The purpose of welder performance qualifications is to ensure that the welder can deposit sound

welds. There are several tests, both destructive and nondestructive, that are used to evaluate a
welder’s ability to deposit good welds. Below are the four of the most common test applied for
these qualifications:

Visual Inspection (VT)

Visual inspection is the first test performed during performance qualifications. Specific instruction
can be found in AWS D1.1 Structural Welding Code – Steel 4.9 Methods of Testing and Acceptance
Criteria for WPS Qualifications (same applies to performance qualification). After a fillet weld or
groove weld is made, visual examination looks for weld discontinuities such as cracks, craters,
excessive reinforcement, weld size, undercut and others. No sense is performing destructive
testing if performance fails initial visual inspection of the weld.

Bend Test
Bend tests are specific to groove welds. They can be side, root or face bends. This type of testing is
ensuring soundness of the weld. The goal is to have no discontinuities on the bent surface,
although most codes have allowances for certain types of discontinuities. After the parts are bent,
VT is performed and all discontinuities are measured and then compared to maximum allowed
values.

Root and face bend tests for a 2G GMAW test

Macroetch Test
A macroetch test is done to evaluate if the welder achieved fusion to the root of the joint as well as
the side walls. This is only required on fillet welds as bend tests would reveal any problems
associated with lack of fusion on groove welds. The macroetch can be measured so we know other
important values such as depth of penetration at the root and sides. AWS D1.1 requires fusion to
the root but not necessarily beyond. This is a useful test, but has one important limitation: you are
evaluating fusion and penetration at one specific spot. Cut the part an eighth of an inch to either
side or you may have different results. To compensate for this, fillet break tests are performed.
A macroetch tests can reveal lack of root fusion which is not acceptable in welder performance qualification for fillet
welds.

Fillet Break Tests

In a fillet break test a section of the joint is cut out, usually about 4 inches in length. The specimen
is then placed on a vise or a press and the root of the joint is placed under tension until the part
breaks or folds over itself. The break is then examined to assure that there was fusion to the root.

A fillet break test reveals if root fusion was achieved over a specific length of weld.
Codes allow for the use of radiographic testing (RT) in lieu of bend tests in some
cases. Additionally, depending on what standard you are following you may be able to use other
testing methods such as ultrasonic testing (UT) and leak testing (LT). As always, know the code or
standard you are working with as it will provide all the necessary information regarding the tests
needed for performance qualification.