INSPECTA

AWS Qualification Program

Dr. Eng. Hamed A. Nagy

Weld-Inspecta Engineering
Services Company

Hamed A. Nagy, Ph.D.

WELDING INSPECTION AND INSPECTA
CERTIFICATION

In todays world there is increasing emphasis on the need for

quality.
Weld quality is an important part of the quality effort.
This concern for product quality is due to several factors,
including economics, safety, government regulations, global
competition, and the use of less conservative designs.
In reality, many people participate in the creation of a quality
welded product.
The welding inspector is one of the front line individuals who
must check to see if all of the required manufacturing steps
have been completed properly.

Hamed A. Nagy, Ph.D.

WELDING INSPECTION AND INSPECTA
CERTIFICATION

Section 4 of AWS QC1, Standard for Qualification and

Certification of Welding Inspectors. outlines the various
responsibilities of the welding inspector.
A successful quality control program begins before the first arc
is struck.
Before welding, the inspector will check drawings and
specifications to determine such information as the
configuration of the component, its specific weld quality
requirements, and what degree of inspection is required.
Once welding begins, the welding inspector may observe
various processing steps to assure that they are done properly.
Final inspection should simply confirm the success of those
operations.

Hamed A. Nagy, Ph.D.

WELDING INSPECTION AND INSPECTA
CERTIFICATION

The ten modules listed below are sources for examination

information.
Module 1 : Welding Inspection & Certification
Module 2 : Safe Practices for Welding Inspectors
Module 3 : Metal Joining and Cutting Processes
Module 4 : Weld Joint Geometry and Symbols
Module 5 : Documents Governing Welding Inspection and
Qualification

Hamed A. Nagy, Ph.D.

WELDING INSPECTION AND INSPECTA
CERTIFICATION

Module 6 : Metal Properties and

Destructive Testing
Module 7 : Metric Practice for
Welding Inspection
Module 8 : Welding Metallurgy for the
Welding Inspector
Module 9 : Weld and Base Metal
Discontinuities
Module 10 : Visual Inspection and
Other NDE Methods
Hamed A. Nagy, Ph.D.
Who is the INSPECTA
Welding Inspector ?

The welding inspector is a responsible person,

involved in the determination of weld quality
according to applicable codes and/or specifications.
The inspection workforce may include destructive
testing specialists, nondestructive examination
(NDE) specialists, code inspectors, military or
government inspectors, owner representatives, in-
house inspectors, and others. These individuals may,
at times, consider themselves welding inspectors. ,
since they inspect welds as part of their job
responsibility.

Hamed A. Nagy, Ph.D.

Who is the INSPECTA
Welding Inspector ?

Overseer
Specialist
Combination Overseer Specialist

It is common to see inspectors servicing as both

overseer and specialist.
For the purposes of this course we will refer to the
welding inspector in general, without regard to how
each individual will be used by an employer.
It is impractical to address each individuals situation
in the scope of this discussion.

Hamed A. Nagy, Ph.D.

 INSPECTA
Important Qualities

1-Professional attitude:
Determines the degree of respect and cooperation received
from others during the performance of inspection duties.
Ability of the welding inspector to make decisions based on
facts so that inspectors are fair, impartial and consistent.
Familiarity with the job requirements so that decisions are
neither too critical nor too lax.
Inspectors will often find themselves being tested by other
personnel on the job, especially when newly assigned to some
task. Maintaining a professional attitude helps overcome
obstacles to successful job performance.

Hamed A. Nagy, Ph.D.

 INSPECTA
Important Qualities

2- Physical condition:
Should have good vision, whether natural or
corrected. The AWS CWI program requires a
minimum 20/40 visual acuity, natural or corrected,
and the completion of a color perception test.
Should be in good enough physical condition to go to
any location where the welder has been. This does
not imply that inspectors must violate safety
regulations just to do their duties.

Hamed A. Nagy, Ph.D.

