AWS D1.1 SMAW Welding Certification Procedure Specifications
|The AWS SMAW 4G welding certification procedure
specifications are almost identical to the AWS SMAW 3G welding
certification procedure specifications. This certification is very
similar to the 3G welding certification with a few exceptions. The first
main difference is that the AWS D1.1 4G welding certification certifies
you to do fillet welds in the 1F, 2F, 4F, positions, and groove welds
in the 1G, 2G, 4G, positions, but it does not certify you to weld in the
3F and 3G positions. By taking the 3G and 4G welding certifications
together, it certifies you to weld plate in all positions, and to do
fillet welds on pipe with a minimum diameter of 24 inches. When taking
these certifications together it also put them into a single procedure.
The other main difference is more customary then a procedure
specification that involves horizontal and overhead welding. When doing
horizontal and overhead welds they are typically done in stringer beads
verses flat and vertical welds using weave welds.
The 4G welding certification also comes in two thick nesses. The first is the 3/8 inch limited thickness procedure. This is the one I am taking. The second is the 1 inch thick plate and it the unlimited thickness procedure. The limited thickness procedure certifies a welder to steel between 1/8 to 3/4 of an inch thick steel.
SMAW Welding Machine Set-Up
Preparation of the SMAW 4G Test CouponsUnlike the 3G welding certification were I took a lot of pictures. I did get caught up in the moment of taking the 4G welding certification and forgot to take many key pictures. Unfortunately this is the real test and there are no retakes while doing it!
The preparation of the 4G test coupons is the same as the 3G procedure. These are the AWS D1.1 notes for the 4G SMAW procedure with pictures:
|Here are the test coupons and this is how I received them.|
5. After the fit-up is completed the inspector will check all the fit-up specifications
SMAW 4G Certification Welding Techniques
Overhead Root Pass Welding TechniquesTo start the root pass I positioned myself in a way that I can weld toward myself. The first picture is exactly my view from behind the helmet while I am welding. The root took two and a half E7018 electrodes and had two restart. I did a weave technique holding the sides of the bevel until the arc of the electrode would roll and washes into the bevel. If I remember correctly I held each side for about one second. The second picture is the first root weld with the slag covering. Once I put in the root I cleaned it with a chipping hammer and wire wheel. The root was then inspected because the procedure stated:
7. The root pace shall be inspected.
Preparation of the Test Coupons
The Bend TestThe first bend done was the root bend followed by the face bend. Both pieces passed and I did not need the alternate. As you can see below the test coupon were not completely clean. I had a few minor defects that were well within the AWS D1.1 acceptance criteria. The openings were less then 1/32 of an inch so they did not count as discontinuities. I asked why these pieces had these openings and I was told these are common when using weave techniques.
Here are the acceptance criteria for the bend test in the words of the American Welding Society.
“Acceptance Criteria for Bend Tests. The convex surface of the bend test specimen shall be visually examined for surface discontinuities. For acceptance, the surface shall contain no discontinuities exceeding the following dimensions: (1) 1/8 in. (3 mm) measured in any direction of the surface
(2) 3/8 in. (10 mm) – the sum of the greatest dimensions of all discontinuities exceeding 1/32 in. (1 mm) , but less than or equal to 1/8 in (3 mm).
(3) ¼ in. (6 mm) – the maximum corner crack resulting from visible slag inclusions or other fusion type discontinuities, then 1/8 in. (3 mm) maximum shall apply
Specimens with corner cracks exceeding ¼ in. (6 mm) with no evidence of slag inclusions or other fusion type discontinuities shall be disregarded, and a replacement test specimen from the original weldment shall be tested.”
|Here are the results of the bend test. As you can see there are some minor openings but well within the acceptance critera.|