welding inspection q and ans

7/27/2019 Welding Inspection Q and Ans.

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Welding Inspection Q and Ans.

Name: ______________________ Date: ___________

Multi -Choice Question Paper (MSR-WI-1)

1. Which of the following butt-weld preparations isusually the most susceptible to lack of sidewallfusion during the manual metal arc process?a. A double-U butt.b. A single-V butt.c. A double-V butt.d. It is not normally a defect associated with the

MMA welding process.

2. What is the leg length of a fillet weld?a. The distance from the toe to face.b. The distance from the root to face centre.c. The distance from the root to the toe.d. The distance from toe to toe.

3. What is the throat thickness of a fillet weld (equalleg lengths)?a. The distance from the toe to the face.b. The distance from the root to the face centre.c. The distance from the root to the toe.d. The distance from toe to toe.

4. Lap joints contain:a. Fillet welds.b. Corner joints.c. Butt-welds.d. Single-bevel butts.

5. A duty not normally undertaken by a weldinginspector is to:a. Check the condition of the parent material.b. Check the condition of the consumables.c. Measure residual stress.

d. Check calibration certificates.

6. Under most conditions, which of the followingwelding positions will deposit the most weldmetal.a. Vertical down.b. Overhead.c. Horizontal-vertical.d. Flat (down hand)

7. What meant by the term crater pipe:a. Another term for concave rootb. Another term given for a burn through.c. A type of gas pore, found in the weld crater.d. A shrinkage defect, found in the weld crater.

8. What is meant by the term weld junction?a. The area containing the HAZ and the weld

metal.

b. The weld metal and parent metal.c. The boundary between the fusion zone and

the HAZ.d. The part of the weld, which has undergone

metallurgical changes due to the heat fromwelding.

9. The strength of a fillet weld is primarycontrolled by:a. Leg length.b. Throat thickness.c. Weld thickness.

d. All of the above.

10. A crater crack may also be termed:a. Cold crack.b. Tearing.c. Fatigue crackd. Star crack.

11. Which of the following weldingprocesses/technique is likely to be used for therepair welding of localised porosity in a buttweld?

a. MMA, PG position.b. Mechanised MAG.c. Submerged arc.d. All of the above.e. None of the above.


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12. Which of the following welds would beconsidered in a situation where two plates are tobe joined that overlap (assume no external assess).a. A fillet weld.b. A single-bevel butt weld.c. A plug weld.

d. A single-U butt weld.

13. In the MMA welding process, which of thefollowing is most likely to be caused by a welderwith a poor technique?a. Deep weld craters/crater cracks.b. Copper inclusionsc. Hydrogen cracksd. All of the above.

14. Root concavity is caused by:a. Excessive back purge pressure and entrapped

gas.b. Excessive back purge pressure and very high

heat inputs.c. Excessive root grinding and a slow travel

speed.d. Excessive root grinding and excessive back

purge pressure.

15. When inspecting a critical component, the toes ofa weld must be:a. Always ground flush.b. Must always overlap at least 1.5 mm onto the

parent material.c. Must always be inspected using a crack

detection method (MPI, DPI).d. None of the above can be selected -

specification requirements unknown.

16. When carrying out visual inspection, thespecification makes no mention of therequirements for visual inspection, in this situationwhat should you do?a. Carry out normal visual inspection.b. Seek advice from higher authority.

c. Carry out no visual inspection.d. Re-write the requirements of the specification.

17. Under most circumstances, which of the followingdo you consider to be duties of a weldinginspector?a. The supervision of welders.b. Procedure writing.c. Qualifying welders


18. Which of the following is most likely to cause aburn througha. Root gap too small.b. Travel speed too fast.

c. Root face too smalld. All of the above.

19. In an arc welding process, which of thefollowing is the correct term used for the amountof weld metal deposited per minute?a. Filling rate.b. Deposition rate.c. Weld deposition.d. Weld duty cycle.

20. What is the term given for the area of a welded

joint just outside the weld metal that hasundergone micro-structural changes?a. Heat affected zone.b. The weld zone.c. Fusion zone.d. All of the above terms may be used.

21. When carrying out visual inspection, whichdefect (s) is likely to be missed?a. Linear misalignment.b. Cap undercut.c. Porosity.

d. Lack of fusion (inter run).

22. Cold lapping is another term for:a. Lack of fusion at the toe of a weld.b. Lack of fusion between weld metal and weld

metal.c. Undercut at the toe of a weld.d. Both a and b.

23. Incomplete root penetration is most likely dueto:a. Welding speed too slow.

b. Welding current too high.c. Root gap too small.d. Electrode diameter too small.

24. Crater cracks are caused mainly by:a. Excessively fast welding speedsb. Improper electrode anglec. Hot shrinkage.d. Improper joint design.


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25. On a single-V butt weld, the distance through thecentre of the weld from root to face is called:a. Reinforcement.b. Penetration.c. Throat thickness.d. None of the above.

26. The throat thickness of a % inch fillet weld is?a. 27.5 mmb. 24 mm.c. 13.5 mm.d. 12.5 mm.

27. The need for pre-heat for steel will increase if:a. The material thickness reduces.b. Faster welding speedsc. The use of a larger welding electrode.d. All of the above.

28. Which of the following butt weld preparations ismost likely to be considered for the welding of a6mm thick plate?a. Double-V butt.b. Asymmetrical double-V butt.c. Single-U butt.d. Single-V butt.

29. A welding inspectors main attributes include:a. Knowledge.b. Honesty and integrity.

c. Good communicator.d. All of the above.

30. A code of practice for visual inspection shouldcover:a. Before, during and after welding.b. Before welding activities only.c. After welding activities only.d. None of the above.


1. Defects outside the permissible limits of theapplicable specification should be:a. The decision is up to the welding inspector.b. Repaired.c. Always double checked using NOT.d. All of the above.

