Download - AWS- Use of Measuring Tools

Copyright American Welding Society Provided by IHS under license with AWS

Not for ResaleNo reproduction or networking permitted without license from IHS

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STDaAWS HOT-ENGL 1i987 = 07842b5 O534398 4 T 0 m

USE OF MEASURING TOOLS FOR THE AWS CERTIFIED WELDING INSPECTOR

HANDS-ON EXAMINATION

EDUCATION DEPARTMENT AMERICAN WELDING SOCIETY, INC.

550 N W LE JEUNE RD. MIAMI, FLORIDA 33126



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USE OF MEASURING TOOLS FOR THE AWS CERTIFIED WELDING INSPECTOR

HANDS-ON EXAMINATION

Copyright 1987 by American Welding Society Inc. 550 N. W. Lejeune Road

Miami, Florida 33126 All rights reserved.

No part of this module may be produced in any form or by any means without permission in writing from the publisher.



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USE OF MEASURING TOOLS FOR THE AWS CWI HANDS-ON EXAMINATION

. As of July, 1987, the format of the AWS Certified Welding

Inspector Examination was altered by the Qualification and Cer-

tification Committee. Presently, the three sections of the test

include: Part A : Fundamentals (Closed-book; 150 multiple choice

questions), Part B: Practical Hands-on (Closed-book; 46 multiple

choice questions) and Part C: Code/Standard (Open-book; 46 mul-

tiple choice questions). Two ( 2 ) hours will be allowed for each

separate section of the examination, for a total of 6 hours.

The major change occurring in the examination format is the

fact that the Practical portion is now referred to as the "Hands-

On" test. In this part of the examination, toolkits will be dis-

tributed to each person. In addition to the tools, each kit in-

cludes plastic replicas of welds and destructive test specimens,

plus an illuminated slide viewer containing several pictures. In

order to answer the questions on the examination, each person

must demonstrate their ability to utilize the tools to measure

various aspects of the plastic replicas provided. In addition,

there will be questions referring to the pictures appearing in

the illuminated viewer.

A l s o included with this examination is a sample code to

which you must refer in order to answer some of the questions.

The code provided consists of only a few pages and is generally

arranged in the same manner as AWS D1.l. However, the require-

ments in this sample code are NOT the same as those found in AWS -

s-1 Copyright American Welding Society Provided by IHS under license with AWS


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STDoAWS HOT-ENGL 1987 O784265 0514401 a15 H

D1.1. During this part of the examination, you will be asked to

measure certain aspects of the plastic replicas. Then you may

have to refer to this sample code to determine if the result of

that measurement is acceptable in accordance with these code

requirements.

The purpose of this discussion is to familiarize those in-

dividuals taking the examination with the tools and their proper

usage. Before describing their operation, the list below in-

cludes all of the tools contained in the kit:

- 6 inch machinist's rule (or scale) in 1/32 and 1/64 inch graduations

- O to 1 inch micrometer in 0.001 inch graduations (adjustable - hex wrench provided)

- 150 mm metric dial caliper in 0.1 mm graduations

- 2 inch diameter reading glass (6.50 dioptre)

- Set of Fibre Metal template fillet weld gages (1/8 to 1 inch fillet weld sizes)

- Palmgren weld gage

Figure 1 is a picture showing all of the tools found in a

typical toolkit for the examination.

In addition to these tools, the kit also includes an il-

luminated slide viewer containing pictures showing the equipment

for several different nondestructive test methods. Other pic-

tures shown in the viewer illustrate weld radiographs containing

various types of weld discontinuities.

Finally, the kit contains plastic replicas of welds and

destructive test specimens. These replicas include: a groove

weld in a butt joint, single and multiple pass fillet welds on



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STD=AWS HOT-ENGL 1787 078Y2b5 051YY02 751 W

Figure 1, Tools Found in the Examination T o o l k i t

different sides of a T- or lap joint, a single pass fillet weld

on a T-joint with porosity located in segments identified on the

sample, a rectangular tensile specimen, and a series of four face

or root bends showing their convex surfaces after bending.

Now that all of the components of the kit have been iden-

tified, it's appropriate to describe how each particular instru-

ment will be used by the inspector, either during the test or in

normal day-to-day inspection activities.



