FCAW NC II study plan

Map every clause of a sample welding procedure specification (WPS) for FCAW to the variables you must control at the arc: current, voltage, wire feed speed, travel speed, stick-out, gas flow, and preheat.

Demonstrate correct donning, inspection, and doffing of a welding helmet, respirator, leathers, and hearing protection, and state the failure mode each item guards against.

Identify the ventilation and fume-extraction controls required for flux-cored arc welding indoors, and explain why self-shielded and gas-shielded wires demand different fume control.

Set up a hot-work permit scenario: locate the nearest fire extinguisher, clear combustibles within the required radius, and assign a fire watch for 30 minutes after completion.

Label the hazards of the FCAW arc circuit, including open-circuit voltage, secondary voltage, and the risk of electric shock when changing wire or nozzles.

Set the FCAW machine from scratch: select polarity, connect the work lead and gun, thread the wire through the drive rolls, and set wire feed speed and voltage to a given WPS.

Diagnose and correct three common feed faults: birdnesting at the drive rolls, burnback into the contact tip, and wire slipping from incorrect tension.

Adjust stick-out and travel angle deliberately and describe how each change shifts penetration, bead width, and spatter.

Run stringer beads in the flat position on mild steel and record the parameters used for each bead.

Explain why gas-shielded FCAW uses direct current electrode positive and what changes when you switch to a self-shielded wire.

Prepare plate edges by grinding and cleaning to bright metal, then set a single-V butt joint with the correct root gap, land, and included angle.

Fit up a T-joint and a lap joint within tolerance and verify squareness and alignment before tacking.

Tack weld in the correct sequence to control distortion and explain the effect of tack size and placement.

Execute a root pass on a single-V butt joint in the flat position with consistent penetration and no burn-through.

Identify the causes of lack of fusion and incomplete penetration in the root and correct them on the next pass.

Complete multi-pass welds on a single-V butt joint in the flat and horizontal positions, maintaining interpass temperature and cleaning between passes.

Weld in the vertical-up position with a weave or step technique and control the puddle to avoid undercut and slag entrapment.

Weld in the overhead position and adjust current, travel speed, and electrode angle to keep the puddle manageable.

Troubleshoot porosity by isolating shielding gas loss, contaminated base metal, and excessive stick-out, and correct each cause.

Record and justify any parameter change you make away from the WPS, and state when a procedure qualification would be required.

Perform a visual inspection of your own test plates against acceptance criteria and classify each discontinuity by type, size, and location.

Distinguish porosity, slag inclusion, undercut, overlap, spatter, arc strike, and crater cracks on sight and state the likely process cause of each.

Describe how penetrant testing, magnetic particle testing, ultrasonic testing, and radiographic testing each detect subsurface or surface flaws, and select an appropriate method for a given joint.

Prepare a weld for destructive testing by cutting and etching a cross-section, and interpret the macro etch for penetration and fusion.

Explain the difference between a procedure qualification record and welder performance qualification, and what each proves.

Read a fabrication drawing and extract dimensions, weld symbols, joint types, and any supplementary symbols such as all-around or field welds.

Decode the standard welding symbol: reference line, arrow, tail, groove and fillet symbols, size, length, pitch, and tail references.

Convert a written joint description into a correct welding symbol and vice versa for at least ten cases.

Apply dimensional tolerances and fit-up limits from a specification to decide whether a joint is acceptable before welding.

Identify the base metal specification and filler metal classification called out on a drawing and confirm they match the WPS.

Inspect and maintain the FCAW power source, wire feeder, gun, liner, and contact tip on a scheduled basis, and replace worn consumables.

Diagnose power tool faults such as a binding grinder, a damaged cord, and a worn disc, and remove the tool from service correctly.

Perform post-weld cleaning: remove slag and spatter, grind welds to profile, and finish surfaces without gouging the base metal.

Complete weld documentation including welder identification, WPS number, date, joint location, and inspection results.

Explain how weld records support traceability and what must be retained for a qualified procedure.

Apply a plan-do-check-act cycle to a recurring defect in your own work, identifying the root cause and verifying that the corrective action reduced the defect rate.

Audit your work area against housekeeping, fume control, and electrical safety requirements and close out every finding.

Explain how welding variables, consumable storage, and fit-up accuracy feed into a quality management system and continuous improvement.

Re-inspect all test plates from earlier weeks and confirm the defects you identified were correctly classified.

Assemble a personal study summary that maps each exam domain to the evidence you produced during the eight weeks.