2. Electrodes used in manual metal arc welding canbe grouped into three main types, these are:a. Oxidising, basic and rutile.

b. Cellulose, basic and acidic.c. Granular, rutile and basic.d. Rutile, basic and cellulose.

3. Movement of the arc by magnetic forces in anarc welding process is termed:

a. Arc deviation.b. Arc misalignment.c. Arc blow.d. Stray arc.

4. A crack type most associated with thesubmerged arc welding process is:a. Hydrogen cracking in the HAZ.b. Solidification cracking.c. Lamellar tearing.d. Fatigue cracking.

5. Which of the following processes joins metalsplastically?a. Friction welding.b. Resistance welding.c. Arc welding.d. Plasma welding.e. All of the above.

6. What type of power source characteristic isrequired for a manual process?a. Constant voltage.b. Flat characteristic.

c. Drooping characteristic.d. None of the above.

7. Which of the following electrodes and currenttypes may be used for the TIG welding of nickeland its alloys?a. Cerium electrode, DC -ve.b. Zirconium electrode, AC.c. Thorium electrode, DC +ve.d. All of the above may be used.

8. What are the possible results of having a heat

input to low?a. An increase in hardness, lower yield

strength and lack of fusion.b. A reduction in toughness, hydrogen

entrapment and an increase in hardness.c. Entrapped hydrogen, an increase in hardness

and lack of fusiond. Entrapped hydrogen, a reduction in carbon

content and lack of fusion.


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9. The main reason for using a back purge whenwelding 18-8 stainless steel with the TIG weldingprocess is to:a. Improve positional welding.

b. Prevent the possibility of porosity.c. Prevent excessive root penetrationd. Prevent the formation of a dense oxide layer

forming in the root.

10. The possible effects of having a travel speed toofast:a. Low toughness, slag inclusions and cap

undercut.b. High hardness, slag inclusions and a narrow

thin weld bead.c. High hardness, excessive deposition and cold

lapsd. Low toughness, poor fusion and slag

inclusions.

11. If arc blow exists when welding with the MMAwelding process, this can be best reduced oreliminated by:a. A change from AC to DC current.b. A change from DC to AC current.c. A change from DC +ve to DC -ve.d. A change from DC -ve to DC +ve.

12. When welding a double-V butt weld with thesubmerged arc welding process the presence ofcentre line porosity may be due to:a. Damp flux.b. Contamination on the weld preparations.c. Incorrect flux depthd. All of the above.

13. The inclusion of an inductance in the weldingcircuit when using MIG/MAG welding process isto:a. Control the rate of spatter in the dip transfer

mode.b. It enables the welder to weld in position with

the spray transfer mode.c. It allows for thicker filler wires to be used

(2.6-3.6mm diameter).d. It allows full control over droplet size in the

spray transfer mode.

14. An undesirable property of aluminium oxideresidue, when welding is that it:a. Decrease weld pool fluidity.b. Requires more heat to melt it when

compared to aluminium.c. Causes the welder to travel to quickly.d. The presence of the oxide makes aluminium

impossible to weld.

15. Which of the following welding process is mostlikely to be used for the welding of a smalldiameter stainless steel pipe, 6mm-wallthickness?a. GTAWb. SMAW.c. Submerged arc welding.

d. GMAW.

16. When considering the tungsten arc weldingprocess what is the purpose of the down-slope(slope-out) control?a. Ensure good penetration.b. To prevent arc striking on the parent

material.c. To help prevent the formation of crater pipe

and possible cracking.d. To help prevent tungsten inclusions during

welding.

17. When considering thermal cutting localhardening can be reduced by:a. Increasing the cutting speed.b. The use of propane as a fuel gas.c. Pre heating the material to be cut.d. All of the above.

18. In a semi-automatic welding process, which ofthe following shielding gas/gas mixtures wouldnormally give the deepest penetration on steel?a. 100% argon.

b. 100% CO2.c. 75% argon + 25% CO2.d. All of the above would give the same depth

in penetration.


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19. In a MMA welding process, which of thefollowing statements are false?a. An arc gap, which remains almost constant

even if as usual the welder varies the positionof the electrode.

b. A voltage, which remains almost constant

even if as usual the welder, varies the arc gap.c. A current, which remains almost constant even

if as usual the welder, varies the arc gap.d. A and b.e. All of the above.

20. Which of the following welding process, after theweld is completed normally requires a post weldheat treatment to restore toughness values ~a. ESW.b. MMA.c. MAG.

d. All completed welds require a post heattreatment, regardless of welding process.

21. Which of the following current types would youexpect to be used for the welding of aluminiumwith the TIG welding process?a. DC -ve.b. DC +ve.c. ACd. All of the above.

22. Which of the following statements is false?

a. In the MMA welding process electrode DC +produces a deep narrow weld pool, which isfast freezing.

b. DC electrode positive is used for the MAGwelding of steel plate.

c. The word calcium carbonate means limestoned. All of the above

23. When considering hydrogen, which of thefollowing welding process would produce thelowest levels in the completed weld (undercontrolled conditions)

a. MMA.b. SAW.c. TIG.d. FCAW.

24. Pre heat prior to the welding of a carbon steel buttweld:a. Must always be carried out.b. Is always carried out using a gas flame C

c. Need not be carried out if post weld heattreatment is to follow

d. None of the above.

25. In steel the element with the greatest effect onhardness is:

a. Chromium.b. Manganese.c. Carbon.d. Nickel.

26. For a given voltage and current settings on aMMA welding plant, when the arc length isshortened, which of the following will be mostaffected.a. The current will increase.b. The current will decrease.c. The voltage will decrease.

d. The voltage will increase.

27. Which of the following best describes a semi-automatic welding process?a. The welder is responsible for the

maintaining the arc gap and travel speed.b. The welder is responsible for travel speed

only; arc gap is kept constant by the weldingplant.

c. Both travel speed and arc gap is controlledby the welding plant


28. What is purpose of a rectifier in a welding setselectrical circuit?a. To keep the arc stable when using low

current settingsb. To convert AC current to DC current.c. To convert DC current to AC current.d. To initiate the arc at start up.

