2025 Welding Code Updates: What Fabricators Must Change Now

If you build to AWS D1.1, ASME Section IX, or API 1104, the latest editions have practical implications for your welding procedures (WPSs), procedure qualifications (PQRs), welder continuity, and NDE acceptance. This post distills the most impactful changes and gives you a shop-ready checklist to update variables, traceability, and documentation so you pass audits without delays.

What actually changed in the big three codes?

Across recent editions—AWS D1.1 (latest 2024 release), ASME Section IX (2023/2025 editions), and API 1104 (recent editions)—you’ll see a consistent trend: clearer essential variables, better alignment with modern processes (pulsed GMAW/GTAW, hybrid/laser-arc, mechanized/autonomous welding), and more explicit expectations for traceability and nondestructive examination (NDE) procedures.

High-level themes you should plan for:

Modern process clauses: clearer treatment of pulsed waveforms, transfer modes, hot wire GTAW, and mechanized setups.
Qualification rationalization: revised or clarified essential/nonessential variables to reduce ambiguity and tighten heat input and interpass control.
NDE harmonization: updated language for UT/PAUT/AUT procedures and acceptance, plus better definitions of indications.
Traceability and documentation: stronger expectations for filler and base-metal traceability, welder continuity, and calibration records.

Even if you’re not switching processes, you’ll likely need to refresh how you document variables and how your NDE procedures cite acceptance criteria in the latest clauses/annexes.

WPS actions to take this week

Start with the documents your welders use every day. Your WPSs should reflect current code language, process variants, and realistic parameter ranges that fit how your shop actually welds.

1) Verify process naming, mode, and waveform

Spell out the exact process variant: GMAW spray vs. pulsed vs. short-circuit; GTAW vs. hot-wire GTAW; SAW with tandem or twin; FCAW gas-shielded vs. self-shielded.
State the transfer mode and waveform where applicable. Many codes treat a change in transfer mode (short-circuit to spray/pulsed) as an essential variable requiring requalification.
If you rely on pulsed programs, list the acceptable parameter windows (average current/voltage or arc energy) and whether alternate power sources are allowed.

2) Tighten heat input and interpass control

Record arc energy/heat input ranges on the WPS and PQR and include the measurement method (travel speed timing, wire feed to travel energy calculation, or data logger).
State how interpass temperature is measured (contact thermometer, IR gun with emissivity setting) and the location of measurement (e.g., 1 inch from weld toe).

3) Update base metal and filler references

Map base metals to the current grouping system: AWS material groups for D1.1, P-Numbers for Section IX, and applicable material categories/strength ranges for API 1104.
List filler classification families approved for use (e.g., ER70S-6, E7018-H4R) and any hydrogen designators/applications that are required by your customers or service conditions.

4) Make joint details unambiguous

Include clear joint sketches with root opening, groove angle, land, backing type/material, and acceptable variations.
If you rely on prequalified joints in D1.1, ensure the joint designation matches the current edition numbering and restrictions.

PQR: when you must requalify—and when you don’t

You don’t need to requalify everything just because a new edition is out. But you do need to verify that your existing PQRs support your current WPS ranges under the updated essential variables.

Trigger points that often force requalification:

Changing transfer mode (e.g., short-circuit to spray or pulsed) or switching to power sources with materially different waveforms.
Increasing thickness, heat input, or interpass beyond what was recorded during qualification for impact-tested applications.
Altering joint details that affect essential variables (backing to open-root, position changes, or groove configuration updates).
Switching filler metal classifications or shielding gas compositions beyond listed ranges.

Actions to take now:

Crosswalk your PQR variables to the latest edition’s essential-variable tables. Confirm your WPS ranges are within what the PQR actually demonstrated.
For impact/CVN applications, double-check toughness test temperatures, welding heat input, and interpass temps are properly bounded.
If your shop adopted pulsed programs after your original PQR, plan a focused requalification to lock in realistic ranges—and capture mechanicals with the modern parameters.

Welder performance and the six-month continuity rule

All three codes maintain the familiar six-month continuity expectation: each welder must perform a process within six months to stay current. Auditors will look for evidence that ties a welder to a process, position, and the applicable code.

Best practices that pass audits:

Digital or paper continuity log listing: welder ID, process, position, base metal/filler family, WPS used, and date of production weld.
Link continuity to traveler numbers, weld maps, or WPS IDs so the activity is traceable.
For multiple processes (e.g., GTAW root, SMAW fill), record both. If a welder changes employers, retain continuity documents for your records per contract requirements.

If a welder lapses, don’t guess—schedule a quick performance test per the governing code edition and restart continuity from that date.

