Welding Variables- Essential

variable, Non- Essential

Variables & Supplementary
Essential Variables
Essential variables in Welding are those variables that affects the mechanical
& technological properties of a welding. They are classified for:
 Essential variables for WPS Procedure Qualification
 Essential variables for Welder Performance Qualification
This article covers Essential Variables, Non-Essential Variables &
Supplementary essential Welding for WPS & Welder qualification both.

Table of Contents
 What are Welding Variables?
 What is Essential Variable in Welding?
 Examples of Essential Variables in Welding for WPS
 What are Supplementary Essential Variables in Welding?
 Examples of Supplementary Essential Variables in welding for WPS
 What are Nonessential Variables in Welding?
 Examples of Supplementary Essential Variables in welding for WPS
 What are Special Process Variables?
 WPS essential Variables
 List of Essential and Nonessential variables in welding
 Essential Variables for Welder Qualification
 What must be done if an essential variable on a WPS is changed?
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What are Welding Variables?

It is important to remember that the requirements of different welding codes
and standards (E.g. ASME Section IX, AWS D1.1, or ISO 15614-1) have been
adjusted to meet specific service requirements.
Each welding code and standard such as ASME Section IX or AWS D1.1 or
ISO 15614-1 have given & considered:

1. Essential,
2. Nonessential, and
3. Supplementary essential variables differently.
Hence, to properly develop welding documents such as WPS, PQR, or WPQ,
shall be reviewed by competent qualified Welding Engineer or Welding
Inspector.
These qualified and responsible person shall review and decide the relevant &
applicable welding variables such as essential, non-essential and
supplementary essential variables for each qualification. A righteous review
will ensure the documents comply to the code requirements to maintain the
welding quality on job.

A qualified PQR & WPS specifying these variables within the qualified range
is mandatory for a good welding quality and integrity. This is hence essential
to perform this task with proper due diligence and utmost care.

A variable listed on a wps is required to be comply the qualification code. For

example, ASME Section IX, requires all essential variables, non-essential &
supplementary essential variable to be listed in WPS.

 What is the welding variable?

 Types of welding variables?
 Procedure and Performance variables?
 What are essential, supplementary, Non-essential, and special
variables?
 Importance of welding variables?
What is Essential Variable in Welding?
What is P Number A Number and F Number in Welding?

Essential welding variables are listed in the ASME Section IX,

clause QG-105.1, QW-251.2, and QW-401.1.
For Essential Welding variables, a change in the essential variable is
considered to affect the mechanical properties (E.g. tensile strength, yield
strength & ductility) of the weldment and shall require the requalification of the
WPS. Hence, the WPS must be requalified, if any of the essential variable is
changed.

Examples of Essential variables are P-Number for base metal, welding

process or PWHT, etc.

Examples of Essential Variables in Welding for

WPS
The examples of some essential welding variables as per ASME Section
IX are:

1. Base Metal P. Number

2. Base Metal Thickness qualified range
3. Decrease in preheat temperature more than 100 Degree
Fahrenheit
4. Change in PWHT

What are Supplementary Essential Variables

in Welding?
Supplementary Essential welding variables are listed in the ASME Section IX,
clause- QG-105.3 & QW-251.2, QW-401.3
Supplementary essential variable affects the weld toughness properties
(CVN). So, the supplementary essential variables shall be considered as
essential variables for procedure qualification (WPS-PQR) when CVN
toughness is applicable for the welding.
For example- a pressure vessel fabrication has toughness requirements for its
weld, then supplementary essential variables must be considered too.

If there is no requirements for weld toughness, supplementary essential

variables are non-essential variable only. For example- a weld operating at
elevated temperature does not requires weld toughness as material is already
having good ductility a high temperature.

Examples of Supplementary essential variables are for example- Group

Number for base metal, thickness limit qualified in the PQR.

Examples of Supplementary Essential

Variables in welding for WPS
The examples of some Supplementary-essential welding variables as
per ASME Section IX are:

1. Groove design
2. Removal of backing
3. Change in welding rod diameter
4. Change in welding position
5. Change in welding progression
6. Change in polarity
7. Change in welding technique
8. Method of cleaning

What are Nonessential Variables in Welding?

