You are on page 1of 136

--`,,```,,,,````-`-`,,`,,`,`,,`---

Copyright American Welding Society


Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
--`,,```,,,,````-`-`,,`,,`,`,,`---

Originated/Compiled by
Kenneth W. Coryell, P.E.
Welding Quality Consultant, Cleveland, Ohio

© 2005 by American Welding Society. All rights reserved


Printed in the United States of America

550 N.W. LeJeune Road, Miami, Florida 33126

NOTE: Although care was taken in choosing and presenting the data in this guide, AWS cannot guarantee that it is error free. Further, this
guide is not intended to be an exhaustive treatment of the topic; therefore, it may not include all available information, particularly with respect
to safety and health issues. By publishing this guide, AWS does not insure anyone using the information contained herein against any liability or
injury to property or persons arising from such use.

ii
-2
Copyright American Welding Society
Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
Table of Contents
Chapter 1—Introduction ......................................................................................................1
Chapter 2—Welding Procedure Specifications (WPSs)......................................................3
Chapter 3—Forms................................................................................................................7
AWS B2.1-1-004:2002 ....................................................................................................8
AWS B2.1:2005.............................................................................................................12
AWS D1.1/D1.1M:2004 ................................................................................................16
AASHTO/AWS D1.5M/D1.5:2002...............................................................................22
2001 ASME IX with 2003 Addenda..............................................................................26
API 1104 Twentieth Edition, 2005 ................................................................................34
Chapter 4—Procedure Qualification Variables—SAW ....................................................39
Chapter 5—Procedure Qualification Variables—SMAW.................................................49

--`,,```,,,,````-`-`,,`,,`,`,,`---
Chapter 6—Procedure Qualification Variables—GMAW ................................................59
Chapter 7—Procedure Qualification Variables—FCAW..................................................71
Chapter 8—Procedure Qualification Variables—GTAW .................................................83
Chapter 9—Terms and Definitions....................................................................................93
Annex I—Observations ...................................................................................................123
Annex II—Standard Welding Procedure Specifications .................................................127

Copyright American Welding Society iii


-1
Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
Additional Credits

Kent Baucher Vice President, Technicon Engineering Services, Inc., Fresno, CA; Member, Product Development Reviewer, General
Committee; Member, AWS Board of Directors
Harvey H. Castner Chair, Product Development Committee; AWS Director-at-Large; Past Chair, AWS Welding Reviewer, General
Handbook Committee; Member, AWS Board of Directors
Leonard P. Connor Consultant, Hollywood, FL; Managing Director, AWS Technical Services (Retired); Member, AWS Reviewer, Primary
Board of Directors
David Landon Corporate Welding Engineer, Vermeer Manufacturing Company, Pella, IA; Chair, AWS Technical Reviewer, General
Activities Committee
David L. McQuaid President, D. L. McQuaid & Associates, Bethel Park, PA; Vice Chair, D1 Subcommittee 10 Reviewer, D1.5 (2002)
ASSHTO/AWS Bridge Welding
Ronald C. Pierce Chair, Welding Engineering Supply Company, Prichard, AL; Advisor, AWS Product Development Reviewer, General

--`,,```,,,,````-`-`,,`,,`,`,,`---
Committee; AWS Past President
Allen W. Sindel President, Sindel and Associates, Whitehouse, TX; Past Chair, D1 Subcommittee 2 Qualification Reviewer, D1.1 (2004)
Walter J. Sperko President, Sperko Engineering Services, Greensboro, NC; AWS Technical Representative to Reviewer, ASME, IX
ASME (2001/2003)
Debrah C. Weir Secretary, AWS Product Development Committee General Editor
Mat Wisbrock QA Materials/QE Test Supervisor, Lockheed Martin Missiles, Dallas, TX; Chair, B2 Committee on Reviewer, B2.1 (2005)
Procedure and Performance Qualification
Robert R. Wright President, Moody International, Inc. (Retired), Knoxville, TN; AWS Technical Representative to API 1104, 20th Edition
API

iv
0
Copyright American Welding Society
Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
--`,,```,,,,````-`-`,,`,,`,`,,`---
Chapter 1—Introduction
This Professional’s Advisor is intended to provide insight and guidance (2) AWS D1.1/D1.1M:2004, Structural Welding Code—Steel
to the welding professional in the preparation of welding procedure specifi- (3) AASHTO/AWS D1.5M/D1.5:2002, Bridge Welding Code
cations and procedure qualification records. In no way is this a substitute
nor should it be used in lieu of a code or other standards document. (4) Section IX, Welding and Brazing Qualifications, ASME Boiler and
Standards, whether codes or specifications, provide the authoritative and Pressure Vessel Code 2001 with 2003 Addenda
comprehensive requirements for the WPS and PQR. (5) API 1104 2005, Welding and of Pipelines and Related Facilities
This Advisor has concentrated on the common arc welding processes,
including SAW, SMAW, GMAW, FCAW, and GTAW. Documentation The American Welding Society and the Welding Research Council have
and qualification requirements differ somewhat among the various qualifi- joined in a cooperative effort to generate standard welding procedures for
cation standards. This Advisor is not intended to be comprehensive for all industry. The need for pretested welding procedures that are supported by
applications, but rather is focused on five common standards: adequate test data and that satisfy the technical requirements for the com-
monly used construction codes and specification has been expressed by many
(1) AWS B2.1:2005, Specification for Welding Procedure and Perfor- individuals and organizations. The purpose of a welding procedure qualifica-
mance Qualification tion is to provide test data for assessing the properties of a weld joint.

NOTE: The documentation and qualification requirements from the codes or specifications cited in this Advisor are those listed in the specific edition of the
code or specification referenced. Documentation and qualification requirements are subject to change in later editions of the reference codes or specifications.

Copyright American Welding Society 1


Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
Notes

--`,,```,,,,````-`-`,,`,,`,`,,`---

2
Copyright American Welding Society
Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
Chapter 2—Welding Procedure Specifications (WPSs)

Data to be Recorded C. Filler Metal


1. Specification classification, F- and A-Number, or if not classified
Welding Procedure Specifications may be prepared in many different the nominal chemical composition
ways and may be either brief or long and detailed. Some codes and specifi- 2. Weld metal thickness by process and filler metal classification
cations have suggested forms which provide sufficient information, but 3. Filler metal size or diameter
will not cover complex welding conditions. More complex and critical 4. Flux classification
applications should have more detailed procedure specifications. These
5. Supplemental filler metal
forms may be supplemented with additional notes or instructions or new
6. Consumable insert and type
forms devised to suit the specific requirement. The sample WPSs which
follow illustrate examples of formats suggested by AWS B2.1, AWS D1.1, D. Position
AASHTO/AWS D1.5, ASME IX, and API 1104. Supporting Procedure 1. Welding position(s)
Qualification Records (PQRs) are also shown. The data shown is illustrative 2. Progression for vertical welding
only, and not the results of actual testing. It is simply typical of results com- E. Preheat and Interpass
monly found and is provided as a guide for preparation of the documents. 1. Preheat minimum
The following information is typical of the type of data which is 2. Interpass temperature maximum (if applicable)
included in a WPS. Additional information may be required, depending on 3. Preheat maintenance
specific applications.
F. Heat Treatment (if applicable)
A. Joint Design 1. PWHT temperature and time
1. Joint type and dimensions
G. Shielding Gas
2. Treatment of backside, method of gouging/preparation 1. Torch shielding gas and flow rate range
3. Backing material, if used 2. Root shielding gas and flow rate range
B. Base Metal H. Electrical
1. Material number, subgroup 1. Current (or wire feed speed), current type, and polarity
2. Thickness range qualified 2. Voltage range (except for manual welding)
3. Diameter (tubular only) 3. Type and diameter of tungsten electrode
--`,,```,,,,````-`-`,,`,,`,`,,`---

Copyright American Welding Society 3


Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
4. Transfer mode welding plans, within specific ranges. However, certain other variables,
5. A change from pulsed current such as joint geometry, welding position, and accessibility may not be con-
I. Variables sidered to be WPS qualification variables.
1. Welding process and whether manual, semiautomatic, mechanized, The recommended steps in the qualification of a welding procedure are
or automatic as follows:
2. For mechanized or automatic, single or multi electrode and spacing (1) Prepare a preliminary WPS.
3. Single or multi pass (2) Prepare and weld a suitable test weldment using the preliminary WPS.
4. Contact tube to work distance (3) Conduct the nondestructive and destructive tests required by the
5. Cleaning qualification standard in use.
6. Peening (4) Evaluate the results of preparation, welding, and testing.
7. Stringer or weave bead (5) Document the results on a PQR.
8. Travel speed range for mechanized or automatic welding (6) Issue approved PQR.
(7) Issue qualified WPS.

Qualification of WPSs
Test of Procedure Qualification Welds
The purpose of the procedure qualification is to determine, by prepara-
tion and testing of standard specimens, that welding in accordance with the Test specimens are usually removed from the sample joints for exami-
WPS will produce sound welds and adequate mechanical properties. The nation to determine certain properties. The type and number of specimens
type and number of tests required are designated in the standard. The tests removed and test details depend on the particular application, code, or
are selected to provide sufficient information on strength, ductility, tough- specification. Usually, the tests included tensile and guided bend speci-
ness, or other properties of the joint. The qualification variables are speci- mens to determine strength, ductility, and soundness. Additional tests may
fied to maintain desired properties. When significant changes are made to be specified:
the WPS qualification variables, the properties of the weld joint may be • Fracture tests to determine the notch toughness of the weld and the
affected, and requalification or a new WPS is required. heat-affected zone. Fracture tests are usually conducted at a speci-
Qualification tests may or may not simulate the actual conditions antici- fied temperature to minimize the risk of brittle fracture above that

--`,,```,,,,````-`-`,,`,,`,`,,`---
pated for a given project. Usually, such tests involve conventional butt temperature. Charpy V-notch specimens are most commonly used
joints on pipes or plates, or fillet welds between two plates. Base metals, for such tests, but many other tests, including drop weight and crack-
welding consumables, and thermal treatments must follow production opening-displacement (COD) tests, are sometimes employed.

4
Copyright American Welding Society
Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
• Nick-break tests to determine weld soundness at selected locations. when the qualifier signs the PQR. If the results meet the requirements of a
• Free bend tests to determine the ductility of weld metal. job, code, or specification, then the WPS may be finalized and issued for
• Shear tests to determine the shear strength of fillet welds or clad production welding. Since the PQR is a certified record of a qualification
bonding. test, it should not be revised. If information needs to be added later, it can
• Hardness tests to determine adequacy of heat treatment, preheat, be in the form of a supplement or attachment; records should not be
postheat, and suitability for certain service conditions. Such tests changed by revision. A PQR may support several WPSs. Similarly, several
may be performed on surfaces or on cross sections of welds. PQRs may support a single WPS.
• All-weld metal tension tests to determine the mechanical properties
of the weld metal in the diluted condition.
• Elevated temperature tests to determine mechanical properties at Changes in a Qualified Procedure
temperatures resembling service conditions. If a fabricator has qualified a welding procedure and desires at some
• Restraint tests to determine crack susceptibility and the ability to later date to make changes in that procedure, it may be necessary to con-
achieve sound welds under restrained conditions. duct additional qualifying tests. Those tests should establish that the
• Corrosion tests to determine the properties needed to withstand changed welding procedure will produce satisfactory results.
aggressive environments. Such requalification tests are not usually required when only minor
• Nondestructive examination and macroetch or microetch tests to details of the original procedure are changed. They are required, however,

--`,,```,,,,````-`-`,,`,,`,`,,`---
determine the soundness of the weld. if the changes might alter properties of the resulting welds. Reference
• Delayed cracking tests to detect resistance to hydrogen cracking in should always be made to the governing code or specification to determine
high strength, low alloy steels, and some other alloys. whether an essential variable has been changed. Typical procedure vari-
• Others ables that may require requalification of the WPS are presented in the
tables that follow. Variables identified with a “Q” require requalification.
Variables identified with a “T” require requalification when toughness test-
Recording Test Results ing is required. Variables identified with an “A” require requalification for
The details of the welding of the test weld, the tests, and the results of automatic welding processes.
all tests and examinations are entered on a Procedure Qualification Record The tables present the variables for the SAW, SMAW, GMAW,
(PQR). Typical record formats follow the sample WPSs provided. FCAW, and GTAW processes for five common standards: B2.1, D1.1,
(Remember: The data shown is illustrative only.) When the qualifier is D1.5, ASME IX, and API 1104. The tables should be regarded as illustra-
satisfied that the records and results are accurate, they become certified tive only, since the various standards are revised periodically.

Copyright American Welding Society 5


Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
Notes

--`,,```,,,,````-`-`,,`,,`,`,,`---

6
Copyright American Welding Society
Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
Chapter 3—Forms
The sample forms in this chapter (WPSs and PQRs) were taken from of these 8-1/2" × 11" forms have been split in half for the purposes of this
the following publications: AWS B2.1, AWS D1.1, AASHTO/AWS D1.5, Professional’s Advisor, so that the top and bottom half of the forms are
ASME Boiler and Pressure Vessel Code (Section IX), and API 1104. Each viewable as visual spreads, beginning with pages 12 and 13.

Form No. Source Title Page No.


— AWS B2.1-1-004 Standard Welding Procedure Specification (SWPS) for Gas Metal Arc Welding
(Short Circuiting Transfer Mode) of Carbon Steel (M-1, Group 1), 18 through 10 Gauge,
in the As-Welded Condition, with or without Backing................................................................... 8
AWS B2.1 Suggested Procedure Qualification Record (PQR) Format to Accommodate

--`,,```,,,,````-`-`,,`,,`,`,,`---
Provisions of AWS B2.1 (Page 1 of 2) ......................................................................................... 12
AWS B2.1 Suggested Procedure Qualification Record (PQR) Format to Accommodate
Provisions of AWS B2.1 (Page 2 of 2) ......................................................................................... 14
E-1 (Front) AWS D1.1 D1.1-Approved Welding Procedure Specification (WPS) (Qualified by Testing) ........................... 16
E-1 (Front) AWS D1.1 D1.1-Approved Welding Procedure Specification (WPS)................................................................ 18
E-1 (Back) AWS D1.1 D1.1-Approved Procedure Qualification Record (PQR) Test Results.............................................. 20
III-2 AASHTO/AWS D1.5 D1.5-Approved Welding Procedure Specification............................................................................ 22
III-1 AASHTO/AWS D1.5 D1.5-Approved Procedure Qualification Record (PQR) for Qualification,
Pretest, and Verification Results ................................................................................................... 24
E00006 (Front) ASME IX QW-482 Suggested Format for Welding Procedure Specification (WPS) ....................................... 26
E00006 (Back) ASME IX QW-482 Suggested Format for Welding Procedure Specification (WPS) ....................................... 28
E00007 (Front) ASME IX QW-483 Suggested Format for Procedure Qualification Records (PQR) ........................................ 30
E00007 (Back) ASME IX QW-483 Suggested Format for Procedure Qualification Records (PQR) ........................................ 32
— API 1104 Sample Procedure Specification Form .................................................................................. 34 and 35
— API 1104 Sample Coupon Test Report Form........................................................................................ 36 and 37

Copyright American Welding Society 7


Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
Standard Welding Procedure Specification (SWPS) for Gas Metal Arc Welding (Short Circuiting Transfer Mode)
of Carbon Steel (M-1, Group 1), 18 through 10 Gauge, in the As-Welded Condition, with or without Backing

LIMITATIONS
This procedure is not qualified for Notch Toughness or PWHT applications.

WELDING PROCESSES
Welding Process: GMAW-S (Gas Metal Arc Welding)
Method of Application: Semiautomatic
--`,,```,,,,````-`-`,,`,,`,`,,`---

Mode of Metal Transfer: Short Circuiting Transfer Mode

BASE METALS
Base Metal:2 Carbon Steel, M-1, Group 1 to M-1, Group 1
Thickness Range:3 Groove Weld: 18 ga. (0.0478 in.) through 10 ga (0.1345 in.)
Fillet Weld: 18 ga. (0.0478 in.) through 10 ga. (0.1345 in.)
Coating: Uncoated

FILLER METALS
Filler Metal Specification:2 AWS A5.18
A-Number or Chemical Composition: A Number None, ER70S-6
F-Number: F Number 6
Classification: ER70S-6
Supplementary Filler Metal: Not permitted
Supplementary Powder: Not permitted
Deposit Thickness Range: Groove Weld: Sheet metal thickness plus reinforcement, maximum
Fillet Weld Leg: Sheet metal thickness, minimum

8
Copyright American Welding Society
Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
Maximum Bead Thickness: Sheet metal thickness plus reinforcement

JOINT DESIGNS
Joint Designs: See Figure 1
Backing: Optional
Backing Material: Carbon Steel, M-1. Nonmetallic or nonfusing metal retainers are not permitted.

POSITIONS
Welding Positions: All
Vertical Progression: Uphill or Downhill

GAS
Torch Shielding Gas: 75% Argon, 25% Carbon Dioxide or AWS A5.32, Class SG-AC-25
Flow Rate: 20 to 40 ft3/h
Gas Nozzle Size: 1/2 in. diameter minimum (I.D.)
Root Shielding Gas: None
Trailing Gas: None

PREHEAT AND INTERPASS TEMPERATURE

--`,,```,,,,````-`-`,,`,,`,`,,`---
Preheat Temperature: 50°F minimum, 120°F maximum
Interpass Temperature: No maximum
Preheat Maintenance: Continuous or special heating not required

POST WELD HEAT TREATMENT


Postweld Heat-Treatment: None (not qualified for PWHT)

Copyright American Welding Society 9


Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
ELECTRICAL CHARACTERISTICS

Filler Metal Amperes Voltage Current

Base Metal Classification Dia. (in.) Groove Fillet Volts Type/Polarity

18 ga. ER70S-6 0.035 60/85 70/90 15/17 DCEP (Reverse)


17 ga. ER70S-6 0.035 65/92 76/93 15/17 DCEP (Reverse)
16 ga. ER70S-6 0.035 70/99 81/96 15/17 DCEP (Reverse)
15 ga. ER70S-6 0.035 75/105 087/100 16/19 DCEP (Reverse)
14 ga. ER70S-6 0.035 80/112 092/105 16/19 DCEP (Reverse)
13 ga. ER70S-6 0.035 85/118 098/108 16/19 DCEP (Reverse)
12 ga. ER70S-6 0.035 90/127 103/112 18/20 DCEP (Reverse)
11 ga. ER70S-6 0.035 95/132 109/116 18/20 DCEP (Reverse)
10 ga. ER70S-6 0.035 100/140 115/120 18/20 DCEP (Reverse)

Pulsing Current: Not Permitted


Contact Tube to Work Distance: 1/2 inch nominal
Mode of Metal Transfer: Short Circuiting Transfer Mode

TECHNIQUE
Weave or Stringer Beads: Stringer or weave
Peening: No
Initial Cleaning: Mechanical or chemical, joint shall be dry prior to welding
Interpass Cleaning: Mechanical only
Single or Multiple Electrodes: Single
Single or Multiple Pass: Either

--`,,```,,,,````-`-`,,`,,`,`,,`---
10
Copyright American Welding Society
Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
Backgouging: Not required, mechanical or thermal if used
Repair: Defects in welds shall be removed by mechanical or thermal methods. The repair cavity may dif-
fer in contour and dimension from a normal joint preparation and may present different restraint
conditions.

COMPANY NAME _________________________________________________________________________________________________

In the name of the Company stated above, I accept full responsibility for the application of this SWPS for use with:

______________________________________________________________________ Dated ___________________________________


Fabrication Document(s): (Such as Code, Specification, or Contract Document)

Date _______________ Approved By _______________________________________ Title ____________________________________

--`,,```,,,,````-`-`,,`,,`,`,,`---

Copyright American Welding Society 11


Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
Suggested Procedure Qualification Record (PQR) Format to Accommodate Provisions of AWS B2.1
WPS-101 (Preliminary)
WPS No. Used for Test ____________________________ GMAW-S
Welding Process(es)______________________________
Any Welding Company
Company_______________________________________ Equipment Type and Model (sw) ____________________

JOINT DESIGN USED WELD INCREMENT SEQUENCE

Single X Double Weld POSTWELD HEAT TREATMENT


N.A.
Backing Material _________________________________ None
Temp. _________________________________________
3/32
Root Opening ________ 1/16
Root face dimension ________ N.A.
Time __________________________________________
75°
Groove angle_______________ N.A.
N.A.Radius (J-U) ________ N.A.
Other__________________________________________
Backgouging: Yes No X Method ______________ GAS
BASE METALS CO2
Gas Type(s) ____________________________________
A53
Material Spec. __________ A53
To ____________________ 100% Welding Grade
Gas Mixture Percentage ___________________________
A
Type or Grade __________ A
To ____________________ 25 cfh
Flow Rate ______________________________________
M-1
Material No.____________ M-1
To Material No.__________ None
Root Shielding Gas___________ N.A.
Flow Rate _________
1
Group No. _____________ 1
To Group No. ___________ N.A.
EBW Vacuum _________ N.A.
Absolute Pressure _________
0.432
Thickness ______________________________________

--`,,```,,,,````-`-`,,`,,`,`,,`---
6 NPS
Diameter (Pipe) __________________________________ ELECTRICAL CHARACTERISTICS
None
Surfacing: Material ___________ N.A.
Thickness ________ 1/2 in.
Electrode Extension ______________________________
N.A.
Chemical Composition ____________________________ 9/16 in.
Standoff Distance ________________________________
N.A.
Other __________________________________________ Short Circuiting
Transfer Mode (GMAW) ___________________________

12
Copyright American Welding Society
Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
FILLER METALS N.A.
Electrode Diameter Tungsten _______________________
1
Weld Metal Analysis A No. _________________________ N.A.
Type Tungsten Electrode __________________________
6
Filler Metal F No. _________________________________ Current: AC DCEP X DCEN Pulsed
5.18
AWS Specification________________________________ 6720-12075 J/in.
Heat Input ______________________________________
ER70S-3
AWS Classification _______________________________ EBW: Beam Focus Current ______N.A. Pulse Freq. ______
N.A.
None
Flux Class _____________ N.A.
Flux Brand _____________ N.A.
Filament Type _______ N.A.
Shape _______ N.A.
Size________
None
Consumable Insert: Spec. __________ N.A.
Class. _______ N.A.
Other__________________________________________
Supplemental Filler Metal Spec. None N.A.
_______ Class._______ TECHNIQUE
None
Nonclassified Filler Metals _________________________ N.A.
Oscillation Frequency ________ N.A.
Weave Width ________
--`,,```,,,,````-`-`,,`,,`,`,,`---

Consumable Guide (ESW): Yes No N.A.