 INSPECTA
Important Qualities
3- Knowledge:
To understand and apply the various documents describing weld
requirements. These can include drawings, codes, standards and
specifications.
Documents provide most of the information regarding what, when,
where and how the inspection is to be done.
It is important that these documents are reviewed before the start of
any work or production, because the welding inspector must be aware
of the job requirements.
Often this pre-job review will reveal required hold points for
inspections, procedure and welder qualification requirements.
Requirements should be memorized. These are reference documents
and should be readily available for detailed information any time in the
fabrication process.

Hamed A. Nagy, Ph.D.

 INSPECTA
Important Qualities

4. Experience:
Better ways of thinking and working will develop with
time.
Experience will also help the inspector develop the
proper attitude and point of view regarding the job.
We often see a novice inspector paired with an
experienced one so the proper techniques can be
passed along.
5. Safe work habits:
Hamed A. Nagy, Ph.D.
 INSPECTA
Important Qualities

Records:
All records developed should be understandable to anyone
familiar with the work. Reports that can only be deciphered by
the welding inspector are useless when he or she is absent.
Therefore, neatness is important as well.
The welding inspector should look at these reports as his or her
permanent records should a question arise later.
When reports are generated, they should contain information
regarding how the inspection was done so it can be duplicated
later by someone else with similar results.

Hamed A. Nagy, Ph.D.

 INSPECTA
Important Qualities
There are few rules of etiquette relating to inspection reports.
First, they should be completed in ink, or typewritten.
If an error is made in a hand written report, it can be single-
lined out and corrected (the error should not be totally
obliterated). This corrective action should then be initialed and
dated.
The report should also accurately and completely state the job
name and inspection location as well as specific test
information.
Use of sketches and pictures may also help to convey
information regarding the inspection results. Then the
completed report should be signed and dated by the inspector
who did the work.

Hamed A. Nagy, Ph.D.

 INSPECTA
Ethical Requirements

Ethics simply detail what is considered to be common sense

and honesty.
The welding inspectors position also carries with it a certain
responsibility to the public.
So, it is their responsibility to report any condition that could
result in a safety hazard.
If the inspector is involved in a dispute regarding the inspection,
he or she may be asked to publicly express an opinion.
Probably the best way to deal with public statements, however,
is simply to avoid them whenever possible.

Hamed A. Nagy, Ph.D.

 INSPECTA
Ethical Requirements

The inspector should not volunteer

information just to gain publicity.
However, in some situations, the welding
inspector may wish to solicit the advice of a
legal representative before speaking.
Many inspectors are required to make
decisions that may have great financial
impact on certain parties.
Hamed A. Nagy, Ph.D.
 INSPECTA
WI as a Communicator
Communication is not a one way street.
Communication sequence must be a continuous loop so that both
parties have an opportunity to express their thoughts or interpretations.
It is wrong for any individual to think that their ideas will always prevail.
Welding inspectors may be the central figure of the communication
network.
Some people that the inspector may communicate with are welders,
welding engineers, inspection supervisors, welding supervisors,
welding foremen, design engineers, and production supervisors.
Suppose the welders are asked to weld a joint having a root opening
which is so tight that a satisfactory weld cannot be accomplished.

Hamed A. Nagy, Ph.D.

 INSPECTA
WI as a Communicator
Communication between the welder and an inspector is usually
improved if the welding inspector has some welding experience.
Welding engineers rely heavily on welding inspectors to be their eyes
on the shop floor or, construction site to spot problems relating to the
techniques and processes specified.
If a welding procedure is not producing consistent, reliable results, the
welding inspector may be the first person to spot the problem.
In some situations, instead of communicating directly with the welders,
the welding inspector will deal with the welding supervisor or foreman.
The welding inspector may also have to gain information form design
engineers about the actual weld requirements.

Hamed A. Nagy, Ph.D.

 INSPECTA
WI as a Communicator

Another way in which this aspect of communication

takes place is through drawings and welding
symbols.
Finally, the welding inspector will have some
occasion to discuss job scheduling with production
personnel.
.
Several ways in which people effectively
communicate. They include speaking, writing,
drawing, gesturing, and the use of pictures or
photographs.

