except otherwise specified in thestandard for the particular application.7.3 Submerged Arc WeldingElectrode wire shall conform to IS 7280 : 1974.The electrode wire and flux combination shallsatisfy the requirements dictated by factors suchas the welding procedure and position and shall. _comply with the appropriate sections ofIS 3613 : 1974. The combination should beselected having regard to particular application.7.4 Gas-Shielded Processes1.4.1 Fil ler Rods and W ir esWhen a solid metal filler rod or wire is used1with a gas shielded process, it shall comply withthe requirements of IS 6419 : 1971 and shouldthat fabrication experience above this level is be selected having regardlimited, particularly with respect to the effects application.of higher strength levels and higher alloycontents ( as in quenched and tempered weather- 7.4.1.1 Cored electrodes,resistance grades of steel ). In this respect, the appropriate shielding

to the particular

when used withgas nor gas mixture,2

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shall give weld metal properties not less thanthe minimum specified for grade of materialbeing welded.7.4.2 Shielding GnsesWhen a gas or gas mixture is used, it shall be+the following quality as appropriate:

a) Argon - The gas shall conform toIS 5760 : 1983.b) Carbon Dioxide - The gas shall conformto IS 307 : 1966. Sound welds can bemade consistently if the electrodedesigned for use with carbon dioxidecontains the appropriate balance ofde-oxidizers.

.c) Gas M ixt ures - The use of gas mixturesis permissible provided they have beenproved to be satisfactory. This may beas a result of procedure approval testswhere in sufficient previous experienceexists. When a gas mixture is used w~hichhas specified additions, the variation ofsuch additions shall not exceed f10percent of the stated.

The following are some typical gas mixtures:a) Gas shielded tungsten arc process

1) Argon2) Argon + Helium

b) Gas shield metal arc welding1)2)3)4)5)

6)7)

Argon -1 3 to 5 percent oxygenArgon + 1 to 2 percent oxygenCarbon dioxide using de-oxidizingelectrodesArgon + 20 to 50 percent carbondioxideArgon + 10 percent carbon dioxide+ 5 percent oxygen using de-oxidizingelectrodesCarbon dioxide i- 20 percent oxygen75 percent argon + 25 percent carbondioxide

7.5 Unshielded Semi-Automatic Arc WeldingElectrodes for this process are generally of the,cored type and shall deposit weld metal withmechanical properties not less than thosespecified as satisfactory for the particular gradeof steel being welded. Exceptions may beallowed if specified in the particular applicationstandard being used.7.6 Hydrogen LevelsWhen hydrogen controlled welding consumablesare to be used the contractor shall be able to

IS 595 : 1996demonstrate that he has used the consumablesin the manner recommended by the consumablesmanufacturer and that the cosumables havebeen dried or baked to the appropriatetemperature levels and times.7.7 Storage and Handling7.7.1 GeneralAll consumables shall be stored and handledwith care and in accordance with the manufac-turers recommendations. Electrodes, fillerwires and rods and fluxes that show signs ofdamage or deterioration shall not be used.Examples of damage or deterioration includecracked or flaked coatings on covered electrodes,rusty or dirty electrode wires and wires withflaked or damaged copper coatings.7.7.2 Covered ElectrodesElectrodes shall be stored in their originalpackets or cartons in a dry and well ventilated,preferably under heated conditions whererelative humidity ( RH ) shall be less than theexternal conditions ( preferred RII is approxi-mately less than 50 percent ). Use of racks,pallets or other suitable means to storeelectrodes off the floor is recommended. Theideal storage temperature is about lo-15Cabove the ambient temperature. When specialprotection or other treatment during storage orimmediately prior to use is recommended by themanufacturers of the electrodes, they shall betreated in accordance with the recommendationsof the mauufacturers ( see 3.1 of IS 13851 :1993 ).7.7.2.1 In order to ensure that the weld metaldeposited by hydrogen controlled electrodes fallswithin the limits of the appropriate carbon equi-valent scale besides the weld metal soundness,these electrodes shall be redried at 360C for anhour or as recommended by the manufacturers(see 6 of 1s 13851 : 1993 ).7.7.2.2 After removal from the drying oven,the electrodes shall -be protected from exposureto conditions conductive to moisture absorption,preferably by being kept in n heated secondaryoven, if the lowest hydrogen levels are desired.All unused electrodes shall be returned to thestorage so that they are not exposed to un-heated and possible damp working area wherethey can regain moisture ( see 6 of IS 13851 :1993).7.7.3 Aut omatic and Semi-A utomati c WeldingWire or cored electrodes shallbe suitably packedto guard.against damage, including that duringtransportation. When stored, the wire or elec-trode should be kept in its original bundle orpackage in a dry store room.

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IS 9595:19967.7.3.1he performance of copper coated wiresdepends on the continuity and regulaiity of thecopper coating. Such considerations should bethe subject of agreement between the fabricatorand the supplier of copper coated wires.7.7.3.2 Flux shall be packed in moisture,resistant containers and shall be protected fromdamage, including that during transportation.-When stored,. the Aux should be kept in itsoriginal container in a dry store room.7.7.3.3 If the composition of the flux is suchthat special protection during storage or specialtreatment before use is desirable details of suchspecial protection or treatment shall be furni-shed by the manufacturer of flux and implemen-ted by the fabricator. Regrinding of welding slagto be used in admixture with fresh flux is notrecommended.8 EQUIPMENT8.1 ower SourceWelding power source, instruments, cables andaccessories shall comply with the requirementsof the appropriate Indian Standards whereavailable. The contractor shall be responsiblefor ensuring that their capacity is adequate forthe welding procedure to be used and maintain-ing all welding plant and ancillary equipment ingood working order.

8.2 EarthingAll power sources and implements in connectionwith the welding operation shall be adequatelyearthed. The welding return lead from the workshall be adequate in cross section and shall becorrectly connected and earthed.8.2.1 The importance of proper earthmg cannotbe over-stressed since incorrect earthing maylead to lower current, lower arc voltage, over-heating of electrode holders, defective welds,etc.8.3 InstrumentationAdequate means of measuring the current shallbe available, either as part of the welding power,source or by the provision of a portable amme-ter.8.3,1 In the cases of automatic and semi-automatic welding, means shall be provided formeasuring the arc voltage, current and/or wirefeed speed, and the rate of flow of shieldinggases.9 BUTT-WELD DETAILS9.1 he details of all butt-welds, for example,form of joint, angle between fusion faces andgap between parts,- shall be arranged to permit

the use of a satisfactory welding procedure and.the combination of weld detail and welding pro-cedure shall be such that the resultant joint willcomply with the requirements of the design( see Annexes A,B, C and D ).9.2 Throat ThicknessThe ends of butt joints in plate shall be weldedso as to provide the full throat thickness. Thismay be done by the use of extension pieces orother means approved by the purchaser.9.3 Weld ProfileIn the as-welded condition, the weld face shallbe ground ( having some reinforcement ) of thesurface of the parent metal. Where a flushsurface is required, the excess weld metal shallbe dressed off. When no dressing is to be carriedout, the permissible weld profile shall either beas specified in the application standard or besubject to agreement between the purchaser andthe fabricator.9.4 Full PenetrationFull penetration single V.U.J bevel or squarebuttwelds shall be completed by grinding, chip-ping or gouging the root run from opposite sideto sound metal and then depositing a sealing runof weld metal on the back of the joint. Wherethese or other butt welds are to be welded fromone side only, suitable backing material shall beused except where it is agreed between thepurchaser and the contractor that, by the adop-tion of an approved special method of welding,full penetration will be obtained without the useof backing material. It should be appreciated,however, that under fatigue and corrosiveconditions backing material may be undesirable.9.5 Backing Material9.51 Backing material, if used, shall be of samequality as that of parent material or as agreed toby the purchaser.

NOTE - Care shall be taken when using copper asa backing material as there is a risk of copper pickup in the weld metal.9.5.2 Where backing material is employed, the.joint shall be arranged in such a way as toensure that complete fusion of the parts to be.joined is readily obtained.9.6 Back GougingIn all complete penetration butt-welds, where.these are to be welded frdm both sides, certainwelding procedures allow this to be donewithout back gouging, but where complete pene--tration cannot be achieved, the back off the firstrun shall be gouged out by suitable means to,clean sound metal before welding is started omthe gouged out side ( see Fig. 1 ).

