Australian Welding Procedure — AS 1554 Specification Guide
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Reference for welding procedure specifications (WPS) per AS/NZS 1554.1 for Australian structural steel. Covers preheat, interpass temperature, electrode selection, welder qualifications, and procedure qualification records (PQR).
Electrode Selection per AS/NZS 1554.1
| Steel Grade | Manual Metal Arc (MMAW) | Gas Metal Arc (GMAW) | Flux Cored (FCAW) |
|---|---|---|---|
| Grade 300 | E48XX (E4918) | ES4 or EM12 | E71T-1 |
| Grade 300PLUS | E48XX (E4918) | ES4 or EM12 | E71T-1 |
| Grade 350 | E48XX (E4918) | ES4 or EM12 | E71T-1 |
| Grade 400 | E55XX (E5518) | EM13 or ER80S | E81T-1 |
| Grade 450 | E55XX or E62XX | ER90S | E91T-1 |
Minimum Preheat Temperatures — AS/NZS 1554.1 Table 4.2
| Steel Grade | CEV | t≤12mm | 12-20mm | 20-30mm | 30-40mm | >40mm |
|---|---|---|---|---|---|---|
| Grade 300 | ≤0.44 | None | None | 50°C | 50°C | 75°C |
| Grade 300PLUS | ≤0.42 | None | None | None | 50°C | 50°C |
| Grade 350 section | ≤0.48 | None | 50°C | 75°C | 100°C | 125°C |
| Grade 350 plate | ≤0.46 | None | 50°C | 75°C | 100°C | 125°C |
| Grade 400 | ≤0.52 | 50°C | 75°C | 100°C | 125°C | 150°C |
Welder Qualification Requirements
| Requirement | AS/NZS 1554.1 Clause |
|---|---|
| Welder qualification test | Clause 5.2 — bend test + macro etch |
| Qualification period | 2 years (unless lapsed) |
| Position qualification | 1F, 2F, 3F, 4F (fillet) / 1G, 2G, 3G, 4G (butt) |
| Thickness qualification | Qualified for t/2 to 2t of test piece |
| Minimum re-qualification | 1 test per electrode type every 2 years |
Worked Example: WPS Selection
Problem: Specify WPS for 25 mm Grade 350 plate, full-pen butt weld, GP category.
Solution:
- Electrode: E48XX (E4918) MMAW, or ES4 wire for GMAW
- Preheat: t=25 mm, Grade 350 plate → 75°C minimum preheat
- Interpass temp: Maintain min 75°C, max 250°C
- Heat input: 1.0-3.0 kJ/mm (min to avoid hard HAZ, max to avoid toughness loss)
- GP category: 100% visual + 100% UT
- Welder must be qualified for 3G (vertical) and 25 mm thickness range.
Design Resources
- [[Australian Steel Grades|/reference/australian-steel-grades/]] | [[Australian Steel Properties|/reference/australian-steel-properties/]] | [[Australian Beam Sizes|/reference/au-beam-sizes/]] | [[Australian Bolt Capacity|/reference/australian-bolt-capacity/]] | [[AS 4100 Beam Design|/reference/as4100-beam-design-example/]] | [[All Australian References|/reference/]]
FAQ
What electrode is standard for Grade 300 welding? E48XX (E4918) for manual metal arc, or ES4/EM12 wire for gas metal arc welding per AS/NZS 1554.1.
When is preheat required for Grade 300 steel? None required for t≤20mm (CEV ≤0.44). For 20-30mm: 50°C. Over 40mm: 75°C. Grade 300PLUS has lower CEV enabling less preheat.
How long is a welder qualification valid? 2 years per AS/NZS 1554.1 Clause 5.2. Requires re-testing if lapsed or if welding procedures change significantly.
Educational Use Only — This reference is for educational and preliminary design purposes only. All structural designs must be independently verified by a licensed Professional Engineer (PE) or Structural Engineer (SE) in accordance with AS 4100:2020 and all applicable Australian Standards. Results are not for construction.