3 Reasons Why You Need to Make Smaller Welds

Bigger is not always better, at least not in welding.  Making welds bigger than they need to be is not only wasteful and costly, but can cause other problems such as distortion and premature failure. Below are 3 reasons why you may need to pay close attention to your weld sizes.  1. Bigger welds cost […]

The Importance of the Heat Affected Zone (HAZ)

When we weld we generate enough heat in the welding arc to melt the filler metal and base material.  Or just the base material is we are welding autogenously (as in GTAW without filler).  The edges of the base material melt and combine with the filler metal to create what is called the composite zone.  […]

5 MORE Questions You Should Know for the CWI Exam

And fundamental principles for the fabrication of steel structures

Today we’ll cover 5 more very important concepts that are governed by the AWS D1.1 Structural Welding Code (Steel). If you missed our last post with the first five questions simply click here.  These concepts can show up as questions in the Certified Welding Inspector (CWI) Exam. As stated in our article from last week, […]

5 Questions and Answers You Must Know for the CWI Exam

And fundamental principles for the fabrication of steel structures

If you have taken or hope to take the CWI exam you probably have searched for some practice exam questions.  In practicing for the code book portion of the test you may have come across a few questions for which you could find the answer, but didn’t really understand the importance of the question or […]

What To Do When Welding Codes Are Not Clear

Or when the code does not provide enough information to make an important decision

If you are a CWI, welding engineer or serve in a capacity that requires you to use and interpret welding codes, you probably have run into instances where the code is not very clear.  Many of the questions we receive from our readers deal with interpreting codes and standards.  Many times it is not about […]

21 Changes to PQR Essential Variables that Require WPS Requalification

​Have you ever seen a welding procedure specification with established amperage ranging from 200 to 550 amps? Or voltage ranging from 21 to 29 volts? Or some other variable with a huge window? This is all too common, but extremely dangerous. Why? Because changes to essential variables beyond that which is reasonable will affect the […]

7 Areas of Study for Aspiring Welding Engineers

Welding engineering is a complex field that requires expertise in many different engineering disciplines.  The welding engineer must take advanced courses in metallurgy (including welding metallurgy), material science, mechanics of materials, thermodynamics, chemistry and fundamentals of all welding processes.  Welding engineers are tasked with many different activities which include but are not limited to:   […]

The Relationship between Heat Input and Weld Size

Heat input is important because it has an effect on cooling rates which in turn can significantly affect the mechanical properties of the weld and heat affected zone. It also plays a role in susceptibility to distortion.  High heat input can be beneficial in some cases and detrimental in others.  A common misconception is that […]

Rule of Thumb for Fillet Weld Sizes

Many fabricators can lower their welding costs significantly if they paid close attention to weld sizes.  If a print calls for a ¼” fillet weld and in production you make a 5/16” fillet weld, you are overwelding by 56%!  If the print calls for a 3/16” fillet, the 5/16” fillet weld you deposit would be […]

4 Key Factors Affecting the Fatigue Life of Welded Structures

Designing for fatigue is very different than designing for static loads.  One of the biggest challenges is being able to estimate the loads, timing of the loads and duration of the loads.   If you look at a bridge you have to estimate the number of vehicles going on the bridge every day, the weight of […]