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STD-AWS HOT-ENGL L987 E 07842b5 0534403 698 E

Use of the Tools for Measuring and Weld Evaluation

Measuring With the 6 Inch Machinist's Rule

The simplest, and probably the most common, measuring device

included in the toolkit is the 6 inch machinist's rule, sometimes

referred to as a scale. Figure 2 shows a closeup of the type in-

cluded in the kit.

Figure 2, 6 Inch Machinist's Rule

The particular type found in the kit is graduated in incre-

ments of 1 / 3 2 inch on the one (top) side and 1/64 inch on the

other (bottom) side. The large numbers indicate whole inches,

and the smaller numbers indicate the appropriate number of 1/32



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STD=AWS HOT-ENGL 1787 0784265 0514404 524 W

or 1/64 inch increments, depending which side of the rule is

being used. The significance of these graduations is depicted in

Figure 3 .

Figure 3, Ruler Increments of One Inch

Measuring With the O to 1 Inch Micrometer

The next measuring device to be discussed here will be the O

to 1 inch micrometer. A micrometer, or "mike" for short, is an

instrument that measures in thousandths of an inch (1/1000 inch).

The type found in the test kit is adjustable, so there is an ac-

companying hex wrench. These items are shown in Figure 4 .

In Figure 5, the various parts of the micrometer are iden-

tified, including the frame, the barrel, the thimble, the

spindle, and the anvil. On this particular model, there is a l s o

a friction stop. The friction stop, located at the end of the



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___

STD-AWS HOT-ENGL 3987 = 07842b5 0534405 4b0

Figure 4, Adjustable Micrometer with Hex Wrench

5PIN

ANVI

FR I CTI ON STOP

\ LOCK NUT

/ - F R A M E

Figure 5, Parts of a Micrometer

S - 6 Copyright American Welding Society Provided by IHS under license with AWS


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STD-AWS HOT-ENGL 1987 W 07842b5 051440b 3T7 m

thimble, can be used to tighten the micrometer on the object to

be measured. Since the friction stop always slips at a particu-

l a r pressure, the micrometer can be tightened the same amount for

each measurement, allowing for more repeatable results.

Since the micrometer found in the test kit is an adjustable

type, the first operation involves checking to make certain that

the micrometer is "zeroed." To do this, hold the micrometer as

shown in Figure 6 , and turn the friction stop until the spindle

and anvil are in contact. With the micrometer closed, the "O" on

the thimble should be aligned with the " 0 " mark on the barrel, as

shown in Figure 7. If this is not the case, then the instrument

must be adjusted as explained below.

Figure 6, Proper Way to Hold a Micrometer

Figure 7, Testing the Exactness of a 1 Inch Micrometer



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STD*AWS HOT-ENGL A987 0784265 0514407 233

To begin this adjustment, loosen the setscrew located near

the friction stop end of the thimble, while holding the spindle

stationary. Then move the thimble until the I I O " marks on both

the barrel and the spindle are aligned as shown in Figure 7 . The

hex wrench can then be used to tighten the thimble in this posi-

tion. The thimble should then be loosened and the initial step

repeated to make certain that the instrument is now properly

calibrated.

The micrometer is now ready to be used for measuring.

However, in order to determine the size of some object, it is

necessary to understand how to read dimensions on the micrometer.

The marks on the thimble represent 0.001 inch each. By turning

the thimble in the direction shown in Figure 8, the spindle moves

away from the anvil. If the thimble is turned so that the first

mark on the thimble is aligned with the I I O " on the barrel, that

represents a distance between the spindle and anvil of 0.001

inch, as shown in Figure 8.

0.00IH I Figure 8, One Thousandth of an Inch (0.001")

Additional turning in the same direction will move the

S-8 Copyright American Welding Society Provided by IHS under license with AWS


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STD-AWS HOT-ENGL 1987 0781i2b5 0514408 17T

thimble so that the " 0 " mark on the barrel is aligned with the

thimble mark identified by the number " 5 " , which is shown in

Figure 9. This represents a dimension of 0.005 inch.

