Minimum Requirements Iwe [PDF]

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Doc. IAB-002-2000/EWF-409 Revision2

MINIMUM REQUIREMENTS FOR THE EDUCATION, TRAINING, EXAMINATION, AND QUALIFICATION OF PERSONNEL

International Welding Engineer (IWE)

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Published by: IIW – IAB Secretariat C/o ISQ TagusPark - Apartado 012 – CTT Porto Salvo P-2780-994 PORTO SALVO - OEIRAS – PORTUGAL Tel: Fax: E-mail:

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+351.21.4211351 +351.21.4228122 [email protected]

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TABLE OF CONTENTS

Preface..................................................................................................................................... 3 1. Introduction

........................................................................................................................... 4

2. Routes to Qualification ............................................................................................................... 5 3. General Access Conditions ........................................................................................................ 5 4. Special Requirements................................................................................................................ 6

Section I: Theoretical and Practical Education, Syllabus and Performance Objectives............................................................................................. 8 I.1 Theoretical Education .............................................................................................................. 8 I.2 Practical Education................................................................................................................. 40 Section II: Examination and Qualification ...................................................................................... 41 Appendix I: Requirements for Equipment, Facilities and Specimens for the IWE course leading to the award of IIW qualification ...................................................................... 44 Appendix II: Abbreviations ........................................................................................................... 45 Appendix III: ANB Check ............................................................................................................. 46 Appendix IV: ANB Detailed Assessment ....................................................................................... 47

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Preface This document is based upon the European Welding Engineer as developed by the European Federation for Welding, Joining and Cutting (EWF), through an Agreement first signed 19 July, 1997, at the Annual Meeting of the International Institute of Welding (IIW) in San Francisco, California, USA and which has been renewed and further developed since then. It is established in that Agreement that the International Welding Engineer Diploma is equivalent to the European Welding Engineer Diploma. The former EWF ANBs may issue the European Welding Engineer diploma for 5 years and/or as long as it is referenced in the standard EN 719 and standard ISO 14731 (which ever is longer). Copies of this document are available from the IIW IAB Secretariat or their designated distributor.

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Doc. IAB-002-2000/EWF-409 Revision2 SECTION 1 MINIMUM REQUIREMENTS FOR THE EDUCATION, TRAINING, EXAMINATION AND QUALIFICATION OF PERSONNEL INTERNATIONAL WELDING ENGINEER (IWE)

1.

Introduction

This guideline for the international education, training, examination and qualification of Welding Engineers has been prepared, evaluated and formulated by Group A “Education, Training and Qualification” of the International Authorisation Board (IAB) of the International Institute of Welding IIW. Section I of the guideline covers the minimum requirements for education and training, agreed upon by all IIW Authorised National Bodies (ANB), in terms of objectives, scope, expected results and recommended times to be devoted achieving them. It will be revised periodically by IAB Group A to take into account any changes which may affect the "state of the art". Students having successfully completed this course of education and the appropriate examinations will be expected to be capable of applying the technology required in welding engineering as covered by this guideline. Section II of the guideline covers the rules for examination and qualification. The contents are given in the following structure: Theoretical Education 1. Welding processes and equipment

Recommended teaching hours 97 ( 35)

2. Materials and their behaviour during welding

110 ( 36)

3. Construction and design

64 ( 12)

4. Fabrication, applications engineering

110 __ Subtotal 381 ( 83)

Fundamental practical skills

60 total :

441

Figures with and without brackets are given for the Standard Route (see 4.1)

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Routes to Qualification

Three distinct routes to gaining the qualification described in this document have been agreed. 1. The Standard Route 2. The Alternative Route 3. Distance Learning Programs 2.1

The Standard Route

The Standard Route requires attendance at IIW accredited Training Courses designed to meet all the requirements in this Guideline. This is the route (Route 1 in diagram 1) recommended by the Committee as offering the fastest, most comprehensive manner in which the syllabus may be covered. The Standard Route also allows for a limited amount of prior learning to be taken into account, for example during University courses or by distance learning (Route 2 in diagram 1). This prior learning shall be approved by the ANB. 2.2

The Alternative Route

The Alternative Route allows those who have gained the knowledge of the syllabus in the full detail defined n i this Guideline and who can demonstrate their capability in all respects, to proceed to examination without compulsory attendance at an ANB approved Training Course. 2.3

Distance Learning Programs

In addition Part I of the IWE may be taught in Distance Learning Programs under control of the ANB as approved by an IAB assessment. Lectures of Part III may be taught following the Distance Learning Guideline IAB xxxx. 3.

General Access Conditions

It is agreed that entry to such a program should be on a postgraduate level.. Participants should have a primary degree in an engineering discipline or its equivalent recognised by the national government and assessed by the ANB. Therefore, it would be expected that participants should have at least a Bachelor degree. In a separate document (Directory of Access Conditions) the definitions for every country are given in detail. Applicants not fulfilling the access conditions may follow the course as guests, but entry to the IIW examination is not permitted. In case of co-operation arrangements e.g. with universities, according to which basic parts of the course (IWE Part I in the following structure) are given under careful control of the ANB, before the participant complies with the access conditions (access route 2), the following conditions shall be observed: 1. Students who have successfully passed the intermediate examination of Part I of the IWE course are allowed to attend Part II of the IWE course; 2. Students who have authenticated evidence that they have passed the examinations in all subjects of their engineer study – except the diploma thesis – are allowed to attend Part III of the IWE course and the corresponding written parts of the final examination; 3. Students shall present their degree diploma to the Board of Examiners before being allowed to take the final oral examination for IWE. 4. All procedures are under the responsibility of the ANB.

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all university exams passed

Route 1 IWE I Max. 837 h

1

Route 2

IWE II 60 h

IWE III Min. 297 300 h

Intermediate examination

Engineer’s Diploma W E

O E

Final examination

2 WE: written examination OE: oral examination

Diagram 1 The rules for the conduct of the final examination by the ANB are prescribed under Examination and Qualification (Section II) in this guideline. The intermediate examination is mandatory for access route two and it is the responsibility of the training school to ensure that those entering by this route two have achieved the required knowledge to enter Part II of the course. Failure in the intermediate examination will require the student to enter Part I of the course. 4.

Special Requirements

4.1

Standard Route

An applicant shall satisfy the ANB access conditions. If the ANB decides that the access conditions are adequately met, the applicant is then required to attend a training course conducted by an Authorised Training Body (ATB) giving as a minimum the hours of instruction detailed in this Guideline as recommended teaching hours. At the conclusion of this course of instruction the student may enter the examinations for the award of the IIW Diploma. The maximum amount of hours of the lectures, which can be included in an IWE Part I are given in brackets in the following definition of the theoretical education. The definition of the precise syllabus of Part I is the responsibility of the ANB. A "teaching hour" shall contain at least 50 minutes of direct teaching time. It is not obligatory to follow exactly the order of the topics given in this guideline and choice in the arrangement of the syllabus is permitted. The depth to which each topic is dealt with is indicated by the number of hours allocated to it in the guideline. This will be reflected in the scope and depth of the examination. 4.2

Alternative Route

An applicant shall submit to the ANB together with an application form: Ø A copy of a diploma showing graduation in an engineering subject complying with the Access Conditions. Ø A curriculum vitae (CV)/ resume containing professional information • Evidence of at least four years job function in welding at the level of an engineer (in a period of six years before application) • A justification of candidate’s experience, training, and education to become IWE (may include other test results)

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Doc. IAB-002-2000/EWF-409 Revision2 The ANB shall determine (paper check, Appendix III)) if the application is suitable for further detailed assessment (Appendix IV).

Routes to Qualification (Standard and Alternative Route)

Details of Standard Route see also Diagram 1

Standard Route

IWE I

Intermediate Examination

IWE II

IWE III

At the discretion of the ANB

• •Engineering Engineeringdegree degree(see (seeaccess accessconditions) conditions) • •Curriculum vitae resumé Curriculum vitae - resumé(professional (professional information) information) ––min. min.44years yearsjob jobfunction functionininwelding welding (engineers (engineerslevel) level) ––justification justificationofofcandidate‘s candidate‘sexperience, experience, training, and education training, and educationtotobecome becomeIWE IWE (may (mayinclude includeother othertest testresults) results)

no

Final Examination

IWT IWS

no

ANB check check

yes

ANB ANB detailed detailed assessment assessment

yes

Alternative Route Diagram 2

The rules for the conduct of the final examination by the ANB are described in Section II: “Examination and Qualification” of this guideline.

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Section I:

Theoretical and Practical Education, Syllabus and Performance Objectives

(Figures are minimum teaching hours. Those in brackets are maximum teaching hours which can be included in IWE Part I)

I.1.

Theoretical Education IWE I and IWE III Recommended hours

Module 1: Welding processes and equipment 1.1

General introduction to welding technology

3 (3)

Objective: Understand the developments in welding processes including accepted terminology, standards and abbreviations. Scope: History Definitions and terminology Schematic presentation of welding processes General applications for welding Abbreviations in use for welding processes Classification of welding processes (IIW, ISO, CEN and national standards) Expected Result: 1. Detail the differences between each major type of welding process, e.g. fusion, resistance, flame, forge, etc. 2. Differentiate between processes with reference to standards. 3. Recognise a welding process by the common abbreviation. 4. Explain the historical evolution of welding.

1.2

Oxy-gas welding and related processes

2 (2 )

Objective: Understand the fundamentals of oxy -gas combustion, characteristics of the different fuel gases, equipment, safety and typical applications. Scope: Process principles Characteristics of fuel gases, (acetylene, propane, etc.) Combustion reactions, types of flames Temperature distribution effects Equipment Fuel gases generation Handling and storage of gases Typical joint design for welding, Welding techniques, rightward, leftward Standards for filler materials Welding applications, typical problems Special techniques and their methods of use (preheating, straightening, cleaning, etc.) Health and safety specific to the process Expected Result: 1. Explain fully the characteristics of the three flame types and reasons for application of each. 2. Detail the characteristics of flames from different fuel gases. 3. Define comprehensively potential hazards and methods of safe handling and working. 4. Explain the purpose and working principle of each component of the equipment. 5. Interpret appropriate standards.

