iiw welding guidelines

IIW Guideline

INTERNATIONAL WELDING INSPECTION PERSONNEL

Minimum Requirements for the Education, Examination and Qualification

IAB-041r3-08

IAB INTERNATIONAL AUTHORISATION BOARD IAB-041r3-08

International Welding Inspection Personnel Approved July 2008 2 of 95

MINIMUM REQUIREMENTS FOR THE EDUCATION, TRAINING, EXAMINATION AND QUALIFICATION OF INSPECTION PERSONNEL

INTERNATIONAL WELDING INSPECTION PERSONNEL

(IWIP)

Guideline of the International Institute of Welding

INTERNATIONAL AUTHORISATION BOARD

Published by: IIW IAB Secretariat C/o ISQ Taguspark Apartado 012 P 2780-994 Porto Salvo Oeiras PORTUGAL Tel: +351.21.4211351 Fax: +351.21.4228122

E-mail: [email protected]

IAB-041r3-08



TABLE OF CONTENTS Preface..... 4 SECTION I: Minimum Requirements for the Education and training of International Welding Inspection Personnel 1. Introduction... 5 2. Levels of Inspection Personnel......... 5 3. Standard Routes to Qualification ..... 6 4. Alternative Route to Qualification........... 10 5. Distance learning programs............ 11 6. Recognition of NDT certification.................................. 11 7. Definitions....... 11

7.1. Education and training...... 11 7.2. Qualification.... 11 7.3. Relevant inspection experience...... 11 7.4. Certification.... 12

8. The Inspectors Role ..................................................................................................... 12 8.1. Reports ...................................................................................................................... 13 8.2. Certification system ...................................................................................................... 13

9. Syllabus... 14 Theoretical education: Welding Technology Modules........ 15 1. Module 1. Welding processes and equipment. 15 2. Module 2. Materials and their behaviour during welding... 32 3. Module 3. Construction and design.......51 4. Module 4. Fabrication, applications engineering.... 59 Theoretical education: Welding Inspection Modules... 69 1. General introduction to welding inspection..... 69 2. Mechanical tests on welded joint ..... 70 3. Weld Imperfections. 71 4. Testing methods......... 72 5. Quality Assurance. Principles and levels.... 80 6. Management of inspection function. 81 7. Practical work...... 82 Theoretical education: Basic technology Module 0..... 83 SECTION II: Minimum requirements for experience, examination and qualification 1. Introduction...... 85 2. Route from IWI-B to IWI-S and from IWI-S to IWI-C. 85 3. Verification of visual acuity. 85 4. Approval of courses 85 5. Examination Board ........ 85 6. Examination procedures.............. 85

6.1 Theoretical written examination......... 86 6.2 Practical examination...... 86

7. Re-examination....... 86 8. Diploma of the International Institute of Welding ...... 87 9. Appeals procedure...... 87 10. Transition arrangements... 87 Appendix I. Equipment ....................... ......... 88 Appendix II. ANB detailed assessment.... ...... 89



Preface

This document is based upon the European Welding Inspection Personnel Guideline as developed by the European Federation for Welding, Joining and Cutting (EWF), through an Agreement first signed in 19 July, 1997, at the Annual Meeting of the International Institute of Welding in San Francisco, California, USA and which has been renewed and further developed since then. Any EWF ANB is permitted to issue EWF diplomas equivalent to IIW ones that have been issued by the same ANB. Copies of this document are available from the IIW IAB Secretariat or their designated distributor.



Section I: Minimum requirements for the education and training of International Welding Inspection Personnel 1. Introduction This guideline for the education of International Welding Inspection Personnel to be employed in the job function of Inspector has been devised by members of the Working Group A3b of International Authorisation Board (IAB) of the International Institute of Welding (IIW). It is designed to provide the core education in welding and inspection technology required by those responsible for performing inspection tasks at various levels. It is possible that additional training and/or experience may be required beyond the core education to meet the requirements of specific applications or job functions. Section 1 of this guideline covers the minimum requirements for education and training, agreed upon by all national welding societies within the IIW, in terms of themes, keywords and times devoted to them. It will be revised periodically by the WG A3b to take into account any changes that may affect the state of the art. Students having successfully completed this course of education will be expected to be capable of applying welding inspection technology as covered by this guideline. Section 2 of this document covers examination and qualification. 2. Levels of Inspection Personnel This Guideline sets out the education for three levels of personnel, as follow: COMPREHENSIVE (IWI-C): A candidate completing the Comprehensive level of training under this programme shall possess an intimate knowledge of welding and inspection theory and application. This knowledge base will enable the candidate to understand and effectively apply the knowledge in the areas of:

Non-destructive, mechanical testing and visual welding iInspection techniques Review and application of welding instructions, welding procedure specifications and

qualified welding procedures. Material specifications Consumable specifications Engineering drawings, joint fit up and workmanship tolerances Preparation and application of welding procedure specifications,. Preparation and implementation of inspection procedures and acceptance criteria Quality Control Programmes Welding equipment functionality and application/limitations International and national welder qualification programmes Identification of weld imperfections associated with pre-production, fabrication and

post fabrication Inspection requirements based on national specifications or codes

STANDARD (IWI-S): A candidate completing the Standard level of training under this programme shall possess an advanced knowledge of welding and inspection theory and application. This knowledge base will enable the candidate to understand and apply the knowledge in the areas of:

Non-destructive, mechanical testing and visual welding inspection techniques



Application of welding instructions, welding procedure specifications and qualified welding procedures.

Material specifications Consumable specifications Engineering drawings, joint fit up and workmanship tolerances Welding procedure specifications and welding instructions and qualified of

procedures Inspection procedures and acceptance criteria Welding equipment functionality and applications/limitations International and national welder qualification programmes Identification of weld imperfections associated with pre-production, fabrication

and post fabrication Inspection requirements based on national specifications or codes

BASIC (IWI-B): A candidate completing the Basic level of training under this program shall posses a general knowledge of welding and inspection application and theory. This knowledge base will enable the candidate to effectively understand the following topics:

Non-destructive, mechanical testing and visual inspection techniques Material specifications Consumable specifications Engineering drawings, joint fit up and workmanship tolerances Welding procedure specifications Inspection procedures and acceptance criteria Identification of weld imperfections associated with pre-production, fabrication and

post fabrication 3. Standard Routes to Qualification

This Guideline provides two principal routes to qualification, as follows: 3.1 Route 1 is for those fulfilling the access conditions defined in Fig. 1 at the relevant level.

Candidates may decide, after self-assessment on the basis of prior learning and/or experience, whether to take the Welding Technology Module first, or proceed directly to the intermediate examination through the Approved Training Body (ATB) assessment. A pass in the intermediate examination is required before taken the Welding Inspection Module examination.

At the description of the ANB, and only for students attending the full stantard courses training, the Welding Technology Module exam (intermediate examination) can be performed at the same day of the Welding Inspection Technology Module exam

3.2 Route 2 is for those already holding an existing IIW qualification who may proceed direct

to the Welding Inspection Module at the relevant level.

The routes to qualification are summarised in Fig. 1 Standard Route and in Fig. 2 there are presented other routes "Routes no. 2, 3 and 4". The figures in brackets are the recommended minimum number of teaching hours specified for each education module. A teaching hour will contain at least 50 minutes of direct teaching time.

For IWI-S only the Guideline recognises the current situation in several countries, by

providing entry for inspectors not meeting the full specified access conditions but having at least 5 years authenticated experience in general engineering inspection (Route 3). Such inspectors may decide through self-assessment whether to complete the 40 hours of Basic Technology Module 0 first or to proceed directly to the intermediate examination following the Module 0. The Welding Technology Module WT II is mandatory for Route 3.



