Iiw Welding Guidelines

IIW Guideline
INTERNATIONAL WELDING INSPECTION

PERSONNEL
Minimum Requirements for the Education,
Examination and Qualification
IAB-041r3-08
IAB INTERNATIONAL AUTHORISATION BOARD
IAB-041r3-08

International Welding Inspection Personnel
Approved J uly 2008 2 of 95

MINIMUM REQUIREMENTS FOR THE EDUCATION, TRAINING, EXAMINATION AND
QUALIFICATION OF INSPECTION PERSONNEL

INTERNATIONAL WELDING INSPECTION PERSONNEL

(IWIP)

Guideline of the International Institute of Welding

INTERNATIONAL AUTHORISATION BOARD

Published by: IIW IAB Secretariat
C/o ISQ
Taguspark Apartado 012
P 2780-994 Porto Salvo Oeiras
PORTUGAL

Tel: +351.21.4211351
Fax: +351.21.4228122
E-mail: ewf-iab@isq.pt
IAB-041r3-08
IAB-041r3-08
TABLE OF CONTENTS
Preface..... 4

SECTION I: Minimum Requirements for the Education and training of International Welding
Inspection Personnel
1. Introduction... 5
2. Levels of Inspection Personnel......... 5
3. Standard Routes to Qualification ..... 6
4. Alternative Route to Qualification........... 10
5. Distance learning programs............ 11
6. Recognition of NDT certification.................................. 11
7. Definitions....... 11
7.1. Education and training...... 11
7.2. Qualification.... 11
7.3. Relevant inspection experience...... 11
7.4. Certification.... 12
8. The Inspectors Role ..................................................................................................... 12
8.1. Reports ...................................................................................................................... 13
8.2. Certification system ...................................................................................................... 13
9. Syllabus... 14

Theoretical education: Welding Technology Modules........ 15
1. Module 1. Welding processes and equipment. 15
2. Module 2. Materials and their behaviour during welding... 32
3. Module 3. Construction and design.......51
4. Module 4. Fabrication, applications engineering.... 59

Theoretical education: Welding Inspection Modules... 69
1. General introduction to welding inspection..... 69
2. Mechanical tests on welded joint ..... 70
3. Weld Imperfections. 71
4. Testing methods......... 72
5. Quality Assurance. Principles and levels.... 80
6. Management of inspection function. 81
7. Practical work...... 82

Theoretical education: Basic technology Module 0 ..... 83

SECTION II: Minimum requirements for experience, examination and qualification
1. Introduction...... 85
2. Route from IWI-B to IWI-S and from IWI-S to IWI-C. 85
3. Verification of visual acuity. 85
4. Approval of courses 85
5. Examination Board ........ 85
6. Examination procedures.............. 85
6.1 Theoretical written examination......... 86
6.2 Practical examination...... 86
7. Re-examination....... 86
8. Diploma of the International Institute of Welding ...... 87
9. Appeals procedure...... 87
10. Transition arrangements... 87

Appendix I. Equipment ....................... ......... 88
Appendix II. ANB detailed assessment.... ...... 89
IAB-041r3-08

Preface

This document is based upon the European Welding Inspection Personnel Guideline as
developed by the European Federation for Welding, J oining and Cutting (EWF), through an
Agreement first signed in 19 J uly, 1997, at the Annual Meeting of the International Institute of
Welding in San Francisco, California, USA and which has been renewed and further developed
since then.

Any EWF ANB is permitted to issue EWF diplomas equivalent to IIW ones that have been
issued by the same ANB.

Copies of this document are available from the IIW IAB Secretariat or their designated
distributor.
IAB-041r3-08

Section I: Minimum requirements for the education and training of

1. Introduction

This guideline for the education of International Welding Inspection Personnel to be employed in
the job function of Inspector has been devised by members of the Working Group A3b of
International Authorisation Board (IAB) of the International Institute of Welding (IIW). It is
designed to provide the core education in welding and inspection technology required by those
responsible for performing inspection tasks at various levels. It is possible that additional
training and/or experience may be required beyond the core education to meet the requirements
of specific applications or job functions.

Section 1 of this guideline covers the minimum requirements for education and training, agreed
upon by all national welding societies within the IIW, in terms of themes, keywords and times
devoted to them. It will be revised periodically by the WG A3b to take into account any changes
that may affect the state of the art. Students having successfully completed this course of
education will be expected to be capable of applying welding inspection technology as covered
by this guideline. Section 2 of this document covers examination and qualification.

2. Levels of Inspection Personnel

This Guideline sets out the education for three levels of personnel, as follow:

COMPREHENSIVE (IWI-C): A candidate completing the Comprehensive level of training
under this programme shall possess an intimate knowledge of welding and inspection theory
and application. This knowledge base will enable the candidate to understand and effectively
apply the knowledge in the areas of:
Non-destructive, mechanical testing and visual welding iInspection techniques
Review and application of welding instructions, welding procedure specifications and
qualified welding procedures.
Material specifications
Consumable specifications
Engineering drawings, joint fit up and workmanship tolerances
Preparation and application of welding procedure specifications,.
Preparation and implementation of inspection procedures and acceptance criteria
Quality Control Programmes
Welding equipment functionality and application/limitations
International and national welder qualification programmes
Identification of weld imperfections associated with pre-production, fabrication and
post fabrication
Inspection requirements based on national specifications or codes

STANDARD (IWI-S): A candidate completing the Standard level of training under this
programme shall possess an advanced knowledge of welding and inspection theory and
application. This knowledge base will enable the candidate to understand and apply the
knowledge in the areas of:

Non-destructive, mechanical testing and visual welding inspection
techniques
IAB-041r3-08
Application of welding instructions, welding procedure specifications and qualified
welding procedures.
Welding procedure specifications and welding instructions and qualified of
procedures
Inspection procedures and acceptance criteria
Welding equipment functionality and applications/limitations
International and national welder qualification programmes
Identification of weld imperfections associated with pre-production, fabrication
and post fabrication
Inspection requirements based on national specifications or codes

BASIC (IWI-B): A candidate completing the Basic level of training under this program shall
posses a general knowledge of welding and inspection application and theory. This knowledge
base will enable the candidate to effectively understand the following topics:
Non-destructive, mechanical testing and visual inspection techniques
Welding procedure specifications
Inspection procedures and acceptance criteria
Identification of weld imperfections associated with pre-production, fabrication and
post fabrication

3. Standard Routes to Qualification

This Guideline provides two principal routes to qualification, as follows:

3.1 Route 1 is for those fulfilling the access conditions defined in Fig. 1 at the relevant level.
Candidates may decide, after self-assessment on the basis of prior learning and/or
experience, whether to take the Welding Technology Module first, or proceed directly to
the intermediate examination through the Approved Training Body (ATB) assessment. A
pass in the intermediate examination is required before taken the Welding Inspection
Module examination.
At the description of the ANB, and only for students attending the full stantard courses
training, the Welding Technology Module exam (intermediate examination) can be
performed at the same day of the Welding Inspection Technology Module exam

3.2 Route 2 is for those already holding an existing IIW qualification who may proceed direct
to the Welding Inspection Module at the relevant level.

The routes to qualification are summarised in Fig. 1 Standard Route and in Fig. 2 there
are presented other routes "Routes no. 2, 3 and 4". The figures in brackets are the
recommended minimum number of teaching hours specified for each education module.
A teaching hour will contain at least 50 minutes of direct teaching time.

For IWI-S only the Guideline recognises the current situation in several countries, by
providing entry for inspectors not meeting the full specified access conditions but having
at least 5 years authenticated experience in general engineering inspection (Route 3).
Such inspectors may decide through self-assessment whether to complete the 40 hours
of Basic Technology Module 0 first or to proceed directly to the intermediate examination
following the Module 0. The Welding Technology Module WT II is mandatory for Route 3.
IAB-041r3-08

The Guideline also provides for the experienced IWI-B to progress to IWI-S via Route 4
as shown in Fig. 2. The candidate may decide whether or not to take Module 0 or WT II
on the basis of self-assessment and after ATB assessment. His/her knowledge will be
checked by intermediate examinations and a failure will require that the candidate take a
respective omitted module.

For all routes, if the candidate fails an intermediate examination, having exercised an
option to proceed directly to that examination, he/she must take the omitted training
module before re-sitting the examination failed. Welding Inspection Module examination
can only be taken after passing intermediate examination of Welding Technology
Module (see last sentence for route 1).

The rules for the conduct of final examinations by the Authorised National Body are
prescribed in Section 2 of this Guideline. The intermediate examinations are mandatory
and are the responsibility of the ATB to ensure that those entering the next module have
achieved the required level of knowledge.

IAB-041r3-08
Figure 1. Standard Route no. 1

- ATB Assessment

Figure 2. Routes no. 2, 3 and 4

Education Modules Education Modules IWI
Route No. Access conditions Welding Technology Welding Inspection Diploma
IWI-C
Welding
Inspection
Module WI III
(97 h)
Welding
Technology
Module WT III
(122 h)
ATB
Check
Those satisfying the access
1 conditions for I/EWT or higher
IWI-S
Welding
Inspection
Module WI II
(63 h)
Welding
Technology
Module WT II
(94 h)
ATB
Check
Those satisfying the access
1 conditions for IWS/EWS or higher
IWI-B
Welding
Inspection
Module WI I
(40 h)
Welding
Technology
Module WT I
(65 h)
ATB
Check
Professional workers or persons
having relevant experience in
1 metalworking professions
ATB
Check
IWI-C
Self
assessment
Welding
Inspection
Module WI III
(97 h)
Self
assessment
Welding
Inspection
Module WI II
(63 h)
IWI-S
Self
assessment
Welding
Inspection
Module WI I
(40)
IWI-B
- Intermediate examination

- Final examination
IAB-041r3-08

- A single examination but module WT II is compulsory for Route 3, optional for Route 4.

- ATB Assessment

Standard education IWI-S. Route 3: Inspectors with at least 5 years experience in general
engineering inspection.

Route No. Basic Technology Education Modules Education Modules IWI
Access cond. Module Welding Technology Welding Inspection Diploma

Welding
Inspection
Module WI III
(97 h)
Welding
Technology
Module WT III
(122 h)
IWI-C
IWI-S
Welding
Inspection
Module WI II
(63 h)
Welding
Technology
Module WT II
(94 h)
ATB
Check
2 years
experience
3
Module 0
(40 h)
3
4
IWI-B
Welding
Inspection
Module WI I
(40 h)
5 years
experience
2 years
experience
!
ATB
Check
ATB
Check
ATB
Check
2 Holders of IWT/EWT Diploma

2 Holders of IWP/EWP Diploma
Holders of an IWI-Standard Diploma
Holders of an IWI-Basic Diploma
ATB
Check
!
Self
assessment
Welding
Inspection
Module WI II
(63 h)
IWI-S
Self
assessment
Welding
Inspection
Module WI III
(97 h)
IWI-C
2 Holders of IWS/EWS
Diploma
- Intermediate examination

- Final examination
IAB-041r3-08
4. Alternative route to qualification (Fig. 3)

Figure 3. Alternative versus Standard Routes for IWIP qualifications

An applicant must submit the following documentation to the ANB with the application form:

IWI-C:
IWT/EWT diploma or evidence of satisfying the access conditions for IWT/EWT.
A curriculum vitae (CV)/ resume containing the following professional information:
- Evidence of at least three years job function in welding and inspection at the technologist
level (in a period of 4 years before application)
- A justification of the candidates experience, training, and education to become IWI-C
(may include other test results)

IWI-S:
IWS/EWS diploma or evidence of satisfying the access conditions for IWS/EWS.
A curriculum vitae (CV)/ resume containing the following professional information
- Evidence of at least two years job function in welding and inspection at the specialist
level (in a period of 3 years before application)
- A justification of the candidates experience, training, and education to become IWI-S

IWI-B:
IWP/EWP diploma or evidence of satisfying the access conditions for IWP/EWP.
A curriculum vitae (CV)/ resume containing professional information
- Evidence that the candidate was working in welding and inspection at the practitioner
level during last two years before application.
- A justification of the candidates experience, training, and education to become IWI-B

IWIP
Diploma
WI III
WI II
WI I
Standard Route
(see also Figure 1)
yes
Final exams
IWI-C
IWI-S
IWI-B
Project or Technical
Interview (see app. II)
yes
yes
no
no
yes
Paper assessment (of the ANB detailed assessment; see appendix II)
Alternative
Route
WT III
WT II
WT I
At the discretion of the ANB
Module 4 of
WT III, WT II
or WT I
ANB check no
no
Professional
assessment interview
An applicant must submit to the ANB, together with an application form, the information
described in the item 4 of the Section 1 of this guideline depending of the IWIP level
sought
IAB-041r3-08
The ANB shall determine, by paper check, if the application is suitable for further detailed
assessment.

5. Distance Learning Programs

Distance Learning Programs can be implemented in accordance with IAB-195-2004 Guideline
under ANB control.

6. Recognition of NDT certification

Those having certification in NDT in accordance with ISO 9712, EN 473 or equivalent
recognised by the ANB may be granted exemption from the NDT parts of the modules for
Welding Inspection on a method by method basis, but not from the final examination. The
approval of such arrangements is at the discretion of the ANB.

It is recommended that NDT Level 2, 3 Certification should apply to Module Welding
Inspection ll and Welding Inspection lll. NDT Level 1 certification should apply to Module
Welding Inspection ll.

7. Definitions

7.1 Education and training: A process of instruction in relevant theory and practice that
takes the form of courses to an approved syllabus and periods of practical work under
qualified supervision (but shall not include the use of specimens used in the practical
examination). All educational courses leading to the award of qualification covered by this
Guideline shall be approved by the Authorised National Body.

7.2 Qualification: A demonstration, conducted by the Authorised National Body, involving an
examination of the knowledge and skill related to specified criteria. Success in this
examination leads to the issue, by the ANB, of an appropriate diploma.

7.3 Relevant inspection experience: The period during which the candidate performed
welding inspection as his main activity under qualified supervision including personal
application of inspection to materials, parts or structures but not including tests performed
during training courses.

7.4 Certification: The procedure leading to a written testimony of an individual's competence
demonstrated by examination and assessment of experience and subsequent
surveillance to confirm that the competence has been retained. This does not form part
of the Guideline and is normally the subject of an independent certification scheme.

8. The Inspectors role

The inspectors role begins well before welding starts, continues during the welding operation,
involves action after welding is completed, and is finished only when the results are properly
reported. As part of the quality system, inspection activities are defined in an inspection and test
plan, which clearly describes what is required. The inspector is frequently responsible for
producing documents that ensure traceability of the components and related fabricating action.

Prior to welding, the inspector must be assured that the materials are correct and that the shop
has approved welding procedures and appropriately qualified welders. Written procedures and
competent operators are important to the production of a quality-welded product, but the actual
execution of the weld is also a critical point for the inspector. Once the inspector is satisfied that
IAB-041r3-08
all is in order for the welding to proceed, the task becomes one of witnessing and monitoring.
There are two basic interests at this point: ensuring that the written procedures are being
followed; and, of course, watching for any physical signs of non-conformance of the final
product.

The inspectors responsibilities are to verify base metals and welding consumables, observe the
fit-up and preparation for the weld, and watch the welding operation itself. Once the welding is
completed, a new series of inspection tasks begin, which starts with executing an inspection
program according to an approved procedure, keeping track of the status of examination and
testing and selecting specific welds for further NDT or mechanical testing.

Heat treatment (such as preheating, post-heating and post-weld heat treatment) can be a
critical parameter in a welding operation and the inspector is often required to ensure that it has
been done properly. Heat treatment must be carried out following an approved written
procedure. The inspector must know enough about the technique, the equipment and the
reports to have confidence in the results.

8.1 Reports

When preparation, production and inspection are over, the inspector must collate the
observations, checklists, and results into a report that is structured to meet the needs of
the client, a jurisdiction, or a code. This report is the document of reference, which could
allow the tracing of a production parameter that proves after years of service to be
contributing to a failure. It allows the tracing of responsibility to a specific supplier or
contractor.

One or more interim reports might well be necessary to show progress during a long or
complicated construction project. Reports must detail the inspection stages, parameters,
and results, including corrective actions if required. It is important to recognise quality
related problems into a contract as early as possible. Interim reports and observations
are extremely valuable as they provide engineering and production personnel with
information they might not otherwise be aware of. The inspectors observations might
highlight quality problems that could, perhaps, be remedied by design or production
changes if found early enough. The inspector should remember to quantify observations
where possible.

Typical duties of a welding inspector are as follows:
1) Interpretation of drawings and specifications;
2) Verification of procedure (WPS) and welder or welding operator qualifications;
3) Verifying the application of approved welding procedures;
4) Selection of production test samples;
5) Interpretation of test results;
6) Preparation of reports and keeping of records;
7) Preparation of inspectionprocedures;
8) Check the correct application of NDT methods.

The authority to stop work or call for immediate remedial action to resolve a quality
problem is particularly important in defining the responsibility of the inspector.

8.2 Certification system

This Guideline is intended to provide a curriculum for the education of Welding
Inspectors only, and does not imply that the individual is competent to complete the job
functions of a Welding Inspector. Relevant certification programmes for the certification
of Welding Inspectors must be used to verify the competency and detail job functions.
IAB-041r3-08

9. Syllabus

It is not obligatory to follow exactly the order of the modules and topics given in this Guideline, and
choice in the arrangement of the syllabus is permitted.

However, caution must be exercised by the ANB to ensure that any changes in the order of
presentations of the Welding Technology modules and in the Welding Inspection modules do
not alter the points of entry intended in Figs. 1 and 2.

