AUGUST 2016 / VOL. 19 / NO.

Inspection
Trends
THE MAGAZINE FOR MATERIALS INSPECTION AND TESTING PERSONNEL

AWS.ORG

Visual Weld Inspection of

Structural Steel
Ultrasonic Transducers
Explained
The CWI Part B Practical
Exam
For Info, go to aws.org/ad-index

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of AUGUST 2016 / VOL. 19 / NO. 3

Inspection
Trends
THE MAGAZINE FOR MATERIALS INSPECTION AND TESTING PERSONNEL

Features

On the cover: Welding inspection using the

EPOCH® 365 ultrasonic flaw detector. (Photo
courtesy of Olympus Scientific Solutions Ameri-
cas, Waltham, Mass.)
14 22

INSPECTION TRENDS (ISSN 1523-7168) is Visual Weld Inspection of Structural Steel Buildings
published quarterly by the American Welding by R. Zaske and T. Price / Visual inspection remains the most common
Society. Editorial and advertising offices are located
at 8669 NW 36th St., #130, Miami, FL 33166;
and widely used inspection method for inspecting welds on steel
telephone (305) 443-9353. Printed by R. R. structures / 14
Donnelley & Sons Co., Senatobia, Miss.
Subscriptions $30.00 per year for noncertified, An Introduction to Ultrasonic Transducers
nonmembers in the United States and its
possessions; $50.00 per year in foreign countries; Here are some tips for selecting an ultrasonic transducer, which is the
$20.00 per year for noncertified members and starting point for any ultrasonic test setup / 18
students; $10.00 single issue for nonmembers and
$7.00 single issue for members. American Welding
Society is located at 8669 NW 36th St., #130, Understanding the Updated CWI Practical Exam
Miami, FL 33166; telephone (305) 443-9353. by K. Coryell / Development and implementation of the updated CWI
Periodicals postage paid in Miami, Fla., and Part B practical exam are explained / 22
additional mailing offices.
POSTMASTER: Send address changes to
Inspection Trends c/o American Welding Society,
8669 NW 36th St., #130, Miami, FL 33166.

Readers of Inspection Trends may make copies of arti-

cles for personal, archival, educational, or
research purposes, and which are not for sale or
resale. Permission is granted to quote from articles,
provided customary acknowledgment of authors
and sources is made. Starred (*) items excluded from Departments
copyright.

Editor’s Note ................................6 Just the Facts.............................30

AWS MISSION STATEMENT
The mission of the American Welding Society News Bulletins .............................8 The Answer Is.............................32
is to advance the science, technology, and
application of welding and allied joining
processes worldwide, including, brazing, Print and Product Showcase .....12 Mail Bag .....................................33
soldering, and thermal spraying.
Technology Notes ......................24 Classifieds ..................................36

Mark Your Calendar ..................26 Advertiser Index ........................36

Certification Schedule ...............28

Inspection Trends / Summer 2016 5
 Editor’s Note
Publisher
Andrew Cullison, cullison@aws.org
Editorial
Dear Readers,
Editor
Mary Ruth Johnsen, mjohnsen@aws.org
Are you all inspectors or examiners? I
never realized this was a question that
needed to be answered until I started Senior Editor
working on this issue. After all, you are Cindy Weihl, cweihl@aws.org
Certified Welding Inspectors. That’s
your title and it’s the name of the Features Editor
program, so in my mind that’s what you Kristin Campbell, kcampbell@aws.org
are. And when I looked up both terms in
my Webster’s New World Thesaurus, Design and Production
Mary Ruth Johnsen they’re synonyms of each other.
Production Editor
But I never cease to discover new
Zaida Chavez, zaida@aws.org
things about the inspection profession
through the pages of this magazine, and it turns out that while the
terms are often used interchangeably, whether you are an inspector Senior Production Coordinator
or an examiner and whether you are performing a weld inspection or Brenda Flores, bflores@aws.org
a weld examination depend upon which code/standard you’re
working to. Manager of International Periodicals
I learned that because, as promised, the popular Just the Facts and Electronic Media
column has returned to the pages of Inspection Trends. Jim Merrill Carlos Guzman, cguzman@aws.org
decided he could not continue, but Rich Campbell has volunteered
to take on the column beginning with this issue. You can read his Advertising
first contribution, which covers this topic of inspector vs. examiner,
on pages 30 and 31. I think you’ll find it informative. Over the years, Manager of Sales Operations
I’ve found it fascinating that each time we get a new contributor Lea Paneca, lea@aws.org
to the magazine, we get a new perspective and new areas of
concentration. I think that will prove true with Rich’s contributions Senior Advertising Sales Executives
as well. Sandra Jorgensen, sjorgensen@aws.org
Here are just some of Rich’s credentials: He is a Bechtel Fellow Annette Delagrange, adelagrange@aws.org
and Welding Technical Specialist with Bechtel Corp., Houston, Tex.,
an AWS Senior Certified Welding Inspector, a Canadian Welding Senior Advertising Production Manager
Bureau Level 2 Welding Inspector, an ASNT NDT Level III Visual Frank Wilson, fwilson@aws.org
Testing Inspector, a registered metallurgical engineer, and a member
of the AWS D1 Committee on Structural Welding. Subscriptions Representative
I hope you enjoy this issue. I look forward to your comments and Evelyn Andino, eandino@aws.org
ideas. Contact me anytime at mjohnsen@aws.org or (800/305) 443-
9353, ext. 238.
American Welding Society
8669 NW 36th St., #130
Miami, FL 33166-6672
(800/305) 443-9353

Copyright
Copyright © 2016 by American Welding Society in both
printed and electronic formats. The Society is not responsi-
ble for any statement made or opinion expressed herein.
Data and information developed by the authors of specific
articles are for informational purposes only and are not
intended for use without independent, substantiating
investigation on the part of potential users.

6 Inspection Trends / August 2016

American Welding Society®
EDUCAATION
T
aws.org

CALLL FO
OR PA
PAPER
APERS
RS
40TH IN
NTERNATTIO
ONAL
BRAZING AND SSOLLDERING SYMPOS
SIUM
Presented by the Am
mericcan Welding Society (A
AW
WS)
November 116, 20016 - Las Vegas, NV

WS C3 Committee on Brazing and Soldering invites yoou take part in this prestigious
The AW
program by submitting a research papeer for consideration. This is your opportunity to present
p your
research to peers and leaders in the inddustry.

The programm organizers are acceptiing 500--600-wword abstrracts describing original, previously
unpublished woork. The work may includde currentnt res
research
earch, actuual or potential applications,
ons new
developments, or an outlook into actual technical areenas. Subm missions must be receivved on or
before Septembber 3, 2016 and authors will be notifieed whetherr their papers have beenn accepted
for presentationn at the Symposium.

For more details and

a to submit abstracts electronically,
visit: go.a
g ws.org/bbrazeabstr
tracts

**Note: If you have

v any co-authors on your suubmitted paper,
please make sure to supply all name and affiliation details througgh the link above when submitting.
 News Bulletins

Improved Inspection Techniques for
Submarine Pressure Hulls Will Save
Construction Costs
Improved inspection techniques could reduce the cost of
inspecting the pressure hull of Virginia Class submarines, such
as the one shown here, by as much as $1.2 million per hull per
inspection cycle.
The Navy Metalworking Center (NMC) is conducting a
Navy ManTech project expected to reduce the cost of the peri-
odic inspection of submarine pressure hulls. Current process-
es, which include visual and ultrasonic inspection, require sig-
nificant amounts of special hull treatment (SHT) be removed
to access the hull structure underneath. Afterward, the SHT
must be reinstalled.
Technologies that can inspect directly through the SHT,
or minimize the amount of SHT that must be removed, will
significantly reduce the cost of hull inspection. Technologies
of significant interest include the use of ultra-wide-band
radar, phased array ultrasonic with reduced contact area,
and terahertz imaging.
In Phase I, NMC is evaluating the feasibility of these ad-
vanced inspection technologies for use in this application.
Reducing the amount of SHT that must be removed and re-
installed to accommodate hull integrity inspection during
availability of the Virginia Class submarines has the oppor-
tunity to reduce cost by as much as $1.2 million per hull per
inspection cycle, or $6 million over a five-year period.
A prototype system to demonstrate/validate the tech-
nology will be developed in Phase II.
For additional information, contact Dr. Daniel L. Win-
terscheidt, senior program director, at winter@ctc.com, or
(814) 269-6840.
Pipeline Inspection Certification Program
Could Prove a Benefit to AWS Certified
Welding Inspectors
American Welding Society (AWS) Certified Welding In-

SO YOU’RE THEE
American Welding Society®
NEW
N W WELDING
G ENGINEER
R
EDUCAATTION Novem
mber 16-18, 20166
aws.org Lass Vegas Conventioon Center, Nevadaa

If you’re interested in expandding your career knowledggee, and taking on broader responsibility for welding
w activity in your company,
this is a unique opportunity too hear and talk with experrts who will explain many of the wide range of
o topics that a Welding Engineer
may have to consider – and direct
d you toward the thinnggs you will
w need to do to increase your valuue to your company.
But don’t come alone – BRIN NG YOUR BOSS! With thiss information
t and direction,
direction you can work together
t to improve your quality,
product reliability, and reducee your costs.

Keep an eye on fabtechheexpo

x .coom
m for registration opening dates.

8 Inspection Trends / August 2016

 This graphic displays the structure of inspection certification
programs. (Courtesy of INGAA.)

spectors (CWIs) could potentially benefit from a new

pipeline inspection certification program jointly developed
by the Interstate Natural Gas Association of America
(INGAA), INGAA Foundation, and the Canadian Energy
Pipeline Association and its foundation.
These pipeline trade associations in the United States
and Canada have voted to endorse a program to ensure that
all pipeline inspectors doing work for their member compa-
nies are certified by 2018.
The new certification program uses, as its base require-
ment, the American Petroleum Institute (API) 1169 Pipeline
Inspector Certification test. This certification has also been
revised to meet industry requirements in Canada.
Additional certifications are required for specialty in-
spectors, such as AWS CWI and Canadian Welding Bureau
(CWB) Level 2 for welding, plus National Association of
Corrosion Engineers (NACE) Level 2 for coating.
The program developed by INGAA and its partners will
not allow grandfathering into certification from other pro-
grams. All inspectors will be required individually to obtain
the certifications required by the program. There is no
ability to apply for equivalent certifications.
For info, go to aws.org/ad­index

Measure Ferrite Content with

h
the FISCHER FERITS ®

• Measurement range g 00.1

1 to 80%
% Fe or 0.1 1 to 110 FN
‡&RQWLQXRXVGLVSOD\PRGHWR¿QGZHOGVHDPVRQ
polished surfaces
‡8VHRQGXSOH[VWHHODXVWHQLWLFVWHHOZHOGVWXEHV
VKHHWVQRUPDOVWHHOZLWKDXVWHQLWLFFKURPHDOOR\
VWHHOZHOGHGFODGGLQJERLOHUVYHVVHOV

(860) 283-07
781
ZZZ¿VFKHUWHFKQRORJ\FRP
LQIR#¿VFKHUWHFKQRORJ\FRP

Coating Thickness Material Analysis

Microhardness Material Testing
e
For info, go to aws.org/ad­index For info, go to aws.org/ad­index
Inspection Trends / Summer 2016 9
 Training for the appropriate certifications is available
from AWS (aws.org) as well as CWB, API, and NACE.
This new program could prove beneficial to AWS CWIs
as more companies and regulatory bodies adopt these
guidelines. Where fully adopted, this will require that all
weld inspection be done by an AWS CWI or a CWB Level 2
Inspector. The program is expected to be fully implement-
ed over the next two years.
In addition, AWS CWIs now doing inspection on pipelines
will need to obtain the additional API 1169 certification to
continue working where the new guidelines are adopted.

