WPS-IEW-2026-106
Rev. 1NON_COMPLIANTAWS D1.1Structural MemberFCAW girder flange-web fillet welds, shop fabrication (winter shift preheat)
97
score
Base Metals & Thickness — QW-403 / QW-451
- Specification
- IS 2062 E350C
- P-Number
- P-No. 1
- Group No.
- 1
- Dissimilar side
- Same P-No.
- Qualified range
- 10 – 40 mm
- Coupon T
- 20 mm
- Diameter
- All
- Toughness
- Not invoked
Filler Metals — QW-404 / QW-432 / QW-442
- Filler spec
- AWS A5.20
- Classification
- E71T-1C H8
- F-Number
- F-No. 6
- A-Number
- A-No. 1
- Process
- FCAW
- Transfer mode
- —
- Joint type
- Fillet (Tee/Lap)
- Position
- 3G
Thermal Cycle — QW-406 / QW-407
- Preheat min
- 15 °C
- Interpass max
- 260 °C
- PWHT
- Not required
- PWHT soak
- —
- PWHT hold
- —
- Joint design
- Tee joint, 8 mm continuous fillet both sides
Electrical, Technique & Shielding — QW-408 / QW-409
- Current
- DCEP
- Amperage
- 220–300 A
- Voltage
- 26–32 V
- Travel speed
- 200–350 mm/min
- Heat input cap
- 3.2 kJ/mm
- Shielding
- CO2 100% (C1)
- Flow
- 20 L/min
- Backing
- —
- Supporting PQR
- PQR-AWS-2026-106
Validation Findings
latest run 18 Feb 2026 by p.mahato@tbsl.in
Minimum preheat temperature
EssentialD1.1 Table 5.8Declared preheat 15°C below required minimum 65°C for P-No. 1 at thickness > 38 mm.
Supporting PQR referenced
EssentialD1.1 §6.3Qualified by PQR PQR-AWS-2026-106. Traceability established.
Base metal P-Number assigned
EssentialD1.1 Table 5.3Base metal group P-No. 1 Gr.1 — IS 2062 E350C.
Dissimilar-metal weld compatibility
EssentialD1.1 §6.3.2Joint is between identical P-Numbers — no dissimilar-metal restrictions apply.
Thickness qualification range (coupon)
EssentialD1.1 Table 6.3Range 10–40 mm within qualified 1.5–40 mm for 20 mm test coupon.
Thickness range sanity
Non-EssentialD1.1 Table 6.3Commercial range 10–40 mm is within conventional procedure limits.
Small-bore thin-wall root control
Non-EssentialD1.1 §6.10Small-bore root check applicable to piping only.
Interpass temperature ceiling
EssentialD1.1 §5.6Interpass 260°C within 315°C ceiling.
Thermal window logic
Non-EssentialD1.1 §5.6Thermal window 15–260°C is internally coherent.
Mandatory PWHT by thickness/code
EssentialD1.1 §5.8PWHT not invoked — permitted for this material/thickness/code combination.
PWHT cycle parameters
EssentialD1.1 §5.8.1PWHT not required — cycle parameters not applicable.
PWHT soak window & hold adequacy
Suppl. EssentialD1.1 §5.8.2PWHT not required — soak band check not applicable.
F-Number consistent with process
EssentialD1.1 §6.3.3F-No. 6 (E71T-1C H8) is consistent with FCAW.
Shielding gas / medium per process
EssentialD1.1 §6.3.4Shielding medium “CO2 100% (C1)” acceptable for FCAW.
Root backing gas protection
Suppl. EssentialD1.1 §6.3.4FCAW — backing gas not driven by process.
Shielding gas flow rate
Non-EssentialD1.1 §6.3.4Flow 20 L/min within the 10–30 L/min band for FCAW.
Current type & polarity
EssentialD1.1 Table 5.5DCEP polarity consistent with FCAW and E71T-1C H8.
Amperage operating window
Non-EssentialD1.1 Table 5.5Amperage 220–300 A inside the FCAW operating envelope.
Arc voltage operating window
Non-EssentialD1.1 Table 5.5Voltage 26–32 V inside the FCAW operating envelope.
Travel speed control
Non-EssentialD1.1 §6.3.5Travel speed 200–350 mm/min is plausible for FCAW.
Heat input ceiling (toughness)
Suppl. EssentialD1.1 §6.3.5Computed worst-case heat input ≈ 2.88 kJ/mm (declared ceiling 3.2 kJ/mm) — no toughness restriction invoked.
Welding position qualification
Non-EssentialD1.1 §6.6Position 3G is a recognised EN ISO 6947 / QW-461 designation.
GMAW metal-transfer mode
EssentialD1.1 §4.7.1Transfer-mode variable applies to GMAW only (FCAW exempt).
Process admissibility under code
EssentialD1.1 §4.7FCAW is an admissible process under AWS D1_1.
ISO 15614 impact-test mandate
Suppl. EssentialD1.1 §6.6.3Impact regime not invoked for the declared thickness/application.
Storage-tank qualification route
EssentialD1.1 §6Tank-specific routing not applicable.
IBR statutory governance
EssentialD1.1 §6.1IBR statutory route not applicable to this scope.
Administrative data completeness
Non-EssentialD1.1 §6.2Administrative header fields adequately populated for issue.
Group Number under toughness
Suppl. EssentialD1.1 §6.3.2Group-No. split applies only when notch toughness is specified.
Run History
p.mahato@tbsl.in
18 Feb 2026, 09:30 pm
FAIL
28/0/1