AWS Certified Welding Inspector — Fundamentals flashcards

A specialized tool used in visual inspection to measure the size, leg length, and throat thickness of fillet welds, and to check for excessive convexity or concavity.

• Contains various blades or profiles to match weld contours.
• Essential for verifying compliance with weld size specifications.
• Quick and easy to use on the shop floor.

Memory trick: Fillet needs a gauge, general needs a rule, cracks need a magnifier.

The tagout component of Lockout/Tagout (LOTO) provides a warning to others that equipment is de-energized and must not be operated, indicating the reason and responsible party.

• Visual warning.
• Communicates 'do not operate'.
• Identifies who applied the LOTO.
• Supplements the physical lockout device.

Memory trick: Lock Stops, Tag Tells!

The correct proportion of magnetic particles suspended in a liquid carrier to ensure effective detection of discontinuities without excessive background.

• Measured using a centrifuge tube (settling test).
• Too high concentration causes background; too low reduces sensitivity.
• Must be checked regularly during inspection.

Memory trick: Concentrate your particles, illuminate your findings, measure your bath.

For flare-V groove welds, the dimension to the left of the weld symbol usually specifies the effective throat, which is the minimum distance from the root of the weld to its face.

• Specific to flare-type grooves.
• Dimension on the left.
• Represents weld strength/size.

Memory trick: Flare-V's 'effective' size is on the 'left' side.

To indicate that a backing strip must be removed after welding, the letter 'R' is placed within the standard backing symbol on the welding drawing.

• Backing symbol is usually a rectangle.
• 'R' inside means remove.
• Ensures no permanent backing material.

Memory trick: The 'R' inside the 'brick' means 'remove' the backing.

For groove welds, the root face dimension is typically shown below the root opening dimension or as the second dimension in a sequence of root dimensions.

• Part of groove weld preparation.
• Indicated below root opening.
• Ensures proper root fusion.

Memory trick: ROOF: Root Opening, then Root Face, then Groove Angle.

Factors that reduce the intensity or amplitude of an ultrasonic signal as it travels through a material.

• Includes scattering, absorption, and beam divergence.
• Surface conditions, material properties, and transducer parameters affect attenuation.
• Leads to reduced signal-to-noise ratio and missed indications.

Memory trick: Rough surfaces scatter sound like a broken mirror scatters light.

Welding gloves, typically made of leather, provide electrical insulation to protect the welder from electric shock during welding operations.

• Dry leather is an effective insulator.
• Protects against accidental contact with live parts.
• Damaged or wet gloves compromise insulation.

Memory trick: Gloves are your shield, keeping current at bay, so you can weld safely every day.

The groove angle, or included angle of a groove weld, is commonly indicated by a numerical value (in degrees) placed immediately to the right of the groove weld symbol.

• Indicates the total angle of the groove opening.
• Expressed in degrees.
• Located to the right of the groove weld symbol.

Memory trick: Angle's to the Right of the Groove.

In Magnetic Particle Testing (MT), to ensure detection of discontinuities of all orientations, the component should be magnetized in at least two directions, typically 90 degrees apart, or a multi-directional field should be applied.

• Flaws detected perpendicular to magnetic field.
• Single direction misses some flaws.
• Two directions (e.g., 90° apart) ensure coverage.
• Can be achieved by rotating yoke or using systems with multiple fields.

Memory trick: Lines cross the defect, not run with it.

Due to the high fume generation of flux-cored arc welding (FCAW), advanced respiratory protection like Powered Air-Purifying Respirators (PAPRs) are often necessary.

• FCAW produces heavy fumes.
• Fumes contain metallic particles and flux chemicals.
• PAPRs offer superior respiratory protection.

Memory trick: FCAW's fumes are no joke, a PAPR's your best respiratory cloak.

The concave contour symbol, resembling an inward curve, indicates that the weld face should be curved inward from the toes of the weld.

• Looks like an inverted arc.
• Located above or below the weld symbol.
• Specifies weld face shape.

Memory trick: Convex 'e' bulges out, Concave 'a' caves in, flush is just flat.

The placement of a groove weld symbol (e.g., bevel, V, U) on the reference line indicates which member of the joint is to be prepared (e.g., beveled) for the weld.

• Symbol on arrow side: Preparation on arrow-side member.
• Symbol on other side: Preparation on other-side member.
• Symmetric groove symbols (e.g., V-groove) typically imply preparation on both members if on both sides of the reference line.

