AWS D1.1:2025 · Clause 5 · Clause 6

Weld Procedure Qualification Record (PQR) — When You Need It (and When You Don't)

A procedure qualification record proves a non-prequalified welding procedure produces sound welds. Under D1.1:2025, prequalified WPSs written to Clause 5 require no PQR at all. Non-prequalified procedures must be qualified by testing per Clause 6.2.1, with essential variables documented in Table 6.6.

Decision tree: If your joint detail, welding process, filler metal, and parameters all fall within the prequalified limits of Clause 5 and Figure 5.1 — no PQR is required. If any element falls outside those prequalified limits, you need a non-prequalified WPS supported by a PQR per Clause 6.2.1. Either way, start with the WPS form walkthrough.

What Does a PQR Document?

A PQR records the actual welding parameters used during a test weld and the results of destructive testing performed on that weld. It is the physical evidence that a welding procedure produces acceptable results under controlled conditions.

The test weld is performed following a preliminary WPS. After welding, test specimens are removed and subjected to destructive testing — typically guided bend tests, macro-etch examination, and in some cases tensile tests. The specific test requirements depend on whether the procedure is for a CJP groove weld, PJP groove weld, or fillet weld, and whether the application is nontubular or tubular.

The PQR documents the essential variables used during the test: the welding process, filler metal classification, base metal group, preheat and interpass temperatures, electrical characteristics, joint geometry, position, and shielding gas (if applicable). These variables define the boundaries of the qualified WPS. Any production weld made using that WPS must stay within the ranges recorded on the PQR.

D1.1:2025 Table 6.6 lists 35 essential variables for procedure qualification. Clause 6.8 adds supplementary essential variables that apply only when Charpy V-notch (CVN) toughness testing is specified in the contract documents. If CVN testing is required and you change a supplementary variable, you must re-qualify even if the essential variables remain the same.

Do You Need a PQR Under D1.1?

D1.1:2025 provides two distinct paths to a qualified welding procedure specification. The path you take determines whether a PQR is required.

The Prequalified Path (Clause 5)

Clause 5 defines prequalified WPSs — welding procedures that the code has already validated through decades of industry experience. If your procedure meets all of the following conditions, no PQR is required:

The welding process is one of the four prequalified processes: SMAW, SAW, GMAW (except GMAW-S short-circuit transfer), or FCAW. The joint detail matches one of the prequalified configurations in Figure 5.1, including the specified root opening, groove angle, and root face dimensions. The base metal is listed in Table 5.6 and matched with an approved filler metal per Table 5.7. Preheat and interpass temperatures meet the minimums in Table 5.11. And all other provisions of Clause 5 are satisfied, including electrode storage, maximum heat input limits, and pass thickness restrictions.

Many structural fabrication shops work exclusively with prequalified joints. A typical building frame using A992 steel, V-groove CJP joints per Figure 5.1, and E71T-1 FCAW wire qualifies entirely under Clause 5. No test welds. No bend specimens. No PQR.

The Non-Prequalified Path (Clause 6)

When any element of your procedure falls outside the prequalified limits — a joint detail not in Figure 5.1, a welding process not listed in Clause 5, or a parameter outside the prequalified range — you must qualify the WPS by testing per Clause 6.2.1. This requires producing a test weld, extracting specimens, performing destructive tests, and documenting the results on a PQR.

Common situations that require a PQR include: using GMAW-S short-circuit transfer (excluded from prequalified processes), welding a joint geometry not covered in Figure 5.1, welding base metals not listed in Table 5.6, or exceeding the maximum heat input limits specified in Clause 5. Any single element outside the prequalified envelope triggers the requirement.

D1.1’s prequalified path has no equivalent in ASME IX. Under Section IX, every WPS requires procedure qualification — there is no prequalified exemption. This is one of the most significant structural differences between the two codes. For ASME IX or API 1104, separate qualification requirements apply.

What Triggers PQR Re-Qualification?

For non-prequalified WPSs where a PQR is required, the following changes to essential variables trigger re-qualification. Table 6.6 lists 35 essential variables total — these five are the most common triggers in structural fabrication:

Welding process change: Switching from one process to another — such as SMAW to FCAW — requires a new PQR. Each process has fundamentally different heat input characteristics, deposition rates, and metallurgical effects. A procedure qualified with SMAW does not demonstrate that FCAW will produce acceptable results on the same joint.
Filler metal classification change: Changing filler metal classification — such as E7018 to E71T-1 — requires a new PQR. Different filler metals produce different weld metal chemistry, mechanical properties, and diffusible hydrogen levels. Table 6.6 treats each AWS classification as a separate essential variable.
Base metal group change: Moving to a different base metal group per Table 5.6 requires a new PQR. D1.1 organizes approved base metals into groups (I through V) based on chemistry and weldability. A procedure qualified on Group I steel (such as A36) does not automatically qualify for Group II steel (such as A588) because the higher alloy content changes preheat requirements and heat-affected zone behavior. Confirm your steel’s group using your mill test report.
Welding position change: Adding a welding position not covered by the original test weld requires a new PQR. A procedure qualified in the flat position (1G) does not qualify for vertical (3G) or overhead (4G) welding. Table 6.6 requires qualification in each position, though a 3G qualification also qualifies 1G and 2G for groove welds.
Preheat decrease: Decreasing preheat below the minimum temperature recorded on the PQR requires re-qualification. Preheat directly affects cooling rate, which controls hydrogen diffusion and hardness in the heat-affected zone. The qualified minimum is the floor — production welds may use higher preheat but not lower.

Beyond these five, Table 6.6 covers variables including electrode diameter, shielding gas composition, electrical characteristics (AC vs DC, polarity), travel speed range, and interpass temperature. A change to any single essential variable beyond the recorded range on the PQR invalidates the qualification for production use.

Once the WPS is qualified and production welding begins, Clause 8 governs inspection. Table 8.1 defines visual acceptance criteria for eight discontinuity categories — see the weld defects overview for the complete breakdown.

ASME IX PQR Requirements

Under ASME Section IX, every WPS must be backed by a PQR — there is no prequalified exemption. The PQR documents the actual welding conditions and destructive test results from a test coupon welded per QW-200.

Test coupon preparation. The test coupon must be welded by a welder or welding operator under the full supervision of the qualifying organization. The coupon base metal must be assigned a P-Number in Table QW/QB-422. The welding process, filler metal F-Number, position, and all essential variables must be recorded during welding.

Destructive testing. ASME IX requires tension tests per QW-150 (two specimens, must meet the minimum tensile value from QW/QB-422) and guided bend tests per QW-160 (four specimens — two face bends and two root bends, or four side bends for thicker material). The bend specimens must withstand 180-degree bending without open discontinuities exceeding 1/8 inch in any dimension. Impact testing per QW-170 is required when the referencing construction code mandates toughness testing.

Essential variables. ASME IX organizes essential variables by welding process in Tables QW-252 through QW-265. A change in any essential variable requires a new PQR. The three most impactful essential variables are: base metal P-Number change (QW-403.18), filler metal F-Number change (QW-404.12), and addition or deletion of PWHT (QW-407.1). Unlike D1.1 which has a single list of 35 variables, ASME IX tailors the variable list to each welding process — SMAW has different essential variables than GMAW or GTAW.

Dissimilar Metal Welding and PQR Qualification

Dissimilar metal welds — joining two different P-Number materials — are common in power plants, refineries, and chemical processing where carbon steel piping transitions to stainless steel or alloy steel components. Each dissimilar P-Number combination requires its own qualified WPS supported by a PQR.

Under ASME IX, QW-424 defines the rules for dissimilar metal procedure qualification. A PQR qualified on P-Number 1 to P-Number 1 (carbon steel to carbon steel) does not qualify P-Number 1 to P-Number 8 (carbon steel to austenitic stainless steel). The filler metal selection for dissimilar joints must be compatible with both base metals — typically a higher-alloy filler is used (e.g., ERNiCr-3 or E309L for carbon steel to stainless transitions).

Under D1.1, dissimilar base metal group joints also require separate qualification per Clause 6. A PQR qualified on Group I to Group I does not cover Group I to Group III. The filler metal must match the higher-strength base metal group per Table 5.7.

Common dissimilar metal combinations:

P1 to P8 (carbon steel to austenitic stainless) — power plant transition pieces, heat exchanger tube-to-tubesheet
P1 to P5A (carbon steel to 2.25Cr-1Mo) — refinery reactor piping transitions
P8 to P43 (stainless to Inconel) — chemical processing, high-temperature service
P1 to P4 (carbon steel to 1.25Cr-0.5Mo) — boiler and heat recovery applications

PQR Documentation and Record Keeping

A PQR is a permanent quality record. It must be maintained for the life of the equipment or structure it supports. Under ASME codes, the Authorized Inspector reviews and signs the PQR. Under D1.1, the fabricator’s designated representative signs the PQR.

The PQR must include: the actual welding parameters used (not ranges — the specific values recorded during the test weld), the base metal specification and P-Number, the filler metal classification and F-Number, the preheat and interpass temperatures actually used, the PWHT parameters if applicable, and all destructive test results with pass/fail determination. The PQR must reference the WPS it supports.

Multiple WPSs can reference the same PQR, provided each WPS stays within the qualification ranges established by that PQR. Conversely, a single WPS can be supported by multiple PQRs if the combined qualification ranges of those PQRs cover the full range of variables specified on the WPS.

