Welder Certification Audit Checklist: What Inspectors Check Under ISO 9606-1

1 Verify the Welder’s Identity
The first step is to check if the qualification certificate clearly shows who did the test.

– Inspectors may compare:
– Full name
– Welder ID number
– Employee records
– Welder identification system
– Qualification certificate
– Production welding records

The identification should connect the qualified welder to the actual welds made in production.

2 Check the Applicable Standard
The auditor needs to make sure the qualification was done according to the right standard.

For steel fusion welding, the standard is ISO 9606-1:2012.
ISO currently lists the 2012 edition as the latest published version, but they are working on updates.

Organizations should decide which edition and contract requirements apply to their project.

3 Verify the Welding Process
The certificate should say which welding process was used during the test.

– Examples include:
– 111 — Manual metal arc welding
– 131 — MIG welding
– 135 — MAG welding
– 136 — Flux-cored arc welding
– 141 — TIG welding

The auditor checks if the production welding process is within the welder’s qualified range.

A welder qualified for one process is not automatically qualified for another.

4 Check the Test Material and Material Group
The qualification record should show what material was used in the test.

The inspector checks if the production material is within the qualified range.

This is important when manufacturers use different steel grades or material groups in production.

The qualification range should be checked against the ISO 9606-1 requirements, not assume one test covers all steel grades.

5 Verify Joint Type
The auditor checks if the qualification covers the type of weld being made.

Common types include:
– Butt welds
– Fillet welds

The qualification record and ranges should match the actual joints being welded.

ISO has official interpretations that explain how butt and fillet weld qualifications relate, so it’s important to check the specific clauses.

6 Check Welding Position
Welding position is a key part of qualification.

The inspector checks the position used in the test and the positions the welder is qualified for.

Examples include:
– PA
– PB
– PC
– PD
– PE
– PF
– PG

The qualified range depends on the test setup and ISO 9606-1 requirements.

ISO’s interpretations also address how positions like H-L045 and J-L045 affect the qualified range.

7 Verify Thickness and Diameter Range
Inspectors check if the production weld is within the welder’s qualified:
– Material thickness range
– Weld deposit thickness range, if any
– Outside diameter for pipe welds

This is a common area where a certificate might be wrongly assumed to cover more than it actually does.

For example, a test thickness does not mean the welder is qualified for all thicknesses.

8 Check Filler Material and Consumables
The audit should check the filler metal and if the production consumables are within the qualification range.

– Depending on the welding process, this might include:
– Filler classification
– Filler designation
– Electrode type
– Consumable identification
– Grouping requirements

The goal is to make sure the welding conditions stay within the qualified scope.

9 Verify Shielding and Backing Conditions
– When needed, inspectors check:
– Shielding gas
– Gas mixture
– Gas backing
– Material backing
– Flux backing
– Consumable insert

These factors can affect the qualified range.

ISO’s official interpretations cover questions about how backing conditions relate to qualification ranges.

10 Review the Qualification Test Results
The auditor checks if the welder passed the required tests.

Depending on the test and requirements, methods may include:

– Visual inspection
– Radiographic testing
– Ultrasonic testing
– Bend testing
– Fracture testing
– Macro examination

The exact testing requirements depend on the setup and ISO 9606-1 rules.

The important thing is that the certificate is supported by real test results showing the qualification was met.

11 Check the Welder’s Continuity
A qualification certificate isn’t valid forever without considering continuity rules.

Auditors may check records showing the welder has kept working within the qualification conditions.

Useful records can include:

– Welding logs
– Production weld records
– Welder continuity logs
– Job cards
– Weld maps
– Welding reports
– Project records
– Keeping continuity records helps show that the qualification is still good under the right rules.

12 Check Certificate Dates and Status
Inspectors need to check:

– Qualification or test date
– Certificate issue date
– Valid or extended dates
– Continuity status
– Requalification records 

The company should have a way to find qualifications that are about to expire or need action.

An expired or not properly kept qualification should not be treated as if it’s still valid, even if the original certificate is in the worker’s file.

13 Verify WPS and WPQR Compatibility
A welder’s qualification and the welding procedure are connected but not the same.

During an audit, inspectors might compare:

Welder Qualification → WPS → WPQR → Production Weld

The WPS gives the instructions for making the weld during production, while the welder’s qualification shows they can make a good weld within their qualification range.

So, having a valid welder certificate doesn’t mean the welder can use every WPS.

14 Check Welder Traceability
A good welding quality system should let the company know who did each weld.

Auditors might look at:

– Welder ID
– Weld number
– Weld map
– WPS number
– Material or heat number
– Welding process
– Production records
– Inspection reports

This creates a chain that shows:

Welder → Qualification → WPS → Production Weld → Inspection Record

This is especially important for companies that follow welding quality systems like ISO 3834.

15 Check Document Control
Inspectors also check if welder qualification documents are managed properly.

The company should be able to quickly find:

– Current certificates
– Expired certificates
– Continuity records
– Requalification records
– Welder ID
– Applicable welding processes
– Qualified ranges
– Supporting test reports

Having a central welder qualification matrix can help with this process a lot.