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newSchoolWorks.com › VoTechWorks › Building & Construction › Welding › Certification Exam Preparation: AWS D1.1 CW, AWS SENSE L1-2, NCCER Welding L1-4, and ASME Sec. IX › Lesson 3
BLD-WELD01-14 · Lesson 3 · 36 clock hours · lab

Performance Skill Stations: Welding and Inspection to Code

Objective. Students produce groove and fillet weld test coupons in the positions required by their chosen credential qualifications — using SMAW, GMAW/FCAW, and GTAW on plate and SMAW or GTAW on pipe — that meet the visual, bend, and break acceptance criteria specified in AWS D1.1 and ASME Section IX.

Performance Skill Stations: Welding and Inspection to Code

This lab puts you in conditions that closely mirror the actual credential performance tests for AWS D1.1 Certified Welder, AWS SENSE L1-2, NCCER Welding L1-4, and ASME Section IX. Every coupon you produce today is evaluated against the same acceptance criteria a third-party examiner would use on test day. Work deliberately, follow the WPS, and treat each station as a real exam attempt.

Station Overview

You will rotate through six timed stations:

1. SMAW 3G and 4G groove weld on carbon steel plate per a prequalified AWS D1.1 WPS

2. GMAW or FCAW 3G fillet and groove welds on carbon steel plate

3. GTAW root pass with SMAW fill and cap on 2-inch schedule carbon steel pipe in the 6G position per ASME Section IX

4. SMAW pipe in 2G and 5G positions

5. Visual inspection of completed coupons using D1.1 Table 6.1 and ASME Section IX QW-194 criteria

6. Guided-bend and nick-break testing on previously welded samples

Pre-Station Procedure: WPS Review

Before you strike an arc, review the Welding Procedure Specification for that station. Identify every essential variable: base metal P-number or group, filler metal classification and diameter, shielding gas type and flow rate, polarity, amperage and voltage range, travel speed range, and position. Set your machine within the WPS range and verbally confirm your setup with the instructor. This step is not optional — credentialing sites require you to demonstrate that you understand the procedure before testing begins. A welder who ignores the WPS and produces a visually acceptable coupon can still be disqualified if machine settings fall outside the specified range.

Safety Requirements at Every Station

PPE is mandatory and non-negotiable. Wear your welding helmet with the correct shade lens for the process and amperage, flame-resistant (FR) clothing with no exposed synthetic fibers, leather welding gloves, steel-toed boots, safety glasses under your helmet, and hearing protection whenever grinding, air-arcing, or working near loud equipment. Long sleeves and a collar prevent arc flash burns to skin. Never substitute standard work gloves for leather welding gloves when handling hot coupons or electrodes.

Lockout/Tagout (LOTO) applies any time you open a wire feeder, clear a wire jam, change a contact tip, or perform any maintenance on welding equipment. Follow your school's written LOTO procedure: de-energize the machine, apply your personal lock, verify zero energy by attempting to start the machine, then proceed. Re-energize only after guards are replaced and all personnel are clear. LOTO violations are a leading cause of serious electrical injury in the shop — treat every LOTO step as if your life depends on it, because it does.

When using the guided-bend jig, keep fingers clear of the ram path. Inspect the jig for cracks or loose bolts before each use. When using oxy-fuel or plasma cutting equipment to prepare coupons, confirm gas hoses are free of damage, purge lines before lighting, and keep the cutting area clear of flammables.

Visual Inspection to Code

After welding, complete your self-inspection checklist before handing the coupon to the instructor. For AWS D1.1 plate coupons, apply the visual acceptance criteria from Table 6.1: cracks are not acceptable in any form; undercut must not exceed the depth limit for the weld category; reinforcement height must fall within the specified range; porosity, overlap, and crater fill requirements must all be met. For ASME Section IX pipe coupons, QW-194 governs visual examination of the completed weld prior to bending.

Use a weld gauge to measure reinforcement and undercut — eyeballing is not sufficient. Mark any questionable area with a soapstone mark and note it on your Performance Test Log before the instructor evaluates it. Honesty in self-inspection is a professional habit that credentialed welders carry throughout their careers.

