Overview
A welding procedure qualification is intended to demonstrate that an intended procedure can produce suitable welded joints for the defined scope. ADLER CertConsulting reviews the starting position together with the manufacturer, prepares the necessary documents and coordinates the test piece, the test body, non-destructive testing and laboratory examinations. Once complete, the results and range of validity are classified and transferred into the manufacturing documents. The type, extent and recognition of the qualification follow the applicable rules and the relevant test or acceptance body.
Qualification need and rules
Whether a welding procedure has to be newly qualified can only be answered after the intended fabrication scope has been reviewed. The material group, welding process, joint, dimensions, welding position, filler material, heat input and other influencing factors can limit the range of validity of an existing qualification. The product standard, execution class, customer specification or regulatory requirements can also determine the permissible qualification method and the involvement of a test or acceptance body.
ISO 15607 sets out the general rules for the specification and qualification of welding procedures. A procedure test to ISO 15614-1 is a common method for arc and gas welding of steels and for arc welding of nickel and nickel alloys. However, it is not automatically the right basis for every material, process or application. The rules that apply in each case must be established before work begins.
Procedure test and coordination
For a procedure test, a preliminary welding procedure specification — the pWPS — is defined first. The test piece is welded under defined conditions and then examined to the prescribed extent. Depending on the standard and the application, visual testing, further non-destructive testing and mechanical-technological or metallographic laboratory tests may be required. These include, for example, tensile, bend, impact, hardness or macro-section tests. The specific extent of testing is not fixed as a blanket figure but derived from the governing requirement.
ADLER CertConsulting supports this planning and holds together the interfaces between the manufacturer, the welding coordination, the test body and the laboratory. This includes agreeing the input data, preparing the pWPS, marking and tracking test pieces, compiling the test requirements and checking the incoming reports for completeness and correct assignment. The tests themselves are carried out by the bodies suited to them.
From the WPQR to a production-ready WPS
Once the requirements are met, the test conditions, results and range of validity are documented in the WPQR, or confirmed by the competent body. On this basis, the manufacturer can draw up a production-ready WPS. ADLER CertConsulting helps to transfer the qualified limits correctly into the manufacturing documents and to link the evidence with ISO 3834, EN 1090 or other applicable requirements.
Areas of service
- Review of existing WPS and WPQR against the intended scope
- Determining the required qualification route
- Preparation and coordination of the pWPS
- Defining and documenting the relevant input data
- Coordination of the test piece and the test bodies involved
- Coordination of non-destructive testing and laboratory examinations
- Bringing together test reports and WPQR documents
- Classifying the qualified range of validity
- Deriving and structuring production-ready WPS
- Integrating the evidence into ISO 3834, EN 1090 and other rules
- Support with non-conformities, additional tests and further qualification steps
Frequently asked questions
When is a new welding procedure qualification needed?
That depends on the intended fabrication scope and the applicable rules. A new qualification or an extension may be required if, for example, the material group, welding process, joint, dimension or other essential conditions are not covered by an existing WPQR.
What is the difference between a pWPS, a WPS and a WPQR?
The pWPS describes the preliminary conditions for the procedure test. The WPQR documents the test conditions, results and the qualified range of validity. The WPS transfers the qualified procedure into production as a concrete work instruction.
Which tests are required?
The extent of testing follows the qualification standard, the material, the welding process and the application requirements. Visual testing, further non-destructive testing and mechanical-technological and metallographic laboratory tests are possible. A reliable test list only emerges after the technical assessment.
Does ADLER CertConsulting also handle coordination with the laboratory?
Yes. ADLER CertConsulting can support the selection of a body suited to the testing need, coordinate the test requirements and documents, coordinate test pieces and dates, and place the results within the evidence documentation. The laboratory and testing services are provided by the bodies suited to them.
Does a passed procedure test guarantee every later welded joint?
No. The procedure test demonstrates suitability within the defined range of validity. The manufacturer must then control the procedure in production, with suitable welders or operators, equipment, materials, welding procedure specifications and quality controls.
Can an existing WPQR be used for a new order?
That is possible if its range of validity covers the planned fabrication and the applicable product rules or the customer specification allow its use. This check should be carried out before fabrication begins.