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Topic Welding Textbook for high school students? By pipewelder_1999 Date 02-14-2015 04:47
When I was a HS student in welding I never noticed a better or worse book. The interest that was generated in welding kinda caused me to look at all that my teacher had. We used one from Giachino, Weeks, and Brune (I think as I pulled that ooutta my head) but I remember lusting after his "Jeffersons Welding Encyclopedia" and the AWS Welding Handbooks.

I think a the Books from the James F Lincoln Arc Welding Foundation are awesome. Are they "textbooks". Maybe not in the sense of modularized powerpoint presentation cool graphics books of today.

I sincerely believe there are tremendous free resources on the internet that can augment any classroom text to encourage engagement of students interested in welding. And there are not any materials that will change the view of those that don't without the proper encouragement and guidance.

I think the challenge comes from the application of whatever you have and the "complication" results from the presentation. I am not stating that is your problem or that you even have one. I am a babe when it comes to teaching and have a tendancy to "show up and throw up" whenever it comes to welding. So even with something simple, I may "over complicate".

I like the NCCER books I purchased but after looking at the Jeffus/Bower book . The NCCER books have some interesting info too.

Sorry if I didn't help you much. I could probably be asking you for suggestions. Thanks for sharing the trade for 19 years !

Have a good day

Topic best weld mapping program By pipewelder_1999 Date 02-14-2015 04:25
Everything still has "glitches" in it Henry. Often times they are the result of one setting, one tool, one file, one program, or other minor detail. The largest software companies in the world continue to release updates for program that they have had ownership of for 20+ years. Praise in my opinion is well warranted. When I look at the overall effectiveness of this forum (An internet App using a database fed by Html forms), then I become impressed with the effectiveness of this type of "program".

A standalone computer, not EVER connected to the internet is extremely stable. But of course if its not working correctly, it will probably need to be "connected" soon. As with all systems of security, there are flaws. That "security" risk could be the possibility of me dropping my laptop off of a scaffold with 3 days of inspection data on it including the images or one single user transposing a id number with a name on his "custom built standalone spreadsheet" and archiving the data, and some other individual trying to figure out whether the Name is wrong for all the related data, or the ID is wrong.

The program is probably hosted on a regular Windows/Linux server and I am pretty sure redundancy is available. But not sure. I do understand your concerns though. One thing that I feel should be required is the ability to export ALL raw data at any time by any admin users with full mapping information to allow the owners of the data to reconstruct any information previously recorded.

I am hoping the $1000.00 setup and 250 annual is for an unlimited (within reason) number of users/projects. If that is a per seat cost, then I'm not a fan either. But people have noo problem putting out 5-10k for autodesk software doing things they could do with opensource or lower end products. If it costs more, it must be better.

I'd love to build a program like this for documenting individual welder training tasks completed under the requirements of a standardized program to allow users to verify individuals stated credentials. Including video or documented "certification".   Just a thing in my head.  Have a good night Henry.

Topic best weld mapping program By pipewelder_1999 Date 02-14-2015 03:56
I went back and made a few entries with Chrome and everything worked fine. Besides a few things, it pretty much does what I did with the Access Application I made.  Much less complicated than what I did and obviously some added benefit being a web based database (depending on your views of course).

Some incredible similarities to the access application I built before. It was done for a construction company in the US for use at multiple sites. I am not sure how successful it was but I did do a search for it once and found it posted on someones resume :).

I think its a great idea but have not looked at the pricing. The ability to perform "real" programming is something I sometimes regret not developing to allow for sharing of some of the programs I have built with access.

Everything worked well and I can see it as a useful tool. Maybe a bit more customization for actual individual data importing (Drawing Indexes, Piping indexes, existing welder data, WPS's etc in CSV format)

If individual projects can be added yet separate from others and partial data imported then some some capabilities are increased.

Since there is a wide variation among companies as to how they document data related to welding, importing with field mapping can be nice too.

I think your on to something. Been studying up on php and mysql for a few weeks but by the time I get any good at it, there will be some better way and I will be too long disconnected from actually documenting welding data.

I am working on one now for tracking training activities related to welding training but still in Access/VBA.

Gonna go look at the "pricing" now.

Have a good day and thanks for sharing this. It has been a "dream" to do something like this but really didn't have the skillset.

Probably gonna share the link elsewhere .

Have a good day

Gerald Austin
Topic best weld mapping program By pipewelder_1999 Date 02-13-2015 13:02
I did try to add an annotation to a drawing and it has been saving for 15 minutes. Is this product in use or still under development or are there restrictions on the login accounts?
Topic best weld mapping program By pipewelder_1999 Date 02-13-2015 12:40
I have just logged in am pretty impressed just from the aspect of capabilities for a cloud bases resource. I haven't looked at the costs etc but just as a welder/wannabe programmer its pretty cool. Probably not the kind of review to do much for anyone, but its worth looking around for a bit.

