CWI WPS and PQR Qualification 4 — Questions and Answers
Question 1: Under ASME Section IX, if a WPS lists SMAW in the flat position and a welder qualifies using SMAW in the vertical position, which production welding positions are the welder qualified for?
- Flat position only
- Vertical and overhead only
- Flat, horizontal, and vertical positions (Correct answer)
- All positions
Correct answer: Flat, horizontal, and vertical positions
Per ASME Section IX QW-461, qualification in the vertical (3G) position qualifies the welder for flat, horizontal, and vertical positions.
Question 2: A WPS written for SMAW using E7018 electrodes. If the manufacturer changes and the new E7018 electrode has a different coating formulation, does the WPS require requalification?
- Yes, because the electrode brand is an essential variable
- No, because the AWS classification number is unchanged (Correct answer)
- Yes, because any filler change requires a new PQR
- No, only if the F-Number also changes
Correct answer: No, because the AWS classification number is unchanged
Under ASME Section IX, the controlling factor is the F-Number and AWS classification, not the manufacturer; the same classification from a different manufacturer does not require requalification.
Question 3: Under ASME Section IX, which of the following changes to a GTAW WPS constitutes an essential variable requiring requalification?
- Changing from DCEN to DCEP (Correct answer)
- Changing the shielding gas flow rate by 5 CFH
- Changing the tungsten electrode diameter by one size
- Changing the torch brand
Correct answer: Changing from DCEN to DCEP
A change in current type or polarity (e.g., DCEN to DCEP) is an essential variable for GTAW under ASME Section IX QW-409.
Question 4: A PQR qualifies a WPS for base metal 0.25 inches thick. What is the MINIMUM production base metal thickness the WPS covers under ASME Section IX QW-451?
- 0.0625 inch (Correct answer)
- 0.125 inch
- 0.250 inch
- 0.375 inch
Correct answer: 0.0625 inch
For a PQR test coupon of 0.25 inch, the minimum qualified production thickness is 1/16 inch (the absolute minimum), as the lower limit is T/2 but not less than 1/16 inch.
Question 5: Under AWS D1.1, a prequalified WPS requires which of the following for the inspector to accept the procedure?
- A PQR signed by a Certified Welding Inspector
- Documentation that all prequalified joint, process, and material requirements are met (Correct answer)
- Approval from the AWS D1 Committee
- A mockup weld tested by bend specimens
Correct answer: Documentation that all prequalified joint, process, and material requirements are met
A prequalified WPS under AWS D1.1 requires written documentation demonstrating compliance with all prequalified requirements; no test coupon PQR is needed.
Question 6: Which organization's authorized representative must certify the accuracy of a PQR under ASME Section IX?
- An AWS Certified Welding Inspector
- The manufacturer or contractor who performed the qualification (Correct answer)
- An ASME-authorized third-party inspector
- The base metal supplier
Correct answer: The manufacturer or contractor who performed the qualification
Under ASME Section IX QW-103.1, the manufacturer or contractor must certify the PQR and is responsible for its accuracy.
Question 7: Under ASME Section IX, which variable governs when a change in base metal requires a new procedure qualification for austenitic stainless steels?
- A change in plate thickness exceeding 25%
- A change in P-Number (Correct answer)
- A change in yield strength exceeding 10 ksi
- A change in UNS number
Correct answer: A change in P-Number
A change in P-Number (e.g., from P-8 to P-8X or another group) is an essential variable requiring requalification, not the UNS number alone.
CWI WPS and PQR Qualification 4
Under ASME Section IX, if a WPS lists SMAW in the flat position and a welder qualifies using SMAW in the vertical position, which production welding positions are the welder qualified for?