AWS Certified Welding Engineer Program

Introduction

Individuals with AWS Certified Welding Engineer certification have demonstrated their skills for preparing or reviewing written instructions to produce welded joints. They are thoroughly familiar with various codes, specifications, standards, and other aspects of fabrication and assembly. The CWEng often prepares and produces reports, which accurately reflect the professional judgment and is able to work with management representatives, inspection personnel, welders, and support crafts, understanding the integrated role of each in the development of weldments.

The pivotal role of engineers: pre-production to final completion. The welding engineer¹s activities begin before production or construction welding begins and continues through the production process…ending when the production process is complete. Each employer is responsible for defining the specific duties of the CWEng in their place of employment.

NOTE: While the AWS CWEng has established excellent credentials, qualification to this specification alone may not legally qualify the engineer to provide technical services to the public.

Contract documents, building, or jurisdiction laws may require technical services to be performed under the direction and responsibility of others such as a registered Professional Engineer. The AWS CWEng designation DOES NOT imply the status of a registered Professional Engineer (P.E.) under the laws of any state or other governmental entity.

Objectives

• This Course which jointly constitutes this Certified Welding Inspector Exam Preparation course:
• API 1104 Preparation Course:
• This Course Is designed as a preparation for the AWS CWI (QC- 1) Part C Code Book Exam. The Participant will learn how to use the codebook to solve inspection problems.
• Fundamental Welding Inspection Preparation Course:
• This course is designed as a preparation for the AWS CWI (QC- 1) Exam, Part A, and Fundamental welding Inspection Exam. The participant will learn how to take the exam and the basic fundamentals of welding inspection. Information for Inspector training is emphasized in this dual goal course.
• Practical Welding Inspection Preparation Course:
• This course is designed as a preparation for the AWS CWI (QC-1) Exam, part B, practical welding inspection (hands-on) Exam. This course is a must for the nine-year renewal CWI. The participant will learn how to use the tools required for the exam, as well as the AWS Specification Book.
• The participant will receive in-depth instruction pertaining to pass the AWS CWI (QC-1) Exam, as well as insight into the intricacies students may expect to encounter in the working environment. This course is offered as both in-house and an open enrollment class. Topics include:-
• Additionally, quizzes are given at the end of each section; homework is handed at the end of each class day, and is reviewed at the beginning of the following day and a “practice” exam is administered at the end of the course.

Training Methodology

This is an interactive course. There will be open question and answer sessions, regular group exercises and activities, videos, case studies, and presentations on best practice. Participants will have the opportunity to share with the facilitator and other participants on what works well and not so well for them, as well as work on issues from their own organizations. The online course is conducted online using MS-Teams/ClickMeeting.

Who Should Attend?

• Welding Engineer
• Welding Inspector
• Corrosion Engineer
• Any person who involved for Welding Decisions

Course Outline

Day 1: Basic Sciences Fundamentals

• Mathematics:
  • simple calculations (multiple choice)
  • special functions (exp, log)
  • trigonometric functions (sin, cos, tan, cot, sec, csc, degrees, radians)
  • algebraic equations (linear, quadratic, polynomial)
  • graphs and equations (slope, intercept, roots, derivatives, minimum, maximum, interpolation, and extrapolation)
  • geometry (common geometric shapes)
  • hyperbola, parabola
  • complex numbers
  • calculus (fundamentals of differential equations)
  • statistics (population and samples: normal distribution, mean, standard deviation, variance
  • simple correlation: linear regression via least squares method, r2 correlation)
• Physics:
  • unit conversion (dimension, mass, temperature, time, energy, power)
  • mass, weight, volume, density
  • force, energy, work done, power
  • stress, strain, Hooke’s Law (elasticity)
  • moment and momentum
  • temperature, heat, temperature measurement, thermocouples, pyrometers
  • thermal properties of materials (thermal conductivity, thermal expansion, thermal stress and strain)
• Chemistry:
  • symbols (elements and inorganic compounds—gases, fluxes, etc.)
  • molecular weight and stoichiometry
  • acids and bases
  • balance chemical equations
  • gas combustion reactions (chemical heat generation) and oxidation-reduction reactions
  • ideal gas law (pressure, volume, temperature)
  • mass balance (as in E7018 coating decomposition to gas, slag and metal)
  • bulk and chemical analysis methodologies)
  • reactivity, toxicity, environmental effect, disposal.

