AWS D9.1M/D9.1:2006

An American National Standard

Sheet Metal Welding Code

AWS D9.1M/D9.1:2006

An American National Standard

Approved by the American National Standards Institute

July 25, 2006

Sheet Metal Welding Code

5th Edition

Supersedes AWS D9.1M/D9.1:2000

Prepared by the American Welding Society (AWS) D9 Committee on Welding, Brazing, and Soldering of Sheet Metal

Under the Direction of the AWS Technical Activities Committee

Approved by the AWS Board of Directors

Abstract

This code covers the arc and braze welding requirements for nonstructural sheet metal fabrications using the commonly welded metals available in sheet form. Requirements and limitations governing procedure and performance qualification are presented, and workmanship and inspection standards are supplied. The informative annexes provide useful informa- tion on materials and processes.

550 N.W. LeJeune Road, Miami, FL 33126

International Standard Book Number: 0-87171-034-X

American Welding Society 550 N.W. LeJeune Road, Miami, FL 33126

© 2006 by American Welding Society

All rights reserved Printed in the United States of America

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Statement on the Use of American Welding Society Standards

All standards (codes, specifications, recommended practices, methods, classifications, and guides) of the American Welding Society (AWS) are voluntary consensus standards that have been developed in accordance with the rules of the American National Standards Institute (ANSI). When AWS American National 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 govern- mental 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 governmental 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 agreement between the contracting parties.

AWS American National Standards are developed through a consensus standards development process that brings together volunteers representing varied viewpoints and interests to achieve consensus. While AWS administers the process and establishes rules to promote fairness in the development of consensus, it does not independently test, evaluate, or verify the accuracy of any information or the soundness of any judgments contained in its standards.

AWS disclaims liability for any injury to persons or to property, or other damages of any nature whatsoever, whether special, indirect, consequential or compensatory, directly or indirectly resulting from the publication, use of, or reliance on this standard. AWS also makes no guaranty or warranty as to the accuracy or completeness of any information published herein.

In issuing and making this standard available, AWS is not undertaking to render professional or other services for or on behalf of any person or entity. Nor is AWS undertaking to perform any duty owed by any person or entity to someone else. Anyone using these documents should rely on his or her own independent judgment or, as appropriate, seek the advice of a competent professional in determining the exercise of reasonable care in any given circumstances.

This standard may be superseded by the issuance of new editions. Users should ensure that they have the latest edition.

Publication of this standard does not authorize infringement of any patent or trade name. Users of this standard accept any and all liabilities for infringement of any patent or trade name items. AWS disclaims liability for the infringement of any patent or product trade name resulting from the use of this standard.

Finally, AWS does not monitor, police, or enforce compliance with this standard, nor does it have the power to do so.

On occasion, text, tables, or figures are printed incorrectly, constituting errata. Such errata, when discovered, are posted on the AWS web page (www.aws.org).

Official interpretations of any of the technical requirements of this standard may only be obtained by sending a request, in writing, to the Managing Director, Technical Services Division, American Welding Society, 550 N.W. LeJeune Road, Miami, FL 33126 (see Annex K). With regard to technical inquiries made concerning AWS standards, oral opinions on AWS standards may be rendered. However, such opinions represent only the personal opinions of the particular individuals giving them. These individuals do not speak on behalf of AWS, nor do these oral opinions constitute official or unofficial opinions or interpretations of AWS. In addition, oral opinions are informal and should not be used as a substitute for an official interpretation.

This standard is subject to revision at any time by the AWS D9 Committee on Welding, Brazing, and Soldering of Sheet Metal. It must be reviewed every five years, and if not revised, it must be either reaffirmed or withdrawn. Comments (recommendations, additions, or deletions) and any pertinent data that may be of use in improving this standard are required and should be addressed to AWS Headquarters. Such comments will receive careful consideration by the AWS D9 Committee on Welding, Brazing, and Soldering of Sheet Metal 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 D9 Committee on Welding, Brazing, and Soldering of Sheet Metal to express their comments verbally. Procedures for appeal of an adverse decision concerning all such comments are provided in the Rules of Operation of the Technical Activities Committee. A copy of these Rules can be obtained from the American Welding Society, 550 N.W. LeJeune Road, Miami, FL 33126.

