Determine what happens when a welder qualified under one AWS D1.1 process/position needs to add a new process (e.g., adding GMAW after being qualified only in SMAW) for continued shop work

Steps

1. Identify the specific essential variables that changed (welding process is itself an essential variable under both D1.1 and ASME IX) and confirm a new performance qualification test is required for the new process
2. Confirm the qualification path used: prequalified WPS (if the shop is using D1.1's prequalified provisions) vs. a WPS validated by its own PQR, since the requalification test must be run against the applicable WPS for the new process
3. Check whether the welder's existing qualification expires or needs renewal for continuity reasons (e.g., a welder not having worked in a qualified process/position within the code-specified time period) at the same time as adding the new process, to avoid two separate test cycles
4. Confirm which positions must be retested for the new process — position qualification is generally process-specific, so an all-position SMAW qualification does not carry over to GMAW automatically
5. Have the shop's certified welding inspector or engineer document the new WPQ test record (process, position, material, thickness range) and file it alongside, not in place of, the prior qualification record