IAB 252 07 Personnel Responsibility Welding Coordination

IIW Guideline PERSONNEL WITH RESPONSIBILITY FOR WELDING COORDINATION

Minimum Requirements for the Education, Examination and Qualification

IAB-252-07

IAB – INTERNATIONAL AUTHORISATION BOARD IAB-252-07

Personnel with Responsibility for Welding Coordination Approved: January 2007 0 of 103

MINIMUM REQUIREMENTS FOR THE EDUCATION, TRAINING, EXAMINATION, AND QUALIFICATION

Personnel with Responsibility for Welding Coordination (as described in ISO 14731 and other International and National Standards)

International Welding Engineer (IWE) former : Doc. IAB-002-2000/EWF-409 Rev. 2

International Welding Technologist (IWT)

former : Doc. IAB-003-2000/EWF-410 Rev. 2

International Welding Specialist (IWS) former : Doc. IAB-004-2000/EWF-411 Rev. 1

International Welding Practitioner (IWP)

former : Doc. IAB-005-2002/EWF-451 Rev. 1

Prepared and issued by the IAB-International Authorisation Board Under the authority of the IIW-International Institute of Welding

Published by: EWF-IAB/IIW Secretariat Av. Prof. Dr. Cavaco Silva, 33 Taguspark – Apartado 012 P-2741-901 Porto Salvo Portugal Tel: +351.21 4211351 Fax: +351.21 4228122 E-mail: [email protected] www.iiw-iis.org



TABLE OF CONTENTS Preface 2 1. Introduction .......................................................................................................................................3 2. Routes to Qualification .........................................................................................................................3 2.1 Standard Route ....................................................................................................................3 2.2 Alternative Route ..................................................................................................................4 2.3 Distance Learning Programs ................................................................................................4 2.4 Teaching Hours ....................................................................................................................4 3. General Access Conditions ..................................................................................................................4 3.1 International Welding Engineer IWE ....................................................................................4 3.2 International Welding Technologist IWT ...............................................................................5 3.3 International Welding Specialist IWS ...................................................................................5 3.4 International Welding Practitioner IWP .................................................................................7 4. Special Requirement ............................................................................................................................7 4.1 Standard Route ....................................................................................................................7 4.2 Alternative Route ..................................................................................................................8 4.2.1 International Welding Engineer IWE ............................................................................8 4.2.2 International Welding Technologist IWT .......................................................................9 4.2.3 International Welding Specialist IWS ...........................................................................9 4.2.4 International Welding Practitioner IWP .......................................................................10 Section I: Theoretical and Practical Education – Part 1; Part 2 and Part 3, Syllabus and Performance Objectives for IWE; IWT; IWS and IWP ....................................................12 I.1 Theoretical Education Part 1 and Part 3 ………………………………………………………..12 Module 1: Welding Processes and Equipment ....................................................................12 Module 2: Materials and their Behaviour During Welding ...................................................34 Module 3: Construction and Design ....................................................................................57 Module 4: Fabrication, Applications Engineering ................................................................80 I.2 Specific for IWS – Module 0 ................................................................................................81 I.3 Practical Education – Part 2 ................................................................................................88 I.3.1 For IWE; IWT and IWS ................................................................................................88 I.3.2 For IWP ........................................................................................................................88 Section II: Examination and Qualification .............................................................................................90 1. Introduction ...........................................................................................................................90 2. Approval of postgraduate training (for IWE, IWT, IWS, IWP) course ...................................90 3. Board of Examiners ..............................................................................................................90 4. Admission to the Examination ..............................................................................................90 5. Examination Procedures ......................................................................................................90 5.1 Written Examination .......................................................................................................91 5.2 Oral Examination ...........................................................................................................91 5.3 Practical Examination ...................................................................................................91 6. Evaluation of Performance ...................................................................................................91 7. Re-Examination and Appeals Procedure .............................................................................92 8. International Welding Diplomas ............................................................................................92 9. Transition Arrangements ......................................................................................................92 Appendix I: Requirements for Equipment, Facilities and Specimens for courses leading to the award of IIW qualifications .......................................................................................93 Appendix II: Abbreviations ....................................................................................................................94 Appendix III: ANB Detailed Assessment ..............................................................................................95 Appendix IV: List of Referenced Standards .......................................................................................102



Preface This document is based upon the European Welding Engineer/ Technologist/ Specialist/ Practitioner Guide-lines as developed by the European Federation for Welding, Joining and Cutting (EWF), through an Agree-ment first signed 19 July, 1997, at the Annual Meeting of the International Institute of Welding (IIW) in San Francisco, California, USA and which has been renewed and further developed since then. It has been es-tablished in that Agreement that the International Welding Engineer/ Technologist/ Specialist/ Practitioner Di-ploma is equivalent to the European Welding Engineer/ Technologist/ Specialist/ Practitioner Diploma. The former EWF ANBs may issue the European Welding Engineer/ Technologist/ Specialist/ Practitioner di-plomas for as long as these qualifications are referenced in the standard EN 719. Copies of this document are available from the IIW IAB Secretariat or their designated distributor.



MINIMUM REQUIREMENTS FOR THE EDUCATION, TRAINING, EXAMINATION

AND QUALIFICATION OF PERSONNEL

1. Introduction This guideline for the international education, training, examination and qualification of welding personnel has been prepared, evaluated and formulated by Group A “Education, Training and Qualification” of the In-ternational Authorisation Board (IAB) of the International Institute of Welding IIW. Section I of the guideline covers the minimum requirements for education and training, agreed upon by all IIW Authorised National Bodies (ANB), in terms of objectives, scope, expected results and the teaching hours to be devoted to achieving them. It will be revised periodically by IAB Group A to take into account changes to reflect the "state of the art". Students having successfully completed this course of education and the appropriate examinations will be expected to be capable of applying the technology required in welding engineering as covered by this guideline. Section II of the guideline covers the rules for examination and qualification. The contents are given in the following structure (overview):

teaching hours* IWE IWT IWS IWP Modules of Theoretical Education and fundamental

practical skills MT P1 MT P1 MT P1 MT P1

1. Welding processes and equipment 93 35 76 35 45 14 22 142. Materials and their behaviour during welding 111 39 82 39 47 18 22 123. Construction and design 64 14 40 14 22 4 8 04. Fabrication, applications engineering 110 0 80 0 53 0 28 0

Sub-total 378 88 278 88 167 36 80 26 Fundamental practical skills (Part 2) 60 60 60 60

Total 438 338 227 140 * teaching hours are the minimum for the Standard Route, see 2.4; MT = Module Total (Part 1 + Part 3); P1 = Part 1; Figures under P1 are given for the Standard Route (see 4.1). It is to be noted that the overall structure of the syllabus for all levels (IWE, IWT, IWS, and IWP) is similar, but some topics are not considered in all levels of qualification. These topics are indicated by 0 hours in this guideline. The depth to which a topic is dealt with is indicated by the number of hours allocated to it in the guideline. This will be reflected in the scope and depth of the examination. 2. Routes to Qualification Three distinct routes to gaining the qualifications described in this document have been agreed.

1. The Standard Route 2. The Alternative Route 3. Distance Learning Programs

2.1 The Standard Route

The Standard Route requires attendance at IIW approved Training Courses designed to meet all the re-quirements in this Guideline. This is the route (Route 1 in diagrams 1, 2, 3, and 4) recommended by IIW as offering the fastest, most comprehensive manner in which the syllabus may be covered.



The Standard Route also allows for a limited amount of prior learning (Part 1 of each qualification course; see Section I) to be taken into account, for example during University or College courses or by distance learning (Route 2 in diagrams 1, 2, 3, and 4). This prior learning shall be approved by the ANB. 2.2 The Alternative Route The Alternative Route allows those who have gained the knowledge of the syllabus in the full detail defined in this Guideline and who can demonstrate their capability in all respects, to proceed to examination without compulsory attendance at an ANB approved Training Course. 2.3 Distance Learning Programs The Part 1 theory module may be taught in Distance Learning Programs under control of the ANB. When the Part 1 and Part 3 theory modules are combined or the Part 3 theory module is taught separately the requirements of the Distance Learning Guideline IAB 195-2004 shall be followed. 2.4 Teaching hours The meaning of the teaching hours is the following: Standard Route: minimum number of hours devoted to the subject Alternative Route: recommended number of hours devoted to the subject Distance Learning: recommended number of hours devoted to the subject Part 1: maximum number of hours devoted to the subject in Part 1 A "teaching hour" shall contain at least 50 minutes of direct teaching time. 3. General Access Conditions In a separate document (Directory of Access Conditions, Doc. IAB-020-2000) the defined access conditions approved by Group B “Implementation and Authorisation” of the International Authorisation Board (IAB) of the International Institute of Welding IIW are given in detail for all countries participating in the IAB system. Applicants not fulfilling the access conditions may follow the course as guests, but entry to the IIW examina-tion is not permitted. The following general conditions shall be observed when passing through the IWE, IWT, IWS and IWP courses:

1. Students who have successfully passed the intermediate examination of Part 1 of the course are al-lowed to attend Part 2 and Part 3 of the course;

2. The implementation of the access conditions is the responsibility of the ANB.

3.1 International Welding Engineer IWE It is agreed that entry to the program should be on a postgraduate level. Participants should have a primary degree in an engineering discipline or its equivalent recognised by the national government and assessed by the ANB. Therefore, it would be expected that participants should have at least a Bachelor degree. In case of co-operation arrangements, e.g. with universities, according to which the IWE Part 1 of the curricu-lum structure (see Section I) is presented under careful control of the ANB, the participant is allowed to enter the IWE course through the Route 2 (see item 2.1 and the diagram 1).



The following additional conditions shall be observed for the different routes through the IWE course:

1. Students who have authenticated evidence that they have passed the examinations in all subjects of their engineer study – except the diploma thesis – are allowed to attend Part 2 and Part 3 of the IWE course and the corresponding written parts of the final examination;

2. Students shall present their degree diploma to the Board of Examiners before being allowed to take

the final oral examination for IWE.

Diagram 1 3.2 International Welding Technologist IWT It is agreed that entry to the program should be on the basis of a higher technical education below that re-quired for the International Welding Engineer. Participants should have a primary degree in an engineering discipline or its equivalent recognised by the national government and assessed by the ANB. In case of co-operation arrangements, e.g. with technical colleges, according to which the IWT Part 1 of the curriculum structure (see Section I) is presented under careful control of the ANB, the participant is allowed to enter the IWT course through the Route 2 (see item 2.1 and the diagram 2).

Diagram 2 3.3 International Welding Specialist IWS It is agreed that entry to the program through the Routes 1 and 2 should be on the basis of a specific techni-cal education below that required for the International Welding Technologist. In case of co-operation arrangements, e.g. with technical colleges, according to which the IWS Part 1 of the curriculum structure (see Section I) is presented under careful control of the ANB, the participant is allowed to enter the IWS course through the Route 2 (see item 2.1 and the diagram 3).

IWE DiplomaIWE 1

Max. 88 h IWE 260 h

IWE 3 Min. 290 h

All university exams passed

Engineer’s Diploma

OE WESTOP STOP

Intermediate examination

Final examination WE: written examination OE: oral examination

Route 1

Route 2

IWT Diploma IWT 1

Max. 88 h IWT 260 h

IWT 3 Min. 190 h


Final examination

Route 1

Route 2



Diagram 3 The following additional conditions shall be observed for the different routes through the IWS course:

1. Route 1 and 2: a minimum age of 20 years including 2 years of job related experience is required; 2. Route 3: For the access to the module IWS Part 0 the minimum requirements are:

• International Welding Practitioner (IWP) or (see on above diagram option 2) • Qualification of a professional worker (with diploma after examination) in metalworking profes-

sions and minimum 3 years experience in welding related activities, and a minimum age of 22 years. National definitions are given in the Directory of Access Conditions (see on above diagram option 2).

3. A qualified professional worker (as stated above) or an IWP Diploma holder not fulfilling the IWS Na-

tional Access Requirements should be allowed to go directly to the IWS Part 0 examination if they can prove that they have achieved the knowledge prescribed by the IWS Part 0 (see on above dia-gram option 3).

4. If the IWP Diploma holder fulfills the IWS National Access Requirements, he may skip the entry test

(IWS Part 0 examination) and IWS Part 1 and only perform the IWS Part 1 intermediate exam (see on above diagram option 4).

IWS DiplomaIWS 1

Max. 36 h IWS 260 h

IWS 3 Min. 131 h


Final examination

Route 1

Route 2

Check Entry test(IWS 0 examination)

Route 3

IWP 20 years old

2 years experience

Professional Worker 22 years old

3 years experience

IWS 0 71 h

Option 4

Option 3

Option 2



3.4 International Welding Practitioner IWP In order to enter the International Welding Practitioner course, participants are required to be skilled in prac-tical welding and to have had experience as a welder in industry. As well as assuming theoretical education, the International Welding Practitioner course also serves to entrance the practical welding skills level of the participants. In case of co-operation arrangements, e.g. with technical colleges, according to which the IWP Part 1 of the curriculum structure (see Section I) is presented under careful control of the ANB, the participant is allowed to enter the IWP course through the Route 2 (see item 2.1 and the diagram 4). The following standard access conditions are applicable to the IWP course. Applicants are required to

1. Hold a valid welder qualification certificate ISO 9606 H-L045 ss nb in one of the welding processes listed in 5.1 of ISO 9606, or equivalent, e.g. EN 287 H-L045 ss nb, or ASME IX 6G.

or hold a valid welder qualification as a plate welder for the following conditions: PE ss nb or PC and PF

ss nb, according to ISO 9606 at least in one process, and/or other national equivalent in the IIW member country.

2. Be a minimum age of 20 years including 2 years experience as a welder.

Diagram 4 4. Special Requirements 4.1 Standard Route An applicant (excluding guests) shall satisfy the ANB access conditions. If the ANB decides that the access conditions are adequately met, the applicant is then required to attend a training course conducted by an Approved Training Body (ATB) giving as a minimum the hours of instruction detailed in this Guideline as teaching hours. At the conclusion of this course of instruction the student may enter the examinations for the award of the applicable IIW Diploma. The maximum amount of hours of the lectures, which can be included in Part 1 are given after “P1=” in the following definition of the theoretical education (see Section I). The definition of the precise syllabus of Part 1 is the responsibility of the ANB. It is not obligatory to follow exactly the order of the topics given in this guideline and choice in the arrange-ment of the syllabus is permitted. The depth to which each topic is dealt with is indicated by the number of hours allocated to it in the guideline. This will be reflected in the scope and depth of the examination.

IWP Diploma IWP 1

Max. 26 h IWP 260 h

IWP 3 Min. 54 h

Max. 33 h

Final examination Written Di l

Route 1

Route 2



The rules for the conduct of the final examination by the ANB are prescribed under Examination and Qualifi-cation Section in this guideline (Section II). The intermediate examination is mandatory for access Route 2 and it is the responsibility of the training school to ensure that those entering by this Route 2 have achieved the required knowledge of Part 1 to enter Part 2 and Part 3 of the course. Failure in the intermediate exami-nation will require the student to enter Part 1 of the course. 4.2 Alternative Route An applicant shall submit to the ANB the documents indicated in the items 4.2.1, 4.2.2, 4.2.3 and 4.2.4 for a paper assessment together with an application form. The ANB shall determine through a paper assessment if the application is suitable for further detailed as-sessment (Appendix III). The following Access Conditions for the alternative route shall be checked by a paper assessment (see the list of access conditions, doc IAB-020-2000). This assessment is an evaluation of practice of related job func-tion in welding. 4.2.1 International Welding Engineer IWE

A copy of a diploma showing graduation in an engineering subject complying with the Access Condi-

tions. A curriculum vitae (CV) - resume containing professional information:

• evidence of at least 4 years job function in welding at the level of an engineer (in a period of 6 years before application);

• justification of candidate’s experience, training, and education to become IWE (may include other test results).

Diagram 5 Alternative versus Standard Routes for IWE qualification

(see also appendix III)

1. Engineer degree (see National Access Conditions). 2. Curriculum Vitae – resumé (professional information):

• min. 4 years job function in welding (engineer level); • justification of candidate’s experience, training, and education to become

IWE (may include other test results).

IWE DiplomaIWE 1 IWE 2

Standard Route (see Diagram 1 for more details)

Alternative Route

no

no yes

no

IWT or IWS standard or alternative route ANB check

IWE 3 Modules

1 2 3 4

Final exams

At the discretion of the ANB

Project or Technical Interview

yes

yes

no

no

yes Paper assessment

Professional assessment interview



4.2.2 International Welding Technologist IWT A copy of a diploma showing graduation as technologist complying with the Access Conditions. A curriculum vitae (CV) - resume containing professional information:

• evidence of at least 4 years job function in welding at the level of a technologist (in a period of 6 years before application);

• justification of candidate’s experience, training, and education to become IWT (may include other test results).

Diagram 6 Alternative versus Standard Routes for IWT qualification (see also appendix III)

1. Technology degree (see National Access Conditions). 2. Curriculum Vitae – resumé (professional information):

• min. 4 years job function in welding (technologist level); • justification of candidate’s experience, training, and education to become

IWT (may include other test results).

IWT DiplomaIWT 1 IWT 2


Alternative Route

no

no yes

no

IWS standard or alternative route ANB check

IWT 3 Modules

1 2 3 4

Final exams



yes

yes

no

no





4.2.3 International Welding Specialist IWS A copy of documentary proof showing compliance with the Access Conditions for IWS. A curriculum vitae (CV) - resume containing professional information:

• evidence of at least 3 years job function in welding at a level equivalent to that of a specialist (in a period of 6 years before application);

• justification of candidate’s experience, training, and education to become IWS (may include other test results).

Diagram 7 Alternative versus Standard Routes for IWS qualification (see also appendix III)

1. Specialist qualification (see National Access Conditions, see also chapter 3.3). 2. Curriculum Vitae – resumé (professional information):

• min. 3 years job function in welding (specialist level); • justification of candidate’s experience, training, and education to become

IWS (may include other test results).

IWS DiplomaIWS 1 IWS 2


Alternative Route

no

no yes

no

IWP standard or alternative route ANB check

IWS 3 Modules

1 2 3 4

Final exams



yes

yes

no

no





4.2.4 International Welding Practitioner IWP A copy of a valid welder qualification certificate according with chapter 3.4 of the standard route. A curriculum vitae (CV) - resume containing professional information:

• min. 3 years job function in welding as a certified plate or tube welder in a period of 5 years before application plus

• min. 1 year job function in welding practitioner level in a period of 3 years before application; • justification of candidate’s experience, training, and education to become IWP (may include other

test results).

Diagram 8 Alternative versus Standard Routes for IWP qualification (see also appendix III)

1. Welder Qualification Certificate (see chapter 3.4). 2. Curriculum Vitae (professional information):

• min. 3 years job function as certified welder; • min. 1 year job function in welding (practitioner level); • justification of candidate’s experience, training, and education to become

IWP.

IWP DiplomaIWP 1 IWP 2


Alternative Route

no yes

no

ANB check

IWP 3 Modules

1 2 3 4

Final exams



yes

yes

no

no





Section I: Theoretical and Practical Education – Part 1, Part 2 and Part 3, Syllabus and Performance Objectives (Figures are teaching hours. Those after “P1=” are maximum teaching hours which can be included in Part 1) I.1. Theoretical Education - Part 1 and Part 3 Module 1: Welding processes and equipment

1.1 General introduction to welding technology

Objective for IWE, IWT and IWS: Understand (gain knowledge to understand in general) the develop-ments in welding processes including accepted terminology, standards and abbreviations. Objective for IWP: Explain the different welding processes including terminology, standards and abbre-viations.

IWE IWT IWS IWP 3 3 1 1

QualificationTeaching hours

Scope: P1=3 P1=3 P1=1 P1=1 History ……………………………………………………………………….…... Definitions ……………………………………………………………………..… Schematic presentation of welding processes ………………….……………Terminology …………………………………………………………….………..Picture and brief description with characteristics ………………………….... Applicability of the most common welding processes …………………….... General applications for welding ………………………………….…………...Abbreviations used for welding processes ……………………….………..…Hints in use for welding processes ……………………………….…………...Classification of welding processes (IIW, ISO, CEN and national stan-dards) ………………………………....…………………………......…………..

X X X X X X X X X

X

X X X X X X X X X

X

X X X X X X X X

X

X X X X X X X X

X

Expected Result for IWE: 1. Detail the differences between each major type of welding process, e.g. arc, resistance, flame, forge,

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

etc. 2. Differentiate between processes with reference to standards. 3. Recognise a welding process by the common abbreviation. 4. Explain the historical evolution of welding.

Expected Result for IWS: 1. Outline the major differences between each main type of welding process, e.g. fusion arc, resistance,

flame, forge, etc. 2. Differentiate between processes with reference to standards. 3. Recognise a welding process by the common abbreviation.

Expected Result for IWP: 1. Identify the differences between each major type of welding process. 2. Designate a welding process by the common abbreviation.



1.2 Oxy-gas Welding and related processes

Objective: Understand (gain knowledge to understand) /associate the fundamentals of oxy-gas combus-tion, characteristics of the different fuel gases, equipment, safety and typical applications.



Scope: P1=2 P1=2 P1=2 P1=2 Process principles ……………………………………………….………………Range of Application …………………………………………………………… Types of Flames ………………………………………………………….…….. Characteristics of fuel gases, (acetylene, propane, etc.) …………….….….Combustion reactions………………….………………………………….……. Temperature distribution effects ……………………………………….………Equipment ………………………………………………………………….…….Acetylene cylinder component parts…………………………………...……... Fuel gas generation …………………………………………………………. Handling and storage of gases ……………………………………………….. Typical joint design for welding ……………………………………………….. Methods of welding techniques, rightward, leftward ………………….……..Standards for filler materials …………………………………………………...Welding applications, typical problems and imperfections………….……….Special techniques and their methods of use (preheating, straightening, cleaning, etc.) …………………………………………………………………… Health and safety issues specific to the process …………………….………

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

X X


X X

X X X X X X X X

X X X X X

X X

X X X

X

X X

X X X X

X X

Expected Result for IWE: 1. Explain fully the characteristics of the three flame types and reasons for application of each. 2. Detail the characteristics of flames produced by different fuel gases. 3. Define the potential hazards and methods of safe handling and working. 4. Explain the purpose and working principle of each component of the equipment. 5. Interpret appropriate standards. 6. Define the range of application for this process and potential problems to overcome. Expected Result for IWT: 1. Explain the characteristics of the three flame types and reasons for application of each. 2. Detail the characteristics of flames produced by different fuel gases. 3. Define the potential hazards and methods of safe handling and working 4. Explain the purpose and working principle of each component of the equipment 5. Interpret appropriate standards. 6. Define the range of application for this process and potential problems to overcome. Expected Result for IWS: 1. Outline the characteristics of the three flame types and typical applications for each type. 2. Compare the characteristics of flames produced by different fuel gases. 3. Recognise and define in general the potential hazards and methods of safe handling, storage and

working practices. 4. Outline the purpose and working principle of each component of the equipment. 5. Basic knowledge on how to use appropriate standards. 6. Identify the limitations and the range of application of the process and recognise how to overcome the

potential problems associated with this process. Expected Result for IWP: 1. Interpret the characteristics of the different types of flames and their application. 2. Illustrate potential hazards and methods of safe handling and working. 3. Name the working principle of each component of the equipment. 4. Translate appropriate standards



1.3 Electrotechnics, a review Objective for IWE, IWT and IWS: Understand (gain knowledge to understand in general) the basics of electricity in relation to the requirements of welding technology and appreciate the key electronic compo-nents used in welding power sources. Objective for IWP: Have an outline working knowledge of electricity and the characteristics of the most important electrical components used in electrical welding power sources.