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Personnel

AWS D9 Committee on the Welding, Brazing, and Soldering of Sheet Metal

J. J. Sekely, Chair Welding Services, Incorporated

J. R. Miller, 1st Vice Chair International Training Institute

1. A. Navas, 2nd Vice Chair SMACNA

   1. M. Alonso, Secretary American Welding Society

J. L. Cooley JC & Associates, Incorporated

W. S. Harker U.S. Department of Energy

R. James International Training Institute

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Foreword

This foreword is not a part of AWS D9.1M/D9.1:2006, Sheet Metal Welding Code, but is included for informational purposes only.

This code was developed to provide standardized requirements for the qualification, production, and acceptance of welding or braze welding of nonstructural sheet metal components. Preparation of this document is in response to the many requests received from the sheet metal and construction industries.

The AWS Committee on Welding, Brazing, and Soldering of Sheet Metal was organized in May 1978 and has published four previous versions of D9.1.

The first, D9.1-80, Specification for Welding of Sheet Metal, was limited to the more common welding processes. The second, D9.1-84, bore the same title, but was augmented to provide coverage of braze welding.

D9.1-90, Sheet Metal Welding Code, was written to refine and clarify several areas of the standard and to upgrade it to the status of a code in order to enhance its use and to promote a minimum quality level for those who invoke it.

The 2000 edition, D9.1M/D9.1:2000, Sheet Metal Welding Code, provides for maintenance of the document and updates to keep abreast of practices being encountered in sheet metal welding and joining processes since the last revision.

The 2006 edition D9.1M/D9.1:2006, Sheet Metal Welding Code, also provides for maintenance of the document and presents up to date practices in sheet metal welding and joining processes since the 2000 revision.

Underlined text indicates a revision from the 2000 edition.

As new applications are developed and more experience is gathered, it is anticipated that changes in this standard will be required. Comments and suggestions for the improvement of this standard are welcome. They should be sent to the Secretary, AWS D9 Committee on the Welding, Brazing, and Soldering of Sheet Metal, American Welding Society, 550

N.W. LeJeune Road, Miami, FL 33126.

Official interpretations of any of the technical requirements of this standard may be obtained by sending a request, in writing, to the Managing Director, Technical Services Division, American Welding Society. A formal reply will be issued after it has been reviewed by the appropriate personnel following established procedures.

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Dedication

The AWS D9 Committee on Welding, Brazing, and Soldering of Sheet Metal dedicates this edition of the D9.1M/D9.1, Sheet Metal Welding Code, to James E. Roth for his significant contri- bution to both sheet metal and welding, and to the memory of Paul B. Dickerson.

In 1978, Jim recognized the need for a standard for welding nonstructural sheet metal and spearheaded the effort soliciting support from SMACNA, the Sheet Metal National Training Fund, the American Welding Society, and the welding community at large in the development of D9.1. Under his leadership, D9.1 has become the internationally accepted “standard” for welding sheet metal.

Paul was an AWS Fellow and contributed unselfishly to several technical committees of the American Welding Society, including D9. He is missed by all for whom he so generously shared his prodigious knowledge and wisdom.

The AWS D9 Committee on Welding, Brazing, and Soldering of Sheet Metal dedicates this edition of the D9.1M/D9.1, Sheet Metal Welding Code, to James E. Roth for his significant contri- bution to both sheet metal and welding, and to the memory of Paul B. Dickerson.

In 1978, Jim recognized the need for a standard for welding nonstructural sheet metal and spearheaded the effort soliciting support from SMACNA, the Sheet Metal National Training Fund, the American Welding Society, and the welding community at large in the development of D9.1. Under his leadership, D9.1 has become the internationally accepted “standard” for welding sheet metal.

Paul was an AWS Fellow and contributed unselfishly to several technical committees of the American Welding Society, including D9. He is missed by all for whom he so generously shared his prodigious knowledge and wisdom.

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Table of Contents

Page No.

Personnel v

Foreword vii

Dedication ix

List of Tables xiii

List of Figures xiii

1. Scope, Purpose, and Applications 1

   1. Scope. 1

   2. Purpose 1

   3. Applications 1

   4. Required Information. 1

   5. Symbols 1

   6. Standard Units of Measurement 1

   7. Safety and Health 1

2. Normative References 1

3. Terms and Definitions 2

   Part A—Arc Welding 2

4. General Provisions for Arc Welding 2

   1. Base Metal 2

   2. Filler Metal 2

   3. Processes 2

5. Arc Welding Procedure Qualification 2

   1. Prior Procedure Qualification 2

   2. Required Procedure Qualification Tests 2

   3. Limitations of Procedure Qualification 4

   4. Inspection of Procedure Qualification Test Welds 4

   5. Responsibility for Qualification 7

   6. Duration of Procedure Qualification 7

6. Qualification of Arc Welders and Arc Welding Operators 7

   1. Prior Welder and Welding Operator Qualification 7

   2. Required Welder and Welding Operator Qualification Tests 7

   3. Limitations of Welder and Welding Operator Qualifications 7

   4. Inspection of Welder and Welding Operator Qualification Test Welds 8

   5. Responsibility for Qualification 9

   6. Duration of Qualification 9

7. Arc Welding Workmanship 9

   1. Uniformity 9

   2. Joint Cleanliness 9

   3. Position 9

   4. Current and Polarity 9

   5. Inspection of Workmanship 9

8. Inspection of Production Arc Welding Work 9

   1. Fusion 9

      Page No.

