{"id":7187,"date":"2024-08-10T13:26:56","date_gmt":"2024-08-10T13:26:56","guid":{"rendered":"https:\/\/www.sirfull.com\/?p=7187"},"modified":"2024-10-03T12:14:03","modified_gmt":"2024-10-03T12:14:03","slug":"7-aspects-assurance-control-quality-welding","status":"publish","type":"post","link":"https:\/\/www.sirfull.com\/en\/blog\/7-aspects-assurance-control-quality-welding\/","title":{"rendered":"7 things you need to know about quality assurance and welding quality control"},"content":{"rendered":"[vc_row type=”in_container” full_screen_row_position=”middle” column_margin=”default” column_direction=”default” column_direction_tablet=”default” column_direction_phone=”default” scene_position=”center” constrain_group_2=”yes” text_color=”dark” text_align=”left” row_border_radius=”none” row_border_radius_applies=”bg” overflow=”visible” overlay_strength=”0.3″ gradient_direction=”left_to_right” shape_divider_position=”bottom” bg_image_animation=”none” gradient_type=”default” shape_type=””][vc_column column_padding=”no-extra-padding” column_padding_tablet=”inherit” column_padding_phone=”inherit” column_padding_position=”all” column_element_direction_desktop=”default” column_element_spacing=”default” desktop_text_alignment=”default” tablet_text_alignment=”default” phone_text_alignment=”default” background_color_opacity=”1″ background_hover_color_opacity=”1″ column_backdrop_filter=”none” column_shadow=”none” column_border_radius=”none” column_link_target=”_self” column_position=”default” gradient_direction=”left_to_right” overlay_strength=”0.3″ width=”3\/5″ tablet_width_inherit=”default” animation_type=”default” bg_image_animation=”none” border_type=”simple” column_border_width=”none” column_border_style=”solid” column_padding_type=”default” gradient_type=”default”][vc_column_text el_class=”dark”]\n

What is Quality Assurance (QA)?<\/h3>\n[\/vc_column_text][vc_column_text el_class=”dark”]Quality assurance<\/strong> is a set of processes that validate the manufacturing procedures followed.<\/p>\n

This helps prevent manufacturing defects and guarantee product quality.[\/vc_column_text][divider line_type=”No Line” custom_height=”20px”][vc_column_text]\n

What is Welding Quality Control (QC)?<\/h3>\n[\/vc_column_text][vc_column_text]Quality control<\/strong> is the process of confirming that a product conforms to specifications. It includes the verification and testing of manufacturing procedures and finished products. The results of these tests are compared with a set of defined acceptance criteria.<\/p>\n

By performing QC tests during manufacturing, defects can be identified and rectified.
\nIf necessary, adjustments can then be made to the manufacturing process to prevent any further defective production.<\/p>\n

In welding, quality assurance and quality control play an essential role in ensuring the production of solid, reliable welds and minimizing rework.[\/vc_column_text][\/vc_column][vc_column column_padding=”padding-1-percent” column_padding_tablet=”inherit” column_padding_phone=”inherit” column_padding_position=”left” column_element_direction_desktop=”default” column_element_spacing=”default” desktop_text_alignment=”default” tablet_text_alignment=”default” phone_text_alignment=”default” background_color_opacity=”1″ background_hover_color_opacity=”1″ column_backdrop_filter=”none” column_shadow=”none” column_border_radius=”none” column_link_target=”_self” column_position=”default” gradient_direction=”left_to_right” overlay_strength=”0.3″ width=”2\/5″ tablet_width_inherit=”default” animation_type=”default” bg_image_animation=”none” border_type=”simple” column_border_width=”none” column_border_style=”solid” column_padding_type=”default” gradient_type=”default”][image_with_animation image_url=”7182″ image_size=”medium_featured” animation_type=”entrance” animation=”None” animation_movement_type=”transform_y” hover_animation=”none” alignment=”” border_radius=”none” box_shadow=”none” image_loading=”lazy-load” max_width=”100%” max_width_mobile=”default”][\/vc_column][\/vc_row][vc_row type=”in_container” full_screen_row_position=”middle” column_margin=”default” column_direction=”default” column_direction_tablet=”default” column_direction_phone=”default” scene_position=”center” top_padding=”5%” bottom_padding=”5%” constrain_group_2=”yes” text_color=”dark” text_align=”left” row_border_radius=”none” row_border_radius_applies=”bg” overflow=”visible” overlay_strength=”0.3″ gradient_direction=”left_to_right” shape_divider_position=”bottom” bg_image_animation=”none” gradient_type=”default” shape_type=””][vc_column column_padding=”no-extra-padding” column_padding_tablet=”inherit” column_padding_phone=”inherit” column_padding_position=”all” column_element_direction_desktop=”default” column_element_spacing=”default” desktop_text_alignment=”default” tablet_text_alignment=”default” phone_text_alignment=”default” background_color_opacity=”1″ background_hover_color_opacity=”1″ column_backdrop_filter=”none” column_shadow=”none” column_border_radius=”none” column_link_target=”_self” column_position=”default” gradient_direction=”left_to_right” overlay_strength=”0.3″ width=”1\/1″ tablet_width_inherit=”default” animation_type=”default” bg_image_animation=”none” border_type=”simple” column_border_width=”none” column_border_style=”solid”][divider line_type=”No Line” custom_height=”20px”][vc_column_text]\n

