AWS D9.1M/D9.1:2012

An American National Standard

Sheet Metal Welding Code

AWS D9.1M/D9.1:2012

An American National Standard

Approved by the American National Standards Institute

July 20, 2012

Sheet Metal Welding Code

6th Edition

Supersedes AWS D9.1M/D9.1:2006

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 information on materials and processes.

International Standard Book Number: 978-0-87171-820-4

American Welding Society 8669 Doral Blvd., Doral, FL 33166

© 2012 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 the AWS administers the process and establishes rules to promote fairness in the development of consensus, it does not independently test, evalu- ate, 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 guarantee or warranty as to the accuracy or completeness of any information published herein.

In issuing and making this standard available, AWS is neither 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. It is assumed that the use of this standard and its provisions is entrusted to appropriately qualified and competent personnel.

This standard may be superseded by the issuance of new editions. This standard may also be corrected through publication of amendments or errata. It may also be supplemented by publication of addenda. Information on the latest editions of AWS standards including amendments, errata, and addenda are posted on the AWS web page (www.aws.org). Users should ensure that they have the latest edition, amendments, errata, and addenda.

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.

The 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 appropriate technical committee. Such requests should be addressed to the American Welding Society, Attention: Managing Director, Technical Services Division, 8669 Doral Blvd., Doral, FL 33166 (see Annex K). With re- gard to technical inquiries made concerning AWS standards, oral opinions on AWS standards may be rendered. These opinions are offered solely as a convenience to users of this standard, and they do not constitute professional advice. 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, 8669 Doral Blvd., Doral, FL 33166.

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Personnel

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

J. J. Sekely, Chair Welding Services, Incorporated

1. S. Harker, Vice Chair U.S. Department of Energy

   1. L. Diaz, Secretary American Welding Society

E. W. Beckman Consultant

T. J. White First Energy

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

J. L. Cooley J C & Associates, Incorporated

G. E. Donovan International Training Institute

D. L. McQuaid D L McQuaid & Associates, Incorporated

Special Contributors

M. J. Brooks Fronius

E. P. Howard Sheet Metal and Air Conditioning Contractors’ National Association

G. A. Navas Sheet Metal and Air Conditioning Contractors’ National Association—Retired

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Foreword

This foreword is not part of AWS D9.1M/D9.1:2012, 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 weld- ing 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 five 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 pre- sents up to date practices in sheet metal welding and joining processes since the 2000 revision.

The 2012 edition D9.1M/D9.1:2012, Sheet Metal Welding Code, provides for maintenance of the document and incorpo- rates many of the comments received during the balloting process for the 2006 edition.

Underlined text in clauses, tables, or figures indicates an editorial or technical change from the 2006 edition. A vertical line in the margin also indicates a revision from 2006 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, 8669 Doral Blvd., Doral, FL 33166.

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Table of Contents

Page No.

Personnel v

Foreword vii

List of Tables xi

List of Figures xi

1. General Requirements 1

   1. Scope. 1

   2. Units of Measurement. 1

   3. Safety 1

2. Normative References 2

3. Terms and Definitions 2

   Part A—Arc Welding 2

4. General Provisions for Arc Welding 2

   1. Base Metal 2

   2. Filler Metal 3

   3. Processes 3

5. Arc Welding Procedure Qualification 3

   1. Prior Procedure Qualification 3

   2. Required Procedure Qualification Tests 3

   3. Limitations of Procedure Qualification 3

   4. Inspection of Procedure Qualification Test Welds 5

   5. Responsibility for Qualification 8

   6. Duration of Procedure Qualification 8

6. Qualification of Arc Welders and Arc Welding Operators 8

   1. Prior Welder and Welding Operator Qualification 8

   2. Required Welder and Welding Operator Qualification Tests 9

   3. Limitations of Welder and Welding Operator Qualifications 9

   4. Inspection of Welder and Welding Operator Qualification Test Welds 10

   5. Responsibility for Qualification 10

   6. Duration of Qualification 11

7. Arc Welding Workmanship 11

   1. Uniformity 11

   2. Joint Cleanliness 11

   3. Position 11

   4. Current and Polarity 11

   5. Inspection of Workmanship 11

8. Inspection of Production Arc Welding Work 11

   1. Fusion 11

   2. Penetration 11

   3. Reinforcement of Groove Welds 11

   4. Throat and Convexity of Fillet Welds 11

   5. Porosity or Inclusions 11

   6. Undercut 12

      Page No.

   7. Cracks 12

   8. Conformance. 12

      Part B—Braze Welding 12

9. General Provisions for Braze Welding 12

   1. Base Metal 12

   2. Filler Metal 12

   3. Processes 12

10. Braze Welding Procedure Qualification 12

    1. Prior Procedure Qualification 12

    2. Required Procedure Qualification Tests 12

    3. Limitations of Procedure Qualification 13

    4. Inspection of Procedure Qualification Test Braze Welds 15

    5. Responsibility for Qualification 15

    6. Duration of Procedure Qualification 18

11. Qualification of Braze Welders and Braze Welding Operators 18

    1. Prior Braze Welder and Braze Welding Operator Qualification 18

    2. Required Braze Welder and Braze Welding Operator Qualification Tests 18

    3. Limitations of Braze Welder and Braze Welding Operator Qualifications 18

    4. Inspection of Braze Welder and Braze Welding Operator Qualification Test Braze Welds 20

    5. Responsibility for Qualification 20

    6. Duration of Qualification 20

12. Braze Welding Workmanship 20

    1. Uniformity 20

    2. Joint Cleanliness 20

    3. Position 20

    4. Current and Polarity 21

    5. Inspection of Workmanship. 21

13. Inspection of Production Braze Welding Work 21

    1. Bonding 21

    2. Reinforcement of Groove Braze Welds 21

    3. Throat and Convexity of Fillet Braze Welds 21

    4. Porosity or Inclusions 21

    5. Cracks 21

    6. Conformance 21

Annex A (Informative)—Recommended Filler Metals 23

Annex B (Informative)—Supplemental Terms and Definitions 25

Annex C (Informative)—Gage Numbers and Equivalent Thicknesses in SI Units and U.S. Customary Units 27

