Reference libraries · Welding

Welding Reference Library

Sizes, standards, wall charts and how to identify what’s in front of you, written for welding supply counters, buyers and the customers they serve.

149 sheets planned · 38 published · 9 sections. New sheets are added as they’re written.

Written in the open: anyone can suggest an edit on any sheet. Help write or review it →

Published now

Technical Reference

Welding processes, filler metal classifications, consumables and equipment.

Measure & Identify

Identifying filler metals, gases, cylinders and equipment in the field.

Gases & Cylinder Safety

Shielding and fuel gases, cylinders, regulators and safe handling.

  • Compressed Gas Cylinder Storage and HandlingSecuring, capping, separation and transport rulesRef WG-0401 · Safety-critical
  • Cylinder Markings, Labels and CGA Valve ConnectionsDOT stamps, labels and connection numbersRef WG-0402 · Safety-critical
  • Shielding Gas Selection by ProcessArgon, CO2, helium, oxygen and mixes by process and metalRef WG-0403
  • Argon and Argon Mixes75/25, 90/10, 98/2 and tri-mix usesComing soon
  • Carbon Dioxide for WeldingCO2 vs mixes, regulator freeze-up, liquid withdrawalComing soon
  • Helium and Helium MixesHeat input and use in TIG and aluminumComing soon
  • Acetylene SafetyPressure limit, valve-up storage and withdrawal rateComing soon
  • Propane, Propylene and Other Fuel GasesFuel gas comparison for cutting and heatingComing soon
  • Oxygen Safety and Oil/Grease ContaminationWhy oxygen equipment must be kept cleanComing soon
  • Nitrogen and Inert Gas Asphyxiation HazardOxygen displacement in confined areasComing soon
  • Cryogenic Liquid Dewars and Bulk SystemsLiquid cylinders, pressure relief, frostbiteComing soon
  • Hydrogen and Specialty GasesHydrogen mixes for stainless and plasmaComing soon
  • Regulator Setup and Leak TestingCracking the valve, setting pressure, leak checkComing soon
  • Oxy-Fuel Lighting and Shutdown SequencePurging, lighting and shutting down per manufacturerComing soon
  • Manifold Systems and Gas DistributionCylinder manifolds and pipelinesComing soon
  • Transporting Cylinders in VehiclesSecuring cylinders and materials of tradeComing soon
  • Cylinder Hydrostatic Retest IntervalsRequalification concept and who may perform itComing soon
  • Cylinder Ownership, Leases and RentalsCustomer-owned vs rented cylinders and demurrageComing soon
  • Gas Purity GradesWelding grade vs higher purity, dew point conceptsComing soon
  • Gas Cage and Storage Area DesignSignage, ventilation, separationComing soon

Weld Quality & Failure Analysis

Weld discontinuities, their causes and how distributors help troubleshoot.

  • Porosity: Causes and FixesGas coverage, contamination, moistureComing soon
  • Cracking: Hot, Cold and Hydrogen CrackingMechanisms and preventionComing soon
  • Undercut, Overlap and Lack of FusionTechnique and parameter causesComing soon
  • Excessive SpatterGas, voltage, wire and polarity causesComing soon
  • Burn-Through on Thin MaterialHeat input and joint designComing soon
  • Wire Feeding Problems (Birdnesting, Burnback)Drive rolls, liners, tipsComing soon
  • Arc Instability in TIGTungsten prep, gas, contaminationComing soon
  • Distortion ControlSequencing, fixturing, preheatComing soon
  • Stainless Steel Discoloration and SensitizationHeat tint, carbide precipitation, low-carbon fillersComing soon
  • Aluminum Weld ProblemsOxide, porosity, cracking, feedingComing soon
  • Visual Weld Inspection BasicsWhat a visual inspector checksComing soon
  • Nondestructive Testing Methods OverviewVT, PT, MT, UT, RT basicsComing soon
  • Electric Shock Hazards in WeldingWet conditions, damaged cables and OCVComing soon
  • Welding Fume Hazards: Manganese and Hexavalent ChromiumFume constituents and the governing exposure limitsComing soon
  • Fire and Explosion in Hot WorkSparks, containers that held flammables, fire watchesComing soon

Procedures, Qualification & Specification Control

Codes, WPS/PQR, welder qualification and filler substitution control.