Note:
This guideline is dividided in two main modules they are:
- Welding Technology (WT)
- Welding Inspection (WI)

Each main module is divided in three (3) levels, corresponding the IWIP qualification levels

Main
Modules
Modules
Levels
IWIP
Qualification Levels
WT III IWI-C
WT II IWI-S Welding Technology - WT
WT I IWI-B
WI III IWI-C
WI II IWI-S
Welding Inspection
Technology - WI
WI I IWI-B

IAB-041r3-08

Theoretical education: Welding Technology Modules

Number of Course Hours in Modules

WT III WT II WT I

Module 1. Welding processes and equipment 25 13 11

1.1 General introduction to welding technology:
Objectives for IWI-C and IWI-S: Understand (for IWI-S - gain knowledge to understand in general)
developments in welding processes including accepted terminology, standards and abbreviations.

Objectives for IWI-B: Understand the difference between welding processes, and to get familiarized with
terminology, standards and abbreviations.
WT III WT II WT I Module
Scope Teaching hours
1 1 1
History
Definitions
Schematic presentation of welding processes
Terminology
Picture and brief description with characteristics
Applicability of the most common welding processes
General applications for welding
Abbreviations used for welding processes
Hints in use for welding processes
Classification of welding processes (IIW, ISO, CEN and national standards)
x
x
x
x
x
x
x
x
x
x

x
x
x
x
x
x
x
x
x

x
x
x
x
x
x
x
x
x
Expected results for IWI-C
1. List the differences between each major type of welding process, e.g. arc, resistance, flame, forge, etc.
2. Differentiate between processes with reference to standards.
3. Recognise a welding process by the common abbreviation.
4. Explain the historical evolution of welding

Expected results for IWI-S
1. Outline the major differences between each main type of welding process, e.g. fusion arc, resistance,
flame, forge, etc.
2. Differentiate between processes with reference to standards.
3. Recognise a welding process by the common abbreviation.

Expected results for IWI-B
1. Identify the differences between each major type of welding process.
2. Designate a welding process by its common abbreviation.

IAB-041r3-08

1.2 Oxy-gas welding and related processes:
Objectives for IWI-C, IWI-S and IWI-B: Understand (for IWI-S - gain knowledge to understand in general;
for IWI-B associate) the fundamentals of oxy -gas combustion, characteristics of the different fuel gases,
equipment, safety and typical applications.
1 1 1
Process principles
Range of application
Types of flames
Characteristics of fuel gases, (acetylene, propane, etc.)
Combustion reactions
Temperature distribution effects
Equipment
Acetylene cylinder component parts
Fuel gas generation
Handling and storage of gases
Typical joint design for welding
Methods of welding techniques, rightward, leftward
Standards for filler materials
Welding applications, typical problems and imperfections
Special techniques and their methods of use (preheating, straightening,
cleaning, etc.)
Health and safety issues specific to the process

X
X
X
X
X
X
X
X
X
X
X
X
X
X

X
X
X
X
X
X
X
X
X
X

X
X
X
X
X

X
X
X
X
X

X

X
X

X
X
X
X

X
X
1. Explain the characteristics of the three flame types and reasons for application of each.
2. Detail the characteristics of flames produced by different fuel gases.
3. Define the potential hazards and methods of safe handling and working
3. Explain the purpose and working principle of each component of the equipment
4. Interpret appropriate standards.
6 Define the range of application for this process and potential problems to overcome.

1. Outline the characteristics of the three flame types and typical applications for each type.
2. Compare the characteristics of flames produced by different fuel gases.
3. Recognise and define in general the potential hazards and methods of safe handling, storage and
working practices.
4. Outline the purpose and working principle of each component of the equipment.
5. Basic knowledge on how to use appropriate standards.
6. Identify the limitations and the range of application of the process and recognise how to overcome the
potential problems associated with this process.

1. Interpret the characteristics of the different types of flames and their application.
2. Illustrate potential hazards and methods of safe handling and working.
3. Name the working principle of each component of the equipment.
4. Translate appropriate standards

IAB-041r3-08

1.3 Electrotechnics: a review
Objectives for IWI-B: Have an outline working knowledge of electricity and the characteristics of
the most important electrical components used in electrical welding power sources.
0 0 1
Basics of electricity and electronics (define current, voltage and resistance)
Ohm's Law
Parallel and serial circuits
Direct current (DC), polarity, alternating current (AC)
Magnetism in welding
Capacity, condenser
Transformer, and rectifying bridge (half wave and full wave rectification) ..
Transistor, thyristor, Inductance, inductors
Hazard
Health and safety
X
X
X
X

X
X

X
X
Expected results for IWI-C and IWI-S : Not applicable.

Expected results for IWI-B:
1. General outline of current, voltage and resistance.
2. Recognise and give examples of the functions of the main components of a welding power.source
3. Give examples of the main differences between DC and AC current.
4. Show practical application of knowledge of electricity to welding.

IAB-041r3-08
1.4 The arc
Objective for IWI-C and IWI-S: Understand (for IWI-S - gain knowledge to understand in general) the
fundamentals of an electric arc, its characteristics, limitations and application in welding, including arc
ability problems.

Objective for IWI-B:
Describe what is an electric arc, its characteristics, limitations and application in welding.
1 1 1
Arc physics (producing an electric arc, the main arc areas, stability of the
arc)
Voltage distribution across the arc
Heat generation at the cathode and anode
Polarity and arc characteristics in AC and DC and its control for the key
welding processes
Influence on the welding process
Temperature distribution in the arc and effects
Influence of the magnetic fields on the arc (why, how to solve)
Limits of application

X
X
X

X
X
X
X
X

X
X
X

X

X
X
X

X
X
X

X

X
X
X
1. Explain in detail the fundamental physics of an electrical arc, including the main parameters influencing
arc stability.
2. Detail the generation of heat in the arc and the arc voltage distribution.
3. Outline the influence of magnetic fields on the electric arc.
4. Predict how to solve magnetic deflection problems.
5. Explain arc characteristics for DC and AC including control and limitations.

1. Describe an electrical arc; its main areas and their importance to welding and arc stability.
2. Outline the generation of heat in the arc and the arc voltage distribution.
3. Give examples of the influence of magnetic fields on the electric arc.
4. Outline appropriate solutions to solve magnetic deflection problems.
5. Describe arc characteristics for DC and AC.

1. Give examples of the main arc areas, and their importance to welding.
2. List the hot arc areas and their influence on the weld pool.
3. Explain the arc characteristics of DC and AC.
4. Outline the influence of magnetic fields on an electric arc.
5. Give examples of solving magnetic deflection problems.

IAB-041r3-08
1.5 Power sources for arc welding
Objectives for IWI-C and IWI-S: Understand (for IWI-S gain knowledge to understand in
general) the characteristics and main components of arc welding power
sources.

Objectives for IWI-B: Gain an outline
working knowledge on arc welding power sources characteristics and components.

2 1 1
Power source classification, types and characteristics
(static and generators, and each sub-group)
Power source electrical characteristics (static and dynamic
Relationship between static characteristic and welding process
Control of the electrical static characteristic (flat and drooping)
Arc stability for the main processes (MMA, TIG, MIG/MAG, SAW, PAW)
The operation working point
Inverter technology
Power sources controlled by a CPU
Stability of processes in AC and DC
AC (sine wave and square wave) and DC power sources
Open circuit voltage, short circuit current, power factor of transformers
Duty cycle of a power source and typical values for the most
common arc welding processes
Voltage losses, relationship between welding current value and
cable section
Pulse welding techniques
Arc striking methods and devices, slope up and down, pre- and post-flow
Current and voltage setting (electromagnetic and electronic devices)
Standards related with welding power sources and their requirements

X
X
X
X
X
X
X
X
X
X
X

X

X
X
X
X
X

X
X
X

X
X
X
X
X
X
X

X

X
X
X

X

X
X
X

X
X

X

X

X
X
X

X

1. Explain each type of arc welding power source for both AC and DC including the most common devices
used.
2. For each type of welding power source detail the static and dynamic electrical characteristics, operation
point and control of arc stability.
3. Explain the meaning of open circuit voltage, arc voltage short circuit current, duty cycle of a power
source, voltage losses, and welding current to cable cross section relationship.
4. Explain the differences of the above characteristics for each type of power source and welding process
for a specific application.
5. Recognise the various functions and switches on different power sources and their effects.

Expected results for IWI-S and IWI-B
1. Outline how each type of welding power source works (AC and DC) including the most common devices
used.
2. Describe for each type of arc welding power source the static characteristic, operation point and control
of arc stability.
3. Outline the meaning of open circuit voltage, arc voltage short circuit current, duty cycle of a power
source, voltage losses, and current to cable section relationship.
4. Be able select the appropriate power sources for a given welding process.
5. Recognise the various settings and switches on different power sources and their effects

IAB-041r3-08
1.6 Introduction to Gas-shielded arc welding
Objectives forIWI-C and IWI-S: Understand (for IWI-S gain knowledge to understand in
general) the principles and physical phenomena of gas shielded welding
processes

Objective for IWI-B: Gain an outline working knowledge on the principles of gas shielded welding
processes
1 1 1
Physical phenomena
Operating principles of TIG, MIG/MAG and flux-cored
Shielding gases (inert, active) and their effect on arc characteristics
Handling and storage of gases
Filler materials
Standards (international and national) for shielding gases and filler materials
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
1. Explain the characteristics and operating principles of TIG, MIG/MAG and Flux-cored welding.
2. Interpret arc characteristics associated with each type of shielding gas used for each process.
3. Detail the methods for safe handling and storage of shielding gases.
4. Interpretation and use of standards for shielding gases and filler materials.

1. Describe and compare the characteristics and operating principles of TIG, MIG/MAG and Flux-cored
welding.
2. Compare and outline arc characteristics associated with each type of shielding gas used for each
process.
3. Outline the methods for safe handling and storage of shielding gases.
4. Demonstrate the use of standards for shielding gases and filler materials.

1. Differentiate the operating principles of TIG, MIG/MAG and Flux-cored welding.
2. Outline the arc characteristics associated with each type of shielding gas used for each process.
3. Demonstrate a general knowledge of the basic rules of handling and storing shielding gases.

IAB-041r3-08
1.7 Tungsten-inert gas welding
Objective IWI-C and IWI-S: Understand (for IWI-S gain knowledge to understand in
general) TIG welding fundamentals, including equipment, applications, procedures and specific
problems.

Objective IWI-B: Explain TIG welding fundamentals, including equipment, and applications.
2 1 1
Power source characteristics
Methods for arc ignition and necessary equipment
Equipment and accessories: torches, gas lens, control panel, up and
down slope, pulse techniques
Effect of current type and polarity: DC(+), DC(-) and AC
Specific requirements for different materials, e.g. aluminium
Consumables: shielding gases, filler materials, electrodes
Welding parameters: current, voltage, travel speed, gas flow rate
J oint preparation: typical joint design for welding, fit-up, cleaning
Welding procedures
Special techniques: spot-welding, key-hole, hot-wire, orbital welding, tube
to tube and tube to sheet , and others
Standards for filler materials, electrodes, and gases
Welding applications, typical problems and how to solve them
Health and safety issues specific to the process
X
X

X
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X
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X
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X
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X

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X
1. Explain and compare in detail the principles of TIG welding including arc ignition methods and their
applications.
2. Explain the selection of appropriate type of current, polarity, shielding gas and electrode type according
to application.
3. Identify the range of application, appropriate joint preparations and potential problems to be overcome
4. Identify appropriate welding parameters for particular applications.
5. Explain the purpose and functions of each component of the equipment and accessories.
7. Define potential hazards and methods of safe handling and working.
8. Recognise the various settings and switches on different TIG power sources and their effects.

1. Describe and compare the principles of TIG welding including arc ignition methods and their
applications.
2. Explain the selection of appropriate type of current, polarity, shielding gas and electrode type
according to the application.
3. Identify the range of application, appropriate joint preparations and potential problems to be
overcome.
4. Identify an appropriate range of welding parameters for particular applications.
6. Interpret the use of appropriate standards.
7. Describe potential hazards and methods of safe handling and working..

1. Outline TIG welding including arc ignition methods and their most common applications.
2. Give examples of the most common applications for each type of current, polarity and electrode. type
3. Give examples of the most important applications and select the appropriate values for welding
parameters.
4. Know how to use and care for the equipment and accessories.
5. Read given standards for consumables
6. Give examples of TIG applications, joint preparation and potential problems to overcome.
7. Outline potential hazards and methods of safe handling and working.

IAB-041r3-08
1.8 MIG / MAG and Flux Cored welding

Objectives for IWI-C, IWI-S and IWI-B: Understand in detail (for IWI-S - gain knowledge to
to understand in genera; for IWI-B - explain) MIG/MAG and Flux Cored Arc welding fundamentals, including
equipment, applications, procedures and common problems

2 2 1
Power source characteristics for conventional process and CPU controlled
power sources
Effect of current type and polarity
Equipment and accessories: torches, wire feeders, hose assembly, control
panel
Metal transfer modes (dip, globular, spray, and pulsed), and their
application
Welding parameters and settings: current, voltage, travel speed, gas flow
rate, etc.
Consumables: shielding gases, filler materials (solid and flux cored wires),
and their combinations
Welding procedures
Special techniques: electro -gas welding, high efficiency processes
Standards for filler materials, and gases
Welding applications, typical problems and how to solve them
Health and safety specific to the process
X

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X

X

X
X
X
X
X
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X
X

X

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X

X

X
X
X
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X
X
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X

X

X

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X
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X

X
X
X
1. Explain and compare in detail the principles of MIG/MAG and Flux Cored Arc welding including metal
transfer modes and their applications.
2. Compare the selection of appropriate type of current, polarity and electrode according to application.
3. Identify the range of application, appropriate joint preparations and potential problems to be overcome.
7. Interpret appropriate standards
8. Explain selection of consumables.
9. Recognise the various settings and switches on different MIG/MAG and Flux Cored Arc welding power
sources and their effects.

1. Describe and compare the principles of MIG/MAG and Flux Cored Arc welding including metal transfer
modes and their applications.
2. Identify the most common applications for each type of current, polarity and electrode.
4. Identify an appropriate range of welding parameters for particular applications.
5. Describe potential hazards and methods of safe handling and working.
6. Outline the various functions of the main components of the equipment and accessories.
7. Demonstrate the use of appropriate standards
8. Give examples on how consumables should be selected..

1. Outline MIG/MAG and Flux Cored Arc welding, comparing metal transfer modes and their application.
2. Give examples of the most common applications of each type of current, polarity and electrode.
3. Give examples of the most important applications and select appropriate welding parameters.
5. Read given standards for consumables.
6. Give examples of MIG/MAG application range, joint preparation and potential problems to overcome.

IAB-041r3-08
1.9 Manual Metal arc welding
Objectives for IWI-C, IWI-S and IWI-B: Understand (for IWI-S - gain knowledge
to understand in general; for IWI-B - explain) MMA welding fundamentals, including equipment,
applications, procedures and common problems.
2 2 1
Process principles and arc characteristics
Power source characteristics applicable to MMA (open circuit voltage, static
and dynamic characteristics, types of current, arc striking methods)
Equipment and accessories
Process application range and typical problems
Covered electrodes (functions of the coating and rod, types of electrodes,
slag-metal and gas-meta covered l reactions)
Production of electrodes (how, typical defects)
Handling and storage of electrodes (storage environment, redrying
Electrode classification (International and national standards)
Selection of covered electrodes for applications
Welding parameters: current, voltage, run out length, etc
J oint preparation: typical joint design for welding, fit-up, cleaning, welding
position
Relationship between electrode diameter and current range, rod material,
electrode length and welding position
Welding procedures
Special techniques (gravity welding, vertical down welding, on-site welding)
Health and safety specific to this process
X
X

X
X
X

X
X
X
X
X
X

X

X
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X
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X

X
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X
1. Explain in detail the principles of MMA welding including with particular emphasis on special techniques, arc
striking methods and their applications.
2. Explain the selection of appropriate type of current, polarity and electrode according to application.
4. Identify appropriate welding parameters for particular applications
5. Define potential hazards and methods of safe handling and working
7. Explain the handling, control and storage of the various types of electrodes.
9. Identify the influence of electrode coating on droplet transfer and weld metal properties..

1. Describe the principles of MMA welding
2. Describe how to do the selection of appropriate type of current, polarity and electrode according to
application.
4. Identify an appropriate range of welding parameters for particular applications
5. Describe potential hazards and methods of safe handling and working
6. Outline the purpose and functions of each component of the equipment and accessories.
7. Describe the appropriate methods of handling, control and storage of the various types of electrodes.
8. Demonstrate the use of appropriate standards.
9. Describe the influence of electrode coating on droplet transfer and weld metal properties.

1. Outline MMA welding working principles, special techniques, arc striking methods and their applications.
2. Outline the handling and storage of each type of consumable.
3. Give examples of the most important applications and select appropriate welding parameters.
5. Read given standards for electrodes.
6. Give examples of MMA application range, joint preparation and potential problems to overcome.

IAB-041r3-08
1.10 Submerged-arc welding
Objectives for IWI-C: Understand SAW welding
fundamentals, including equipment, applications, procedures and common problems.
2 0 0
SAW process principles and arc characteristics
Power source characteristics applicable to SAW (open circuit voltage, static
and dynamic characteristics, types of current, arc striking methods)
Process application range and typical problems
Consumables (functions of the flux and wire, types of flux and wire, wire-flux
combination, slag-metal and gas-metal reactions)
Production of consumables (how, typical defects)
Handling and storage of consumables (storage environment, redrying)
Consumable classification (International and national standards)
Welding parameters: current, voltage, travel speed, type of flux and particle
size, stick-out, etc
J oint preparation: typical joint design for welding, fit-up, cleaning.
Relation between the wire flux combination and the characteristics of
deposited material..
Welding procedures...
Single-wire and multi -wire techniques
Special techniques (strip-cladding, iron-powder addition, cold and hot wire
addition)
Health and safety specific to SAW process
X
X

X
X
X

X
X
X
X

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X

X
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X
X

1. Explain the principles of SAW process including arc striking methods, special techniques and their
applications.
2. Explain the selection of appropriate type of current, polarity and consumable according to application.
6. Explain slag-metal/gas-metal reactions and their influence on weld metal properties

Not applicable
IAB-041r3-08
1.11 Resistance welding
Objectives for IWI-C: Understand resistance welding
fundamentals, applications and specifications, including common problems and their solution.

