Minimum Requirements Iwe

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IAB-002-2000/EWF-409
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MINIMUM REQUIREMENTS FOR THE EDUCATION, TRAINING, EXAMINATION,

AND
QUALIFICATION OF PERSONNEL
International Welding Engineer

(IWE)
Copyright 2004 Page 0

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Published by: IIW – IAB Secretariat

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P-2780-994 PORTO SALVO - OEIRAS – PORTUGAL
Tel: +351.21.4211351
Fax: +351.21.4228122
E-mail: roferraz@isq.pt

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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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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
Recommended teaching hours

1. Welding processes and equipment 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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2. 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 Engineer’s
Route 1 exams passed Diploma
IWE I IWE II IWE III W O

1 Max. 837 h 60 h Min. 297 E E
300 h
Intermediate Final
Route 2 examination examination
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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The ANB shall determine (paper check, Appendix III)) if the application is suitable for further
detailed assessment (Appendix IV).
Details of
Routes to Qualification
Standard Route (Standard and Alternative Route)
see
also Diagram 1
Standard Intermediate Final

IWE I Examination
IWE II IWE III Examination
Route
IWT
IWS
At the discretion
of the ANB
• •Engineering
Engineeringdegree
degree(see(seeaccess
accessconditions)
conditions) no no
• •Curriculum
Curriculum vitae - resumé(professional
vitae - resumé (professional
information)
information) ANB
ANB
––min.
min.44years
yearsjob
jobfunction
functionininwelding
welding detailed
ANB check
check detailed
(engineers
(engineerslevel)
level) assessment
––justification assessment
justificationofofcandidate‘s
candidate‘sexperience,
experience, yes yes
training,
training, and educationtotobecome
and education becomeIWEIWE
(may
(mayinclude
includeother
othertest
testresults)
results)
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 in-
cluded 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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6. Define the range of application and potential problems to overcome.
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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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, op-
eration 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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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
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.
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
Welding procedures
Typical problems and their solution
Special techniques:, electro -gas welding, high efficiency processes
Standards for filler materials, and gases
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.
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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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.
4. Detail appropriate welding parameters for particular applications
5. Define potential hazards and methods of safe handling and working
7. Detailed explanation of the handling and storage of the various types of consumable.
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)
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
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)

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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.
6. Explain slag-metal/gas-metal reactions and their influence on weld metal properties
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
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
Relation between welding parameters and the characteristics of the weld nugget
Monitoring systems, process control, measuring
Specific testing
Welding procedures
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.
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-pres-
sure 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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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 over-
come for each process for a given application.
4. Explain the purpose and functions of each major component of the equipment and accessories.
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, elec-
tron beam, LASER, and water jet cutting.
3. Detail the range of applications for: flame, arc, plasma, electron beam, and water jet cutting.
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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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.
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)
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 mechanisa-
tion.
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.
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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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
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
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
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.
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

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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.
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 hours 97 (35)

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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. Explain the various steel making processes.
2. Detail the reasons for and principles of special treatments in steel making.
3. Explain the different methods of desoxidation
4. Explain potential defects, their cause and elimination.
5. 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. Discuss the reasons for destructive testing and the limitations of the data generated.
2. Describe in detail each of the major testing methods and the measurements to be made.
3. Predict when and why special testing should be specified.
4. 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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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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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 tem-
perature 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 ap-
plication 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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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 prop-
erties.
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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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 tempera-
ture) 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 prop-
erties 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 tempera-
ture) 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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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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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
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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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
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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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 solu-
tion.
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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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
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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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
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
Filler materials (choice, storage and handling)
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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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 hours 110 (36)

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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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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).
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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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
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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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
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.
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.
Expected Results:
1. Explain the advantages of different weld details.
2. Explain design of given structural weld details.
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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Special design regarding profiles
Significance of defects
Fields of application (vehicles, rolling stocks, ships, aircraft, vessels and space)
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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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 hours 64 (12)

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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 2 hours from 14
Welders and welder operator qualification 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 fabrica-
tion.
2. Compile and review detailed WPS for welded components in accordance with national and interna-
tional 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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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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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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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
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 automation to minimise
production costs.
4. Operate software packages used in weld cost calculations.

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4.9 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 pre-
senting special cases and project work of the students split up into groups followed by a general discus-
sion 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 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 10

MMA 10
TIG 10
MIG/MAG 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
b) Main teachers of the subjects
c) Experts from industry and other organisations)
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) Who comply with the minimum requirements specified in the directory of access conditions, and
b) 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.
c) Alternative Route: Who have successfully passed the ANB detailed assessment
5. 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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b) Materials and their behaviour during welding
c) Construction and design
d) Fabrication and applications engineering
5.1 Written examination
At the discretion of the Board of Examiners the examination shall consist of:
a) A series of essay questions covering the whole field of the module

or
b) A series of multiple choice questions covering the whole field of the module
or
c) 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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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. Applicants shall possess the basic engineering / technical access qualification as outlined for the
country concerned in this guideline.
2. 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 European USA Full name