Guided-Bend and Nick-Break Testing

Coupons that pass visual inspection proceed to mechanical testing. The guided-bend test bends a machined or flame-cut test strip around a mandrel of specified diameter to a specified angle. For AWS D1.1, acceptance requires that after bending, no single discontinuity on the convex surface exceed the length limits specified in the code. For ASME Section IX, similar limits apply per QW-163. Face bends and root bends test different weld zones — make sure you label each strip before testing.

The nick-break test is used for fillet welds and some groove weld categories. A notch is cut into the weld, and the coupon is broken open. The fracture face must show complete fusion and be free of cracks, incomplete fusion, and porosity beyond the allowable size and number.

Record every result — pass or fail — on your Performance Test Log. Three consecutive failures on the same position and process trigger a mandatory conference and a remediation plan. Use failures as diagnostic data: identify whether the defect is a root problem (wrong amperage, wrong rod angle) or a technique problem (travel speed, weave pattern) and adjust accordingly.

Connecting Lab Work to Credential Requirements

Each credential has specific position and process requirements. AWS D1.1 Certified Welder qualification in 3G and 4G covers a range of positions. NCCER levels build from flat and horizontal positions upward. ASME Section IX 6G qualification is the broadest pipe qualification because it encompasses the most demanding fixed-position challenge. Passing each station here means you arrive at the actual credentialing site having already performed the test under realistic conditions — the only difference on test day is a different examiner watching.

Key terms10

Welding Procedure Specification (WPS)A written document that specifies the essential and non-essential variables a welder must follow to produce a weld that meets a particular code — including base metal, filler metal, position, preheat, amperage, voltage, and travel speed ranges.
Essential VariableAny welding variable whose change, as defined by the applicable code (AWS D1.1 or ASME Section IX), requires re-qualification of the welder or procedure; examples include a change in process, base metal group, or position.
3G PositionA groove weld made on a vertical plate; the weld axis is vertical and the weld face is in a vertical plane. AWS D1.1 qualification in 3G covers flat and horizontal positions as well.
6G PositionA pipe groove weld made with the pipe axis fixed at approximately 45 degrees to horizontal and not rotated during welding; qualification in 6G covers all other pipe positions under ASME Section IX.
Guided-Bend TestA mechanical test in which a machined strip cut from a weld coupon is bent around a mandrel of specified diameter to a specified angle; used to evaluate ductility and soundness of the weld and heat-affected zone.
Nick-Break TestA destructive test in which a notch is sawed or cut into a fillet weld or groove weld and the coupon is fractured open so the weld interior can be examined for fusion, porosity, and other discontinuities.
UndercutA groove melted into the base metal at the weld toe that is not filled by weld metal; AWS D1.1 specifies a maximum allowable depth depending on weld category and location.
Lockout/Tagout (LOTO)An OSHA-required procedure to de-energize equipment and apply a personal lock before performing maintenance or clearing jams, ensuring the equipment cannot be accidentally re-energized while someone is working on it.
QW-194 (ASME Section IX)The subsection of ASME BPVC Section IX that specifies visual examination requirements for welder performance qualification test coupons prior to mechanical testing.
Performance Test LogA student-maintained record documenting position, process, WPS number, machine settings, visual inspection result, and mechanical test result for each coupon welded during lab; used to track readiness for credentialing.