Dwell Time _____________________________________
Supplemental Deoxidant (EBW) _____________________ As req’d
String or Weave Bead ______ Weave Width __________
POSITION Multiple
Multipass or Single Pass (per side) __________________
5G
Position of Groove _____________ N.A.
Fillet_____________ Single
Number of Electrodes_____________________________
Vertical Progression: Up Down X None
Peening________________________________________
______________________________________________ N.A.
Electrode Spacing _______________________________
PREHEAT N.A.
Arc Timing (SW) _______________ N.A.
Lift _____________
70°F
Interpass Temp., Actual Min ________________________ PAW: Conventional Keyhole
150°F
Interpass Temp., Actual Max________________________ Wire brush
Interpass Cleaning _______________________________

Filler Metal Travel Speed Filler Metal Slope Special Notes


Pass No. Size Amps Volts (ipm) Wire (ipm) Induction (Process, etc.)
All .035" 140-175 20-23 20-25 225-305 N.A. N.A.

Note: Those items that are not applicable should be marked N.A. Page 1 of 2

Data included in this suggested PQR format is illustrative only.

Copyright American Welding Society 13


Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
Suggested Procedure Qualification Record (PQR) Format to Accommodate Provisions of AWS B2.1
(Continued)
TENSILE TEST SPECIMENS: SUGGESTED PROCEDURE QUALIFICATION RECORD PQR No.
Rectangular
Type________________________________ Tensile Specimen Size: per Fig. II-3A of B2.1:2004 Q225
______________________________________
Groove X Reinforcing Bar Stud Welds
48,000
Tensile Test Results: (Minimum Required UTS ___________ psi)

Specimen No. Width, in. Thickness, in. Area, in.2 Max Load, lbs UTS, psi Typical Failure and Location
1 0.752 0.432 0.325 23,200 71,400 Base Metal-Ductile
2 0.754 0.432 0.326 23,500 72,100 Base Metal-Ductile

Full width per Figure B2C of B2.1


GUIDED BEND TEST SPECIMENS—SPECIMEN SIZE ___________________________________________________

Type Result Type Result


Side 1 Accept Side 3 Accept
Side 2 Accept Side 4 Accept
MACRO-EXAMINATION RESULTS: Reinforcing Bar Stud
None 1.____________________ 4._____________________
2.____________________ 5._____________________
3.____________________
SHEAR TEST RESULTS—FILLETS: 1.____________________ 3._____________________
None 2.____________________ 4._____________________
IMPACT TEST SPECIMENS
None
Type___________________________________________ N.A.
Size___________________________________________

--`,,```,,,,````-`-`,,`,,`,`,,`---
14
Copyright American Welding Society
Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
N.A.
Test Temperature ________________________________
Specimen Location: WM = Weld Metal; BM = Base Metal; HAZ = Heat-Affected Zone
Test Results:

Welding Specimen Energy Absorbed Ductile Fracture Area Lateral Expansion


Position Location (ft-lbs) (Percent) (mils)

IF APPLICABLE RESULTS
Hardness Tests: Values __________________________________________ Acceptable Unacceptable
Visual (Special Weldments) X Acceptable X Unacceptable
Torque psi Acceptable Unacceptable
Proof Test Method ____________________________________________ Acceptable Unacceptable
Chemical Analysis Acceptable Unacceptable
Radiography
Nondestructive Exam X Process_____________________________________ Acceptable X Unacceptable
Other ____________________________________________________________ Acceptable Unacceptable
Weld Test Lab, USA
Mechanical Testing by (Company) _________________________________________________ Q225
Lab No. _________

We certify that the statements in this Record are correct and that the test welds were prepared, welded, and tested in
accordance with the requirements of the American Welding Society Specification for Welding Procedure and Performance
Qualification (AWS B2.1).

Joseph Plunkett
Qualifier________________________________________ 02-15-05
Date __________________________________________
Page 2 of 2
Data included in this suggested PQR format is illustrative only.
--`,,```,,,,````-`-`,,`,,`,`,,`---

Copyright American Welding Society 15


Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
D1.1-Approved Welding Procedure Specification (WPS) Yes X
Prequalified __________ Qualified by Testing __________
X
or Procedure Qualification Records (PQR) Yes
WPS-132
Identification # _________________________________
Revision ____ 02-15-05
1 Date ____________ W. Lye
By ____________
RED Inc.
Company Name _______________________________ Authorized by ________________
S. McBride 02-15-05
Date _____________
FCAW
Welding Process(es) ____________________________ Type—Manual Semi-Automatic X
PQR 231
Supporting PQR No.(s) __________________________ Machine Automatic
--`,,```,,,,````-`-`,,`,,`,`,,`---

JOINT DESIGN USED POSITION


Butt
Type: ________________________________________ 4G
Position of Groove: ______________ —
Fillet: __________
Single X Double Weld Vertical Progression: Up Down
Backing: Yes X No
Any Group I steel
Backing: Backing Material: ______________________ ELECTRICAL CHARACTERISTICS
1/4" Root Face Dimension ________
Root Opening ______ — ______________________
52-1/2° Radius (J–U) _________
Groove Angle: ___________ — Transfer Mode (FCAW) Short-Circuiting
Backgouging: Yes No X —
Method _______ Globular Spray X
Current: AC DCEP X DCEN Pulsed
BASE METALS Other ________________________________________
Any Group I steel
Material Spec. _________________________________ Tungsten Electrode (GTAW) None
A
Type or Grade _________________________________ Size: ______________
3/4-1 1/2” Fillet __________
Thickness: Groove ____________ — Type: ______________

Diameter (Pipe) ________________________________
TECHNIQUE
FILLER METALS Stringer
Stringer or Weave Bead: _________________________
A5.20
AWS Specification______________________________ Multipass
Multi-pass or Single Pass (per side)_________________
E71T-1
AWS Classification _____________________________ 1
Number of Electrodes ___________________________

16
Copyright American Welding Society
Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale

Electrode Spacing None Longitudinal ____________

Lateral_________________
SHIELDING Angle _________________


Flux ___________________ CO2
Gas _________________
100% CO2
Composition __________ 1/2-1"
Contact Tube to Work Distance ____________________
45-55 cfh
Electrode-Flux (Class)_____ Flow Rate ____________ None
Peening ______________________________________
#4
______________________ Gas Cup Size _________ Wire Brush
Interpass Cleaning: _____________________________

PREHEAT POSTWELD HEAT TREATMENT


Preheat Temp., Min _____________________________
60° None
Temp. ________________________________________
60°
Interpass Temp., Min____________ Max__________
350°F None
Time _________________________________________

WELDING PROCEDURE

Pass or Filler Metals Current


Weld Type & Amps or Wire Travel
Layer(s) Process Class Diam. Polarity Feed Speed Volts Speed Joint Details

--`,,```,,,,````-`-`,,`,,`,`,,`---
All FCAW E71T-1 .045" DC+ 180-220 25-26 8-12
ipm

Form E-1 (Front)


Data included in this suggested PQR format is illustrative only.

Copyright American Welding Society 17


Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
D1.1-Approved Welding Procedure Specification (WPS) Yes
Prequalified __________ Qualified by Testing __________
or Procedure Qualification Records (PQR) Yes X
PQR 231
Identification # _________________________________
Revision ____1 Date ____________
02-15-05 By ____________
W. Lye
RED Inc.
Company Name _______________________________ J. Jones
Authorized by __________________ 02-15-05
Date __________
FCAW
Welding Process(es) ____________________________ Type—Manual Semi-Automatic X

Supporting PQR No.(s) __________________________ Machine Automatic

JOINT DESIGN USED POSITION


Butt
Type: ________________________________________ 4G
Position of Groove: ______________ —
Fillet: __________
Single X Double Weld Vertical Progression: Up Down
Backing: Yes X No
ASTM A 131A
Backing: Backing Material: ______________________ ELECTRICAL CHARACTERISTICS
1/4" Root Face Dimension ________
Root Opening ______ — ______________________
52-1/2° Radius (J–U) _________
Groove Angle: ___________ — Transfer Mode (GMAW) Short-Circuiting
Backgouging: Yes No X —
Method _______ Globular X Spray
Current: AC DCEP X DCEN Pulsed
BASE METALS Other ________________________________________
ASTM A 131
Material Spec. _________________________________ Tungsten Electrode (GTAW)

--`,,```,,,,````-`-`,,`,,`,`,,`---
A
Type or Grade _________________________________ Size: ______________
1"
Thickness: Groove ____________ —
Fillet __________ Type: ______________

Diameter (Pipe) ________________________________
TECHNIQUE
FILLER METALS Stringer
Stringer or Weave Bead: _________________________
A5.20
AWS Specification______________________________ Multipass
Multipass or Single Pass (per side) _________________
E71T-1
AWS Classification _____________________________ 1
Number of Electrodes ___________________________

18
Copyright American Welding Society
Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
Electrode Spacing —
Longitudinal ____________
--`,,```,,,,````-`-`,,`,,`,`,,`---

Lateral_________________
SHIELDING —
Angle _________________

Flux ___________________ CO2
Gas _________________
100% CO2
Composition __________ 3/4-1"
Contact Tube to Work Distance ____________________
45 cfh
Electrode-Flux (Class)_____ Flow Rate ____________ None
Peening ______________________________________
#4
______________________ Gas Cup Size _________ Wire Brush
Interpass Cleaning: _____________________________

PREHEAT POSTWELD HEAT TREATMENT


75° (Ambient)
Preheat Temp., Min _____________________________ N.A.
Temp. ________________________________________
75°
Interpass Temp., Min____________ 350°F
Max__________ —
Time _________________________________________

WELDING PROCEDURE

Pass or Filler Metals Current


Weld Type & Amps or Wire Travel
Layer(s) Process Class Diam. Polarity Feed Speed Volts Speed Joint Details
1 FCAW E71T-1 .045" DC+ 180 26 8
2-8 " " " " 200 27 10
9-11 " " " " 200 27 11
12-15 " " " " 200 27 9
16 " " " " 200 27 11

Form E-1 (Front)


Data included in this suggested PQR format is illustrative only.

Copyright American Welding Society 19


Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
D1.1-Approved Procedure Qualification Record (PQR) # __________
231
Test Results
TENSILE TEST
Specimen Width, Thickness, Area, Ultimate Tensile Ultimate Unit Character of Failure
No. in. in. sq. in. Load, lb Stress, psi and Location
231-1 0.75" 1.00" 0.75" 52,500 70,000 Ductile
231-3 0.75" 1.00" 0.75" 52,275 69,700 Ductile

GUIDED BEND TEST


Specimen
No. Type of Bend Result Remarks
231-2 Side Pass
231-4 Side Pass Small (< 1/16") Opening Acceptable
231-6 Side Pass
231-5 Side Pass
VISUAL INSPECTION
Acceptable
Appearance___________________________________ Radiographic-Ultrasonic Examination
Acceptable
Undercut _____________________________________ RT Report No.: __________
D231 Passed
Result ________________
None
Piping Porosity ________________________________ UT Report No.: __________ Result ________________
None
Convexity_____________________________________ FILLET WELD TEST RESULTS
02-15-05
Test date _____________________________________ Minimum Size Multiple Pass Maximum Size Single Pass
Michael Collins
Witnessed by__________________________________ Macroetch Macroetch
1. _______ 3. ________ 1._________ 3._________
2. _______ 2._________

20
--`,,```,,,,````-`-`,,`,,`,`,,`---

Copyright American Welding Society


Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
Other Tests All-Weld-Metal Tension Test
83,100
Tensile Strength, psi _____________________________
72,600
Yield Point/Strength, psi __________________________
28
Elongation in 2 in., % ____________________________
PW 231
Laboratory Test No. ________________________

Dennis McSweny
Welder’s Name ________________________________ 261
Clock No. ______________ Stamp No. ____________
RED Inc. & ABC Testing
Tests Conducted by_________________________________________________________ Laboratory
PQR 231
Test Number ___________________________________
D. Miller
Per __________________________________________

We, the undersigned, certify that the statements in this record are correct and that the test welds were prepared, welded, and
2004 ) Structural Welding Code—Steel.
tested in accordance with the requirements of Section 4 of AWS D1.1, ( __________
(year)

RED Inc.
Signed _______________________________________
Manufacturer or Contractor
Sean McBride
By ___________________________________________

--`,,```,,,,````-`-`,,`,,`,`,,`---
Q.C. Mgr.
Title _________________________________________
02-15-05
Date _________________________________________

Form E-1 (Back)

Data included in this suggested PQR format is illustrative only.

Copyright American Welding Society 21


Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
D1.5-Approved Welding Procedure Specification

M270M Gr. 690


Material Specification ______________________________________________________________________________
FCAW-G
Welding Process __________________________________________________________________________________
Manual
Manual or Machine ________________________________________________________________________________
1G
Position of Welding ________________________________________________________________________________
AWS A5.29
Filler Metal Specification ____________________________________________________________________________
E110TS-K3-H4
Filler Metal Classification ___________________________________________________________________________
N.A.
Flux ____________________________________________________________________________________________
Welding Grade CO2 (Max Dew Point -40°C) Flow Rate __________________________
Shielding Gas ________________________________________________ 45 cfh or 21.2 L/min
Multiple
Single or Multiple Pass _____________________________________________________________________________
Single
Single or multiple Arc ______________________________________________________________________________

--`,,```,,,,````-`-`,,`,,`,`,,`---
180-220 amps
Welding Current __________________________________________________________________________________
DCEP
Polarity _________________________________________________________________________________________
N.A.
Welding Progression _______________________________________________________________________________
Backing Removed
Root Treatment ___________________________________________________________________________________
80°C min 230°C max
200°C
Preheat and Interpass Temperature ___________________________________________________________________
None
Postheat Temperature ______________________________________________________________________________
Heat Input 0.9 kJ/mm
Min _______________ 1.5 kJ/mm
Max _______________

22
Copyright American Welding Society
Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
WELDING PROCEDURE

Welding Current mm/min


--`,,```,,,,````-`-`,,`,,`,`,,`---

Pass Electrode
No. Size Amperes Volts Travel Speed Joint Detail
1 .045 180 26 200
2-8 .045 200 27 250
9-11 .045 220 28 280
12-15 .045 200 27 250
16 .045 220 28 280

This procedure may vary due to fabrication sequence, fit-up, pass size, etc., within the limitation of variables given in
Section 5.
W44
Procedure No. _________________________________ Any Welding Company
Contractor ____________________________________
0
Revision No. __________________________________ James Connolly
Authorized By __________________________________

Form III-2 02-15-05


Date _________________________________________

Data included in this suggested PQR format is illustrative only.

Copyright American Welding Society 23


Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
D1.5-Approved Procedure Qualification Record for Qualification, Pretest, and Verification Results
Any Welding Co.
Contractor ____________________________________ 02-15-05
Test Date _____________________________________
FCAW-G
Process ______________________________________ A5.29
Filler Metal ____________________________________
1G
Position ______________________________________
Electrode(s) Mfg. Designation_____________________ E110T5-K3
AWS Classification ______________________________
None
Flux Mfg. Designation ___________________________ N.A.
AWS Classification ______________________________
3/4 in. or 19 mm
Electrode Extension _______________________________________________________________________________
Current and
Diam.
_________ Current
_________ WFS*
_________ Voltage
_________ Polarity
_________
Electrode (1) .045
_________ 220
_________ N.A.
_________ 28
_________ DCEP
_________
(2) _________ _________ _________ _________ _________
(3) _________ _________ _________ _________ _________
Calculated Heat Input ___________________________
CO2
Shielding Gas _________________________________ 45 cfh or 21.2 L/min
Flow Rate _____________________________________
-50°C
Dew Point ____________________________________ 250 mm
Travel Speed __________________________________
M270M Gr. 690 50 mm
Base Metal Specification and Thickness________________________________________________________________
(Attach Certified Copy of Mill Test Report)
80°C
Preheat Temp._________________________________ 80°C
Interpass Temp. Min __________ 200°C
Max ____________

SPECIMEN TEST RESULTS

--`,,```,,,,````-`-`,,`,,`,`,,`---
All-Weld-Metal Tension (AWMT) 810 MPa
Tensile Strength (MPa) __________________________________________
700 MPa
Yield Strength (MPa) ____________________________________________
20%
Elongation in 50 mm (%) _________________________________________
40%
Reduction in Area % ____________________________________________

24
Copyright American Welding Society
Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
Side Bends Accept
1. ____________ Accept
2. ____________ Accept
3. ____________ Accept
4. ____________

Reduced Section Tension Tension Strength 780 MPa


1. ____________ Base Metal
Location of Break 1. ____________
770 MPa
2. ____________ Base Metal
2. ____________

Charpy V-Notch Impact 27J


( ___________ 28J
, ___________ 31J
, ___________ 29J
, ___________ 27J
, ________ )
Toughness of Weld Metal 28J
Avg. J** ___________ -40
@ ___________ °C
SMAW, SAW, FCAW, GMAW—5 Reg. ( ___________ , ___________ , ___________ , ___________ , ________ )
Avg. J** ___________ @ ___________ °C
ESW and EGW—8 Reg. **Discard the highest and lowest values and average the remaining values.

Chemistry of Deposited Weld Metal C ________ Mn _______ Si ________ P ________ S ___________


When Required by Contract Ni ________ Cr________ Mo _______ V ________ Cu __________
Documents

REMARKS Acceptable
Visual ________________________ Acceptable
Radiographic Test ________________

*Wire feed may be used in lieu of current when a correlation curve is provided for the same electrode diameter and same
electrode extension.

Jean McDermott
Test Witness:__________________________________ Independent Lab, Inc.
Agency: ______________________________________

Michael Collins
Results Reviewed:______________________________ Eamon Kent
State Acceptance: ______________________________

Form III-1 02-15-05


Date:_________________________________________

Data included in this suggested PQR format is illustrative only.


--`,,```,,,,````-`-`,,`,,`,`,,`---

Copyright American Welding Society 25


Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
QW-482 Suggested Format for Welding Procedure Specification (WPS)
(See QW-200.1, Section IX, ASME Boiler and Pressure Vessel Code)

Any Welding Company Patrick Pearse, Welding Engineer


100 02-15-05 Q211
— —
GMAW-S Semi-Automatic

Single-V
X
--`,,```,,,,````-`-`,,`,,`,`,,`---

N.A.

26
Copyright American Welding Society
Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
--`,,```,,,,````-`-`,,`,,`,`,,`--- 1 1 1 1

N.A.
N.A.

N.A.
N.A.

3/16-1 1/8 N.A.


Unlimited N.A.

SFA 5.18
ER70S-3
6
1
.035 in.

1-1/4 in.
N.A.
None
N.A.
N.A.

This form (E00006) may be obtained from the


Order Dept., ASME, 22 Law Drive, Box 2300,
Data included in this suggested PQR format is illustrative only. Fairfield, NJ 07007-2300, (800) 843-2763.

Copyright American Welding Society 27


Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
QW-482 (Back)
100 —
None
All N.A.
X X (Last N.A.
All Pass Only)

70°F Min
250°F Max
70°F Min
CO2 Welding Gr. 25 cfh
--`,,```,,,,````-`-`,,`,,`,`,,`---

None — —
None — —

Electrode
DC Positive
140-175 20-23

None

Short Circuiting

225-305 ipm

28
Copyright American Welding Society
Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
String and Weave
1/2 in.
Wire Brushing

None
Manually Controlled as Necessary to Fill Groove
1/2 in.
Multiple
Single
5-20 ipm
None
N.A.
--`,,```,,,,````-`-`,,`,,`,`,,`---

All GMAW-S ER70S-3 0.035 DCEP 140-175 20-23

Data included in this suggested PQR format is illustrative only.


Copyright American Welding Society 29
Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
QW-483 Suggested Format for Procedure Qualification Records (PQR)
(See QW-200.2, Section IX, ASME Boiler and Pressure Vessel Code)
Record Actual Conditions Used to Weld Test Coupon

Any Welding Company


--`,,```,,,,````-`-`,,`,,`,`,,`---

Q211 02-15-05
100
GMAW-S
Semi-Automatic

None
ASME SA53 N.A.
A N.A.
1 1 N.A.
0.562 in.
24 in.

30
Copyright American Welding Society
Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
N.A.

CO2 Welding Gr. 25 cfh


None — —
None — —
5.18
ER70S-3
6 DC
1 Electrode Positive
.035 145-170 21-22
N.A. N.A.
Wire Feed Speed: 300-450 ipm
0.562

--`,,```,,,,````-`-`,,`,,`,`,,`---
5G 22-23 ipm
Downhill root pass Both-As Required
N.A. Balance uphill N.A.
Multiple
Single
Short Circuiting Metal Transfer
70°F
250°F max
N.A.

This form (E0007) may be obtained from the Order Dept., ASME, 222 Law Drive, Box 2300, Fairfield, NJ 07007-2300, (800) 843-2763.

Data included in this suggested PQR format is illustrative only.

Copyright American Welding Society 31


Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
QW-483 (Back)
Q211
--`,,```,,,,````-`-`,,`,,`,`,,`---

5G-0 0.752 0.550 0.414 36,400 88,000 Ductile-Base


Metal
5G-180 0.754 0.550 0.415 37,100 89,500 "

45 Side Bend QW-463.2 Acceptable-No Visible Defect


135 " " " "
225 " " " "
315 " " " "

None
Required

32
Copyright American Welding Society
Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
N.A.

Visual Examination
N.A.
N.A.

Edward Daly 17 W23


Weld Test Lab, USA 211-AWC

Any Welding Company

--`,,```,,,,````-`-`,,`,,`,`,,`---
02-15-05 Patrick Pearse

Data included in this suggested PQR format is illustrative only.

Copyright American Welding Society 33


Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
5.2

Sample

Manual SMAW 5L-X52


Shielded Metal Arc Welding
API 5L Std. Line Pipe Gr. X-52
Pipe Outside Diameter and Wall Thickness
4 1/2-12 3/4 in. dia. 3/16-3/4 in. Thickness
Single Vee Groove-See Sketch
See Sketch and Table Below
DCEP
Fixed-Pipe Axis Horizontal (5G)
--`,,```,,,,````-`-`,,`,,`,`,,`---

Downhill
One
Unlimited
None
Grinding/Wire Brush to Remove Slag
None
External—Must complete 70% of weld before removal
N.A.

Plasma Gas Composition _______________ Plasma Gas Orifice Size _______________ Plasma Gas Flow Rate ________________

Dolan Shamrock John Gargas


Michael Brandon Michael Brandon
John Doe John Doe, P.E.

34
Copyright American Welding Society
Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
5.2
--`,,```,,,,````-`-`,,`,,`,`,,`---

NOTE: Dimensions are for example only.

1 1/8" E6010 26 115 DCEP N.A.