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IS 9595 : 1996

Ir) FIRST SIDE WELDED

(b) BACK OF FiRST RUN GOiJGEDOUT TO C~LEAN METAL

FIG. I METHOD OF GOUGING OUT COMPLEIBPENETRATION BUTT-JOINTSWELDED FROM BOTH SIDES10 PARTIAL PENETRATION bUTT-WELDS10.1 A butt-weld which is designed as a partialpenetration weld shall have a throat thicknessnot less than specified.10.2 An incomplete penetration but.t-weld whichis welded from one side only shall not be sub-jected to a bending moment which would causethe root of the weld to be in tension, unless thisis allowed by the application standard.10.3 The use of inbomplete penetration. butt-welds to resist repeating or alternating dynamicfQrces should be avoided ( see Annex A ).Jl FILLET WELD DETAILS11.1 A fillet weld, as deposited, shall be not lessthan the specified dimensions which shall be,clearly indicated as throat thickness and/or leglength as appropriate, taking into account theuse of deep penetration processes or partialpreparations ( see Annex D ).

11.2 For concave fillet welds, the act 1 throatthickness shall be not less than 07 % es thespecified leg length. For convex fillet yelds,the actual throat thickness shall be not morethan 09 times the actual leg length.11.3 Where the specified leg length of a filletweld at the edge of a plate or section is.suchthat the parent metal does not project beyondthe weld, melting of the outer corner or corners,which reduces the throat thickness, shall not beallowed ( see Fig. 2 ).

NOTE - Guidance on the design of fillet welds isgiven ID A-2.12 WELDS IN SLOTSSlots that are required to be filled with weldmetals +a11 only be filled after the fillet weld hasbeen inspected and approved. When filling slotswith weld metal, care shall be taken to avoidcracking.

Ja ) DESIRABLE (~IACCEPTABLE BECAUSE orFULL THROAT THICKNESSFIG.~ FILLET WELDS APPLIED TO THE EDGE OF A PART

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IS 9595 : 199613 PREPARATION OF J OINT FACESla.1 If preparation or cutting of the material isnecessary, this shall be done by shearing, chipp-ing grinding, machining, thermal cutting orthermal gouging. Other methods shall only be.used by agreement between the contractingparties. When shearing is used, the effect ofwork hardening shall be taken to ensure thatthere is no cracking of the edges.13.2 In cases where the cut edge is not a fusionface, the effect of embrittlement from shearing,thermal cutting or thermal gouging shall not beto the detriment of the performance of the fabri-eation. As a general guide, a hardness of 350HV is considered to be the maximum allowablevalue for a thermally cut edge that is not fullyfused into a weld.13.3 Local hardening can be reduced by suitablethermal treatment or removed by mechanicalmeans. The removal of 1 mm to 2 mm from acut face normally eliminates the layer of hard-ness. When using thermal cutting, local harden-ing can be reduced by considerable decrease innormal cutting speed or by pre-heating beforecutting. The steel supplier should be consultedfor recommendations on achieving a reductionin hardness.14 FUSION FACES34.1 The preparation of fusion faces, angle ofbevel, root radius and root face shall be suchthat the limits of accuracy required by theappropriate application standard can be achie-ved. When however, no appropriate applicationstandard exists and this standard is itself to beused, it is recommended that, for manual weld-ing, the tolerances on limits of gap and rootface should be f 1 mm on the specified dimen-sions for materialc up to and including 12 mmthick and &2 mm for material over 12 mmthick. The tolerance on the included anglebetween the fusion faces of a V preparation isrecommended to be _rt5 and for U and Jpreparations + 10. For an automatic process,0closer limits are necessary and particular requi-rements depend on the characteristics of theprocess.14.2 It shall be ensured, if necessary, by suitablenon-destructive tests that the fusion faces andadjacent surfaces shall be free from cracks,notches or other irregularities which might bethe cause of defects or would interfere with thedeposition of the weld.14.3 Fusion faces and the surrounding surfacesshall be free from heavy scale, moisture, oil,paint or any other substance which might affectthe quality of the weld or impede the progressof welding. Certain proprietary protectiveroatings are specially formulated with the inten-

tion that they should not interfere with welding_The use of such coatings is not excluded by therequirements of this clause but, shall be demon-strated by means of specimen welds that the-coating complies with the above requirements.15 ASSEMBLY FOR WELDING15.1 Parts to be welded shall be assembled suchthat the joints to be welded are easily accessibleand visible to the operator.15.2 Jigs and manipulators should be used,nhere practicable, so that the welding can becarried out in the most suitable position. Jigsshall maintain the alignment with the minimumrestraint so as to ieduce the possibility of lockedin-stress.16 ALIGNMENT OF BUTT J OINTSThe root edges or root faces of butt joints shallnot be out of alignment by more than 25 percentof the thickness of the thinner material formaterial up to and including 12 mm thick, or bymore than 3 mm for thicker material. Forcertain applications and welding processes, closertolerances may be necessal y.17 FIT-UP OF PARTS J OlNED BY BILLETWELDS17.1 The edges and surfaces to be joined byfillet welds shall be in as close a contact aspossible, since any gap increases the risk ofcracking. In no case should the gap exceed I5mm ( see 11 and Annex F >.17.2 Because of variation in the shape of sectionsdue to mill tolerances, and subsequent methodsof forming, deviations from the true profile arelikely to be met. When such sections areattached to any plate or member by a fillet weid,the fit-up at a rrJunded edge of a section shallbe within 15 mm measured at a distance fromthe edge not exceeding half the thickness of thesection ( SM Fig. 3A ). When the full throatthickness is assumed in stress calculation andthe rolled section has a thickness i greater than12 mm, the rounded portion shall be filled witha single pass of weld proceeds. The roundedportion shall be filled up with a single pass ofweld as shown in Fig. 3C.17.3 Good workmanship as regards fit up forfillet welds is more important than for buttwelds. It is also important with high tensile steelthan with mild steel.18 TACK WELDS18.1 Tack welds shall be not less than the throat:thickness or leg length of the root run to beused in the joint and shall be subject to the.

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IS 9595 : 1996

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FICL 3 ALLOWANCEFOR THE ROUNDEDTOE OF A SECTIONsame welding conditions as those specified forthe root run. The length of the tack weld shallnot be less than four times the thickness of thethicker part or 50 mm whichever is the smaller.18.2 Where a tack weld is incorporated in awelded joint, the shape, size and quality of thetack shall be suitable for incorporation in thefinished weld ( see 32 ) and it shall be free fromall cracks and other welding defects. Tack weldswhich crack, shall be cut out and rewelded.18.3 In joints welded by an automatic processor where smaller tat k welds are desired, theconditions for deposition shall be as givenin 24.18.4 Tack welds shall not be made at extremeends of joints.19 TEMPORARY ATTACHMENTSWelded temporary attachments should beavoided as far as possible, but when used the

welds should be remote from principal joints asfar as practicable and shall be made in accor-dance with 18 and 24.20 PROTECTION FROM THE WEATHER20.1 Surfaces to be welded shall be dry. Whenrain or snow is falling or during periods of highwind, necessary precautions shall be taken toprotect outdoor welding areas. Warming shallbe carried out at all ambient-temperatures belowIOC and whenever there is evidence of conden-sation taking place on the metal surfaces.20.2 Droughts shall be prevented from blowingalong the bores of structural hollow sectionswhen the bore will be penetrated during weld-ing.20.3 Where gas-shielded welding processes arebeing used, air currents at speeds as low as8 km/h can remove the shielding gas, and, there-fore, sufficient screening shall be used to keepIwinds and droughts away from the welding area.Droughts shall be prevented from blowing alongstructural hollow sections to be welded.21 STRAY ARCING ON WORKStray arcing shall be avoided as this can leavelocal hard spots or cracking which may need tobe removed by mechanical means and be checkedby inspection ,depending upon the application.Removed hard spots can be made good by thedeposition of weld metal in accordance with thisstandard.

