Prequalified WPS — What D1.1:2025 Allows
A prequalified WPS meets D1.1:2025 Clause 5 without a Kaynak Prosedür Onay Raporu (PQR). Prequalification covers four processes — SMAW (Table 5.1), SAW (Table 5.2), GMAW wire (Table 5.3), and FCAW/GMAW metal core (Table 5.4) — when essential variables stay within Kod-defined Sınırlar.
Bir WPS'i Nitelikli Yapan Nedir?
Under D1.1:2025 Clause 5, a WPS is prequalified when every essential variable — process, Ana Malzeme group, İlave Metal, joint detail, position, Ön Isıtma, and Pasolar Arası Sıcaklık — falls within the limits specified in the relevant code tables. Process limits are in Tables 5.1–5.4, essential variables in Table 5.5, base metals in Table 5.6, filler metals and shielding gases in Tables 5.7–5.10, and preheat and interpass temperatures in Table 5.11. When all variables meet the code Gereksinimler, no qualification Testi (PQR) is required before production Kaynak begins.
Ön yeterlilik durumu proses bazlıdır. Table 5.1 SMAW'ı, Table 5.2 SAW'ı, Table 5.3 GMAW'ı (yalnızca dolu tel — GMAW-S ön yeterliliği onaylanamaz) ve Table 5.4 hem FCAW hem de GMAW metal özlüyü birlikte kapsar. Her tablo, o proses için izin verilen parametre aralıklarını belirtir.
Ön Yeterliliği Onaylanmış Ana Malzeme Grupları
Table 5.6, ön yeterliliği onaylanmış WPS'ler için onaylanmış ana malzemeleri listeler. 2025 sürümü, ASTM A913 Grade 80'den oluşan yeni bir Grup V eklemiştir — bu yüksek mukavemetli kategorideki tek malzeme. Grup I'den IV'e kadar olanlar, yaygın yapı çeliklerini kapsar: A36, A572, A992, A913 Gr50/65/70 ve diğerleri. Table 5.6'da listelenmeyen ana malzemeler, Clause 6 uyarınca PQR testi ile nitelikli bir WPS gerektirir.
Ön Yeterliliği Onaylanmış WPS'ler İçin Ön Isıtma Gereksinimleri
Ön yeterliliği onaylanmış WPS'ler için Minimum ön ısıtma ve pasolar arası sıcaklıklar, çelik şartname, proses kategorisi (A'dan G'ye) ve malzeme kalınlığına göre gereksinimleri listeleyen Table 5.11 (bkz. Clause 5.7) tarafından belirlenir. 2025 sürümü üç yeni kategori eklemiştir: Kategori E (H8 Elektrotlar ile A1066 Gr.50/60/65), Kategori F (H8 Elektrotlar ile A913 Gr.70) ve Kategori G (H4 Elektrotlar ile A913 Gr.80). A'dan D'ye kadar olan kategoriler, geleneksel ve düşük hidrojen prosesleri ile yaygın yapısal ve daha yüksek mukavemetli çelikleri kapsar. Table 5.11'deki ön ısıtma değerleri zorunlu minimumlardır — WPS, belirli malzeme ve kalınlık için tablo değerine eşit veya üzerinde bir ön ısıtma sıcaklığı belirtmelidir.
Ön Yeterliliğin Uygulanmadığı Durumlar
Electroslag welding (ESW) and electrogas welding (EGW) are not prequalifiable — they require qualification testing under Clause 6. Joints not shown in the prequalified joint details of Clause 5.4 must also be qualified. If any essential variable falls outside the Table 5.1–5.4 limits, the WPS requires a PQR. See the PQR guide for D1.1's two qualification paths.
Why a Generic D1.1 WPS Pack Is Not Enough
A purchased or template WPS pack is only useful if each WPS actually matches the job. D1.1 Clause 5.1 exempts prequalified WPSs from Clause 6 testing only when the WPS conforms to all applicable Clause 5 requirements. Clause 5.2.1 also requires the written WPS to specify the variables in Table 5.5, and changes beyond permitted limits require a new or revised prequalified WPS or qualification by test.
That means "AWS D1.1 WPS included" is not a compliance answer by itself. The project still has to match the base metal group, filler metal, process, transfer mode, joint detail, position, preheat Kategori, interpass limits, and contract requirements. If the pack does not cover the actual joint or the contract documents require something stricter, it is a starting template, not a production WPS.
