AWS D1.6:1999 An American National Standard Structural Welding Code— Stainless Steel SANsKey Words— Allowable stress, cyclically londed AWS D1.6:1999 structures, inspection, qualification, An American National Standard structural details, statically loaded structures, stainless steel welding, Approved by stainless stel, stud welding, tubular structures, welded joi details American National Standards Institute March 10, 1999 Structural Welding Code— Stainless Steel Prepared by AWS Committee on Structural Welding Under the Direction of AWS Technical Activities Committee Approved by AWS Board of Directors Abstract ‘This code covers the requirements for welding stainless steel structural assemblies. American Welding Society 550 NW. LeJeune Road, Miami, Florida 33126Statement on Use of AWS Standards All standards (codes, specifications, recommended practices, methods, classifications, and guides) of the American Welding Society are voluntary consensus standards that have been developed in accordance with the rules of the Ameri- ‘can National Standards Institute. When AWS standards are either incorporated in, or made part of, documents that are included in federal or state laws and regulations, or the regulations of other governmental bodies, their provisions carry the full legal authority of the statute. In such cases, any changes in those AWS standards must be approved by the gov- ‘ernmental body having statutory jurisdiction before they can become a part of those laws and regulations. In all cases, these standards carry the full legal authority of the contract or other document that invokes the AWS standards. Where this contractual relationship exists, changes in or deviations from requirements of an AWS standard must be by agroe- ‘ment between the contracting parties. International Standard Book Number: 0-87171-563-5 ‘American Welding Society, 550 N.W. LeJeune Road, Miami, FL 33126 (© 1999 by American Welding Society. All rights reserved Printed in the United States of America Note: The primary purpose of AWS is to serve and benefit its members. To this end, AWS provides a forum for the exchange, consideration, and discussion of ideas and proposals that are relevant to the welding industry and the consen sus of which forms the basis for these standards, By providing such a forum, AWS does not assume any duties to which ‘2 user of these standards may be required to adhere. By publishing this standard, the American Welding Society does not insure anyone using the information it contains against any liability arising from that use. 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It must be reviewed every five years and if not revised, it must be either reapproved or withdrawn. Comments (recommendations, additions, or deletions) and any pertinent data that may be of use in improving this standard are requested and should be addressed 10 AWS Headquarters. Such comments will receive careful consideration by the AWS Structural Welding Committee and the author of the comments will be informed of the Committee's response to the comments. Guests are invited to attend all meetings of the AWS Structural Welding Committee to express their comments verbally. Procedures for appeal of an adverse decision concerning all such comments are provided in the Rules of Opera Committee. A copy of these Rules can be obtained from the American Welding Society, 550 N.W. Leleune Road, Miami, FL 33126. Photocopy Rights Authorization to photocopy items for internal, personal, or educational classroom use only, or the internal, personal, or educational classroom use only of specific elients, is granted by the American Welding Society (AWS) provided that the appropriate fee is paid to the Copyright Clearance Center, 222 Rosewood Drive, Danvers, MA 01923; Tel: 978-750-8400; online: http:\www.copyright.comAWS Committee on Struct ral Welding (Continued) 1, Seum Bragg Crane and Rigging Company D. Shapira Mortison-Kaudsen Corporation J.G.Shaw Mountain Enterprises, Incorporated R.E.Shaw, Jr Steel Structures Technology Center, Incorporated D.L. Sprow McDermott Incorporated, Retired J.T. Staley Minnesota