tmschrader:
Your post is somewhat vague and providing you with a complete answer with the information posted is difficult.

Information such as:
Process
Position
Joint Type
Weld Type
Filler Metal
Service/application

would help.

We are qualifing the WPS with

GMAW
flat, horz, and possiblly overhead
A butt  single Groove weld, B-U2a or B-U2b (whichever works best) anex B AWS1.2
5083 aluminum
5356 filler,  (as we may have some small brackets of 6061)
weld is for  all aluminum cranes, we usally use the corner fillet weld, but as you know, passing the groove will qualify the fillet. We may have one or two butt welds (which we normally do with a large splice plate), but maybe we should try and change to the double bevel vs the single on the 1" plate

We are very close to passing the bend test, (ie with the roller), before we call the CWI in. They forgot to radius the specimens, which might be one of the major reasons for the cracks on the corners.

I could not find specific WPS parameters on the web like the pre-quals for steel. Do any companies or services have qualified WPS that you can buy.

tmschrader:
Well your on the right track.

1.) The preparation of test specimens is critical for this material (the radius on the corners of the bend specimens) and a wrap-around bend testing fixture are required in lieu of a plunger-type. Be sure the correct bend radius is used for your M25 material (1-1/4").

2.) The qualification of the 5083 H116 will qualify all M25 group designated alloys.

3.) It is usually desirable to use the GMAW process in the spray arc transfer mode when welding in the 1G/2G positions. This will not be possible in the overhead (4G) position without pulsing the arc (GMAW-P) or short circuiting (GMAW-S). The 2G plate qualification will cover the flat and horizontal groove and fillet welds. The overhead plate must be qualified separately, but will cover the 4G/1G and 4F/1F positions.

4.) With regards to your original post, the codes do not provide specific electrical parameters for procedures, only the prequalified maximum electrical variables and deposition rates for specific weld and joint types (e.g.: AWS D1.1, Table 3.7).

The electrode diameter and shielding gas composition must be provided to further assist you with your procedure.

Thank you very much for your reply.

We use argon and 1/16" dia wire.  We will try the double bevel and play with these other settings and see how it tests.

We also need to test with 316 stainless. I plan to get a copy of ANSI/AWS B2.1 (refered to in AWS 1.6) which is supposed to have some PRE-qualified WPS's for Stainless. Does what you mentioned (see below) about only giving max variables also apply to B2.1 ?

"the codes do not provide specific electrical parameters for procedures, only the prequalified maximum electrical variables and deposition rates for specific weld and joint types (e.g.: AWS D1.1, Table 3.7)."


  I just would think you could buy complete WPS's packages for various aluminum groups and weld types/groups.

tmschrader:
1.a) Your starting point current-wise should be somewhere in the range of 250 - 300 amps in the 1G position.
1.b) Your voltage should start at around 28 volts.
1.c) Shielding (IMHO) should contain 60-70% He w/a flow rate of about 35 cfh.
1.d) ESO should be around 3/4" w/an arc length of at least 1/4" to let the wetting action of the spray arc do it's job.

2.) Your addition of 6061 materials (M23) will require additional procedure qualification to the 5083 (M25) in accordance with Table 3.1 (Base-Metal Alloy) of the D1.2 code.

3.) If you are referring to the AWS B2.1:2000 Specification for Welding Procedure and Performance Qualification noted in subsection 4.1.3 in the AWS D1.6:1999, this is specified as acceptance in lieu of qualification in accordance with the requirments of the D1.6 code.

The B2.1 specification does NOT contain prequalifed welding parameters or variables for any process. It is a document used to qualify a procedure (WPS) or personnel (WPQR) which do not fall within the test or dimensional criteria of a particular code or standard. I use the B2.1 specification often to supplement codes/standards where weld joints, process or material combinations do not fall within the scope of codes/standards typically used for similar applications (e.g: structural).

Get a copy of this article, it will answer a lot of your questions and some you haven't thought of yet.

What you should know about Welding Aluminum
Jan 2000 Welding Journal page 54