Worked examples4

1. Your WPS specifies a reinforcement height of 1/8 inch (3.2 mm) maximum for a 3G groove weld on 3/8-inch plate. You measure the reinforcement with a weld gauge and get a reading of 5/32 inch (approximately 4.0 mm). Does the coupon pass or fail the visual check for reinforcement?
  1. Step 1 — Identify the acceptance limit: the WPS (referencing D1.1) states reinforcement must not exceed 1/8 inch = 0.125 inch.
  2. Step 2 — Convert your measurement to the same unit: 5/32 inch = 5 ÷ 32 = 0.15625 inch.
  3. Step 3 — Compare measured value to limit: 0.15625 inch > 0.125 inch.
  4. Step 4 — Apply the acceptance criterion: the measured reinforcement exceeds the maximum allowed.
Answer: The coupon FAILS the visual inspection for reinforcement. The excess must be noted on the self-inspection checklist. The coupon cannot proceed to bend testing until the discrepancy is discussed with the instructor — excess reinforcement cannot be corrected by grinding without also evaluating the weld profile per code.
2. You are performing a guided-bend test on a face-bend strip. After bending, you observe three separate open discontinuities on the convex surface: one measuring 1/16 inch, one measuring 3/16 inch, and one measuring 1/8 inch. AWS D1.1 requires that no single discontinuity exceed 1/8 inch (3.2 mm). Do any individual discontinuities cause failure?
  1. Step 1 — List each discontinuity and its size: 1/16 inch (0.0625 in), 3/16 inch (0.1875 in), 1/8 inch (0.125 in).
  2. Step 2 — State the single-discontinuity limit: 1/8 inch = 0.125 inch maximum.
  3. Step 3 — Compare each discontinuity to the limit: 0.0625 in ≤ 0.125 in (pass); 0.1875 in > 0.125 in (exceeds limit); 0.125 in = 0.125 in (at the limit, acceptable — not exceeding).
  4. Step 4 — Apply the result: the 3/16-inch discontinuity exceeds the individual limit.
Answer: The bend test FAILS because the 3/16-inch discontinuity exceeds the 1/8-inch maximum for a single discontinuity. The 1/8-inch indication is at the limit and acceptable by itself, but the overall coupon does not pass. Record the failure on the Performance Test Log and schedule a conference if this is the third consecutive failure.
3. Your GMAW WPS specifies a wire feed speed that produces an amperage range of 160–200 A and a voltage range of 22–26 V for ER70S-6 at 0.035-inch diameter. You set the machine and read 185 A and 24 V at the arc. Are you within the WPS range?
  1. Step 1 — Check amperage: lower limit 160 A, upper limit 200 A, your reading 185 A. 160 ≤ 185 ≤ 200 — within range.
  2. Step 2 — Check voltage: lower limit 22 V, upper limit 26 V, your reading 24 V. 22 ≤ 24 ≤ 26 — within range.
  3. Step 3 — Both parameters are within the WPS limits.
Answer: Yes, the machine is set within WPS range on both essential variables. Confirm the shielding gas type and flow rate as well before proceeding. Document these settings on your Performance Test Log before striking the arc.
4. A nick-break test specimen from a 3/8-inch fillet weld is broken open. You count five individual pores on the fracture face. AWS D1.1 allows a maximum of five pores in any given linear inch of weld. The fracture surface represents approximately 1.5 inches of weld length. How many pores per linear inch is that, and does it meet the limit?
  1. Step 1 — Total pores observed: 5.
  2. Step 2 — Length of weld represented by the fracture face: 1.5 inches.
  3. Step 3 — Calculate pores per linear inch: 5 ÷ 1.5 = 3.33 pores per inch.
  4. Step 4 — Compare to limit: 3.33 pores per inch is less than 5 pores per inch.
Answer: The specimen meets the porosity limit. At 3.33 pores per linear inch, the count is below the maximum of 5 per linear inch. Record the result as a pass for the nick-break criterion on your Performance Test Log, provided individual pore sizes also fall within any applicable size limits in the code.