The Guideline also provides for the experienced IWI-B to progress to IWI-S via Route 4

as shown in Fig. 2. The candidate may decide whether or not to take Module 0 or WT II on the basis of self-assessment and after ATB assessment. His/her knowledge will be checked by intermediate examinations and a failure will require that the candidate take a respective omitted module.

For all routes, if the candidate fails an intermediate examination, having exercised an

option to proceed directly to that examination, he/she must take the omitted training module before re-sitting the examination failed. Welding Inspection Module examination can only be taken after passing intermediate examination of Welding Technology Module (see last sentence for route 1).

The rules for the conduct of final examinations by the Authorised National Body are

prescribed in Section 2 of this Guideline. The intermediate examinations are mandatory and are the responsibility of the ATB to ensure that those entering the next module have achieved the required level of knowledge.



Figure 1. Standard Route no. 1

- ATB Assessment

Figure 2. Routes no. 2, 3 and 4

Education Modules Education Modules IWI Route No. Access conditions Welding Technology Welding Inspection Diploma

IWI-C

Welding Inspection

Module WI III (97 h)

Welding Technology

Module WT III(122 h)

ATB Check

Those satisfying the access 1 conditions for I/EWT or higher

IWI-S

Welding Inspection

Module WI II (63 h)

Welding Technology

Module WT II(94 h)

ATB Check

Those satisfying the access 1 conditions for IWS/EWS or higher

IWI-B

Welding Inspection

Module WI I (40 h)

Welding Technology Module WT I

(65 h)

ATB Check

Professional workers or persons having relevant experience in 1 metalworking professions

ATB Check

IWI-CSelf assessment

Welding Inspection


Self assessment

Welding Inspection

Module WI II (63 h)

IWI-S

Self assessment

Welding Inspection

Module WI I (40)

IWI-B

- Intermediate examination - Final examination



- A single examination but module WT II is compulsory for Route 3, optional for Route 4.

- ATB Assessment

Standard education IWI-S. Route 3: Inspectors with at least 5 years experience in general

engineering inspection.

Route No. Basic Technology Education Modules Education Modules IWI Access cond. Module Welding Technology Welding Inspection Diploma

Welding Inspection


Welding Technology

Module WT III(122 h)

IWI-C

IWI-S

Welding Inspection

Module WI II (63 h)

Welding Technology

Module WT II(94 h)

ATB Check

2 years experience

3

Module 0 (40 h)

3

4

IWI-B

Welding Inspection

Module WI I (40 h)

5 years experience

2 years experience

!

ATB Check

ATB Check

ATB Check

2 Holders of IWT/EWT Diploma

2 Holders of IWP/EWP Diploma

Holders of an IWI-Standard Diploma

Holders of an IWI-Basic Diploma

ATB Check

!

Self assessment

Welding Inspection

Module WI II (63 h)

IWI-S

Self assessment

Welding Inspection


IWI-C

2 Holders of IWS/EWS Diploma

- Intermediate examination - Final examination



4. Alternative route to qualification (Fig. 3)

Figure 3. Alternative versus Standard Routes for IWIP qualifications An applicant must submit the following documentation to the ANB with the application form: IWI-C: IWT/EWT diploma or evidence of satisfying the access conditions for IWT/EWT. A curriculum vitae (CV)/ resume containing the following professional information:

- Evidence of at least three years job function in welding and inspection at the technologist level (in a period of 4 years before application)

- A justification of the candidates experience, training, and education to become IWI-C (may include other test results)

IWI-S: IWS/EWS diploma or evidence of satisfying the access conditions for IWS/EWS. A curriculum vitae (CV)/ resume containing the following professional information

- Evidence of at least two years job function in welding and inspection at the specialist level (in a period of 3 years before application)

- A justification of the candidates experience, training, and education to become IWI-S (may include other test results)

IWI-B: IWP/EWP diploma or evidence of satisfying the access conditions for IWP/EWP. A curriculum vitae (CV)/ resume containing professional information

- Evidence that the candidate was working in welding and inspection at the practitioner level during last two years before application.

- A justification of the candidates experience, training, and education to become IWI-B (may include other test results)

IWIP Diploma

WI IIIWI IIWI I

Standard Route (see also Figure 1)

yes

Final exams IWI-C IWI-S IWI-B

Project or Technical Interview (see app. II)

yes

yes

no

no

yes

Paper assessment (of the ANB detailed assessment; see appendix II)

Alternative Route

WT III WT II WT I

At the discretion of the ANB

Module 4 ofWT III, WT II

or WT I

ANB checkno

no

Professional assessment interview

An applicant must submit to the ANB, together with an application form, the information described in the item 4 of the Section 1 of this guideline depending of the IWIP levelsought



The ANB shall determine, by paper check, if the application is suitable for further detailed assessment. 5. Distance Learning Programs Distance Learning Programs can be implemented in accordance with IAB-195-2004 Guideline under ANB control. 6. Recognition of NDT certification Those having certification in NDT in accordance with ISO 9712, EN 473 or equivalent recognised by the ANB may be granted exemption from the NDT parts of the modules for Welding Inspection on a method by method basis, but not from the final examination. The approval of such arrangements is at the discretion of the ANB. It is recommended that NDT Level 2, 3 Certification should apply to Module Welding Inspection ll and Welding Inspection lll. NDT Level 1 certification should apply to Module Welding Inspection ll. 7. Definitions

7.1 Education and training: A process of instruction in relevant theory and practice that takes the form of courses to an approved syllabus and periods of practical work under qualified supervision (but shall not include the use of specimens used in the practical examination). All educational courses leading to the award of qualification covered by this Guideline shall be approved by the Authorised National Body.

7.2 Qualification: A demonstration, conducted by the Authorised National Body, involving an

examination of the knowledge and skill related to specified criteria. Success in this examination leads to the issue, by the ANB, of an appropriate diploma.

7.3 Relevant inspection experience: The period during which the candidate performed

welding inspection as his main activity under qualified supervision including personal application of inspection to materials, parts or structures but not including tests performed during training courses.

7.4 Certification: The procedure leading to a written testimony of an individual's competence

demonstrated by examination and assessment of experience and subsequent surveillance to confirm that the competence has been retained. This does not form part of the Guideline and is normally the subject of an independent certification scheme.

8. The Inspectors role The inspectors role begins well before welding starts, continues during the welding operation, involves action after welding is completed, and is finished only when the results are properly reported. As part of the quality system, inspection activities are defined in an inspection and test plan, which clearly describes what is required. The inspector is frequently responsible for producing documents that ensure traceability of the components and related fabricating action. Prior to welding, the inspector must be assured that the materials are correct and that the shop has approved welding procedures and appropriately qualified welders. Written procedures and competent operators are important to the production of a quality-welded product, but the actual execution of the weld is also a critical point for the inspector. Once the inspector is satisfied that



all is in order for the welding to proceed, the task becomes one of witnessing and monitoring. There are two basic interests at this point: ensuring that the written procedures are being followed; and, of course, watching for any physical signs of non-conformance of the final product. The inspectors responsibilities are to verify base metals and welding consumables, observe the fit-up and preparation for the weld, and watch the welding operation itself. Once the welding is completed, a new series of inspection tasks begin, which starts with executing an inspection program according to an approved procedure, keeping track of the status of examination and testing and selecting specific welds for further NDT or mechanical testing. Heat treatment (such as preheating, post-heating and post-weld heat treatment) can be a critical parameter in a welding operation and the inspector is often required to ensure that it has been done properly. Heat treatment must be carried out following an approved written procedure. The inspector must know enough about the technique, the equipment and the reports to have confidence in the results. 8.1 Reports

When preparation, production and inspection are over, the inspector must collate the observations, checklists, and results into a report that is structured to meet the needs of the client, a jurisdiction, or a code. This report is the document of reference, which could allow the tracing of a production parameter that proves after years of service to be contributing to a failure. It allows the tracing of responsibility to a specific supplier or contractor. One or more interim reports might well be necessary to show progress during a long or complicated construction project. Reports must detail the inspection stages, parameters, and results, including corrective actions if required. It is important to recognise quality related problems into a contract as early as possible. Interim reports and observations are extremely valuable as they provide engineering and production personnel with information they might not otherwise be aware of. The inspectors observations might highlight quality problems that could, perhaps, be remedied by design or production changes if found early enough. The inspector should remember to quantify observations where possible. Typical duties of a welding inspector are as follows: 1) Interpretation of drawings and specifications; 2) Verification of procedure (WPS) and welder or welding operator qualifications; 3) Verifying the application of approved welding procedures; 4) Selection of production test samples; 5) Interpretation of test results; 6) Preparation of reports and keeping of records; 7) Preparation of inspectionprocedures; 8) Check the correct application of NDT methods. The authority to stop work or call for immediate remedial action to resolve a quality problem is particularly important in defining the responsibility of the inspector.