Hamed A. Nagy, Ph.D.

 INSPECTA
CERTIFICATION
The American Society for Nondestructive Testing has issued
guidelines for certification of NDE personnel in ASNT SNT TC-
1A.
This document describes the recommended procedures for
certifying inspectors performing nondestructive testing. ASNT
recognizes three levels of certification, Levels I, II, and III.
The document AWS QC-G, Guide to AWS Qualification and
Certification, provides the necessary applications and
background information.
AWS QC-1 Standard for AWS Certification of Welding
Inspectors establishes the requirements for AWS certification of
welding inspection personnel, describes how personnel are
qualified, lists the principles of conduct, and notes the practice
by which certification may be maintained.

Hamed A. Nagy, Ph.D.

 INSPECTA
CERTIFICATION
Experience:
Candidates with a high school education, either by diploma or
state or military equivalency, must have at least 5 years
experience.
With supporting documentation (e.g., copies of transcripts,
reference letters, credited hours of training, quarter hours or
semester hours) up to two years of work experience may be
substituted for post high school educational experience.
Substituted educational experience includes as Associate or
higher degree in engineering, physics or physical science and
welding technology.
Trade and vocational courses can be applied to work
experience substitution for completed courses related to
welding (up to one year maximum).

Hamed A. Nagy, Ph.D.

 INSPECTA
CERTIFICATION

Individuals with eighth grade schooling are required

to have not less than 10 years job experience to
qualify for the examination.
For individuals with less than eighth grade schooling,
not less than 15 years is required.
A subordinate level of qualification is the Certified
Associate Welding Inspector (CAWI), which requires
fewer years of experience for each educational level.
Individuals who qualify for the Certified Welding
Inspector Examination take a three-part examination.

Hamed A. Nagy, Ph.D.

 INSPECTA
CERTIFICATION

Part A Fundamentals.
The Fundamental examination is a closed book test
consisting of 150 multiple choice questions.
The topics covered in this portion of the exam
include reports and records, destructive tests,
welding performance, duties and responsibilities,
weld examination, definitions and terminology,
safety, welding and nondestructive examination
symbols, nondestructive examination methods
welding processes, heat control, metallurgy,
mathematical conversions and calculations.

Hamed A. Nagy, Ph.D.

 INSPECTA
CERTIFICATION
Part B Practical.
The Practical examination consists of 46 questions.
It requires measurement of weld replicas with provided
measuring tools, and evaluation in accordance with a supplied
Book of Specifications.
Not all questions require the use of the Book of Specifications;
they do require the individual to answer from practical
knowledge.
The Practical Test covers welding procedures, welder
qualification, mechanical tests and properties, welding
inspection and flaws, and nondestructive test. Test candidates
should be familiar with fillet and butt weld gages, micrometer,
dial calipers, and machinists scale.

Hamed A. Nagy, Ph.D.

 INSPECTA
CERTIFICATION

Part C Open Book Code.

This portion consists of 46 questions on the code the individual
has selected for this part of the examination.
AWS D1.1.
API 1104.
ASME B31.1.
ASME Section VIII.
ASME Section IX.
MIL-STD-1689 (SH) (83).
MIL-STD-248D(89).

Hamed A. Nagy, Ph.D.

 INSPECTA
CERTIFICATION

The passing score in each part for the CWI is 72 percent; the
passing for CAWI is 50 percent.
Part of the welding inspectors job is there view and
interpretation of various documents relating to the welded
fabrication.
This requires that the individual have a full understanding of the
proper terms and definitions that are used.
ANSI/AWS A3.0 was developed by the Committee on
Definitions and Symbols to aid in welding information
communication.
When non-standard terms are mentioned, they appear in
parentheses after the preferred words.

Hamed A. Nagy, Ph.D.

 INSPECTA
CERTIFICATION

While most of the terms used apply to the

actual welding operation, it is important for
the welding inspector to understand other
definitions which apply to other related
operations.

Hamed A. Nagy, Ph.D.

