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Let’s start with WPS, Weld Procedure Specifications, the main purpose of a WPS is to ensure consistent, high-quality, and code-compliant welds by providing a standardized set of instructions for welders to follow. These specifications are set forth by AWS (American Welding Society), ASME (American Society of Mechanical Engineers), and ISO (International Organization for Standardization).

When using Stud Welding Products Pre-Qualified Studs in a qualified position, the Weld Procedure Specification is all you need.

Key Components of WPS

1. Process Type

• Drawn Arc Stud Welding: Most common for structural applications.
• Capacitor Discharge Stud Welding: Used for thin materials and small-diameter studs.

2. Base Material

• Specifies the type and grade of the material the stud will be welded to.

3. Stud Material

• Usually mild steel, stainless steel, or aluminum.
• Includes stud type (threaded, unthreaded, shear connector).

4. Stud Dimensions

• Diameter and length.
• Weld base shape (flat, flanged, etc.)

5. Welding Parameters

• Current (Amps): Depends on stud size.
• Voltage: Typically, 30-200 V.
• Time: Arc duration in milliseconds.
• Polarity: Usually DCEN (Direct Current Electrode Negative).

6. Shielding

• Ferrule: Ceramic ring used to contain the arc and protect the weld.
• Shielding Gas: Sometimes used instead of ferrules (argon or CO2).

7. Position

• Usually flat or horizontal; vertical positions may require special procedures.

8. Preheat/Post-heat Requirements

• Often not required unless welding on thick or alloyed materials.

9. Inspection & Testing

• Visual Inspection: Check for burn-through, misalignment, or incomplete fusion.
• Bend Test/Torque Test: Ensures weld integrity.
• Ultrasonic or Radiographic Testing: For critical applications.

When is a PQR needed?

In addition, the Procedure Qualification Record is a document that supports the WPS.  It records the actual welding variables and test results from a weld made under controlled conditions to qualify a welding procedure. Stud Welding Products can help you with this qualification process as well, in the field or in your shop.

It is required when:

• Using studs that are not pre-qualified or,
• Welding in the vertical (side-hand) or overhead position.

Key Points of a PQR

1. Identification Information

• PQR number
• Date of test
• Welder or operator ID
• WPS number it supports

2. Base Materials

• Type and grade of materials welded
• Thickness and joint configuration
• Material specification (e.g., ASTM A36)

3. Filler Metal

• Type and classification (e.g., ER70S-6)
• Manufacturer (optional)

4. Welding Process

• Process used (e.g., SMAW, GMAW, Stud Welding)
• Polarity and electrical characteristics
• Number of passes and technique

5. Welding Parameters

• Amperage, voltage, travel speed
• Preheat and interpass temperature
• Shielding gas type and flow rate (if applicable)

6. Joint Details

• Joint design and position (e.g., butt joint, flat position)
• Backing or backing gas used

7. Test Results

Mechanical Tests:

• Tensile strength
• Bend tests
• Impact tests (Charpy V-notch, if required)

Visual and NDT Results:

• Radiographic, ultrasonic, or dye penetrant inspection
• Acceptance criteria based on applicable code

8. Compliance

• Reference to applicable code (e.g., ASME Section IX, AWS D1.1)
• Statement of conformance

This information was compiled from the most current Structural Welding Code – Steel (AWS D1.1/D1.1M:2025). Refer to Clause 9. Stud Welding.

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