Memory trick: Where the symbol sits, there the bevel fits.

The diameter of a spot weld is indicated on the welding symbol by the 'ø' (diameter) symbol followed by a numerical value, representing the nominal size of the weld nugget.

• Dimension is typically in millimeters.
• Placed directly on the spot weld symbol.
• Refers to the effective diameter of the weld.

Memory trick: Circle Size is Diameter.

The notation 'Number @ Pitch' (e.g., 6 @ 100) for an intermittent weld specifies the total number of individual weld segments and their center-to-center spacing (pitch).

• Indicates quantity and spacing.
• Often used when length is standard or implied.
• Distinct from 'length-pitch' notation.

Memory trick: Segments and Spacing: 'Length-Pitch' or 'Number @ Pitch'.

Mechanical damage refers to surface or subsurface discontinuities caused by external mechanical forces like grinding, impact, or abrasion, resulting in indentations, gouges, or scratches.

• Caused by external forces.
• Includes dents, gouges, scratches.
• Visible on the surface.
• Distinguished from inherent material defects.

Memory trick: Look at the base metal, not just the weld.

A type of groove weld used when one or both members being joined have a curved surface, where the natural curvature forms part of the groove.

• Typically used for joining a round bar/pipe to a flat plate.
• The 'flare' refers to the curved surface.
• The other member is usually beveled to fit the curve.
• Symbol is a curved line with a straight line.

Memory trick: Grooves are cut, flares are curved, J-U-V are shapes.

A discontinuity whose length is significantly greater than its width, appearing as a line or elongated mark during visual inspection.

• Examples include cracks, undercut, and lack of penetration.
• Often more critical than volumetric discontinuities due to stress concentration.
• Detected visually by observing distinct elongated features.

Memory trick: Lines are long, points are short, planes are flat.

A lead screen placed behind the radiographic film (film side) primarily absorbs scattered radiation generated within the object, improving image contrast and reducing fogging.

• Reduces scatter, which degrades image quality.
• Leads to higher contrast and better definition.
• Also provides some intensifying action, though less than the front screen.

Memory trick: Front intensifies, back stops scatter, both help the image matter.

Phased array ultrasonic testing (PAUT) utilizes multiple small ultrasonic elements in a single probe to electronically steer, focus, and scan the ultrasonic beam without physical probe movement.

• Enables inspection of complex geometries and curved surfaces.
• Allows for multiple beam angles and focal depths from one probe.
• Generates real-time, detailed cross-sectional images (B-scans, C-scans).

Memory trick: Single is simple, phased is smart, both find flaws with a sound heart.

In Radiographic Testing (RT), scatter radiation can degrade image quality (cause haziness). Using lead screens is a primary method to absorb scatter and improve film clarity.

• Scatter radiation causes film haziness.
• Lead screens absorb scatter.
• Front screen reduces scatter entering film from object.
• Back screen reduces backscatter from objects behind film.

Memory trick: Contrast, Definition, Sensitivity: Controlled by kV, SFD, and Scatter.

High voltage electrical circuits pose a significant risk of severe electric shock, which can cause serious injury or death due to the body's reduced resistance at higher voltages.

• Voltage is the 'push' of electrical current.
• Higher voltage can overcome body resistance more easily.
• Electric shock can cause cardiac arrest, burns, muscle contractions.

Memory trick: High Voltage, High Danger, Higher Shock!

Damaged insulation on welding cables exposes live electrical conductors, posing severe risks of electric shock to personnel and potential short circuits leading to fires or equipment damage.

• Insulation protects against shock.
• Exposed wires are live and dangerous.
• Can cause short circuits and fires.
• Requires immediate repair or replacement.

Memory trick: Bare Wires Bite, So Keep Them Tight!

An acute illness caused by inhaling metal oxide fumes, often zinc oxide, characterized by flu-like symptoms, fever, chills, nausea, and sometimes a sweet taste in the mouth.

• Caused by inhaling metal oxide fumes (e.g., zinc oxide).
• Symptoms include fever, chills, nausea, dizziness.
• Often associated with welding galvanized steel.

Memory trick: When zinc gets hot, the fumes start to float, making you feel sick, like a rocking boat.

Before performing hot work on containers that held flammable materials, they must be thoroughly cleaned, purged with inert gas, or filled with water to eliminate residual vapors and prevent explosion.