Figure 9, Five Thousandths of an Inch (O.OOS1')

Note that one complete turn of the thimble is 0.025 inch on

the barrel, as depicted in Figure 10. For each complete revolu-

tion of the thimble, the thimble moves over one more mark on the

barrel. This means that each mark on the barrel is 0.025 inch.

Figure

O. 025 " i , Twenty-five Thousandths of an Inch \3.025")

Every fourth line on the barrel is a little longer than the

others and is stamped 1, 2 , 3 , etc., which stands for 0.100,

0.200, 0.300 inch, etc. Figure 11 shows the position of the



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STD-AWS HOT-ENGL 1987 07842b5 05Lr1404 006 W

thimble f o r a setting of 0.100 inch.

5

I"' 7 O

0 -

A

20

0.100" i Figure 11, One Hundred Thousandths of an Inch (0.100")

To find out how much the micrometer is opened (the distance

between the anvil and the spindle) the marks on the barrel may be

read like any ordinary rule, remembering that the numbers 1, 2,

3 , etc., mean 0.100, 0 . 2 0 0 , 0.300 inch, etc. To this number, add

the thousandths that show on the thimble. So, the measured

dimension of some object is arrived at by closing the spindle and

anvil around the object and adding the following indications on

the micrometer: the number on the barrel (increments of 0.100

inch), the smaller graduation on the barrel (increments of 0.025

inch), and the graduation on the thimble ali.gned with " 0 " line on

the barrel (increments of 0.001 inch).

Figure 12 illustrates four different dimensions indicated on

a micrometer. In Figure 12(A), the end of the thimble is aligned

with the number " 2 " on the barrel and the " O " on the thimble is

aligned with the i l O " line on the barrel. This represents a

dimension of 0.200 inch.

In Figure 1 2 ( B ) , the reading shown is 0.250 inch ( o r 0.200"

+ 0.025" + 0 . 0 2 5 " ) . Figure 1 2 ( C ) represents the dimension 0.562



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STD-AWS HOT-ENGL 1987 = 0784265 0514410 828

inch ( o r 0.500" + 0.050" + 0.012"). Finally, in F i g u r e 12(D),

the measurement is shown to be 0.787% inch (or 0 .700" + 0 .075 +

0 .012+" ) .

0.200" I

1 4

I (0) -

Figure

I I u O . 562"

I " c . 7 ~

12, Reading a Micrometer



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Measuring With the Metric Dial Caliper

A closeup of the metric dial caliper included in the toolkit

is shown in Figure 13.

Figure 13, Closeup of Metric Dial Caliper

This instrument can be used for measuring either inside or

outside dimensions of objects. In addition, dimensions such as

depths or heights of steps can also be determined. This par-

ticular style can be used to measure dimensions as large as 150

mm in increments of 0.1 mm. The various parts of the dial

caliper include: main beam (with 10 mm increments), slider, dial

(with 0.1 mm increments), bezel (movable rim of dial used for

zeroing), inside jaws, outside jaws, thumb wheel (for moving

slider), and depth indicator. Figure 14 depicts how the caliper

s-12



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STD-AWS HOT-ENGL 1987

is positioned to measure various

0784265 0534432 bTO W

types of dimensions.

Figure 14, Positioning Dial Caliper for Various Measurements

As with the micrometer, the first step toward using the dial

caliper is to determine if it is properly zeroed. This is ac-

complished by moving the slider until the outside jaws are com-

pletely closed. While holding the slider in this position, move

the bezel until the dial indicator needle is centered over the

" O " mark on the dial.

Once the instrument is properly zeroed, it is now ready for

use. Depending on the type of dimension desired (outside, in-

side, depth or step height) the dial caliper will be positioned

as shown in Figure 14. At a given slider position, the dimen-

sions indicated by the outside jaws, inside jaws, and depth in-



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dicator are identical. The dimension of the object can then be

determined by observing the positions of the main beam and dial

indicators. The total dimension of the object is the sum of

these two indicators. The beam indicator will point to gradua-

tions which are 10 mm apart. To that. indication will be added

the dial indication. This allows for the measurement of objects

to an accuracy of 0.1 mm.

Figure 15 shows a slider position and the corresponding

dimension measurement.