April 2000 Abbreviation Abbreviation
111 MMA Manual Metal Arc Welding,
SMAW Shielded Metal Arc Welding
114 FCAW Flux-cored wire metal arc welding without
gas shield
FCAW Flux-cored arc welding
12 SAW SAW Submerged Arc Welding
13 Gas Shielded Metal Arc Welding
Gas Metal Arc Welding
131 MIG Metal Inert Gas Welding
GMAW Gas Metal Arc Welding
135 MAG Metal-arc Active Gas Welding
GMAW Gas Metal Arc Welding
136 MAG Flux-cored wire metal-arc welding with
active gas shield
FCAW Flux-cored arc welding
137 FCAW Flux-cored wire metal-arc welding with
inert gas shield
FCAW-S Flux-cored arc welding
141 TIG Tungsten Inert Gas Welding,
GTAW Gas Tungsten Arc Welding
21 Spot Welding
Resistance Spot Welding
25 Resistance Butt Welding
Upset Welding
3 Gas Welding
Oxyfuel Gas Welding
311 Oxy- acetylene Welding
Oxyacetylene Welding
81 Flame Cutting
Oxygen Cutting
86 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. Final
exams
Paper Oral
assess- assess- project
ment ment
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 applica-
tion 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:
max. No. of Points
Module 1: Welding processes 22 points
Module 2: Materials and their…. 21 points
Module 3: Construction and design 19 points
Module 4: Fabrication, applications engineering 22 points
Sum 84 points

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The detailed points are distributed as following:
Module 1: Welding processes
111 - MMA 3 points

141 - TIG and 15 - Plasma 2 points
131 - MIG 2 points
135 - MAG 2 points
114, 136 and 137 - Flux-cored methods 3 points
91, 93 and 97 - Brazing methods 2 points
81, 82 and 83 - Thermal cutting 2 points
12 - SAW 3 points
Other methods 3 points
∑ = 22 points
Module 2: Materials (acc. to CR ISO/TR 15608) and their behaviour during welding
Steel alloys groups 1 – 3 and 11 4 points

Cr-Mo- and vanadium steels: groups 4 - 6 2 points
Ferritic and martensitic steels group 7 3 points
Austenitic and aust./fer. steels groups 8 and 10 4 points
Steel-Ni- alloys, max 10% Ni group 9 1 point
Aluminium and alloys groups 21 - 26 3 points
Copper and alloys groups 31 - 38 1 point
Nickel and alloys groups 41 - 48 1 point
Ti, Zr and alloys groups 51-54 and 61-62 1 point
Cast iron groups 71 - 76 1 point
∑ = 21 points
Module 3: Construction and design
Stresses and strains 5 points

Design of welded structures - static loading 3 points
Design of welded structures - dynamic loading 3 points
Joint design & design principles of welded structures 4 points
Design of structures of aluminium and its alloys 4 points
∑ = 19 points
Module 4: Fabrication, applications engineering
Quality assurance in welded fabrication 4 points

Quality control during manufacture 3 points
Welding stresses and distortion 4 points
Plant facilities, welding jigs and fixtures 2 points
NDT 3 points
Economics 2 points
Health and safety 2 points
Repair welding 2 points
∑ = 22 points
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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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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– 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.
C2) Project work - Practical part on the construction or on test pieces –simulating the
same construction - provided by the ANB
• checking:
– 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
c3) 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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Doc.

MINIMUM REQUIREMENTS FOR THE EDUCATION, TRAINING, EXAMINATION,

International Welding Engineer

Copyright 2004 Page 0

Published by: IIW – IAB Secretariat

Copyright 2004 Page 1

2. Routes to Qualification ............................................................................................................... 5

3. General Access Conditions ........................................................................................................ 5

Section I: Theoretical and Practical Education,

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

Appendix II: Abbreviations ........................................................................................................... 45

Appendix III: ANB Check ............................................................................................................. 46

Appendix IV: ANB Detailed Assessment ....................................................................................... 47

Copyright 2004 Page 2

Copyright 2004 Page 3

The contents are given in the following structure:

Recommended teaching hours

Copyright 2004 Page 4

2.1 The Standard Route

2.2 The Alternative Route

2.3 Distance Learning Programs

3. General Access Conditions

Copyright 2004 Page 5

IWE I IWE II IWE III W O

WE: written examination

4.1 Standard Route

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

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Standard Intermediate Final

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I.1. Theoretical Education IWE I and IWE III

1.1 General introduction to welding technology 3 (3)

1.2 Oxy-gas welding and related processes 2 (2 )

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1. 3 Electrotechnics, a review 2 (2)

1. 4 The Arc 4 (4)

1.5 Power sources for arc welding 4 (4)

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1. 6 Introduction to gas shielded arc welding 2 (2)

1. 7 TIG Welding 6 (4)

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1. 8 MIG/MAG and Flux Cored Welding 10 (4)

1. 9 MMA Welding 8 (4)

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1.10 Submerged-Arc Welding 6 (4)

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1.11 Resistance Welding 8

1.12 Other Welding Processes 10

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1.13 Cutting and other edge preparation processes 4 (2)

1.14 Surfacing and Spraying 2

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1.15 Fully mechanised processes and robotics 6

1.16 Brazing and soldering 4

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1.17 Joining processes for plastics 4

1.18 Joining processes for ceramics and composites 2

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1.19 Welding laboratory 10