2014 Beijing “ARC Cup” International Welding Competition Technical Files ( to be revised )
(Manual Welding)
I. Competition standards
DIN, EN and ISO standards will be complied with.
II. Qualifications for welders
Welders born after Jan 1st, 1979 are allowed to participate. Identification document (ID card or passport) shall be issued for registration.
III. Welding processes
1. Manual Shielded Metal Arc Welding (111/SMAW)
2. MIG/MAG Welding (135/GMAW)
3. Argon tungsten-arc welding (141/GTAW)
4. Oxygen fuel gas welding (311/OFW)
5. Finished-product welding (111SMAW/135GTAW/141GMAW/136FCAW)
IV. Competition regulations
Only practical welding competition is conducted.
Three welding forms are set for each welding process. According to DIN EN ISO6947 standards, three welding positions will be chosen at random for competition from welding positions when competition starts. Please see attachment 1 for manual welding tasks, see attachment 2 for assessment table, see attachment 3 for specifications of test pieces and attachment 4 for the welding positions. Finished-products welding allow four welding processes, many weld forms such as butt weld and fillet and welding positions are set. See attachment 5 for test piece specifications and welding elements, and see attachment 6 for assessment table.
V. Operating regulations
WPS will be given before the competition and the following rules shall be followed:
1) General requirements
1. Test pieces and welding materials provided by Organizing Committee
shall be used (foreign participants may bring their own welding materials).
2. Protective equipments must be worn and the operating instructions for assembly shall be followed strictly. Ancillary tools can be brought by welders (see following for the tools list).
3. Each welder will be given one special number for the cabinet, with which welders get test pieces and welding materials.
4. Welders get their own assembled test pieces and welding materials 15 minutes before the competition. Competition will start on the common starting signal. 10 minutes lateness will cause disqualification from the competition.
5. Operating time
|
Manual Shielded Metal Arc Welding (111/SMAW) |
150 min |
|
MIG/MAG Welding (135/GMAW) |
100 min |
|
Argon tungsten-arc welding (141/GTAW) |
100 min |
|
Oxygen fuel gas welding (311/OFW) |
90 min |
|
Finished-product welding
(111SMAW/135GTAW/ 141GMAW/136FCAW) |
180min |
6. Welding machine, welding gun, electrode holder, wire and welding torch will be provided and are not allowed to bring by welders.
7. The following tools can be brought by welders: mask, hammer, shovel, file, wire brush, grinding machine, saw blade, torch, tungsten electrode, wrench (these tools can be provided at the request in advance) and electric tools.
8. Current test can only be done on test piece provided. Test piece fixture is not allowed for current test. Otherwise, violation will be imposed.
9. Test pieces can only be repaired with manual tools or electric tools by welders during competition when test pieces are damaged. Anyway, replacement of test pieces is not allowed. Repair welding and re-melting are not allowed on the front side and reverse side of the weld.
10. When affected by power failure and other reasons, welders can resort to head jury.
11. Welders’ rest, drinking and toilet time will also be counted as the competition time.
12. After finishing the welding, welders shall clean the slag and spatter on the test piece surface without damaging the original weld. Electric tool is not allowed. After cleaned, the test piece shall be submitted to the supervisor for check to make sure the test piece has been cleaned clearly. Otherwise, re-cleaning maybe asked. The cleaned test piece shall be taken to the designated place for sealing and signing by welder and the supervisor. The jury shall take down the submitting time.
13. Fair competition principle shall be followed. Damaging or disassembling equipments in the competition area is prohibited. Otherwise, disqualification will be caused.
14. During the competition, supervisors will be available as the contact person.
15. When the stopping signal for the competition is given, welders shall stop operation immediately and leave the competition area.
2) Test pieces Assembly
1. Welders shall check the test pieces before tacking to make sure the test pieces are suitable for welding. Usually, replacement is not allowed. Any dispute is up to the site jury to make the decision.
Attention! Dimensional tolerances must be expected.
The organizer will make available test pieces required for the welding.
2. Welders assemble the test pieces according to the stipulated time and place.
3. The gap, root face and anti-deformation during butt seam welding assembly are up to the welders; seam and anti-deformation are not allowed for fillet weld assembly; the same welding process and welding material shall be adopted both in the assembly and competition. It’s up to welders to choose the size of the welding materials.
4. The plates shall be tacked at both ends of the groove with the length of tack weld being no more than 15mm. Run-on tab and run-off tab are not allowed to use on both ends of test pieces to be tacked.
5. As for the tack weld of fillet, 25mm long tack weld shall be made within 50mm around the middle of the weld at the back side, and 15mm long tack weld at most shall be made at both ends; there is no any requirement on the tack weld for 311/OFW welding process.
6. The tack weld for tube shall be made in the front groove with the length being no more than 15mm and the tack welding points shall be no more than 3.
7. Ancillary tools are allowed for finished-product assembly, and there is no requirement on the tack weld length and the quantity. The same welding process and welding material shall be adopted both in the assembly and competition.
8. When damaged in the assembly, the test pieces can be repaired by the
welders, but the replacement of test pieces is not allowed.
9. Time for test pieces tacking: 60 minutes for 111/SMAW, 135/GMAW, 141/GTAW and 311/OFW; 100 minutes for finished products assembly.
10. Supervisors shall fill in the card for each step of test pieces assembly to ensure the assembled test pieces qualified, and then sign with the welder together. For those unqualified assembled test pieces, welders shall assemble the test pieces again. Without qualification check, the assembled test pieces are not allowed for competition.