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1. 3

Electrotechnics, a review

2 (2)

Objective: Understand the basics of electricity and electronic components used in electrical welding power sources. Scope: Basics of electricity and electronics (what is current, voltage and resistance), Ohm's Law Parallel and series circuits Direct current (DC), polarity, alternating current (AC) Magnetism in welding Capacity, condensor Transformer, and rectifying bridge (half wave and full wave) Transistor, thyristor Inductance, inductors Hazard Health and safety Expected Result: 1. Explain current, voltage and electrical resistance. 2. Detail the functions of the most important components of welding power sources. 3. Discuss competently the differences between DC and AC current. 4. Interpret and apply knowledge of electricity and electronics to welding applications.

1. 4

The Arc

4 (4)

Objective: Understand in detail the fundamentals of an electric arc, its characteristics, limitations and application in welding, including arc stability problems. Scope: Arc physics (production of an electric arc, the main arc areas, stability of the arc) Voltage distribution across the arc Heat generation at the cathode and anode Polarity and arc characteristics in AC and DC and its control Influence on the welding process Temperature distribution in the arc and effects Influence of the magnetic fields on the arc (why, how to solve) Limits of application Expected Result: 1. Explain in detail the physical fundamentals of an electrical arc, including the major parameters influencing arc stability. 2. Detail arc heat generation, and the arc voltage distribution. 3. Deduce the influence of magnetic fields on the electric arc. 4. Predict how to solve magnetic deflection problems. 5. Explain arc characteristics for DC and AC including control and limitations.

1.5

Power sources for arc welding

4 (4)

Objective: Understand in detail the characteristics and main components of arc welding power sources.

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Doc. IAB-002-2000/EWF-409 Revision2 Scope: Power source classification, types and characteristics (static and generators, and each sub-group) Power source electrical characteristics (static curves and dynamic curves) Relationship between static curves and welding process Control of the electrical static curve characteristics (flat and drooping) Arc stability curve for the main processes (MMA, TIG, MIG/MAG, SAW, PAW) The operation point Inverter technology Power sources controlled by a CPU Stability of processes in AC and DC AC (sinusoidal and square) and DC power sources Open circuit voltage, short circuit current, power factor of transformers Duty cycle of a power source and typical values for the most common arc welding processes Voltage losses, relationship between current and cable section Pulse techniques Arc striking types and devices, slope up and down, pre- and post-flow Current and voltage set up (electromagnetic and electronic devices) Expected Result: 1. Explain each type of arc welding power source both AC and DC including the most common devices used. 2. Detail for each type of arc welding power source the static and dynamic electrical characteristics, operation point and control of arc stability. 3. Explain the meaning of open circuit voltage, short circuit current, duty cycle of a power source, voltage losses, and current to cable section relationship. 4. Explain the differences of the above characteristics for each type of power source and welding process.

1. 6

Introduction to gas shielded arc welding

2 (2)

Objective: Understand the principles and physical phenomena of gas shielded welding processes. Scope: Physical phenomena and working principles of TIG, MIG/MAG and Flux-cored Shielding gases (inert, active) and their effect on arc characteristics Handling and storage of gases Filler materials Standards (International and National) for shielding gases and filler materials Expected Result: 1. Explain the characteristics and working principles of TIG, MIG/MAG and Flux-cored welding. 2. Interpret arc characteristics associated with each type of shielding gas used for each process. 3. Detail methods for safe handling and storage of shielding gases. 4. Interpret and use standards for shielding gases and filler materials.

1. 7

TIG Welding

6 (4)

Objective: Understand in detail TIG welding fundamentals, including equipment, applications, procedures and common problems. Scope: Power source characteristics Arc ignition techniques and necessary equipment Equipment and accessories: torches, gas lens, panel control, up and down slope, pulse techniques Effect of current and polarity: DC(+), DC(-) and AC Appropriate use for different materials, e.g. Al Consumables: shielding gases, filler materials, electrodes

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Doc. IAB-002-2000/EWF-409 Revision2 Welding parameters: current, voltage, welding speed, gas flow Joint preparation: typical joint design for welding, fit-up, cleaning Welding procedures Typical problems and their solution Special techniques: spot-welding, hot-wire, orbital welding, tube to tube and tube to sheet Standards for filler materials, electrodes, and gases Welding applications, typical problems Health and safety specific to the process Expected Result: 1. Explain in detail the principles of TIG welding including arc ignition techniques and their applications. 2. Explain the selection of appropriate type of current, polarity, shielding gas and electrode according to application. 3. Detail the range of application, appropriate joint preparations and potential problems to be overcome. 4. Detail appropriate welding parameters for particular applications. 5. Explain the purpose and functions of each component of the equipment and accessories. 6. Interpret appropriate standards. 7. Define potential hazards and methods of safe handling and working.

1. 8

MIG/MAG and Flux Cored Welding

10 (4)

Objective: Understand in detail MIG/MAG and Flux Cored welding fundamentals, including equipment, applications, procedures and common problems. Scope: Power source characteristics for conventional process and CPU controlled power sources Effect of current and polarity Equipment and accessories: torches, wire feeders, hose assembly, panel control Transfer metal modes in the arc (dip, globular, spray, and pulsed), and their application Welding parameters and settings: current, voltage, welding speed, gas flow, etc. Consumables: shielding gases, filler materials (solid and flux cored wires), and their combinations Joint preparation: typical joint design for welding, fit-up, cleaning Welding procedures Typical problems and their solution Special techniques:, electro -gas welding, high efficiency processes Standards for filler materials, and gases Welding applications, typical problems Health and safety specific to the process Expected Result: 1. Explain in detail the principles of MIG/MAG and Flux Cored welding including metal transfer modes and their applications. 2. Explain the selection of appropriate type of current, polarity and electrode according to application. 3. Detail the range of application, appropriate joint preparations and potential problems to be overcome. 4. Detail appropriate welding parameters for particular applications. 5. Define potential hazards and methods of safe handling and working. 6. Explain the purpose and functions of each component of the equipment and accessories. 7. Interpret appropriate standards 8. Explain selection of consumables.

1. 9

MMA Welding

8 (4)

Objective: Understand in detail MMA welding fundamentals, including equipment, applications, procedures and common problems. Scope: Process principles and arc characteristics

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Doc. IAB-002-2000/EWF-409 Revision2 Effect of current type and polarity Power source characteristics applicable to MMA (open circuit voltage, static and dynamic characteristics, types of current, arc striking methods) Equipment and accessories Process application range and typical problems Covered electrodes (functions of the coating and rod, types of electrodes, slag-metal and gas-metal reactions) Production of electrodes (how, typical defects) Handling and storage of electrodes (storage environment, redrying) Electrode classification (International and national standards) Selection of Covered electrodes for applications Welding parameters: current, voltage, run out length, etc Joint preparation: typical joint design for welding, fit-up, cleaning, welding position Relationship of electrode diameter with current range, rod material, electrode length and welding position Welding procedures Special techniques (gravity welding, vertical down welding, on-site welding) Health and safety specific to this process Expected Result: 1. Explain in detail the principles of MMA welding including special techniques, arc ignition techniques and their applications. 2. Explain the selection of appropriate type of current, polarity and electrode according to application. 3. Detail the range of application, appropriate joint preparations and potential problems to be overcome. 4. Detail appropriate welding parameters for particular applications 5. Define potential hazards and methods of safe handling and working 6. Explain the purpose and functions of each component of the equipment and accessories. 7. Detailed explanation of the handling and storage of the various types of consumable. 8. Interpret appropriate standards. 9. Identify the influence of electrode coating on droplet transfer and weld metal

1.10

Submerged-Arc Welding

6 (4)

Objective: Understand in detail SAW welding fundamentals, including equipment, applications, procedures and common problems. Scope: Process principles and arc characteristics Effect of current type and polarity Power source characteristics applicable to SAW (open circuit voltage, static and dynamic characteristics, types of current, arc striking methods) Equipment and accessories Process application range and typical problems Consumables (functions of the flux and wire, types of flux and wire, wire-flux combination, slag-metal and gas-metal reactions) Production of consumables (how, typical defects) Handling and storage of consumables (storage environment, redrying) Consumable classification (International and national standards) Welding parameters: current, voltage, welding speed, type of flux and mesh size, stick-out, etc Joint preparation: typical joint design for welding, fit-up, cleaning Relation between the wire flux combination and the characteristics of deposited material Welding procedures Single-wire and multi -wire techniques Special techniques (strip-cladding, iron-powder addition, cold and hot wire addition) Health and safety specific to this process

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Doc. IAB-002-2000/EWF-409 Revision2 Expected Result: 1. Explain in detail the principles of SAW welding including arc ignition methods, special techniques and their applications. 2. Explain the selection of appropriate type of current, polarity and consumable according to application. 3. Detail the range of application, appropriate joint preparations and potential problems to be overcome. 4. Detail appropriate welding parameters for particular applications. 5. Explain the purpose and functions of each component of the equipment and accessories. 6. Explain slag-metal/gas-metal reactions and their influence on weld metal properties 7. Interpret appropriate standards. 8. Define potential hazards and methods of safe handling and working

1.11

Resistance Welding

8

Objective: Understand in detail resistance welding fundamentals, applications and specifications, including common problems and their solution. Scope: Process principles and overview on types of processes (spot, projection, butt, seam, and flash) Joule effect and temperature distribution Equipment and accessories Process application range and typical problems (welding thin to thick material, welding of coated/ painted materials, welding dissimilar materials, mass effect, shunt effect, Peltier effect, resistance brazing) Electrodes (functions, types, shapes, material) Electrode classification (International and national standards) Welding parameters: current, pressure, time, type of current, pulse, etc Joint preparation: typical joint design for welding, fit-up, cleaning Relation between welding parameters and the characteristics of the weld nugget Monitoring systems, process control, measuring Specific testing Welding procedures Health and safety specific to this process Expected Result: 1. Explain in detail the principles of resistance welding and the application of the various sub-processes. 2. Explain the selection of appropriate parameters to give sound welds. 3. Detail the range of application, appropriate material preparation and potential problems to be over come. 4. Detail appropriate welding parameters for particular applications. 5. Explain the purpose and functions of each component of the equipment and accessories. 6. Interpret appropriate standards. 7. Define potential hazards and methods of safe handling and working.

