WPS, PQR, and WPQ: What Each Record Does
A WPS tells the welder how to weld a joint: process, base metal group, filler classification, preheat, interpass temperature, position, current and voltage ranges, travel speed, and shielding gas. A PQR is the test record that proves the procedure works, with the actual parameters used and the mechanical test results. A welder performance qualification record, called WPQ or WPQR depending on the code, shows that a specific welder passed a test for a process, position, and thickness range.
6 for stainless require PQR-backed procedures. Mixing code rules is a classic source of audit findings.
- One WPS may cite several PQRs, and one PQR can support several WPSs within code limits
- Essential variable changes can invalidate a WPS and require requalification
- Welder qualification is tied to process, position, material, and thickness range
What Goes Wrong in Binders and Spreadsheets
The usual failures are not dramatic. A WPS revision is updated but the old copy stays on the shop floor. 1 means the qualification may need renewal.
A job calls for a process and position nobody on shift is qualified for, found only at final inspection. A PQR is referenced but cannot be found. Each of these is a nonconformance that can trigger rework, a corrective action, or a lost AISC or customer audit.
Because the data lives in several places, no one sees the whole picture until the audit.
- Obsolete WPS revisions in circulation
- Welder continuity logs not updated by supervisors
- No link between the job's required WPS and the welders assigned
What WPS and Welder Software Should Do
At minimum, it should keep controlled WPS and PQR documents with revision history, link each WPS to its supporting PQRs and code, store welder qualifications with expiry and continuity dates, and flag who is qualified for a given procedure. Better systems attach the required WPS to the work order or traveler, so the welder and CWI see the right procedure at the station, and capture weld logs by joint and welder for traceability. Integration with your ERP or fabrication system matters because the job routing is where welding requirements originate.
Procedure development tools exist, but they should never replace engineering review and qualification testing.
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Where AI Is Useful and Where It Must Stay in Its Lane
AI can do the clerical work around the records. A private model can read scanned PQRs and WPSs, extract the variables into structured fields, flag a WPS whose parameters fall outside the cited PQR range for review, and answer questions such as which of our welders are qualified for 3G SMAW with E7018 on Group II material. It can also check a job's weld symbols against the available WPS list and surface gaps before release.
It must not approve a procedure, certify a welder, or decide that a variable change is nonessential. Those judgments belong to a qualified person such as a CWI or welding engineer, and the system should record that approval.
When a Full System Is Overkill
A shop with a small crew, one or two processes, and a short list of prequalified WPSs can manage with a disciplined document control folder and a simple expiry tracker. 1 and ASME IX, run several shifts, or face frequent customer audits. Start by cleaning up the master list of procedures and welder qualifications before you buy anything, because migrating bad records into a new tool just moves the problem.
Frequently asked questions
What is the difference between a WPS and a PQR?
A WPS is the written procedure welders follow. A PQR is the record of the test weld and mechanical testing that proves the procedure works. Under AWS D1.1, prequalified WPSs can be used without a PQR within the code limits, while ASME Section IX generally requires a PQR to support each WPS.
How long does a welder qualification last?
It depends on the code. Under AWS D1.1 a welder's qualification generally remains in effect unless the welder has not used the process for a period of six months or there is reason to question ability. ASME Section IX has its own continuity rule. Always check the edition and contract-specified code before relying on a date.
Can software generate a WPS automatically?
Software can draft or populate a WPS from existing PQR data, but a qualified person must review it against the code and confirm essential variables. Qualification testing and the CWI or welding engineer sign-off cannot be automated away. Use software to organize and check, not to certify.
Netray can load your WPS, PQR, and welder records into a private on-prem assistant that answers qualification questions and flags gaps, with every answer pointing to the source record.