2 1/8" E7010 26 115 DCEP N.A.
3-5 5/32" E7010 25 135 DCEP N.A.

Data included in this suggested PQR format is illustrative only.


Copyright American Welding Society 35
Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
API-Approved Coupon Test Report
02-15-05
Date _______________________________________________ 485
Test No. _____________________________________________
New York
Location ___________________________________________________________________________________________________
NY
State_______________________________________________ Weld Position: Roll Fixed X
John Gargas
Welder _____________________________________________ (Enter Welder’s Symbol)
Mark _______________________________________________
30 minutes
Welding Time ________________________________________ 9:00 a.m.
Time of Day__________________________________________
70°F
Mean Temperature ____________________________________ None
Weld Break Used _____________________________________
Indoors
Weather Conditions __________________________________________________________________________________________
24-27
Voltage _____________________________________________ 110-120
Amperage ___________________________________________
DC Generator
Welding Machine Type _________________________________ 300 amp
Welding Machine Size__________________________________
--`,,```,,,,````-`-`,,`,,`,`,,`---

E6010 Root, E6010 Fill


Filler Metal _________________________________________________________________________________________________
1/32”-1/16”
Reinforcement Size __________________________________________________________________________________________
API 5L-X 52
Pipe Type and Grade _________________________________________________________________________________________
0.203
Wall Thickness _______________________________________ 8 in.
Outside Diameter _____________________________________

1 2 3 4 5 6 7

Coupon Stenciled A B
0.945 x 1.022 x
Original Specimen Dimensions
0.203 0.203
Original Specimen Area 0.192 0.207

Maximum Load 15,300 16,500


Tensile Strength per square inch of
79,700 79,700
Plate Area
Fracture Location

36
Copyright American Welding Society
Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
X Procedure X Qualifying Test X Qualified
Welder Line Test Disqualified

80,000
Maximum Tensile ___________________ 79,500
Minimum Tensile_____________________ 79,500
Average Tensile __________________
Remarks on Tensile-Strength Tests ______________________________________________________________________________
Failed in Base Metal 1 in. from Weld Toe
1. ________________________________________________________________________________________________________
Failed "n"Base "etal 1-1/2 in. frr"
2. ________________________________________________________________________________________________________
3. ________________________________________________________________________________________________________
4. ________________________________________________________________________________________________________

Remarks on Bend Tests_______________________________________________________________________________________


Face Bend One Tear <1/32 in. Pass
1. ________________________________________________________________________________________________________
Face Bend One T"ar <1/"2 in. Pass
2. ________________________________________________________________________________________________________
Root Bend No Visible Defects Pass
3. ________________________________________________________________________________________________________
Root Bend No Vi"ible D"fects Pass
4. ________________________________________________________________________________________________________

Remarks on Nick-Break Tests __________________________________________________________________________________


No Visible Defects-Pass
1. ________________________________________________________________________________________________________
No Visible Defects-Pass
2. ________________________________________________________________________________________________________
3. ________________________________________________________________________________________________________
4. ________________________________________________________________________________________________________
Shamrock Testing
Test Made at ________________________________________ 02-15-05
Date________________________________________________

--`,,```,,,,````-`-`,,`,,`,`,,`---
Joseph Dolan
Tested by ___________________________________________ Michael Brandon
Supervised by ________________________________________

Note: Use back for additional remarks. This form can be used to report either a procedure qualification test or a welder qualification test.

Data included in this suggested PQR format is illustrative only.


Copyright American Welding Society 37
Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
Notes

--`,,```,,,,````-`-`,,`,,`,`,,`---
38
Copyright American Welding Society
Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
Chapter 4—SAW Procedure Qualification Variables
The tables in this chapter illustrate submerged arc welding procedure The following legend applies to the five standards (AWS B2.1:2005,
qualification variables for the following criteria: AWS D1.1/D1.1M:2004, AASHTO/AWS D1.5M/D1.5:2002, 2001ASME
(1) Joint Design IX with 2003 Addenda, and API 1104 Twentieth Edition, 2005) used for
(2) Base Metal comparison in the tables:
(3) Filler Metal
(4) Position Q = Variable requires requalification
(5) Preheat and Interpass Temperature T = Variable requires requalification when toughness testing is required
(6) Postweld Heat Treatment A = Variable requires requalification for automatic welding
(7) Electrode
(8) Electrical Characteristics The tables should be regarded as illustrative only, since the various
(9) Other standards are revised periodically.

--`,,```,,,,````-`-`,,`,,`,`,,`---
Copyright American Welding Society 39
Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
Table 4-1—Joint Design
SAW PQR Variables B2.1 D1.1 D1.5 ASME IX API 1104

A change from a fillet to a groove weld. Q Q Q Q Q


A change in the M-Number of backing. Q
The addition of thermal backgouging on M-11, M-23, M-24, M-26, and M-27 heat-treatable base metal. Q
A change in groove type (e.g., single-V to double-V). Qualification of any CJP groove weld qualifies for any groove
--`,,```,,,,````-`-`,,`,,`,`,,`---

Q
detail complying with the requirements of 3.12 or 3.13 of D1.1.
A change in the type of groove to a square groove and vice versa. Q Q
A major change in joint design (for example, from V groove to U groove). Minor changes in the angle of bevel or the
Q
land of the welding groove are not essential variables.
Any change beyond the range established in the procedure specification for such factors as spacing, root face, and
Q
angle of bevel.
A change exceeding the tolerances of 3.12, 3.13, 3.13.4, 5.22.4.1, or 5.22.4.2 of D1.1 involving:
(1) A decrease in the groove angle,
Q
(2) A decrease in the root opening,
(3) An increase in the root face.
A change exceeding the tolerances of 2.9, 2,10, or 3.3.4 of D1.5 in the shape of any type of groove involving:
(1) A decrease in the groove angle,
Q
(2) A decrease in the root opening,
(3) An increase in the root face which will not be subsequently removed by backgouging.
The omission, but not inclusion, of backing or backgouging. Q Q
A change from U-groove to a V-groove (but not vice versa). Q
Q = Variable requires requalification. T = Variable requires requalification when toughness testing is required. A = Variable requires requalification for automatic welding.

40
Copyright American Welding Society
Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
Table 4-2—Base Metal
SAW PQR Variables B2.1 D1.1 D1.5 ASME IX API 1104

A change from one M-Number to another M-Number or to an unlisted base metal, except as 2.3 of B2.1 permits. Q
A change from one P-Number to another P-Number or to an unassigned base metal, except as QW-424 of ASME IX
Q
permits.
A change of a Group Number within an M-Number. T
A change of a Group Number within a P-Number. T
A change from a joint between the same M-Numbers, to a joint between different M-Numbers or vice versa except as
permitted; or for M-Numbers 1, 3, 4, and 5A (of 3% max nom chromium), a procedure test with one M-Number shall Q
also qualify for that metal welded to each of the lower M-Number metals.
A change from M5A to M5B or M5C, and vice versa.
A change from M9A to M9B, but not vice versa. Q
A change from M10A to M10B, M10C, M10F, M10H, M10I, M10J, or M10K, and vice versa.
A change from P5A to P5B or P5C, and vice versa.
A change from P9A to P9B, but not vice versa. Q
A change from P10A to P10B, P10C, P10F, P10H, P10I, P10J, or P10K, and vice versa.
A change in base metals as specified in 4.7.3 of D1.1. Q
A change in base metal or combination of base metals not listed on the PQR or qualified by Table 4.7 of D1.1. Q
A change in base metal specification and grade as specified in 5.4 of D1.5. Q
A change in pipe material as specified in 12.5.2.2 of API 1104. Q
A change in wall-thickness group as specified in 12.5.2.4 of API 1104. Q
A change in base metal thickness beyond the range permitted in 2.5 of B2.1. Q

Q = Variable requires requalification. T = Variable requires requalification when toughness testing is required. A = Variable requires requalification for automatic welding.

--`,,```,,,,````-`-`,,`,,`,`,,`---

Copyright American Welding Society 41


Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
Table 4-2—Base Metal (Continued)
SAW PQR Variables B2.1 D1.1 D1.5 ASME IX API 1104

A change in diameter, or thickness, or both not qualified by Table 4.2 of D1.1. Q


A change in base metal thickness beyond the range permitted in Table 5.2 of D1.5. Q
For M270M (A 709M) Gr. 690, 690W, increase in plate thickness greater than 12 mm or decrease of 25 mm or more. Q
A change in base metal thickness beyond the range qualified in QW-451 of ASME IX. Q
A change from an uncoated metal to a coated (such as painted or galvanized) metal unless the coating is removed from
Q
the weld area prior to welding, but not vice versa.
Each grade of base metal with a specified minimum yield strength of 65,000 psi requires a separate qualification test. Q
A change in wall thickness beyond the range qualified in the procedure specification. Q
A change in pipe diameter beyond the range established in the procedure specification. Q

--`,,```,,,,````-`-`,,`,,`,`,,`---
The minimum thickness qualified is T or 5/8 in., whichever is less. However, where T is less than 1/4 in. the minimum is
1/2T. This limitation does not apply when a WPS is qualified with a PWHT above the upper transformation temperature T
or when an austenitic material is solution annealed after welding.
The minimum thickness qualified for thicknesses 5/8 in. or less is the thickness of the procedure qualification test plate. T
The minimum thickness qualified is T or 5/8 in., whichever is less, except that if T is less than 1/4 in., the minimum
T
thickness is 1/8 in.
Q = Variable requires requalification. T = Variable requires requalification when toughness testing is required. A = Variable requires requalification for automatic welding.

42
Copyright American Welding Society
Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
Table 4-3 —Filler Metals
SAW PQR Variables B2.1 D1.1 D1.5 ASME IX API 1104
A change from one F-Number to any other F-Number or to any filler metal not listed in Annex III of B2.1. Q
A change from one F-Number in QW-432 of ASME IX to any other F-Number or to any other filler metal not listed
Q
in QW-432.
For ferrous materials, a change from one A-Number to any other A-Number or to a filler metal analysis not listed in
Annex III of B2.1 or QW-432 of ASME IX (the PQR and WPS shall state the nominal chemical composition or
Q Q
manufacturer’s designation for filler metals which do not fall into an A-Number group). Qualification with A-1 shall
qualify for A-2 and vice versa.
A change in AWS filler metal classification. T T Q
A change from one filler-metal group to another as specified in Table 1 of API 1104. Q
For pipe materials with a specified minimum yield strength greater than or equal to 65,000 pounds per square inch
Q
(448.16 megapascals), a change in the AWS classification of the filler metal.
Change to an electrode or flux-electrode combination not covered in AWS A5.17 or A5.23. Q
A change in the filler metal classification strength designator exceeding 10,000 psi, or to a filler metal classification
Q
strength designator less than the base metal tensile strength.
A change in manufacturer’s brand and type of cored electrode. Q
A change in manufacturer’s brand and type of flux. Q
A change in the indicator for minimum tensile strength (e.g., the 7 in F7A2-EM12K) when the flux wire combination
is classified in ASME II, Part C. A change in either the flux trade name or wire trade name when neither the flux nor the
Q
wire is classified in ASME II, Part C. A change in the flux trade name when the wire is classified in ASME II, Part C,
but the flux is not. A change in wire classification within the requirements of QW-404.5 does not require requalification.
A change in either the flux trade name or wire trade name when neither the flux nor the wire is classified in ASME II,
Q
Part C.
A change in the flux trade name or when the wire is classified in ASME II, Part C but the flux is not classified. A
Q
change in the wire classification within the requirements of QW-404.5 of ASME IX does not require requalification.
A change in the flux trade name for A-No. 8 deposits. Q
An increase in filler metal classification strength. Q
Q = Variable requires requalification. T = Variable requires requalification when toughness testing is required. A = Variable requires requalification for automatic welding.

--`,,```,,,,````-`-`,,`,,`,`,,`---

Copyright American Welding Society 43


Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
Table 4-3 (Continued)—Filler Metals
SAW PQR Variables B2.1 D1.1 D1.5 ASME IX API 1104
If the weld metal alloy content is largely dependent upon the composition of the flux, any change in the welding
procedure which would result in the important weld metal alloying elements being outside the specified chemical Q Q Q Q
composition range of the WPS.
An addition or deletion of supplementary filler metal (powder or wire), or a change of 10% in the amount. Q Q
An addition or deletion of supplemental powdered or granular filler metal or cut wire. Q Q
An addition or deletion, or a change in the nominal amount or composition of supplementary metal (in addition to
Q
filler metal) beyond that qualified.
An increase in the amount of supplemental powdered or granular filler metal or wire. Q
An increase or decrease in the amount of supplemental powdered or granular filler metal or wire. Q
A change from wire to strip electrodes and vice versa. Q
A change from one electrode or flux-electrode classification listed to any other electrode or flux-electrode classification.
Q
A change decreasing filler metal strength level is permitted without WPS requalification.
A change from one AWS electrode-flux classification listed to any other electrode-flux classification, or to an unlisted
electrode-flux classification. A variation of 0.5% of the molybdenum content of the weld metal does not require Q
requalification.
A change in the flux/wire classification or a change in either the electrode or flux trade name when not classified in an
SFA specification. Requalification is not required when the wire/flux combination conforms to an SFA specification and T
a change is made from one diffusible hydrogen level to another.
A change in the weld metal thickness beyond that permitted in 2.5 of B2.1 or QW-451 of ASME IX as applicable. Q Q
A change in flux type (i.e., neutral to active or vice versa) for multilayer deposits in P-No. 1 materials. Q
When flux from re-crushed slag is used, each batch or blend, as defined in SFA-5.01 of ASME II Part C, shall be
tested in accordance with ASME II Part C by either the manufacturer or user, or qualified as an unclassified flux in Q
accordance with QW-404.9 of ASME IX.
A change in flux as described in footnote to Table 1 of API 1104. Q
A change in the size of filler metal wire. Q
A change in the flux/wire classification or a change in either the electrode or flux trade name when not classified in an
SFA specification. Requalification is not required when a wire/flux combination conforms to an SFA specification and
a change is made from one diffusible hydrogen level to another (i.e., a change from F7A2-EA1-A1H4 to F7A2, EA1- T
A1H16). This variable does not apply when the weld metal is exempt from impact testing by other Sections. This
exemption does not apply to hard facing and corrosion-resistant overlays.
Q = Variable requires requalification. T = Variable requires requalification when toughness testing is required. A = Variable requires requalification for automatic welding.
--`,,```,,,,````-`-`,,`,,`,`,,`---

44
Copyright American Welding Society
Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
Table 4-4—Position
SAW PQR Variables B2.1 D1.1 D1.5 ASME IX API 1104

A change in position not qualified by Table 4.1 of D1.1. Q


A change from any position except that flat positions qualify for flat and horizontal welding. Q

Table 4-5—Preheat and Interpass Temperature


SAW PQR Variables B2.1 D1.1 D1.5 ASME IX API 1104

A decrease in preheat of more than 100°F from that qualified. Q T Q


An increase of more than 100°F in the maximum interpass temperature from that recorded on the PQR. For ASME IX
applications, this limitation does not apply when a WPS is qualified with a PWHT above the upper transformation T T
temperature or when an austenitic material is solution annealed after welding.
Decrease from preheat temperature by >25°F. Preheat temperature may be less than that of the PQR, but the preheat
Q
shall not be less than that shown on the WPS.
Decrease from preheat temperature by >15°C. The production welding preheat or interpass temperature may be less
than the PQR preheat or interpass temperature provided that the provisions of Table 4.4 and Annex VIII of D1.5 are Q
met, and the base metal temperature shall not be less than the PQR temperature at the time of subsequent welding.
Increase in interpass temperature by >55°C. Q
Decrease from interpass temperature by >25°F. The production welding preheat or interpass temperature may be less
than the PQR preheat or interpass temperature provided that the provisions of 5.6 and Table 3.2 of D1.1 are met, and Q
the base metal temperature shall not be less than the PQR temperature at the time of subsequent welding.
A change in preheat treatment requirements. Q

Q = Variable requires requalification. T = Variable requires requalification when toughness testing is required. A = Variable requires requalification for automatic welding.

--`,,```,,,,````-`-`,,`,,`,`,,`---

Copyright American Welding Society 45


Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
Table 4-6—Postweld Heat Treatment
SAW PQR Variables B2.1 D1.1 D1.5 ASME IX API 1104
For the following M-Numbers 1, 3, 4, 5, 6, 9, 10, 11, and 12, and for P-Numbers 1, 3, 4, 5, 6, 9, 10, and 11, a change
from any one condition to any other requires requalification:
(1) No PWHT
(2) PWHT below the lower transformation temperature
Q Q
(3) PWHT within the transformation temperature range
(4) PWHT above the upper transformation temperature
(5) PWHT above the upper transformation temperature followed by treatment below the lower transformation
temperature
A separate PQR is required for no PWHT and PWHT. Q Q
The qualification test weldment shall be subjected to heat treatment essentially equivalent to that of the production
T T T
weldment, including at least 80% of the aggregate time at temperature.
A change in post-heat treatment requirements. Q

Table 4-7—Electrode
SAW PQR Variables B2.1 D1.1 D1.5 ASME IX API 1104
Change in nominal electrode diameter by any increase. For WPSs using alloy flux, any increase or decrease in the
Q
electrode diameter shall require WPS requalification.
Increase or decrease in electrode diameter by more than one standard size. Q
Change in number of electrodes. Q Q Q
A change from single electrode to multiples electrodes in the same weld pool, and vice versa. For ASME IX
applications, this limitation does not apply when a WPS is qualified with a PWHT above the upper transformation T T T
temperature or when an austenitic material is solution annealed after welding.
Change in electrode classification. T Q
Change in electrode/flux combination. Q
Q = Variable requires requalification. T = Variable requires requalification when toughness testing is required. A = Variable requires requalification for automatic welding.

--`,,```,,,,````-`-`,,`,,`,`,,`--- 46
Copyright American Welding Society
Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
Table 4-8—Electrical Characteristics
SAW PQR Variables B2.1 D1.1 D1.5 ASME IX API 1104
An increase of heat input or volume of weld metal deposited per unit length of weld, over that qualified, except when
a grain refining austenitizing heat treatment is applied after welding. The increase may be measured by either of the
following:
Volts × Amps × 60 T T T
(1) Heat Input (J/in.) = ------------------------------------------------------
Travel Speed (in./min)

(2) Weld Metal Volume—An increase in bead size, or a decrease in the length of weld bead per unit length of
electrode.
--`,,```,,,,````-`-`,,`,,`,`,,`---

A change in the amperage for each diameter used by >10% increase or decrease. Q Q
A change in type of current (ac or dc) or polarity. Q T Q
A change in type of current (ac or dc) or polarity, only when using an alloy flux or quenched and tempered material. Q
A change in the voltage for each diameter used by >7% increase or decrease. Q Q
For WPSs using alloy or active fluxes, any increase in the maximum voltage. Q
An increase or decrease in the wire feed speed for each electrode diameter (if not amperage controlled) by >10%. Q
A change in the travel speed (unless heat input control is required) by >15% increase or decrease. Q
A change in the travel speed by >15% increase or decrease. Q
A change in the range for speed of travel. Q
An increase in heat input by >10%. This essential variable applies only when heat input control is a contract document
requirement. Heat input in joules per inch shall be calculated as 60EI/V where: E = PQR voltage, I = PQR amperage, Q
and V = PQR travel speed.
An increase in heat input by more than 10% or decrease of more than 30%. For M270M, (A 709M) Gr. 690, 690W,
Q
allowable heat input increase or decrease shall be limited to 10%.
A change in electrical characteristics. Q
Q = Variable requires requalification. T = Variable requires requalification when toughness testing is required. A = Variable requires requalification for automatic welding.

Copyright American Welding Society 47


Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
Table 4-9—Other
SAW PQR Variables B2.1 D1.1 D1.5 ASME IX API 1104
A change in welding process. Q Q Q Q Q
A change between manual, semiautomatic, or automatic welding or any combination of these. Q
A change from multiple-pass per side to single pass per side. T T
A change from multiple-pass per side to single pass per side. This limitation does not apply when a WPS is qualified
with a PWHT above the upper transformation temperature or when an austenitic material is solution annealed after T
welding.
A change exceeding ±20% in the oscillation variables for mechanized or automatic welding. T T
A change from a stringer bead to a weave bead in vertical uphill welding. For ASME IX applications, this limitation
does not apply when a WPS is qualified with a PWHT above the upper transformation temperature or when an T T
austenitic material is solution annealed after welding.
For multiple electrodes, a change of >10%, or 1/8 in., whichever is greater, in the longitudinal spacing of the arcs. Q
For multiple electrodes, change of >10%, or 3 mm, whichever is greater, in the longitudinal spacing of the arcs. Q
For multiple electrodes, a change of >10%, or 1/8 in., whichever is greater, in the lateral spacing of the arcs. Q
For multiple electrodes, a change of >10%, or 2 mm, whichever is greater, in the lateral spacing of the arcs. Q
For multiple electrodes, an increase or decrease of more than 10° in the angular orientation of any parallel electrode. Q Q
For machine or automatic SAW; an increase or decrease of more than 3° in the angle of the electrode. Q
For machine or automatic SAW; an increase or decrease of more than 3° in the direction of travel. A
For machine or automatic SAW, an increase or decrease of more than 5° normal to the direction of travel. A A
For the PQR groove area, an increase or decrease >25% in the number of passes. If the production weld groove area
differs from that of the PQR groove area, it is permissible to change the number of PQR passes in proportion to the Q
area without requiring WPS requalification.
An increase in the maximum time between completion of the root bead and the start of the second bead. Q
Q = Variable requires requalification. T = Variable requires requalification when toughness testing is required. A = Variable requires requalification for automatic welding.

--`,,```,,,,````-`-`,,`,,`,`,,`---
48
Copyright American Welding Society
Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
Chapter 5—SMAW Procedure Qualification Variables
The tables in this chapter illustrate shielded metal arc welding procedure The following legend applies to the five standards (AWS B2.1:2005,
qualification variables for the following criteria: AWS D1.1/D1.1M:2004, AASHTO/AWS D1.5M/D1.5:2002, 2001ASME
(1) Joint Design IX with 2003 Addenda, and API 1104 Twentieth Edition, 2005) used for
(2) Base Metal comparison in the tables:
(3) Filler Metal
(4) Position Q = Variable requires requalification
(5) Preheat and Interpass Temperature T = Variable requires requalification when toughness testing is required
(6) Postweld Heat Treatment A = Variable requires requalification for automatic welding
(7) Electrode
(8) Electrical Characteristics The tables should be regarded as illustrative only, since the various
(9) Other standards are revised periodically.

