IIW IWT study plan

Map every arc welding process (SMAW, GMAW, GTAW, FCAW, SAW, plasma) to its power source type, duty cycle and typical current range, writing a one-page comparison table from memory.

Explain the operating principle and typical application window of at least four pressure-welding or high-energy processes (resistance spot, flash butt, friction stir, electron beam or laser).

Describe the effect of polarity, electrode configuration and shielding gas composition on arc stability and mode of metal transfer for GMAW.

Classify the main steel families (carbon, low-alloy, stainless, duplex) and state one welding behaviour risk for each, such as hardenability, sensitisation or hot cracking.

Sketch the iron-carbon diagram and mark the eutectoid point, A1 and A3 lines, then state what happens to a 0.2% C and a 0.8% C steel on slow cooling.

Derive the carbon equivalent of three given steel compositions using both the CE and Pcm formulas and predict cracking susceptibility for each.

Explain the metallurgical events in the heat-affected zone of a low-alloy steel weld, naming each sub-zone and the transformation it undergoes.

Describe the mechanism of hydrogen-assisted cold cracking and list the four factors that must coincide for it to occur.

Explain solidification cracking and lamellar tearing: cause, susceptible microstructure and one preventive measure for each.

State the purpose, typical temperature range and effect on properties of stress-relief, normalising and solution-annealing post-weld heat treatments.

Explain how heat input (kJ/mm) is calculated from voltage, current and travel speed, and compute it for three worked examples.

Describe the effect of heat input and preheat on cooling rate, hardness and toughness in the HAZ, and state the practical limits for a given steel.

Compare butt, T-joint, corner and lap joints for load path, weldability and inspection access, and select one for a stated loading case with justification.

Explain the design basis of a fillet weld under shear and compute the throat thickness needed for a given load per unit length.

Identify the main weld imperfections that are design-driven (misalignment, poor fit-up, excessive restraint) and state the design change that removes each.

Sequence a fabrication route from cutting to final inspection for a pressure-retaining component, naming the hold points and the documentation produced at each.

Match each common non-destructive test method (visual, penetrant, magnetic particle, ultrasonic, radiographic) to the defect types it detects and its main limitation.

Explain how a welding procedure specification is qualified by a procedure qualification record and how a welder is qualified by a performance test, including the range of approval concept.

Interpret an acceptance criterion for porosity or undercut against a quality level and decide accept or reject for three described indications.

Describe the purpose of preheat, interpass temperature control and post-weld heat treatment within the fabrication sequence, not just as metallurgical measures.

Explain the structure of a quality management system for welding and the role of the responsible welding coordinator at each level of responsibility.

Distinguish between procedure qualification, welder qualification and production monitoring, and state who owns each.

Calculate the cost per metre of a fillet weld from labour, consumables, power and overhead inputs, and identify which input dominates.

Compare the economics of increasing deposition efficiency versus reducing rework, using a simple numerical example.

Explain how welding position, joint access and mechanisation level affect productivity and the choice of process.

Describe how a tensile, bend, impact and hardness test are performed on a welded test piece and what each proves about the joint.

Explain the significance of the fracture appearance of a Charpy specimen and the transition temperature concept.

Describe how macro- and micro-sections are used to assess penetration, HAZ width and defect distribution.

Explain how residual stress arises from restrained shrinkage and how it is measured or relieved.

State the acceptance logic for a procedure qualification test that fails one impact test, and the re-test rules in principle.

List the principal hazards of arc welding (fume, UV and IR radiation, electric shock, fire, noise, confined-space atmosphere) and the control measure that sits highest in the hierarchy for each.

Explain the health basis of welding fume control, including extraction, respiratory protection and the difference between dilution and local exhaust ventilation.

Describe safe practice for gas cylinders, flashback arrestors and hot-work permits.

Set up and run a bead on plate in at least two processes, and record the parameter set used (current, voltage, travel speed, gas flow).

Diagnose three common bead defects (porosity, lack of fusion, spatter) from their appearance and state the parameter change that corrects each.

Describe at least three specialised applications (e.g. narrow-gap welding, cladding or hardfacing, dissimilar-metal joining, additive manufacturing) and state the key metallurgical or equipment challenge of each.

Explain the problems of welding dissimilar metals: dilution, carbon migration, thermal expansion mismatch and the role of a buttering layer.

Explain the principles of weld overlay and hardfacing, including dilution control and the choice of deposit chemistry.

Revisit the highest-weight domains (1, 2, 3, 4) and answer 40 mixed recall questions, recording the score per domain.

Consolidate a one-page formula and definition sheet covering heat input, carbon equivalent, fillet throat, duty cycle and range of qualification.