8.2 Certification system

This Guideline is intended to provide a curriculum for the education of Welding Inspectors only, and does not imply that the individual is competent to complete the job functions of a Welding Inspector. Relevant certification programmes for the certification of Welding Inspectors must be used to verify the competency and detail job functions.



9. Syllabus It is not obligatory to follow exactly the order of the modules and topics given in this Guideline, and choice in the arrangement of the syllabus is permitted. However, caution must be exercised by the ANB to ensure that any changes in the order of presentations of the Welding Technology modules and in the Welding Inspection modules do not alter the points of entry intended in Figs. 1 and 2. Note: This guideline is dividided in two main modules they are:

- Welding Technology (WT) - Welding Inspection (WI)

Each main module is divided in three (3) levels, corresponding the IWIP qualification levels

Main Modules

Modules Levels

IWIP Qualification Levels

WT III IWI-C WT II IWI-S Welding Technology - WT WT I IWI-B WI III IWI-C WI II IWI-S Welding Inspection Technology - WI WI I IWI-B



Theoretical education: Welding Technology Modules Number of Course Hours in Modules WT III WT II WT I Module 1. Welding processes and equipment 25 13 11 1.1 General introduction to welding technology: Objectives for IWI-C and IWI-S: Understand (for IWI-S - gain knowledge to understand in general) developments in welding processes including accepted terminology, standards and abbreviations. Objectives for IWI-B: Understand the difference between welding processes, and to get familiarized with terminology, standards and abbreviations.

WT III WT II WT I Module

Scope Teaching hours 1 1 1

History Definitions Schematic presentation of welding processes Terminology Picture and brief description with characteristics Applicability of the most common welding processes General applications for welding Abbreviations used for welding processes Hints in use for welding processes Classification of welding processes (IIW, ISO, CEN and national standards)

x x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

Expected results for IWI-C 1. List the differences between each major type of welding process, e.g. arc, resistance, flame, forge, etc. 2. Differentiate between processes with reference to standards. 3. Recognise a welding process by the common abbreviation. 4. Explain the historical evolution of welding Expected results for IWI-S 1. Outline the major differences between each main type of welding process, e.g. fusion arc, resistance,

flame, forge, etc. 2. Differentiate between processes with reference to standards. 3. Recognise a welding process by the common abbreviation. Expected results for IWI-B 1. Identify the differences between each major type of welding process. 2. Designate a welding process by its common abbreviation.



1.2 Oxy-gas welding and related processes: Objectives for IWI-C, IWI-S and IWI-B: Understand (for IWI-S - gain knowledge to understand in general; for IWI-B associate) the fundamentals of oxy -gas combustion, characteristics of the different fuel gases, equipment, safety and typical applications.



Process principles Range of application Types of flames Characteristics of fuel gases, (acetylene, propane, etc.) Combustion reactions Temperature distribution effects Equipment Acetylene cylinder component parts Fuel gas generation Handling and storage of gases Typical joint design for welding Methods of welding techniques, rightward, leftward Standards for filler materials Welding applications, typical problems and imperfections Special techniques and their methods of use (preheating, straightening, cleaning, etc.) Health and safety issues specific to the process

X X X X X X X X X X X X X X

X X

X X X X X X X X

X X X X X

X X

X X X

X

X X

X X X X

X X

Expected results for IWI-C 1. Explain the characteristics of the three flame types and reasons for application of each. 2. Detail the characteristics of flames produced by different fuel gases. 3. Define the potential hazards and methods of safe handling and working 3. Explain the purpose and working principle of each component of the equipment 4. Interpret appropriate standards. 6 Define the range of application for this process and potential problems to overcome. Expected results for IWI-S 1. Outline the characteristics of the three flame types and typical applications for each type. 2. Compare the characteristics of flames produced by different fuel gases. 3. Recognise and define in general the potential hazards and methods of safe handling, storage and

working practices. 4. Outline the purpose and working principle of each component of the equipment. 5. Basic knowledge on how to use appropriate standards. 6. Identify the limitations and the range of application of the process and recognise how to overcome the

potential problems associated with this process. Expected results for IWI-B 1. Interpret the characteristics of the different types of flames and their application. 2. Illustrate potential hazards and methods of safe handling and working. 3. Name the working principle of each component of the equipment. 4. Translate appropriate standards



1.3 Electrotechnics: a review Objectives for IWI-B: Have an outline working knowledge of electricity and the characteristics of the most important electrical components used in electrical welding power sources.



Basics of electricity and electronics (define current, voltage and resistance) Ohm's Law Parallel and serial circuits Direct current (DC), polarity, alternating current (AC) Magnetism in welding Capacity, condenser Transformer, and rectifying bridge (half wave and full wave rectification) .. Transistor, thyristor, Inductance, inductors Hazard Health and safety

X X X X

X X

X X

Expected results for IWI-C and IWI-S : Not applicable. Expected results for IWI-B: 1. General outline of current, voltage and resistance. 2. Recognise and give examples of the functions of the main components of a welding power.source 3. Give examples of the main differences between DC and AC current. 4. Show practical application of knowledge of electricity to welding.



1.4 The arc Objective for IWI-C and IWI-S: Understand (for IWI-S - gain knowledge to understand in general) the fundamentals of an electric arc, its characteristics, limitations and application in welding, including arc ability problems. Objective for IWI-B: Describe what is an electric arc, its characteristics, limitations and application in welding.



Arc physics (producing an electric arc, the main arc areas, stability of the arc) Voltage distribution across the arc Heat generation at the cathode and anode Polarity and arc characteristics in AC and DC and its control for the key welding processes Influence on the welding process Temperature distribution in the arc and effects Influence of the magnetic fields on the arc (why, how to solve) Limits of application

X X X

X X X X X

X X X

X

X X X

X X X

X

X X X

Expected results for IWI-C 1. Explain in detail the fundamental physics of an electrical arc, including the main parameters influencing

arc stability. 2. Detail the generation of heat in the arc and the arc voltage distribution. 3. Outline the influence of magnetic fields on the electric arc. 4. Predict how to solve magnetic deflection problems. 5. Explain arc characteristics for DC and AC including control and limitations. Expected results for IWI-S 1. Describe an electrical arc; its main areas and their importance to welding and arc stability. 2. Outline the generation of heat in the arc and the arc voltage distribution. 3. Give examples of the influence of magnetic fields on the electric arc. 4. Outline appropriate solutions to solve magnetic deflection problems. 5. Describe arc characteristics for DC and AC. Expected results for IWI-B 1. Give examples of the main arc areas, and their importance to welding. 2. List the hot arc areas and their influence on the weld pool. 3. Explain the arc characteristics of DC and AC. 4. Outline the influence of magnetic fields on an electric arc. 5. Give examples of solving magnetic deflection problems.



