§ WPS template
AWS D1.1:2025 FCAW WPS for ASTM A588
How to draft an AWS D1.1:2025 Welding Procedure Specification for Flux-Cored Arc Welding (FCAW) on ASTM A588 Weathering Steel. Recommended filler: E81T1-W. Below: process notes, base metal properties, prequalification path, typical parameters, and which essential variables to watch.
About FCAW (Flux-Cored Arc Welding)
Tubular flux-cored electrode with either external gas shielding (FCAW-G) or self-shielding (FCAW-S). Higher deposition rates than SMAW or GMAW. Slag covering the bead helps stability and out-of-position performance. Note: A5.36 was dropped from the 2025 Table 6.6 allowed-spec list for FCAW.
Process family: semi-auto. Suited to: high-deposition shop and field welding, out-of-position welding (fcaw-s with self-shield), and similar work.
About ASTM A588
Atmospheric corrosion-resistant (weathering) HSLA steel. The Cor-Ten family. Used unpainted; develops a stable oxide layer. Filler metal must be color-matched (weathering grade) or the joint must be painted.
- AWS D1.1 Group (Table 6.9)
- Group I
- Yield (ksi)
- 50
- Tensile (ksi)
- 70
- Weldability
- good
Prequalification path
ASTM A588 (Group I) is on the prequalified base metals list for FCAW per AWS D1.1:2025 Clause 5. A written WPS is still mandatory but no PQR test is required as long as every Clause 5 essential variable (joint geometry, filler, preheat, current/polarity, etc.) is met.
Preheat: 70°F up to 3/4 in; 200°F from 3/4 in to 1-1/2 in; 300°F above 1-1/2 in for low-hydrogen practice. Filler must match weathering chemistry (e.g., E8018-W, ER80S-W).
Typical parameters
Starting points only. Verify against electrode manufacturer data and your PQR.
| Filler | E81T1-W |
| Amperage | 180–280 A (0.045 in wire) |
| Voltage | 24–28 V |
| Travel speed | 8–18 ipm |
| Position(s) typically qualified | All positions (1G–4G); 5G/6G for pipe per Clause 10 |
Essential variables to watch (AWS D1.1:2025 Table 6.6)
If your shop is working from a PQR, these are the FCAW-specific changes that require requalification per Table 6.6. The rule engine flags every one of them with the row number, clause reference, and the actual delta.
- Filler classification change
- Shielding gas composition (FCAW-G)
- Voltage > 7% change
- Amperage > 10% change
- Travel speed > 25% change
A588 weathering steel: the filler metal must color-match (e.g., E8018-W, ER80S-W) unless the joint is painted. A non-weathering filler is a Table 6.6 row 3 essential variable change if it deviates from PQR.
Where FCAW on ASTM A588 fits
- Highway bridges (unpainted)
- Exposed architectural structures
- Outdoor sculptures
- Industrial buildings without painted finish
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FAQ
Does AWS D1.1:2025 prequalify FCAW on ASTM A588?
Yes — ASTM A588 is on the Clause 5 prequalified base metals list and FCAW is a Clause 5 prequalified process. You still need a written WPS but no PQR.
What filler is recommended for FCAW on ASTM A588?
E81T1-W. Verify against your project specification and the consumable manufacturer's data sheet. Filler classification change is a Table 6.6 essential variable.
What preheat does ASTM A588 need?
70°F up to 3/4 in; 200°F from 3/4 in to 1-1/2 in; 300°F above 1-1/2 in for low-hydrogen practice. Filler must match weathering chemistry (e.g., E8018-W, ER80S-W).