No. AWS D1.1 PQRs do not have an expiration date. They remain valid as long as the qualified essential variables stay within range and the code edition's essential-variable table hasn't fundamentally redefined a row.

Does updating the code edition force requalification?

Usually not. Most table changes between editions are renumbering or content tweaks that preserve the underlying qualification. But specific changes (like Table 6.6 row 4 dropping A5.36 for GMAW/FCAW in 2025) can disqualify a WPS's prequalified status without disqualifying the PQR itself.

If my PQR was qualified at 1G, can I use it for 4G?

Position is essential. AWS D1.1 Clause 6 position tables specify which positions a given test position qualifies. A 1G test does NOT qualify 4G. You'd need a separate qualification or a multi-position coupon.

What if I switch to a different filler brand of the same classification?

Generally not a requalification trigger. As long as both products meet the same AWS A5.X classification and any specified hydrogen designator, the change is nonessential. Document the substitution on the WPS.

When does a PQR require requalification?

A PQR is valid for the life of the procedure — until you cross an essential variable. Here are the specific changes that force requalification under AWS D1.1:2025.

A PQR is a one-time investment that supports WPSs for years — sometimes decades. Knowing exactly what forces requalification is the difference between a $50,000/year welding QA budget and a $5,000/year one. Here are the triggers under AWS D1.1:2025.

The core rule

A PQR no longer supports a WPS when any essential variable drifts outside the range qualified by that PQR. The essential variables are listed in Tables 6.6 (baseline) and 6.8 (CVN supplementary).

If the WPS stays inside the qualified envelope, the PQR is still valid. If the WPS crosses an essential variable boundary, you need new qualification for that variable.

Triggers that require new qualification

The most common:

Filler classification change. A5.1 → A5.5 (E70XX → E80XX), or A5.18 → A5.28 (carbon steel solid wire → low-alloy). Same diameter, same brand — doesn't matter. The classification change is essential.
F-number change. Moving across F-number groups in the same A-spec — requalify.
Base metal group change. Group I → Group II (or to a different P-number under ASME terminology). The 2025 edition uses Table 6.9 groups.
Current type or polarity flip. DCEP to DCEN, AC to DC, pulsed to spray transfer — requalify.
Heat input outside the qualified band. This is the most frequently violated essential. Production crews push travel speed, heat input drops below the qualified range, the procedure is no longer supported.
Filler diameter beyond one size. A WPS qualified for 1/8 in electrodes generally covers 3/32 in and 5/32 in. Going to 3/16 in usually requires requalification.
Position outside what the test position qualifies. 1G qualifies 1G + 1F. 3G + 4G qualifies all positions. Check the position table in Clause 6.

Triggers under CVN (Table 6.8 supplementary)

When CVN is required, Table 6.8 adds:

Heat input increase beyond a tighter band than Table 6.6
Interpass temperature maximum increase beyond the qualified value
Thickness floor (1/2 in in 2025, was 5/8 in in 2020) — the PQR's plate thickness defines the lower bound

The 2025 edition relaxed the supplementary preheat requalification trigger (Row 8) — preheat changes alone no longer force requalification under CVN-supplementary rules.

What does NOT trigger requalification

Switching between brands of the same AWS classification (E70S-6 from Lincoln → E70S-6 from ESAB)
Adjusting amperage / voltage / travel speed within the qualified range
Changing welder (welders are qualified separately via WPQ)
Changing the joint sketch label format
Reformatting the WPS document
Updating the code edition citation (with caveats — see below)

Edition migration

Migrating a WPS from D1.1:2020 to D1.1:2025 usually does not require requalification of the underlying PQR. The 2025 edition mostly renumbered tables and tweaked specific rows. Three things to check:

Table 6.6 row 4 — if your prequalified WPS for GMAW or FCAW listed A5.36, that filler is no longer on the allowed list in 2025
Table 6.6 row 7 — the electrode-to-supplemental-filler ratio threshold is now ±10%; check if your PQR's recorded ratio supports the production range
Table 6.8 row 2(a) — minimum thickness floor changed; CVN-required work in the 1/2–5/8 in band may now have wider qualified range under 2025

In each case, the migration is a paperwork update, not a new test weld.

The economics

A new PQR is $1,500–$4,000. Avoiding unnecessary requalification by understanding which changes are essential vs nonessential saves real money. The decision tree is the same for every WPS:

What changed?
Is it listed as essential in Table 6.6 (or 6.8 for CVN)?
Does the change stay inside the qualified range?
If yes, update the WPS revision; the PQR still supports it.
If no, you need new qualification — but only for the variable that crossed.