Department of Transportation R.W.Stieve New York Department of Transportation C.R Swart Shell Offshore, Incorporated PJ. Sullivan Massachusetts Highway Department (Retired) WA, Svekric Welding Consultants, Incorporated G.R. Swank State of Alaska A.A. Taylor KPEF Consulting Engineers “I. D. Theisen Exxon Company, USA. WA. Thornton ives Corporation RHR. Tide , Janney, Elstner Associates .Uang University of California-San Diego JE, Uebele Waukesha County Technical College K.K. Verma Federal Highway Administration B.D. Wright Consultant B. Young Westinghouse Savannah River ‘D1k—Subcommittee 11 on Stainless Steel Welding. A.W. Sindel, Chair M.J. Harker B.M. Buler, View Chair Gd. Hill RE, Avery ML. Hoitome D. Baird *E.R Holby RD. Block W.Jaxa-Rozen R. Bonneau RM. Kotan F.C. Breismeister D. Kotecki “11. Chambers JW. MeGrew R.B. Corbit J. Merrill %£.G. Costello J.E.Roth D.A. DelSignore D. Shapira *.D. Duncan +d. D. Theisen "GA. Gix B.D. Wright AdvisorForeword (This Foreword is not a part of AWS D1.6:1999, Seructural Welding Code—Stainless Steel, but is included for information purposes only.) ‘This code covers the requirements for welding stainless steel components other than pressure vessels or pressue pip- ing. For many years, fabrications involving stainless steel welding have used ANSI/AWS D1.1, Structural Welding Code—Sieel, o provide the requirements for quality construction, However, as the D1.1 document is writen for the car- bon and low alloy steels commonly encountered in structural fabrication, it does not explicitly address the unique re- quirements of the stainless steels. The AWS DI Structural Welding Committee thus recognized the industry need for a 1.1 analogue designed for the welding of stainless steel wrought and cast shapes and plates. ‘The mast noticeable feature of D1.6:1999 is the allowance of prequalified Welding Procedure Specifications (WPSs) for the austenitic stainless steels. This exemption from qualification testing is based on considerable experience with the ost widely used stainless steels. ‘The D1.6 Code is the product of a pool of experts arriving at a consensus position, in keeping with the American National Standard Institute's requirements. Like all prototype documents, D1.6:1999 is acknowledged by the D1 sub- committee on stainless stee! as being subject to considerable scrutiny by industry. Criticism, comments and suggestions are welcomed by AWS as a means fo improve the technical and economical aspects of the D1.6 provisions. Requests for official interpretations, comments or suggestions should be sent to the Secretary, Structural Welding Committee, American Welding Society, 550 N.W. Lefeune Road, Miami, FL 33126,Table of Contents Personnel. Foreword List of Tables List of Figures e. 1. General Provisions LL. Scope. 1.2. Base Metal 13. Welding Terms... 1.4 Welding Symbols... 15. Safety Precautions. 1.6. Standard Units of Measurement 1.7 Acceptance Criteria 13 Wolding Procodate Specification owes. 1.9 Approval. 1.10 Mandatory Provisions 2. Design of Welded Connections ..n Part A—General Requirements. x 2.1 Drawings 22. Allowable Stresses. 23. Increased Unit Stresses Part B~-Weld Lengths and Areas. 24 Fillet Welds.. 25. Plug and Slots Welds (Sizes and Spacings) Part C—Miscellaneous Structural Detail. 2.6 General 2.7. Filler Plates 28 Lap Joints oan : 29 ‘Transitions of But Joints in Nontubular Connections 2.10 Transitions in Tubular Connections. 2.11 Connections or Splice... 2.12 Built-Up Members in Statically Loaded Structures, 2.13 Noncontinuous Beams — 2.14 Plug and Slot Weld Dimensions. 2.15 Specific Requirements for Cyetically Loaded Structures 2.16 Combinations of General Types of Welds. 2.17 Skewed T-Ioints... ee 3. Prequalification. 13 3.0 Scope, B Part A—General Requirements... 13 3.1 Limitation of Variables for Prequalified WPSs. 13 3.2 Combination of WPSs.. —— BPart B—Prequalified Processes. 33. General : 3.4. Welding Processes 3.5. Other Welding Processcs.. Part C—Base Metals 3.6 Base Metals for Prequalified WPSs.. 3.7. Auxiliary Component Base Metals... 3.8 Base Metal for Weld Tabs and Backing... Part D—Prequalified Filler Metals, Fluxes and Gases. 