I\ fi 19+7.05 =17.85mn

Figure 15, Reading a D i a l Caliper

Looking at this Figure, the main beam indicator is posi-

tioned between the 10 and 20 graduations. The dial indicator

then points to the exact number of millimeters to be added to the

10 mm indication of the main beam. So, for this example, the to-

tal dimension is equal to 10 mm (from main beam) plus 7.85 mm

(from dial indicator) for a total of 17.85 mm. As shown, this is

the dimension, regardless of whether the measurement is an out-

side, an inside, a depth, or a step height.



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STDmAWS HOT-ENGL 1987 W 07842b5 0514414 473 I

Using the Reading Glass

The next tool in the kit is the 2 inch diameter reading

glass, or magnifier, which is shown in Figure 16.

Figure 16, 2 Inch Diameter Reading Glass

The primary purpose of this instrument is to magnify objects

so they can be more accurately analyzed. As far as the use of

the reading glass, it is positioned between the eye and the ob-

ject being viewed to produce a magnified image. An example of

its use for the examination might be in the measurement of

porosity occurring in the fillet weld. The combined use of the

reading glass with one of the measuring instruments will allow

for the most accurate determination of the porosity size.



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Measuring Fillet Weld Size With the Fibre Metal Template Gages

The Fibre Metal template fillet weld gages are sold in a set

as shown in Figure 17.

Figure 17, Fibre Metal Template Fillet Weld Gages

This set of gages permits the accurate measurement of fillet

welds from 1/8 to 1 inch, regardless of whether the contour of

the fillet weld is flat, convex or concave.

Before discussing the application of these gages, it is ap-

propriate to briefly mention what is meant by fillet weld size.

AWS defines the size of a fillet weld as being the size of the

largest right isosceles triangle which can be totally contained

within the cross section of the fillet weld. With this in mind,



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it becomes apparent that the part of the fillet weld limiting the

size of this theoretical triangle is different depending on

whether the weld is convex (humped up) or concave (dished in).

For the convex fillet weld, its size is determined by the leg

dimension. In the case of the concave fillet weld, the throat

dimension is the limiting factor. Consequently, these fillet

weld gages have been designed to facilitate the measurement of

either of these dimensions, depending on which part of the gage

is used.

In Figure 18, one of these template gages is shown. It is

noted that there are two different shapes of cutouts present.

One shape (shown on the bottom of this gage) is a single ap-

proximately circular cutout (or arc). The other shape noted

(shown on the top of this gage) consists of two circular cutouts

(or arcs) on either side of a flat surface.

Figure 18, Typical Fibre Metal Template Gage



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The different cutout shapes are to be applied to different

weld contours. If the weld appears to be convex, the single arc

portion of the gage is applied. Similarly, the double arc por-

tion of the gage is used for determining the size of a concave

fillet weld. Their typical application is shown in Figure 19.

w i o

CONVEX WELDS W a O

CONCAVE WELDS

Figure 19, Typical Application of Fibre Metal Gages

The convex fillet weld size is determined by placing the

proper portion of the gage against the two base metal surfaces.

The weld is considered to be the size specified on the gage if

the top corner of the gage touches the weld face or the weld toe

when positioned as shown in Figure 19 (bottom left illustration).

Similarly, the size of a concave fillet weld is found by

positioning the proper portion of the gage against the two base

metal reference surfaces. This weld is then considered to be the

size indicated on the gage if the flat reference surface touches



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the weld face when the gage is held in the position shown in

Figure 19 (bottom right illustration). So, even though the p a r t

of the fillet weld being measured varies depending on whether it

is convex or concave, the actual sizes of the welds will be iden-

tical, provided the sizes etched on the gage surfaces are the

same.

Figure 20 illustrates the proper application of these types

of gages for several different conditions.

Fillet size is difficult io measure without gages.

There Are 2 T y p s of Gages

2. To measure

Mooruring Conwx Fillets

RIGHT Medsure the smaller 01 two legs tor a true mdimion ot I i i let sue

RIGHT 5/16" ltllet 51 16'' i~>sceles riyfit triangle Cdn be inscribed i*irhin weld cro% rPction

WRONG not 3/8" Do not use pi* l o r concave t ~ ~ l e t s on conven lilleis

convex

MMsuring Concave Fillets

RIGHT

114" isosules r ight triangle u n be inscribed within m l d crot(..sxtion

WRONG Not 5/16'

DO not use gage for c o n w x l i l le tson concave lillets

concaw

M ~ r u i i n g 45" Flat Fillets With Equol legs (Idwl Fillet Shop.)

