Welding is a vital component in numerous industries, from construction and manufacturing to aerospace and shipbuilding. Ensuring the quality and safety of these welds falls to a specialized profession – the AWS Certified Welding Inspector (CWI).
As an AWS Certified Welding Inspector, these professionals are responsible for overseeing the entire welding process, from start to finish. Their role is essential in guaranteeing that welds adhere to project specifications and safety standards.
What Does a Welding Inspector Do?
CWIs are involved at every stage of the welding process. Before welding begins, they review critical documentation like Welding Procedure Specifications, welder qualifications, and project requirements. They inspect the base metals and filler materials to confirm compliance.
During the welding process, CWIs monitor key factors like interpass temperature, fusion, and weld size. They ensure the welders are following the approved procedures to the letter. This ongoing inspection is vital to catching any issues before the final product is complete.
After welding, the CWI conducts a thorough inspection, measuring the welds and checking for any defects like porosity, cracks, or incomplete fusion. If any issues are found, they must be repaired to meet specifications. The CWI then documents the overall quality and any necessary corrections in a detailed report.
Role of the Certified Welding Inspector (CWI) in the Welding Process
As a Certified Welding Inspector (CWI), I play a crucial role in ensuring the quality and safety of welded structures and components across a wide range of industries. My responsibilities span the entire welding process – from before the first weld is made, to during the fabrication, and after the welds are completed.
Before Welding Begins
Before any welding work starts, I thoroughly review all the relevant documents, such as Welding Procedure Specifications (WPS), welder qualifications, test records, project specifications, and applicable welding codes. My in-depth knowledge of these documents allows me to verify that the WPS and welder qualifications fully conform to the requirements.
I also carefully inspect the base metals, filler metals, joint fit-up, preheat conditions, and environmental factors to confirm they meet the WPS and project specifications. Catching any issues at this stage helps prevent costly rework down the line.
Monitoring the Welding Process
During the actual welding fabrication, I keep a close eye on a variety of critical parameters. This includes monitoring interpass temperatures, ensuring adequate fusion, verifying proper cleaning between passes, checking travel speeds, and measuring weld bead sizes.
Many people don’t realize the importance of in-process inspection. If I only inspected the welds after they were completed, I would have no way of knowing if the fit-up was correct, the right filler metal strength was used, or the weld passes were properly cleaned. My role as a CWI is to be accountable to the employer, purchaser, and end users for the quality and safety of the final product.
Final Weld Inspection
After the welding is finished, I conduct a comprehensive inspection of the completed welds. Using various tools, I carefully check for any discontinuities like porosity, undercut, cracks, or incomplete fusion. I also measure the weld sizes to verify they meet the project specifications.
Any defects I identify must be repaired. Once the welds pass my inspection, I document the results in detailed reports to the employer and client. These reports provide a full record of the welding quality and any issues that needed to be addressed.
The Tools of the Trade
Welding inspectors utilize a variety of specialized tools to assess weld quality. This includes rulers, magnifiers, flashlights, and an array of gauges to measure size, reinforcement, undercut, and other critical factors.
Becoming a Certified Welding Inspector
To earn the CWI certification, candidates must pass a rigorous three-part exam administered by the American Welding Society (AWS). This six-hour test evaluates their knowledge of welding codes, procedures, and inspection practices. Applicants must also meet education and experience requirements set by AWS.
Becoming a Certified Welding Inspector (CWI) requires candidates to successfully complete a rigorous three-part examination process administered by the American Welding Society (AWS).
Part A: Fundamentals Exam
The Part A Fundamentals Exam is a computer-based test that consists of 150 questions covering a wide range of topics, including:
- Destructive Testing
- Fabrication Math
- Safety in Welding
- Metallurgy
- Nondestructive Testing
- Understanding Welding Symbols
- Welding Procedures and Qualifications
- Welding Fundamentals
Part B: Practical Exam
The Part B Practical Exam is a hands-on assessment where candidates perform various welding-related activities and answer 46 questions related to those tasks. The activities include:
- Application of Welding Procedure Specifications (WPSs) and Procedure Qualification Records (PQRs)
- Use of Inspection Tools and Methods
- Execution of Required Welds
Part C: Code Book Exam
The Part C Code Book Exam is an open-book test that evaluates the candidate’s ability to locate and understand information in specific code books, such as:
- AWS D1.1 – Structural Steel Code
- API 1104 – Welding of Pipelines and Related Facilities
- AWS D1.2 – Structural Aluminum Code
- AWS D1.5 – Bridge Welding Code
- AWS D15.1 – Railroad
- AWS D17.1 – Aerospace
- ASME BPVC Section IX, B31.1, and B31.3
- ISO Standards
To successfully earn the CWI credential, candidates must achieve a minimum score of 72% on each of the three exam parts
The Rewards of Welding Inspection
CWIs are in high demand due to their critical role in ensuring the safety and quality of welded structures and components. According to PayScale, certified welding inspectors can command an average salary of $80,000 per year – significantly more than the $30,000-$40,000 typical for general welders.
Beyond the pay, CWIs play a vital part in protecting the public. Their attention to detail and commitment to upholding standards is what allows bridges, buildings, vehicles, and other vital infrastructure to be constructed with confidence. It’s a responsibility that demands expertise, communication skills, and an unwavering ethical compass.
If you’re interested in exploring a career as an AWS Certified Welding Inspector, be sure to check out our resources on the CWI certification process and exam preparation.
