Welding Procedure Development for Non-Welding Engineers (eBook)

Learn and follow the process used by welding engineers to developed welding procedures that maximize quality and productivity

Not being a welding engineer is not an excuse for avoiding due diligence.  The principles needed to properly develop a welding procedure are clearly explained in this publication.  The intent is to provide the knowledge necessary to make the right selection of the many welding variables.  It has been written in order for anyone, regardless of level of education, to read and apply it. 

This guide focuses on procedures for carbon steels; however, the same principles can be followed for any base metal.

NOTE: This product is offered as a PDF file available for immediate download. This is not a physical product.


Welding Procedure Development for Non-Welding Engineers will help the user understand how each of the welding variables affects the weld. Easy to understand language (no fancy engineering terms) is used to provide the knowledge necessary to make informed decisions.

This eBook will guide you through the selection of the following variables when developing a welding procedure specification:

  • Amperage
  • Voltage
  • Filler metal
  • Travel Speed
  • Travel and Work Angles
  • Shielding Gas or Flux
  • Welding Process
  • Welding Position
  • Joint Types
  • Preheat (when to preheat and to what temperature)
  • Interpass Temperature
  • Post Weld Heat Treatment
  • And many more

Welding Procedure Development for Non-Welding Engineers is more than a simple guide on how to select the right welding parameters for a given application. By providing detailed explanations of how welding variables affect the weld, the basics of many topics are learned by the user. Some of these topics include:

  • Welding metallurgy
  • Cooling rates
  • Preheat requirements
  • Post weld heat treatment requirements
  • Mechanical properties of the weld
  • Distortion
  • Deposition rates
  • Welding defects

These topics don't have specific sections. Rather, they are covered and explained when they are relevant to the specific welding procedure development task. This way, only information relevant to the selection of specific variables is provided.


Effects of welding variables

What happens when certain essential variables are changed? How does increasing or decreasing amperage affect the weld? What's the effect of voltage? How important is travel speed? Does the composition of the shielding gas matter? Are there certain gas mixtures that are better suited for certain base metals?  How does welding position impact the selection of welding variables?

Considerations when selecting the right filler metal

It is common to simply match the strength of the filler metal to the strength of the base metal. But it is sometimes advantageous to undermatch the strength. Welding high strength steels can lead to cracking, but the right selection of filler metal and welding process will allow you to develop a welding procedure that produces sound welds. Selecting the right filler metal involves an evaluation of the base metal, the intended service conditions of the weldment, the required strength, the base metal surface condition and many other variables.

When to preheat and to what temperature

Carbon steels need to be preheated when their chemistry is susceptible to hydrogen induced cracking. They must also be preheated when they surpass a certain thicknesses. Determining the right temperature for preheat and interpass temperature is essential for controlling both quality and costs. A detailed list of structural steels and their required preheat temperatures is provided.

Heat treatment consideration (base metal)

The condition in which the base metal is supplied is very important. Is it annealed? Is it normalized? Is it quenched and tempered? Knowing this and understanding the implications of each is very important when developing a welding procedure specification. Some steels should be welded with extreme care. Others should not be welded at all.

When should you consider Post Weld Heat Treatment?

When we weld, the heating and cooling cycle of the weld can significantly affect the mechanical properties of the base metal, more specifically of the Heat Affected Zone. It can also create distortion which can negatively impact dimensional tolerance and add to manufacturing costs. Post Weld Heat Treatment can be used to regain the desired mechanical properties and reduce residual stresses.

Start developing welding procedures the right way!


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