CWS Welding key terms

A written document that specifies the welding process, materials, joint design, and operating parameters a welder must follow to produce a weld meeting the required code.

A record of the tests used to prove that a proposed welding procedure produces welds meeting code requirements; it supports and validates the WPS.

A record showing that an individual welder passed the required test for a specific process, position, and material, confirming the welder can follow a qualified procedure.

A formal authorization issued before welding, cutting, or grinding in a designated area; it confirms fire hazards are controlled and required precautions are in place.

A trained person assigned to monitor the work area for sparks, slag, and smoldering materials during and after hot work, with authority to stop work and sound an alarm.

Local exhaust ventilation that captures welding smoke and metal fumes near the arc before they enter the welder's breathing zone.

Equipment such as helmets, gloves, flame-resistant clothing, respirators, and safety glasses worn to protect the welder from arc radiation, heat, sparks, and fumes.

A sudden release of intense radiant energy and heat from an electric arc, capable of burning skin and eyes; welding helmets and screens block this radiation.

Inspection methods that examine welds without destroying them, such as visual, radiographic, ultrasonic, magnetic particle, and dye penetrant testing, to detect discontinuities.

A direct examination of the weld and surrounding area using eyes, magnifiers, and gauges to find surface defects and verify size, shape, and cleanliness.

Small gas pockets trapped in solidified weld metal, often caused by moisture, oil, drafts, or poor shielding; they reduce weld density and can fail acceptance criteria.

A condition where weld metal fails to bond to the base metal or to a previous pass, often from low heat input, poor angle, or contaminated surfaces.

A groove melted into the base metal along the weld toe that is left unfilled, reducing the throat thickness and creating a stress concentration.

The code-specified limits for defect type, size, and frequency that determine whether a completed weld is accepted, repaired, or rejected.

A nondestructive method that passes X-rays or gamma rays through a weld to create a film image showing internal voids, inclusions, and cracks.

A nondestructive method that sends high-frequency sound waves into a weld and interprets returning echoes to locate internal defects such as cracks and lack of fusion.

The amount of energy delivered to the weld per unit length, calculated from voltage, current, and travel speed; it influences cooling rate, hardness, and distortion.

The rate at which the arc moves along the joint. It affects bead shape, penetration, heat input, and the risk of defects such as lack of fusion.

The percentage of a ten-minute period a welding machine can operate at a given current without overheating; it guides safe equipment loading and production planning.

The weight of filler metal deposited per unit time, usually expressed in pounds per hour; higher rates reduce welding time and labor cost.

The percentage of paid work time a welder actually spends striking an arc; improving it raises productivity without changing welding speed.

The total cost of completing one foot of weld, including labor, filler metal, shielding gas, power, equipment, and overhead.

The alignment and gap between parts before welding. Poor fit-up causes excessive gaps, distortion, extra rework, and higher consumption of filler metal.

The percentage of welds that must be repaired because they fail inspection; it measures quality performance and directly adds labor and material cost.

A workplace organization method using sort, set in order, shine, standardize, and sustain to reduce wasted motion, improve safety, and make welding operations more efficient.

The available production time divided by customer demand, representing the pace at which a weldment must be completed to meet the schedule.

Documented, repeatable steps and times for a task, used to train welders, reduce variation, and provide a baseline for improvement.

Scheduled inspection and servicing of welding machines, wire feeders, and fixtures to prevent breakdowns, downtime, and inconsistent weld quality.

A step-by-step review of a job that identifies hazards, assesses risk, and defines controls before work begins; it supports safe welding planning.

A short, focused safety briefing held before or during a shift to communicate hazards, controls, and reminders about safe work practices.

A structured review of an accident or near miss that determines what happened, why it happened, and what changes will prevent recurrence.

A problem-solving method that traces a defect or incident beyond immediate symptoms to the underlying system or process failure that allowed it.

A documented change to a process, procedure, or training program that eliminates the cause of a nonconformity or incident and prevents it from recurring.

A supervisor's ongoing process of observing performance, giving specific feedback, and guiding a welder to improve skills and independence.

Assigning a task, along with the authority and resources needed to complete it, to a team member while the supervisor retains accountability for the result.

A structured approach to addressing disagreements between team members by clarifying issues, listening to both sides, and agreeing on a workable solution.

A periodic, evidence-based discussion between supervisor and welder about results, behaviors, and development needs, linked to clear expectations and improvement goals.

A planned check of procedures, qualifications, records, and completed welds against the governing welding code to confirm requirements are being met.

Files documenting each welder's tests, certifications, continuity, and scope of qualification; supervisors use them to assign only qualified welders to code work.