Annex D (Informative)—Welding Procedure Specification (WPS) Form 29

Annex E (Informative)—Procedure Qualification Record (PQR) Form 31

Annex F (Informative)—Welder and Welding Operator Qualification Test Record Form 33

Annex G (Informative)—Joint Design and Details 35

Annex H (Informative)—Recommended Arc Welding Practices 43

Annex I (Informative)—Recommended Braze Welding Practices 51

Annex J (Informative)—General Knowledge Test 53

Annex K (Informative)—Guidelines for the Preparation of Technical Inquiries for Structural Welding Committee...61

x

List of Tables

Table Page No.

A.1 F Number Grouping of Welding Electrodes and Rods 23

1. Hot-Rolled and Cold-Rolled Steel Sheet 27

2. Galvanized Steel Sheet 27

3. Stainless Steel Sheet 28

4. Aluminum and Aluminum Alloy Sheet 28

5. Copper and Copper Alloy Sheet 28

1. Suggested Covered Electrode Size for Various Currents and Gages 44

2. Typical Storage and Drying Conditions for Covered Arc Welding Electrodes 45

3. Suggested Welding Conditions for Carbon Steel and Low Alloy Steel Sheet Metal 46

4. Suggested Welding Conditions for Aluminum Sheet Metal 48

List of Figures

Figure Page No.

1. Procedure Qualification Test Assemblies 4

2. Butt Joint Groove Weld Test Positions 6

3. Fillet Weld Test Positions 7

4. Braze Weld Procedure Qualification Test Assemblies 14

5. Braze Groove Weld Test Positions 16

6. Braze Fillet Weld Test Positions 17

GA.1 Square-Groove Weld 35

GA.2 Square-Groove Weld with Backing 35

GA.3 Single-V-Groove Weld 35

GA.4 Edge Weld (in a Flanged Joint) 36

GA.5 Flare-Bevel-Groove Weld (in T-Joint or Inside Corner Joint) 36

GA.6 Flare-V-Groove Weld 36

GA.7 Square-Groove Corner Weld. 36

GA.8 Flare-Bevel Weld (in an Offset Lap Joint) 37

GA.9 Flare-Bevel-Groove Weld 37

GA.10 Plain Lap Joint Fillet Weld 37

GA.11 Fillet Weld in T-Joint (One or Both Sides) 37

GA.12 Fillet Weld in Open (Offset) Corner Joint (Angle May Vary from 90°) 38

GA.13 Corner Weld with Backing 38

GB.1 Square-Groove Braze Weld 38

GB.2 Square-Groove Braze Weld with Backing 39

GB.3 Single-V-Groove Braze Weld 39

GB.4 Edge Braze Weld (in a Flanged Joint) 39

GB.5 Flare-Bevel-Groove Braze Weld (in T-Joint or Inside Corner Joint) 39

GB.6 Flare-V-Groove Braze Weld 40

GB.7 Square-Groove Corner Braze Weld 40

GB.8 Fillet Braze Weld T-Joint 40

GB.9 Fillet Braze Weld in Open (Offset) Corner Joint (Angle May Vary from 90°) 41

GB.10 Plain Lap Joint Braze Weld 41

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Sheet Metal Welding Code

1. General Requirements

   1. Scope. This code provides qualification, workmanship, 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.

      1. This code was developed to provide standardized requirements for the qualification, production, and acceptance of welding or braze welding of nonstructural sheet metal components.

      2. 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 thicknesses up to and including 6.07 mm [0.239 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.

         1.1.2.1 Limitations/Exceptions. This code does not apply:

         1. Where negative pressure or positive pressure exceeds 30 kPa [5 psi], which is approximately 3 m [120 in] of standing water

         2. Where structural requirements are concerned (including AWS D1.3/D1.3M, Structural Welding Code—Sheet Steel)

         3. Where sheet metal products related to automotive applications are concerned

      3. This code requires values to be specified by the Engineer for subclauses 8.2, 8.4, 13.1, and 13.3.

      4. Symbols used in this code shall be in accordance with the latest edition of AWS A2.4, Standard Symbols for Welding, Brazing, and Nondestructive Examination.

   2. 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 figures. The measurements are not exact equivalents; therefore, each system must be used independently.

   3. Safety. Safety and health issues and concerns are beyond the scope of this standard and therefore are not addressed herein. Safety and health information is available from the following sources:

American Welding Society:

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

2. AWS Safety and Health Fact Sheets

3. Other safety and health information on the AWS website Material or Equipment Manufacturers:

1. Material Safety Data Sheets supplied by materials manufacturers

2. Operating Manuals supplied by equipment manufacturers