This semester you will have four opportunities to achieve certifications as an all position plate and pipe welder. The tests will be conducted by an AWS CWI and are intended to provide you with the realistic experience of taking a weld test for employment.  Testing days will be held on four Fridays during each semester. The testing dates are posted throughout the welding labs, at the tool crib windows, and on the welding department website. The first test will be on 3/8” plate, 3G , with backing.

The following welding codebook is optional.  It is quite expensive and applies only to a por­tion of this course.  However, you should purchase it if you intend to pursue a career in welding or in­spection, and your instructor will assist you in ordering it at a discount from the American Welding Society.  Your instructor will also provide you with infor­mation from this code as you progress through the course:

American Welding Society (AWS): D1.1, Structural Welding Code—Steel.

WLDG 2179: Welder Qualification students, you will have four opportunities per semester to achieve certifications in plate and pipe. Testing days will be held on four Fridays during each semester. The testing dates are posted throughout the welding labs, at the tool crib windows, and online on the Welding Department website.

1)  3/8” PL – 3G, Per AWS D1.1  - SMAW E7018……………………………….……75%

2)  3/8” PL – 4G, Per AWS D1.1  -  SMAW E7018…………………………….………80%

3)  1” PL – 3G, Per AWS D1.1  -  SMAW E7018 and/or FCAW-G……………….……85%

4)  1” PL – 4G, Per AWS D1.1  - SMAW E7018 and/or FCAW-G……………….……90%

5)  6” Sch 80 Pipe, 6G, SMAW, Per ASME Sec. IX

                             Or                                      
     2.5” Sch XXH Pipe, 6G, GTAW root/hot passes, SMAW fill/cover passes ……...…100%

If no certifications are achieved, grading will be as follows

1)  Four test days attended, no certifications attained …………………………….70%

2)  Three test days attended, no certifications attained …………………………....65%

3)  Two test days attended, no certifications attained………………………….….60%

4)  One test day attended, no certifications attained………………………………55%

Weld Test Progression

SMAW - 3/8-inch Thick Limited Plate Certification

Code:                    American Welding Society (AWS): D1.1, Structural Welding Code—Steel.

Process:                Shielded Metal Arc Welding

Current:               DCEP (DCRP)

Positions:              3G (vertical up) and

                              4G (overhead) 

Material:              ASTM A-36 steel plate. Each piece is

                              3/8-inch thick by 3 ¼” wide by 7” long, with 1/4" x 1" backing bar

Filler Metal:         E-7018 electrodes – 1/8” diameter

Fit-Up:                  See joint configuration diagram

                              1/4" root opening

                              No root face                     

                              45º included groove angle

Technique:           No grinding of any weld passes

                              Interpass cleaning by power brush, chipping, hand brush

Visual Acceptance Criteria:

1.  The finished weld shall exhibit a neat, uniform workman-like appearance.

2.  The weld root shall not have any cracks, incomplete fusion, or inadequate joint penetration.        

      3.  No reinforcement >1/8"……….……….….AWS D1.1: paragraph 4.9.1.1(3)

                              4.  No undercut >1/32"....................................................................... 4.9.1.1(4)

                              5.  No arc strikes......................................................................................... 5.29

                              6.  No underfill at craters.................................................................    4.9.1.1(2)

7. Beads must be sequential from one side of the joint to the other.  See drawing below.

Figure 1   
*The numbers displayed on weld passes in Figure 1 are to meant to emphasize bead sequence only
and are not intended to indicate the actual number of weld passes.

Joint Configuration Diagram

Specimens:           Inspector will designate specimen locations if areas are questionable:

                              One 1-1/2" wide x 3/8" thick guided bend root specimen

                              One 1-1/2" wide x 3/8" thick guided bend face specimen           

Guided Bend Acceptance Criteria:

                              1.  No discontinuity >1/8" in any direction.... AWS D1.1: paragraph 4.9.3.3(1)  2.  3/8" maximum accumulation of flaws >1/32"......................................................................... 4.9.3.3(2)

                              3.  1/4" maximum corner crack, if not fusion related......................... 4.9.3.3(3)    

Qualification:       Welder is qualified to weld in all positions with all SMAW electrodes on a                                    maximum thickness of 3/4" plate.  Other qualifications also apply, and are        given in AWS D1.1: 2010 Table 4.10

SMAW - 1-inch Thick Unlimited Plate Certification

Code:                    American Welding Society (AWS): D1.1, Structural Welding Code—Steel.