I know many are reluctant regarding cloud based "programs/apps" but I think there is some great potential. A thought on cloud based vs desktop, If you don't own the source code, you don't really have "control" over the program. There is a great advantage to your programs travelling with you no matter where you go with a username/password as opposed to being tied to a physical machine.

Thanks and have a nice day.

Gerald Austin
Topic best weld mapping program By pipewelder_1999 Date 02-11-2015 04:08
I'd love to see it. I have built some custom programs in the past for Power and Pharmaceutical projects and would love to see a "commercial" application. I filled out the demo request on the form.

Here is a link to a video showing the one I made. (Remember I'm a welder) but am hoping to learn something besides VB and MS Access. But a long way to go.
Topic Weld sofware By pipewelder_1999 Date 02-11-2015 03:53
There are formulas in AWS Welding Handbook, Volume 1 that calculate "theoretical" angular distortion, transverse shrinkage and other things. I wrote some GWBAsic code many years ago trying to simulate the formulas but gave up based upon my very limited math background. (This was well before Excel, MSDOS and Dual Floppy Drives).

So someone could probably whip up some spreadsheets with all the needed formulas.

Topic I am new at welding and am having trouble seeing the By pipewelder_1999 Date 02-11-2015 03:49
I think for consistent clarity no matter where you look through the lens or angle, you can't beat a regular glass lens.

Bang for the buck, that can't be beat. I have used some autohoods and still do but when I really need to see the "guts" of it.

I break out the huntsman 490P with a shade 10 lens.

Autohoods that I have liked for the money are the 39.99 harbor freight blue flame model, the Miller Elite 9400 Titanium, and Hornel Speedglass Air Supplied Hoods. I have used hoods in between those from Arc One, Jackson, and Hobart. As with vehicles, there are tremendous differences between manufacturers and models.

As with many things welding, much is opinion and based upon individual experience. Many things you just gotta check out on your own.
Topic Boy Scout Merit Badge day last week. By pipewelder_1999 Date 02-09-2015 12:20
I may have gotten more out of  it than they did. But it was all a good time.

Have a great day.

Topic Boy Scout Merit Badge day last week. By pipewelder_1999 Date 02-06-2015 18:41
Just wanted to post here about the Merit Badge program that I was fortunate enough to help with last week. I have a longer description on one of my websites talking about what we did but I wanted to share a couple of things with those interested.

1) I'm glad I didn't have to compete with Tim Gary for this job, I would still be in Mississippi.
2) I have only taught Community College Workforce Training courses which is great, but teaching kids or young men and women almost ready to enter the workforce is something I desire.
3) It's a great joy to see someone enjoy doing something that you have enjoyed for 35 years. Even if only for a day!
4) If you want to talk about what we did and would like to talk, my cell number is 660-0162.. You can call or text. The area code is 662

From a Wordpress Page I wrote early this AM. (They gave me steroids for a numb leg, so I was up late and woke up early, hopped up on drugs and welding stuff in my head)

I have been fairly idle in teaching since getting here a few months back and this day really encouraged me. The welding trade has been very good to me for over 35 years. My 1st introduction was in 9th grade shop. Then from the 10th grade on, I was blessed with being able to learn at Kingsbury Vocation Center in Memphis for 3 hours a day. My instructor was Mr. Ed Hemmingway. He was a person that really got my interest in the trade stirred up (that and maybe a little firebug in me). He often challenged me to learn and do more than was required. I ate it up. Point is, do not reduce the value of vocational education because you think everyone MUST go to college. I was able to work for 2x the minimum wage as a 15 year old. 39.5 hours a week. I WAS RICH! But not nearly as rich as I was this day watching these boys weld.

If you enjoy sharing welding, I think this is a great chance. Contact your local Council or Troop.

Have a good day

Gerald Austin
Attachment: BSATim1small.jpg - Tim Workin the magic (547k)
Attachment: BSAGroup1resize.jpg - Part of the group (344k)
Topic Standard for distance from weld to flange By pipewelder_1999 Date 02-03-2015 00:40
Ullman K2
Topic Standard for distance from weld to flange By pipewelder_1999 Date 02-03-2015 00:39
I like this one the best, or maybe just a touch longer .
Topic QW. 452.3 Welder Can weld 3/4 Inch or not ? By pipewelder_1999 Date 02-02-2015 12:28
Outside diameter not "pipe size" is the variable used. 3/4" Pipe is 1.050 OD.
Topic 2015 codes By pipewelder_1999 Date 02-01-2015 23:08
In my opinion there is no more correlation between welding ability and inspection than there being an air traffic controller and pilot, police officer and judge, president and member of the armed forces, and so many others. Sure, sometimes it helps with perspective and understanding, but is by no means needed. I also feel there is some overlapping knowledge that is needed.

