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The American Welding Society was created in accordance with the American National Standards Institute codes and requirements, because welding fabrication has become a very sophisticated and technical science. Hence, a certified welder must be a competent industrial metal fabricator, as demonstrated by meeting the minimum requirements and experience of a proficient welder. This guide will cover some basic steps to successfully pass a welding certification test.
Steps
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Decide which welding certification applies to the work you want to do. In the USA, there are many federal and state laws and regulations, and governing bodies that enforce and require certain building codes, rules, and welding fabrication standards.
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Learn the 6 major welding categories you will be tested on. Although, there are a vast number of different metal fabrication processes and techniques, the AWS certification tests mainly cover: [1] X Research source
- Shielded Metal Arc Welding - SMAW.
- Gas Metal Arc Welding - GMAW.
- Flux Cored Arc Welding - FCAW.
- Gas Tungsten Arc Welding - GTAW.
- Oxy-fuel Gas Cutting and;
- Plasma Arc Cutting.
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Study and follow all the A.W.S. (American Welding Society) standards (codes, specifications, recommended practices, methods, guides, etc.). Most types of metal fabrication will fall under one of the various AWS codes in USA. [2] X Research source
- ASME - This code covers the same variety of metal fabrication types as AWS does, but in the USA it is used mainly for the production of pressure vessels and high pressure piping.
- API - This code covers the production of low pressure tanks and piping for the transport and storage of fuels and crude oil.
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Find an updated copy of the test plate's blueprint. Practice every type of welding (methods, metals, thickness) and all body positioning, working space clearance, and weather conditions you could be tested on. [3] X Research source
- The usual steel plate groove test for the AWS D1.1 code consists of two plates with a 45 degree inclusive angle (22.5 degree bevel on each plate).
- The bevels are placed facing each other, leaving 1/4" gap between the feather edges.
- A backing plate is tacked onto the back of the two plates to hold them together while the weld is completed.
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Master welding the two most difficult positions and the thickest steel plate on the test. In the D1.1 test, you will commonly complete two positions: vertical up and overhead positions.
- If you pass both of these tests you will be qualified in all positions and if you complete the test using 1" thick plate you will be qualified from 1/8" to unlimited thickness.
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Practice diligently until every weld is flawless and continuously uniform. The most common failures are found on initial visual examination.
- While the code does allow for discontinuities such as undercut, porosity and other issues, these are clues that an examiner will use to understand the skill level of the welder, so practice until your welds are as close to perfect as you can make them. This way when you you actually perform the test you will have already been harder on yourself then anyone else will be.
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Invite over your most critical and perfectionist friends to nitpick your work. Don't rely on your supportive friends; they will only give you excuses instead of helping you get better.
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Don't settle for a good-looking surface weld. A bad weld can be masked to look strong. If your weld passes visual inspection, then the next step is to perform destructive testing, otherwise known as the bend test.
- If the plate you welded was thicker than 3/8" then the test strips will be 3/8" strips cut from across the weld and will be bent to the side with the point of maximum stretch where the weld is.
- If the plate is less than 3/8" thick then two strips will be cut from each plate and these will be bent with one plate face out and the other root out to stretch each side.
- There should be no cracks, tears, flux inclusions or other defects.
- It should bend just like a solid bar would bend.
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Don't go too fast. Match the filler metal feed rate, depth and thickness of the weld, and the applied heat intensity to the speed rate of your welds.
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Avoid incorrect settings on the welder. Double check every instrument you use and adjust all settings for the correct application.
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Avoid improper storage, handling, and use of welding materials and supplies. If you use 7018 you need to keep the electrode in a rod oven to keep moisture out of the flux. [4] X Research source
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Take your time to clean any contaminant residue after every pass. This occurs most often when leaving flux behind. No, the next pass will not burn it out.
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Ensure you achieve fusion on the sides of the weld. Completely infuse the entire joint area. It should be a smooth transition between filler weld metal and base metal.
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Carefully read the entire instructions and double check every measurement of the blueprint. Take your time and cut one part at the time even if you have practiced making the same blueprint before.
- The test plate blueprint measurements could have been slightly changed without prior notice.
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Use common sense and always follow correct safety procedures. [5] X Research source
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Inspect the entire work area and equipment paying close attention to electrical connections and any safety hazards.
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Wear proper fitting work clothes that protect your entire body from molten metal, intense radiating heat, sparks, and electric shock.
- Never use baggy or loose clothes. You are working in a hazardous environment with moving machinery and power tools where you could easily be dismembered or burned.
- Don't wear pants, jackets, aprons or coveralls with exposed pockets, sleeves, or collars. You could be seriously injured if a 2000 degree molten metal object or spark gets caught inside your clothes.
- You will be tested on safety procedures and work space tidiness as well.
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Clean and put all materials and equipment on their proper storage location before presenting your work for inspection.
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Good Luck!
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Expert Q&A
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QuestionHow do I become a welding inspector?Surekha Krishnan is a Metallurgy Expert based in Columbia, South Carolina. Surekha specializes in both arc welding and solid-state welding and has been a Plant Metallurgist at FN America, LLC since 2021. Surekha has over 7 years of experience, and is an expert in all Heat Treat processes and record retention, has prior experience as a Weld Engineer, and has taught various IIW welding courses in the past.You can become a welding inspector by following a structured pathway that involves specific courses and certifications. First, start by considering the American Welding Society certifications, which offer a clear progression. The lowest level is the AWS-certified welding supervisor. They are responsible for manual checks, checking that welders are performing their tasks correctly. Next, you can aim to become a certified welding inspector, who handles tasks such as reviewing welding procedure specifications and welder qualifications. If you want to pursue the CWI certification, you should enroll in relevant courses designed to prepare you for the certification exams. These courses cover various aspects of welding inspection, including non-destructive testing techniques. As a prospective welding inspector, you have to choose your area of specialization, such as structural applications or boiler vessels, which will determine the specific exam code you need to take. This certification process involves two key exams. The first one is a basic exam that covers a broad range of topics, including some of the NDT methods, and the second is a code-specific exam that is tailored to your field of expertise. Successfully passing both exams will earn you the CWI certification, which allows you to work as a certified welding inspector in your chosen area.
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Tips
- Continuously practice and carefully watch for the common mistakes and you will have a better chance of passing.Thanks
- Keep in mind that with enough persistence this skill like any other can be mastered.Thanks
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Warnings
- Don't weld without using good quality safety gear and taking a class or having someone show you how.Thanks
- This isn't a safety course. It is assumed you know the precautions to take. If not then educate yourself and remember, the world isn't foam padded. Lots of stuff will hurt or kill you. It’s up to you to stay alive.Thanks
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Expert Interview
Thanks for reading our article! If you’d like to learn more about welding, check out our in-depth interview with Surekha Krishnan .
References
- ↑ https://pubs.aws.org/content/free_downloads/B51-AMD1-Print.pdf
- ↑ https://pubs.aws.org/content/free_downloads/B51-AMD1-Print.pdf
- ↑ https://awo.aws.org/2013/04/how-to-prepare-for-the-certified-welding-inspector-exam-part-2-understanding-the-test/
- ↑ https://pubs.aws.org/content/free_downloads/B51-AMD1-Print.pdf
- ↑ https://www.aws.org/standards/page/safety-health-fact-sheets
- AWS D1.1
- AWS-EG4, 0 -96 Guide for the training and qualification of welding personnel. Level III - Expert welders
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