WPS and PQR review drill: does this qualification cover that weld?

How the drill works

Each document set shows a short description and a sheet with three columns: the entry, what the PQR supports (or what the welder's WPQ qualifies), and what the WPS says (or what the job needs). Pick the one entry that falls outside the record, or pick "Everything is covered". At most one entry is out in any set. After you check, the explanation says why the entry matters, what fixes it, and which part of D1.1 Clause 6 sets the limit.

All 13 sets come in a shuffled order and you score one point each. At the end you get a list of your misses, such as calling a narrower range a problem, so you know which check to drill. Hit New shuffle for a fresh order, and quote the set number if you report an error.

Read-order checklist for a WPS and PQR pair

Check in the same order every time, so nothing gets skipped under the clock:

1. Match the documents. Confirm the WPS cites this PQR by number. If the WPS claims to be prequalified instead, you are in Clause 5, not Clause 6.
2. Process first. Same process, and the same combination of processes if more than one is used. A different process ends the review.
3. Filler. Same classification, and no step up in strength.
4. Shielding gas for gas-shielded processes. Same composition.
5. Base metal and thickness. The WPS range sits inside the range the PQR supports. Convert units before you compare.
6. Positions. Every production position on the WPS is one the test position covers.
7. Preheat and interpass. No drop below what the PQR supports.
8. Then the person. The welder's WPQ covers the process, position, thickness and backing of the actual joint, and the qualification is still in effect.

The full lookup routine for a Part C question, from task to clause, is in the Part C D1.1 navigation workflow.

Essential and nonessential variables, in plain words

A PQR proves one set of conditions made a sound weld. An essential variable is a condition that, changed past its limit, could change the strength, ductility or soundness of the weld, so the old test stops speaking for the new work and a new PQR is needed. A nonessential change stays inside what the test supports: you revise the WPS and keep citing the same PQR. When the contract calls for toughness testing, extra supplementary essential variables come into play, because heat input and similar changes affect toughness more than strength.

Where to find them in AWS D1.1:2025:

• Clause 5: prequalified WPSs, which need no PQR when every prequalification condition is met.
• Clause 6, Part A: general qualification rules shared by procedures and people.
• Clause 6, Part B: WPS qualification by test: positions a test covers, specimens and thickness ranges, and the essential variable changes that need requalification, by process.
• Clause 6, Part C: welder, welding operator and tack welder qualification: positions, ranges, welder essential variables and period of effectiveness.
• Clause 6, Part D: CVN toughness testing and the supplementary essential variables.

The part numbers follow the 2025 edition; see which D1.1 edition Part C uses. We cite clause and part numbers only. The limits themselves live in your copy of the code.

Worked example: the units trap

Step 1: the process and electrode match. Step 2: vertical is one of the three positions the PQR supports. Step 3: convert the thickness. 0.375 to 1.000 in. is 3/8 to 1 in., inside 1/8 to 1 in. Step 4: convert the preheat. 40°C is 104°F, at or above the 100°F minimum. Nothing is out, so the answer is everything is covered. Numbers that look different are not always different values.

Keep practicing

For the exam itself, read the CWI Part C D1.1 exam guide. To get to the Clause 6 tables fast with word search off, time yourself on the D1.1 code navigation drill.

WPS and PQR review FAQ