Why are QA\/QC processes necessary?<\/h3>\n[\/vc_column_text][vc_column_text]Quality assurance and quality control play an essential role in ensuring the production of sound, reliable welds and minimizing rework.<\/p>\n

Supply contracts<\/strong> for fabrications may specify compliance with certain welding standards, which in turn may stipulate adherence to defined quality assurance and quality control processes.<\/p>\n

In some cases, the customer specifies a more rigorous QA\/QC regime than the current standard. In some disciplines, compliance with certain welding standards is a regulatory requirement,<\/strong> making the use of specific QA\/QC processes mandatory.<\/p>\n

These disciplines include pressure vessels, structural steel and lifting equipment. Quality assurance and quality control are also good ways of showing that due diligence has been exercised during the manufacturing process. It also captures the condition of the product during and at the end of the manufacturing process.<\/p>\n

This information can be used in the future to counter claims of defective products.[\/vc_column_text][divider line_type=”No Line” custom_height=”20px”][vc_column_text]\n

What can happen if QA\/QC procedures are not followed?<\/h4>\n[\/vc_column_text][vc_column_text]Failure to carry out adequate quality assurance and control during manufacture can result in welds of variable quality<\/strong>. When weld defects appear, rectification is necessary and can delay delivery of<\/strong> the product to the customer. This can also result in a loss of reputation<\/strong> for the manufacturer.<\/p>\n

If the contractual agreement with the customer requires compliance with standards, and the applicable quality assurance and control requirements have not been met, this can lead to contractual problems and legal sanctions<\/strong>. The latter scenario is all the more likely if quality problems are identified after manufacturing has been completed, leading to delays and, worse still, product failure during use.[\/vc_column_text][divider line_type=”No Line” custom_height=”20px”][vc_column_text]\n

QA\/QC documents<\/h3>\n[\/vc_column_text][vc_column_text]A Quality Assurance Plan<\/strong> (QAP) provides the framework for QA\/QC activities before and during the manufacturing process. The QAP defines the schedule of inspections and tests to be carried out. It defines the roles of key personnel and assigns responsibilities to the various roles. The details, class and compliance standards of welds are defined by the design engineer, taking into account the application and customer requirements. This will determine the quality control requirements for the project. On the basis of the above, the welding engineer<\/strong> generally creates the welding documentation<\/strong> for product manufacture. These documents include Welding Operation Descriptions (WPS)<\/strong> and a Weldmap<\/strong>. They form the basis of welding QA\/QC.[\/vc_column_text][image_with_animation image_url=”7148″ image_size=”full” animation_type=”entrance” animation=”None” animation_movement_type=”transform_y” hover_animation=”none” alignment=”center” border_radius=”none” box_shadow=”none” image_loading=”lazy-load” max_width=”100%” max_width_mobile=”default”][vc_column_text]\n