1 0 0
Process principles and overview on types of processes (spot, projection, butt,
seam, and flash)
J oule effect and temperature distribution
Process application range and typical problems (welding thin to thick
material, welding of coated/ painted materials, welding dissimilar materials,
mass effect, shunt effect, Peltier effect, resistance brazing)
Electrodes (functions, types, shapes, material)
Electrode classification (International and national standards)
Welding parameters: current, pressure, time, type of current, pulse, etc
Relation between welding parameters and the characteristics of the weld
nugget
Monitoring systems, process control, measuring
Specific testing
Welding procedures
Health and safety specific to this process

X
X
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X
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X
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X
X

1. Explain the principles of resistance welding and the application of the various sub-processes.
2. Explain the selection of appropriate parameters to give sound welds.
3. Identify the range of application, appropriate material preparation and potential problems to be overcome.
8. Recognise the various settings and switches on different power sources and their effects.
Not applicable

IAB-041r3-08

1.12 Other welding processes
Objectives for IWI-C: Understand principles, the filed of application and common
problems of plasma; electron beam; Laser, electro-slag, friction; friction stir, magnetically impelled arc butt
(MIAB); magnetic pulse welding, ultrasonic; explosive; diffusion; aluminothermic; high-frequency; stud,
cold-pressure welding, hybrid processes, etc.

3 0 0
Basic principles for all mentioned processes
Heat generation for each type of process
Equipment and accessories for each type of process
Typical process applications and problems
Consumables
Welding parameters for each process
Relation between welding parameters and joint configuration
Comparison between high energy processes
Health and safety specific to the processes
Appropriate national and international standards for each process
X
X
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X

1. Explain the principles of the processes mentioned in the objective and their application.
2. Determine appropriate applications for each type of process, and the precautions necessary to achieve
a sound weld.
3. Describe the welding parameters, appropriate joint preparations and potential problems to be overcome
for each process for a given application.
4. Explain the purpose and functions of each major component of the equipment and accessories.

Not applicable

IAB-041r3-08

1.13 Cutting and other edge preparation processes
Objectives for IWI-C, IWI-S and IWI-B: Understand for IWI-S and IWI-B
interpret the basic principles and the field of application of the most common cutting and edge preparation
processes used in welded constructions, including equipment, procedures and common problems.

WT III WT II WT I Qualification Module
2 2 1
Survey of edge preparation processes
Mechanical cutting
Principles of flame and flame powder cutting, equipment, applications and
auxiliaries
Flame cutting parameters, edge quality, oxygen purity grades
Materials suitable for flame cutting
Basic principles of the various arc cutting processes (arc-air, carbon and
metal-arc, oxy-arc cutting, gauging with carbon electrode) equipment and
auxiliaries
Materials suitable for arc-cutting, applications, cutting parameters for each
process
Fundamentals of plasma cutting, equipment and auxiliaries
Materials suitable for plasma cutting, applications, cutting parameters, cutting
gases
Plasma cutting special applications (under water cutting, cutting with water
vortex)
Plasma gouging
Fundamentals of electron beam drilling and Laser cutting, equipment,
parameters, applications
Fundamentals of water jet cutting, equipment, parameters, applications
Fundamentals of arc gouging and flame gouging, parameters and
applications
Appropriate national and international standards for each process
Health and safety
X
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X
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X
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X
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1. Explain the principles of: mechanical, flame, arc, plasma, electron beam, Laser, and water jet cutting.
2. Explain the influence of each parameter for the above mentioned processes on the edge surface quality.
3. Identify the range of applications for: flame, arc, plasma, electron beam, and water jet cutting.
4. Identify potential risks, hazards and methods of safe handling and working.

1. Explain the principles of: mechanical, flame, arc, plasma, electron beam, Laser, and water jet cutting.
2. Identify the characteristic parameters for the above mentioned processes
3. Make a comparison among different edge preparation processes, considering technical and economic
aspects.
4. Evaluate potential risks and hazards related with edge preparation processes.

1. Explain the principles of flame, arc, plasma, Laser, water jet cutting and gouging.
2. Identify the influence of characteristic parameters on the edge surface quality.
3. Point out the range of applications for flame, arc, plasma and Laser cutting.
4. Outline potential risks, hazards and methods of safe handling and working.

IAB-041r3-08

1.14 Surfacing
Objectives for IWI-C: Understand the fundamentals and field of application of the
most common surfacing techniques including equipment, procedures and
common problems.
1 0 0
Working principles and applications for cladding techniques (rolling,
explosive, strip, plasma-MIG, electroslag, Laser, etc)
Working principles and applications of the spraying techniques (flame
spraying with powder, flame spraying with wire, arc spraying with powder, arc
spraying with wire, plasma spraying with powder, HVOF spraying
Equipment and parameters for each technique
Surface preparation of the base material
Spraying materials
Sprayed layer structure, and substrate structure
"Cold " and "fusion techniques"
Applications and special problems
Health and safety

X

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X
X
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X

1. Explain the principles and characteristics of the most common cladding techniques.
2. Explain the principles o and characteristics f the most common spraying techniques.
3. Evaluate the quality of a surfacing layer with respect to the base material preparation.
4. Predict the different applications between "cold" and "fusion" spraying techniques.
5. Describe the most common spraying techniques and their industrial applications.
6. Define potential risks, hazards and methods of safe handling and working.

Not applicable

IAB-041r3-08

1.15 Fully Mechanised processes and robotics

Objectives for IWI-C: Understand the principle and industrial applications of welding
Mechanisation and the use of robotics in welding, including applications and systems.

1 0 0
Survey of welding mechanisation for higher productivity
Robotics, mechanisation, and automation: difference, advantages
disadvantages and applications
Robotics (on line and off line programming, simulation, flexible manufacturing
systems)
CAD/CAM systems
Virtual factory (factory simulation)
Seam tracking, types and typical applications
Arc sensing, magnetic induction, vision system
Narrow gap welding (SAW, MIG/MAG, TIG)
Orbital welding (MIG/MAG, TIG)
Special problems
Gases and filler materials (optimisation for mechanised welding)..
Health and safety
X

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X
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X
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X

1. Predict solutions for higher productivity in welding using robotics, automation and mechanisation.
2. Explain the differences between off line and on line programming.
3. Explain the principle and applications of each type of seam tracking system.
4. Explain the principle, benefits and applications of narrow gap and orbital welding.

Not applicable

IAB-041r3-08
1.16 Brazing and soldering
Objectives for IWI-C, IWI-S, IWI-B: Understand (the fundamentals)
and the field of application of brazing and soldering, procedures, equipment, applications, and common
problems
1 1 1
Fundamentals of brazing and soldering (bonding mechanisms, surface
tension, wetting, capillary)
MIG/ MAG pulsed brazing
Survey of brazing and soldering techniques, equipment, range of applications
Consumables and fluxes for brazing and soldering, types, applications, and
main functions of the fluxes
Brazable materials, brazing requisites
High vacuum brazing, brazing under controlled atmosphere
Braze welding
Survey of soldering techniques (dip, wave flow, vapour phase, soldering)
Brazing and soldering advantages and disadvantages
Health and safety

X
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X
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1. Explain in detail each brazing and soldering technique.
2. Compare in detail each type of brazing and soldering technique with fusion welding.
3. Explain the precautions to obtain a sound joint using brazing or soldering techniques.
4. Describe the different applications for each brazing and soldering techniques.
5. Describe the types and characteristics of consumable and flux to used in certain applications.

1. Describe the different techniques for brazing and soldering.
2. Compare each type of brazing and soldering technique with fusion welding.
3. Illustrate the standard operating procedures for brazing or soldering techniques.
4. Describe the most relevant applications for each brazing and soldering techniques.
5. Describe the influence of surface preparation in brazing and soldering techniques.
6. Describe the types and characteristics of consumables and fluxes employed.
7. Define risks, hazards and methods of safe handling and working.

IAB-041r3-08

1.17 Joining processes for plastics
Objectives for IWI-C: Understand the basic principles involved in joining plastics,
including the common techniques, equipment, applications, procedures and common problems.

1 0 0
General information on materials and joining processes
Study the operating principle for each type of process
Hot plate welding, butt fusion, hot gas welding, extrusion welding, induction
welding, resistance welding, implant welding, high frequency, friction, electro-
fusion welding, ultrasonic welding, vibration welding, adhesive bonding
Control of welding parameters, types of equipment, joint design
Advantages and disadvantages
Health and safety
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X
X
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X

1. Explain the fundamentals of each joining process.
2. Explain the precautions to obtain a sound joint for each process.
3. Describe the different applications for each joining process.

Not applicable

1.18 Joining processes for advanced materials
Objectives for IWI-C: Understand the general principles of joining ceramics and composites,
including the common techniques, applications, procedures and common problems.

1 0 0
General information on ceramics and composites and typical joining
processes
General study of the operating principles for each process
Advantages and disadvantages
X

X
X
X

1. Explain the fundamentals of joining ceramics and composites.
2. Identify precautions to produce a sound joint for some advanced materials.

Not applicable

IAB-041r3-08
WT III WT II WT I

Module 2. Materials and their behaviour during welding 52 41 25

2.1 Manufacture and designation of steels
Objectives for IWI-C, IWI-S and IWI-B: Understand (for IWI-S and IWI-B describe) the principles of iron
metallurgy, steel making and designation of steels
1 1 1
Introduction to metallurgy of steel making
Steel making processes
Special treatments
Deoxidation
Designation of steels
Defects in steels
X
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Expected results for IWI-C and IWI-S
1. Explain the various steel making processes.
2. Detail the reasons for and principles of special treatments in steel making.
3. Explain the different methods of deoxidation
4. Explain potential defects, their cause and elimination.
5. Explain the designation of steels
1. Interpret the various steel making processes.
2. Name the reasons for and the principles of special treatments in steel making.
3. Describe the different methods of deoxidation.
4. Describe potential defects, their cause and elimination.
5. Describe the designation of steels.

IAB-041r3-08
2.2 Testing materials and the weld joint
Objectives for IWI-C, IWI-S and IWI-B: Understand (for IWI-S and IWI-B name) the fundamental aspects o
testing materials with particular reference to weldment test pieces
11 7 6
Review of destructive testing
Testing welded joints (technological specimen
Destructive testing
Tensile and bend tests
Impact tests (ductile and brittle fracture, transition temperature)
Hardness tests
Special tests (CTOD, etc.)
Fatigue tests
Creep tests
Corrosion tests
Overview on related standards
X
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1. Discuss the objectives of each destructive testing and the limitations of the data generated
2. Describe in detail each of the major testing methods and the parameters to be measured
3. Predict when and why special testing should be specified

1. Discuss the objectives of each destructive testing and the limitations of the data generated.
2. Describe each of the major testing methods and the parameters to be measured.
3. Predict when and why special testing should be specified

1. Discuss the reasons for destructive testing.
2. Describe major testing methods and the parameters to be measured.

IAB-041r3-08
2.3. Structure and properties of pure metals
Objectives for IWI-C, IWI-S and IWI-B: Understand (for IWI-S and IWI-B describe) the principles of
solidification, deformation and recrystallisation and the characteristics of typical metal structures.
2 1 1
Crystalline structures
Crystal lattice structure types
Micro structures of metals
Solid state transformation
Elastic/plastic deformation
Recrystallisation
Cold and hot deformation
Work hardening and strain aging
Mechanical properties (influence of temperature, etc.)
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1. Explain basic crystalline structures.
2. Explain in detail elastic-plastic deformation and their role in cold and hot deformation.
3. Explain recrystallisation giving examples.
4. Demonstrate understanding of the relationship between mechanical properties and temperature, grain size
and structure

1. Describe basic crystalline structures.
2. Explain elastic-plastic deformation and their role in cold and hot deformation.
3. Describe recrystallisation, giving examples.
4. Demonstrate understanding of the relationship between mechanical properties and temperature, grain
size and structure.

IAB-041r3-08
2.4 Alloys and phase diagrams
Objectives for IWI-C, IWI-S and IWI-B: Understand (for IWI-S and IWI-B - describe the principles of
alloying, the structures of alloys and their representation in phase diagrams.

4 2 1
Pure metals and alloys
Alloying elements
Solidification
Solid solution crystals
Structure of alloys
Type of structures
Strengthening mechanisms (cold working, solid solution, precipitation
hardening, grain size control, solid state transformation)
Intermetallic compounds
Ageing
Basic types of phase diagrams (non-, fully- and partly soluble components).
Fe-C equilibrium diagram
Influence of alloy elements on the Fe-C equilibrium diagram
Iron-alloys with closed gamma-loop, with broadened gamma-area
The structure of castings
Segregation and coring
Mechanical properties
Ternary diagrams
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1. Describe crystalline lattice distortion due to alloying elements and subsequent structural changes.
2. Explain in detail solidification structure and segregation with relevant examples.
3. Detail mechanisms of precipitation, types of precipitates and their location within the microstructure.
4. Explain in detail the principles of transformation and conditions under which it occurs.
5. Detail the principles of strengthening mechanisms with appropriate examples.
6. Interpret the relationship between microstructure and mechanical properties.
7. Explain in detail the principles of phase diagrams, their construction and use.
8. Interpret the relationship between microstructure and phase diagrams.

1. Describe crystalline lattice distortion due to alloying elements and subsequent structural changes.
2. Describe the principles of strengthening mechanisms with appropriate examples.
3. Interpret the relationship between microstructure and phase diagrams.
4. Outline the significant points(temperatures, weight %) of from the Fe-C diagram.

1. Point out solidification structure and segregation on relevant examples.
2. Outline the principles of transformation and conditions under which it occurs.
3. Describe the principles of strengthening mechanisms with appropriate examples.
4. Outline the significant points (temperatures, weight %) of the Fe-C diagram.

IAB-041r3-08
2.5 Iron-Carbon alloys
Objectives for IWI-C, IWI-S and IWI-B: Understand (for IWI-S and IWI-B name) the principles of alloying
iron with carbon, the crystalline structures developed under equilibrium and non-equilibrium conditions and
their representation in phase and transformation diagrams.
2 2 1
Equilibrium and non equilibrium transformations
Time-temperature-transformation (TTT) diagrams
Different types of TTT diagrams (isothermal, continuous cooling, TTT
diagrams for welding)
Influence of alloying elements
Carbide forming elements
Control of toughness
T
8/5
concept
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1. Interpret the reasons for different structures under equilibrium and non-equilibrium conditions.
2. Explain the use of TTT diagrams (isothermal, continuous cooling, TTT diagrams for welding) to show the
development of particular steel microstructures.
3. Predict the changes strengthening structure caused by alloying additions with reference to TTT
diagrams.
4. Detail hardening mechanisms with reference to the microstructure developed.
5. Interpret the relationship between microstructure and toughness.

1. Interpret the reasons for different structures under equilibrium and non-equilibrium conditions.
2. Explain the use of TTT diagrams (isothermal, continuous cooling, TTT diagrams for welding) to show the
development of particular steel microstructures.
3. Identify the changes strengthening structure caused by alloying additions with reference to TTT
diagrams.
4. Describe hardening mechanisms with reference to the microstructure developed.
5. Interpret the relationship between microstructure and toughness.

1. Identify TTT diagrams (isothermal, continuous cooling, TTT diagrams for welding)
2. Compare the changes strengthening structure caused by alloying additions with reference to TTT
diagrams.
3. Desribe hardening mechanisms with reference to the microstructure developed.
4. Draw the relationship between microstructure and toughness

IAB-041r3-08
2.6 Heat treatments of base materials and welded joints
Objectives for IWI-C, IWI-S and IWI-B: Understand (for IWI-S and IWI-B name) the metallurgical
transformations of materials during different heat treatment.
2 2 1
Normalising
Hardening
Quenching and tempering
Solution annealing
Homogenisation
Stress relieving (PWHT
Recrystallisation annealing
Precipitation hardening
Heat treatment in practice
Heat treatment equipment
Regulations (codes and technical reports)
Temperature measurement and recording
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Expected Results for IWI-C
1. Explain each of the major heat treatments and their objectives.
2. Explain the mechanisms of structural changes, which take place when a material is heat treated.
3. Interpret the effects of temperature and time on transformations including the effect of temperature
change rate.
4. Explain code requirements for heat treatment and why they are stipulated.
5. Predict the necessity to heat treatment after welding depending of the type and thickness of steel, the
application and the code.
6. Deduce appropriate heat treatment equipment for a given application.
7. Detail appropriate temperature measurement and recording methods for typical applications.

Expected Results for IWI-S
1. Explain each of the major heat treatments and their objectives.
2. Explain the mechanisms of structural changes, which take place when a material is heat treated.
3. Describe the effects of temperature and time on transformations including the effect of temperature
change rate.
4. Describe code requirements for heat treatment.
5. Predict the necessity to heat treatment after welding depending of the type and thickness of steel, the
6. Name appropriate heat treatment equipment for a given application.
7. Detail appropriate temperature measurement and recording methods for typical applications.

Expected Results for IWI-B
1. Describe the major heat treatments and their objectives.
2. Associate the effects of temperature and time on transformations of temperature change.
3. Describe code requirements for heat treatment and why they are stipulated.
4. Discuss the necessity to heat treatment after welding depending of the type and thickness of steel, the
5. Name heat treatment equipment for a given application.
6. Describe temperature measurement and recording methods for typical applications.