Eithcr type wge can be und.

Measuring Fillets When Shop Ir N o t Apparent

Check with b o t h type gages to determine true Y&?.

WRONG A- I . I RIGHT Correct si le 5/16"

Thisgage indicates l i l let s i e is greater than 5/16'' this is incorrect

In this example - Gage lor concaw fillets touches bonorn leg. belore it touches vertical plate Bot tom leg IS larger than vertical leg The important thing IS to

1 check wi th b o t h piges dnd 2 Check both l e p wilh lhe convex qdw

Figure 20, Using the Fibre Metal Type Fillet Weld Gages



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STD-AWS HOT-ENGL 1967 07842b5 0514417 T55

It is noted in these examples that multiple applications of

the gage may be necessary in order to properly measure a f i l l e t

weld. Since these gages are supplied in 1/16 inch increments,

fillet weld sizes can be determined only to the closest 1/32

inch. So, the inspector will have to make a judgment as to w h i c h

gage comes closest to actual weld size.

For example, let's consiüer the measurement of a convex fil-

let weld. In this example, we'll assume that t w o separate gages

(1/4 and 5/16 inch) were applied, but the weld appeared larger

than 1/4 inch but less than the 5/16 inch. In this case, the in-

spector must make a decision as to which of the two gages comes

closest to the actual weld size. If the weld appears to be less

than 1/32 inch larger than the 1/4 inch gage, it would be class-

ified as a 1/4 inch weld. However, if the measurement showed

that the weld size was less than 1/32 inch smaller than the 5 / 1 6

inch gage, it would then be considered to be a 5/16 inch fillet

weld.

s-20

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STDmAWS HOT-ENGL 1987 07842b5 0514420

Using the Palmgren Weld Gage

The final tool to be discussed here is the Palmgren weld

gage. It is pictured in Figure 21. This gage can be utilized to

measure a number of different weld dimensions, including: weld

reinforcement, convex fillet weld s i z e , concave fillet weld size,

maximum convexity, il8 inch root opening, and 5/16 inch root

opening.

Figure 21, Palmgren Weld Gage

While a number of different dimensions can be determined

with this gage, only that part of the gage designed to measure

the amount of weld reinforcement will be needed for the hands-on

test. This gage is not really suited for measuring the fillet

welds on the examination, because the specimens are not large



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STD-AWS HOT-ENGL L987 07842b5 051442L 603 W

enough to properly position the gage.

To utilize this gage for measuring the height of weld rei.n-

forcement present on a groove weld, the gage is positioned as

shown in Figure 22. There, the base (the edge where the root

opening spacers are attached) of the gage is positioned such that

the t w o legs are on either side of the weld reinforcement. Once

positioned, the slider is then moved until it is in contact with

the highest point of the weld reinforcement. The amount of weld

reinforcement present can then be read directly from the scale

labelled "butt weld reinforcement , ' I

Figure 22, Measuring Weld Reinforcement

s-22



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STDmAWS HOT-ENGL 3987 W 078Y2b5 0534422 5LiT

Summary

This section is intended to provide an individual preparing

for the AWS CWI Examination with information about what to expect

during the closed-book "Practical Hands-On" portion of the test.

It's primary purpose is to explain the use of the various tools

in the test kit.

Since it is difficult to fully understand how to use some

instrument simply from some written explanation, each individual

is urged to practice with each of these tools prior to the day of

the test. Only then will it be possible to most efficiently

apply these tools during the brief test period.