--`,,```,,,,````-`-`,,`,,`,`,,`---
Copyright American Welding Society 49
Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
Table 5-1—Joint Design
SMAW PQR Variables B2.1 D1.1 D1.5 ASME IX API 1104

A change from a fillet to a groove weld. Q Q Q Q Q


A change in the M-Number of backing. Q
The addition of thermal backgouging on M-11, M-23, M-24, M-26, and M-27 heat-treatable base metal. Q
A change in groove type (e.g., single-V to double-V). Qualification of any CJP groove weld qualifies for any groove
Q
detail complying with the requirements of 3.12 or 3.13 of D1.1.
A change in the type of groove to a square groove and vice versa. Q Q
A major change in joint design (for example, from V groove to U groove). Minor changes in the angle of bevel or the
Q
land of the welding groove are not essential variables.
A change exceeding the tolerances of 3.12, 3.13, 3.13.4, 5.22.4.1, or 5.22.4.2 of D1.1 involving:
(1) A decrease in the groove angle,
Q
(2) A decrease in the root opening,
(3) An increase in the root face.

--`,,```,,,,````-`-`,,`,,`,`,,`---
A change exceeding the tolerances of 2.9, 2,10, or 3.3.4 of D1.5 in the shape of any type of groove involving:
(1) A decrease in the groove angle,
Q
(2) A decrease in the root opening,
(3) An increase in the root face which will not be subsequently removed by backgouging.
The omission, but not inclusion, of backing or backgouging. Q Q
A change from U-groove to a V-groove (but not vice versa). Q
Q = Variable requires requalification. T = Variable requires requalification when toughness testing is required. A = Variable requires requalification for automatic welding.

50
Copyright American Welding Society
Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
Table 5-2—Base Metal
SMAW PQR Variables B2.1 D1.1 D1.5 ASME IX API 1104

A change from one M-Number to another M-Number or to an unlisted base metal, except as 2.3 of B2.1 permits. Q
A change from one P-Number to another P-Number or to an unassigned base metal, except as QW-424 of ASME IX
Q
permits.
A change of a Group Number within an M-Number. T
A change of a Group Number within a P-Number. T
A change from a joint between the same M-Numbers, to a joint between different M-Numbers or vice versa except as
permitted, or for M-Numbers 1, 3, 4, and 5 (of 3% max nom chromium); a procedure test with one M-Number shall Q
also qualify for that metal welded to each of the lower M-Number metals.
A change from M5A to M5B or M5C, and vice versa.
A change from M9A to M9B, but not vice versa.
Q
A change from M10A to M10B, M10C, M10F, M10H, M10I, M10J, or M10K, and vice versa.
A change from M11A to M11 B, and vice versa.
A change from P5A to P5B or P5C, and vice versa.
A change from P9A to P9B, but not vice versa. Q
A change from P10A to P10B, P10C, P10F, P10H, P10I, P10J, or P10K, and vice versa.
A change in base metals as specified in 4.7.3 of D1.1. Q
A change in base metal or combination of base metals not listed on the PQR or qualified by Table 4.7 of D1.1. Q

--`,,```,,,,````-`-`,,`,,`,`,,`---
A change in base metal specification and grade as specified in 5.4 of D1.5. Q
A change in pipe material as specified in 5.4.2.2 of API 1104. Q
A change in wall-thickness group as specified in 5.4.2.5 of API 1104. Q
Q = Variable requires requalification. T = Variable requires requalification when toughness testing is required. A = Variable requires requalification for automatic welding.

Copyright American Welding Society 51


Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
Table 5-2—Base Metal
SMAW PQR Variables B2.1 D1.1 D1.5 ASME IX API 1104

A change in base metal thickness beyond the range permitted in 2.5 of B2.1. Q
A change in diameter, or thickness, or both not qualified by Table 4.2 of D1.1. Q
A change in base metal thickness beyond the range permitted in Table 5.2 of D1.5. Q
For M270M (A 709M) Gr. 690, 690W, increase in plate thickness greater than 12 mm or decrease of 25 mm or more. Q
A change in base metal thickness beyond the range qualified in QW-451 of ASME IX. Q
A change from an uncoated metal to a coated (such as painted or galvanized) metal unless the coating is removed from
Q
the weld area prior to welding, but not vice versa.
Each grade of base metal with a specified minimum yield strength of 65,000 psi requires a separate qualification test. Q
The minimum thickness qualified is T or 5/8 in., whichever is less. However, where T is less than 1/4 in. the minimum is

--`,,```,,,,````-`-`,,`,,`,`,,`---
1/2T. This limitation does not apply when a WPS is qualified with a PWHT above the upper transformation temperature T
or when an austenitic material is solution annealed after welding.
The minimum thickness qualified for thicknesses 5/8 in. or less is the thickness of the procedure qualification test plate. T
The minimum thickness qualified is T or 5/8 in., whichever is less, except that if T is less than 1/4 in., the minimum
T
thickness is 1/8 in.

Q = Variable requires requalification. T = Variable requires requalification when toughness testing is required. A = Variable requires requalification for automatic welding.

52
Copyright American Welding Society
Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
Table 5-3—Filler Metals
SMAW PQR Variables B2.1 D1.1 D1.5 ASME IX API 1104

A change from one F-Number to any other F-Number or to any filler metal not listed in Annex III of B2.1. Q
A change from one F-Number in QW-432 of ASME IX to any other F-Number or to any other filler metal not listed
--`,,```,,,,````-`-`,,`,,`,`,,`---

Q
in QW-432.
Change from low hydrogen to non-low hydrogen SMAW electrode. Q
For ferrous materials, a change from one A-Number to any other A-Number or to a filler metal analysis not listed in
Annex III of B2.1 or QW-432 of ASME IX (the PQR and WPS shall state the nominal chemical composition or
Q Q
manufacturer’s designation for filler metals which do not fall into an A-Number group). Qualification with A-1 shall
qualify for A-2 and vice versa.
A change in AWS filler metal classification. T Q T
A change from one filler-metal group to another as specified in Table 1 of API 1104. Q
For pipe materials with a specified minimum yield strength greater than or equal to 65,000 pounds per square inch
Q
(448.16 megapascals), a change in the AWS classification of the filler metal.
A change to an electrode or flux-electrode combination not covered in AWS A5.1 OR A5.5. Q
A change in the filler metal classification strength designator exceeding 10,000 psi, or to a filler metal classification
Q
strength designator less than the base metal tensile strength.
An increase in filler metal classification strength. Q Q
An addition or deletion of supplementary filler metal (powder or wire), or a change of 10% in the amount. T
A change in the weld metal thickness beyond that permitted in 2.5 of B2.1 or QW-451 of ASME IX as applicable. Q Q

Q = Variable requires requalification. T = Variable requires requalification when toughness testing is required. A = Variable requires requalification for automatic welding.

Copyright American Welding Society 53


Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
Table 5-3—Filler Metals (Continued)
SMAW PQR Variables B2.1 D1.1 D1.5 ASME IX API 1104

A change in the filler metal classification within an SFA specification or to a filler metal not covered by an SFA
specification, or from one filler metal not covered by an SFA specification to another filler metal that is not covered by
an SFA specification.
When a filler metal conforms to a filler metal classification within an SFA specification, requalification is not required
if a change is made in any of the following:
(1) from a filler metal that is designated as moisture-resistant to one that is not designated as moisture-resistant and vice
versa (i.e., from E7018R to E7018)
(2) from one diffusible hydrogen level to another (i.e., from E7018-H8 to E7018-H16)
(3) for carbon, low alloy, and stainless steel filler metals having the same minimum tensile strength and the same nom-
inal chemical composition, a change from one low hydrogen coating type to another low hydrogen coating type (i.e., a T
change among EXX15, 16, or 18 or EXXX15, 16, or 17 classifications
(4) from one position-usability designation to another for flux-cored electrodes (i.e., a change from E70T-1 to
E71T-1 or vice versa
(5) from a classification that requires impact testing to the same classification which has a suffix which indicates that
impact testing was performed at a lower temperature or exhibited greater toughness at the required temperature or both,
as compared to the classification which was used during procedure qualification (i.e., a change from E7018 to E7018-1)
(6) from the classification qualified to another filler metal within the same SFA specification when the weld metal is
exempt from Impact Testing by other sections
This exemption does not apply to hard-facing and corrosion-resistant overlays.

Q = Variable requires requalification. T = Variable requires requalification when toughness testing is required. A = Variable requires requalification for automatic welding.

54 --`,,```,,,,````-`-`,,`,,`,`,,`---

Copyright American Welding Society


Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
Table 5-4—Position
SMAW PQR Variables B2.1 D1.1 D1.5 ASME IX API 1104
A change from any position to the vertical position, uphill progression. Vertical uphill progression qualifies all positions. T T T
A change in position not qualified by Table 4.1 of D1.1. Q
A change from any position except that flat positions qualify for flat and horizontal welding. Q
Vertical welding: For any pass from uphill to downhill or vice versa. Q Q
Vertical welding shall be vertical up unless qualified by tests approved by the Engineer. Q
A change in position from roll to fixed, or vice versa. Q

Table 5-5—Preheat and Interpass Temperature


SMAW PQR Variables B2.1 D1.1 D1.5 ASME IX API 1104
A decrease in preheat of more than 100°F from that qualified. Q Q
An increase of more than 100°F in the maximum interpass temperature from that recorded on the PQR. For ASME IX
applications, this limitation does not apply when a WPS is qualified with a PWHT above the upper transformation T T T
temperature or when an austenitic material is solution annealed after welding.
A decrease from preheat temperature by >25°F. The production welding preheat or interpass temperature may be less
than the PQR preheat or interpass temperature provided that the provisions of 5.6 and Table 3.2 of D1.1 are met, Q
and the base metal temperature shall not be less than the PQR temperature at the time of subsequent welding.
A decrease from preheat temperature by >15°C. The production welding preheat or interpass temperature may be less
than the PQR preheat or interpass temperature provided that the provisions of Table 4.4 and Annex VIII of D1.5 are met, Q
and the base metal temperature shall not be less than the PQR temperature at the time of subsequent welding.
An increase in interpass temperature by >55°C. Q
A decrease from interpass temperature by >25°F. The production welding preheat or interpass temperature may be less
than the PQR preheat or interpass temperature provided that the provisions of 5.6 and Table 3.2 of D1.1 are met, and Q
the base metal temperature shall not be less than the PQR temperature at the time of subsequent welding.
A decrease in the specified minimum preheat temperature. Q
Q = Variable requires requalification. T = Variable requires requalification when toughness testing is required. A = Variable requires requalification for automatic welding.
--`,,```,,,,````-`-`,,`,,`,`,,`---

Copyright American Welding Society 55


Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
Table 5-6—Postweld Heat Treatment
SMAW PQR Variables B2.1 D1.1 D1.5 ASME IX API 1104

For the following M -Numbers 1, 3, 4, 5, 6, 9, 10,11, and 13, and for P-Numbers 1, 3, 4, 5, 6, 9, 10, and 11, a change
from any one condition to any other requires requalification:
(1) No PWHT,
(2) PWHT below the lower transformation temperature,
Q Q
(3) PWHT within the transformation temperature range,
(4) PWHT above the upper transformation temperature,
(5) PWHT above the upper transformation temperature followed by treatment below the lower transformation
temperature.
Addition or deletion of PWHT. Q Q
The qualification test weldment shall be subjected to heat treatment essentially equivalent to that of the production
T T T
weldment, including at least 80% of the aggregate time at temperature.
The addition of PWHT or a change in the specified ranges of PWHT. Q

Table 5-7—Electrode
SMAW PQR Variables B2.1 D1.1 D1.5 ASME IX API 1104

A change in nominal electrode diameter by >1/32 in. increase. Q


An increase or decrease in electrode diameter by more than one standard size. Q
A change in number of electrodes. Q
A change in electrode classification. T T Q
Q = Variable requires requalification. T = Variable requires requalification when toughness testing is required. A = Variable requires requalification for automatic welding.

--`,,```,,,,````-`-`,,`,,`,`,,`---
56
Copyright American Welding Society
Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
Table 5-8—Electrical Characteristics
SMAW PQR Variables B2.1 D1.1 D1.5 ASME IX API 1104

An increase of heat input or volume of weld metal deposited per unit length of weld, over that qualified, except when
a grain-refining austenitizing heat treatment is applied after welding. The increase may be measured by either of the
following:

Volts × Amps × 60 - T T T
(1) Heat Input (J/in.) = -----------------------------------------------------
Travel Speed (in./min)

(2) Weld metal volume—an increase in bead size, or a decrease in the length of weld bead per unit length of electrode.
A change in the amperage for each diameter used to a value not recommended by manufacturer. Q Q
A change in type of current (ac or dc) or polarity. Q T Q
A change in the voltage for each diameter used to a value not recommended by the electrode manufacturer. Q
A change in the range for speed of travel. Q
An increase in heat input by >10%. This essential variable applies only when heat input control is a contract document
requirement. Heat input in joules per inch shall be calculated as 60EI/V where: E = PQR voltage, I = PQR amperage, Q
and V = PQR travel speed.

--`,,```,,,,````-`-`,,`,,`,`,,`---
An increase in heat input by more than 10% or decrease of more than 30%. For M270M, (A 709M) Gr. 690, 690W,
Q
allowable heat input increase or decrease shall be limited to 10%.

Q = Variable requires requalification. T = Variable requires requalification when toughness testing is required. A = Variable requires requalification for automatic welding.

Copyright American Welding Society 57


Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
Table 5-9—Other
SMAW PQR Variables B2.1 D1.1 D1.5 ASME IX API 1104

A change in welding process. Q Q Q Q Q


A change between manual, semiautomatic, or automatic welding or any combination of these. Q
A change from multiple-pass per side to single pass per side. T T
A change from multiple-pass per side to single pass per side. This limitation does not apply when a WPS is qualified
with a PWHT above the upper transformation temperature or when an austenitic material is solution annealed after T
welding.
A change from a stringer bead to a weave bead in vertical uphill welding. For ASME IX applications, this limitation
does not apply when a WPS is qualified with a PWHT above the upper transformation temperature or when an T T T
austenitic material is solution annealed after welding.
For the PQR groove area, an increase or decrease >25% in the number of passes. For M270M (A 709M) Gr. 690,
690W, passes any change in the number of groove weld passes requires requalification, except proportional changes
Q
to accommodate a change in weld cross-sectional area. For fillet welds in these steels, any change in the number of
passes requires a fillet weld T-test per Figure 5.8 of D1.5 to be performed.
An increase in the maximum time between completion of the root bead and the start of the second bead. Q
A change from stringer bead to weave bead for manual vertical uphill welding. T T

Q = Variable requires requalification. T = Variable requires requalification when toughness testing is required. A = Variable requires requalification for automatic welding.

--`,,```,,,,````-`-`,,`,,`,`,,`---
58
Copyright American Welding Society
Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
Chapter 6—GMAW Procedure Qualification Variables
The tables in this chapter illustrate gas metal arc welding procedure The following legend applies to the five standards (AWS B2.1:2005,
qualification variables for the following criteria: AWS D1.1/D1.1M:2004, AASHTO/AWS D1.5M/D1.5:2002, 2001ASME
(1) Joint Design IX with 2003 Addenda, and API 1104 Twentieth Edition, 2005) used for
(2) Base Metal comparison in the tables:
(3) Filler Metal
(4) Position Q = Variable requires requalification
(5) Preheat and Interpass Temperature T = Variable requires requalification when toughness testing is required
(6) Postweld Heat Treatment A = Variable requires requalification for automatic welding
(7) Electrode
--`,,```,,,,````-`-`,,`,,`,`,,`---

(8) Electrical Characteristics The tables should be regarded as illustrative only, since the various
(9) Other standards are revised periodically.

Copyright American Welding Society 59


Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
Table 6-1—Joint Design
GMAW PQR Variables B2.1 D1.1 D1.5 ASME IX API 1104

A change from a fillet to a groove weld. Q Q Q Q Q


A change in the M-Number of backing. Q
The addition of thermal backgouging on M-11, M-23, M-24, M-26, or M-27 heat-treatable base metal. Q
A change in groove type (e.g., single-V to double-V). Qualification of any CJP groove weld qualifies for any groove
Q
detail complying with the requirements of 3.12 or 3.13 of D1.1.
A change in the type of groove to a square groove and vice versa. Q Q
A major change in joint design (for example, from V groove to U groove). Minor changes in the angle of bevel or the
Q
land of the welding groove are not essential variables.
Any change beyond the range established in the procedure specification for such factors as spacing, root face, and
Q

--`,,```,,,,````-`-`,,`,,`,`,,`---
angle of bevel.
A change exceeding the tolerances of 3.12, 3.13, 3.13.4, 5.22.4.1, or 5.22.4.2 of D1.1 involving:
(1) A decrease in the groove angle,
Q
(2) A decrease in the root opening,
(3) An increase in the root face.
A change exceeding the tolerances of 2.9, 2,10, or 3.3.4 of D1.5 in the shape of any type of groove involving:
(1) A decrease in the groove angle,
Q
(2) A decrease in the root opening,
(3) An increase in the root face which will not be subsequently removed by backgouging.
The omission, but not inclusion, of backing or backgouging. Q Q
A change from U-groove to a V-groove (but not vice versa). Q
Q = Variable requires requalification. T = Variable requires requalification when toughness testing is required. A = Variable requires requalification for automatic welding.

60
Copyright American Welding Society
Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
Table 6-2—Base Metal
GMAW PQR Variables B2.1 D1.1 D1.5 ASME IX API 1104

A change from one M-Number to another M-Number or to an unlisted base metal, except as 2.3 of B2.1 permits. Q
A change from one P-Number to another P-Number or to an unassigned base metal, except as QW-424 of ASME IX
Q
permits.
A change of a Group Number within an M-Number. T
A change of a Group Number within a P-Number. T
A change from a joint between the same M-Numbers, to a joint between different M-Numbers or vice versa except as
permitted, or for M-Numbers 1, 3, 4, and 5 (of 3% max nom chromium); a procedure test with one M-Number shall Q
also qualify for that metal welded to each of the lower M-Number metals.
A change from M5A to M5B or M5C, and vice versa.

--`,,```,,,,````-`-`,,`,,`,`,,`---
A change from M9A to M9B, but not vice versa.
Q
A change from M10A to M10B, M10C, M10F, M10H, M10I, M10J, or M10K, and vice versa.
A change from M11A to M11 B, and vice versa.
A change from P5A to P5B or P5C, and vice versa.
A change from P9A to P9B, but not vice versa. Q
A change from P10A to P10B, P10C, P10F, P10H, P10I, P10J, or P10K, and vice versa.
A change in base metals as specified in 4.7.3 of D1.1. Q
A change in base metal or combination of base metals not listed on the PQR or qualified by Table 4.7 of D1.1. Q
A change in base metal specification and grade as specified in 5.4 of D1.5. Q
A change in pipe material as specified in 12.5.2.2 of API 1104. Q
A change in wall-thickness group as specified in 12.5.2.4 of API 1104. Q
A change in base metal thickness beyond the range permitted in 2.5 of B2.1. Q
Q = Variable requires requalification. T = Variable requires requalification when toughness testing is required. A = Variable requires requalification for automatic welding.

Copyright American Welding Society 61


Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
Table 6-2—Base Metal (Continued)
GMAW PQR Variables B2.1 D1.1 D1.5 ASME IX API 1104

A change in diameter, or thickness, or both not qualified by Table 4.2 of D1.1. Q


A change in base metal thickness beyond the range permitted in Table 5.2 of D1.5. Q
For M270M (A 709M) Gr. 690, 690W, increase in plate thickness greater than 12 mm or decrease of 25 mm or more. Q
A change in base metal thickness beyond the range qualified in QW-451 of ASME IX. Q
A change from an uncoated metal to a coated (such as painted or galvanized) metal unless the coating is removed from
Q
the weld area prior to welding, but not vice versa.
Each grade of base metal with a specified minimum yield strength of 65,000 psi requires a separate qualification test. Q
A change in wall thickness beyond the range qualified in the procedure specification. Q
A change in pipe diameter beyond the range established in the procedure specification. Q
The minimum thickness qualified is T or 5/8 in., whichever is less. However, where T is less than 1/4 in. the minimum is
1/2T. This limitation does not apply when a WPS is qualified with a PWHT above the upper transformation temperature T
or when an austenitic material is solution annealed after welding.
The minimum thickness qualified for thicknesses 5/8 in. or less is the thickness of the procedure qualification test plate. T
The minimum thickness qualified is T or 5/8 in., whichever is less, except that if T is less than 1/4 in., the minimum
T
thickness is 1/8 in.

Q = Variable requires requalification. T = Variable requires requalification when toughness testing is required. A = Variable requires requalification for automatic welding.

--`,,```,,,,````-`-`,,`,,`,`,,`---
62
Copyright American Welding Society
Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
Table 6-3—Filler Metals
GMAW PQR Variables B2.1 D1.1 D1.5 ASME IX API 1104

A change from one F-Number to any other F-Number or to any filler metal not listed in Annex III of B2.1. Q
--`,,```,,,,````-`-`,,`,,`,`,,`---

A change from one F-Number in QW-432 of ASME IX to any other F-Number or to any other filler metal not listed
Q
in QW-432.
For ferrous materials, a change from one A-Number to any other A-Number or to a filler metal analysis not listed in
Annex III of B2.1 or QW-432 of ASME IX (the PQR and WPS shall state the nominal chemical composition or
Q Q
manufacturer’s designation for filler metals which do not fall into an A-Number group). Qualification with A-1 shall
qualify for A-2 and vice versa.
A change in AWS filler metal classification. T T Q
A change from one filler-metal group to another as specified in Table 1 of API 1104. Q
For pipe materials with a specified minimum yield strength greater than or equal to 65,000 pounds per square inch
Q
(448.16 megapascals), a change in the AWS classification of the filler metal.
A change to an electrode or flux-electrode combination not covered in AWS A5.18 or A5.28. Q
A change in the filler metal classification strength designator exceeding 10,000 psi, or to a filler metal classification
Q
strength designator less than the base metal tensile strength.
An increase in filler metal classification strength. Q Q
An addition or deletion of supplementary filler metal (powder or wire), or a change of 10% in the amount. Q Q
A change in the weld metal thickness beyond that permitted in 2.5 of B2.1 or QW-451 of ASME IX as applicable. Q Q

Q = Variable requires requalification. T = Variable requires requalification when toughness testing is required. A = Variable requires requalification for automatic welding.

