Pipe weld test

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I have a test coming up this week.  It is a 5g, 6" Sch. 80, 6010 root, 7018 out.  Most of what I learned in the past couple months was tig root, although I did do a couple stick roots.  Also, everything was sch. 40, I have never done sch. 80.  Called my old instructor who is a hell of a guy, and he was nice enough to let me come in (on a holiday at that) and prep up a couple pipes.  Unfortunately he was never a fitter, so he couldn't tell me a whole lot other than what they will probably look for (he was a CWI).  I spent all day today putting coupons together so I can get some practice this week.Does anyone have any tips or advice?  I have never taken a real test before and am just trying my hardest to make sure I don't make any stupid mistakes.  My list of tools is pretty limited, but I plan on bringing my own 4.5" grinder, chipping hammer, file, striker, tape, etc.
Reply:Schedule 80 pipe has a thicker wall than schedule 40.I offer three choices: Good, Fast, & Cheap. You may pick two.Hobart AC/DC StikMate LXHarbor Freight AD HoodHarbor Freight Industrial Chop SawDeVilbis 20 Gallon, 5 HP Compressor
Reply:Wow, a instructor that can't weld, and can't tel you what to look for on a test...My....oh....MyIt's amazing how many worthless educators are out there.Not only was he not a fitter, it sounds like he was never a welder.IMOAssuming you can run Sched. 40 w/ no issues?Do the same for Sched 80.You get four tacs. 12,3,6,9.I always make 6 my longest tac....Relax, take a breath during the test, and replicate what your body already knows.When you get to the cap; take a short break and let it cool off. 1/2 hour max.Collect yourself, turn the heat up 10, and run a smooth *** bead. Run it hot, and stay smooth, short arc to avoid undercut.Why on earth would you need tape?Call ahead and see what your allowed to bring if anything?Most places I've been don't want you to bring anything other than PPE.I'd recommend a crescent wrench for leaning on, grinder, file, chipping happer, and maybe if your super lucky a wire wheel. Throw in a new lense cover and bring a spare.I personally have a magnetic shop light so I can see my peice. Some booths are a little dark for me.Maybe some cutting discs as well in case you mess up the fitup and need to restick it or make a repair.GLLast edited by jsm11; 07-04-2011 at 07:31 PM.1981 Lincoln SA 200Miller Trailblazer 302gMiller 211 Mig Welder w/ AutosetI'm learning to stick metal together
Reply:My instructor can weld, maybe I just worded it incorrectly.  What I was getting at is that there is a difference between knowing what to do and actually doing it.  He looked at my fitup today and made a recommendation that helped tremendously.    So you are saying to do the root and fill without stopping?  That is the kind of stuff I'm looking for, thanks.Tape = tape measure
Reply:The test supervisor will probably want to see your root before you start your hot pass. Ask before the test starts. We aren't allowed to grind the root until after it's inspected, either (except for blending starts and stops, but no visible grind marks after welding). No visible grinding on the cap, either.
Reply:Is the test up hill or down hill?Lincoln 225 RangerSa200            01 dodge  3500 welding rig
Reply:4d, that is a good point.  We had to do the same, and generally also show it before capping.  I'll get that straightened out beforehand.bgroves, it is an uphill test.
Reply:This is how I do my test: 3/32 land and gap, I do 4 1/4" tacks normally in the 2g position so I can visually verify the high/lo from looking inside the pipe, and I take a small square and check that the high/ lo is good from the outside. If the fit up is bad from the get go break the tacks and redo it. When putting it into the 5g or 6g I roll the tacks so they are at 5, 8, 11, 2 roughly so Im not starting on the dead bottom, then I start around the 5 oclock and work up to the next tack using my elbow to brace myself being Im right handed. When I get close to the next tack I break the arc and feather my stop with a 1/16 waffer disk and use that same disc to grind out my tack and leave a gap to weld through. On the machine I use I will use 1/8th 6010 around 82-85 amps (but your machine and style of welding may change your heat range, no one is the same) and I long arc the start to heat it up and then punch through and drag the rad with a tight arc length, if the keyhole gets too big I will start coming out of the puddle and whip it in and out to let it cool. But that normally signals to me to turn it down a few amps and let it cool.Now on your bad side, mine if the 6 oclock to 1 I use a nice long file and wedge it in the end of the pipe (make sure that thing is not near you weld, I once welded to my file on accident haha) and rest your elbow high on the file to brace you as you come up the side of the pipe. Just remember to feather your starts and stops for clean tie ins. Once I'm done with the root visually inspect it with a flashlight inspection mirror, if its good I grind my root almost completely flat, because any little high or low on every pass will show on the next pass, so I always try and grind it even all around. With the hot pass just turn it up 10 and whip it in and out just like you would be welding on a piece of plate just pay attention when you pause that your burning in to the edged of the pipe. The 7018 is the easy part, and as long as you keep a tight arc length to avoid porosity and don't have any undercut you can have a pretty bad looking weld and still pass.
Reply:In school we weren't allowed to grind between passes before it was inspected. The best advice I ever got was practice practice practice. If at all possible, get a couple pieces of pipe and practice at home before you go in to test. That's what I did, and it made a world of difference. As for advice during the actual weld- just breath. Breath and relax. I had to learn to do that because I would always be so nervous that my body would tense up, and it showed in my welds. Maybe you can get something usefull from what I said. Keep us updated with what happens and good luck manGo Cards!!!!!