3.9. Filler Metals ees 3.10 Electeodes for SMAW 3.11 Electrodes and Fluxes for SAW 3.12 Consumables for GMAW, GTAW, and FCAW.. Part E—Weld Sizes for Prequalified Joints... 3.13 General vue : 3.14 Prequalified Fillet Welds. — 3.15 Prequalified Partial Joint Penetration (PIP) Groove Welds in Nontubular Connections... 3.16 Prequalified Partial Joint Penetration (PIP) Groove Welds in Tubular Connections... 3.17 Prequalified Flare-Bevel Groove Sizes. a ns 3.18 Prequalified Skewed Joints 3.19 Prequalified Plug and Slot Weld Sizes... ns 3.20 Prequalified Complete Joint Penetration (CIP) Groove Welds in Nontubular Connections... 3.21 Prequalified Complete Joint Penetration (CIP) Groove Welds in Tubular Connections. Part F—Prequalified Nontubular Joint Details. 3.22 General on 3.23 Partial Joint Penetration (PIP) Groove Welds... 3.24 Complete Joint Penetration (CIP) Groove Welds... 3.25 Plug and Slot Welds... : 3.26 Flare-Bevel Groove Welds... Part G—Prequalified Tubular Joint Details. 3.27 General 3.28 Prequalified Joints. Par H—Proualified WPS Requirements 3.29 General. 3.30 Plug and Slot Welds... Quatification Part A—WPS Qualification Requirement 4.1 General 42. Essential Variables for WPS Qualification 4.3 WPS Qualification Requirements 44 Fillet Welds 4.5. Tests Required for Groove and Fillet Welds... wT 4.6. “Types, Purposes, and Acceptance Criteria of Tess for WPS Qualification. 2 art Performance Qualification Requirement for Welders and Welding Operators. 7 47 General 77 4.8 Limitation of Variables for Welder Performance Qualification 82 4,9 Limitation of Variables for Welding Operator Performance Qualification 84 4.10 ‘Types, Purposes, and Acceptance Criteria of Tests and Examinations for Welders and Welding Operators 4.11 Overlay Requirements.5. Fabrication 5.0 General... 5.1 Responsibilities 5.2. Preparation of Base Metal 53. Assembly. 54 Assembly Tolerances 5.5. Distortion of Members... 5.6 Groove Weld Backing, 5.7 Tack Welds and Temporary Welds 58. Peening... 59. Weld Termination.. 5.10 Weld Cleaning... 5.11 Weld Profiles. 5.12 Weld Metal Removal and Repair 5.13 Base Metal Repairs by Welding, 5.14 Mislocated Holes... 5.15 Inaccessbity of Unacceptable Wel... 5.16 Postweld Heat Treatment and Recommendations. 6. Inspection Part A—General Requirements... 6.1 General 62. Inspection Personnel Qualification 6.3 Inspection and Verification of Materials. 64 Verifeation of Procedure Quaifetion Record (POR) Weng Ps Procedure Specitcaton (WPS), and Performance Qualification 65 Inspection and Verification of Work and Records 6.6 Obligations of the Contractor, 6.7 Nondestructive Te 68. Extent of Testing, Part B—Radiographic Testing of Groove Welds in Butt Joints 69 General 6.10 Radiographic Procedures 6.11 Acceptability of Welds... : 6.12 Examination, Report, and Disposition of Radiographs Fart CUlrasnie Teng (UT) of Groove Welds 6.13 General . : 6.14 UT Operator Requirement... 6.15 UT Equipment 6.16 UT Procedure ern 6.17 Reference Standard 6.18 Calibration Methods 6.19 Scanning Patterns and Methods... 6.20 Weld Discontinuity Characterization Methods 6.21 Weld Discontinuity Sizing and Location Methods... 6.22 Interpretation Problems With Discontinuities... 6.23 Weld Classes and Amplitude Level. 6.24 Acceptance-Rejection Cri 6.25 Preparation and Disposition of Reports. Part D—Other Examination Methods... 6.26 GeneralPart E-—Quality of Welds... 6.28 Quality of Welds—Statically Loaded 6.29 Quality of Welds—Cyclically Loaded. 7. Stud Welding TA Scope. 7.2. General Requirements. 73. Mechanical Requirements 7.4 Workmanship 78 Technique. 7.6 Stud Application Qualification Requirements. 