BODY OF KNOWLEDGE

Certified Welding Engineer

The AWS Certified Welding Engineer (CWEng) examination is four parts. Parts 1 and 2 must be successfully completed in order to take Parts 3 and 4. The first two parts of the exam are closed book and cover basic science fundamentals and applied science fundamentals. Parts 1 and 2 are each two hour written multiple-choice exams (total time of four hours). Part 1 is a 35 question multiple choice exam and Part 2 is a 25 question multiple choice exam. They are given together and must be passed together. If the candidate fails only one part, only that part must be repeated. Parts 3 and 4 of the exam are open book examinations on welding related disciplines and practical welding and related applications. They are each three hours in length. Part 3 is a 45 question essay exam. Part 4 is a 39 question multiple choice exam. Candidates that successfully pass Parts 1 and 2 will be invited to sit for these exams and a separate application must be submitted to AWS. The exams may be taken at any location where the CWI examinations are given. Candidates are invited to bring any textbooks, articles or codes in their library. Programmable calculators are allowed that do not have audible sounds. Laptops are also allowed, but no modem or wireless connections will be permitted. Candidates must pass each of the four examinations with an individual score no less than 60% and attain a minimum weighted percentage of 70% for all 4 parts. Note: The D1.1 2010 edition is applicable to the current CWEng Part 4 exam only (subject to change). All applicants shall successfully meet the CWEng requirements as contained in clauses 6 and 7 of AWS B5.16, Specification for the Qualification of Welding Engineers.

Approximate subject weights for the four examination parts are as follows:
Part 1 Basic Science Fundamentals Mathematics Physics Chemistry 25% 50% 25% Part 2 Applied Science Fundamentals Strength of Materials Heat Transfer and Fluid Mechanics Electricity Part 4 Practical Welding and Related Applications Exam using references on the application of welding engineering concepts in the areas of: Welding safety, weldment design, welding metallurgy, materials, welding process selection, NDE including visual weld inspection, quality assurance, quality control in accordance with codes, specifications, other standards, and/or drawings. 40% 30% 30% 100%

Part 3 Welding Related Disciplines (Essay Exam) NDE/Weld Discontinuities 10% Welding Heat Sources and Arc Physics 20% Welding Processes and Controls 20% Welding and Joining Metallurgy 20% Weld Design 20% Brazing and Soldering 5% Safety 5%

Body of Knowledge Extended Subject Areas as per AWS B5.16: 8.1 Basic Sciences Fundamentals
8.1.1 Mathematics: simple calculations (multiple choice) special functions (exp, log) trigonometric functions (sin, cos, tan, cot, sec, csc, degrees, radians) algebraic equations (linear, quadratic, polynomial) graphs and equations (slope, intercept, roots, derivatives, minimum, maximum, interpolation, and extrapolation) geometry (common geometric shapes) hyperbola, parabola complex numbers calculus (fundamentals of differential equations) statistics (population and samples: normal distribution, CWEng BOK mean, standard deviation, variance simple correlation: linear regression via least squares 2 method, r correlation) 8.1.2 Physics: unit conversion (dimension, mass, temperature, time, energy, power) mass, weight, volume, density force, energy, work done, power stress, strain, Hookes Law (elasticity) moment and momentum temperature, heat, temperature measurement, thermocouples, pyrometers thermal properties of materials (thermal conductivity, thermal expansion, thermal stress and strain) September 26, 2013

8.1.3 Chemistry: symbols (elements and inorganic compoundsgases, fluxes, etc.) molecular weight and stoichiometry acids and bases balance chemical equations gas combustion reactions (chemical heat generation) and oxidation-reduction reactions ideal gas law (pressure, volume, temperature) mass balance (as in E7018 coating decomposition to gas, slag and metal) bulk and chemical analysis methodologies) reactivity, toxicity, environmental effect, disposal.

