CWB Welding Inspector Level 2 flashcards

32 cards. Read the term and the definition here. The deck at the top of this page is optional.

Heat input formula

Heat input (kJ/mm) equals voltage times current times 60 divided by travel speed in mm/min times 1000. Higher heat input generally means slower cooling and a wider HAZ.

Short-circuit transfer

GMAW transfer in which the wire contacts the puddle and extinguishes the arc repeatedly. It operates at low current and suits thin plate and out-of-position work.

Spray transfer

GMAW transfer above a transition current in which fine droplets detach axially. It requires argon-rich shielding and gives high deposition with deep penetration.

E7018 electrode

A low-hydrogen, iron-powder, all-position SMAW electrode used on DCEP. Its low hydrogen content reduces cold-cracking risk in high-strength or restrained joints.

GTAW electrode polarity

Direct current electrode negative concentrates heat in the workpiece and is standard for steel. Alternating current is used for aluminium to break up the oxide film.

Submerged arc welding

An arc process using a continuous bare wire under granular flux. It gives high deposition and smooth beads but is limited to flat and horizontal positions.

CSA W47.1 scope

The Canadian standard for certification of companies performing fusion welding of steel. It sets requirements for personnel, procedures, and quality control systems.

CSA W59 scope

The Canadian welded steel construction code. It covers design, fabrication, and inspection of steel structures and is commonly used with W47.1 certification.

AWS D1.1 scope

The structural steel welding code. It provides prequalified joint details, filler metal matching, and acceptance criteria for statically and cyclically loaded structures.

ASME Section IX scope

The ASME Boiler and Pressure Vessel Code section governing qualification of welding procedures and personnel. It defines essential variables and mechanical test requirements.

Essential variable

A welding parameter whose change requires requalification of the procedure or the welder. Examples include process, base metal group, thickness, and position.

Specification versus code

A specification states requirements for a product or work. A code is a body of rules adopted by law or contract and is mandatory once referenced.

Arrow side convention

The side of the joint the arrow touches. Groove symbols on the arrow side of the reference line denote arrow-side welds; symbols on the other side denote other-side welds.

Fillet weld symbol

A triangle placed on the reference line. Leg size is written to the left of the symbol; length and pitch are written to the right.

All-around symbol

A circle at the junction of the reference line and arrow. It indicates the weld continues completely around the joint.

WPS versus PQR

A WPS is the written qualified procedure used in production. A PQR is the record of the test that qualified it, including essential variables and test results.

Welder performance qualification

A record of an individual welder's test demonstrating ability to produce acceptable welds within a defined process, position, and thickness range.

Drawing units

Drawings must state whether dimensions are in millimetres or inches. Dual dimensions are shown with one unit in parentheses.

Visual inspection limits

Visual inspection verifies fit-up, bead profile, undercut, spatter, and dimensions. It is the primary method and precedes most other NDE.

Penetrant testing

A surface method using a liquid penetrant drawn into surface-breaking defects. It requires a clean, non-porous surface and is unsuitable for rough or porous materials.

Magnetic particle testing

A method using magnetic fields and ferromagnetic particles to reveal surface and near-surface defects. It works only on ferromagnetic materials such as carbon steel.

Ultrasonic testing

A volumetric method using high-frequency sound, typically 1-10 MHz. It detects internal planar defects well and requires trained operators and reference blocks.

Radiographic testing

A volumetric method using penetrating radiation to image internal defects. Planar defects oriented parallel to the beam may be missed, and radiation safety controls apply.

Hold point

A stage in fabrication where work cannot proceed until the required inspection has been performed and accepted. It is distinct from a witness point.

Heat-affected zone

Base metal that is not melted but is thermally altered by welding. It is often the weakest region because of grain growth or hardening.

Hydrogen cold cracking

Cracking below about 200 degrees Celsius, often hours after welding. It is prevented by low-hydrogen consumables, preheat, and controlled cooling.

Sensitisation

Chromium carbide precipitation at grain boundaries in austenitic stainless steel between roughly 425 and 870 degrees Celsius, causing intergranular corrosion.

Aluminium oxide film

A tenacious oxide layer melting near 2050 degrees Celsius versus aluminium near 660 degrees Celsius. It must be removed mechanically or by AC cleaning action.

Post-weld heat treatment

Controlled heating after welding to relieve residual stress and temper hard microstructures. The temperature range must be controlled to avoid degrading properties.

Procedure qualification record

The documented record of the test that qualified a welding procedure. It lists essential variables, test results, and mechanical test outcomes.

Nonconformance handling

A defined path for defective work: identify, document, disposition (rework, repair, or scrap), re-inspect, and close out the record.

Consumable control

Storage and handling requirements for welding consumables. Low-hydrogen electrodes must be stored dry and baked per manufacturer instructions before use.