1.5 Power sources for arc welding Objectives for IWI-C and IWI-S: Understand (for IWI-S gain knowledge to understand in general) the characteristics and main components of arc welding power sources. Objectives for IWI-B: Gain an outline working knowledge on arc welding power sources characteristics and components.



Power source classification, types and characteristics (static and generators, and each sub-group) Power source electrical characteristics (static and dynamic Relationship between static characteristic and welding process Control of the electrical static characteristic (flat and drooping) Arc stability for the main processes (MMA, TIG, MIG/MAG, SAW, PAW) The operation working point Inverter technology Power sources controlled by a CPU Stability of processes in AC and DC AC (sine wave and square wave) and DC power sources Open circuit voltage, short circuit current, power factor of transformers Duty cycle of a power source and typical values for the most common arc welding processes Voltage losses, relationship between welding current value and cable section Pulse welding techniques Arc striking methods and devices, slope up and down, pre- and post-flow Current and voltage setting (electromagnetic and electronic devices) Standards related with welding power sources and their requirements

X X X X X X X X X X X

X

X X X X X

X X X

X X X X X X X

X

X X X

X

X X X

X X

X

X

X X X

X

Expected results for IWI-C 1. Explain each type of arc welding power source for both AC and DC including the most common devices

used. 2. For each type of welding power source detail the static and dynamic electrical characteristics, operation

point and control of arc stability. 3. Explain the meaning of open circuit voltage, arc voltage short circuit current, duty cycle of a power

source, voltage losses, and welding current to cable cross section relationship. 4. Explain the differences of the above characteristics for each type of power source and welding process

for a specific application. 5. Recognise the various functions and switches on different power sources and their effects.

Expected results for IWI-S and IWI-B 1. Outline how each type of welding power source works (AC and DC) including the most common devices

used. 2. Describe for each type of arc welding power source the static characteristic, operation point and control

of arc stability. 3. Outline the meaning of open circuit voltage, arc voltage short circuit current, duty cycle of a power

source, voltage losses, and current to cable section relationship. 4. Be able select the appropriate power sources for a given welding process. 5. Recognise the various settings and switches on different power sources and their effects



1.6 Introduction to Gas-shielded arc welding Objectives forIWI-C and IWI-S: Understand (for IWI-S gain knowledge to understand in general) the principles and physical phenomena of gas shielded welding processes Objective for IWI-B: Gain an outline working knowledge on the principles of gas shielded welding processes



Physical phenomena Operating principles of TIG, MIG/MAG and flux-cored Shielding gases (inert, active) and their effect on arc characteristics Handling and storage of gases Filler materials Standards (international and national) for shielding gases and filler materials

X X X X X X

X X X X X X

X X X X X X

Expected results for IWI-C 1. Explain the characteristics and operating principles of TIG, MIG/MAG and Flux-cored welding. 2. Interpret arc characteristics associated with each type of shielding gas used for each process. 3. Detail the methods for safe handling and storage of shielding gases. 4. Interpretation and use of standards for shielding gases and filler materials. Expected results for IWI-S 1. Describe and compare the characteristics and operating principles of TIG, MIG/MAG and Flux-cored

welding. 2. Compare and outline arc characteristics associated with each type of shielding gas used for each

process. 3. Outline the methods for safe handling and storage of shielding gases. 4. Demonstrate the use of standards for shielding gases and filler materials. Expected results for IWI-B 1. Differentiate the operating principles of TIG, MIG/MAG and Flux-cored welding. 2. Outline the arc characteristics associated with each type of shielding gas used for each process. 3. Demonstrate a general knowledge of the basic rules of handling and storing shielding gases.



1.7 Tungsten-inert gas welding Objective IWI-C and IWI-S: Understand (for IWI-S gain knowledge to understand in general) TIG welding fundamentals, including equipment, applications, procedures and specific problems. Objective IWI-B: Explain TIG welding fundamentals, including equipment, and applications.



Power source characteristics Methods for arc ignition and necessary equipment Equipment and accessories: torches, gas lens, control panel, up and down slope, pulse techniques Effect of current type and polarity: DC(+), DC(-) and AC Specific requirements for different materials, e.g. aluminium Consumables: shielding gases, filler materials, electrodes Welding parameters: current, voltage, travel speed, gas flow rate Joint preparation: typical joint design for welding, fit-up, cleaning Welding procedures Special techniques: spot-welding, key-hole, hot-wire, orbital welding, tube to tube and tube to sheet , and others Standards for filler materials, electrodes, and gases Welding applications, typical problems and how to solve them Health and safety issues specific to the process

X X

X X X X X X X

X X X X

X X

X X X X X X X

X X X X

X X

X X

X X X

X X X

Expected results for IWI-C 1. Explain and compare in detail the principles of TIG welding including arc ignition methods and their

applications. 2. Explain the selection of appropriate type of current, polarity, shielding gas and electrode type according

to application. 3. Identify the range of application, appropriate joint preparations and potential problems to be overcome 4. Identify appropriate welding parameters for particular applications. 5. Explain the purpose and functions of each component of the equipment and accessories. 6. Interpret appropriate standards. 7. Define potential hazards and methods of safe handling and working. 8. Recognise the various settings and switches on different TIG power sources and their effects. Expected results for IWI-S

1. Describe and compare the principles of TIG welding including arc ignition methods and their applications.

2. Explain the selection of appropriate type of current, polarity, shielding gas and electrode type according to the application.

3. Identify the range of application, appropriate joint preparations and potential problems to be overcome.

4. Identify an appropriate range of welding parameters for particular applications. 5. Explain the purpose and functions of each component of the equipment and accessories. 6. Interpret the use of appropriate standards. 7. Describe potential hazards and methods of safe handling and working..

Expected results for IWI-B

1. Outline TIG welding including arc ignition methods and their most common applications. 2. Give examples of the most common applications for each type of current, polarity and electrode. type3. Give examples of the most important applications and select the appropriate values for welding

parameters. 4. Know how to use and care for the equipment and accessories. 5. Read given standards for consumables 6. Give examples of TIG applications, joint preparation and potential problems to overcome. 7. Outline potential hazards and methods of safe handling and working.



1.8 MIG / MAG and Flux Cored welding Objectives for IWI-C, IWI-S and IWI-B: Understand in detail (for IWI-S - gain knowledge to to understand in genera; for IWI-B - explain) MIG/MAG and Flux Cored Arc welding fundamentals, including equipment, applications, procedures and common problems



Power source characteristics for conventional process and CPU controlled power sources Effect of current type and polarity Equipment and accessories: torches, wire feeders, hose assembly, control panel Metal transfer modes (dip, globular, spray, and pulsed), and their application Welding parameters and settings: current, voltage, travel speed, gas flow rate, etc. Consumables: shielding gases, filler materials (solid and flux cored wires), and their combinations Joint preparation: typical joint design for welding, fit-up, cleaning Welding procedures Special techniques: electro -gas welding, high efficiency processes Standards for filler materials, and gases Welding applications, typical problems and how to solve them Health and safety specific to the process

X

X

X

X

X

X X X X X X X

X

X

X

X

X

X X X X X X X

X

X

X

X

X X X

X X X

Expected results for IWI-C 1. Explain and compare in detail the principles of MIG/MAG and Flux Cored Arc welding including metal

transfer modes and their applications. 2. Compare the selection of appropriate type of current, polarity and electrode according to application. 3. Identify the range of application, appropriate joint preparations and potential problems to be overcome. 4. Identify appropriate welding parameters for particular applications. 5. Define potential hazards and methods of safe handling and working. 6. Explain the purpose and functions of each component of the equipment and accessories. 7. Interpret appropriate standards 8. Explain selection of consumables. 9. Recognise the various settings and switches on different MIG/MAG and Flux Cored Arc welding power

sources and their effects. Expected results for IWI-S 1. Describe and compare the principles of MIG/MAG and Flux Cored Arc welding including metal transfer

modes and their applications. 2. Identify the most common applications for each type of current, polarity and electrode. 3. Identify the range of application, appropriate joint preparations and potential problems to be overcome. 4. Identify an appropriate range of welding parameters for particular applications. 5. Describe potential hazards and methods of safe handling and working. 6. Outline the various functions of the main components of the equipment and accessories. 7. Demonstrate the use of appropriate standards 8. Give examples on how consumables should be selected..