Copyright American Welding Society 63


Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
Table 6-3—Filler Metals
GMAW PQR Variables B2.1 D1.1 D1.5 ASME IX API 1104

A change in the filler metal classification within an SFA specification or to a filler metal not covered by an SFA
specification, or from one filler metal not covered by an SFA specification to another filler metal that is not covered by
an SFA specification.
When a filler metal conforms to a filler metal classification within an SFA specification, requalification is not required
if a change is made in any of the following:
(1) from a filler metal that is designated as moisture-resistant to one that is not designated as moisture-resistant and vice
versa (i.e., from E7018R to E7018)
(2) from one diffusible hydrogen level to another (i.e., from E7018-H8 to E7018-H16)
(3) for carbon, low alloy, and stainless steel filler metals having the same minimum tensile strength and the same nom-
inal chemical composition, a change from one low hydrogen coating type to another low hydrogen coating type (i.e., a T
change among EXX15, 16, or 18 or EXXX15, 16, or 17 classifications
(4) from one position-usability designation to another for flux-cored electrodes (i.e., a change from E70T-1 to
E71T-1 or vice versa
(5) from a classification that requires impact testing to the same classification which has a suffix which indicates that
impact testing was performed at a lower temperature or exhibited greater toughness at the required temperature or both,
as compared to the classification which was used during procedure qualification (i.e., a change from E7018 to E7018-1)
(6) from the classification qualified to another filler metal within the same SFA specification when the weld metal is
exempt from Impact Testing by other sections
This exemption does not apply to hard-facing and corrosion-resistant overlays.
A change from one of the following filler metal product forms to another:
(1) Flux cored,
Q
(2) Bare (solid) or metal cored,
(3) Powder.
A change in the size of filler metal wire. A

Q = Variable requires requalification. T = Variable requires requalification when toughness testing is required. A = Variable requires requalification for automatic welding.

64 --`,,```,,,,````-`-`,,`,,`,`,,`---

Copyright American Welding Society


Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
Table 6-4—Position
--`,,```,,,,````-`-`,,`,,`,`,,`---
GMAW PQR Variables B2.1 D1.1 D1.5 ASME IX API 1104
A change from any position to the vertical position, uphill progression. Vertical uphill progression qualifies all positions. T T T
A change in position not qualified by Table 4.1 of D1.1. Q
A change from any position except that flat positions qualify for flat and horizontal welding. Q
Vertical welding: for any pass from uphill to downhill or vice versa. Q Q
Vertical welding shall be vertical up unless qualified by tests approved by the Engineer. Q
A change in position from roll to fixed, or vice versa. Q

Table 6-5—Preheat and Interpass Temperature


GMAW PQR Variables B2.1 D1.1 D1.5 ASME IX API 1104
A decrease in preheat of more than 100°F from that qualified. Q Q
An increase of more than 100°F in the maximum interpass temperature from that recorded on the PQR. For ASME IX
applications, this limitation does not apply when a WPS is qualified with a PWHT above the upper transformation T T T
temperature or when an austenitic material is solution annealed after welding.
A decrease from preheat temperature by >25°F. The production welding preheat or interpass temperature may be less
than the PQR preheat or interpass temperature provided that the provisions of 5.6 and Table 3.2 of D1.1 are met, and Q
the base metal temperature shall not be less than the PQR temperature at the time of subsequent welding.
A decrease from preheat temperature by >15°C. The production welding preheat or interpass temperature may be less
than the PQR preheat or interpass temperature provided that the provisions of Table 4.4 and Annex VIII of D1.5 are Q
met, and the base metal temperature shall not be less than the PQR temperature at the time of subsequent welding.
An increase in interpass temperature by >55°C. Q
A decrease from interpass temperature by >25°F. The production welding preheat or interpass temperature may be less
than the PQR preheat or interpass temperature provided that the provisions of 5.6 and Table 3.2 of D1.1 are met, and Q
the base metal temperature shall not be less than the PQR temperature at the time of subsequent welding.
A change in preheat requirements. Q
Q = Variable requires requalification. T = Variable requires requalification when toughness testing is required. A = Variable requires requalification for automatic welding.

Copyright American Welding Society 65


Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
Table 6-6—Postweld Heat Treatment
GMAW PQR Variables B2.1 D1.1 D1.5 ASME IX API 1104

For the following M-Numbers 1, 3, 4, 5, 6, 9, 10, 11, and 12, and for P-Numbers 1, 3, 4, 5, 6, 9, 10, and 11, a change
from any one condition to any other requires requalification:
(1) No PWHT,
(2) PWHT below the lower transformation temperature,
Q Q
(3) PWHT within the transformation temperature range,
(4) PWHT above the upper transformation temperature,
(5) PWHT above the upper transformation temperature followed by treatment below the lower transformation
temperature.
Addition or deletion of PWHT. Q Q
The qualification test weldment shall be subjected to heat treatment essentially equivalent to that of the production
T T T
weldment, including at least 80% of the aggregate time at temperature.
A change in post-heat treatment requirements. Q

Q = Variable requires requalification. T = Variable requires requalification when toughness testing is required. A = Variable requires requalification for automatic welding.

66
--`,,```,,,,````-`-`,,`,,`,`,,`---

Copyright American Welding Society


Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
Table 6-7—Shielding Gas
GMAW PQR Variables B2.1 D1.1 D1.5 ASME IX API 1104

The addition or deletion of torch shielding gas. Q Q Q


A change in shielding gas from a single gas to any other shielding gas or mixture of gas, or in the specified nominal
Q Q Q
composition of a gas mixture, or to no, and vice versa.
A change in shielding gas from a single gas to any other shielding gas or mixture of gases, or a change of more than
Q
25% in any of the minor elements of the gas mixture, or a change from a gas mixture to a single gas.
A change from one shielding gas to another or from one mixture of gases to another. Q
For M-10I, M-15, M-52, or M-61, base metal, a change in the nominal composition or a decrease of 15% in the root
Q
shielding flow rate.
The addition, deletion, or a change in composition, or a decrease exceeding 15% in the flow rate of root shielding gas
on single sided M-41 through M-46 groove joints and for all welds in M-51 through M-54, M-61 and M-62, M-10I, Q
M-10J, and M-10K.
For groove welds in P-No. M-41 through M-46 and all welds of P-No. M-51 through M-54, P-No. M-61 and M-62,
P-No. 10I, P-No 10J, and P-No. 10K metals, the deletion of backing gas or a change in the nominal composition of the Q
backing gas from an inert to a mixture including non-inert gas(es).
For M or P No-10I, M-51 through M-54, and M-61 and M-62, the deletion of, or a change in composition of, or a
Q Q
decrease exceeding 10% in the trailing gas flow rate.
A change in total gas flow rate by ≥25% increase; ≥10% decrease. Q
A change to a shielding gas not covered in ANSI/AWS A5.18 or A5.28. Q
A major increase or decrease in the range of flow rates for the shielding gas. Q
A change in total gas flow rate by ≥50% increase or ≥10% decrease. Q
For M-21 through M-27, an increase of 50% or more or a decrease of 20% or more of the torch shielding gas flow rate
Q
used in qualification.
Q = Variable requires requalification. T = Variable requires requalification when toughness testing is required.
--`,,```,,,,````-`-`,,`,,`,`,,`--- A = Variable requires requalification for automatic welding.

Copyright American Welding Society 67


Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
Table 6-8—Electrode
GMAW PQR Variables B2.1 D1.1 D1.5 ASME IX API 1104

A change in nominal electrode diameter by any increase or decrease. Q


An increase or decrease in electrode diameter by more than one standard size. T Q
A change in number of electrodes. Q Q
A change from single electrode to multiples electrodes in the same weld pool, and vice versa. For ASME IX
applications, this limitation does not apply when a WPS is qualified with a PWHT above the upper transformation T T
temperature or when an austenitic material is solution annealed after welding.
A change in electrode classification. Q
A change in electrode-shielding gas combination. Solid wire electrodes conforming to the same AWS filler metal
Q
classification may be interchanged without requalification (see Table 5.1 of D1.5).
Q = Variable requires requalification. T = Variable requires requalification when toughness testing is required. A = Variable requires requalification for automatic welding.

--`,,```,,,,````-`-`,,`,,`,`,,`---
68
Copyright American Welding Society
Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
Table 6-9—Electrical Characteristics
GMAW PQR Variables B2.1 D1.1 D1.5 ASME IX API 1104

An increase of heat input or volume of weld metal deposited per unit length of weld, over that qualified, except when
a grain refining austenitizing heat treatment is applied after welding. The increase may be measured by either of the
following:

Volts × Amps × 60 - T T T
(1) Heat Input (J/in.) = -----------------------------------------------------
Travel Speed (in./min)

(2)Weld metal volume—an increase in bead size, or a decrease in the length of weld bead per unit length of electrode.
A change in the mode of metal transfer from short circuiting to globular, spray, or pulsed and vice versa. Q Q Q Q
A change in the amperage for each diameter used by >10% increase or decrease. Q Q
A change in type of current (ac or dc) or polarity. Q Q T Q
A change in the voltage for each diameter used by >7% increase or decrease. Q Q
An increase or decrease in the wire feed speed for each electrode diameter (if not amperage controlled) by >10%. Q
A change in the travel speed (unless heat input control is required) by >25% increase or decrease. Travel speed ranges
for all sizes of fillet welds may be determined by the largest single pass fillet weld and the smallest multiple pass fillet Q
weld qualification tests.

--`,,```,,,,````-`-`,,`,,`,`,,`---
A change in the travel speed by >10% increase or decrease. Q
A change in the range for speed of travel. Q
An increase in heat input by >10%. This essential variable applies only when heat input control is a contract document
requirement. Heat input in joules per inch shall be calculated as 60EI/V where: E = PQR voltage, I = PQR amperage, Q
and V = PQR travel speed.
An increase in heat input by more than 10% or decrease of more than 30%. For M270M, (A 709M) Gr. 690, 690W,
Q
allowable heat input increase or decrease shall be limited to 10%.
A change in electrical characteristics. Q

Q = Variable requires requalification. T = Variable requires requalification when toughness testing is required. A = Variable requires requalification for automatic welding.

Copyright American Welding Society 69


Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
Table 6-10—Other
GMAW PQR Variables B2.1 D1.1 D1.5 ASME IX API 1104

A change in welding process. Q Q Q Q Q


A change between manual, semiautomatic, or automatic welding or any combination of these. Q
A change from multiple-pass per side to single pass per side. T T
A change from multiple-pass per side to single pass per side. This limitation does not apply when a WPS is qualified
with a PWHT above the upper transformation temperature or when an austenitic material is solution annealed after T
welding.
A change from a stringer bead to a weave bead in vertical uphill welding. For ASME IX applications, this limitation
does not apply when a WPS is qualified with a PWHT above the upper transformation temperature or when an T T T
austenitic material is solution annealed after welding.
For the PQR groove area, an increase or decrease >25% in the number of passes. For M270M (A 709M) Gr. 690,
690W, passes any change in the number of groove weld passes requires requalification, except proportional changes to
Q
accommodate a change in weld cross-sectional area. For fillet welds in these steels, any change in the number of
passes requires a fillet weld T-test per Figure 5.8 of D1.5 to be performed.
An increase in the maximum time between completion of the root bead and the start of the second bead. Q
A change exceeding ±20% in the oscillation variables for mechanized or automatic welding. T T
A change in the width, frequency, or dwell time of oscillation for machine or automatic welding only. T

Q = Variable requires requalification. T = Variable requires requalification when toughness testing is required. A = Variable requires requalification for automatic welding.

70
--`,,```,,,,````-`-`,,`,,`,`,,`---

Copyright American Welding Society


Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
Chapter 7—FCAW Procedure Qualification Variables
The tables in this chapter illustrate flux cored arc welding procedure The following legend applies to the five standards (AWS B2.1:2005,
qualification variables for the following criteria: AWS D1.1/D1.1M:2004, AASHTO/AWS D1.5M/D1.5:2002, 2001ASME
(1) Joint Design IX with 2003 Addenda, and API 1104 Twentieth Edition, 2005) used for
(2) Base Metal comparison in the tables:
(3) Filler Metal
(4) Position Q = Variable requires requalification
(5) Preheat and Interpass Temperature T = Variable requires requalification when toughness testing is required
(6) Postweld Heat Treatment A = Variable requires requalification for automatic welding
(7) Shielding Gas
(8) Electrode The tables should be regarded as illustrative only, since the various
(9) Electrical Characteristics standards are revised periodically.
(10) Other

--`,,```,,,,````-`-`,,`,,`,`,,`---

Copyright American Welding Society 71


Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
Table 7-1—Joint Design
FCAW PQR Variables B2.1 D1.1 D1.5 ASME IX API 1104

A change from a fillet to a groove weld. Q Q Q Q Q


A change in the M-Number of backing. Q
The addition of thermal backgouging on M-11, M-23, M-24, M-26, or M-27 heat-treatable base metal. Q
A change in groove type (e.g., single-V to double-V). Qualification of any CJP groove weld qualifies for any groove
Q
detail complying with the requirements of 3.12 or 3.13 of D1.1.
A change in the type of groove to a square groove and vice versa. Q Q
A major change in joint design (for example, from V groove to U groove). Minor changes in the angle of bevel or the
Q
land of the welding groove are not essential variables.
Any change beyond the range established in the procedure specification for such factors as spacing, root face, and angle
Q
of bevel.
A change exceeding the tolerances of 3.12, 3.13, 3.13.4, 5.22.4.1, or 5.22.4.2 of D1.1 involving:
(1) A decrease in the groove angle,
Q
(2) A decrease in the root opening,
(3) An increase in the root face.
A change exceeding the tolerances of 2.9, 2,10, or 3.3.4 of D1.5 in the shape of any type of groove involving:
(1) A decrease in the groove angle,
Q
(2) A decrease in the root opening,

--`,,```,,,,````-`-`,,`,,`,`,,`---
(3) An increase in the root face which will not be subsequently removed by backgouging.
The omission, but not inclusion, of backing or backgouging. Q Q
A change from U-groove to a V-groove (but not vice versa). Q

Q = Variable requires requalification. T = Variable requires requalification when toughness testing is required. A = Variable requires requalification for automatic welding.

72
Copyright American Welding Society
Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
Table 7-2—Base Metal
FCAW PQR Variables B2.1 D1.1 D1.5 ASME IX API 1104

A change from one M-Number to another M-Number or to an unlisted base metal, except as 2.3 of B2.1 permits. Q
A change from one P-Number to another P-Number or to an unassigned base metal, except as QW-424 of ASME IX
Q
permits.
A change of a Group Number within an M-Number. T
A change of a Group Number within a P-Number. T
A change from a joint between the same M-Numbers, to a joint between different M-Numbers or vice versa except as
permitted, or for M-Numbers 1, 3, 4, and 5 (of 3% max nom chromium), a procedure test with one M-Number shall Q
also qualify for that metal welded to each of the lower M-Number metals.
A change from M5A to M5B or M5C, and vice versa.
A change from M9A to M9B, but not vice versa.
Q
A change from M10A to M10B, M10C, M10F, M10H, M10I, M10J, or M10K, and vice versa.
A change from M11A to M11 B, and vice versa.
A change from P5A to P5B or P5C, and vice versa.
A change from P9A to P9B, but not vice versa. Q
A change from P10A to P10B, P10C, P10F, P10H, P10I, P10J, or P10K, and vice versa.
A change in base metals as specified in 4.7.3 of D1.1. Q
A change in base metal or combination of base metals not listed on the PQR or qualified by Table 4.7 of D1.1. Q
A change in base metal specification and grade as specified in 5.4 of D1.5. Q
A change in pipe material as specified in 12.5.2.2 of API 1104. Q
A change in wall-thickness group as specified in 12.5.2.4 of API 1104. Q
A change in base metal thickness beyond the range permitted in 2.5 of B2.1. Q
Q = Variable requires requalification. T = Variable requires requalification when toughness testing is required. A = Variable requires requalification for automatic welding.

--`,,```,,,,````-`-`,,`,,`,`,,`---

Copyright American Welding Society 73


Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
Table 7-2—Base Metal (Continued)
FCAW PQR Variables B2.1 D1.1 D1.5 ASME IX API 1104

A change in diameter, or thickness, or both not qualified by Table 4.2 of D1.1. Q


A change in base metal thickness beyond the range permitted in Table 5.2 of D1.5. Q
For M270M (A 709M) Gr. 690, 690W, increase in plate thickness greater than 12 mm or decrease of 25 mm or more. Q
A change in base metal thickness beyond the range qualified in QW-451 of ASME IX. Q
A change from an uncoated metal to a coated (such as painted or galvanized) metal unless the coating is removed from
Q
the weld area prior to welding, but not vice versa.
Each grade of base metal with a specified minimum yield strength of 65,000 psi requires a separate qualification test. Q
A change in wall thickness beyond the range qualified in the procedure specification. Q
A change in pipe diameter beyond the range established in the procedure specification. Q
The minimum thickness qualified is T or 5/8 in., whichever is less. However, where T is less than 1/4 in. the minimum is
1/2T. This limitation does not apply when a WPS is qualified with a PWHT above the upper transformation temperature T
or when an austenitic material is solution annealed after welding.
The minimum thickness qualified for thicknesses 5/8 in. or less is the thickness of the procedure qualification test plate. T
The minimum thickness qualified is T or 5/8 in., whichever is less, except that if T is less than 1/4 in., the minimum
T
thickness is 1/8 in.
Q = Variable requires requalification. T = Variable requires requalification when toughness testing is required. A = Variable requires requalification for automatic welding.

--`,,```,,,,````-`-`,,`,,`,`,,`---
74
Copyright American Welding Society
Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
Table 7-3—Filler Metals
FCAW PQR Variables B2.1 D1.1 D1.5 ASME IX API 1104

A change from one F-Number to any other F-Number or to any filler metal not listed in Annex III of B2.1. Q
A change from one F-Number in QW-432 of ASME IX to any other F-Number or to any other filler metal not listed
Q
in QW-432.
For ferrous materials, a change from one A-Number to any other A-Number or to a filler metal analysis not listed in
Annex C of B2.1 or QW-432 of ASME IX (the PQR and WPS shall state the nominal chemical composition or
Q Q
manufacturer’s designation for filler metals which do not fall into an A-Number group). Qualification with A-1 shall
qualify for A-2 and vice versa.
A change in AWS filler metal classification. T T Q T
A change from one filler-metal group to another as specified in Table 1 of API 1104. Q
For pipe materials with a specified minimum yield strength greater than or equal to 65,000 pounds per square inch
Q
(448.16 megapascals), a change in the AWS classification of the filler metal.
A change to an electrode or flux-electrode combination not covered in AWS A 5.20 or A5.29. Q
A change in the filler metal classification strength designator exceeding 10,000 psi, or to a filler metal classification
Q
strength designator less than the base metal tensile strength.
A change in manufacturer’s brand and type of cored electrode. T Q
An increase in filler metal classification strength. Q Q

--`,,```,,,,````-`-`,,`,,`,`,,`---
Addition or deletion of supplementary filler metal (powder or wire), or a change of 10% in the amount. T Q
A change from one electrode or flux-electrode classification listed to any other electrode or flux-electrode classification. Q
A change in the weld metal thickness beyond that permitted in 2.5 of B2.1 or QW-451 of ASME IX as applicable. Q Q

Q = Variable requires requalification. T = Variable requires requalification when toughness testing is required. A = Variable requires requalification for automatic welding.

Copyright American Welding Society 75


Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
Table 7-3—Filler Metals (Continued)
FCAW PQR Variables B2.1 D1.1 D1.5 ASME IX API 1104

A change in the filler metal classification within an SFA specification or to a filler metal not covered by an SFA
specification, or from one filler metal not covered by an SFA specification to another filler metal that is not covered by
an SFA specification.
When a filler metal conforms to a filler metal classification within an SFA specification, requalification is not required
if a change is made in any of the following:
from one diffusible hydrogen level to another
from one position-usability designation to another for flux-cored electrodes (i.e., a change from E70T-1 to E71T-1 or
T
vice versa
from a classification that requires impact testing to the same classification which has a suffix which indicates that
impact testing was performed at a lower temperature or exhibited greater toughness at the required temperature or both,
as compared to the classification which was used during procedure qualification
from the classification qualified to another filler metal within the same SFA specification when the weld metal is
exempt from Impact Testing by other sections
This exemption does not apply to hard-facing and corrosion-resistant overlays.
A change from one of the following filler metal product forms to another:
(1) Flux cored,
Q
(2) Bare (solid) or metal cored,
(3) Powder.
A change in the size of filler metal wire. Q

Q = Variable requires requalification. T = Variable requires requalification when toughness testing is required. A = Variable requires requalification for automatic welding.

--`,,```,,,,````-`-`,,`,,`,`,,`---
76
Copyright American Welding Society
Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
Table 7-4—Position
FCAW PQR Variables B2.1 D1.1 D1.5 ASME IX API 1104
A change from any position to the vertical position, uphill progression. Vertical uphill progression qualifies all positions. T T T
A change in position not qualified by Table 4.1 of D1.1. Q
A change from any position except that flat positions qualify for flat and horizontal welding. Q
Vertical welding: for any pass from uphill to downhill or vice versa. Q Q
Vertical welding shall be vertical up unless qualified by tests approved by the Engineer. Q
A change in position from roll to fixed, or vice versa. Q

Table 7-5—Preheat and Interpass Temperature


FCAW PQR Variables B2.1 D1.1 D1.5 ASME IX API 1104
A decrease in preheat of more than 100°F from that qualified. Q Q
An increase of more than 100°F in the maximum interpass temperature from that recorded on the PQR. For ASME IX
applications, this limitation does not apply when a WPS is qualified with a PWHT above the upper transformation T T T
temperature or when an austenitic material is solution annealed after welding.
A decrease from preheat temperature by >25°F. The production welding preheat or interpass temperature may be less
than the PQR preheat or interpass temperature provided that the provisions of 5.6 and Table 3.2 of D1.1 are met, and Q
the base metal temperature shall not be less than the PQR temperature at the time of subsequent welding.
A decrease from preheat temperature by >15°C. The production welding preheat or interpass temperature may be less
than the PQR preheat or interpass temperature provided that the provisions of Table 4.4 and Annex VIII of D1.5 are Q
met, and the base metal temperature shall not be less than the PQR temperature at the time of subsequent welding.
A increase in interpass temperature by >55°C. Q
A decrease from interpass temperature by >25°F. The production welding preheat or interpass temperature may be less
than the PQR preheat or interpass temperature provided that the provisions of 5.6 and Table 3.2 of D1.1 are met, and Q
the base metal temperature shall not be less than the PQR temperature at the time of subsequent welding.
A change in preheat requirements. Q

Q = Variable requires requalification. T = Variable requires requalification when toughness testing is required. A = Variable requires requalification for automatic welding.
--`,,```,,,,````-`-`,,`,,`,`,,`---

Copyright American Welding Society 77


Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
Table 7-6—Postweld Heat Treatment
FCAW PQR Variables B2.1 D1.1 D1.5 ASME IX API 1104

For the following M or P-Numbers 1, 3, 4, 5, 6, 9, 10, and 11 a change from any one condition to any other requires
requalification:
(1) No PWHT,
(2) PWHT below the lower transformation temperature,
Q Q
(3) PWHT within the transformation temperature range,
(4) PWHT above the upper transformation temperature,
(5) PWHT above the upper transformation temperature followed by treatment below the lower transformation
temperature.
Addition or deletion of PWHT. Q Q
The qualification test weldment shall be subjected to heat treatment essentially equivalent to that of the production
T T T
weldment, including at least 80% of the aggregate time at temperature.
A change in post-heat treatment requirements. Q

--`,,```,,,,````-`-`,,`,,`,`,,`---
Q = Variable requires requalification. T = Variable requires requalification when toughness testing is required. A = Variable requires requalification for automatic welding.

