Understanding Prequalified WPSs and What QA/QCs Should Know

Prequalified Welding Procedure Specifications (WPSs) underpin many structural welding operations. They allow qualified combinations of materials, joints, and parameters to be used without further testing, as long as every variable falls within the boundaries established by the governing code.

In AWS D1.1 – Structural Welding Code (Steel), these conditions are defined in Clause 5, which identifies the requirements for prequalified procedures, from joint geometry and base-metal groupings to filler-metal compatibility and process limitations.

For QA/QC professionals, understanding not just what makes a WPS prequalified, but where those limits end, is essential for optimizing code compliance and production consistency.

The Role of Prequalification in Welding Control

Prequalification standardizes what is already proven. Rather than qualifying a WPS by testing every variable combination, the code provides a list of joint configurations, processes, and materials that have demonstrated acceptable mechanical performance over time.

A prequalified WPS must therefore:

• Use approved joint details shown in the code figures

• Specify base metals that fall within the prequalified groupings

• Employ matching or slightly overmatching filler metals

• Stay within the defined limits of current, voltage, travel speed, and position

If any variable goes beyond these conditions, the WPS no longer meets prequalification criteria and must be qualified through a PQR.

For QA/QC teams, this shifts focus from qualification testing to verifying accuracy and consistency in documentation, welder setup, and in-process readings.

QA/QC Focus Areas

1. Verification of Code Alignment
   Each WPS must reference the correct figures, tables, and edition year. Even a small change in a joint angle or filler classification can move a procedure out of compliance.
   
   

2. Parameter Control
   QA/QC checks during production should confirm that amperage, voltage, travel speed, wire feed speed, and shielding gas flow (where applicable) all remain within prequalified limits. Consistent parameter recording is a key audit requirement.
   
   

3. Material Traceability
   Verify that base-metal and filler-metal group numbers match code-approved combinations. See Table 5.6, Table 5.7, and Table 5.10.

   See Table 5.11 to check that minimum preheat and interpass temperatures meet requirements for prequalified procedures.
   
   

4. Revision Management
   When a new code edition is released, prequalified WPSs must be reviewed for table updates and structural changes, even when the underlying welding process hasn’t changed.

AWS D1.1 2025: Clause 5 Reorganization

The 2025 edition of AWS D1.1 brings a notable update to how prequalified WPSs are structured.
Clause 5 has been reorganized into process-specific tables, improving clarity and reducing errors caused by cross-referencing:

• Table 5.1 – SMAW

• Table 5.2 – SAW

• Table 5.3 – GMAW (Solid Wire)

• Table 5.4 – FCAW and GMAW (Metal-Cored Wire)

This change helps engineers and inspectors focus directly on the parameters relevant to each process.

Key Updates

Minimum Current Requirements:
For GMAW (Solid Wire), minimum current limits are now tied to electrode diameter for non-short-circuit and pulsed modes. WPSs must reflect these minima, and recorded amperage must not fall below them.

Reorganized FCAW/Metal-Cored Data:
Table 5.4 has been revised to clarify acceptable ranges by electrode diameter, welding position, and base-metal thickness, streamlining parameter selection.

Revised Supporting Tables:

• Essential-variable tables moved (Table 5.2 → 5.5).

• Base-metal groupings renumbered (Table 5.3 → 5.6).

• Matching-strength filler metals updated (now Table 5.7), including a new Group V.

• Clause 5.6.2 limits overmatching filler metals to ≤ 10 ksi above matching strength.

• Joint-detail figures (5.1 and 5.2) replaced with clearer, proportionate drawings.

For QA/QC, the practical outcome is the need to revalidate all existing prequalified WPSs — ensuring amperage values, filler-metal classifications, and table references align with the new edition.

How ProWrite Supports AWS D1.1 2025 Alignment

ProWrite incorporates the essential Clause 5 updates from the 2025 AWS D1.1 revision directly into its prequalified WPS framework.

The software now provides:

• Automatic validation of minimum current requirements, including GMAW solid-wire limits by electrode diameter

• Built-in lookup tables for base-metal and filler-metal groupings (Tables 5.6 and 5.7), including new Group V

• Process-specific templates aligned with Tables 5.1 through 5.4

• Real-time compliance checks that flag out-of-range parameters before approval

These integrations reduce manual verification effort and help ensure every WPS produced or revised reflects the current AWS D1.1 requirements.

To see the complete review of updates and detailed guidance, download the full 2025 AWS D1.1 Guide prepared by CEI’s CWI.

Conclusion

Prequalified WPSs remain essential for ensuring weld quality, consistency, and efficiency. Their effectiveness depends on strict adherence to code-defined variables, joint details, and material combinations.

The 2025 AWS D1.1 updates strengthen this framework through clearer process separation and defined current and filler-metal requirements.

With tools like ProWrite integrating these revisions, engineers and QA/QC teams can maintain compliance, traceability, and confidence that every WPS aligns fully with the latest code standards.