29. When calibrating a mechanised MAG weldingplant, which of the following applies (WFS =

Wire feed speed)?a. Check -WFS, current, volts and wire

diameter.b. Check -WFS, joint set-up, gas flow rate and

WFS.c. Check -Gas flow rate, stick out length, WFS

and current.d. All of the above.


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30. The main usage of the arc air process is:a. The cutting of a weld preparation.b. The removal of defective welds.c. For the cutting of non-ferrous materials only.d. For the cutting of ferrous materials only.


1. The likelihood of a brittle fracture in steels willincrease with:a. The formation of a fine grain structure.b. A reduction in-service temperature to sub-zero

conditions.c. A slow cooling rate.d. All of the above.

2. Hydrogen cracking in a weld zone is most likely tooccur when welding:a. Carbon manganese steels.b. Austenitic stainless steel.c. Micro alloyed steel (HSLA).d. Low carbon steel.

3. Preheating for arc welding applies to:a. Assembly and tack welding only.b. Joint over 25 mm thick only.c. Assembly welding only.d. When using the MMA welding process only.e. Both a and b.

4. Which of the following destructive tests wouldindicate the toughness value of the weldmetal/parent metal and HAZ?a. Macro.b. Nick break.c. Tensile.d. Charpy Vee notch.

5. What constituent is needed in a coating of anelectrode to prevent the formation of porositywhen welding rimming steel?a. Iron powder.b. Potassium silicate.c. Silicond. Calcium carbonate.

6. Welds made with high heat inputs show areduction in one of the following properties?a. Ductility.b. Toughness.c. Elongation.

d. Penetration.7. Which of the following steel types would give

rise to the formation of porosity whenautogenously welded with an arc weldingprocessa. Fully killed steel.

b. Semi killed steel.c. Rimming steel.d. Balanced steel.

8. Which of the following elements, which may beadded to steel, has the greatest affect on creepstrength.a. Tungsten.b. Manganese.c. Carbon.d. Molybdenum.

9. The HAZ associated with a fusion weld:a. Can not be avoided.b. Usually has the highest tensile strength.c. Is usually martensitic.d. Both a and b.e. All of the above.

10. What four criteria are necessary to producehydrogen induced cold cracking?a. Hydrogen, moisture, martensitic grain

structure and heat.b. Hydrogen, poor weld profiles, temperatures

above 200C and a slow cooling rate.c. Hydrogen, a grain structure susceptible to

cracking, stress and a temperature below200C.

d. Hydrogen, existing weld defects, stress anda grain structure susceptible to cracking.

11. A carbon equivalent (CE) of 0.5%:a. Is high for carbon manganese steel and may

require a preheat over 100Cb. Is generally significant for carbon for

manganese steels and is certainly not to be

taken into consideration for preheattemperatures.

c. Is high for carbon manganese steels and mayrequire a preheat temperature over 300C asto avoid cracking

d. Is calculated from the heat input formula.


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12. In a martensitic grain structure what would youexpect to increase?a. Ductility.b. Hardness.c. Toughness.d. All of the above.

13. What do you understand by the term minimuminter-pass temperature?a. Minimum post weld heat treatment applied to

a weld.b. Minimum stress relief temperature.c. The lowest temperature to be used during

preheat.d. The lowest temperature allowed during

welding and between weld passes.

14. Which of the following heat treatments on steel

cools down in air from the austenite region?a. Normalising.b. Annealing.c. Tempering.d. Stress relieving.

15. What is the purpose of microscopic examinationof a weld?a. To determine the number and type of defects

present.b. To determine the grain size.c. To determine the strength of the weld.

d. Both a and b.e. All of the above.

16. Which of the following units could a tensilespecimen be measured in?a. Pounds per square inch.b. Newton per square inches.c. Joules.d. Both a and b.

17. Assuming that the welding process, materialthickness, carbon equivalent and the welding

parameters to be the same, which of the followingjoint types would normally require the highestpreheat temperature.a. Edge joint.b. Lap joint.c. Butt joint (single-V).d. Tee joint (fillet welded).

18. Austenitic stainless steels are more susceptibleto distortion when compared to ferritic steels thisis because:a. High coefficient, low thermal conductivity.b. High coefficient, high thermal conductivity.c. Low coefficient, high thermal conductivity.

d. Low coefficient, low thermal conductivity.

19. Which of the following will most likely requirethe preheat temperature to be increased?a. An Increase in travel speed.b. A reduction in material thicknessc. An increase in electrode diameter.d. None of the above

20. Which of the following properties may beapplicable to a carbon steel weld (CE 0.48)welded without preheat?

a. Narrow heat affected zone and hardnessvalue in excess of 400 HV.

b. Broad heat affected zone and hardnessvalues in excess of 400 HV.

c. A very tough and narrow heat affected zone.d. Narrow heat affected zone and low hardness

values.

21. Which of the following materials is consideredto be the easiest to weld?a. Mild steel.b. Medium carbon steels.

c. Martensitic stainless steeld. Forging steel.

22. Which of the following NOT methods would bebest suited for the detection of surface breakingdefects on an austenitic stainless steel pipea. MPI.b. UT.c. DPI.d. All of the above can be used.

23. Which of the following butt weld preparations

would be considered for a mechanised weldingprocessa. Single-V butt, root gap 2.5 mm (welded

from on side only).b. Double-V butt-welded both sides, root gap

2.0 mm.c. Single-U butt with backing.d. None of the above can be used for

mechanised welding.


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24. Which is the correct heat input for the followingparameters, amps 350, volts 32 and the travelspeed 310 mm/minute (MMA welding process)?a. 2.16 kJ/mm.b. 0.036 kJ/mm.c. 2160 kJ/mm.

d. 3.6 kJ/mm.