Expected results for IWI-B 1. Outline MIG/MAG and Flux Cored Arc welding, comparing metal transfer modes and their application. 2. Give examples of the most common applications of each type of current, polarity and electrode. 3. Give examples of the most important applications and select appropriate welding parameters. 4. Know how to use and care for the equipment and accessories. 5. Read given standards for consumables. 6. Give examples of MIG/MAG application range, joint preparation and potential problems to overcome. 7. Outline potential hazards and methods of safe handling and working.



1.9 Manual Metal arc welding Objectives for IWI-C, IWI-S and IWI-B: Understand (for IWI-S - gain knowledge to understand in general; for IWI-B - explain) MMA welding fundamentals, including equipment, applications, procedures and common problems.



Process principles and arc characteristics Effect of current type and polarity Power source characteristics applicable to MMA (open circuit voltage, static and dynamic characteristics, types of current, arc striking methods) Equipment and accessories Process application range and typical problems Covered electrodes (functions of the coating and rod, types of electrodes, slag-metal and gas-meta covered l reactions) Production of electrodes (how, typical defects) Handling and storage of electrodes (storage environment, redrying Electrode classification (International and national standards) Selection of covered electrodes for applications Welding parameters: current, voltage, run out length, etc Joint preparation: typical joint design for welding, fit-up, cleaning, welding position Relationship between electrode diameter and current range, rod material, electrode length and welding position Welding procedures Special techniques (gravity welding, vertical down welding, on-site welding) Health and safety specific to this process

X X

X X X

X X X X X X

X

X X X X

X X

X X X

X

X X X X

X

X X

X

X X

X

X

X

X X

X

X

X X

X Expected results for IWI-C 1. Explain in detail the principles of MMA welding including with particular emphasis on special techniques, arc

striking methods and their applications. 2. Explain the selection of appropriate type of current, polarity and electrode according to application. 3. Identify the range of application, appropriate joint preparations and potential problems to be overcome. 4. Identify appropriate welding parameters for particular applications 5. Define potential hazards and methods of safe handling and working 6. Explain the purpose and functions of each component of the equipment and accessories. 7. Explain the handling, control and storage of the various types of electrodes. 8. Interpret appropriate standards. 9. Identify the influence of electrode coating on droplet transfer and weld metal properties.. Expected results for IWI-S 1. Describe the principles of MMA welding 2. Describe how to do the selection of appropriate type of current, polarity and electrode according to

application. 3. Identify the range of application, appropriate joint preparations and potential problems to be overcome. 4. Identify an appropriate range of welding parameters for particular applications 5. Describe potential hazards and methods of safe handling and working 6. Outline the purpose and functions of each component of the equipment and accessories. 7. Describe the appropriate methods of handling, control and storage of the various types of electrodes. 8. Demonstrate the use of appropriate standards. 9. Describe the influence of electrode coating on droplet transfer and weld metal properties. Expected results for IWI-B 1. Outline MMA welding working principles, special techniques, arc striking methods and their applications. 2. Outline the handling and storage of each type of consumable. 3. Give examples of the most important applications and select appropriate welding parameters. 4. Know how to use and care for the equipment and accessories. 5. Read given standards for electrodes. 6. Give examples of MMA application range, joint preparation and potential problems to overcome. 7. Outline potential hazards and methods of safe handling and working.



1.10 Submerged-arc welding Objectives for IWI-C: Understand SAW welding fundamentals, including equipment, applications, procedures and common problems.



SAW process principles and arc characteristics Effect of current type and polarity Power source characteristics applicable to SAW (open circuit voltage, static and dynamic characteristics, types of current, arc striking methods) Equipment and accessories Process application range and typical problems Consumables (functions of the flux and wire, types of flux and wire, wire-flux combination, slag-metal and gas-metal reactions) Production of consumables (how, typical defects) Handling and storage of consumables (storage environment, redrying) Consumable classification (International and national standards) Welding parameters: current, voltage, travel speed, type of flux and particle size, stick-out, etc Joint preparation: typical joint design for welding, fit-up, cleaning. Relation between the wire flux combination and the characteristics of deposited material.. Welding procedures... Single-wire and multi -wire techniques Special techniques (strip-cladding, iron-powder addition, cold and hot wire addition) Health and safety specific to SAW process

X X

X X X

X X X X

X X

X X X

X X

Expected results for IWI-C 1. Explain the principles of SAW process including arc striking methods, special techniques and their

applications. 2. Explain the selection of appropriate type of current, polarity and consumable according to application. 3. Identify the range of application, appropriate joint preparations and potential problems to be overcome. 4. Identify appropriate welding parameters for particular applications. 5. Explain the purpose and functions of each component of the equipment and accessories. 6. Explain slag-metal/gas-metal reactions and their influence on weld metal properties 7. Interpret appropriate standards. 8. Define potential hazards and methods of safe handling and working.

Expected results for IWI-S and IWI-B

Not applicable



1.11 Resistance welding Objectives for IWI-C: Understand resistance welding fundamentals, applications and specifications, including common problems and their solution.



Process principles and overview on types of processes (spot, projection, butt, seam, and flash) Joule effect and temperature distribution Equipment and accessories Process application range and typical problems (welding thin to thick material, welding of coated/ painted materials, welding dissimilar materials, mass effect, shunt effect, Peltier effect, resistance brazing) Electrodes (functions, types, shapes, material) Electrode classification (International and national standards) Welding parameters: current, pressure, time, type of current, pulse, etc Joint preparation: typical joint design for welding, fit-up, cleaning Relation between welding parameters and the characteristics of the weld nugget Monitoring systems, process control, measuring Specific testing Welding procedures Health and safety specific to this process

X X X

X X X X X

X X X X X

Expected results for IWI-C 1. Explain the principles of resistance welding and the application of the various sub-processes. 2. Explain the selection of appropriate parameters to give sound welds. 3. Identify the range of application, appropriate material preparation and potential problems to be overcome.4. Identify appropriate welding parameters for particular applications. 5. Explain the purpose and functions of each component of the equipment and accessories. 6. Interpret appropriate standards. 7. Define potential hazards and methods of safe handling and working. 8. Recognise the various settings and switches on different power sources and their effects. Expected results for IWI-S and IWI-B Not applicable



1.12 Other welding processes Objectives for IWI-C: Understand principles, the filed of application and common problems of plasma; electron beam; Laser, electro-slag, friction; friction stir, magnetically impelled arc butt (MIAB); magnetic pulse welding, ultrasonic; explosive; diffusion; aluminothermic; high-frequency; stud, cold-pressure welding, hybrid processes, etc.