 INSPECTA
JOINING & CUTTING PROCESSES

There are certain aspects of the various joining and

cutting processes which the successful welding
inspector must understand in order to perform most
effectively.
First, the inspector should realize the important
advantages and limitations of each process.
The inspector should also be aware of those
discontinuities which may result when a particular
process is used.

Hamed A. Nagy, Ph.D.

 INSPECTA
JOINING & CUTTING PROCESSES

Some discontinuities can occur during the

application of a particular process.
When the welding inspector has some
understanding of these process fundamentals, he or
she is better prepared to perform visual welding
inspection. The inspector who is capable of spotting
problems in-process will be a definite asset to both
production and quality control.
Production elders will have greater respect for the
inspector and resulting decisions.

Hamed A. Nagy, Ph.D.

 INSPECTA
JOINING & CUTTING PROCESSES

The processes discussed here can be divided into

three basic groups: welding, brazing and cutting.
The Welding Processes can be divided into seven
groups, Arc Welding, Solid State Welding,
Resistance Welding, Oxyfuel Gas Welding,
Soldering, Brazing, and Other Welding.
The Allied Processes include Thermal Spraying,
Adhesive Bonding, and Thermal Cutting (Oxygen,
Arc and Other Cutting).

Hamed A. Nagy, Ph.D.

 INSPECTA
WELDING PROCESSES

According to AWS, a weld is, a localized

coalescence of metals or nonmetals produced either
by heating the materials to the welding temperature,
with or without the application of pressure, or by the
application of pressure alone and with or without the
use of filler metal.
Process features include a source of energy to
provide heating, a means of shielding the molten
metal from the atmosphere, and a filler metal
(optional with some processes and joint
configurations).

Hamed A. Nagy, Ph.D.

 INSPECTA
SMAW

Shielded Metal Arc welding.

It is referred to also as stick welding.
This process operates by heating the metal with an
electric are between a covered metal electrode and
the metals to be joined.
The arc is created between the electrode and the
work piece due to the flow of electricity.
This arc provides heat, or energy, to melt the base
metal, filler metal and electrode coating.
Hamed A. Nagy, Ph.D.
 INSPECTA
SMAW

As the welding arc progresses, it leaves behind

solidified weld metal covered by a layer of converted
flux, referred to as slag.
Slag tends to float to the outside of the metal since it
solidifies after the molten metal has solidified.
Another feature is the presence of shielding gas
which is produced when the electrode coating is
heated and decomposed.
Electrode is made up of a solid metal core wire
covered with a layer of granular flux held in place by
some type of bonding agent.

Hamed A. Nagy, Ph.D.

 INSPECTA
SMAW
Electrode
Covering

Shielding atmosphere
Core Wire
Metal & Slag
Droplets

Depth of Penetration

Direction of Welding Hamed A. Nagy, Ph.D.

 INSPECTA
SMAW
Base or
Slag
Parent Metal

Weld Metal

Hamed A. Nagy, Ph.D.

 INSPECTA
SMAW

All carbon and low alloy steel electrodes use essentially the
same type of steel core wire, a low carbon, rimmed steel.
Any alloying is provided form the coating, since it is more
economical to achieve alloying in this way.
The electrode coating serves five separate functions:
Shielding.
Deoxidation.
Alloying.
Ionizing.
Insulating. (minor effect).

Hamed A. Nagy, Ph.D.

 INSPECTA
SMAW
Eletrode Position

EXXXX
Strength Coating & Operating
Characteristics

Hamed A. Nagy, Ph.D.

 INSPECTA
SMAW

AWS Specifications A5.1 and A5.5 describe the

requirements for carbon and low alloy steel
electrodes, respectively.
AWS Classification:
The identification consists of an E, which stands for
electrode, followed by four or five digits.
The first two, or three, numbers refer to the minimum
tensile strength of the deposited weld metal in ksi.

Hamed A. Nagy, Ph.D.

 INSPECTA
SMAW

The next number refers to the positions which the electrode can
be used:
A 1 indicates the electrode, is suitable for use in any position.
A 2 means that the molten metal for the flat or horizontal fillet
positions.
A 4 means the electrode is suitable for welding in a downhill
progression.
The number 3 has no designation.
The last number describes other characteristics which are
determined by the composition of the coating present on the
electrode.