Scope: P1=2 P1=2 P1=2 P1=2 Basics of electricity and electronics (define current, voltage and resis-tance) ………………………………………………....…….………….......….... Ohm's Law ………………………………………………………………………. Parallel and serial circuits ………………………………………………….….. Direct current (DC), polarity, alternating current (AC) ………...……………. Magnetism in welding ………………………………………………………….. Capacity, condenser …………………………………………………………… Transformer, and rectifying bridge (half wave and full wave rectification) .. Transistor, thyristor, Inductance, inductors…………………………….…….. Hazard …………………………………………………………………………… Health and safety ………………………………………………………………..

X X X X X X X X X X

X X X X X X X X X X

X X X X X X X X X X

X X X X

X X

X X

Expected Result for IWE: 1. Define and explain the effect of current, voltage and electrical resistance in welding. 2. Detail the functions of the most important components of welding power sources. 3. Discuss competently the differences between DC and AC current. 4. Interpret and apply knowledge of electricity and electronics to welding applications.

Expected Result for IWT: 1. Define and explain the effect of current, voltage and electrical resistance in welding. 2. Detail the functions of the most important components of welding power sources. 3. Discuss competently the differences between DC and AC current. 4. Interpret and apply knowledge of electricity and electronics to welding applications.

Expected Result for IWS: 1. Outline the relation between current, voltage and electrical resistance, and also define each electrical

parameter. 2. Outline the major functions of the most important components of welding power sources. 3. Describe the major differences between DC and AC current and give examples of their individual ap-

plication to different welding processes. 4. Demonstrate and apply knowledge related to electricity and electronics in welding applications. Expected Result for IWP: 1. General outline of current, voltage and resistance. 2. Recognise and give examples of the functions of the main components of a welding power source. 3. Give examples of the main differences between DC and AC current. 4. Show practical application of knowledge of electricity to welding.



1.4 The arc Objective for IWE, IWT and IWS: Understand in detail (gain knowledge to understand in general) the fundamentals of an electric arc, its characteristics, limitations and application in welding, including arc stability problems. Objective for IWP: Describe what is an electric arc, its characteristics, limitations and application in weld-ing.



Scope: P1=4 P1=4 P1=0 P1=0 Arc physics (producing an electric arc, the main arc areas, stability of the arc) …………………….………………………………………………………….Voltage distribution across the arc ………………………………….….…...…Heat generation at the cathode and anode…………………………….….….Polarity and arc characteristics in AC and DC and its control for the key welding processes………………………………………………………...……. Influence on the welding process ……………………………………….……. Temperature distribution in the arc and effects ..………………………….... Influence of the magnetic fields on the arc (why, how to solve) ..…………. Limits of application …………………...……………………………….……….

X X X

X X X X X

X X X

X X X X X

X X X

X

X X X

X X X

X

X X X

Expected Result for IWE: 1. Explain in detail the fundamental physics of an electrical arc, including the main parameters influenc-

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

ing arc stability. 2. Detail the generation of heat in the arc and the arc voltage distribution. 3. Outline the influence of magnetic fields on the electric arc. 4. Predict how to solve magnetic deflection problems. 5. Explain arc characteristics for DC and AC including control and limitations. Expected Result for IWS: 1. Describe an electrical arc; it’s main areas and their importance to welding and arc stability. 2. Outline the generation of heat in the arc and the arc voltage distribution. 3. Give examples of the influence of magnetic fields on the electric arc. 4. Outline appropriate solutions to solve magnetic deflection problems. 5. Describe arc characteristics for DC and AC.

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



1.5 Power sources for arc welding

Objective for IWE, IWT and IWS: Understand in detail (gain knowledge to understand in general/having a outline working knowledge) the characteristics and main components of arc welding power sources.

Objective for IWP: Understand (gain knowledge to understand in general/having a outline working knowledge) of components of arc welding power sources.



Scope: P1=4 P1=4 P1=1 P1=1 Power source classification, types and characteristics (static and generators, and each sub-group) …………………………………Power source electrical characteristics (static and dynamic)….....…………Relationship between static characteristic and welding process …….…….Control of the electrical static characteristic (flat and drooping) .………….. Arc stability for the main processes (MMA, TIG, MIG/MAG, SAW, PAW) .. The operation working point …………………………………….…………..… Inverter technology ………………………………………………………...……Power sources controlled by a CPU …………………………………………..Stability of processes in AC and DC …………………………………….…….AC (sine wave and square wave) and DC power sources ………….………Open circuit voltage, short circuit current, power factor of transformers …. Duty cycle of a power source and typical values for the most common arc welding processes ……………………………………………….Voltage losses, relationship between welding current value and cable section…………………………………………………………………….. Pulse welding techniques ………………………………………………………Arc striking methods and devices, slope up and down, pre- and post-flow .Current and voltage setting (electromagnetic and electronic devices) …….Standards related with welding power sources and their requirements……

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X Expected Result for IWE: 1. Explain each type of arc welding power source for both AC and DC including the most common de-

vices used. 2. Detail for each type of welding power source the static and dynamic electrical characteristics, opera-

tion point and control of arc stability. 3. Explain the meaning of open circuit voltage, short circuit current, duty cycle of a power source, voltage

losses, and welding current to cable cross section relationship. 4. Explain the differences of the above characteristics for each type of power source and welding proc-

ess. 5. Recognise the various functions and switches on different power sources and their effects. Expected Result for IWT: 1. Explain each type of arc welding power source for both AC and DC including the most common de-

vices used. 2. For each type of welding power source detail the static and dynamic electrical characteristics, opera-

tion point and control of arc stability. 3. Explain the meaning of open circuit voltage, arc voltage short circuit current, duty cycle of a power

source, voltage losses, and welding current to cable cross section relationship. 4. Explain the differences of the above characteristics for each type of power source and welding proc-

ess for a specific application. 5. Recognise the various functions and switches on different power sources and their effects.



Expected Result for IWS: 1. Outline how each type of welding power source works (AC and DC) including the most common de-

vices used. 2. Describe for each type of arc welding power source the static characteristic, operation point and con-

trol of arc stability. 3. Outline the meaning of open circuit voltage, arc voltage short circuit current, duty cycle of a power

source, voltage losses, and current to cable section relationship. 4. Be able select the appropriate power sources for a given welding process. 5. Recognise the various settings and switches on different power sources and their effects. Expected Result for IWP: 1. Outline how each type of welding power source works (AC and DC) including the most common de-

vices used. 2. Describe for each type of arc welding power source the static characteristic, operation point and con-

trol of arc stability. 3. Outline the meaning of open circuit voltage, arc voltage short circuit current, duty cycle of a power

source, voltage losses, and current to cable section relationship. 4. Be able select the appropriate power sources for a given welding process. 5. Recognise the various settings and switches on different power sources and their effects.



1.6 Introduction to gas shielded arc welding Objective for IWE, IWT and IWS: Understand (gain knowledge to understand in general/gain an outline working knowledge) the principles and physical phenomena of gas shielded welding processes.

Objective for IWP: Understand (gain knowledge to understand in general/gain an outline working knowl-edge) the principles of gas shielded welding processes.



Scope: P1=2 P1=2 P1=2 P1=2 Physical phenomena ……………………………………………………..……. Operating principles of TIG, MIG/MAG and flux-cored …………………….. Shielding gases (inert, active) and their effect on arc characteristics ……. Handling and storage of gases ……………………………………………….. Filler materials ………………………………………………………………….. Standards (International and National) for shielding gases and filler materials …………………………………………………..…………..

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Expected Result for IWE: 1. Explain the characteristics and operating principles of TIG, MIG/MAG and Flux-cored welding. 2. Interpret arc characteristics associated with each type of shielding gas used for each process. 3. Detail the methods for safe handling and storage of shielding gases. 4. Interpretation and use of standards for shielding gases and filler materials. Expected Result for IWT: 1. Explain the characteristics and operating principles of TIG, MIG/MAG and Flux-cored welding. 2. Interpret arc characteristics associated with each type of shielding gas used for each process. 3. Detail the methods for safe handling and storage of shielding gases. 4. Interpretation and use of standards for shielding gases and filler materials.

Expected Result for IWS: 1. Describe and compare the characteristics and operating principles of TIG, MIG/MAG and Flux-cored

welding. 2. Compare and outline arc characteristics associated with each type of shielding gas used for each

process. 3. Outline the methods for safe handling and storage of shielding gases. 4. Demonstrate the use of standards for shielding gases and filler materials. Expected Result for IWP: 1. Differentiate the operating principles of TIG, MIG/MAG and Flux-cored welding. 2. Outline the arc characteristics associated with each type of shielding gas used. 3. Demonstrate a general knowledge of the basic rules of handling and storing shielding gases.



1.7 TIG Welding Objective for IWE, IWT and IWS: Understand in detail/gain knowledge to understand in general/explain TIG welding fundamentals, including equipment, applications, procedures and specific problems. Objective for IWP: Understand in detail (gain knowledge to understand in general/explain) TIG welding fundamen-tals, including equipment, and applications.



Scope: P1=4 P1=4 P1=2 P1=2 Power source characteristics ………………………………………….….…....Methods for arc ignition and necessary equipment ……..........................… Equipment and accessories: torches, gas lens, control panel, up and down slope, pulse techniques………………………………………………..... Effect of current type and polarity: DC(+), DC(-) and AC………………..…..Specific requirements for different materials, e.g. Al…………………….….. Consumables: shielding gases, filler materials, electrodes …………….…..Welding parameters: current, voltage, travel speed, gas flow rate…………Joint preparation: typical joint design for welding, fit-up, cleaning………….Welding procedures ………………………………………………………….....Special techniques: spot-welding, key-hole, hot-wire, orbital welding, tube to tube and tube to sheet , and others…………………………………….......Standards for filler materials, electrodes, and gases ……………………..... Welding applications, typical problems and how to solve them …………....Health and safety issues specific to the process ………………………..…..

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Expected Result for IWE: 1. Explain in detail the principles of TIG welding including arc ignition methods and their applications. 2. Explain the selection of appropriate type of current, polarity, shielding gas and electrode type accord-

ing to application. 3. Detail the range of application, appropriate joint preparations and potential problems to be overcome. 4. Detail appropriate welding parameters for particular applications. 5. Explain the purpose and functions of each component of the equipment and accessories. 6. Interpret appropriate standards. 7. Define potential hazards and methods of safe handling and working. 8. Recognise the various settings and switches on different TIG power sources and their effects. Expected Result for IWT: 1. Explain and compare in detail the principles of TIG welding including arc ignition methods and their

applications. 2. Explain the selection of appropriate type of current, polarity, shielding gas and electrode type accord-

ing to application. 3. Identify the range of application, appropriate joint preparations and potential problems to be overcome 4. Identify appropriate welding parameters for particular applications. 5. Explain the purpose and functions of each component of the equipment and accessories. 6. Interpret appropriate standards. 7. Define potential hazards and methods of safe handling and working. 8. Recognise the various settings and switches on different TIG power sources and their effects. Expected Result for IWS: 1. Describe and compare the principles of TIG welding including arc ignition methods and their applica-

tions. 2. Explain the selection of appropriate type of current, polarity, shielding gas and electrode type accord-

ing to the application. 3. Identify the range of application, appropriate joint preparations and potential problems to be overcome.4. Identify an appropriate range of welding parameters for particular applications. 5. Explain the purpose and functions of each component of the equipment and accessories. 6. Interpret the use of appropriate standards. 7. Describe potential hazards and methods of safe handling and working.



Expected Result for IWP: 1. Outline TIG welding including arc ignition methods and their most common applications. 2. Give examples of the most common applications for each type of current, polarity and electrode. type 3. Give examples of the most important applications and select the appropriate values for welding pa-

rameters. 4. Know how to use and care for the equipment and accessories. 5. Read given standards for consumables. 6. Give examples of TIG applications, joint preparation and potential problems to overcome. 7. Outline potential hazards and methods of safe handling and working.



1.8 MIG/MAG and Flux Cored Arc Welding

Objective for IWE, IWT, IWS and IWP: Understand in detail/gain knowledge to understand in gen-eral/explain MIG/MAG and Flux Cored Arc welding fundamentals, including equipment, applications, procedures and common problems



Scope: P1=4 P1=4 P1=2 P1=2 Power source characteristics for conventional process and CPU con-trolled power sources………………………………………...………………….Effect of current type and polarity.....…………………………………………..Equipment and accessories: torches, wire feeders, hose assembly, con-trol panel…………………………………………………………………………. Metal transfer modes (dip, globular, spray, pulsed and rotating), and their Application………...........……………………………………………………….. Welding parameters and settings: current, voltage, travel speed, gas flow rate, etc..................………………………………………………………………Consumables: shielding gases, filler materials (solid and flux cored wires), and their combinations……………………………………………….…............Joint preparation: typical joint design for welding, fit-up, cleaning………….Welding procedures……………………..…………….............………………..Special techniques: electro-gas welding, high efficiency processes...…... Standards for filler materials, and gases………………….............………… Welding applications, typical problems and how to solve them......…..….. Health and safety specific to the process…..………….............…………….

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Expected Result for IWE: 1. Explain in detail the principles of MIG/MAG and Flux Cored Arc welding including metal transfer

modes and their applications. 2. Explain the selection of appropriate type of current, polarity and electrode according to application. 3. Detail the range of application, appropriate joint preparations and potential problems to be overcome. 4. Detail appropriate welding parameters for particular applications. 5. Define potential hazards and methods of safe handling and working. 6. Explain the purpose and functions of each component of the equipment and accessories. 7. Interpret appropriate standards 8. Explain selection of consumables. 9. Recognise the various settings and switches on different MIG/MAG and Flux Cored power sources

and effects. Expected Result for IWT: 1. Explain and compare in detail the principles of MIG/MAG and Flux Cored Arc welding including metal

transfer modes and their applications. 2. Compare the selection of appropriate type of current, polarity and electrode according to application. 3. Identify the range of application, appropriate joint preparations and potential problems to be overcome.4. Identify appropriate welding parameters for particular applications. 5. Define potential hazards and methods of safe handling and working. 6. Explain the purpose and functions of each component of the equipment and accessories. 7. Interpret appropriate standards 8. Explain selection of consumables. 9. Recognise the various settings and switches on different MIG/MAG and Flux Cored power sources

and effects.



Expected Result for IWS: 1. Describe and compare the principles of MIG/MAG and Flux Cored Arc welding including metal transfer

modes and their applications. 2. Identify the most common applications for each type of current, polarity and electrode. 3. Identify the range of application, appropriate joint preparations and potential problems to be overcome.4. Identify an appropriate range of welding parameters for particular applications. 5. Describe potential hazards and methods of safe handling and working. 6. Outline the various functions of the main components of the equipment and accessories. 7. Demonstrate the use of appropriate standards 8. Give examples on how consumables should be selected. Expected Result for IWP: 1. Outline MIG/MAG and Flux Cored Arc welding, comparing metal transfer modes and their application. 2. Give examples of the most common applications of each type of current, polarity and electrode. 3. Give examples of the most important applications and select appropriate welding parameters. 4. Know how to use and care for the equipment and accessories. 5. Read given standards for consumables. 6. Give examples of MIG/MAG application range, joint preparation and potential problems to overcome. 7. Outline potential hazards and methods of safe handling and working.



1.9 MMA Welding

Objective for IWE, IWT, IWS and IWP: Understand in detail/gain knowledge to understand in gen-eral/explain MMA welding fundamentals, including equipment, applications, procedures and common problems



Scope: P1=4 P1=4 P1=2 P1=2 Process principles and arc characteristics .............……….…………….. Effect of current type and polarity ……………..............……...………..… Power source characteristics applicable to MMA (open circuit voltage, static and dynamic characteristics, types of current, arc striking methods) Equipment and accessories…….............…………………………...……... Process application range, typical problems and how to solve them....... Covered electrodes (functions of the coating and rod, types of electrodes, slag-metal and gas-metal covered reactions) .....................……………. Production of electrodes (how, typical defects) ……..….............………. Handling and storage of electrodes (storage environment, redrying)..... Electrode classification (International and national standards) …………. Selection of covered electrodes for applications .….............……………. Welding parameters: current, voltage, run out length, etc ...........….…… Joint preparation: typical joint design for welding, fit-up, cleaning, welding position. Relationship between electrode diameter and current range, rod material, electrode length and welding position ..............……………………………... Welding procedures ….………..............…………………………………….…Special techniques (gravity welding, vertical down welding, on-site weld-ing)………………………………………………………………………......….. Health and safety specific to this process …….............…………….……

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X Expected Result for IWE: 1. Explain in detail the principles of MMA welding including special techniques, arc striking methods and

their applications. 2. Explain the selection of the appropriate type of current, polarity and electrode according to application.3. Detail the range of application, appropriate joint preparations and potential problems to be overcome. 4. Detail appropriate welding parameters for particular applications. 5. Define potential hazards and methods of safe handling and working. 6. Explain the purpose and functions of each component of the equipment and accessories. 7. Explain the handling and storage of the various types of electrodes. 8. Interpret appropriate standards. 9. Identify the influence of electrode coating on droplet transfer and weld metal properties. 10. Recognise the various functions and switches on different MMA power sources and their effects. Expected Result for IWT: 1. Explain in detail the principles of MMA welding including with particular emphasis on special tech-

niques, arc striking methods and their applications. 2. Explain the selection of the appropriate type of current, polarity and electrode according to application.3. Identify the range of application, appropriate joint preparations and potential problems to be overcome.4. Identify appropriate welding parameters for particular applications. 5. Define potential hazards and methods of safe handling and working. 6. Explain the purpose and functions of each component of the equipment and accessories. 7. Explain the handling, control and storage of the various types of electrodes. 8. Interpret appropriate standards. 9. Identify the influence of electrode coating on droplet transfer and weld metal properties.



Expected Result for IWS: 1. Describe the principles of MMA welding 2. Describe how to select the appropriate type of current, polarity and electrode according to application. 3. Identify the range of application, appropriate joint preparations and potential problems to be overcome.4. Identify an appropriate range of welding parameters for particular applications. 5. Describe potential hazards and methods of safe handling and working. 6. Outline the purpose and functions of each component of the equipment and accessories. 7. Describe the appropriate methods of handling, control and storage of the various types of electrodes. 8. Demonstrate the use of appropriate standards. 9. Describe the influence of electrode coating on droplet transfer and weld metal properties. Expected Result for IWP: 1. Outline MMA welding working principles, special techniques, arc striking methods and their applica-

tions. 2. Outline the handling and storage of each type of consumable. 3. Give examples of the most important applications and select appropriate welding parameters. 4. Know how to use and care for the equipment and accessories. 5. Read given standards for electrodes. 6. Give examples of MMA application range, joint preparation and potential problems to overcome. 7. Outline potential hazards and methods of safe handling and working.



1.10 Submerged-Arc Welding

Objective for IWE, IWT, IWS and IWP: Understand in detail/get a complete knowledge/explain SAW welding fundamentals, including equipment, applications, procedures and common problems.



Scope: P1=4 P1=4 P1=0 P1=0 SAW process principles and arc characteristics ........……………….……....Effect of current type and polarity...…………………...............………………Power source characteristics applicable to SAW (open circuit voltage, static and dynamic characteristics, types of current, arc striking methods) Equipment and accessories …………………………………...….............…. Process application range, typical problems and how to solve them......…. Consumables (functions of the flux and wire -solid or flux cored-, types of flux and wire, wire-flux combination, slag-metal and gas-metal reactions) Production of consumables (how, typical defects) Handling and storage of consumables (storage environment, re-drying) Consumable classification (International and national standards) Welding parameters: current, voltage, travel speed, type of flux and parti-cle size, stick-out, etc …………………………….............................………. Joint preparation: typical joint design for welding, fit-up, cleaning .........… Relationship between the wire-flux combination and the characteristics of deposited material….………………………..........................………………. Welding procedures.…………………………………………….............….... Single-wire and multi -wire techniques… ….............……………………..… Special techniques (strip-cladding, iron-powder addition, cold and hot wire addition) ……………………………………………………....................………Health and safety specific to SAW process..………….............……………..

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their applications. 2. Explain the selection of appropriate type of current, polarity and consumable according to application. 3. Identify the range of application, appropriate joint preparations and potential problems to be overcome.4. Identify appropriate welding parameters for particular applications. 5. Explain the purpose and functions of each component of the equipment and accessories. 6. Explain slag-metal/gas-metal reactions and their influence on weld metal properties 7. Interpret appropriate standards. 8. Define potential hazards and methods of safe handling and working. Expected Result for IWT: 1. Explain in detail the principles of SAW process including arc striking methods, special techniques and

their applications. 2. Explain the selection of appropriate type of current, polarity and consumable according to application. 3. Identify the range of application, appropriate joint preparations and potential problems to be overcome.4. Identify appropriate welding parameters for particular applications. 5. Explain the purpose and functions of each component of the equipment and accessories. 6. Explain slag-metal/gas-metal reactions and their influence on weld metal properties. 7. Interpret appropriate standards. 8. Define potential hazards and methods of safe handling and working.



Expected Result for IWS: 1. Explain the principle of the SAW process including arc striking methods, special techniques and their

applications. 2. Explain the criteria for evaluating the applicable welding parameters. 3. Identify the application range, joint edge preparation and potential problems to overcome. 4. Clarify the procedures for the set-up of power sources. 5. Explain the criteria for the selection of flux-wire combinations. 6. Interpret appropriate standards and welding procedures. 7. Define welding instructions for welders and operators. 8. Define potential hazards and methods of safe handling and working. Expected Result for IWP: 1. Explain the principles of SAW process including arc striking methods , special techniques, and their

applications. 2. Outline the handling and storage of each type of consumable. 3. Identify the application range, appropriate joint preparation and potential problems to overcome. 4. Know how to use and care for the equipment and accessories. 5. Read given standards for consumables. 6. Give examples of SAW application range, joint preparation and potential problems to overcome. 7. Define potential hazards and methods of safe handling and working.



1.11 Resistance Welding

Objective for IWE, IWT, and IWS: Understand in detail/get a complete knowledge/explain resistance welding fundamentals, applications and specifications, including common problems and their solution.



