I audited a vendor once. I was reviewing their welding documentation and commented to the "Welding Engineer" there was no test witness listed by the PQR. He replied that the code didn't require a test witness. I agreed, but noted that the PQR listed the arc voltage, amperage, travel speed, etc. and asked who recorded those values?
"The welder records that information while he welds the test assembly." was his reply.
"That's got to be one hell of a welder. I'ld like to meet him." I said.
"That's no problems. He's probably in his booth welding something right now." said the engineer.
We went out into the shop area, located the welder and once the introductions were out of the way, I said to the young man, "I understand you welded the test plates for this aluminum procedure."
"Yea, I did all the aluminum tests. That stuff is a pain in the behind. If I never welded any more of it, it would be fine by me!" he responded.
"I see here that you recorded the welding parameters when you welded the test assembly." I said.
"You don't know jack about welding do you." was his retort.
Baffled I responded, "What ever do you mean?"
"If you ever welded in your life, you would know I couldn't concentrate on welding and be looking at the meters on the machine at the same time, never mind trying to play with a stop watch!" was his response.
"My point exactly." I said looking at the "welding engineer".
The validity of the PQRs has now evaporated, the WPSs based on the PQRs are now void. The welders qualified to the WPSs are now invalidated. All the welding that had been completed up to that point; rejected.
If the welding parameters are recorded on the PQR, it has to be actual data recorded during the test, not made up by the "engineer" back at the desk a day or two later.
The pedigree of the base metal should be verified before any welding is performed. More than once I've had vendors provide material test reports for material other than what was being used. One time I checked the CMTR provided by the supplier. The CMTR was for 1/2-inch plate. The material was 3/8-inch thick. Oops, screwed again.
In my opinion, there needs someone to witness the qualification process to verify the correct materials are used, the joint is prepared properly, the parameters recorded while the assembly is being welded, etc. I've even had a case or two where the welder decided he wanted to use a different filler metal than what was suppose to be used. Who would know the difference if there was no witness to object to making the substitution?
Best regards - Al
