Is first-article weld inspection required by AWS D1.1:2025?

AWS D1.1 does not mandate a specific 'first article' checkpoint by that name, but it does require that welding conform to a qualified WPS and that the Inspector verify this. First-article inspection is a fabricator or contract-imposed quality control practice that makes early verification systematic.

Who sets the first-article inspection requirements — the code or the contract?

Usually the contract or the fabricator's internal QC plan. Owner specs, AISC fabricator certification requirements, and project-specific welding inspection plans often specify hold points that function as first-article checks on new procedures.

What is the difference between a PQR weld and a first-article weld?

A PQR weld qualifies the procedure under controlled test conditions before any production work. A first-article weld is the first production joint welded under that WPS on the actual project, with the actual welder, equipment, and material. Both must pass, but they serve different purposes.

What happens if the first-article weld fails inspection?

Stop the run, document the nonconformance, determine whether the failure is in the procedure, the welder, or the setup, and correct the root cause before welding additional joints. A first-article failure caught early costs one weld repair; a failure caught at final inspection costs the whole assembly.

First-Article Weld Inspection for New WPS Deployments

First-article weld inspection verifies a new WPS works in production before releasing the full run. Here is how to structure the checkpoint, what to examine, and how to document it.

Deploying a new WPS on a production job carries risk that the qualification process only partially addresses. The PQR test was run under controlled conditions — flat plate, clean material, a skilled welder working carefully under supervision. The first production joint under that WPS may involve a different welder, an awkward position, a tight assembly, or material from a new heat. First-article weld inspection is the quality checkpoint that bridges the gap between qualification and production.

The goal is simple: before releasing a full run of joints under a new WPS, verify that the first joint meets the acceptance criteria and that the welding setup matches what the WPS prescribes. A nonconformance caught at the first joint is a cheap lesson. The same nonconformance found at final inspection on 40 assembled joints is an expensive one.

What First-Article Weld Inspection Is

First-article inspection (FAI) in structural fabrication is an enhanced review of the first production joint welded under a WPS that is either:

New to the shop
New to a specific project or contract (even if the shop has used it before)
Deployed by a welder who has not previously used that WPS in production
Deployed on a material heat or thickness that is near the limits of the qualified range

FAI is not a code-mandated step under AWS D1.1:2025, but it is a widely recognized practice in quality plans, AISC fabricator certification programs, and owner-imposed inspection plans. Many project-specific welding inspection plans include hold points at "first joint under each WPS" as a matter of course.

The distinction from routine in-process inspection is one of intent and intensity. Routine inspection verifies conformance to a known, established process. FAI verifies that the production setup has been correctly translated from the WPS before the run begins.

When to Use First-Article Inspection

Not every weld needs a formal FAI checkpoint. The cases where FAI adds real value:

New WPS first use in the shop. When a PQR has been completed and a new WPS is written and approved, the first production weld under that document is the first test of whether the procedure works as written in actual production conditions. Errors in heat input calculation, wrong electrode classification ordered, or amperage range errors in the WPS document surface here.

New WPS on a new project. A WPS may have been used successfully on previous projects, but if the current project involves a different base metal heat, a different joint configuration, or a different set of welders, FAI provides a production verification.

Welder first use of a WPS. A welder who is qualified for the process and position but has not yet made a production weld under this specific WPS should be reviewed at their first joint. This is especially relevant for WPS documents that have narrow parameter ranges (tight interpass temperature limits, specific electrode diameters, restricted amperage bands).

High-consequence joint types. On CJP groove welds in primary load-carrying members, the cost of a failure or missed nonconformance is high enough that enhanced first-joint review is justified regardless of WPS history.

After a documented procedure deviation. If a prior run on this WPS had a confirmed deviation — wrong electrode, preheat missed, interpass temperature exceeded — the corrective action should include re-verifying the first joint of the corrected run.

What the FAI Covers

A well-structured first-article weld inspection covers these items in sequence:

Pre-Weld Setup Verification

Before the first arc is struck, confirm that the production setup matches the WPS:

WPS on hand. The correct WPS document (current revision) must be at the weld station or accessible to the welder. Verify the WPS number, the revision, and that it covers the joint being welded.
Base metal identity. Check the mill certificate or heat markings against the WPS base metal specification. Confirm the material falls within the WPS's qualified base metal group (AWS D1.1:2025 Table 6.9 groupings).
Electrode/filler metal. Verify the classification, diameter, and heat/lot against the WPS filler metal specification. Check storage conditions — low-hydrogen electrodes require oven storage at the correct temperature, and FCAW wire must be from an undamaged, dry spool.
Preheat. Measure preheat on both pieces within the required distance of the joint. Preheat must meet the minimum specified in the WPS and in AWS D1.1:2025 for the base metal and thickness combination. Document the measured temperature and the method used (thermocouple, contact pyrometer, or tempilstik).
Welding machine settings. Check that the machine is set within the WPS amperage and voltage ranges before the first pass. Take measurements with a clamp meter or the machine's calibrated display. If the machine has not been recently calibrated, note the date of last calibration.
Welder qualification. Confirm that the welder holds a valid WPQ for the process and position. Check the qualification date against the six-month continuity clock. See Welder re-qualification after continuity lapse if continuity is in question.

