SYNTHETIC TRAINING DATA — NO WELDING OR TESTING TOOK PLACE. This fictional WPS does not establish qualification and is not for production use. No actual PQR, lab, report, signature, approval, company record, or test result exists. “Recorded” and “pass” below refer only to stipulated fictional inputs/statuses.
| WPS No. / revision | TR-GMAWS-001 / T0 (fictional) | Date | 2026-10-08 — training artifact date only |
|---|---|---|---|
| Manufacturer / contractor | EXAMPLE FABRICATOR — fictional training name | Project / weld ID | None; classroom scenario |
| Governing code | AWS D1.1/D1.1M:2025 base edition + registered 2026-07-28 base errata; AMD1 excluded | Units | SI |
| Qualification basis | Fictional Clause 6 PQR training record TR-GMAWS-001 Rev T0. This is not a Clause 5 prequalified WPS. GMAW-S is handled through the Clause 6 route. | ||
| Record locator | Synthetic teaching dataset only; no controlled record exists. | ||
| Weld type / branch | Non-tubular CJP groove weld; single-V butt joint | Production position | 3G plate position V; vertical-up only |
|---|---|---|---|
| Base-metal thickness | 6 mm only for this final WPS example | Tube diameter | Not applicable |
| Production weld size / deposit | CJP; stipulated three-pass total deposited thickness 6 mm (2 mm/pass) | Scope limits | ASTM A36 to ASTM A36 only; 6 mm plate only; exact joint, backing, process, filler, gas, position and parameter set on this form. No unlisted steel, tubular weld, other position, or alternate procedure. |
| Field | Synthetic input |
|---|---|
| PQR ID / revision; organization | TR-GMAWS-001 Rev T0; EXAMPLE FABRICATOR, fictional |
| Code / date | AWS D1.1/D1.1M:2025 basis stated above; no actual test date |
| Coupon | Two non-tubular ASTM A36 plates; 510 mm × 360 mm minimum × 6 mm nominal (transverse-bend specimen layout per Figure 6.7(2), no-CVN branch); CJP single-V; 3G vertical-up |
| Test joint detail | 60° included angle; 2 mm root opening; 1 mm root face; carbon-steel backing 6 mm thick × 25 mm wide; weld from one side; no backgouging; backing retained |
| Process segment | GMAW-S only; conventional non-waveform-controlled CV source; DCEP; vertical-up; root → fill → cap |
| Filler / diameter | AWS A5.18/A5.18M ER70S-6 solid wire; 0.9 mm |
| Gas | Argon 75% / CO₂ 25%; stipulated flow 15 L/min |
| Per-pass synthetic recorded parameters | Passes 1–3 each: 110 A; 18.0 V; 3.8 m/min wire-feed speed; 200 mm/min travel speed |
| Deposited metal | Stipulated 2 mm root + 2 mm fill + 2 mm cap = 6 mm total |
| Preheat / interpass | Stipulated coupon preheat 20°C; stipulated minimum interpass 20°C; no maximum recorded as required under these no-CVN assumptions |
| CVN / PWHT | Contract CVN requirement stipulated No; PWHT none |
| Qualification tests | Fictional assumed set for 3–10 mm plate CJP: under 6.11.3, VT and completed-coupon NDT; stipulated RT of the entire weld length except discard lengths at each end before cutting specimens, under 6.10.2.1; 2 reduced-section tension, 2 root bends, 2 face bends. Teaching-only assumed acceptable status under Clause 8 Part C; no welding, RT, measured results, images, specimens, report or lab exists. |
| Supporting real documents | None: no actual material certificates, filler certificates, gas certificate, drawing, contract, welding log, test report, lab, signatures, review or approval. |
| Member | Stipulated test material | Group assignment | Coupon thickness | Code-supported result in this fictional branch | Final WPS scope |
|---|---|---|---|---|---|
| Both members | ASTM A36 plate to ASTM A36 plate | Group II to Group II (A36 appears in Table 5.6 Group II for all thicknesses) | 6 mm | Table 6.9 Group II-to-II combination includes Group II-to-II. Table 6.2 row 3–10 mm supports base-metal thickness 3 mm minimum to 2T = 12 mm maximum, subject to the stated branch and conditions. | A36 to A36; 6 mm only. |
The Table 6.2 output is nominal base-metal thickness coverage. It is not a deposited weld-metal thickness multiplier. This training WPS deliberately selects only the exact 6 mm target and does not create independent extreme ranges.