Every PQR is tied to a specific welding procedure specification (WPS) — the PQR test validates that the WPS parameters produce acceptable mechanical properties and soundness under the applicable code.

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Key Takeaways

D1.1 prequalified WPSs need no PQR. Only non-prequalified procedures require qualification testing. ASME IX has no prequalified path — every WPS needs a PQR.
The PQR records actual values, not ranges. The specific parameters used during the test weld are documented. The WPS defines the ranges; the PQR proves the procedure works at specific conditions within those ranges.
Dissimilar metal joints need separate PQRs. Each P-Number combination must be independently qualified under both ASME IX and D1.1.
Multiple WPSs can reference one PQR as long as each WPS stays within the PQR’s qualification ranges.

"The PQR is the foundation of the welding program. Every non-prequalified weld on the project traces back to a PQR that proved the procedure works."
D1.1:2025 Clause 6.2.1 requires procedure qualification testing for any WPS not meeting the prequalified requirements of Clause 5

Frequently Asked Questions

What is a PQR in welding?

A PQR proves that a welding procedure actually works — but under D1.1, you may not need one. A procedure qualification record documents a test weld performed under controlled conditions, along with the destructive test results (bend tests, macro-etch, tensile tests) that confirm the procedure produces sound welds. The PQR becomes the evidence that supports a non-prequalified WPS. Under D1.1:2025, prequalified WPSs written to Clause 5 do not require a PQR at all.

Does D1.1 always require a PQR?

No. D1.1:2025 provides two paths to a qualified WPS. The prequalified path under Clause 5 requires no PQR — the code has already validated those joint configurations, processes, and parameters. Only non-prequalified WPSs require qualification by testing per Clause 6.2.1. Many structural fabrication shops work exclusively with prequalified joints and never need to produce a PQR.

What is the difference between a WPS and a PQR?

A WPS tells the welder what to do — the instructions. A PQR proves those instructions work — it documents a test weld with destructive test results. The WPS is the recipe; the PQR is the proof. Under D1.1, prequalified WPSs per Clause 5 do not require a PQR.

What changes to a WPS require a new PQR?

Table 6.6 lists the essential variables for procedure qualification. Changes that require a new PQR include switching welding process (such as SMAW to FCAW), changing filler metal classification (such as E7018 to E71T-1), moving to a different base metal group per Table 5.6, adding a new welding position not covered by the original test, and decreasing preheat below the qualified minimum. Table 6.6 contains 35 essential variables total — these five are the most common triggers in structural fabrication.

Does ASME IX require a PQR for every WPS?

Yes. ASME Section IX has no prequalified exemption. Every WPS must be supported by at least one PQR with documented destructive test results per QW-200. The test coupon must be welded using the WPS parameters, then subjected to tension tests (QW-150) and guided bend tests (QW-160). This is one of the most significant differences between ASME IX and D1.1, where prequalified WPSs under Clause 5 require no testing at all. Standard Welding Procedure Specifications (SWPSs) published by AWS may be adopted per QW-500 as an alternative to in-house qualification.

Can one PQR support multiple WPSs?

Yes. A single PQR establishes a qualification range based on the actual test conditions. Any WPS whose parameters fall within that qualification range can reference the same PQR. For example, a PQR qualified with SMAW using E7018 on P-Number 1 material in the 3G position establishes a range that could support WPSs for 1G, 2G, and 3G positions on P-Number 1 material with E7018. Conversely, a WPS can be supported by multiple PQRs if the combined qualification ranges cover all the variables specified on the WPS.

How do you qualify a dissimilar metal weld?

Each dissimilar P-Number combination requires its own PQR. Under ASME IX, QW-424 defines the qualification rules — a PQR qualified on P-Number 1 to P-Number 1 does not cover P-Number 1 to P-Number 8. Under D1.1, a PQR qualified on Group I to Group I does not cover Group I to Group III. The filler metal must be compatible with both base metals. Common dissimilar combinations include carbon steel to stainless steel using ERNiCr-3 or E309L filler, and carbon steel to Cr-Mo alloy steel using matching or over-alloyed filler metal.

What variables carry over from a PQR to the WPS?

The essential variables listed in D1.1:2025 Table 6.6 must be recorded on both the PQR and the WPS. Changes beyond the limitations shown in Table 6.6 require requalification. Key variables include welding process, filler metal classification, base metal group, preheat temperature, position, shielding gas, electrical characteristics, and single-pass vs multi-pass technique. For prequalified WPSs, Table 5.5 lists the essential variables.

Reference data from AWS D1.1/D1.1M:2025 and ASME BPVC IX:2025. Not affiliated with AWS or ASME.