IIW IWE study plan

Map every arc welding process (SMAW, GMAW variants, GTAW, SAW, FCAW, plasma) to its heat-source characteristics, current type, and typical duty cycle, then explain in writing why each suits particular thickness ranges.

Derive the heat input formula from arc voltage, current, and travel speed, and calculate heat input for five worked examples spanning 0.8 kJ/mm to 4 kJ/mm.

Relate t8/5 cooling time to heat input, preheat, and plate thickness for a 20 mm C-Mn steel joint, and state the direction of change when each variable moves.

Sketch a power source output characteristic (constant current vs constant voltage vs drooping) and match each to a process and its self-regulation behaviour.

List the main weldability tests (CEV, Pcm, CTS, Tekken, implant, Gleeble simulation) and state what each one actually measures.

Construct continuous-cooling-transformation diagrams for a C-Mn steel and a low-alloy steel and identify the microstructural path at three cooling rates each.

Explain hydrogen-assisted cold cracking by tracing the four interacting factors (hydrogen, susceptible microstructure, stress, temperature) and describe how each is controlled in practice.

Classify stainless steels (ferritic, martensitic, austenitic, duplex, superduplex) by composition, and predict their solidification mode and sensitisation risk.

Describe the metallurgical consequences of welding aluminium alloys (heat-affected-zone softening in 6xxx/7xxx, oxide film, hydrogen porosity) and the practical countermeasures.

Interpret a Schaeffler or WRC-1992 diagram to predict ferrite content for three dissimilar austenitic joints.

Apply the standard joint types (butt, T, corner, lap, edge) and weld types (groove, fillet, plug) to a fabricated assembly and justify each selection.

Calculate weld throat thickness, leg length, and effective length for a fillet weld under static shear, and compare against a butt weld of equal capacity.

Explain the design basis behind preheat and interpass temperature tables and derive a preheat recommendation for a given CEV and thickness.

Describe residual stress generation and the main mitigation routes (sequence, peening, PWHT, low-transformation-temperature consumables) with their limits.

Sketch weld symbols to ISO 2553 conventions for six joint configurations and read them back correctly.

Assemble the document hierarchy of a welded fabrication: contract specification, application standard, welding procedure specification, procedure qualification record, welder qualification, and inspection plan.

Write a welding procedure specification for one GMAW butt joint that is complete enough for a competent third party to execute without asking questions.

Explain the essential, supplementary essential, and non-essential variables in procedure qualification and classify ten example changes correctly.

Describe welder qualification ranges (position, thickness, process, diameter) and state how a welder's qualification is extended or revoked.

Draft a manufacturing sequence including fit-up, tacking, welding, and post-weld operations, with hold points and witness points identified.

Explain fabrication tolerances for distortion, angularity, and misalignment, and state their effect on fatigue and static performance.

Describe the causes and remedies of the main distortion modes (longitudinal, transverse, angular, bowing, buckling) for a thin-plate stiffened panel.

Explain welding position limitations and how position affects deposition rate, defect risk, and procedure qualification.

Describe the role of consumable control (storage, baking, re-drying, hydrogen designation) and its link back to cold cracking.

Outline a root-cause analysis for a production porosity problem, ranking candidate causes by likelihood and testability.

Match non-destructive examination methods (visual, penetrant, magnetic particle, radiographic, ultrasonic, phased array, eddy current) to the defect types they detect best and their blind spots.

Explain acceptance levels for porosity, lack of fusion, and undercut in a typical application standard and state how they differ between quality levels.

Describe fatigue design approaches (nominal stress, hot-spot, notch stress) and the role of weld toe geometry and post-weld improvement techniques.

Interpret a radiographic image description and a phased-array indication report, and state the follow-up action for each.

Explain the principles of destructive testing (tensile, bend, impact, hardness, macrograph) and what each proves about a procedure qualification.

Identify the principal welding health hazards (fume, ozone, hexavalent chromium, noise, radiation, electric shock, fire, confined space) and the control hierarchy for each.

Explain fume extraction and respiratory protection selection, and state when local exhaust ventilation alone is insufficient.

Describe the content and purpose of the environmental aspects of welding (energy, shielding gas, waste, spill control) and the practical reduction measures.

List the roles and responsibilities of the welding coordinator, inspection body, and notified body in certification, and distinguish accreditation from certification.

Explain traceability requirements for consumables and base materials, and how a certificate of conformity supports a fabrication record.

Structure a technical report for a welding engineering investigation: scope, method, evidence, analysis, conclusion, recommendation, and traceability of sources.

Integrate content from all domains into a single worked engineering judgement, showing how process, metallurgy, design, inspection, and quality decisions constrain one another.

Write a concise technical note defending a welding-related decision to a non-specialist project manager in under 400 words.

Review your own weak areas from weeks 1 to 7 and produce a prioritised revision list with a scheduled action for each.

Complete a timed 60-question mixed-domain self-test and record accuracy by domain to identify the remaining gaps.