IAB-041r3-08
2.7 Structure of the welded joint
Objectives for IWI-C, IWI-S and IWI-B: Understand (for IWI-S get knowledge; for IWI-B get general
understanding) the formation on the different metallurgical structures within a weldment.
2 2 1
Thermal field
Equations for the heat distribution
Heat input and efficiency of heat input
Peak temperature
Cooling rate and thermal cycle
Dilution
Weld metal
Solidification of weld pool
Structure of the weld
Fusion line
Heat-affected zone (HAZ)
Microstructure of HAZ
Grain growth and grain refinement
Relationship grain size toughness (equations from regression)
Transition temperature
Weldability (definitions)
Single and multi -pass welding
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1. Explain the temperature distribution in welds and the microstructure formed as a result for a single pass
weld versus a multi pass weld.
2. Interpret the effects of heat input, cooling rate and multi -pass operation on weld metal solidification and
the microstructure formed for a single pass weld versus a multi pass weld.
3. Explain the effects of the weld protection, the type of consumables on the microstructure of the weld
metal and on it properties for a single pass weld versus a multi pass weld.
4. Detail areas of HAZ, the reasons for grain size and microstructure changes and their effects on prop-
erties for a single pass weld versus a multi pass weld.
5. Discuss the various aspects of weldability
6. Deduce the micro structural and weldability changes induced by dilution

1. Explain the temperature distribution in welds and the microstructure formed as a result for a single pass
weld versus a multi pass weld.
2. Interpret the effects of heat input, cooling rate and multi -pass operation on weld metal solidification and
the microstructure formed for a single pass weld versus a multi pass weld.
3. Explain the effects of the weld protection, the type of consumables on the microstructure of the weld
metal and on it properties for a single pass weld versus a multi pass weld.
4. Draw areas of HAZ, the reasons for grain size and microstructure changes and their effects on
properties for a single pass weld versus a multi pass weld.
5. Discuss the various aspects of weldability.

1. Associate the temperature distribution in welds and the microstructure formed as a result
2. Describe the effects of heat input, cooling rate and multi -pass operation on weld metal solidification and
the microstructure formed.
3. Draw areas of HAZ, the reasons for grain-size and microstructure changes and their effects.
4. Compare the various aspects of weldability.

IAB-041r3-08
2.8 Plain carbon- and carbon-manganese steels
Objectives for I IWI-C, IWI-S and IWI-B: Understand (for IWI-S get knowledge: for IWI-B get general
understanding) the metallurgical effects induced by welding C and C-Mn steels.
2 2 2
Application of TTT diagrams
Hardening effects
Carbon equivalent
Weldability
Effects of multi pass welding
Structure of the weld and the HAZ
Factors influencing cracking
Relationship C%max hardness
Relationship Ceq hardenability
Determination of preheat temperature (diagrams)
Weld simulation (Weld thermal cycle simulation)
Determination of the optimal heat input
Influence of restraint
Standards
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1. Explain the concept and use of carbon equivalent.
2. Explain the principle and use of TTT diagrams (isothermal, continuous cooling, TTT diagrams for
welding).
3. Predict the structure of welds and HAZ for given thermal cycles and composition.
4. Explain in detail the effects of a multi pass welding on the structure, the mechanical properties.
5. Discuss the factors affecting cold cracking.
6. Predict optimal heat input and appropriate pre-heat for given materials, conditions and applications
utilising Codes and Standards as required.

1. Explain the concept and use of carbon equivalent.
2. Describe the principle and use of TTT diagrams (isothermal, continuous cooling, TTT diagrams for
welding).
3. Explain in detail the effects of a multi pass welding on the structure, the mechanical properties.
4. Discuss the factors affecting cold cracking.
5. Predict optimal heat input and appropriate preheat for given materials, conditions and applications
utilising Codes and Standards as required.

1. Describe the concept and use of carbon equivalent.
2. List the structure of welds and HAZ for given thermal cycles.
3. Name the effects of a multi pass welding on the structure, the mechanical properties.
4. Name the factors affecting cold cracking.
5. Predict optimal heat input and appropriate preheat for given materials, conditions and applications.

IAB-041r3-08
2.9 Fine-grained steels
Objectives for IWI-C, IWI-S and IWI-B: Understand for IWI-S - get knowledge; for IWI-B get general
understanding) the effects of micro-alloying elements on structure, mechanical properties and weldability
with reference to fine-grained steels.
Scope Teaching hours 2 2 1
Concept of grain refinement (micro-alloying elements, formation and dilution
of particles)
Effect on mechanical properties
Normalised grades
Quenched and tempered grades
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concept and weldability
Standards

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1. Explain the different methods to obtain fine-grained steels and effects of micro alloying.
2. Explain thoroughly the relationship between grain refinement and mechanical properties
3. Detail appropriate applications
4. Interpret the relationship between grade and weldability
5. Detail applicable welding processes and potential problems
6. Explain the effects of heat treatment after welding and deduce the conditions (in particular temperature)
of such treatment

1. Explain the different methods to obtain fine-grained steels and effects of micro alloying.
2. Explain thoroughly the relationship between grain refinement and mechanical properties.
3. Detail appropriate applications.
4. Interpret the relationship between grade and weldability.
5. Identify applicable welding processes and potential problems.
7. Name the effects of heat treatment after welding and deduce the conditions (in particular temperature) of
such treatment.

1. List the different methods to obtain fine-grained steels effects of micro alloying.
2. Explain thoroughly the relationship between grain refinement and mechanical properties.
3. Interpret the relationship between grade and weldability.
4. Identify applicable welding processes and potential problems.
5. Name the effects of heat treatment after welding and deduce the conditions of such treatment.

IAB-041r3-08
2.10 Thermomechanically treated steels
Objectives IWI-C, IWI-S and IWI-B: Understand (for IWI-S get knowledge; for IWI-B get general
understanding) the principles of thermomechanical treatment and its influence on mechanical properties and
weldability.

2 1 1
Principles of treatment (controlled rolling, accelerated cooling, direct quench,
etc
Chemical composition
Mechanical properties
High strength steels
Applications
Consequences on weldability
Standards
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1. Explain the effects of different treatment times and temperatures.
2. Explain the structural modifications of material and control methods.
3. Interpret the relationship between grade and weldability
4. Detail applicable welding processes and potential problems
5. Explain the effects of heat treatment after welding and deduce the conditions of such treatment

1. Understand the effects of different treatment times and temperatures.
2. Name the structural modifications of material and control methods.
3. Interpret the relationship between strength and weldability.
4. Identify applicable welding processes grade and potential problems.
5. Name the effects of heat treatment after welding and deduce the conditions of such treatment.

IAB-041r3-08
2.11 Cracking phenomena in steels
Objectives for IWI-C, IWI-S and IWI-B: Understand (for IWI-S and IWI-B name) the fundamentals of cracking
mechanisms in welded joints and the way in which welding variables affect the incidence of cracking. Understand/name
causes and avoidance.
2 2 1
For C-Mn, low alloy, high alloy and stainless steels as appropriate:

Cold cracking:
Cracking mechanisms in weld metal and HAZ , causes and avoidance
Effect of hydrogen, microstructure and stress
Source and diffusion of hydrogen
Control of hydrogen
Susceptible microstructure and its control
Influence of alloying elements on susceptibility
Testing of cold cracking susceptibility
Effect of preheat
Effect of austenitic weld metal

Hot cracking:
Cracking mechanisms in particular in weld metal (solidification cracking, liquation
cracking, etc.); causes and avoidance
Effect of alloy elements, heat input, bead shape, nugget shape
Control of hot cracking
Testing for hot cracking susceptibility

Reheat cracking:
Cracking mechanisms in weld metal and HAZ; causes and avoidance
Type of steels sensitive to reheat cracking
Effect of alloy elements, thermal cycles, stress
Cracking during heat treatment and multi -pass welding
Control of reheat cracking
Testing for reheat cracking susceptibility

Lamellar tearing:
Cracking mechanism ; causes and avoidance
Effects of inclusions, joint configuration, stress, and fatigue
Control of lamellar tearing by material control and joint configuration
Testing for susceptibility, through thickness properties
Steels with increased resistance to lamellar tearing

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1. Compare the metallurgical mechanisms for each of the major types of cracking.
2. Describe the effects of chemical and physical variables for each of the major types of cracking.
3. Appraise the susceptibility to cracking by reference to the key parameters and suggest appropriate precautions to avoid
cracking.
4. Appraise the type of cracking and the reason for its occurrence from study of fractured material and its history.
5. Choose suitable tests which will assist in finding the solution of cracking problems.
6. Propose alternatives which will reduce or eliminate the occurrence of lamellar tearing in welded construction/fabrication.
7. Appraise the effects of inclusions, joint configuration, stress and fatigue in the control of cracking of welds.

2. Describe the effects of chemical and physical variables for each of the major types of cracking.
3. Appraise the susceptibility to cracking and suggest appropriate precautions to avoid cracking.
4. Name the type of cracking and the reason for its occurrence from study of fractured material and its history.
5. Choose suitable tests which will assist in finding the solution of cracking problems.
6. Propose alternatives which will reduce or eliminate the occurrence of lamellar tearing in welded construction/fabrication.

2. Appraise the susceptibility to cracking and suggest appropriate precautions to avoid cracking.
3. Name the type of cracking and the reason for its occurrence.
4. List alternatives, which will reduce or eliminate the occurrence of lamellar tearing in welded construction/fabrication

IAB-041r3-08
2.12 Application of structural and high strength steels
Objectives for IWI-C, IWI-S and IWI-B:: Not applicable
0 0 0
Bridges,
Cranes,
Pressure vessels,
Automotive equipment,
Low temperature applications,

2.13 Low-alloy steels for very low temperature applications
Objectives for IWI-C, IWI-S and IWI-B: Understand (for IWI-S get knowledge about; for IWI-B get general
uderstanding of) solutions to welding applications requiring the use of the relationship between toughness
and temperature, metallurgical structure and the weldability of cryogenic steels.
2 1 1
Survey/list of types of cryogenic steels (including 9% Ni)
Effects of nickel on low temperature properties of low alloy steels
Applicable welding processes
Filler materials
Welding problems and precautions
Properties and application of various types of cryogenic steels
Controlling the quality of the welded joint
Standards on low temperature steels and consumables
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1. State the toughness testing and the parameters affecting toughness
2. Identify the effect of nickel on crystallographic structure.
3. Describe the effect of nickel content on weldability.
4. Appraise the range of applications for the various types of cryogenic steels.

1. Identify the effect of nickel on crystallographic structure.
2. Describe the effect of nickel content on weldability.
3. Name the range of applications for the various types of cryogenic steels.

IAB-041r3-08
2.14 Low alloy creep resistant steels

Objectives for IWI-C, IWI-S and IWI-B: Not applicable
0 0 0
Mechanism of creep resistance,
Testing of creep resistance,
Rest life prediction,
Oxidation resistance,
Survey of types of creep/heat resistant steels,
Filler materials,
Welding problems and precautions,
Controlling the quality of a welded joint,
475 -brittleness,
Standards,

2.15 Introduction to Corrosion
Objectives for IWI-C, IWI-S and IWI-B: Outline (for IWI-S get knowledge about; for IWI-B get general
understanding of) the fundamentals of the various types of corrosion.

2 2 2
Fundamentals of electrochemistry
Redox potential
Passivation
Overall corrosion
Differential aeration
Cathodic, anodic protection
Types of corrosion (intercrystalline, transcrystalline, knife-line attack
pitting, crevice, and stress-corrosion)
Pickling and passivating
Corrosion testing
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Expected results for IWI-C, IWI-S and IWI-B:
1. Outline the chemical and electrochemical phenomena involved in corrosion.
2. Recognize and describe the most common types of corrosion.
3. Give examples of common protection methods.

IAB-041r3-08
2.16 High-alloyed (stainless) steels
Objectives for IWI-C, IWI-S and IWI-B: Identify (for IWI-S get a knowledge; for IWI-B describe the
fundamentals of the various types of stainless steel and their weldability including the principles of joining
dissimilar materials and filler material choice.
2 2 1
Effect of alloying elements
Systems Fe-Cr, Fe-Ni, Fe-Cr-Ni
Austenite and ferrite formers
Influence of nitrogen
Cr- and Ni-equivalent
Schaeffler diagram, DeLong and other constitution diagrams
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weldability concept
Measuring of ferrite content
Survey on stainless steels (fully austenitic, ferrite-containing steels,
ferritic, martensitic, duplex stainless steels, chemically resistant,
creep resistant, heat resistant steels, cryogenic use)
Knife-line attack
475 C-embrittlement
Weld decay (intergranular corrosion)
Pitting index
Types of filler materials
Shielding and backing gases
Welding of stainless steels
Details of joint design
Heat treatment
Post-weld heat treatment (PWHT)
Passivation
Standards
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1. Describe the metal structures of the various stainless steels;
2. Identify the results of a given high alloy welding situation
3. State the rules and principles governing embrittlement
4. State the rules and principles governing corrosion
5. Identify the results of a given high alloy welding situation contents.
6. Predict the choice of consumables for each type of stainless steel using different diagrams.
7. Predict the necessity of treatment after welding.

1. Outline the structures of the various stainless steels and explain their behaviour during welding.
2. State the rules and principles governing corrosion phenomena.
3. Predict the choice of consumables for each type of steel using different diagrams.
4. Describe the different treatment after welding.

1. Outline the structures of the various stainless steels.
2. State the rules and principles governing corrosion phenomena.
3. Identify consumables for each type of steel.
4. Describe the necessity of treatment after welding.

IAB-041r3-08
2.17 Introduction to Wear
Objectives for IWI-C: Identify the fundamentals of wear and its control

1 0 0
Different types of wear (hydrodynamic friction, reaction, layer wear,
adhesive wear, abrasive wear, fatigue wear, fretting, erosion,
cavitation, impact, thermal, dynamic)
Buttering
Wear tests

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1. Describe wear situations that involve the mechanisms of the different types of wear.
2. Distinguish the basis and results of tests to define wear resistance.
3. Describe precautions and procedures designed to avoid excessive wear.

Not applicable

2.18 Protective layers
Objectives for IWI-C and IWI-S: Identify (for IWI-S outline) the fundamentals of protective layers and the
methods and materials used.
1 1 0
Cladding:
Reasons for cladding
Processes for cladding (dilution)
J oining clad steels
J oint design and welding procedures in respect of the access to the joint .
Applications
Standards

Linings:
Welding of linings
J oint design and welding procedures
Surfacing:
Corrosion-resistant layers
Wear-resistant layers
Coatings:
Surface-coated steels
Galvanised steels (Si-content)
Painting
Problems of joining

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Expected results for IWI-C and IWI-S:
1. Describe in general the various techniques for applying protective layers and the reasons for their
choice.
2. Outline the problems associated to each method and how would you solve them.

Not applicable

IAB-041r3-08
2.19 High alloy creep resistant and heat resistant steels
Objectives for IWI-C and IWI-S: Identify the relationship between microstructure and creep resistance
including knowledge of different types of creep resistant and heat resistant steels.
2 2 0
Creep resistance of high alloy steels
Mechanism of heat resistance
Types of creep resistant steels
Types of heat resistant steels (austenitic, ferritic)
Weldability and selection of consumables
Application and special problems
Standards
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1. Distinguish the effects of alloying elements on creep and heat resistance.
2. Describe the microstructural phenomena occurring in materials at high temperature.
3. List the types of creep resistant and heat resistant steels.
4. Describe the weldability of creep and heat resistant steels.

Not applicable

2.20 Cast irons and steels
Objectives for WT III, WT II: Interpret the metallurgy and /outline the different types of cast irons and steels,
their application fields and weldability.
1 1 0
Survey of cast steels
Survey of cast irons
Applicable welding processes and procedures
Weldability
Filler materials
Application and special welding problems
Standards
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1. Explain the Fe - C phase diagram with particular attention to carbon content over 2%.
2. Identify the different types of cast irons and steels, their chemical composition and crystallographic structures.
3. Appraise the weldability problems and applicable welding processes and types of consumable for the welding
of cast irons.

1. Recognise the different types of cast irons and steels.
2. Describe the weldability problems and applicable welding processes and types of consumable for the welding
of cast irons.

Not applicable

IAB-041r3-08
2.21 Copper and copper alloys
Objectives for IWI-C, IWI-S, IWI-B: Not applicable
0 0 0
Survey of types,
Deoxidisation and weldability,
Physical and mechanical properties,
Applicable joining processes (welding, brazing, soldering),
Filler materials,
Shielding and backing gases,
Application and special problems,
Standards,

2.22 Nickel and Nickel alloys
Objectives for IWI-C, IWI-S: Understand the metallurgy and (for IWI-S) outline the range of application and
weldability of nickel and nickel alloys.
2 1 0
Survey on classification of nickel and nickel alloys
Applicable welding processes and filler materials
Welding problems (hot cracking) and prevention
Quality control of the welded joint
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Expected results for IWI-C and IWI-S:
1. Explain nickel and nickel alloy weldability.
2. List applicable welding processes and types of consumable for nickel and nickel alloys.
3. State examples of nickel and nickel alloys applications.

Not applicable

IAB-041r3-08
2.23 Aluminium and aluminium alloys
Objectives for IWI-C, IWI-S and IWI-B: Understand the metallurgy and (for IWI-S and IWI-B) outline the
range of application and weldability of aluminium and aluminium alloys.
3 3 2
Survey on classification of aluminium and aluminium alloys (pure, cold work
alloys, heat treatable alloys)
Weldability
J oint preparation
Oxide layer cleaning (cathodic cleaning, trailing and trailing shield)
Filler materials (choice, storage and handling)
Welding problems, (HAZ softening, porosity and hot cracking, cracking
Diagrams, distortion) and their avoidance
Design details
Application and special problems (lightweight structures, cryogenic use)

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1. Describe aluminium and aluminium alloy weldability including dissimilar joints.
2. Explain applicable welding processes and types of consumable for aluminium and aluminium alloys.
3. Explain aluminium and aluminium alloys range of application.