78
Copyright American Welding Society
Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
Table 7-7—Shielding Gas
FCAW PQR Variables B2.1 D1.1 D1.5 ASME IX API 1104
The addition or deletion of shielding gas. Q Q
A change in shielding gas from a single gas to any other shielding gas or mixture of gas, or in the specified nominal
Q Q Q
composition of a gas mixture, or to no gas.
A change in shielding gas from a single gas to any other shielding gas or mixture of gases, or a change of more than
Q
25% in any of the minor elements of the gas mixture, or a change from a gas mixture to a single gas.
A change from one shielding gas to another or from one mixture of gases to another. Q
A change in total gas flow rate by ≥50% increase; ≥10% decrease. Q
A change to a shielding gas not covered in AWS A5.20 or A5.29. Q
A change from external shielding to self shielding. Q
A major increase or decrease in the range of flow rates for the shielding gas. Q
A change in total gas flow rate by ≥25% increase; ≥10% decrease. Q
The addition, deletion, or change in composition, or a decrease of 15% in the flow rate of root shielding gas or single-
sided M-41 through M-46 single-sided groove welds.

Table 7-8—Electrode
FCAW PQR Variables B2.1 D1.1 D1.5 ASME IX API 1104
A change in nominal electrode diameter by any increase. Q
An increase or decrease in electrode diameter by more than one standard size. Q
A change in number of electrodes. Q Q
A change from single electrode to multiples electrodes in the same weld pool, and vice versa. For ASME IX
applications, this limitation does not apply when a WPS is qualified with a PWHT above the upper transformation Q T
temperature or when an austenitic material is solution annealed after welding.
A change in electrode classification. Q Q
A change in electrode-shielding gas combination. Q
Q = Variable requires requalification. T = Variable requires requalification when toughness testing is required. A = Variable requires requalification for automatic welding.
--`,,```,,,,````-`-`,,`,,`,`,,`---

Copyright American Welding Society 79


Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
Table 7-9—Electrical Characteristics
FCAW PQR Variables B2.1 D1.1 D1.5 ASME IX API 1104

An increase of heat input or volume of weld metal deposited per unit length of weld, over that qualified, except when
a grain refining austenitizing heat treatment is applied after welding. The increase may be measured by either of the
following:

Volts × Amps × 60 - T T T
(1) Heat Input (J/in.) = -----------------------------------------------------
Travel Speed (in./min)

(2) Weld metal volume—an increase in bead size, or a decrease in the length of weld bead per unit length of electrode.
A change in the mode of metal transfer from short circuiting to globular, spray, or pulsed and vice versa. Q Q
A change in the amperage for each diameter used by >10% increase or decrease. Q Q
A change in type of current (ac or dc) or polarity. Q Q T Q
A change in the voltage for each diameter used by >7% increase or decrease. Q Q
An increase or decrease in the wire feed speed for each electrode diameter (if not amperage controlled) by >10%. Q
A change in the travel speed (unless heat input control is required) by >25% increase or decrease. Travel speed ranges
for all sizes of fillet welds may be determined by the largest single pass fillet weld and the smallest multiple pass fillet Q

--`,,```,,,,````-`-`,,`,,`,`,,`---
weld qualification tests.
A change in the travel speed by >10% increase or decrease. Q
A change in the range for speed of travel. Q
An increase in heat input by >10%. This essential variable applies only when heat input control is a contract document
requirement. Heat input in joules per inch shall be calculated as 60EI/V where: E = PQR voltage, I = PQR amperage, Q
and V = PQR travel speed.
An increase in heat input by more than 10% or decrease of more than 30%. For M270M, (A 709M) Gr. 690, 690W,
Q
allowable heat input increase or decrease shall be limited to 10%.
A change in electrical characteristics. Q

Q = Variable requires requalification. T = Variable requires requalification when toughness testing is required. A = Variable requires requalification for automatic welding.

80
Copyright American Welding Society
Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
Table 7-10—Other
FCAW PQR Variables B2.1 D1.1 D1.5 ASME IX API 1104

A change in welding process. Q Q Q Q Q


A change between manual, semiautomatic, or automatic welding or any combination of these. Q
A change from multiple-pass per side to single pass per side. T T
A change from multiple-pass per side to single pass per side. This limitation does not apply when a WPS is qualified
with a PWHT above the upper transformation temperature or when an austenitic material is solution annealed after T
welding.
A change exceeding ±20% in the oscillation variables for mechanized or automatic welding. T T
A change from a stringer bead to a weave bead in vertical uphill welding. For ASME IX applications, this limitation
does not apply when a WPS is qualified with a PWHT above the upper transformation temperature or when an T T T

--`,,```,,,,````-`-`,,`,,`,`,,`---
austenitic material is solution annealed after welding.
For the PQR groove area, an increase or decrease >25% in the number of passes. For M270M (A 709M) Gr. 690,
690W, passes any change in the number of groove weld passes requires requalification, except proportional changes
Q
to accommodate a change in weld cross-sectional area. For fillet welds in these steels, any change in the number of
passes requires a fillet weld T-test per Figure 5.8 of D1.5 to be performed.
An increase in the maximum time between completion of the root bead and the start of the second bead. Q
A change in the width, frequency, or dwell time of oscillation for machine or automatic welding only. T

Q = Variable requires requalification. T = Variable requires requalification when toughness testing is required. A = Variable requires requalification for automatic welding.

Copyright American Welding Society 81


Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
Notes

82
--`,,```,,,,````-`-`,,`,,`,`,,`---

Copyright American Welding Society


Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
Chapter 8—GTAW Procedure Qualification Variables
The tables in this chapter illustrate gas tungsten arc welding procedure The following legend applies to the five standards (AWS B2.1:2005,
qualification variables for the following criteria: AWS D1.1/D1.1M:2004, AASHTO/AWS D1.5M/D1.5:2002, 2001ASME
(1) Joint Design IX with 2003 Addenda, and API 1104 Twentieth Edition, 2005) used for
(2) Base Metal comparison in the tables:
(3) Filler Metal
(4) Position Q = Variable requires requalification
(5) Preheat and Interpass Temperature T = Variable requires requalification when toughness testing is required
(6) Postweld Heat Treatment A = Variable requires requalification for automatic welding
(7) Shielding Gas
(8) Electrode The tables should be regarded as illustrative only, since the various
(9) Electrical Characteristics standards are revised periodically.
(10) Other

--`,,```,,,,````-`-`,,`,,`,`,,`---

Copyright American Welding Society 83


Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
Table 8-1—Joint Design
GTAW PQR Variables B2.1 D1.1 D1.5 ASME IX API 1104

A change from a fillet to a groove weld. Q Q Q Q Q


A change in the M-Number of backing. Q
The addition of thermal backgouging on M-11, M-23, M-24, M-26, and M-27 heat-treatable base metal. Q
A change in groove type (e.g., single-V to double-V). Qualification of any CJP groove weld qualifies for any groove
Q
detail complying with the requirements of 3.12 or 3.13 of D1.1.
--`,,```,,,,````-`-`,,`,,`,`,,`---

A major change in joint design (for example, from V groove to U groove). Minor changes in the angle of bevel or the
Q
land of the welding groove are not essential variables.
Any change beyond the range established in the procedure specification for such factors as spacing, root face, and
Q
angle of bevel.
A change in the type of groove to a square groove and vice versa. Q
A change exceeding the tolerances of 3.12, 3.13, 3.13.4, 5.22.4.1, or 5.22.4.2 of D1.1 involving:
(1) A decrease in the groove angle,
Q
(2) A decrease in the root opening,
(3) An increase in the root face.
The omission, but not inclusion, of backing or backgouging. Q

Q = Variable requires requalification. T = Variable requires requalification when toughness testing is required. A = Variable requires requalification for automatic welding.

84
Copyright American Welding Society
Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
Table 8-2—Base Metal
GTAW PQR Variables B2.1 D1.1 D1.5 ASME IX API 1104

A change from one M-Number to another M-Number or to an unlisted base metal, except as 2.3 of B2.1 permits. Q
--`,,```,,,,````-`-`,,`,,`,`,,`---

A change from one P-Number to another P-Number or to an unassigned base metal, except as QW-424 of ASME IX
Q
permits.
A change of a Group Number within an M-Number. T
A change of a Group Number within a P-Number. T
A change from a joint between the same M-Numbers, to a joint between different M-Numbers or vice versa except as
permitted, or for M-Numbers 1, 3, 4, and 5 (of 3% max nom chromium), a procedure test with one M-Number shall Q
also qualify for that metal welded to each of the lower M-Number metals.
A change from M5A to M5B or M5C, and vice versa.
A change from M9A to M9B, but not vice versa.
Q
A change from M10A to M10B, M10C, M10F, M10H, M10I, M10J, or M10K, and vice versa.
A change from M11A to M11 B, and vice versa.
A change from P5A to P5B or P5C, and vice versa.
A change from P9A to P9B, but not vice versa. Q
A change from P10A to P10B, P10C, P10F, P10H, P10I, P10J, or P10K, and vice versa.
A change in base metals as specified in 4.7.3 of D1.1. Q
A change in base metal or combination of base metals not listed on the PQR or qualified by Table 4.7 of D1.1. Q
A change in pipe material as specified in 12.5.2.2 of API 1104. Q
A change in wall-thickness group as specified in 12.5.2.4 of API 1104. Q
A change in base metal thickness beyond the range permitted in 2.5 of B2.1. Q
Q = Variable requires requalification. T = Variable requires requalification when toughness testing is required. A = Variable requires requalification for automatic welding.

Copyright American Welding Society 85


Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
Table 8-2—Base Metal (Continued)
GTAW PQR Variables B2.1 D1.1 D1.5 ASME IX API 1104

A change in diameter, or thickness, or both not qualified by Table 4.2 of D1.1. Q


A change in base metal thickness beyond the range qualified in QW-451 of ASME IX. Q
A change from an uncoated metal to a coated (such as painted or galvanized) metal unless the coating is removed from
Q
the weld area prior to welding, but not vice versa.
Each grade of base metal with a specified minimum yield strength of 65,000 psi requires a separate qualification test. Q
A change in wall thickness beyond the range qualified in the procedure specification. Q
A change in pipe diameter beyond the range established in the procedure specification. Q
The minimum thickness qualified is T or 5/8 in., whichever is less. However, where T is less than 1/4 in. the minimum is
1/2T. This limitation does not apply when a WPS is qualified with a PWHT above the upper transformation temperature T
or when an austenitic material is solution annealed after welding.
The minimum thickness qualified for thicknesses 5/8 in. or less is the thickness of the procedure qualification test plate. T
The minimum thickness qualified is T or 5/8 in., whichever is less, except that if T is less than 1/4 in., the minimum
T
thickness is 1/8 in.

Q = Variable requires requalification. T = Variable requires requalification when toughness testing is required. A = Variable requires requalification for automatic welding.

--`,,```,,,,````-`-`,,`,,`,`,,`---
86
Copyright American Welding Society
Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
Table 8-3—Filler Metals
GTAW PQR Variables B2.1 D1.1 D1.5 ASME IX API 1104
A change from one F-Number to any other F-Number or to any filler metal not listed in Annex III of B2.1. Q
A change from one F-Number in QW-432 of ASME IX to any other F-Number or to any other filler metal not listed
Q
in QW-432.
For ferrous materials, a change from one A-Number to any other A-Number or to a filler metal analysis not listed in
Annex III of B2.1 or QW-432 of ASME IX (the PQR and WPS shall state the nominal chemical composition or
Q Q
manufacturer’s designation for filler metals which do not fall into an A-Number group). Qualification with A-1 shall
qualify for A-2 and vice versa.
A change from one filler-metal group to another as specified in Table 1 of API 1104. Q
For pipe materials with a specified minimum yield strength greater than or equal to 65,000 pounds per square inch
Q
(448.16 megapascals), a change in the AWS classification of the filler metal.
A change in AWS filler metal classification. T
A change to an electrode or flux-electrode combination not covered in AWS A5.18 or A5.28. Q
A change in the filler metal classification strength designator exceeding 10,000 psi, or to a filler metal classification
Q
strength designator less than the base metal tensile strength.
The addition or deletion of filler material. Q Q Q
The addition or deletion of supplementary filler metal (powder or wire), or a change of 10% in the amount. T
A change from one electrode or flux-electrode classification listed to any other electrode or flux-electrode classification. Q
A change in the weld metal thickness beyond that permitted in 2.5 of B2.1 or QW-408.3 of ASME IX as applicable. Q Q
A change from cold wire feed to hot wire feed or vice versa. Q
A change in the SFA specification filler metal classification or to a filler metal not covered by an SFA specification,
or from one filler metal not covered by an SFA specification to another which is not covered by an SFA specification.
T
When a filler metal conforms to an SFA specification, requalification is not required if a change is made to any of the
conditions listed in QW-404.12 of ASME IX.
A change from one of the following filler metal product forms to another:
(1) Flux cored,
Q
(2) Bare (solid) or metal cored,
(3) Powder.
A change in the size of filler metal wire. A
Q = Variable requires requalification. T = Variable requires requalification when toughness testing is required. A = Variable requires requalification for automatic welding.
--`,,```,,,,````-`-`,,`,,`,`,,`---

Copyright American Welding Society 87


Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
Table 8-4—Position
GTAW PQR Variables B2.1 D1.1 D1.5 ASME IX API 1104
--`,,```,,,,````-`-`,,`,,`,`,,`---

A change from any position to the vertical position, uphill progression. Vertical uphill progression qualifies all positions. T T T
A change in position not qualified by Table 4.1 of D1.1. Q
Vertical welding: for any pass from uphill to downhill or vice versa. Q Q
A change in position from roll to fixed, or vice versa. Q

Table 8-5—Preheat and Interpass Temperature


GTAW PQR Variables B2.1 D1.1 D1.5 ASME IX API 1104

A decrease in preheat of more than 100°F from that qualified. Q Q Q


An increase of more than 100°F in the maximum interpass temperature from that recorded on the PQR. For ASME IX
applications, this limitation does not apply when a WPS is qualified with a PWHT above the upper transformation T T T
temperature or when an austenitic material is solution annealed after welding.
A decrease from preheat temperature by >100°F. The production welding preheat or interpass temperature may be less
than the PQR preheat or interpass temperature provided that the provisions of 5.6 and Table 3.2 of D1.1 are met, and Q
the base metal temperature shall not be less than the PQR temperature at the time of subsequent welding.
A decrease from interpass temperature by >100°F. The production welding preheat or interpass temperature may be less
than the PQR preheat or interpass temperature provided that the provisions of 5.6 and Table 3.2 of D1.1 are met, and Q
the base metal temperature shall not be less than the PQR temperature at the time of subsequent welding.
A change in preheat requirements. Q
For M-23, M-24, M-26, and M-27, an increase in preheat or interpass temperature of more than 100°F above that
Q
qualified.

Q = Variable requires requalification. T = Variable requires requalification when toughness testing is required. A = Variable requires requalification for automatic welding.

88
Copyright American Welding Society
Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
--`,,```,,,,````-`-`,,`,,`,`,,`---
Table 8-6—Postweld Heat Treatment
GTAW PQR Variables B2.1 D1.1 D1.5 ASME IX API 1104
For the following M or P-Numbers 1, 3, 4, 5, 6, 9, 10, and 11 a change from any one condition to any other requires
requalification:
(1) No PWHT,
(2) PWHT below the lower transformation temperature,
Q Q
(3) PWHT within the transformation temperature range,
(4) PWHT above the upper transformation temperature,
(5) PWHT above the upper transformation temperature followed by treatment below the lower transformation
temperature.
A separate PQR is required for no PWHT and PWHT. Q Q Q
The qualification test weldment shall be subjected to heat treatment essentially equivalent to that of the production
Q T
weldment, including at least 80% of the aggregate time at temperature.
A change in post-heat treatment requirements. Q

Table 8-7—Shielding Gas


GTAW PQR Variables B2.1 D1.1 D1.5 ASME IX API 1104
The addition or deletion of shielding gas. Q Q Q
A change in shielding gas from a single gas to any other shielding gas or mixture of gas, or in the specified nominal
Q Q Q
composition of a gas mixture, or to no gas, and vice versa.
For M-10I, M-51, M-52, or M-61 base metal, a change in the nominal composition or a decrease of 15% in the root
Q
shielding flow rate.
The addition, deletion, or a change in composition, or a decrease exceeding 15% in the flow rate of root shielding gas
on single sided M-41 through M-46 groove joints and for all welds in M-51 through M-54, M-61 and M-62, M-10I, Q
M-10J, and M-10K.
Q = Variable requires requalification. T = Variable requires requalification when toughness testing is required. A = Variable requires requalification for automatic welding.

Copyright American Welding Society 89


Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
Table 8-7—Shielding Gas (Continued)
GTAW PQR Variables B2.1 D1.1 D1.5 ASME IX API 1104
For groove welds in P-No. M-41 through M-46 and all welds of P-No. M-51 through M-54, P-No. M-61 and M-62,
P-No. 10I, P-No 10J, and P-No. 10K metals, the deletion of backing gas or a change in the nominal composition of the Q
backing gas from an inert to a mixture including non-inert gas(es).
For M or P No-10I, M-51 through M-54, and M-61 and M-62, the deletion of, or a change in composition of, or a
Q Q
decrease exceeding 10% in the trailing gas flow rate.
A change in total gas flow rate by ≥50% increase; ≥20% decrease.
A major increase or decrease in the range of flow rates for the shielding gas. Q
For M-21 through M-27, an increase of 50% or more or a decrease of 20% or more of the torch shielding gas flow rate
Q
used in qualification.
The addition or deletion of trailing shielding gas or a change in composition. T
A change in the specified flow rate range of the shielding gas or mixture of gases. T
The addition or deletion of gas backing, a change in the backing gas composition, or a change in the specified flow rate
T
range of the backing gas.
For P10I, P-10J, P-10K, P-51 through P-53 and P-61 and P-62, the deletion of trailing shielding gas, or a change in the
Q
nominal composition of the trailing gas(es) or a decrease of 10% or more in the trailing gas flow rate.
For groove welds in P-41 through P-46 and all welds of P-10I, P-10J, P-10K, P-51 through P-53, P-61 and P-62, the
deletion of backing gas or a change in the nominal composition of the backing gas from an inert gas to a mixture includ- Q
ing non-inert gas(es).
A change from one shielding gas to another. Q
Q = Variable requires requalification. T = Variable requires requalification when toughness testing is required. A = Variable requires requalification for automatic welding.

--`,,```,,,,````-`-`,,`,,`,`,,`---
90
Copyright American Welding Society
Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
--`,,```,,,,````-`-`,,`,,`,`,,`---
Table 8-8—Electrode
GTAW PQR Variables B2.1 D1.1 D1.5 ASME IX API 1104
A change in nominal electrode diameter by >1/16 in. increase or decrease. Q
A change from single electrode to multiples electrodes in the same weld pool, and vice versa. For ASME IX
applications, this limitation does not apply when a WPS is qualified with a PWHT above the upper transformation T T
temperature or when an austenitic material is solution annealed after welding.
A change in tungsten electrode type as shown in AWS A5.12. Q

Table 8-9—Electrical Characteristics


GTAW PQR Variables B2.1 D1.1 D1.5 ASME IX API 1104
An increase of heat input or volume of weld metal deposited per unit length of weld, over that qualified, except when
a grain refining austenitizing heat treatment is applied after welding. The increase may be measured by either of the
following:
Volts × Amps × 60 - T T T
(1) Heat Input (J/in.) = -----------------------------------------------------
Travel Speed (in./min)
(2) Weld Metal Volume—An increase in bead size, or a decrease in the length of weld bead per unit length of electrode.
A change in the amperage for each diameter used by >25% increase or decrease. Q
A change in type of current (ac or dc) or polarity. T Q
A change in the voltage for each diameter used by >25% increase or decrease. Q
A change in the travel speed (unless heat input control is required) by >50% increase or decrease. Q
Any increase in heat input. This essential variable applies only when CVN tests are required, or when heat input control
is a contract document requirement. Heat input in joules per inch shall be calculated as 60EI/V where: E = PQR voltage, Q
I = PQR amperage, and V = PQR travel speed.
A change in electrical characteristics. Q
A change in the range of speed of travel. Q
Q = Variable requires requalification. T = Variable requires requalification when toughness testing is required. A = Variable requires requalification for automatic welding.