Stray arcing can occur:a) between the electrode and the work awayfrom the weld preparation;b) between the electrode holder and thework;c) between the work and the welding earthreturn lead connection;d) between the work and any part at ear the)

f)

potential;with automatic and semi-automatic weld-ing, between parts of the welding head ortorch ( for example loose contact tube inMIG gun ) and the workpiece; andwith the TIG process, between the tungs.-ten electrode and the work which cangive rise to tungsten inclusions in theworkpiece. This contaminatiou is not soserious as copper contamination but wherethe inclusions are large and angular ornumerous they should be removed bymechanical means

Items f b ), (c ) and ( e ) result in localizedcontamination with copper. The contaminatedarea may be brittle and/or cracked due to inter-7

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IS 9595 : 1996granular penetration of copper. These areasshall be removed by mechanical means asabove.Items (c ) and ( d > can be avoided by a firmearth connection ( see 8.2 ).22 INTER-RUN CLEANINGEach run of weld bead shall be thoroughlycleaned to remove particles of slag, spatters,etc, before the subsequent bead is superimposedduring multi-pass welding. Similarly, eachlayer of weld should be thoroughly cleaned ofslag, spatters, etc, before depositing subsequentlayers of weld with particular reference tothorough cleaning of toes of the welds. Visibledefects,. such as cracks, cavities and otherdeposItIon faults, if any, shall be removed tosound metal before depositing subsequent runor layer of weld.23 DETAILS OF WELDING PROCEDUREA typical welding procedure sheet is given inAnnex E.24 WELDING PROCEDURES TO AVOIDCRACKING24.1 Cracking is a defect which may impairservice performance (see 32 ). Depending uponthe particular duty of a joint, considerationshall be given to the avoidance of thefollowing:

a) Hydrogen induced delayed cracking ( seeAnnex F),b) Solidification cracking ( see Annex G),andc) Lamellar tearing ( see ~Annex. H ),

24.1.1 It is emphasized that the weldingprocedure is arrived at by the adherence to thegraphs given for guidance in Annex F, coupledwith past experiencemethods, if any. and quality control25 APPROVAL AND TESTING OFWELDING PROCEDURES25.1 If so required by the purchaser, thecontractor shall carry out proceduretests in accordance with IS 7307 ( Part 1 ) :1974 to demonstrate by meanb,of a specimenweld of adequate length on a steel represen-tative of that to be used, that he canmake satisfactory welds with the weldingprocedure to be used on the contract. The testweld shall include weld details from the actualconstruction and it shall be welded in a mannersimulating the most unfavourable instances offit-up, electrode condition, etc, within. therequirements of this standard which it is anti-

cipated may occur on the particular fabrication..Where material analysis are available, thewelding procedure test shall be carried out ommaterial with the highest carbon equivalent.25.2 After welding, but before the relevant testgiven in IS 7307 ( Part 1 1 : 1974 are carried out,.the test weld shall be held as long as possible atroom temperature, but in any case not less than72 hours, and shall, then be examined forcracking. The examination procedure shall beagreed between purchaser and contractor asbeing sufficiently rigorous to be capable ofrevealing significant defects in both parent metal.and weld metal.26 APPRQVAL AND TESTING OF.WELDERSThe contractor shall satisfy thepurchaser thatthe welders are suitable for the work upon which:they will be employed. For this purpose thewelders shall have satisfied the relevant require-ments of IS 7315 ( Part 1 1 : 1974. If the welderswill be working to approved welding procedures,they shall satisfy the relevant requirements ofof IS 7310 ( Part 1 ) : 1974.27 IDENTIFICATIONWhen specified by the purchaser, adequatemeans of identification either by an identificationmark or other record, shall be provided toenable each weld to be traced to the weldersby whom it was made. Attention is drawn to-the danger of hard stamping in highly stressedarea and the designer should give guidance as to.the location of such marks. Indentation used.for marking in radiographic examination come:into the same category.28 PEENING28.1 Peening of welds shall be carried out only-by agreement between the purchaser and thecontractor.28.2 If specified, peening may be employed tobe effective on each weld layer except the first.-Peening, to _,be effective, should induce somecold work In the layer subjected to peening.Peening shall be avoided between the temperatureiange of 250-450C because peening in thisrange may result in loss of notch toughnqss.29 REMOVAL OF TEMPORARYATTACHMENTSWhen welded attachments used to facilitateconstruction are required to be removed, thisshall be done carefully by cutting or chippingand the surface of the material shall always befinished smooth by grinding. The practice ofhammering off temporary attachments i&not recommended.

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IS,'9595996:30 SUPERVISIONIt shall be the responsibility of the contractor to\ensure that all welding is carried out inaccordance with the, terms of this standards,.and he shall provide all the supervision tofulfil this requirement.

.31 INSPECTION AND TESTING

.31.1 The method of inspection shall be in

.accordance with IS 822 : 1970 and extent ofinspection and testing shall be in accordance,with the relevant application standard or, in theabsence of such a standard, as agreed betweenthe contracting parties ( see 4 ).NOTE -Because of the risk of delayed crackling,IAperiod of at least 48 hours is recommendedbefore inspection is made of as.welded fabrica-tions. Whatever period is used it should be statedin the inspzcion records.

.31.2 The purchaser or his representative shallhave access to the contractors work at allreasonable times, and the contractor shallprovide hiti with all facilities necessary forinspection during manufacture and oncompletion.31.3 Welds which by agreement are to be,inspected and approved shall not be painted or*otherwise obscured until they have beenaccepted.:32 QUALITY OF WELDS ANDCORRECTIONS32.1 Quality of WeldsWelded joint shall be free from defects thatwould impair the genuine service performanceof the construction. Such acceptance require-ments, covering both surface and sub-surfacedefects, shall be as specified in the application,standard or be the subject of agreement betweenthe contracting parties ( see 4 ).32.2 Corrections of Faulty WeldsWhen welds do not comply with therequirements of 32.1, the defective portionsshall be removed. They shall then be reweldedand reinspected in accordance with thisstandard. Unacceptable under cutting shall bemade good by grinding or preferably, by thedeposition of additional weld metal inaccordance with this standard. If undercuttingis blended out by grinding, care should be takento ensure that the design thickness of the parentmetal is not reduced.

32.2.1 Defective welds (whole or portions) shallbe corrected either by removing, replacing or asfoIlows:a) Excessive convexity, reduced to size byremoval of excess weld metal; andb) Shrinkage cracks, cracks in parent plateand crater, defective portions removeddown to sound metal and rewelded.

32.2.2 Wherever corrections necessitate thedeposition of additional weld metal, an electrodeor welding rod of a size not exceeding 4 mmmay be used.32.2.3 A crack shall be removed throughout itslength and depth. To ensure that the whole ofthe crack is removed, visual or magneticinspection or any other equally positive meansmay be used and material beyond lo to 25 mmof each end of the crack preferably be removed.32.2.4 In removing defective parts or a weldgouging, chipping, oxygen cutting or grindingshall not extend into the parent metal to anysubstantial amount beyond the depth of weldpenetration unless cracks or other defects existin the parent plate. The weld or parent plateshall not be nicked or undercut in chipping,grinding, gouging or oxygen cutting.32.2.5 Improperly fitted or misaligned parts maybe cut apart and rewelded. Members distortedby the heat of welding may be straightoned bymechanical means or by the careful applicationof a limitedamount of heat. The temperatureof such areas shall not exceed 650C ( dull redheat ). Under no circumstances shall the heatedportions be quenched. The parts to be heatedfor straightening shall be substantially unloadedat the time.33 POST WELD HEAT TREATMENTWhen heat treatment of welds is specified, thisshall be done in accordance with the standardfor the particular application where this existsor shall be fully detailed, taking account of theeffect on joint properties, wbere there is nosuch standard.:ot;;k;ING AND PROTECTIVE

All welds shall be cleaned of slag and otherdeposits after completion. Till the work isinspected and approved, painting shall not bedone. The surfaces to be painted shall becleaned of spatter, rust, looso scale, oil anddirt.

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IS 9595 : 1996ANNEX A

( Chuses 9.1,10.3 and 11.3 )NOTES ON DESIGN ( see also Annex H )

(Typical application standards covering weld design aspects are IS 816 : 1969 and IS 1~024 1979 )A-l BUTT JOINTS ( see also Annex B )A-l.1 utt joints between parts of unequalcross section arranged in line will result in alocal increase in stress in addition to the stressconcentration caused by the profile o.f the welditself. If the centre planes of the two partsjoined do not coincide, local bending also willbe induced at the joints. If the stresses inducedby these effects are unacceptable, the partsshould be shaped so as to reduce the stresses.Examples of plain and shaped parts are shownin Fig 4. The slope of the taper should be basedon design ~requirements. If no such requirementis stated, it is recommended that the slopeshould not be steeper than 1 in 4.A-l.2 An incomplete penetratidn butt weldwhich is welded from one side only, should notbe subjected to a bending moment about thelongitudinal axis- of the weld which wouldcause the root of the weld to be in tension,unless this is allowed by the applicationstandard.A-l.3 The use of incomplete penetration buttwelds to resist repeating or alternating dynamicforces should be avoided where possible but,where they are used, the design stresses shouldbe suitable for the loading conditions.