• Flammable liquids leave explosive vapors.
• Cleaning alone may not be sufficient.
• Inert gas purging or water filling are effective methods.

Memory trick: Purge the Pipe, Prevent the Pop!

Excessive convexity (for fillet welds) or excessive reinforcement (for groove welds) is a discontinuity where the weld metal extends too far above the theoretical weld face or base metal surface, exceeding specified limits.

• Weld profile is too high.
• Exceeds WPS or code limits.
• Can lead to stress concentrations.
• Often visually apparent.

Memory trick: Too high, too low, or just right.

Magnetic writing is a non-relevant indication in Magnetic Particle Testing (MT) that appears as broad, fuzzy, or indistinct lines, often caused by localized magnetism from friction or impact, rather than a material discontinuity.

• Non-relevant indication.
• Caused by localized residual magnetism.
• Appears broad, fuzzy, indistinct.
• Does not represent a defect.

Memory trick: Sharp lines mean cracks, fuzzy lines often mean friction.

In welding symbols, the length of a weld is indicated by a number placed to the right of the basic weld symbol. For intermittent welds, the pitch (center-to-center spacing) is specified after the length, separated by a dash.

• Length = number to the right of the weld symbol.
• Pitch = number after a dash, following the length (e.g., 50-100).
• If no length is specified, the weld is continuous for the full length of the joint.

Memory trick: Length is right, pitch is dashed, size is left, depth is within.

The tail of a welding symbol is used to convey supplementary information not otherwise covered by standard symbols, often including references to specifications, processes, or qualification requirements.

• WPQ in the tail refers to Welder Performance Qualification.
• Other common abbreviations include WPS (Weld Procedure Specification), NDE methods, or special instructions.
• Ensures the welder performing the task is certified for the specific weld.

Memory trick: Tail tells the tale: procedures, processes, people.

Dry magnetic particles offer benefits like suitability for hot surfaces, rough welds, and detecting some subsurface flaws, compared to wet methods.

• Can be used on surfaces up to 600°F (315°C).
• Effective on rougher surfaces where wet methods might drain or pool.
• Often used for detecting larger, deeper flaws or subsurface indications.

Memory trick: Dry for hot and rough, wet for fine and smooth.

The minimum distance fire extinguishing equipment must be located from hot work operations to ensure immediate access in case of fire.

• ANSI Z49.1 standard applies.
• Minimum distance is 35 feet (10 meters).
• Ensures quick access for fire control.

Memory trick: Thirty-five feet, not too far, not too near, keeps the fire from spreading, have no fear.

After removing excess liquid penetrant, the inspection surface must be thoroughly dried before applying developer to ensure accurate defect detection.

• Moisture interferes with developer action.
• Insufficient drying can mask discontinuities.
• Over-drying can evaporate penetrant from shallow defects.

Memory trick: Clean, Penetrate, Remove, Dry, Develop, Inspect, Clean.

Dual-element (pitch-catch) transducers in UT offer improved near-surface resolution and a reduced dead zone compared to single-element transducers, making them ideal for detecting flaws close to the inspection surface.

• Separate transmitter and receiver.
• Eliminates dead zone caused by single element ringing.
• Excellent for near-surface flaw detection.
• Often used for corrosion mapping and thin materials.

Memory trick: One ear and mouth, or two dedicated ones.

A fire watch must be stationed within a specific distance, typically 35 feet (10.7 meters), of hot work operations to monitor for and promptly extinguish any fires.

• Sparks and slag can travel significant distances.
• 35 feet is a common regulatory minimum.
• Fire watch must have fire extinguishing equipment readily available.
• Fire watch remains for at least 30 minutes after hot work.

Memory trick: Thirty-Five Feet, No Retreat for the Heat!

A painful inflammation of the cornea caused by exposure to intense ultraviolet (UV) radiation from a welding arc, even brief exposure can cause it.

• Caused by UV radiation from welding arc.
• Symptoms include pain, gritty feeling, light sensitivity.
• Can occur from even brief exposure (e.g., tack welds).

Memory trick: UV from the arc, even a flash, can make your eyes feel like they're going to crash.

A supplementary symbol used in welding drawings to indicate that the face of the weld should be flat and flush with the surface of the adjacent base metal.