Basic principles for all mentioned processes Heat generation for each type of process Equipment and accessories for each type of process Typical process applications and problems Consumables Welding parameters for each process Joint preparation: typical joint design for welding, fit-up, cleaning Relation between welding parameters and joint configuration Comparison between high energy processes Health and safety specific to the processes Appropriate national and international standards for each process


Expected results for IWI-C 1. Explain the principles of the processes mentioned in the objective and their application. 2. Determine appropriate applications for each type of process, and the precautions necessary to achieve

a sound weld. 3. Describe the welding parameters, appropriate joint preparations and potential problems to be overcome

for each process for a given application. 4. Explain the purpose and functions of each major component of the equipment and accessories. 5. Interpret appropriate standards. 6. Define potential hazards and methods of safe handling and working. Expected results for IWI-S and IWI-B Not applicable



1.13 Cutting and other edge preparation processes Objectives for IWI-C, IWI-S and IWI-B: Understand for IWI-S and IWI-B interpret the basic principles and the field of application of the most common cutting and edge preparation processes used in welded constructions, including equipment, procedures and common problems.

WT III WT II WT I Qualification Module


Survey of edge preparation processes Mechanical cutting Principles of flame and flame powder cutting, equipment, applications and auxiliaries Flame cutting parameters, edge quality, oxygen purity grades Materials suitable for flame cutting Basic principles of the various arc cutting processes (arc-air, carbon and metal-arc, oxy-arc cutting, gauging with carbon electrode) equipment and auxiliaries Materials suitable for arc-cutting, applications, cutting parameters for each process Fundamentals of plasma cutting, equipment and auxiliaries Materials suitable for plasma cutting, applications, cutting parameters, cutting gases Plasma cutting special applications (under water cutting, cutting with water vortex) Plasma gouging Fundamentals of electron beam drilling and Laser cutting, equipment, parameters, applications Fundamentals of water jet cutting, equipment, parameters, applications Fundamentals of arc gouging and flame gouging, parameters and applications Appropriate national and international standards for each process Health and safety

X X

X X X

X

X X

X

X X

X X

X X X

X

X X X

X

X X

X

X

X

X X X

X

X X X

X

X X

X

X

X

X X X

Expected results for IWI-C 1. Explain the principles of: mechanical, flame, arc, plasma, electron beam, Laser, and water jet cutting. 2. Explain the influence of each parameter for the above mentioned processes on the edge surface quality. 3. Identify the range of applications for: flame, arc, plasma, electron beam, and water jet cutting. 4. Identify potential risks, hazards and methods of safe handling and working. Expected results for IWI-S 1. Explain the principles of: mechanical, flame, arc, plasma, electron beam, Laser, and water jet cutting. 2. Identify the characteristic parameters for the above mentioned processes 3. Make a comparison among different edge preparation processes, considering technical and economic

aspects. 4. Evaluate potential risks and hazards related with edge preparation processes. Expected results for IWI-B 1. Explain the principles of flame, arc, plasma, Laser, water jet cutting and gouging. 2. Identify the influence of characteristic parameters on the edge surface quality. 3. Point out the range of applications for flame, arc, plasma and Laser cutting. 4. Outline potential risks, hazards and methods of safe handling and working.



1.14 Surfacing Objectives for IWI-C: Understand the fundamentals and field of application of the most common surfacing techniques including equipment, procedures and common problems.



Working principles and applications for cladding techniques (rolling, explosive, strip, plasma-MIG, electroslag, Laser, etc) Working principles and applications of the spraying techniques (flame spraying with powder, flame spraying with wire, arc spraying with powder, arc spraying with wire, plasma spraying with powder, HVOF spraying Equipment and parameters for each technique Surface preparation of the base material Spraying materials Sprayed layer structure, and substrate structure "Cold " and "fusion techniques" Applications and special problems Health and safety

X

X X X X X X X X

Expected results for IWI-C 1. Explain the principles and characteristics of the most common cladding techniques. 2. Explain the principles o and characteristics f the most common spraying techniques. 3. Evaluate the quality of a surfacing layer with respect to the base material preparation. 4. Predict the different applications between "cold" and "fusion" spraying techniques. 5. Describe the most common spraying techniques and their industrial applications. 6. Define potential risks, hazards and methods of safe handling and working. Expected results for IWI-S and IWI-B Not applicable



1.15 Fully Mechanised processes and robotics Objectives for IWI-C: Understand the principle and industrial applications of welding Mechanisation and the use of robotics in welding, including applications and systems.



Survey of welding mechanisation for higher productivity Robotics, mechanisation, and automation: difference, advantages disadvantages and applications Robotics (on line and off line programming, simulation, flexible manufacturing systems) CAD/CAM systems Virtual factory (factory simulation) Seam tracking, types and typical applications Arc sensing, magnetic induction, vision system Narrow gap welding (SAW, MIG/MAG, TIG) Orbital welding (MIG/MAG, TIG) Special problems Gases and filler materials (optimisation for mechanised welding).. Health and safety

X

X

X X X X X X X X X X

Expected results for IWI-C 1. Predict solutions for higher productivity in welding using robotics, automation and mechanisation. 2. Explain the differences between off line and on line programming. 3. Explain the principle and applications of each type of seam tracking system. 4. Explain the principle, benefits and applications of narrow gap and orbital welding. 5. Define potential risks, hazards and methods of safe handling and working. Expected results for IWI-S and IWI-B Not applicable



1.16 Brazing and soldering Objectives for IWI-C, IWI-S, IWI-B: Understand (the fundamentals) and the field of application of brazing and soldering, procedures, equipment, applications, and common problems



Fundamentals of brazing and soldering (bonding mechanisms, surface tension, wetting, capillary) MIG/ MAG pulsed brazing Survey of brazing and soldering techniques, equipment, range of applications Consumables and fluxes for brazing and soldering, types, applications, and main functions of the fluxes Brazable materials, brazing requisites High vacuum brazing, brazing under controlled atmosphere Braze welding Survey of soldering techniques (dip, wave flow, vapour phase, soldering) Brazing and soldering advantages and disadvantages Applications and special problems Health and safety

X X X

X X X X X X X X

X X X

X X X X X X X X

X X X

X X X X X X X X

Expected results for IWI-C 1. Explain in detail each brazing and soldering technique. 2. Compare in detail each type of brazing and soldering technique with fusion welding. 3. Explain the precautions to obtain a sound joint using brazing or soldering techniques. 4. Describe the different applications for each brazing and soldering techniques. 5. Describe the types and characteristics of consumable and flux to used in certain applications. 6. Define potential risks, hazards and methods of safe handling and working. Expected results for IWI-S and IWI-B 1. Describe the different techniques for brazing and soldering. 2. Compare each type of brazing and soldering technique with fusion welding. 3. Illustrate the standard operating procedures for brazing or soldering techniques. 4. Describe the most relevant applications for each brazing and soldering techniques. 5. Describe the influence of surface preparation in brazing and soldering techniques. 6. Describe the types and characteristics of consumables and fluxes employed. 7. Define risks, hazards and methods of safe handling and working.



1.17 Joining processes for plastics Objectives for IWI-C: Understand the basic principles involved in joining plastics, including the common techniques, equipment, applications, procedures and common problems.



General information on materials and joining processes Study the operating principle for each type of process Hot plate welding, butt fusion, hot gas welding, extrusion welding, induction welding, resistance welding, implant welding, high frequency, friction, electro-fusion welding, ultrasonic welding, vibration welding, adhesive bonding Control of welding parameters, types of equipment, joint design Advantages and disadvantages Applications and special problems Health and safety

X X

X X X X X

Expected results for IWI-C 1. Explain the fundamentals of each joining process. 2. Explain the precautions to obtain a sound joint for each process. 3. Describe the different applications for each joining process. 4. Define potential risks, hazards and methods of safe handling and working. Expected results for IWI-S and IWI-B Not applicable

1.18 Joining processes for advanced materials Objectives for IWI-C: Understand the general principles of joining ceramics and composites, including the common techniques, applications, procedures and common problems.