References

Oswald, Ludwig A . , Metal Work Technoloqy and Practice (McKnight and McKnight Publishing Company, Bloomington, Illinois, 1962)

"Stick Electrode Welding Guide" (Lincoln), pages 48 and 49

General Hardware Manufacturing Company, Inc., Sales literature accompanying adjustable micrometer and dial caliper

Fibre Metal Products Company, Sales literature accompanying fillet weld template gages

Palmgren Steel Company, Sales literature accompanying weld gage



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STDeAWS HOT-ENGL 3987 078Y2b5 0534423 48b W

QUIZ



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s-1

s-2

s-3

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STDSAWS HOT-ENGL 1787 m 07842b5 0514424 312 m

PRACTICE QUIZ FOR USE OF CWI HANDS-ON TOOLKIT

What is the size of the item being measured with the machinist's ruler shown in the sketch below?

a. 1-23/32 in. b. 1-23/64 in. c. 1-21/64 in. d. 1-21/32 in. e. none of the above

A micrometer is being used to measure the width of a rectangular tensile specimen. What is its dimension if the micrometer appears as shown below?

a. 0.658 in. b. 0.568 in. c. 0.762 in. d. 0.678 in. e. none of the above

The dial caliper is being used to measure the thickness of the rectangular tensile specimen in the question above. What is its dimension if the dial caliper appears as shown below?

a. 18.90 mm b. 10.87 mm c. 187.0 mm d. 18.70 mm e. none of the above



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s-4

s-5

S-6

s-7

STD-AWS HOT-ENGL I1987 W 0784Zb5 0534425 259

PRACTICE QUIZ FOR USE OF CWI HANDS-ON TOOLKIT, Page 2

Using a conversion factor provided on the back page, what is the equivalent dimension in SI units for the width shown in question S-2 above?

a. 22.76 mm b. 20.69 mm c. 19.35 mm d. 19.15 mm e. 18.77 mm

Using what units

' a conversion factor provided on the back page, is the equivalent dimension in U. S . customary for the thickness shown in question S-3 above?

a. 0.936 in. b. 0.778 in. c. 0.887 in. d. 0.966 in. e. 0.736 in.

What is the calculated area of the tensile bar measured above?

a. b. c. d . e. none of the above

0.777 in2 and 501.29 mm2 0.555 in2 and 358.06 mm2 0.738 in2 and 476.13 mm2 0.561 in2 and 361.85 mm2

If the tensile specimen above failed at a load of 51,550 pounds, what is the ultimate tensile strength of this metal?

a. 91,890 psi b. 82,800 psi c. 56,400 psi d. 37,000 psi e. none of the above



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S - 8

s-9

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S T D D A W S HOT-ENGL 1787 07842b5 051442b 175


A fillet weld gage is being used to measure the size of the fillet weld shown below. From this sketch, what would be the size of this weld.

a. 5/16 inch b. 1/4 inch c. less than 1/4 inch d. cannot properly measure this weld with the gage

e. none of the above shown

The fillet weld shown below is being measured to determine if it satisfies the drawing requirement of 3 / 8 inch. What can be said about the measurement being made in the sketch?

rl a. This weld is not acceptable because it is too

b. This weld is acceptable. c. This weld is not acceptable because it is too

d. Unable to accurately determine if the weld is of

e. none of the above

large.

small.

proper size, because the wrong gage is being used.



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STD-AUS HOT-ENGL 1987 II 07842b5 0534427 021


s-10 The groove weld shown below is required to have a maximum weld reinforcement of 1/32 inch. Judging from the measurement shown in the sketch, what would you say about this weld?

a. The weld is unacceptable, because there is not enough weld reinforcement.

b. The weld is unacceptable, because there is too much weld reinforcement.

c. This weld is unacceptable, because the requirement only applies to face reinforcement and the root reinforcement is being measured.

d. The weld is acceptable, as far as the amount of permissible weld reinforcement.

e. none of the above

Conversion Factors

To Convert From

in.

mm

To

mm

in.

Multiply By

25.4

3 . 9 3 7 x



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STD-AUS HOT-ENGL 1987 m 07842b5 0534428 Tb8 m

ANSWERS



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STD-AWS HOT-ENGL 1787 = 0784265 0534427 ï T 4 m


Answer Sheet for Hands-on Toolkit Quiz

s-1

s-2

s-3

S-4

S-5

S-6

s-7

S-8

s-9

s-10

d

C

d

C

e

d

a

b

d

d



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Download - AWS- Use of Measuring Tools

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