Scope: P1=0 P1=0 P1=0 P1=0 Process principles and overview on types of processes (spot, projection, butt, seam, and flash)………………………………………………………….. Joule effect and temperature distribution.……………………………….…. Equipment and accessories …………………………………………….......... Process application range and typical problems (welding thin to thick ma-terial, welding of coated/ painted materials, welding dissimilar materials, mass effect, shunt effect, Peltier effect, resistance brazing).………………. Electrodes (functions, types, shapes, material).…………………………….. Electrode classification (International and national standards).…………….Welding parameters: current, pressure, time, type of current, pulse, etc …Joint preparation: typical joint design for welding, fit-up, cleaning ….......... Relationship between welding parameters and the characteristics of the weld nugget ……………………………………………………….................. Monitoring systems, process control, measuring …………………………… Specific testing.…………………………………………………………………..Welding procedures.……………………………………………………………. Health and safety specific to this process.…………………………………….

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Expected Result for IWE: 1. Explain in detail the principles of resistance welding and the application of the various sub-processes. 2. Explain the selection of appropriate parameters to give sound welds. 3. Identify the range of application, appropriate material preparation and potential problems to be over

come. 4. Identify appropriate welding parameters for particular applications. 5. Explain the purpose and functions of each component of the equipment and accessories. 6. Interpret appropriate standards. 7. Define potential hazards and methods of safe handling and working. 8. Recognise the various settings and switches on different power sources and their effects. Expected Result for IWT: 1. Explain in detail the principles of resistance welding and the application of the various sub-processes. 2. Explain the selection of appropriate parameters to give sound welds. 3. Identify the range of application, appropriate material preparation and potential problems to be over-

come. 4. Identify appropriate welding parameters for particular applications. 5. Explain the purpose and functions of each component of the equipment and accessories. 6. Interpret appropriate standards. 7. Define potential hazards and methods of safe handling and working. 8. Recognise the various settings and switches on different power sources and their effects. Expected Result for IWS: 1. Explain the principle of the resistance welding process and the application of the various sub-

processes. 2. Explain the selection of appropriate parameters to give sound welds 3. Explain the criteria for the selection of the correct pressure and current cycles and clarify the proce-

dures for the setting up the power sources. 4. Discuss the influence of the surface characteristics on the final quality of the joints. Explain the causes

of the common discontinuities and their prevention. 5. Interpret appropriate standards and welding procedures. 6. Define welding instructions for welders and operators. 7. Define potential hazards and methods of safe handling and working.

Expected Result for IWP: Not Applicable



1.12.1 Other Welding Processes – LASER; Electron Beam; Plasma

Objective for IWE, IWT, and IWS: Understand in detail/get a complete knowledge/explain the principle and the filed of application of plasma; electron beam; LASER. Fundamentals, including equipment, appli-cations, procedures and common problems.

Objective for IWP: Gain an outline knowledge of plasma; electron beam; LASER, their application and most common problems.



Scope: P1=0 P1=0 P1=0 P1=0 Basic principles for all mentioned processes…..……………………………..Heat generation for each type of process …………………………..….……..Equipment and accessories for each type of process ………….…………...Typical process applications and problems ……….………………………….Consumables………………………………………………….………………….Welding parameters for each process ………………….………….………….Joint preparation: typical joint design for welding, fit-up, cleaning …...…....Relationship between welding parameters and joint configuration ….……. Comparison between high energy processes ……………………….……….Health and safety specific to the processes ……………………………...…..Appropriate national and international standards for each process ..…...…



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Expected Result for IWE: 1. Explain the principles of the processes mentioned in the objective and their application. 2. Determine appropriate applications for each type of process, and the precautions necessary to

achieve a sound weld. 3. Describe the welding parameters, appropriate joint preparations and potential problems to be over-

come for each process for a given application. 4. Explain the purpose and functions of each major component of the equipment and accessories. 5. Interpret appropriate standards. 6. Define potential hazards and methods of safe handling and working. Expected Result for IWT: 1. Explain the principles of the processes mentioned in the objective and their application. 2. Determine appropriate applications for each type of process, and the precautions necessary to


come for each process for a given application. 4. Explain the purpose and functions of each major component of the equipment and accessories. 5. Interpret appropriate standards. 6. Define potential hazards and methods of safe handling and working. Expected Result for IWS: 1. Explain the principles of the processes mentioned in the objective and their application. 2. Explain the common applications of the processes in the different industrial fields. 3. Define and describe, for each process, the suitable welding parameters. 4. Define potential hazards and methods of safe handling and working.

Expected Result for IWP: 1. Outline the working principles of the processes mentioned in the objective and their application. 2. Give examples of typical applications of different types of process. 3. Know how to use and care for the equipment and accessories for different processes. 4. Outline potential hazards and methods of safe handling and working.



1.12.2 Other Welding Processes, other than 1.12.1

Objective for IWE, IWT, and IWS: Understand in detail/get a complete knowledge/explain the principle and the field of application electro-slag, friction; friction stir, magnetically impelled arc butt (MIAB); mag-netic pulse welding, ultrasonic; explosive; diffusion; aluminothermic; high-frequency; stud, cold-pressure welding, hybrid processes, etc. Fundamentals, including equipment, applications, procedures and com-mon problems.

Objective for IWP: Gain an outline knowledge of electro-slag, friction; explosive; diffusion; aluminother-mic; high-frequency; cold-pressure welding their application and most common problems.



Scope: P1=0 P1=0 P1=0 P1=0 Basic principles for all mentioned processes…..……………………………..Heat generation for each type of process …………………………..….……..Equipment and accessories for each type of process ………….…………...Typical process applications and problems ……….………………………….Consumables………………………………………………….………………….Welding parameters for each process ………………….………….………….Joint preparation: typical joint design for welding, fit-up, cleaning …...…....Relationship between welding parameters and joint configuration ….……. Comparison between high energy processes ……………………….……….Health and safety specific to the processes ……………………………...…..Appropriate national and international standards for each process ..…...…



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Expected Result for IWE: 7. Explain the principles of the processes mentioned in the objective and their application. 8. Determine appropriate applications for each type of process, and the precautions necessary to


come for each process for a given application. 10. Explain the purpose and functions of each major component of the equipment and accessories. 11. Interpret appropriate standards. 12. Define potential hazards and methods of safe handling and working. Expected Result for IWT: 7. Explain the principles of the processes mentioned in the objective and their application. 8. Determine appropriate applications for each type of process, and the precautions necessary to


come for each process for a given application. 10. Explain the purpose and functions of each major component of the equipment and accessories. 11. Interpret appropriate standards. 12. Define potential hazards and methods of safe handling and working. Expected Result for IWS: 5. Explain the principles of the processes mentioned in the objective and their application. 6. Explain the common applications of the processes in the different industrial fields. 7. Define and describe, for each process, the suitable welding parameters. 8. Define potential hazards and methods of safe handling and working.

Expected Result for IWP: 5. Outline the working principles of the processes mentioned in the objective and their application. 6. Give examples of typical applications of different types of process. 7. Know how to use and care for the equipment and accessories for different processes. 8. Outline potential hazards and methods of safe handling and working.



1.13 Cutting and other edge preparation processes

Objective for IWE, IWT, IWS and IWP: Understand in detail/get a complete knowledge/explain/interpret the basic principles and the field of application of the most common cutting and edge preparation proc-esses used in weld construction, including equipment, procedures and common problems.



Scope: P1=2 P1=2 P1=0 P1=0 Survey of edge preparation processes…………………..…………………... Mechanical cutting ………………………………………………………………Principles of flame and flame powder cutting, equipment, applications and auxiliaries……………………………………………………………….……...... Flame cutting parameters, edge quality, oxygen purity grades……………. Materials suitable for flame cutting………………………………………….... Basic principles of the various arc cutting processes (arc-air, carbon and metal-arc, oxy-arc cutting, gauging with carbon electrode) equipment and auxiliaries……………………………………………………………………...… Materials suitable for arc-cutting, applications, cutting parameters for each process…………………………………………………………………………... Fundamentals of plasma cutting, equipment and auxiliaries………………. Materials suitable for plasma cutting, applications, cutting parameters, cutting gases……………………………………………………………….……. Plasma cutting special applications (under water cutting, cutting with wa-ter vortex)………………………………………………………………………... Plasma gouging……………………………………………………….………... Fundamentals of electron beam drilling and LASER cutting, equipment, parameters, applications……………………………………………………….. Fundamentals of water jet cutting, equipment, parameters, applications …Fundamentals of arc gouging and flame gouging, parameters and appli-cations……………………………………………………………….……… Appropriate national and international standards for each process………. Health and safety………………………………………………………………..

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Expected Result for IWE: 1. Explain in detail the principles of: mechanical, flame, arc, plasma, electron beam, LASER, and water jet

cutting. 2. Explain the influence of each parameter for the abovementioned processes on the edge surface quality. 3. Detail the range of applications for: flame, arc, plasma, electron beam, and water jet cutting. 4. Define potential risks, hazards and methods of safe handling and working. Expected Result for IWT: 1. Explain in detail the principles of: mechanical, flame, arc, plasma, electron beam, LASER, and water jet

cutting. 2. Explain the influence of each parameter for the abovementioned processes on the edge surface quality. 3. Identify the range of applications for: flame, arc, plasma, electron beam, and water jet cutting. 4. Identify potential risks, hazards and methods of safe handling and working. Expected Result for IWS: 1. Explain the principles of: mechanical, flame, arc, plasma, electron beam, LASER, and water jet cutting. 2. Identify the characteristic parameters for the above mentioned processes 3. Make a comparison among different edge preparation processes, considering technical and economic

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



1.14 Surfacing and Spraying

Objective for IWE, IWT and IWS: Understand in detail/get a complete knowledge/explain the principle and field of application of the most common surfacing techniques and their working principles, including equipment, procedures and common problems.



Scope: P1=0 P1=0 P1=0 P1=0 Working principles and applications for cladding techniques (rolling, ex-plosive, strip, plasma-MIG, electroslag, LASER, etc)………………………. Working principles and applications of the spraying techniques (flame spraying with powder, flame spraying with wire, arc spraying with powder, arc spraying with wire, plasma spraying with powder, HVOF spraying)….. Equipment and parameters for each technique…………………………..…. Surface preparation of the base material………………………….…………. Spraying materials……………………………………………………….……... Sprayed layer structure, and substrate structure……………..…………….. "Cold " and "fusion techniques" ……………………………………................ Applications and special problems…………………………………….……… Health and safety ........................................................................................

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Expected Result for IWE: 1. Explain the principles and characteristics of the most common cladding techniques. 2. Explain the principles and characteristics of the most common spraying techniques. 3. Evaluate the quality of a surfacing layer with respect to the base material preparation. 4. ? Explain the reasons for the different applications of "cold" and "fusion" spraying techniques. 5. Describe the most common spraying techniques and their industrial applications. 6. Define potential risks, hazards and methods of safe handling and working. Expected Result for IWT: 1. Explain the principles and characteristics of the most common cladding techniques. 2. Explain the principles and characteristics of the most common spraying techniques. 3. Evaluate the quality of a surfacing layer with respect to the base material preparation. 4. ? Explain the reasons for the different applications of "cold" and "fusion" spraying techniques. 5. Describe the most common spraying techniques and their industrial applications. 6. Define potential risks, hazards and methods of safe handling and working. Expected Result for IWS: 1. Explain the characteristics of the most common cladding and spraying techniques. 2. Clarify the influence of surface preparation on spraying procedures. 3. Describe the most common spraying techniques and their industrial applications. 4. Identify risks, hazards related with the abovementioned techniques. Expected Result for IWP: Not Applicable



1.15 Fully mechanised processes and robotics

Objective for IWE, IWT, and IWS: Understand in detail/get a complete knowledge/explain the principle and industrial applications of welding mechanisation and the use of robotics in welding, including applica-tions and systems.



Scope: P1=0 P1=0 P1=0 P1=0 Survey of welding mechanisation for higher productivity ……………...……Robotics, mechanisation, and automation: differences, advantages disad-vantages and applications..……………………………………...……………. Robotics (on-line and off-line programming, simulation, flexible manufac-turing systems) ……………………………………………………………….. CAD/CAM systems…………………………………………………………….. Virtual factory (factory simulation)…………………………………………….. Seam tracking, types and typical applications………………………………. Gas nozzle sensor, arc sensing, magnetic induction, vision system ….….. Narrow gap welding (SAW, MIG/MAG, TIG) ……………………….............. Orbital welding (MIG/MAG, TIG) …………………………………….............. Application, typical problems and how to solve them………………............Gases and filler materials (optimisation for mechanised welding) ..….…….Health and safety………………………………………………………………..

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Expected Result for IWE: 1. Predict the best solution for higher productivity in welding using robotics, automation and mechanisa-

tion. 2. Explain in detail the differences between off-line and on-line programming. 3. Explain the principle, benefits and applications of each type of seam tracking system. 4. Explain the principle and applications of narrow gap and orbital welding. 5. Describe the different applications for each welding process when applied to narrow gap or orbital

welding. 6. Define potential risks, hazards and methods of safe handling and working.

Expected Result for IWT: 1. Predict solutions for higher productivity in welding using robotics, automation and mechanisation. 2. Explain the differences between off-line and on-line programming. 3. Explain the principle and applications of each type of seam tracking system. 4. Explain the principle, benefits and applications of narrow gap and orbital welding. 5. Describe the different applications for each welding process when applied to narrow gap and orbital

welding. 6. Define potential risks, hazards and methods of safe handling and working.

Expected Result for IWS: 1. Describe the advantages and disadvantages of robotics, automation and mechanisation of welding

processes. 2. Explain the techniques used for seam tracking and their differences. 3. Explain the features of the most common industrial applications (e.g. narrow gap and orbital welding). 4. Identify potential risks, hazards and methods of safe handling and working related with automatic,

mechanised and robotics in welding processes.




1.16 Brazing and soldering

Objective for IWE, IWT, and IWS: Understand in detail/get a complete knowledge/explain the principle and the field of application of brazing and soldering, procedures, equipment, applications, and common problems.



Scope: P1=0 P1=0 P1=0 P1=0 Fundamentals of brazing and soldering (bonding mechanisms, surface tension, wetting, capillary) ……………………………………………………...Survey of brazing and soldering techniques, equipment, range of applica-tions ………………………………………………...……………………………. Consumables and fluxes for brazing and soldering, types, applications, and main functions of the fluxes ……………………………………………….Materials suitable for brazing, brazing requisites ………………………….. High vacuum brazing, brazing under controlled atmosphere ……...............Braze welding (Arc and laser brazing)…………...........................................Survey of soldering techniques (dip, wave flow, vapour phase, soldering) .Brazing and soldering advantages and disadvantages ……………….…….Applications and special problems ………………………………………….…Overview on standards……………………………………………………....….Health and safety …………………………………………………………….….

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Expected Result for IWE: 1. Explain in detail each brazing and soldering technique. 2. Compare in detail each type of brazing and soldering technique with fusion welding. 3. Explain the precautions to obtain a sound joint using brazing or soldering techniques. 4. Describe the different applications for each brazing and soldering techniques. 5. Describe the types and characteristics of consumable and flux used in a certain applications. 6. Define potential risks, hazards and methods of safe handling and working. Expected Result for IWT: 1. Explain in detail each brazing and soldering technique. 2. Compare in detail each type of brazing and soldering technique with fusion welding. 3. Explain the precautions to obtain a sound joint using brazing or soldering techniques. 4. Describe the different applications for each brazing and soldering techniques. 5. Describe the types and characteristics of consumable and flux to used in certain applications. 6. Define potential risks, hazards and methods of safe handling and working.

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




1.17 Joining processes for plastics

Objective for IWE, IWT, and IWS: Understand in detail/get a complete knowledge/explain the basic prin-ciples involved in joining plastics, including the common techniques, equipment, applications, procedures and common problems.



Scope: P1=0 P1=0 P1=0 P1=0 General information on materials and joining processes …………….……..Study the operating principle for each type of process …..………………… Hot plate welding, butt fusion, hot gas welding, extrusion welding, induc-tion welding, resistance welding, implant welding, high frequency, friction, electro-fusion welding, ultrasonic welding, vibration welding, adhesive bonding ………………………………………………………………………….. Control of welding parameters, types of equipment, joint design …………. Advantages and disadvantages ………………………………………………. Applications and typical problems and how to solve them …………..……. Health and safety ………………………………………………………………..

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Expected Result for IWE: 1. Explain the fundamentals of each joining process. 2. Explain the precautions to obtain a sound joint for each process. 3. Describe the different applications for each joining process. 4. Define potential risks, hazards and methods of safe handling and working.

Expected Result for IWT: 1. Explain the fundamentals of each joining process. 2. Explain the precautions to obtain a sound joint for each process. 3. Describe the different applications for each joining process. 4. Define potential risks, hazards and methods of safe handling and working.

Expected Result for IWS: 1. Explain the basic characteristics and the range of application for each joining process. 2. Make a comparison, where possible, between plastic joining processes and fusion welding processes

in the same industrial field (e.g., polyethylene / plain carbon steel pipes) 3. Describe the operating principle of the most common joining processes. 4. Describe the state of the art of the industrial applications for each joining process. 5. Define risks and hazards related with plastics joining. Expected Result for IWP: Not Applicable



1.18 Joining processes for ceramics and composites

Objective for IWE, and IWT: Understand the general principles of joining ceramics and composites, in-cluding the common techniques, applications, procedures and common problems.



Scope: P1=0 P1=0 P1=0 P1=0 General information on ceramics and composites and typical joining proc-esses…………………………………………………………………………….. General study of the operating principles for each process ..……………… Advantages and disadvantages………………………………………………. Applications and special problems…………………………………………….

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Expected Result for IWE: 1. Explain the fundamentals of joining ceramics and composites. 2. Explain the precautions to obtain a sound joint 3. Define potential risks, hazards and methods of safe handling and working. Expected Result for IWT: 1. Explain the fundamentals of joining ceramics and composites. 2. Identify precautions to produce a sound joint 3. Define potential risks, hazards and methods of safe handling and working. Expected Result for IWS and IWP: Not Applicable



1.19 Welding laboratory

Objective for IWE, IWT, and IWS: Understand in detail/get a complete knowledge/explain the effect of parameters on weld bead shape and cut surface quality.



Scope: P1=0 P1=0 P1=0 P1=0 Practical exercises showing the effect of each main welding parameter on the weld bead shape…………………………………………..……………….. Discussion of results to help future evaluation and diagnosis……….…….. Exercises should cover: MMA, TIG, MIG/MAG, Flux Cored wires, SAW, Oxy-gas………………………………………………………………………….. Practical exercises showing the effect of each main cutting parameter on the cut surface…………………………………………………………….…….. Exercises should cover: Oxy-cutting, Arc-Air, Plasma, Arc-Cutting……….

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Expected Result for IWE: 1. Predict weld bead shape and morphology (internal and external), according to the welding parameters

used. 2. Explain in detail the factors that can change the weld bead profile, and why. 3. Predict the morphology of cut surfaces, according to the cutting parameters used. 4. Explain in detail the factors that can change the cut surface quality, and why. 5. Be able to evaluate and diagnose weld beads and cut surfaces. Expected Result for IWT: 1. Predict weld bead shape and morphology (internal and external), according to the welding parameters

used. 2. Explain in detail the factors that can change the weld bead profile, and why. 3. Predict the morphology of cut surfaces, according to the cutting parameters used. 4. Explain in detail the factors that can change the cut surface quality, and why. 5. Be able to evaluate and diagnose weld beads and cut surfaces. Expected Result for IWS: 1. Manage and apply the common techniques for edge preparation, with special reference to operating

procedures. 2. Evaluate the right joint and edge preparation, considering the expected characteristic of the joint. 3. Discuss the weld bead shape and morphology, as function of the welding parameters used. 4. Get knowledge of the welding parameters involved, their set-up, effect and how to check them during

welding, in accordance with the applicable procedures. 5. Predict welding discontinuities and faults, considering the chosen welding process and the applied pa-

rameters. Expected Result for IWP: Not Applicable

Module 1 - Welding processes and equipment

IWE IWT IWS IWP Module 1 MT P1 * MT P1 * MT P1 * MT P1 *

Teaching Hours 93 35 76 35 45 14 22 14 * P1 = Part 1, Figures under P1 are given for the Standard Route (see 4.1)



Module 2: Materials and their behaviour during welding

2.1 Manufacture and designation of steels Objective for IWE, IWT, IWS, and IWP: Understand/describe the principles of iron metallurgy, steel mak-ing and designation of steels.



Scope: P1=2 P1=2 P1=1 P1=1 Introduction to metallurgy of steel making …………………………………… Steel making processes………………………………………….…………….. Special treatments………………………………………………….…………... Deoxidation ……………………………………………………….………….…. Designation of steels……………………………………………….…………... Defects in steels………………………………………………………….……...

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Expected Result for IWE: 1. Explain the various steel making processes. 2. Detail the reasons for and principles of special treatments in steel making. 3. Explain the different methods of deoxidation 4. Explain potential defects, their cause and elimination. 5. Explain the designation of steels.

Expected Result for IWT: 1. Explain the various steel making processes. 2. Detail the reasons for and principles of special treatments in steel making. 3. Explain the different methods of deoxidation 4. Explain potential defects, their cause and elimination. 5. Explain the designation of steels

Expected Result for IWS: 1. Explain the various steel making processes. 2. Explain the special treatments in steel making. 3. Explain the different methods of deoxidation. 4. Explain potential defects, their cause and elimination. 5. Explain the designation of steels. Expected Result for IWP: 1. Interpret the various steel making processes. 2. Name the reasons for and the principles of special treatments in steel making. 3. Describe the different methods of deoxidation. 4. Describe potential defects, their cause and elimination. 5. Describe the designation of steels.



2.2 Testing Materials and the weld joint Objective for IWE, IWT, IWS, and IWP: Understand/name the fundamental aspects of testing materials with particular reference to weldment test pieces.



Scope: P1=4 P1=4 P1=2 P1=2 Review of destructive testing…………………………………………….……. Testing welded joints (technological specimen)……..……………………… Destructive testing………………………………………….……….………….. Tensile and bend tests…………………………………………………………. Impact tests (ductile and brittle fracture, transition temperature)….………. Hardness tests………………………………………………………………….. Special tests (CTOD, etc.) …………………………………………………….. Fatigue tests………………………………………………………….…………. Creep tests…………………………………………………………….………… Corrosion tests…………………………………………………………….……. Overview on related standards……………………………………...…………. Laboratory exercises for IWE / IWT - 4 hours from 8 Laboratory exercises for IWS - 3 hours from 6 Laboratory exercises for IWP - 1 hour from 3



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Expected Result for IWE: 1. Discuss the reasons for destructive testing and the limitations of the data generated. 2. Describe in detail each of the major testing methods and the parameters to be measured. 3. Predict when and why special testing should be specified. 4. Show competence in carrying out testing to a given schedule.

Expected Result for IWT: 1. Discuss the objectives of each destructive test and the limitations of the data generated 2. Describe in detail each of the major testing methods and the parameters to be measured 3. Predict when and why special testing should be specified 4. Show competence in carrying out testing to a given schedule. Expected Result for IWS: 1. Discuss the objectives of each destructive test and the limitations of the data generated. 2. Describe each of the major testing methods and the parameters to be measured. 3. Predict when and why special testing should be specified. 4. Show competence in carrying out testing to a given schedule.

