Arc Welding 101: Three keys to a successful CWI

Q: I was recently interviewed by a writer who was researching how welders make the transition to certified welding inspectors (CWI). One of the questions he asked was, “What key skills make for the best certified welding inspector?”

A: Communication—written, photographed, or verbal—is the key to becoming a successful CWI.

I received a report the other day evaluating a set of bend coupons for a welder qualification test. The document stated, “All his welds looked very good except he failed the bend test in a few spots.”

Words mean nothing if they are not intelligible. A CWI needs to be able to speak and write clear, accurate reports that state, in the world of Joe Friday, “Just the facts, ma’am.” No opinions or spin, half truths, or sugar coatings. Just clear and accurate accounts of what was seen, measured, found to be acceptable or unacceptable, and why. You should also include what couldn’t be seen, was not measured, and why.

Here’s how that report should have read (AWS D1.1, Fillet Option 2):

• Fillet welds were visually acceptable.
• Completed test plate was visually acceptable.
• Coupon 1 (C1); Root bend: One discontinuity less than 1/32 in. Acceptable.
• Coupon 2 (C2); Root bend: One discontinuity greater than 1/32 in. but less than 1/8 in. One defect greater than 1/8 in. No corner cracks. Unacceptable.

When a CWI is called on to review his past records, those records need to be clear. You may not recall the conditions that led to your report, but you will be thankful that you developed a clear, accurate report and that you filed it with copies of the marked-up prints, inspection requirements, relevant weld procedure, specifications (WPS), and weld personnel qualification report (WPQR).

Pictures are an excellent means of communication. They can quickly clarify a condition to those not on-site. However, most photographs of welds I’ve seen lack size perspective. I rarely photograph a weld that doesn’t show my 5-in. Starrett scale. Also, I never make the call based on a photo. There are far too many unknowns for my comfort level.

Verbal communication needs to be clear and respectful. Statements need to be founded on adequate knowledge of the facts, which means the CWI needs to possess a background of technical competence pertinent to the issue. It’s equally important that the CWI get feedback from those in the conversation to ensure the message is being received correctly and as intended.