Central Arizona College Adds Inspection

Course
Central Arizona College is adding Welding Inspection
Technology to its course offerings with the fall semester.
The class, listed as WLD 298, will be offered on Monday
evenings from 4:30 to 9:30 pm.
The course is designed for the welding professional who
has an interest in becoming a Certified Welding Inspector,
or transitioning from welding to inspection. It will also ben-
efit those already in the inspection field who may want to
advance or refresh their skills.
Brent Couch, welding technology professor, said, “I am
recommending all welding students take this course. It will
help them better understand the requirements of inspection
and meeting the standards of industry codes.”
The college offers an associate of applied science degree
in Welding Technology, a structural certificate, and is seek-
ing approval for a pipe welding certificate.
For info, go to aws.org/ad­index

American Welding Society®

aws.org

Want access
ess to reliable,
re
accurate welding
ngg information
in
any timee you
y needeed it?
The AW
AWS
W Weldin
e ing Handbookk
pu it at yourr fingertips.
puts

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w book
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10 Inspection Trends / August 2016

Pinnacle Expands Advanced Nondestructive
Testing Team

PinnacleART’s growing inspection team includes (from left) Jeff

Johnson, Reggie Thomson, Adam Gardner, and Mike Brown.

Pinnacle Advanced Reliability Technologies (Pinna-

cleART™) has expanded its advanced nondestructive testing
inspection team. According to the company, the team in-
cludes two of the 41 American Petroleum Institute (API)
Qualification of Ultrasonic Sizing Examiners (QUSE) certifi-
cation recipients worldwide. The expansion of the compa-
ny’s NDT service line comes as a result of the growing de-
mand from clients for highly trained, certified, and educated
inspectors to meet rigorous integrity program processes and
procedures.
— continued on page 35 For info, go to aws.org/ad­index

For info, go to aws.org/ad­index

For info, go to aws.org/ad­index

Inspection Trends / Summer 2016 11
 Print and Product Showcase

UT Instrument Offers Large plex inspections, and onboard volu-

metric merge and measurement tools
Multitouch Screen and to speed up the analysis process. The
Onboard Software 16-channel instrument has a wide op-
erating temperature range, a rugged
The TOPAZ16 phased array ultra- aluminum casing with no air intake,
sonic instrument features onboard Ul- and was built to meet a wide range of
traVision Touch software, an advanced inspection demands. Common applica-
focal law calculator with visual feed- tions include weld inspections, corro-
back simplifies preparation for com- sion mapping, encoded or manual in-
spections, and inspections of complex
components. It offers a 10.4-in. high-
resolution display and a responsive
multitouch screen.

Zetec, Inc.
American Welding Society® zetec.com
CERTIFICAATION
T
aws.org Video Borescopes Updated

AWS
W CERTIFIC
T ATION
T PROGGRAMS
GRAMS:
SERIOUS
US WORK. SIGNIFICANTT IMP
MPPA
PAACCTT.
The update to the XL Vu™ video
borescope includes improved light out-
With “manufacturingg sskills gap” put for enhanced image quality, stereo
conversations beco
co coming mmore and more measurement, 4 GB of internal memo-
ry, video output, and multiple USB
comm
mmonplace, e, it’
i s hard too ignore the
ports. The durable, field-ready product
need forr ccre
credentialed skills. is rated to IP55 and tested to tempera-
tures up to 212°F. In addition, the
AWS Certificatio
tions are thhe most company’s XL Lv™ video borescope is
now available globally. This utility
recognized credential
tials in the welding videoprobe offers high-quality still and
industry; created and baccked by a video images. Both instruments weigh
collective of experience aandd ddistinction.
n. 3.9 lb and offer multiple probe lengths
and diameters with interchangeable
tip optics.
So, by earning an AWS Certification
C ca on,
you’re positioning yoursellf fo
for success.
s GE Inspection Technologies
Why wait? Secure yourr fuuture now. gemeasurement.com/inspection-
and-non-destructive-testing
Start your
ur path to
t ward Gauge Measures Coatings
AWS Certification at Up to 20 mm Thick
go.aws.org/pa
ws thtoceertification When the probe is exchanged on
the Multigauge 5650 Surveyor thick-
ness gauge, it automatically switches to
single echo mode for measuring uncoat-

12 Inspection Trends / August 2016

 tional option of being encoded as a vides a description of each of the appli-
third axis, if required. cation areas of the nondestructive in-
spection market, which includes the fol-
Phoenix Inspection Systems Ltd. lowing testing techniques: visual, mag-
phoenixisl.com netic particle, liquid penetrant, eddy
current, ultrasonic, radiography,
Report Forecasts NDT and acoustic emission, and terahertz imag-
Inspection Markets ing. Ultrasonic testing is expected to
hold the largest market share between
ed metal, glass-reinforced plastic, or The report Non-Destructive Testing 2016 and 2022. Applications in the oil
plastic. For metal measurement, the and Inspection Market by Technique, Serv- and gas industries are expected to hold
gauge utilizes the multiple echo tech- ice, Vertical, and Geography – Global Fore- the largest market share to 2022.
nique to ignore coatings up to 20 mm cast to 2022 details that the NDT mar-
thick and just measure the metal sub- ket is expected to reach $11.39 billion Research and Markets
strate without the need to grind or oth- by 2022 at a compounded annual researchandmarkets.com
erwise remove the coatings. Either growth rate of 8.3%. The report pro-
probe can also be used in echo-echo
mode by selecting the option from the
keypad during measurement, which
negates the need for special probes. All
probes have Intelligent Probe Recogni-
tion, which automatically adjusts set-
tings in the gauge when connected to
match the probe and the gauge. The
gauge uses only single crystal probes.
The gauge comes as a complete, ready-
to-use kit with a three-year warranty
and free calibration for the life of the
gauge.

Tritex NDT
tritexndt.com

System Inspects Weld

Nozzles

NozzleScan, a manual scanning

instrument for the inspection of noz-
zle welds, works with both set-through
and set-on configurations. The instru-
ment comes in both two- and three-
axis configurations and is adaptable to
cover a wide range of 90-deg nozzle
sizes, from 3-in. OD upward, on ferrit-
ic and austenitic materials. It features
an overhead gimballed probe holder
that allows the operator to hold the
transducer conventionally for a more
tactile inspection. Probe skew orienta-
tion is also changeable, which is criti-
cal for inspecting many nozzles. In
that orientation, it can be free running
or accurately adjustable with the addi-
For info, go to aws.org/ad­index

Inspection Trends / Summer 2016 13

 Feature
Visual Weld Inspection of
Structural Steel Buildings
Following specific sequential steps with properly trained and certified
weld inspectors are key elements of a sound quality control program
NASA test stand 4693, which was designed to test the hydrogen tank for the new NASA
SLS Rocket program. The tank will be tested to failure.
Technical and scientific advances
over the past century have provided
many options for inspecting structural
welds when erecting steel-framed struc-
tures and buildings. Radiography, dye
penetrant testing, and standard ultra-
sonic testing right through to the most
recent advances in phased array are only
a few of these technologies. Even with
these advances, by far the most com-
mon and widely used inspection
method for inspecting welds on steel
structures is the good old human eye.
Visual weld inspection is always
the first inspection method used to
14 Inspection Trends / August 2016
ensure the quality of any weld, and in
many, many instances visual inspec-
tion is the final means of approval to
ensure the integrity and compliance of
the weld in question. Nevertheless, as
simple as it may sound, just as with
many other things in life, there is
much more to visual weld inspection
than there may seem. There are certain
sequenced steps an erector must take
and very strict criteria that a responsi-
ble steel erector must meet to ensure
not only the integrity of the weld be-
ing inspected, but also to maintain
compliance with project requirements,
By Ricky Zaske and Tim Price
governing codes, and the steel erec-
tor’s own quality control program.
The first step prior to any welding
activities being performed on a project
is to review the contract documents,
which include the erection drawings.
These documents will provide you the
information of what codes and stan-
dards to which the structural steel is to
be erected and welded. The erection
drawings also provide details of the
welded connections. These details will
provide the information necessary for
determining what prequalified welding
procedures will be required for the weld-
ing activities or if you need to perform
procedure qualification for developing a
Welding Procedure Specification (WPS)
for a welded joint connection.
Often, after review of the contract
documents, it is identified that the
steel shall be welded and inspected in
accordance with AWS D1.1: 2015,
Structural Welding Code — Steel (Ref.
1), and AISC 360-10, Specification for
Structural Steel Buildings (Ref. 2).
Within AWS D1.1 and AISC 360, there
are requirements for inspection that
shall be met by the erector.
Erector’s Responsibility
When reviewing AISC 360, you’ll
find Chapter N provides the minimum
requirements for quality control (QC),
quality assurance (QA), and nonde-
structive testing (NDT). Quality control
in this chapter is defined as provided by
the fabricator and erector. AISC 360 N2
requires the erector maintain quality
control procedures and perform inspec-