1. Describe aluminium and aluminium alloy weldability.
2. List applicable welding processes and types of consumable for aluminium and aluminium alloys.
3. State examples of aluminium and aluminium alloy applications.

2.24 Other metals and alloys
Objectives for IWI-C, IWI-S and IWI-B Not applicable
Titanium
Magnesium
Tantalum
Zirconium
Applicable welding processes and filler materials
Special problems

IAB-041r3-08
2.25 Joining dissimilar materials
Objectives for IWI-C, IWI-S and IWI-B Understand (for IWI-S and IWI-B outline) the principles of joining
dissimilar materials and the problems involved.
Fundamentals
Use of the Schaeffler / De Long diagram for welding dissimilar metals
Choice of processes
Effect of dilution
Consumables
Welding problems and measures, (formation of intermetallic
compounds, carbon migration)
In service failures (thermal fatigue, disbonding)
Typical applications:
J oining high alloyed steel and mild steel
J oining stainless steel and mild steel
J oining CuNi-alloys with mild steel/stainless steel
J oining Ni-alloys with mild steel
J oining stainless steel and copper alloys
J oining steel and Al / Al alloys
J oining Cu and Al / Al alloys
J oining Ni and Cu
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1. Explain metallurgical and weldability
2. Interpret and use Schaeffler / De Long diagram.
4. Deduce welding methods which can solve metallurgical problems.
5. Interpret the correct choice of filler material.

1. Briefly describe the weldability aspects involved when joining dissimilar materials.
2. Use Schaeffler / De Long diagram and choose the appropriate consumables.
3. List the welding methods for typical applications which decreases metallurgical problems.
IAB-041r3-08
2.26 Metallographic examination
Objectives for IWI-C: Understand crystallographic structures and the application of metallographic
examination

Objectives IWI-S and IWI-B : Get familiarized with the metallographic examination as a tool for study of the
structures of materials.

2 2 1
Specimen preparation for micro and macro examination
Macro and microstructure examination
Micro chemical analysis of crystallographic structure
Reference standards EN 1321, CR 12363
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1. Explain and be able to use methods for sample preparation.
2. Explain aspects of macro and micro examination.
3. Interpret microstructure, metallurgical imperfections.

1. Explain in general and be able to use methods for sample preparation.
2. Describe aspects of macro and micro examination.
3. Interpret macro and microstructure, metallurgical imperfections.

IAB-041r3-08
WT III WT II WT I

Module 3 Construction and design 21 17 12

3.1 Basic theory of structural systems
Objectives for IWI-C, IWI-S and IWI-B: Explain (for IWI-S and IWI-B understand) the effect of external
loads on structures, the types of structural systems and the relationship between external loads and internal
forces.
1 1 1
Structural elements (cables, bars, beams, plates, slabs, shells)
Theory of forces
Combination and resolution of forces
Equilibrium of forces and torques
Bearings, constraints and basic types of connections
Equilibrium of structural systems
Statically determinate and indeterminate systems
Stress in structural systems resulting from external actions
Relationship between external loads and internal forces
Calculation and determination of the internal forces and moments of simple
statically determinate systems
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1. Explain the composition of forces.
2. Explain the resolution of forces.
3. Define the conditions of equilibrium.
4. Explain the equilibrium of structural systems.
5. Explain bearings, constraints and the basic types of connections.
6. Explain the difference between a statically determinate and a statically indeterminate system.
7. Determine the internal forces and moments of simple statically determinate systems.
8. Explain and sketch the shearing force and bending moment diagram of simple statically determinate
systems.
1. Understand in general the composition of forces.
2. Understand in general the resolution of forces.
3. Name the conditions of equilibrium.
4. Understand in general the equilibrium of structural systems.
5. Name bearings, constraints and the basic types of connections.

IAB-041r3-08
3.2 Fundamentals of the strength of materials
Objectives for IWI-C, IWI-S and IWI-B: Explain (for IWI-S and IWI-B understand) the principles governing
the behaviour of metallic structures under loading.
2 2 1
Types of stresses (normal stress, shear stress)
Types of deformation (axial strain, shear strain)
Stress-strain relationship, yielding theories
Elastic and plastic deformation
Youngs modulus, shear modulus, transverse contraction coefficient
Characteristic material properties
Different stresses resulting from internal forces and moments
Different types of section properties
Calculation of section properties
Calculation of stresses
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1. Explain the different types of stresses (normal stress, shear stress).
2. Explain the different types of deformation (axial strain, shear strain etc.).
3. Explain the stress-strain relationships.
4. Deduce Youngs modulus; shear modulus and transverse contraction coefficient from the stress-strain
relationships.
5. Explain the determination of characteristic material properties.
6. Explain the stresses resulting from internal forces and moments.
7. Calculate the different types of section properties.
8. Calculate nominal stresses in sections.

1. Understand in general the different types of stresses (normal stress, shear stresses).
2. Understand in general the different types of deformation (axial strain, shear strain etc.).
3. Understand in general the stress-strain relationships.
4. Understand in general the stresses resulting from internal forces and moments.

IAB-041r3-08
3.3 Welded Joint Design
Objective for IWI-C, IWI-S and IWI-B: Design and draw (for IWI-B understand) weld details related to a
given material, wall thickness, accessibility, loading, welding process, welding position, NDT, available
equipment, tolerances.
2 2 2
Introduction (importance of welding joint design and grove shapes, influence
on welding stresses and distortion)
Types of welded joints (ISO 9692 series, EN 14324 brazing)
Importance of weld joint design and groove shapes, types of welded
joints, design of welded joints
Classification of groove shapes (by material type, thickness, welding process,
accessibility)
Tolerance requirements (ISO 13920)
Welding symbols on drawings, symbols for groove shapes
Symbolic representation of welded, brazed and soldered joints according
to ISO 2553
National standards

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1. Classify different types of welded joints.
2. Design a weld according to the given conditions.
3. Detail and use appropriate weld symbols.
4. Explain the symbolic representation of welded, brazed and soldered joints on drawings.

1. Describe different types of welded joints.
2. Know how to apply each type of joint in function of material, thickness and welding process
3. Explain the symbolic representation of welded, brazed and soldered joints on drawings.

3.4 Basics of Weld Design
Objectives for IWI-C, IWI-S and IWI-B: Understand the relationship between external loads on structures,
internal forces and the stresses induced with especially with regard to welds.
Types of stresses in welded joints (nominal stress, hot spot stress, notch
stress)
Stresses in butt welds, stresses in fillet welds
Calculation of section properties of welded joints
Determination of nominal stresses in single welded joints
Determination of reference values of stresses due to multi-axial stressing
Determination of design resistance of arc-welded and resistance-welded
joints
Worked examples of calculation of nominal stresses in welded joints

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1. Explain the different types of stresses in welded joints (nominal stress, hot spot stress, notch stress)
2. Calculate simple welded joints (internal forces).
3. Calculate the values of cross sections for welded joints.
4. Calculate nominal stresses in welds.
5. Calculate combined stresses in welds (superposition).
1. Understand in general the different types of stresses in welded joints (nominal stress, hot spot stress,
notch stress).
2. Understand simple welded joints (internal forces).
3. Understand cross sections for welded joints.

IAB-041r3-08
3.5 Behaviour of welded structures under different types of loading
Objectives for IWI-C, IWI-S and IWI-B: Explain (for IWI-S and IWI-B understand the different types of
loading and the influence of ambient conditions on structures
Static strength
Elevated temperature strength
Low-temperature strength
Creep resistance
Impact behaviour
Influence of notches and weld defects
Types of fracture (ductile fracture, fatigue fracture, brittle fracture,
lamellar tearing)
Selection of steel quality groups
Typical data for common steels
Use of standards and specifications
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1. Explain the requirements according to different types of loading and temperatures.
2. Select appropriate materials according to specific applications.
3. Explain different types of fracture (ductile fracture, fatigue fracture, brittle fracture, lamellar tearing).
1. Understand the requirements for the construction according to different types of loading and
temperatures.
2. Identify globally groups of materials which meet strength / temperature requirements.
3. Identify the various types of facture.

3.6 Design of welded structures with predominantly static loading
Objectives for IWI-C, IWI-S and IWI-B: Understand (for IWI-S and IWI-B get knowledge) principles of
design and calculation of joints and relevant details of welded metallic structures.
1 1 1
Steel constructions including lightweight structures
Structural details e.g. (stiffeners, knots, columns, base- and cap-plates,
re-inforced structures, supports, frame-corners, frame structures, trusses,
nodal joints, weld connections, braces / bracing, lattice work structures,
etc.)
Use of different types of welds related to joint types
Worked examples
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1. Understanding principles of design different connection zones.
2. Outline stresses in frames.
3. Nominate the stresses in welds in frames.
4. Explain the advantage and disadvantage of different types of welds.

1. Identify different connection zones.
2. Read and understand appropriate weld geometry.
3. Outline stresses in structural details.
4. Global knowledge of advantage and disadvantage of different types of welds.

1. Describe appropriate welded connection zones
2. Demonstrate differences between similar profiles.
3. Identify advantage and disadvantage of different types of welds.

IAB-041r3-08
3.7 Behaviour of welded structures under dynamic loading

Objectives for IWI-C, IWI-S and IWI-B: Understand the development of fatigue, calculation of load cycles,
the influence of notches and their avoidance.
3 2 1
Types of cyclic loading
Statistical stress analysis on real structures
S-N diagram
Stress collective
Fatigue strength (low cycle, and others
Effect of mean stress
Effect of stress range
Stress distribution
Influence of notches
Influence of weld defects
Fatigue improvement technique (needle peening, TIG dressing, burr
grinding, hammering, stress relieving, etc.)
Standards
Palmgren-Miner rule
Classification of weld joints
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1. Draw and use an S-N diagram.
2. Detail the influence of notches and weld defects.
3. Describe the methods applied to welds for improved fatigue performance.

1. Understand an S-N diagram.
2. Name the influence of notches and weld defects.
3. Name possible modifications to welds for improved performance.

1. Understand in general the influence of notches and weld defects.
2. Define simple recommendations for fatigue improvement in case of welded joints.

IAB-041r3-08
3.8 Design of dynamically loaded welded structures
Objectives for IWI-C, IWI-S and IWI-B: Understand the different design details and notch classes in the
range of application.
1 1 1
Range of application: bridges, cranes, machines, ships and offshore
constructions, chimneys, towers and masts, vehicles (cars, trucks, railway
vehicles) etc.
Acceptance criteria
Worked examples

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1. Understand princiles of design of welded joints in accordance with given details.
2. Explain the influence of notch effects on the classification of welded joints.
3. Compare details in different standards and classify them.

1. Recognise welded joints in accordance with given details.
2. Know the influence of notch effects and stresses on the classification of welded joints.

3.9 Design of welded pressure equipment
Objectives for IWI-C, IWI-S and IWI-B: Understand the special requirements of design and construction of
structural elements in this field of application with regard to the calculation of welds.
1 1 1
Construction of boilers, pressure vessels, pipelines, etc
Calculation (formulae) of the welds
High and low temperatures applications
Details of design (flanges, nozzles, shells, compensating plates etc.)
Use of laws and design rules, standards and specifications
Worked examples of construction and design
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2. Calculate circumferential and longitudinal welds.
3. Design given structural details.
4. Explain the advantages of different structural details

1. Recognise the advantages of different weld details.
2. Outline the calculation of circumferential and longitudinal welds.
3. Understand design of given structural weld details.

1. Describe the advantages of different details.
2. Nominate the relevant standards.

IAB-041r3-08
3.10 Design of aluminium alloys structures
Objectives for IWI-C, IWI-S and IWI-B: Understand the behaviour of welded aluminium structures with
respect to strength, stresses and design.
1 1 1
Comparison of design between steel and aluminium structures
Lightweight structures
Standard alloys for practical use and relevant stresses and strains
Effects of heat-affected zone softening
Special design regarding profiles
Significance of defects
Range of application (vehicles, rolling stocks, ships, aircraft, vessels and
space)
Worked examples
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1. Explain how to minimize the softening of the heat-affected zone.
2. Give examples of common aluminium weld joints.
3. Discuss how to solve the most common imperfections on aluminium welds.

1. Recognise typical aluminium joints and preparation.
2. Recognise the common aluminium imperfections and solutions to avoid them.
3. Name some typical applications and the advantages against steel construction.

3.11 Reinforcing-steel welded joints
Objectives for IWI-C, IWI-S and IWI-B: Understand the principles of choice of joints and their design.
2 1 1
Reinforcing-steel types, properties
Direct and indirect loading
Types of joints used (lap, cruciform)
Calculation
Weldability with respect to weld joint strength
Preheating in respect to bar diameter
Application of welding processes
Standards and specifications (ISO 17660 series and National Standards)
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1. Explain the basics of the different joints.
2. Differentiate between load bearing and non-load bearing joints.
3. Detail applicable processes.
4. Determine the length of weld with respect to diameter.
5. Deduce the required preheating temperature.

1. Outline the basics of the different joints
2. Recognise between load bearing and non-load bearing joints.
3. Classify applicable welding processes.
4. Outline the length of weld with respect to diameter.
5. Understand the application of preheats.

IAB-041r3-08
3.12 Introduction to fracture mechanics
Objectives for IWI-C and IWI-S: Understand the use of fracture mechanics for welded structures.
3 2 0
Viewpoint of fracture mechanics
Application of fracture mechanics
Linear elastic fracture mechanics
Fundamentals of elastic-plastic fracture mechanics
Critical flaw size, KIc-value
Fracture mechanics testing (CTOD, etc.)
Sub-critical crack growth
Fatigue testing
Standards
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1. Name the principles of linear-elastic and elastic-plastic fracture mechanics.
2. Name the influence factors for linear-elastic and elastic-plastic fracture mechanics.
3. Describe the use of fracture mechanics for dynamically loaded structures.

Not applicable

IAB-041r3-08
WT III WT II WT I

Module 4. Fabrication, applications engineering 24 23 17

4.1 Introduction to quality assurance in welded constructions
Objectives for IWI-C, IWI-S and IWI-B:: Understand in detail (for IWI-S - get a complete knowledge; for
IWI-B get knowledge) the principles of quality assurance and quality control and recognise the related
standards and their application to welded fabrication as a special process.
6 5 3
Concept of quality assurance and quality control (including analysis,
continuous improvement
Weldability
Quality manual
Quality plan
Audit of plant
Personnel and equipment
Maintenance
Inspection
Activities of the welding engineer/technologist/specialist/practitioner in the
different functions in industry
Standards (QMS guidebook, ISO 9000 series, ISO 3834, national and
international standards

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1. Explain the principles of quality assurance, quality control and inspection systems and their usage for
welded fabrication.
2. Be capable of writing quality control procedures and quality plans for welded fabrication.
3. Explain in detail the purpose of an audit of plant.
4. Be capable of carrying out audits of welding related plant, personnel, equipment and product.
5. Interpret appropriate standards (e.g. ISO 9000, and ISO 3834 series).
6. Explain in detail the main factors related to personnel and equipment, which influence the quality in a
welded fabrication.
7. Explain the role of the Welding Inspector of the Comprehensive level in the fabrication industry.

1. Explain the main differences between quality assurance, quality control and inspection systems and
their usage for welded fabrication.
2. Be capable of writing quality control procedures.
3. Interpret appropriate standards (e.g. ISO 9000, and ISO 3834 series).
4. Know the basic factors related to personnel and equipment, which influence the quality in a welded
fabrication.
5. Explain the role of the Welding Inspector of the Standard level in the fabrication industry.

1. General outline on the goals for quality assurance and quality control.
2. Recognise some factors related to personnel and equipment, which influence the quality of a welded
construction.
3. Explain the role of the Welding Inspector of the Basic level in the fabrication industry.

IAB-041r3-08
4.2 Quality control during manufacture
Objectives for IWI-C, IWI-S and IWI-B: Understand in detail for IWI-S - get a complete knowledge; fior IWI-B get
knowledge) the requirements and function of Quality Control during manufacture. Explain the standards related to
welders/operators and welding procedure qualification including traceability, need for calibration and monitoring of
welding parameters. The same objectives to be covered in the scope for brazing.
6 6 4
Documentation to national, regional and international standards, e.g. WPS
Advantages to the quality of welded constructions
Welding sequence
Welding coordination and inspection personnel; qualification tasks and
responsibilities (ISO 14731, ISO 9712, and national standards)
Procedure qualification (as described in ISO 15607) and national standards
Welding procedure specification (WPS) - how to create and develop
Welder qualification (ISO 9606 series, EN 287-1, and national standards
Welding operator qualification (EN 1418, ISO and national standards)
Traceability (materials identification, welder/operator, procedures, certificates)
Possible methods of monitoring, control and storage of fabrication data
Calibration and validation of measuring equipment
Practical exercises on welding: Procedure qualification, practical exercises on welder
qualification tests
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1. Explain the main purpose of a WPS/WPQR/pWPS and the advantages to the quality of welded fabrication.
2. Compile and review WPSs for welded components in accordance with national and international standards.
3. Interpret the standard for the qualification of a WPS, determine the main variables for a particular WPS qualification and its
range of qualification in accordance with National and/or International standards.
4. Explain the main purpose of a welder qualification and the main advantages to the quality of welded fabrication.
5. Interpret the standard for welder qualification, determine the main variables for a particular welder qualification and its
range of qualification.
6. Explain the main purpose of a welding operator qualification and the main advantages to the quality of welded fabrication.
7. Interpret the standard for welding operator qualification, determine the main variables for a particular welding operator
qualification and its range of qualification.
8. Define the traceability requirements for materials procedures and certificates and give examples.
9. Give examples of methods available for the monitoring and storage of fabrication data.
10. Recognise the equipment and instruments needing calibration and explain why.
11. Explain the tasks and responsibilities of the welding coordination personnel.
12. Explain the tasks and responsibilities of the different inspection personnel

1. Explain the main purpose of a WPS/WPQR/pWPS and the advantages to the quality of welded fabrication.
2. Compile and review WPSs for welded components in accordance with national and international standards.
3. Interpret the standard for qualification of a WPS, determine the main variables for a particular WPS qualification and its
range of qualification in accordance with National and/or International standards.
4. Explain the main purpose of a welder qualification and the main advantages to the quality of welded fabrication.
5. Interpret the standard for welder qualification, determine the main variables for a particular welder qualification and its
range of qualification.
6. Explain the main purpose of a welding operator qualification and the main advantages to the quality of welded fabrication.
7. Interpret the standard for welding operator qualification, determine the main variables for a particular welding operator
qualification and its range of qualification.
8. Define the traceability requirements for materials procedures and certificates and give examples.
9. Give examples of methods available for the monitoring and storage of fabrication data.
10. Know the equipment and instruments needing calibration
11. Explain the tasks and responsibilities of the different inspection personnel.

