The Hidden Assumptions Built Into Most Welding Procedures
Most welding procedures are created with good intentions. They are based on prior experience, established practices, and an understanding of code requirements. On the surface, they appear reasonable and complete. Yet once production begins, unexpected problems emerge—often repeatedly and without an obvious cause. In many cases, these problems are not the result of incorrect variables […]
How Engineering Intent Gets Lost Between the Welding Procedure and the Shop Floor
Most welding procedures do not fail because they are ignored. They fail because the engineering intent behind them never reaches the people doing the work, mainly the welders. A Welding Procedure Specification (WPS) may be technically sound, approved, and readily available, yet still produce inconsistent results. Welders interpret it differently. Supervisors enforce it unevenly. Inspectors […]
The Difference Between Writing a Welding Procedure and Developing One
In most organizations, welding procedures exist because they are required. They are created to satisfy a code, meet a customer requirement, or pass an audit. Once the document is complete, approved, and filed, the assumption is that the work is done. Yet this is precisely where many welding programs begin to struggle. The issue is […]
Why Most Welding Procedures Fail Before Production Starts
In many fabrication shops, welding procedures specifications (WPS) exist—but they don’t always work. They may be technically correct, code-compliant, and properly documented, yet once production begins, problems start to surface. Welders struggle to follow them. Inspectors flag recurring issues. Rework increases. Productivity suffers. And eventually the welding procedures end up as simply a compliance document […]
The Real Purpose of a Welding Procedure Specification
Despite decades of standards, many shops still weld without a written welding procedure specification (WPS). A common misconception is that if the parameters used meet the conditions for prequalified status, no written procedure is needed. This is not true. The AWS D1.1 Structural Welding Code – Steel explicitly requires written WPSs for all fabrication—whether prequalified […]
Excessive Contact Tip Consumption: Causes and Remedies
The following article has been adapted from Weld Troubleshooting for Non-Welding Engineers Contact tips aren’t supposed to disappear like magic tricks. When you’re constantly replacing them — something is wrong. Yes — buying “better” contact tips may help temporarily. But that is just a band-aid. Excessive consumption of contact tips is a symptom. The goal […]
Hot Cracking of 304 and 304L Stainless Welds
If you’ve ever welded 304 stainless and suddenly found cracks running through your weld, you’re not alone. Many fabricators are shocked when this happens — especially after years of successful welding with 304. In many of the cases we’ve seen, the cause wasn’t the welder, the process, or the settings. The real reason was that […]
How to Weld Abrasion Resistant Plate
Abrasion-resistant (AR) steel plate is a type of quenched and tempered steel specifically engineered for superior hardness and wear resistance. It’s designed to withstand constant friction, gouging, and impact in demanding environments — the kinds of conditions that quickly wear down regular carbon steel. What Is Abrasion Resistance Plate? AR plate achieves its toughness and […]
Commonly overlooked steps in developing a welding procedure
A Welding Procedure Specification (WPS) is much more than a formality — it’s the foundation of weld quality and consistency. A WPS outlines the essential and nonessential variables that control the welding process, along with their acceptable ranges. When welders stay within these limits — and have the right skills — they can produce sound, […]
How Welding Quality Documentation Protects Fabricators from Liability
When a product fails in service, who gets the blame? If there’s a weld anywhere near the failure point, the finger usually points straight at the fabricator. Even if the failure was caused by misuse, customer abuse, or the product being pushed beyond its design limits, the perception is almost always the same: “It must […]