Is using the Annex J form mandatory under AWS D1.1:2025?

No. Annex J is informative (not mandatory). However, Clause 6.2.1 requires that a WPS be written and that it contain sufficient information for the welder to follow. The Annex J form meets this requirement by design, which is why most shops and EORs accept it as the default. Custom WPS forms must contain all the same required fields.

What happens if a field on the Annex J form is left blank?

A blank field is treated as undocumented. If the blank field corresponds to an essential variable (e.g., filler metal classification, preheat temperature, shielding gas), the WPS is nonconforming and cannot be used for production until corrected. If it is a nonessential variable, the WPS may still be valid but the blank is a quality flag.

How many WPS forms does one PQR support?

One PQR can support multiple WPS, as long as each WPS falls within the essential variable ranges the PQR establishes. A single groove weld PQR test coupon can cover multiple WPS for different joint geometries, provided those geometries fall within the thickness and position ranges the PQR qualifies.

Can a WPS be revised without a new PQR?

Only for nonessential variable changes. Revising a field that corresponds to an essential variable per Table 6.6—such as changing the electrode classification, preheat temperature, shielding gas, or welding position beyond the qualified range—requires either a new PQR or supplemental test data.

Sep 29, 20267 min read

AWS D1.1 Annex J WPS Form: How to Fill It Correctly

A field-by-field guide to the AWS D1.1:2025 Annex J WPS form—what each section requires, common errors CWIs find, and how the form connects to Table 6.6 essential variables.

WPS AWS D1.1 Annex J Documentation CWI PQR

New to procedures? Start with WPS welding: what a welding procedure specification is, with a filled-in example.

Every WPS used for production welding under AWS D1.1:2025 must contain sufficient written information to guide the welder and demonstrate compliance with the applicable qualification requirements. Annex J provides the standard form designed to capture that information in a consistent, auditable layout.

Most CWIs know the form by sight. Fewer understand exactly which fields are essential variables, which are administrative, and which are the ones that most often appear in audit nonconformance reports.

This guide goes field by field through the Annex J WPS form and explains what belongs in each section, what "blank" means legally, and where the form connects to Table 6.6.

Structure of the Annex J Form

The Annex J WPS form is organized into four logical sections:

Identification and authorization — WPS number, revision, date, and the supporting PQR numbers
Joint design — Groove type, joint geometry, backing, fit-up parameters
Base metal and filler metal — Materials, electrode/wire classification, supplemental filler
Technique and welding parameters — Position, preheat, interpass temperature, amperage, voltage, travel speed, shielding gas, technique (stringer/weave), and pass sequence

The CWI signature line appears at the bottom, along with the certifying individual's name and CWI number. This signature is the formal attestation that the WPS is based on qualified PQR data (or a prequalified joint) and is appropriate for the intended application.

Section 1: Identification

WPS Number: Every WPS must have a unique identifier within the shop's welding program. Numbering schemes are shop-specific, but the WPS number must be traceable to the shop's WPS index and the relevant project weld maps. Revision levels (Rev 0, Rev 1, etc.) must increment whenever an essential variable is changed.

PQR Number(s): List every PQR that supports this WPS. If a WPS covers both 1G/2G positions and the shop ran separate PQRs for flat and horizontal, both PQR numbers belong here. The PQR number is the bridge between the tested procedure and the production WPS — an auditor will pull both documents and cross-check essential variable consistency.

Date: Use the date of the current revision. An undated WPS is not useful for continuity-of-record purposes — an auditor cannot confirm which version was in effect on a given production date if revisions lack dates.

Section 2: Joint Design

Joint type: CJP, PJP, fillet, plug/slot. This field is critical for confirming that the WPS is being applied to an appropriate joint. A WPS qualified for PJP groove welds cannot be used for a CJP without either a prequalified CJP joint or a separate CJP PQR.

Groove angle, root opening, root face: These are the prequalified joint geometry parameters. For prequalified WPS per Clause 5, the values must fall within the listed Clause 5 tolerances. For tested WPS, these define the joint used during PQR testing — variations within Clause 6 tolerance ranges may be permitted without requalification.

Backing: Yes/No and type (steel, flux, ceramic, copper, none). The presence or absence of backing is an essential variable under Table 6.6. A WPS tested without backing cannot be used for a joint with steel backing without evaluation, and vice versa.

Rule library based on AWS D1.1:2025; verify against your governing edition.

Section 3: Base Metal and Filler Metal

Base metal specification and group: Identify the ASTM specification (e.g., A572 Grade 50) and the AWS D1.1:2025 Table 6.9 base metal group. Qualified base metal substitutions are governed by Table 6.9 — a WPS qualified with one Group I material generally covers other Group I materials, but substitutions outside the group require requalification.

Base metal thickness range: State the minimum and maximum thickness the WPS qualifies per Table 6.6 coverage rules. For a CJP groove weld qualified on a test plate of thickness T, the WPS covers a thickness range determined by the code rules — typically from ⅛ in [3 mm] to 2T. This range must appear on the WPS.

Filler metal classification: Full AWS A5-series designation including the complete suffix. For FCAW-G, this means something like E71T-1C-H4 — not just "E71T-1." The full designation matters because the -H4 suffix (diffusible hydrogen) is an essential variable. Stripping it to a partial designation hides an essential variable qualification boundary.

Supplemental filler and flux: For SAW, list both the wire and flux classifications. The flux classification is an essential variable per Table 6.6 row 7. For electroslag/electrogas (ESW/EGW), list the filler and flux per Table 6.7 requirements.

