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Bend test coupons for welding procedure qualification.A Welding Procedure Specification (WPS) is a formal document describing welding procedures. It is an internal document used by welding companies to instruct welders (or welding operators) on how to achieve quality production welds that meet all relevant code requirements. Each company typically develops their own WPS for each material alloy and for each welding type used. Specific codes and/or engineering societies are often the driving force behind the development of a company's WPS. A WPS is supported by a Procedure Qualification Record (PQR or WPQR), a formal record of a test weld performed and rigorously tested to ensure that the procedure will produce a good weld. Individual welders are certified with a qualification test documented in a Welder Qualification Test Record (WQTR) that shows they have the understanding and demonstrated ability to work within the specified WPS.
Introduction
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The following are definitions for WPS and PQR found in various codes and standards:
According to the American Welding Society (AWS), a WPS provides in detail the required welding variables for specific application to assure repeatability by properly trained welders. The AWS defines welding PQR as a record of welding variables used to produce an acceptable test weldment and the results of tests conducted on the weldment to qualify a Welding Procedure Specification. For steel construction (civil engineering structures) AWS D1.1 is a widely used standard. It specifies either a pre-qualification option (chapter 3) or a qualification option (chapter 4) for approval of welding processes.[1]
The American Society of Mechanical Engineers (ASME) similarly defines a WPS as a written document that provides direction to the welder or welding operator for making production welds in accordance with Code requirements.[2] ASME also defines welding PQR as a record of variables recorded during the welding of the test coupon. The record also contains the test results of the tested specimens.
The Canadian Welding Bureau, through CSA Standards W47.1,[3] W47.2[4] and W186,[5] specifies both a WPS and a Welding Procedure Data Sheet (WPDS) to provide direction to the welding supervisor, welders and welding operators. The WPS provides general information on the welding process and material grouping being welded, while the WPDS provides specific welding variables/parameter/conditions for the specific weldment. All WPS and WPDS must be independently reviewed and accepted by the Canadian Welding Bureau prior to use. These CSA standards also define requirements for procedure qualification testing (PQT) to support the acceptance of the WPDS. A record of the procedure qualification test and the results must be documented on a procedure qualification record (PQR). All PQTs are independently witnessed by the Canadian Welding Bureau.
In Europe, the European Committee for Standardization (CEN) has adopted the ISO standards on welding procedure qualification (ISO to ISO ), which replaced the former European standard EN 288. EN ISO defines a WPS as "A document that has been qualified by one of the methods described in clause 6 and provides the required variables of the welding procedure to ensure repeatability during production welding". The same standard defines a Welding Procedure Qualification Record (WPQR) as "Record comprising all necessary data needed for qualification of a preliminary welding procedure specification".[6] In addition to the standard WPS qualification procedure specified in ISO , the ISO 156xx series of standards provides also for alternative WPS approval methods. These include: Tested welding consumables (ISO ), Previous welding experience (ISO ), Standard welding procedure (ISO ) and Preproduction welding test (ISO ).
In the oil and gas pipeline sector, the American Petroleum Institute API standard is used almost exclusively worldwide. API accepts the definitions of the American Welding Society code AWS A3.0.[7]
WPS is of two types- Prequalified WPS(pWPS) & qualified WPS.
See also
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References
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AWS D1.1/D1.1M: "Structural welding code - Steel"
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ASME Boiler and Pressure Vessel Code section IX: "Qualification Standard for welding and brazing procedures, welders, brazers and welding and brazing operators", Article II, Section QW-200.
CSA Standard W47.1: Certification of companies for the fusion welding of steel ()
CSA Standard W47.2: Certification of companies for the fusion welding of aluminum ()
CSA Standard W186: Welding of Reinforcing Bars in Reinforced Concrete Construction ()
EN ISO : "Specification and qualification of welding procedures for metallic materials - General rules (ISO :)"
API : "Welding of pipelines and related facilities", parts 3 (Definition of Terms)
List of standards
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A weld test coupon is a small piece of metal used to test a welder's proficiency in various welding procedures. Weld coupons are commonly utilized for applications such as welder qualifications, training, practicing difficult joints, and more. Here, we will dive into the specifics of weld coupons and their different applications, as well as the purpose of welder qualification tests.
Welding is critical to various industrial tasks; therefore, it's important for welders to demonstrate their proficiency to ensure they can deliver quality results. Many welding certifications require welders to showcase their skill level by passing a welding coupon test according to the required standards and codes.
Welding coupons are small pieces of metal, typically in plate or pipe form, used to evaluate a welder's skill through destructive testing, visual inspection, and other methods. This allows welding professionals to demonstrate and determine another welder's ability to deposit a high-quality weld joint.
Weld coupon testing is ideal for various applications, including:
A welding qualification test is a hands-on skills test conducted by a certified welding inspector to determine the quality of a welder or machine's welds based on the code or procedure required by the industry standard, job site, or company. Specifically, a welding qualification test demonstrates a welder's ability to deposit a quality weld when following a qualified welding procedure. As such, welders are typically provided with a Welding Procedure Specification (WPS) to follow while performing the test.
If a welder can demonstrate their ability to perform a weld that requires a high skill level, they will be deemed competent to perform welding procedures that are easier than what was demonstrated during the qualification test.
Welder qualification tests can take various forms. The reasons for this include:
Welding coupons play a critical role in evaluating a person or machine's ability to accurately carry out certain welding procedures and create high-quality joints. At AAA Metals, we can manufacture weld test coupons in high quantities for use in various applications, including qualification tests, recalibrating robotic welders, training/practice, and more. Using grinders, we can create weld coupons with specific angles that can be used to practice and perform welding tests at difficult angles.
For more information about our weld coupon capabilities, contact AAA Metals or request a quote today. You can learn more by browsing our precision waterjet cutting, precision sawing, and precision laser cutting services.
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