Expected Result for IWP: 1. Discuss the reasons for destructive testing. 2. Describe the major testing methods and the parameters to be measured. 3. Classify competence in carrying out testing to a given schedule.



2.3 Structure and properties of pure metals Objective for IWE, IWT, and IWS: Understand in detail the principles of solidification, deformation and recrystallisation and the characteristics of typical metal structures.



Scope: P1=4 P1=4 P1=2 P1=0 Crystalline structures…………………………………………………….……... Crystal lattice structure types and imperfections……………………….…….Micro structures of metals……………………………………………………... Solid state transformation…………………………………………….…….….. Elastic/plastic deformation…………………………………………….….……. Recrystallisation ……………………………………………………………....... Cold and hot deformation ……………………………………………………… Work hardening and strain aging ………………………………………………Mechanical properties (influence of temperature, etc.) ………………….….

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Expected Result for IWE: 1. Explain basic crystalline structures. 2. Explain in detail elastic-plastic deformation and their role in cold and hot deformation. 3. Explain recrystallisation giving examples. 4. Demonstrate understanding of the relationship between mechanical properties and temperature, grain

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

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

size and structure. Expected Result for IWP: Not Applicable



2.4 Alloys and Phase Diagrams Objective for IWE, IWT, IWS, and IWP: Understand (in detail)/describe the principles of alloying, the structures of alloys and their representation in phase diagrams.



Scope: P1=5 P1=5 P1=3 P1=2 Pure metals and alloys………………………..…………………………..…… Alloying elements……………………………………….………………………. Solidification…………………………………………………….….……………. Solid solution crystals…………………………………………….…….………. Structure of alloys………………………………………………………………. Type of structures…………………………………………..….……………….. Strengthening mechanisms (cold working, solid solution, precipitation hardening, grain size control, solid state transformation) ……Intermetallic compounds…………….………………………………….……….Ageing………………………………………….……………………………...… Basic types of phase diagrams (non-, fully- and partly soluble compo-nents)…………………………………………………………………………….. Fe-C equilibrium diagram .…………………………………….………………..Influence of alloy elements on the Fe-C equilibrium diagram……..………. Iron-alloys with closed gamma-loop, with broadened gamma-area………. The structure of castings…………………………………….………………… Segregation and coring……………………………………….………….…….. Mechanical properties…………………………………………………..……… Ternary diagrams………………………………………………………….…….

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Expected Result for IWE: 1. Describe crystalline lattice distortion due to alloying elements and subsequent structural changes. 2. Explain in detail solidification structure and segregation with relevant examples. 3. Detail mechanisms of precipitation, types of precipitates and their location within the microstructure. 4. Explain in detail the principles of transformation and conditions under which it occurs. 5. Detail the principles of strengthening mechanisms with appropriate examples. 6. Interpret the relationship between microstructure and mechanical properties. 7. Explain in detail the principles of phase diagrams, their construction and use. 8. Interpret the relationship between microstructure and phase diagrams. Expected Result for IWT: 1. Describe crystalline lattice distortion due to alloying elements and subsequent structural changes. 2. Explain in detail solidification structure and segregation with relevant examples. 3. Detail mechanisms of precipitation, types of precipitates and their location within the microstructure. 4. Explain in detail the principles of transformation and conditions under which it occurs. 5. Detail the principles of strengthening mechanisms with appropriate examples. 6. Interpret the relationship between microstructure and mechanical properties. 7. Explain in detail the principles of phase diagrams, their construction and use. 8. Interpret the relationship between microstructure and phase diagrams. Expected Result for IWS: 1. Describe crystalline lattice distortion due to alloying elements and subsequent structural changes. 2. Describe the principles of strengthening mechanisms with appropriate examples. 3. Interpret the relationship between microstructure and phase diagrams. 4. Outline the significant points from the Fe-C diagram. Expected Result for IWP: 1. Point out solidification structure and segregation on relevant examples. 2. Outline the principles of transformation and conditions under which it occurs. 3. Describe the principles of strengthening mechanisms with appropriate examples. 4. Outline the significant points (temperatures, weight %) of the Fe-C diagram.



2.5 Iron – Carbon Alloys Objective for IWE, IWT, IWS, and IWP: Understand/name the principles of alloying iron with carbon, the crystalline structures developed under equilibrium and non-equilibrium conditions and their representation in phase and transformation diagrams.



Scope: P1=4 P1=4 P1=2 P1=1 Equilibrium and non equilibrium transformations………………………….… Time-temperature-transformation (TTT) diagrams………………….………. Different types of TTT diagrams (isothermal, continuous cooling, TTT diagrams for welding)…………………………………………………….. Influence of alloying elements……………………………………….………… Carbide forming elements ………………………………………………………Control of toughness …………………………………………………………… t8/5 concept………………………………………………….…………...……….

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Expected Result for IWE: 1. Interpret the reasons for different structures under equilibrium and non-equilibrium conditions. 2. Explain the use of TTT diagrams (isothermal, continuous cooling, TTT diagrams for welding) to show

the development of particular steel microstructures. 3. Predict the changes that strengthen structure caused by alloying additions with reference to TTT dia-

grams. 4. Detail hardening mechanisms with reference to the microstructure developed. 5. Interpret the relationship between microstructure and toughness.

Expected Result for IWT: 1. Interpret the reasons for different structures under equilibrium and non-equilibrium conditions. 2. Explain the use of TTT diagrams (isothermal, continuous cooling, TTT diagrams for welding) to show

the development of particular steel microstructures. 3. Predict the changes that stregthen structure caused by alloying additions with reference to TTT dia-

grams. 4. Detail hardening mechanisms with reference to the microstructure developed. 5. Interpret the relationship between microstructure and toughness.

Expected Result for IWS: 1. Interpret the reasons for different structures under equilibrium and non-equilibrium conditions. 2. Explain the use of TTT diagrams (isothermal, continuous cooling, TTT diagrams for welding) to show

the development of particular steel microstructures. 3. Identify the changes that strengthen structure caused by alloying additions with reference to TTT dia-

grams. 4. Describe hardening mechanisms with reference to the microstructure developed. 5. Interpret the relationship between microstructure and toughness. Expected Result for IWP: 1. Identify TTT diagrams (isothermal, continuous cooling, TTT diagrams for welding) 2. Compare the changes that strengthen structure caused by alloying additions with reference to TTT

diagrams. 3. Describe hardening mechanisms with reference to the microstructure developed. 4. Draw the relationship between microstructure and toughness



2.6 Heat treatment of base materials and welded joints Objective for IWE, IWT, IWS, and IWP: Understand in detail/name the metallurgical transformations of materials during different heat treatment.



Scope: P1=4 P1=4 P1=2 P1=1 Normalising……………………….…………………….……………………..... Hardening………………………………….…………………………………….. Quenching and Tempering……………………….……………………………. Solution annealing………………………………………….……………...…… Homogenisation…………………………….……………………………...…… Stress relieving (PWHT)……………………………….………………….…….Recrystallisation annealing…………………………………..………………... Precipitation hardening……………………………………….……….……….. Heat treatment procedures……………………..……………....……………....Heat treatment equipment……………………………….….……………….... Regulations (codes and technical reports)………………….…..………….... Temperature measurement and recording………………..………………….

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Expected Result for IWE: 1. Explain each of the major heat treatments and their objectives. 2. Explain the mechanisms of structural changes which take place when a material is heat treated. 3. Interpret the effects of temperature and time on transformations including the effect of temperature

change rate. 4. Explain code requirements for heat treatment and why they are stipulated. 5. Predict the necessity to perform heat treatment after welding depending of the type and thickness of

steel, the application and the code. 6. Deduce appropriate heat treatment equipment for a given application. 7. Detail appropriate temperature measurement and recording methods for typical applications. Expected Result for IWT: 1. Explain each of the major heat treatments and their objectives. 2. Explain the mechanisms of structural changes, which take place when a material is heat treated. 3. Interpret the effects of temperature and time on transformations including the effect of temperature

change rate. 4. Explain code requirements for heat treatment and why they are stipulated. 5. Predict the necessity to perform heat treatment after welding depending of the type and thickness of

steel, the application and the code. 6. Deduce appropriate heat treatment equipment for a given application. 7. Detail appropriate temperature measurement and recording methods for typical applications. Expected Result for IWS: 1. Explain each of the major heat treatments and their objectives. 2. Explain the mechanisms of structural changes, which take place when a material is heat treated. 3. Describe the effects of temperature and time on transformations including the effect of temperature

change rate. 4. Describe code requirements for heat treatment. 5. Predict the necessity to perform heat treatment after welding depending of the type and thickness of

steel, the application and the code. 6. Name appropriate heat treatment equipment for a given application. 7. Detail appropriate temperature measurement and recording methods for typical applications. Expected Result for IWP: 1. Describe the major heat treatments and their objectives. 2. Associate the effects of temperature and time on transformations of temperature change. 3. Describe code requirements for heat treatment and why they are stipulated. 4. Discuss the necessity to perform heat treatment after welding depending of the type and thickness of

steel, the application and the code. 5. Name heat treatment equipment for a given application. 6. Describe temperature measurement and recording methods for typical applications.



2.7 Structure of the welded joint Objective for IWE, IWT, IWS, and IWP: Understand in detail/get a complete knowledge/explain the for-mation of the different metallurgical structures within a weldment.



Scope: P1=4 P1=4 P1=2 P1=2 Thermal field …………………………………..…………….………………...... Equations for the heat distribution ………………….………………..…….…. Heat input and efficiency of heat input…………………….….………….….... Peak temperature ……………………………………………………….……… Cooling rate and thermal cycle………………………………………………… Dilution ……………………………….…………………….………………..…... Weld metal ……………………………………..………….………………..…… Solidification of weld pool …………………………….……….……………….. Structure of the weld ………………………………………….………………... Fusion line ……………………………………………………………….………. Heat-affected zone (HAZ) ……………………………………………………… Microstructure of HAZ ………………………………………..………………… Grain growth and grain refinement………………………………..…………… Relationship grain size – toughness (equations from regression) ………… Transition temperature ………………………….……………………………… Weldability (definitions) ………………………………….………….………….. Single and multi -pass welding ………………………………….……………..

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Expected Result for IWE: 1. Explain the temperature distribution in welds and the microstructure formed as a result. 2. Interpret the effects of heat input, cooling rate and multi- pass operation on weld metal solidification and the mi-

crostructure formed. 3. Explain the effects of the weld protection, the type of consumables on the microstructure of the weld metal and on

it properties. 5. Detail areas of HAZ, the reasons for grain, size and microstructure changes and their effects on properties. 6. Discuss the various aspects of weldability. 7. Deduce the microstructural and weldability changes induced by dilution.

Expected Result for IWT: 1. Explain the temperature distribution in welds and the microstructure formed as a result for a single pass weld ver-

sus a multi-pass weld. 2. Interpret the effects of heat input, cooling rate and multi -pass operation on weld metal solidification and the mi-

crostructure formed for a single pass weld versus a multi-pass weld. 3. Explain the effects of the weld protection, the type of consumables on the microstructure of the weld metal and on

it properties for a single pass weld versus a multi-pass weld. 4. Detail areas of HAZ, the reasons for grain, size and microstructure changes and their effects on properties for a

single pass weld versus a multi-pass weld. 5. Discuss the various aspects of weldability 6. Deduce the microstructural and weldability changes induced by dilution. Expected Result for IWS: 1. Explain the temperature distribution in welds and the microstructure formed as a result for a single pass weld ver-

sus a multi-pass weld. 2. Interpret the effects of heat input, cooling rate and multi -pass operation on weld metal solidification and the mi-

crostructure formed for a single pass weld versus a multi-pass weld. 3. Explain the effects of the weld protection, the type of consumables on the microstructure of the weld metal and on

it properties for a single pass weld versus a multi -pass weld. 4. Draw areas of HAZ, the reasons for grain size and microstructure changes and their effects on properties for a

single pass weld versus a multi-pass weld. 5. Discuss the various aspects of weldability. Expected Result for IWP: 1. Associate the temperature distribution in welds and the microstructure formed as a result 2. Describe the effects of heat input, cooling rate and multi -pass operation on weld metal solidification and the mi-

crostructure formed. 3. Draw areas of HAZ, the reasons for grain-size and microstructure changes and their effects. 4. Compare the various aspects of weldability.



2.8 Plain Carbon and Carbon-Manganese Steels Objective for IWE, IWT, IWS and IWP: Understand in detail/get a complete knowledge/explain the met-allurgical effects induced by welding C and C-Mn steels.



Scope: P1=4 P1=4 P1=2 P1=2 Application of TTT diagrams …………………………………….……………..Hardening effects ……………………………………………….……………….Carbon equivalent …………………………………………….…………………Weldability …………………………………………………….………………….Effects of multi-pass welding……………………………….………………….. Structure of the weld and the HAZ …………………………………………….Factors influencing cracking ………………………………….…………..........Relationship C% max – hardness …………………………...………………...Relationship Ceq – hardenability ………………………….……………..........Determination of preheat and interpass temperature (diagrams) ……...…..Weld – simulation (Weld thermal cycle simulation) ………………………….Determination of the optimal heat input ……………………………….………Influence of restraint …………………………………………………………….Standards ………………………………………………………………………...




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welding). 3. Predict the structure of welds and HAZ for given thermal cycles and composition. 4. Explain in detail the effects of a multi -pass welding on the structure, the mechanical properties. 5. Discuss the factors affecting cold cracking. 6. Predict optimal heat input and appropriate preheat for given materials, conditions and applications util-

ising Codes and Standards as required. Expected Result for IWT: 1. Explain the concept and use of carbon equivalent. 2. Explain the principle and use of TTT diagrams (isothermal, continuous cooling, TTT diagrams for

welding). 3. Predict the structure of welds and HAZ for given thermal cycles and composition. 4. Explain in detail the effects of a multi pass welding on the structure, the mechanical properties. 5. Discuss the factors affecting cold cracking. 6. Predict optimal heat input and appropriate pre-heat for given materials, conditions and applications

utilising Codes and Standards as required. Expected Result for IWS: 1. Explain the concept and use of carbon equivalent. 2. Describe the principle and use of TTT diagrams (isothermal, continuous cooling, TTT diagrams for

welding). 3. Explain the effects of a multi-pass welding on the structure, the mechanical properties. 4. Discuss the factors affecting cold cracking. 5. Predict optimal heat input and appropriate preheat for given materials, conditions and applications util-

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



2.9 Fine - grained steels Objective for IWE, IWT, IWS, and IWP: Understand in detail/get a complete knowledge/explain the ef-fects of micro-alloying elements on structure, mechanical properties and weldability with reference to fine-grained steels.



Scope: P1=2 P1=2 P1=0 P1=0 Concept of grain refinement (micro-alloying elements, formation and dilution of particles) ………………………………………….……………..Effect on mechanical properties ………………………………………….……Normalised grades …………………………………………….…………..........Quenched and tempered grades, high strength steels ………....…………..t 8/5 concept and weldability, preheat and interpass temperature ….....……Standards ………………………………………………………………………...

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

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

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

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



2.10 Thermomechanically controlled process steels (TMCP -steels) Objective for IWE, IWT, IWS and IWP: Understand in detail/get a complete knowledge/explain the prin-ciples of thermomechanical treatment and its influence on mechanical properties and weldability.



Scope: P1=4 P1=4 P1=2 P1=1 Principles of treatment (controlled roll, accelerated cooling, direct quench, etc.) ………………….…………………………………………..Chemical composition …………….…………………………………………….Mechanical properties …………………….…………………………………….High strength steels .....................................................................................Applications ……………………………………….…………………………….. Consequences for weldability ………………………………………………….Standards ………………………………….……………………………………..

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Expected Result for IWE: 1. Explain the effects of different treatment times and temperatures. 2. Explain the structural modifications of material and control methods. 3. Interpret the relationship between grade and weldability. 4. Detail applicable welding processes and potential problems. 5. Explain the effects of heat treatment after welding and deduce the conditions of such treatment. Expected Result for IWT: 1. Explain the effects of different treatment times and temperatures. 2. Explain the structural modifications of material and control methods. 3. Interpret the relationship between grade and weldability 4. Detail applicable welding processes and potential problems 5. Explain the effects of heat treatment after welding and deduce the conditions of such treatment

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

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



2.11 Cracking phenomena in welded joints Objective for IWE, IWT, IWS and IWP: Understand/name the fundamentals of cracking mechanisms in welded joints and the way in which welding variables affect the incidence of cracking. Understand/name causes and avoidance.



Scope: P1=2 P1=2 P1=0 P1=0 For C-Mn, low alloy, high alloy and stainless steels as appropriate: Cold cracking: Cracking mechanisms in weld metal and HAZ, causes and avoidance..… Effect of hydrogen, microstructure and stress .......…………........……..….. Source and diffusion of hydrogen …………………..................................... Control of hydrogen …………………………………..................................... Susceptible microstructure and its control ......………………………........… Influence of alloying elements on susceptibility .................…….………….. Testing of cold cracking susceptibility…….……….….....................……….. Effect of preheat.…….………….……………..….……….....................….. Effect of austenitic weld metal ..............………………….……........…….. Hot cracking: Cracking mechanisms in particular in weld metal (solidification cracking, liquation cracking, etc.); causes and avoidance ……................………… Effect of alloy elements, heat input, bead shape, nugget shape........…. Control of hot cracking ……..............……………………........…………… Testing for hot cracking susceptibility ..........……………........................ Reheat cracking: Cracking mechanisms in weld metal and HAZ; causes and avoidance…. Type of steels sensitive to reheat cracking ............……………….……….. Effect of alloy elements, thermal cycles, stress…...............……………….. Cracking during heat treatment and multi -pass welding ….............……... Control of reheat cracking …………….............…….…........…………..….. Testing for reheat cracking susceptibility ……….............…....................... Lamellar tearing: Cracking mechanism; causes and avoidance ..............………...………. Effects of inclusions, joint configuration, stress, and fatigue……………. Control of lamellar tearing by material control and joint configuration…. Testing for susceptibility, through-thickness properties….………........… Steels with increased resistance to lamellar tearing...................………..

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Expected Result for IWE: 1. Compare the metallurgical mechanisms for each of the major types of cracking. 2. Describe the effects of chemical and physical variables for each of the major types of cracking. 3. Appraise the susceptibility to cracking by reference to the key parameters and suggest appropriate

precautions to avoid cracking. 4. Appraise the type of cracking and the reason for its occurrence from study of fractured material and its

history. 5. Choose suitable tests which will assist in finding the solution of cracking problems. 6. Propose alternatives which will reduce or eliminate the occurrence of lamellar tearing in welded con-

struction/fabrication. 7. Appraise the effects of inclusions, joint configuration, stress and fatigue in the control of cracking of

welds.



Expected Result for IWT: 1. Compare the metallurgical mechanisms for each of the major types of cracking. 2. Describe the effects of chemical and physical variables for each of the major types of cracking. 3. Appraise the susceptibility to cracking by reference to the key parameters and suggest appropriate

precautions to avoid cracking. 4. Appraise the type of cracking and the reason for its occurrence from study of fractured material and its


struction/fabrication. 7. Appraise the effects of inclusions, joint configuration, stress and fatigue in the control of cracking of

welds. Expected Result for IWS: 1. Compare the metallurgical mechanisms for each of the major types of cracking. 2. Describe the effects of chemical and physical variables for each of the major types of cracking. 3. Appraise the susceptibility to cracking and suggest appropriate precautions to avoid cracking. 4. Name the type of cracking and the reason for its occurrence from study of fractured material and its


struction/fabrication. Expected Result for IWP: 1. Compare the metallurgical mechanisms for each of the major types of cracking. 2. Appraise the susceptibility to cracking and suggest appropriate precautions to avoid cracking. 3. Name the type of cracking and the reason for its occurrence. 4. List alternatives, which will reduce or eliminate the occurrence of lamellar tearing in welded construc-

tion/fabrication.



2.12 Application of structural and high strength steels Objective for IWE, IWT, IWS and IWP: Understand/describe welding problems dealing with the funda-mental aspects of the application of structural and high strength steels with particular reference to physi-cal, chemical and mechanical characteristics.



Scope: P1=0 P1=0 P1=0 P1=0 Bridges …………………………………………………………………………... Cranes …………………………………………………………………………… Buildings ………………………………………………………………………….Ships…………………………………………………………………….............. Pipelines ………………………………………………………………………….Pressure vessels ………………………………………………….……………..Automotive equipment …………………………………………………………. Low temperature applications ………………………………………………….Standards ………………………………………………………………………...

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Expected Result for IWE: 1. Explain in detail the importance of choice of material with reference to application. 2. Appraise the use of structural and high strength steels and their application fields 3. Describe examples of the practical application and design of bridges, cranes, pressure vessels, auto-

motive equipment.

Expected Result for IWT: 1. Explain in detail the importance of choice of material with reference to application. 2. Appraise the use of structural and high strength steels and their application fields 3. Describe examples of the practical application and design of bridges, cranes, pressure vessels, auto-

motive equipment. Expected Result for IWS: 1. List the importance of choice of material with reference to application. 2. Identify the use of structural and high strength steels and their application fields. 3. Name examples of the practical application and design of bridges, cranes, pressure vessels, automo-

tive equipment, buildings (architectures), ships, and pipelines etc. Expected Result for IWP: 1. List the importance of choice of material with reference to application. 2. Identify the use of structural and high strength steels and their application fields 3. Name examples of the practical application and design of bridges, cranes, pressure vessels, automo-

tive equipment.



2.13 Low alloy steels for cryogenic applications Objective for IWE, IWT, IWS, and IWP: Describe/name solutions to welding applications requiring the use of the relationship between toughness and temperature, metallurgical structure and the weldability of cryogenic steels.

IWE IWT IWS IWP 4 2 1 0,5


Scope: P1=0 P1=0 P1=0 P1=0 Survey/list of types of cryogenic steels (including 9% Ni) ………............... Effects of nickel on low temperature properties of low alloy steels ……….. Applicable welding processes ………………………………………………….Filler materials …………………………………………………………………...Welding problems and precautions …………………………………..............Properties and application of various types of cryogenic steels…………….Controlling the quality of the welded joint ……………………………………. Standards on low temperature steels and consumables ……………………

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Expected Result for IWE: 1. State the toughness testing and the parameters affecting toughness. 2. Appraise the relationship between microstructure and toughness. 3. Identify the effect of nickel on crystallographic structure. 4. Describe the effect of nickel content on weldability. 5. Appraise the range of applications for the various types of cryogenic steels. Expected Result for IWT: 1. State the toughness testing and the parameters affecting toughness 2. Identify the effect of nickel on crystallographic structure. 3. Describe the effect of nickel content on weldability. 4. Appraise the range of applications for the various types of cryogenic steels.

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



2.14 Low alloy creep resistant steels Objective for IWE, IWT, IWS, and IWP: Appraise/outline the fundamental/repeat aspects of creep phe-nomena. Understand in detail/get a complete knowledge/explain in general creep resistant steel types, their structure and alloying elements.