Reply:Make sure you make a good fit up,also play with the machine to tune it in. I saw a guy being looked out the other day because he got in a hurry and had a poor fit and didn't even get a feel for the machine. If it's not a timed test then just take your time and do the best you can. Once you start the butterflies will probably go away. Also if your cutting straps make sure you clean out the slag from the torch after you cut each strap. I've seen a few guys mess up their straps because the slag inside the pipe from the torch hindered their next cut
Reply:I would put tacks in at 3 0'clock, 9, and 12. you're starting on the bottom anyway, so I figured, why not eliminate one step. A trick I learned for a hand rest, was to clamp a chaingrip [made by Vise- Grip] around the pipe: quick to apply and move as you need it.And, as others have said here, it is generally not a race............take your time and keep your wits about you.Good luck.             Bgbkwndo.
Reply:I know when I give 6010/7018 test, I don't allow for any kind of abrasive wheel on a grinder, just a wire wheel. I always inspect the root, then the hot.Try and make your cap pretty, I fail on visual a lot. (My customers don't want see cruddy welds, either do I.)Good luck on your test!P.S. I only allow welders to bring a grinder with a wire wheel, a hood, a tig rig (If they are taking a tig test) an inspection mirror, a flashlight, and PPE.
Reply:Thanks for all the info guys.  I did some practicing the last couple days on 6" sch. 40 and pretty much shot myself in the foot from the get go.  I was trying to hurry when putting the coupons together and didn't get enough of a land on them.  That coupled with the machine not wanting to run 5p at lower amps = me cussing.  Thankfully it runs 7018 Excaliburs like a dream so at least I got some practice on the fill and cap, on the areas where there was something left to weld to, LOL.  I have already learned that fitup is everything but some of us need repeat lessons it seems.  Its now seared into my mind since that would have been a nightmare if it would have happened during the test.I have one pipe coupon left and plan on cutting the tacks, cleaning it up, and putting a healthy land on them with a file.  Hopefully they will let me tack it up and practice on it to get the machine set before I start the actual test.
Reply:Yeah fitup is what I neglected to mention, but that makes all the difference in the world. And make sure you are shoving your 6010 in the gap hard on your root. Good luck dude and let us know how it goesGo Cards!!!!!
Reply:I've made my living welding pipe for about 35 years and during all those years I've taken many welding test, so I am talking from experience. A welding test is a test-weld to see if you can do the job or not.  Make a good test and you'll prove to anyone that looks at it that you do have what it takes to do the job and do it well.  Thats what they want.  Welders that can actually weld, and do the work....  If not then "why the test?"   Walk in there and show them what you can do with the confidence that you can do your best in front of them - with steady nerves.  Actually you have nothing to loose.  Either you can do it and prove that to them or not.Because - believe me on this.  If you can't do it then you need to be the first one to know that fact - then you need to face up to that fact in an honest way - and then go your way and do something about it.  Either learn to pass that test and make a good weld - or change your profession to something that doesn't require a welding test.  Either way - the only way to pass a welding test is to actually know how to make a test weld.  If you can't do that then you're not where you are supposed to be in life, or you're not ready yet.  lolYea, there is always the "get lucky" thinking, and yes I've seen it happen and yes it's happened to be too, but you can't rely on getting lucky.  Because at some point you're going to haft to learn how to do it then you're going to haft to prove that you can to them "by making a good test weld".  There actually is no other way around it.Learn how to setup your nipples "so you can make it good", then you'll be like the rest of us are and like we have been doing it for a very long time.  A bad fit can bust anyone.  If you don't believe me then ask any experienced welder you want and they will tell you.Be confident in the ability you have and show that confidence in your attitude, but mildly.  Show no weakness in your ability - but don't try to cover up for what you don't know.  Freely admit you didn't know that.  Don't fake it, nothing, ever.  Do it right the first time because you know how to do it right and be proud of the fact that you can!!!!! Remember this.  If you don't tell me - I don't know.  If I ask answer my question, nothing more.  If I don't like you will I give you the benefit of the doubt if you need it?  And if I know this is your first welding test - am I going to buy something from you I won't buy from experienced welders?   To both of those questions I'd more than likely say I'm sorry but - No.  lolGood luck manLast edited by slowhand; 07-07-2011 at 08:57 PM.
Reply:Well I took the "test" on friday and it went pretty well.  I was told it was not actually a test but an evaluation, although I treated it like it was a test.  The guy also said they usually do it in 6g not 5g, so it ended up being a 6.  It was not timed, so my fit up took a long time but I knew it needed to be perfect.  The admin. said most guys run 1/8 and 1/8, and since he's forgotten more than I'll ever know, I took his advice.  The machine was a V350 Pro and wow, it almost lays the stringers for you   Super soft and stable, focused arc, seemed a lot better than the V300 Pros I've used.So would it have passed a real test?  No.  Had a couple small spots of incomplete fusion on the root since I was deathly afraid of blowing a hole in it, and therefore not pushing the rod deep enough.  The cap wasn't perfect either but the admin. gave me a little tip after I had finished one quarter of my last cap pass.  The rest of that pass was probably one of the best beads I've ever put on a pipe.  Anyways, they didn't scream profanities at me while throwing my gear out the door, and they told me to fill out an application ASAP.  Could have been a lot worse
Reply:Good deal man.
Reply:Sounds to me like you did fine.
Reply:Good for you man. CongratsGo Cards!!!!!