Hamed A. Nagy, Ph.D.

 INSPECTA
SMAW

This coating will determine its operating characteristics and

recommended electrical current: AC (alternating current), DCEP
(direct current, electrode positive) or DCEN (direct current,
electrode negative).
Electrodes ending in 5 6 or 8 are classified as low
hydrogen types.
To maintain this low hydrogen (moisture) content, they must be
stored in their original factory-sealed container or an acceptable
storage oven.
This oven should be heated electrically and have a temperature
control capability in the range of 150 to 350F.

Hamed A. Nagy, Ph.D.

 INSPECTA
SMAW

Since this device will assist in the maintenance of a

low moisture content (less than 0.2%), it must be
suitably vented. Any low hydrogen electrodes .
Most codes require that low hydrogen electrodes be
held at a minimum oven temperature of 250F
(120C) after removal form their sealed container.
Electrodes other than those mentioned above may
be harmed if placed in the oven.
Those SMAW electrodes used for joining low alloy
steels may also have an alpha-numeric suffix which
is added to the standard designation after a hyphen.

Hamed A. Nagy, Ph.D.

 INSPECTA
SMAW
Suffix Major Alloy Elements(s)
A1 0.5% Molybdenum
B1 0.5% Molybdenum-0.5% Chromium
B2 0.5% Molybdenum-1.25% Chromium
B3 1.0% Molybdenum-2.25% Chromium
B4 0.5% Molybdenum-2.0% Chromium
C1 2.5% Nickel
C2 3.5% Nickel
C3 1.0% Nickel
D1 0.3% Molybdenum-1.5% Manganese
D2 0.3% Molybdenum-1.75% Manganese
G* 0.2% Molybdenum; 0.3% Chromium;
0.5% Nickel; 1.0% Manganese; 0.1%
Vanadium
* Need to have minimum content of one element only.

Hamed A. Nagy, Ph.D.

 INSPECTA
SMAW
The power source for SMAW is referred to as a constant
current power supply, having a drooping characteristic.
As the welder draws the electrode away from the work piece,
the arc length increases which reduces the current, and
consequently, reduces the heat input to the weld.
Because the lower curve has less slope than the upper curve, a
greater change in arc current is obtained from a given change
in arc length (voltage).
SMAW is used in most industries for numerous applications. It
is used for most materials except for some of the more exotic
alloys.
SMAW remains as a popular process which will continue to be
in great use by the welding industry.

Hamed A. Nagy, Ph.D.

 INSPECTA
SMAW
Voltage Max. OCV

Min. OCV

Current, A
Hamed A. Nagy, Ph.D.
 INSPECTA
SMAW

Advantages:
equipment is relatively simple and inexpensive.
So, quite portable (Numerous gasoline or diesel
engine-driven types and also, some so small and
lightweight of the newer solid state power sources).
Availability of numerous types of electrodes, the
process is considered quite versatile.
Cheapness of alloying.

Hamed A. Nagy, Ph.D.

 INSPECTA
SMAW

Limitations:
1- Speed (Productivity): Periodically change
of stick (14 or 18 inches in length)
+ Cleaning between passes.
2- low hydrogen type electrodes require
storage in an appropriate electrode holding
oven which will help to maintain their low
moisture levels.

Hamed A. Nagy, Ph.D.

 INSPECTA
SMAW

Associated Discontinuities:
1- Porosity: Presence of moisture or contamination in the weld
region. It could be present in the electrode coating, on the
surface of the material, or come from the atmosphere
surrounding the welding operation + long arcing. + Arc blow.
There is a perpendicular magnetic field developed whenever an
electric current is passed through a conductor.
Magnetic Field can be visualized as a series of concentric
circles surrounding the conductor.
This magnetic field is strongest when contained entirely within a
magnetic material and resists having to travel through the air
outside this magnetic material.

Hamed A. Nagy, Ph.D.