25. Assuming that the applicable specification makesno mention of arc strikes, what would you expectto do as a welding inspector if arc strikes werefound on a component made of a high tensilestrength material.a. Have the welder re-qualified.b. Ignore them.c. Have the area checked for possible cracking.d. Cut out the entire weld where the arc strikes

exist.

26. A multi-pass MMA butt weld made on carbonsteel consists of 5 passes deposited using a 6mmdiameter electrode. A 12-pass weld made on thesame joint deposited using a 4mm diameterelectrode on the same material will have:

a. A lower heat input and a higher degree ofgrain refinement.

b. A lower heat input and a coarse grainstructure.

c. A lower amount of distortion and a higher

degree of grain refinement.d. A higher amount of distortion and a lower

degree of grain refinement.

27. What is the purpose of a tensile test?a. To measure ultimate tensile strength.b. To measure the elongation of a materialc. To measure the yield strength of a materiald. All of the above.

28. Which of the following mechanical tests can beused to give a quantitative measurement of weld

zone ductility?a. Tensile test.b. Bend test.c. Charpy V notch test.d. All of the above.

29. Which of the following are reasons for applyingpreheat?a. The removal of residual stress.b. To aid slow cooling and reduce the carbon

content.c. To reduce the chance of a brittle grain

structure and to reduce the chance ofhydrogen entrapment.

d. Increase the ultimate tensile strength valuesand increase overall weldability.

30. Which of the following are true with regards to aCharpy test.a. Its a static test used to determine a

materials notch toughness in the weldregion.

b. Its a dynamic test used to determine amaterials notch toughness in the weld

region.c. Its a destructive test to give a measurement

of through thickness ductility.d. None of the above.


1. Degreasing components are essential for qualitywelding. but when welded some agent may:a. Cause corrosion problems.b. Leave residuesc. Give off toxic gases.d. All of the above.

2. Cellulose electrodes are often used for thedeposition of a root pass on pipes welded in thefield. This is because?a. Hydrogen control is required.b. The high deposition rate due to the iron

powder content.c. The hydrogen gas produced in the flux

increases the arc voltage.d. All of the above.

3. In the welding of austenitic stainless steels, theelectrode and plate materials are often specifiedto be low carbon content. The reason for this:a. To prevent the formation of cracks in the

HAZ.b. To prevent the formation of chromium

carbidesc. To prevent cracking in the weld.d. Minimise distortion.


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4. With regards to a welding procedure, an essentialvariable may:a. Change the properties of the weld.b. Influence the visual acceptance.c. Require re-approval of a weld procedure.

d. All of the above

5. Which of the following NOT methods can onlydetect surface breaking defects?a. MPIb. OPI.c. UTd. RT.e. Both a and b.

6. Which of the following defects would show up aslight indications on a radiograph?

a. Slag inclusions and copper inclusion.b. Tungsten inclusions and excessive root

penetration.c. Cap undercut and root piping.d. Excessive cap height and incomplete root

penetration.

7. Which of the following electrodes is the mostlikely to contain the largest quantity ofcombustible organic compounds?a. Basic.b. Acidic.

c. Rutile.d. Cellulose.

8. Lamellar tearing is best prevented by:a. The use of plate materials containing low

levels of impurities.b. The use of buttering runs.c. Post weld stress relief.d. Both a and b.e. All of the above.

9. When considering radiography using X-ray, which

of the following techniques is most likely to beused for a pipe to pipe weld (circumferentialseam), 610mm diameter with no internal access?a. SWSI.b. DWSI.c. DWDI.d. SWSI-panoramic.

10. A balanced welding technique for example backstep welding is most often used for:a. Controlling lamellar tearing.b. Increasing weld toughness.c. Reducing weld zone hardness.

d. Reducing distortion.

11. Basic coated electrodes have which of thefollowing properties.a. High mechanical properties may be used to

produce welds of high deposition rates andto produce welds of low hydrogen content.

b. Friable slag, high mechanical strength, andto produce welds of a low hydrogen content.

c. Low hydrogen content welds, goodstop/start properties and high strength.

d. Low carbon content welds, friable slag and

high strength.

12. On a radiograph, the most likely appearance oflack of root fusion on a single-V butt weld is:a. A dark straight 1ine with a light root.b. A dark root with straight edges.c. A dark uneven line following the edge of the

rootd. None of the above lack of root fusion can

not be seen on a radiograph.

13. What do you understand by the term minimum

interpass temperature?a. Minimum post weld heat treatment applied

to a weld.b. Minimum stress relief temperature.c. The lowest temperature to be used during

preheat.d. The lowest temperature allowed during

welding and between weld passes.

14. Which of the following is applicable to a platelaminationa. They are best detected by radiography.

b. They are mainly caused by hydrogenentrapment.

c. They originate in the parent material.d. They are caused when welding stresses act

parallel with the rolled direction of theparent plate.


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15. Which of the following NOT methods would bethe least effective on an austenitic stainless steelbutt weld.a. UT.b. RT.c. OPI.

d. MPI.

16. The hardest part of a multi-pass welded joint,assuming no post weld heat treatment has havetaken place is:a. The HAZ of the cap.b. The HAZ of the root.c. The root.d. The cap.

17. Is it permissible to allow a single pass butt weld tocool down between weld passes?

a. It should be up to the welding inspector.b. No the weld must be kept hot at all times.c. It depends on the welderd. It depends on the specification requirements.

18. A tee joint on a support bracket is to be weldedboth sides using a 5 mm leg length fillet weld,each weld is to be intermittent 50 mm in totallength, the gap between each weld is to be 25 mm.Which of the fallowing is the correct symbol inaccordance with ISO 2553?

19. The usual method of assessing the sensitivity anddensity of a radiograph is by means of:a. Densitometer and dosimeter.b. Penetrameter and a densitometer.c. IQI and a dosimeter.d. IQI and a fluxmeter.

