CWS (ABWM) key terms

The person who directs and coordinates welding work on the shop floor, ensuring welders follow approved procedures, meet quality requirements, and work safely. Duties include assigning work, verifying qualifications, and solving production problems.

The positioning and alignment of parts before welding, including root opening, joint geometry, and tack welds. Poor fit-up can force a welder to deviate from the procedure and cause defects.

A document that authorizes and tracks a specific manufacturing job, listing parts, quantities, procedures, and due dates. Supervisors use it to plan labor and confirm that correct materials and procedures are used.

A written statement, signed by the employer, that a welder has passed the required performance qualification test and is authorized to weld under specified conditions. It remains valid only while the welder is employed by that company.

A written document listing the variables, such as process, filler metal, current, and preheat, required to make a production weld that meets the applicable code. It is supported by a qualified procedure record.

A record of the actual welding variables and test results used to prove that a welding procedure produces welds meeting code requirements. It provides the basis for writing the corresponding procedure specification.

A test that demonstrates a welder's ability to produce sound welds using a qualified procedure. Records show the process, position, thickness, and other limits the welder is qualified for.

A welding parameter that, if changed beyond the range allowed by the procedure qualification, requires requalification because it can affect weld properties or soundness. Examples include welding process and filler metal classification.

A welding parameter that can be changed without requalifying the procedure because it does not affect the mechanical properties of the weld, although the procedure specification may still limit it.

Applying heat to the base metal before welding to slow cooling, remove moisture, and reduce the risk of cracking, especially in thick sections or steels with high carbon equivalent.

The temperature of the weld and surrounding base metal just before the next pass is deposited. It is controlled to prevent loss of toughness and excessive distortion.

The amount of energy delivered to the weld per unit length, calculated from voltage, current, and travel speed. Higher heat input generally means slower cooling and a wider heat-affected zone.

Controlled heating and cooling of a completed weldment to relieve residual stress, soften the heat-affected zone, or reduce hydrogen. It is often required for thick sections and certain alloys.

An unwanted change in the shape or dimensions of a weldment caused by uneven heating, cooling, and shrinkage. It is controlled by fit-up, welding sequence, balanced passes, and fixturing.

The rate at which the arc moves along the joint. It affects bead size, penetration, heat input, and productivity, and is usually listed as an allowable range on the procedure.

The height of weld metal above the base metal surface on a groove weld, or above the fusion line on a fillet weld. Excess reinforcement concentrates stress and may exceed code limits.

A groove melted into the base metal at the weld toe or root that is not filled with weld metal. It reduces cross-section and acts as a stress concentrator, so codes limit its depth and length.

Cavities in the weld metal formed by trapped gas. Small amounts may be acceptable depending on the code, but clustered or aligned porosity often causes rejection.

Nonmetallic solid material from flux or electrode coating trapped in the weld metal. It is common in flux-shielded processes and usually detected by radiography or ultrasonics.

A condition where the weld metal does not bond to the base metal or to a previous pass. It is a serious planar defect that reduces strength and is often missed by visual inspection.

Weld metal that does not extend through the full joint thickness in a groove weld, leaving an unfused gap at the root. It is a planar defect that reduces load-carrying capacity.

An interruption in the normal structure of a weld, such as a void, crack, or inclusion. A discontinuity becomes a defect only when it exceeds the acceptance criteria of the applicable code.

The limits set by a code or specification that define whether an inspected weld is acceptable. They specify the type, size, and quantity of allowable discontinuities.

Inspection methods that reveal surface or internal discontinuities without damaging the part, such as visual, radiographic, ultrasonic, magnetic particle, and penetrant testing.

Examination of a weld by eye, aided by lighting, gauges, and magnifiers. It is the most common and least expensive method and precedes most other examination techniques.

Passing penetrating radiation through a weld onto film or a detector to produce an image of internal discontinuities. It is sensitive to volumetric defects such as porosity and slag.

Directing high-frequency sound waves into a weld and analyzing returning echoes to locate internal discontinuities. It is especially effective for planar defects such as lack of fusion and cracks.

Magnetizing a ferromagnetic part and applying iron particles so discontinuities near the surface produce visible indications. It works only on ferromagnetic materials such as carbon steel.

Applying a liquid penetrant that seeps into surface-breaking discontinuities, then drawing it out with a developer to form a visible indication. It works on most nonporous materials.

The cable connecting the workpiece back to the welding power source. A poor connection causes erratic arcs, overheating, and stray current that can damage bearings or electronic equipment.

A formal authorization required before welding or cutting in areas where fire or explosion hazards exist. It verifies that the area is cleared, a fire watch is posted, and extinguishers are available.

An enclosed area with limited entry and exit that is not designed for continuous occupancy. Welding inside one requires atmospheric testing, ventilation, an attendant, and a rescue plan.

Clothing and gear worn to protect the welder from arc radiation, sparks, fumes, and heat, including helmet, gloves, jacket, and safety glasses. It complements engineering controls such as ventilation.

Local exhaust ventilation that captures welding smoke at or near the arc before it enters the welder's breathing zone. It is required by many regulations and improves comfort and productivity.

The percentage of a ten-minute period a welding machine can operate at rated output without overheating. Exceeding it triggers thermal protection shutdowns and delays production.

The weight of filler metal deposited per unit of time, usually expressed in pounds per hour. Higher deposition rates lower the labor cost per meter of completed weld.

The percentage of a welder's paid time spent actually welding. Raising it through good fit-up, material handling, and positioners reduces the cost per weld.

Repairing or replacing a weld that failed inspection or did not meet requirements. Rework adds cost, disrupts schedules, and can degrade material, so supervisors track it as a quality measure.