Question 1

Which of the following is NOT an essential variable for a WPS?

Accepted Answer

The welder's name is administrative. Essential variables (filler, gas, preheat) affect the mechanical properties of the weld.

Question 2

A decrease in the preheat temperature below the minimum specified in the WPS:

Accepted Answer

Decreasing preheat increases the cooling rate, potentially causing cracking or hardness issues. It is an essential variable requiring requalification.

Question 3

The PQR must record:

Accepted Answer

The PQR is a record of *actual* conditions. The WPS defines the *ranges* allowed based on that PQR.

Question 4

Which test is NOT required for a groove weld PQR on plate?

Accepted Answer

Standard D1.1 groove weld PQRs require Visual, Tension, and Bend tests. RT is used for *welder* qualification (optionally) but is not a standard requirement for *procedure* qualification unless NDT is substituted for bends (rare in initial PQR). Wait, standard PQR is mechanical testing. RT is NDT.

Question 5

If a WPS is qualified in the 2G position, it qualifies for:

Accepted Answer

Procedure qualification in 2G qualifies for 1G (Flat) and 2G (Horizontal). It does NOT qualify for Vertical or Overhead. (Note: This differs from *Welder* qual where 3G/4G are key. Procedure qual positions are non-transferable to 'harder' positions without testing). *Correction:* D1.1 Table 4.1: Plate test in 2G qualifies for 1G and 2G. Qualification in *all* positions usually requires 1G+3G+4G tests, or a pipe 6G test.

Question 6

For CVN (Charpy) testing in a PQR, the location of the notch must be:

Accepted Answer

Toughness requirements usually specify notches in the Weld Metal Centerline AND the HAZ (and sometimes Fusion Line + 1mm, etc.) to ensure all zones meet the criteria.

Question 7

Changing the current from AC to DC:

Accepted Answer

Current type and polarity are essential variables. Changing AC to DC changes penetration and heat input significantly.

Question 8

WPSs for Electroslag Welding (ESW) must always be:

Accepted Answer

ESW (and EGW) are NEVER prequalified processes in AWS D1.1. They always require qualification testing.

Question 9

What is the primary purpose of a Welding Procedure Specification (WPS)?

Accepted Answer

The WPS is the written instruction set — the 'recipe' — that directs the welder in producing a weld that meets the code. The PQR records results; welder qualification is a separate document.

Question 10

The Procedure Qualification Record (PQR) documents:

Accepted Answer

A PQR records the actual values used to make the qualification test weld and the mechanical-test results, providing the evidence that the WPS will produce sound welds.

Question 11

The relationship between a PQR and a WPS is best described as:

Accepted Answer

A single PQR can support one or more WPSs, as long as each WPS stays within the essential-variable ranges qualified by that PQR.

Question 12

Changing a NONESSENTIAL variable on a qualified WPS requires:

Accepted Answer

Nonessential variables do not affect the tested mechanical properties, so the WPS can simply be revised. Only essential-variable changes force requalification (a new PQR).

Question 13

A change in an ESSENTIAL variable beyond its qualified range requires:

Accepted Answer

By definition, an essential variable affects weld mechanical properties, so exceeding its qualified range requires requalifying the procedure with a new PQR.

Question 14

A prequalified WPS under AWS D1.1 is one that:

Accepted Answer

AWS D1.1 allows certain conforming joints, processes, and materials to be used without qualification testing. Such a prequalified WPS still must conform to all of the code's prequalification rules.

Question 15

Which process is NOT allowed to be prequalified under AWS D1.1 and must be qualified by testing?

Accepted Answer

GMAW-S (short-circuiting transfer) is specifically excluded from prequalification in AWS D1.1 because of fusion concerns, so it always requires qualification testing. Electroslag and electrogas are likewise excluded.

Question 16

The mechanical tests normally required for a groove-weld procedure qualification on plate are:

Accepted Answer

A groove-weld PQR on plate typically requires reduced-section tension tests (for strength) and guided-bend tests (for soundness and ductility). Additional tests such as CVN are added only when required.

Question 17

For PROCEDURE (WPS) qualification, welding position is:

Accepted Answer

For procedure qualification the mechanical properties of the coupon do not depend on position, so a WPS qualified in one position may be used in all positions. Position IS essential for WELDER qualification — a classic exam contrast.

Question 18

Charpy V-notch (CVN) impact testing is included in a PQR when:

Accepted Answer

CVN testing is a supplementary requirement performed when notch toughness is specified by the contract or code. It is not part of every procedure qualification.

Question 19

A decrease in the qualified minimum preheat temperature is:

Accepted Answer

Lowering the preheat below the qualified minimum raises cooling rate and can harm properties/promote cracking, so it is an essential-variable change that requires requalification.

Question 20

Base metals are grouped for qualification purposes primarily by their:

Accepted Answer

Base metals of similar weldability are grouped so that qualification on one member of the group can cover others. ASME Section IX uses P-numbers; AWS D1.1 uses its own grouping tables.

Question 21

In ASME Section IX, filler metals are grouped by their:

Accepted Answer

Filler metals/electrodes are grouped by F-number based on usability characteristics. (A-numbers describe weld-metal chemistry; P-numbers group base metals.)

Question 22

Who is responsible for certifying (signing) the WPS and PQR?

Accepted Answer

The organization performing the welding — the manufacturer or contractor — is responsible for the WPS and PQR and certifies them. The CWI verifies compliance but does not own the documents.

Question 23

A WPS must reference which of the following as a minimum?

Accepted Answer

A WPS must address the welding variables needed to reproduce the weld: process, base and filler metals, joint design, positions, preheat/interpass, and electrical characteristics, among others.

Question 24

If a WPS is revised because of a nonessential-variable change, the PQR:

Accepted Answer

Because nonessential variables do not affect the qualified mechanical properties, the original PQR remains valid and continues to support the revised WPS.

WPS/PQR Requirements Practice Questions

Answer a few WPS/PQR Requirements questions now

More AWS Certified Welding Inspector Exam Topics