CWS (ABWM) cheat sheet

Supervisor verifies that each welder's qualification covers the process, position, thickness, and filler being used before production starts.

A WPS is a written, qualified instruction; a PQR is the record of the test that qualified it; they are not interchangeable.

Essential-variable changes outside WPS/PQR limits require requalification before the revised WPS is used.

Continuity: welder qualifications lapse when the welder has not used the process for the period set by the applicable code; records must show dates.

Shift handover log should capture WPS number, base-metal heat, filler lot, preheat/interpass readings, and open NCRs.

First-pass yield = (welds accepted first inspection / total welds inspected) x 100; repair rate is the complement.

Nonconforming weld disposition options are accept-as-is, rework, repair, or reject, and each requires documented approval.

Supervisor has authority and duty to stop work when the WPS, qualified personnel, or safety controls are not in place.

Calibrated measuring and monitoring equipment such as gauges, meters, and thermometers must be identified and within calibration before use.

Heat input (kJ/in) = (60 x arc voltage x amperage) / (1000 x travel speed in in/min).

Carbon equivalent, CE = C + Mn/6 + (Cr + Mo + V)/5 + (Ni + Cu)/15; higher CE raises preheat and cracking risk.

SMAW E7018 is a low-hydrogen electrode and must be stored in a holding oven and exposed only per manufacturer limits.

GTAW uses DCEN for carbon steel and AC for aluminum; the tungsten electrode is non-consumable.

GMAW transfer modes include short-circuit, globular, spray, and pulsed spray; mode affects penetration and spatter.

FCAW may be self-shielded with no external gas or gas-shielded; self-shielded is common for field work.

SAW uses granular flux and is normally automatic; flux must be dry and free of contamination.

WPS essential variables commonly include process, base-metal specification and thickness, filler classification, position, preheat, PWHT, shielding gas, and current type/polarity.

PQR testing commonly includes tensile and bend tests; impact or hardness tests are added when the code or service requires them.

Visual inspection is performed before, during, and after welding; it detects profile, undercut, cracks, porosity, and spatter.

PT detects open surface discontinuities; MT detects surface and near-surface flaws in ferromagnetic materials.

RT and UT are volumetric methods; RT is strong for internal porosity and slag, UT for planar flaws and thick sections.

NDT personnel must be certified to the applicable standard, and inspection equipment must be within calibration.

Fillet weld size is checked with a fillet gauge; leg size, throat, convexity, and undercut are measured against code limits.

Acceptance criteria come from the contract and referenced code; they are not set by the inspector's preference.

A nonconformance report should identify location, type, size, code reference, and required disposition.

Document hierarchy commonly runs contract, code, project specification, then WPS and drawings; conflicts are resolved in that order.

Welding symbols per AWS A2.4 define joint, weld size, length, spacing, and contour; the tail may carry process or reference.

Welding fume extraction must be adequate; stainless and hardfacing fumes may contain hexavalent chromium and require respiratory protection.

Hot-work permit and fire watch: combustibles within 35 ft must be protected or moved; fire watch continues per permit after work.

Compressed gas cylinders are secured upright, capped when not in use, and oxygen is separated from fuel gas by 20 ft or a barrier.

Welding arc shade number increases with amperage; the helmet filter must match the process and current.

Confined-space entry requires atmospheric testing, a permit, an attendant, and rescue provisions before entry.

Arc-on time divided by paid time equals operator factor; improving fit-up, position, and consumable supply raises operator factor.

Deposition efficiency = weight of deposited metal / weight of consumable consumed; it affects consumable cost.

Cost per welded foot = (labor + consumables + equipment + rework) / feet of acceptable weld.

Higher travel speed lowers heat input and can raise productivity, but must stay within WPS limits for fusion and profile.