1. Outline the purpose of a WPS, and the advantages to the quality of the welded construction.
2. Recognise the main variables for a certain WPS qualification and its range of approval.
3. Outline the purpose of welder qualification and the advantages to the quality of the welded construction.
4. Recognise the EN and ISO standards for welder qualification and outline the main variables for a specific welder
qualification and its range of approval.
5. Outline the meaning of traceability when related to the welded constructions.
6. Identify the equipment, and instruments needing calibration.
7. Explain the tasks and responsibilities of the different inspection personnel.

IAB-041r3-08
4.3 Welding stresses and distortion
Objectives for IWI-C, IWI-S and IWI-B: Understand (for IWI-S . get a knowledge; for IWI-B get a general
knowledge) the main factors affecting welding stress and distortion in welded fabrications and how these
effects can be measured and minimised.
2 2 2
Influencing factors
Thermal data of the materials
Origin of the residual stresses and deformation
Magnitude of longitudinal and transverse shrinkage stresses
Relationship between heat input, shrinkage stresses and distortion
Methods of residual stress measurement
Welding sequence techniques
Effects of residual stresses on the behaviour of the structure in service
Methods of reducing residual stresses or distortion
Correction and removal of welding deformation (pressing, rolling, local
heating, etc.)
Examples of control of distortion
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1. Explain the origin, influencing factors and magnitude of residual stress and distortion in welded
fabrications.
2. Predict quantitatively contraction and distortion in joints and structures.
3. Develop procedures to minimise distortion and stress.
4. Explain how residual stresses may affect the behaviour of a structure in service.

1. Explain in general terms the origin, influencing factors and magnitude of residual stress and distortion in
welded fabrications.
2. Predict qualitatively contraction and distortion in joints and structures.
3. Develop procedures to minimise distortion and stress.
4. Describe how residual stresses may affect the behaviour of a structure in service.

1. Outline in general terms he origin, influencing factors and magnitude of residual stress and distortion in
welded fabrications.
2. Predict qualitatively contraction and distortion in joints and structures.
3. Name procedures to minimise distortion and stress.
4. Interpret how residual stresses may affect the behaviour of a structure in service.

IAB-041r3-08
4.4 Plant facilities. Welding jigs and fixtures
Objectives for IWI-C and IWI-S: Understand the need for, and function of, auxiliary
equipment, jigs and fixtures from the viewpoint of quality, economics and the environment.

Objectives for IWI-B: Acquire knowledge about the main plant facilities used during welded construction
and auxiliary equipment, to be able to recognise technical solutions for a certain welded construction
1 1 1
Layout of production line
J igs, fixtures and positioners (types, applications, advantages, special
precautions)
Roller beds, manipulators
Cables, electrical connections, and special precaution
Operational environment
Auxiliary equipment (for fit up, movement, backing gas devices, flow meters,
etc
Fume extraction (type of equipment, air flow)
J oint fit up
Tack welding and their removal
Storage, distribution and handling of consumables (gases and filler material,
baking and drying ovens)
Equipment for preheat, postheat, and other heat treatments, as well as
temperature control including furnace and local heat treatment
Maintenance
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1. Detail workshop layout principles for improved productivity, safety and comfort.
2. Explain the advantages of using fixtures, jigs and positioners.
3. Select the type of fixture, jig or positioner to be used for a particular welded fabrication.
4. Select the type of auxiliary equipment to be used in a particular welded fabrication, including fume
extraction, and cables, heat treatment and temperature control equipment.
5. Identify the special requirements of facilities for handling and storing welding consumables.
6. Deduce the special requirements related to joint fit up and tack welding.

Expected results for IWI-S:
1. Describe layout principles for improved productivity, safety and comfort.
2. Describe the advantages of using fixtures, jigs and positioners.
3. Select the type of fixture, jig or positioner to be used for a particular welded fabrication.
4. Select the type of auxiliary equipment to be used in a particular welded fabrication, including fume
extraction, and cables, heat treatment and temperature control equipment.
5. Identify the special requirements of facilities for handling and storing welding consumables.
6. Deduce the special requirements related to joint fit up and tack welding.

1. Outline the layout importance to achieve a higher and easier production.
2. Recognise the advantages of using fixtures, jigs and positioners.
3. Recognise the type of fixture, jig and positioner to be used in a certain welded construction.
4. Recognise the necessary characteristics for the auxiliary equipment to be used in a certain welded
construction, including fume extraction, cables, heat treatment equipment and temperature control.
5. Outline the general precautions related with the handling, and storage of welding consumables,
6. Outline the general precautions related with joint fit up and tack welding.

IAB-041r3-08
4.5 Health and safety
Objectives for IWI-C, IWI-S and IWI-B: Understand (for IWI-S - get a complete knowledge; for IWI-B
describe) the health and safety hazards associated with welding and fabrication processes, including
techniques to minimise them.
2 2 2
Introduction to health and safety requirements
Survey of safety and environmental aspects, risk assessment
Hazards of electric power
Electro-magnetic fields
Connecting of equipment
Problems with shielding gases
Radiation and eye protection
Welding fume emission
Exposure limits MAC and OEL values
Ventilation and fume extraction
Ergonomics
Determination of acceptable emissions
Tests for measuring emissions
Noise levels and ear protection
Special risks for automated processes
Standards and regulations
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1. Explain the risk factors associated with welding from electricity, gases, fumes, fire, radiation and noise.
2. Interpret health and safety regulations with respect to the above hazards.
3. Select the appropriate methods to reduce each type of welding risk factors.
4. Produce safe working procedures to ensure the requirements are met.
5. Perform measurements of welding hazards.

1. Explain the risk factors associated with welding from electricity, gases, fumes, fire, radiation and noise.
3. Select the appropriate methods to reduce each type of welding risk factors.
4. Describe safe working procedures to ensure the requirements are met.
5. Know how to measure welding hazards.

1. Describe the risks associated with welding from electricity, gases, fumes, fire, radiation and noise.
3. Name the risks associated with welding operations.
4. Describe safe working procedures to ensure the requirements are met.

IAB-041r3-08
4.6 Measurement, control and recording in welding
Objectives for IWI-C, IWI-S and IWI-B:: Understand (for IWI-S know; for IWI-B name)
the requirements for measurement, control and recording during welding and allied operations.
2 2 1
Methods of measurement (electrical parameters, gas flow rate, temperature,
velocity)
Instruments (types, measuring applications)
Temperatures (ISO 13916), humidity, wind
Cooling time e.g. t 8/5
Welding parameters (voltage, current, speed, gas flow rate, etc
Control in heat treatment (heating and cooling rate, CR ISO 17663)
Calibration and validation of equipment (ISO 17662)
Laboratory exercises.

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1. Explain the methods of measurement used in the control of welding and allied operations.
2. Detail working procedures for the measurement of welding parameters.
3. Detail working procedures for the measurement and control of heat treatment operations.
4. Detail procedures for the calibration, validation and monitoring of welding operations.

1. Describe the methods of measurement used in the control of welding and allied operations.
2. Explain working procedures for the measurement of welding parameters.
3. Explain working procedures for the measurement and control of heat treatment operations.
4. Explain procedures for the calibration, validation and monitoring of welding operations.

1. Repeat the methods of measurement used in the control of welding.
2. Name working procedures for the measurement of welding parameters.

IAB-041r3-08
4.7 Non-destructive testing (introduction to WI module)
Objectives for IWI-C, IWI-S and IWI-B: Understand in detail (for IWI-S understand; for IWI-B describe)
the use of Non Destructive Testing as applied to welding fabrications.
1 1 1
Types of weld imperfections (IIW-designations classification according to ISO
standards)
Acceptance criteria (e.g. ISO 5817, ISO10042, and EN 12062)
Fundamentals of NDT methods (visual, liquid penetrant, magnetic particle,
eddy current, acoustic emission, radiography, ultrasonics, etc.)
Field of application and limitations
Design in respect of NDT
Calibration
Interpretation (IIW Reference radiographs)
Recording of data
Correct selection of the NDT methods versus application (e.g. CEN/TR
15135)
Qualification and certification of NDT personnel
NDT procedures
Automation of NDT (computer aid evaluation, etc.)
Health and safety aspects
Laboratory exercises

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1. Explain the modes of operation of the principal NDT methods, their advantages and disadvantages
when applied to welded fabrications.
2. Identify weld imperfections, their causes and avoidance and methods of detection.
3. Interpret acceptance standards for weld imperfections.
4. Identify the principles of NDT interpretation.
5. Select weld configurations and design to allow adequate application of NDT methods.
6. Interpret the qualification of NDT personnel.
7. Recognise safety aspects

1. Know the modes of operation of the principal NDT methods, their advantages and disadvantages when
applied to welded fabrications.
2. Identify weld imperfections, their causes and avoidance and methods of detection.
4. Identify the principles of NDT interpretation.
6. Identify the qualification of NDT personnel.

1. Interpret the modes of operation of the principal NDT methods, their advantages and disadvantages
when applied to welded fabrications.
2. Name weld imperfections, their causes and methods of detection.

IAB-041r3-08
4.8 Economics
0 0 0
Introduction,
Analysis of welding costs,
Deposition rate,
Costs of labour,
Costs of consumables,
Costs of equipment,
Return on investment,
Costs of energy,
Welders duty cycle,
Calculation of welding costs,
The application of software, calculation programmes,
Measures for decreasing welding costs,
Mechanisation,
Automation,
Robotics,

4.9 Repair-welding
Objectives IWI-C, IWI-S and IWI-B: Understand (for IWI-S explain; for IWI-B - understand/ name) the
problems of repair welding both for in-manufacture and in-service situations.
2 2 2
Welding repair procedure specification
Welding repair plan
Welding repair procedure qualification
NDT of the weld repair
Special precautions
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1. Explain the problems and implications of making repair welds.
2. Predict the possible hazards likely to occur in making repair welds particularly for in-service repairs.
3. Understand in details procedures to be applied to weld repairs.
4. Specify the procedural and operator qualifications to be applied to repair welds.

1. Explain the problems and implications of making repair welds.
3. Understand procedures to be applied to weld repairs.
4. Specify the procedural and operator qualifications to be applied to repair welds.

1. Describe the problems of making repair welds.
3. Understand procedures to be applied to weld repairs.
4. Name the procedural and operator qualifications to be applied to repair welds.

IAB-041r3-08

4.10 Fitness for purpose
Objectives for IWI-C, IWI-S and IWI-B:: To gain an understanding of the need for and use of engineering
critical assessment techniques.
2 2 1
Introduction to IIW SST 1093-8 and ISO/TR 15235
Significance of defects
Engineering critical assessment techniques
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Expected results for IWI-C, IWI-S and IWI-B
1. Describe the principles of fitness for purpose.
2. Describe in detail the effect of imperfection size, morphology and position on structural integrity.
3. Explain typical methods on conducting an engineering critical assessment of a welded structure.

4.11 Case Studies
0 0 0
Subjects:
Steel and lightweight structures, boilers and pressure vessels, chemical
plants and pipelines, shipbuilding and offshore applications, Transportation
automobiles, railways), aerospace applications.
Common items to be covered:
Standards and specifications,
Design,
Choice of materials,
Welding processes,
Site welding (transport and final assembly),
Consumables,
Welding procedures,
Tolerances on weld preparation and fit-up,
Post-weld heat treatment,
NDT and quality control,

TOTAL: 122 94 65
Note: The above syllabus follows the content of that adopted for the core Guideline Personnel with
Responsibility for Welding Coordination. Items which do not apply to welding inspection personnel are
allocated 0 hrs.
IAB-041r3-08
Theoretical education: Welding Inspection Modules

1. General introduction to welding inspection WI III WI II WI I
Number of Course Hours: 3 3 2

1.1 Scope of activity
Objectives for IWI-C, IWI-S and IWI-B:Understand the role and responsibilities of the welding inspector
and the inspector's relationship with other welding and inspection personnel. Understand the purpose of
destructive and non destructive testing.
WI III WI II WI I Module
2 2 1
Objectives of inspection in welded construction
Construction and quality standards
Role of inspection personnel in the assurance of product quality; concept of
fitness for purpose
Inspection before, during and after welding
Levels of personnel and their qualification
Responsibilities of inspector; liability for actions
Relationship to welding co-ordination and other welding tasks
Concepts of destructive and non-destructive testing
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1. Understand the role and responsibilities of welding inspectors in construction codes and quality standards
2. Understand welding inspectors authority levels in relation to contract and regulatory requirements
3. Understand the levels of personnel qualification and the associated job tasks and responsibilities in weldin
ordination (ISO 3834) and inspection and testing
4. Understand the role of the welding inspector and the relationship with the welder, welding co-ordinator and
destructive testing staff
5. Understand the advantages and disadvantages of destructive and non destructive testing
6. Explain the role of inspection in assuring product quality

1. Understand the role and responsibilities of welding inspectors in construction codes and quality standards
2. Understand welding inspectors authority levels in relation to contract and regulatory requirements
3. Understand the levels of personnel qualification and the associated job tasks and responsibilities in weldin
ordination (ISO 3834) and inspection and testing
4. Understand the role of the welding inspector and the relationship with the welder, welding co-ordinator and
destructive testing staff
5. Understand the advantages and disadvantages of destructive and non destructive testing

IAB-041r3-08

1.2 Terms and definitions
Objectives for IWI-C, IWI-S and IWI-B Understand inspection and NDT terminology
1 1 1
Common Inspection and NDT terms
Reference standards for terminology
IIW collections of terms

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Expected results for IWI-C, IWI-S and IWI-B
Ability to understand and use Inspection and NDT terms included in National and International standards
and IIW collection of terms

2. Mechanical tests on welded joints WI III WI II WI I

Objectives for IWI-C, IWI-S and IWI-B: Understand the purpose and value of welding procedure and
welder performance testing. Understand the requirements for material used for procedure and performance
testing
1 1 1
Objectives in relation to welder and procedure qualification, and to service
performance
Test welds; sources of test pieces
Material certificates: essential features and data

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1. Understand the objectives of welding procedure and welder performance testing
2. Understand material certification content and data
3. Be capable of selecting appropriate material for test purposes
4. Explain the purpose and value of testing in relation to service performance

1. Understand the objectives of welding procedure and welder performance testing
2. Understand material certification content and data
3. Be capable of selecting appropriate material for test purposes

IAB-041r3-08
3. Weld Imperfections WI III WI II WI I

3.1 Types of imperfections
Objectives for IWI-C, IWI-S and IWI-B: Clarify the characteristics of the fundamental types of weld
imperfection. Explain their possible position with reference with the welded joint. Verify their visibility with the
current NDT techniques

5 4 3
Review of weld imperfections, their cause and characteristics, in particular
Porosity and cavities
Imperfect and profile shape
Arc strikes
Cracks
Inclusions
Lack of fusion
Lack of penetration
Lamellar tearing
Overlap
Poor surface condition
Seams and laminations
Spatter
Undercut
Classification (EN-ISO 6520)
Others

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1. Get the capability of manage the different types of weld imperfection
2. Identify the causes of weld imperfections, with reference to the different welding processes and welded
materials
3. Predict the possibility of detection for each type of imperfection with the current NDT techniques

2. Predict the possibility of detection for each type of imperfection with the current NDT techniques


IAB-041r3-08
3.2 Evaluation of imperfections
Objectives for IWI-C, IWI-S and IWI-B: Fully understand the morphology of the imperfections. Predict
possible influence of each type of imperfection. Manage the application of international / national standards
codes for acceptance/rejections of weld imperfections
2 1 0
Features of weld imperfections:
volumetric form
nature of surface
size
location
orientation
Significance of defects in relation to service performance
Compliance with specifications
Acceptance/rejection criteria

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1. Get the knowledge of the most common codes and standards regarding weld imperfections
2. Manage the application of acceptance / rejection weld imperfections criteria
3. Approach the inspection of the welded joints in relationship with their service conditions

1. Get the knowledge of the most common codes and standards regarding weld imperfections
2. Manage the application of acceptance / rejection weld imperfections criteria

Not applicable

4. Testing methods WI III WI II WI I

4.1 Review of testing methods

Objectives for IWI-C, IWI-S and IWI-B: Understand the different methods of NDT and their range of
application.
1 1 1
Role of visual and non-destructive testing methods
Application ranges of availabel methods.
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1. Detail the objectives of testing methods.
2. (see item 1.1. of the Welding Inspection Modules)
3. (see item 1.1. of the Welding Inspection Modules)
4. Detail different types of testing (including destructive ones) and their ranges of applciation.