In-Process Inspection During Welding

Watch the first joint through at least the root pass and the first fill pass:

Travel speed and technique. Verify that the welder's technique (torch angle, stringer vs. weave, interpass cleaning) matches what the WPS allows.
Interpass temperature. Measure with contact pyrometer or thermocouple before each pass after the root. Document measured temperatures. Maximum interpass temperature is an essential variable under AWS D1.1:2025 Table 6.6 — exceeding it on the first production joint flags a training or setup issue.
Interpass cleaning. For SMAW, FCAW, and SAW, each pass must be cleaned of slag before the next. Document any visible slag inclusions caught during welding.
Pass sequence. On CJP groove welds, confirm that the weld sequence follows any requirements on the WPS or the drawing. Box sections and T-joints sometimes have specific bead sequences for distortion control.

Post-Weld Inspection

After the joint cools to the required inspection temperature:

Visual examination. Inspect the completed weld per the applicable acceptance criteria in AWS D1.1:2025. Check for cracks, undercut, overlap, porosity, and crater fills at terminations. Document the results.
Dimensional check. Verify weld size (for fillet welds), crown height (for groove welds), and joint dimensions where applicable.
NDE if required by the ITP or contract. Some project inspection plans require MT on the first joint under each CJP WPS. Complete any NDE specified before releasing the run.

Documenting the FAI

FAI documentation does not need to be complex, but it must be retained with the project quality record. A simple FAI checklist tied to the WPS number, the joint mark, and the welder stamp covers the pre-weld, in-process, and post-weld items. The CWI signs and dates the form.

Document at minimum:

WPS number and revision
Joint identifier (piece mark, weld number per the weld map)
Welder stamp/ID
Date and time
Pre-weld setup readings (preheat, machine settings, electrode verification)
In-process observations (interpass temperatures, pass-by-pass notes)
Post-weld visual result (accept or reject with reason)
NDE results if performed
CWI name, certification number, and signature
Release to production: yes/no, and if no, the corrective action required

On projects with multiple WPS and multiple welders, the FAI log becomes a useful first-day-of-production record showing that each WPS was verified before the run began. AISC auditors and owner's inspectors regularly review this type of record during surveillance visits.

Tie-In to the Project Quality Plan

FAI checkpoints are most effective when they are defined in the project welding inspection test plan (ITP) before fabrication begins. The ITP identifies each WPS, the welder assignment, and the inspection activities — including whether FAI is a hold point (work stops until the CWI clears it) or a witness point (CWI should be present but work can proceed if the CWI is not available in time).

For high-consequence joints on critical primary members, a hold point at FAI is appropriate. For routine secondary connections, a witness point is usually sufficient. The project engineer, owner, or AISC audit requirements dictate which applies.

For background on setting up the full inspection plan, see Welding ITP under AWS D1.1 and CWI WPS review checklist.

WPS management platforms such as the one at WPS Welding track WPS versions, welder qualifications, and continuity status in one place, making the pre-weld setup check faster and more reliable.

Common FAI Failures and Their Root Causes

The most frequent issues uncovered at first-article inspection fall into a few repeating categories:

Wrong electrode in the shop. The WPS specifies E7018-H4 low-hydrogen SMAW, but the welder was issued E7018 from standard stock. The H4 diffusible hydrogen designation is required by the WPS and is not automatically provided unless the shop ordered to that suffix. This is caught at the electrode verification step.

Preheat missed or under-measured. A new WPS for A572 Grade 65 or A913 steel may require higher preheat than the welders are accustomed to from routine A36/A572-50 work. The first joint fails preheat inspection because the welder applied the same preheat they always use.

Interpass temperature exceeded early. On multi-pass CJP welds, the first production run sometimes shows interpass overruns because the welder is working quickly and not measuring. The FAI measurement reveals the problem. The maximum interpass temperature in AWS D1.1:2025 Table 6.6 is an essential variable — exceeding it on the first joint is a signal to stop and reset expectations.

WPS range not matched to the joint. A WPS qualified for 1/4 in. through 1-1/2 in. base metal thickness may be assigned to a joint involving 2 in. plate. This is a coverage error caught at the pre-weld step when the inspector reads the WPS range against the material thickness.

Each of these failures is inexpensive to catch at the first joint and expensive to find after 40 joints have shipped.

Summary

First-article weld inspection is not a code requirement under AWS D1.1:2025, but it is a standard quality practice that every shop deploying a new WPS on production work should conduct. The pre-weld setup check, in-process temperature monitoring, and post-weld visual at the first joint confirm that the translation from WPS document to actual weld was successful. Documented FAI records support AISC certification audits, owner surveillance, and the shop's own corrective action history. A failure caught at the first joint costs one weld; a failure caught later costs far more.