IIW IWP study plan

Map the IIW IWP syllabus for welding processes and equipment, listing the main process families (arc, resistance, oxy-fuel, high-energy) and their key variants.

Explain the operating principles of SMAW, GMAW, GTAW, FCAW, and SAW, including current types, polarity, and typical applications.

Identify the major equipment components for each process (power source, wire feeder, torch, shielding gas system) and their functions.

Compare deposition rates, heat input, and typical joint penetration for at least four common arc processes.

Classify steels, stainless steels, aluminium alloys, and copper alloys by composition and typical weldability.

Describe the iron-carbon diagram and the effect of cooling rate on microstructure and hardness in the heat-affected zone.

Explain hydrogen-assisted cracking, solidification cracking, and lamellar tearing in terms of material and process causes.

Relate process selection (from week 1) to material behaviour, e.g., shielding gas choice for stainless steel or heat input limits for aluminium.

Interpret a carbon equivalent value and state its implication for preheat and cracking risk.

Define weldability and list the factors that influence it (composition, thickness, joint design, process, restraint).

Explain the practical measures to avoid cracking in high-carbon-equivalent steels, including preheat, interpass control, and post-weld heat treatment.

Describe the fabrication sequence for a typical welded assembly, from fit-up to final inspection.

Identify common weld discontinuities (porosity, slag inclusion, lack of fusion, undercut) and their process/material causes.

Outline the effect of restraint and joint design on residual stress and distortion.

Explain the purpose and content of a welding procedure specification (WPS) and a procedure qualification record (PQR).

Describe the essential variables in procedure qualification and how they affect the validity of a WPS.

Interpret basic weld symbols and joint designs on a drawing, including butt, fillet, and T-joints.

Calculate heat input from welding parameters (voltage, current, travel speed) and state its influence on design and material properties.

Outline the design considerations for static and fatigue-loaded welded joints, including stress concentration and weld toe geometry.

List the main non-destructive testing methods (visual, penetrant, magnetic particle, ultrasonic, radiographic) and their principles.

Select the appropriate NDT method for a given defect type, material, and joint configuration, with justification.

Describe the scope of destructive tests (tensile, bend, impact, hardness, macro) used in procedure qualification.

Explain the role of a quality plan, inspection and test plan (ITP), and hold points in fabrication.

Interpret acceptance criteria for common weld defects according to a typical quality standard.

Identify the main health hazards in welding (fume, gases, radiation, noise, electric shock) and their control measures.

Explain the principles of fume extraction, ventilation, and personal protective equipment selection.

Describe the supervisor's responsibilities for safety briefings, permits, and housekeeping in a welding workshop.

Outline the elements of production planning for a welded fabrication, including resource allocation, sequence, and time estimation.

Explain how supervision ensures compliance with the WPS and quality plan during production.

Demonstrate correct setup and safe operation for at least two processes (e.g., SMAW and GMAW) on a practice plate.

Produce a butt weld and a fillet weld that meet visual acceptance criteria for uniformity, penetration, and profile.

Adjust welding parameters to control spatter, undercut, and penetration on a test piece.

Perform a visual inspection of your own welds and record defects with their likely causes.

Describe the practical assessment format for the IWP and the criteria used to judge weld quality.

Review all eight domains using a self-made summary sheet of key facts, standards references, and definitions.

Complete a timed mock examination covering all domains and review incorrect answers to identify weak areas.

Revisit the two weakest domains from the mock exam and produce a focused revision list.

Recite the essential variables for one WPS and the acceptance criteria for one NDT method from memory.