7.7. Production Control 7.8. Fabrication and Verification Inspection Requirements Mandatory Annexes... I— Effective Throat. I Effective Throats of Fillet Welds in Skewed T Joints IIlManufacturers” Stud Base Qualification Requirements. IV—Discontinuity Acceptance Criteria Nonmandatory Annexes. A—Recommended Inspection Practice. B—Non-Prequalified Stainless Steels—Guidelines for WPS Qualification and Use. CSafe Practices, D—Guidelines for Preparation of Technical Inquires forthe Structural Welding Committee. E—Terms and Definitions, FSample Welding Forms nu G—Btchant Solutior H—Ultrasonie Unit Ce Annex Forms Form F-1 Welding Procedure Specification (WPS) Form F-2 Procedure Qualification Record (PQR)... Form F-3 Welder or Welding Operator Qualification Test Record Form H-1 Ultrasonic Unit Certification Example of the Use of Form H-1—Ultrasonic Unit Certification. Form H-2_ 4B Accuracy Evaluation. Example of the Use of Form H-2—dB Accuracy Evaluation.. Form H-3 Decibel (Attenuation or Gain) Values Nomograph. Example of the Use of Form H-3—Decibel (Attenuation or Gain) Values Nomograph « Index. Normative References uwTable 2a 22 31 32 33 34 35 41 41s 42 43 4a 45 46 47 Sa 61 62 63 7 712 73 car A2 A3 List of Tables Allowable Unit Stresses in PIP Groove Welds. Allowable Unit Stresses in CJP Groove Weld: Prequalified Variables to be Specified in the WPS. Prequalified Austenitic Stainless Steels.. Prequalified Filler Metal Classifications Effective Weld Sizes of Flare-Groove Welds. Prequalified WPS Requirements. WPS Qualification Variables ‘Overlay Essential Variables forall Processes. POR—Type, Number of Test Specimens, and Range of Thickness Qualified. Performance Qualification—Thickness Limits and Test Specimens. Performance Qualification—Position and Diameter Limitations. F-Numbers—Grouping of Electrodes and Welding Rods for Qualification. = A-Numbers—Classifications of Stainless Steel Weld Metal Analysis for WPS Qualification Thickness Limitations for Overlay WPS and Welding Operator Performance Qualification. Recommended Backing Thicknesse —— : Hole‘Type Image Quality Indicator (OD Requirement. Wire Image Quality Indicator 1) Requirement. UT Acceptance-Rejection Criteria Mechanical Property Requirements of Studs. Minimum Fillet Weld Size for Small Diameter Studs... ‘Stud Torque Values (UNC)... Equivalent Fillet Weld Leg Size Factors for Skewed T-Joints.. Weld Classification nn ; Nondestructive Testing/Examination Methods. Recommended Undercut CriterFigure 2a 22 23 24 25 34 32 33 34 35 36 37 4d 42 43 44 4s 46 47 48 49 4.10 411 412 4,13(A) Tension Speci 4,13(B) Tension Speci 414 445 4.16 47 418 419 420 42 42 423 S 52 61 62 63 List of Figures Fillet Welds on Opposite Side fs Common Plane of Conte for Cyt Loaded Sucre Fillet Welded Lap Joint in Tubular Connections ....u.ee 7 Double-Fillet Welded Lap Joint ns ‘Transition of Butt Joins in Nontubular Connections of Unequal Thickness ‘Transition of Butt Joints in Tubular Connections of Unequal Thickness... ‘Weld Metal Delta Ferrite Content Deiails for Prequalified Fillet Welds. Fillet Welded Prequalified Joints... Prequalified PJP Groove Welded Joints. ? Prequalified Joint Details for PJP Groove Welds Prequalified CIP Groove Welded Joints Weld Bead Width/Depth Limitations. Positions of Groove Welds. Positions of Fillet Welds. ‘Test Positions of Weld: Location of Test Specimens on POR Plate or Pipe POR Fillet Weld Specimens Bottom Ejecting Guided-Bend Test Jig, Bottom Guided-Bend Test Jig Alternative Wrap-Around Guided-Bend Test Jig, ‘Nomogram for Selecting Minimum Bend Radius Transverse Rectangular Tension Test Specimen.. Tension Specimens (Longitudinal) . : ‘Tension Specimen for Pipe Size Greater than 2 in. (60 mm) Nominal Diameter. wens—Reduced Section—Turned Specimens. yens—Full Section—Small Diameter Pipe... 6 in (150 mm) or 8 in, (200 mm) Pipe Assembly for Performance Qualification 2G and SG Position 91 Plates—Longitudinal Performance Qualification... ee ‘Transverse Side-Bend Specimens—Plat... ‘Teansverse Face-Bend and Root-Bend Specimens —Plat ‘Transverse Face-Bend and Root-Bend Specimens—Pipe Longitudinal Face-Bend and Root-Bend Specimens—Plate.. Fillet Weld Root-Bend Test Specimens ... . Overlay WPS and Performance Qualification Chemical Analysis Test. . Performance Qualification Specimen Location Typical Weld Access Hole Geometries. Typical Weld Profiles. Radiographic ldemification and Hole Type or Wire IOI Locations on Approximately Equal 103 106 ‘Thickness Joints 10 in. (250 mm) and Greater in Length. us Radiographic dentfiation and Hole-Type or Wire 101 Locations on Approximately Equal ‘Thickness Joints Less Than 