R. Michael Whitten, PE, performs fitup
inspection of a W40  431 CJP single
bevel groove with a copper backing bar.
He is verifying alignment.
tions in accordance with the specifica-
tion and contract documents. The field
welding is to be inspected by the erec-
tor’s quality control inspector (QCI).
AISC N4 describes the requirements
that need to be met for qualification of
the QCI. There are two options within
N4: 1) qualified and certified to a level
of Associate Welding Inspector (CAWI)
or higher in accordance with AWS B5.1,
Standard for the Qualification of Welding
Inspectors (Ref. 3), and 2) qualified in
accordance to AWS D1.1 Clause 6.1.4.
Note: AISC 360 Chapter N also re-
quires other inspections to be per-
formed or observed by the erector that
are not listed in this article. The reader
must review AISC 360 Chapter N for
other inspection requirements that
pertain to erection of structural steel.
Weld Inspector Qualification
AWS B5.1 is an employer-based
qualification standard that “establishes
the requirements for qualification and
defines the body of knowledge applica-
ble to welding inspection personnel.”
AWS B5.1 has three levels of qualifica-
tion: Certified Associate Welding In-
spectors (CAWI), Certified Welding In-
spector (CWI), and Senior Certified
Welding Inspector (SCWI). Each of
these qualification levels has defined du-
ties as specified in AWS B5.1. When
qualifying welding inspectors in accor-
dance to the standard, the erector must
determine its needs in regard to the
welding inspector’s capabilities based on
In-process weld inspection. As the welder works, the weld inspector, R. Michael Whitten, is
verifying weld technique and travel speed.
qualification level. Along with ensuring
the qualification level meets the erec-
tor’s inspection requirements, the weld
inspection personnel who are to be
qualified must meet education and ex-
perience requirements, pass a written
examination, have the ability to pass a
Jaeger 2 eye exam in at least one eye
with or without correction, take a color
perception test, and a contrast differen-
tiation shades of grey test.
AWS D1.1 Clause 6.1.4 has three
acceptable options for the qualification
of welding inspection personnel: 1) The
welding inspector has a “current or pre-
vious certification as an AWS Certified
Welding Inspector (CWI) in confor-
mance with AWS QC1, Standard for AWS
Certification of Welding Inspectors,” 2)
“current or previous qualification by the
Canadian Welding Bureau (CWB) in
conformance with requirements of the
Canadian Standard Association (CSA)
Standard W178.2, Certification of Weld-
ing Inspectors,” or 3) “an individual who,
by training or experience, or both, in
metal fabrication, inspection, and test-
ing, is competent to perform inspection
of the work.” AWS D1.1 also requires
that the weld inspector pass an eye
exam with or without correction to a
Jaeger 2 every three years.
The contract documents should be
reviewed carefully on the subject of the
welding inspector’s qualification level.
The contract documents may state the
level of qualification that is required for
the project and may exceed the mini-
mum requirements stated within AISC
360 and AWS D1.1.
Once the erector determines the
level of qualification for the welding in-
spector, AISC 360 N5 lists the mini-
Inspection Trends / Summer 2016 15
mum requirements for inspection of
structural steel buildings and states “QC
inspection tasks shall be performed by
the erector’s quality control inspector
(QCI) as applicable, in accordance with
AISC N5.4, N5.6, and N5.7.” Inspection
of welding is addressed in AISC N5.4
and Tables N5.4-1 through N5.4-3. The
erector is responsible for the observa-
tion of the welding operation, in-
process weld inspection, and final weld
inspection. All the provisions of AWS
D1.1 for statically loaded structures
apply to structural steel.
Weld Inspection
Requirements and
Frequency
AISC Tables N5.4-1 through
N5.4-3 list the inspection require-
ments for the erector’s QCI. These re-
quirements will either be a perform
(P) as defined “perform these tasks for
each welded joint or member” or ob-
serve (O) as defined “observe these
items on a random basis, operation
need not be delayed pending these ob-
servations.”
AISC Table N5.4-1 lists the in-
spection tasks that must be done prior
to welding being performed. Following
are the eight items that need to be ei-
ther performed or observed by the
erector’s QCI:
1. Welding Procedure Specifica-
tion (WPS) available (Perform)
2. Manufacturer’s certifications
for welding consumables available
(Perform)
3. Material identification
(type/grade) (Observe)