Copyright American Welding Society 91


Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
Table 8-10—Other
GTAW PQR Variables B2.1 D1.1 D1.5 ASME IX API 1104

A change in welding process. Q Q Q Q


A change from multiple-pass per side to single pass per side. T T
A change from multiple-pass per side to single pass per side. This limitation does not apply when a WPS is qualified
with a PWHT above the upper transformation temperature or when an austenitic material is solution annealed after T
welding.
A change exceeding ±20% in the oscillation variables for mechanized or automatic welding. T T T
A change from a stringer bead to a weave bead in vertical uphill welding. For ASME IX applications, this limitation
does not apply when a WPS is qualified with a PWHT above the upper transformation temperature or when an T T T
austenitic material is solution annealed after welding.
An increase in the maximum time between the completion of the root bead and the start of the second bead. Q
A change among manual, semiautomatic welding, or automatic welding of any combination of these. Q

--`,,```,,,,````-`-`,,`,,`,`,,`---
92
Copyright American Welding Society
Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
Chapter 9—Terms and Definitions Related to Welding Procedure Specifications and Procedure Qualifications
These terms and definitions are derived from AWS A3.0:2001, Standard As-welded, adj. Pertaining to the condition of weld metal, welded joints,
Welding Terms and Definitions, Including Terms for Adhesive Bonding, Braz- and weldments after welding, but prior to any subsequent thermal,
ing, Soldering, Thermal Cutting, and Thermal Spraying, unless indicated ( ) mechanical, or chemical treatments.
as AWS (D1.1), Structural Welding Code—Steel, AWS (D1.5), Bridge Weld-
Autogenous weld. A fusion weld made without filler metal.
ing Code, AWS (B2.1), Specification for Welding Procedure and Perfor-
mance Qualification, (API 1104), Welding of Pipelines and Related Facilities, Automatic welding. Welding with equipment that requires only occa-
or ASME Boiler and Pressure Vessel Code (Section IX), Welding and Braz- sional or no observation of the welding, and no manual adjustment of
ing Qualifications. Note: The standards referenced are revised periodically. the welding equipment. See also Manual welding, Mechanized weld-
Active flux, submerged arc welding. A flux formulated to produce a weld ing, and Semiautomatic welding.
metal composition that is dependent on the welding parameters, Automatic welding (API 1104). Arc welding with equipment that per-
especially arc voltage. forms the entire welding operation without manual manipulation of the
Active flux, submerged arc welding (D1.5). A flux which contains small arc or electrode other than guiding or tracking and without a manual
amounts of manganese or silicon, or both, added to improve the weld in welding-skill requirement of the operator.
certain single pass applications. Change in arc voltage or the number of A-Number (B2.1). A designation used to classify ferrous weld metal for
weld passes can significantly change weld metal chemistry and procedure qualification based upon chemical composition.
mechanical properties.
Alloy flux, submerged arc welding (D1.1). A flux upon which the alloy Backgouging. The removal of weld metal and base metal from the weld
content of the weld metal is largely dependent. root side of a welded joint to facilitate fusion and complete joint pene-
tration upon subsequent welding from that side.
Alloy flux, submerged arc welding (D1.5). A flux which contains alloy
ingredients intended to modify the weld metal chemistry. Changes in Backing. A material or device placed against the back side of the joint,
arc voltage can significantly change weld metal chemistry. adjacent to the root or at both sides of a joint in electroslag and electro-

--`,,```,,,,````-`-`,,`,,`,`,,`---
Alloy. A substance with metallic properties and composed of two or more gas welding, to support and shield molten weld metal. The material may
chemical elements of which at least one is a metal. be partially fused or remain unfused during welding and may be either
metal or nonmetal. See Figure 9-1.
Arc voltage, arc welding. The electrical potential between the electrode
and workpiece. Base material. The material that is welded, brazed, soldered, or cut.

Copyright American Welding Society 93


Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
Consumable insert. Filler metal that is placed at the joint root before
welding, and is intended to be completely fused into the joint root to
become part of the weld.
Covered electrode. A composite filler metal electrode consisting of a core
of a bare electrode or metal cored electrode to which a covering suffi-
cient to provide a slag layer on the weld metal has been applied. The
covering may contain materials providing such functions as shielding
from the atmosphere, deoxidation, and arc stabilization, and can serve
as a source of metallic additions to the weld.
Deposited metal. Filler metal that has been added during brazing, solder-
ing, or welding.
Dilution. The change in chemical composition of a welding filler metal
caused by the admixture of the base metal or previous weld metal in the
weld bead. It is measured by the percentage of base metal or previous
weld metal in the weld bead. See Figure 9-3.
Direct current electrode negative. Abbreviated as DCEN. The arrange-
ment of direct current arc welding leads in which the electrode is the
Figure 9-1—Single V-Groove Weld with Backing negative pole and workpiece is the positive pole of the welding arc. See
Figure 9-4.
Base metal. The metal or alloy that is welded, brazed, soldered, or cut. Direct current electrode positive. Abbreviated as DCEP. The arrange-
ment of the direct current arc welding leads in which the electrode is the
Base metal test specimen. A test specimen composed wholly of base metal.
positive pole and the workpiece is the negative pole of the welding arc.
Bend test. A test in which a specimen is bent to a specified bend radius. See Figure 9-5.
Bevel angle. The angle between the bevel of a joint member and a plan Downhill, adv. Welding with a downward progression.

--`,,```,,,,````-`-`,,`,,`,`,,`---
perpendicular to the surface of the member. See Figure 9-2. Edge preparation. The preparation of the edges of the joint members, by
Consumable electrode. An electrode that provides filler metal. cutting, cleaning, plating, or other means.

94
Copyright American Welding Society
Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
--`,,```,,,,````-`-`,,`,,`,`,,`---

Figure 9-2—Bevel Angle, Depth of Bevel,


Groove Angle, Groove Radius, and Root Opening

Copyright American Welding Society 95


Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
Figure 9-2 (Continued)—Bevel Angle, Depth of Bevel, Groove Angle, Groove Radius, and Root Opening

96 --`,,```,,,,````-`-`,,`,,`,`,,`---

Copyright American Welding Society


Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
--`,,```,,,,````-`-`,,`,,`,`,,`---
Figure 9-3—Dilution

Copyright American Welding Society 97


Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
--`,,```,,,,````-`-`,,`,,`,`,,`---
Figure 9-4—Direct Current Electrode NEGATIVE

98
Copyright American Welding Society
Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
Figure 9-5—Direct Current Electrode POSITIVE

--`,,```,,,,````-`-`,,`,,`,`,,`---

Copyright American Welding Society 99


Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
Electrode extension (FCAW, EGW, GMAW, SAW). The length of
electrode extending beyond the end of the contact tip.
--`,,```,,,,````-`-`,,`,,`,`,,`---
Face bend test. A test in which the weld face is on the convex surface of a
specified bend radius.
Filler material. The material added in making a welded, brazed, or
soldered joint.
Filler metal. The metal or alloy to be added in making a welded, brazed, or
soldered joint.
F-Number (B2.1). A designation used to group welding filler metal for Figure 9-6—Multiple Welding Test Position—5F
procedure and performance qualifications.
5F. A welding test position designation for a circumferential fillet weld
applied to a joint in pipe, with its axis approximately horizontal, in
which the weld is made in the horizontal, vertical, and overhead weld-
ing positions. The pipe remains fixed until the welding of the joint is
complete. See Figure 9-6.
5G. A welding test position designation for a circumferential groove weld
applied to a joint in a pipe with its axis horizontal, in which the weld is
made in the flat, vertical, and overhead welding positions. The pipe
remains fixed until the welding of the joint is complete. See Figure 9-7.
Flat welding position. The welding position used to weld from the upper
side of the joint at a point where the weld axis is approximately hori-
zontal, and the weld face lies in an approximately horizontal plane. See
Figures 9-8 through 9-14.
Flux. A material used to hinder or prevent the formation of oxides and other
undesirable substances in molten metal and on solid metal surfaces, and
to dissolve or otherwise facilitate the removal of such substances. Figure 9-7—Multiple Welding Test Position—5G

100
Copyright American Welding Society
Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
Tabulation of Positions of Groove Welds
Position Diagram Reference Inclination of Axis Rotation of Face
Flat A 0° to 15° 150° to 210°
80° to 150°
Horizontal B 0° to 15°
210° to 280°
0° to 80°
Overhead C 0° to 80°
280° to 360°
D 15° to 80° 80° to 280°
Vertical
E 80° to 90° 0° to 360°

Notes:
1. The horizontal reference plane is always taken to lie below the weld under
consideration.
2. The inclination of the weld axis is measured from the horizontal reference
plane toward the vertical reference plane.
3. The angle of rotation of the weld face is determined by a line perpendicular
to the weld face at its center which passes through the weld axis. The refer-
ence position (0°) of rotation of the weld face invariably points in the
direction opposite to that in which the axis angle increases. When looking
at point P, the angle of rotation of the weld face is measured in a clockwise
direction from the reference position (0°).

--`,,```,,,,````-`-`,,`,,`,`,,`---
Figure 9-8—Welding Position Diagram for Groove Welds in Plate
Copyright American Welding Society 101
Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
Tabulation of Positions of Fillet Welds
Position Diagram Reference Inclination of Axis Rotation of Face
Flat A 0° to 15° 150° to 210°
125° to 150°
Horizontal B 0° to 15°
210° to 235°
0° to 125°
Overhead C 0° to 80°
235° to 360°
D 15° to 80° 125° to 235°
Vertical
E 80° to 90° 0° to 360°

Notes:
1. The horizontal reference plane is always taken to lie below the weld under
--`,,```,,,,````-`-`,,`,,`,`,,`---

consideration.
2. The inclination of the weld axis is measured from the horizontal reference
plane toward the vertical reference plane.
3. The angle of rotation of the weld face is determined by a line perpendicular
to the weld face at its center which passes through the weld axis. The refer-
ence position (0°) of rotation of the weld face invariably points in the
direction opposite to that in which the axis angle increases. When looking
at point P, the angle of rotation of the weld face is measured in a clockwise
direction from the reference position (0°).

Figure 9-9—Welding Position Diagram for Fillet Welds in Plate


102
Copyright American Welding Society
Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
--`,,```,,,,````-`-`,,`,,`,`,,`---
Figure 9-10—Welding Position for Groove Welds in Pipe

Copyright American Welding Society 103


Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
--`,,```,,,,````-`-`,,`,,`,`,,`---

Figure 9-11—Flat Welding Test Position—1G

Figure 9-12—Flat Welding Test Position—1F

104
Copyright American Welding Society
Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
Flux cored arc welding. Abbreviated as FCAW. An arc welding process
that uses an arc between a continuous filler metal electrode and the
weld pool. The process is used with shielding gas from a flux
contained within the tubular electrode, with or without additional
shielding from an externally supplied gas, and without the application
of pressure.

Flux cored arc welding (Section IX). A gas metal arc welding process that
uses an arc between a continuous filler metal electrode and the weld
pool. Shielding is provided by a flux contained within the tubular elec-
trode with or without additional shielding from an externally supplied
gas and without the application of pressure.
--`,,```,,,,````-`-`,,`,,`,`,,`---

Figure 9-13—Flat Welding Test Position—1G Flux cored electrode. A composite tubular filler metal electrode consist-
ing of a metal sheath and a core of various powdered materials, produc-
ing an extensive slag cover on the face of a weld bead.

4F, plate. A welding test position designation for a linear fillet weld
applied to a joint in which the weld is made in the overhead welding
position. See Figure 9-15.

4F, pipe. A welding test position designation for a circumferential fillet


weld applied to a joint in pipe, with its axis vertical, in which the weld
is made in the overhead welding position. See Figure 9-16.

4G. A welding test position designation for a linear groove weld applied to
a joint in which the weld is made in the overhead welding position. See
Figure 9-14—Flat Welding Test Position—1F Figure 9-17.

Copyright American Welding Society 105


Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
Figure 9-16—Overhead Welding Test Position—4F

Figure 9-15—Overhead Welding Test Position—4F Figure 9-17—Overhead Welding Test Position—4G

--`,,```,,,,````-`-`,,`,,`,`,,`---
106
Copyright American Welding Society
Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
Gas metal arc welding. Abbreviated as GMAW. An arc welding process
that uses an arc between a continuous filler metal electrode and the weld
pool. The process is used with shielding from an externally supplied gas
and without the application of pressure.

Gas metal arc welding (Section IX). An arc welding process that uses an
arc between a continuous filler metal electrode and the weld pool. The
process is used with shielding from an externally supplied gas and with-
out the application of pressure.

Gas shielded flux cored arc welding. Abbreviated as FCAW-G. A flux


cored arc welding process variation in which shielding gas is supplied
through the gas nozzle, in addition to that obtained from the flux within
the electrode.

Gas tungsten arc welding. Abbreviated as GTAW. An arc welding pro-


cess that uses an arc between a tungsten electrode (nonconsumable) and
the weld pool. The process is used with shielding gas and without the
application of pressure.

Globular transfer, gas metal arc welding. The transfer of molten metal in
large drops from a consumable electrode across the arc. See Figure 9-18. Figure 9-18—Globular Transfer

Groove angle. The included angle between the groove faces of a weld
groove. See Figure 9-2.
Horizontal welding position, fillet weld. The welding position in which
Heat-affected zone. Abbreviated as HAZ. The portion of the base metal the weld is on the upper side of an approximately horizontal surface and
whose mechanical properties or microstructure have been altered by the against an approximately vertical surface. See Figures 9-9 and 9-19
heat of welding, brazing, soldering, or thermal cutting. through 9-21.
--`,,```,,,,````-`-`,,`,,`,`,,`---

Copyright American Welding Society 107


Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
Figure 9-20—Horizontal Welding Test Position—2F

--`,,```,,,,````-`-`,,`,,`,`,,`---
Figure 9-19—Horizontal Welding Test Position—2F Figure 9-21—Horizontal Welding Test Position—2FR

108
Copyright American Welding Society
Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
Horizontal welding position, groove weld. The welding position in which
the weld face lies in an approximately vertical plane and the weld axis
at the point of welding is approximately horizontal. See Figures 9-8,
9-10, 9-22, and 9-23.
Interpass temperature, welding. In a multipass weld, the temperature of
the weld area between weld passes. See also Preheat temperature.
Longitudinal weld test specimen. A weld test specimen with its major
axis parallel to the weld axis.

--`,,```,,,,````-`-`,,`,,`,`,,`---
Figure 9-22—Horizontal Welding Test Position—2G Figure 9-23—Horizontal Welding Test Position—2G

Copyright American Welding Society 109


Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
Machine welding. A nonstandard term when used for Mechanized 1F, plate. A welding test position designation for a linear fillet weld
welding. applied to a joint in which the weld is made in the flat welding position.
See Figure 9-12.
Manual welding. Welding with the torch, gun, or electrode holder held
and manipulated by hand. Accessory equipment, such as part motion 1G, pipe. A welding test position designation for a circumferential groove
devices and manually controlled filler material feeders may be used. weld applied to a joint in pipe, in which the weld is made in the flat
See also Automatic welding, Mechanized welding, and Semiauto- welding position by rotating the pipe about its axis. See Figure 9-13.
matic welding.
Open circuit voltage. The voltage between the output terminals of the
Mechanized welding. Welding with equipment that requires manual power source when no current is flowing to the torch or gun.
adjustment of the equipment controls in response to visual observation
of the welding, with the torch, gun, or electrode holder held by a Open root joint. An unwelded joint without backing or consumable insert.
mechanical device. See also Automatic welding, Manual welding, Overhead welding position. The welding position in which welding is
and Semiautomatic welding. performed from the underside of the joint. See Figures 9-8 through 9-10
--`,,```,,,,````-`-`,,`,,`,`,,`---

M-Number (B2.1). A designation used to group base metals for procedure and 9-15 through 9-17.
and performance qualifications consistent with the P-Number and Postheating. The application of heat to an assembly after brazing, solder-
S-Number designations established by the ASME Boiler and Pressure ing, thermal spraying, thermal cutting, or welding,.
Vessel Code, Section IX, but which also incorporate materials not rec-
ognized or used under ASME rules. Position welding (API 1104). Welding in which the pipe or assembly is
held stationary.
Neutral flux, submerged arc welding. A flux formulated to produce a weld
metal composition that is not dependent on the welding parameters, Preheat temperature, welding. The temperature of the base metal in the
especially arc voltage. volume surrounding the point of welding immediately before welding is
started. In a multipass weld, it is also the temperature immediately
Nonconsumable electrode. An electrode that does not provide filler metal. before the second and subsequent passes are started.
1F, pipe. A welding test position designation for a circumferential fillet Prequalified welding procedure specification. A welding procedure
weld applied to a joint in pipe, with its axis approximately 45° from the specification that complies with the stipulated conditions of a particular
horizontal, in which the weld is made in the flat welding position by welding code or specification and is therefore acceptable for use under
rotating the pipe about its axis. See Figure 9-14. that code or specification without a requirement for qualification testing.

110
Copyright American Welding Society
Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
Procedure. The detailed elements of a process or method used to produce Reverse polarity. A nonstandard term for direct current electrode
a specific result. positive.

Procedure qualification. The demonstration that welds made by a specific Roll welding (API 1104). Welding in which the pipe or assembly is rotated
procedure can meet prescribed standards. while the weld metal is deposited at or near the top center.

Procedure Qualification Record (B2.1). Abbreviated as PQR. A written Root bend test. A test in which the weld root is on the convex surface of a
record of welding variables used to produce an acceptable test weld- specified bend radius.
ment and the results of tests conducted on that weldment to qualify a
welding procedure specification. Self-shielded flux cored arc welding. Abbreviated as FCAW-S. A flux
cored arc welding process variation in which shielding gas is obtained
Procedure qualification variable (B2.1). A controllable detail which if exclusively from the flux within the electrode.
changed beyond the limits of 2.14 Procedure Qualification Variables,
requires requalification of the WPS. Semiautomatic welding. Manual welding with equipment that automati-
cally controls one or more of the welding conditions. See also Auto-
Pulsed gas metal arc welding. Abbreviated as GMAW-P. A gas metal arc matic welding, Manual welding, and Mechanized welding.
welding process variation in which the current is pulsed.
Semiautomatic welding (D1.5, API 1104). Arc welding with equipment
Pulsed gas tungsten arc welding. Abbreviated as GTAW-P. A gas tung- that controls only the filler metal feed. The advance of the welding is
sten arc welding process variation in which the current is pulsed. manually controlled.

Pulsed power welding. An arc welding process variation in which the Shielded metal arc welding. Abbreviated as SMAW. An arc welding pro-
welding power source is programmed to cycle between low and high cess with an arc between a covered electrode and the weld pool. The
power levels. process is used with shielding from the decomposition of the electrode
covering, without the application of pressure, and with filler metal from
Pulsed spray welding. An arc welding process variation in which pulsed the electrode.

--`,,```,,,,````-`-`,,`,,`,`,,`---
spray transfer occurs.
Short circuit gas metal arc welding. Abbreviated as GMAW-S. A gas
Reduced section tension test. A test in which a transverse section of the metal arc welding process variation in which the consumable electrode
weld is located in the center of the reduced section of the specimen. is deposited during repeated short circuits.

Copyright American Welding Society 111


Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
Side bend test. A test in which the side of a transverse section of the weld

--`,,```,,,,````-`-`,,`,,`,`,,`---
is on the convex surface of a specified bend radius.

6F. A welding test position designation for a circumferential fillet weld


applied to a joint in pipe, with its axis approximately 45° from horizontal,
in which the weld is made in flat, vertical, and overhead welding posi-
tions. The pipe remains fixed until welding is complete. See Figure 9-24.
6G. A welding test position designation for a circumferential groove weld
applied to a joint in pipe, with its axis approximately 45° from hori-
zontal, in which the weld is made in the flat, vertical, and overhead
welding positions. The pipe remains fixed until welding is complete.
See Figure 9-25.

Figure 9-25—Multiple Welding Test Position—6G

6GR. A welding test position designation for a circumferential groove weld


applied to a joint in pipe with its axis approximately 45° from horizon-
tal, in which the weld is made in the flat, vertical, and overhead welding
positions. A restriction ring is added, adjacent to the joint, to restrict
access to the weld. The pipe remains fixed until welding is complete.
Figure 9-24—Multiple Welding Test Position—6F See Figure 9-26.

112
Copyright American Welding Society
Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
Figure 9-26—Multiple Welding Test Position
with Restriction Ring—6GR

Figure 9-27—Spray Transfer


Spray transfer, gas arc welding. Metal transfer in which molten metal from
a consumable electrode is propelled axially across the arc in small drop-
lets. See Figure 9-27.
Specimen (B2.1). The article made from a specimen blank that is evaluated Specimen blank (B2.1). That portion of a test weldment removed for the
for qualification purposes. In some cases, the test weldment is also the production of a specimen. In some cases, the specimen blank is also the
specimen. specimen.
--`,,```,,,,````-`-`,,`,,`,`,,`---

Copyright American Welding Society 113


Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
Standard Welding Procedure Specification (SWPS) (B2.1). A Standard
Welding Procedure Specification published by the American Welding
Society.

Standoff distance. The distance between a nozzle and the workpiece. See
Figures 9-28 and 9-29.
--`,,```,,,,````-`-`,,`,,`,`,,`---

Stickout, gas metal arc welding and gas shielded flux cored arc welding.
The length of unmelted electrode extending beyond the end of the gas
nozzle.

Stickout, gas tungsten arc welding. The length of the tungsten electrode
extending beyond the end of the gas nozzle. See Figure 9-29.

Straight polarity. A nonstandard term for direct current electrode


negative.

Stress-relief heat treatment. Uniform heating of a structure or a portion


thereof to a sufficient temperature to relieve the major portion of the
residual stresses, followed by uniform cooling.

Stringer bead. A weld bead formed without appreciable weaving. See


Figure 9-30.

Submerged arc welding. Abbreviated as SAW. An arc welding process


that uses an arc or arcs between a bare metal electrode or electrodes and
the weld pool. The arc and molten metal are shielded by a blanket of
granular flux on the workpieces. The process is used without pressure
and with filler metal from the electrode and sometimes from a supple- Figure 9-28—Gas Metal Arc Welding Gun Nomenclature
mental source (welding rod, flux, or metal granules). including Stickout and Standoff Distance

114
Copyright American Welding Society
Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
Figure 9-29—Gas Tungsten Arc Welding Torch Nomenclature
including Stickout and Standoff Distance

--`,,```,,,,````-`-`,,`,,`,`,,`---

Copyright American Welding Society 115


Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
Test weldment (B2.1). Workpieces joined by welding to qualify welding
procedures, welders, or welding operators.

3F. A welding test position designation for a linear fillet weld applied to a
joint in which the weld is made in the vertical welding position. See
Figure 9-31.

3G. A welding test position for a linear groove weld applied to a joint in
which the weld is made in the vertical welding position. See Figure
9-32.

Transverse weld test specimen. A weld test specimen with its major axis
perpendicular to the weld axis.
2F, pipe. A welding test position designation for a circumferential fillet
weld applied to a joint in pipe, with its axis approximately vertical, in
Figure 9-30—Stringer Bead which the weld is made in the horizontal welding position. See Figure
9-20.

--`,,```,,,,````-`-`,,`,,`,`,,`---
T (B2.1). A symbol for base metal thickness, or for identifying a procedure 2F, plate. A welding test position designation for a linear fillet weld
qualification variable for fracture toughness applications, as appropriate. applied to a joint in which the weld is made in the horizontal welding
t (B2.1). A symbol for weld metal thickness, which is equal to groove weld position. See Figure 9-19.
size, or to fillet weld leg size, as appropriate. 2FR. A welding test position designation for a circumferential fillet weld
Tension test. A test in which a specimen is loaded in tension until failure around a joint in a pipe, with its axis approximately horizontal, in which
occurs. the weld is made in the horizontal welding position by rotating the pipe
about its axis. See Figure 9-21.
Test coupon (ASME IX). A weld or braze assembly for procedure or per-
formance qualification testing. The coupon may be any product from 2G, pipe. A welding test position designation for a circumferential groove weld
plate, pipe, tube, etc., and may be a fillet weld, overlay, deposited weld applied to a joint in a pipe, with its axis approximately vertical, in which
metal, etc. the weld is made in the horizontal welding position. See Figure 9-23.