General information on ceramics and composites and typical joining processes General study of the operating principles for each process Advantages and disadvantages Applications and special problems

X

X X X

Expected results for IWI-C 1. Explain the fundamentals of joining ceramics and composites. 2. Identify precautions to produce a sound joint for some advanced materials. 3. Define potential risks, hazards and methods of safe handling and working. Expected results for IWI-S Not applicable



WT III WT II WT I Module 2. Materials and their behaviour during welding 52 41 25 2.1 Manufacture and designation of steels Objectives for IWI-C, IWI-S and IWI-B: Understand (for IWI-S and IWI-B describe) the principles of iron metallurgy, steel making and designation of steels



Introduction to metallurgy of steel making Steel making processes Special treatments Deoxidation Designation of steels Defects in steels

X X X X X X

X X X X X X

X X X X X X

Expected results for IWI-C and IWI-S 1. Explain the various steel making processes. 2. Detail the reasons for and principles of special treatments in steel making. 3. Explain the different methods of deoxidation 4. Explain potential defects, their cause and elimination. 5. Explain the designation of steels Expected results for IWI-B 1. Interpret the various steel making processes. 2. Name the reasons for and the principles of special treatments in steel making. 3. Describe the different methods of deoxidation. 4. Describe potential defects, their cause and elimination. 5. Describe the designation of steels.



2.2 Testing materials and the weld joint Objectives for IWI-C, IWI-S and IWI-B: Understand (for IWI-S and IWI-B name) the fundamental aspects otesting materials with particular reference to weldment test pieces



Review of destructive testing Testing welded joints (technological specimen Destructive testing Tensile and bend tests Impact tests (ductile and brittle fracture, transition temperature) Hardness tests Special tests (CTOD, etc.) Fatigue tests Creep tests Corrosion tests Overview on related standards


X X X X X X X X

X

X X X X X X

Expected results for IWI-C 1. Discuss the objectives of each destructive testing and the limitations of the data generated 2. Describe in detail each of the major testing methods and the parameters to be measured 3. Predict when and why special testing should be specified Expected results for IWI-S 1. Discuss the objectives of each destructive testing and the limitations of the data generated. 2. Describe each of the major testing methods and the parameters to be measured. 3. Predict when and why special testing should be specified Expected results for IWI-B 1. Discuss the reasons for destructive testing. 2. Describe major testing methods and the parameters to be measured.



2.3. Structure and properties of pure metals Objectives for IWI-C, IWI-S and IWI-B: Understand (for IWI-S and IWI-B describe) the principles of solidification, deformation and recrystallisation and the characteristics of typical metal structures.



Crystalline structures Crystal lattice structure types Micro structures of metals Solid state transformation Elastic/plastic deformation Recrystallisation Cold and hot deformation Work hardening and strain aging Mechanical properties (influence of temperature, etc.)

X X X X X X X X X

X X X

X X X X X

X X X

X X X X X

Expected results for IWI-C 1. Explain basic crystalline structures. 2. Explain in detail elastic-plastic deformation and their role in cold and hot deformation. 3. Explain recrystallisation giving examples. 4. Demonstrate understanding of the relationship between mechanical properties and temperature, grain size

and structure Expected results for IWI-S and IWI-B 1. Describe basic crystalline structures. 2. Explain elastic-plastic deformation and their role in cold and hot deformation. 3. Describe recrystallisation, giving examples. 4. Demonstrate understanding of the relationship between mechanical properties and temperature, grain

size and structure.



2.4 Alloys and phase diagrams Objectives for IWI-C, IWI-S and IWI-B: Understand (for IWI-S and IWI-B - describe the principles of alloying, the structures of alloys and their representation in phase diagrams.



Pure metals and alloys Alloying elements Solidification Solid solution crystals Structure of alloys Type of structures Strengthening mechanisms (cold working, solid solution, precipitation hardening, grain size control, solid state transformation) Intermetallic compounds Ageing Basic types of phase diagrams (non-, fully- and partly soluble components). Fe-C equilibrium diagram Influence of alloy elements on the Fe-C equilibrium diagram Iron-alloys with closed gamma-loop, with broadened gamma-area The structure of castings Segregation and coring Mechanical properties Ternary diagrams

X X X X X X


X X

X X

X

X X X

X

X

X X

X X

X

X

X

X

X

Expected results for IWI-C 1. Describe crystalline lattice distortion due to alloying elements and subsequent structural changes. 2. Explain in detail solidification structure and segregation with relevant examples. 3. Detail mechanisms of precipitation, types of precipitates and their location within the microstructure. 4. Explain in detail the principles of transformation and conditions under which it occurs. 5. Detail the principles of strengthening mechanisms with appropriate examples. 6. Interpret the relationship between microstructure and mechanical properties. 7. Explain in detail the principles of phase diagrams, their construction and use. 8. Interpret the relationship between microstructure and phase diagrams. Expected results for IWI-S 1. Describe crystalline lattice distortion due to alloying elements and subsequent structural changes. 2. Describe the principles of strengthening mechanisms with appropriate examples. 3. Interpret the relationship between microstructure and phase diagrams. 4. Outline the significant points(temperatures, weight %) of from the Fe-C diagram. Expected results for IWI-B 1. Point out solidification structure and segregation on relevant examples. 2. Outline the principles of transformation and conditions under which it occurs. 3. Describe the principles of strengthening mechanisms with appropriate examples. 4. Outline the significant points (temperatures, weight %) of the Fe-C diagram.



2.5 Iron-Carbon alloys Objectives for IWI-C, IWI-S and IWI-B: Understand (for IWI-S and IWI-B name) the principles of alloying iron with carbon, the crystalline structures developed under equilibrium and non-equilibrium conditions and their representation in phase and transformation diagrams.



Equilibrium and non equilibrium transformations Time-temperature-transformation (TTT) diagrams Different types of TTT diagrams (isothermal, continuous cooling, TTT diagrams for welding) Influence of alloying elements Carbide forming elements Control of toughness T8/5 concept

X X

X X X X X

X X

X X X X X

X

X X X X

Expected results for IWI-C 1. Interpret the reasons for different structures under equilibrium and non-equilibrium conditions. 2. Explain the use of TTT diagrams (isothermal, continuous cooling, TTT diagrams for welding) to show the

development of particular steel microstructures. 3. Predict the changes strengthening structure caused by alloying additions with reference to TTT

diagrams. 4. Detail hardening mechanisms with reference to the microstructure developed. 5. Interpret the relationship between microstructure and toughness. Expected results for IWI-S 1. Interpret the reasons for different structures under equilibrium and non-equilibrium conditions. 2. Explain the use of TTT diagrams (isothermal, continuous cooling, TTT diagrams for welding) to show the

development of particular steel microstructures. 3. Identify the changes strengthening structure caused by alloying additions with reference to TTT

diagrams. 4. Describe hardening mechanisms with reference to the microstructure developed. 5. Interpret the relationship between microstructure and toughness. Expected results for IWI-B 1. Identify TTT diagrams (isothermal, continuous cooling, TTT diagrams for welding) 2. Compare the changes strengthening structure caused by alloying additions with reference to TTT

diagrams. 3. Desribe hardening mechanisms with reference to the microstructure developed. 4. Draw the relationship between microstructure and toughness



2.6 Heat treatments of base materials and welded joints Objectives for IWI-C, IWI-S and IWI-B: Understand (for IWI-S and IWI-B name) the metallurgical transformations of materials during different heat treatment.