20. In the submerged arc welding process, the use ofexcessive high voltages would result in?

a. Insufficient flux melting.b. Excessive flux meltingc. Slag removal difficulties.d. Excessive spatter.

21. Welding a steel plate with a CE of 0.45 would

require preheating to?a. Prevent the formation of sulphides.b. Prevent hardening in the HAZ.c. Prevent the formation of carbides.d. To reduce the amount of current required.

22. Which of the following welding process uses aresistive heating system to achieve weld metaldeposition?a. MMAb. Resistant spot welding.c. Electro-slag.

d. Friction welding.

23. What does the 70 represent on an E70 10 AWSA5.1 classified electrode?a. 70 N/mm2 minimum UTS.b. 70 joules minimum impact strength.c. 70,000 p.s.i. Minimum yield strength.d. 70,000 psi minimum UTS.

24. Basic electrode provided in a standardpackaging:a. Should be baked as to manufactures

recommendations prior to use.b. The baking conditions depend upon the

welder.c. Are recommended for use where porosity

free welds are required.d. Are only suitable for welding in the flat,

vertical, and down hand positions.

25. Cellulose electrodes have which of the followingproperties?a. Viscous slag, large volumes of shielding gas

and UTS values above 90,000 psi.

b. Large volumes of shielding gas, high spattercontents and hydrogen levels < 15 ml per100g of weld metal deposited

c. Large volumes of shielding gas, hydrogencontents> 15 ml per 100g of weld metaldeposited and should be never baked.

d. High spatter contents, high deposition andlarge volumes of gas shield.


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26. From the following electrode coding E50 4 B 16020 H5, the compulsory part is:a. E50 3 B 160 20 H5.b. B 160 20 H5.c. E50 4 B.d. None of the above.

27. Which of the following is applicable to electrodeefficiency?a. The mass of metal deposited as a percentage

of the mass of core wire melted.b. Iron powder electrodes have efficiencies

above 100%.c. Electrodes of high efficiencies tend to produce

welds of a smooth flat profile.d. Both a and b.e. All of the above.

28. A Fatigue cracks fracture surface is:

a. Rough randomly torn.b. Smooth.c. Step like appearance.d. Bright crystalline.

29. E6014 electrode would most probably used for

welding:a. Low pressure pipe work.b. High-pressure pipe work.c. Vertical down welding on storage tanks.d. In a situation where low hydrogen welds are

specified.

30. Which element in steel if present in significantamounts may lead to hot shortness?a. Phosphorus.b. Manganese.c. Silicon.

d. Sulphur.

WELDING INSPECTION, STEELS -WIS 5

MULTI-CHOICE QUESTION PAPER (MCQ.004 & MCQ.001+Own)

Name: _______________________________Answer all questions1. Movement of the arc by magnetic forces inMMA welding is termed:a) Arc deviationb) Arc misalignment

c) Arc blowd) Arc eye

2. A metallurgical problem most associated withsubmerged arc welding is :a) Hydrogen cracking in the HAZb) Solidification cracking in the weld metalc) Hydrogen cracking in the weld metald) Lamellar tearing in the weld metal

3. Oxy pressure and nozzle size would influencewhat in flame cutting:

a) The temperature required for cut initiationb) The ability to cut stainless steelsd) V The depth of cut obtainabled) None of the above

4. The main usage of arc cutting/gougingprocesses is in:a) The cutting of single bevel preparationsb) The removal of deposited weldsc) The cutting of single U-type preparations

d) The cutting/gouging of non-ferrous materialsonly

5. Which of the following processes joins metals

plastically:a) Friction Weldingb) Resistance Weldingc) Plasma Weldingd) All of the above

6. Which electrode classification would berelevant to AWS A5.1 81:a) E6013b) E 5133c) E7018Gd) Fleetweld 5

7. Which of the following coatings is associatedwith Stove welding:a) Rutileb) Cellulosicc) Basic Vd) Oxidising8. A common gas/mixture used in MIG weldingnickel alloys to combine good levels ofpenetration with good arc stability would be:


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a) 100% Carbon dioxideb) 100% argonc) 80% argon 20% Carbon dioxided) 98% argon 2% oxygen

9. The type of SAW flux is more resistant tomoisture absorption:a) Fusedb) Agglomeratedc) Basicd) All of about the same resistance

10. The flame temperature of oxy/acetylenemixture gas is given as:a) 3200Cb) 2 300 C

c) 5000Cd) None of the above

11. A large grain structure in steels is said toproduce:a) Low ductility valuesb) Low fracture toughness valuesc) High fracture toughness valuesd) High tensile strength

12. The likelihood of brittle fracture in steels willincrease with:

a) A large grain formationb) A reduction of in-service temperature to subzero levelsc) Ferritic rather than austenitic steelsd) All the above

13. Repair welding is often more difficult thanproduction due to:a) The material being ingrained with in-servicecontaminatesb) Restricted access within the repair areac) The possible position of the weld repair

d) Any of the above

14. Hydrogen cracking in the weld metal is likelywhen welding:a) Carbon manganese steelsb) Stainless steelsc) Micro alloyed steels (HSLA)d) Low carbon steels

15. EN standard 288 would refer to which of thefollowing:a) Welder approval testingb) Welding equipment

c) Welding procedure approvald) Consumables for submerged arc welding

16. Porosity is caused by:a) Entrapped slag in the solidifying weldb) Entrapped gas in the solidifying weldc) Entrapped metallic inclusions in the solidifyingweldd) None of the above

17. In a bend test, the face of the specimen is intension and root is in compression; the type of test

being carried out would be:a) A root bend testb) A side bend testc) A face bend testd) None of the above

18. Ultrasonic testing is of advantage in detectingwhich of the following weld imperfections overother NDT methods:a)Lack of side wall fusionb) Surface undercutc) Incompletely filled groove

d) Overlap

19. The process of tempering is often carried outto regain toughness after which of the followingprocesses:a) Annealingb) Normalisingc) Hardeningd) Stress relieving

20. The presence of iron Sulphide in the weldmetal is most likely to produce which of the

following upon contraction of the weld:a) Solidification crackingb) Hydrogen crackingc) Intergranular corrosiond) Stress corrosion cracking

21. When "hydrogen control" is specified for amanual metal arc welding project the electrodewould normally be:


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a) Cellulosic?b) Iron oxide?c) Acid?d) Basic?