IWE IWT IWS IWP 4 2 1 0,5


Scope: P1=0 P1=0 P1=0 P1=0 Mechanism of creep failure ....……………………………………...…………. Testing of creep resistance ………………………………………………….…Creep sensitivity testing ……………………………………………………….. Temper embrittlement, e.g. step cooling test ..……………………………….Remaining life prediction ………………………………………………………. Oxidation resistance …………………………………………………………….Survey of types of creep/heat resistant steels ………………….…………....Applicable welding processes …………………………………….……………Filler materials - special chemical requirements for creep resistance ….….Welding problems and precautions …………………………………..............Controlling the quality of a welded joint …………………………………….…Standards ………………………………………………………………………...




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Expected Result for IWE: 1. Identify the fundamental aspects of the phenomena and phases of creep. 2. Appraise the effects of alloying elements and steel structure on creep resistance. 3. Appraise the weldability of Cr-Mo steels considering appropriate welding processes and types of con-

sumables. 4. Identify remaining life by use of the most common methods. Expected Result for IWT: 1. Describe the fundamental aspects of the phenomena and phases of creep. 2. Outline the effects of alloying elements and steel structure on creep resistance. 3. Outline the weldability of Cr-Mo steels considering appropriate welding processes and types of con-

sumables. 4. Identify remaining life by use of the most common methods. Expected Result for IWS: 1. Describe the fundamental aspects of the phenomena and phases of creep. 2. Outline the effects of alloying elements and steel structure on creep resistance. 3. Outline the weldability of Cr-Mo steels considering appropriate welding processes and types of con-

sumables.

Expected Result for IWP: 1. Describe the phases of creep. 2. Outline the effects of alloying elements on creep resistance. 3. Outline the weldability of Cr-Mo steels considering appropriate welding processes and types of con-

sumables.



2.15 Introduction to corrosion Objective for IWE, IWT, and IWS: Identify /outline the fundamentals of the various types of corrosion.



Scope: P1=0 P1=0 P1=0 P1=0 Fundamentals of electrochemistry …………………………….………………Redox potential ………………………………………………………….……… Passivation …………………………………………………………….…………Overall corrosion ……………………………………………………….………..Differential aeration …………………………………………………………….. Cathodic, anodic protection ………………………………………….…………Types of corrosion (intercrystalline, transcrystalline, knife-line attack .…… pitting, crevice, and stress-corrosion) ……………………………….............. Pickling and passivating ……………………………………………………….. Corrosion testing …………………………………………………………….….. Demonstrations for IWE - 2 hours from 6 Demonstrations for IWT - 1 hour from 2 Demonstrations for IWS and IWP - 0 hours

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Expected Result for IWE: 1. Explain the chemical and electrochemical phenomena involved in corrosion. 2. State the rules involving the mechanisms of the different types of corrosion. 3. Identify different protection methods. Expected Result for IWT and IWS: 1. Outline the chemical and electrochemical phenomena involved in corrosion. 2. Recognize and describe the most common types of corrosion. 3. Give examples of common protection methods. Expected Result for IWP: Not Applicable



2.16 High-alloyed (stainless) steels Objective for IWE, IWT, IWS, and IWP: Identify in detail/get a complete knowledge/explain the funda-mentals of the various types of stainless steel and their weldability including the principles of joining dis-similar materials and filler material choice.



Scope: P1=0 P1=0 P1=0 P1=0 Effect of alloying elements ……….…………………………...……………….. Systems Fe-Cr, Fe-Ni, Fe-Cr-Ni …………..……………………......………… Austenite and ferrite formers ……………………….………………………….. Influence of nitrogen …………………………………………..…………...…… Cr- and Ni-equivalent ……………………………………………………….….. Schaeffler diagram, DeLong and other constitution diagrams .……….…… t 12/8 weldability concept……………………………………………………........ Measuring of ferrite content …………………………………………..…..…… Survey on stainless steels (fully austenitic, ferrite-containing steels, ferritic, martensitic, duplex stainless steels, chemically resistant, creep resistant, heat resistant steels, cryogenic use) ................................. Knife-line attack ………………………….……………………………………… 475 °C-brittlement ..………………………………….………………………….. Weld decay (intergranular corrosion) ………………………..……………….. Pitting Index …………………………………...…………..…………………….. Applicable welding processes ……………………….………………………… Types of filler materials ……………………………….………………………... Shielding and backing gases ……………….……………….………...………. Welding of stainless steels …………………………………………..……...…. Details of joint design ……………………….……………………………......... Heat treatment …………………………………...………..……………………. Post-weld heat treatment (PWHT) ……………………..……………………... Passivation ……………………….……………………………………………… Standards ………………………………….……………………………………..

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Expected Result for IWE: 1. Appraise the structures of the various stainless steels; parent metal, HAZ and weld metal. 2. Identify the results of a given high alloy welding situation using the Fe-Cr-Ni phase diagram. 3. State the rules and principles governing embrittlement phenomena. 4. State the rules and principles governing in detail corrosion phenomena. 5. Identify the results of a given high alloy welding situation using the Fe-Cr-Ni phase diagram with various carbon

contents. 6. Predict the choice of consumables for each type of stainless steel using different diagrams. 7. Predict the necessity of treatment after welding. Expected Result for IWT: 1. Describe the structures of the various stainless steels; parent metal, HAZ and weld metal 2. Identify the results of a given high alloy welding situation using the Fe-Cr-Ni phase diagram. 3. State the rules and principles governing embrittlement phenomena. 4. State the rules and principles governing in detail corrosion phenomena. 5. Identify the results of a given high alloy welding situation using the Fe-Cr-Ni phase diagram with various carbon

contents. 6. Predict the choice of consumables for each type of stainless steel using different diagrams. 7. Predict the necessity of treatment after welding. Expected Result for IWS: 1. Outline the structures of the various stainless steels and explain their behaviour during welding. 2. State the rules and principles governing corrosion phenomena. 3. Predict the choice of consumables for each type of steel using different diagrams. 4. Describe the different treatment after welding. 5. Predict the necessity of treatment after welding. Expected Result for IWP: 1. Outline the structures of the various stainless steels. 2. State the rules and principles governing corrosion phenomena. 3. Identify consumables for each type of steel. 4. Describe the necessity of treatment after welding. 5. Predict the necessity of treatment after welding.



2.17 Introduction to wear Objective for IWE and IWT: Identify the fundamentals of wear and its control



Scope: P1=0 P1=0 P1=0 P1=0 Different types of wear (hydrodynamic friction, reaction, layer wear, adhesive wear, abrasive wear, fatigue wear, fretting, erosion, cavitation, impact, thermal, dynamic) ……………………….……….………..Buttering ……………………………………………………………………….…Wear tests ………………………………………………………………………..

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Expected Result for IWE: 1. Describe wear situations that involve the mechanisms of the different types of wear. 2. Distinguish the basis and results of tests to define wear resistance. 3. Appraise precautions and procedures designed to avoid excessive wear. Expected Result for IWT: 1. Describe wear situations that involve the mechanisms of the different types of wear. 2. Distinguish the basis and results of tests to define wear resistance. 3. Describe precautions and procedures designed to avoid excessive wear. Expected Result for IWS and IWP: Not Applicable

2.18 Protective layers Objective for IWE, IWT, and IWS: Identify the fundamentals/outline of protective layers and the methods and materials used.



Scope: P1=0 P1=0 P1=0 P1=0 Cladding: Reasons for cladding …………………………………………………………... Processes for cladding (dilution) ……………………………………………… Joining clad steels ……………………………………………………………… Joint design and welding procedures in respect to the access to the joint . Applications …………………………………………………………….……….. Standards ……………………………………………………………………….. Linings: Welding of linings ………………………………………………………………..Joint design and welding procedures ……………………………….............. Surfacing: Corrosion-resistant layers ……………………………………………………... Wear-resistant layers ……………………………………………………………Coatings: Surface-coated steels ………………………………………………………….. Galvanised steels (Si-content) ………………………………………………... Painting ………………………………………………………………………….. Problems of joining ……………………………………………………………...

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Expected Result for IWE: 1. Describe the various techniques for applying protective layers. 2. Design weldments using protective layers stating the materials used and the reasons for their choice. 3. Appraise the problems associated with the different types of protective layer and methods to solve

them. Expected Result for IWT and IWS: 1. Describe in general the various techniques for applying protective layers and the reasons for their

choice. 2. Outline the problems associated to each method and how would you solve them. Expected Result for IWP: Not Applicable



2.19 High alloy creep resistant and heat resistant steels Objective for IWE and IWT: Identify the relationship between microstructure and creep resistance in-cluding detailed knowledge of different types of creep resistant and heat resistant steels



Scope: P1=0 P1=0 P1=0 P1=0 Creep resistance of high alloy steels ……………………………………….…Mechanism of heat resistance ………………………………………….……...Types of creep resistant steels ………………………………………….……..Types of heat resistant steels (austenitic, ferritic) …………………………...Weldability and selection of consumables …………………………….……...Application and special problems ……………………………………….……..Standards ……………………………………………………………………..….

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Expected Result for IWE: 1. Distinguish the effects of alloying elements on creep and heat resistance. 2. Appraise in detail the microstructural phenomena occurring in materials at high temperature. 3. Identify the types of creep resistant and heat resistant steels. 4. Appraise the weldability of creep and heat resistant steels.

Expected Result for IWT: 1. Distinguish the effects of alloying elements on creep and heat resistance. 2. Describe the microstructural phenomena occurring in materials at high temperature. 3. List the types of creep resistant and heat resistant steels. 4. Describe the weldability of creep and heat resistant steels. Expected Result for IWS and IWP: Not Applicable



2.20 Cast irons and steels Objective for IWE, IWT, and IWS: Interpret the metallurgy and /outline the different types of cast irons and steels, their application fields and weldability.



Scope: P1=0 P1=0 P1=0 P1=0 Survey of cast steels …………………………………………………………… Survey of cast irons ……………………………………………………….…….Applicable welding processes and procedures ……………………….……...Weldability ………………………………………………………………….…….Filler materials ……………………………………………………………….…..Application and special welding problems …………………………….……...Standards ..................................................…………………………………...

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Expected Result for IWE: 1. Explain the Fe - C phase diagram with particular attention to carbon content over 2%. 2. Identify the different types of cast irons and steels, their chemical composition and crystallographic struc-

tures. 3. Appraise the weldability problems and applicable welding processes and types of consumable for the weld-

ing of cast irons. Expected Result for IWT: 1. Explain the Fe - C phase diagram with particular attention to carbon content over 2%. 2. Identify the different types of cast irons and steels, their chemical composition and crystallographic struc-

tures. 3. Appraise the weldability problems and applicable welding processes and types of consumable for the weld-

ing of cast irons. Expected Result for IWS: 1. Recognise the different types of cast irons and steels. 2. Describe the weldability problems and applicable welding processes and types of consumable for the weld-

ing of cast irons. Expected Result for IWP: Not Applicable



2.21 Copper and copper alloys Objective for IWE, IWT, and IWS: Understand in detail the metallurgy and /outline the range of applica-tion and weldability of copper and copper alloys.



Scope: P1=0 P1=0 P1=0 P1=0 Survey on classification of copper and copper alloys …………….…………Desoxidation and weldability ……………………………………………….…..Physical and mechanical properties ……………………………………….….Applicable joining processes (welding, brazing, soldering, diffusion welding) ………………………………………………………………..Filler materials ……………………………………………………………….…..Shielding and backing gases ……………………………………………….….Application and special problems ………………………………………….…..Standards ………………………………………………………………………...

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Expected Result for IWE: 1. Explain the metallurgy of copper and copper alloys. 2. Interpret copper and copper alloy weldability including dissimilar joints. 3. Explain applicable welding processes and types of consumable for copper and copper alloys. 4. Explain the range of application for copper and copper alloys.

Expected Result for IWT and IWS: 1. Explain copper and copper alloy weldability 2. List applicable welding processes and types of consumable for copper and copper alloys. 3. State examples of copper and copper alloys applications. Expected Result for IWP: Not Applicable

2.22 Nickel and nickel alloys Objective for IWE, IWT, and IWS: Understand in detail the metallurgy and/outline the range of applica-tion and weldability of nickel and nickel alloys.



Scope: P1=0 P1=0 P1=0 P1=0 Survey on classification of nickel and nickel alloys …………….……………Applicable welding processes and filler materials ……………………….…..Shielding and backing gases …………………………………………….…….Welding problems (hot cracking) and prevention ……………………….…… Quality control of the welded joint ……………………………………….…….

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Expected Result for IWE: 1. Explain the metallurgy of nickel and nickel alloys. 2. Interpret Nickel and nickel alloy weldability. 3. Explain applicable welding processes and types of consumable for Nickel and Nickel alloys. 4. Explain examples of nickel and nickel alloys applications.

Expected Result for IWT and IWS: 1. Explain nickel and nickel alloy weldability. 2. List applicable welding processes and types of consumable for nckel and nickel alloys. 3. State examples of nickel and nickel alloys applications. Expected Result for IWP: Not Applicable



2.23 Aluminium and aluminium alloys Objective for IWE, IWT, IWS and IWP: Understand in detail the metallurgy and/outline the range of ap-plication and weldability of aluminium and aluminium alloys.



Scope: P1=0 P1=0 P1=0 P1=0 Survey on classification of aluminium and Al-alloys (pure, cold work alloys, heat treatable alloys) …………………………………………………... Weldability ……………………………………………………………….……….Joint preparation …………………………………………………………………Applicable welding processes ………………………………………….………Oxide layer cleaning (cathodic cleaning, trailing and trailing shield) ………Filler materials (choice, storage and handling) ……………………………… Shielding and backing gases …………………………………………………..Welding problems, (HAZ softening, porosity and hot cracking, cracking diagrams distortion) and their avoidance …………………………….……….Design details …………………………………………………………….…….. Application and special problems (lightweight structures, cryogenic use) ..

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Expected Result for IWE: 1. Explain the welding metallurgy of aluminium and aluminium alloys. 2. Interpret aluminium and aluminium alloy weldability including dissimilar joints. 3. Explain applicable welding processes and types of consumable for aluminium and aluminium alloys. 4. Explain aluminium and aluminium alloys range of application.

Expected Result for IWT: 1. Describe aluminium and aluminium alloy weldability including dissimilar joints. 2. Explain applicable welding processes and types of consumable for aluminium and aluminium alloys. 3. Explain aluminium and aluminium alloys range of application. Expected Result for IWS and IWP: 1. Describe aluminium and aluminium alloy weldability. 2. List applicable welding processes and types of consumable for aluminium and aluminium alloys. 3. State examples of aluminium and aluminium alloy applications.

2.24 Other metals and alloys Objective for IWE, IWT and IWS: Gain basic knowledge of the metallurgy, application fields and weld-ability of the specified metals.



Scope: P1=0 P1=0 P1=0 P1=0 Titanium ...................................................................................................... Magnesium ................................................................................................. Tantalum ..................................................................................................... Zirconium ………………………………………………………………............. Applicable welding processes and filler materials …………………………...Special problems ………………………………………………………………..

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Expected Result for IWE: 1. Explain the welding metallurgy of the specified metals. 2. Interpret the weldability of these metals. 3. Explain appropriate welding processes and applications. Expected Result for IWT and IWS: 1. Briefly describe the welding metallurgy of the specified metals. 2. Briefly describe the weldability of the specified metals. 3. List appropriate welding processes and some typical applications. Expected Result for IWP: Not Applicable



2.25 Joining dissimilar materials Objective for IWE, IWT, and IWS: Understand/outline the principles of joining dissimilar materials and the problems involved.



Scope: P1=0 P1=0 P1=0 P1=0 Fundamentals ………………………………………………………….............. Use of the Schaeffler / De Long diagram for welding dissimilar metals ….. Choice of processes …………………………………………………………….Effect of dilution ………………………………………………………………….Consumables …………………………………………………………………….Welding problems and measures, (formation of intermetallic compounds, carbon migration) ………………………………………………...In service failures (thermal fatigue, disbonding) …………………………….. Typical applications: Joining high alloyed steel and mild steel …………………………………….. Joining stainless steel and mild steel ………………………………………… Joining CuNi-alloys with mild steel/stainless steel ………………………….. Joining Ni-alloys with mild steel ………………………………………………..Joining stainless steel and copper alloys ……………………………………. Joining steel and Al / Al alloys ………………………………………………… Joining Cu and Al / Al alloys ……………………………………………………Joining Ni and Cu ………………………………………………………………..

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Expected Result for IWE and IWT: 1. Explain in detail metallurgical and weldability aspects involved when joining dissimilar materials. 2. Interpret and use Schaeffler / De Long diagram. 4. Deduce welding methods which can solve metallurgical problems. 5. Interpret the correct choice of filler material.

Expected Result for IWS: 1. Briefly describe the weldability aspects involved when joining dissimilar materials. 2. Use Schaeffler / De Long diagram and choose the appropriate consumables. 3. List for typical applications the Teaching welding methods. Expected Result for IWP: Not Applicable



2.26 Metallographic examinations Objective for IWE and IWT: Understand in detail crystallographic structures and the application of met-allographic examination. Objective for IWS: Metallographic examination in order to understand easier the different structures of typical materials.



Scope: P1=0 P1=0 P1=0 P1=0 Specimen preparation for micro and macro examination ………….…....….Macro and micro structure examination ……………………………...............Micro chemical analysis of crystallographic structure …………………….…Reference standards EN 1321, CR 12363 …………………….……………..

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Expected Result for IWE and IWT: 1. Explain in detail and be able to use methods for sample preparation. 2. Explain aspects of macro and micro examination. 3. Interpret microstructure, metallurgical imperfections.

Expected Result for IWS: 1. Explain in general and be able to use methods for sample preparation. 2. Describe aspects of macro and micro examination. 3. Interpret macro and microstructure, metallurgical imperfections. Expected Result for IWP: Not Applicable

Module 2 – Materials and their behaviour during welding

IWE IWT IWS IWP Module 2 MT P1 * MT P1 * MT P1 * MT P1 *

Teaching Hours 111 39 82 39 47 18 22 12 * P1 = Part 1, Figures under P1 are given for the Standard Route (see 4.1)



Module 3: Construction and design 3.1 Basic theory of structural systems Objectives for IWE, IWT and IWS: Understand the effect of external loads on structures, the types of structural systems and the relationship between external loads and internal forces.



Scope: P1=4 P1=4 P1=0 P1=0 Structural elements (cables, bars, beams, plates, slabs, shells) ……….….Theory of forces ……………………………………….……………………...…Combination and resolution of forces ……………………….……………...... Equilibrium of forces and torques ……………………….………………...…..Bearings, constraints and basic types of connections ….………….……..... Equilibrium of structural systems ……………………….…………….…….....Statically determinate and indeterminate systems ……………..…….…..….Stress in structural systems resulting from external actions ………….…….Relationship between external loads and internal forces ……….…….…….Calculation and determination of the internal forces and moments of sim-ple statically determinate systems ..............................................................

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Expected Result for IWE and IWT: 1. Explain the composition of forces. 2. Explain the resolution of forces. 3. Define the conditions of equilibrium. 4. Explain the equilibrium of structural systems. 5. Explain bearings, constraints and the basic types of connections. 6. Explain the difference between a statically determinate and a statically indeterminate system. 7. Determine the internal forces and moments of simple statically determinate systems. 8. Explain and sketch the shearing force and bending moment diagram of simple statically determinate

systems.

Expected Result for IWS: 1. Understand in general the composition of forces. 2. Understand in general the resolution of forces. 3. Name the conditions of equilibrium. 4. Understand in general the equilibrium of structural systems. 5. Name bearings, constraints and the basic types of connections. Expected Result for IWP: Not Applicable



3.2 Fundamentals of the strength of materials Objectives for IWE, IWT and IWS: Understand the principles governing the behaviour of metallic structures under loading.



Scope: P1=4 P1=4 P1=2 P1=0 Types of stresses (normal stress, shear stress) ……………..…………...….Types of deformation (axial strain, shear strain) .………………………...….Stress-strain relationship, yielding theories………………..……………….…Elastic and plastic deformation …………………..…………………………….Young’s modulus, shear modulus, transverse contraction coefficient ……. Characteristic material properties ……………..…………………………...….Different stresses resulting from internal forces and moments ..………...…Different types of section properties …………..…………………………..…..Calculation of section properties ……………………….…………………...…Calculation of stresses …………………………………………..…………...…

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Expected Result for IWE and IWT: 1. Explain the different types of stresses (normal stress, shear stress). 2. Explain the different types of deformation (axial strain, shear strain etc.). 3. Explain the stress-strain relationships. 4. Deduce Young’s modulus; shear modulus and transverse contraction coefficient from the stress-strain relation-

ships. 5. Explain the determination of characteristic material properties. 6. Explain the stresses resulting from internal forces and moments. 7. Calculate the different types of section properties. 8. Calculate nominal stresses in sections. Expected Result for IWS: 1. Understand in general the different types of stresses (normal stress, shear stresses). 2. Understand in general the different types of deformation (axial strain, shear strain etc.). 3. Understand in general the stress-strain relationships. 4. Understand in general the stresses resulting from internal forces and moments. Expected Result for IWP: Not Applicable



3.3 Welded Joint design Objectives for IWE, IWT and IWS: Design and draw weld details related to a given material, wall thickness, acces-sibility, loading, welding process, welding position, NDT, available equipment, tolerances.



Scope: P1=4 P1=4 P1=0 P1=0 Introduction (importance of welding joint design and grove shapes, influ-ence on welding stresses and distortion) ………………………………….….Types of welded joints (ISO 9692 series, EN 14324 brazing)……….…..….Importance of weld joint design and groove shapes, types of welded joints, design of welded joints …………………………………………….……Classification of groove shapes (by material type, thickness, welding pro-cess, accessibility) ……………………………………………………….…. Tolerance requirements (ISO 13920) ………………………………………... Welding symbols on drawings, symbols for groove shapes …………….….Symbolic representation of welded, brazed and soldered joints according to ISO 2553 ………………………………………………………………………National Standards………………………………………………………………

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Expected Result for IWE, IWT and IWS: 1. Classify different types of welded joints. 2. Design a weld according to the given conditions. 3. Detail and use appropriate weld symbols. 4. Explain the symbolic representation of welded, brazed and soldered joints on drawings. Expected Result for IWP: 1. Describe different types of welded joints. 2. Know how to apply each type of joint in function of material, thickness and welding process 3. Explain the symbolic representation of welded, brazed and soldered joints on drawings.

3.4 Basics of weld design Objectives for IWE, IWT and IWS: Understand the relationship between external loads on structures, internal forces and the stresses induced with especially with regard to welds.



Scope: P1=2 P1=2 P1=2 P1=0 Types of stresses in welded joints (nominal stress, hot spot stress, notch stress) ……………………………………….……………………………….….. Stresses in butt welds, stresses in fillet welds ………….…………………… Calculation of section properties of welded joints ………………..…………. Determination of nominal stresses in single welded joints ………………… Determination of reference values of stresses due to multi-axial stressing Determination of design resistance of arc-welded and resistance-welded joints …………………………………………………………………..…………. Worked examples of calculation of nominal stresses in welded joints …….

