WPS and welder/operator qualification test positions, per AWS D1.1:2020 (WPS: Section 6.4; welder/operator: Section 6.16.1.1). The same positions apply to both.
Most HSS connection welds are considered plate welds and do not require a tubular qualification test. A plate test qualifies the majority of HSS welds, including groove welds and rectangular T-, Y-, and K-connections (AWS D1.1 Table 6.10). A tubular test is needed only in limited cases. Requiring one where it is not needed adds cost and time with no benefit: the welder must qualify by tubular testing, and the welding procedure (WPS) may itself need qualification by testing if no prequalified procedure exists.
Reading the Position Designations
Each designation is a position number plus a joint-type letter — F fillet, G groove (e.g., 3G = vertical groove weld). R Restricted — the test adds a restriction ring to simulate restricted access.
WPS and Welder Qualification Test Positions
Weld Position
Plate Test Setup AWS D1.1 Clause 6 (Figs. 6.3, 6.4)
Tubular Test Setup AWS D1.1 Clause 10 (Figs. 10.12, 10.13)
1
FLAT (F)
Weld axis horizontal
In-position weld (welder above the joint)
Gravity assists the welder
1F1G
1G
HSS rotated during the weld test so the welder stays above the joint
2
HORIZONTAL (H)
Weld axis horizontal
Out-of-position weld
Gravity can sag the molten pool
2F2G
2G2G
HSS fixed; welder moves around it
3
VERTICAL (V)
Weld axis vertical
Out-of-position weld
Progresses upward or downward
Stronger sag risk than horizontal
3F3G
No separate tubular 3G test — the 5G test already covers vertical welding as the welder moves around the fixed HSS.
4
OVERHEAD (OH)
Out-of-position weld
Most difficult standard position
Limited visibility
High spatter risk from gravity
4F4G
No separate tubular 4G test — the 5G test already covers overhead welding as the welder moves around the fixed HSS.
5
HORIZONTAL FIXED PIPE
Combines flat, horizontal, vertical, and overhead in one test
Welder transitions through all four positions around the fixed HSS
No plate test applicable
5F5G5G
HSS fixed horizontal throughout welding
6
INCLINED FIXED PIPE
6G: HSS fixed at 45° throughout welding
6GR: adds a restriction ring limiting access and visibility
6GR required for CJP welds at T-, Y-, and K-connections (AWS Table 10.12)
Most difficult angles and body positions
No plate test applicable
6G6G6GR
HSS fixed at 45° throughout welding
Page 1 of 2 — Continued on reverse: HSS Connection Application ExamplesSteel Tube Institute • steeltubeinstitute.org
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HSS Welding Position Reference
Connection application examples — plate vs. tubular qualification requirements. Badges indicate whether each connection is qualified by a plate test or requires a tubular test.
Connection Application Examples — Plate vs. Tubular Qualification Requirements
Weld Position
Rectangular HSS
Round HSS
1
FLAT (F)
PLATE
PLATE
2
HORIZONTAL (H)
PLATE
PLATE
3
VERTICAL (V)
PLATE
PLATE
4
OVERHEAD (OH)
PLATE
DEPENDS ON DIA.
5
HORIZONTAL FIXED PIPE
PLATE
TUBULAR
6
INCLINED FIXED PIPE
TUBULAR
TUBULAR
Plate Test vs. Tubular Test — What Each Qualifies (Welder Qualification, AWS D1.1 Sections 6.16.1.1, 6.16.2.1, and 10.16.1)
QUALIFIED BY PLATE TESTA plate test qualifies this connection.REQUIRES TUBULAR TESTA tubular test is required.DEPENDS ON DIAMETERDetermined by the round HSS diameter.
A plate test qualifies groove welds on rectangular HSS (both CJP and PJP, at all connection types); CJP and PJP butt-joint welds on round HSS; PJP welds at rectangular T-, Y-, and K-connections; and fillet welds at rectangular T-, Y-, and K-connections with dihedral angles from 60° to 135°. (AWS D1.1 Clause 6, Tables 6.10 and 6.11)
A tubular test is required for CJP welds at round T-, Y-, and K-connections (the 6GR test); fillet welds on round HSS smaller than 24″ in diameter; and any T-, Y-, or K-connection with a dihedral angle below 60°. Round HSS PJP butt joints are qualified by a plate test only at 24″ diameter or larger. (AWS D1.1 Clause 10, Tables 10.12 and 10.13)
Reference Notes
Two separate qualifications are required
Every production weld needs both a qualified Welding Procedure Specification (WPS) — proof the procedure (process, filler, technique) produces sound welds (AWS D1.1 Section 6.4) — and a qualified welder or operator — proof the person can perform it (Section 6.16.1.1).
Where to look up the full rules
To confirm what a given test qualifies, go to AWS D1.1. Plate tests are covered in Clause 6 (WPS: Table 6.1; welder: Table 6.10); tubular tests in Clause 10 (WPS: Table 10.8; welder: Table 10.12).
A groove qualification also covers fillet welds
A welder qualified for a groove weld in a given position is automatically qualified for fillet welds in that same position (AWS D1.1 Section 6.22), subject to the dihedral-angle limits described below.
Dihedral angle sets the fillet test required
At T-, Y-, and K-connections: 60°–135° is qualified by a plate fillet test (AWS D1.1 Table 6.11, Fig. 6.22 or 6.25). 30°–60° requires a tubular fillet test (Table 10.13 and Fig. 10.16). Below 30° follows the special provisions of Section 10.18.1.
Round HSS fillet welds depend on diameter
A plate fillet test qualifies round HSS fillets only at 24″ diameter or larger (AWS D1.1 Table 10.13). Since round HSS runs only up to 28″, most round HSS — anything under 24″ — requires a tubular fillet test (Fig. 10.16; setups in Fig. 10.13).
CJP welds at round T-, Y-, K-connections
A complete-joint-penetration (CJP) weld at a round T-, Y-, or K-connection requires the 6GR tubular test (AWS D1.1 Table 10.12). “R” indicates a restricted joint configuration, and the test setup requires a restriction ring — a collar fixed beside the test weld that blocks access the way an intersecting branch member would at a real connection. A plate test does not qualify this weld.
STI Discourages CJP Welds in HSS Connections Whenever Possible
CJP welds carry significant additional cost. In most cases the strength of the full HSS cross section can be developed using either fillet welds or PJP groove welds.