Yaygın Ön Yeterlilik Hataları
Fabricators frequently encounter prequalification failures from variables that appear minor but violate Clause 5 limits. GMAW short-circuit transfer (GMAW-S) is not prequalifiable under any condition — Clause 5.5.1 requires the mode of transfer to not be short circuit for GMAW prequalification. Using GMAW-S requires qualification under Clause 6 with PQR testing regardless of base metal or joint type.
Exceeding Table 5.1–5.4 parameter limits is another common issue. Each process Tablo specifies Maksimum Elektrot diameter, maximum single-pass filler metal Boyut, maximum welding current ranges, and layer Kalınlık limits. For example, Table 5.1 (SMAW) limits the maximum electrode diameter to 1/4 in [6.4 mm] for flat-position groove welds and 3/16 in [4.8 mm] for all other positions. Root pass electrodes are further restricted to 3/16 in [4.8 mm] maximum. A WPS that specifies an electrode diameter or current outside these ranges cannot claim prequalified status.
Non-prequalified joint details also require qualification testing. Clause 5.4 provides specific joint geometries — groove angles, root openings, root face dimensions, and backing requirements — for CJP and PJP groove welds and fillet welds. Any joint configuration not matching the prequalified details in Clause 5.4 figures requires a qualified WPS under Clause 6, even if all other variables (process, base metal, filler metal) are within prequalified limits. Modifying a prequalified joint detail — such as reducing the groove angle below the listed minimum — invalidates the prequalification.
Tam içerik yakında. Bu sayfa, eksiksiz Tablo 5.1–5.4 parametre aralıkları, bir ön yeterlilik kontrol listesi ve çözülmüş örneklerle genişletilmektedir. Bu arada Table 5.11 aramaları için ön ısıtma hesap makinesini kullanın.
Daha Fazla WPS Kaynağı
Sıkça Sorulan Sorular
A WPS is prequalified when every essential variable — process, base metal group, filler metal, joint detail, position, preheat, and interpass temperature — falls within the limits specified in D1.1:2025 Clause 5. Process limits are in Tables 5.1–5.4, base metals in Table 5.6, filler metals in Tables 5.7–5.10, and preheat in Table 5.11. No PQR testing is required.
Four processes are prequalifiable: SMAW (Table 5.1), SAW (Table 5.2), GMAW with solid wire only (Table 5.3), and FCAW/GMAW metal core combined (Table 5.4). GMAW short-circuit transfer (GMAW-S) is not prequalifiable. Electroslag welding (ESW) and electrogas welding (EGW) require qualification testing under Clause 6.
Tablo 5.6, Grup I'den V'e kadar onaylanmış ana malzemeleri listeler. Grup I–IV, A36, A572, A992 ve A913 Gr50/65/70 dahil olmak üzere yaygın yapı çeliklerini kapsar. 2025 sürümü, ASTM A913 Grade 80 için Grup V'i eklemiştir. Tablo 5.6'da listelenmeyen ana malzemeler, Clause 6 uyarınca PQR testi ile nitelikli bir WPS gerektirir.
Prequalification does not apply when any essential variable falls outside the Table 5.1–5.4 limits, when the joint is not shown in the prequalified joint details of Clause 5.4, or when using ESW or EGW processes. GMAW short-circuit transfer (GMAW-S) is also excluded from prequalification per Clause 5.5.1, even though standard GMAW spray transfer is prequalified. In all these cases, the WPS must be qualified with a PQR under Clause 6.
A prequalified WPS can fail inspection for several reasons even though no PQR testing was required. The most common failures are: exceeding the essential variable limits of Table 5.5 during production welding (for example, welding outside the documented amperage range or exceeding the maximum interpass temperature), using a joint detail that does not match the prequalified joints in Clause 5.4 and Figure 5.1, failing to meet the minimum preheat requirements of Table 5.11, or producing welds that do not meet the visual acceptance criteria of Table 8.1. Prequalified status means the procedure is approved without testing — it does not exempt the production welds from meeting all quality requirements of Clauses 7 and 8.
No. Under D1.1:2025 Clause 5, a prequalified WPS is exempt from the qualification testing required by Clause 6. This means no test coupon, no destructive testing, and no procedure qualification record. The code has already validated the joint configurations, processes, and parameter ranges covered by Clause 5. However, the welder must still be qualified per Clause 6 Part C — prequalification of the procedure does not extend to the welder. If any variable on your WPS falls outside the prequalified limits, the exemption does not apply and you must qualify the WPS with PQR testing per Clause 6.2.1.