Day 2: Applied Sciences

• Strength of Materials:
  • load, deformation (elastic and plastic, buckling), stress-strain, Young’s Modulus, shear modulus, stress-strain curve (yield stress, ultimate tensile stress, elongation), tensile stress and
  • shear stress computation
  • welded member cross-section effect
  • mechanical testing (tensile, bend, fracture toughness, hardness, creep, and fatigue) and data interpretation
  • Law of Conservation of Energy/Momentum
  • stress analysis
  • typical engineering material properties
• Heat Transfer and Fluid Mechanics:
  • heat conduction, convection, and radiation, thermal conductivity and diffusivity, heat transfer coefficients of engineering materials, Fourier’s Law
  • heating rate and cooling rate
  • industrial heating methods and power consumption, gas flow rates
  • laminar and turbulent flow (Reynold’s Number), dew point and relative humidity, pressure and regulators
  • venturi effect and gas velocity calculation
  • atmospheric pressure and hyperbaric conditions
  • vacuum equipment and measurements
• Electricity:
  • current, voltage, resistance, impedance, and circuits
  • Ohm’s Law
  • Kirchoff’s Law
  • Resistance loss and current rectification
  • power generation
  • AC/DC, polarity
  • power factor
  • electromagnetic properties,
  • right-hand rule
  • current and voltage measurements (devices and principles)

Day 3: Welding Related Disciplines

• NDE/Weld Discontinuities:
  • NDE processes (radiographic, ultrasonic, magnetic particle, liquid penetrant,
  • eddy current, etc.—characteristics, advantages, and limitations)
  • NDE symbols
• Welding Heat Sources and Arc Physics:
  • power source static and dynamic characteristics (open circuit voltage and short circuiting current, slope)
  • differences between CC and CV designs (principle of self-adjusting)
  • welding arc characteristics (current and voltage relationship, arc length effect)
  • electron emission (ionization potential, work function, electrode material, shielding gas, arc stability)
  • arc temperature and degree of ionization (shielding gas influence)
  • magnetic arc blow (work lead location and condition)
  • Lorentz Force (effect on droplet detachment and on adjacent power cables)
  • shielding gas drag force (effect on droplet detachment and metal transfer mode) weld penetration and width for different shielding gases
• Welding Processes and Controls:
  • arc welding processes (SMAW, GMAW, FCAW, GTAW, SAW, PAW)
  • resistance welding processes (RW, high frequency RW), high energy density welding processes (LBW, EBW)
  • cutting processes (OFC, CAC, and PAC)
  • surfacing processing (SW, THSP)
  • solid-state welding processes (FRW, FW)

Day 4: Welding Related Disciplines 

• Welding and Joining Metallurgy:
  • crystal structure of metals (FCC, BCC, HCP, unit cells, lattice parameter, c/a ratio, atom positions, interstitial positions)
  • melting, and solidification, phase transformations and phase diagrams (eutectic, eutectoid, peritectic and monotectic, lever rule calculation) metallurgy and weldability of typical engineering materials (low carbon structural steels, cast irons, stainless steels, nickel alloys,
  • aluminum alloys, titanium alloys, etc.) microstructure (e.g., ferrous alloys—grain boundary ferrite, acicular ferrite, bainite, martensite, austenite, delta ferrite, etc.) and mechanical properties
  • carbon equivalent (CEIIW, Pcm, expressions, alloying content and carbon content effect)
  • hydrogen assisted cracking (heat-affected zone cracking, cold cracking) base metal matching (e.g., electrodes with high strength steels)
  • solidification cracking (segregation of impurity atoms, shrinkage cracking, lamellar tearing)
  • delta ferrite in stainless consumables, specifications for consumables (categories; all position, rutile, basic)
  • fluxmetal reactions (oxygen and sulfur control in weld pool)
  • typical temperature range of a heat source
  • temperature distribution in a weldment
  • HAZ formation
  • multipass thermal experience, reheated weld metal properties
  • weld macro and micro-graph interpretation
  • solidification profile and preferred grain orientation (epitaxial growth)
  • origin of weld ripples
  • special attributes of base metal (as-cast structure, deformation texture, oxide on flamecut surfaces)
• Welding and Joining Metallurgy (continued):
  • thermal treatments (preheat, postheat, interpass influence on weld cooling rate and residual stress distribution)
  • solid-state transformations in welds (different forms of ferrite, bainite, and martensite, sigma phase in stainless steels, Guinier-Preston type precipitates zones and aging in aluminum alloys)
  • corrosion (sensitization in stainless steel welds, stress corrosion cracking in welds)

Day 5: Welding Related Disciplines

• Weld Design:
  • structural fabrication requirements, sectional properties, stress gradient
  • stress triaxiality, weld symbols, hardness and microhardness (e.g., across a weld cross-section)
  • tensile properties, ductility, toughness, fillet break test (influence of second phase and porosity), ductile fracture, brittle fracture, fatigue
  • (initiation, propagation, failure, high-cycle, low-cycle), temperature and strain rate effect
• Brazing and Soldering:
  • characteristics of brazing and soldering
  • fluxes and substrates
  • capillary action
  • wetting and spreading
  • contact angle
  • joint clearance
  • viscosity
  • liquidus and solidus
  • flow of molten filler in horizontal and vertical joints (maximum penetration and rate)
  • filler metal systems (Sn-Pb solders, Ni and Cu based alloys, Ag-Cu based brazing alloys)
  • intermetallic compound formation
• Safety:
  • recognize health hazards relating to welding (fumes, toxic gases, noise, radiation)
  • recognize safety hazards (electric shock, compressed gases, fire, welding in a confined space, welding on containers and piping, moving equipment)
  • recognize precautions to avoid injury
  • possess a working knowledge of safety and fire codes