   2. Penetration 9

   3. Reinforcement of Groove Welds 9

   4. Throat and Convexity of Fillet Welds 9

   5. Porosity or Inclusions 9

   6. Undercut 9

   7. Cracks 10

   8. Conformance. 10

      Part B—Braze Welding 10

9. General Provisions for Braze Welding 10

   1. Base Metal 10

   2. Filler Metal 10

   3. Processes 10

10. Braze Welding Procedure Qualification 10

    1. Prior Procedure Qualification 10

    2. Required Procedure Qualification Tests 10

    3. Limitations of Procedure Qualification 10

    4. Inspection of Procedure Qualification Test Braze Welds 12

    5. Responsibility for Qualification 12

    6. Duration of Procedure Qualification 15

11. Qualification of Braze Welders and Braze Welding Operators 15

    1. Prior Braze Welder and Braze Welding Operator Qualification 15

    2. Required Braze Welder and Braze Welding Operator Qualification Tests 15

    3. Limitations of Braze Welder and Braze Welding Operator Qualifications 15

    4. Inspection of Braze Welder and Braze Welding Operator Qualification Test Braze Welds 16

    5. Responsibility for Qualification 16

    6. Duration of Qualification 17

12. Braze Welding Workmanship 17

    1. Uniformity 17

    2. Joint Cleanliness 17

    3. Position 17

    4. Current and Polarity 17

    5. Inspection of Workmanship 17

13. Inspection of Production Braze Welding Work 17

    1. Bonding 17

    2. Reinforcement of Groove Braze Welds 17

    3. Throat and Convexity of Fillet Braze Welds 17

    4. Porosity or Inclusions 17

    5. Cracks 17

    6. Conformance. 17

Annex A (Informative)—Recommended Filler Metals 19

Annex B (Informative)—Supplemental Terms and Definitions 21

Annex C (Informative)—Gage Numbers and Equivalent Thicknesses in SI Units and U.S. Customary Units 23

Annex D (Informative)—Welding Procedure Specification (WPS) Form 25

Annex E (Informative)—Procedure Qualification Record (PQR) Form 27

Annex F (Informative)—Welder and Welding Operator Qualification Test Record Form 29

Annex G (Informative)—Joint Design and Details 31

Annex H (Informative)—Recommended Arc Welding Practices 39

Annex I (Informative)—Recommended Braze Welding Practices 47

Annex J (Informative)—General Knowledge Test 49

Annex K (Informative)—Guidelines for the Preparation of Technical Inquiries 55

List of Tables

Table Page No.

A.1 F Number Grouping of Welding Electrodes and Rods 19

1. Hot-Rolled and Cold-Rolled Steel Sheet 23

2. Galvanized Steel Sheet 23

3. Stainless Steel Sheet 24

4. Aluminum and Aluminum Alloy Sheet 24

5. Copper and Copper Alloy Sheet 24

1. Suggested Covered Electrode Size for Various Currents and Gages 40

2. Typical Storage and Drying Conditions for Covered Arc Welding Electrodes 41

3. Suggested Welding Conditions for Carbon Steel and Low Alloy Steel Sheet Metal 42

4. Suggested Welding Conditions for Aluminum Sheet Metal 44

List of Figures

Figure Page No.