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

stress). 2. Understand simple welded joints (internal forces). 3. Understand cross sections for welded joints. Expected Result for IWP: Not Applicable



3.5 Behaviour of welded structures under different types of loading Objectives for IWE, IWT and IWS: Understand the different types of loading and the influence of ambient conditions on structures.



Scope: P1=0 P1=0 P1=0 P1=0 Static strength …………………………………………………………………... Elevated temperature strength …………………………………………….…..Low-temperature strength ……………………………………………………...Creep resistance ………………………………………………………….……..Impact behaviour ……………………………………………………………….. Influence of notches and weld defects ………………………………………..Types of fracture (ductile fracture, fatigue fracture, brittle fracture, lamellar tearing) ………………………………………………………….………Selection of steel quality groups ……………………………………….………Typical data for common steels………………………………………….……..Use of standards and specifications …………………………………….…….

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Expected Result for IWE: 1. Explain the requirements according to different types of loading and temperatures. 2. Determine materials which meet strength/temperature requirements. 3. Select appropriate materials according to specific applications. 4. Explain different types of fracture (ductile fracture, fatigue fracture, brittle fracture, lamellar tearing). Expected Result for IWT: 1. Explain the requirements according to different types of loading and temperatures. 2. Select appropriate materials according to specific applications. 3. Explain different types of fracture (ductile fracture, fatigue fracture, brittle fracture, lamellar tearing). Expected Result for IWS: 1. Understand the requirements for the construction according to different types of loading and temperatures. 2. Identify globally groups of materials which meet strength / temperature requirements. 3. Identify the various types of facture. Expected Result for IWP: Not Applicable



3.6 Design of welded structures with predominantly static loading Objectives for IWE, IWT, IWS, and IWP: Be able to design and calculate joints and all relevant details of welded metallic structures.



Scope: P1=0 P1=0 P1=0 P1=0 Steel constructions including lightweight structures ….……………….……. Structural details e.g. (stiffeners, knots, columns, base- and cap-plates, reinforced structures, supports, frame-corners, frame structures, trusses, nodal joints, weld connections, braces / bracing, lattice work structures, etc.) ………………………………….............................................................. Use of different types of welds related to joint types ……………………….. Use of standards and specifications ……………………………….………….Worked examples ……………………………………………………………….

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Expected Result for IWE: 1. Competently design different connection zones. 2. Calculate appropriate weld geometry. 3. Calculate the relevant weld stresses. 4. Outline stresses in frames. 5. Nominate the stresses in welds in frames. 6. Detailed knowledge of advantage and disadvantage of different types of welds. Expected Result for IWT: 1. Design different connection zones. 2. Outline stresses in frames. 3. Nominate the stresses in welds in frames. 4. Explain the advantage and disadvantage of different types of welds.

Expected Result for IWS: 1. Identify different connection zones. 2. Read and understand appropriate weld geometry. 3. Outline stresses in structural details. 4. Global knowledge of advantage and disadvantage of different types of welds. Expected Result for IWP: 1. Describe appropriate welded connection zones 2. Demonstrate differences between similar profiles. 3. Identify advantage and disadvantage of different types of welds.



3.7 Behaviour of welded structures under dynamic loading Objectives for IWE, IWT, IWS, and IWP: Understand the development of fatigue, calculation of load cy-cles, the influence of notches and their avoidance.



Scope: P1=0 P1=0 P1=0 P1=0 Types of cyclic loading …………………………………………….……….…...Statistical stress analysis on real structures ………………………….………S-N diagram ………………………………………………………………….…..Stress collective ………………………………………………………………… Fatigue strength (low cycle, and others)……………………………………… Effect of mean stress ……………………………………………………...........Effect of stress range …………………………………………………………...Stress distribution ………………………………………………………………. Influence of notches ……………………………………………………………. Influence of weld defects ……………………………………………………….Fatigue improvement technique (needle peening, TIG dressing, burr grinding, hammering, stress relieving, etc.) …………………………………..Standards ………………………………………………………………………...Palmgren-Miner rule……..………………………………………………...........Classification of weld joints …………………………………………………….

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Expected Result for IWE: 1. Draw and use an S-N diagram. 2. Describe methods of counting load cycles. 3. Calculate the stress ratio. 4. Detail the influence of notches and weld defects. 5. Explain the methods for improving fatigue performance. Expected Result for IWT: 1. Draw and use an S-N diagram. 2. Detail the influence of notches and weld defects. 3. Describe the methods applied to welds for improved fatigue performance. Expected Result for IWS: 1. Understand an S-N diagram. 2. Name the influence of notches and weld defects. 3. Name possible modifications to welds for improved performance. Expected Result for IWP: 1. Understand in general the influence of notches and weld defects. 2. Define simple recommendations for fatigue improvement in case of welded joints.



3.8 Design of dynamically loaded welded structures Objectives for IWE, IWT and IWS: Understand the different design details and notch classes in the range of applica-tion.



Scope: P1=0 P1=0 P1=0 P1=0 Range of application: bridges, cranes, machines, ships and offshore construc-tions, chimneys, towers and masts, vehicles (cars, trucks, railway vehicles) etc. Acceptance criteria ……………………………………………………………... Use of standards and specifications ………………………………………….. Worked examples ……………………………………………………………….

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Expected Result for IWE: 1. Design welded joints in accordance with given details. 2. Interpret the influence of notch effects on the classification of welded joints. 3. Interpret appropriate standards. 4. Compare details in different standards and classify them. Expected Result for IWT: 1. Design welded joints in accordance with given details. 2. Explain the influence of notch effects on the classification of welded joints. 3. Compare details in different standards and classify them. Expected Result for IWS: 1. Recognise welded joints in accordance with given details. 2. Know the influence of notch effects and stresses on the classification of welded joints. Expected Result for IWP: Not Applicable

3.9 Design of welded pressure equipment Objectives for IWE, IWT, IWS, and IWP: Understand the special requirements of design and construction of struc-tural elements in this field of application with regard to the calculation of welds.



Scope: P1=0 P1=0 P1=0 P1=0 Construction of boilers, pressure vessels, pipelines, etc………….......…… Calculation (formulae) of the welds …………………………………………... High and low temperatures applications ………………………………….….. Details of design (flanges, nozzles, shells, compensating plates etc.) …… Use of laws and design rules, standards and specifications …………….... Worked examples of construction and design …………………………….…

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Expected Result for IWE: 1. Explain the advantages of different weld details. 2. Explain design of given structural weld details. 3. Interpret appropriate standards. 4. Calculate circumferential and longitudinal welds. 5. Design given structural details. 6. Explain the advantages of different structural details. Expected Result for IWT: 1. Interpret appropriate standards. 2. Calculate circumferential and longitudinal welds. 3. Design given structural details. 4. Explain the advantages of different structural details Expected Result for IWS: 1. Recognise the advantages of different weld details. 2. Outline the calculation of circumferential and longitudinal welds. 3. Understand design of given structural weld details. Expected Result for IWP: 1. Describe the advantages of different details. 2. Nominate the relevant standards.



3.10 Design of aluminium alloys structures Objectives for IWE, IWT and IWS: Understand fully the behaviour of welded aluminium structures with respect to strength, stresses and design.



Scope: P1=0 P1=0 P1=0 P1=0 Comparison of design between steel and aluminium structures …………... Lightweight structures ………………………………..………………………… Standard alloys for practical use and relevant stresses and strains …….… Effects of heat affected zone (HAZ) (softening) ……………………..…….... Special design regarding profiles ……………………………………….…….. Significance of defects …………………………………………………….…… Range of application (vehicles, rolling stocks, ships, aircraft, vessels and space) Use of standards and specifications ……………………………………….…. Worked examples ………………………………………………………….……

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Expected Result for IWE: 1. Interpret softening on the heat affected zone (HAZ). 2. Design aluminium profiles for a given use. 3. Discuss how to solve the most common imperfections on aluminium welds 4. Explain causes and development of stresses and strains in an aluminium weldment. 5. Explain the strength of different alloys. 6. Select alloys for given applications. Expected Result for and IWT: 1. Explain how to minimize the softening of the heat affected zone. 2. Give examples of common aluminium weld joints. 3. Discuss how to solve the most common imperfections on aluminium welds. Expected Result for IWS: 1. Recognise typical aluminium joints and preparation. 2. Recognise the common aluminium imperfections and solutions to avoid them. 3. Name some typical applications and the advantages against steel construction. Expected Result for IWP: Not Applicable

3.11 Reinforcing-steel welded joints Objectives for IWE, IWT and IWS: Understand the principles of choice of joints and their design.



Scope: P1=0 P1=0 P1=0 P1=0 Reinforcing-steel types, properties …………………………………………… Direct and indirect loading …………………………………………….……….. Types of joints used (lap, cruciform) ………………………………….………. Calculation……………………………………………………………………….. Weldability with respect to weld joint strength .………………………………. Preheating in respect to bar diameter ……………………………….……….. Application of welding processes …………………………………….……….. Standards and specifications (ISO 17660 series and National Standards)..

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Expected Result for IWE and IWT: 1. Explain the basics of the different joints in full. 2. Differentiate between load bearing and non-load bearing joints. 3. Detail applicable processes. 4. Determine the length of weld with respect to diameter. 5. Deduce the required preheating temperature. Expected Result for IWS: 1. Outline the basics of the different joints in full. 2. Recognise between load bearing and non-load bearing joints. 3. Classify applicable welding processes. 4. Outline the length of weld with respect to diameter. 5. Understand the application of preheat. Expected Result for IWP: Not Applicable



3.12 Introduction to fracture mechanics Objectives for IWE and IWT: Understand the use of fracture mechanics for welded structures.



Scope: P1=0 P1=0 P1=0 P1=0 Viewpoint of fracture mechanics …………………………………….…………Application of fracture mechanics …………………………………….……….Linear elastic fracture mechanics …………………………………….………..Fundamentals of elastic-plastic fracture mechanics………………….……...Critical flaw size, KIc-value ……………………………………………….…….Fracture mechanics testing (CTOD, etc.) ……………………………………. Sub-critical crack growth ………………………………………………….…....Fatigue testing ……………………………………………………………….…..Standards ………………………………………………………………………...

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Expected Result for IWE: 1. Explain the principles of linear-elastic and elastic-plastic fracture mechanics. 2. Describe the influence factors for linear-elastic and elastic-plastic fracture mechanics. 3. Describe the use of fracture mechanics for dynamically loaded structures. 4. Describe fracture mechanics testing methods. Expected Result for IWT: 1. Name the principles of linear-elastic and elastic-plastic fracture mechanics. 2. Name the influence factors for linear-elastic and elastic-plastic fracture mechanics. 3. Describe the use of fracture mechanics for dynamically loaded structures.

Expected Result for IWS and IWP: Not Applicable

Module 3 – Construction and Design

IWE IWT IWS IWP Module 3 MT P1 * MT P1 * MT P1 * MT P1 * Teaching Hours 64 14 40 14 22 4 8 0 * P1 = Part 1, Figures under P1 are given for the Standard Route (see 4.1)



Module 4: Fabrication, applications engineering

4.1 Introduction to quality assurance in welded fabrication Objective for IWE, IWT, IWS and IWP: Understand in detail/get a complete knowledge/explain the prin-ciples of quality assurance and quality control and recognise the related standards and their application to welded fabrication as a special process.



Scope: P1=0 P1=0 P1=0 P1=0 Concept of quality assurance and quality control (including analysis, con-tinuous improvement)……………………………………………………………Weldability……………………………………………………………………….. Quality manual………………………………………………………………….. Quality plan……………………………………………………………………… Audit of plant……………………………………………………………………. Personnel and equipment……………………………………………………... Maintenance…………………………………………………………………….. Inspection………………………………………………………………………... Activities of the welding engineer/technologist/specialist/practitioner in the different functions in industry…………………………………………………...Standards (QMS guidebook, ISO 9000 series, ISO 3834, national and in-ternational standards)……………………………………………………………

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welded fabrication. 2. Be capable of writing quality control procedures and quality plans for welded fabrication. 3. Explain in detail the purpose of an audit of plant. 4. Be capable of carrying out audits of welding related plant, personnel, equipment and product. 5. Interpret appropriate standards (e.g. ISO 9000, and ISO 3834 series). 6. Explain in detail the main factors related to personnel and equipment, which influence the quality in a

welded fabrication. 7. Explain the role of the Welding Engineer in the fabrication industry. Expected Result for IWS: 1. Explain the main differences between quality assurance, quality control and inspection systems and

their usage for welded fabrication. 2. Be capable of writing quality control procedures. 3. Interpret appropriate standards (e.g. ISO 9000, and ISO 3834 series). 4. Know the basic factors related to personnel and equipment, which influence the quality in a welded

fabrication. 5. Explain the role of the Welding Specialist in the fabrication industry. Expected Result for IWP: 1. General outline on the goals for quality assurance and quality control. 2. Recognise some factors related to personnel and equipment, which influence the quality of a welded

construction.



4.2 Quality control during manufacture Objective for IWE, IWT, IWS and IWP: Understand in detail/get a complete knowledge/explain the re-quirements and function of Quality Control during manufacture. Explain the standards related to weld-ers/operators and welding procedure qualification including traceability, need for calibration and monitor-ing of welding parameters. The same objectives to be covered in the scope for brazing.



Scope: P1=0 P1=0 P1=0 P1=0 Documentation to national, regional and international standards, e.g. WPS ............................................................................................................Advantages to the quality of welded constructions .….............……………. Welding sequence ….…………………………………………….............…… Welding coordination and inspection personnel; qualification tasks and responsibilities (ISO 14731, ISO 9712, and National standards) .........….. Procedure qualification (as described in ISO 15607) and National stan-dards …....................................................................................................…Welding procedure specification (WPS) - how to create and develop ........ Welder qualification (ISO 9606 series, EN 287-1, and National stan-dards)...........................................................................................................Welding operator qualification (EN 1418, ISO and National standards) ..... Traceability (materials identification, welder/operator, procedures, certifi-cates) .......................................................................................................…Possible methods of monitoring, control and storage of fabrication data ....Calibration and validation of measuring equipment ….....……...….............. Practical exercises: IWE - Welding procedure qualification 2 hours from 14 IWE - Welder and welder operator qualification 2 hours from 14 IWT - Welding procedure qualification 2 hours from 12 IWT - Welder and welder operator qualification 2 hours from 12 IWS - Welding procedure qualification 2 hours from 10 IWS - Welder and welder operator qualification 2 hours from 10 IWP - Welding procedure qualification 1 hours from 6 IWP - Welder and welder operator qualification 1 hours from 6

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Expected Result for IWE: 1. Explain in detail the main purpose of a WPS/WPQR/pWPS and the main advantages to the quality of

welded fabrication. 2. Compile and review detailed WPSs for welded components in accordance with national and interna-

tional standards. 3. Interpret the standard for the qualification of a WPS, determine the main variables for a particular

WPS qualification and its range of qualification. 4. Explain in detail the main purpose of a welder qualification and the main advantages to the quality of

welded fabrication. 5. Interpret the standard for a welder qualification, determine the main variables for a particular welder

qualification and its range of qualification. 6. Explain the main purpose of a welding operator qualification and the main advantages to the quality of

welded fabrication. 7. Interpret the standard for a welding operator qualification, determine the main variables for a particular

welding operator qualification and its range of qualification. 8. Detail the traceability requirements for materials procedures and certificates. 9. Detail methods available for the monitoring and storage of fabrication data. 10. Detail the calibration requirements of measuring equipment explaining why they are needed. 11. Explain in detail the tasks and responsibilities of the welding coordination personnel. 12. Explain in detail the tasks and responsibilities of the different inspection personnel



Expected Result for IWT: 1. Explain the main purpose of a WPS/WPQR/pWPS and the advantages to the quality of welded fabri-

cation. 2. Compile and review WPSs for welded components in accordance with national and international stan-

dards. 3. Interpret the standard for the qualification of a WPS, determine the main variables for a particular

WPS qualification and its range of qualification in accordance with National and/or International stan-dards.

4. Explain the main purpose of a welder qualification and the main advantages to the quality of welded fabrication.

5. Interpret the standard for a welder qualification, determine the main variables for a particular welder qualification and its range of qualification.

6. Explain the main purpose of a welding operator qualification and the main advantages to the quality of welded fabrication.

7. Interpret the standard for a welding operator qualification, determine the main variables for a particular welding operator qualification and its range of qualification.

8. Define the traceability requirements for materials procedures and certificates and give examples. 9. Give examples of methods available for the monitoring and storage of fabrication data. 10. Recognise the equipment and instruments needing calibration and explain why. 11. Explain the tasks and responsibilities of the welding coordination personnel. 12. Explain the tasks and responsibilities of the different inspection personnel Expected Result for IWS: 1. Explain the main purpose of a WPS/WPQR/pWPS and the advantages to the quality of welded fabri-

cation. 2. Compile and review WPSs for welded components in accordance with national and international stan-

dards. 3. Interpret the standard for the qualification of a WPS, determine the main variables for a particular

WPS qualification and its range of qualification in accordance with National and/or International stan-dards.

4. Explain the main purpose of a welder qualification and the main advantages to the quality of welded fabrication.

5. Interpret the standard for a welder qualification, determine the main variables for a particular welder qualification and its range of qualification.

6. Explain the main purpose of a welding operator qualification and the main advantages to the quality of welded fabrication.

7. Interpret the standard for a welding operator qualification, determine the main variables for a particular welding operator qualification and its range of qualification.

8. Define the traceability requirements for materials procedures and certificates and give examples. 9. Give examples of methods available for the monitoring and storage of fabrication data. 10. Know the equipment and instruments needing calibration Expected Result for IWP: 1. Outline the purpose of a WPS, and the advantages to the quality of the welded construction. 2. Recognise the main variables for a certain WPS qualification and its range of approval. 3. Outline the welder qualification purpose, and the advantages to the quality of the welded construction. 4. Recognise the EN and ISO standard for a welder qualification, and outline the main variables for a

certain welder qualification and its range of approval. 5. Outline the meaning of traceability when related to the welded constructions. 6. Identify the equipment, and instruments needing calibration.



4.3 Residual Stresses and Distortion Objective for IWE, IWT, IWS and IWP: Understand in detail/get a complete knowledge/explain the main factors affecting welding stress and distortion in welded fabrications and how these effects can be meas-ured and minimised.



Scope: P1=0 P1=0 P1=0 P1=0 Influencing factors ……………………………………………………………….Thermal data of the materials ………………………………………………….Origin of the residual stresses and deformation ……………………………..Magnitude of longitudinal and transverse shrinkage stresses ….…………..Relationship between heat input, shrinkage stresses and distortion ………Methods of residual stress measurement …………………………………….Welding sequence techniques……………………………………………….. Effects of residual stresses on the behaviour of the structure in service…..Methods of reducing residual stresses or distortion ………………………....Correction and removal of welding deformation (pressing, rolling, local heating, etc.) ……………………………………………………………………..Examples of control of distortion ………………………………………………

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Expected Result for IWE: 1. Explain in detail the origin, influencing factors and magnitude of residual stress and distortion in

welded fabrications. 2. Predict quantitatively contraction and distortion in joints and structures. 3. Produce detailed procedures to minimise distortion and stress. 4. Explain how residual stresses may affect the behaviour of a structure in service.

Expected Result for IWT: 1. Explain in detail the origin, influencing factors and magnitude of residual stress and distortion in

welded fabrications. 2. Predict quantitatively contraction and distortion in joints and structures. 3. Develop procedures to minimise distortion and stress. 4. Explain how residual stresses may affect the behaviour of a structure in service.

Expected Result for IWS: 1. Explain in general terms the origin, influencing factors and magnitude of residual stress and distortion

in welded fabrications. 2. Predict qualitatively contraction and distortion in joints and structures. 3. Develop procedures to minimise distortion and stress. 4. Describe how residual stresses may affect the behaviour of a structure in service.

Expected Result for IWP: 1. Outline in general terms he origin, influencing factors and magnitude of residual stress and distortion

in welded fabrications. 2. Predict qualitatively contraction and distortion in joints and structures. 3. Name procedures to minimise distortion and stress. 4. Interpret how residual stresses may affect the behaviour of a structure in service.



4.4 Plant facilities, welding jigs and fixtures Objective for IWE, IWT and IWS: Understand the need for, and function of, auxiliary equipment, jigs and fixtures from the viewpoint of quality, economics and the environment. Objective for IWP: Acquire knowledge about the main plant facilities used during welded construction and auxiliary equipment, to be able to recognise technical solutions for a certain welded construction



Scope: P1=0 P1=0 P1=0 P1=0 Layout of production line ………………………………………………………..Jigs, fixtures and positioners (types, applications, advantages, special precautions) ……………………………………………………………………...Roller beads, manipulators…………………………………………………...…Cables, electrical connections, and special precaution……………………...Operational environment……………………………………………………….. Auxiliary equipment (for fit up, movement, backing gas devices, flow me-ters, etc)………………………………………………………………………...…Fume extraction (type of equipment, air flow) ………………………………..Joint fit up …………………………………………………………………...……Tack welding and their removal……………………………………………...…Storage, distribution and handling of consumables (gases and filler mate-rial, baking and drying furnace) ………………………………………………..Equipment for preheat, postheat, and other heat treatments, also tem-perature control including furnace and local heat treatment………..…… Maintenance………………………………………………………………………

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Expected Result for IWE: 1. Detail workshop layout principles for improved productivity, safety and comfort. 2. Explain in detail the advantages of using fixtures, jigs and positioners. 3. Predict the type of fixture, jig or positioner to be used for a particular welded fabrication. 4. Deduce the type of auxiliary equipment to be used in a particular welded fabrication, including fume extraction,

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

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

cables, heat treatment and temperature control equipment. 5. Identify the special requirements of facilities for handling and storing welding consumables. 6. Deduce the special requirements related to joint fit up and tack welding. Expected Result for IWP: 1. Outline the layout importance to achieve a higher and easier production. 2. Recognise the advantages of using fixtures, jigs and positioners. 3. Recognise the type of fixture, jig and positioner to be used in a certain welded construction. 4. Recognise the necessary characteristics for the auxiliary equipment to be used in a certain welded construction,

including fume extraction, cables, heat treatment equipment and temperature control. 5. Outline the general precautions related with the handling, and storage of welding consumables, 6. Outline the general precautions related with joint fit up and tack welding.



4.5 Health and Safety Objective for IWE, IWT, IWS and IWP: Understand detail/get a complete knowledge/explain the health and safety hazards associated with welding and fabrication processes, including techniques to minimise them.



Scope: P1=0 P1=0 P1=0 P1=0 Introduction to health and safety requirements ……………………………... Survey of safety and environmental aspects, risk assessment …….………Hazards of electric power ………………………………………………….… Electro-magnetic fields ………………………………………………………….Connecting of equipment ……………………………………………………….Problems with shielding gases …………………………………………………Radiation and eye protection …………………………………………………..Welding fume emission ………………………………………………….......... Exposure limits MAC and OEL values ……………………………………….. Ventilation and fume extraction ………………………………………………..Ergonomics ……………………………………………………………….......... Determination of acceptable emissions………………………………………. Tests for measuring emissions ……………………………………………….. Noise levels and ear protection ………………………………………………..Special risks for automated processes ………………………………………..Standards and regulations ……………………………………………………..