IAB-041r3-08
4.2 Visual inspection
Objectives for IWI-C, IWI-S and IWI-B: Understand in detail, visual inspection fundamentals, applications
and specifications, including interpretation of specific imperfections in weldments
WI III WI II WI I Qualification Module
5 5 5
4.2.1 Inspection tools:
Special weld measuring instruments
Internal (bore) viewing systems
Optical magnifying devices

4.2.2 Checking before welding:
Material and consumable type
J oint preparation (ISO 9692)
Storage and condition of consumables
Condition of welding equipment
Equipment setting and calibration
Alignment of component parts
Use of jigs, positioners
Welding procedure and status
Witnessing approval tests
Evaluation of test results
Application of welding procedure

4.2.3 Inspection during welding:
Preheat and its control
Inter-run cleaning and temperature(s) control
Back gouging
Weld metal appearance and profile
Distortion
Weld penetration
Monitoring of welding parameters

4.2.4 Testing (see EN 473 or ISO 9712) after welding:
Weld dimensions
Penetration
Profile
Surface appearance
Distortion
Sputter, arc strikes
Evidence of surface breaking defects - porosity, cracking

4.2.5 Reporting results: visual testing report

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1. Detail different types of tools used in visual inspection
2. Explain interest of inspection before, during and after welding
3. Detail different items of inspection before welding,
4. Detail different items of inspection during welding
5. Detail different items of inspection after welding
6. Detail standards of reference for evaluation of test results
7. Detail different method for monitoring welding parameters
8. Detail presentation of visual testing reports
9. Explain system of visual testing personnel certification

IAB-041r3-08
4.3 Liquid penetrant testing
Objectives for IWI-C, IWI-S and IWI-B: Understand in detail liquid penetrant testing fundamentals,
applications and specifications, including interpretation of specific imperfections in weldments
2 2 2
4.3.1 Principles:
Liquid penetration of surface breaking imperfections; capillary flow
Penetrant liquids; dye and fluorescent; nature and characteristics
Testing procedure
Developing the image
Sensitivity
Scope; type of defect and materials
Limitations of method

4.3.2 Technique :
Choice of penetrant
Testing procedure; pre-cleaning, application of penetrant, penetration
time, washing, developing
Safe working

4.3.3 Interpretation:
Viewing conditions
Locating imperfections; spurious indications
Identifying imperfections type and size

4.3.4 Application:
Types of equipment
Typical components

4.3.5 Standards

4.3.6 Personnel competence

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1. Explain principles of liquid penetrant testing.
2. Explain range of validity of the method for in fabrication testing, in service testing.
3. Detail imperfections expected to be found with this process.
4. Detail standards of reference for evaluation of test results.
5. Detail presentation of liquid penetrant testing reports.
6. Explain certification system for liquid penetrant testing personnel certification.

IAB-041r3-08
4.4 Magnetic particle testing
Objectives for IWI-C, IWI-S and IWI-B: Understand in detail, magnetic particle testing fundamentals,
applications and specifications, including interpretation of specific imperfections in weldments.

4 4 4
4.4.1 Principles:
Magnets and magnetic fields (magnetic fluxes)
Field strength (flux density)
Inducing fields in metal components
Uniform fields
Effect of discontinuities in distorting the field
Field distortion due to component geometry, surface finish or imperfections
Using magnetic particles to locate field distortion
Limitations of method

4.4.2 Technique:
Magnetisation methods
Application to different component geometries
Field strength requirements; calculations
Testing procedure; component preparation; surface preparation of welds;
particle application; dry and wet methods; preparation for interpretation

Factors affecting imperfections recognition
Locating imperfections; irrelevant magnetic disturbances
Identifying imperfections type and size

4.4.4 Application:
Types of equipment
Typical components

4.4.5 Standards


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1. Explain principles of magnetic particle testing
2. Explain range of validity of the method for in fabrication testing, in service testing
3. Detail imperfections expected to be found with this process
5. Detail presentation of magnetic particle testing reports
6. Explain system of magnetic particle testing of personnel certification.

IAB-041r3-08
4.5 Radiographic testing
Objectives for I IWI-C, IWI-S and IWI-B: Understand in detail, radiographic testing fundamentals,
applications and specifications, including interpretation of specific imperfections in weldments
5 3 2
4.5.1 Principles:
Simple concepts of electromagnetic radiation and of radioactive
emissions from isotopes
Characteristics and properties of x- and y-rays
Generation of x-rays; the x-ray tube
Penetration and absorption; effects of tube voltage and current
Isotope disintegration and production of y-rays; concept of half-life
Penetration and absorption; effect of type of isotope
Radiographic procedure and film type; film density; concept of image
unsharpness, sensitivity
Defect orientation and dimensions versus detectability
Effect of materials, thickness and component geometry
Limitation of method; materials, thickness, geometry
Health hazards and their control

4.5.2 Techniques:
Review of component; selection of radiation source and film type
Film handling and storage
Establishment of radiographic procedure and conditions;
single and double exposure
Image quality; selection and use of IQIs
Film processing; effect of variables on image quality
Safe working practice; personnel monitoring

Review of component, welding procedure and radiographic techniques;
expected location of imperfections
Viewing conditions
Assessment of image quality
Recognition of imperfections types and their locations use of reference
radiographs

4.5.4 Specialised radiographic facilities:
High voltage radiography, fluoroscopy;

4.5.5 Legislation and standards


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1. Explain principles of radiographic testing, film processing methods
2. Explain different methods of radiographic testing, selection of radiation type
3. Detail imperfections expected to be found with this process and their location
5. Detail presentation of radiographic testing reports
6. Detail conditions of handling and storage of films
7. Detail legislation rules for handling of radiographic sources
8. Explain system of radiographic testing personnel certification.

IAB-041r3-08

4.6 Ultrasonic testing
Objectives for IWI-C, IWI-S and IWI-B: Understand in detail, ultrasonic testing fundamentals, applications
and specifications, including interpretation of specific imperfections in weldments
7 5 2
4.6.1 Principles :
Sound propagation
Shear, compression and surface waves; velocity
Properties of ultrasound; frequency and wavelength; ultrasonic beam;
beam spread; refraction, reflection, diffraction; defects as reflectors;
transmission and reception; probes, probe angle; coupling to component
Near field, far field, dead zone
Pulse echo system; pulse shape and rate
Generation of pulses; receiving echo signals, amplification and display;
display modes: A, B and C
Defect range; time of pulse flight, time base
Reflection characteristics of defects
Scanning for defects; scanning zone
Limitations; materials, thickness, geometry, structure

4.6.2 Equipment:
The ultrasonic set; probe construction; controls

4.6.3 Thickness testing:
Use of longitudinal wave probes for thickness measurement and corrosion
assessment

4.6.4 Preparation for manual testing:
Pre-welding action; reference marking for key weld preparation features
Component review; identification of scanning zone; welding procedure;
expected imperfections
Scanning procedures for imperfections location; probe type and angle;
single or double probes
Calibration; calibration blocks; range, probe angle, sensitivity

4.6.5 Imperfections location:
Component preparation; surface finish
Coupling
Scanning pattern; marking limits on component
Recording of echo signals and location of reflectors
Accuracy of location of reflectors; root zone problems
Use of special flaw location slides

4.6.6 Nature and size of reflectors:
Detailed examination of located reflectors
Technique to evaluate nature of reflector
Techniques for size estimation; reference reflectors; DGS system; use
of beam boundary; calibration; tolerances; effect of component on
accuracy

4.6.7 The ultrasonic test report

Review of component, and assessment of calibration and testing technique
Assessment of findings in test report; relationship with pre-weld features of
component
Conclusions

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IAB-041r3-08

4.6.9 Mechanised systems:
Multi-probe scanner with data logging; tank testing; production line system
wrought products

4.6.10 P Scan system

4.6.11 Standards

4.6.12 Personnel competency

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1. Explain principles of ultrasonic testing,
2. Explain different methods of ultrasonic testing,
3. Detail imperfections expected to be found with this process and their location
5. Detail presentation of ultrasonic testing reports
6. Explain system for of ultrasonic testing personnel certification.

4.7 Other NDT methods
Objectives for IWI-C: Understand in eddy current testing principles, applications and specifications,
including interpretation of weldments specific imperfections
Objectives for IWI-S and IWI-B: Understand leak testing principles, applications and specifications.
Understand strain gauges measurement principles, applications and interpretation of results
2 1 0
4.7.1 Eddy current testing:
Principles; induction into component of eddy currents by ac magnetic field;
equipment; test coil; presentation of test results
Influence of materials, thickness, component geometry
Interpretation of results
Personnel competence

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4.7.2 Leak testing:
Principles and methods; vacuum box; tracer gases; instrumentation;
detection of leak source

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4.7.3 Strain gauges:
Types of gauge; application; instrumentation
Interpretation of results

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Expected results for IWI-C for Eddy current
1. Explain principles of eddy current testing
2. Range of use of the eddy current testing
3. Explain interpretation of results
4. Explain system of NDT personnel certification.

Expected results for IWI-C and IWI-S for leak testing
1. Detail different methods of leak detection
2. Explain advantages and disadvantages of different methods
3. Explain choose of a method related to welding construction
4. Explain system of NDT personnel certification

Expected results for IWI-C and IWI-S for strain gauges
1. Explain use of strain gauges
2. Detail different types of gauges
3. Explain expected results from measurements

Not applicable
IAB-041r3-08
4.8 Critical review of selection of NDT methods
Objectives for IWI-C and IWI-S: Understand in detail the economics of testing operations applied to
welded fabrications, choice of testing method regarding type of base material and expected imperfections,
sensitivity of detection
2 2 0
4.8.1 NDT methods versus :
Cost, operator competence
Surface-sub/surface detection
Type of imperfection detected
Imperfection measurement achieved
Reliability of detection
Limitations of materials, component size and geometry
Accuracy, validity of information or data obtained

4.8.2 Logical route to selection

4.8.3 Exercises to select optimum method for specific cases

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1. Explain costs of NDT related to method and operators competence
2. Explain choice related to location of imperfections expected (on or sub surface)
3. Explain choice related to sensitivity required
4. Explain accuracy of detection related to NDT process, type of materials, size of construction

Not applicable

4.9 Other test methods
Objectives for IWI-C : Understand pressure test principles, applications and specifications
Objectives for IWI-C, IWI-S and IWI-B: Understand dimensional testing fundamentals, applications and
specifications
2 1 1
4.9.1 Pressure test:
Component pressurisation; equipment and instrumentation; proof testing

X

4.9.2 Dimensional tests:
Size, tolerances; measuring instruments and devices

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Expected results for IWI-C, for pressure test
1. Explain fundamentals of the tests
2. Calculate test pressure related to appropriate standard or specification
3. Details to be taken care of for realisation of the test
4. Detail verification for test measurement tools

Expected results for IWI-S and IWI-B for pressure test
Not applicable
Expected results for IWI-C, IWI-S and IWI-B for dimensional testing
1. Explain fundamentals of the dimensional tests
2. Detail verification for test measurement tools
3. Explain method for reporting of test results????

IAB-041r3-08
4.10 Reporting
Objectives for IWI-C, IWI-S and IWI-B
Understand what shall be included in a testing report and their ???? (its) maintenance rules
1 1 1
4.10.1 Preparation of inspection and test reports;
Essential information and data; standard forms

4.10.2 Procedure for report assessment

4.10.3 Essential records and their maintenance;
Computer software

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1. Explain different information and data needed before inspection can be performed.
2. Detail standards needed before inspection can be performed.
3. Explain different procedures that are required to establish forms of test reports
4. Explain mandatory obligations for maintenance of test reports

1. Explain different information and data needed before inspection can be performed
2. Detail standards needed before inspection can be performed.

5. Quality Assurance. Principles and levels

Objectives for IWI-C and IWI-S: Get the basic knowledge of QA principles. Understand the risks related
with a collapse or a failure of the joints for people, products and environment. Fully understand the role of
QA during fabrication.

Objectives for IWI-B: Get the basic knowledge of QA principles. Fully understand the role of QA during
fabrication.
3 3 1
Level of QA required versus product specification
Risk and consequences of failure
Product liability
Role of quality control and inspection in QA
Implementation of standards in a fabrication environment
Vendor auditing

X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
1. Be capable of interpreting the inspectors role during fabrication activities
2. Manage and interpret the standard connected with QA application
3. Be capable of interfacing with Welding Coordinators and QA personnel

1. Be capable of interpreting the inspectors role during fabrication activities
2. Be capable of interfacing with Welding Coordinators and QA personnel

IAB-041r3-08

6. Management of inspection function

Objectives for IWI-C: Understand the responsibilities associated with inspection activities as they relate to
staff, company organization and record generation and retention. Recognize the importance of accurate
records and monitoring of activities with respect to the inspection process.

Objectives for IWI-S: Recognize the importance of accurate records and monitoring of activities with
respect to the inspection process
3 3 0
Responsibilities; organisation; personnel; personnel management;
discipline; motivation of subordinates; staff development; planning and
scheduling of key activities records and record keeping

X

X

1. Be familiar with typical inspection company procedures relating to staffing and inspection task implementa
2. Understand basic project planning techniques and how they are applied to inspection activities
3. Identify the basic elements of an inspection report and the items to be listed???? in report
4. Be familiar with other inspection reports and how they link to the final inspection documentation
5. Acquire basic writing and communication skills

1. Identify the basic elements of an inspection report and the items to be listed???? in report
2. Be familiar with other inspection reports and how they link to the final inspection documentation
3. Acquire basic writing and communication skills

Not applicable

IAB-041r3-08
7. Practical work

Objectives for IWI-C and IWI-S Acquire the basic operating principles of both mechanical and non
destructive testing methods.

Objectives for IWI-B: Become familiar with basic practial skill of main mechanical and non destructive
testing methods.
49 23 15
Radiographs interpretation
Mechanical testing
Visual inspection
Metallographic
Liquid penetrant and magnetic particle testing
Ultrasonic testing
18
3
6
4
4
14
7
2
6
1
2
5

2
6

7

1. Understand the basic operating principles of radiography
2. Understand the defects detectable with radiography and its limitations
3. Be familiar with mechanical testing equipment
4. Understand and be able to apply visual inspection techniques for welds and fabrications
5. Be able to prepare and examine a metallographic sample
6. Understand the application of liquid penetrant and magnetic particle testing
7. Be able to interpret results of liquid penetrant and magnetic particle testing
8. Understand the principles of ultrasonic testing
9. Understand the defects that can be detected with ultrasonic testing
10. Be familiar with the calibration and the maintenance of the equipment used in ultrasonic testing

1. Understand the basic operating principles of radiography
2. Understand the defects detectable with radiography and its limitations
4. Understand and be able to apply visual inspection techniques for welds and fabrications
5. Be able to examine a metallographic sample
6. Understand the application of liquid penetrant and magnetic particle testing
7. Be able to interpret results of liquid penetrant and magnetic particle testing
8. Understand the principles of ultrasonic testing
11. Understand the defects that can be detected with ultrasonics

8 Understand and be able to apply visual inspection techniques for welds and fabrications
9 Understand the application of liquid penetrant and magnetic particle testing
10 Be able to interpret results of liquid penetrant and magnetic particle testing

Welding Inspection Modules : Total hours 97 63 40

IAB-041r3-08
Theoretical education: Basic technology Module 0

1. Introduction 2
Survey on the contents of this module
Repeat of basic knowledge
Information on education and training system
J ob functions of welding inspection personnel

2. Units 2
Units for length and area
Time and time dependent units

3. Technical calculation 7
Addition, subtraction, multiplication, division
Percentage calculation, rule of three
Use of pocket calculators
Equations and solving of equations
Solving of equations
Calculation of length, area, and volume
Angular units
Trigonometric functions

4. Technical drawing 12
Formats, lines, fonts, scales, drawing aids
Sketch of flat pieces
Drawings
Projections, cross sections
Planar development of shapes
Pieces with hidden lines, hatching
Symbols, size lines
Drawing of diagrams

5. Basics of electrotechnology 2
Direct current
Alternating current
Simple circuits

6. Basics of chemistry 2
Chemical elements
Simple reactions

7. Basics of materials 5
Types and properties of materials
Basics of metals, especially iron
Effect of impurities
Basics of non-iron metals

8. Metal products 2
Plates, profiles, bars
Castings, forgings, extrusions
IAB-041r3-08

9. Machining of materials 2
Sawing, cutting, stamping, drilling, shaping
Milling, thermal cutting

10. Technical mechanics 2
Basics of static loads, forces and stresses
Calculation of forces and stresses
Concept of fatigue and fracture

11. Calculation of strength 2
Working stresses, deflections
Behaviour of structural shapes
Stability of constructions

total hours : 40

Note: This 40 hour course follows the syllabus of Module IWS-0, but only insofar as engineering
knowledge required by International Welding Inspection Personnel level is concerned.

IAB-041r3-08
Section II: Minimum requirements for experience, examination
and qualification

1. Introduction

This Guideline seeks to achieve harmonisation and a common standard in the
examination and qualification of personnel engaged in welding inspection. The national
welding organisations, being members of the IIW, mutually acknowledge the Diploma
awarded in any Member State to International Welding Inspection Personnel, following
education, experience and examination conducted in accordance with this Guideline.

Before examination, education must have been followed that is prescribed in this
Guideline, and the Authorised National Body must have conducted the final examination.

2. Route from IWI-B to IWI-S and from IWI-S to IWI-C

In the case of the bridging route from IWI-B to IWI-S (Route 4), and from IWI-S to IWI-C
(Route 3), the candidate shall have had a minimum of 24 months experience before ATB
assessment (see Fig. 2).

3. Verification of visual acuity

All candidates shall provide evidence of a satisfactory vision test.
Note: Certification may require additional vision test.