1.12

Other Welding Processes

10

Objective: Understand in detail plasma; electron beam; LASER, electro-slag, friction; friction stir, magnetically impelled arc butt (MIAB); magnetic pulse welding, ultrasonic; explosive; diffusion; aluminothermic; high-frequency; stud, cold-pressure welding, hybrid processes, etc. fundamentals, including equipment, applications, procedures and common problems. Scope: Process principles for all mentioned techniques Heat generation for each type of process Equipment and accessories for each type of process Typical process applications and problems Consumables Welding parameters for each type of process

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Doc. IAB-002-2000/EWF-409 Revision2 Joint preparation: typical joint design for welding, fit-up, cleaning Relation between welding parameters and joint configuration Comparison of high energy processes Health and safety specific to the processes Appropriate national and international standards for each process Expected Result: 1. Explain the principles of the processes mentioned in the objective and their application. 2. Determine appropriate applications for each type of process, and the precautions necessary to achieve a sound weld. 3. Describe the welding parameters, appropriate joint preparations and potential problems to be overcome for each process for a given application. 4. Explain the purpose and functions of each major component of the equipment and accessories. 5. Interpret appropriate standards. 6. Define potential hazards and methods of safe handling and working.

1.13

Cutting and other edge preparation processes

4 (2)

Objective: Understand in detail the basic principles of the most common cutting and edge preparation processes used in weld construction, including equipment, procedures and common problems. Scope: Detailed survey of edge preparation processes Mechanical cutting Principles of flame cutting, equipment and auxiliaries Flame cutting parameters, edge quality, oxygen purity grades Materials suitable for flame cutting Flame powder cutting principles and applications Arc cutting (arc-air, carbon and metal-arc, oxy-arc cutting, gauging with carbon electrode) Fundamental principles of the various arc-cutting processes, equipment and auxiliaries Materials suitable for arc-cutting, applications, cutting parameters for each process Fundamentals of plasma cutting, equipment and auxiliaries Materials suitable for plasma cutting, applications, cutting parameters, cutting gases Plasma cutting special applications (cutting under water, cutting with water vortex) Plasma gouging Fundamentals of electron beam drilling and LASER cutting, equipment, parameters, applications Working fundamentals for water jet cutting, equipment, parameters, applications Working fundamentals for arc gouging and flame gouging, parameters and applications Appropriate national and international standards for each process Health and safety Expected Result: 1. Explain in detail the working principles of: mechanical, flame, arc, plasma, electron beam, LASER, and water jet cutting. 2. Explain the influence of each parameter on the edge surface for: mechanical, flame, arc, plasma, electron beam, LASER, and water jet cutting. 3. Detail the range of applications for: flame, arc, plasma, electron beam, and water jet cutting. 4. Define potential hazards and methods of safe handling and working.

1.14

Surfacing and Spraying

2

Objective: Understand in detail the most common surfacing techniques and their working principles, including equipment, procedures and common problems.

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Doc. IAB-002-2000/EWF-409 Revision2 Scope: Working fundamentals and applications for cladding techniques (rolling, explosive, strip, plasma-MIG, electroslag, LASER, etc) Detail survey of the spraying techniques (flame spraying with powder, flame spraying with wire, arc spraying with powder, arc spraying with wire, plasma spraying with powder, HVOF spraying) Working principles for each technique, equipment, parameters Surface preparation of the base material Spraying materials Spraylayer structure, and substrate structure "Cold techniques" and "fusing techniques" Applications and special problems Health and safety Expected Result: 1. Explain the working principles for the most common cladding techniques. 2. Explain the working principles for the most common spraying techniques. 3. Deduce the quality of a surfacing with respect to the base material preparation. 4. Predict the different applications between "cold" and "fusion" spraying techniques. 5. Describe the different applications for each spraying technique. 6. Define potential hazards and methods of safe handling and working.

1.15

Fully mechanised processes and robotics

6

Objective: Understand in detail welding mechanisation and the use of robotics in welding, including applications and systems. Scope: Detail survey of welding processes that can be adapted for higher productivity The difference between robotics, mechanisation, and automation, advantages and disadvantages Range of applications for each type Robotics (on line and off line programming, simulation, flexible manufacturing systems) CAD/CAM systems Virtual factory (factory simulation) Seam tracking, types and typical applications Arc sensing, magnetic induction, vision system Narrow gap welding (SAW, MIG/MAG, TIG), Orbital welding (MIG/MAG, TIG) Applications and special problems Gases and fillers (optimisation for mechanised welding) Health and safety Expected Result: 1. Predict the best solution for higher productivity in welding using robotics, or automation or mechanisation. 2. Explain in detail the differences between off line and on line programming. 3. Detail the working principles and application of each type of seam tracking. 4. Explain the working principles and applications of narrow gap and orbital welding. 5. Describe the different applications for each welding process when applied to narrow gap or orbital welding. 6. Define potential hazards and methods of safe handling and working.

1.16

Brazing and soldering

4

Objective: Understand in detail the fundamentals of brazing and soldering, types of techniques, equipment, applications, procedures and common problems.

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Doc. IAB-002-2000/EWF-409 Revision2 Scope: Detail study of the fundamentals of brazing and soldering (bonding mechanisms, surface tension, wetting, capillary) MIG/ MAG pulsed brazing Detail survey of brazing and soldering techniques, and equipment, range of applications Consumables and fluxes for brazing and soldering, types, applications, and main functions of the fluxes Brazable materials, brazing requisites High vacuum brazing, brazing under controlled atmosphere Braze welding Detail survey of soldering techniques (dip, wave flow, vapour phase, soldering) Brazing and soldering advantages and disadvantages Applications and special problems Health and safety Expected Result: 1. Explain in detail each type of brazing and soldering technique. 2. Predict precautions to obtain a good and sound bound using brazing or soldering techniques. 3. Describe the different applications for each brazing and soldering techniques. 4. Describe the type of consumable and flux to be use in a certain application 5. Define potential hazards and methods of safe handling and working.

1.17

Joining processes for plastics

4

Objective: Understand comprehensively the basic principles involved in joining plastics, including the common techniques, equipment, applications, procedures and common problems. Scope: General information on materials and joining processes Study of the working principles for each type of process Hot plate welding, butt fusion, hot gas welding, extrusion welding, induction welding, resistance welding, implant welding, high frequency, friction, electro-fusion welding, ultrasonic welding, vibration welding, adhesive bonding Control of welding parameters, types of equipment, joint design Advantages and disadvantages Applications and special problems Health and safety Expected Result: 1. Explain the fundamentals of each type of joining technique. 2. Predict precautions to obtain a good and sound joining, for each type of technique. 3. Describe the different applications for each type of technique. 4. Define potential hazards and methods of safe handling and working.

1.18

Joining processes for ceramics and composites

2

Objective: Understand the general principles of joining ceramics and composites, including the common techniques, applications, procedures and common problems. Scope: General information on ceramics and composites and typical joining processes General study of the working principles for each type of process Advantages and disadvantages Applications and special problems

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Doc. IAB-002-2000/EWF-409 Revision2 Expected Result: 1. Explain the fundamentals for joining ceramics and composites. 2. Predict precautions to obtain a good and sound joining for some advanced materials. 3. Define potential hazards and methods of safe handling and working.

1.19

Welding laboratory

10

Objective: Understand in detail the key effects of parameters on weld beads and cut surfaces. Scope: Practical exercises showing the effect of each main welding parameter on the weld bead Discussion of results to help future evaluation and diagnosis Exercises should cover: MMA, TIG, MIG/MAG, Flux Cored wires, SAW, Oxy-gas Practical exercises showing the effect of each main cutting parameter on the cut surface Discussion of results to help future evaluation and diagnosis Exercises should cover: Oxy-cutting, Arc-Air, Plasma, Arc-Cutting Expected Result: 1. Predict weld bead shape and morphology (internal and external), according to the welding parameters used. 2. Explain in detail the factors that can change the weld bead, and why. 3. Predict the morphology of cut surfaces, according to the cutting parameters used. 4. Explain in detail the factors that can change the cut surface, and why. 5. Be able to evaluate and diagnose weld beads and cut surfaces.

Welding processes and equipment

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Module 2: Materials and their behaviour during welding 2.1

Manufacture and designation of steels

2 (2)

Objective: Understand the principles of iron extraction and steelmaking and designation of steels Scope: Introduction to metallurgy of steel making Steel making processes Special treatments Desoxidation Designation of steels Defects in steels Expected Result: 1. 2. 3. 4. 5.

Explain the various steel making processes. Detail the reasons for and principles of special treatments in steel making. Explain the different methods of desoxidation Explain potential defects, their cause and elimination. Explain the designation of steels

2.2

Testing Materials and the weld joint

8 (4)

Objective: Understand the fundamental aspects of testing materials with particular reference to weldment test pieces. Scope: Review of destructive testing Testing welded joints Destructive testing Tensile and bending tests Notch impact tests (ductile and brittle fracture, transition temperature) Hardness tests Technological specimens Special tests Fatigue strength tests Laboratory exercises

4 hours from 8

Expected Result: 1. 2. 3. 4.

Discuss the reasons for destructive testing and the limitations of the data generated. Describe in detail each of the major testing methods and the measurements to be made. Predict when and why special testing should be specified. Show competence in carrying out testing to a given schedule.

2.3

Structure and properties of pure metals

4 (4)

Objective: Understand in detail the principles of solidification, deformation and recrystallisation and the characteristics of typical metal structures. Scope: Crystalline structures Crystal structure types

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Doc. IAB-002-2000/EWF-409 Revision2 Micro structures of metals Solid state transformation Elastic/plastic deformation Recrystallisation Cold and hot deformation Work hardening Mechanical properties (influence of temperature, etc.) Expected Result: 1. Explain basic crystalline structures 2. Explain in detail elastic-plastic deformation and their role in cold and hot deformation. 3. Explain recrystallisation giving examples. 4. Demonstrate understanding of the relationship between mechanical properties and temperature, grain size and structure.