• Represented by a straight line.
• Placed above or below the basic weld symbol, on the reference line.
• Often accompanied by a finish symbol (e.g., G for grinding) to specify the method to achieve flushness.

Memory trick: Contours shape the weld's face, flushness is a flat space.

The tail of the welding symbol is an optional addition used to convey supplementary information, often including specifications, processes, or other references.

• Located at the end of the reference line, opposite the arrow.
• Used for specific instructions, codes, or processes.
• Can contain abbreviations like 'PWHT', 'WPQ', 'NDE' codes etc.

Memory trick: Tail's Tale Tells Extra Details.

On a radiograph, a slag inclusion appears as a dark, irregular, and often elongated indication within the weld metal, typically with random orientation.

• Dark indication (lower density than parent metal).
• Irregular shape, often elongated.
• Randomly oriented.
• Located within the weld bead.

Memory trick: Each defect has its own X-ray signature.

Safe storage of compressed gas cylinders requires them to be secured in an upright position to prevent falling and potential valve damage or rupture.

• Store cylinders vertically.
• Secure with chains or racks.
• Falling cylinders can become dangerous projectiles.

Memory trick: Stand up tall, but don't you fall, secure your tank, or risk it all.

Measures taken to prevent welding cables from causing fires, primarily focusing on maintaining insulation integrity and preventing overheating.

• Damaged insulation causes shorts and arcs.
• Overheating cables can ignite combustibles.
• Regular inspection of cables is crucial.

Memory trick: Cable integrity is key, keeping sparks from breaking free.

The process of determining the precise origin of an acoustic emission event within a material by analyzing the arrival times of the acoustic waves at multiple sensors.

• Achieved using Time Difference of Arrival (TDOA) techniques.
• Requires multiple sensors (typically 4 or more) and known sound velocity.
• Allows for pinpointing active flaws like growing cracks or corrosion.

Memory trick: Hear the crack, time the sound, find the flaw all around.

Eye protection, such as safety glasses or face shields, is mandatory for grinding operations to prevent injury from flying debris, sparks, and abrasive particles.

• Grinding produces high-velocity projectiles.
• Eye injuries can be permanent.
• Safety glasses and face shields are common PPE.

Memory trick: Prioritize Protection, Especially Eyes from Impact!

A fine, absorbent powder applied to the surface after penetrant removal, which acts to draw penetrant from flaws and make indications visible.

• Acts as a blotter, creating a visible bleed-out.
• Comes in various forms: dry, wet, non-aqueous.
• Provides contrast for better visibility of indications.

Memory trick: Clean, Penetrate, Remove, Develop, Inspect.

The size of a fillet weld, typically its leg length, is indicated by a dimension placed on the same side of the reference line as the weld symbol.

• Dimension above for arrow side weld.
• Dimension below for other side weld.
• Dimension represents leg size.

Memory trick: Size is on the side, length is to the right.

A confined space is an area that is large enough for a person to enter and perform work, has limited or restricted means for entry or exit, and is not designed for continuous human occupancy.

• Large enough for entry and work.
• Limited entry/exit points.
• Not designed for continuous occupancy.
• Potential for atmospheric or other hazards.

Memory trick: Limited Entry, Not for Living, Likely Lacking Air!

Ozone (O3) is a gas formed by the reaction of atmospheric oxygen with the intense ultraviolet radiation produced during arc welding, recognizable by its pungent odor and causing respiratory irritation.

• Formed by UV radiation from arc welding.
• Pungent, bleach-like odor.
• Causes respiratory irritation and lung damage.

Memory trick: UV light makes ozone, a pungent smell it has shown, irritating lungs, making breathing moan.

A shrinkage cavity in a weld bead, typically occurring at the termination of the weld.

• Forms when the welding arc is broken too quickly.
• Appears as a circular or elongated depression.
• Can be a source of crack initiation.

Memory trick: Weld craters are like volcanic peaks, but inverted at the end.

Underfill is a weld discontinuity where the weld face or root surface is below the adjacent surface of the base metal, often resulting in a concave profile in fillet welds.

• Weld metal insufficient to fill joint.
• Surface depression below base metal.
• Reduces weld throat or leg size.
• Common in fillet welds with concave profile.

Memory trick: Look for the highs and lows, the gaps and overlaps.

Liquid Penetrant Testing (PT) is a versatile NDE method for detecting surface-breaking discontinuities in non-porous materials, effective on both ferromagnetic and non-ferromagnetic metals, and adaptable to complex geometries.

