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welding procedure development
How to write AWS D1.1 Prequalified Welding Procedure Specifications

The AWS D1.1 Structural Welding Code for Steel allows fabricators to use prequalified welding procedures (WPSs), saving significant time and money by exempting them from testing. This post outlines an 8-step guide to writing a prequalified WPS, covering selecting approved base metals, weld joints, welding processes, filler metals, shielding gases, and determining preheat, interpass, and post-weld heat treatment. It emphasizes that anyone who understands the code can create these essential documents for quality and productivity.

6 Challenges When Increasing Deposition Rates

Want to boost welding productivity? Increasing your deposition rate is one of the most effective ways—but only if done right. This post explains the difference between melt-off and deposition rate, how higher deposition leads to faster travel speeds (and real time savings), and the common mistakes that sabotage these gains. Learn how to avoid costly errors, why simply turning up the amps isn’t enough, and how training and proper welding procedures can unlock major efficiency improvements in your shop.

Welding Procedure Development
Welding Procedure Development: Selecting Welding Parameters

Amperage, voltage, travel speed, and other key variables are crucial for creating a robust welding procedure that ensures sound and high-quality welds.Blog Post Summary This blog post explains the importance of key welding parameters when developing a welding procedure specification. It details how amperage (current) directly influences weld penetration and productivity, while voltage primarily affects bead shape and width. The post also highlights that travel speed is critical, as it impacts weld size, heat input, penetration, and overall weld quality. Additionally, it covers the significance of travel and transverse angles, noting their effects on weld shape and potential for defects. Finally, the post emphasizes the often overlooked but critical role of Contact Tip to Work Distance (CTTWD), explaining how it can drastically alter amperage and potentially lead to a non-compliant or defective weld if not properly controlled.

welding procedure assumptions short circuit globular pulse
Welding Procedure Development: Selecting the right welding process

Selecting the right welding process is a foundational step in developing a welding procedure that balances quality, productivity, and cost. This article explains why the highest deposition rate process is not always the best choice and how real-world constraints—such as available equipment, joint type, welding position, environment, and welder skill—shape process selection. It also examines productivity in terms of deposition rate, cleanup requirements, and electrode efficiency, rather than speed alone. By introducing return on investment as a decision factor, the article highlights when investing in new welding equipment may be justified. Understanding these considerations helps ensure the selected welding process supports both production goals and long-term weld quality.

Burn Through WEld Troubleshooting
Troubleshooting Welding Burn-through

Burn-through is a common welding defect, especially on light gauge materials, that results in holes instead of sound welds. It is often confused with melt-through, which can be acceptable, but true burn-through weakens joints and leads to scrapped parts. The main causes include excessive amperage, poor fit-up, and operator error, all of which make penetration harder to control. Solutions range from adjusting amperage and travel speed to improving upstream processes like cutting and forming, and investing in welder training. By understanding and addressing the root causes, fabricators can dramatically reduce rework, improve weld appearance, and lower overall costs.