What edition of AWS D1.1 should I be writing to?

AWS D1.1/D1.1M:2025 is the current edition, ANSI-approved 2025-03-19. Unless your contract or AHJ specifies an earlier edition, write to 2025. Always cite the edition explicitly on the WPS.

Do I need a separate WPS for each joint?

No. One WPS can cover multiple joints as long as they share the same essential variables (process, filler classification, base metal group, position, thickness range). Many fab shops keep 15-30 WPSs that cover the bulk of their production.

Is a Word template enough?

Functionally yes, but it scales poorly. A Word WPS doesn't validate Tables 6.6 / 6.8 essential variables, doesn't link to its supporting PQR, and doesn't enforce revision control. Most third-party audit findings on WPSs are detectable by a software check.

How to write a WPS for AWS D1.1:2025 (step-by-step)

A practical step-by-step for writing a code-compliant Welding Procedure Specification under AWS D1.1:2025 — from joint sketch to signature.

A code-compliant WPS for AWS D1.1:2025 is not complicated, but it has to be specific. This is the order most engineers write one.

Step 1 — pick the prequalification path

Before you write anything, decide:

Prequalified WPS (Clause 5) — your process, filler, base metal, joint, and position all fall inside the prequalified limits. No PQR required.
Qualified by test WPS (Clause 6) — at least one variable falls outside Clause 5, and you must support the WPS with a PQR.

Most shop welding on common carbon-steel structural shapes can be prequalified. Stainless, high-strength low-alloy with non-prequalified fillers, and unusual joints need qualification.

Step 2 — identification block

The header should always include:

WPS number (use a consistent scheme: WPS-25-001)
Revision number and date
Code edition: AWS D1.1/D1.1M:2025
Scope statement: "For SMAW production welds on ASTM A36, Group I, thicknesses 1/8 in to 3/4 in, in the 1G and 1F positions."
Supporting PQR number, or a citation to Clause 5 if prequalified

Step 3 — process and joint

Process: pick one (or two, if you're documenting a hybrid like GTAW root + SMAW fill)
Joint sketch: groove or fillet, root opening, backing, backgouging
Joint type: B-U2 (complete penetration with backing), B-L1 (with backgouging), etc., from Annex B for prequalified joints

A joint sketch is mandatory. A WPS without one fails review.

Step 4 — base metal

Specification: ASTM A36, A572 Gr. 50, A992, etc.
Group number from Table 6.9 in the 2025 edition (Table 3.1 in 2020)
Thickness range in inches and millimeters
Diameter range, if applicable

Step 5 — filler metal

AWS A5.X classification: A5.1, A5.5, A5.17, A5.18, A5.20, A5.23, A5.28, A5.29, A5.36
Specific classification: E7018, E70S-6, E71T-1C, etc.
Diameter range
For SMAW low-hydrogen, note the moisture control / oven storage requirement

Important: AWS D1.1:2025 dropped A5.36 from the allowed filler list for certain rows of Table 6.6 — if you're writing GMAW/FCAW, double-check the table.

Step 6 — electrical and technique

Current type and polarity: DCEP, DCEN, AC
Amperage range (a range, not a single value)
Voltage range (except SMAW)
Travel speed range (in inches per minute or millimeters per minute)
Transfer mode (GMAW: short circuit, globular, spray, pulsed)
Stringer or weave, with maximum bead width

Step 7 — preheat, interpass, PWHT

Minimum preheat based on Table 5.8 (2025) — function of thickness, material category, and filler hydrogen
Maximum interpass temperature (the rule engine flags increases vs PQR baseline)
PWHT if required by structural code, contract, or AHJ

Step 8 — sign and revision-control

The CWI or welding engineer signs and dates the WPS. Any subsequent change — even a typo — gets a new revision number and date. Old revisions stay on file.

A WPS that follows these eight steps will pass a third-party audit on the first pass.