WELDING PROCEDURE SPECIFICATION (WPS)
Clause 5 — Prequalified — AWS D1.1:2020
Title
SAW F7A2-EM12K — CJP Single-Bevel 45° with Backing — Group III — Flat/Horizontal
JOINT DESIGN
Code Reference
Figure 5.1 — TC-U4a-GF
Backing
steel — A36 or matching, 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
A537 Cl 2, A572 Gr 60, A572 Gr 65, A633 Gr E, A709 Gr HPS70W, A710 Gr A Cl 3, A913 Gr 60, A913 Gr 65
Thickness Range
5/16 in to unlimited
POSITION
Qualified Positions
1G, 2G
PREHEAT & INTERPASS TEMPERATURE
Minimum Preheat
50°F (≤3/4 in) / 150°F (>3/4–1-1/2 in) / 225°F (>1-1/2–2-1/2 in) / 300°F (>2-1/2 in)
Code Reference
Table 5.8, Category C
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 F7A2 |
| 3/32 in | EM12K | 350-600 | 28-34 | F/H only | SAW — with flux F7A2 |
| 1/8 in | EM12K | 400-700 | 30-36 | F/H only | SAW — with flux F7A2 |
| 5/32 in | EM12K | 450-800 | 30-38 | F only | SAW — with flux F7A2 |
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. Vacuum between passes.
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 III · Table 5.4 (F7A2-EM12K) · Figure 5.1 TC-U4a-GF · Table 5.8 Cat C
Generated by WeldIQ™ · AWS D1.1:2020 · Prequalified per Clause 5 — Prequalified