4. Approval of courses

Any training course leading to the IIW examination must be approved by the ANB. The
number of teachers required to give the course shall be sufficient to ensure that the essential
specialist knowledge and industrial experience required to cover the syllabus are adequately
represented in the team of teachers and visiting lecturers.

5. Examination Board

An Examination Board, acting on behalf of the ANB, supervises examinations. In this way,
the independence, integrity and fairness of the examination system is maintained.

6. Examination procedures

The examination procedures described below are designed to simulate different situations
from production sphere which might be handled by a welding inspector.

The examination will be in two parts, the first of which will be a written examination
covering the subject of the course. The second part there will be a practical examination
to test the candidate's ability to apply inspection technology. The following are the
minimum requirements for the duration of examinations:
IAB-041r3-08

IWI-C

IWI-S IWI-B
Time (hrs) Time (hrs) Time (hrs)
Part 1:
Theoretical written
examination Only
WI module 3 2,5 1,5
Part2:
Practical examination

2,5

2,5

2,5

In order to pass the examination, candidates must achieve at least 60% of the maximum
possible mark in each part.

6.1 Theoretical written examination

This part will examine the candidate's knowledge only regarding the welding Inspection
Technology Module.

At the discretion of the ANB it shall consist of:

a) A series of essay questions covering the whole field of the subject
or
b) A series of multiple choice questions covering the whole field of the subject
or
c) A combination of a) and b) with equal marks allocated to each type.

6.2 Practical examination

The objective of this examination is to assess the candidate's competence in undertaking
a range of inspection tasks and it will include both an oral examination to assess the
candidate's comprehension of the tasks involved and written reporting of results.

Oral examination will cover to test the candidate's understanding of and ability to interpret
international quality standards and the quality aspects of welding application standards,
and quality related documentation such as control manuals. The candidate may select
specific standards and codes from among those offered by the ANB.

7. Re-examination

Failure in a final examination shall require re-examination only in the part failed. Final
examinations must be re-taken within 2 weeks to 15 months of the initial examination and,
in the case of a second failure, one further attempt is permitted within 1 to 15 months from
the date of the second examination. If a candidate fails three times in any of the 4
Technology Modules, he/she has to retake the classes of the module failed and the
exams of the 4 Technology Modules, independently if he/she has passed the exams of
the other modules. If a candidate fails three times the Inspection Module, he/she has to
retake only the classes and exam of this module. (irrespective of whether he/she has
passed the exams for the other modules.

IAB-041r3-08
In the case of intermediate and end-of-module examinations conducted by the approved
training organisations, one re-examination is allowed within a period of three months.

A second failure will require the candidate to take (or retake) the preceding welding
technology or welding inspection module.

8. Diploma of the International Institute of Welding

After successful examination an International Institute Welding Diploma, corresponding
to the examined level, is awarded to the candidate by the Authorised National Body.

9. Appeals procedure

Candidates who feel they have been unfairly treated during the examination procedure
have the right to appeal to the Authorised National Body

10.Transition arrangements

All National Transition Arrangements are published on the IAB Transition Arrangements
Directory, doc. IAB-021-2000.

Each countrys specific Transition Arrangements are approved by the IAB Group B and may be
obtained from each Authorised National Body.

An ANB can offer Transitional Arrangements for a period of up to 3,5 years from the
date of approval by the IAB Group B.

Practising welding inspection personnel will be eligible for the award of an appropriate
International Welding Inspection Personnel Diploma if they can demonstrate to the ANB
that their combination of education, training and experience has provided a level of
knowledge equivalent to one of the categories prescribed in this Guideline and if they fulfil
the ANB requirements defined in the Transition Arrangement Directory.

Two additional general rules must be observed when applying the transition arrangements :

1 Applicants must possess the basic engineering / technical access qualification as
outlined for the country concerned, in the guideline relevant to the level sought.

2 Diplomas may be awarded under the transitional arrangements, in the following cases:

i) by the ANB in the country in which the applicant received his welding qualification
or

ii) by the ANB in the country in which the applicant is currently practising in contact with
the ANB of the country that issued the original qualification.

IAB-041r3-08

Appendix I

1. Equipment

The equipment used for the courses must be in good working order and fit for its purpose:

1.1 Welding equipment: Equipment for the following processes must be available for
demonstration:
Manual metal arc welding - 111
MIG welding - 131
MAG welding 135/136
TIG welding - 141
Gas welding - 311

Further processes covered by the syllabus may be shown by means of demonstrations
or video presentations.

1.2 NDT equipment: Equipment for the following methods must be available for
demonstration and/or practical work. The minimum number of pieces of equipment
is shown in brackets.
Ultrasonic flaw detectors (Two persons per set)
X-ray equipment (One set, only for demonstration)
Y-ray equipment (One set, only for demonstration)
Radiographic film viewers (Two persons per viewer)
Magnetic particle testing bench (One bench)
Liquid penetrant testing bench (One bench)

1.3 Measuring instruments
Weld size gauges, magnifying glasses, rules, angle protractors and other
appropriate equipment must be available for visual inspection exercises.

2. Specimens:

A range of weld specimens containing appropriate defects for practical NDT exercises
must reflect the range of joint types found in practice, such as butt joints in plate, Tee
joints, nozzles, pipes and branches. The defects must be fully recorded in control
diagrams.

A range of weld specimens for visual inspection must also be available containing surface
and surface breaking defects.

Weld cross sections containing defects, polished and etched, should be available to
demonstrate the types of defect found in welds made by the processes listed in item 1.1
above.

3. Radiography:

A collection of radiographs covering a range of applications must be available for practical
work on radiographic interpretation.

IAB-041r3-08
Appendix II

ANB detailed assessment

After the candidate has fulfilled the requirements of the ANB check, he will be admitted to the
ANB detailed assessment.

Figure 4: ANB detailed assessment

The full ANB detailed assessment shall contain:
a detailed paper assessment of knowledge (checklist with points)
a professional assessment interview designed to test understanding and ability to reason in
the field of welding and the syllabus of the standard course and
a project or a technical interview to test logical application of knowledge

The sequence of this assessment shall be determined by the ANB. It is at the discretion of the
ANB to terminate the assessment and send the candidate back or into the standard route.

If he/she has a diploma of IIW ( IWE, IWT, IWS, or IWP) and valid certificates of ISO 9712 cover
the syllabus of the Welding Inspection Modules of the present guideline he/she can proceed to
professional assessment interview for equivalent level of qualification without detailed paper
assessment.

a) The detailed paper assessment of knowledge shall be done with the following point
system:

For Welding Technology modules:
Frames of requirements:
Max. No. of points
IWI-C IWI-S IWI-B
Module 1: Welding processes 10 8 8
Module 2: Materials and their. 13 12 10
Module 3: Construction and design 10 9 8
Module 4: Fabrication, applications engineering 8 8 8
Sum 41 37 34

A minimum of 50%

per module is

required
to
proceed further

Detailed paper
assessment of
knowledge

Professional

assessment
interview

Pr oject or
technical
inter view
Final Exam
IWI-C
IWI-S
IWI-B
Modul e 4
of the WT III, WT II or WT I
At the di scretion of the ANB
(
see the Alterna tive Route diagram , p. 7
)
yes
yes
no
no
no
yes

IAB-041r3-08
The detailed points are distributed as following:

Module 1: Welding processes

111 - MMA 2 points 2 points 2 points
141 - TIG and 15 - Plasma 2 points 2 points 2 points
131 MIG 135 MAG 2 points 2 points 2 points
114, 136 and 137 - Flux-cored methods 1 point 1 point 1 point
91, 93 and 97 - Brazing methods 1 point 0,5 point 0 point
81, 82 and 83 - Thermal cutting 0,5 point 0,5 point 1 point
12 - SAW 1 point 0 points 0 points
Other methods 0,5 point 0 points 0 points
= 10 points 8 points 8 points

Module 2: Materials (acc. to CR ISO/TR 15608) and their behaviour during welding

Steel alloys - groups 1 3 and 11 3 points 3 points 3 points
Cr-Mo- and vanadium steels: groups 4 - 6 2 points 2 points 2 points
Ferritic and martensitic steels group 7 3 points 2 points 2 points
Austenitic and aust./fer. steels groups 8 and 10 1 point 1 point 1 point
Steel-Ni- alloys, max 10% Ni group 9 1 point 1 point 1 point
Aluminium and alloys groups 21 - 26 1 point 1 point 1 point
Nickel and alloys groups 41 - 48 1 point 1 point 0 point
Cast iron groups 71 - 76 1 point 1 point 0 point

Module 3: Construction and design

Stresses and strains 3 points 3 points 2 points
Design of welded structures - static loading 1 point 1 point 2 points
Design of welded structures - dynamic loading 1 point 1 point 1 points
J oint design & design principles of welded structures 3 points 2 points 2 points
Design of structures of aluminium and its alloys 2 points 2 points 1 point

Module 4: Fabrication, applications engineering

Quality assurance in welded fabrication 1 point 1 points 1 points
Quality control during manufacture 2 point 2 points 2 points
Welding stresses and distortion 1 point 1 point 1 point
Plant facilities, welding jigs and fixtures 1 point 1 point 1 point
NDT 1 point 1 point 1 point
Repair welding 1 point 1 point 1 point
Health and safety 1 point 1 point 1 point
=8 points 8 points 8 points

As a minimum, each applicant must achieve 50% in each module for IWI-C, S and B, to be
admitted to the professional interview.

IAB-041r3-08
For Welding Inspector modules:

The detailed points are distributed as following:
IWI-C IWI-S IWI-B
1. General introduction to welding inspection 1 points 1 points 1 point
2. Testing 2 points 2 points 2 points
3. Weld Imperfections 3 points 2 points 2 points
4. Testing methods 10 points 8 points 8 points
5. Quality Assurance 2 points 2 points 1 point
6. Managements of inspection function 2 points 2 points 0 point
7. Practical work 8 points 6 points 6 points

As a minimum, each applicant must achieve 50% in Modules 1 to 7 for IWI-C, S and B, to be
admitted to the professional interview

b) Professional assessment interview

The professional interview is designed to test understanding and ability to reason in the field of
welding regarding the IIW relevant guideline syllabus:

The Professional interview duration must be at least:
IWI-C IWI-S IWI-B
45 minutes 30 minutes 30 minutes

For a candidate reaching >75% of the mximum possible points in the paper assessment, he or
she may be exempted from the professional assessment interview in that module. However the
minimun total time shall be not less than half of the time stipulate for the relevant guideline.

If the ANB decides that the candidate should leave the detailed assessment after the
professional assessment interview but before the project or the technical interview, the
candidate, as a minimum, has to go through Module 4 of the WT III, WT II or WT I of the
standard route. After the candidate has attended Module 4, he/she is allowed to perform the
final exams.

c) Project or technical interview

The ANB offers each candidate the option of a project with a project final report including an
oral review of the project report and a practical part or to be assessed via a technical interview.
Each of the assessment routes are explained below.

c.1) Project

In the project, a case study (designed for 60 hours for IWI-C, 40 hours for IWI-S and 20 hours
for IWI-B) with a duration of a maximum of four, three and two weeks respectively, must be
done alone. Where a project has a wide scope of application, the candidate shall be tested on
the logical application of his/her knowledge.

IAB-041r3-08
The ANB offers a choice of construction/fabrication, to be in accordance with an approved
national or international code and/or product standard. One of the following constructions shall
be selected:

Pressure vessel
Construction - static loading
Construction - dynamic loading
Other construction

When a model of the project work has been detailed, the ANB shall decide in each case, the
specific items to be covered by the candidate

SUBJECTS
IWI-C IWI-S IWI-B
Drawings 2 2 1
Establish that the manufacturer / repairer is working to approved
drawings
X X X
Verification that the design of all parts of the fabrication, repairs and
modifications are in accordance with the requirements of the
applicable approved code
X
Quality plans 6 2 1
Verify that the quality plan is approved by manufacturer or repairer,
client and inspection authority.
X X X
Sign and complete the inspection stage requirements of the
inspection authority.
X X X
Verification that an agreed quality plan is to be implemented.
Incorporation of inspection requirements for witness, hold and
surveillance points.
X
Materials 12 6 5
Correlation of material certificates with materials of construction and
checking conformity of material specification
X X X
Identification of material and witnessing of transfer identification X X X
Visual examination of material, cut edges and heat affected zones. X X X
Welding procedures 6 4 2
Approval of welding procedures. X
Verify that applicable approved welding procedures are being used
and followed.
X X X
Witnesses the production procedure test plates, the mechanical
testing of test pieces prepared from the plates, evaluates the results
and validates applicable reports.
X X X
Welder approvals 8 6 4
Approval of welders and operators X X X
Examine fit-up of joint for welding. X X X
Verify second results of dimensional checks. Examine weld
preparations and tack welds
X X X
Inspect the back side of the weld after the face side is completed and
root cleaned
X X X

IAB-041r3-08
SUBJECTS
IWI-C IWI-S IWI-B
Testing 16 4 5
Examine and accept non-destructive test reports. X X
Verify compliance with agreed procedure and acceptability of any
defects
X X
Evaluate radiographs and accept or reject components on such
evaluation.
X X
Verify NDT personnel qualifications. X X
Verify defects reported by NDT personnel as to their capability
against a code.
X X
Examine NDT procedures, techniques, sheets and/or reports for
compliance as having being signed / authorised by the recognised
competent personnel.
X X
Witness and evaluate mechanical testing of production test welds X X
Examine heat treatment records and verify compliance with
procedure.
X X
Witness that pre-and post heat treatments are performed in
accordance with approved procedures if this requirement is included
in the quality plan.
X X X
Witness the pressure test if required and verify code requirements. X X X
If required, record the amount of permanent set. X X X
Visually examine the completed fabrication or the repair /
modification area, as relevant, internally and externally
X X X
Witness dimensional checks made by the manufacturer or repairer.
Controlled against drawing requirements.
X X X
Verify if required marking of nameplate details and attachment of
plate to fabrication.
X X
Heat treatment 2 2
Examine heat treatment records and verify compliance with
procedures
X X
Documentation 8 4 2
Collation of documentation X X
Verify collation of documentation for data book or repair report. X X X
Sign construction and test certificate or record of continuance. X X
Verify certification details and co-sign certification with the
manufacturer or repairer
X X X

c.2) Technical Interview

Technical interview duration is at least:
IWI-C IWI-S IWI-B
4 hours 3 hours 2 hours

The technical interview will be divided into 2 parts, these are:

Part 1: Discussion wIth the applicant regarding evaluation of the applicants knowledge of the
project construction/fabrication (See table below)

Part 2: Discussion with the applicant regarding evaluation of the applicants practical
knowledge (See table below)

IAB-041r3-08
Before the technical interview, the candidate is given at least 1 hour to become familiar with the
documentation that will be used during the interview.

The ANB will supply the applicant with a set of documents (construction drawings - part of a
construction, list of materials, material certificates, NDT reports, destructive testing reports,
WPQRs, WPSs, Welder approvals).

or

The applicant presents a set of documents (construction drawings - part of a construction, list of
materials, material certificates, NDT reports, destructive testing reports, WPQRs, WPSs, Welder
approvals). These documents should be from the company where the applicant is currently
employed. These documents must be initially evaluated by the ANB before being accepted as
documentation to be used in the applicant technical interview.

The technical interview shall address as a minimum, the subjects mentioned in the tables below.

Part 1 Evaluation of the applicants knowledge of the project construction/fabrication
Subjects IWI-C IWI-S IWI-B
Evaluation of drawings and technical specifications. X
Read and understand drawings and technical
specifications.
X X
Evaluation of and comments to the choice of base
materials. Discuss the weldability of the materials.
Any needs for pre- and post weld heating.
X
Knowledge about the choice of base materials.
Discuss the weldability of the materials. Any needs
for pre- and post weld heating.
X X
Evaluation and discussion of the construction based
on the choice of:
X X X
- J oining method(s) for the base material(s);
X X X
- Cutting method(s) for preparation of base
material parts
X X X
- J oint preparation and weld calculation
X X
- J oint preparation
X
- Welding consumables; X X X
- Need of surface treatment before welding; X X X
- Surface treatment of finished construction -
method(s) to be used.
X
Preparation of necessary WPSs and testing
methods.
X X
Interpretation of necessary WPSs. X
Evaluation of necessary welding qualification(s) for
welder(s).
X X

IAB-041r3-08
Interpretation of necessary welding qualification
test(s) for welder(s).
X
Present NDT methods to be used during and after
welding.
X X
Discuss possible NDT methods that can be used
during and after welding, including special tests to
check the entire quality of the construction.
X
Discussion of the construction in terms of:
- Welding plan including welding sequence
and tack welding
X X
- Standards needed for the project; X
Discussion on the construction
- Quality plan for the production based on
relevant part of ISO 3834 or equivalent.
Type of workshop for this kind of production
shall be discussed.
X X
- J igs, fixtures, welding equipment X X X

Part 2 Practical discussion
Checking:
- Certificate(s) on base material(s); X X X
- Welder(s) qualification test certificate(s); X X X
- Qualification of personnel for destructive
testing, NDT and inspection
X X
- Welding Procedure Qualification Record -
WPQR;
X X
- Welding Procedure Specification - WPSs; X X X
Evaluation of test results and discussion of the
reports.
X X
Proposal for a plan for inspection before, during and
after welding and discussion.
X X
Discussion of inspection reports.
X
Evaluation of the welding and test results based on
inspection and NDT reports.
X X
Welds needing repair, plan(s) for repair welding and
eventually, WPSs for repair welding to be made.
X X

After fulfilling all of the requirements for a and b and c.1 or c.2 of the ANB detailed
assessment, the candidate will be admitted to the final examination.

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INTERNATIONAL WELDING INSPECTION

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