I have come across so many golden arm welders put in positions as QC inspectors that have taken it upon them selves to assure quality by creating there own acceptance criteria with no regard for that referenced in the project specifications . I am not saying that being a welder is a hindrance, but I have seen and heard some things that make me roll my eyes. Things that far exceed those heard from CWI's who just got out of 2 week CWI course.

On the other end, how can a guy make a weld that has never opened up a code book, reviewed a WPS, or even knows what range of qualification he possesses?   He can because there are people that are trained to help assure those things happen.

A combination of experience is great, but the skills required are different.  They can be developed together. And there are plenty of welders who are great inspectors, but I strongly suggest judging the quality of an inspector based upon his or her ability to weld is no different than judging the ability of a welder based upon his/her ability to read a project specification, apply it as directed, and accurately report his/her findings.

As with many things there are exceptions. I have made some bad welds, I have done some things incorrectly as an inspector. Both jobs are ones I love. I try to even separate the two. When I am hired as a welder, I try not to get into to deciding if my weld is acceptable or not or if someone else s is. I just weld it up, and head on to the next one.

I could tell a story about a 4" crossover line in t he bottom of a recovery boiler that I welded that I am sure the welders that knew I was both a CWI, QC Inspector for the Company, AND part time welding instructor really got a kick out of. I made a terrible mess of it! 

Point is, that weld I messed up, had nothing to do with my ability to inspect.

Nor was my ability to weld reflected by the times I visually rejected welds in tube coupons with more than 1/16" reinforcement because I believed it was the right thing to do even though the code allowed up to 5/32" and was my only acceptance criteria.

The jobs are different, the skills are different, we all do good, we all do bad, we all grow.

All of the above is based solely upon my opinion and very limited observation of the welding world. Experiences and thoughts may differ :).

Have a good one.

Gerald Austin
Welder-Depending Who you ask
Inspector-Depending who you ask
Teacher-Depending who you ask
And many other things-Depending who you ask.
Topic Arc Strike and "Soundness" By pipewelder_1999 Date 01-30-2015 22:42
We could always add "....blend smoothly..." and a "....gradual...." just to clarify things a bit.

Have a good day.

Topic Standard for distance from weld to flange By pipewelder_1999 Date 01-30-2015 22:19
If its going to be welded AFTER its bolted up, then the bolts/studs can be an issue but t hat shouldn't be the way its done.

Very "Non-Textbook" electrode travel angles are used in real life. An example is water wall panels on a boiler. Extreme "push" or "pull" angles are used at at the membrane or tangent section. the same thing can be done on pipe. As with many things welding related, its not "by the book" but its been working for years.

Topic Standard for distance from weld to flange By pipewelder_1999 Date 01-30-2015 22:15
If you gotta think about how close you CAN get it, you probably need to look at it in real life and see how its gonna be to weld.  Do all you can to make the joint weldable. If its as easy as you can get it, then it is what it is.

The standard is sometimes mentioned in the field its the DU 1.1 "Specification for those who didn't have a clue.". As with many welding terms, the slang version is "I'd like to meet the idiot that drew this"

Have a good one.

Topic Is there an app for the forum By pipewelder_1999 Date 01-28-2015 20:53
I checked out the RSS feed apps and the one I downloaded worked fine. Most will let you click on a feed and view it in your browser. If your browser keeps you logged in, you should be able to post .
Topic Great Job Gerald Austin By pipewelder_1999 Date 01-27-2015 18:06
I did this last week. I'm a better welder than I am a Camera man, Cue Card holder, and speaker. ...and I ain't all that good at welding.
Topic Is there an app for the forum By pipewelder_1999 Date 01-27-2015 17:28
I dont think so but there is or was an RSS feed.
Topic Great Job Gerald Austin By pipewelder_1999 Date 01-27-2015 13:46
Oh yea. The TV will be put to use. I'm a web showing, PowerPoint using kinda guy.

The other equipment consists of small tabletop type training aids for mechanical maintenance. There are some valve cutouts and similar components, but more for the millwright and mechanical maint. trades.  Good stuff cause t hey have had more classes than I have. Industry here has taken a pretty good interest in the maintenance training offerings for mechanical and electrical.

Topic Instructor TIP-Etching Without ACID By pipewelder_1999 Date 01-27-2015 13:00
I do the Weld Tests with quicker acting acids .  But I would not restrict someone from doing this should the code in question not specify what should be done.

