AWS Certified Welding Inspector — FundamentalsInspector Duties and ResponsibilitiesMedium
A CWI is conducting an in-process inspection of an automatic welding operation. The data logger shows that the welding current consistently fluctuates outside the acceptable range specified in the WPS. The welder states that they are unable to adjust the machine to maintain a stable current due to equipment malfunction. What is the CWI's immediate action?
- AConsult with engineering to determine if the fluctuating current will have a significant impact on weld quality.
- BAllow the welding to continue, but document the fluctuating current and note the welder's explanation.
- CInstruct the welder to attempt to manually compensate for the fluctuations as best as possible.
- DStop the welding operation immediately and require that the equipment be repaired or replaced before resuming.
Show answer & explanationAnswer & explanation
Correct answer: D. Stop the welding operation immediately and require that the equipment be repaired or replaced before resuming.
Consistent fluctuation of welding current outside the WPS-specified range due to equipment malfunction is a critical non-conformance. This directly impacts weld quality and can lead to defects. The CWI must stop the operation to prevent further unacceptable welds until the equipment is rectified.
Why the other options are wrong
- A. While engineering consultation might occur later, the immediate priority is to stop the non-compliant welding.
- B. Allowing welding to continue with known non-compliant parameters is a serious breach of CWI responsibility.
- C. Manual compensation for automatic welding parameter fluctuations is generally not feasible or acceptable.
In-Process Parameter Control
The CWI's responsibility to monitor and ensure that all welding parameters (current, voltage, travel speed, gas flow) remain within the ranges specified by the WPS during welding.
- Deviations can lead to critical weld defects.
- Requires continuous monitoring, often with data loggers.
- Immediate corrective action is necessary for non-compliance.
Memory trick: Parameters Must Be Stable, Or Stop.