116
Copyright American Welding Society
Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
--`,,```,,,,````-`-`,,`,,`,`,,`---

Figure 9-31—Vertical Welding Test Position—3F Figure 9-32—Vertical Welding Test Position—3G

Copyright American Welding Society 117


Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
2G, plate. A welding test position designation for a linear groove weld Weld axis. A line through the length of the weld, perpendicular to and at the
applied to a joint in which the weld is made in the horizontal welding geometric center of its cross section. See Figures 9-8, 9-9, and 9-34.
position. See Figure 9-22.
Welding electrode. A component of the welding circuit through which
Uphill, adv. Welding with an upward progression.
current is conducted and that terminates at the arc, molten conductive
Vertical welding position. The welding position in which the weld axis, at slag, or base metal.
the point of welding, is approximately vertical, and the weld face lies in
an approximately vertical plane. See Figures 9-8 through 9-10, 9-31, Welding filler metal. The metal or alloy to be added in making a weld
and 9-32. joint that alloys with the base metal to form weld metal in a fusion
welded joint.
Weave bead. A type of weld bead made using weaving. See Figure 9-33.
Welding position. The relationship between the weld pool, joint, joint
members, and welding heat source during welding. See Figures 9-6
through 9-17, 9-19 through 9-23, 9-25, 9-26, 9-31, and 9-32.
--`,,```,,,,````-`-`,,`,,`,`,,`---

Welding procedure. The detailed methods and practices involved in the


production of a weldment. See also Welding procedure specification.

Welding procedure qualification record. Abbreviated as WPQR. A


record of welding variables used to produce an acceptable test weld-
ment and the results of tests conducted on the weldment to qualify a
welding procedure specification.

Welding procedure specification. Abbreviated as WPS. A document pro-


viding the required welding variables for a specific application to assure
repeatability by properly trained welders and welding operators.

Welding rod. A form of welding filler metal, normally packaged in


Figure 9-33—Weave Bead straight lengths, that does not conduct the welding current.

118
Copyright American Welding Society
Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
--`,,```,,,,````-`-`,,`,,`,`,,`---

Figure 9-34—Weld Axis, Groove Weld

Copyright American Welding Society 119


Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
--`,,```,,,,````-`-`,,`,,`,`,,`---
Figure 9-34 (Continued)—Weld Axis, Fillet Weld

120
Copyright American Welding Society
Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
Welding schedule. A written statement, usually in tabular form, specifying Welding variable (B2.1). Any controllable detail of a welding procedure
values of parameters and the welding sequence for performing a weld- which is required to be addressed on the WPS.
ing operation. Welding wire. A form of welding filler metal, normally packaged as coils
or spools, that may or may not conduct electrical current depending
Welding technique. The details of a welding procedure that are controlled upon the welding process with which it is used.
by the welder or welding operator.
Whipping. A manual welding technique in which the arc or flame is
Welding test position designation. A symbol representation for a fillet manipulated to alternate backwards and forwards in the direction of
weld or a groove weld, the joint orientation and the welding test posi- travel as it progresses along the weld path.
tion. See 1F, 2F, 2FR, 3F, 4F, 5F, 6F, 1G, 2G, 3G, 4G, 5G, 6G, and Wire feed speed. The rate at which wire is consumed in arc cutting, ther-
6GR. mal spraying, or welding.

--`,,```,,,,````-`-`,,`,,`,`,,`---
Copyright American Welding Society 121
Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
Notes

--`,,```,,,,````-`-`,,`,,`,`,,`---
122
Copyright American Welding Society
Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
Annex I—Observations
This Annex contains observations by Duane K. Miller, Sc.D., P.E., on CC systems, the arc voltage is determined by the arc length, which is
manager, Engineering Services, The Lincoln Electric Company. The obser- manipulated by the welder. As arc lengths are increased with SMAW,
vations are from a paper presented to the AISC National Steel Construction the arc voltage will increase, and the amperage will decrease. Arc volt-
Conference and subsequently published in the Welding Journal. These age also controls the width of the weld bead, with higher voltages gen-
items are contained in this Annex because they are useful opinions of a erating wider beads. Arc voltage has a direct effect on the heat input
credible welding professional. They have been excluded from the body of computation. The voltage in a welding circuit is not constant, but is
this work because all of the content in the body is the result of consensus composed of a series of voltage drops. Consider the following example:
committees rather than single individuals. assume the power source delivers a total system voltage of 40 volts.
Between the power source and the welding head or gun, there is a volt-
Amperage. A measure of the amount of current flowing through the elec- age drop of perhaps 3 volts associated with the input cable resistance.
trode and the work. It is a primary variable in determining heat input.
Generally, an increase in amperage means higher deposition rates, From the point of attachment of the work lead to the power source
deeper penetration, and more admixture. The amperage flowing through work terminal, there is an additional voltage drop of, say, 7 volts. Sub-
an electrical circuit is the same, regardless of where it is measured. It tracting the 3 volts and the 7 volts from the original 40, this leaves 30
may be measured with a tong meter or with the use of an electrical volts for the arc. This example illustrates how important it is to ensure
shunt. The role of amperage is best understood in the context of heat that the voltages used for monitoring welding procedures properly rec-
input and current density considerations. For constant voltage (CV) ognize any losses in the welding circuit. The most accurate way to
welding, an increase in wire feed speed will directly increase amperage. determine arc voltage is to measure the voltage drop between the con-
For SMAW on constant current (CC) systems, the machine setting tact tip and the workpiece. This may not be practical for semiautomatic

--`,,```,,,,````-`-`,,`,,`,`,,`---
determines the basic amperage, although changes in the arc length (con- welding, so voltage is typically read from a point on the wire feeder
trolled by the welder) will further change amperage. Longer arc lengths (where the gun and cable connection is made), to the workpiece. For
reduce amperage. SMAW welding, voltage is not usually monitored, since it is constantly
changing and cannot be controlled except by the welder. Skilled weld-
Arc voltage. Arc voltage is directly related to arc length. As the voltage ers hold short arc lengths to deliver the best weld quality.
increases, the arc length increases, as does the demand for arc shielding.
For CV welding, the voltage is determined primarily by the machine Current density. Current density is determined by dividing the welding
setting, so the arc length is relatively fixed in CV welding. For SMAW amperage by the cross sectional area of the electrode. For solid

Copyright American Welding Society 123


Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
electrodes, the current density is therefore proportional to I/d2. For
tubular electrodes where current is conducted by the sheath, the current
density is related to the area of the metallic cross section. As the current
density increases, there will be an increase in deposition rates, as well as
penetration. The latter will increase the amount of admixture for a given
joint. Notice that this may be accomplished by either increasing the
amperage or decreasing the electrode size. Because the electrode diam-
eter is a squared function, a small decrease in diameter may have a
significant effect on deposition rates and plate penetration.

Electrode diameter. A critical WPS variable. Larger electrodes can carry


higher welding currents. For a fixed amperage, however, smaller
electrodes result in higher deposition rates. This is because of the effect
--`,,```,,,,````-`-`,,`,,`,`,,`---

on current density.

Electrode extension. Electrode extension, also known as “electrical stickout”


or ESO, is the distance from the contact tip to the end of the electrode. See
Figure I-1. It applies only to the wire fed processes. As the electrode
extension is increased in a constant voltage system, the electrical resis-
tance of the electrode increases, causing the electrode to be heated. This is
known as resistance heating or “I2R heating.” As the amount of heating
increases, the arc energy required to melt the electrode decreases. Longer
electrode extensions may be employed to gain higher deposition rates at a
given amperage. When the electrode extension is increased without any
change in wire feed speed, the amperage will decrease. This results in less
penetration and less admixture. With the increase in electrical stickout, it
is common to increase the machine voltage setting to compensate for the
greater voltage drop across the electrode. Figure I-1—Gas Metal Arc Welding Gun Nomenclature

124
Copyright American Welding Society
Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
In constant voltage systems, it is possible to simultaneously increase tion rates with negative polarity than with positive. AC exhibits a mix
both the ESO and the wire feed speed in a balanced manner so that the of both positive and negative polarity characteristics. The magnetic
current remains constant. When this is done, higher deposition rates are field that surrounds any DC conductor can cause a phenomenon known
attained. Other welding variables such as voltage and travel speed must as arc blow, where the arc is physically deflected by the field. The
be adjusted to maintain a stable arc and to ensure quality welding. The strength of the magnetic field is proportional to the square of the current
ESO variable should always be within the range recommended by the value, so this is a more significant potential problem with higher
manufacturer. currents. AC is less prone to arc blow, and can sometimes be used to
overcome this phenomenon.
Heat input. Heat input is proportional to the welding amperage, times the
arc voltage, divided by the travel speed. Higher heat inputs relate to Preheat temperature, welding. Preheat and interpass temperatures are used
larger weld cross sectional areas, and larger heat affected zones, which to control cracking tendencies, typically in the base materials. Regarding
may negatively affect mechanical properties in that region. Higher heat weld metal properties, for most carbon-manganese-silicon systems, a
input generally results in slightly decreased yield and tensile strength in moderate interpass temperature promotes good notch toughness. Preheat
the weld metal, and generally lower notch toughness because of the and interpass temperatures greater than 550°F may negatively affect
interaction of bead size and heat input. notch toughness. When the base metal receives little or no preheat, the
resultant rapid cooling may also lead to a deterioration of notch tough-
Polarity. Polarity is a definition of the direction of current flow. Positive ness. Therefore, careful control of preheat and interpass temperatures is
polarity (“reverse”) is achieved when the electrode lead is connected to critical.
the positive terminal of the direct current (DC) power supply. The work
lead is connected to the negative terminal. Negative polarity Travel speed. Travel speed, measured in inches per minute, is the rate at
(“straight”) occurs when the electrode is connected to the negative ter- which the electrode is moved relative to the joint. All other variables
minal and the work lead to the positive terminal. Alternating current being equal, travel speed has an inverse effect on the size of the weld
(AC) is not a polarity, but a current type. With AC, the electrode is beads. As the travel speed increases, the weld size will decrease.
alternately positive and negative. Submerged arc is the only process that Extremely low travel speeds may result in reduced penetration, as the
commonly uses either electrode positive or electrode negative polarity arc impinges on a thick layer of molten metal and the weld puddle rolls
for the same type of electrode. AC may also be used. ahead of the arc. Travel speed is a key variable used in computing heat
input; reducing travel speed increases heat input.
For a fixed wire feed speed, a submerged arc electrode will require
more amperage on positive polarity than on negative. For a fixed Wire feed speed. Wire feed speed is a measure of the rate at which the
amperage, it is possible to utilize higher wire feed speeds and deposi- electrode is passed through the welding gun and delivered to the arc.
--`,,```,,,,````-`-`,,`,,`,`,,`---

Copyright American Welding Society 125


Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
Typically measured in inches per minute (IPM), the deposition rates are the expense of penetration. Wire feed speed is the preferred method of
directly proportional to wire feed speed, and directly related to amper- maintaining welding procedures for constant voltage wire feed pro-
age. When all other welding conditions are maintained constant (e.g., cesses. The wire feed speed can be independently adjusted, and
the same electrode type, diameter, arc voltage, and electrode extension), measured directly, regardless of the other welding conditions. It is
an increase in wire feed speed will directly lead to an increase in amper- possible to utilize amperage as an alternative to wire feed speed
age. For slower wire feed speeds, the ratio of wire feed speed to amper- although the resultant amperage for a given wire feed speed may vary,
age is relatively constant and linear. For higher wire feed speeds, this depending on the polarity, electrode diameter, electrode type, and
ratio may increase, resulting in a higher deposition rate per amp, but at electrode extension.

--`,,```,,,,````-`-`,,`,,`,`,,`---
126
Copyright American Welding Society
Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
Annex II—Standard Welding Procedure Specifications

Standard Welding Procedure Specifications


Base Metal Process Thickness Filler Metal Condition Order No.

SHEET METAL

Aluminum GTAW 10–18 gauge ER4043 or R4043 As-Welded, with or B2.1-22-015:2002


without Backing
Carbon Steel GMAW-S 10–18 gauge ER70S-6 As-Welded, with or B2.1-1-004:2002
without Backing
Carbon Steel GTAW 10–18 gauge ER70S-2, -3 As-Welded, with or B2.1-1-008:2002
without Backing
Carbon Steel SMAW 10–18 gauge E6010 or E6013 As-Welded, with or B2.1-1-012:2002
without Backing
Carbon to GMAW-S 10–18 gauge ER309 As-Welded, with or B2.1-1/8-006:2002
Stainless Steel without Backing
Carbon to GTAW 10–18 gauge ER309 As-Welded, with or B2.1-1/8-010:2002
Stainless Steel without Backing
Carbon to SMAW 10–18 gauge E309-15, -16, -17 As-Welded, with or B2.1-1/8-014:2002
Stainless Steel without Backing
Galvanized Steel GMAW-S 10–18 gauge ER70S-6 As-Welded, with or B2.1-1-003:2002
without Backing
Galvanized Steel GTAW 10–18 gauge ER70S-2, -3 As-Welded, with or B2.1-1-007:2002

--`,,```,,,,````-`-`,,`,,`,`,,`---
without Backing
Galvanized Steel SMAW 10–18 gauge E6010 or E6013 As-Welded, with or B2.1-1-011:2002
without Backing

(Continued)

Copyright American Welding Society 127


Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
Standard Welding Procedure Specifications (Continued)
Base Metal Process Thickness Filler Metal Condition Order No.

SHEET METAL (Continued)

Stainless Steel GMAW-S 10–18 gauge ER3XX As-Welded, with or B2.1-8-005:2002


without Backing
Stainless Steel GTAW 10–18 gauge ER3XX As-Welded, with or B2.1-8-009:2002
without Backing
Stainless Steel SMAW 10–18 gauge E3XX-15, -16, -17 As-Welded, with or B2.1-8-013:2002
without Backing

PIPE or PLATE

--`,,```,,,,````-`-`,,`,,`,`,,`---
Carbon Steel SMAW -3/16 in.–7/8 in.0 E7018 As-Welded, with or B2.1.001-90
without Backing
Carbon Steel SMAW - 1/8 in.–1-1/2 in. E7018 As-Welded or PWHT B2.1-1-016-94R
Carbon Steel SMAW - 1/8 in.–1-1/2 in. E6010 As-Welded or PWHT B2.1-1-017-94R
Carbon Steel GTAW followed by - 1/8 in.–1-1/2 in. ER70S-2 and E7018 As-Welded or PWHT B2.1-1-021-94R
SMAW
Carbon Steel SMAW -1/8 in.–1-1/2 in. E6010* and E7018 As Welded or PWHT B2.1-1-026-94R
Carbon Steel SMAW -1/8 in.–1-1/2 in. E6010 and E7018 As-Welded or PWHT B2.1-1-022-94R
Carbon Steel FCAW, self-shielded -1/8 in.–1-1/2 in. E71T-8 As-Welded B2.1-1-018-94R
Carbon Steel FCAW, self-shielded 1/8 in.–1/2 in. E71T-11 As-Welded B2.1-1-027:1998R
Carbon Steel FCAW, CO2 shielded -1/8 in.–1-1/2 in. E70T-1 or E71T-1 As-Welded B2.1-1-019-94R
Carbon Steel FCAW, Ar-CO2 shielded -1/8 in.–1-1/2 in. E70T-1 or E71T-1 As-Welded or PWHT B2.1-1-020-94

(Continued)
128
Copyright American Welding Society
Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
Standard Welding Procedure Specifications (Continued)

--`,,```,,,,````-`-`,,`,,`,`,,`---
Base Metal Process Thickness Filler Metal Condition Order No.

PIPE or PLATE (Continued)

Carbon Steel GTAW 3/16 in.–7/8 in.- ER70S-2, -3 As-Welded, with or B2.1.002-90
without Backing
Stainless Steel SMAW -1/8 in.–1-1/2 in. E3XX-XX As-Welded B2.1-8-023-94R
Stainless Steel GTAW 1/16 in.–1-1/2 in. ER3XX As-Welded B2.1-8-024:2001
Stainless Steel GTAW followed by 1/8 in.–1-1/2 in. ER3XX and E3XX-XX As-Welded B2.1-8-025:2001
SMAW

PIPE

Carbon Steel SMAW 1/8 in.–3/4 in. E6010 and E7018 As Welded B2.1-1-201-96
Carbon Steel SMAW 1/8 in.–3/4 in. E6010* and E7018 As Welded B2.1-1-202-96
Carbon Steel SMAW 1/8 in.–3/4 in. E6010 As Welded B2.1-1-203-96
Carbon Steel SMAW 1/8 in.–3/4 in. E6010* As Welded B2.1-1-204-96
Carbon Steel SMAW -1/8 in.–1-1/2 in. E6010 and E7018 As Welded or PWHT B2.1-1-205-96
Carbon Steel SMAW -1/8 in.–1-1/2 in. E6010* and E7018 As Welded or PWHT B2.1-1-206-96
Carbon Steel GTAW -1/8 in.–1-1/2 in. ER70S-2 As-Welded or PWHT B2.1-1-207-96
Carbon Steel SMAW -1/8 in.–1-1/2 in. E7018 As-Welded or PWHT B2.1-1-208-96
Carbon Steel GTAW followed by -1/8 in.–1-1/2 in. ER70S-2 and E7018 As-Welded or PWHT B2.1-1-209-96
SMAW

(Continued)

Copyright American Welding Society 129


Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
Standard Welding Procedure Specifications (Continued)
Base Metal Process Thickness Filler Metal Condition Order No.

PIPE (Continued)

Carbon Steel GTAW, consumable insert -1/8 in.–1-1/2 in. INMs-1 and ER70S-2 As-Welded or PWHT B2.1-1-210:2001
Carbon Steel GTAW, consumable insert, -1/8 in.–1-1/2 in. INMs-1, E70S-2, As-Welded or PWHT B2.1-1-211:2001
followed by SMAW and E7018
--`,,```,,,,````-`-`,,`,,`,`,,`---

Carbon Steel GMAW-S followed by -1/8 in.–1-1/2 in. ER70S-3 and E7XT-1 As-Welded or PWHT B2.1-1-232:2005
FCAW-G
Carbon Steel GMAW-S followed by -1/8 in.–1-1/2 in. ER70S-3 As-Welded or PWHT B2.1-1-233:2005
spray transfer
Carbon Steel FCAW-G -1/8 in.–1-1/2 in. E7XT-X As-Welded or PWHT B2.1-1-234:2005
Carbon Steel GMAW spray transfer -1/8 in.–1-1/2 in. ER70S-3 As-Welded or PWHT B2.1-1-235:2005
Carbon to GTAW -1/16 in.–1-1/2 in. ER309(L) As-Welded B2.1-1/8-227:2002
Stainless Steel
Carbon to SMAW - 1/8 in.–1-1/2 in. E309 (L)-15, -16, -17 As-Welded B2.1-1/8-228:2002
Stainless Steel
Carbon to GTAW followed by - 1/8 in.–1-1/2 in. ER309(L) and As-Welded B2.1-1/8-229:2002
Stainless Steel SMAW E309(L)-15, -16, -17
Carbon to GTAW, consumable insert -1/16 in.–1-1/2 in. IN309 and ER309(L) As-Welded B2.1-1/8-230:2002
Stainless Steel
Carbon to GTAW, consumable insert, - 1/8 in.–1-1/2 in. IN309; ER304 and ER304-15, As-Welded B2.1-1/8-231:2002
Stainless Steel followed by SMAW -16, -17; or ER309(L) and
ER309(L)-15, -16, -17
Cr-Mo Steel GTAW 1/8 in.–3/4 in. ER80S-B2 or ER70S-B2L As-Welded or PWHT** B2.1-4-217:1999
(Continued)
130
Copyright American Welding Society
Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
Standard Welding Procedure Specifications (Continued)
Base Metal Process Thickness Filler Metal Condition Order No.

PIPE (Continued)

Cr-Mo Steel SMAW -1/8 in.–1-1/2 in. E8018-B2 or E7018-B2L As-Welded or PWHT** B2.1-4-218:1999
Cr-Mo Steel GTAW followed by SMAW -1/8 in.–1-1/2 in. ER80S-B2 and E8018-B2 As-Welded or PWHT** B2.1-4-219:1999
Cr-Mo Steel GTAW, consumable insert 1/8 in.–3/4 in. IN515 and ER80S-B2 As-Welded or PWHT** B2.1-4-220:1999
Cr-Mo Steel GTAW, consumable insert, -1/8 in.–1-1/2 in. IN515, ER80S-B2, and As-Welded or PWHT** B2.1-4-221:1999
followed by SMAW E8018-B2
Cr-Mo Steel GTAW 1/8 in.–3/4 in. ER90S-B3 or ER80S-B3L As-Welded or PWHT** B2.1-5A-222:1999
Cr-Mo Steel SMAW -1/8 in.–1-1/2 in. E9018-B3 or E8018-B3L As-Welded or PWHT** B2.1-5A-223:1999
Cr-Mo Steel GTAW followed by SMAW -1/8 in.–1-1/2 in. ER90S-B3 and E9018-B3 As-Welded or PWHT** B2.1-5A-224:1999
Cr-Mo Steel GTAW, consumable insert 1/8 in.–3/4 in. IN521 and ER90S-B3 As-Welded or PWHT** B2.1-5A-225:1999
Cr-Mo Steel GTAW, consumable insert -1/8 in.–1-1/2 in. IN521, ER90S-B3, and As-Welded or PWHT** B2.1-5A-226:1999
followed by SMAW E9018-B3
Stainless Steel GTAW -1/16 in.–1-1/2 in. ER3XX As-Welded B2.1-8-212:2001
Stainless Steel SMAW 1/8 in.–1-1/2 in. E3XX-XX As-Welded B2.1-8-213-97
Stainless Steel GTAW followed by SMAW 1/8 in.–1-1/2 in. ER3XXX and E3XX-XX As-Welded B2.1-8-214:2001
Stainless Steel GTAW, consumable insert 1/8 in.–1-1/2 in. IN3XX and ER3XX As-Welded B2.1-8-215:2001
Stainless Steel GTAW, consumable insert, 1/8 in.–1-1/2 in. IN3XX, ER3XX, As-Welded B2.1-8-216:2001

--`,,```,,,,````-`-`,,`,,`,`,,`---
followed by SMAW and E3XX-XX
*Downhill progression on root pass. All other vertical position passes are uphill.
**≤1/2 in. As-Welded or PWHT.
>1/2 in. PWHT.

Copyright American Welding Society 131


Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale
Notes

--`,,```,,,,````-`-`,,`,,`,`,,`---

132
Copyright American Welding Society
Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS Not for Resale

You might also like