BUT AWS D1.1-2010 says "A suitable Solution shall be used for etching to give a clear definition of the weld. "

Other codes are a bit more specific but even those in Sec IX are "Suggested" but do require a visible heat affected zone.

I have seen manufacturers use a torch and heat tint.

One thought though on the level of detail needed, typically the only thing being looked at is penetration, fusion, and discontinuities of a size that can be seen by the naked eye. (1/32" in the case of Section IX for Performance)

Have a good one.
Topic Great Job Gerald Austin By pipewelder_1999 Date 01-27-2015 12:40

The 300K didn't all go to welding. Tim was a key player in getting everything selected and did a good job. We have the following.

5 XMT 350Mpa Power Sources
3 Invision 352Mpa Power SOurces
8 S74Mpa Wire Feeders
2 Syncrowave 250's
1 Realweld Trainer
10 Miller Arcstation Tables
1 Doall 1417 Vertical Bandsaw
1 Scotchman 50 Ton Ironworker
1 Lincoln/Torchmate 4x4 plasma table with Hypertherm Powermax 65
1 Sawyer Guided Bend Tester
10 Miller Filtair Fume Extractors
1 Oxy Acet Cart w/Victor Equipment
1 EH Wachs Electric Pipe Beveler
Ingersoll Rand Air Compressor
and associated accessories.

In addition to the welding equipment, there was a considerable amount of training aids and assessment devices purchased for mechanical, pneumatic, electrical, and PLC's. 

There are also two classroom equipped with  Large Screen TV's and support equipment.

I am looking forward to getting started. I am hoping to get things going soon.

Have a good day
Topic Instructor TIP-Etching Without ACID By pipewelder_1999 Date 01-27-2015 04:58
Many may already know this and many may not have any issues with handling acid. I would think HS instructors may be limited on what they can do when it comes to etching.

Regular White Vinegar from the grocery store will do a pretty decent job but itt may take a day or so. Attached are some pics of a few pieces that were etched this way.
Attachment: etchweldhorizmedium.jpg - 1/2" Vee Groove (192k)
Attachment: acidetc2small.jpg - Bead Sequence Sample (140k)
Topic Completed my first consulting gig By pipewelder_1999 Date 01-27-2015 04:45
Sound like a good deal for them. On that Victor Torch, I have a small one with an "Ergonomic" handle. It too leaked at the tip. Brand new torch, brand new tip.

Have a good day.

Topic Great Job Gerald Austin By pipewelder_1999 Date 01-27-2015 02:24
I offered to wear my "Sunday gotomeetin" overalls but I was told that was not a good idea.

I haven't actually done much yet other than some consulting. My sales skills may need some work. It may be hard to believe, but I talk too much :)

I am looking forward to starting a few projects. I have most of the quality system together for testing welders (ATF and NON-ATF will all be done with the guidelines of AWS B5.4).

The open enrollment classes have not caught on yet. I guess I should quit telling people that a 20.00 per hour job with 4 hours of training is unlikely!

Have  a good one

Topic Great Job Gerald Austin By pipewelder_1999 Date 01-27-2015 02:14
I am not sure where it came from. It was changed once before I even know what it was. I was shooting for the "Grand Pooh-bah of Welding Stuff" but was shot down.

I also am not allowed to publicly refer to the building with the word "center", so there is something to a name.

Topic Great Job Gerald Austin By pipewelder_1999 Date 01-27-2015 02:12
Cool. Thanks !!!!!  Now I have to get that picture at the post office taken down!
Topic Stainless Steel Sugaring By pipewelder_1999 Date 01-27-2015 00:46
I think there may be some issues with mechanical properties if you use copper adjacent to stainless welds if the possibility of contamination exists.

I have used other low melting point alloys to induce cracks in stainless samples for PT.

But as with many things, it may be just fine. I personally would fear the copper more than the sugar!

Have a great day.


Topic Stainless Steel Sugaring By pipewelder_1999 Date 01-27-2015 00:37
If you are in a service environment that requires heat tint and oxidation to be removed, and you do so by chemical means you have t o consider the ability to remove the pickling agent after you are done (faying surfaces that cannot be accessed or internal surfaces that may allow collection.)

You would also normally follow up with a passivation process that restores the chromium oxide layer.

"Sugar" or root oxidation is not a problem in many cases but that is a decision for engineers to put in the specs and not a matter for the lowly inspector. Many codes for piping do not address this "condition" as a defect. As with everything, the service conditions evaluated by engineering professionals should be the deciding factor. 

There are documented research studies  that show the mechanical properties of welds made without purge being equal to or bettter than some welds made without purge.