Non-Essential welding variables are listed in the ASME Section IX, Clause- QG-
105.3 & QW-251.3, QW-401.4

Nonessential welding variables refers to those conditions in which a change

can be done without the need to requalify the existing WPS. The reason-
changes in these variables does not affects the mechanical properties of the
weld.

Although a change in the nonessential variable doesn’t require prequalification

of the WPS but as per ASME, these variables shall be specified in the welding
procedure specification (WPS).

Examples of non-essential welding variables for WPS qualification are:

 Joint design,
 Filler wire/ electrode diameter
 Root spacing
 welding position
 weaving or stringer bead
 Peeing
 Preheat maintenance
 single pass/ multipass
 Cleaning methods
Examples of non-essential welding variables for Welder Performance
Qualification are:

 Root spacing
 Electrode Diameter
 Welding current, voltage
 Travel speed
 Gas shielding
 Base metal group Number
 Base metal thickness
Examples of Supplementary Essential
Variables in welding for WPS
The examples of non-essential welding variables as per ASME Section
IX are:

1. Material Group Number

2. Weld metal Thickness qualified limit
3. Change in welding rod classification
4. Increase in interpass temperature
5. PWHT (Time & temperature change)
 6. Welding Heat Input
7. Welding current & voltage
What are Special Process Variables?
Special welding variables are listed in the ASME Section IX, Clause- QG-105.4 &
QW-251.4

Special process variables are conditions that apply only to special processes
(Such as corrosion resistance overlay & hard-facing) that are described in the
ASME Section IX.

Special processes are such as weld overlay applications. These processes

are used for special purposes instead of joining applications.

WPS essential Variables

WPS Essential Variables are those conditions that influence deposit weld
mechanical properties. Any change in these variables other than qualified will
alter the mechanical properties of the welding. These properties can be:

 Tensile Strength
 Yield Strength
 Toughness
 Hardness
 Ductility
 Microstructural changes
Essential variables are listed in ASME Section IX QW-452 to QW-267
Table. Essential variables examples are:

 Base Metal P-Number

 Welding Electrode F-Number
 Weld A-Number
 Welding Preheat
 PWHT
 Qualified PQR Thickness (T)
 Thickness (t) of weld deposit qualified
List of Essential and Nonessential variables in
welding
Essential and Non-Essential Variables in Welding are covered in ASME
Section IX for:

 WPS Procedure Qualification

 Welder Performance Qualification
WPS Qualification List of Essential and Nonessential variables in welding can
be found in Table QW-452 to QW-267 for different welding processes. Below
is the list of Essential and Nonessential Variables for WPS Qualification.
 List of Essential and Nonessential variables in welding

Welder Performance Qualification List of Essential and Nonessential variables

in welding can be found in Table QW-352 to QW-357 for different welding
processes. Below is the list of Essential Variables for Welder Performance
Qualification.

 Removal for backing

 Change Base Metal P-Number
  Change in Pipe diameter
 Change in F-Number
 Change in t-Weld qualified
 Addition of a welding position
 change from vertical uphill to downhill

List of Essential and Nonessential variables in Welding Performance Qualification

Essential Variables for Welder Qualification

Essential Variables for Welder Qualification are those variables that affect the
welder ability to make a sound weld deposit. So basically, essential Variables
for Welder Qualification influence the weld quality in term of soundness.

Essential Variables for Welder Qualification are listed in Table QW-352 to

QW-357 for different welding processes of ASME Section IX, QW-352 to QW-
357 for different welding processes for SMAW Welding process are given
below (Taken from Table QW-353).

 Removal for backing

 Change Base Metal P-Number
 Change in Pipe diameter
 Change in F-Number
 Change in t-Weld qualified
 Addition of a welding position
 Change from vertical uphill to downhill
What must be done if an essential variable on
a WPS is changed?
If an essential variable on a WPS is changed beyond the range qualified, it
require re-qualification of the WPS by welding a new PQR. This condition is
specified in ASME Section IX QG-105 clause.

An essential variable on a WPS is changed can be addressed in two ways:

 Change in an essential variable within the range qualified

 Change in an essential variable beyond the range qualified
For Change in an essential variable within the range qualified, can be made
by revising the WPS as editorial revision.

For change in an essential variable beyond the range qualified, this required
re-qualification of welding procedure by welding a new test coupon and testing
it according to the welding qualification code, such as ASME Section IX or
AWS D1.1.