5.1 Welder Qualification Test Plates, Positions & Pipe Assemblies

Purpose & Philosophy of Performance Qualification

Under AWS D1.1/D1.1M:2025, qualification is bifurcated into two distinct regulatory domains governed by Clause 6:

1. WPS Qualification (Clause 6, Part B): Evaluates the mechanical, chemical, and metallurgical properties of a welded joint produced under a specific welding procedure specification. Its objective is to prove that the procedure itself—the combination of base metal, filler metal, preheat, electrical parameters, and joint design—yields joints meeting required tensile, ductility, and notch toughness criteria.
2. Performance Qualification (Clause 6, Part C): Evaluates the manual dexterity, technique, and workmanship of an individual craftsperson (Welder, Welding Operator, or Tack Welder). Its objective is to prove that the individual can consistently manipulate the welding arc or control the welding equipment to deposit sound weld metal free of unacceptable discontinuities.

+-----------------------------------------------------------------------------------------+
|                        WPS QUALIFICATION vs. PERFORMANCE QUALIFICATION                  |
+-----------------------------------------------------------------------------------------+
|                                                                                         |
|   CLAUSE 6, PART B: PROCEDURE QUALIFICATION   |   CLAUSE 6, PART C: PERFORMANCE         |
|   -----------------------------------------   |   -----------------------------         |
|   * Focus: Properties of the weldment         |   * Focus: Workmanship of the person    |
|   * Tests: Reduced-section tension, guided    |   * Tests: Guided bend tests (root,     |
|     bends (root/face/side), macroetch, CVN    |     face, side) or NDT (RT/UT), break   |
|   * Proves: Procedure metallurgy & strength   |   * Proves: Ability to deposit sound    |
|   * Result: Procedure Qualification Record    |     weld metal without defects          |
|     (PQR) owned by the contractor             |   * Result: Welder Performance Record   |
|                                               |     (WPQR) tied to individual welder    |
+-----------------------------------------------------------------------------------------+

Craftsperson Classifications in AWS D1.1

AWS D1.1 distinguishes between three distinct welding personnel categories:

• Welder (defined in Clause 3; qualified under Clause 6 Part C): An individual who performs manual or semiautomatic welding operations (e.g., manual SMAW, semiautomatic GMAW or FCAW).
• Welding Operator (defined in Clause 3; qualified under Clause 6 Part C): An individual who operates adaptive control, automatic, mechanized, or robotic welding equipment (e.g., mechanized SAW or robotic GMAW).
• Tack Welder (defined in Clause 3; qualified under Clause 6.24): An individual who makes tack welds intended to maintain structural fit-up and alignment until final production welding is performed.

Standard Plate Test Assemblies (Clause 6.22 & Figure 6.21)

AWS D1.1 standardizes test coupon geometries to evaluate a welder's ability to handle different plate thicknesses, groove angles, root openings, and backing conditions.

                     Standard 1 in. Unlimited Plate Test (Figure 6.21)
                     
                       /|<-------- 45° -------->|\
                      / |                       | \
                     /  |                       |  \
                    /   |                       |   \
                   /    |       1 in.           |    \    t = 1 in. [25 mm]
                  /     |      [25 mm]          |     \   R = 1/4 in. [6 mm]
                 +------+-----------------------+------+  Backing = 3/8 in. x 1 in.
                 |      |<- R = 1/4 in. [6 mm]->|      |  Length = 7 in. min.
                 +------+-----------------------+------+
                 |=====================================|  Steel Backing Strip
                 +-------------------------------------+