Process:                Shielded Metal Arc Welding

Current:               DCEP (DCRP)

Positions:              3G (vertical up) and

                              4G (overhead) 

Material:              ASTM A-36 steel plate. Each piece is

                              1” thick X 3 ¼” wide X 5” long with  1/4" x 1" backing bar

Filler Metal:         E-7018 electrodes – 1/8” diameter

Fit-Up:                  See joint configuration diagram

                              ¼” root opening

                              No root face                     

                              45º included groove angle

Technique:           No grinding of any weld passes

                              Interpass cleaning by power brush, chipping, wire brush

Visual Acceptance Criteria:

1.  The finished weld shall exhibit a neat, uniform workman-like appearance.

2.  The weld root shall not have any cracks, incomplete fusion, or inadequate joint penetration.        

      3.  No reinforcement >1/8”……….……….….AWS D1.1: paragraph 4.9.1.1(3)

Reinforcement can include both convexity, and weld metal extending  beyond the edges of the groove.

                              4.  No undercut >1/32”………………………………………….……4.9.1.1(4)

                              5.  No arc strikes......................................................................................... 5.29

                              6.  No underfill at craters.................................................................    4.9.1.1(2)

7. Beads must be sequential from one side of the joint to the other.  See drawing below.

Figure 2   
*The numbers displayed on weld passes in Figure 1 are to meant to emphasize bead sequence only
and are not intended to indicate the actual number of weld passes.

Joint Configuration Diagram

Specimens:           Inspector will designate specimen locations if areas are questionable:

                              Two 3/8" wide x 1" high guided side bend specimens

Guided Bend Acceptance Criteria:

                              1.  No discontinuity >1/8" in any direction.... AWS D1.1: paragraph 4.9.3.3(1)  2.  3/8" maximum accumulation of flaws >1/32"......................................................................... 4.9.3.3(2)

                              3.  1/4" maximum corner crack, if not fusion related......................... 4.9.3.3(3)    

Qualification:       Welder is qualified to weld in all positions with all SMAW electrodes on         unlimited thickness plate.  Other qualifications also apply, and are given in

                              AWS D1.1: 2010 Table 4.10

FCAW-G - 1-inch Thick Unlimited Plate Certification

Code:                    American Welding Society (AWS): D1.1, Structural Welding Code—Steel.

Process:                Flux Cored Arc Welding – Gas Shielded

Current:               DCEP (DCRP)

Positions:              3G (vertical up) and

                              4G (overhead) 

Material:              ASTM A-36 steel plate. Each piece is

                              1” thick X 3 ¼” wide X 8” long with 1/4" x 1" backing bar

Filler Metal:         E-71T-1, .045” diameter

Fit-Up:                  See Joint Configuration Diagram

                              1/4" root opening

                              No root face                     

                              45º included groove angle

Technique:           No grinding of any weld passes

                              Interpass cleaning by power brush, chipping, wire brush

Visual Acceptance Criteria:

1.  The finished weld shall exhibit a neat, uniform workman-like appearance.

2.  The weld root shall not have any cracks, incomplete fusion, or inadequate joint penetration.       

      3.  No reinforcement >1/8"……….……….….AWS D1.1: paragraph 4.9.1.1(3)

Reinforcement can include both convexity, and weld metal extending  beyond the edges of the groove.

                              4.  No undercut >1/32"………………………………………….……4.9.1.1(4)

                              5.  No arc strikes......................................................................................... 5.29

                              6.  No underfill at craters.................................................................    4.9.1.1(2)

7. Beads must be sequential from one side of the joint to the other.  See drawing below.

Figure 2   
*The numbers displayed on weld passes in Figure 1 are to meant to emphasize bead sequence only
and are not intended to indicate the actual number of weld passes.