A-l.4 Welded joints subjected to fluctuatingloads should be designed so that the stresses.satisfy the requirements of IS 1024 : 1979.A-2 FILLET WELDSA-2,1 The effective length of an open endedfillet weld should be taken as the overall lengthless twice the leg length, thereby discountingthe contribution of the stop and start positionswhich are generally of reduced profile. In anycase, the effective length should not be less thanfour times the leg length. Fillet welds termi-nating at the ends or sides of parts should bereturned not less than twice the leg length of theweld unless access of the configuration -renderthis impracticable. This procedure is particularlyimportant for fillet welds on the tension side ofparts carrying a ,bending load.A-2.1.1 1~ fillet welded joints carrying acompressive load, it should not be assumedthat the parts joined are in contact under thejoint. For critical applications the use of a fullpenetration weld should be considered.A-2.1.2 A single fillet weld should not besubjected to a bending moment about thelongitudinal axis of the joint which would cause,the root of the weld to be in tension.e

FIG. 4 BUTT J OINTSop UNEQUALCROSSSECTION

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A-2.1.3 Where fillet welds are used in slots orholes through one or more of the parts being.joined, the dimensions of the slot or hole shouldgenerally comply with the following limits interms of the thickness of the parts in which theslot or hole is formed:a) The width or diameter should be not lessthan three times the thickness of 25 mm,whichever is the greater;b) Corners at the enclosed ends of slotsshould be rounded with a radius of notless than 15 times the thickness or12 mm, whichever is the greater; andcl The distance between the edge of the partthe edge of the slot~or hole, or betweenadjacent slots or holes, should be not less

than twice the thickness and not less than25 mm for holes.:A-2.1.4 Fillet welds connecting parts, the fusion?faces of which form an angle of more than 120or less than 60, should not be relied upon to.transmit calculated loads at the full workingstresses unless permitted to do so by thestandard for the particular application.A-2.1.5 The design throat thickness of a flat orconvex fillet weld connecting parts the fusionfaces of which form an angle of between 60and 120, may be derived by multiplying theleg length by the appropriate factor as follows:

IS 9595 : 19 MAngle BetweenFusion F aces Factor by Whi ch Leg Length isDegree Mul tipl ied to Give DesignThroat Thickness

60 90 0791 - 100 065101 - 106 06107 - 113 055114 - 120 05A-2.1.6 Due account should be taken offabrication, transport, and erection stressesparticularly for those fillet welds which havebeen designed to carry only a light load duringservice.A-2.1.7 Welded joints subjected to fluctuatingloads should be designed so that the stressessatisfy the requirements of IS 1024 : 1979.A-2.1.8 Minimum sizes of fillet welds shall be asgiven below to avoid cracking:Thi ckness of Thicker Part Size of F il let ~Weldr A ~Over Up to andIncludingmm mm mm- 6 36 12 412 18 618 36 8

36 56 1056 150 12150 - 16

ANNEX BClauses 9.1 and A-l )

NOTES ON BUTT WELDS ( FOR OTHER THAN STRUCTURAL HOLLOW SECTIONS )~-1 INTRODUCTIONB-l.1 The recommended dimensions of thepreparation are intended primarily for manualwelding in the flat position for general types ofwelded constructions. Since overhead andvertical welding require manipulation of theelectrode, comparatively easy access to the rootof the weld is desirable for welding in thesepositions. This is obtained by using a wider.angle for the weld preparation, or sometimesby increasing the root gap. In the case ofhorizontal butt welds the preparation may haveto be asymmetrical with respect to the horizontalplane with a narrow bevel angle for the lowersection to be welded. When using electrodeswith a thick covering, some modification to the

root details of the weld preparation may benecessary. For submerged arc welding, referencemay be made to IS 4353: 1967 and IS 3613:1974.B-2 SUITABLE METHODS OF MAKINGWELD PREPARATIONSB-2.1 Single and double V and bevel prepara-tions may be machined or machine flame cut.Single and double U and J preparations usuallyhave to be machined. The choice of~a machinedor machine flame cut preparation should be atthe option of the contractor except whenspecified by the purchaser or an appropriateapplication standard. Methods like air-arcgouging arealso employed wherever applicable.

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1s 9595 .t 1996B-2.1.1 In assessing the merits of the twomethods of preparation ard the type of joint,the relative costs of machining, flame cutting orair-arc gouging and length of weld should betaken into account.B-3 DISTORTIONB-3.1 Where the control of distortion isimportant, the following factors should begiven

a)jue.considerations:U and J preparation as comparedwith V and bevel preparations serveto reduce distortion by virtue of thelesser amuunt of weld metal required.Likewise, double preparations arebetter than single preparations, inthat the stresses are balanced also, theweld metal can be deposited in alternateruns on each side of the joint. In thecontrol of distortion, accuracy ofpreparation and fit-up of parts areimportant considerations as well as acarefully planned and controlled weldingprocedure.

b1c)

d)e)

A more uniform distribution of heat canbe obtained by using~back step sequence.Clamping may not completely eliminatewarping but is likely to be more effectiveif clamps are kept in position, until thebalaccing weld sequences are completed.When possible parallel joints may bewelded in opposite direction to minimizedistortion.While welding thin sections to very thicksections, use of copper backing materialmay be effective in minimizing distortion.

B-4 TYPICAL FORMS OF WELDPREPARATIONB-4.1 In the case of square butt joints a and b,.the width of the gap de~pends mainly on the size,and type of electrode and the gap should bechosen accordingly.B-4.1.1 The two joints c and Q are probably the,most common butt weld preparations used ingeneral work. A root face without a gap usuallyfacilitates assembly and minimizes contraction.The production of a sound weld, with or withoutgouging out of the back of the first run, is afunction of the gap, root face and the type ofelectrode used. More reliable productionof sound weld, can be achieved by using bsckgouging.While the double V preparation e and f usuallyshow a saving in weld metal. It is more difficultin these joints to ensure full fusion at the centreof the weld. lf a root face is provided forassembly purposes and full fusion is a re uire-ment, adequate gouging out of the back B the,first run is essential.The single and double Upreparation g, h and j,are designed to give easy access for the electrodeand to ensure good arcing conditionsparticularly for the first run.Single and double J preparations k and I I andsingle and double bevel preparations ))1 nd nare used where only one joint member can beprepared. Preparations m and n are used forlesser thicknesses and where plate edges cannotbe machined. To ensure weld soundness greatcare should be exercised, especially at the rootof the double bevel butt weld.

a) Open square butt weld without backing )Weld detai l

Welded from both sides

See 14for~toleran~os.

Welding Thicknessposition T G;P

mm mmFlat 3-6 3 MaxHorizontal- 3-5 3 Maxvertical orvertical

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b) Open square burt weld with backing )IS 9595 : 1996

Weld det ail Weldi ng Thickness Flat Posit ionposition T onlyII GapG

Welded from one side withsteel backing which may bceither temporary or perma-nent, in which case it maybe part of the structure oran integral part of one CL 2

mm mmAll 2:; 6positions 88-16 10

memberThe dimensions of the weld prepxation may have to be modlfjecl for welding in positions othir than flat, inwhich case they should be the subject of agreement between the contracting parties.Where this preparation is used for meterial over 16 mm thick, the gap may be required to be increased.

See 14 for tolerances. See also 9.4.c) Single V butt weld without backiug )

Weld detai l Flat posi t ion onlyGap Angle RootG a faceR

a mmWelded from both sidesor one side only All 5-12positions Over 12

mm mm:

The dimensions of the weld preparation may have to be modified for welding in positions other than flat, inwhich case they should be the subject of agreement between the contracting parties.See 14 for tolerances. See also 9.4.d) Single V butt weld with backing )

Weld det ail-

Welded fromone sidewith steelbac,kingwhich maybe eithertemporaryor perma-nent, inwhich caseit may bepart of thestructure oran integralpart of onemember

_ __ - ____._~I ,Welding Thickness IFlat posi t ion only-positian -T I I

1411positionsmmOver10

A)dihe dimensions of the weld preparation may ha1KCo be mc tied for we1,which case they should be the subject of agreement between the contracting palSee 14 for tolerances. See also 9.4.

j_mm

6 4510 20 xRoot Rootface RunR

SingleDouble

Ing iti positions other thau flat, ines.13

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IS 595 : 1996e) Double V butt weld

Weld detail

Welded fromboth sides

i Weldingposi t ion

Allpositions

Thickness ( Flat posi t ion only- .1 I-GapGmm mm

Over 12 3 60 2

-I-

4ngle Roota faceRmm

-The dimensions of the weld preparation may have to be modified-for welding in positions other than Bat, inwhich case they should be the subject of agreement between the contracting parties.See 14 for tolerance?.

f) Asymmetric double V butt weldWeld detail Welding 1

IThickness I Flat posi t ion onlyposition T I I

aWelded fromboth sides

Allpositionsmm

Over 12mm

3 60 60

RootfaceRmm

2

If the deeper V is welded first, and full root penetration is required, the angle B may be increased to 90 tofacilitate back gouging;The dimensions of the weld preparation may have to be modified for welding in positions other than flat, inwhich case they should be the subject of agreement between the contracting parties.See 14 for tolerances.

