FCAW with gas shielding (FCAW-G) on A992 wide-flange beams is the dominant US structural welding process. It is fast, prequalifies easily under AWS D1.1:2025 Clause 5, and supports the demand-critical CVN-required work invoked by AISC 341. Here is the WPS.

Identification block

  • WPS number: WPS-25-012
  • Revision: 0
  • Date: 2026-05-08
  • Code: AWS D1.1/D1.1M:2025
  • Scope: FCAW-G beam-to-column complete penetration groove welds on ASTM A992, Group II, thickness 1/4 in to 2 in, in 1G / 2G / 3G / 4G positions
  • Status: Prequalified per Clause 5; CVN-supplementary qualified per Table 6.8 for AISC 341 demand-critical applications

Process and joint

  • Process: FCAW-G (Flux Cored Arc Welding, gas-shielded), semi-automatic
  • Joint detail: B-U2 (single-V groove with backing) or B-U3c (double-bevel groove with backgouging) from Annex B
  • Joint sketch: embedded as figure 1

Base metal

  • Specification: ASTM A992
  • Group number: II (per Table 6.9 in 2025)
  • Thickness range: 1/4 in (6.4 mm) to 2 in (50 mm)
  • Diameter range: N/A (rolled wide-flange section)

Filler metal

  • AWS classification: A5.20 E71T-1C (or E71T-1M depending on gas blend)
  • Hydrogen designator: H4 for AISC seismic; H8 otherwise
  • Diameter range: 0.045 in, 0.052 in, 1/16 in
  • Storage: factory-sealed packaging; once opened, kept in a heated container at minimum 120°F [50°C]; max 24-hour exposure to ambient before sealed disposal

E71T-1C requires CO2; E71T-1M requires Ar/CO2 mix. Match the classification suffix to the gas you specify.

Shielding gas

  • Composition (E71T-1C): 100% CO2
  • Composition (E71T-1M): 75% Argon / 25% CO2 (C25)
  • Flow rate: 35–50 CFH [16–24 L/min]
  • Nozzle distance: 5/8 in to 1-1/8 in from work
  • Wind protection: windbreak required for field welding > 5 mph wind

Position

  • 1G, 2G, 3G, 4G groove (flat, horizontal, vertical, overhead)
  • 1F–4F fillet (all positions)
  • Progression for 3G (vertical): up (uphill). Down progression is NOT prequalified for E71T-1 in groove welds.

Electrical

  • Current: DC
  • Polarity: DCEP
  • Amperage range:
    • 0.045 in wire: 150–250 A
    • 0.052 in wire: 170–290 A
    • 1/16 in wire: 200–360 A
  • Voltage range: 22–32 V (matched to amperage)
  • Travel speed range: 10–22 ipm
  • Transfer mode: spray (E71T-1 is typically in the spray range above ~200 A)
  • Wire feed speed: derived from amperage; document if welder-set

Preheat and interpass

  • Minimum preheat: per Table 5.8 — for A992 Group II up to 3/4 in with H8 filler, typically 50°F [10°C]; thicker plate raises to 150°F [65°C] or higher
  • Maximum interpass for non-CVN: 500°F [260°C]
  • Maximum interpass for AISC 341 demand-critical CVN: tighter per Table 6.8 supplementary; typically 550°F [290°C] or lower depending on the PQR
  • Method: contact thermocouple required for demand-critical work; temperature-indicating crayon acceptable for ordinary structural

CVN requirements (AISC 341 demand-critical)

  • Test temperature: 0°F [–18°C] or –20°F [–29°C] depending on project
  • Acceptance: 40 ft-lb average, no single below 30 ft-lb (typical AISC seismic — verify per project specs)
  • Specimen locations: weld metal centerline + HAZ

If the WPS is for non-seismic work, CVN requirements drop out and Table 6.6 baseline essentials are sufficient.

Common pitfalls on this WPS

  1. Filler classification suffix doesn't match the shielding gas. E71T-1C + C25 gas is a mismatch.
  2. Vertical-down position claimed prequalified. Not for E71T-1 grooves.
  3. CVN scope not declared. WPSs intended for AISC 341 must explicitly invoke Table 6.8 and reference the supporting PQR with CVN data.
  4. Storage rules omitted. FCAW-G wires absorb moisture; H-designated material loses its designation if mishandled.
  5. Wind protection omitted on a WPS intended for field use. FCAW-G needs protection above 5 mph.

A rule engine that cross-references base-metal Group, filler classification suffix, shielding gas, position, and CVN scope catches all five at draft time.