Here is a statement from an abstract of an EPRI article at

Moderate to severe surface oxidation (generically referred to as "sugaring") is thought to degrade the mechanical and corrosion properties of SS weldments. This study involved an analysis of surface oxidation on stainless steel weldments.

Test results showed that surface roughness due to severe sugaring could potentially compromise mechanical properties and crack initiation sites if subsurface defects are created. Basic mechanical data (bends, tensile and hardness measurements) showed little affect due to sugaring. Corrosion tests (ASTM Practice A, C and E) also showed no detrimental affects produced by the various degrees of sugaring.

I am not saying sugar is "OK" just that sometimes it just may not matter. Of course its hard to call over all my welding buddies and impress em with the golden wedding band on the inside of my coupon.

Many a superheater pendants have been welded in with no purge and RT.

When I think of "High Purity" the term "paint" never comes to mind however that is based upon a limited exposure to many industries.

Now on to read the rest of the responses :)
Topic Comparing Dry MT Results - With And Without Contrast Paint By pipewelder_1999 Date 01-26-2015 23:54
I have used that before.

Another place the "developer" method comes in handy is leak tests on a gas tight component that is verified by liquid "leak test". 

I did some 3rd party inspection where I was to inspect for "any evidence" of leakage on duct work and air pollution control equipment.  On joints with multiple faying surfaces, it would take a considerable amount of time to both wait for the leak and also get back up in a lift to look (the procedure that was approved did not account for joint configurations that may take a day or so for capillary action to do its thing. Spraying the joints or at least starts/stop and corners would greatly help things become visible faster. On some of the above cases, I never saw any liquid but actually discovered cracks that became evident from shop "dust" gathering at the crack ever so faintly.

In addition, with the liquid leak test, you could wipe it off, spray it again, and see the exact location of the opening.

Have a nice day

Topic Un-accredited schools By pipewelder_1999 Date 01-25-2015 22:27
I am not sure what "accredited" means in relationship to welding education. (Other than SENSE and an AWS ATF)

Schools may be "accredited" by various organizations that may no nothing about welding.

A school that has authorization to display the SENSE accreditation may just be able to support Level I (Entry Welders).

I would strongly suggest talking to the instructor.  2 Weeks of Tig (80 Hours I imagine) may work wonders for you. Then again, it may take a little more time depending on your goals and existing experience.

Gerald Austin
Have a good day.
Topic Pics of Boys at Work By pipewelder_1999 Date 01-15-2015 19:44
Those are incredible. Inspiration !  We just had a "Ribbon Cutting" today where I teach. Right now we are still in the "booth" stage!

Thats a great thing you are doing with your students !

Have a great day .

Topic Professional Development By pipewelder_1999 Date 01-11-2015 01:58
Hey Allan,

I appreciate your response. I have only been to a couple of the local meetings so kinda getting my feet wet there. Though I do probably speak up a little more freely than someone who is "new" should. I have yet to get too deeply involved with industry here but my point about organizing is more of an idea I had for a larger scale. The "Instructors Institute" section of the forum really got my attention when it was put in the forum but I really never did find out what it was about.

The local scene where I am is still being developed on my side and I will keep your information in my mind as I move forward here.

Have a great day and thanks so much for your information. I may have more to post about the subject.

Gerald Austin
Topic Pressure vessel code By pipewelder_1999 Date 01-09-2015 15:22
I would think there is more usable data 1000 year old pieces of paper than there are 40 hear old magnetic media. :)
Topic What's In Your Email Account ? By pipewelder_1999 Date 01-08-2015 13:53
Often times Email Accounts aren't hacked, They are "spoofed".  One way to minimize that is to try to avoid having a text version of your email address online anywhere.

This will prevent and or eliminate spoofing that is generated by Web-bots searching the internet for the @ symbol or the word "at".

That will not prevent your email from having problems.

Another contributing factor is replying to or opening any kind of "unusual" email and especially responding to it. When you do, your email address becomes a valid target.

Here is a site that actually lists one of my old ones for a domain I am no longer in control of and an add

I would just be wary of posting my email address if I was concerned with security issues. I have multiple domains so whenever I want to post an email address online, I can make up a new email address, post it in that location only, and see what kind of junk comes to that address.

If you look at your old one isn't t here but that doesn't mean it isn't floating around somewhere else. If you scroll over the right side of the list, you will see options to validate addresses or mark them as bad. I think the only reason for this is for people to gather email addresses for spam and phishing mail.

Also notice at the top of the page the ability to download as a spreadsheet.  A great way to bulk send messages.

Have a good day.