 INSPECTA
SMAW

Forward Blow Back Blow

Current
Direction
Travel

Hamed A. Nagy, Ph.D.

 INSPECTA
SMAW

Consequently, field can become distorted

when the arc approaches the edge of a plate,
the end of a weld or some abrupt change in
contour of the part being welded.
To reduce the effects of arc blow, several
alternatives can be tried. They include :
Change from DC to AC.
Hold as short an arc as possible.
Reduce welding current.
Hamed A. Nagy, Ph.D.
 INSPECTA
SMAW

Angle the electrode in the direction opposite the arc blow.

Use heavy tack welds at either end of a joint, with intermittent
tack welds along the length of the joint.
Weld toward a heavy tack or toward a completed weld.
Use a backstep technique.
Weld away from the ground to reduce back blow; weld toward
the ground to reduce forward blow.
Ground the work piece at both ends of the joint to be welded.
Wrap ground cable around the work piece and pass ground
current through it in such a direction that the magnetic field set
up will tend to neutralize the magnetic field causing the arc blow.
Extend the end of the joint by attaching runoff plates.

Hamed A. Nagy, Ph.D.

 INSPECTA
SMAW

2- Arc blow can also cause spatter, under out,

improper weld contour, and decreased penetration.
3- Such as any process incorporating a flux, the
possibility of trapping slag within the weld deposit is
a definite concern. Solution: electrode Manipulation
+ Interpass cleaning.
4- Improper manipulation of the electrode could
cause incomplete fusion, incomplete joint
penetration, cracking, undercut, overlap, incorrect
weld size, and improper weld profile.

Hamed A. Nagy, Ph.D.

 INSPECTA
GMAW
Voltage

Current, A
Hamed A. Nagy, Ph.D.
 INSPECTA

Electrode Rod Solid Wire

ER X X S X
Strength Chemical Composition

Hamed A. Nagy, Ph.D.

 INSPECTA

Electrode Position CC & OC

E X X X-X
Strength Tubular

Hamed A. Nagy, Ph.D.

 INSPECTA

Electrode Condition of HT Electrode

F X X X-EXXX
Strength For Impact

Flux Hamed A. Nagy, Ph.D.

 INSPECTA

Contact Tube
Gas Nozzle

Electrode Consumable
Setback
Electrode Extension
Stickout
Standoff Distance
Arc Length

Hamed A. Nagy, Ph.D.

 INSPECTA
Travel

Contact Tube

Flux from
Hopper
Electrode Consumable

Slag

Weld
Solidified Metal Pool

Hamed A. Nagy, Ph.D.

 INSPECTA
Travel
I. Transferred Arc
Tungsten Electrode

Constricting
Nozzle

Secondary
Shielding Gas +
Filler Metal

Orifice Gas

Hamed A. Nagy, Ph.D.

 INSPECTA
Travel
II. Nontransferred Arc
Tungsten Electrode

Constricting
Nozzle

Secondary
Shielding Gas
Filler Metal

Orifice Gas

+
Hamed A. Nagy, Ph.D.
 INSPECTA
Back Cap Shielding Gas In

Gas Nozzle

Collet Body

Nonconsumable Electrode

Filler Metal

Travel Hamed A. Nagy, Ph.D.

 INSPECTA

I. Spray Mode II. Globular

Mode

III. Short Circuiting Mode

Hamed A. Nagy, Ph.D.

 INSPECTA

Hamed A. Nagy, Ph.D.

 INSPECTA

Electrode
Molten Slag
Guide Tube

Molten
Metal Water Out

Solidified Metal Water In

Water Cooled
Copper Shoes
Hamed A. Nagy, Ph.D.
 INSPECTA
Emitter (Cathode)

Grid (Cup)

Anode

Magnetic
Focusing Lens
Magnetic
Deflection Coil
Focal Range

Hamed A. Nagy, Ph.D.

 INSPECTA

Preforms in Brazing

Hamed A. Nagy, Ph.D.

 INSPECTA

Travel

Hamed A. Nagy, Ph.D.