2.4

Alloys and Phase Diagrams

6 (6)

Objective: Understand in detail the principles of alloying, the structures of alloys and their representation in phase diagrams. Scope: Metals and alloys Alloying elements Solidification Solid solution crystals Structure of alloys Type of structures Hardening mechanisms (cold working, solid solution, dispersion hardening, grain size, solid state transformation) Intermetallic phases Ageing Basic types of phase diagrams (non-, fully- and partly mixable components) Fe-C diagram Influence of elements on the Fe-C diagram Iron-alloys with closed gamma-area, with broadened gamma-area Casting structure Crystal segregation Mechanical properties Ternary diagrams Expected Result: 1. Describe lattice distortion of alloying elements and subsequent structural changes. 2. Explain in detail solidification structure and segregation with relevant examples. 3. Detail mechanisms of precipitation, types of precipitate and their location within the microstructure. 4. Explain in detail the principles of transformation and conditions under which it occurs. 5. Detail the principles of hardening mechanisms with appropriate examples. 6. Interpret the relationship between microstructure and mechanical properties. 7. Explain in detail the principles of phase diagrams, their construction and use. 8. Interpret the relationship between microstructure and phase diagrams.

2.5

Iron – Carbon Alloys

4 (4)

Objective: Understand the principles of alloying iron with carbon, the crystal structures developed under equilibrium and non-equilibrium conditions and their representation in phase and transformation diagrams.

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Doc. IAB-002-2000/EWF-409 Revision2 Scope: Equilibrium and non equilibrium transformations Time-temperature-transformation (TTT) diagrams Different types of TTT diagrams (isothermal, continuous cooling, TTT diagrams for welding) Influence of alloying elements Carbide forming elements Control of toughness T8/5 concept Expected Result: 1. Interpret the reasons for different structures under equilibrium and non-equilibrium conditions. 2. Explain the use of TTT diagrams (isothermal, continuous cooling, TTT diagrams for welding) to show the development of particular steel microstructures. 3. Predict the changes to structure caused by alloying by reference to TTT diagrams. 4. Detail hardening mechanisms with reference to the microstructure developed. 5. Interpret the relationship between microstructure and toughness.

2.6

Heat treatment of base materials and welded joints

4 (4)

Objective: Understand in detail the metallurgical principles of material behaviour when heat treated. Scope: Normalising, Hardening Quenching and Tempering Solution annealing Homogenisation Stress relieving Recrystalisation annealing Precipitation hardening Heat treatment in practice Heat treatment equipment, Regulations (codes and technical reports) Temperature measurement and recording Expected Result 1. Explain each of the major heat treatments and their objectives. 2. Explain the mechanisms of structural changes which take place when a material is heat treated. 3. Interpret the effects of temperature and time on transformations including effects from rate of temperature change. 4. Explain code requirements for heat treatment and why they are stipulated. 5. Predict the necessity to heat treat after welding depending of the type and thickness of steel, the application and the code. 6. Deduce appropriate heat treatment equipment for a given application. 7. Detail appropriate temperature measurement and recording for typical applications.

2.7

Structure of the welded joint

4 (4)

Objective: Understand in detail the formation of the different metallurgical structures within a weldment. Scope: Thermal field Equations for the heat distribution Heat input Peak temperature

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Doc. IAB-002-2000/EWF-409 Revision2 Cooling rate Dilution Weld metal Solidification of weld pool Structure of the weld Fusion line Heat-affected zone (HAZ) Microstructure of HAZ Grain growth Relationship grain size – toughness (equations from regression) Transition temperature Weldability (definitions) Single and multi -pass welding Expected Result: 1. Explain the temperature distribution in welds and the microstructure formed as a result. 2. Interpret the effects of heat input, cooling rate and multi -pass operation on weld metal solidification and the microstructure formed. 3. Explain the effects of the weld protection, the type of consumables on the microstructure of the weld metal and on it properties. 4. Detail areas of HAZ, the reasons for grain, size and microstructure changes and their effects on properties. 5. Discuss the various aspects of weldability. 6. Deduce the microstructural and weldability modifications induced by dilution.

2.8

Plain Carbon and Carbon-Manganese Steels

6 (4)

Objective Understand in detail the metallurgical effects induced by welding C and C-Mn steels. Scope Application of TTT diagrams Hardening effects Carbon equivalent Weldability Effects of multi-pass welding Structure of the weld and the HAZ Factors influencing cracking Relationship C%max – hardness Relationship Ceq - hardenability Determination of preheat temperature (diagrams) Weld – simulation (Weld thermal cycle simulation) Determination of the optimal heat input Influence of restraint Standards Expected Result 1. Explain the concept and use of carbon equivalent. 2. Explain the principle and use of TTT diagrams (isothermal, continuous cooling, TTT diagrams for welding). 3. Predict the structure of welds and HAZ for given thermal cycles and composition. 4. Explain in detail the effects of a multi -pass welding on the structure, the mechanical properties. 5. Discuss the factors affecting cold cracking. 6. Predict optimal heat input and appropriate preheat for given materials, conditions and applications utilising Codes and Standards as required.

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Doc. IAB-002-2000/EWF-409 Revision2 2.9

Fine - grained steels

4 (2)

Objective: Understand in detail the effects of micro-alloying elements on structure, mechanical properties and weldability with reference to fine-grained steels. Scope: Concept of grain refinement (micro-alloying elements, formation and dilution of particles) Effect on mechanical properties Normalised grades Quenched and tempered grades T8/5 concept and weldability Standards Expected Result: 1. Explain the different methods to obtain fine-grained steels effects of micro – alloying. 2. Explain thoroughly the relationship between grain refinement and mechanical properties. 3. Detail appropriate applications. 4. Interpret the relationship between grade and weldability. 5. Detail applicable welding processes and potential problems. 6. Explain the effects of heat treatment after welding and deduce the conditions (in particular temperature) of such treatment.

2.10

Thermomechanically treated steels (TMCP -steels)

2

Objective: Understand in detail the principles of thermomechanical treatment and its influence on mechanical properties and weldability. Scope: Principles of treatment Chemical composition Mechanical properties Consequences on weldability Standards Expected Result: 1. Explain the effects of the range of treatment times and temperatures. 2. Explain the structural modifications of material and control methods. 3. Interpret the relationship between grade and weldability. 4. Detail applicable welding processes and potential problems. 5. Explain the effects of heat treatment after welding and deduce the conditions (in particular temperature) of such treatment.

2.11 Cracking phenomena in welded joints

6 (2)

Objective: Understand the fundamentals of cracking mechanisms in welded joints and the way in which variables affect the incidence of cracking. Scope: For C-Mn, low alloy, high alloy and stainless steels as appropriate: Cold cracking: Cracking mechanisms in weld metal and HAZ Effect of hydrogen, microstructure and stress Source and diffusion of hydrogen

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Doc. IAB-002-2000/EWF-409 Revision2 Control of hydrogen Susceptible microstructure and its control Influence of elements on susceptibility Testing of susceptibility Effect of preheat Effect of austenitic weld metal Hot cracking: Cracking mechanisms in particular in weld metal Effect of elements, heat input, bead shape Control of hot cracking Testing for susceptibility Reheat cracking: Cracking mechanisms in weld metal and HAZ Type of steels sensitive to reheat cracking Effect of elements, thermal cycles, stress Cracking during heat treatment and multi -pass welding Control of reheat cracking Testing for susceptibility Lamellar tearing: Cracking mechanism Effects of inclusions, joint configuration, stress, and fatigue Control of lamellar tearing by material control and joint configuration Testing for susceptibility, through thickness properties Expected Result: 1. Compare the metallurgical mechanisms for each of the major types of cracking. 2. Describe the effects of chemical and physical variables for each of the major types of cracking. 3. Appraise the susceptibility to cracking by reference to the key parameters and suggest appropriate precautions to avoid cracking. 4. Appraise the type of cracking and the reason for its occurrence from study of fractured material and its history. 5. Choose tests which will assist in the solution of cracking problems. 6. Propose alternatives which will reduce or eliminate the occurrence of lamellar tearing in welded construction/fabrication. 7. Appraise the effects of inclusions, joint configuration, stress and fatigue in the control of cracking of welds.

2.12

Application of structural and high strength steels

2

Objective: Understand welding problems dealing with the fundamental aspects of structural and high strength steels application with particular reference to physical, chemical and mechanical characteristics Scope: Bridges Cranes Pressure vessels Automotive equipment Low temperature applications Expected Result: 1. Explain in detail the importance of choice of material with reference to application. 2. Appraise the use of structural and high strength steels and their application fields 3. Describe examples of the practical application and design of bridges, cranes, pressure vessels, automotive equipment.

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Doc. IAB-002-2000/EWF-409 Revision2 2.13

Low-alloy steels for very low temperature application

4

Objective: Describe solutions to welding applications requiring the use of the relationship between toughness and temperature, metallurgical structure and the weldability of cryogenic steels. Scope: Survey of types of cryogenic steels (including 9% Ni) Effects of nickel on low temperature properties of low alloy steels Applicable welding processes Filler materials Welding problems and precautions Properties and application of various types of cryogenic steels Controlling the quality of the welded joint Standards on low temperature steels and consumables Expected Result: 1. State the toughness testing and the parameters affecting toughness. 2. Appraise the relationship between microstructure and toughness. 3. Identify the effect of nickel on crystallographic structure. 4. Describe the effect of nickel content on weldability. 5. Appraise the range of applications for the various types of cryogenic steels.

2.14

Low alloy creep resistant steels

4

Objective: Appraise the fundamental aspects of creep phenomena. Understand in detail creep resistant steel types, their structure and alloying elements. Scope: Mechanism of creep resistance Testing of creep resistance Creep sensitivity testing, Temper embrittlement, e.g. step cooling Remaining life prediction Oxidation resistance Survey of types of creep/heat resistant steels Applicable welding processes Filler materials - special chemical requirements for creep resistance Welding problems and precautions Controlling the quality of a welded joint Standards Expected Result: 1. Identify the fundamental aspects of the phenomena and phases of creep. 2. Appraise the effects of alloying elements and Cr-Mo steels structure. 3. Appraise the weldability of Cr-Mo steels considering appropriate welding processes and types of consumables. 4. Identify remaining life by use of the most common methods.