Specimens:           Inspector will designate specimen locations if areas are questionable:

                              Two 3/8" wide x 1" high guided side bend specimens

Guided Bend Acceptance Criteria:

                              1.  No discontinuity >1/8" in any direction.... AWS D1.1: paragraph 4.9.3.3(1)  2.  3/8" maximum accumulation of flaws >1/32"......................................................................... 4.9.3.3(2)

                              3.  1/4" maximum corner crack, if not fusion related......................... 4.9.3.3(3)    

Qualification:       Welder is qualified to weld in all positions with FCAW-G electrodes on           unlimited thickness plate.  Other qualifications also apply, and are given in

                              AWS D1.1: 2010 Table 4.10

                6-inch Schedule 80 Pipe Certification

Code:                    ASME SECTION IX 2010

Process:                Shielded Metal Arc Welding

Current:               DCEP (DCRP)

Positions:              6G   

Material:              API 5L, Grade B steel pipe

                              0.432" thick welded open root without backing ring

Filler Metal:         E-6010 electrodes for root pass

                              E-6010 electrodes for "hot" pass

                              E-7018 electrodes for filler and cap passes

Fit-Up:                  0"-1/8" root opening

                              0"-1/8" root face              

                              75º included groove angle

Technique:           Grinding of root pass permitted, but no grinding of any further weld passes

                              Interpass cleaning by power brush

Visual Acceptance Criteria:

                              As per ASME QW194, and  AWS D1.1

                              1.  No reinforcement >1/8"............................. AWS D1.1: paragraph 4.9.1.1(3) 

                              2.  No undercut >1/32"....................................................................... 4.9.1.1(4)

                              3.  No arc strikes......................................................................................... 5.29    

                              4.  No underfill at craters.................................................................... 4.9.1.1(2)  5.  No inadequate or incomplete joint penetration at root........................................................... 4.9.1.1(5)  6.  Concave root permitted, if total weld thickness base metal......................................................... 4.9.1.1(6)  7.  No root concavity > 1/16"  4.9.1.1(6a)................................................................ 8.  No melt-through > 1/8"  4.9.1.1(6b)

Specimens:           Four 3/8" wide x 0.432" (7/16") high guided side bend specimens taken at     1:30 o'clock, 4:30 o'clock, 7:30 o'clock, and 10:30 o'clock.

Guided Bend Acceptance Criteria:

                              1.  No discontinuity >1/8" in any direction.... AWS D1.1: paragraph 4.9.3.3(1)  2.  3/8" maximum accumulation of flaws >1/32"......................................................................... 4.9.3.3(2)

                              3.  1/4" maximum corner crack, if not fusion related......................... 4.9.3.3(3)    

Qualification:       Welder is qualified to weld in all positions with all SMAW electrodes on 2.5”-

                              unlimmited diameter pipe. Other  qualifications apply.

                2 ½ inch Schedule XXH Pipe Certification

Code:                    ASME SECTION IX 2010

Process:                Shielded Metal Arc Welding

Current:               DCEP (DCRP)

Positions:              6G   

Material:              ASTM A-53/ASME SA-53

                              0.552" thick welded open root without backing ring

Filler Metal:         GTAW ER 70S-2 for root pass

                              GTAW ER 70S-2 for "hot" pass

                              1/8” and 3/32”E-7018 electrodes for filler and cap passes 

Fit-Up:                  1/16"-1/8" root opening

                              0"-1/8" root face              

                              75º included groove angle

Technique:           Interpass cleaning by power brush

                              Limited grinding pemitted with Inspector approval

Visual Acceptance Criteria:

                              As per ASME QW194, and  AWS D1.1

                              1.  No reinforcement >1/8"............................. AWS D1.1: paragraph 4.9.1.1(3) 

                              2.  No undercut >1/32"....................................................................... 4.9.1.1(4)

                              3.  No arc strikes......................................................................................... 5.29    

                              4.  No underfill at craters.................................................................... 4.9.1.1(2)  5.  No inadequate or incomplete joint penetration at root........................................................... 4.9.1.1(5)  6.  Concave root permitted, if total weld thickness base metal......................................................... 4.9.1.1(6)  7.  No root concavity > 1/16"  4.9.1.1(6a)................................................................ 8.  No melt-through > 1/8"  4.9.1.1(6b)

Specimens:           Four 3/8" wide x 0.432" (7/16") high guided side bend specimens taken at     1:30 o'clock, 4:30 o'clock, 7:30 o'clock, and 10:30 o'clock.

Guided Bend Acceptance Criteria:

                              1.  No discontinuity >1/8" in any direction.... AWS D1.1: paragraph 4.9.3.3(1)  2.  3/8" maximum accumulation of flaws >1/32"......................................................................... 4.9.3.3(2)

                              3.  1/4" maximum corner crack, if not fusion related......................... 4.9.3.3(3)    

Qualification:       Welder is qualified to weld in all positions with all SMAW electrodes and

                              GTAW. Welder will be qualified to weld up to twice the thickness of weld

                              metal deposited during the test. Other qualifications apply.