Welder Test Lesson Plan Notes

  • Welder Test Overview

    • Limited thickness D1.1 Groove weld certification test with an open root
    • Two test plates required: 3/8" x 3" x 7" each

  • Preparation of Test Plates

    • Cut plates as stated
    • Beveled edge at approximately 30° (+5°, -0°)
    • Root face of approximately 1/16" (+ or - 1/16")
    • Remove sharp edges and mill scale through grinding or filing

  • Assembly of the Joint

    • Assemble butt joint with 1/16" (+ or - 1/16") opening
    • Use run on/off tabs for alignment
    • Create tack welds on tabs before securing joint

  • Welding Process

    • Groove weld with 2 or more stringer or weave passes
    • Ensure full penetration by adding fill and cap passes if needed
    • If not full penetration, back grind root to sound metal
    • Ensure slag is cleaned between passes, do not grind finished cover pass

  • Visual Inspection Criteria (D1.1, Section 6.10.1)

    • No cracks or craters
    • No incomplete fusion or penetration
    • Reinforcement must not exceed 1/8"
    • No underfill or root concavity > 1/16"
    • Undercut not > 1/32" deep
    • All slag removed, no excessive spatter

  • Sectioning and Testing of Weld

    • Cut straps: 1 inch from ends, 1-1/2" for bend testing
    • Grind reinforcement flush with base metal, maintaining thickness
    • Round corners of straps to approx. 1/8"

  • Bending Test

    • Face bend: weld face down, root bend: weld root down
    • Weld must remain centered during bending
    • Pass criteria:
    1. No discontinuities > 1/8" on convex portion
    2. Total discontinuities 1/32" or greater can’t exceed 3/8"
    3. Corner cracks < 1/4"

  • Final Requirements

    • Pass visual inspection of finished weld
    • Perform 1 face bend and 1 root bend test.