R. Micheal Whitten performs final weld inspection of a W40  431 CJP groove weld. The
inspector is verifying weld reinforcement height.
4. Welder identification system
(Observe)
5. Fitup of groove welds (Observe)
6. Configuration and finish of ac-
cess holes (Observe). This item is nor-
mally a function of the fabricator, but
in some cases the erector may have to
field fabricate beams.
7. Fitup of fillet welds (Observe)
8. Check the welding machine
(Observe).
AISC Table N5.4-2 lists the inspec-
tion tasks that must be done during
welding. Following are the six items the
erector’s QCI needs to observe:
1. Use of qualified welders
2. Control and handling of weld-
ing consumables; packaging, exposure
control
3. No welding over cracked tack
welds
4. Environmental conditions —
wind speed, precipitation, and temper-
ature
5. WPS being followed — setting
on welding machine, travel speed, se-
lected welding materials, shielding gas
type/flow rate, preheat, interpass
temperature maintained, and proper
position
6. Welding techniques — inter-
pass and final cleaning, each pass
within profile limitations, and each
pass meets quality requirements.
AISC Table N5.4-3 lists the inspec-
tion tasks after welding. Following are
the eight items that need to be exam-
ined or performed by the erector’s QCI:
1. Welds cleaned
2. Size, length, and location of
welds
3. Welds meet the visual accept-
ance criteria with regard to crack pro-
hibition, weld/base metal fusion,
crater cross section, weld profiles, weld
size, undercut, and porosity
4. Arc strikes
5. K-area — inspect for cracks
16 Inspection Trends / August 2016
within 3 in. of the weld when welding
doubler plates, continuity plates, or
stiffeners
6. Backing and weld tabs removed
when required
7. Repair activities
8. Document the acceptance or re-
jection of the welded joint.
Again, the contract documents
should be reviewed carefully. The con-
tract documents may stipulate weld in-
spection requirements that are more
stringent than what is listed within
AISC Tables N5.4-1 through N5.4-3 and
work cannot proceed until the weld in-
spections are completed by a Quality
Assurance Inspector (QAI) and meet the
requirement of AWS D1.1 and contract
documents. The QCI may not need to
perform these inspections, but ensure
work does not progress until these in-
spections are complete and in accor-
dance with the contract documents and
referencing code. Examples may include
but not be limited to the following:
1. Perform fitup inspections for all
complete-joint-penetration (CJP) welds
2. Perform root inspection on all
CJP welds
3. Perform magnetic particle test-
ing (MT) on all root welds of CJP welds.
You may be thinking “where did all
these requirements come from?” The
answer is they have always been re-
quired by AWS D1.1. When reviewing
the commentary to the tables listed
above in AISC 360, there are references
to AWS D1.1 sections for each of these
tasks excluding inspection of the K-area.
What is useful about these tables is that
they are easy to understand and specific
to what inspections are required by the
erector when welding structural steel in
accordance with AISC 360.
To perform the weld inspection
tasks required within AISC Tables
N5.4-1 through N5.4-3, you will need
to reference the following at a mini-
mum: AWS D1.1, Prequalified Welding
Procedure Specifications (PWPSs),
WPSs, and the contract documents for
acceptance criteria.
When the erector’s weld inspector
is performing weld inspection, it is im-
portant that an inspection procedure
be available detailing how to perform
the weld inspection. AISC 360 and
AWS D1.1 only state what needs to be
inspected, frequency of inspection,
and acceptance criteria of the item
that is to be inspected. The inspection
procedure should address but is not
limited to the following:
1. Personnel qualification require-
ments
2. Scope of the procedure
3. Use of visual aids
4. Light intensity
5. Lighting equipment
6. Methods or tools for surface
preparation
7. Distance and angle of the eye to
item being inspected
8. Sequence of inspection
9. Required documentation.
Summary
It is very well defined in the re-
quirements of AISC 360 and AWS
D1.1 that weld inspection of structural
steel is the responsibility of the steel
erector, but it is not overly difficult nor
need it be excessively confusing. By
following specific sequential steps
with properly trained and certified
weld inspectors through a sound quali-
ty control program, the steel erector
can confidently assure the client and
the building owner that they are re-
ceiving quality welds.
References
1. AWS D1.1: 2015, Structural
Welding Code — Steel. Miami, Fla.:
American Welding Society.
2. AISC 360-10, Specification for
Structural Steel Buildings. Chicago, Ill.:
American Institute for Steel Construc-
tion.
3. AWS B5.1, Standard for the
Qualification of Welding Inspectors. Mia-
mi, Fla.: American Welding Society.
RICKY ZASKE
(rzaske@lprconstruction.com)
is corporate quality manager, and
TIM PRICE
is executive director, LPR Construction,
Loveland, Colo.
 Feature
An Introduction to Ultrasonic
Transducers
These tips will help you select the type of ultrasonic transducer
best suited for your NDE application
The high-frequency sound waves
used for flaw detection and thickness
gauging in ultrasonic nondestructive
examination (NDE) applications are
generated and received by small
probes called ultrasonic transducers.
Transducers are the starting point for
any ultrasonic test setup, and they
come in a wide variety of frequencies,
sizes, and case styles to meet inspec-
tion needs ranging from flaw detec-
tion in enormous multi-ton steel
forgings to thickness measurement of
paper-thin coatings.
A transducer is generally defined
as any device that converts one form
of energy into another.
In ultrasonic NDE, transducers
convert a pulse of electrical energy
from the test instrument into me-
chanical energy in the form of sound
waves that travel through the test
piece. Sound waves reflecting from the
test piece are, in turn, converted by
the transducer into a pulse of electrical
energy that can be processed and dis-
played by the test instrument. In ef-
fect, the transducer acts as an ultra-
sonic speaker and microphone, gener-
ating and receiving pulses of sound
waves at frequencies much higher than
the range of human hearing.
Typically, the active element of
an NDE transducer is a thin disk,
square, or rectangle of piezoelectric
ceramic or composite that converts
electrical energy into mechanical en-
ergy, and vice versa. This element is
sometimes informally called the crys-
18 Inspection Trends / August 2016
tal because, in the early days of ultra-
sonic NDE, elements were made from
quartz crystals; however, ceramics
such as lead metaniobate and lead zir-
conium titanate have long been used
in most transducers. Recent years
have seen an increasing use of com-
posite elements where the traditional
solid ceramic disk or plate is replaced
by a micro-machined element in
which tiny cylinders of piezoelectric
ceramic are embedded in an epoxy
matrix. Composite elements can pro-
vide increased bandwidth and im-
proved sensitivity in many flaw de-
tection applications.
When it is excited by an electrical
pulse, this piezoelectric element gen-
erates sound waves, and when it is vi-
brated by returning echoes, it gener-
ates a voltage. The active element is
protected from damage by a
wearplate or acoustic lens and backed
by a block of damping material that
quiets the transducer after the sound
pulse has been generated. This ultra-
sonic subassembly is mounted in a
case with appropriate electrical con-
nections. All common contact, angle
beam, delay line, and immersion
transducers utilize this basic design.
The phased array probes used in im-
aging applications simply combine a
number of individual transducer ele-
ments in a single assembly. Dual-
element transducers, commonly used
in corrosion survey applications, dif-
fer in that they have separate trans-
mitting and receiving elements sepa-
rated by a sound barrier, no backing,
and an integral delay line to steer and
couple the sound energy rather than
a wearplate or lens.
Figure 1 illustrates typical trans-
ducer construction.
While the basic concept is simple,
transducers are precision devices that
require great care in design, material
selection, and manufacturing to help
ensure optimum and consistent per-
formance. The transducers commonly
used in conventional ultrasonic NDE
fall into the following five general cat-
egories based on their design and in-
tended use.
Contact Transducers
As the name implies, contact trans-
ducers are used in direct contact with
the test piece. A thin, hard wearplate
cut to a thickness of one-quarter the
wavelength protects the active element
from damage in normal use. Contact
transducers are commonly used in flaw
detection applications involving
straight beam tests, such as when look-
ing for voids in metal ingots or delami-
nations in composites, and also in
many thickness gauging applications.
Angle Beam Transducers
These are similar in construction
to contact transducers, but are de-
signed to be used with angle beam
wedges to generate sound tilted at an
 Fig. 1 — Typical single-element and dual-element transducer construction.
angle to the coupling surface. Wedges
are commonly configured to generate
refracted shear waves at 45, 60, or 70
deg. They are standard in most weld
inspections since testing the most
common weld geometries requires
aiming sound waves at an angle.
These transducers are referenced in
all common weld inspection codes.
Delay Line Transducers
Delay line transducers incorporate
a cylinder of plastic, epoxy, or fused sili-
ca known as a delay line between the ac-
tive element and the test piece. A major
reason for using them is for thin materi-
al applications like testing spot welds in
sheet metal or measuring very thin test
pieces, where it is important to separate
the excitation pulse recovery from back-
wall echoes. A delay line is often used as
a thermal insulator, protecting the heat-
sensitive transducer element from di-
rect contact with hot test pieces. Delay
lines can also be shaped or contoured to
improve sound coupling in sharply
curved or confined spaces.
Immersion Transducers
Immersion transducers, as the
name implies, are designed to be im-
mersed in water and use a column or
bath of water to couple sound energy
into the test piece. These transducers
frequently incorporate an acoustic lens
that focuses the sound beam into a
small spot, increasing sensitivity to
small reflectors. They are commonly
used for on-line or in-process tests on
moving parts, for scanned tests, and
for optimizing sound coupling into
sharp radiuses, grooves, or channels in
test pieces with complex geometry.
Dual-Element Transducers
Dual-element transducers, or
simply “duals,” are used primarily for
tests involving rough, corroded sur-
faces. They incorporate separate
transmitting and receiving elements
mounted on a delay line at a small an-
gle to focus sound energy a selected
distance beneath the surface of a test
piece. Although thickness measure-
ment with duals is sometimes not as
accurate as with other types of trans-
ducers, they usually provide signifi-
cantly better performance in corro-
sion survey applications due to their
higher sensitivity to pitting and im-
proved near-surface resolution. They
are also commonly used for high-
temperature testing since most duals
Inspection Trends / Summer 2016
will tolerate contact with hot surfaces,
and for flaw detection in rough-sur-
faced castings.
Longitudinal and Shear
Waves
The high-frequency vibrations
that are the basis of ultrasonic NDE
commonly occur as either longitudi-
nal waves (particle motion parallel to
wave direction) or shear waves (parti-
cle motion perpendicular to wave di-
rection). All commonly used NDE
transducers generate longitudinal
waves. Thickness gauging and
straight beam flaw detection normal-
ly use longitudinal waves, which are
the easiest to create and propagate
well through typical engineering ma-
terials. Shear waves are used in most
angle beam inspections of welds and
similar structures. Angle beam as-
semblies use refractive mode conver-
sion to turn the longitudinal waves
generated by the transducer into
shear waves, which have a shorter
wavelength than comparable longitu-
dinal waves and are thus more sensi-
tive to small reflectors.
Some immersion tests also utilize
shear waves generated by mode con-
version. Other modes, such as surface
19
waves and plate waves, also exist as
well as contact transducers that gener-
ate shear waves directly, but these are
employed only in specialized tests.
A Variety of Frequencies
In addition to the various design
types, ultrasonic transducers are avail-
able in a wide variety of frequencies,
sizes, and bandwidths to meet differ-
ent application needs. Most ultrasonic
testing is performed at frequencies be-
tween 1 and 10 MHz; however, com-
mercially available transducers range
in frequency from less than 50 KHz to
greater than 200 MHz. (By compari-
son, the range of human hearing is
from approximately 20 Hz to 20 KHz,
decreasing as a person gets older.)
Commonly used element sizes range
from as small as 0.125 in. (3 mm) to
1.5 in. (38 mm). Bandwidth, or the
span of frequencies contained in the
spectrum generated by the transducer,
may be either narrow or broad.
Why all these choices? Because of
basic wave physics, each of these param-
eters affects the behavior of the sound
wave in ways that will have advantages
and disadvantages in a given test.
Higher frequencies permit detec-
tion of smaller flaws and measurement
of thinner test pieces, but the sound
energy won’t travel as far as at lower
frequencies. Lower frequencies pro-
vide better penetration of thick test
pieces, especially in materials like cast
metals and plastics that transmit
sound less efficiently, but they will be
less sensitive to small flaws and may
not measure thin sections.
Large elements can permit quicker
scanning of a test piece, but will reduce
sensitivity to small reflectors and may
not couple well onto curved surfaces
like pipes. Smaller elements will be
more sensitive to small reflectors and
will couple better onto curved surfaces,
but will not test large areas as quickly.
Broadband transducers have good
near-surface resolution, enabling de-
tection of flaws close to the surface
20 Inspection Trends / August 2016
and measuring thin parts. Narrow-
band transducers have better penetra-
tion and can generate stronger echoes
from reflectors, but exhibit less axial
resolution.
What Is Best for Your
Application?
So which one is best for your ap-
plication? In many cases, the choice of
a transducer will be dictated by an es-
tablished inspection code or test pro-
cedure that calls out a specific type.
But if no procedure is available, the in-
spector must decide on the best trans-
ducer for the test based on his or her
knowledge of ultrasonic theory, the
defined test goals (such as the type
and size of flaws that need to be re-
solved), and the specific material,
thickness, and geometry of the test
piece. While knowledge of theory and
some NDE experience are essential, in
some cases an inspector’s skills must
be supplemented by experimentation
on test samples to determine which
transducer will work best.
Transducers are commonly sup-
plied with test forms that document
basic performance characteristics, typ-
ically with respect to a generally recog-
nized test procedure such as ASTM E-
1065. These forms verify product con-
sistency and adherence to specifica-
tions. As an example, the test form
documents peak and center frequen-
cies, upper and lower frequency limits,
bandwidth, and RF waveform under
the listed test conditions. For ad-
vanced users, manufacturers can also
supply more specialized documenta-
tion such as electrical impedance plots
and beam profiles when required.
While the transducer is an essen-
tial part of any test, instrument setup
is also a critical factor. Instrument
manufacturers will typically supply
recommended procedures for calibrat-
ing their instrument with a given
transducer for a given test. At a mini-
mum, this involves setting gain (sensi-
tivity) levels and zero offset with re-
spect to the transducer being used and
material sound velocity. This is usually
accomplished with the aid of appropri-
ate test blocks or reference samples.
Depending on the instrument and the
test, other parameters such as pulse
energy, damping, and receiver filtering
may also need adjustment.
A properly trained inspector will
be familiar with all of these settings
and know how to use them to opti-
mize test results in each case. Good
practice also dictates that instrument
settings be verified whenever the
transducer is changed, or if the trans-
ducer shows signs of excessive wear.
Many test procedures require periodic
calibration checks during inspections
to help ensure that nothing affecting
test results has changed.
Transducers from quality manu-
facturers will usually last for years if
treated well; however, they are sensi-
tive devices that should be protected
from damage due to excessive shock or
vibration, abrasion from scraping
against rough surfaces, exposure to
corrosive liquids, and overheating. Un-
less specified for high-temperature
use, most single-element transducers
should not be subjected to tempera-
tures higher than approximately 125°F
(50°C). Transducers with significant
visible surface wear should be checked
for performance before use. Dual-
element transducers can frequently be
resurfaced, and delay lines can be easi-
ly replaced, but damage to contact
transducers is nonrepairable.
High-pressure environments, un-
derwater use, and other special envi-
ronments should be reviewed with the
transducer manufacturer. In cases
where test piece geometry restricts ac-
cess, special transducers can some-
times be designed to fit. Again,
consultation with the manufacturer is
recommended.
Based on information provided by
Olympus Scientific Solutions Americas,
Waltham, Mass., olympus-ossa.com.
 American Welding Society®
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 Feature
Understanding the Updated
CWI Practical Exam
Before the exam was released to the public last February, it went through several
rigorous rounds of beta tests to make sure the requirements were realistic
The new Certified Welding Inspec-
tor (CWI) practical exam has been in use
since February 1, but it has been in the
planning and development stages for
more than four years. The development
was no easy undertaking, and required
many hundreds of volunteer hours by
dedicated welding inspection profes-
sionals on the Certification Comittee
Exam Bank (CCEB) Subcommittee .
In addition to the CCEB, contribu-
tors included George Hlifka, Bob
Wiswesser, Stan Raymond, Lyndsey
Deckard, Jim Reid, Jeff Hufsey, Blake
Craft, and Dave Landon. AWS staff pro-
vided key planning and coordination
support throughout, which enabled var-
ious milestones to be achieved.
Based on revisions to AWS B5.1,
Specification for Qualification of Welding
Inspectors, as well as feedback and sur-
veys from industrial users of CWIs,
CCEB decided a completely fresh ap-
proach was needed. The Part B Book of
Specifications (BOS), tool kit, examina-
tion specimens, and Book of Exhibits
(BOE) were all on the table.
The Book of Specifications was the
first component studied. The previous
BOS was a collection of tables and text
heavily influenced by AWS D1.1, Struc-
tural Welding Code — Steel. CWI candi-
dates with only pipeline or pressure pip-
ing experience were often unfamiliar
with structural requirements (e.g., pre-
qualified joint details) and would strug-
gle with some of the questions in this
area.
It took about a year for the first
draft of the revised BOS to be written.
Because CWIs commonly work in many
different industries, a minimally quali-
fied CWI should be able to work in dif-
ferent industry sectors requiring differ-
ent approaches to inspection. As a re-
22 Inspection Trends / August 2016
sult, specific clauses were written for ap-
plications involving structural steel,
pipelines, and pressure piping. They are
based on D1.1, API 1104, and ASME
B31.1. Other codes and standards were
considered, but for practical considera-
tions could not be included.
Throughout the rewrite process,
the CCEB’s objective was to keep the re-
quirements realistic and in line
with what a CWI might realistically en-
counter when using a company specifi-
cation developed with these codes and
standards.
A significant effort was spent ad-
dressing welding qualifications that are
different between D1.1, API 1104, and
ASME B31.1. Under the time con-
straints of an examination, addressing
all the different technical nuances be-
tween these three codes would be con-
fusing. Therefore, a fourth clause was
added to the BOS that covers only quali-
fications. It is generally based on AWS
B2.1, which holds some recognition in
D1.1 and ASME. The examination weld-
ing procedure and welding performance
qualification requirements, including
qualification variables and limits, are
based on this clause. The BOS also con-
tains several normative and informative
annexes. Numerous revisions and edits
were required throughout the develop-
ment process. Because of the examina-
tion time limit, candidates should be-
come familiar with the BOS prior to at-
tempting the examination.
Before much thought could be giv-
en to test specimens, tool kits, and the
Book of Exhibits, a detailed analysis of
CWI practical skills was performed.
Throughout the development
process, the driving question was exact-
ly what is it that a minimally qualified
CWI should be able to do? The earlier
By Ken Coryell
practical exams largely concentrated on
final visual examinations with an em-
phasis on evaluation of discontinuities
and weld sizes. Both AWS B5.1 and
AWS 1.11, Guide for the Visual Examina-
tion of Welds, are clear that inspections
are to be performed before, during, and
after welding. Therefore, the examina-
tion body of knowledge was expanded
to put additional emphasis on the “be-
fore” welding activities of documenta-
tion review [e.g., Welding Procedure
Specifications (WPSs), Procedure Quali-
fication Records (PQRs), and Welding
Procedure Qualification Records
(WQTRs)]; edge preparations (e.g.,
roughness); and fitup.
Welding “in-process” tasks now in-
clude bead sequence, placement, and
terminations, plus overall compliance
with WPSs. “Final” inspection tasks con-
tinue to include, but go beyond, evalua-
tion of porosity, undercut, weld size,
and weld reinforcement. Some addition-
al inspection skills added include evalu-
ation of weld width, weld pitch and
length, terminations, end returns and
holdbacks, root surface conditions, and
weld repairs.
Because of added emphasis in
other body of knowledge areas, a Book
of Exhibits (BOE) was needed that
includes other documents in addition to
photographs.
Candidates can be expected to con-
sult WPSs, PQRs, and WQTRs as they
would need to do realistically as part of
normal inspection activities. An assort-
ment of these have been assembled. All
have been prepared by CCEB welding
engineers and are based on actual and
typical jobs. A minimally qualified CWI
is expected to review these documents
for completeness and accuracy and, if
correct, use them to monitor a job for