Gerald Austin
Topic Professional Development By pipewelder_1999 Date 01-08-2015 12:09
Hello Allan, hope all is well with you. Sorry it took awhile for me to follow up on this great response. Your comments are great and bring to light some different things to consider. My desire has been to teach and I am relatively new to the process compared to my work experience. And of course, I enjoy sharing what little things I have gathered over the years with others. The problem is that I may not have gathered all I need too be as effective as I need to be. I think sharing and networking among instructors would be a great way for me to grow personally and hopefully help others.  I sometimes have my "head in the sand" when it comes to the "business side" of teaching.

The stumbling blocks you speak of are so true but I think the "financial" one may also be related to good ole pride and ego. Maybe some people don't want to be helped or to share their ideas for various reasons. Or mmaybe some people don't want to known for sharing their ideas or needing help from others. Maybe there is a concern that supervisors will change opinions, or look for others to do their job.

Regardless of the reason, I think and hope there are individuals who desire to help the skills and abilities of others interested in welding develop in a way better than theirs did.

I attended a conference last summer in Indiana and mentioned organizing instructors. No response or follow up. ( I don't discount the possibility that many shied away from me because sometime I do talk too much about some subjects). But thse people were there ! So I would think they are interested in growing as instructors. Sure the conferences and vendor "show and tells" are great. But I think there is something to be said for peer to peer social learning. Yet it doesn't seem to have "caught on" here for organized subjects related to teaching. The "Instructors Institute" heading has NO activity. I don't even know what the "Instructors Institute"is. 

You and many others have contributed tremendous amounts of wealth and knowledge on this forum. I think this style of forum is unmatched for social learning. Facebook, Linked in and others pale in comparison to this forum and others related to welding.  I have recently tried to spend less time here and more on some of the newer platforms to see how useful they were. And as far as useful information, nothing beats this !  But as instructors, I think there are so many things to discuss, that an entire website could be devoted to it. (But thats another topic).

My weak point in the teaching world is awareness of many of the things you discuss in your reply and I could make quite a few posts/question about many of the things you wrote. Much food for thought.

I wanted to write more but need to get to the shop.

Of course the FLOW is great in the post. My brain operates more like the water splashed from a dixie cup by a dropped bowling ball!

Thank you so much for your time and advice over the years.

have a great day

Gerald Austin
Topic Professional Development By pipewelder_1999 Date 12-30-2014 16:47
Allan, Thanks. I look forward to it !

Have a great day.

Topic happy holidays By pipewelder_1999 Date 12-24-2014 19:46
Same to you !
Topic Professional Development By pipewelder_1999 Date 12-18-2014 16:24
I have often wondered why instructors do not organize a bit better. We all have varying types of skills and experiences. I recently suggested our local section try to network instructors in the area but not really sure how it went over. Even went as far as building a "Welding Instructors" forum to allow for semi-private discussions of topics related to welding education.  But that too, not much interest.

At the Educational Conference that AWS had this past year in Indiana, I brought the topic up. Not much interest.

If you are close to Northeast Tennessee, I have considered hosting an educational session here for instructors to share ideas, develop skills, and discuss training methods.  Haven't went forward with it yet. Things are starting a little slow here so I better not bring up anything new to those I work for.

However, If you are ever in the Greeneville Tn area, look me up.

Gerald Austin
6626600162 Call or Text
Topic 45 year old new welding student By pipewelder_1999 Date 12-02-2014 03:39
I haven't been on the forum in awhile but WELCOME.

Have a great day.

Gerald Austin
Topic The Professor Crisi will be missed By pipewelder_1999 Date 11-09-2014 10:13
Very Sad. A tremendous contributor to my knowledge and understanding.
Topic Preparing for CWI certification seminar/exam. Any advice? By pipewelder_1999 Date 10-02-2014 18:49
Welcome to the forum!

Everyone learns differently so I would try to gain as much information as possible. I strongly Suggest the AWS Welding Handbook Volume 1- 8th or 9th edition. It has a pretty good summary of most of the topics referred to in the BOK. Itt by no means is all inclusive of every question on the test but that along with the Certification Manual for Welding Inspectors is all I used for self study. However I did not use the materials for study only. They were a daily read just because I liked em.

I am not sure what a Pre-Seminar Class is and have not taken one but I am sure for some people its extremely helpful in helping the upcoming information in the seminar soak in better.

The materials listed at would be the place to start. One thing about the Welding Handbook Volume one is the fact that it has quite a bit of information taken from the other referenced documents.