g) Single U butt weldWeld detai l Weldingpo&ions Thickness Flat posi t ion onlyT

Angle Radius Roota r faceR

Welded fromboth sides Allpositions

mmOver 20

mm5

mm5

The dimensions of the weld preparation may bave to be modified for welding in positions other than flat, iqwhich case they should be the subject of agreement between the contractingparties.See 14 for tolerances.14


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17/56

IS 9595 : 1996II) -Doable U butt weld

IW eld detai l 1 Weldi ng Thickness Flat posit icn onlyposit ion T Angle Radius 2:Q:I I

rR

Welded fromboth sidesmm mm mm

Over 40 20 5 5

The dimensions of the weld preparation may have to be modified for welding in positions other than flat. inwhich case they should be the subject of agreement between the contracting parties.See-14 for tolerances.

j) Asymmetric double U butt weld -Ield detai l


Welding Thicknessposit ion T Flat posit ion onIyLandL inglea

mm6 20

Ra-diusrRootfaceR

mmOver 30

mm5

mm5

aAllpositions

The dimensions of the weld preparation may have to be modified for welding in positions other than flat, inwhich case they should be the subject of agreement between the contracting parties.See 14 for tolerances.

k) Single J butt weldWeld detail Welding 1Thickness

posit ion TFlat posit ion only

La;d Ikq-$e Rafius 1Ro$

a

mr T.1-mmm mm

Over 20 ) 5mm

5Welded fromboth sides Allpositions 20 j 5

-The dimensions of the weld preparation may have to be modified for welding in positions other than flat, inwhich case they should be the subject of agreement between the contracting parties.See 14 for tolerances.

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18/56

IS 9595 : 1996m) Double J butt weld

Weld detai l 1 E $;; 1 Thic$wss / Flat posit ion onlyI ngle. Radius Root

a I r IIfaceR

Welded fromboth sides. Allpositions

mmOver 40

mm5

I -mm mm20 1 5 5

1

The dimensions of the weld, preparation may have to be modified for welding in positions other than flat, inwhich case they should be the SUbJeCt of agreement between.the contracting parties.See 14 for tolerances.

II) Single bevel butt weld --Weld detail


Weldingposit ion I GapG

1 mmAll 5-12posltions, Over-12

mni33

Anglea

4545

RootfaceR.

mm:

The dimensions of-the weld preparation may have to be modified for w.elding in positions other than flat, iuwhich case they should be the subject of agreement between the contracting parties.See 14 for tolerances.

p) Doc.ble bevel butt weldWeld detui l Welding Thicknessposition T Flat posit ion only--,_.

iGap Angle RootG a faceR

a

.B

mm mm mmWelded from Allboth sides R positions Over 12 3 45 2

1 ,G

I -_The dimensions of the weld preparation may have 1o be modified for \?relding in positions other than flat, in.which case they should be the subject of agreement between the contractmg parties.Sre 14 for tolerances.

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PS 9595 : WJ tiANNEX C

( Clause 9.1 )TYPICAL DETAILS FOR BUTT WE-LDS FOR STRUCTUh:AL HOLLOW SECTIONS

.OTE - ,411 preparations are for welding from one side only and in all positions.a) 8quare_butt weld ( without backing )_ _ _~~_~___~___ _.__

Weld detai l Thickness Gap G--

~b) Square butt weld ( with backing )Weld detail Thickness I Gap G Thi ckness ofT backing, t

1 M in M ax

mm

-Min Imm

Max

mm356

6~) Single V ( without backing )Weld detail Thickness Gap G Root f ace R

T M in I Max M in I MaxIlain.m mmI I m mm mm mmR up to 20 2 3 1 2.5I I

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ts 9595 : 1996d) Single V with backing )

Weld detai l Thickness Gap GT Root fare R Thickness ofbacking, t-M in ) Max M in Mar M in Max

mm mm mm mm mm mm mmup to 20 5 8 1 25 , 3 6

BOomin.

--?I

e) Single V flame cot preparation with backing ) -Weld detai l I -Thickness Gap GT I Hoofface R Thickness ofbacking, tI__I Min Max-P

mm10

Max M in Maxin

mm8

tim3

mm10

mm2

mm3

mm20-30

f Dotile angle V with backing )Weld detai l ThicknessI I Gap GT Root faceR Thickness ofbacking, t

M in Max MinI Min --Iax--mm10

Maxmm10

-mm8

mm3

-mm20andover

mm2

mm3

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Is 9595 : 1996g) Single bevel without backing )

Weld detai l ThicknessT Gap G

I IRoot face R

Min Max Min I Max

mm mm . mm mm mmup to 20 25 4 1 3

h) Single bevel with backing )Weld detail ThicknessT Gap G

-Root face R - Thickness of -backing, tM in I Max

-.-Min

---Max 1 Min 1 Max

mm5

mm3

mm6

mm mm mm8 1 3

mmup to 20

L -

j ) Single bevel frame cst preparation with backing )Weld de ail Thickness ofbacking, tThicknessT

mm20-30

Gap G Root face RI_- _-

I

-_

Min--mm

3

Max M inIMax

-- I -mm

10mm mm

/-Max- I,mm10

Min

mm8 1 31

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IS 9595 : 1996k) Double angle bevel with backing )

Weld detai l Gap G

Ia-mm I mm20 8

I

and over

Max

mm10

-

-

-oot face Rp-M in i Max7-mm

1mm

3

-2

._-

-

Thickness ofbacking, t--M in Max

mm mm3 10

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IS 595 : 1996ANNEX D

Clauses 9.1 and 11.1 )TYPICAL DETAILS FOR BRANCH CONNECTIONS FOR STRUCTURALHOLLOW SECTIONS

D-1 CIRCULAR STRUCTURAL HOLLOW SECTIONS : BUTT WELDS( THICKNESS UP TO.30 ~rnrn

2TD3mm-J t 2703 t2lOJmme-3&0 90 mm Lzro 3mmG&O0 8=90* e=30TOs@DETAIL AT X 44mind DETACL AT 2

1 DETAIL AT Y

For the smaller anglesfull penetration is notintended provided there isadequate .throat thickness

NOTE - The angle of intersection 8 of the axes of the circular hollow sections should not be less than so*unless adequate efficiency of the junction has been demonstrated.

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IS 9595 : 1996D-2 CIRCULAR STRUCTURAL HOLLOW SECTIONS: FILLET WELDSLeg lengths should be such that the stresses in fillet welds are in accordance ~with the permissiblestresses given in the relevant specification and that the welds will transmit the loads in the member.

SADDLEDBRANCH

OETAIL AT X OETAIL AT VL=LEG LENGTtl

For the smaller anglesfull penetration is notintended provided there isadequate throat thicknesslETAIL AT 2

CRIMPED DR STRAGHCUT BRANCH

NOTE - The angle of intersection 0 of the ax-es of the circular hollow sections should not be less than 30unless adequate efficiency of the junction has been,demonstrated.

22


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25/56

IS 9595 1996

D-3 RECTANGULAR STRUCTURAL HOLLOW SECTIONS : BUiYT WELDS

DETAIL AT X

T

mmH

8= 6010 90

WHERE d=DDETAIL AT Y 8~60DETAIL AT 2

For the smaller anglesfull penetration is notintended provided there isadequate throat thickness

YN0l-E - The angre of intersection o of the axes of the rectangular hollow section should not be less than 30.unless adequate effi:iency of the junction has been demonstrated.

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IS 9595 : 1996

D-4 RECTANGULAR STRUCTURAL HOLLOW SECTIONS: FILLET WELDS

L

mm max.8 ~60 WHERE d 43 4-L

PARED SQUARE

DETAIL AT X WHERE d=DBETAIL AT y

DETAIL AT Z

L =LEG LENGTH

For the smaller anglesfull penetration is notintended provided there is:adequate throat thickness

NOTE - The an;le of intersection 8 VI th: axes of the rectangular hollow sections should not be less than 30.unless adequate e5cieacy of the junction has been demonstrated.