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X Expected Result for IWE: 1. Explain the risks associated with welding from electricity, gases, fumes, fire, radiation and noise. 2. Interpret Health and Safety regulations with respect to the above hazards. 3. Deduce from measurements the risk associated with welding operations. 4. Produce safe working procedures to ensure the requirements are met. 5. Perform measurements of welding hazards.

Expected Result for IWT: 1. Explain the risk factors associated with welding from electricity, gases, fumes, fire, radiation and noise.2. Interpret Health and Safety regulations with respect to the above hazards. 3. Select the appropriate methods to reduce each type of welding risk factors. 4. Produce safe working procedures to ensure the requirements are met. 5. Perform measurements of welding hazards. Expected Result for IWS: 6. Explain the risk factors associated with welding from electricity, gases, fumes, fire, radiation and noise.7. Interpret Health and Safety regulations with respect to the above hazards. 8. Select the appropriate methods to reduce each type of welding risk factors. 9. Describe safe working procedures to ensure the requirements are met. 10. Know how to measure welding hazards. Expected Result for IWP: 1. Describe the risks associated with welding from electricity, gases, fumes, fire, radiation and noise. 2. Interpret Health and Safety regulations with respect to the above hazards. 3. Name the risks associated with welding operations. 4. Describe safe working procedures to ensure the requirements are met.



4.6 Measurement, Control and Recording in Welding Objective for IWE, IWT, IWS and IWP: Understand/know/name the requirements for measurement, con-trol and recording during welding and allied operations. .



Scope: P1=0 P1=0 P1=0 P1=0 Methods of measurement (electrical parameters, gas flow rate, tempera-ture, velocity) ……..……………………………………………………………...Instruments (types, measuring applications) ...…………………………….…Temperatures (ISO 13916), humidity, wind …..………………………….......Cooling time e.g. t 8/5 …………………………………………………………… Welding parameters (voltage, current, speed, gas flow rate, etc.)…….……Control in heat treatment (heating and cooling rate, CR ISO 17663) …….. Calibration and validation of equipment (ISO 17662) ……..…..................... Laboratory exercises: - IWE, IWT and IWS: 1 hour from 4 - IWP: 1 hour from 2

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

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

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



4.7 Non Destructive Testing Objective for IWE, IWT, IWS and IWP: Understand in detail/understand/explain/describe the use of Non Destruc-tive Testing as applied to welding fabrications.



Scope: P1=0 P1=0 P1=0 P1=0 Types of weld imperfections (IIW-designations classification according to ISO standards) ………………………...……………………....................……..............……Acceptance criteria (e.g. ISO 5817, ISO10042, and EN 12062) ….............…….…..Fundamentals of NDT methods (visual, dye penetrant, magnetic particle, eddy current, acoustic emission, radiography, ultrasonic, etc.) …….....................…….… Field of application and limitations ...............……………………………….…..………Design in respect of NDT ………………....................………….………………………Calibration ………………………………………………...............………………………Interpretation (IIW Radiographic reference) …………………...............……………...Recording of data ………………………………………….………………..............……Correct selection of the NDT methods versus application (e.g. CEN/TR 15135) .. Qualification and certification of NDT personnel ……….……….............………….…NDT procedures …………………………………………….…………...........................Automation of NDT (computer aid evaluation, etc.) ….............….….……….............Use of standards and specifications …………….………….….............………………Health and safety aspects …………………………………..…………….............……. Laboratory exercises (50% of the teaching hours): - IWE: 10 hours from 20 - IWT: 5 hours from 10 - IWS: 5 hours from 10 - IWP: 5 hours from 10

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Expected Result for IWE: 1. Explain the modes of operation of the principal NDT methods, their advantages and disadvantages when applied

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

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

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

to welded fabrications. 2. Name weld imperfections, their causes and methods of detection. 3. Interpret acceptance standards for weld imperfections. 4. Point weld configurations and design to allow adequate application of NDT methods. 5. Recognise safety aspects

Note: Welding coordination personnel may need qualifications according to ISO 9712. In this guideline a part of that

education already is covered.



4.8 Economics Objective for IWE, IWT, IWS and IWP: Understand in detail/understand/know/interpret the economics of welding operations applied to welded fabrications.



Scope: P1=0 P1=0 P1=0 P1=0 Analysis of welding costs………………………………….…………………… Deposition rate…………………………………………………………….……. Costs of labour…………………………………………….………………….… Costs of welding consumables.………………………………….….…………. Costs of equipment……………………………..……………………………… Return on investment………………………………………..……………….… Costs of energy…………………………………………………………………. Welders duty cycle …………………………………………………...………… Calculation of welding costs ……………………………………...…………… Cost awareness (of labour, consumables, equipment, gases, energy, etc.) The application of software, calculation programmes ……………………… Measures for decreasing welding costs …………………………...………… Mechanisation………………………………………………………..…………. Automation………………………………………………………………………. Robotics……………………………………………………….………………….

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Expected Result for IWE: 1. Explain in detail the make up of costs associated with welding. 2. Calculate the cost of welding operations. 3. Devise welding and handling procedures including mechanisation and automation to minimise produc-

tion costs. 4. Operate software packages used in weld cost calculations. Expected Result for IWT: 1. Explain the elements of costs associated with welding. 2. Calculate the cost of welding operations. 3. Select welding and handling procedures including mechanisation and automation to minimise produc-

tion costs. 4. Operate software packages used in weld cost calculations. Expected Result for IWS: 1. Describe the elements of costs associated with welding. 2. Know about the costs of welding operations. 3. Select welding and handling procedures including mechanisation and automation to minimise produc-

tion costs. Expected Result for IWP: 1. Interpret the make up of costs associated with welding. 2. Describe welding and handling procedures including mechanisation and automation to minimise pro-

duction costs. 3. Interpret welder’s duty cycle.



4.9 Repair Welding Objective for IWE, IWT, IWS and IWP: Understand in detail/understand/name the problems of repair welding both for in-manufacture and in-service situations.



Scope: P1=0 P1=0 P1=0 P1=0 Welding repair procedure specification…………………………………….… Welding repair plan……………………………………………….…………….. Welding repair procedure qualification………………………….……………. NDT of the weld repair…………………………………………………………. Special precautions……………………………………………………………..

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Expected Result for IWE: 1. Explain in detail the problems of making repair welds. 2. Predict the possible hazards likely to occur in making repair welds particularly for in-service repairs. 3. Detail comprehensive procedures to be applied to weld repairs. 4. Specify the procedural and operator qualifications to be applied to repair welds.

Expected Result for IWT: 1. Explain the problems and implications of making repair welds. 2. Predict the possible hazards likely to occur in making repair welds particularly for in-service repairs. 3. Develop procedures to be applied to weld repairs. 4. Specify the procedural and operator qualifications to be applied to repair welds. Expected Result for IWS: 1. Explain the problems and implications of making repair welds. 2. Predict the possible hazards likely to occur in making repair welds particularly for in-service repairs. 3. Understand procedures to be applied to weld repairs. 4. Specify the procedural and operator qualifications to be applied to repair welds. Expected Result for IWP: 1. Describe the problems of making repair welds. 2. Predict the possible hazards likely to occur in making repair welds particularly for in-service repairs. 3. Define comprehensive procedures to be applied to weld repairs. 4. Name the procedural and operator qualifications to be applied to repair welds.

4.10 Fitness for Purpose Objective for IWE and IWT: To gain an understanding of the need for and use of engineering critical as-sessment techniques.



Scope: P1=0 P1=0 P1=0 P1=0 Introduction to IIW SST 1093-8 and ISO/TR 15235……………......…..……Significance of defects …………………………………………..…………….. Engineering critical assessment techniques ……………………..………..…

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Expected Result for IWE: 1. Explain the principles of fitness for purpose. 2. Describe in detail the effect of imperfection size, morphology and position on structural integrity. 3. Explain typical methods on conducting an engineering critical assessment of a welded structure. Expected Result for IWT: 1. Describe the principles of fitness for purpose. 2. Describe in detail the effect of imperfection size, morphology and position on structural integrity. 3. Explain typical methods on conducting an engineering critical assessment of a welded structure. Expected Result for IWS and IWP: Not Applicable



4.11 Case Studies Objective for IWE, IWT and IWS: To understand and be able to handle welding related tasks in respect to the manufacture of specific welded products. The best way to give this education is a combination of experts from industry presenting special cases and project work of the students split up into groups fol-lowed by a general discussion and comments by the experts. All of the following subjects have to be dealt with, the depth to which, however, will depend on the national needs.



Scope: P1=0 P1=0 P1=0 P1=0 Steel and lightweight structures, boilers and pressure vessels, chemical plants and pipelines, shipbuilding and offshore applications, transportation (automobiles, railways), aerospace applications. Common items to be covered:

Standards and specifications, design, Choice of materials, welding processes, Site welding (transport and final assembly), Consumables, welding procedures, Tolerances on weld preparation and fit-up, Post weld heat treatment, NDT and quality control,

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Expected Result: Not Applicable

Module 4 – Fabrication, applications engineering

IWE IWT IWS IWP Module 4 MT P1 * MT P1 * MT P1 * MT P1 * Teaching Hours 110 0 80 0 53 0 28 0

* P1 = Part 1, Figures under P1 are given for the Standard Route (see 4.1)



I.2 Theoretical Education - IWS 0 The module IWS 0 aims at teaching basic technical knowledge, which in general is lacking in participants en-tering via the route 3 when compared to participants entering via routes 1 and 2. It provides the chance for professional workers and International Welding Practitioners to become qualified as International Welding Specialists. The module IWS 0 deals with the following subjects:

Teaching hours 0.1 Introduction 1

0.2 Units 2

0.3 Technical Calculation 12

0.4 Technical Drawings 12

0.5 Basics of Electro-technology 6

0.6 Basics of Chemistry 2

0.7 Basics of Materials 8

0.8 Metal Products 2

0.9 Machining of Materials 2

0.10 Technical Mechanics 10

0.11 Calculation of Strength 10

0.12 Joining Elements 2

0.13 Survey on Welding Processes 2

71

Teaching hours 0.1 Introduction 1 Objectives: To be aware of the IIW education and training system and job functions of a qualified IWS. Scope: Review of basic knowledge Information on the IWS education and training system IIW education and training system Job function of the IWS in relation to Standards (e.g. ISO 3834) Survey on the contents of this module Expected Results: 1. Explain the reason for contents of the module IWS 0. 2. Review of basic knowledge. 3. Provide information on the IWS education and training system. 4. Explain the job functions of a certified IWS in relation to Standards (e.g. ISO 3834)



0.2 Units 2 Objectives: To acquire a working knowledge of the metric system of measurements, i.e. the International System of Units (SI) related to welding. Scope: Units for length and area, Angular units, SI base units Time and time dependent units, SI derived units Expected Results: 1. List all SI base units and their symbols for length, mass, time, electric current, voltage, temperature,

plane angle and other commonly used units related to welding. 2. List all SI derived units and their symbols for area, density, energy, force, frequency, power, pressure,

volume, area, linear velocity, and other commonly used units related to welding. 3. List commonly used multiplication factors, prefixes and their symbols. 0.3 Technical Calculation 12 Objectives: To demonstrate how to make calculations related to welding involving various combinations of mathematical operations, powers, square roots, logarithms, basic trigonometric functions, equations, variables including linear and angular measurements and time. Scope: Simple mathematical operations such as addition, subtraction, multiplication, division, powers, square roots, percentage calculation, rule of three (transposition) Use of calculators Equations, Rearranging of equations Calculation of length, area and volume Trigonometric functions Calculations involved in welding technology Expected Results: 1. Show examples of mathematical operations of addition, subtraction, multiplication and division of whole

numbers of different signs, decimals and fractions. 2. Show examples of powers of 0, 1, 2, …. of a number including 10. 3. Show examples of square roots of numbers greater than 1 and less than 1. 4. Show examples of linear equations and how the equations can be re-arranged, manipulated and solved. 5. Explain the definition of basic trigonometric functions of sine, cosine and tangent in terms of the ratios of

the sides of a right-angled triangle. 6. Show calculations related to welding involving various combinations of mathematical operations, powers,

square roots, basic trigonometric functions and equations. 7. Show the use of pocket calculators for the above calculations and functions.



0.4 Technical Drawings 12 Objectives: To be able to read, understand and draw basic technical drawings related to welding technology. Scope: Formats, lines, fonts, scales, drawing aids Sketch of flat pieces Drawings Projections, cross sections Planar development of shapes Pieces with hidden lines, hatching Symbols, size lines Drawing of diagrams Expected Results: 1. List all the basic drawing aids and their uses. 2. Indicate the basic forms of letters and numerals and character usage. 3. Illustrate the various types of lines and their usage. 4. Explain the use and indication of scales in engineering drawings. 5. Illustrate the formats of drawing sheets. 6. List dimensioning symbols and illustrate dimensioning of common features. 7. Explain sectioning symbols and methods and illustrate different sectional views. 8. List the basic symbols of gas and arc welding processes and illustrate how they are applied. 9. Illustrate the standard welding symbol and how it is applied to the actual weld. 10. Explain fits and tolerances in relation to welded structures. 0.5 Basics of Electrotechnology 6 Objectives: To acquire a basic knowledge of electricity and magnetism in relation to the requirements of welding tech-nology. Scope: Basics of electricity and magnetism Ohm’s law Parallel and series circuits Polarity, direct current (DC), alternating current (AC), half wave and full wave rectification Circuit components and their symbols Simple circuits Magnetic fields due to current-carrying conductors Magnetic force on moving charges Magnetism in welding Coils and transformers Circuits, connection diagram Expected Results: 1. Briefly describe atomic structure, electron, proton, electric charge, current as charge in motion, potential

difference, positive and negative polarities, resistance as opposition to current, direction of current, direct current, alternating current, sources of electricity and common types of resistors.

2. Define Volt as the unit of potential difference, Ampere as the unit of current, Ohm as the unit of resis-tance and Coulomb as the unit of charge.

3. Explain Ohm’s law, the variation of current with voltage and resistance and the application of Ohm’s law to both dc and ac circuits.

4. Explain electric power, power formulae, power dissipation in resistance, Watt as the unit of electric power and kilowatt-hour as the practical unit of power.

5. List various circuit components and their symbols.



6. Explain the effects of open circuit and short circuits. 7. Show how to determine the total resistance and total power of series and parallel circuits of resistances. 8. Describe an alternating current and its sine or sinusoidal waveform, 50-Hz AC and 3-phase AC power

line. 9. Define peak value and RMS value for either current or voltage. 10. Show examples of simple series AC circuit with resistance, parallel AC circuit with resistance and series-

parallel AC circuit with resistance. 11. Explain the basic arc welding circuit. 12. Explain the working of voltmeters, ohmmeters and multi-meters including digital multi-meters, and their

applications related to welding. 13. Explain the presence of a magnetic field around an electric current. 14. Explain welding arc deflection in terms of the magnetic force on moving electric charges. 15. Explain self inductance and transformer action. 0.6 Basics of Chemistry 2 Objectives: To acquire a basic knowledge of chemistry for the understanding of chemical reactions in welding processes, casting processes and chemical analysis of welds. Scope: Chemical elements Simple reactions Expected Results: 1. List all chemical elements and their symbols in engineering steel, aluminium, nickel and copper, and

their alloys. 2. Explain chemical reaction and its representation by the chemical equation with examples of chemical

reactions in steel manufacturing and welding processes. 3. Briefly explain chemical analysis of weld metal and filler metal. 4. List the various types of plain carbon, low alloy and high alloy steels, and their chemical compositions. 0.7 Basics of Materials 8 Objectives: To acquire the properties of the metals especially of iron and non ferrous metals. To be informed about the production of steel and non ferrous metals. To know the effects of the main steel impurities. Scope: Structure of metals Physical properties Different metal and non-metal and combined materials Iron and non ferrous metals Differences in the main physical properties with influence of the welding process Effect of Cr, Ni, Si, Mn, S, P, N, H, in steel Production of steel Production of Aluminium and Copper Effect of carbon in steel products Expected Results: 1. List the units of the main properties. 2. Explain the terms crystal and amorphous. 3. To know the effects of S, P, N and H. 4. Explain the difference between austenitic and ferritic iron. 5. To know which kind of materials have a distinctive yield strength. 6. To know how the mechanical properties are determined. 7. To acquire the main processes to produce steel. 8. To know the difference between the main properties of steel and aluminium.



0.8 Metal products 2 Objectives: To be able to explain the wrought production methods for plates, profiles, bars, castings, forging and extru-sions. Understand the effects of the different wrought production methods on the welding process. Scope: Different methods to produce plates, profiles, bars, castings, forging and extrudes profiles Effect of the wrought production methods on welding process Expected Results: 1. List the main types of wrought products. 2. Recognise the different wrought products and know the correct terms. 3. Explain the effect of the different kinds of wrought production methods on the welding process. 4. Explain why the different properties are dependent on the wrought production method. 5. Know the special effect of castings for the welding process. 6. Be able to identify materials by their designation. 0.9 Machining of Materials 2 Objectives: To be informed about the different methods to machine metals, ferrous and non ferrous alloys Scope: Sawing, cutting, stamping, drilling, shaping, milling and thermal cutting Expected Results: 1. To know the most important machining methods. 2. Be able to describe the difference between cutting and non cutting methods. 3. List the non cutting methods for metals. 4. List the most important cutting methods. 5. List the thermal methods for machining of ferrous and non- ferrous alloys. 0.10 Technical Mechanics 10 Objectives: To be able to calculate forces, stresses and moments of cross sections. Recognise the difference between statically determinate and statically indeterminate systems Scope: Units of forces Basic of static Static systems Description of forces Dimension of forces Splitting (resolving) and addition of forces Scale of forces Moments and balance Supports Main axes System of coordinates Expected Results: 1. Determine simple bending moments. 2. Calculate support forces. 3. Determine bending forces. 4. Graphically splitting of forces. 5. Find the resultant force from more forces through one point. 6. Recognise if a system is either statically determinate and statically indeterminate.



0.11 Calculation of Strength 10 Objectives: Understand the difference between static mechanics and strength of materials. Knows what data can be de-termined during a tensile test. Recognise the different kinds of girders. Scope: Elongation, deflections Areas of complex cross sections Moment of inertia, section modulus Stress calculation Stability of pieces Different cross sections Bending of girders and frames Expected Results: 1. Able to draw a tensile test diagram. 2. Able to explain the tensile test diagram. 3. Calculate/verify tension. 4. Calculate section modulus. 5. Calculate moment of inertia. 6. Calculate cross section area. 0.12 Joining elements 2 Objectives: The student knows the difference between transfer forces by elastic joining, material adhesion, force adhe-sion and form adhesion and the other possibilities of joining different materials Scope: Dismantling and non dismantling joining Screw joining Force transfer by adhesion of form, force material elastic joining Mechanical fastening, (e.g. Pin joining, Keying, Springs, Riveting) Brazing, Soldering Welding Expected Results: 1. List the different possibilities of joining elements. 2. Knows the number of the main welding processes. 3. Able to explain the 3 soldering processes. 0.13 Survey of Welding Processes 2 Objectives: To get a survey of the welding processes. Scope: Welding, Welding processes chart Fusion welding Resistance welding Welding energy Plastic welding



Expected Results: 1. List the main fusion welding processes. 2. List the resistance welding processes. 3. List the type of energy required by a welding process. 4. Able to explain the difference between welding and soldering. 5. Able to explain the terms adhesion and cohesion. 71 hours



I.3. Practical Education – Part 2 I.3.1 For the IWE; IWT and IWS This part does not aim at providing practical skills to the welding engineer/technologist/specialist but on gain-ing knowledge on the control of the different welding processes. The students shall become as familiar as possible with the problems and typical defects associated with incorrect use of the different welding methods. During their exercises the students are guided by skilled welding teachers. Practical Training hours: Oxyacetylene welding and cutting 6 MMA 10 TIG 10 MIG/MAG + Flux Cored Arc Welding 14 Demonstrations or video presentations on processes 20 Gouging Brazing Plasma welding Plasma cutting Submerged-arc welding Resistance welding Friction welding Electron beam welding Laser welding Other processes ___ total : 60 Candidates may be exempted by the ATB from the practical training, on a process by process basis, if they can demonstrate practical experience and/or training in the process concerned. The laboratory exercises contained in the foregoing modules 1 to 4 of the theoretical part are additional and given usually at a later stage of the education. I.3.2 For the IWP The practical training has to be done on an individual basis. The main processes are: MMA, MIG/MAG, FCAW, TIG and Gas Welding. 40 hours shall be reserved to broaden the student’s skill in other relevant materials within his welder qualification/s. This training shall end with a practical examination in more than one process or more than one group of material (according ISO 9606 or national standards). For MIG welding only material group 22 and for Gas welding only material groups 1.1 and 1.2 are relevant. If a student can demonstrate existing practical skill in and an understanding of the welding of different mate-rials, it is accepted that he can sit for the practical examination in these processes and materials without prior practical training. Typical test pieces and positions are given in Table 1. The test pieces shall be welded as single side welding without backing, except for aluminium, where backing is allowed. Each ANB will work to a similar table based on comparable national standards.



Valid national certificates are accepted as replacements for the practical examinations with test pieces in Ta-ble 1. Table 1: Recommended test pieces and positions for practical examinations: The dimensions given in the table are recommended/proposed, but not mandatory, other dimensions are ac-cepted.

Welding process Practical Test

ISO/EN 9606/287

ISO/EN 9606/287

Material Group

(ISO TR 15608) Weld

Position Test

Dimension(s) Diameter/Thickness

1 PF/BW 6,0 – 13,0 3 PF/BW 6,0 – 13,0

4, 5, 6 H-L045/BW ∅60,3 – ∅114.3/ 3.9 – 7.11

7 PF/BW 6,0 – 13,0

MMA 111

8 PB/FW 6,0 – 13,0

1 H-L045/BW ∅60,3 – ∅114.3 3.9 – 7.11

3 PF/BW 2,0 – 6,0

4, 5, 6 H-L045/BW ∅60,3 – ∅114.3 3.9 – 7.11

7 PF/BW 2,0 – 6,0

8 H-L045/BW ∅60,3 – ∅114.3 3.9 – 7.11

TIG 141

22 PF/BW 2,0 – 6,0

MIG 131 22 PF/BW 6,0 – 13,0

1 PF/BW 6,0 – 13,0 MAG (and/or metal

cored)

135 (136) 8 PB/FW 6,0 – 13,0

1 PF/BW 6,0 – 13,0

8 PF/BW 6,0 – 13,0 FCAW (flux cored only) 136

3 PA/FW 6,0 – 13,0

GAS 311 1 H-L045/BW ∅60,3 – ∅114.3 3.9 – 7.11

Twenty hours shall be reserved to give the student basic understanding of the possibilities and limitations of the other processes mentioned in Table 1. The purpose of this training is only to demonstrate the possibilities and limitations of these processes, and no practical examination is required. If the student can demonstrate to the training establishment skill in and understanding of the other processes, he may be exempted from this training. Acceptance criteria for the practical examination: The quality of welding shall comply with ISO 9606, or comparable quality levels defined in National welders qualification standards used by IIW IAB Group A countries. A welder qualification certificate may be issued.



