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CAWI: Welding Processes, Procedures, and Qualifications

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Welding Processes, Procedures, and Qualifications

Welding Processes, Procedures, and Qualifications

This domain tests how a WPS, PQR, and welder qualification fit together. A WPS is the written instruction; a PQR is the record of the test that supports it; a welder performance qualification shows that a specific welder can produce sound welds. A WPS must be available at the point of use and followed.

Core rules

  • Essential variables change the qualification. Typical variables include process, base-metal thickness, filler classification or F-number, preheat, postweld heat treatment, position, joint design, and electrical characteristics.
  • Process-specific variables matter: GMAW transfer mode, FCAW flux classification, SAW flux/filler combination, and GTAW current type.
  • Under ASME IX, a change from one F-number to another is essential for procedure qualification. Under AWS D1.1, prequalified WPSs must stay within prequalified limits; otherwise qualify by testing.
  • SMAW electrode E7018: E means electrode, 70 means minimum tensile strength 70 ksi, 1 means all position, and 8 means low-hydrogen iron-powder coating usable on AC or DC.
  • PQR testing commonly includes tensile and guided-bend tests; impact tests are added when the specification requires notch toughness.
  • Welder qualification is separate from procedure qualification. A welder qualified on one thickness or position may not be qualified for all production work. Revisions to a WPS need approval.

Worked example

A PQR is qualified with E7018 (F4) in the root. Production proposes E6010 (F3) for the root without a new PQR. Under ASME IX, changing the F-number is an essential variable for procedure qualification, so the existing PQR does not support the proposed WPS. The inspector stops the work and requests a WPS supported by a PQR that covers F3, or a new qualification. The reasoning is not that both are electrodes; it is that the code lists F-number as essential.

Traps

Assuming a welder qualification also qualifies the procedure; assuming a WPS is valid for any thickness; missing filler classification changes; accepting a WPS without a supporting PQR; and confusing prequalified D1.1 joints with qualified-by-test procedures.