Welding Process Improvements

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Welding Process Improvements
Welding Requirements
Approved for Public Release
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Objectives

• Improve compliance to welding requirements
• Reduce product non-conformances
• Reduce project cost

Approved for Public Release
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Main Points

• Non-conforming welds
• Non-conforming vs. poor quality welds
• Welding audit results
• Impact of non-conformances
• Understanding requirements
• Identify the applicable welding specification.
• Know the weld class and/or application.
• Reference to applicable welding specification.
• Tools to improve
• Self audit checklist / Overview of system
  requirements

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Non-conforming vs. Poor Quality
Poor quality
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Main Points

• Non-conforming welds
• Non-conforming vs. poor quality welds
• Welding audit results
• Impact of non-conformances
• Understanding requirements
• Identify the applicable welding specification.
• Know the weld class and/or application.
• Reference to applicable welding specification.
• Tools to improve
• Self audit checklist / Overview of system
  requirements

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Audit Results
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Weld Records Do Not Meet Specification
Requirements

• Mil-Std-278 / Tech-Pub, 4.1.3, 4.1.3.1, 10.3.5,
  13.2.5(b) and 13.2.10
• PPD 802-6335720 (PPD-5720) or Tech-Pub
  S9074-AD-GIB-010/1688 (TP-1688), paragraph 5.6

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Welder Workmanship Program

• As specified within Mil-Std-248
• or Tech-Pub 248
• paragraphs 5.2.3 (a) and 5.2.3.1 (a) through (g)

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Welder Personnel Qualification

• The most common cause of this non-compliance is a
  failure to maintain welder qualification
• Mil-Std / Tech-Pub-248 requires qualification
  maintenance via process use

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Use of Unapproved Welding Procedures

• Welding procedures are required to be EBC
  approved per EB Specification 2678
• The most current revision of an approved
  procedure is issued for used on EBC work

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Use of Unapproved Welding Procedures
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Weld Wire Not Per Test Requirements

• Welding consumables lacked the additional testing
  as required by the invoked fabrication standards
• The fabrication standards filler material
  tables, and are many times overlooked
• When the welding consumables are procured or when
  previously procured consumables are used on EBC
  orders

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Commercial Weld Wire Used

• Material test reports were either not reviewed or
  were improperly reviewed
• Fabrication standards require material test
  reports to be reviewed for all welding
  consumables used in fabrication.

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Commercial Weld Wire Used
AWS A5.9-ER309, ASMESFA5.9-ER309 Mil E
19933-Mil309, Mil E 22200/2 Subject to
availability
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Commercial Weld Wire Used
Specifications AWS 5.18 ER70-2
ASME SFA 5.18 ER70S-2 Additional
Information Conforms to Mil E23765/1
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Commercial Weld Wire Used
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Commercial Weld Wire Used
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Commercial Weld Wire Used
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Commercial Weld Wire Used
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Main Points

• Non-conforming welds
• Non-conforming vs. poor quality welds
• Welding audit results
• Impact of non-conformances
• Understanding requirements
• Identify the applicable welding specification.
• Know the weld class and/or application.
• Reference to applicable welding specification.
• Tools to improve
• Self audit checklist / Overview of system
  requirements

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Cost Impact of Non-conforming Welds

• Engineering support (No rework) typically costs
  10K
• Shipyard rework typical cost in excess of 100K

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Cost Impact of Non-conforming Welds

• Supplier Incurred
• Replacement material
• Testing
• Material Shipping

• Electric Boat Incurred
• Shipyard planning
• Rip-outs
• Schedule changes
• Engineering support
• System testing
• Travel cost

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Main Points

• Non-conforming welds
• Non-conforming vs. poor quality welds
• Welding audit results
• Impact of non-conformances
• Understanding requirements
• Identify the applicable welding specification.
• Know the weld class and/or application.
• Reference to applicable welding specification.
• Tools to improve
• Self audit checklist / Overview of system
  requirements

Approved for Public Release
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Identifying the Applicable Welding Specification

• NAVSEA S9074-AR-GIB-010/278 (Mil-Std-278)
• NAVSEA S9074-AD-GIB-010/1688
• EB Specification
• American Welding Society (AWS)

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Welding Specification

• NAVSEA
• S9074-AR-GIB-010/278
• Requirements for Fabrication Welding
  Inspection, Casting Inspection Repair for
  Machinery, Piping, Pressure Vessels

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Welding Specification

• NAVSEA
• S9074-AD-GIB-010/1688
• Requirements for Fabrication, Welding and
  Inspection of Submarine Structure

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Welding Specification

• EB Specification 4189
• Mil-Std-1688, (PPD802-6335720), Fabrication,
  Welding and Inspection of HY-80/100 Submarine
  Applications Requirements and Modifications

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Finding the Requirements

• Purchase Order
• Document Field
• Standard Clauses
• Remarks
• Drawings
• Fabrication Standards
• EB Specifications
• Invoke additional requirements
• Modify NAVSEA fabrication standards

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Finding the Requirements
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Finding the Requirements

• Purchase Order
• Standard Clauses. (Over 70)
• EB Specifications (10)
• Remarks section

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Weld Procedure Approval

• Welding and Brazing Procedural Approval
• Standard Clause
• 60-77, 60-78, 60-66 and 60-68
• Vendor Procedure Approval Request (VPAR)
• The requirement for approval of weld procedures
  by EB is also invoked on all sub-tier suppliers

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Understanding Requirements

• Identify the applicable welding specification.
• Know the weld class and/or application.
• Reference to applicable welding specification.

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Main Points

• Non-conforming welds
• Non-conforming vs. poor quality welds
• Welding audit results
• Impact of non-conformances
• Understanding requirements
• Identify the applicable welding spec.
• Know the weld class and/or application.
• Reference to applicable welding specification.
• Tools to improve
• Self audit checklist / Overview of system
  requirements

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Tools

• System requirements (Procedures and Records)
• Self audit checklist
• In-process welding
• Welding consumable control
• Welding records
• Welder Workmanship Training (WWT) curriculum
• Welding Engineering Helpful Points

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Summary

• Understand the impact
• Quality
• Project Cost
• Understand the requirements
• Purchase Order
• Drawings
• Specifications
• Have and use the tools necessary to assure success

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The stakes are high! Sailors lives depend on
the integrity of your welds!
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