8.2 Applied Sciences

8.2.1 Strength of Materials: load, deformation (elastic and plastic, buckling), stressstrain, Youngs Modulus, shear modulus, stress -strain curve (yield stress, ultimate tensile stress, elongation), tensile stress and shear stress computation welded member cross-section effect mechanical testing (tensile, bend, fracture toughness, hardness, creep, and fatigue) and data interpretation Law of Conservation of Energy/Momentum stress analysis typical engineering material properties 8.2.2 Heat Transfer and Fluid Mechanics: heat conduction, convection, and radiation, thermal conductivity and diffusivity, heat transfer coefficients of engineering materials, Fouriers Law heating rate and cooling rate industrial heating methods and power consumption, gas flow rates laminar and turbulent flow (Reynolds Number), dew point and relative humidity, pressure and regulators venturi effect and gas velocity calculation atmospheric pressure and hyperbaric conditions vacuum equipment and measurements 8.2.3 Electricity: current, voltage, resistance, impedance, and circuits Ohms Law Kirchoffs Law Resistance loss and current rectification power generation AC/DC, polarity power factor electromagnetic properties, right-hand rule current and voltage measurements (devices and principles)

8.3 Welding Related Disciplines

8.3.1 NDE/Weld Discontinuities: NDE processes (radiographic, ultrasonic, magnetic particle, liquid penetrant, eddy current, etc.characteristics, advantages, and limitations) NDE symbols

8.3.2 Welding Heat Sources and Arc Physics: power source static and dynamic characteristics (open circuit voltage and short circuiting current, slope) differences between CC and CV designs (principle of selfadjusting) welding arc characteristics (current and voltage relationship, arc length effect) electron emission (ionization potential, work function, electrode material, shielding gas, arc stability) arc temperature and degree of ionization (shielding gas influence) magnetic arc blow (work lead location and condition) Lorentz Force (effect on droplet detachment and on adjacent power cables) shielding gas drag force (effect on droplet detachment and metal transfer mode) weld penetration and width for different shielding gases 8.3.3 Welding Processes and Controls: arc welding processes (SMAW, GMAW, FCAW, GTAW, SAW, PAW) resistance welding processes (RW, high frequency RW), high energy density welding processes (LBW, EBW) cutting processes (OFC, CAC, and PAC) surfacing processing (SW, THSP) solid-state welding processes (FRW, FW) 8.3.4 Welding and Joining Metallurgy: crystal structure of metals (FCC, BCC, HCP, unit cells, lattice parameter, c/a ratio, atom positions, interstitial positions) melting, and solidification, phase transformations and phase diagrams (eutectic, eutectoid, peritectic and monotectic, lever rule calculation) metallurgy and weldability of typical engineering materials (low carbon structural steels, cast irons, stainless steels, nickel alloys, aluminum alloys, titanium alloys, etc.) microstructure (e.g., ferrous alloysgrain boundary ferrite, acicular ferrite, bainite, martensite, austenite, delta ferrite, etc.) and mechanical properties carbon equivalent (CEIIW, Pcm, expressions, alloying content and carbon content effect) hydrogen assisted cracking (heat-affected zone cracking, cold cracking) base metal matching (e.g., electrodes with high strength steels) solidification cracking (segregation of impurity atoms, shrinkage cracking, lamellar tearing) delta ferrite in stainless consumables, specifications for consumables (categories; all position, rutile, basic) fluxmetal reactions (oxygen and sulfur control in weld pool) typical temperature range of a heat source temperature distribution in a weldment HAZ formation multipass thermal experience, reheated weld metal properties weld macro and micro-graph interpretation solidification profile and preferred grain orientation (epitaxial growth) origin of weld ripples special attributes of base metal (as-cast structure, deformation texture, oxide on flamecut surfaces) September 26, 2013

CWEng BOK

8.3.4 Welding and Joining Metallurgy (continued): thermal treatments (preheat, postheat, interpass influence on weld cooling rate and residual stress distribution) solid-state transformations in welds (different forms of ferrite, bainite, and martensite, sigma phase in stainless steels, Guinier-Preston type precipitates zones and aging in aluminum alloys) corrosion (sensitization in stainless steel welds, stress corrosion cracking in welds) 8.3.5 Weld Design: structural fabrication requirements, sectional properties, stress gradient stress triaxiality, weld symbols, hardness and microhardness (e.g., across a weld cross section) tensile properties, ductility, toughness, fillet break test (influence of second phase and porosity), ductile fracture, brittle fracture, fatigue (initiation, propagation, failure, high-cycle, low-cycle), temperature and strain rate effect

