WELDING PROCEDURE SPECIFICATION (WPS)
Clause 5 — Prequalified — AWS D1.1:2020
WPS Number
WIQ-SAW-EM12K-G2-003
Title
SAW F7A2-EM12K — CJP Single-Bevel 45° with Backing — Group II — Flat/Horizontal
JOINT DESIGN
Code Reference
Figure 5.1 — TC-U4a-GF
Backing
steel — A36, min 3/8 in × 1 in
DESIGNATION: TC-U4a-GF
| DIMENSION | AS DETAILED | AS FIT-UP TOLERANCE | NOTES |
|---|
| Groove Angle (α) | 45° | +10°, −5° | Single bevel |
| Root Opening (R) | 1/4 in | +1/16 in, −0 | — |
| Root Face (f) | 0 to 1/8 in | Not limited | — |
| Backing Thickness | 3/8 in min | −0 | A36 steel |
| Backing Width | 1 in min | −0 | — |
BASE METAL
Specifications
A36 (all thk), A53 Gr B, A500 Gr B/C, A501, A516 Gr 65/70, A529 Gr 50/55, A572 Gr 42, A572 Gr 50, A572 Gr 55, A588, A709 Gr 36, A709 Gr 50, A709 Gr 50S, A709 Gr 50W, A709 HPS50W, A710 Gr A, A913 Gr 50, A992, A1011 HSLAS Gr 50, A1018, A1085, API 5L X52, API 5L X60, API 5L X65, ABS Gr A/B/D/E
Thickness Range
5/16 in to unlimited
POSITION
Qualified Positions
1G, 2G
PREHEAT & INTERPASS TEMPERATURE
Minimum Preheat
32°F (≤3/4 in) / 50°F (>3/4–1-1/2 in) / 150°F (>1-1/2–2-1/2 in) / 300°F (>2-1/2 in)
Code Reference
Table 5.8, Category B
SHIELDING
Flux
Lincoln 860 or equivalent
APPROVED FILLER METAL SIZES
Welder may use any size listed below. Each size has its own amperage/voltage range and position limit per Table 5.1.
| Size | Class | Amps | Volts | Position Limit | Notes |
|---|
| 5/64 in | EM12K | 300-500 | 28-33 | F/H only | SAW — with flux |
| 3/32 in | EM12K | 350-600 | 28-34 | F/H only | SAW — with flux |
| 1/8 in | EM12K | 400-700 | 30-36 | F/H only | SAW — with flux |
| 5/32 in | EM12K | 450-800 | 30-38 | F only | SAW — with flux |
WELDING PARAMETERS
| Pass | Process | Filler / Class | Size | Current | Amps | Volts | Speed | Technique |
|---|
| Root | SAW | EM12K | 5/64 in | DCEP | 300-500 | 28-33 | 12-30 in/min | stringer |
| Root | SAW | EM12K | 3/32 in | DCEP | 350-600 | 28-34 | 12-30 in/min | stringer |
| Root | SAW | EM12K | 1/8 in | DCEP | 400-700 | 30-36 | 10-25 in/min | stringer |
| Root | SAW | EM12K | 5/32 in | DCEP | 450-800 | 30-38 | 8-20 in/min | stringer |
| Fill | SAW | EM12K | 5/64 in | DCEP | 300-500 | 28-33 | 12-30 in/min | stringer |
| Fill | SAW | EM12K | 3/32 in | DCEP | 350-600 | 28-34 | 12-30 in/min | stringer |
| Fill | SAW | EM12K | 1/8 in | DCEP | 400-700 | 30-36 | 10-25 in/min | stringer |
| Fill | SAW | EM12K | 5/32 in | DCEP | 450-800 | 30-38 | 8-20 in/min | stringer |
| Cap | SAW | EM12K | 5/64 in | DCEP | 300-500 | 28-33 | 12-30 in/min | stringer |
| Cap | SAW | EM12K | 3/32 in | DCEP | 350-600 | 28-34 | 12-30 in/min | stringer |
| Cap | SAW | EM12K | 1/8 in | DCEP | 400-700 | 30-36 | 10-25 in/min | stringer |
| Cap | SAW | EM12K | 5/32 in | DCEP | 450-800 | 30-38 | 8-20 in/min | stringer |
PREQUALIFIED VARIABLE TOLERANCES (TABLE 5.2)
| VARIABLE | TOLERANCE | NOTES |
|---|
| Amperage (Current) | ± 10% | From values specified on WPS |
| Voltage | ± 15% | From values specified on WPS |
| Travel Speed | ± 25% | From values specified on WPS |
| Wire Feed Speed | ± 10% | GMAW, FCAW, SAW only |
TABLE 5.1 ADDITIONAL LIMITS
•Pass width at surface ≥ pass depth (width/depth rule)
•Vertical progression: uphill (except undercut repair with ≥70°F preheat)
TECHNIQUE
Cleaning
Remove slag and unfused flux.
FIELD TIPS — WeldIQ
▸Keep flux dry — store per manufacturer spec. Contaminated flux = porosity and hydrogen cracking.
▸Recycle unfused flux up to 3 times (mix with fresh). Fused slag CANNOT be recycled as flux.
▸Flat/horizontal ONLY — SAW puddle is too fluid for out-of-position.
▸Single bevel: bevel the plate that's easier to access. Unbeveled plate acts as natural backing in T-joints.
▸Verify preheat with a temperature-indicating crayon (Tempilstik) or contact pyrometer. Check 3 inches from the weld on both sides.
CODE CITATIONS
D1.1:2020 Clause 5.2 · Table 5.3 Group II · Figure 5.1 TC-U4a-GF · Table 5.8 Cat B
Generated by WeldIQ™ · AWS D1.1:2020 · Prequalified per Clause 5 — Prequalified