Fig. 1 — The current AWS tool kit. It includes (from left) hi-lo
gauge, dial caliper, ruler, mirror, C4.1, magnifying glass,
protractor, V-Wac, fillet gauges, and flashlight.
compliance. Based on qualification
limits defined in a standard, the CWI
should be able to recognize whether or
not a welder is qualified to perform a
specific job.
Test Specimens
With an overall plan in place, a ma-
jor amount of effort went into the de-
velopment of new test specimens. Vari-
ous replication processes were consid-
ered and this was factored into the plan-
ning. Subtle flaws had to be consistent
from one specimen to the next. Early in
the planning, it was recognized that
some type of a pipe specimen would be
required and that it would be necessary
to replicate detail on both the exterior
as well as the interior pipe surfaces. This
proved to be a challenge for some of the
replica suppliers.
In addition to the pipe, butt, T, and
lap joint specimens were planned and
detailed drawings prepared showing
what weld sizes were needed and what
flaws were needed and at what loca-
tions. Some joints are at various stages
of welding.
The drawings were thoroughly re-
viewed against the matrix of required
CWI skills to verify that all body of
knowledge skills were covered in some
way. The master specimens then needed
to be produced. Different weld shops
were used and a CCEB member was
present during the welding of the speci-
mens to make sure that all desired fea-
tures were present and that flaws ap-
peared to be realistic. Countless bend
specimens were reviewed for both speci-
men preparation issues and discontinu-
ities. Several specimens were selected
for exam purposes.
Once the replication of plastic spec-
imens went into production, it was nec-
essary to design a detailed inspection
plan to ensure replica-
tion consistency be-
tween specimens. One
hundred percent of the
specimens being used in
the examination were
checked in accordance
with a written checklist
developed by CCEB.
AWS staff were trained
by CCEB members re-
garding what had to be
examined and measured.
All inspection features
for each specimen were
recorded on a checklist.
Any discrepant speci-
mens were discarded.
Tool Kit
Selection of the specific inspec-
tion tools for the tool kit provided a
different challenge. Nearly every weld-
ing gauge that is commercially avail-
able in the United States was consid-
ered at some point. Each CCEB mem-
ber tried each tool as appropriate on
each specimen. Consideration was giv-
en to required precision and accuracy,
whether or not the tool was commonly
used, and how frequently the tool
would be used on the exam.
Tool preferences can vary from in-
spector to inspector, so the CCEB
members concentrated on the required
precision and accuracy needed for the
weld replicas. Some tools had reliabili-
ty issues, meaning it was difficult to
obtain consistent results on the same
specimen. These factors were also con-
sidered. The subcommittee worked
with the gauge manufacturer to modi-
fy the design of some of the tools to
make them more usable both on the
exam and on actual jobs. These tool de-
signs have replaced the earlier designs
in the commercial catalogs.
The final tool kit reflects the overall
best balanced decision. Some of the
tools may not be the first choice on an
actual job, but for the CWI exam speci-
mens, they worked best. Tools that
could be used for more than one pur-
pose were favored. Following is a sum-
mary of the tools in the new kit (Fig. 1):
• Flashlight (same as old kit)
• Magnifier (same as old kit)
• Fillet Gauges (same as old kit)
• V-Wac Gauge (slightly modified
to extend reach and reliability)
• 6-in. Steel Rule (now has both
fraction scales and decimal scales)
Inspection Trends / Summer 2016 23
• Caliper
• Protractor (new)
• Mirror (new)
• Surface Roughness Guide (new)
• Hi-Lo Gauge (new)
The weld size gauge (palmgren)
was removed from the kit because of
precision and cost.
It should be mentioned that with
the new convexity limits in D1.1,
CCEB could not locate a suitable com-
mercially available tool that could
measure these limits, especially when
considering convexity limits for indi-
vidual beads in a split-bead layer.
CCEB developed a new tool for this ap-
plication in cooperation with a gauge
manufacturer. It is now commercially
available, in use, and will be added to
the kit in the near future.
Exam Questions
Exam question writing started once
enough of the major pieces were in
place. The writing of multiple choice test
questions that are clear and unambigu-
ous is no easy task. Some questions un-
intentionally ended up being more diffi-
cult than intended, and some were un-
intentionally so easy they could be an-
swered without even looking at a speci-
men. The CCEB members debate fre-
quently about whether a question is
something that a minimally qualified
CWI should be able to answer. Each
question must be agreed to and ap-
proved by all members before it is used.
When a sufficient number of questions
are written, an exam must be generated
that distributes the number of ques-
tions proportionally across the body of
knowledge as specified by B5.1. The
exam is then beta tested with candi-
dates who were not involved in the
question development process. Feed-
back is received and revisions are made.
Before the exam was released to the
public last February, it underwent sever-
al rigorous rounds of beta tests. The
CCEB carefully monitors performance
of the exam and continues to make im-
provements where needed.
KEN CORYELL
is a Senior Certified Welding Inspector
and has been an AWS member for more
than 40 years. Formerly a long-time AWS
instructor who prepared candidates for
the CWI exam, he now works as a
member of the Certification Committee
Exam Bank Subcommittee. He is a
semiretired welding quality consultant.
 Technology Notes
AWS Log: D1.1-15-I01 ing machine, and the welding personnel
Interpretations call up the welding procedure from the
Inquiry:
D1.1/D1.1.M:2015, Structural Weld- 1) Does AWS D1.1:2015, clause welding machine’s memory?
ing Code — Steel 5.10, preclude the use of “waveform” 3) Does AWS D1.1:2015, clause
power supplies? 3.2.1, preclude the use of GMAW-P
Subject: Waveform Power Supplies 2) Does AWS D1.1:2015, clause from use with prequalified WPSs?
Code Edition: D1:1:2015 5.10, preclude the use of “waveform” 4) Does AWS D1.1:2015, clause
Code Provision: Subclauses 5.10, power supplies where the welding pro- 3.2.4, preclude the use of waveform-
3.2.1, and 3.2.4 cedure is preprogrammed into the weld- controlled power supplies from being
used with prequalified WPSs?
5) Does AWS D1.1:2015, clause 3,
permit the use of prequalified WPSs
that use GMAW-P?
Response:
1) No. Any type of power supply is ac-
ceptable, providing the equipment is
American Welding Society® “…so designed and manufactured...as to
STTAANDARDS enable designated personnel to follow
aws.org the procedures and attain the results de-
scribed elsewhere in this code.”
2) No. Any type of power supply
Buyy your copy of control is acceptable, so long as the
controls are such that designated per-
sonnel are enabled to “...follow the
D1.11/D1.1M:2015,
1 procedures and attain the results de-
scribed elsewhere in this code.” The in-
Structural Welding Code - Steel
S dividuals responsible for the WPSs
should make certain that the stored
now at htt
tttp://go.a
tp://go aws.org/buy
ws org/buyyd1 WPSs meet the applicable require-
ments of D1.1, including compliance
with D1.1:2015, clause 5.3.1.2.
3) No. Clause 3.2.1 permits the use
of all modes of GMAW, except for
GMAW-S, which is precluded from
prequalification.
4) No. Clause 3.2.4 was developed
to preclude the use of constant current
power supplies for FCAW and GMAW
when using prequalified WPSs; this
provision was developed without any
intention of imposing requirements
on GMAW-P.
5) Yes, providing all the requirements
of Clause 3 are met.

Subject: Waveform Power Supplies

Code Edition: D1:1:2010
Code Provision: Subclauses 5.11,
3.2.1, and 3.2.4
AWS Log: D1.1-10-I21
Inquiry:
1) Does AWS D1.1:2010, clause 5.11,
preclude the use of “waveform” power
supplies?
2) Does AWS D1.1:2010, clause 5.11,
preclude the use of “waveform” power
supplies where the welding procedure is
preprogrammed into the welding ma-