  • Welding Codes OverviewD1.1, D1.2, D1.5, ASME IX, API 1104 and where each appliesComing soon
  • WPS vs PQR vs WPQWhat each document is and who controls itComing soon
  • Prequalified WPS (AWS D1.1)What prequalification covers and limitsComing soon
  • Filler Metal Substitution RulesWhy a different brand may need requalificationComing soon
  • F-Numbers and A-NumbersASME grouping of filler metalsComing soon
  • Welder Qualification and ContinuityTest, essential variables and continuity logsComing soon
  • Certified Welding Inspector (CWI) RoleWhat a CWI does and does not certifyComing soon
  • Filler Metal Certifications (AWS A5.01 Lot Classes)Lot classes and schedule types for test reportsComing soon
  • Writing a Filler Metal Purchase SpecificationClassification, diameter, package, cert levelComing soon
  • Hot Work Program RequirementsPermits, fire watch and authorized individualComing soon
  • Welding Safety Program ElementsVentilation, PPE, training under Z49.1Coming soon
  • Construction vs General Industry Welding Rules1926 Subpart J vs 1910 Subpart QComing soon

Procurement & Cost Reduction

Buying welding consumables and gas for lower cost per foot of weld.

  • Cost per Foot of WeldDeposition rate, efficiency and labor shareComing soon
  • Filler Metal Deposition EfficiencyStick vs solid vs cored wire efficiencyComing soon
  • Package Size OptimizationSpools vs drums and changeover laborComing soon
  • Gas Cost Reduction: Flow Rate and LeaksFlow control and leak auditsComing soon
  • Bulk Gas vs CylindersMicrobulk and bulk economicsComing soon
  • Consumable StandardizationRationalizing contact tips, nozzles, wiresComing soon
  • Equipment Lease, Rental and PurchaseWelder and plasma acquisition optionsComing soon
  • Contact Tip Life ProgramsTip changes, premium tips and downtimeComing soon
  • Supplier Qualification for Filler MetalsCerts, traceability and AWS conformanceComing soon
  • Cylinder Rent and Demurrage ControlAuditing cylinder countsComing soon

Quality, Compliance & Traceability

Certs, heat lots, cylinder records and compliance.

  • Filler Metal Heat and Lot TraceabilityRecording lot numbers to weldsComing soon
  • Certificates of Conformance and Test Reports for Filler MetalWhat a CoC vs actual test report containsComing soon
  • Storing Filler Metals to Maintain CertificationHumidity, opened packages and segregationComing soon
  • Cylinder Tracking and Requalification RecordsSerial-level cylinder recordsComing soon
  • Hazmat Shipping Papers for Gas CylindersShipping descriptions and materials of tradeComing soon
  • Hazmat Employee Training for Gas DistributorsTraining requirements for handlersComing soon
  • SDS for Gases and Filler MetalsWhere fume information livesComing soon
  • Calibration of Welding EquipmentMeter verification conceptsComing soon
  • Customer Audit Support for WeldingDocuments shops are asked to provideComing soon
  • Nonconforming Product HandlingDamp rods, damaged spools, mislabeled cylindersComing soon

Inventory, VMI & Vending

Stocking welding consumables and managing cylinder fleets.

  • Welding Consumables VendingTips, nozzles, wire and ADF lenses in vendingComing soon
  • Min/Max for Filler MetalsUsage and lead-time based levelsComing soon
  • Cylinder Fleet Inventory ManagementFull, empty and in-use countsComing soon
  • Cylinder Exchange Route ServiceScheduled swaps and par levelsComing soon
  • Point-of-Use Consumable KitsKitting tips, nozzles and diffusers by gunComing soon
  • Shelf Life and Rotation of ConsumablesFIFO for electrodes, cored wire and ADF batteriesComing soon
  • Rod Oven and Moisture-Controlled Storage at Customer SitesManaging low-hydrogen stock on siteComing soon
  • Barcode and RFID Cylinder TrackingTechnology optionsComing soon
  • Usage Reporting by Machine or CellConsumable cost per cellComing soon
  • Seasonal and Project-Based Gas PlanningShutdowns and project surgesComing soon

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