Joining Processes
Cutting Processes
Thermal Spraying

Supplementary Reading List

Fusion and Solid-State Welding
Energy Sources for Welding
Arc Characteristics
Metal Transfer
Melting Rates
Physical Properties of Metals and Shielding Gases
Supplementary Reading List

Heat Flow Fundamentals
Quantitative Calculation of Heat Transfer in Fusion Welding
Conduction of Heat during Fusion Welding
Convective Heat Transfer in the Weld Pool
Relative Importance of Conduction and Convection
Supplementary Reading List

Physical Metallurgy
Metallurgy of Welding
Weldability of Commercial Alloys
Corrosion in Weldments
The Brazed or Soldered Joint
Corrosion in Brazed and Soldered Joints
Supplementary Reading List

Properties of Metals
Weldment Design Program
Welded Design Considerations
Design of Welded Joints
Selection of Weld Type
Sizing of Steel Welds
Tubular Connections
Aluminum Structures
Supplementary Reading List

Testing for Strength
Hardness Tests
Bend Tests
Fracture Toughness Testing
Fatigue Testing
Corrosion Testing
Creep and Rupture Testing
Testing of Thermal Spray Applications
Weldability Testing
Supplementary Reading List

Nature and Causes of Residual Stress
Effects of Residual Stress
Measurement of Residual Stress
Residual Stress Distribution Patterns
Effects of Specimen Size and Weight
Effects of Welding Sequence
Residual Stress in Welds Made with Different Welding Processes
Weld Distortion
Reducing or Controlling Residual Stress and Distortion
Supplementary Reading List

Welding Symbols
Welding Symbols for Specific Weld
Brazing Symbols
Soldering Symbols
Inspection Symbols
Supplementary Reading List

Supplementary Reading List

Principles of Monitoring and Control
Sensing Devices
Process Instrumentation
Process Monitoring Systems
Process Control Systems
Monitoring and Control Systems
Supplementary Reading List

Mechanized Welding
Automated Welding
Robotic Welding
Planning for Automated and Robotic Welding
Supplementary Reading List

The Cost Estimate
Economics of Welding
Automated and Robotic Systems
Economics of Resistance Spot Welding
Capital Investment in Welding Automation and Robotics
Control of Welding Costs
Economics of Brazing and Soldering
Economics of Thermal Cutting
Supplementary Reading List

Defining Weld Quality
Overview of Weld Discontinuities
Discontinuities Associated with Fusion Welding
Discontinuities Associated with Resistance Welding
Discontinuities Associated with the Solid-State Welding Processes
Discontinuities in Brazed and Soldered Joints
Significance of Weld Discontinuities
Supplementary Reading List

Personnel Qualifications
The Inspection Plan
Nondestructive Examination
Metallographic Examination Methods
Inspection of Brazed and Soldered Joints
Supplementary Reading List

Welding and Brazing Procedure Specifications
Qualification of Welding and Brazing Procedures
Performance Qualification
Standardization of Qualification Requirements
Supplementary Reading List

Types of Regulatory Documents
Standards-Developing Organizations and Welding-Related Publications
Guidelines for Participating in International Standards Activities
Supplementary Reading List

Safety Management
Protection of the Work Area
Personal Protective Equipment
Protection against Fumes and Gases
Safe Handling of Compressed Gases
Protection against Electromagnetic Radiation
Electrical Safety
Fire Prevention
Explosion Prevention
Process-Specific Safety Considerations
Safety in Robotic Operations
Supplementary Reading List


Here is the BOK for the Fundamentals.
Subject  Percentage
Welding Processes  10%- Chapter 1
Heat Control & Metallurgy (carbon and low-alloy steel)  6% Chapter 2,3,4
Weld Examination  9% Chapter14
Welding Performance  9% Chapter 15
Definitions and Terminology  12% Appendix A
Symbols - Welding and NDE  10% Chapter 8
Test Methods - NDE  8% Chapter 6, 13, 14
Reports and Records  6% Various
Duties and Responsibilities  4%
Safety  5%- Chapter 17
Destructive Tests  4%-Chapter 6
Cutting  3% Chapter 1
Brazing  2% Chapter 1
Soldering  1% Chapter 1

Of course if you can get ALL of the referenced books, then do it. I imagine with the online prep course there is a pretty good amount of material provided. The Welding Handbook is what I suggest as a learning tool more than a prep for a test tool.

If all of your experience is as an operator and not welding related, then it may take a few different methods to soak it all in.  If you already have some core knowledge based upon prior study/interests then it may be no problem and the courses may be all you need. BUT you can never go wrong getting welding books.

Gerald Austin
Topic manipulating welds By pipewelder_1999 Date 09-28-2014 01:18
Is it possible that this "idea" is taken from the prequalified procedure limitations of D1.1 ? My 2010 is at the office but the single pass layer thickness I am pretty sure is limited to 1/4" (Slightly over the distance for theoretical face to root of 5/16" fillet weld).