NDE acceptance: get your procedures and reports aligned

Recent editions improved language around UT/PAUT/AUT procedures and acceptance terms. The biggest risk is not that acceptance got radically tighter—it’s that shops keep using outdated references and tables.

Audit-proof your NDE program:

Verify your written practice, NDE procedures, and acceptance tables cite the current edition clauses/annexes used by the project.
Confirm calibration blocks, reference levels, and scan plans match the method in your procedure (UT vs. PAUT/AUT) and the acceptance class specified by the owner.
Standardize indication terminology and reporting formats so “length,” “height,” “amplitude,” and “location” are unambiguous.
Train technicians and weld inspectors on any renumbered clauses so report templates and checklists reflect the right paragraphs.

For RT users: ensure image quality indicator (IQI) placement, density range, and sensitivity settings meet the edition and technique. For VT: keep a current lighting verification method and calibrated brightness meter or standard where required by contract.

Filler metal and material traceability: small changes, big audit wins

Owners and inspectors increasingly expect lot-level control. Even when the base code is silent, contract documents often mandate it. Get ahead of the curve:

Filler metals: record manufacturer, classification, lot/heat, diameter, and storage/conditioning details (e.g., oven temperature for low-hydrogen electrodes).
Fluxes and SAW wires: log blend ratios, lot numbers, and re-bake parameters if applicable.
Base metal: keep MTRs tied to heat numbers on travelers/weld maps. If you cut parts from multiple heats, track where each piece ends up.
Shielding gases: list mix ratios and supplier certs when required by procedure or owner specs.

Practical tip: barcode or QR your consumable lots and link them to WPS IDs and work orders. It makes root-cause analysis and NCRs much faster—and impresses auditors.

Shop-ready checklist to roll the updates into production

Use this as your step-by-step plan. Most small and mid-size fab shops can complete it in 2–4 weeks.

Identify governing editions: for each active project, confirm the exact AWS D1.1, ASME Section IX, or API 1104 edition/appendix. Record contract-specific addenda.
Crosswalk matrix: build a one-page matrix mapping your WPS/PQR variables to the latest essential-variable language. Flag any gaps.
Refresh WPSs: update process names, transfer modes, heat input/arc energy ranges, interpass measurement methods, joint details, and gas blends. Issue a fresh revision.
Spot requalify: plan PQRs where transfer mode, heat input, position, or backing changed. Capture mechanicals and, if required, impact tests at service temperatures.
Continuity system: implement a simple digital log (spreadsheet or app) linking welder IDs to process, position, WPS used, and production weld dates.
NDE procedure check: align UT/PAUT/RT procedures and acceptance with the current edition; update report templates and technician training notes.
Traceability upgrade: label wire spools, flux bins, and rods by lot; tie lots and MTRs to travelers. Add a one-page consumables control SOP.
Calibrations: verify due dates and methods for temperature indicators, ammeters/voltmeters on power sources, ovens, and NDE instruments. Keep certificates accessible.
Document control: archive superseded WPSs/PQRs, publish the current set, and train supervisors on what changed and why.

Code-specific watch items for 2025

Keep an eye on these focal points as you adopt the latest editions and owner specs:

AWS D1.1: prequalified language and joint references continue to evolve; verify whether your use of pulsed GMAW is prequalified or must be qualified by testing. Ensure joint designations and fit-up tolerances match the current tables.
ASME Section IX: transfer mode, heat input/arc energy, impact-tested essential variables, and updated alloy listings in QW/QB-422 can affect your WPS ranges. Carefully review automatic/mechanized variables if you’re adding cobots or wire feeders on slides.
API 1104: confirm your acceptance criteria and procedure qualifications align with the latest UT/PAUT/AUT provisions adopted by the pipeline owner, and ensure your welder performance tests match the pipe size, position, and process actually used in the field.

Key Takeaways

Don’t blanket requalify—target requalification where transfer mode, heat input, or joint variables changed.
Update WPSs to explicitly state process variant, transfer mode, heat input method, and interpass control.
Align NDE procedures and acceptance with the exact edition and annexes your contract requires.
Strengthen traceability for filler, flux, and base metal; it’s a fast path to smoother audits.

Conclusion

The newest code editions aren’t trying to trip you up—they’re reflecting the way modern welding actually happens. If you update your WPS language, verify your PQR coverage, tighten continuity records, and align NDE procedures with the right clauses, you’ll pass audits, avoid rework, and set your team up for faster, more consistent production. Start with the checklist above, and your shop will be 2025-ready without missing a beat.