AWS D1.1 Endorsement cheat sheet

D1.1 applies to welded carbon and low-alloy steel structures with base metal thickness 1/8 in [3 mm] and greater, unless the contract specifies another code or limit.

Base metals shall be listed in Table 1.1; an unlisted steel requires approval by the engineer and may require WPS qualification before use.

Clause 1 contains general requirements, Clause 2 design of welded connections, Clause 3 fabrication, Clause 4 qualification, and Clause 5 inspection.

A prequalified joint detail is limited to the configurations in Clause 3; any deviation in groove angle, root opening, or backing requires a qualified WPS.

Minimum fillet weld size based on thicker part: 1/8 in for ≤1/4 in; 3/16 in for >1/4 to 1/2 in; 1/4 in for >1/2 to 3/4 in; 5/16 in for >3/4 in.

Maximum fillet weld size along an edge: equal to material thickness when thickness <1/4 in; equal to thickness minus 1/16 in when thickness ≥1/4 in, unless design requires larger.

Minimum fillet weld length is four times nominal size; a shorter weld has effective size limited to one-quarter of its length; intermittent welds have minimum length rules.

Effective throat of an equal-leg 45° fillet weld is 0.707 times leg size; effective area is throat times effective length.

For CJP groove welds, effective throat equals the thinner part thickness when backing or backgouging removes unsound root material.

WPS qualification is by prequalified WPS under Clause 3 or by testing under Clause 4; a PQR records the variables and test results.

A prequalified WPS must use a prequalified joint detail, listed base metal, prequalified filler metal, qualified position, and D1.1 preheat and interpass limits.

Changes in essential variables beyond permitted ranges require requalification; examples are process, filler classification, base metal group, thickness range, joint design, and preheat.

Groove WPS qualification uses reduced-section tension and guided-bend specimens; tension must meet minimum specified strength and bends must show no unacceptable defects.

Welder performance qualification uses visual examination plus bend tests, or radiography where permitted, and records position, process, thickness, and backing.

Minimum preheat depends on steel group, thickness, and process; preheat and interpass temperatures must be measured and maintained during welding.

Low-hydrogen electrodes require heated storage and limited atmospheric exposure; damp or contaminated electrodes shall not be used for code welding.

Fit-up and misalignment must be within D1.1 tolerances; temporary welds and strongbacks must follow a qualified WPS and be removed without damaging base metal.

Weld surfaces must be free of cracks and unacceptable undercut, porosity, slag, and arc strikes; cleaning is required before inspection.

The inspector verifies WPS, welder qualification, base and filler metals, preheat, fit-up, workmanship, and NDE before accepting a weld.

Visual inspection is required for all welds; it covers joint preparation, fit-up, preheat, cleaning, and final weld appearance.

CJP groove welds in tension generally require UT or RT in addition to visual inspection unless a specific exemption applies.

Ultrasonic testing rejects cracks, incomplete fusion, and indications exceeding the D1.1 reference level; angle-beam techniques are used for T-joints.

Radiographic testing rejects cracks and incomplete fusion or penetration; porosity and slag limits depend on thickness and weld type.

Magnetic particle testing detects surface and near-surface defects in ferromagnetic steel; penetrant testing is used for nonmagnetic materials or where MT is unsuitable.

Undercut acceptance is generally 1/32 in for material under 1 in and 1/16 in for 1 in and thicker; cracks are never acceptable.

NDE personnel shall be qualified to ASNT SNT-TC-1A or an equivalent program; reports must identify method, procedure, calibration, personnel, and results.

Defects are excavated and rewelded with a qualified WPS, then reexamined by the same NDE method to the original acceptance criteria.

The inspector verifies compliance with D1.1 and the contract documents and has authority to reject nonconforming work; the inspector does not approve design changes.

A written WPS and supporting PQR must be available at the work site before welding; prequalified WPS still require documented compliance with prequalified conditions.

Welder qualification records identify welder, process, position, thickness qualified, test date, and results, and are maintained by the contractor.

Material traceability includes mill certificates, heat numbers, and filler metal classifications checked against the contract and WPS.

Nonconformance reports state the condition, location, code requirement, disposition, repair or retest, and closure verification.

The final inspection report summarizes inspections, NDE, nonconformances, repairs, and acceptance status and is signed by the inspector.

NDE reports are traceable to weld identification and include method, procedure, equipment calibration, personnel, indications, and acceptance decision.

Where contract documents are more restrictive than D1.1, the contract governs; design conflicts are resolved by the engineer of record.