Section II: Examination and Qualification Note: Other rules/procedures are covered in Document IAB-001-2000. 1. Introduction This guideline seeks to achieve harmonisation and a common standard in the examination and qualification of professional welding engineers, technologist, specialist and practitioner, internationally. The national weld-ing organisations, being members of the IIW, mutually acknowledge the Diplomas awarded in any Member Country to International Welding Engineers, Technologist, Specialist and Practitioner, following examination conducted in accordance with this Guideline. Education must have followed this IIW guideline and the examination must have been conducted by the na-tional body authorised by IIW for this purpose. This "Authorised National Body” will normally be operated by the National Welding Organisation which is the IIW member but may be also another organisation with the agreement of the IIW Member. 2. Approval of the postgraduate training (for IWE, IWT, IWS, IWP) course Any training course leading to the IIW examination must be approved by the ANB. The number of teachers required to give the course shall be sufficient to ensure that the essential specialist knowledge and industrial experience to cover the syllabus are adequately represented in the team of teachers and visiting lecturers. 3. Examination Board An Examination Board, acting on behalf of the ANB supervises examinations. In this way, independence, in-tegrity and fairness of the examination system are maintained. 4. Admission to the Examination Admission to the examination leading to the award of the International Welding Engineer, Technologist, Spe-cialist and Practitioner diploma will be restricted to those:

a) Who comply with the minimum requirements specified in the directory of access conditions, and b) Standard Route: Who have attended at least 90% of the course, approved by the ANB, according to

this guideline. Exceptions are at the discretion of the ANB c) Who have attended a Distance Learning Course approved by the ANB fulfilling the requirements of

guideline IAB 195-2004 d) Alternative Route: Who have successfully passed the ANB detailed assessment

5. Examination procedures This guideline defines the minimum requirements for examinations. ANBs are free to exceed these if they wish. The examination procedures described below are designed to test the candidate’s knowledge and under-standing of different situations in welding technology. There will be written and oral examinations in each of the following modules:

a) Welding processes and equipment b) Materials and their behaviour during welding c) Construction and design d) Fabrication and applications engineering



5.1 Written examination At the discretion of the Examination Board the examination shall consist of: a) A series of essay questions covering the whole field of the module or b) A series of multiple choice questions covering the whole field of the module or c) A combination of a) and b) The time devoted to the written examination shall be a minimum of: IWE level – 2.0 hours per module, i.e. 8 hours in all. IWT level – 1.5 hours per module, i.e. 6 hours in all. IWS level – 1.0 hour per module, i.e. 4 hours in all. IWP level – 2.0 hours in total for the four modules 5.2 Oral Examination Oral examination is only mandatory for the IWE level, for the other levels of training the oral examination will be optional at the discretion of the Examination Board, except in the borderline cases, where it will be manda-tory. The oral examination is designed to test understanding and ability to reason in the field of welding. For the IWE level the total time devoted to the oral examination, covering all four modules, shall be a mini-mum of 1 hour per candidate. IWE Candidates reaching >75% of the maximum possible mark in the written examination in one module may be dispensed from the oral examination in that module. 5.3 Practical examination The practical examination is only applied for the IWP qualification level. It shall be implemented as described in I.3.2. 6. Evaluation of Performance Written and oral examinations shall usually have equal importance (50%), but the weight of the oral examina-tion may, at the discretion of the Board of Examiners be set anywhere within the range of 40% to 60%. This shall be announced before the start of the examination. In order to pass the examination candidates shall achieve at least

60% of the maximum possible mark in each module examination

The examination in all four modules shall be completed within a period of 3 years from the date of the first (modular) examination. If a candidate has failed an examination, the 3 years validity of the individual passed parts of the examination in IWE /IWT/IWS/IWP course, may be extended by decision of the Lead Assessor, if it has not been possible for the ANB to organise the necessary re-examinations within the three years period.



7. Re-examination and Appeals Procedure Failure in any individual module of the examination shall require re-examination only in the module failed. Examinations shall be retaken within 2 weeks to 15 months of the initial examination and, in the case of a second failure, one further attempt is permitted within 1 to 15 months from the date of the second examina-tion. If a candidate fails three times in any of the 4 modules, he/she has to retake the classes of the modules failed and the exams of the 4 modules, independently if he/she has passed the exams of the other modules. Candidates who feel they have been unfairly treated during the examination procedure have the right to ap-peal to the Authorised National Body. 8. International Welding Diploma’s After successful examination a diploma is awarded to the candidate by the Authorised National Body. 9. Transition Arrangements

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

Each country’s specific Transition Arrangements are approved by the IAB Group B and may be obtained from each Authorised National Body. An ANB can offer Transitional Arrangements for a period of up to 3,5 years from the date of approval by the IAB Group B. If an ANB wants to change the Transition Arrangements period, it must seek for the IAB Group B approval. Practising Welding Engineers, Technologists, Specialists and Practitioners will be eligible for the award of the International Welding Engineer, Technologist, Specialist and Practitioner Diploma, if they can demonstrate to the ANB that their combination of education, training and experience in welding technology has provided a level of knowledge equivalent to the current IIW requirements and if they fulfil the ANB requirements defined in the Transtition Arrangement Directory. Two additional general rules shall be observed when applying the Transitional Arrangements: 1. Applicants shall possess the basic qualification and experience defined in relevant guideline and in the

Access Condition Directory, Doc. IAB-020-2000. 2. Diplomas may be awarded under Transitional Arrangements in the following cases:

a) by the ANB in the country in which the applicant received his/her welding qualification or b) by the ANB in the country in which the applicant is currently practising, in contact with the ANB

of the country in which the original qualification was issued.



APPENDIX I: Requirements for equipment, facilities and specimens for the International Welding Engi-neer (IWE), Technologist (IWT), Specialist (IWS) and Practitioner (IWP) course leading to the award of IIW qualification 1. Equipment

The following equipment shall be in good working order and fit for its purpose:

1.1 Welding equipment Equipment for the following processes shall be available for practical exercises. Manual metal arc welding - 111 MIG welding - 131 MAG welding - 135/136 TIG welding - 141 Gas welding - 311 Gas flame cutting - 81 Further processes covered by the syllabus may be shown by means of demonstrations or video

presentations. 1.2 Other equipment

Mechanical testing, metallurgical examination and NDT equipment shall be available for both demonstra-tion and laboratory work purposes.

2. Specimens

A reference collection of well documented weld specimens, polished and etched, should reflect the proc-esses covered by the Guideline and, as a minimum, one specimen per process is required. Preferably the specimens should cover a number of materials and thicknesses.



APPENDIX II: Abbreviations for Processes: The following abbreviations used in the document show the relation between the ISO designation, the proc-ess abbreviations used in Europe and those used in the USA.

ISO 4063

European (EA) and American (AA) abbreviations Full name

EA MMA Manual Metal Arc Welding 111

AA SMAW Shielded Metal Arc Welding

EA FCAW Flux-cored wire metal arc welding 114

AA FCAW Flux-cored arc welding

EA SAW Submerged Arc Welding 12

AA SAW Submerged Arc Welding

EA GMAW Gas Shielded Metal Arc Welding 13

AA GMAW Gas Metal Arc Welding

EA MIG Metal-arc Inert Gas Welding 131


EA MAG Metal-arc Active Gas Welding 135


EA FCAW Flux-cored wire metal-arc welding with active gas shield 136

AA FCAW Flux-cored arc welding

EA FCAW Flux-cored wire metal-arc welding with inert gas shield 137

AA FCAW-S Flux-cored arc welding

EA TIG Tungsten Inert Gas Welding 141

AA GTAW Gas Tungsten Arc Welding

EA Spot Welding 21

AA RSW Resistance Spot Welding

EA Resistance Butt Welding 25

AA RSEW Upset Welding

EA Gas Welding 3

AA OFW Oxy-fuel Gas Welding

EA Oxy-acetylene Welding 311

AA OAW Oxy-acetylene Welding

EA Flame Cutting 81

AA OFC Oxyfuel Gas Cutting

EA Flame Gouging 86

AA Thermal Gouging



APPENDIX III: ANB Detailed Assessment After the candidate has fulfilled the requirements of the ANB paper check he will be admitted to the ANB De-tailed Assessment (Diagram 9).

Diagram 9: ANB detailed Assessment The full ANB detailed assessment shall contain:

a) a detailed paper assessment (checklist with points)

b) a professional assessment interview designed to test understanding and ability to reason in welding technology regarding the IIW relevant guideline syllabus

c) a project or a technical interview to test logical application of knowledge regarding the IIW relevant guideline Module 4 syllabus

The sequence of this assessment shall be determined by the ANB. It is at the discretion of the ANB to termi-nate the assessment and send the candidate back or into the standard route. a) The detailed paper assessment shall be done with the following point system:

Frames of requirements (max. number of points) for: Modules

IWE and IWT IWS and IWP Module 1: Welding processes and equipment Module 2: Materials and their behaviour during welding Module 3: Construction and design Module 4: Fabrication and applications engineering

22 21 19 22

22 15 11 20

Sum: 84 68

A minimum of 50% per module is required to proceed further

Paper assessment

Professional assessment

interview

Project or technical interview

Final exams

Part 3 (Module 4) At the discretion of the ANB, (See Diagrams 5 to 8)

yes yes

no no no

yes



Detailed distribution of points for Modules 1, 2, 3 and 4

Module 1: Welding processes and equipment Max. number of points IWE and IWT IWS IWP 111 - MMA 141 - TIG and 15 - Plasma 131 - MIG 135 - MAG 114, 136 and 137 - Flux-cored methods 91, 93 and 97 - Brazing methods 81, 82 and 83 - Thermal cutting 12 - SAW Other methods

3 2 2 2 3 2 2 3 3

3 2 2 2 3 2 2 3 3

4 2 2 2 3 0 3 3 3

Sum: 22 22 22

Max. number of points Module 2: Materials (acc. to CR ISO/TR 15608) and their behaviour during welding IWE and IWT IWS IWP

Steel alloys groups 1 – 3 and 11 Cr-Mo- and vanadium steels: groups 4 - 6 Ferritic and martensitic steels group 7 Austenitic and aust./fer. steels groups 8 and 10 Steel-Ni- alloys, max 10% Ni group 9 Aluminium and alloys groups 21 - 26 Copper and alloys groups 31 - 38 Nickel and alloys groups 41 - 48 Ti, Zr and alloys groups 51 – 54 and 61 - 62 Cast iron groups 71 - 76

4 2 3 4 1 3 1 1 1 1

4 1 2 2 1 2 1 1 0 1

6 1 2 3 1 2 0 0 0 0

Sum: 21 15 15

Module 3: Construction and design Max. number of points IWE and IWT IWS IWP Stresses and strains Design of welded structures - static loading Design of welded structures - dynamic loading Joint design & design principles of welded structures Design of structures of aluminium and its alloys

5 3 3 4 4

2 3 1 4 1

0 4 2 5 0

Sum: 19 11 11

Module 4: Fabrication and applications engineering Max. number of points IWE and IWT IWS and IWP Quality assurance in welded fabrication Quality control during manufacture Welding stresses and distortion Plant facilities, welding jigs and fixtures NDT Economics Health and safety Repair welding

4 3 4 2 3 2 2 2

3 3 4 2 3 1 2 2

Sum: 22 20 At minimum the applicant shall reach 50% in each module to be admitted to the professional interview. Note: If an applicant has a certification in the relevant level covering the module it is up to the ANB to accept this as given 50%.



Welder Qualification Certificate (for IWP candidate only) A minimum of two valid welder qualification certificates corresponding with Section I, Chapter 6 of the stan-dard route shall demonstrate in common with the paper assessment. b) Professional Assessment Interview The professional assessment interview is designed to test understanding and ability to reason in the field of welding regarding the IIW relevant guideline syllabus

Professional interview duration is at least:

IWE level IWT level IWS level IWP level

1,0 hours 45 minutes 30 minutes 30 minutes For a candidate reaching > 75% of the max. possible points in the paper assessment, he or she may be dis-pensed from the professional assessment interview in that module. However the minimum total time shall be not less than half of the time stipulate on the above table for the relevant guideline.

If the ANB decides that the candidate may leave the detailed assessment after the Professional as-sessment interview but before the project or the technical interview the candidate at minimum has to

go through module 4 (Fabrication and applications engineering) of the standard route. After the candidate has attended the module 4 he/she is allowed to perform the final exams

c) Project or Technical Interview The ANB proposes to the candidate to develop a project and to discuss a project final report including a practical part or to be assessed via a technical interview. Each of the assessment routes are explained be-low. c.1) Project The project shall be in form of a case study designed for performance within a special amount of hours de-pending on the qualification level of the candidate (Allocated time). It has to be finished in an allowed time (Maximum time permitted) which also corresponds to the qualification level of the candidate. Depending on the capability of the candidate the study may also be finished in a shorter time. This case study may be done by a team study with max. 7 participants. However the final report and the presentation shall be carried out by the examination candidates individually.

Qualification level Time conditions IWE IWT IWS IWP Allocated time 80 hours 60 hours 40 hours 8 hours Maximum time permitted 4 weeks 3 weeks 3 weeks 1 week

In the project with a wide scope of application the candidate shall be tested to the logical application of his knowledge. The project shall be carried out by the candidate independently.



The ANB takes a choice of construction according to codes and/or product standards. One of the following type of construction shall be taken:

Qualification level Type of construction IWE IWT IWS IWP Pressure vessel X X X X Construction – static loading X X X X Construction – dynamic loading X X X Other construction X X X X

At the ANB discretion, it is possible to accept a project based on the candidates’ real work. The project work is detailed as following:

c.1 - 1 Pre-study IWE IWT IWS IWP

• Pre-study including a workmanship example. X • Understand the consequences of the desired manufacturing code. X X X • Evaluation of drawings and technical specifications. X X • Read and understand drawings and technical specifications. X X • Evaluation of and comments to the choice of base materials. Discuss

the weldability of the materials. Any needs for pre- and post weld heating.

X X

• Knowledge about the choice of base materials. Discuss the weldability of the materials. Any needs for pre- and post weld heating.

X X

• Evaluation of the construction based on the choice of: X X X • Discussion of the construction based on the choice of: X

– Joining method(s) for the base material(s); X X X X – Cutting method(s) for preparation of base material parts; X X X X – Joint preparation and weld calculation; X X X – Joint preparation; X – Welding consumables; X X X X – Need of surface treatment before welding; X X X X – Surface treatment of finished construction - method(s) to be used. X X

• Preparation of necessary WPSs and testing methods. X X X • Interpretation of necessary WPSs. X • Evaluation of necessary welding qualification(s) for welder(s). X X X • Interpretation of necessary welding qualification test(s) for welder(s). X • Present NDT methods to be used during and after welding. X X X • Discuss possible NDT methods that can be used during and after

welding, including special tests to check the entire quality of the con-struction.

X

• Prepare: – Production plan; X X X – Welding plan – including welding sequence and tack welding; X X X – List of standards needed for the project; X X – Quality plan for the production based on relevant part of ISO 3834

or equivalent. Type of workshop for this kind of production shall be discussed.

X X X



c.1 - 2 Practical part on the construction or on test pieces – simulat-ing the same construction – provided by the ANB IWE IWT IWS IWP

• Checking: – Marking(s) and certificate(s) on base material(s); X X X X – Welder(s) qualification test certificate(s); X X X X – Qualification of personnel for destructive testing, NDT and inspec-

tion. X X X

• Evaluation of test results and compare with pre-study figures. X X X • Plan for inspection before and during welding. X X X • Inspection after welding based on pre-study plans – (visual inspection

and other NDT methods, eventually pressure testing or other testing methods).

X X X

• Discussion of inspection reports. X • Evaluation of the welding and test results based on inspection and

NDT reports. X X X

• If evaluation shows need for repair, plan(s) for repair welding and eventually WPSs for repair welding to be made.

X X X

• Evaluation of fabrication costs. X

c.1 - 3 Final report and presentation IWE IWT IWS IWP

• The candidate shall prepare a final written report with results from his project based on the pre-study figures and the practical part.

X X X

• The report shall include view points regarding economical production and at same time ensure the quality of the product.

X X X

• The candidate shall give an oral presentation of the project in front of the board of examiners.

X X X

• The candidate shall give an oral report of results from his project based on the pre-study figures and the practical part.

X

c.2) Technical Interview Technical Interview:

Technical Interview duration is at least:

IWE level IWT level IWS level IWP level

6 hours 4 hours 3 hours 2 hours The Technical Interview will be divided in 2 parts, they are:

i) Applicant discussion regarding Part 1 – Evaluation of the Knowledge (see table below)

ii) Applicant discussion regarding Part 2 – Evaluation of Practical knowledge (see table below) Before the Technical Interview the candidate as at least 1 hour to be acquitted to the documentation that will be used during the interview.



The ANB will supply to the applicant a set of documents (construction drawings - part of a construction, list of materials, materials certificates, NDT reports, destructive testing reports, WPQRs, WPSs, Welder Approv-als). Or The applicant presents a set of documents (construction drawings - part of a construction, list of materials, materials certificates, NDT reports, destructive testing reports, WPQRs, WPSs, Welder’s Approvals), these documents should be from the company where the applicant is currently employed. These documents must be first of all evaluated by the ANB before been accepted as documentation to be used on the applicant Technical Interview. The technical interview shall address at least the subjects mentioned on the tables below. i) Part 1 - Evaluation of the Knowledge

c.2 - 1 Discussion of the Construction IWE IWT IWS IWP

• Evaluation of drawings and technical specifications. X X • Read and understand drawings and technical specifications. X X • Evaluation of and comments to the choice of base materials. Discuss

the weldability of the materials. Any needs for pre- and post weld heating.

X X

• Knowledge about the choice of base materials. Discuss the weldability of the materials. Any needs for pre- and post weld heating.

X X

• Evaluation of the construction based on the choice of: X X X • Discussion of the construction based on the choice of: X

– Joining method(s) for the base material(s); X X X X – Cutting method(s) for preparation of base material parts; X X X X – Joint preparation and weld calculation; X X X – Joint preparation; X – Welding consumables; X X X X – Need of surface treatment before welding; X X X X – Surface treatment of finished construction - method(s) to be used. X X

• Preparation of necessary WPSs and testing methods. X X X • Interpretation of necessary WPSs. X • Evaluation of necessary welding qualification(s) for welder(s). X X X • Interpretation of necessary welding qualification test(s) for welder(s). X • Present NDT methods to be used during and after welding. X X X • Discuss possible NDT methods that can be used during and after

welding, including special tests to check the entire quality of the con-struction.

X

• Discussion of the construction in terms of: – Welding plan – including welding sequence and tack welding; X X X – Standards needed for the project; X X – Quality plan for the production based on relevant part of ISO 3834

or equivalent. Type of workshop for this kind of production shall be discussed.

X X X

– Jigs, fixtures, welding equipment X X X X



ii) Part 2 – Practical discussion

c.2 – 2 Practical Part IWE IWT IWS IWP

• Checking: – Certificate(s) on base material(s); X X X X – Welder(s) qualification test certificate(s); X X X X – Qualification of personnel for destructive testing, NDT and inspec-

tion. X X X

– Welding Procedure Qualification Record - WPQR; X X X – Welding Procedure Specification - WPSs; X X X X

• Evaluation of test results and discussion of the reports. X X X • Proposal for a Plan for inspection before, during and after welding and

discussion. X X X

• Discussion of inspection reports. X • Evaluation of the welding and test results based on inspection and

NDT reports. X X X

• Welds needing for repair, plan(s) for repair welding and eventually WPSs for repair welding to be made.

X X X

• Brief discussion on fabrication costs. X Overall note (for IWE, IWT, IWS and IWP): After fulfilling all requirements defined in a) and b) and c.1 or c.2 of the ANB detailed assessment and after been approved the candidate will be admitted to the final examination defined for the relevant guideline.



Appendix IV: List of Referenced Standards

Standard (-series) Title ASME IX American Society of Mechanical Engineers; Boiler and Pressure Vessel

Code, Section IX: Welding and Brazing Qualifications

EN 287-1 Qualification test of welders - Fusion welding - Part 1: Steels

IIW SST 1093-8 (draft)

IIW recommendation on the application of an engineering critical as-sessment in design, fabrication and inspection to assess the fitness for purpose of welded structures

EN 1418 Welding personnel - Approval testing of welding operators for fusion welding and resistance weld setters for fully mechanized and automatic welding of metallic materials

ISO 2553 Welded, brazed and soldered joints - Symbolic representation on draw-ings

ISO 3834 Quality requirements for fusion welding of metallic materials (series)

ISO 4063 Welding and allied processes - Nomenclature of processes and refer-ence numbers

ISO 5817 Welding - Fusion-welded joints in steel, nickel, titanium and their alloys (beam welding excluded) - Quality levels for imperfections

ISO 9000 Quality management systems (series)

ISO 9606 Approval testing of welders - Fusion welding (series)

ISO 9692 Welding and allied processes - Recommendation for joint preparation

ISO 9712 Non-destructive testing - Qualification and certification of personnel

ISO10042 Welding - Arc-welded joints in aluminium and its alloys - Quality levels for imperfections

EN 12062 Non-destructive examination of welds - General rules for metallic materi-als

ISO 13916 Welding - Guidance on the measurement of preheating temperature, in-terpass temperature and preheat maintenance temperature

ISO 13920 Aluminium and aluminium alloys – Scrap (series)



Standard (-series) Title EN 14324 Brazing - Guidance on the application of brazed joints

ISO 14731 Welding coordination - Tasks and responsibilities

CEN/TR 15135 Welding - Design and non-destructive testing of welds

ISO/TR 15235 Welding - Methods for assessing imperfections in metallic structures

ISO 15607 Specification and qualification of welding procedures for metallic materi-

als - General rules

CR ISO/TR 15608 Welding - Guidelines for a metallic material grouping system

ISO 15609 Specification and qualification of welding procedures for metallic materi-als – Welding procedure specification (series)

ISO 15610 Specification and qualification of welding procedures for metallic materi-als - Qualification based on tested welding consumables

ISO 15611 Specification and qualification of welding procedures for metallic materi-als - Qualification based on previous welding experience

ISO 15612 Specification and qualification of welding procedures for metallic materi-als - Qualification by adoption of a standard welding procedure

ISO 15613 Specification and qualification of welding procedures for metallic materi-als - Qualification based on pre-production welding test

ISO 15614 Specification and qualification of welding procedures for metallic materi-als - Welding procedure test (series)

ISO 17660 Welding - Welding of reinforced steel (series)

ISO 17662 Welding - Calibration, verification and validation of equipment used for welding, including ancillary activities

CR ISO 17663 Welding - Guidelines for quality requirements for heat treatment in connection with welding and allied processes

Documents

IAB 252 07 Personnel Responsibility Welding Coordination