10 in. (250 mm) in Length. . IS Radiographic identification and Hole-Type or Wire IOI Locations on Transition Joints 10 in (250 mm) and Greater in Lengt 1664 65 66 67 68 69 6.10 6.1L 6.12 6.13 6.14 61S 6.16 6.17 6.18 6.19 620 621 6.22 623 6.24 2 72 73 74 15 Wt Mea m2 IV-L v2 V3 1-4 ws 1V-6 var Ha H2 Radiographic Identification and Hole-Type or Wire [Q1 Locations on Transition Joins Less Than 10 in, (250 mm) in Length : Hote-Type image Quality nits (10 Desi. Wire Image Quality Indicator Radiographic Edge Blocks. ‘Transducer Crystal Standard Reference Reflector... Recommended Calibration Block ‘Typical Alternate Reflectors (Located in Weld Mock-ups and Production Welds). Transfer Correction o ‘Compression Wave Depth (Horizonial Sweep Calibration) ‘Compression Wave Sensitivity Calibration ‘Shear Wave Distance and Sensitivity Calibration Plan Viow of UT Scanning Patterns... ‘Scanning Methods seo Spherical Discontinuity Characteristics. Cylindrical Discontinuity Characteristics Planar Discontinuity Characteristic Discontinuity Height Dimension Discontinuity Length Dimension Screen Marking Report of Ultrasonic Examination Dimension and Tolerances of Standard-Type Shea Connectors. ‘Typical Tensile Test Fixture for Stud Welds Position of Test Stud Weld. ‘Torque Testing Arrangement for Stud Welds. Stud Weld Bend Fixtut.rocno Details for Skewed T-joints Bend Testing Device enn as Suggested Type of Device for Qualification Testing of Small Studs. eld Quay Reaurens for logsed Disconinies sDtemindby Radiography fr Statically Loaded Structures 158 Maximum Acceptable Radiographic Images. 163 For Radiography of Joints 1-1/8 in. (30 mm) and Greater, Typical Examples of Random Acceptable Discontinuites. so 164 ‘Weld Quality Requirements for Discontinuities Occurring in Tension Welds (Limitations of Porosity and Fusion Characteristics)... 1-165 ‘Weld Quality Requirements for Discontinuities' Occuring in Compression Welds (Limitations of Porosity or Fusion Type Discontinuities). Class R Indications. Class X Indications. Transducer Positions (Typical), Qualification BlockAWS D1.6:1090 Structural Welding Code—Stainless Steel 1. General Provisions 1.1 Scope ‘This code covers welding requirements applicable to stainless steel weldments subject to design stress. It shall be used in conjunction with any complementary code or specification for the design or construction of stainless steel weldments, 1.2 Base Metal The base metals to be welded under this code are stainless steel with the following limits; 1) Carbon (C) equal to or less than 0.5% TM) Chromium (Cr) equal to or greater than 10.5% U1) Iron (Fe) exceeds any other single element. Stainless steel base metals may include any of the fol- lowing types: (1) Austenitic (2) Ferritic and martensitic) (5) Duplex (6) Dissimilar (any combinations of the types above or with weldable carbon steels or low alloy steels). The stainless stecl types may be in any of the follow= ing form: ‘A, Cold rolled—sheet B. Hot rolled—sheet, plate . Shapes D. E. F Structural E. Tubular Clad materials & combinations G. Castings H. Forgings Stainless steel types are generally listed by American Iron and Steel Institute (AISI) Numbers, Unified Num- bering System (UNS), ot by American Society of Testing and Materials (ASTM) Specifications for product form Newer proprictary steels may not be numbered and must be identified by chemical composition or other suitable ‘means which clearly define the steel, 1.2.1 Specified Base Metal. The contract documents shall designate the specification and classification of ‘base metal to be used. Normally, they will be selected in accordance with the specifications. When welding to this cove is involved, the base metals, a8 defined in 1.2, should be used wherever possible. The designer shall specify application limits for temperature in the contract documents, The provisions of this code are not intended to apply to welding base metals thinner than 1/16 in, @.mm) 0 16 gage. 1.2.2 Base Metal Prequalification, Austenitic stainless steels whose filler metals normally produce a small amount of ferrite (see Table 3.2 for prequalified limits) shall