8.3.6 Brazing and Soldering: characteristics of brazing and soldering fluxes and substrates capillary action wetting and spreading contact angle joint clearance viscosity liquidus and solidus flow of molten filler in horizontal and vertical joints (maximum penetration and rate) filler metal systems (Sn-Pb solders, Ni and Cu based alloys, Ag-Cu based brazing alloys) intermetallic compound formation 8.3.7 Safety: recognize health hazards relating to welding (fumes, toxic gases, noise, radiation) recognize safety hazards (electric shock, compressed gases, fire, welding in a confined space, welding on containers and piping, moving equipment) recognize precautions to avoid injury possess a working knowledge of safety and fire codes

AWS Welding Engineer Examination Preparatory Material

Reference Title ANSI Z49.1 Safety in Welding, Cutting and Allied Processes Applied Fluid Mechanics, 4th Ed. ASM Handbook Vol. 17, NDE ASM Handbook Vol. 6 Welding/ Brazing 10th Ed. AWS D1.1 Structural Welding CodeSteel Design of Weldments Engineer in Training Manual Essentials of Engineering Economics, 2nd ed. Fracture & Fatigue Control in Structures, Application of Fracture Mechanics Fundamentals of Engineering: The Most Effective FE/EIT Review Fundamentals of Welding Technology, Modules 1 - 9 Handbook of Arc Welding HB for Mechanical Engineers Introduction to the Practice of Statistics ISBN 0 7167 2250 X Introductory Physical Metallurgy of Welding Introductory Welding Metallurgy Manufacturing, Engineering & Technology ISBN 0 201 538460 Mechanical Metallurgy Metals and How to Weld Them Modern Welding Technology Physics of Arc Welding Product Design for Manufacture and Assembly ISBN 0 8247 9176 2 Quality Control, 5th Ed. Robots & Manufacturing Automation Stainless Steel CWEng BOK Author Mott Publisher AWS Merrill Publishing Company ASM ASM AWS The James F. Lincoln Arc Welding Foundation McGraw Hill Prentice Hall - Second Edition, 1987 Great Lakes Press CWB Group cwbstore.org James F. Lincoln Arc Welding Foundation Avallone or Baumeister Freeman Butterworths AWS Addison Wesley McGraw Hill James F. Lincoln Arc Welding Foundation, Second Edition, 1990 Prentice Hall Pergamon Marcel Dekker Prentice Hall John Wiley ASM International, 1986 September 26, 2013

Omer W. Blodgett Riggs & West John M. Barson & Stanley T. Rolfe Merle C. Potter

Mark Standard Moore & McCabe Easterling Serope and Kalpakjian Dieter

Cary J. Lancaster Boothroyd, Dewhust & Knight Besterfield Asfahl R.A. Lula

Reference Title Statics & Strength of Materials, 3rd Edition, ISBN 0-13453201-5 Statics & Strength of Materials: A Parallel Approach to Understanding Structures Weldability of Steels Welding Aluminum: Theory and Practice Welding Design, Modules 30-39 Welding Encyclopedia Welding Handbook Vol. 1, 2, 3, 8th Ed. Welding Metallurgy Welding Metallurgy Welding Metallurgy Welding Metallurgy, Modules 8, 9, 12, 20-23, 30

Author Morrow Lawrence J. Wolf Stout & Doty

Publisher Prentice Hall Merrill Publishing Company Welding Research Council The Aluminum Association, Second Edition, June 1991 CWB Group cwbstore.org AWS AWS John Wiley & Sons AWS Pergamon CWB Group cwbstore.org

Jefferson Sindo Kou Linnert J. Lancaster

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