2.15 Introduction to corrosion

6

Objective: Identify the fundamentals of the various types of corrosion.

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Doc. IAB-002-2000/EWF-409 Revision2 Scope: Fundamentals of electrochemistry Redox potential Passivation, Overall corrosion, Differential aeration Cathodic, anodic protection Types of corrosion (intercrystalline, transcrystalline, knife-line attack, pitting, crevice, and stress-corrosion) Pickling and passivating Corrosion testing Demonstrations 2 hours from 6 Expected Result: 1. Appraise the chemical and electrochemical phenomena involved in corrosion. 2. State the rules involving the mechanisms of the different types of corrosion. 3. Appraise different protection methods.

2.16

High-alloyed (stainless) steels

8

Objective: Identify in detail the fundamentals of the various types of stainless steel and their weldability including the principles of joining dissimilar materials and filler material choice. Scope: Effect of alloying elements Systems Fe-Cr, Fe-Ni, Fe-Cr-Ni Austenite and ferrite formers Influence of nitrogen Cr- and Ni-equivalent Schaeffler diagram, DeLong and other prediction diagrams Measuring of ferrite content Survey on stainless steels (fully austenitic, ferrite-containing steels, ferritic, martensitic, duplex stainless steels, chemically resistant, creep resistant, heat resistant steels) 475-brittleness Applicable welding processes Types of filler materials Shielding and backing gases Welding of stainless steels Details of design Heat treatment Post-weld heat treatment (PWHT) Passivation Standards Expected Result: 1. Appraise the structures of the various stainless steels; parent plate, HAZ and weld metal 2. Identify the results of a given high alloy welding situation using the Fe-Cr phase diagram. 3. State the rules and principles governing embrittlement phenomena. 4. State the rules and principles governing in detail corrosion phenomena. 5. Identify the results of a given high alloy welding situation using the Fe-Cr phase diagram with various carbon contents. 6. Predict the choice of consumables for each type of stainless steel using different diagrams. 7. Predict the necessity of treatment after welding.

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Doc. IAB-002-2000/EWF-409 Revision2 2.17

Introduction to wear

2

Objective: Identify the fundamentals of wear and its control Scope: Different types of wear (hydrodynamic friction, reaction layer wear, adhesive wear, abrasive wear, fatigue wear fretting, erosion, cavitation, impact, thermal, dynamic) Buttering Wear tests Expected Result: 1. Describe wear situations which involve the mechanisms of the different types of wear. 2. Distinguish the basis and results of tests to define wear resistance. 3. Appraise precautions and procedures designed to avoid excessive wear.

2.18

Protective layers

4

Objective: Identify the fundamentals of protective layers and the methods and materials used Scope: Cladding: Reasons for cladding Processes for cladding (dilution) Joining clad steels Joint design and welding procedures in respect to the access to the joint Standards Linings: Welding of linings Joint design and welding procedures Surfacing: Corrosion-resistant layers Wear-resistant layers Coatings: Surface-coated steels Galvanised steels (Si-content) Painting Problems of joining Expected Result: 1. Describe the various techniques for applying protective layers. 2. Design weldments using protective layers stating the materials used and the reasons for their choice. 3. Appraise the problems associated with the different types of protective layer and methods of their solution.

2.19 High alloy creep resistant and heat resistant steels

2

Objective: Identify the relationship between microstructure and creep resistance including detailed knowledge of different types of creep resistant and heat resistant steels

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Doc. IAB-002-2000/EWF-409 Revision2 Scope: Creep resistance of high alloy steels Mechanism of heat resistance Types of creep resistant steels Types of heat resistant steels (austenitic, ferritic) Weldability and selection of consumables Application and special problems Standards Expected Result: 1. Distinguish the effects of alloying elements on creep and heat resistance. 2. Appraise in detail the microstructural phenomena occurring in materials at high temperature. 3. Identify the types of creep resistant and heat resistant steels. 4. Appraise the weldability of creep and heat resistant steels.

2.20

Cast irons and steels

2

Objective: Interpret the metallurgy of the different types of cast irons and steels, their application fields and weldability. Scope: Survey of cast steels Survey of cast irons Applicable welding processes and procedures Weldability Filler materials Application and special welding problems Standards Expected Result: 1. Explain the Fe - C phase diagram with particular attention to carbon content over 2%. 2. Identify the different types of cast irons and steels, their chemical composition and crystallographic structures. 3. Appraise the weldability problems and applicable welding processes and types of consumable for the welding of cast irons.

2.21

Copper and copper alloys

4

Objective Understand in detail the metallurgy, application fields and weldability of copper and copper alloys Scope Survey on classification of copper and copper alloys Desoxidation and weldability Physical and mechanical properties Applicable joining processes (welding, brazing, soldering, diffusion welding) Filler materials Shielding and backing gases Application and special problems Standards Expected Result 1. Explain the metallurgy of copper and copper alloys. 2. Interpret copper and copper alloys weldability including the dissimilar joint. 3. Explain applicable welding processes and type of consumable for copper and copper alloys. 4. Explain copper and copper alloys application fields.

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Doc. IAB-002-2000/EWF-409 Revision2 2.22

Nickel and nickel alloys

4

Objective Understand in detail the metallurgy, application fields and weldability of nickel and nickel alloys Scope Survey on classification of nickel and nickel alloys Applicable welding processes and filler materials Shielding and backing gases Welding problems (hot cracking)and prevention Quality control of the welded joint Expected Result 1. Explain the metallurgy of nickel and nickel alloys. 2. Interpret nickel and nickel alloys weldability. 3. Explain applicable welding processes and type of consumable for nickel and nickel alloys. 4. Explain examples of nickel and nickel alloys application fields.

2.23

Aluminium and aluminium alloys

6

Objective Understand in detail the metallurgy, application fields and weldability of aluminium and aluminium alloys Scope Survey on classification of aluminium and Al-alloys (pure , non heat- treatable , heat treatable ) Weldability Joint preparation Applicable welding processes Filler materials (choice, storage and handling) Shielding and backing gases Welding problems, (porosity and hot cracking, cracking diagrams distortion) and their avoidance Application and special problems (lightweight structures, cryogenic use) Expected Result 1. Explain the metallurgy of aluminium and aluminium alloys. 2. Interpret aluminium and aluminium alloys weldability including the dissimilar joint. 3. Explain applicable welding processes and type of consumable for aluminium and aluminium alloys. 4. Explain aluminium and aluminium alloys application fields.

2.24

Other metals and alloys

2

Objective Gain basic knowledge of the metallurgy, application fields and weldability of the specified metals Scope Titanium Magnesium Tantalum Zirconium Applicable welding processes and filler materials Special problems Expected Result 1. Explain the metallurgy of the specified metals. 2. Interpret the weldability of the metals. 3. Explain appropriate welding processes and applications.

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Doc. IAB-002-2000/EWF-409 Revision2 2.25

Joining dissimilar materials

4

Objective Understand the principles of joining dissimilar materials and the problems involved Scope Fundamentals Use of the Schaeffler / De Long diagram for welding dissimilar metals Choice of processes Effect of dilution Consumables Welding problems and measures, (formation of intermetallic compound, carbon migration) Typical applications: Joining stainless steel and mild steel Joining CuNi-alloys with mild steel/stainless steel Joining Ni-alloys with mild steel Joining stainless steel and copper alloys Joining steel and Al / Al alloys Joining Cu and Al / Al alloys Joining Ni and Cu Expected Result 1. Explain weldability aspects involved when joining dissimilar materials. 2. Interpret and use Schaeffler / De Long diagram. 3. Deduce welding methods which decrease metallurgical problems. 4. Interpret the correct choice of filler material.

2.26

Metallographic examinations

6

Objective Understand in detail crystallographic structures and the application of metallographic examination Scope Specimen preparation for optical microscope Macro and micro structure examination Micro chemical analysis in crystallographic structure Expected Result 1. Explain in detail and be able to use methods for sample preparation. 2. Explain aspects of macro and micro examination. 3. Interpret micro structure, metallurgical imperfections.

Materials and their behaviour during welding

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Module 3: Construction and design

3.1

Basic theory of structural systems

4 (4)

Objectives: Understand the effect of external loads on structures, the kinds of structural systems and the relationship between external loads and internal forces. Scope: Structural elements (cables, bars, beams, plates, slabs, shells) Theory of forces Combination and resolution of forces Equilibrium of forces and torques Bearings, constraints and basic types of connections Equilibrium of structural systems Statically determinate and indeterminate systems Stressing of structural systems resulting from actions Relationship between external loads and internal forces Calculation and determination of the internal forces and moments of simple statically determinate systems Expected Results: 1. Explain the composition of forces. 2. Explain the resolution of forces. 3. Define the conditions of equilibrium. 4. Explain the equilibrium of structural systems. 5. Explain bearings, constraints and the basic types of connections. 6. Explain the difference between a statically determinate and a statically indeterminate system. 7. Determine the internal forces and moments of simple statically determinate systems. 8. Explain and sketch the equilibrium diagram of simple statically determinate systems

3.2

Fundamentals of the strength of materials

4 (4)

Objectives: Understand in detail the principles controlling the behaviour of metallic structures under loading. Scope: Types of stresses (normal stress, shear stress) Types of deformation (axial strain, shear strain) Stress-strain relationship Elastic and plastic deformation Young’s modulus, shear modulus, transversal contraction coefficient Characteristic material properties Different stresses resulting from internal forces and moments Different types of section properties Calculation of section properties Calculation of stresses Expected Results: 1. Explain the different types of stresses (normal stress, shear stresses). 2. Explain the different types of deformation (axial strain, shear strain etc.). 3. Explain the stress-strain relationships. December 2003 3 von 3 4. Deduce Young’s modulus; shear modulus and transversal contraction coefficient from the stress-strain relationships. 5. Explain the determination of characteristic material properties.