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IS 9595 : 1996ANNEX E

( Chse 23 )PROCEDURE SPECIFICATION SHEET FOR METAL ARC WELDING

E-l GENERAL-E-1.0 The procedure specification sheet formetal arc welding shall contain the followinginformation:

a)b)c)d)e)

f)dh)3k)ddP)9)

E-l.1

Process ( see E-l.1 );Parent plate ( see E-1.2 );Filler metal ( see E-l.3 );Welding position ( see E-l.4 >;Preparation of parent plate, such as jointpreparatron cleaning -the edges of rust,grease, etc ( see E-l.7 );Nature of electric current ( see E-1.8 );Welding technique ( see E-l.7 );Cleaning ( see E-l.8 );Defects ( see B-1.9);Peening ( see E-1.10 );Treatment of underside of welding groove( see E-l.11 );Preheating and interpass temperatures( see E-1.12 );Heat treatment ( see E-P.13 ); andWelding procedure data sheet ( seeE-1.14 ).Process

The welding shall be done by the manual orsemi-automatic or automatic metal arc process.E-l.2 Parent Plate

The parent plate shall conform to the specifica-tions for ( insert here reference to standard orother code designations, or give the chemicalanalysis and physical properties ).E-1.3 Filler MetalThefiller metal shall conform to Indian Standardclassification number ( see IS 8 14 : 199 1 >.El.4 Welding PositionThe welding shall be done in ( state > the posi-tion or positions in which the welding is to becarried out.

E-l.5 Preparation of Parent PlateThe edges or surfaces of the parts to be joinedby welding shall be prepared by ( state whether )sheared, machined, ground, gas cut, etc as shownon the attached sketches and shall be cleanedof all oil or grease and excessive amounts ofscale or rust, except that a thin coat of linseedoil, if present, need not be removed. ( Thesketch referred to show the arrangement ofparts to be welded with the spacing and detailsof the welding groove, if used. Such sketchesshould be comprehensive and cover the fullrange of material or parent plate thicknesses tobe welded. )E-l.6 Nature of Electric CurrentThe current used shall be ( state whether ) director alicrnating, and if alternating give the OCV.The parent plate shall be connected to thepositive or negative pole.E-P.7 Welding TechniqueThe welding technique, electrode sizes, andmean voltage and currents for each electrodeshall be substantially as shown on the attachedsketches. (The sketches referred to may bethe same as mentioned under Preparationof Parent Plate or may be separate sketches.They should show for the minimum thick-ness and for several intermediate thickne.sesof parent plate, the welding technique tobe used, whether weaving or beading, thenumber of layers or passes and diameter ofelectrode with the mean voltage and current ~foreach layer of pass, and in the case of verticalwelds, the progression of each pass, whetherupward or dowJword. iE-l.8 CleaningAll slag or flux remaining on any bead of weld-ing shall be removed before laying down thenext successive bead.E-l;9 DefectsAny crack or other welding defects that appearon the surface of any bead of welding shall beremoved by chipping, grinding or gas gougingbefore depositing the next successive bead ofwelding.

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lb 9595 : 1996E-1.10 Peening that should be done.If peening is to be used, it shall be incorporatedas part of the specification, a description being E-1.13 Heat Treatmentgiven of the degree of peening to be done.E-l.11 Treatment of Underside of WeldingGroove

This paragraph should describe any heat treat-ment or stress relieving that is given to thewelded parts after welding.

The method of preparing the under or secondside of :3 groove for welding on that side should E-1.14 Welding Procedore Data Sheetbe stated in this paragraph.E-1.,12 Preheating and Interpass Temperatures For uniformity of record a recommended form.of Manufacturers Welding Procedure DataThis paragraph should describe any preheating Sheet is given below:

TYPICAL WELDING PROCEDURE DATA SHEETSpecification No. Date _Welding Process Manualor MachineMaterial Specification : Grade -ofIS: Batch/Cast No.Thickness. ( if pipe, diameter and wall thick-ness )Filler Metal SpecificationWeld Metal AnalysisFLUX OR SHIELDING GASFlux Trade Name or CompositionInert Gas CompositionTrade Name Flow RateIs Backing Strip UsedPreheat Temperature RangeInterpass Temperature RangePostheat Treatment

Welding Engineer( Inspecting Authority )

WELDING PROCEDURESingle or Multiple Pass _Single or Multiple Arc _Welding Position(s)FOR INFORMATION ONLYElectrode/Filler Wire DiameterTrade NameType of BackingForehand or BackhandWELDING TECHNIQUESJoint DetailsAmps VoltsElectrode Consumed ( cm/m )Current PolaritySize of ReinforcementWhether RemovedInspection and Test Schedules

Signature

For and on Behalf of ManufacturerDate

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IS 9595 : 1996ANNEX F

( Clauses 7.7.2.1, 17.1, 24.1 and 24.1-l)AVOIDANCE OF HYDROGEN CRACKING

F-l GENERALF-l.1 If the cooling rate associated with weldingis too rapid, excessive hardening may occur inthe heat affected zone. This may be unaccept-able in it self, but if sufficient hydrogen ispresent in the weld, the hardened zone maycrack spontaneously under the influence ofresidual stress after the weld has cooled to nearambient temperature. The occurrence of crack-ing depends on a number of factors: thecomposition of steel, the welding procedure,welding consumables and the stress involved.Welding conditions can be selected to avoidcracking which ensure that the heat affectedzone cools sufficiently slowly, by control ofweld run dimensions in relation to materialthickness and if necessary by applying pre-heatand controlling interpass temperature. Thehydrogen input to the weld can be controlled byusing hydrogen controlled welding processesand consumables.F-1.1.1 In giving general welding proceduresbased on ladle analysis and appropriate to a widerange of practical conditions,realistic conditionshave been assumed in order to establish theprocedures detailed in this appendix, and theseare recommended except when alternativeprocedures have been demonstrated as satis-factory either by experience or test.F-2 COND.ITIONS FOR AVOIDINGHYDROGEN CRACKINGWelding conditions for avoiding hydrogencracking in carbon manganese steels have beendrawn up in graphical form in Fig. 5a to 5n forthe range of compositions, expressed as carbonequivalent values, covered by this standard.The conditions have been drawn up to takeaccount of differences in behaviour betweendifferent steeIs of the same carbon equivalent( making allowance for scatter in hardenability )and of normal variations between ladle andproduct analysis. They are valid for the avoi-dance of heat effected zone cracking in normalwelding situations, but ignore the possibility ofweld metal hydrogen cracking due to conditionsof high restraint.F-3 CONDITIONS FOR WHICHPROCEDURES BASED ON FIGURES5s to5n ARE VALIDF-3.1 Composition : Carbon Equivalent ValuesThe graphs relating combined thickness, arcenergy and pre-heat required given in Fig. 5a

to 5n are provided to assist the fabricator inselecting optimum welding procedures. In theabserce of mill sheet data, the carbon equiva-lent values in Table 1 provide a good basis forthe deviations of welding procedures.Attention is drawn to the need to compare thecarbon equivalent of material delivered as.derived from the mill sheets, with that used inderiving the welding procedure from Table 1.The table refers to further simplified tables ( SMTables 2 to 5 ) for manual metal-arc filletwelding conditions. Where the mill sheetcarbon equivalent is higher than the value usedfor deriving the welding procedure, or the jointis not a fillet weld, or the welding process is notmanual metal-arc, or the fabricator is able to,take advantage of a lower carbon equivalentvalue identified from the mill sheets, referenceshould be made to the appropriate graph orgraphs within Fig. 5a to 5n. Where steels ofdifferent carbon equivalent or graph are beingjoined, the higher carbon equivalent value shouldbe used. If, of the elements in the formula in 5for calculating carbon equivalent, only carbonand manganese are stated on the mill sheet, then0.03 shall be added to the calculated value to.allow for residual elements.For carbon manganese steels of low csrbon,content ( less than about 010 percent ) thecarbon equivalent formula specified in 5.1 does.not adequately indicate the risk of heat-affectedzone hydrogen cracking and may underestimateit. Thus welding procedures for such steels mayrequire modification. In addition, weldingprocedures derived from 24.U may not beadequate for avoiding weld metals hydrogencracking. When welding steels of low carbonequivalent ( less .than approximately 042 ). Thisis more likely to be the case when welding thicksections ( that is greater than about 50 mm )and with higher yield steels. Whether or notthis causes an increased risk of heat-affectedzone cracking, the weld deposit would generallybe harder and more susceptible to crackingitself.Recent experience and research has indicatedthat lowering the inclusion content in the steel,priircipally by lowering the sulphur content(also the oxygen content > may increase thehardenability of the steel. From a practicalpoint of view this effect may result in increasein the hardness of the heat-affected zone, andpossibly a small increase in the risk of heat-affected zone hydrogen cracking, Accuratequantification of the effect is not presentlypracticable but some increase in hardness ( and

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IS 9595 : 1996risk of heat affected zone hydrogen cracking 1might be observed in steels with sulphur levelsless than approximately 0008 percent.F-3.2 Hydrogen ScalesThe scale to be used in Fig. 5a to 5n willdepend principally on the weld deposit diffusi-ble hydrogen content given bv the consumables,appropriately dried to the manufacturers

recommendations, when sampled and analyzedto IS 814 : 1991 using evolution over mercury.That standard deals with the testing of coveredelectrodes, but with slight modifications of speci-men size it can be used to assess other consuma-bles and welding processes. This standardpermits only the use of mercury as a collectingfluid for diffusible hydrogen and the levels givenbelow are based on measurements usingmercury.

