CWI WPS, PQR, and Welder Qualification 5 — Questions and Answers
Question 1: A contractor uses an AWS D1.1 prequalified WPS for a structural steel project. Which statement about prequalified WPSs is correct?
- They require a PQR to support them before use
- They do not require testing if all prequalified conditions are met (Correct answer)
- They must be qualified by a third-party testing laboratory
- They are valid only for fillet welds, not groove welds
Correct answer: They do not require testing if all prequalified conditions are met
AWS D1.1 prequalified WPSs are exempt from qualification testing provided all conditions listed in the prequalified requirements are strictly met.
Question 2: Under ASME Section IX, what is the minimum number of bend specimens required for procedure qualification of a groove weld?
- One face bend and one root bend
- Two side bend specimens (for material 3/4 inch or thicker) (Correct answer)
- Four specimens: two face bends and two root bends
- Six specimens: three face bends and three root bends
Correct answer: Two side bend specimens (for material 3/4 inch or thicker)
For base metal 3/4 inch or thicker, ASME Section IX requires two side-bend test specimens; thinner material uses face and root bends instead.
Question 3: A welder's qualification record shows qualification with E7018 (F4) electrodes. Can this welder also use E6013 (F3) electrodes without requalification under ASME Section IX?
- Yes, because qualification with a higher F-number qualifies for all lower F-numbers in the same base metal P-group (Correct answer)
- No, because each F-number requires separate welder qualification
- Yes, but only for fillet welds, not groove welds
- No, because the two electrodes have different minimum tensile strengths
Correct answer: Yes, because qualification with a higher F-number qualifies for all lower F-numbers in the same base metal P-group
Under ASME Section IX, welder qualification with a higher F-number filler metal qualifies the welder to use any lower F-number filler metal of the same process.
Question 4: On a WPS, the term 'PWHT' refers to:
- Pre-Weld Heat Treatment applied before welding begins
- Post-Weld Heat Treatment applied after welding is complete (Correct answer)
- Preheat temperature required throughout the weld
- Peak Weld Hardness Test performed on the completed weld
Correct answer: Post-Weld Heat Treatment applied after welding is complete
PWHT (Post-Weld Heat Treatment) is a controlled heating and cooling process applied to the weld after completion to relieve residual stresses and improve properties.
Question 5: Which of the following changes to a WPS would require a new PQR under AWS D1.1 structural welding?
- Changing the root pass electrode diameter from 3/32 to 1/8 inch
- Increasing the interpass temperature above the maximum listed in the WPS (Correct answer)
- Changing the weld groove angle from 45° to 60° within prequalified limits
- Changing the welder assigned to perform the work
Correct answer: Increasing the interpass temperature above the maximum listed in the WPS
Exceeding the maximum interpass temperature specified in the WPS/PQR is an essential variable change that may require requalification depending on the code requirements.
Question 6: A CWI is asked to verify that a welder is qualified for the groove weld position being used in production. Where should the inspector look first?
- The Welding Procedure Specification (WPS)
- The Welder Qualification Test Record (WQTR) or Performance Qualification Record (Correct answer)
- The contract drawings and specifications
- The manufacturer's filler metal data sheet
Correct answer: The Welder Qualification Test Record (WQTR) or Performance Qualification Record
The Welder Qualification Test Record (WQTR) documents the specific positions, processes, and base metals for which a welder is qualified.
Question 7: Under ASME Section IX, the 'P-number' system is used to group:
- Welding processes by heat input requirements
- Base metals with similar weldability and mechanical properties to reduce qualification testing (Correct answer)
- Filler metals by their chemical composition
- Welders by the range of positions they are qualified for
Correct answer: Base metals with similar weldability and mechanical properties to reduce qualification testing
ASME Section IX assigns P-numbers to base metals with similar composition, weldability, and mechanical properties to minimize the number of procedure qualifications needed.
CWI WPS, PQR, and Welder Qualification 5
A contractor uses an AWS D1.1 prequalified WPS for a structural steel project.
Which statement about prequalified WPSs is correct?