Worked example · AWS D1.1/D1.1M:2025 Clause 6

GMAW-S PQR-to-WPS example: a complete synthetic training case

SYNTHETIC TRAINING DATA — NO WELDING OR TESTING TOOK PLACE. Every record identifier, material certificate, procedure value, coupon detail, test count and assumed outcome below is fictional and was created for instruction. There is no actual PQR, laboratory, test report, signature, approval, company record or production result. This is not an issued or usable production WPS and does not establish qualification.

This bounded exercise follows one fictional plate CJP record through three distinct stages: the supplied training input, the Clause 6 coverage supported under the stated assumptions, and a deliberately narrow final WPS. GMAW-S follows the Clause 6 qualification route; it is not a Clause 5 prequalified process.

Scenario: one 6 mm ASTM A36-to-A36 plate CJP groove weld, tested in the fictional record at 3G vertical-up with steel backing. The final example covers that same material pair, thickness, joint detail, position, process, consumable, gas and exact recorded parameter set. It does not combine independent parameter extremes.

Download the synthetic input and field-by-field coverage CSV · Download the complete WPS preview (HTML)

1. Fictional input record

The table below is the complete stipulated training input. “Recorded” means a fictional value in this exercise only; it does not report a real measurement.

Record field	Synthetic training value	Purpose in this exercise
Code and units	AWS D1.1/D1.1M:2025 base edition; registered 2026-07-28 base errata; AMD1 excluded; SI	Locks the stated rule basis.
Fictional record IDs	Training organization: EXAMPLE FABRICATOR (fictional); PQR TR-GMAWS-001 Rev T0; WPS TR-GMAWS-001 Rev T0	Identifiers are visibly reserved for training.
Coupon	Non-tubular plate; two 6 mm ASTM A36 plates; CJP single-V butt joint; 3G vertical-up; transverse-bend layout plate 510 mm × 360 mm minimum under Figure 6.7(2) (synthetic dimensions)	Defines the branch and the tested condition.
Joint and backing	60° included groove angle; 2 mm root opening; 1 mm root face; 6 mm × 25 mm carbon-steel backing; one side welded; no backgouging; backing retained	Final WPS repeats this exact configuration.
Process and sequence	GMAW-S only; conventional non-waveform-controlled CV power source; DCEP; vertical-up; three stringer passes, root/fill/cap; synthetic deposit allocation 2/2/2 mm	No process segment or deposit value is borrowed from another record.
Filler and gas	AWS A5.18/A5.18M ER70S-6 solid wire, 0.9 mm; argon 75% / CO₂ 25%; 15 L/min	Classification, diameter and gas composition remain fixed.
Per-pass recorded parameter set	110 A; 18.0 V; 3.8 m/min wire-feed speed; 200 mm/min travel speed; same stipulated set for all three passes	These are invented record values, not measured or manufacturer-certified settings.
Temperature	Coupon preheat recorded as 20°C; stipulated minimum interpass 20°C; no maximum specified for this non-CVN example	The fictional WPS uses a 20°C minimum.
Heat treatment and CVN	No PWHT; contract CVN requirement stipulated “No”	Table 6.8 CVN supplementary variables and PWHT branch are not invoked by the stated assumptions.
Qualification test record	Fictional assumed test set for a 3–10 mm CJP plate test: VT; RT of the entire weld length except discard lengths at each end before specimen cutting; 2 reduced-section tension, 2 root bends, 2 face bends; all outcomes stipulated “pass for teaching example only”	No welding, RT or mechanical testing occurred; there are no specimens, measured results, images, reports or lab.
External records	No actual material/filler certificates, drawing, contract, weld log, lab report, review, signature or Engineer/customer acceptance	These missing real-world records prevent use as a production document.

