IIW IWS study plan

Classify the main arc welding processes (SMAW, GMAW, GTAW, FCAW, SAW) by their heat source, electrode type and shielding method, and state one typical application for each

Explain how a welding power source characteristic (constant current versus constant voltage, drooping versus flat slope) matches a given process and electrode type

Identify the function of the key items of welding equipment for each process: wire feeder, torch, gas regulator and flowmeter, contact tip, nozzle, flux hopper

Describe the effect of the main process variables (current, voltage/arc length, travel speed, wire feed speed, gas flow rate) on bead shape, penetration and spatter

Interpret a continuous cooling transformation diagram and explain how cooling rate, carbon equivalent and plate thickness together determine the risk of hard, crack-sensitive microstructures

Apply the carbon equivalent formula to several steel compositions and justify the preheat decision for each

Distinguish the weldability problems of carbon-manganese steels, stainless steels and aluminium alloys and name the countermeasure for each

Explain hydrogen-assisted cold cracking and describe how hydrogen content, restraint and preheat/interpass temperature interact

Read a welded joint detail and identify the joint type, weld type, penetration requirement and welding position symbols

Explain how joint design and restraint influence residual stress and distortion, and select a mitigation method for a given case

Relate a static design load to the required throat thickness or weld size for a simple fillet and butt connection, using a stated allowable stress

Describe the purpose and content of a welding procedure specification and how essential variables are qualified

Sequence the fabrication workflow from drawing review and material traceability through cutting, fit-up, welding, inspection and release

Explain the purpose of a welding procedure qualification record and how it supports the welding procedure specification and welder qualification

Describe how welder performance qualification differs from procedure qualification and what conditions invalidate a qualification

List the main causes of weld defects introduced at the fabrication stage and match each to a preventive control

Compare visual, penetrant, magnetic particle, radiographic and ultrasonic testing by what they detect, their limitations and the stage at which they are applied

Explain how acceptance criteria in a standard are applied to an indicated imperfection and decide accept or reject for three described cases

Describe the correct sequence of non-destructive testing relative to post-weld heat treatment and hydrostatic testing, and justify the order

Interpret the information a welder or supervisor should extract from an inspection report before release

Identify the principal health hazards of arc welding (fume, ozone, ultraviolet and infrared radiation, noise, heat) and the control measure that ranks highest for each

Explain the electrical hazard mechanisms in arc welding and the protective measures for the welder and the surrounding area

Describe fire and explosion precautions for hot work, including permit-to-work, fire watch and the handling of gas cylinders

Select appropriate personal protective equipment for a stated welding task and justify each item

Set up a welding station for a stated process and position, including parameter selection, gas flow setting and work return connection

Diagnose three common weld imperfections from their visual appearance and state the parameter or technique change that corrects each

Describe how technique (travel angle, work angle, arc length, weaving, stringer versus weave) affects penetration and bead profile in the flat, vertical and overhead positions

Explain the storage, conditioning and re-drying requirements for covered electrodes and the consequence of ignoring them

Plan a small weldment: break the work into operations, estimate labour hours and consumable quantities, and build a simple cost estimate

Explain the supervisor's role in enforcing procedure compliance, traceability and document control on the shop floor

Prepare a short revision summary of the weakest areas identified in earlier weeks and self-test against it

Justify decisions in a mock scenario combining process choice, weldability, inspection and safety