This 3-day intensive is designed to take an experienced welder and push them toward the "Gold Standard" of manual welding: the 6G Pipe Certification. The 6G position—where the pipe is fixed at a 45-degree angle—is the ultimate test of a welder's ability to manage the puddle against gravity in every possible orientation (Flat, Horizontal, Vertical, and Overhead).

Day 1: Advanced Pipe Prep & Root Pass Mastery

In 6G welding, the weld is won or lost in the preparation. If your fit-up is inconsistent, your root pass will fail.

• Pipe Preparation: Grinding a $37.5\text{°}$ bevel to create a $75\text{°}$ included angle.

• The "Penny" Gap: Setting a consistent $1.6\text{ mm}$ to $3.2\text{ mm}$ root opening using spacers.

• Tack Welding: Placing four small, feathered tacks at the 12, 3, 6, and 9 o'clock positions to maintain alignment without obstructing the final bead.

• The Root Pass (E6010/E6011): Mastering the "Keyhole" technique. You will learn to use high-cellulose electrodes to "dig" into the root and create a uniform internal bead (the "wedding band").

Day 2: The 6G Progression (Hot Pass to Cap)

Day two focuses on the 45-degree fixed position. You cannot move the pipe; you must move your body around it while maintaining a consistent arc length.

• The Hot Pass: Using higher amperage to "burn out" any remaining slag from the root and flatten the profile for the filler passes.

• Fill Passes (E7018): Switching to low-hydrogen electrodes. You will practice the "step-up" technique, ensuring the weld metal fuses perfectly to both bevel walls to avoid "sidewall lack of fusion."

• Gravity Management: * Bottom (6 o'clock): Fighting overhead gravity.

  • Sides (3 & 9 o'clock): Managing vertical-up progression.

  • Top (12 o'clock): Transitioning to a flat/horizontal finish.

• The Cap: Learning the "weaving" or "stringer" method to create a visually aesthetic and structurally sound final layer with no undercut.

Day 3: WQT (Welder Qualification Test)

The final day is a formal simulation of the Welder Qualification Test under AWS D1.1 or ASME IX standards.

• Test Assembly: You will prepare your "coupon" (test pipe) under the supervision of an instructor.

• The "Stop and Restart": One of the most common fail points. You will be tested on your ability to restart an arc in the middle of a pass without creating a defect.

• Visual Inspection: Your finished weld must meet strict criteria:

  • No cracks.

  • Undercut less than $0.8\text{ mm}$.

  • Reinforcement (cap height) between $0\text{ mm}$ and $3\text{ mm}$.

• Destructive Testing (Bent Test): We will cut your pipe into "straps" and perform Root and Face bends. If the metal snaps or opens up more than $3\text{ mm}$, the test is a fail.