Weld replacement trailer cross members with gas metal arc welding

What is going on

Non-conformance NCR-26-087 recorded porosity in the fillet welds on three cross members of drop deck trailer WO-26-0420. The cause was low shielding gas flow at bay 4, which maintenance has now repaired. The Leading Hand Welder has asked you to weld the replacement cross members to the welding procedure specification and present them to the fabrication gate so the trailer can move to final inspection and meet its delivery date of 18 September. The shop has just had an arc flash injury and the safety committee is watching screen and extraction discipline. Your welder qualification for gas metal arc welding in the required position is current in the training records.

Your brief

Set up the bay and the machine to the welding procedure specification, weld the cross members to the drawing, inspect the welds, record the work on the work order and update the non-conformance register when the rework is verified at the gate.

Work through it

You do not need to do it all. Doing a few of these will show you what the work is like. Your ticks and notes stay on this device.

• Read the drawing supplied by your assessor and identify each weld symbol, the joint type, the size and the welding procedure specification that applies.
• Complete the set up checklist from the Welding and Hot Work Procedure: leads, earth clamp, gas supply and flow rate, extraction position, screens, combustibles and extinguisher.
• Record the machine parameters you will use from the welding procedure specification and explain how you will check the gas flow at the torch, given the cause of the original defect.
• Cut the cross member blanks to length using mechanical cutting and describe the pre-start and guarding checks for the cold saw.
• Describe the tack and weld sequence you will follow to control distortion and the visual inspection you will make of each weld for profile, undercut, porosity and cracks.
• Record your welder identification, the procedure specification and the inspection result on WO-26-0420 in the Work Orders and Build Tracker.
• Update NCR-26-087 in the Non-Conformance Register with the rework completed and describe what the gate inspector must verify before closing it.
• Complete the end of shift hot work steps and record a hazard you noticed in the bay on an Incident and Hazard Report Form.

What someone in this role would produce

• Weld symbol and procedure identification
• Completed bay set up checklist
• Machine parameter and gas flow record
• Updated work order and non-conformance register entries
• Incident and Hazard Report Form