Welding Inspection Course

Lesson 1 • Role and Responsibilities of the Inspector

Defines the inspector's duties, authority, and ethical obligations on a job site. Establishes the professional framework that governs all subsequent inspection activities.

Lesson 2 • Quality Management in Welding

Introduces quality systems, inspection hold points, and traceability requirements used in fabrication. Connects quality management principles to the inspector's daily workflow.

Lesson 3 • Weld Joint Design and Terminology

Introduces standard joint types, groove geometries, and weld symbols used in engineering drawings. Accurate symbol interpretation is essential for verifying conformance to design intent.

Lesson 4 • Basic Metallurgy for Inspectors

Covers metal crystal structure, heat effects, and weldability concepts relevant to inspection decisions. Links metallurgical behaviour to defect formation and acceptance criteria.

Lesson 1 • Acceptance Criteria and Fitness for Service

Compares workmanship-based and engineering-critical acceptance criteria for weld discontinuities. Prepares inspectors to apply the correct standard for each project context.

Lesson 2 • Contract Documents and Specifications

Examines how project specifications, purchase orders, and drawings interact with referenced codes. Inspectors learn to resolve conflicts and identify the governing document hierarchy.

Lesson 3 • Welding Procedure Specifications

Details the content, purpose, and review process for welding procedure specifications. Inspectors use these documents to verify that production welding matches qualified parameters.

Lesson 4 • Welder Performance Qualification

Covers qualification testing requirements, position limitations, and continuity rules for welders. Ensures inspectors can verify that only qualified personnel perform production welds.

Lesson 1 • Shielding Gases and Fluxes

Reviews shielding gas compositions, purity requirements, and flux types used in arc welding processes. Gas and flux selection directly affects weld chemistry and discontinuity formation.

Lesson 2 • Filler Metal Storage and Control

Covers moisture control, low-hydrogen electrode handling, and consumable traceability requirements. Improper storage is a leading cause of hydrogen-induced cracking in welds.

Lesson 3 • Preheat, Interpass, and PWHT Requirements

Explains how thermal treatments are specified, measured, and documented to control weld metallurgy. Correct thermal management prevents cracking and ensures required mechanical properties.

Lesson 4 • Filler Metal Classification Systems

Explains how filler metals are classified by strength, composition, and usability characteristics. Inspectors use classification knowledge to verify correct consumable selection.

Lesson 1 • Lighting, Access, and Viewing Conditions

Establishes minimum lighting levels, viewing angles, and access requirements for valid visual inspection. Proper conditions are prerequisites for reliable discontinuity detection.

Lesson 2 • Weld Measurement Tools and Gauges

Introduces standard weld gauges, rulers, and optical aids used to measure weld dimensions. Accurate measurement is fundamental to confirming conformance with dimensional tolerances.

Lesson 3 • In-Process Visual Inspection

Addresses inspection tasks performed between weld passes to catch defects before they are buried. Timely in-process checks reduce the need for costly nondestructive examination.

Lesson 4 • Pre-Weld Inspection Activities

Covers material verification, joint preparation checks, and fit-up measurements before welding begins. Early detection of setup errors prevents costly rework and weld defects.

Lesson 1 • Magnetic Particle Testing

Explains magnetic field generation, particle application, and indication evaluation for ferromagnetic welds. Covers both wet and dry methods and their applicable weld geometries.

Lesson 2 • Radiographic Testing of Welds

Introduces radiation sources, film and digital imaging, and radiograph interpretation for weld examination. Students identify volumetric discontinuities and evaluate image quality indicators.

Lesson 3 • NDE Method Selection and Reporting

Guides inspectors in selecting the most effective NDE method based on discontinuity type, material, and geometry. Covers report content requirements and record retention.

Lesson 4 • Liquid Penetrant Testing

Covers the principles, materials, and procedure steps for liquid penetrant examination of welds. Students interpret indications and apply acceptance criteria for surface-open discontinuities.

Lesson 1 • Classification of Weld Discontinuities

Defines the difference between discontinuities and defects and organises them by origin category. Accurate classification is the foundation for applying correct acceptance criteria.

Lesson 2 • Geometric and Dimensional Discontinuities

Addresses undercut, underfill, excessive reinforcement, and misalignment as dimensional nonconformances. Students measure and evaluate these against code-specified dimensional limits.

Lesson 3 • Corrective Action and Repair Welding

Outlines the process for excavating, re-welding, and re-inspecting rejected welds. Proper repair procedures prevent reintroduction of the original defect.

Lesson 4 • Cracking Types and Root Causes

Analyses hot cracking, cold cracking, lamellar tearing, and stress-corrosion cracking mechanisms. Understanding root causes enables inspectors to recommend effective preventive measures.

Lesson 1 • Structural Steel Fabrication Inspection

Covers inspection requirements specific to structural connections, beam-column joints, and moment frames. Students apply structural welding code requirements to fabrication shop and field conditions.

Lesson 2 • Pressure Vessel and Piping Inspection

Addresses fabrication inspection for pressure vessels and piping systems under pressure equipment codes. Inspectors verify joint categories, radiography requirements, and hydrostatic test readiness.

Lesson 3 • Dimensional and Fit-Up Inspection

Covers dimensional verification of fabricated assemblies against engineering drawings and tolerances. Dimensional nonconformances detected early prevent costly rework during final assembly.

Lesson 4 • Weld Map and Traveler Documentation

Explains how weld maps, travellers, and as-built records are created and maintained during fabrication. Complete documentation supports code compliance and future maintenance inspections.

Lesson 1 • Audit and Surveillance of Welding Operations

Covers planning and conducting quality audits and surveillance visits of welding fabricators. Audits verify that quality systems are implemented and effective, not just documented.

Lesson 2 • Developing an Inspection and Test Plan

Teaches how to build a comprehensive inspection and test plan aligned with code and contract requirements. A well-structured plan ensures no inspection activity is missed on complex projects.

Lesson 3 • Nonconformance and Corrective Action Management

Establishes a systematic process for raising, tracking, and closing nonconformances on welding projects. Effective NCR management prevents recurrence and supports continuous improvement.

Lesson 4 • Risk-Based Inspection Prioritisation

Introduces risk-based thinking to prioritise inspection resources on highest-consequence welds. Students assess probability and consequence of failure to allocate inspection effort effectively.