22. You would with certainty recognise ahydrogen controlled flux covered electrode fromits:a) Colour?b) Length?c) Trade Name?d) AWS/BS639 Code Letter?

23. When manual metal arc welding is beingcarried out on an open construction site, which

group of welders are the most likely to requirecontinuous monitoring?a) Concrete shuttering welding teams?b) Pipe welding team?c) Plater welders?d) Plant maintenance welders?

24. You notice manual metal arc electrodes,stripped of flux, are being used as filler wire, forTIG welding. You would object because:a) It is too expensive ?b) The wire would be too thick?

c) The weld metal composition may be wrong?d) The wire is too short ?

25. When open site working, serious porosity inmetal arc welds is brought to your attention. Whatwould you investigate?a) Electrode type?b) Power plant type?c) Electrode storage?d) Day temperature?

26. The steel composition in a structural contractis changed from 0.15% carbon, 0.6% manganese,to 0.2% carbon, 1.2% manganese. Might thisinfluence the incidence of :a) Porosity ?b) Cracking in the weld area?c) Undercut for fillet welds?d) Lack of root fusion defects?

27. One of the following alloys is non-magneticWhich?

a) 4.0% Chromium molybdenumb) 12.0% Chromiumc) Austenitic Stainless Steeld) 9.0% Nickel Steel

28. When TIG welding Austenitic stainless steelpipe, Argon gas backing is called for.This is to :a) Prevent oxidation?b) Prevent underbead cracking?c) Prevent porosity ?d) Control the penetration bead shape?

29. Pre-heating a Carbon steel manual metal arcwelding is carried out to minimise the risk of:a) Scattered porosity ?b) Worm hole porosity?c) Parent metal cracking?d) Lack of penetration?

30. In UK practice, BS499 Part 2 specifies thatthe drawing dimension quoted for a fillet weld isthe:a) Leg length?

b) Actual throat thickness? /c) Weld width?

31. For open site manual metal welding thefollowing equipment is available. Which wouldyou choose for safe working?a) Single operator transformer?b) Multi operator transformers?c) AC/DC composite power unit?d) Diesel engine driven motor generator?

32. If submerged arc welding is to be used tomake butt welds, which would you be mostcritical of:a) The root-gap tolerance?b) The angle of-preparation?c) The root face width?d) The gas cut finish?


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33. During CO2 welding, the arc length is mostlikely to be affected by :a) The wire diameter?b) The current return connections?

c) The gas flow rate?d) The torch to work angle?

34. Preheating for arc welding applies to :a) Assembly welding only?b) Assembly and tack welding?c) Joints over 25mm thick only?d) Cruciform welds only?

35. You see a welder using an oxy-acetyleneflame with a long feathered inner cone. What

would be the effect of this on a carbon steel.a) The weld could be hard and brittle?b) The weld metal could be too soft ?c) There will be no effect on the weld?d) The weld will have undercut?

36. A welder qualification test is to verify :a) The skill of the welder?b) The quality of the materials?c) The non-destructive test procedures?d) The manufacturing methods?

37. A fabricating procedure calls for fillet weldsto be "blended in" by grinding. This is toinfluence:a) H.A.Z. cracking?b) Fatigue life?c) Residual stress?d) Yield strength?

38. Bend test specimens have been taken from a25mm thick carbon steel butt weld. Which wouldshow lack of inter-run fusion:a) Side bend?

b) Root bend?c) Face bend?d) Guided bend?

39. Lamellar tearing has occurred in a steelfabrication. BEFORE welding could it have beenfound by :a) X-ray examination?b) Dye penetrant?

c) Ultrasonic inspection?d) It would not have been found by any inspectionmethod?

40. You are to oversee the arc welding of somemachined fittings and find they are cadmiumplated. Would you:a) Permit it to proceed?b) Permit it to proceed with fume extraction?c) Stop the operation at once?d) Advise the welder to drink milk and proceed?

41. Heating a metal to 550-650C, holding andcooling in air would be defined as --------.a) Annealingb) Normalizing

c) Sub-critical annealingd) Stress relieving

42. The welding inspectors duties should include.a) Verification of base materialb) The verification of a weld filler metal typec) The development of weld repair proceduresd) a and b abovee) b and c above

43. A fatigue failure is characteristic by theappearance of the fracture surface. It would be:

a) Rough and tornb) Cheveron likec) Smoothd) None of the above

44. A change in supplementary essential variablesrequires requalification, when notch- toughness isa consideration.a) Trueb) False

45. The term used to describe lack of fusion in a

casting is ------------.a) Chillb) Finc) Cold shutd) Shrinkage cavity

46. In the welding of austenitic stainless steels,the electrode and the plate material can be


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purchased with low carbon contents. The reasonfor this is to prevent?a) Cracking in the HAZb) The formation of chromium carbides

c) Cracking in the weld metald) Distortion

47. The marking of a reject able weld should.a) Be clear and understandable to all involvedb) Be made with a steel impression stampc) Note the proper repair procedured) Always be in rede) Always include the welders identification.