Standard Plate Coupon Configurations

1. Unlimited Thickness Plate with Backing (Figure 6.21):
   • Nominal Thickness ($T$): $1\text{ in.} \ [25\text{ mm}]$
   • Groove Type: Single-V groove, included angle $45^\circ$, root opening $R = 1/4\text{ in.} \ [6\text{ mm}]$, with steel backing strip ($3/8\text{ in.} \times 1\text{ in.} \ [10\text{ mm} \times 25\text{ mm}]$ minimum).
   • Qualified Production Range: Qualifies the welder for groove and fillet welds on base metal of unlimited thickness ($1/8\text{ in.} \ [3\text{ mm}]$ to $\infty$) on plate and pipe $\ge 24\text{ in.} \ [600\text{ mm}]$ OD with backing.
   • Testing Required: Visual inspection followed by two side bend specimens (or RT/UT).
2. Limited Thickness Plate with Backing (Figure 6.21):
   • Nominal Thickness ($T$): $3/8\text{ in.} \ [10\text{ mm}]$
   • Groove Type: Single-V groove, included angle $45^\circ$, root opening $R = 1/4\text{ in.} \ [6\text{ mm}]$, with steel backing.
   • Qualified Production Range: Qualifies base metal thicknesses from $1/8\text{ in.} \ [3\text{ mm}]$ up to $3/4\text{ in.} \ [20\text{ mm}]$ (or $2T$ maximum) on plate and pipe $\ge 24\text{ in.} \ [600\text{ mm}]$ OD with backing.
   • Testing Required: Visual inspection followed by two guided bend tests (one face bend and one root bend, or two side bends) (or RT).
3. Plate without Backing / Open Root (Figure 6.21):
   • Configuration: Single-V groove welded from one side without backing (open root) or welded from both sides with backgouging.
   • Significance: Qualifying without backing is a higher-tier qualification that qualifies the welder for production welds both with and without backing (and with or without backgouging). Conversely, qualifying with backing qualifies the welder only for joints with backing.

Standard Pipe Test Assemblies & Positions (Clause 10 Part D & Figures 10.17 through 10.22)

Pipe test coupons present severe geometric and positional challenges because the welding angle, travel angle, and gravitational pull on the molten weld pool continuously change around the circumference.

+-----------------------------------------------------------------------------------------+
|                         AWS D1.1 PIPE TEST POSITIONS                                    |
+-----------------------------------------------------------------------------------------+
|                                                                                         |
|     1G (Rotated)             2G (Fixed Vertical)             5G (Fixed Horizontal)      |
|   +---------------+            +---------------+               +---------------+        |
|   | Pipe Horizontal|           | Pipe Vertical |               |Pipe Horizontal|        |
|   | Rotated during|           | Axis Fixed    |               | Axis Fixed    |        |
|   | welding (Flat)|           | Horiz. Groove |               | Vert./Overhead|        |
|   +---------------+            +---------------+               +---------------+        |
|                                                                                         |
|                 6G (Fixed Inclined 45°)           6GR (45° with Ring)                   |
|               +-----------------------+         +---------------------+                 |
|               | Pipe Fixed at 45° ± 5°|         | Pipe Fixed at 45°   |                 |
|               | Inclined Axis         |         | Restriction Ring    |                 |
|               | Qualifies All Pos.    |         | Qualifies T-, Y-, K-|                 |
|               +-----------------------+         +---------------------+                 |
+-----------------------------------------------------------------------------------------+

Pipe Coupon Sizes and Diameter Ranges (Table 10.12)

• 2 in. Schedule 80 Pipe ($2.375\text{ in.} \ [60\text{ mm}]$ Nominal OD): Qualifies production pipe diameters from $3/4\text{ in.} \ [20\text{ mm}]$ OD up to $4\text{ in.} \ [100\text{ mm}]$ OD.
• 6 in. Schedule 80 Pipe ($6.625\text{ in.} \ [168\text{ mm}]$ Nominal OD): Qualifies production pipe diameters from $4\text{ in.} \ [100\text{ mm}]$ OD to unlimited OD and all plate thicknesses up to the coupon's qualified thickness.
• Small Diameter Tubing ($< 3/4\text{ in.} \ [20\text{ mm}]$ OD): Qualifies from test diameter $D$ up to $2D$.

Test Positions and Qualification Matrix (Table 6.11)

AWS D1.1 Table 6.11 establishes the exact production welding positions and weld types qualified by each test position. Candidates must memorize the primary pathways across plate and pipe.

Key Navigational Rules for Table 6.11

1. Groove Qualifies Fillet: Successfully qualifying on a groove weld test coupon automatically qualifies the welder for production fillet welds in the corresponding positions shown in Table 6.11.
2. Fillet Never Qualifies Groove: Qualifying on a fillet weld test assembly qualifies the welder only for fillet welds—never for groove welds.
3. The 3G + 4G Plate Combination: In structural steel fabrication shops, welders are frequently qualified on plate using a combination of 3G (Vertical) and 4G (Overhead) test plates. This combination qualifies all groove and fillet positions for plate and large-diameter pipe ($\ge 24\text{ in.} \ [600\text{ mm}]$ OD).
4. 6G vs. 6GR: The 6G pipe test qualifies for all non-tubular and tubular butt joints, but does not qualify T-, Y-, and K-connections in tubular construction where backing is restricted or omitted. Qualifying on 6GR (with the restriction ring) is required to qualify for tubular T-, Y-, and K-connections (Clause 10).