WT III WT II WT I ModuleScope Teaching hours 2 2 1 Normalising Hardening Quenching and tempering Solution annealing Homogenisation Stress relieving (PWHT Recrystallisation annealing Precipitation hardening Heat treatment in practice Heat treatment equipment Regulations (codes and technical reports) Temperature measurement and recording

X X X X X X X X X X X X

X X X X X X X X X X X X

X X X X X X X

X X X X

Expected Results for IWI-C 1. Explain each of the major heat treatments and their objectives. 2. Explain the mechanisms of structural changes, which take place when a material is heat treated. 3. Interpret the effects of temperature and time on transformations including the effect of temperature

change rate. 4. Explain code requirements for heat treatment and why they are stipulated. 5. Predict the necessity to heat treatment after welding depending of the type and thickness of steel, the

application and the code. 6. Deduce appropriate heat treatment equipment for a given application. 7. Detail appropriate temperature measurement and recording methods for typical applications. Expected Results for IWI-S 1. Explain each of the major heat treatments and their objectives. 2. Explain the mechanisms of structural changes, which take place when a material is heat treated. 3. Describe the effects of temperature and time on transformations including the effect of temperature

change rate. 4. Describe code requirements for heat treatment. 5. Predict the necessity to heat treatment after welding depending of the type and thickness of steel, the

application and the code. 6. Name appropriate heat treatment equipment for a given application. 7. Detail appropriate temperature measurement and recording methods for typical applications.

Expected Results for IWI-B 1. Describe the major heat treatments and their objectives. 2. Associate the effects of temperature and time on transformations of temperature change. 3. Describe code requirements for heat treatment and why they are stipulated. 4. Discuss the necessity to heat treatment after welding depending of the type and thickness of steel, the

application and the code. 5. Name heat treatment equipment for a given application. 6. Describe temperature measurement and recording methods for typical applications.



2.7 Structure of the welded joint Objectives for IWI-C, IWI-S and IWI-B: Understand (for IWI-S get knowledge; for IWI-B get general understanding) the formation on the different metallurgical structures within a weldment.



Thermal field Equations for the heat distribution Heat input and efficiency of heat input Peak temperature Cooling rate and thermal cycle Dilution Weld metal Solidification of weld pool Structure of the weld Fusion line Heat-affected zone (HAZ) Microstructure of HAZ Grain growth and grain refinement Relationship grain size toughness (equations from regression) Transition temperature Weldability (definitions) Single and multi -pass welding

X X X X X X X X X X X X X X X X X

X X X X X X X X X X X X X

X

X X X X X X X X X X X X X

X Expected results for IWI-C 1. Explain the temperature distribution in welds and the microstructure formed as a result for a single pass

weld versus a multi pass weld. 2. Interpret the effects of heat input, cooling rate and multi -pass operation on weld metal solidification and

the microstructure formed for a single pass weld versus a multi pass weld. 3. Explain the effects of the weld protection, the type of consumables on the microstructure of the weld

metal and on it properties for a single pass weld versus a multi pass weld. 4. Detail areas of HAZ, the reasons for grain size and microstructure changes and their effects on prop-

erties for a single pass weld versus a multi pass weld. 5. Discuss the various aspects of weldability 6. Deduce the micro structural and weldability changes induced by dilution Expected results for IWI-S 1. Explain the temperature distribution in welds and the microstructure formed as a result for a single pass

weld versus a multi pass weld. 2. Interpret the effects of heat input, cooling rate and multi -pass operation on weld metal solidification and

the microstructure formed for a single pass weld versus a multi pass weld. 3. Explain the effects of the weld protection, the type of consumables on the microstructure of the weld

metal and on it properties for a single pass weld versus a multi pass weld. 4. Draw areas of HAZ, the reasons for grain size and microstructure changes and their effects on

properties for a single pass weld versus a multi pass weld. 5. Discuss the various aspects of weldability. Expected results for IWI-B 1. Associate the temperature distribution in welds and the microstructure formed as a result 2. Describe the effects of heat input, cooling rate and multi -pass operation on weld metal solidification and

the microstructure formed. 3. Draw areas of HAZ, the reasons for grain-size and microstructure changes and their effects. 4. Compare the various aspects of weldability.



2.8 Plain carbon- and carbon-manganese steels Objectives for I IWI-C, IWI-S and IWI-B: Understand (for IWI-S get knowledge: for IWI-B get general understanding) the metallurgical effects induced by welding C and C-Mn steels.



Application of TTT diagrams Hardening effects Carbon equivalent Weldability Effects of multi pass welding Structure of the weld and the HAZ Factors influencing cracking Relationship C%max hardness Relationship Ceq hardenability Determination of preheat temperature (diagrams) Weld simulation (Weld thermal cycle simulation) Determination of the optimal heat input Influence of restraint Standards



X X X X X X X X X X

X

X Expected results for IWI-C 1. Explain the concept and use of carbon equivalent. 2. Explain the principle and use of TTT diagrams (isothermal, continuous cooling, TTT diagrams for

welding). 3. Predict the structure of welds and HAZ for given thermal cycles and composition. 4. Explain in detail the effects of a multi pass welding on the structure, the mechanical properties. 5. Discuss the factors affecting cold cracking. 6. Predict optimal heat input and appropriate pre-heat for given materials, conditions and applications

utilising Codes and Standards as required. Expected results for IWI-S 1. Explain the concept and use of carbon equivalent. 2. Describe the principle and use of TTT diagrams (isothermal, continuous cooling, TTT diagrams for

welding). 3. Explain in detail the effects of a multi pass welding on the structure, the mechanical properties. 4. Discuss the factors affecting cold cracking. 5. Predict optimal heat input and appropriate preheat for given materials, conditions and applications utilising Codes and Standards as required. Expected results for IWI-B 1. Describe the concept and use of carbon equivalent. 2. List the structure of welds and HAZ for given thermal cycles. 3. Name the effects of a multi pass welding on the structure, the mechanical properties. 4. Name the factors affecting cold cracking. 5. Predict optimal heat input and appropriate preheat for given materials, conditions and applications.



2.9 Fine-grained steels Objectives for IWI-C, IWI-S and IWI-B: Understand for IWI-S - get knowledge; for IWI-B get general understanding) the effects of micro-alloying elements on structure, mechanical properties and weldability with reference to fine-grained steels.

WT III WT II WT I ModuleScope Teaching hours 2 2 1 Concept of grain refinement (micro-alloying elements, formation and dilution of particles) Effect on mechanical properties Normalised grades Quenched and tempered grades T8/5 concept and weldability Standards

X X X X X X

X X X X X X

X X X X X X

Expected results for IWI-C 1. Explain the different methods to obtain fine-grained steels and effects of micro alloying. 2. Explain thoroughly the relationship between grain refinement and mechanical properties 3. Detail appropriate applications 4. Interpret the relationship between grade and weldability 5. Detail applicable welding processes and potential problems 6. Explain the effects of heat treatment after welding and deduce the conditions (in particular temperature)

of such treatment Expected results for IWI-S 1. Explain the different methods to obtain fine-grained steels and effects of micro alloying. 2. Explain thoroughly the relationship between grain refinement and mechanical properties. 3. Detail appropriate applications. 4. Interpret the relationship between grade and weldability. 5. Identify applicable welding processes and potential problems. 7. Name the effects of heat treatment after welding and deduce the conditions (in particular temperature) of

such treatment. Expected results for IWI-B 1. List the different methods to obtain fine-grained steels effects of micro alloying. 2. Explain thoroughly the relationship between grain refinement and mechanical properties. 3. Interpret the relationship between grade and weldability. 4. Identify applicable welding processes and potential problems. 5. Name the effects of heat treatment after welding and deduce the conditions of such treatment.



2.10 Thermomechanically treated steels Objectives IWI-C, IWI-S and IWI-B: Understand (for IWI-S get knowledge; for IWI-B get general understanding) the principles of thermomechanical treatment and its influence on mechanical properties and weldability.



Principles of treatment (controlled rolling, accelerated cooling, direct quench, etc Chemical composition Mechanical propertie

iiw welding guidelines

Documents

welding inspection modules

levels of inspection

welding processes

qualification iab041r3

examination board

welding technology modules

theoretical education

relevant inspection