CWS (ABWM) study plan
CWS · Give each week a clear focus.
8 weeks · About 7 hours per week
Welding Processes, Procedures, and Qualification
Diagram and label the four core arc processes (SMAW, GMAW, FCAW, SAW), listing current polarity, shielding medium, and typical deposition range for each
Compare electrode/wire classification systems (AWS A5.x designations) and decode five given classification codes without reference notes
List five common weld discontinuities per process and match each to its most likely process-based root cause
Calculate deposition rate, arc time, and operating factor for three worked examples
Your checkpoint
A one-page process selection matrix covering all four processes with 10 self-written decode/calculation problems solved to 90% accuracy
Welding Processes, Procedures, and Qualification
Differentiate WPS, PQR, and welder performance qualification and state what each document must contain
Map the essential variables for a given process and explain the requalification trigger for changing each one
Order the steps of procedure qualification from prequalified joint detail through PQR approval and WPS issuance
Determine welder qualification test positions and validity ranges for groove and fillet tests
Your checkpoint
A sample WPS and matching PQR outline written from a blank template, plus a 10-item essential-variable quiz scored at 80% or better
Quality Assurance, Inspection, and Codes & Welding Processes, Procedures, and Qualification
Locate and apply acceptance criteria for weld discontinuities in a structural welding code, distinguishing visual from volumetric limits
Select the correct NDT method (PT, MT, UT, RT) for five described defect scenarios and justify each choice
Explain the qualification and duties of welding inspectors and the limits of visual inspection
Identify the documents a supervisor must verify before allowing production welding to start
Your checkpoint
A discontinuity acceptance-criteria reference sheet cross-referenced to code clause topics, plus five NDT selection justifications
Quality Assurance, Inspection, and Codes & Welding Supervision and Management
Trace the flow of a nonconformance from detection through disposition, corrective action, and closure
Write three audit-style checklist items a supervisor would use to verify code compliance on the floor
Distinguish supervisor responsibilities from inspector responsibilities in a documented quality system
Solve eight mixed code-application and documentation review questions under timed conditions
Your checkpoint
Pass a 25-question timed mixed-domain practice set at 80% or higher and a written nonconformance workflow diagram
Welding Supervision and Management
Define the scope of welding supervision and contrast it with inspection, engineering, and quality-assurance roles
Build a crew-planning scenario that assigns qualified welders to positions matching their qualification limits
Draft a pre-weld briefing script covering WPS review, joint prep, fit-up, and documentation
Identify records that must be retained and for how long under a typical quality system
Your checkpoint
A one-page supervisory pre-weld checklist plus a solved crew-to-qualification assignment scenario with no mismatches
Welding Supervision and Management & Safety, Productivity, and Cost Control
Estimate weld cost per unit length from labor, consumables, power, and overhead inputs
Calculate the cost impact of rework and compare repair versus rejection for three scenarios
Link productivity levers (fit-up quality, positioning, process choice, operating factor) to measurable output gains
Produce a training and competency plan outline for a small welding crew
Your checkpoint
A cost-per-meter worksheet solved for three scenarios plus a written rework-versus-reject recommendation for each
Safety, Productivity, and Cost Control
Identify welding hazards (fume, arc radiation, electric shock, fire, confined space) and match each to a control per the hierarchy of controls
Interpret ventilation and fume-control requirements for a described shop layout
Explain hot-work permitting and fire-watch requirements
Outline supervisor duties during an incident investigation
Your checkpoint
A shop-floor hazard and control matrix with at least 12 hazards mapped to controls, plus a hot-work permit checklist
Welding Supervision and Management & Welding Processes, Procedures, and Qualification & Quality Assurance, Inspection, and Codes & Safety, Productivity, and Cost Control
Complete two full-length timed practice exams and log every missed item by domain
Re-study only the top three weakest sub-topics identified in the error log
Recite key code acceptance limits and essential-variable rules from memory in a self-quiz
Build a one-page summary sheet of formulas, definitions, and code references for final review
Your checkpoint
Two completed practice exams scoring 80% or higher, with a written error log and a finalized one-page summary sheet
Milestones
Week 2: Can explain and produce WPS/PQR/WPQ documentation and essential variables without notes; week 2 deliverable complete
Week 4: Scores 80%+ on a 25-question timed mixed domain 2 and 3 set; NDT selection and acceptance criteria recalled accurately
Week 6: Completes supervision and cost scenarios with correct crew qualification matching and correct cost-per-meter arithmetic
Week 8: Two full-length practice exams at 80%+ with a documented error log showing no domain below 70%