24 Inspection Trends / August 2016

chine, and the welding personnel call up
the welding procedure from the welding
machine’s memory?
3) Does AWS D1.1:2010, clause 3.2.1,
preclude the use of GMAW-P from use
with prequalified WPSs?
4) Does AWS D1.1:2010, clause
3.2.4, preclude the use of waveform-
controlled power supplies from being
used with prequalified WPSs?
5) Does AWS D1.1:2010, clause 3,
permit the use of prequalified WPSs
that use GMAW-P?
Response:
1) No. Any type of power supply is ac-
ceptable, providing the equipment is
“…so designed and manufactured...as to
enable designated personnel to follow
the procedures and attain the results de-
scribed elsewhere in this code.”
2) No. Any type of power supply
control is acceptable, so long as the
controls are such that designated per-
sonnel are enabled to “…follow the
procedures and attain the results de-
scribed elsewhere in this code.” The in-
dividuals responsible for the WPSs
should make certain that the stored
WPSs meet the applicable require-
ments of D1.1, including compliance
with D1.1:2010, clause 5.3.1.2.
3) No. Clause 3.2.1 permits the
use of all modes of GMAW, except for
GMAW-S, which is precluded from
prequalification.
4) No. Clause 3.2.4 was developed
to preclude the use of constant current
power supplies for FCAW and GMAW
when using prequalified WPSs; this
provision was developed without any
intention of imposing requirements
on GMAW-P.
5) Yes, providing all the require-
ments of Clause 3 are met.
A3.0M/A3.0:2010, Standard Weld-
ing Terms and Definitions
Subject: Definition for Heat Input
Code Edition: A3.0M/A3.0:2010
Code Provision: Glossary
AWS Log: A3.0-10-I02
Inquiry: Can you please clarify
whether this definition refers to the
total energy of the arc applied to the
workpiece during welding, or does it
refer only to the amount of heat actu-
ally absorbed into the workpieces dur-
ing welding (the total energy of the arc
minus the heat losses)?
Interpretation:
The definition refers to the input ener-
gy applied to the workpiece during
welding. There is no attempt to differ-
For info, go to aws.org/ad­index
Inspection Trends / Summer 2016 25
entiate the amount of energy ab-
sorbed, reflected, miscalculated, misdi-
rected, lost, etc,. as this is considered
beyond the scope of the definition. It
is important to realize that this defini-
tion applies to all types of welding
processes, not just arc welding.
Errata
The following errata have been
identified for AWS D1.1/D1.1M:2000,
Structural Welding Code — Steel.
Pages 80, 83, Figure 3.4, Detail B-
U3a-S, B-U5b and TC-U5a. Change “3 X
R” to “18⁄ X R” and “6 X R” to “14⁄ X R”.
Pages 139, 141, Table 4.9, under (1)
Test on Plate, Type of Test Weld (Applic-
able Figures): Change “Groove (Fig. 4.30
or 4.31)” for 38⁄ < T < 1 to “Groove (Fig.
4.21, 4.22 or 4.29).”
Page 176, Table 6.1 under “(6) Un-
dersized welds.” Change “In all cases,
the undersize portion of the shall…” to
“In all cases, the undersize portion of
the weld shall…”
Page 226, Clause 7.5.5.7, change
reference to subclause 6.6.1 to sub-
clause 6.9.
Annex M, page 342 — Bottom
Row, under “Electrode Classification.”
Change “E10018- X” to “E11018-X.”
 Mark Your Calendar
3rd Welding Education, Skills & Certification Confer-
ence (AWS-sponsored event)
August 10–12. Houston, Tex. Contact American Welding
Society, (800) 443-9353, ext. 455, or aws.org/w/a/confer-
ences/index.
NDE/NDT for Highway and Bridges: Structural Materi-
als Technology 2016
August 29–September 1. DoubleTree by Hilton Hotel Port-
land, Portland, Ore. Contact American Society for Nonde-
structive Testing, (800) 222-2768 or asnt.org.
ASNT Annual Conference 2016
October 24–27. Long Beach Convention & Entertainment
Center, Long Beach, Calif. Contact American Society for
Nondestructive Testing, (800) 222-2768 or asnt.org.
FABTECH 2016 (AWS-sponsored event)
November 16–18. Las Vegas Convention Center, Las Vegas,
Nev. Contact American Welding Society, (800) 443-9353, or
fabtechexpo.com.
For info, go to aws.org/ad­index
26 Inspection Trends / August 2016
26th ASNT Research Symposium 2017
March 13–16, 2017. Jacksonville, Fla. Contact American Socie-
ty for Nondestructive Testing, (800) 222-2768 or asnt.org.
Educational Opportunities
GE Inspection Academy Courses. Online e-courses, on-
site classes, and week-long classroom programs in the major
industrial evaluation techniques. For information, visit gein-
spectionacademy.com.
NDE Classes. Moraine Valley Community College, Palos
Hills, Ill., offers NDE classes in PT, MT, UT, RT, Radiation
Safety, and Eddy Current, as well as API 510 exam prep and
weld inspection. For more information, contact (708) 974-
5735; wdcs@morainevalley.edu; morainevalley.edu/NDE.
EPRI NDE Training Seminars. EPRI offers NDE technical
skills training in visual examination, ultrasonic examina-
tion, ASME Section XI, UT operator training, etc. Contact
Sherryl Stogner, (704) 547-6174, e-mail: sstogner@epri.com.
American Welding Society®
aws.org
IMAGIN
INEE IT.
Direct access to an enccyclopedia
of weldingg kno
kn wledge,
g writtetten by
subject-m
-matter experts, at any tim
ime.
go.aws.org/awshandboo
w book
Nondestructive Examination Courses. A course sched-
ule is available from Hellier, 277 W. Main St., Ste. 2, Niantic,
CT 06357; (860) 739-8950; FAX (860) 739-6732.

Preparatory and Visual Weld Inspection Courses. One-

and two-week courses presented in Pascagoula, Miss., Hous-
ton, Tex., and Houma and Sulphur, La. Contact RealEducation-
al Services, Inc.; (800) 489-2890; info@real educational.com.

CWI/CWE Course and Exam. A ten-day program present-

ed in Troy, Ohio. Contact Hobart Institute of Welding Tech-
nology, (800) 332-9448; hiwt@welding.org; welding.org.

T.E.S.T. NDT, Inc., Courses. CWI preparation, NDE cours-

es, including ultrasonic thickness testing and advanced
phased array. On-site training available. T.E.S.T. NDT, Inc.,
193 Viking Ave., Brea, CA 92821; (714) 255-1500; FAX
(714) 255-1580; ndtguru@aol.com; testndt.com.

NDE Training. NDE training at the company’s St. Louis-area

facility or on-site. Level III services available. For a schedule of
upcoming courses, contact Quality Testing Services, Inc., 2305
Millpark Dr., Maryland Heights, MO 63043; (888) 770-0103;
training@qualitytesting.com; qualitytesting.net.

CWI/CWE Prep Course and Exam and NDT Inspector

Training Courses. An AWS Accredited Testing Facility.
Courses held year-round in Allentown, Pa., and at cus-
tomers’ facilities. Contact: Welder Training & Testing Insti-
tute (WTTI). Call (800) 223-9884, info@wtti.edu; wtti.edu.
For info, go to aws.org/ad­index

American Welding Society®

aws.org

OWN EX
EXPE
PERT
KNOWLE
WLEDG
DGE.
Own the
t
AWS
W Welding
e g Handbookk.

To purchase your copy by volume or chapter

pte , visit
go.aws.org/awshandboo
w book
For info, go to aws.org/ad­index

Inspection Trends / Summer 2016 27

 Certification Schedule
Certified Welding Inspector (CWI) 9-Year Recertification Seminar for CWI/SCWI
For current CWIs and SCWIs needing to meet education re-
Location Seminar Dates Exam Date quirements without taking the exam. The exam can be tak-
Baton Rouge, LA Aug. 7–12 Aug. 13 en at any site listed under Certified Welding Inspector.
Las Vegas, NV Aug. 7–12 Aug. 13
Philadelphia, PA Aug. 7–12 Aug. 13 Location Seminar Dates
Seattle, WA Aug. 7–12 Aug. 13 San Diego, CA July 31–Aug. 5
Miami, FL Exam only Aug. 18 Orlando, FL Aug. 21–26
Mobile, AL Aug. 14–19 Aug. 20 Denver, CO Sept. 11–16
Portland, ME Aug. 14–19 Aug. 20 Dallas, TX Sept. 25–30
Charlotte, NC Aug. 14–19 Aug. 20 New Orleans, LA Oct. 23–28
Fargo, ND Aug. 14–19 Aug. 20 Seattle, WA Oct. 30–Nov. 4
San Diego, CA Aug. 21–26 Aug. 27
Minneapolis, MN Aug. 21–26 Aug. 27
Kansas City, MO Aug. 21–26 Aug. 27 Certified Welding Educator (CWE)
San Antonio, TX Aug. 21–26 Aug. 27 Seminar and exam are given at all sites listed under Certified
Salt Lake City, UT Aug. 21–26 Aug. 27 Welding Inspector. Seminar attendees will not attend the Code
Miami, FL Sept. 11–16 Sept. 17 Clinic portion of the seminar (usually the first two days).
Nampa, ID Sept. 11–16 Sept. 17
St. Louis, MO Sept. 11–16 Sept. 17
Houston, TX Sept. 11–16 Sept. 17 Certified Welding Sales Representative
Anchorage, AK Sept. 18–23 Sept. 24 (CWSR)
Long Beach, CA Sept. 18–23 Sept. 24 CWSR exams are given at Prometric testing centers. More
New Orleans, LA Sept. 18–23 Sept. 24 information at aws.org/certification/detail/certified-welding-
Pittsburgh, PA Sept. 18–23 Sept. 24 sales-representative.
Indianapolis, IN Sept. 25–30 Oct. 1
Tulsa, OK Sept. 25–30 Oct. 1
Portland, OR Sept. 25–30 Oct. 1
Nashville, TN Sept. 25–30 Oct. 1 Certified Welding Supervisor (CWS)
El Paso, TX Sept. 25–30 Oct. 1 CWS exams are given at Prometric testing centers. More in-
Miami, FL Exam only Oct. 13 formation at aws.org/certification/detail/certified-welding-
Shreveport, LA Oct. 16–21 Oct. 22 supervisor.
S. Plainfield, NJ Oct. 16–21 Oct. 22
Beaumont, TX Oct. 16–21 Oct. 22
Atlanta, GA Oct. 23–28 Oct. 29 Certified Radiographic Interpreter (CRI)
Des Moines, IA Oct. 23–28 Oct. 29 The CRI certification can be a stand-alone credential or can
Detroit, MI Oct. 23–28 Oct. 29 exempt you from your next 9-Year Recertification.
Roanoke, VA Oct. 23–28 Oct. 29
Spokane, WA Oct. 23–28 Oct. 29 Location Seminar Dates Exam Date
Cleveland, OH Oct. 30–Nov. 4 Nov. 5 Kansas City, MO Aug. 22–26 Aug. 27
Huntsville, AL Nov. 6–11 Nov. 12 Chicago, IL Sept. 19–23 Sept. 24
Sacramento, CA Nov. 6–11 Nov. 12 Pittsburgh, PA Oct. 17–21 Oct. 22
Miami, FL Nov. 6–11 Nov. 12 Miami, FL Exam only Nov. 19
Annapolis, MD Nov. 6–11 Nov. 12
Dallas, TX Nov. 6–11 Nov. 12
Las Vegas, NV FABTECH Nov. 18
Miami, FL Exam only Dec. 8 Certified Robotic Arc Welding (CRAW)
St. Louis, MO Exam only Dec. 10 ABB, Inc., Auburn Hills, MI; (248) 391–8421
Los Angeles, CA Dec. 4–9 Dec. 10 OTC Daihen, Inc., Tipp City, OH; (937) 667-0800, ext. 218
Orlando, FL Dec. 4–9 Dec. 10 Lincoln Electric Co., Cleveland, OH; (216) 383-8542
Reno, NV Dec. 4–9 Dec. 10 Genesis-Systems Group, Davenport, IA; (563) 445-5688
Houston, TX Dec. 4–9 Dec. 10 Wolf Robotics, Fort Collins, CO; (970) 225-7736
On request at MATC, Milwaukee, WI; (414) 456-5454

IMPORTANT: This schedule is subject to change without notice. Please verify your event dates with the Certification Dept. to confirm your
course status before making travel plans. Applications are to be received at least six weeks prior to the seminar/exam or exam. Applications
received after that time will be assessed a $250 Fast Track fee. Please verify application deadline dates by visiting our website
aws.org/certification/docs/schedules.html. For information on AWS seminars and certification programs, or to register online, visit
aws.org/certification or call (800/305) 443-9353, ext. 273, for Certification; or ext. 455 for Seminars.