Capture: WPS created with Welding Cloud<\/em><\/p>\n[\/vc_column_text][vc_column_text]WPS are instructions on how to perform specific welds. They typically specify the welding standard, welding process, weld type, weld preparation, preheating and postheating requirements, welding position(s), interpenetration temperatures, electrode\/filler specifications, gas details, amperage\/voltage range, speeds, current type, polarity, etc. Weldmap – shows the location of welds and assigns the appropriate DMOS to each weld.[\/vc_column_text][image_with_animation image_url=”7152″ image_size=”full” animation_type=”entrance” animation=”None” animation_movement_type=”transform_y” hover_animation=”none” alignment=”center” border_radius=”none” box_shadow=”none” image_loading=”lazy-load” max_width=”100%” max_width_mobile=”default”][vc_column_text]\n

Weldmap included in a PDF welding notebook produced with the Welding Cloud solution<\/em><\/p>\n[\/vc_column_text][image_with_animation image_url=”7156″ image_size=”full” animation_type=”entrance” animation=”None” animation_movement_type=”transform_y” hover_animation=”none” alignment=”center” border_radius=”none” box_shadow=”none” image_loading=”default” max_width=”100%” max_width_mobile=”default”][vc_column_text]\n

Weldmap included in a PDF welding notebook produced with the Welding Cloud solution<\/em><\/p>\n[\/vc_column_text][divider line_type=”No Line” custom_height=”20px”][vc_column_text]\n

Qualification of WPS and welders<\/h3>\n[\/vc_column_text][vc_column_text]Welder Qualification (WPQ)<\/strong> Welder Quali\ufb01cation<\/strong> must be performed to confirm the welder’s ability to deposit sound weld metal for a specific weld type, material and weld position. WPS Qualification<\/strong> WPS<\/strong> qualification is used to determine whether welds are capable of providing the characteristics required for its application. The extent of testing required to qualify the WPS<\/strong> will depend on whether pre-qualified weld preparation and consumables are used. In some cases (e.g. where pre-qualified standard welds are used), minimal or no testing may be required. Where DMOS qualification is required, weld test coupons are manufactured in accordance with the DMOS and the compliance standard. Non-destructive testing (NDT)<\/strong> and destructive testing (DTP)<\/strong> are then carried out on the test coupons to check for weld defects and joint properties. A Procedure Qualification Record (PQR)<\/strong> is used to document weld qualification.[\/vc_column_text][image_with_animation image_url=”7161″ image_size=”full” animation_type=”entrance” animation=”None” animation_movement_type=”transform_y” hover_animation=”none” alignment=”center” border_radius=”none” box_shadow=”none” image_loading=”lazy-load” max_width=”100%” max_width_mobile=”default”][vc_column_text]\n

Example of a Welding Procedure Specification (WPS)<\/em><\/p>\n[\/vc_column_text][vc_column_text]QS<\/strong> must be performed to confirm the welder’s ability to deposit sound weld metal for a specific weld type, material and welding position.
\nThe welder’s qualification is valid for a range of materials, thicknesses, positions and weld types, according to the qualification standard.
\nIt is documented on the welder’s qualification test certificate and the welder’s performance qualification.[\/vc_column_text][image_with_animation image_url=”7165″ image_size=”full” animation_type=”entrance” animation=”None” animation_movement_type=”transform_y” hover_animation=”none” alignment=”center” border_radius=”none” box_shadow=”none” image_loading=”default” max_width=”100%” max_width_mobile=”default”][vc_column_text]\n

Example of Welder Qualification (WPQ)<\/em><\/p>\n[\/vc_column_text][vc_column_text]Inspection and test plan, test follow-up sheets<\/strong> – These documents are created on the basis of the WPS<\/strong> and design documentation. They are completed as QC inspections\/tests<\/strong> are carried out, for recording purposes.[\/vc_column_text][divider line_type=”No Line” custom_height=”20px”][vc_column_text]\n

QC before\/during\/after welding<\/h3>\n[\/vc_column_text][vc_column_text]QC before the actual welding generally includes the following elements:<\/strong><\/p>\n