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Module 4: Weld Quality & Safety

Overview

This module covers weld quality assessment and welding safety. Students will learn to visually inspect welds and identify common defects (porosity, lack of fusion, undercut, spatter), understand the causes and implications of each defect, and apply corrective actions. Safety content includes arc flash and arc radiation PPE, fume extraction and respiratory protection, hot work permits and facility controls, and emergency response procedures specific to welding operations.

Learning Objectives

  1. Perform visual weld inspection using industry acceptance criteria
  2. Identify common weld defects by appearance and location
  3. Relate defects to welding parameters and technique (root causes)
  4. Explain arc flash hazards and required PPE for welding
  5. Understand fume composition and health effects for each material type
  6. Implement engineering controls (ventilation) and administrative controls
  7. Respond to welding emergencies (eye injury, burns, electrical shock)

Module Structure

  • Slide 1: Visual Weld Inspection & Acceptance Criteria
  • Slide 2: Common Weld Defects (Porosity, Lack of Fusion, Undercut, Spatter, Tungsten Inclusion)
  • Slide 3: Arc Flash Protection & Welding PPE
  • Slide 4: Fume Hazards, Extraction, & Respiratory Protection
  • Slide 5: Hot Work Procedures, Fire Watch, & Emergency Response

Assessment

  • Practical inspection: Students evaluate sample welds and identify defects
  • Defect diagnosis: Given a defect photo, students identify the cause and suggest correction
  • Safety competency: Correct PPE donning and identification of facility hazards
  • Scenario response: Appropriate action for eye injury, fire, or electrical hazard
  • Written assessment: Fume hazards by material type and control measures

Time Allocation

  • Instructor Delivery: 3.5 hours
  • Practical Weld Inspection: 2 hours
  • Safety Training & Scenario Response: 2.5 hours
  • Assessment: 1 hour
  • Total Module Time: 9 hours

Prerequisites

  • Modules 1–3 (arc physics, both welding processes, technique)
  • General shop safety awareness

Resources

  • Sample welds (good and defective examples)
  • Weld defect reference guide with photos
  • Arc-rated welding jackets/aprons, gloves, helmets
  • PPE inspection checklist
  • OEM safety data sheets (SDS) for all materials (metals, gases)
  • Hot work permit form (facility-specific)
  • Fire extinguisher, fire blanket
  • First aid kit with burn treatment supplies
  • Ventilation system demonstration (fume extraction effectiveness)
  • Emergency eyewash/shower station location reference

Module Version: 1.0 Created: 2026-03-15