WELDING CHECKLISTS

Machine voltage, wire feed, and polarity verified for the process. Gun / torch liner, contact tip size, and nozzle condition checked. Shielding gas cylinder pressure adequate, flow set for the joint. Consumables stored dry — wire and electrodes free of rust and oil. Joint cleaned to bright metal, no paint, scale, or moisture. Fit-up within tolerance — root gap and alignment, tacked as required. Preheat and interpass temperature reached where specified. Ground clamp clean and tight on the workpiece, not the table. PPE complete — helmet lens, gloves, and sleeves for the process. Fume extraction or air movement confirmed before striking the arc.

Base metal cleaned at least 25 mm each side of the joint. Bevel angles and root face per the weld procedure. Root gap measured and within the specified range. Alignment checked — no offset beyond allowed mismatch. Tack welds placed away from full-penetration zones, cleaned before welding. Backing bar or consumable insert confirmed, if specified. No forced fit-up — distortion handled with restraint, not brute force. Preheat verified with a contact thermometer at the joint, not the flame.

Slag and spatter removed before any evaluation. Visual check for cracks, undercut, and crater defects. Weld size measured — fillet leg or groove profile matches the drawing. Porosity check — surface pores or wormholes noted and flagged. Overlap and excessive reinforcement beyond acceptable limits checked. Distortion measured against the assembly tolerance. NDT requirements confirmed and scheduled if the code calls for it. Weld completed and marked — traceability kept for inspection sign-off.