Certificate Scope Versus the Welder's Actual Production Task
A welder's EN ISO 9606-1 certificate, issued by the employer's examiner, lists: process 135, material group 1, butt weld, single side, plate thickness 8 mm (qualified 8–16 mm), position PA (flat). The welder is assigned to a production job: 6 mm plate, process 135, group 1, butt weld, welded in the PB (horizontal-vertical) position, with a permanent ceramic backing left in place. The welder says the certificate covers 'MAG butt welding in group 1', so the job is fine. The QA engineer must decide whether to release the job to this welder and what the certificate should have said.
1. Identify every essential variable where the production job differs from the certificate scope.
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Compare job against certificate:
| Variable | Certificate | Production job | Match? |
|---|---|---|---|
| Process | 135 | 135 | Yes |
| Material group | 1 | 1 | Yes |
| Joint type | Butt | Butt | Yes |
| Thickness | 8–16 mm | 6 mm | No - below minimum |
| Position | PA | PB | No - different position |
| Welding condition | Single side | Backing left in place | No - backing changes the condition |
Three mismatches: thickness, position and the backing condition. The welder's summary ('MAG butt in group 1') is far too broad.
2. Explain the effect of the permanent ceramic backing on the qualification, and whether the existing certificate could ever cover it.
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A test welded from one side without backing is the more demanding condition; it qualifies the same joint welded with a removable backing only if the standard's rules allow, but a permanent backing that remains in the joint is a distinct welding condition and must be reflected in the qualification. The existing certificate, obtained without backing, does not state or imply coverage of a permanent-backing weld. To cover the production job the welder would need a test piece welded with the same permanent backing, and the certificate entry must state the backing condition explicitly.
Leaving a ceramic backing in place also affects inspection and fitness-for-service, so it is not a trivial detail.
3. Give your release decision and the minimum re-qualification needed to cover the production job.
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Decision: do not release the job to this welder on the current certificate - three essential variables are outside scope.
Minimum re-qualification: a test piece in 6 mm (or a thickness that brackets 6 mm), process 135, group 1, butt, welded in PB, with permanent ceramic backing, tested to the standard's requirements. On success the certificate should read, for example: 135, group 1, butt, PB, permanent backing, t = 6 mm (qualified range stated). Alternatively, reassign the job to a welder whose certificate already matches all variables. Document the check so the scope decision is auditable.