• Detects surface-breaking flaws only.
• Requires non-porous material.
• Applicable to both ferromagnetic and non-ferromagnetic.
• Good for complex shapes and rough surfaces (within limits).

Memory trick: Match the defect, material, and geometry to the NDE.

In Acoustic Emission Testing (AE), a 'burst' signal is a discrete, transient elastic wave indicating a sudden release of energy from a localized event within the material, such as crack initiation or propagation.

• Discrete, transient signal.
• Indicates sudden energy release.
• Associated with active damage mechanisms.
• Commonly linked to crack growth.

Memory trick: Bursts are cracks, continuous is noise or steady change.

For resistance spot welds, the required shear strength per spot, if not otherwise dimensioned, is indicated by a number placed above or below the spot weld symbol.

• Dimension above/below symbol.
• Represents shear strength.
• Units often in pounds or kilonewtons.

Memory trick: Shear strength is 'above' the spot, like a force.

An ultrasonic transducer that introduces sound waves into the material perpendicular (at a 0-degree angle) to the test surface.

• Used for detecting discontinuities parallel to the surface.
• Commonly used for thickness measurement and detection of laminations.
• Produces longitudinal waves.

Memory trick: Normal is straight, angle is bent, surface is a special friend.

For a plug weld symbol, the depth of filling is indicated by a dimension placed inside the circle representing the plug weld.

• Dimension inside the circle.
• Represents the depth of fill.
• Different from diameter, pitch, or quantity.

Memory trick: Inside the hole is how 'deep' it goes.

A heat treatment process applied to stainless steels to dissolve undesirable phases, such as chromium carbides, and restore uniform corrosion resistance.

• Involves heating to a high temperature (typically 1000-1150°C for austenitic stainless steels).
• Followed by rapid cooling (quenching) to prevent reprecipitation of carbides.
• Restores chromium to solid solution, improving corrosion resistance.

Memory trick: Corrosion's grip can be released by a hot solution and a quick chill.

A weld discontinuity where the weld metal extends beyond the toe or root of the weld, over the surface of the base metal, without being fused to it.

• Appearance: convex weld bead that 'rolls over' the edges.
• Occurs at the weld toe or root.
• Indicates lack of fusion in the overlapping area.
• Often caused by low travel speed, incorrect electrode angle, or low heat input.

Memory trick: Overlap is when the weld metal 'laps over' without sticking.

The ability of a material to resist permanent deformation under prolonged stress at elevated temperatures.

• Critical for high-temperature applications
• Influenced by alloying elements
• Related to microstructural stability
• Temperature and stress are key factors

Memory trick: Mo makes it strong, even when it's hot for long.

A heat treatment process in steel involving heating above the critical temperature, followed by air cooling, to refine grain structure and improve mechanical properties like ductility and toughness.

• Refines grain structure
• Improves ductility and toughness
• Reduces internal stresses
• Air cooling is characteristic

Memory trick: Normalize the grains by letting them cool naturally.

Martensite is a very hard and brittle microstructure formed by rapid cooling of steel, and its presence significantly increases the steel's susceptibility to hydrogen-induced cracking (HIC).

• Martensite is highly stressed and brittle.
• Its lattice structure provides traps for hydrogen.
• Low fracture toughness makes it prone to cracking under hydrogen and stress.
• Formation is controlled by cooling rate and alloying elements (hardenability).

Memory trick: Martensite's rigid grip holds hydrogen, leading to a sudden, brittle break.

The addition of specific elements to steel to improve its resistance to permanent deformation (creep) when subjected to prolonged stress at elevated temperatures.

• Involves elements that form stable carbides or intermetallic compounds.
• These precipitates resist coarsening and dissolution at high temperatures.
• Carbides pin grain boundaries, preventing grain boundary sliding.
• Elements like Mo, V, Cr, W are effective for this purpose.

Memory trick: Mo's carbides are the anchors that hold strength at scorching heights.

A heat treatment process that involves heating a metal to a specific temperature, holding it there, and then slowly cooling it to relieve internal stresses, soften the material, and improve ductility.

• Increases ductility and toughness.
• Reduces hardness and strength.
• Relieves internal stresses.
• Refines grain structure.

Memory trick: Annealing's gentle path makes metal soft and pliable.