How many tensile specimens are required for a PQR?

For groove welds, two reduced-section tensile specimens are typically required. The exact count depends on the coupon size and Clause 6 specimen tables — pipe coupons may require different counts than plate.

Face bend vs root bend vs side bend — when does each apply?

For plate up to about 3/8 in thickness, face and root bends are standard. For thicker plate, side bends (taken transverse) replace face/root. Clause 6 specifies the cutover thickness.

Can I skip the bend test if the tensile passes?

No. Both tensile and bend tests must pass for a PQR to qualify. Tensile proves strength; bend proves ductility and freedom from defects. They test different failure modes.

What if one bend specimen fails?

The code allows for retest under specific conditions — typically welding a new coupon. A single failed specimen does not always disqualify the procedure if the failure is shown to be a coupon-prep issue rather than a procedure issue. Consult Clause 6 for retest rules.

PQR tensile and bend test requirements under AWS D1.1:2025

What specimens to cut, what tests to run, what pass-fail criteria apply. A field-ready summary of mechanical-test requirements for AWS D1.1 PQR qualification.

A PQR is only as valid as the mechanical tests that support it. AWS D1.1:2025 Clause 6 specifies which specimens to cut from the test coupon, which tests to run, and what pass-fail criteria apply. This is a working summary for groove welds; pipe and tubular work have additional considerations.

Tensile-test specimens

For a typical plate groove-weld PQR coupon:

Two reduced-section tensile specimens are cut transverse to the weld
Specimen geometry per AWS B4.0 (or the corresponding Clause 6 figure)
Cross-sectional area measured carefully — the lab uses it to calculate ultimate tensile strength (UTS)
Reduced section ensures fracture occurs in the gauge length, not at the grips

Pass criteria: UTS must equal or exceed the minimum specified UTS of the base metal listed in the WPS. Fracture location matters less than UTS — a fracture in the base metal at acceptable UTS is a pass; a fracture in the weld at low UTS is a fail.

If your base metal is A572 Gr. 50 (65 ksi minimum tensile), each tensile specimen must reach at least 65 ksi UTS.

Bend-test specimens

Bend tests detect lack of fusion, slag inclusion, cracking, and other discontinuities that tensile alone won't catch.

For plate ≤ approximately 3/8 in thick: two face bends + two root bends
For plate > approximately 3/8 in thick: four side bends (two from each side of the weld)
Bend radius and angle per Clause 6 figures

Pass criteria: the convex (tension) surface of each bend specimen must show no discontinuity exceeding 1/8 in [3 mm] in any direction. Open discontinuities at the corner (within ~1/8 in of the edge) are evaluated separately.

A bend with a single 3/16 in linear discontinuity is a fail.

CVN (impact) specimens — when required

If CVN is required by code or contract:

Three specimens per location, typically from the weld metal centerline and from the HAZ (heat-affected zone)
Specimen geometry per ASTM E23 Charpy V-Notch
Test temperature specified by the structural code (often 0°F, –20°F, or –40°F depending on application)
Pass criteria: average of three specimens must meet the minimum absorbed energy specified, with no single specimen below a lower limit (e.g., "20 ft-lb average, no single below 15 ft-lb")

CVN failures are unforgiving — a single low specimen can fail the lot.

Macroetch — sometimes required

For fillet weld PQRs (and for some groove configurations) a macroetched cross-section is also required:

One cross-section through the weld
Etched with appropriate reagent for the base metal
Visually examined for fusion, root penetration, and discontinuities

Pass criteria: complete fusion, no cracks, no incomplete fusion or penetration, slag inclusions within Clause 6 limits.

Retest rules

If a single specimen fails, Clause 6 permits a controlled retest:

If the failure is shown to be a coupon-prep issue (e.g., specimen was machined out of tolerance), the lab can re-cut from the same coupon
If the failure is a true procedure issue, the welder welds a new coupon and the full test set is rerun

Two failures from the same coupon — same test type — usually means the procedure itself is the problem.

Cost vs value

Tensile + bend on one coupon: ~$800–$1,500. Adding CVN: another $400–$800. Adding macroetch: $100–$300. The full lab bill for a complete PQR is usually under $2,500.

That's a one-time cost. The WPSs you write off the PQR are good for the procedure's lifetime.