48. You see a welder using an oxy-acetyleneflame with long feathered inner cone. What would

be the effect of this on carbon steel?a) The weld could be hard and brittle.b) The weld metal could be too soft.c) There will be no effect on weld metald) The weld will have undercut

49. Oxygen pressure and nozzle size wouldinfluence what in flame cuttinga) the temperature required for cut initiationb) the ability to cut stainless steelsc) the depth of cut obtainabled) all of the above

50. An austenitic stainless steel may suffer :a) Weld decayb) Sensitizationc) Solidification crackingd) All of the above

51. In the construction of a welding symbol, thebasic element is the.a) Arrowb) Reference linec) Weld symbol

d) None of the above

52. The steel composition in a structural contractis changed from 0.15% carbon, 0.6% manganese,to 0.2% carbon, 1.2% manganese. Might thisinfluence the incidence of ----------------.a) Porosityb) Cracking in the weld areac) Undercut for fillet welds

d) Lack of root fusion defects

53. What constituent is needed in a coating of anelectrode to prevent the formation of porosity in

welding of rimming steel?a) Iron powderb) Calcium fluoridec) Silicond) Calcium carbonate

54. Which of the following alloys is non-magnetic?a) 4.0% chromium molybdenumb) 12.0% chromiumc) Austenitic stainless steeld) 9.0% nickel steel

55. When welding aluminum with the GTAWprocess, what type of welding current is mostcommonly used?a) DCEPb) DCENc) ACd) Both a & b above

56. Ultraviolet light is utilized with which NDTmethod?a) VT

b) PTc) MTd) b and c above

57. Solidification cracks occur most commonlyin which part of weld?a) Parent materialb) HAZc) Weld centre lined) Any of the above

58. As tempering temperature increase:

a) hardness increasesb) hardness decreasesc) elongation decreasesd) b and c above

59. Brazing differs from welding in that.a) No tiller metal is usedb) An oxyfuel flame is usedc) The base metal is not melted


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d) All of the above

60. What type of power source characteristic isrequired for SMAW?

a) Constant Voltageb) Flat characteristicc) Drooping characteristicd) Motor generator

61. The size of the a spot weld is determined byits:a) depth of fusionb) spot diameterc) depth of penetrationd) thickness

62. The carbon content of cast iron isapproximately.a) 1%b) 2%c) 0.5%d) 3%

63. For concave fillet weld, which throatdimensions is the same?a) theoretical and effectiveb) effective and actualc) theoretical and actual

d) none of the above

64. When hydrogen control is specified for aSMAW project the electrode would normally be -----------.a) Celluloseb) Iron oxidec) Acidd) Basic

65. A repair organization has a WPS which statesit is qualified for P-8 to P-8 material welded with

either E308, E308L, E309, E316 electrodes(SMAW process). The PQR, supporting thisWPS, states the weld test coupons were SA-240type 304L materials, welded with E308electrodes. Is the WPS properly qualified for thebase materiallisted?a) Yesb) No

c) Not enough information givend) Yes, if properly heat treated

66. Which of the following is used for position

welding in MIG / MAG welding?a. Spray Transferb. Globular Transferc. Dip Transferd. Pulse Transfer

67. What you will do when you notice that the jobyou are inspecting is coated with Cd?a. Stop the welding at onceb. Continue inspection and allow weldingc. Advise the inspector to have a glass of milk and

proceed with welding.

d. Fume it then continue welding

68. What would be the effect on the weldingwhen the Carbon and manganese content arechanged from 0.15 & 0.6 to 0.2 & 1.2?a. more chances of porosityb. more chance of HAZ crackingc. more under cutd. concave cap profile

69. Which of the following NDT method is mosteffective to find out a surface crack in austenitic

stainless steel?a. RTb. UTc. MTd. PT

70. Which of the following process producesmore heat input?a. MMAb. MIG / MAGc. SAWd. TIG

71. Which of the following NDT method is bestsuited to detect lamination defects?a. RTb. UTc. MTd. PT


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72. What will be the result of using excessivevoltage in SAW process?a. excessive spatterb. high penetration

c. over depositiond. burn through

73. In SAW process bulk porosities are formeddue to _____.a. dampened fluxb. contamination in the bevelc. high level fluxd. misalignment

74. Which of the following elements when addedinto steel provides corrosion resistance?

a. Carbonb. Manganesec. Magnesiumd. Chromium

75. Which of the following position requireshighest welder skill?a. Plate down handb. Fillet weld with plate axis fixed verticallyc. Pipe rotatedd. Pipe axis fixed horizontally

76. The bend test performed with root facingtension side is called ______.

a. side bend testb. face bend testc. root bend testd. nick break test

77. A low Carbon steel specimen is heat treated toachieve which of the following?a. minimize the mechanical damage caused by

further machiningb. to reduce chance of hydrogen crackingc. to reduce stressd. to minimize the distortion

78.What you will do as an inspector when thespecification does not specify about the visualinspection requirement?

a. do visual inspection as usualb. dont do visual inspection and accept allc. report to higher authorities and ask advised. write visual inspection procedure

79. When the specification does not give anycriteria for arc-strike, what will be your action ifyou find arc-strikes?a. accept allb. reject allc. request MT or PT to make sure there is no

crack.

d. none of the above.

Welding Inspection, Steels -WIS 5 Multi -Choice End of Course Assessment

Question Paper (MSR-AWI-1)

Name: __________________________

Answer all questions

1. What is the ratio between the leg length and thedesign throat thickness on a mitre fillet weld withequal leg lengthsa. 1:1

b. 2 : 1c. 1.414 : 1.d. It depends on the fillet welds dimensions andfit up requirements.

2. What is the leg length of a fillet weld?a. The distance from the toe to face.b. The distance from the root to face centre.c. The distance from the root to the toe.

d. The distance from toe to toe.

3. Why is the arc shielded, when using an arcwelding process?

a. To eliminate hydrogen from the arc.b. To retard the cooling rate of the solidifyingmetal.c. To excluded the atmosphere from the arcregion.d. The arc is not always shielded when using anarc welding process.


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4. Which of the following is applicable for a noneplanar defects?a. They are always repaired.b. Their existence will result in the removal of the

entire weld.c. They are not usually as significant as planardefects.d. They can only be detected using radiography.