28 Inspection Trends / August 2016

 Just the Facts
Are CWIs Examiners or Inspectors?
Is this CWI performing visual examination or visual inspection?
A Certified Welding Inspector’s
(CWI’s) duties include visually examin-
ing welds to ensure they meet the
specification or code requirements.
But are CWIs performing examina-
tions or inspections, and does it mat-
ter what we are called? These terms are
often used interchangeably, yet some
welding codes and standards clearly
define the terms and responsibilities.
Inspection and Examination
Responsibilities in ASME
B31.3 and AWS D1.1
ASME B31.3-2014, Process Piping
Code
ASME B31.3, Process Piping Code,
incorporates what is arguably the
most distinct difference in the applica-
tion of examination vs. inspection and
examiner vs. inspector of most weld-
ing codes. This code includes Chapter
VI “Inspection, Examination, and Test-
ing,” which describes the requirements
(such as percentages of welds) and ac-
ceptance criteria for examination, in-
spection, and testing of process piping
30 Inspection Trends / August 2016
welds. But, in this international code,
what is meant by the terms inspection
and examination? And what role does
a CWI perform in this code: inspector
or examiner?
Inspection is defined in paragraph
340.1 as duties and “functions per-
formed for the owner by the owner’s
Inspector or the Inspector’s delegates.”
Later in the same chapter, examina-
tion is defined through paragraph
341.1 as “quality control functions
performed by the manufacturer (for
components only), fabricator, or erec-
tor.” Thus, the initial differences are re-
garding who the person reports to; an
inspector works for the owner whereas
an examiner works for the manufac-
turer, fabricator, or erector.
Responsibilities of Inspector and
Examiner
Paragraph 340.2 states that the
owner’s Inspector’s responsibility is
“…to verify that all required examina-
tions and testing have been completed
and to inspect the piping to the extent
necessary to be satisfied that it con-
forms to all applicable examination re-
By Rich Campbell
quirements…” Notice this does not re-
quire the Inspector to inspect all or
any welds, but rather to verify that the
examinations and testing have been
completed (by the examiner) and to
inspect welds as the Inspector deems
necessary. Typically, this inspection is
accomplished by verifying documenta-
tion of examinations and testing and
occasional inspection of welds.
In paragraph 341.2, it clarifies
that the manufacturer, fabricator, or
erector is still responsible to meet code
requirements and perform the re-
quired examinations (such as a mini-
mum of 5% visual examination of all
piping girth welds for normal fluid
service) and prepare appropriate
records of examinations and tests for
the Inspector’s use, regardless of what
actual inspection the Inspector may
perform. Thus, an inspector may nev-
er actually perform visual inspection of
a weld in accordance with this code,
but, an examiner will perform the re-
quired hands-on visual examination.
Qualifications of
Inspector and Examiner
The ASME B31.3 code continues
with qualifications of inspectors and
examiners. The “owner’s Inspector”
(paragraph 340.4) shall be
• Designated by the owner
• The owner or an employee of the
owner
• An employee of an engineering or
scientific organization or of a recog-
nized insurance or inspection compa-
ny acting as the owner’s agent.
And shall not:
• Represent nor be an employee of the
piping manufacturer, fabricator, or
erector unless the owner is also the
manufacturer, fabricator, or erector.
This further defines the require-
ments for qualification of the owner’s
Inspector [paragraphs 340.4(b)(1)–(4)]
and one of those options now includes
being an AWS CWI or Senior Certified
Welding Inspector (SCWI) in accor-
dance with AWS QC1, Standard for the
AWS Certification of Welding Inspectors.
This was added in the 2012 edition to
acknowledge the breadth and depth of
background that CWIs and SCWIs bring
to process piping weld inspection.
Options for qualifications of an
inspector (who reports to the owner)
include being a CWI or SCWI per AWS
QC1, as well as being a professional
engineer and other options.
Paragraph (c) also requires that
the owner’s Inspector is responsible to
ensure that an Inspector’s delegate is
qualified to perform the inspection
function they are being delegated to
perform. However, it does not spell
out what those requirements are.
Finally, paragraph 342 addresses
qualification of examination person-
nel. In the 2012 and earlier editions,
this simply recommended qualification
to ASNT SNT-TC-1A, while the 2014
edition now requires qualification and
certification in accordance with the
ASME Boiler & Pressure Vessel Code,
Section V, which requires qualification
to ASNT SNT-TC-1A.
Rights of the Owner’s Inspector
In paragraph 340.3, ASME B31.3
gives rights to the owner’s Inspector
and Inspector’s delegates to have access
to any place where work is being per-
formed and to audit any examination,
inspect the piping, and review records.
Summary of ASME B31.3
Inspector vs. Examiner
Who the CWI works for deter-
mines if he or she is an inspector or an
examiner in ASME B31.3. CWIs em-
ployed or contracted by the owner are
the owner’s Inspector or Inspector’s
delegate. CWIs employed or contracted
by a manufacturer, welding fabricator,
or contractor, are examiners. If em-
ployed or contracted by an independ-
ent, third-party inspection company
(such as a nondestructive examination
contractor), they might be examiners
or inspectors, depending upon who
has hired their third-party company.
AWS D1.1/D1.1M:2015,
Structural Welding Code —
Steel
AWS D1.1, Structural Welding Code
— Steel, only addresses inspectors; it
does not use the term examiner. D1.1
distinguishes between a Verification
Inspector who performs inspection for
the Owner or Engineer and a Contrac-
tor’s Inspector who performs inspec-
tion for the contractor.
Clause 6, “Inspection,” addresses
in paragraph 6.1.2 that fabrication or
erection inspection and testing are
separate functions from verification
inspection and testing.
Responsibilities for Contractor’s
Inspection vs. Verification
Inspection
The responsibilities are further de-
scribed in paragraph 6.1.2.1 for
Contractor’s Inspection as fabrica-
tion/erection inspection and testing
for which the Contractor is responsible
and in paragraph 6.1.2.2 for Verifica-
tion Inspection as “…prerogatives of
the Owner who may perform this
function or, when provided in the con-
tract, waive independent verification,
or stipulate that both inspection and
verification shall be performed by the
Contractor.” Thus, fabrication/erection
inspection and testing is always re-
quired and is performed by the con-
tractor. Verification inspection and
testing may be waived by the Owner or
the Owner may require that verifica-
tion be performed by the Contractor.
Inspector Categories
The categories of inspectors are
defined in paragraph 6.1.3. A Contrac-
tor’s Inspector (paragraph 6.1.3.1) is
designated as such and he or she acts
for the Contractor on all inspection
and quality matters. The Verification
Inspector (paragraph 6.1.3.2) is also
designated as such and acts for the
Owner or Engineer on all inspection
and quality matters. In this code, there
are occasions where the term inspec-
tor is used without qualification as to
being a Contractor’s Inspector or a
Verification Inspector, meaning the re-
quirements apply to both parties
(paragraph 6.1.3.3).
Qualifications of Inspectors
Qualifications of inspectors who
perform visual inspection to AWS
D1.1 are found in paragraph 6.1.4 and
apply to both Contractor’s Inspectors
and Verification Inspectors. Acceptable
qualification bases include any of the
Inspection Trends / Summer 2016 31
following:
1) Current or previous certifica-
tion as an AWS CWI, or
2) Current or previous qualifica-
tion by the Canadian Welding Bureau
(CWB), or
3) A person who “…by training or
experience, or both, in metals fabrica-
tion, inspection, and testing, is compe-
tent to perform inspection of the
work.”
Summary of AWS D1.1
Contractor’s Inspector vs.
Verification Inspector
The Contractor’s inspection is the
responsibility of the Contractor and ver-
ification inspection is the responsibility
of the Owner or Engineer. So, a CWI
working for the Contractor is a Contrac-
tor’s Inspector and a CWI who is em-
ployed or contracted by the Owner or
Engineer is a Verification Inspector.
Summary
Certified Welding Inspectors must
know who they are working for — the
Owner or Engineer, or a manufacturer,
fabricator, or Contractor. Depending
on the code to which the welding is be-
ing performed, the legal title of a CWI
may be owner’s Inspector or Verifica-
tion Inspector, or it might be Examin-
er or Contractor’s Inspector, or a dif-
ferent title as defined in another code
or standard. Regardless of the legal or
official code title, CWIs must continue
to perform their work with the highest
ethical standards to ensure public
health and safety.
RICH CAMPBELL, PhD, PE
(rdcampbe@bechtel.com), is a Bechtel
Fellow and Welding Technical Specialist
with Bechtel Corp., Houston, Tex. He is an
AWS Senior Certified Welding Inspector,
a CWB Level 2 Welding Inspector, an
ASNT NDT Level III Visual Testing
Inspector, a registered metallurgical
engineer, member of the AWS D1
Committee on Structural Welding, chair
of the D1K Subcommittee on Stainless
Steel, member of the D1H Subcommittee
on Sheet Steel, member of the ASME
B31.3 Process Piping Section Committee,
vice chair of the ASME B31.3 Subgroup E
on Fabrication, Examination, and Testing,
and member of the ASME B31 Fabrication
and Examination Committee.
 The Answer Is
Q: I have been an AWS CWI now for
nearly 12 years. I have decided to
forego the permanent employment
route and pursue a career change
as an independent contractor. This
will permit me the option to travel
and work when I choose. More im-
portantly, I will be able to decide on
the types of projects that I commit
my time to and the wages that I can
negotiate. Can you provide me with
some sources and information that
will help me obtain contract CWI
employment?
A: (by K. Erickson) To help simplify this
process, you should have a basic under-
standing of what you are trying to ac-
complish before you reach out to the
contract world. Consider the following:
1) Minimum pay rate/living al-
lowance for which you will accept an as-
signment
2) Locations you choose to work
and not work
3) Project types you choose to work
and not work
4) Yearly time periods you choose
to work and not work
5) Minimum/maximum amount of
hours you choose to work per week/
project
6) Any safety/other considerations
per projects (heights, shift/night work,
weekends, etc.)
7) Items for which you will be re-
sponsible for providing (safety equip-
ment/insurance, etc.)
There are a number of resources
and websites available to search out po-
tential contract employers and suitable
projects. Before any of this happens,
you need to have a current résumé and
documentation package available to for-
ward via e-mail that has the following
suggested as a minimum to provide:
1) Current contact information
2) All current certifications and
CWI number with expiration date
3) Prior duties and responsibilities
4) Employment history
5) Safety/equipment qualifications
such as OSHA 10/30, high lift, etc.
6) Current passport status and ex-
piration date
7) Citizenship status
8) Availability
Note: Employment recruiters flag
32 Inspection Trends / August 2016
certain information on résumés that is
a plus, such as project completion. Un-
der employment history, indicate each
project for which you fulfilled your
contract obligations for the entire
project duration.
The following are a few current
websites that search out contract CWIs
for employment:
1) inspectionjobs.com
2) roadtechs.com
3) indeed.com
4) ndtcabin.com
5) monster.com
6) careerbuilder.com
7) simplyhired.com
8) glassdoor.com
9) ziprecruiter.com
It would also be advisable to speak
with a financial planner and your ac-
countant first to obtain advice on how
these anticipated earnings may be taxed
and what may be eligible for deduction
including living expenses and/or living
accommodations. It may even be benefi-
cial for you to establish your own inde-
pendent company.
Make sure all your questions have
been answered thoroughly and com-
pletely before you accept any employ-
ment. Obtain a signed written employ-
ment agreement that addresses all the
terms and conditions of your contract
employment including any mobiliza-
tion, demobilization, and any considera-
tion as to contract completion compen-
sation that may be applicable for longer
term contracts.
With each assignment, you will
gain additional information on expedit-
ing this process, upcoming contract
projects, and beneficial contacts.
Q: While qualifying a WPS, the volt-
age readings seem to be much
higher than I expected. The welding
process is GTAW using an inverter
power supply. The meters on the
power supply have been checked
and are “calibrated.” The typical
voltage readings are on the order of
19 to 21 V. We are using argon as
the shielding gas. Based on previ-
ous experience, I would expect to
see voltage readings on the order of
9 to 13 V. What could be the cause
of the high voltage readings?
By K. Erickson and A. Moore
A: (by A. Moore) I agree with your ob-
servations; voltage readings of 19 to 21
V seem rather high for the conditions
you described. I am happy to hear you
had the meters checked to verify they
are in proper working order. Let’s con-
sider a key point, the voltage that
should be recorded by the Procedure
Qualification Record (PQR) is the arc
voltage, or to be more precise, the volt-
age drop across the arc.
When measuring the welding pa-
rameters arc voltage and amperage, one
must remember amperage is constant
regardless of where the ammeter is
placed along the length of the welding
leads. The same is not true when meas-
uring the arc voltage. The parallel of
voltage is the pressure in a hydraulic cir-
cuit. Current is the parallel of volume of
flowing fluid in the same hydraulic cir-
cuit. The volume of flow of fluid through
the circuit is limited by the volume flow-
ing through the most restrictive portion
of the circuit. Pressure, on the other
hand, drops as restrictions are added to
the circuit. The restrictions can include a
reduction of the diameter of the pipe,
adding elbows and valves to the circuit,
increasing the length of the piping, etc.
As increases in resistance are added to
the electrical circuit by increasing the
length of the welding leads, reducing
the diameter of the welding leads, loose
or corroded connectors, increased arc
length, or changes in the shielding gas
used, there is a corresponding voltage
drop in the series electrical circuit. In
the hydraulic system there is a pressure
drop at each of the added restrictions.
Likewise, there is a voltage drop across
each electrical component that adds re-
sistance in the series circuit.
When recording arc voltage, it is
best to locate the voltmeter as close to
the welding arc as practical. This is espe-
cially true when using the gas tungsten
arc welding (GTAW) process. The longer
the electrode lead and the work lead, the
greater the voltage drop in the circuit. If
the leads are short, the meter readings
are probably “good enough.” However,
as the welding leads get longer, it is best
to locate the voltmeter close as practical
to the GTAW torch.
To obtain a more accurate arc
voltage reading, I connect a small-
diameter insulated lead (wire) to the
GTAW torch. The insulating handle of

