Welding Inspector Course

Lesson 1 • Metals and Basic Metallurgy

Covers ferrous and non-ferrous base metals, grain structure, and heat effects. Understanding metallurgy explains why defects form and how material selection affects weldability.

Lesson 2 • Overview of Welding Processes

Surveys major arc and non-arc welding processes and their industrial applications. Process knowledge enables inspectors to anticipate process-specific defect types.

Lesson 3 • Role and Responsibilities of the Inspector

Defines inspector duties, authority limits, and ethical obligations. Establishes the professional framework that inspectors operate on industrial projects.

Lesson 4 • Welding Terminology and Joint Geometry

Introduces standardised welding vocabulary and joint design classifications. Accurate terminology is essential for reading drawings and communicating defect findings.

Lesson 1 • Engineering Drawing Fundamentals

Reviews orthographic projection, views, and drawing conventions used in fabrication. Drawing literacy is the prerequisite for interpreting welding symbol instructions.

Lesson 2 • Groove and Fillet Weld Symbols

Applies symbol reading to detailed groove and fillet weld configurations. These two categories represent the majority of structural and pressure weld joints.

Lesson 3 • Pipe and Structural Drawing Conventions

Addresses drawing conventions specific to piping isometrics and structural steel details. Inspectors working in these sectors encounter unique notation and view formats.

Lesson 1 • Reviewing and Approving Qualification Documents

Trains inspectors to audit WPS, PQR, and welder qualification records for compliance. Systematic document review prevents non-conforming welds from entering production.

Lesson 2 • Welding Procedure Specification Essentials

Explains the purpose, structure, and essential variables of a Welding Procedure Specification. A valid WPS is the baseline document inspectors verify before any weld is made.

Lesson 3 • Welder Performance Qualification

Details the testing process that certifies individual welders for specific variables. Inspectors monitor qualification tests and validate continuity of certification.

Lesson 1 • Post-Weld Visual Examination

Applies systematic visual examination to completed welds against code acceptance criteria. Students document findings using standardised terminology and reporting formats.

Lesson 2 • In-Process Inspection Monitoring

Covers real-time monitoring of interpass temperature, pass sequence, and technique. In-process oversight catches deviations before they become embedded defects.

Lesson 3 • Weld Discontinuities and Defect Classification

Classifies surface and subsurface discontinuities by type, cause, and severity. Accurate classification directs the correct remediation or rejection decision.

Lesson 4 • Pre-Weld Inspection Activities

Identifies checks performed before welding begins, including fit-up, cleanliness, and preheat. Early detection of setup errors prevents costly rework after welding.

Lesson 1 • NDE Method Selection and Limitations

Guides the selection of NDE methods based on material, joint geometry, and defect type. Understanding limitations prevents over-reliance on a single method for critical welds.

Lesson 2 • Magnetic Particle Testing Principles

Covers magnetic field generation, particle types, and indication interpretation for MT. MT detects surface and near-surface discontinuities in ferromagnetic materials.

Lesson 3 • Radiographic Testing Fundamentals

Introduces X-ray and gamma-ray sources, film exposure, and image quality indicators. RT provides a permanent volumetric record of internal weld discontinuities.

Lesson 4 • Liquid Penetrant Testing Principles

Explains the capillary action mechanism, materials, and procedure steps for PT. PT efficiently detects surface-breaking discontinuities in non-porous materials.

Lesson 1 • Macroscopic and Microscopic Examination

Describes macro-etch and micro-examination procedures for weld cross-sections. These examinations reveal pass count, fusion quality, and microstructural anomalies.

Lesson 2 • Hardness Testing Methods

Introduces Vickers, Brinell, and Rockwell hardness scales and their application to welds. Hardness surveys detect over-hardened HAZ regions susceptible to hydrogen cracking.

Lesson 3 • Tensile and Bend Testing

Explains specimen preparation, test procedures, and acceptance criteria for tensile and bend tests. These tests confirm that weld strength and ductility meet procedure qualification limits.

Lesson 1 • Statistical Sampling and Inspection Frequency

Applies statistical sampling concepts to determine NDE scope and inspection frequency. Risk-based sampling optimises inspection resources without compromising quality assurance.

Lesson 2 • Final Inspection and Turnover Documentation

Covers final inspection activities, data book compilation, and project turnover packages. Complete documentation packages are the inspector's deliverables at project completion.

Lesson 3 • Inspection and Test Plan Development

Guides creation of Inspection and Test Plans that define hold, witness, and review points. ITPs align inspection activities with project milestones and contractual requirements.

Lesson 4 • Quality Management System Principles

Introduces QMS structure, document control, and continuous improvement concepts. Inspectors operating within a QMS contribute to systemic quality rather than isolated checks.

Lesson 1 • Weld Repair Inspection

Defines inspection requirements for weld repairs, including excavation verification and re-examination. Repair welds must meet the same acceptance criteria as original production welds.

Lesson 2 • Non-Conformance and Rejection Process

Establishes the formal process for documenting, tagging, and dispositioning rejected welds. A controlled rejection process ensures traceability and prevents unauthorised repairs.

Lesson 3 • Pressure Vessel and Piping Criteria

Covers acceptance criteria specific to pressure-containing welds in vessels and piping. Higher safety factors in pressure applications result in stricter discontinuity limits.