However as a procedure variable outside the scope of D1.1 prequalified, no such requirement exists that I am aware of (And that does not mean it does not exist) But in my limited experience that is not where limits exist for many other codes.  Is that a good idea YES IT IS. I firmly believe that one of the leading causes of fusion related discontinuities is the thickness of the puddle and where the arc falls in that puddle.

I understand the requirement in that context. I just do not understand a "blanket statement" based upon the text you reference.  The 1st "Welding Supervisor" that brings that one to my attention as a criteria for rejection will definitely be queried as to a "REAL" acceptance criteria that binds that requirement. If he/she refers to the CMWS then I will probably follow up with something more in tune with the actual requirements related to the project.

There are just SO MANY welding wives tales that get generated from valid requirements that apply to a particular situation, Those requirements then become accepted as facts and many never question  the context of when they apply. Who is to doubt the word of a "Certified" person. Thinks  that happen in D1.1 Preq don't apply to qualified which don't apply to sec IX blah, blah blah.

Again, shop requirements, individual company requirements are those of the shop or company. Good/Bad or otherwise, they are what they are. Actual acceptance criteria is what it is. Neither one by itself make for a quality program.

Have a good day.


ALSO, I ran into some of your HR people at a recent conference, they spoke very highly of you. I told them what I thought about you based on what I've seen here.
Topic manipulating welds By pipewelder_1999 Date 09-27-2014 13:32
I'll have to find one of them and check it out. There may be tons of stuff I have been missing out on. :).  I'm excited.
Topic manipulating welds By pipewelder_1999 Date 09-26-2014 23:53
Tell me more about WHY this is true ? I have not seen the CM for welding supervisors but I have made quite a few welds on various structures with groove welds with individual passes larger than a 5/16" fillet weld equivalent size. Many of said structures and vessels still in service.

And again, I may be missing something in the context of this conversation. Just wondering if another welding wives tail is going to start from the highly peer reviewed reference you mention. Again, I understand company requirements, heat input blah, blah.. but does that book really say that ?

Topic manipulating welds By pipewelder_1999 Date 09-26-2014 23:43
If those were pushed then I should send you a Lobster too. Maybe just a few Tenn Mudbugs. I don't doubt you are telling me the truth but I have fought this on MANY welder tests that continued to fail.

Of course I may be completely lost as I received a poster from the blue company a week or two ago that says amperage goes down as wire feed speed goes up. So I am throwing my knowledge out the window.

Topic GMAW Wire Sticks By pipewelder_1999 Date 09-26-2014 23:36
After industry gets involved then all of the shops with regular non-engieered for safety welding equipment are burdened with being non-compliant or upgrading the equipment. Sounds like a good deal for the equipment manufacturers.

For some companies the cost to implement "engineering controls" is nothing. They just buy new $10000.00 power sources and wire feeders. What if we all decided that smoke, EMF, repetitive strain, are all things that need to be eliminated. Though the risk is small probably based on the number of welders, it is still a risk. EVERYTHING can be engineered out. The level at which it becomes a problem for an organization is more related to the organization than it is to the problem.

How many companies have installed fume extracting Mig Guns to limit welders exposure to ozone? Not many. But how many have strict and strongly enforced policies for the lifesaving safety glasses ?

Just some of my thoughts.

As I said before, I'm all for safety. I also believe all accidents could have been prevented but also believe they NEVER will be. I gotta worry about mine 1st, others 2nd.

Awareness, A Safety Culture that promotes Employee input on hazard elimination, Management that supports safety for safety and not compliance, and training to support it all.

Topic GMAW Wire Sticks By pipewelder_1999 Date 09-26-2014 23:23
I may be looking at this the wrong way. I too am very concerned with safety. But the idea of "engineering out" hazards can really get into some tricky places. 

When engineering is not practical, protective measures are completely fine. PPE to protect the individuals skin from hot/sharp wire is the same PPE that is used to protect the individual from molten sparks. If the engineering controls are workable, then by all means do them. But Could the safety Nazis then also decide its better to use a certain transfer mode, process etc.. just because it makes less sparks?

I truly think PPE and Training for awareness are key. Lets not assume all welders must have engineering controls. When I have taught "Welding Safety" in the past I have tried to stress the safety hazards that are inherent to that process.

Topic QW 404.5 ASME IX By pipewelder_1999 Date 09-26-2014 20:34
I am not understanding.

If the WPS says ER70S-6 then that is what must be used. If the WPS says A Number 1, then that is what must be used . If the contractor listed ER70S-6 in the PQR and the WPS says Er70S-6 then there is no problem. As long as they are using ER70S-6. If an electrode does not have an A-number (70S-6) then that is OK.

I apologize for not being sure on what you are asking.


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