Minimum preheat temperature: Do not list zero unless the material, thickness, and code clause genuinely allow zero preheat. For A572 Grade 50 at thickness above 1½ in, the AWS D1.1 minimum preheat per Table 5.3 is not zero. A WPS preheat entry that is lower than the Table 5.3 minimum is a deficiency.

Maximum interpass temperature: This must be a number. "As required" is not acceptable. Interpass temperature limits affect mechanical properties — particularly CVN toughness in Table 6.8 applications — and the CWI needs a specific maximum to enforce in the field.

Section 4: Technique and Parameters

Position: List each qualified welding position (1G, 2G, 3G, 4G, or the pipe equivalents 1F through 4F). Welding in a position not listed — or in a position qualified by a different PQR that is not referenced on this WPS — is a position essential variable violation.

Amperage (current) range: Specify minimum and maximum for each pass type or pass group. Wide ranges (e.g., "100–400A") are red flags — they suggest the range was not derived from PQR test conditions and was instead chosen arbitrarily. The CWI reviewing the WPS should compare the range to the PQR actual parameters.

Voltage range: Same constraint as amperage. Must be consistent with the PQR parameters and derived from actual test data.

Travel speed range: See WPS Travel Speed: Essential Variable Under AWS D1.1:2025 for a full discussion. Minimum and maximum in/min (or mm/min), per pass group.

Shielding gas: For GMAW and FCAW-G, list the gas composition (e.g., 75% Ar / 25% CO₂) and flow rate range. Shielding gas composition is an essential variable. A change from C25 to C10 (different CO₂ percentage) requires WPS evaluation and may require requalification.

Technique — stringer or weave: Check the applicable box and, if weave, note the maximum weave width. AWS D1.1:2025 limits weave bead width. A weave exceeding 3× the electrode diameter (commonly cited for SMAW) without documentation is a technique deviation. For FCAW-G on structural fillet welds, stringer beads are generally the preferred technique for mechanical property reasons.

Pass sequence sketch or table: For multi-pass welds, a pass sequence diagram showing bead order is required. It need not be detailed engineering art — a simple numbered sketch showing pass order, bead location, and any inter-run cleaning requirements is sufficient.

The CWI Signature and Its Meaning

The signature on an Annex J WPS form is not a rubber stamp. It certifies that:

The WPS is based on a valid PQR (for a tested procedure) or conforms to Clause 5 prequalified requirements.
The essential variable fields are consistent with the PQR or prequalified limits.
The procedure is appropriate for the intended base metal, joint, and position.

A CWI who signs a WPS that does not meet these criteria is signing under false pretense. The exposure is both professional (risk to CWI certification) and legal (the WPS becomes evidence in any subsequent failure investigation).

For qualification authority, see Who Can Sign a WPS: CWI Requirements Under AWS D1.1.

Common Annex J Filing Errors in AISC Audits

Wrong revision number — WPS Rev 1 on file, Rev 0 listed on the weld map. The inspector cannot confirm the correct revision was in effect for production welds.
PQR number not on WPS — No cross-reference between the WPS and the supporting test record. The auditor cannot verify the procedure is qualified without a manual file search.
Base metal thickness range missing or inconsistent with PQR — The WPS says "unlimited" for maximum thickness when the PQR test plate thickness limits the maximum to 2T per Table 6.6. This overstates coverage.
Technique section blank — Travel speed, voltage, and heat input fields left empty. Common in shops that copied an old template and never completed it. Leaves the CWI with no reference to enforce parameters in the field.
Preheat listed below Table 5.3 minimum — The WPS shows "50°F minimum preheat" for 2-inch A572 Grade 50 plate when the table requires 225°F. The WPS preheat cannot be lower than the code minimum regardless of what the shop prefers.

Generating Annex J Forms from Digital Records

When WPS parameters are stored in a structured database rather than a Word document, the Annex J PDF becomes a generated output rather than a hand-keyed form. This eliminates the transcription errors that produce most Annex J deficiencies — the form cannot misrepresent a parameter that was typed once and stored consistently.

For fabricators wanting to see how a compliant Annex J WPS looks in practice, see WPS Template vs. Annex J Form: AWS D1.1 Requirements. For a walkthrough of an actual WPS built on SMAW for A36 base metal, see SMAW WPS for ASTM A36: A Complete Walkthrough.

Ready to generate Annex J-compliant WPS forms with automatic Table 6.6 essential variable enforcement? View plans and pricing.

FAQ

Frequently asked.

Is using the Annex J form mandatory under AWS D1.1:2025?: No. Annex J is informative (not mandatory). However, Clause 6.2.1 requires that a WPS be written and that it contain sufficient information for the welder to follow. The Annex J form meets this requirement by design, which is why most shops and EORs accept it as the default. Custom WPS forms must contain all the same required fields.
What happens if a field on the Annex J form is left blank?: A blank field is treated as undocumented. If the blank field corresponds to an essential variable (e.g., filler metal classification, preheat temperature, shielding gas), the WPS is nonconforming and cannot be used for production until corrected. If it is a nonessential variable, the WPS may still be valid but the blank is a quality flag.
How many WPS forms does one PQR support?: One PQR can support multiple WPS, as long as each WPS falls within the essential variable ranges the PQR establishes. A single groove weld PQR test coupon can cover multiple WPS for different joint geometries, provided those geometries fall within the thickness and position ranges the PQR qualifies.
Can a WPS be revised without a new PQR?: Only for nonessential variable changes. Revising a field that corresponds to an essential variable per Table 6.6—such as changing the electrode classification, preheat temperature, shielding gas, or welding position beyond the qualified range—requires either a new PQR or supplemental test data.