Fig. 1 — The photograph depicts a typical
gas-cooled GTAW torch with the red ex-
tension lead (wire) extending out from the
end of the insulating handle. A small-di-
ameter insulated wire can be used for the
extension lead because the amperage
flowing through the voltmeter is on the or-
der of milliamps. A lead with an alligator
clip is used to simplify attaching the lead
from the voltmeter. The extension lead
can be taped to the welding lead to keep
it from tangling.
the torch is pulled back to expose the
brass connections for the shielding gas,
electrode lead, and where applicable, the
cooling hoses. I strip a couple inches of
the insulation from the end of the ex-
tension lead (wire) and connect the bare
end of the wire to the connection of the
welding lead inside the welding torch.
Then snake the small insulated lead
back through the insulating handle so
that it extends a foot or so beyond the
GTAW torch. Slide the insulating handle
back into its proper position. Strip
about an inch of insulation from the ex-
posed end of the lead and connect one
of the voltmeter leads to the extension
Fig. 2 — The GTAW torch is shown with
the insulating handle slid back to expose
the connection of the torch head and the
welding/shielding gas connector. The red
lead wire extends through the torch han-
dle and is wrapped snuggly around the
welding lead/shielding gas connector.
Once the extension lead is connected,
the insulating handle is slid back into po-
sition. The length of the extension lead is
not critical; however, it is best to keep it
relatively short but long enough so it
doesn’t interfere with the welder.
lead extending from the torch handle.
The other voltmeter lead is held directly
against the workpiece once the arc is es-
tablished and stable.
Now, keep this in mind, the high-
frequency circuit of the GTAW power
supply will destroy the voltmeter in a
flash — literally in a flash and a cloud of
smoke. Do not use a standard volt-
meter to check voltage when welding
with AC, or to check voltage when
welding with DC if the high frequency
is set to continuous — Figs. 1, 2.
Verify the high frequency is
switched to “start only” before starting
to weld. This precaution is to ensure the
high frequency disconnects from the
welding circuit a few seconds after the
welding arc is initiated. Do not touch
the second lead of the voltmeter to
the workpiece until the welding arc
has stabilized and the high frequency
is no longer on.
Connecting the voltmeter directly
to the GTAW torch eliminates the volt-
age drop due to the length of the weld-
ing leads. The values of arc voltage
measured will be more accurate. Using
the extension lead (wire) I have de-
scribed will not damage the GTAW
torch and it can be removed easily once
it is no longer needed.
The Society is not responsible for any state-
ments made or opinion expressed herein. Data
and information developed by the authors are
for specific informational purposes only and
are not intended for use without independent,
substantiating investigation on the part of po-
tential users.
KENNETH ERICKSON is manager of qual-
ity at National Inspection & Consultants,
Inc., Ft. Myers, Fla. He is an AWS Senior
Certified Welding Inspector, an ASNT Na-
tional NDT Level III Inspector in four meth-
ods, and provides expert witness review
and analysis for legal considerations.
ALBERT J. MOORE JR. is vice president,
Marion Testing & Inspection, Canton,
Conn. He is an AWS Senior Certified
Welding Inspector and an ASNT ACCP
NDT Level III. He is also a member of the
AWS Certification Committee and the
Committee on Methods of Inspection of
Welds.

Mail Bag
Articles Proved Inspirational for Seasoned
Inspector I’m glad you got so much out of the May (Spring) issue,
Thomas. I’ve received many comments regarding the first CWIs.
That May 2016 issue was a big hit! Beside Brent Boling’s Since we keep learning about more original CWIs who were left
home run (What’s in Your Inspection Toolbag?), the article on off the list, I’m running their names one final time.
the first CWIs was very interesting as well as inspirational in To the best of my knowledge, the CWIs who became certified
content. I also like “The Answer Is” with Ken Erickson and Al- in 1976 or in the second round of testing in 1977 and maintain
bert Moore contributing. that certification to this day are as follows:
Brent Boling’s article did inspire me. A lot of truth in
those words. It motivated me to write a piece and send it to a Ken Jobes Charles W. Holmes Ralph Johnson
younger inspector as sage advice as well as providing examples Ray Wilsdorf Arthur Sumrall Bob Johnson
as to my own personal plans for improvement. We work a lot Robert Wiswesser David Norris Glenn Peloquin
of hours in this business, and I think that the article opens our John Moore Kenneth Chorniak Michael Carcieri
eyes as to what was taught to us in the beginning of our in- Charles McGowan Marshall Farley Peter Palko
spection careers. It sends a message of “let’s get back to the ba- Vernon Peterson Jr. Richard Timko Stephen Fowler
sic fundamentals that inspection and materials examination William Via Jr. Robert Hay Steven Carter
are built on.” I think it’s time for us old-timers to slow down Walter Goodwin Donald Swiney Danny Finstad
and carry the torch for the newcomers. Boling’s message truly Joseph Crosson Jerry Takeuchi Richard Kemlage
reminds me of what the foundation of inspection is built on.
Mary Ruth Johnsen
Editor
Thomas C. Langley, AWS CWI, ASME Section IX, B31.1,
B31.3 Endorsement, ASNT ACCP Level II VT

Inspection Trends / Summer 2016 33

News Bulletins
— continued from page 11

Recently added to the team is Mike Brown, a 23-year and electronic measurement technologies. He has been with
industry veteran who has extensive experience in ad- EWI since 2004, and his main focus has been advanced and
vanced ultrasonic testing with a specific focus on hydro- specialized NDE methods and technologies for a broad range
gen-induced damage mechanisms. His certifications in- of applications.
clude API QUSE, API Qualification of Ultrasonic Testing
Examiners for shear wave testing, and ASNT Level III.
The company’s services include inspection drawing and ASTM Presents Top Award
planning services, on-stream and visual inspections, posi-
tive material identification, quality control vendor surveil- ASTM International’s Commit-
lance, and tank inspections. Additional information is avail- tee on Accreditation and Certifica-
able at pinnacleart.com. tion (E36) recently presented the
Award of Merit, its top annual
award, to Peter Unger of the Amer-
EWI Appoints New Colorado-Based ican Association for Laboratory Ac-
Technology Leader creditation (A2LA), Frederick, Md.
Unger was honored for outstanding
EWI, Columbus, Ohio, recently service, significant contributions,
appointed Dr. Evgueni Todorov as and leadership in improving lab ac-
technology leader for Nondestruc- creditation processes through his
Peter Unger
tive Evaluation. He is based in Love- service with ASTM.
land, Colo., where he will oversee the The award includes the accompa-
technical team in setting up EWI nying title of fellow. It is the West Conshohocken, Pa.-based
Colorado, a new center for advanced organization’s highest recognition for individual contributions
process monitoring and control tech- to developing standards.
nologies. The center is expected to The A2LA is a nonprofit membership society. It offers a
open in September. full range of comprehensive laboratory and laboratory-
Todorov has more than 30 years related accreditation services and training. Unger was
Dr. Evgueni Todorov of experience in the development named president emeritus in January. He previously served
and industrial application of NDE as president and vice president.

American Welding Society®

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Join or Renew:
CONTACT INFORMATION
q New Member q Renewal
AWS MEMBERSHIP APPLICATION
Mail: Form with your payment, to AWS Call: Membership Department at (800) 443-9353, ext. 480
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STUDENT MEMBERSHIP J q Thermal spray
K q Cutting
q AWS STUDENT MEMBERSHIP (with digital Welding Journal magazine)................................................$15 L q NDT
M q Safety and health
q AWS STUDENT MEMBERSHIP (with hard copy Welding Journal magazine)..............................................$35
N q Bending and shearing
Option available only to students in U.S., Canada & Mexico.
O q Roll forming
P q Stamping and punching
PAYMENT INFORMATION Q q Aerospace
R q Automotive
Payment can be made (in U.S. dollars) by check or money order (international or foreign), payable to the American Welding Society, or by charge card. S q Machinery
q Check q Money Order q AMEX q Diners Club q MasterCard q Visa q Discover q Other T q Marine
U q Piping and tubing
CC#:____________ / ____________ / ____________ / ____________ Expiration Date (mm/yy) ________ / ________ V q Pressure vessels and tanks
W q Sheet metal
X q Structures
Signature of Applicant:_________________________________________ Application Date:_______________________
Y q Other
Z q Automation
OFFICE USE ONLY Check #:_______________________________ Account #____________________________________ 1 q Robotics
Source Code: IT Date:_________________________________ Amount:_____________________________________ 2 q Computerization of Welding
REV. 11/15
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