be considered prequalified, provided they are welded with filler metals in accordance with Table 3.3 and the WPSs used conform to all the applicable req ‘ments of this code. All other stainless steels or combina- tions, and WPSs which are not prequalified, shall be qualified in conformance to this code. 1.2.3 Use of Unlisted Base Metals. When a stainless steel other than one of those listed in Table 3.2 is pro- posed for welded construction under this code, WPSs shall be established by qualification in accordance with the requirements of section 4, except as allowed in 1.2.3.1. The fabricator shall have the responsibility for establishing the WPS by qualification. 1.2.3.1 Unlisted base metals which have the same chemical composition and strength as a listed steel may be welded with a prequalified or qualified WPS for the listed steel 1.2.4 Weldability. The Engineer may prescribe addi- tional weldability testing of the unlisted steel. The re- sponsibility for determining weldability is assigned toAWS D1.6:1999 the party who either specifies a material not listed in ‘Table 3.2, except as permitted by 1.2.3.1, or who pro- poses the use of a substitute material not listed in Table 3.2. The Engineer may also prescribe additional corro- sion tests, toughness tests, creep tests, etc. These tests shall be conducted by a competent organization before the award of a contract. If not, the specific test method ‘and acceptance standards shall be specified in the con- tract documents 1.3 Welding Terms ‘The welding terms used in this code shall be inter- preted in accordance with the definitions given in the lat- est edition of ANSUAWS A3.0, Standard Welding Terms ‘and Definitions, supplemented by Annex E of this code. 1.4 Welding Symbols ‘Welding symbols shall be those shown in the latest edition of ANSVAWS A2.4, Symbols for Welding, Braz- ing, and Nondestructive Examination. Special conditions shall be fully explained by added notes or details. 1.5 Safety Precautions Safety precautions shall conform to applicable regula- tions. The latest edition of ANSVASC Z49.1, Safety in Welding, Cutting, and Allied Processes, published by the American Welding Society (also see Annex C, Safe Prac: tices), is recommended. Note: Work to this code may involve hazardous materi- als, operations, and equipment. The code does not pur- port to address all of the safety problems associated with its use. It is the responsiblity of the user fo establish ap- propriate safety and health practices. The user should determine the applicability of any regulatory limitations prior to use. GENERAL PROVISIONS 1.6 Standard Units of Measurement ‘The values stated in U.S. Customary Units are to be re- garded as the standard. The metric (S1) equivalents of US. Customary Units given inthis code may be approximate. 1.7 Acceptance Criteria ‘The fundamental premise of the code is to provide ‘general acceptance criteria applicable to any situation. Acceptance criteria for production welds different from those specified in the code may be used for a particular application, provided they are suitably do the proposer and approved by the Engineer. nate acceptance criteria can be based upon evaluation of | suitability for service using past experience, experimen- tal evidence or engineering analysis considering material type, service load effects, and environmental factors 1.8 Welding Procedure Specification (WPS) Each contractor or fabricator shall prepare written WPSs which are qualified, prequalified or a combination of qualified and prequalified in accordance with this ‘code. An example is shown in Annex F. 1.9 Approval [All references to the need for approval shall be inter- preted to mean approval by the Engineer. Hereinafter, if the consituction is under the jurisdiction of the Building ‘Commissioner, the term Enginecr shall be used, and shall be construed to mean the Building Commissioner or the Engineer. 1.10 Mandatory Provi Most provisions of the code are mandatory when the use of the code is specified, Certain provisions are op- tional and apply only when specified in contract docu- ments for a specific project. ons