ICC S2 Welding cheat sheet

A fillet weld gauge measures leg size and throat; the theoretical throat equals 0.707 times the leg length for a 90-degree joint with equal legs.

Undercut acceptance under AWS D1.1 is limited: for material under 1 inch thick, undercut shall not exceed 1/32 inch; deeper or longer undercut is a rejectable discontinuity.

Weld reinforcement limits on butt joints in D1.1 Table 6.1: flush or maximum 1/8 inch for welds subject to static load; excessive crown is a rejectable condition.

Visual inspection is performed after the weld has cooled and before final acceptance; the inspector verifies size, length, profile, and fit-up against the approved drawing.

Weld size for a fillet is the leg dimension; for a partial-joint-penetration groove weld it is the effective throat, not the groove depth.

Minimum fillet weld size depends on the thickness of the thicker part joined; D1.1 Table 5.8 sets the minimum leg based on base metal thickness.

The effective length of a fillet weld is the overall length minus twice the weld size at each end when end returns are absent, per common practice.

A discontinuity is a flaw in the weld; a defect is a discontinuity that exceeds acceptance criteria and requires repair or rejection.

A WPS is the written welding procedure; a PQR is the record of the test that qualified it; the WPS must be supported by a qualified PQR.

Essential variables for SMAW procedure qualification include filler metal classification, current type and polarity, and preheat/interpass temperature range.

A change from F4 (E7018) to F3 (E6010) filler metal group requires requalification because the filler metal classification change is essential.

The PQR test assembly is mechanically tested: two reduced-section tensile specimens and, for groove welds, guided bend specimens (root and face).

AWS D1.1 accepts prequalified joint details (Table 3.1) with prequalified WPS when base metal, filler, and process are within listed ranges.

Heat input in kJ/in equals (voltage x amperage x 60) divided by travel speed in inches per minute.

Preheat is specified based on base metal thickness and chemistry; higher carbon equivalent increases the required preheat to avoid hydrogen cracking.

Filler metal must be stored and handled per manufacturer requirements; low-hydrogen electrodes (E7018) require dry storage to prevent hydrogen pickup.

A welder performance qualification tests the individual's ability; procedure qualification tests the WPS; both are required before production welding.

Under D1.1, a welder qualified on a groove weld test is also qualified for fillet welds; a fillet-only qualification does not cover groove welds.

Welder qualification test position: 3G covers vertical groove welding; 4G covers overhead groove welding; 1G is flat groove.

A welder qualification remains valid indefinitely under D1.1 as long as the welder is continuously engaged in the process, unless requalification is triggered.

A welder who has not welded with a process for six months or more must requalify; the six-month lapse rule is a common D1.1 requirement.

Visual and bend tests are used for welder qualification; the test coupon must pass visual inspection and bend testing per the code.

A welder qualified with one process (e.g., SMAW) is not qualified for another process (e.g., FCAW) without separate qualification.

Welder qualification records must identify the welder, the process, the position, the test coupon, and the test results.

Ultrasonic testing (UT) detects internal discontinuities and is commonly required for complete-joint-penetration groove welds in D1.1.

Radiographic testing (RT) reveals internal volumetric discontinuities; it is less effective for planar defects oriented parallel to the beam.

Magnetic particle testing (MT) detects surface and near-surface discontinuities in ferromagnetic material only.

Penetrant testing (PT) detects surface-breaking discontinuities in nonporous materials; it does not detect internal defects.

Acceptance criteria for UT in D1.1 are based on discontinuity length and amplitude relative to reference standards; rejectable indications must be repaired.

Visual inspection is the most common method and must precede other NDE; surface must be clean and free of slag, spatter, and scale before MT or PT.

The acceptance standard for RT/UT of CJP groove welds in D1.1 is found in Clause 6; inspectors compare indications to the specified quality level.

NDE personnel should be qualified to a recognized standard (e.g., ASNT SNT-TC-1A) and certified for the method and level being performed.

A325 and A490 are the common high-strength structural bolts; A490 is heat-treated and has higher tensile strength than A325.

Turn-of-nut is a pretensioning method: the nut is tightened a specified fraction of a turn after snug-tight condition, per the bolt length and diameter.

The calibrated wrench method requires a torque wrench calibrated daily and for each bolt size and condition.

Direct-tension indicators (DTIs) have bumps that compress during tightening; the gap is measured with a feeler gauge to verify pretension.

Snug-tight is the condition where the plies are in firm contact; it is the required condition for bearing-type connections in many cases.

Slip-critical connections require pretensioned bolts; the slip coefficient depends on the faying surface condition (e.g., unpainted clean mill scale).

Bolt holes for structural connections are typically standard holes, oversized holes, short-slotted, or long-slotted; hole type affects the connection design.

Inspection of bolted connections includes verifying bolt grade, length, hole size, washer use, and the tightening method and verification.