AWS Certified Welding Inspector — FundamentalsInspector Duties and ResponsibilitiesMedium
A CWI is conducting a post-weld visual inspection of a structural steel connection fabricated to AWS D1.1. The WPS specifies a 5/16-inch fillet weld. The CWI measures several areas of the weld and finds the actual leg size to be consistently 1/4 inch. What is the appropriate next step for the CWI?
- ADocument the undersized weld and issue a Non-Conformance Report (NCR).
- BConsult the project engineer to see if the undersized weld can be approved by deviation.
- CRequire the welder to add an additional pass to increase the leg size to 5/16 inch.
- DAccept the weld, as a 1/16-inch undersize is generally acceptable.
Show answer & explanationAnswer & explanation
Correct answer: A. Document the undersized weld and issue a Non-Conformance Report (NCR).
According to AWS D1.1, undersized fillet welds are considered defects if they fall below specified tolerance limits. For a 5/16-inch fillet weld, a consistent 1/4-inch leg size (1/16 inch undersize) exceeds the typical permissible undersize of 1/32 inch for fillet welds less than 3/8 inch. Therefore, it is a non-conformance that must be documented and addressed.
Why the other options are wrong
- B. Consulting an engineer for a deviation is a possible subsequent step, but the CWI's immediate responsibility is to identify and document the non-conformance.
- C. While adding a pass might correct the issue, the CWI's immediate step is to document the non-conformance, not to instruct repair without proper procedure.
- D. This is incorrect. A 1/16-inch undersize for a 5/16-inch fillet weld is typically not acceptable per AWS D1.1 without specific allowances.
Fillet Weld Undersize
A condition where the leg size of a fillet weld is smaller than that specified in the WPS or required by the applicable code, potentially reducing strength.
- Typically a defect if exceeding code-specified tolerance.
- AWS D1.1 has specific limits for undersize, often 1/32 inch for smaller fillets.
- Requires documentation and disposition (repair, accept-as-is with engineering approval, or reject).
Memory trick: Measure the weld, compare to spec, if it's small, it's a defect.