AWS D1.5 Endorsement flashcards

32 cards. Read the term and the definition here. The deck at the top of this page is optional.

D1.5 Scope

AASHTO/AWS D1.5M/D1.5 is the bridge welding code covering fabrication and erection of welded steel highway bridges designed to AASHTO LRFD specifications, including procedure, personnel, inspection, and fracture-control requirements.

Fracture-critical member

A tension member or component whose failure would cause collapse of the bridge; D1.5 imposes additional fracture control plan, toughness testing, and inspection requirements on these members.

Fracture control plan

A documented plan required for fracture-critical work that specifies material toughness, welding procedure qualification, consumable control, NDT methods and extent, and recordkeeping to reduce brittle fracture risk.

Charpy V-notch testing

Notch-toughness testing used under D1.5 to verify that base metals, filler metals, and production weldments meet specified absorbed-energy and lateral-expansion criteria at a defined test temperature.

WPS essential variables

Parameters that, if changed beyond code limits, require requalification of the welding procedure; examples include process, filler classification, base metal group, joint geometry, position, and preheat.

Prequalified joint detail

A joint configuration listed in the code that may be used without procedure qualification testing, provided all specified conditions on material, process, position, and technique are satisfied.

Welder performance qualification

Testing of an individual welder or operator on a representative test coupon to demonstrate the ability to produce sound welds for a specific process, position, and joint type.

Continuity of qualification

Rule governing how long a welder's or procedure's qualification remains valid; qualification lapses if the welder does not use the process within the code-specified period or if conditions change.

AASHTO M 270

Standard specification for structural steel for bridges (equivalent to ASTM A709), defining grades such as 36, 50, 50W, and HPS 70W with strength, toughness, and weathering requirements.

HPS 70W steel

High-performance weathering steel grade with 70 ksi minimum yield strength, used in bridge girders; welding requires procedures and consumables matched to its higher strength and toughness demands.

Carbon equivalent

A calculated value from base metal chemical composition used to assess weldability and hydrogen cracking susceptibility; higher values generally require greater preheat or stricter welding controls.

Preheat requirement

Minimum base metal temperature before welding, determined by thickness, chemistry, and ambient conditions, intended to slow cooling and prevent hydrogen-assisted cracking.

Interpass temperature

Maximum allowable temperature of the weld and base metal between passes; exceeding it can degrade toughness and mechanical properties, especially in high-strength quenched-and-tempered steels.

FCM fabrication plan

A project-specific document describing how fracture-critical members will be fabricated, including WPSs, toughness testing, NDT, material traceability, and handling to satisfy D1.5 fracture control.

Ultrasonic testing

Volumetric NDT method using high-frequency sound to detect internal discontinuities; D1.5 commonly requires it for complete-joint-penetration tension welds in fracture-critical members.

Radiographic testing

Volumetric NDT method using radiation to image internal weld discontinuities; acceptance limits and required extent depend on weld type and member classification under D1.5.

Visual inspection acceptance

Criteria for weld surface condition, including limits on undercut, porosity, cracks, and profile; visual inspection is required on all welds before and after other NDT methods.

Complete joint penetration

A groove weld in which fusion extends through the entire joint thickness; CJP welds in tension typically receive stricter NDT and acceptance criteria than partial joint penetration welds.

Partial joint penetration

A groove weld that does not extend through the full joint thickness; its design and inspection requirements are generally less stringent than those for complete joint penetration welds.

Welding consumable control

Requirements for storing, handling, and documenting filler metals, including protection from moisture and lot traceability, to prevent hydrogen pickup and ensure toughness performance.

Shop welding

Welding performed at a fabrication facility under controlled conditions; requires approved WPSs, qualified personnel, inspection records, and conformance to D1.5 fabrication provisions.

Field welding

Welding performed at the bridge site; D1.5 imposes additional controls for weather protection, preheat, access, and inspection, and some joint types may be restricted in the field.

Erection plan

A document describing how bridge members will be assembled and welded in the field, including sequencing, temporary supports, fit-up, and welding and inspection procedures.

Base metal grouping

Classification of steels by strength and metallurgical characteristics; welding procedures qualified on one group may cover other listed steels within the same group under code rules.

Weathering steel welding

Welding of steels such as A709 50W or HPS 70W that form a protective patina; consumables must match weathering and toughness requirements, and preheat rules still apply.

Hydrogen cracking

Delayed cracking caused by hydrogen absorbed during welding combined with restrained, high-hardness weld zones; controlled by preheat, low-hydrogen consumables, and proper drying and storage.

Procedure qualification record

Documentation of the test welds, variables, and mechanical test results used to qualify a WPS; it supports the WPS and is subject to review during inspection.

Weld acceptance criteria

Code-defined limits on discontinuity size and type for each inspection method; welds exceeding limits must be repaired or removed and re-inspected to the same criteria.

Repair welding

Welding to correct a rejected weld or base metal defect; repairs require an approved procedure, removal of the defect, and re-inspection to the original acceptance criteria.

Fillet weld inspection

Verification of fillet weld size, length, leg dimensions, and profile, plus surface quality; fillet welds are typically inspected visually with additional NDT only when specified.

Ambient temperature limits

Minimum ambient and base metal temperatures below which welding must be halted or specially controlled, because low temperature promotes rapid cooling and cracking.

Record retention

Requirement to keep WPSs, qualification records, consumable certificates, and inspection reports for the period specified by the contract, supporting traceability and quality assurance.