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Doc. IAB-002-2000/EWF-409 Revision2 6. Explain the stresses resulting from internal forces and moments. 7. Calculate the different types of section properties. 8. Calculate nominal stresses in sections.

3.3

Welded Joint design

4 (4)

Objectives: Design and draw weld details related to given material, wall thickness, accessibility, loading, welding process, welding position, NDT, available equipment, tolerances Scope: Types of welded joints Importance of weld joint design and groove shapes, types of welded joints, design of welded joints Classification of groove shapes (by material type, thickness, welding process, accessibility) Tolerance requirements Welding symbols on drawings, symbols for groove shapes Mode of symbolic representation of welded, brazed and soldered joints according to ISO 2553 Expected Results: 1. Classify different types of welded joints. 2. Design a weld according to the given conditions. 3. Detail and use appropriate weld symbols. 4. Explain the symbolic representation of welded, brazed and soldered joints on drawings

3.4

Basics of weld design

8

Objectives: Understand in detail the relationship between external loads on structures, internal forces and the stresses induced with special regard to welds. Scope: Types of stresses in welded joints (nominal stress, hot spot stress, notch stress) Stresses in butt welds, stresses in fillet welds Calculation of section properties of welded joints Determination of nominal stresses in single-welded joints Determination of reference values of stresses due to multi-axial stressing Determination of design resistance of arc-welded and resistance-welded joints Worked examples of calculation of nominal stresses in welded joints Expected Results: 1. Explain the different types of stresses in welded joints (nominal stress, hot spot stress, notch stress) 2. Calculate in detail simple welded joints (internal forces). 3. Calculate the values of cross sections for welded joints. 4. Calculate nominal stresses in welds. 5. Calculate combined stresses in welds (superposition). December 2003 4 von 4

3.5

Behaviour of welded structures under different types of loading

4

Objectives: Understand in detail the different types of loading and the influence of ambient conditions on constructions. Scope: Static strength Elevated temperature strength

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Doc. IAB-002-2000/EWF-409 Revision2 Low-temperature strength Creep resistance Impact behaviour Influence of notches Types of fracture (ductile fracture, fatigue fracture, brittle fracture, lamellar tearing) Selection of steel quality groups Use of standards and specifications Expected Results: 1. Explain the requirements according to different types of loading and temperatures. 2. Determine materials which meet strength / temperature requirements. 3. Select appropriate materials according to application. 4. Explain different types of fracture (ductile fracture, fatigue fracture, brittle fracture, lamellar tearing)

3.6

Design of welded structures with predominantly static loading

8

Objectives: Be able to design and calculate joints and all relevant details of welded metallic structures Scope: Steel constructions including lightweight constructions Structural details e.g. (stiffeners, knots, columns, base- and cap-plates, reinforced structures, supports, frame-corners, frame structures, trusses, nodal joints, etc.) Use of different types of welds related to joint types Use of standards and specifications Worked examples Expected Results: 1. Competently design different connection zones. 2. Calculate appropriate weld geometry. 3. Calculate the relevant weld stresses. 4. Outline stresses in frames. 5. Nominate the stresses in welds of frames. 6. Detailed knowledge of advantage and disadvantage of different types of welds.

3.7

Behaviour of welded structures under dynamic loading

6

Objectives: Understand fully the development of fatigue, calculation of load cycles, the influence of notches and their avoidance. Scope: Types of loading Statistical stress analysis on real structures S-N diagram Stress collective Fatigue strength Effect of mean stress Stress distribution Influence of notches Influence of weld defects Improvement of fatigue strength (peening, TIG dressing, grinding, hammering, stress relieving, etc.) Standards

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Doc. IAB-002-2000/EWF-409 Revision2 Expected Results: 1. Draw and use a S-N diagram. 2. Describe methods of counting load cycles. 3. Calculate the stress ratio. 4. Detail the influence of notches and weld defects. 5. Describe modifications to welds for improved performance.

3.8

Design of dynamically loaded welded structures

8

Objectives: Understand the different design details and notch classes in the fields of application Scope: Fields of application: bridges, cranes, machines, ships and offshore constructions, chimneys, towers and masts, vehicles, (cars, trucks, railway vehicles) etc. Acceptance criteria Use of standards and specifications Worked examples Expected Results: 1. Design welded joints in accordance with given details. 2. Interpret the influence of notch effects on the classification of welded joints. 3. Interpret appropriate standards. 4. Compare details in different standards and classify them.

3.9

Design of welded pressure equipment

6

Objectives: Understand in detail the special requirements of design of structural elements in this field of application with regard to the calculation of welds Scope: Construction of boilers, pressure vessels, pipelines, etc., Calculation (formulae) of the welds, Details of design (flanges, nozzles, shells, compensating plates etc.), Use of laws, standards and specifications, Worked examples of construction and design. December 2003 6 von 6 Expected Results: 1. Explain the advantages of different weld details. 2. Explain design of given structural weld details. 3. Interpret appropriate standards. 4. Understand isometric drawings. 5. Calculate circumferential and longitudinal welds. 6. Design given structural details. 7. Explain the advantages of different structural details.

3.10

Design of structures of aluminium and its alloys

4

Objectives: Understand fully the behaviour of welded aluminium structures with respect to strength, stresses and design Scope: Lightweight constructions Standard alloys for practical use and relevant stresses and strains Heat affected (softening) zone (HAZ)

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Doc. IAB-002-2000/EWF-409 Revision2 Special design regarding profiles Significance of defects Fields of application (vehicles, rolling stocks, ships, aircraft, vessels and space) Use of standards and specifications Worked examples Expected Results: 1. Interpret stress calculations in the HAZ. 2. Design aluminium profiles for a given use. 3. Explain causes and development of stresses and strains in an aluminium weldment. 4. Explain the strength of different alloys. 5. Select alloys for given applications.

3.11

Reinforcing-steel welded joints

2

Objectives: Understand the principles of choice of joints and their design in full. Scope: Reinforcing-steel types, properties Direct and indirect loading Types of joints used (lap, cruciform) Weldability in respect of weld joint strength Calculation, Application of welding processes Standards and specifications Expected Results: 1. Explain the basics of the different joints in full. 2. Differentiate between load bearing and non-load bearing joints. 3. Detail applicable processes. 4. Determine the length of weld with respect to diameter. 5. Deduce the required preheating temperature.

3.12

Introduction to fracture mechanics

6

Objectives: Understand the use of fracture mechanics for welded structures Scope: Viewpoint of fracture mechanics Application of fracture mechanics Linear elastic fracture mechanics Fundamentals of elasto-plastic fracture mechanics Critical flaw size, KIc-value Fracture mechanics testing (CTOD, etc.) Sub-critical flaw growth Fatigue testing Standards

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Doc. IAB-002-2000/EWF-409 Revision2 Expected Results: 1. Explain the principles of linear-elastic and elasto-plastic fracture mechanics. 2. Describe the influence factors for linear-elastic and elasto-plastic fracture mechanics. 3. Describe the use of fracture mechanics for dynamically loaded structures. 4. Describe fracture mechanics testing methods.

Construction and design

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Module 4: Fabrication, applications engineering 4.1

Introduction to quality assurance in welded fabrication

6

Objective: Understand in detail the principles of quality assurance and quality control as applied to welded fabrication. Scope: Quality assurance and quality control Weldability Quality manual Quality plan Audit of plant Personnel and equipment Maintenance Inspection Activities of the welding engineer in the different functions in industry Standards (QMS guidebook, EN ISO 9000 series, EN 729, ISO 3834, national and international standards) Expected Result: 1. Explain the principles of quality assurance, quality control and inspection systems and their usage for welded fabrication. 2. Be capable of writing quality control procedures and quality plans for welded fabrication. 3. Explain in detail the purpose of an audit of plant. 4. Be capable of carrying out audits of welding related plant, personnel, equipment and product. 5. Interpret appropriate standards (e.g. ISO 9000, and ISO 3834/EN 729). 6. Explain in detail the main factors related to personnel and equipment, which influence the quality in a welded fabrication. 7. Explain the role of the welding engineer in the fabrication industry.

4.2

Quality control during manufacture

14

Objective: Understand in detail the requirements and function of Quality Control during manufacture. Scope: Documentation to national, regional and international standards, e.g. WPS Welding sequence Procedure qualification (ISO 9956 ,EN 288 series, and National standards) Welding procedures - how to create and develop Welder qualification (ISO 9606, EN 287 series, and National standards) Welding operator qualification (EN 1418, ISO and National standards) Traceability (materials identification, procedures, certificates) Possible methods of monitoring and storage of fabrication data Calibration and validation of measuring equipment Practical exercises Welding procedure qualification Welders and welder operator qualification

2 hours from 14 4 hours from 14

Expected Result: 1. Explain in detail the main purpose of a WPS and the main advantages to the quality of welded fabrication. 2. Compile and review detailed WPS for welded components in accordance with national and international standards. 3. Interpret the standard for the qualification of WPS, determine the main variables for a particular WPS qualification and its range of qualification. 4. Explain in detail the main purpose of a welder qualification and the main advantages to the quality of

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Doc. IAB-002-2000/EWF-409 Revision2 welded fabrication. 5. Interpret the standard for a welder qualification, determine the main variables for a particular welder qualification and its range of qualification. 6. Explain the main purpose of a welding operator qualification and the main advantages to the quality of welded fabrication. 7. Interpret the standard for a welding operator qualification, determine the main variables for a particular welding operator qualification and its range of qualification. 8. Detail the traceability requirements for materials procedures and certificates. 9. Detail methods available for the monitoring and storage of fabrication data. 10. Detail the calibration requirements of measuring equipment explaining why it is needed.

4.3

Welding Stresses and Distortion

6

Objective: Understand in detail the factors affecting welding stress and distortion in welded fabrications and how these effects can be measured and minimised. Scope: Influencing factors Thermal data of the materials Origin of the residual stresses and deformation Magnitude of longitudinal and transverse shrinkage stresses Relationship between heat input, shrinkage stresses and distortion Methods of residual stress measurement Welding sequence technique Effects of residual stresses on the behaviour of the structure in service Methods of reducing residual stresses or distortion Examples of control of distortion Expected Result: 1. Explain the origin, influencing factors and magnitude of residual stress and distortion in welded fabrications. 2. Predict qualitatively contraction and distortion in joints and structures. 3. Produce detailed procedures to minimise distortion and stress. 4. Explain how residual stresses may affect the behaviour of a structure in service.