ARC ENERGY kJ/mmSa

0 I 24RC ENERGY kJ/mm

5b

( Hydrogen Scale ( seeF-3.2

To be usedfor carbonequivalent notexceedingFIG. 5 CONDITIONS FOR WELDING STEEL OF

STATED CARBON EQUIVALENT - Co

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ARC ENERGY


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IS 9595 : 1996

ARC ENERGY kJ/mm

- To be used for carbonequivalent notexceeding -

Hydrogen Scale see F-3,2 )A j B 1 C.1 D

___G-47 051 1o-571,I

11 For guidance onlyFro. 5 CONDITIONS FOR WELDING STEEL OF STATED CARBON EQUIVALENT Conrd.

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ARC ENERGY kJ /mm5k

HydrogenScale ( seeF-3.2 )

AlBlC D0.49 0.51 0.53 0.591)I I Io be used forcarbon equivalentnot exeeeding ,

1) For guidance onlyFIG. 5 CONDITIONS FOR WELDING STEELOF STATED CARBON EQUIVALENT - Gw&. a

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ARC ENERGY kJ/mm

To be used forcarbon equivalentnot exceeding

5m-_Hydrogen Scale see F-3.2 )--A B I c0 53 0 55) 0.5711

11 For guidance onlyFIG. 5 CONDITIONS FOR WELDING STEEL OF STATED CARBON EQUIVALENT - Confd.


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F-3.2.1 Scale A should be used under conditionsof normal fit for consumables which give welddeposit hydrogen contents more than 15 ml/100 g after any appropriate drying treatment.F-3.2.2 Scale B should be used under conditionsof normal fit for consumables which given welddeposit hydrogen contents not more than 15 ml/101) g ( but more than 10 ml/100 g ) after anyappropriate drying treatment.F-3.2.3 Scale C should be used und:r conditionsof normal fit for consumables which give welddeposit hydrogen contents not more than 10 ml/100 g ( but more than 5 ml/l00 g ) after anyappropriate drying treatment. Scale C shouldalso be used under conditions of close fit forconsumables otherwise defined for Scale B.

F-3.2.4 Scale D should be used under conditionsof normal fit for consumables which give welddeposit hydrogen contents not more than 5 ml/100 g after any appropriate drying treatment.F-3.2.5 Covered electrodes in Classes El - -,E2 - -, E3 - -, E4 - -, ES - -, andE9 - - should be used with Scale A, unlessotherwise assessed.F-3.2.6 Covered electrodes in Classes E6 7 -( including E6 - - H and E6 - - HJ ) unlessotherwise assessed should be used with Scale B.F-3.2.7 Solid electrode wire for gas-shielded arcwelding should be used with Scale C unlessotherwise assessed.F-3.2.8 The scale should be used also with othersuitably assessed consumables after appropriatedrying treatments, as recommended by themanufacturer.F-3.2.9 TIG welding should be used with Scale Dsimilarly with other suitably assessed consu-mables after drying or other treatments, forexample, clean solid electrode wires for gas-shielded arc welding, and some E6 - - coveredelectrodes after drying at temperatures recom-mended by the manufacturer. It should benoted that on occassions these temperaturescould exceed 400C.F-3.2.10 Submerged_ arc welding, flux cored wirewelding and continuous covered wire weldingconsumables can have hydrogen levels corres-ponding tc any of the Scales A to D and,therefore, need assessing in the case of eachnamed product.F-3.3 Pre-HeatingThis is the temperature of the parent materialimmediately before welding commences. It isassumed to be locally applied and measured for

IS 9595 : 1996at least 75 mm on each side of the weld line. Ifpossible the temperature should be measured onthe face opposite to that being heated. Alterna-tively, if there is access to only one face, theheat source should be removed ~to allow fortemperature equalization ( 1 minute for each 25.mm of piate thickness ) before- measuring. Thepre-heat temperature will also be the minimuminterpass temperature in the case of multi-runwelds, except where advantage can be taken ofusing filling runs ~larger than the root run.F-3.4 Combined Thickness see Fig. 6 )This is the sum of the plate thicknesses averagedover a distance of 75 mm from the weld line.If the thickness increases greatly just beyond 75mm from the weld line it may be necessary touse a higher combined thickness value.F-3.5 Fit UpFit-up in fillet welds is defined as normal iathis context when the root gap is 1.5 mm andwhen the root gap is 0.4 mm or less, the fit isreferred to as close.

NOTE -It may be necessary for reasons otherthan the avoidance of hydrogen cracking to limitfillet weld root gaps to maximum values somewhatless than 3 mm.F-3.6. Arc EnergyArc energy values given in this Appendix ayerelevant to manual metal-arc welding withcovered electrodes using a-c. and d.c. positive.Arc energy ( kJ/mm )

Arc voltage X Welding current x I=- Welding speed ( mm/s ) 1 000F-3.6.1 An appropriated factor shall be appliedfor processes other than manual metal arcwelding with covered electrodes.F-3.6.1.1 For guidance in using other weldingprocess, the arc energy values calculated fromthis formula should be divided by the followingfactors to give the values to be used in Fig. 5:

Submerged arc welding ( single wire ) 08TIG Welding 12MIG/MAG welding ( solid, cored or 10self shielded wire )

NOTE - It may be necessary in some applicationsto limit energy input values either to avoid solidi-fication cracking or to achieve toughness. Thisshould be established by welding procedure testswhere satisfactory evidence is not available.F-3.7 Weld Run DimensionsWelding conditions in Fig. Sa to 5n are specifiedin terms of arc energy These values may be

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IS 9593 : 1996COMBINED THICKNESS=t,+t +tst.l =AVERAGE THICKNESS OZERA LENGTH OF 75mm f-bt1595m 12ta=O

COMBINED THICKNESSh-e02

2FIG. 6 EX+PLES OF COMBINED THICKNESS

converted in terms of electrode size, weld runlength and run out ratio by Table,s 9A to 9C.Where minimum fillet leg lengths are specified,Table 10 should be used to obtain theappropriate arc energy values.F-3.8 RestraintRestraint is that appropriate to normalsituations, not for extreme cases such as forfilling holes or slots.F-4 RELAXATIONSF-4.1 If some of the factors involved are morefavourable than those enumerated in F-3.3,alternative procedures may be used providedthey have been proved as satisfactory either byexperience or tests. Guidance on some aspectsis given below.F-4.1.1 General Pre-heatingIf the whole component, or a width more thantwice that stated in F-3.3, is pre-heated it isgenerally possible to reduce the pre-heatingtemperature by as much as 50C.F-4.2 Limited Heat SinkIf the heat sink is limited in one or moredirections ( for example, when shortest beatpath is < 10 x leg length ), especially in the

thicker plate ( for example, when fillet weldinga narrow flange to the web ofa girder ) it ispossible to reduce pre-heating levels.F-4.3 Austenltic Stainless Steel ElectrodesIn some circumstances where sufficient pre-heating to ensure crack free welds isimpracticable, an advantage may be gained byusing certain austenitic electrodes. In suchcases, pre-heating may be reduced oreliminated.F-5 EXAMPLE FOR USING THlSANNEXUREStep I - Decide carbon equivalent values usingTable 1 and F-3.1. Assume a steel of carbonequivalent value 0.45.Step 2 - Decide provisionally on weldingprocess and consumables. Classify as A, B, Cor D using F-3.2 to determine which carbonequivalent scale to use.Assume manual metal-arc welding usingelectrodes conforming to IS 814 : 1991 and thatweld hydrogen level is appropriate to Scale B.Step 3 - Decide whether fillet or ~butt-weld andrefer to Table 1.

Assume fillet weld.Table 1 refers to Table 6.

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IS 9595 : 1996Step 4 - Decide minimum specified individual Assume 4 mm electrode to be run out in aboutfillet leg length required by design drawing. 320 mm of run length.

Assume 5 mm. Refer to Table 9B. This gives mimmum arcTable 6, Scale B, 5 mm leg length now energy for individual runs forming the butt weldrequires Step 5. of 1.2 kJ/mm.Step 5 - Decide combined thickness of joint towelded with single run fillet of 5 mm leg length.

Refer to F-3.4.Assume calculated combined thickness of 70mm.

