Existing-PQR review · Clause 6

How do you review a multi-process PQR without blending its process records?

A single coupon can contain multiple welding processes, but its overall thickness and combined pass record do not create one shared qualification range. Trace each process segment to its own deposited thickness, actual variables, and applicable PQR support.

Decision rule: Create a separate evidence row for every process segment and preserve its sequence. Apply each process’s Table 6.6 variables and, when CVN applies, Table 6.8 additions. Do not use the coupon’s full thickness as each process’s deposit range.

Build one evidence line per process segment

Record field	What to transcribe from the source	Why it stays separate
Sequence and purpose	Root, fill, cap; process order; pass or layer identifiers	Changing sequence or which process deposits a layer may affect qualification and the production WPS.
Deposit thickness	Actual deposited weld-metal thickness attributed to that process, with record/page locator	Coupon base-metal thickness is a different dimension. One process’s deposit cannot be assigned to another.
Filler and equipment	Classification, diameter, flux/wire pairing, gas, polarity, transfer mode, CV/CC, waveform and electrode count as applicable	Essential-variable changes differ by process and can be narrower than the coupon’s geometric range.
Operating values	Actual amperage, voltage, wire-feed, travel speed, heat input and temperature values where recorded	Limits are based on actual PQR values and the correct process-specific rule, not generic symmetric ranges.
Supporting evidence	PQR ID/revision, test assembly, test reports/results, edition and any CVN/PWHT records	A WPS may combine processes only where each segment and their combined arrangement are supported.

Intersect the records; do not add their ranges

First establish the applicable base-metal thickness and joint branch for the coupon. For a plate CJP test, Table 6.2 addresses nominal base-metal thickness and its test conditions. It does not prescribe a universal per-process weld-metal multiplier. The process deposits must come from the PQR/pass records, then be reviewed against the applicable variables and clauses.

For each segment, compare the proposed production condition to its own PQR record and the relevant Table 6.6 process column. If contract CVN requirements apply, Table 6.8 supplementary essential variables add constraints. Preserve the PQR value, code allowance and selected WPS range as separate fields.

When separate PQRs support separate segments, map each WPS segment to its source record. Confirm the joint/test assembly and sequence are compatible across the combined procedure. Do not take the widest material range from one record, widest deposit from another and widest electrical range from a third unless the actual qualification basis supports that exact combination.

Bounded example: root and fill processes

Suppose one hypothetical successful CJP plate coupon used Process A for the root and Process B for fill/cap. If the nominal coupon thickness is 1/2 in, Table 6.2’s applicable row may establish a base-metal thickness result subject to row conditions and exceptions. That 1/2 in value does not mean Process A deposited 1/2 in or Process B deposited 1/2 in.

The records must show each process’s actual deposit and operating variables. If the split cannot be established from the PQR or its supporting record, that process-specific field remains unresolved. No automatic equal split or presumed fill percentage is justified.

If a combined WPS cannot show source support for one process segment or for the proposed process sequence, narrow the WPS to the supported arrangement or treat that target as requiring additional qualification.

Practical review sequence

Identify every process and its order in the coupon and target joint.
Record each process’s filler, deposit, pass details and actual variables with source locations.
Determine the applicable base-metal/joint coverage separately under Tables 6.2–6.5 or the tubular route.
Compare each process to its Table 6.6 variables; add Table 6.8 for CVN requirements and check special clauses.
Write only supported combinations and retain a traceability row for every WPS process segment.

When several PQRs are offered for one WPS

Make one coverage row for each original PQR and process segment, with the actual coupon, material pair, joint, position, deposit and essential variables. A second PQR can support a different documented segment or condition only where the applicable qualification rules support the target arrangement. Do not take the largest base-metal thickness from PQR A, the highest filler deposit from PQR B and the widest parameter change from PQR C as a new combined range that no qualifying path supports.

Compare the proposed production configuration with each record and then with the rules for the combined process sequence. If the sources cannot establish one coherent supported configuration, narrow the WPS or keep the proposed combination unresolved. The number of PQRs does not itself expand qualification.

Code basis and limits

This guide follows AWS D1.1/D1.1M:2025 base edition plus the registered July 28, 2026 base-edition errata; AMD1 is not included. The contract edition governs each project. Review the actual PQR, supporting test reports, applicable table notes and project requirements before issuing a production WPS.

Primary provisions: Clause 6.7–6.8, applicable Tables 6.2–6.8, and special process or joint provisions as identified above. References describe the review method; they do not replace the purchased standard or establish that a particular PQR passed.

Existing-PQR WPS service inputs Editable PQR coverage matrix Base-metal versus deposit thickness

Read the edition and errata basis.

Have an existing PQR?

Use the complete qualification record and project target to set the WPS scope.

Start a WPS request