4.4

Plant facilities, welding jigs and fixtures

4

Objective: Understand the need for and function of auxiliary equipment, jigs and fixtures from the viewpoint of quality, economics and the environment. Scope: Layout of production line Jigs, fixtures and positioners (types, applications, advantages, special precautions) Cables, electrical connections Operational environment Auxiliary equipment (for fit up, movement, backing gas devices, flow meters, etc) Fume extraction Joint fit up Tack welding Storage, distribution and handling of consumables (gases and filler material) Equipment for preheat, postheat, and other heat treatments, also temperature control Expected Result: 1. Detail workshop layout principles for improved productivity, safety and comfort. 2. Explain in detail the advantages of using fixtures, jigs and positioners. 3. Predict the type of fixture, jig or positioner to be used for a particular welded fabrication. 4. Deduce the type of auxiliary equipment to be used in a particular welded fabrication, including fume

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Doc. IAB-002-2000/EWF-409 Revision2 extraction, and cables, heat treatment and temperature control equipment. 5. Detail the requirements of facilities for handling and storing consumables. 6. Explain in detail the requirements related to joint fit up and tack welding.

4.5

Health and Safety

4

Objective: Understand in detail the health and safety hazards associated with welding and fabrication processes. Scope: Introduction to health and safety requirements Survey of safety and environmental aspects, risk assessment Risks of electric power Electro-magnetic fields Connecting of equipment Problems with shielding gases Radiation and eye protection Welding fume emission Exposure limits MAC and OEL values Ventilation and fume extraction Ergonomics Determination of acceptable emissions Tests for measuring emissions Noise levels and ear protection Standards and regulations Expected Result: 1. Explain the risks associated with welding from electricity, gases, fumes, fire, light and noise. 2. Interpret Health and Safety regulations with respect to the above hazards. 3. Deduce from measurements the risk associated with welding operations. 4. Produce safe working procedures to ensure the requirements are met.

4.6

Measurement, Control and Recording in Welding

4

Objective: Understand in detail the requirements for measurement, control and recording during welding and allied operations. Scope: Methods of measurement Instruments Temperatures Cooling time e.g. t8/5 Welding parameters (voltage, current, speed, gas flow rate etc.) Control in heat treatment (heating and cooling rate) Calibration and validation of equipment Laboratory exercises

2 hours from 4

Expected Result: 1. Explain the methods of measurement used in the control of welding and allied operations. 2. Detail working procedures for the measurement of welding parameters. 3. Detail working procedures for the measurement and control of heat treatment operations. 4. Detail procedures for the calibration, validation and monitoring of welding operations.

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Doc. IAB-002-2000/EWF-409 Revision2 4.7

Non Destructive Testing

20

Objective: Understand in detail the use of Non Destructive Testing as applied to welding fabrications. Scope: Types of weld imperfections (IIW-designations classification according to EN and ISO standards) Acceptance criteria (e.g. ISO 5817.3 and 10042) Fundamentals of NDT methods (visual, dye penetrant, magnetic particle, eddy current, acoustic emission, radiography, ultrasonic, etc.) Field of application and limitations Design in respect of NDT Calibration Interpretation (IIW Radiographic reference) Recording of data Qualification and certification of NDT personnel NDT procedures Use of standards and specifications Health and safety aspects Laboratory exercises (about 50% of the time)

Approx. 10 hours from 20

Expected Result: 1. Explain the modes of operation of the principal NDT methods, their advantages and disadvantages when applied to welded fabrications. 2. Explain weld imperfections, their causes and methods of detection. 3. Interpret acceptance standards for weld imperfections. 4. Understanding of the principles of NDT interpretation. 5. Detail weld configurations and design to allow adequate application of NDT methods. 6. Interpret the qualification of NDT personnel.

4.8

Economics

8

Objective: Understand in detail the economics of welding operations applied to welded fabrications. Scope: Analysis of welding costs Deposition rate Costs of labour Costs of consumables Costs of equipment Return on investment Costs of energy Welders duty cycle Calculation of welding costs The application of software, calculation programmes Measures for decreasing welding costs Mechanisation Automation Robotics Expected Result: 1. Explain in detail the make up of costs associated with welding. 2. Calculate the cost of welding operations. 3. Devise welding and handling procedures including mechanisation and production costs. 4. Operate software packages used in weld cost calculations.

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Repair Welding

2

Objective: Understand in detail the problems of repair welding both for in-manufacture and in-service situations. Scope: Welding repair procedure specification Welding repair plan Welding repair procedure qualification NDT of the weld repair Special precautions Expected Result: 1. Explain in detail the problems of making repair welds. 2. Predict the possible hazards likely to arise in making repair welds particularly for in-service repairs. 3. Detail comprehensive procedures to be applied to weld repairs. 4. Specify the procedural and operator qualifications to be applied to repair welds.

4.10

Fitness for Purpose

2

Objective: To gain an understanding of the need for and use of engineering critical assessment techniques. Scope: Introduction to IIW SST 1093-8 Significance of defects Engineering critical assessment techniques Expected Result: 1. Explain the principles of fitness for purpose. 2. Describe in detail the effect of imperfection size, morphology and position on structural integrity. 3. Explain typical methods of conducting an engineering critical assessment of a welded structure.

4.11

Case Studies

40

The aim of this final part of the course is to assess the students knowledge in respect to the manufacture of specific welded products. The best way of doing this is a combination of experts from industry presenting special cases and project work of the students split up into groups followed by a general discussion and comments by the experts. All of the following subjects have to be dealt with, the depth to which, however, will depend on the national needs. Subjects: Steel and lightweight structures, boilers and pressure vessels, chemical plants and pipelines, shipbuilding and offshore applications, Transportation (automobiles, railways), aerospace applications. Common items to be covered: Standards and specifications, design, Choice of materials, welding processes, Site welding (transport and final assembly), Consumables, welding procedures, Tolerances on weld preparation and fit-up, Postweld heat treatment, NDT and quality control,

Fabrication, applications engineering

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hours

____ 110

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I.2.

Practical Education (IWE Part II)

This part does not aim at practical skills of the welding engineer but on gaining knowledge on the control of the different welding processes. The students shall become as familiar as possible with the difficulties and typical defects associated with incorrect use of the different welding methods. During their exercises the students are guided by skilled welding teachers.

Practical Training oxyacetylene welding and cutting MMA TIG MIG/MAG

10 10 10 10

Demonstrations or video presentations on processes

20

Gouging, Brazing, Plasma welding Plasma cutting Submerged-arc welding Resistance welding Friction welding Electron beam welding Laser welding Other processes,

hours :

____ 60

Candidates may be exempted by the ATB from the practical training on a process by process basis, where they can demonstrate practical experience and/or training in the process concerned. The laboratory exercises contained in the foregoing modules 1 to 4 of the theoretical part are additional and given usually at a later stage of the education.

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Section II: Examination and Qualification 1.

Introduction

This guideline seeks to achieve harmonisation and a common standard in the examination and qualification of professional welding engineers internationally. The national welding organisations, being members of the IIW, mutually acknowledge the Diplomas awarded in any Member Country to International Welding Engineers, following examination conducted in accordance with this Guideline. Education shall have followed this IIW guideline “International Welding Engineer” and the examination shall have been conducted by the national body authorised by IIW for this purpose. This "Authorised National Body” will normally be operated by the National Welding Organisation which is the IIW member but may be also another organisation with the agreement of the IIW Member.

2.

Approval of the postgraduate course

Any training course leading to the IIW examination shall be approved by the ANB. The number of teachers required to give the course shall be sufficient to insure that the essential specialist knowledge and industrial experience to cover the syllabus is adequately represented in the team of teachers and visiting lecturers.

3.

Board of Examiners

The Chairman and the members of the Board of Examiners shall be nominated by the ANB. The Board of Examiners shall consist of a)

The Chairman who shall be a representative of the ANB. He shall be independent from the training school Main teachers of the subjects Experts from industry and other organisations)

b) c)

The responsibilities of the Board of examiners are: a) Organise the examination b) Set the examination questions (written and oral) c) Conduct and mark the written and oral examinations d) Decide on borderline results

4.

Admission to the Examination

Admission to the examination leading to the award of the International Welding Engineer diploma will be restricted to those: a) b) c)

5.

Who comply with the minimum requirements specified in the directory of access conditions, and Standard Route: Who have attended at least 90% of the course, approved by the ANB, according to this guideline. Exceptions are at the discretion of the ANB. Alternative Route: Who have successfully passed the ANB detailed assessment

Examination procedures

The examination procedures described below are designed to test the candidate’s knowledge and understanding of different situations in welding technology. There will be written and oral examinations in each of the following modules:

a)

Welding processes and equipment

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Doc. IAB-002-2000/EWF-409 Revision2 b) c) d) 5.1

Materials and their behaviour during welding Construction and design Fabrication and applications engineering Written examination

At the discretion of the Board of Examiners the examination shall consist of: a) b) c)

A series of essay questions covering the whole field of the module or A series of multiple choice questions covering the whole field of the module or A combination of a) and b) with equal marks allocated to each type

The time devoted to the written examination shall be a minimum of 2 hours per module, i.e., 8 hours in all. 5.2

Oral Examination

The total time devoted to the oral examination, covering all four modules, shall be a minimum of 1 hour per candidate. Candidates reaching >75% of the maximum possible mark in the written examination in one module may be dispensed from the oral examination in that module.

6.

Evaluation of Performance

Written and oral examinations shall usually have equal importance (50%), but the weight of the oral examination may, at the discretion of the Board of Examiners be set anywhere within the range of 40 to 60%; this shall be announced before the start of the examination. In order to pass the examination candidates shall achieve at least 60% of the maximum possible mark in each module examination Successfully completed individual parts of the examination remain valid for a period of 3 years. The examination in all four modules shall be completed within a period of 3 years from the start of Part II of the course. If an examinee has failed an examination, the 3 years validity of the individual passed parts of the examination in IWE /EWE course, may be extended by decision of the Lead Assessor, if it has not been possible for the ANB to organise the necessary re-examinations within the three years period.

