Study each topic below — these are the core knowledge areas tested in Year 1. Build a solid foundation here before advancing to Year 2 material.
📖AWS Electrode Classification System
- E6010/E6011: cellulose electrodes for root pass; high penetration, iron powder
- E7018/E7024: low hydrogen iron powder; ductility and impact resistance
- AWS A5.5 stainless steel electrodes; ER308, ER316 classifications and composition
- AWS A5.2/A5.3 filler metal classifications; rod and wire designations per composition
- Specialty electrodes: nickel alloys, cast iron repair, hard-facing applications
🔥Preheat & Interpass Temperature Requirements
- Carbon equivalency (CE) calculation; predicting hardenability and cracking susceptibility
- Preheat requirements based on carbon content and section thickness
- Interpass temperature control; maintaining between minimum and maximum limits
- Post-weld heat treatment (PWHT); stress relief for critical applications
- ASME and CSA requirements; code mandates for different material grades
📖Advanced Joint Design & Qualification
- Complete joint penetration (CJP) vs. partial joint penetration (PJP) design
- Groove angle optimization; balance between material volume and accessibility
- Backing bar use; permanent or temporary backing affecting joint design
- Procedure qualification test (PQT) requirements per CSA W47.1 standard
- Multi-pass qualification; mapping of approval ranges for thickness and diameter
📐Heat Input Calculations & Control
- Heat Input (HI) formula: HI = (V × A × 60) / (1000 × S) in kJ/mm
- Effects of excessive heat input: coarse grain structure, reduced strength
- Effects of insufficient heat input: incomplete fusion and lack of penetration
- Cooling rate control; post-weld heat treatment and thermal management
- Thermal cycling effects; residual stress and distortion minimization
📖Distortion Control & Stress Management
- Types of distortion: longitudinal, transverse, angular, bowing, buckling
- Causes of distortion; uneven heating and cooling during welding
- Prevention techniques: sequence planning, clamping, backstep welding
- Residual stress effects; impact on fatigue life and service performance
- Stress relief methods: thermal PWHT, mechanical stress relief, shot peening
⚙️Non-Destructive Testing (NDT) Methods
- Visual inspection (VT); surface defects, dimensions, and acceptance criteria
- Liquid penetrant testing (PT); surface-breaking defect detection
- Magnetic particle testing (MT); subsurface defect detection in ferrous metals
- Ultrasonic testing (UT); internal defect detection and sizing capability
- Radiographic testing (RT); internal porosity and lack-of-fusion documentation
⚙️Procedure Specification & Welder Certification
- Welding Procedure Specification (WPS) requirements per CSA W47.1
- Procedure Qualification Record (PQR); test data and acceptance criteria
- Welder Performance Qualification (WPQ); individual certification through testing
- Approval range mapping; positions, thicknesses, and diameters covered by qualification
- Re-qualification requirements; time limits and refresh testing procedures
🔧Material Properties & Metallurgy
- Carbon and carbon-manganese steels; ASME and CSA classification
- Chromium-molybdenum steels; high-temperature applications and PWHT requirements
- Stainless steels; austenitic, ferritic, duplex types and corrosion resistance
- Alloying elements; effects on strength, ductility, and hardenability
- Weld metal vs. heat-affected zone properties; mechanical testing focus areas
📋Pipeline Welding Standards
- CSA Z662: Oil and gas pipeline systems; design and construction standards
- ASME B31.1/B31.3: Power piping and refinery piping design codes
- 6G certification; horizontal fixed pipe position qualification standard
- Test coupon preparation and testing procedures per pipeline codes
- Backing ring removal and repair procedures; root pass inspection requirements
📋Quality Assurance & Inspection Standards
- CSA W47.1 standard; qualification and certification requirements for welders
- AWS D1.1; structural steel welding code with acceptance criteria
- ISO 5817; weld defect classification and acceptance levels (Level B, C)
- Destructive testing acceptance levels; tensile and bend test minimum properties
- Documentation requirements; traceability and record retention for code compliance