1. Procedure Qualification Test Assemblies 3

2. Butt Joint Groove Weld Test Positions 5

3. Fillet Weld Test Positions 6

4. Braze Weld Procedure Qualification Test Assemblies 11

5. Braze Groove Weld Test Positions 13

6. Braze Fillet Weld Test Positions 14

GA.1 Square-Groove Weld 31

GA.2 Square-Groove Weld with Backing 31

GA.3 Single-V-Groove Weld 31

GA.4 Edge Weld (in a Flanged Joint) 32

GA.5 Flare-Bevel-Groove Weld (in T-Joint or Inside Corner Joint 32

GA.6 Flare-V-Groove Weld 32

GA.7 Square-Groove Corner Weld 32

GA.8 Flare-Bevel Weld (in an Offset Lap Joint) 33

GA.9 Flare-Bevel-Groove Weld 33

GA.10 Plain Lap Joint Fillet Weld 33

GA.11 Fillet Weld in T-Joint (One or Both Sides) 33

GA.12 Fillet Weld in Open (Offset) Corner Joint (Angle May Vary from 90°) 34

GA.13 Corner Weld with Backing 34

GB.1 Square-Groove Braze Weld 34

GB.2 Square-Groove Braze Weld with Backing 35

GB.3 Single-V-Groove Braze Weld 35

GB.4 Edge Braze Weld (in a Flanged Joint) 35

GB.5 Flare-Bevel-Groove Braze Weld (in T-Joint or Inside Corner Joint) 35

GB.6 Flare-V-Groove Braze Weld. 36

GB.7 Square-Groove Corner Braze Weld 36

GB.8 Fillet Braze Weld T-Joint 36

GB.9 Fillet Braze Weld in Open (Offset) Corner Joint (Angle May Vary from 90°) 37

GB.10 Plain Lap Joint Braze Weld 37

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Sheet Metal Welding Code

1. Scope, Purpose, and Applications

   1. Scope. This code provides qualification, workman- ship, and inspection requirements for both arc welding (Part A) and braze welding (Part B), as they apply to the fabrication, manufacture, and erection of nonstructural sheet metal components and systems.

   2. Purpose. This code was developed to provide stan- dardized requirements for the qualification, production, and acceptance of welding or braze welding of nonstruc- tural sheet metal components.

   3. Applications. General applications of this code are in the following industrial areas:

      1. Heating, ventilating, and air conditioning systems

      2. Food processing equipment

      3. Architectural sheet metal and similar applications

      4. Other nonstructural sheet metal applications

      This code covers sheet metal up to and including 6.4 mm [0.250 in]. Also covered are the attachment of accessories and components of the system, and joining or attachment of any member, regardless of thickness, whose sole purpose is stiffening, supporting, or reinforcing the sheet metal.

      Where negative pressure or positive pressure exceeds

      30 kPa [5 psi] which is approximately 3 meters [120 in] of standing water or where structural requirements are concerned, other codes or standards shall be used.

   4. Required Information. This code requires values to be specified by the Engineer for paragraphs 8.2, 8.3, 13.1, and 13.3.

   5. Symbols. Symbols used in this code shall be in accor- dance with the latest edition of AWS A2.4, Standard Sym-

      
      

      fore, each system must be used independently of the other without combining in any way.

      1.7 Safety and Health. Safety and health issues and con- cerns are beyond the scope of this standard and therefore are not fully addressed herein. Safety and health information is available from other sources, including, but not limited to, ANSI Z49.1, Safety in Welding, Cutting, and Allied Pro- cesses and applicable federal, state, and local regulations.

      Additional information may be found in the Safety and Health Fact Sheets, a document of the AWS Safety and Health Committee.1 The equipment manufacturer’s oper- ating manual and safety instructions should always be carefully studied and complied with when operating welding or related equipment. Material Safety Data Sheets (MSDSs) for materials used in these processes are available from the material supplier.

      
      

2. Normative References

The following standards contain provisions which, through reference in this text, constitute provisions of this AWS standard. For undated references, the latest edition of the referenced standard shall apply. For dated references, subsequent amendments to, or revisions of, any of these publications do not apply.

ANSI Z49.1, Safety in Welding, Cutting, and Allied Processes;2 and

AWS documents:3

1. AWS A2.4, Standard Symbols for Welding, Braz- ing, and Nondestructive Examination; and

2. AWS A3.0, Standard Welding Terms and Defini- tions Including Terms for Adhesive Bonding, Brazing, Soldering, Thermal Cutting, and Thermal Spraying.

bols for Welding, Brazing, and Nondestructive Examination.

1 Safety and Health Fact Sheets are published by the American

1.6 Standard Units of Measurement. This standard

makes use of both the International System of Units (SI) and U.S. Customary Units. The latter are shown within brackets [ ] or in appropriate columns in tables and fig- ures. The measurements are not exact equivalents; there-

Welding Society, 550 N.W. LeJeune Road, Miami, FL 33126. 2 ANSI Z49.1 is published by the American Welding Society, 550 N.W. LeJeune Road, Miami, FL 33126.

3 AWS standards are published by the American Welding Society, 550 N.W. LeJeune Road, Miami, FL 33126.