In the world of welding, every mistake has consequences. Whether you’re welding a pipeline in a chemical plant or fabricating high-pressure vessels, there are industry standards that must be followed—no excuses.
Yet, every welding instructor or inspector has heard some version of this:
“You didn’t tell me I couldn’t do that.”
Recently, one of my students failed a welding test because he welded outside the designated weld area. His response? “You should have told me I’m not allowed to do that.”
But here’s the truth: If I had to personally tell every welder what NOT to do, we’d be here all day.
Welding Tests Are Not a Game
A welding test isn’t just about making a bead—it’s about proving you can follow real-world job expectations. No refinery, power plant, or fabrication shop is going to babysit you. Inspectors aren’t there to hold your hand; they’re there to verify your skills.
If a welder fails because they made a critical mistake, it’s not the inspector’s fault. It’s not the instructor’s fault. It’s on the welder.
The Long List of Things You Aren’t Allowed to Do
To put things in perspective, here’s a non-exhaustive list of things that would result in failure on a welding test (and in the real world).
General Test Violations
• Welding outside the designated weld area
• Arc strikes outside the weld zone
• Grinding where not allowed
• Using incorrect filler metal
• Failure to follow the WPS (Welding Procedure Specification)
• Overheating the test coupon
• Starting over without approval
Defects That Result in Failure
• Lack of fusion
• Incomplete penetration
• Excessive reinforcement
• Undercut
• Porosity
• Slag inclusions
• Cracks of any kind
• Burn-through
Equipment & Technique Violations
• Using the wrong amperage/voltage settings
• Incorrect travel speed
• Inconsistent arc length
• Stopping mid-weld without a restart procedure
• Holding the electrode at the wrong angle
• Not cleaning between passes
• Excessive weaving when stringers are required
• Too many welding restarts
Testing Environment & Safety Violations
• Not wearing proper PPE
• Failure to clean before welding
• Mishandling welding coupons
• Leaving slag on the weld before inspection
• Not following instructions from the inspector
• Using unauthorized tools
• Allowing shielding gas to run out mid-weld
Professionalism & Conduct Violations
• Arguing with the test inspector
• Refusing to accept a test failure
• Blaming equipment instead of technique
• Failing to ask questions when unsure
• Complaining about strict standards
• Not taking the test seriously
The Big Lesson: Welding Requires Accountability
If a student fails a welding test, they might think it’s unfair. But failing in a test booth is far better than failing on the job—where a single bad weld could cost thousands of dollars or even endanger lives.
A professional welder doesn’t wait to be told every single rule. They study, they prepare, and if they’re unsure, they ask questions before they strike an arc.
If you can’t handle a welding test failure, how will you handle a real welding inspection on the job?
There’s a reason welding is a respected trade: It demands skill, discipline, and personal responsibility. And if you want to be successful, blaming someone else isn’t an option.
What’s Your Take?
Have you ever failed a welding test? What did you learn from it?
Check out our other blog posts here https://www.southernarc.org/blog
About the author: Luis Alejandro is the owner and one of the instructors at Southern Arc Welding Services Ltd. Co.. He enjoys family, reading books on history, and writing to share his knowledge about the many situations welding can place us in.
Comentários