| Production detail | Single-V CJP butt joint; included angle 60°; root opening 2 mm; root face 1 mm; same as stipulated test joint |
|---|---|
| Backing / backgouging | Carbon-steel backing, 6 mm × 25 mm; retained; weld from one side; no backgouging |
| Qualification geometry | Exact stipulated joint repeated; no alternate groove, backing condition, root opening, root face or angle included. |
| Fit-up | Maintain the specified dimensions; any change requires review against the original test details, applicable code limits and project drawing. |
| Sequence | Process / role | Position | Stipulated deposit | Pass count |
|---|---|---|---|---|
| 1 | GMAW-S root | 3G vertical-up | 2 mm | 1 stringer pass |
| 2 | GMAW-S fill | 3G vertical-up | 2 mm | 1 stringer pass |
| 3 | GMAW-S cap | 3G vertical-up | 2 mm | 1 stringer pass |
| Total | 6 mm | 3 passes | ||
| Pass | Filler / diameter | Current / polarity | Transfer / source | Gas / flow | Synthetic PQR value | Final WPS value |
|---|---|---|---|---|---|---|
| Root | ER70S-6 / 0.9 mm | 110 A / DCEP | GMAW-S / CV, non-waveform | Ar 75% / CO₂ 25%; 15 L/min | 18.0 V; WFS 3.8 m/min; travel 200 mm/min | 110 A; 18.0 V; WFS 3.8 m/min; travel 200 mm/min |
| Fill | ER70S-6 / 0.9 mm | 110 A / DCEP | GMAW-S / CV, non-waveform | Ar 75% / CO₂ 25%; 15 L/min | 18.0 V; WFS 3.8 m/min; travel 200 mm/min | 110 A; 18.0 V; WFS 3.8 m/min; travel 200 mm/min |
| Cap | ER70S-6 / 0.9 mm | 110 A / DCEP | GMAW-S / CV, non-waveform | Ar 75% / CO₂ 25%; 15 L/min | 18.0 V; WFS 3.8 m/min; travel 200 mm/min | 110 A; 18.0 V; WFS 3.8 m/min; travel 200 mm/min |
Parameter correlations and ranges: one exact set per pass as shown; no free combinations or operating ranges are authorized by this training artifact. Heat-input limit: none established for this no-CVN scenario. Waveform-controlled welding: No. SAW / ESW / EGW variables: not applicable.
| Minimum preheat | 20°C (stipulated value; for the exercise, established by the hypothetical qualification test under 6.8.4.1(3)) |
|---|---|
| Minimum interpass | 20°C; Clause 6.8.4.2 sets the minimum interpass equal to the qualified minimum preheat |
| Maximum interpass | Not specified for the stated no-CVN assumption; re-evaluate if the actual material, contract or code basis requires a maximum |
| Measurement / timing | Before welding and before resuming after the plate falls below the stated minimum; verify using a suitable temperature-measurement method and Clause 7 requirements. This form defines no actual customer instrumentation. |
| PWHT | None on the stipulated record; none in this training WPS |
| Contract CVN | No — fictional scenario assumption only |
|---|---|
| CVN temperature / results / lab | Not applicable under the stipulated assumption; no CVN testing took place |
| CJP qualification tests | Under 6.11.3, the completed coupon requires VT, coupon NDT, bend specimens and tensile specimens. The synthetic scenario stipulates RT under 6.10.2.1 of the entire weld length except discard lengths at each end, before mechanical specimen cutting; it assumes acceptance under Clause 8 Part C solely for teaching. It also stipulates the Table 6.2 3–10 mm specimen set: 2 reduced-section tension, 2 root bends and 2 face bends, with assumed teaching-only pass status. No weld, radiograph, specimen, measured result, report, laboratory or accepted PQR exists. |
| Failures / retests | No real test history exists; not applicable to this fictional exercise |
| Preparation / cleaning | Clean joint faces and adjacent surfaces before welding; clean each pass and remove visible contamination/spatter before the next pass. |
|---|---|
| Pass technique | Three stringer passes in root, fill, cap order; vertical-up only. Keep the stated pass sequence and backing condition. |
| Consumable / gas handling | Use the stated wire classification and size; keep wire clean and dry per applicable manufacturer instructions. Verify the actual gas product/composition and flow against the production equipment and governing requirements. |
| Tack / sequence | Fit and tack to maintain the specified root opening/alignment; remove or incorporate tacks only under approved project practice and applicable requirements. |
| Environment | Protect the joint and gas shield from conditions that prevent sound welding; comply with Clause 7 and project requirements. This synthetic example supplies no site conditions. |
| Start / stop / backing | Backing remains in place. Fill craters and remove arc starts/stops that do not meet applicable workmanship requirements. |
| Other restrictions | Single process; non-tubular plate; CJP; 6 mm A36-to-A36; 3G vertical-up; exact detail and parameters only. Welder qualification and production inspection are separate requirements. |
| Prepared by | Training artifact; no actual preparer of a production WPS |
|---|---|
| Reviewed by / date | NOT REVIEWED — no signature |
| Authorized by / date | NOT AUTHORIZED — no signature |
Rule references: AWS D1.1/D1.1M:2025, 5.5.1–5.5.2; 6.4–6.8; 6.10–6.11; Tables 6.1, 6.2, 6.6, 6.8 and 6.9. Base-edition errata dated 2026-07-28 applied where relevant; AMD1 excluded. The actual contract edition governs real work. This HTML is an original instructional artifact and not an AWS form.