AWS A5.36 is a filler-metal specification that uses an open-classification system for flux-cored welding electrodes — both gas-shielded and self-shielded. It allows manufacturers more flexibility in chemistry compared to the legacy A5.20 / A5.29 fixed classifications.

Why did D1.1:2025 drop A5.36 from some prequalified positions?

AWS D1.1:2025 Table 6.6 row 4 specifically removed A5.36 from the allowed filler-classification list for GMAW/FCAW essential-variable groupings. The technical committee's reasoning was that A5.36's open-classification flexibility allowed too much variance for prequalified use without project-specific testing.

Can I still use A5.36-classified fillers under D1.1:2025?

Yes — but the WPS must be qualified by test (PQR-supported), not prequalified. A5.36 fillers can still produce excellent welds; they just don't fit the prequalified envelope anymore.

AWS A5.36 designators: what changed in D1.1:2025

A5.36 is the open-classification filler standard for FCAW. Its prequalification status changed in D1.1:2025. Here's what shops need to update.

AWS A5.36 is the open-classification filler-metal standard for flux-cored welding electrodes — both gas-shielded (FCAW-G) and self-shielded (FCAW-S). When it was introduced, A5.36 gave manufacturers more chemistry flexibility than the legacy A5.20 and A5.29 classifications. That flexibility helped innovation but complicated prequalification.

AWS D1.1:2025 made one specific change: A5.36 was dropped from the prequalified filler-classification list in Table 6.6 row 4. Shops with WPSs that used A5.36 fillers in prequalified procedures need to update.

What A5.36 actually does

A5.36 uses an "open-classification" system. Instead of fixed designators (E71T-1C, E71T-8, etc.) that lock in deposit chemistry, A5.36 classifications include modular descriptors:

E71T-1C-H4 under A5.20 has a specific chemistry envelope
E71T-1C-H4 under A5.36 has a wider chemistry envelope and includes modular designators for tensile, position, charpy, and hydrogen

This means A5.36 wires labeled with the same primary classification can have somewhat different chemistry between manufacturers — within the open-classification envelope.

Why the prequalification change

The AWS D1.1 technical committee's view: prequalification depends on predictable filler behavior. The A5.36 open-classification system, while useful for filler-metal manufacturers, introduced enough variance that prequalified use without project-specific PQR testing was no longer supported.

In the 2025 edition, Table 6.6 row 4 explicitly removes A5.36 from the prequalified filler list for the GMAW/FCAW essential-variable groupings.

What this means for your WPS library

If your shop has WPSs that:

Cite A5.36 fillers (E71T-1 under A5.36, E71T-8 under A5.36, E70T-X under A5.36)
Claim prequalified status per Clause 5
Were written under AWS D1.1:2020

…then migrating to 2025 requires either:

Switch to a legacy classification. If your filler is also classified under A5.20 (most are dual-classified), update the WPS to cite the A5.20 classification. The filler-metal manufacturer can confirm dual classification.
Qualify by test. Run a PQR with the A5.36 filler in use. The procedure becomes PQR-supported instead of prequalified. Cost: ~$2,000-$4,000 per PQR.
Stay on the 2020 edition for that specific work (acceptable if contract / AHJ permits 2020 citation).

Most shops choose option 1 — switch to A5.20. The filler is physically the same wire; the documentation just uses the legacy classification.

Affected products

Common FCAW wires that have A5.36 classifications:

Lincoln Electric Innershield series (some grades)
ESAB Dual Shield series
Hobart Fabshield series
Several import brands

Most are dual-classified under A5.20 (gas-shielded) or A5.29 (self-shielded). Check the certification on each lot.

How to update the WPS

The simplest update:

Identify all WPSs citing A5.36
For each filler, verify dual classification under A5.20 or A5.29
Update the WPS filler block to cite the legacy classification
Increment the revision number, document the change in revision history, re-sign
Verify the floor copy is current

A rule engine that knows the 2025 row 4 change can flag every A5.36 citation in the library and propose the A5.20/A5.29 equivalent.

What stays the same

The 2025 change is documentation-driven, not physically-driven:

The filler wire is the same product
The welding behavior is the same
The mechanical properties are the same
Existing PQRs that used A5.36 wires are not invalidated
WPSs that are PQR-supported (not prequalified) can continue to cite A5.36

The change only affects prequalified WPSs claiming Clause 5 status.

Field implications

For shops doing field structural erection with FCAW-S using A5.36 wires, the change is significant:

Field erection often relies on prequalified WPSs for speed
An A5.36 self-shielded wire that was prequalified under 2020 needs documentation update
Updating mid-project requires careful revision control and welder notification

For shops doing shop production where PQR-supported procedures are already the norm, the change is paperwork.

What's coming next

The next edition of AWS D1.1 (expected 2030) may either:

Further restrict A5.36 in prequalification
Re-add A5.36 with more specific subset rules
Maintain the 2025 exclusion as the new normal

Either way, the move toward stricter prequalified filler tracking will continue. Shops planning library architecture should organize WPSs by classification type, making future updates straightforward.