3) Practical welding requirements
1. After fixing the tube on the holder, welders shall mark the position for 12 o’clock and the tack welding are not allowed at the overhead position (namely 5-7 o’clock); there is no requirement on the vertical fixing position (PC) of tube.
2. After fixing test pieces, welders shall report to the supervisor to check for confirmation. Without confirmation, the test pieces on the fixture are not allowed for welding. Otherwise, 0 score will be given.
3. Except for the fillet, other welds have to be finished by single side welding and double side shaping.
4. Welding sequences: to follow the information if it is single or multiple layer joint (concerning multiple layer joints: the number of layers (intermediate runs and capping runs) is free to the competitor).
5. No use of pulse technology and no use of welding programs
6. During the welding, test pieces are not allowed to take off the fixture, move or change the welding position.
7. The bottom plate in finished-product welding shall remain at flat position of welding.
8. Butt welding for plate only allows single direction welding, welding from the middle towards both ends or welding from both ends towards the middle are not allowed. The direction of other layers shall be the same as the backing weld.
9. Butt welding for pipe adopts two semicircle uphill welding. There is no requirement on pipe vertical fixed position (PC), which shall be welded towards one direction.
10. As for 311/OFW, rightward welding shall be adopted, which means that welding wire and welding nozzle shall be moving from the left side to the right side of the weld, welding flame shall direct to the welded part while the wire shall stay behind the flame.
11. Any violation of above-mentioned rules will be given 0 score.
4) Rules on arc stopping
1. During root run and capping run (FW and BW) welding, starting arc and stopping arc shall be made within 50mm of the run center, and supervisor shall be informed for marking. Starting arc and stopping arc are required only on the last run of the capping run.
2. Without check and confirmation from the supervisor, welders are not allowed to restart arc for welding. Otherwise, 5 scores deduction will be given to the same piece.
5) Grinding and weld cleaning regulations
1. Grinding is not allowed on all the back of root run and surface of the capping run;
2. Grinding machine is allowed to use before capping run welding. Other WPS parameters are not mandatory and are depend on welders.
6) Assessment on the test piece
1. Please see Table 2.1 - Table 2.4 for the assessment standards (including finished-product assessment standards);
2. Assessment will not be done to the part within 20mm range at each end for butt welding and fillet weld of plates;
3. When having the same total score on visual examination and internal quality examination, welders using shorter time win.
7) Competition disciplines
1. Welders shall follow the supervision of the supervisors and comply with the technical files during the competition. Supervisors are entitled to stop the welders who violate the disciplines. Those who ignore the supervision will be reported to the Chief Jury and punishment will be given.
2. Silence shall be kept in the competition area. Noising and discussing are prohibited. Welders can report to the supervisor when encountering problem. After getting consent, welders can suspend. Otherwise, time for suspension will also be counted in.
3. Only supervisors are allowed to stay inside the competition area.
8) Welding machines and welding materials
1. Manual Shielded Metal Arc Welding (111/SMAW)
Welding machine:
Company: Beijing ARC Xinxing Science & Technology Co., Ltd.
Type: ARC-UP 400M
Welding materials:
Company: Atlantic
China Welding Consumables, Inc.
Type: AWS E6013(z.B. EN ISO 2580 - E38 2 RB 12)
Specifications: Φ2.5mm, Φ3.2mm, Φ4.0mm
2. MIG/MAG Welding (135/GMAW)
Welding machine:
Company: Beijing ARC Xinxing Science & Technology Co., Ltd.
Type: ARC-UP 400M
Welding materials:
Company: Atlantic
China Welding Consumables, Inc.
Type: AWS ER70S-6 (z.B. EN ISO 14341 - G4 Si1 / 1.5130)
Specifications: Φ1.2mm
3. Argon tungsten-arc welding (141/GTAW)
Welding machine:
Company: Beijing ARC Xinxing Science & Technology Co., Ltd.
Type: ARC-UP 400M
Welding materials:
Company: Atlantic
China Welding Consumables, Inc.
Type: AWS ER70S-6 (z.B. EN ISO 14341 - G4 Si1 / 1.5130)
Specifications: Φ2.0mm, Φ2.5mm; electrode: Φ2.5mm
4. Oxygen fuel gas welding (311/OFW)
Type of welding torch: H01-6 (overseas welders are allowed to bring and use their own type)
Enough welding nozzles (gas lenses are not allowed, gas nozzle size: 3, 4 and 5), gas lighter and nozzle cleaner.
Welding materials:
Company: Atlantic
China Welding Consumables, Inc.
Type: AWS ER70S-6 (z.B. EN ISO 14341 - G4 Si1 / 1.5130)
Specifications: Φ2.0mm, Φ2.5mm;
5. Finished-product welding (111SMAW/135GTAW/141GMAW/136FCAW)
Welding machine:
Company: Beijing ARC Xinxing Science & Technology Co., Ltd.
Type: ARC-UP 400M
Welding materials:
Company: Atlantic
China Welding Consumables, Inc.
Type: AWS E6013(z.B. EN ISO 2580 - E38 2 RB 12)
Specifications: Φ2.5mm, Φ3.2mm; Φ4.0mm;
Type: AWS ER70S-6 (z.B. EN ISO 14341 - G4 Si1 / 1.5130)；
Specifications: Φ2.0mm, Φ2.5mm; electrode: Φ2.5mm
Type: AWS A5.18 ER70S-6
Specifications: Φ1.2mm
Type: AWS A5.20E71T-1C
Specifications: Φ1.2mm
