NCCER Certification Welding Syllabus

Welding syllabus — full chapter and topic list

Expand any chapter to see its topics and sub-topics. This is the whole examinable outline for Welding in NCCER Certification, not a summary of it.

1. 1

   Welding Safety and Preparation

   3 topics

   • Welding Safety
     • Arc radiation, fumes, and ventilation
     • Fire watch and hot work permits
     • PPE for welding operations
   • Base Metal and Joint Preparation
     • Cleaning, beveling, and fit-up
     • Joint types and weld positions
   • Reading Welding Symbols
2. 2

   Oxyfuel and Plasma Cutting

   3 topics

   • Oxyfuel Cutting
     • Equipment setup and gas pressures
     • Straight, bevel, and washing cuts
   • Plasma Arc Cutting
   • Air Carbon Arc Gouging
3. 3

   Shielded Metal Arc Welding (SMAW)

   3 topics

   • SMAW Equipment and Electrodes
     • Machine setup and polarity
     • Electrode classification (AWS)
   • Beads, Fillet, and Groove Welds
   • Weld Quality and Defect Identification
4. 4

   GMAW, FCAW, and GTAW Processes

   3 topics

   • Gas Metal and Flux-Cored Arc Welding
     • GMAW transfer modes and shielding gases
     • FCAW self-shielded and dual-shielded
   • Gas Tungsten Arc Welding (GTAW)
   • Welder Qualification and Testing

Welding flashcards for NCCER Certification

25 of 52 cards from the Welding deck — real questions with worked answers.

1. What is the primary cause of welder's flash (arc eye), and how is it prevented?

   Overexposure of unprotected eyes to ultraviolet (UV) radiation from the welding arc. It is prevented by wearing a welding helmet with the correct shade lens and using screens to protect bystanders.

2. What does the term 'hot work permit' authorize, and why is it required?

   It is a written authorization to perform welding, cutting, or grinding in areas where a fire or explosion hazard may exist. It ensures fire watches, fire extinguishers, and area inspections are in place before and after work.

3. How do you select the proper lens shade number for a welding helmet?

   Choose a shade based on the welding process and amperage. Higher amperage requires a darker (higher-number) shade. Common ranges: shade 10-13 for arc welding, lower shades for oxyfuel cutting. Start dark and lighten only enough to see the weld zone clearly.

4. What is the recommended fire-watch duration after completing hot work?

   A fire watch must be maintained during the work and for at least 30 minutes (often up to 60 minutes per site policy) after work is completed to ensure no smoldering fires develop.

5. Why must galvanized (zinc-coated) metal be welded only with adequate ventilation?

   Welding galvanized steel vaporizes zinc, producing fumes that can cause metal fume fever (a flu-like illness). Adequate ventilation or respiratory protection and removing the coating from the weld area are required.

6. What is the purpose of preheating a base metal before welding?

   Preheating slows the cooling rate, reduces residual stress and distortion, drives off moisture, and helps prevent cracking and the formation of hard, brittle microstructures in the heat-affected zone—especially in thick or high-carbon steels.

7. Define the 'heat-affected zone' (HAZ) in a weld.

   The HAZ is the region of base metal adjacent to the weld that was not melted but whose microstructure and mechanical properties were altered by the heat of welding.

8. What are the five basic types of welded joints?

   Butt joint, lap joint, tee joint, corner joint, and edge joint.

9. Why must mill scale, rust, oil, and paint be removed before welding?

   These contaminants cause porosity, inclusions, poor fusion, and weld defects. Cleaning the joint to bright metal ensures sound, defect-free welds.

10. What is a bevel in joint preparation, and why is it used?

    A bevel is an angled edge cut on the base metal to create a groove. It is used on thicker materials to allow the weld to penetrate fully to the joint root and achieve complete fusion.

11. On a welding symbol, what does the location of the weld symbol relative to the reference line indicate?

    A symbol below the reference line means the weld is on the arrow side of the joint; a symbol above the reference line means the weld is on the other (far) side. Symbols on both sides mean weld both sides.

12. On a welding symbol, what does the tail of the reference line contain?

    The tail contains supplementary information such as the welding process, specification, procedure, or other references. If no such information is needed, the tail is omitted.

13. What does a circle at the elbow (junction of the arrow and reference line) of a welding symbol indicate?

    A solid circle (weld-all-around symbol) indicates the weld is to be made completely around the joint.

14. What does a filled-in flag at the junction of the reference line and arrow of a welding symbol mean?

    It is the field-weld symbol, indicating the weld is to be made in the field (at the job site) rather than in the shop.

15. On a fillet weld symbol, where is the weld size shown and where is the length shown?

    The size (leg dimension) is shown to the left of the fillet weld symbol; the length of the weld is shown to the right of the symbol.

16. What two gases are most commonly used in oxyfuel cutting, and what is the fuel gas's role?

    Oxygen and a fuel gas (commonly acetylene). The fuel gas preheats the metal to its kindling/ignition temperature; the high-pressure oxygen stream then oxidizes and blows away the metal to make the cut.

17. What is the kindling (ignition) temperature for cutting steel with oxyfuel, and what does the cutting oxygen do?

    Steel must be preheated to about 1,600-1,800°F (its kindling temperature) so it glows cherry red. The cutting oxygen jet then rapidly oxidizes (burns) the steel and blows the molten oxide (slag) out of the kerf.

18. Why can oxyfuel cutting NOT be used effectively on aluminum or stainless steel?

    These metals form refractory oxides with melting points higher than the metal itself, so the oxidation reaction needed for oxyfuel cutting cannot be sustained. Plasma arc cutting is used instead.

19. What is a 'backfire' versus a 'flashback' in oxyfuel equipment?

    A backfire is a momentary flame extinguishing with a loud pop, often caused by touching the tip to the work. A flashback is the flame burning back inside the torch/hoses—a dangerous condition that requires immediate shutoff and is prevented by flashback arrestors.

20. What is the correct shutdown sequence for an oxyfuel torch?

    Close the torch fuel valve first, then the torch oxygen valve, close the cylinder valves, bleed/drain both lines, then back out the regulator adjusting screws.

21. How does plasma arc cutting (PAC) sever metal?

    PAC uses a constricted, high-velocity ionized gas (plasma) jet at very high temperature to melt the metal, while the high-velocity gas blows the molten metal out of the kerf. It cuts any electrically conductive metal.

22. What is the key advantage of plasma arc cutting over oxyfuel cutting?

    PAC can cut any electrically conductive metal—including aluminum, stainless steel, and copper—that cannot be oxyfuel cut, and it cuts thin material faster with a narrower kerf and smaller heat-affected zone.

23. What is the function of the air carbon arc cutting/gouging (CAC-A) process?

    CAC-A uses a carbon electrode arc to melt the metal and a high-velocity compressed-air jet to blow the molten metal away. It is used to gouge grooves, remove defective welds, and back-gouge joints.

24. In air carbon arc gouging, why must the compressed air be turned on, and where is the air directed?

    The compressed air blows the molten metal out of the gouge before it resolidifies. The air jet is directed behind the carbon electrode, beneath it, flowing in the direction of travel.

25. What polarity is normally used for air carbon arc gouging, and what does the electrode consist of?

    Direct current electrode positive (DCEP / reverse polarity) is normally used. The electrode is a copper-coated carbon-graphite rod; the copper coating improves conductivity and electrode life.

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