2. Field-by-field qualification derivation

Dimension	Training record value	Code-supported result for the fictional branch	Final WPS choice	Rule check
Route / process	GMAW short-circuit transfer (GMAW-S)	Clause 6 qualification route; not prequalified under Clause 5	GMAW-S only	5.5.1–5.5.2; 6.16.1.1
Coupon type / weld	Non-tubular plate CJP groove	Use plate CJP qualification branch	Plate CJP butt groove only	6.5–6.6, 6.11, Table 6.2
Base-metal pair	A36 / A36, each assigned Group II for this all-thickness entry	Group II-to-II record supports the Table 6.9 combinations, including Group II-to-II; material identity still must match the target	ASTM A36 to ASTM A36 only	Table 5.6; 6.8.3; Table 6.9
Coupon thickness	T = 6 mm	Printed SI row 3–10 mm; qualified base-metal thickness 3 mm minimum to 2T = 12 mm maximum	6 mm only	Table 6.2, 3–10 mm row. This is base-metal thickness, not deposit thickness.
Position / progression	3G plate, vertical-up	Plate CJP 3G supports production vertical position (V)	V, vertical-up only	6.4; Table 6.1. This does not establish welder qualification.
Joint detail / backing	Single-V, 60°, 2 mm opening, 1 mm face, steel backing retained, no backgouge	Use the same stipulated CJP configuration; omission of backing or a material change to the test arrangement is outside this narrow example	Exact stated detail only	6.6 Table 6.6 general joint variables; 6.11.1; 6.7
Process deposit	Three GMAW-S passes; stipulated deposits 2 + 2 + 2 = 6 mm	No generic per-process multiplier is inferred from Table 6.2. Retain the fictional pass record and its exact sequence.	Three passes, same sequence; 6 mm total deposited metal	6.7; read process deposit from the record, not the coupon thickness.
Filler / diameter	ER70S-6, 0.9 mm	No change is selected. Any classification or diameter change must be assessed under the applicable Table 6.6 row and other applicable requirements.	ER70S-6, 0.9 mm only	6.7–6.8; Table 6.6.
Transfer / current / source	GMAW-S; DCEP; CV; non-waveform	No mode, polarity, source characteristic or waveform change is selected.	Same values only	Table 6.6; 6.8.5 applies to heat-input calculation only when CVN is contractually required.
Amps / volts / WFS / travel	Each pass: 110 A / 18.0 V / 3.8 m/min / 200 mm/min	Final selected point equals each fictional PQR value (zero change); this avoids using the Table 6.6 thresholds as invented operating ranges.	Same point set for root, fill and cap	Table 6.6 GMAW rows: any proposed change is compared to actual process records; the table limits are requalification triggers, not automatic WPS ranges.
Shielding gas	Ar 75% / CO₂ 25%, 15 L/min	No composition or flow change selected.	Same mixture and 15 L/min only	Table 6.6 GMAW gas rows; 6.7 requires recorded WPS variables.
Preheat / interpass	20°C stipulated preheat; stipulated minimum interpass 20°C	Minimum preheat is established by the fictional qualification test under 6.8.4.1(3); minimum interpass equals the qualified minimum preheat under 6.8.4.2.	Minimum preheat 20°C; minimum interpass 20°C	6.8.4; any decrease from PQR minimum remains subject to Table 6.6 and 7.6.
CVN / heat input	Contract CVN: No	Table 6.8 supplementary CVN variables and 6.8.5 CVN heat-input limit are not triggered by this stated assumption.	No CVN requirement stated; no qualified heat-input limit in this example	6.8.1 and 6.8.5; a real contract could change this branch.
PWHT	None	No addition or deletion relative to the stipulated record.	No PWHT	Table 6.6 PWHT variable; Clause 7 and project requirements still apply.
Tests / validity	Assumed synthetic VT, RT, tensile and bend statuses	Clause 6.11.3 requires visual inspection, completed-coupon NDT, bend tests and tensile tests. Under 6.10.2, RT or UT examines the entire weld length except end discard lengths before mechanical specimen cutting; the synthetic scenario stipulates RT. Nothing was actually tested.	Training demonstration only	6.10.1–6.10.3, 6.11.3 and Table 6.2. Real NDT and mechanical-test reports are indispensable for production issue.

Table 6.6 limits do not create a free Cartesian product of amperage, voltage, WFS, travel speed, gas and filler values. This example selects one exact parameter set, one joint configuration and one base-metal pair. Its “code-supported result” assumes, solely for the exercise, a complete successful record; it is not an independently established real qualification.

3. Complete training WPS

The download below contains the complete English WPS form for this exercise: document control, application limits, supporting record, base metals, joint geometry, pass/deposit matrix, parameter schedule, temperatures, CVN/PWHT status, production technique and document control. Each field repeats the assumptions and warnings shown on this page.

WPS field	Final training value
Scope	Single non-tubular 6 mm A36-to-A36 plate CJP single-V butt joint; 3G vertical-up; one-side GMAW-S over retained steel backing.
Pass plan	Three stringer passes in root/fill/cap order; stipulated deposit 2 mm per pass, 6 mm total.
Parameters (each pass)	ER70S-6 0.9 mm; DCEP; CV; GMAW-S; 110 A; 18.0 V; WFS 3.8 m/min; travel 200 mm/min; Ar 75% / CO₂ 25% at 15 L/min.
Temperature / special requirements	Minimum preheat 20°C; minimum interpass 20°C; no stated CVN requirement; no PWHT.

Open the complete WPS training preview · Download HTML WPS · Download input and derivation CSV

Limits before any real WPS can be issued

This exercise teaches how a complete PQR record would be mapped. It does not satisfy the PQR evidence requirement: no welded coupon, actual variable log, mechanical test, laboratory report, material/filler certificate, project drawing, contract review, signatures or acceptance exists. The fictional “pass” labels are assumptions in a synthetic dataset, not test results. A real WPS must be rebuilt from actual, legible and traceable source records and the governing contract edition.

Code basis for the rule demonstration: AWS D1.1/D1.1M:2025 base edition plus the registered 2026-07-28 base-edition errata; AMD1 excluded. Primary provisions: 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. Clause/table references identify the rule path; consult the standard and applicable project documents for an actual WPS.

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