Step 6 - Return to Table 6 and read off theminimum pre-heat required; Scale B, 5 mmfillet of 70 mm combined thickness requires pre-heating to 100C.Step 7 - TRbles 6 and 10 give arcenergy values( see F-3.6 ) corresponding to the 5 mm filletusing the particular electrode, chosen ( 17 kJ/mm ). Tables 9A, 9B and 9C give the electrodessize and run out conditions which correspond.Thus Table 9B offers a choice of electrode sizeand run lengths from 450 mm of electroderanging;

From 32 mm diameter and 145 mm runlength to 8 mm diamenter and 910 mm runlength.Practical considerations would probablylimit this to a maximum diameter of 5 mmelectrode and corresponding run lengthof 355 mm.

Variation at Step 3:Step A Assume butt weld

Table 1 refers to Fig. 5a, 5e, 5g and 5h.Figure 5g is relevant to 0.45 carbonequivalent and scale B.

Step B - Decide minimum run dimensions tobe used in making butt weld.This will most often be the root run.

Step C - Decide combined thickness of buttjoint, referring to F-3.4. Assume calculatedcombined thickness of 50 mm.Step D - Return to Fig. 5g and plot coordinatesof 1.2 kJ/mm arc energy and 50 mm combinedthickness.Read c7ff minimum gre-heating and interpasstemperature (by interpolation, if necessary, orby reading the pre-heat line immediately aboveorto the left of the co-ordinated point ) which inthe present example is 100C.Variation at either Step 7 or Step D.In the event that pre-heat is undesirable,proceed as follows:Step W - Re-examine Fig. 5g to determineminimum arc energy for no pre-heat ( 20C line,normally ).

For fillet example : 22 kJ/mmFor butt example : 16 kJ/mm

Step X - If by referen-- tp Table 9B these arcenergies are practicnily feasible, proceed usingelectrode diameter and run length chosen fromTable 9B.If not feasible, proceed to Step Y.

Step Y - Using Table 6 for the fillet example ofFig. 5a and 5e for weld example, examine thefeasibility of using ,lower hydrogen levels ( bythe use of higher electrode drying temperaturesor change of consumables ) ( see F-3.2 ) to avoidthe need for pre-heat at acceptable arc energylevels.

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IS 9595 : 1996Table 1 References to Tables and Figures to be Used for DifferentCarbon Equivalent Values

Clauses F-3.1 and F-5 )Quality ofSpecification

(1)IS 2062 : 1992IS 8500 : 1991

IS 2062 : 1992IS 8500 : 1991IS 2062 : 1992

IS 8500 : 1991

--IS 8500 : 1991

IS 8500 : 1991

-NOTES

Steel Grade CarbonEqt+i;;alpt Manual Metal-Arc Fillet Welds:Refer to Table No.Glven Below

Other Processes,or Consumables,or Joints OtherThan Fillet WeldsRefer to Figure No.Given Below

(2)Fe 410 WCFe 440 1Fe 440B ,

(3)0.39

(4)33

(5)5a and 5c

0.40 5a, 5b and 5d

Fe 410WB 0.41 4 5b. 5c and 5eFe 490 1Fe 490B }Fe 410 WAJ 0.42 5 Sd and 5f

- 0.43 5 5c, 5e and 5gFe 540 1Fe 540B ] 0.44 6 5dand 5f

- 0.45 6 5a, 5e. 5g and 5hFz 570 7Fe 570B 1 O-46 7 5b and 5f

Fe 590 1Fe 590B 1) 0.48 5c

- 0.50 5e

For Higher orLower CarbonEquivalentValues ObservedFrom Mill Sheet

(5)Select graph fromFigures 5a to 5naccording tocarbon equivalentand scale( see F-3.2 )

1 If the amount of residual elements is not known, a value of 0.03 should be added to the C + F valueto obtain the equivalent, except in the case of steel from a known supply of low residual element content.2 The carbon equivalent values for grades of steel covered in IS 8500 : 1991 and IS 2062 : 1992 arerecommended values.

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IS 9595: la96Table 2 Simplified Conditions for Fillet Welds in Steel with a Maximum CarbonEquivalent of 038 Using Manutil Metal-Arc Welding Electrodes

Clause F-3.1 )HydrogenPotentalScalei

(1)Scale A

Scale B or D

SpecifiedMinimumLegLength)mm kJ/mm(2) (3)4 1.05 1.46 208 2.810 3.84 l-3 0 0 0 0 0 0 0 0 05 1.7 0 0 0 0 0 0 0 0 06 2.2 0 0 0 0 0 0 0 0 08 3.4 0 0 0 0 0 0 0 0 0

10 50 0 0 0 0 0 0 0 0 0

MinimumArcEnergy*)Minimum Pre-heating Temperature for Welding Plates of followingCombined Thicknessess

11 For individual run.*\ In situations of high restraint, a higher pre-heating temperature may nevertheless be necessary to avoidweld metal hydrogen cracking.

20 30 40 50 60 70 80mm mm mm mm mm mm mmC C VJ C C OC C(4) (5) (6) (7) (8) (9) (10)0 0 0 50 50 75 1000 0 0 0 0 0 200 0 0 0 0 0 00 0 0 0 0 0 00 0 0 0 0 0 0

m9I111im $&C C(11) (12)100 10050 500 00 00 0

Table 3 Simplified Conditions for Fillet Welds in Steel baving Maximum CarbonEquivalent -of 040 Using Manual Metal-Arc Welding ElectrodesClause F-3.1 )

Hydrogen SpecifiedPotenUai MinimumScale LegLength)MinimumarcEnergy)

mm kJ/mm=(i) (2) (3)

Scala A 4 1.05 146 2.08 2.810 3.8Scale B 456810Scale C 456810

13I.72.2345.01.317223.45.0

Minimum Prc-heating Temperature for Welding Plates of followingCombined Thicknessess20 30 40 50mm mm mm mmC C C C(4) c55) (6) (7)0 0 0 500 0 0 00 0 0 00 0 0 00 0 0 . 0

-0 70 80 90 un-mm mm mm mm limited)$ ;E

C ;:, OC(10) (12)100 125 125 125 12520 75 100 100 1000 0 20 50 so0 0 0 0 00 0 0 0 a

0 0 0 0 0 20 50 50 500 0 0 0 0 0 0 0 00 0 0 0 0 0 ~0 0 00 0 0 0 0 0 0 0 00 0 0 0 0 0 0 0 00 10 0 0 0 0 0 0 00 0 0 0 0 0 0 0 00 0 0 0 0 0 0 0 00 0 0 0 0 0 0 0 00 0 0 0 0 0 0 0 0

1) For individual run.1 In situation, of high restraint a higher pro-heating temperature may nevorthloasbe necessary to avoid weldmetal hydrogen cracking.

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26 9595 : 1996Table 4 Simplified Conditions for Fillet Welds in Steel Having Maximum CarbonEquivalent of 041 Manual Metal-Arc Welding Electrodes

Clause F-3.1 )HydrogenPotential Specified Minimum

MinimArc

Scale Energy\Leogthl)mm

(1) (2)a__*_ IiJf&Ilt: A 4568

10Scale B 4

568

10Scale C 4

568

10Scale D 4

568

10

kJ/mm(3)l.01.42.0283.8I.31.7223.45.01.31.72. 23-490

l -3l -72-23. 45. 0

20 30 40 50 60 70 80mm mm mm mm mm mm mmC C C C OC C C(4) (5) (6) (7) (8) (9) (10)0 5 : 100 125 125 125 :250 0 0 0 50 100 1000 0 0 0 0 0 500 0 0 0 0 0 00 0 0 0 0 0 0

90 Un- mm limited\

000000000000000

000000000000000

000000000000000

000000000000000

2000000000000000

500000

20000000-000

7520000

50000000000

C(11)125l257500

10050000

50000000000

C(12):25-12$5100

00

100JO

000

50000000000

Minimum Pre-heating Temperature for Welding Plates of FollowingCombined Thicknessese

,I\ For individual run.8) In situations of high restraint a higher pre-heating temperature may nevertheless be necessary to avoidweid metai hydrogen cracking.

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IS 9595 : 1996-Table 5 Simplified Conditions for Fillet Welds in Steel Having Maximam CarbonEquivalent of 043 Manual Metal-Arc Welding Electrodes

CIuusc F-3.1 )

Nyd rogmPohz;pI Specltlcd MinimumMinimum ArcL:z;thQ Energy)

mm(1) (2)

Scale A 4568

10Scale B 4

568

10Scale C 4

568

10Scale D 4

568

10

kJ /mm(3)1-ol-42.02.33.81.31.722345-Ol-3l-72.2.3.45.lo1.3l-72.23.45.0

1 For individual run.*I In sit

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Metal Arc Welding of Carbon & Carbon Manganees Steel(9595-1996)