7.

Re-examination and Appeals Procedure

Failure in any individual module of the examination shall require re-examination only in the module failed. Examinations shall be retaken within 2 weeks to 15 months of the initial examination and, in the case of a second failure, one further attempt is permitted within l to l5 months from the date of the second examination. Failure of this third attempt will result in the candidate being treated as an initial candidate and a retake of the whole course will be required. Candidates who feel they have been unfairly treated during the examination procedure have the right to appeal to the Authorised National Body. The remaining procedures are covered in IAB Document IAB-001-2000/EWF-416.

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Doc. IAB-002-2000/EWF-409 Revision2 8.

International Welding Engineer's Diploma

After successful examination a diploma is awarded to the candidate by the Authorised National Body.

9.

Transition Arrangements

Each country’s specific Transition Arrangements are approved by the IAB Group B and may be obtained from each Authorised National Body. An ANB can offer Transitional Arrangements for a period of up to 3 years from the implementation of the guideline by the ANB. ANBs which have already offered EWE or IWE diplomas under Transitional Arrangements, may continue to do so until 31 December 2001. Practising welding engineers, who are professional engineers qualified in accordance with the national scheme of the member state, and having a qualification in welding engineering issued by the Authorised National body will be eligible for the award of the International Welding Engineer's Diploma if they can demonstrate to the Authorised National Body that their combination of education, training and experience in welding engineering has provided a level of knowledge equivalent to the current IIW requirements. If, in the judgement of the Authorised National Body, the candidate has not received an adequate level of formal training in welding engineering, he shall be recommended to attend a professional interview conducted by an assessment committee of the Authorised National Body. Two additional general rules shall be observed when applying the Transitional Arrangements: 1. 2.

Applicants shall possess the basic engineering / technical access qualification as outlined for the country concerned in this guideline. Diplomas may be awarded under Transitional Arrangements in the following cases: a) by the ANB in the country in which the applicant received his welding qualification or b) by the ANB in the country in which the applicant is currently practising, in contact with the ANB of the country that issued the original qualification.

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APPENDIX I: Requirements for equipment, facilities and specimens for the International Welding Engineer (IWE) course leading to the award of IIW qualification 1.

Equipment The following equipment shall be in good working order and fit for its purpose:

1.1

Welding equipment Equipment for the following processes shall be available for practical exercises. Manual metal arc welding MIG welding MAG welding TIG welding Gas welding Gas cutting Further processes covered by the syllabus may be shown by means of demonstrations or video presentations.

1.2

Other equipment Mechanical testing, metallurgical examination and NDT equipment shall be available for both demonstration and laboratory work purposes.

2.

Specimens A reference collection of well documented weld specimens, polished and etched, should reflect the processes covered by the Guideline and, as a minimum, one specimen per process is required. Preferably the specimens should cover a number of materials and thicknesses.

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APPENDIX II: Abbreviations for Processes: The following abbreviations used in the document show the relation between the ISO designation, the process abbreviations used in Europe and those used in the USA.

EN ISO 4063 April 2000 111

European

USA

Abbreviation Abbreviation MMA SMAW

114

FCAW

12 13

SAW

131

MIG

135

MAG

136

MAG

137

FCAW

FCAW SAW

GMAW GMAW FCAW FCAW-S 141

TIG GTAW

21 25 3 311 81 86

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Full name Manual Metal Arc Welding, Shielded Metal Arc Welding Flux-cored wire metal arc welding without gas shield Flux-cored arc welding Submerged Arc Welding Gas Shielded Metal Arc Welding Gas Metal Arc Welding Metal Inert Gas Welding Gas Metal Arc Welding Metal-arc Active Gas Welding Gas Metal Arc Welding Flux-cored wire metal-arc welding with active gas shield Flux-cored arc welding Flux-cored wire metal-arc welding with inert gas shield Flux-cored arc welding Tungsten Inert Gas Welding, Gas Tungsten Arc Welding Spot Welding Resistance Spot Welding Resistance Butt Welding Upset Welding Gas Welding Oxyfuel Gas Welding Oxy- acetylene Welding Oxyacetylene Welding Flame Cutting Oxygen Cutting Flame Gouging Thermal Gouging

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Appendix III: ANB Check According to Diagram 2 the following access conditions for the alternative route shall be checked by a paper assessment:

• Engineering degree (see access conditions) • Curriculum vitae - resume (professional information) -

min. 4 years job function in welding at the level of an engineer (in a period of 6 years before application) a justification of candidate‘s experience, training, and further education to become IWE (may include other test results)

This assessment is an evaluation of practice of related job function in welding.

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Appendix IV: ANB Detailed Assessment After the candidate has fulfilled the requirements of the ANB paper check he will be admitted to the ANB Detailed Assessment (Diagram 3).

A minimum of 10 points per module and 63 points for modules 1 to 4 is required to proceed further.

Paper assessment

Final exams

Oral assessment

project

ANB detailed Assessment

Diagram 3 The full ANB detailed assessment shall contain:

• a detailed paper assessment (checklist with points) • an oral assessment of at least two hours designed to test understanding and ability to reason and • a project with a wide scope to be completed within four weeks designed to test logical application of knowledge The sequence of this assessment shall be determined by the ANB. It is at the discretion of the ANB to terminate the assessment and send the candidate back or into the standard route. a) The detailed paper assessment shall be done with the following point system:

•

Frames of requirements: Module 1: Welding processes Module 2: Materials and their…. Module 3: Construction and design Module 4: Fabrication, applications engineering

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max. No. of Points 22 points 21 points 19 points 22 points Sum 84 points

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Doc. IAB-002-2000/EWF-409 Revision2 The detailed points are distributed as following: Module 1: Welding processes 111 - MMA 141 - TIG and 15 - Plasma 131 - MIG 135 - MAG 114, 136 and 137 - Flux-cored methods 91, 93 and 97 - Brazing methods 81, 82 and 83 - Thermal cutting 12 - SAW Other methods

∑

=

3 points 2 points 2 points 2 points 3 points 2 points 2 points 3 points 3 points 22 points

Module 2: Materials (acc. to CR ISO/TR 15608) and their behaviour during welding Steel alloys Cr-Mo- and vanadium steels: Ferritic and martensitic steels Austenitic and aust./fer. steels Steel-Ni- alloys, max 10% Ni Aluminium and alloys Copper and alloys Nickel and alloys Ti, Zr and alloys Cast iron

groups 1 – 3 and 11 groups 4 - 6 group 7 groups 8 and 10 group 9 groups 21 - 26 groups 31 - 38 groups 41 - 48 groups 51-54 and 61-62 groups 71 - 76 ∑ =

4 points 2 points 3 points 4 points 1 point 3 points 1 point 1 point 1 point 1 point 21 points

Module 3: Construction and design Stresses and strains Design of welded structures static loading Design of welded structures dynamic loading Joint design & design principles of welded structures Design of structures of aluminium and its alloys ∑

=

5 points 3 points 3 points 4 points 4 points 19 points

∑

4 points 3 points 4 points 2 points 3 points 2 points 2 points 2 points = 22 points

Module 4: Fabrication, applications engineering Quality assurance in welded fabrication Quality control during manufacture Welding stresses and distortion Plant facilities, welding jigs and fixtures NDT Economics Health and safety Repair welding

At minimum the applicant shall reach 10 points in each module and 63 points in module 1 to 4 to be admitted to the oral assessment.

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Doc. IAB-002-2000/EWF-409 Revision2 b) Oral Assessment The oral assessment of at least two hours is designed to test understanding and ability to reason in the field of welding the syllabus of the standard course. If the ANB decides that the candidate shall leave the detailed assessment after the oral assessment but before the project the candidate at minimum has to go through module 4 (applications engineering) of the standard route. c) Project In the project a work in form of a case study (designed for 80 hours) with the duration of maximum four weeks shall be done alone. In the project with a wide scope of application the candidate shall be tested to the logical application of his knowledge. The ANB takes a choice of construction according to codes and/or product standards. One of the following constructions shall be taken:

• • • •

pressure vessel Construction - static loading Construction - dynamic loading Other construction

The project work is detailed as following: c1)

• • •

Project work - Pre study Evaluation of drawings and technical specifications. Evaluation of and comments to the choice of base materials. Discuss the weldability of the materials. Any needs for pre- and postweld heating. Evaluation of the construction based on the choice of:

– – – – – –

• • • •

Joining method(s) for the base material(s). Cutting method(s) for preparation of base material parts. Joint preparation and weld calculation Welding consumables. Need of surface treatment before welding. Surface treatment of finished construction - method(s) to be used.

Preparation of necessary WPS´s and testing methods. Evaluation of necessary welding approval(s) for welder(s). Present NDT-methods to be used during and after welding Prepare:

– – –

Production plan. Welding plan - including welding sequence and tack welding. List of standards needed for the project.

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– C2)

•

Project work - Practical part on the construction or on test pieces –simulating the same construction - provided by the ANB checking:

– – –

• • • • • • c3)

• • •

Quality plan for the production based on relevant part of ISO 3834 or equivalent. Type of workshop for this kind of production shall be discussed.

Marking(s) and certificate(s) on base material(s). Welder(s) approval test certificate(s). Qualification of personnel for destructive testing, NDT and inspection.

Evaluation of test results and compare with pre-study figures. Plan for inspection before and during welding. Inspection after welding based on pre-study plans. - (visual inspection and other NDT methods, eventually pressure testing or other testing methods). Evaluation of the welding- and test results based on inspection and NDT reports. If evaluation shows need for repair, plan(s) for repair welding and eventually WPS´s for repair welding to be made. Evaluation of fabrication costs Project work - Final report and presentation The candidate shall prepare a final written report with results from his project based on the pre-study figures and the practical part The report shall include view points regarding economical production and at same time ensure the quality of the product. The candidate shall give an oral presentation of the project in front of the board..

After fulfilling all requirements (a, b, c) of the ANB detailed assessment the candidate will be admitted to the final examination.

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