The math in this lesson1

Learners compare reinforcement, bend-test discontinuities, and amp and volt readings against WPS and code limits.
N-Q.3
Brush up in the math halls at newSchoolWorks.com:
In class: Students rotate through six timed welding stations that replicate actual credential performance test conditions: (1) SMAW 3G and 4G groove weld on carbon steel plate per AWS D1.1 prequalified joint WPS; (2) GMAW or FCAW 3G fillet and groove welds on carbon steel plate; (3) GTAW root pass with SMAW fill and cap on 2-inch schedule carbon steel pipe in 6G position per ASME Sec. IX QW-250; (4) SMAW pipe in 2G and 5G positions; (5) visual inspection of completed coupons using D1.1 Table 6.1 and ASME Sec. IX QW-194 criteria; (6) guided bend test and break test on previously welded samples using the school's guided-bend jig — students wear required PPE (welding helmet with correct shade lens, flame-resistant clothing, leather gloves, steel-toed boots, hearing protection) at all times and execute LOTO procedures before any machine maintenance. · Before each station, students review the applicable WPS, identify essential variables, set machine parameters within the WPS range, and verbally confirm setup with the instructor or a qualified welding supervisor acting as the test administrator — this mirrors the pre-test documentation review required at credentialing sites. · After each coupon is welded, students complete a self-inspection checklist using D1.1 visual acceptance criteria (reinforcement height, undercut depth, cracks, porosity, overlap, crater fill) before submitting the coupon for instructor evaluation; coupons that pass visual proceed to guided-bend or nick-break testing; students record all results on a Performance Test Log that tracks position, process, WPS number, visual result, and mechanical test result — logs are reviewed in Lesson 4.
Materials: SMAW power sources (constant-current), GMAW and FCAW power sources (constant-voltage) with wire feeders, GTAW power source with high-frequency start, oxy-fuel and plasma cutting stations for coupon preparation, pipe positioners and rotation fixtures, guided-bend test jig, carbon steel plate (various thicknesses per WPS), carbon steel pipe (2-inch and larger schedule fittings), E6010, E6011, E7018, ER70S-6, E71T-1, ER70S-2 filler metals, prequalified WPS documents, AWS D1.1 current edition, ASME BPVC Section IX current edition, personal PPE for each student (helmet, FR clothing, leather gloves, steel-toed boots, hearing protection, safety glasses), LOTO equipment, self-inspection checklists, Performance Test Logs
Check: Each coupon evaluated by instructor using D1.1 Table 6.1 visual criteria and guided-bend or nick-break results per D1.1 or ASME Sec. IX acceptance criteria; visual acceptance is required before mechanical testing; students must pass at least one coupon at each required position and process combination for their intended credential before sitting the mock exam in Lesson 4 — any coupon failing three consecutive attempts triggers a mandatory conference with the instructor and a remediation plan addendum.

Practice check8

Answer each question, then check it. Nothing is recorded; this is your own practice.

AWS D1.1 Certified Welder / ASME Section IX welder qualification
1. Before starting any welding station, students are required to review the WPS and confirm machine settings with the instructor. Which of the following best explains why this step is required by credentialing bodies?
Safety — Lockout/Tagout
2. A student is about to clear a wire jam inside a GMAW wire feeder cabinet. According to LOTO procedures, what is the correct first action?
AWS D1.1 Certified Welder — visual inspection
3. Under AWS D1.1 visual acceptance criteria, which weld discontinuity is never acceptable regardless of size or location?
ASME Section IX welder qualification
4. A welder qualifies in the 6G pipe position under ASME Section IX. Which statement correctly describes the range of qualification?
AWS D1.1 Certified Welder — mechanical testing
5. During a guided-bend test of a root-bend strip, a student finds an open discontinuity on the convex surface measuring 1/4 inch. The applicable AWS D1.1 limit for any single discontinuity is 1/8 inch. What is the correct determination?
AWS SENSE L1-2 / NCCER Welding — filler metal identification
6. Which filler metal classification would a student select when welding a GTAW root pass on carbon steel pipe per ASME Section IX, using solid wire?
AWS D1.1 Certified Welder — visual inspection
7. A student completes a 3G SMAW groove weld coupon and measures undercut at the weld toe at 3/32 inch depth. The WPS references AWS D1.1 structural welds, which limits undercut to 1/32 inch for most structural weld categories. What should the student record on the self-inspection checklist?
Program policy / professional readiness
8. A student fails the same 4G SMAW groove weld coupon three consecutive times during skill stations. According to the lab policy, what happens next?
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