5. Lamellar tearing is:a. A product defect caused during themanufacturing of certain steelsb. A crack type, which occurs in the parentmaterial due to welding strains acting in the shorttransverse direction of the parent material.c. A type of hot crack associated with impurities

(sulphur, carbon and phosphorous).d. A type of crack that occurs in the weld orparent material due to cyclic stresses.

6. The weld zone associated with a welded jointis:a. Weld metal, HAZ and the parent material in theimmediate vicinity.b. Weld metal only.c. The weld metal plus parent material.d. HAZ and parent material.

7. Which of the following elements if present insignificant quantities in steel may lead to coldshortness.a. Sulphur.b. Phosphorous.c. Silicon.d. Copper.

8. A black triangular flag used in conjunctionwith a weld symbol as to EN 22553 means:A specific welding process is required.b. The weld is to be made under constant

supervision of a qualified welding inspector.c. Welding to be carried out on site (field weld).d. The weld must be subjected to NOT.

9. Austenitic stainless steel can be readilyidentified by:a. Lack of magnetic attraction.b. Its extreme hardness.c. Very shinny appearance.

d. None of the above.

10. Which of the following is likely to beconsidered an essential variable on a welding

procedurea. A change from an electrode classified to AWSE6011 to an electrode E6012.b. A change in preheat temperature from 500C to1500C.c. A change in welding position from PA to PF.d. All of the above

11. Which of the following is applicable if theheat input is to high during the deposition of aweld made using the MMA welding process?a. Low toughness.

b. High susceptibility to hydrogen entrapment.c. High hardness.d. High susceptibility to lack of fusion.

12. Which of the following will influence theamount of distortion on a component during andafter welding?a. Heat input.b. Lack of restraint.c. Material properties.d. Both a and b.e. All of the above.

13. When welding with the MIG welding processusing pure argon as the shielding gas on carbonsteel, which of the following problems are likelYto occur?a. Copper inclusion$ and excessive cap heights.b. Excessive root penetration and porosity.c. Slag inclusions and crater pipe.d. Lack of fusion and poor cap profiles.

14. It is a requirement to excavate a crack in awelded component; the defect is at least 25 mm in

depth, which of the following would you expectto be done to remove the defect?a. Arc air, ground finish and checked with crackdetectionb. Thermal gouging, ground finish and check withMPI.c. Oxy-gas cutting, ground finish and checkedwith crack detection.d. Both a and b.


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e. All of the above.

15. The heat affected zone associated with afusion weld:

a. Usually has the highest tensile strength.b. Always exists in a fusion-welded joint.c. Is usually the area of a welded joint that is themost susceptible to HICCd. All of the above.

16. Which of the following welding processeswould be the most suited for the welding ofcarbon steel in excess of 100 mm thicknessa. Tungsten inert gasb. Electro-slagc. Manual metal arc.

d. Plasma arc.

17. A welding process where the welding plantcontrols the travel speed and arc gap, but under aconstant supervision using a shielding gas mixtureof 80% argon -20% carbon dioxide is termed as:a. A manual MAG process.b. A semi automatic MAG process.c. A mechanised MIG process.d. A mechanised MAG process.

18. The purpose of normalising steel:

a. To modify the grain structure by making itmore uniform in order to improve mechanicalproperties.b. To soften a material for extensive machining.c. To reduce fracture toughness.d. To reduce ductility.

19. Which of the following destructive testswould show the results in joules?a. Tensile testb. Charpy test.c. Bend test.

d. Hardness test.

20. Generally the most suitable method ofdetecting lack of sidewall fusion on a single-Vbutt weld (30o to 35obevel angles) would be:a. Ultrasonic testing.b. Radiographic testingc. Magnetic particle testingd. Both a and b.

e. All of the above

21. Ultrasonic testing is preferable to radiographictesting due to:

a. Ability to find all defects.b. Lower amount of operator skill requiredc. Ability to detect laminations.d. None of the above

22. Lamellar tearing has occurred in a steelfabrication BEFORE welding could,which of the following test methods could havedetected it?a. Radiographic testing.b. Ultrasonic testing.c. Magnetic particle testing.

d. It could not be found by any testing method.

23. Incomplete root penetration is most likely dueto:a. Welding speed too slow.b. Welding current too high.c. Root gap too small.d. Electrode diameter too small.

24. You are to oversee the arc welding of somemachined fittings and find that they are cadmiumplated. What would you do in this situation?

a. Permit the welding to proceed.b. Permit the welding to proceed with fumeextraction.c. Stop the operation at once.d. Advise the welders to drink milk then proceed.

29. Which of the following welding processrequire a drooping characteristic power sourcea. TIG and MMA.b. MIG/MAG and MMA.c. TIG and SAW.d. All of the above.

30. When considering the MIG/MAG weldingprocess which of the following metal transfermodes would be the best suited to the welding ofthick plates over 25 mm, flat welding position.a. Dip transfer.b. Pulse transfer.c. Spray transfer.d. Globular transfer.


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KeyWI-1 WI-2 WI-3 WI-4 MCQ004 & MCQ 001 MSR-AWI-1

1. a2. c

3. b4. a5. c6. d7. d8. c9. b10. d11. e12. c13. a14. d

15. d16. b17. c18. c19. b20. a21. d22. a23. c24. c25. c26. c

27. b28. d29. d30. a

1. b2. d

3. c4. b5. a6. c7. a8. c9. d10. a11. b12. d13. a14. b

15. a16. c17. c18. b19. d20. a21. c22. a23. c24. d25. c26. c

27. b28. b29. c30. b

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15. d16. a17. d18. a19. a20. a21. a22. c23. c24. a25. c26. a

27. d28. a29. c30. b

1. d2. c

3. b4. d5. b6. b7. d8. d9. b10. d11. a12. a13. d14. c

15. d16. a17. d18. b19. b20. b21. b22. c23. d24. a25. c26. c

27. e28. b29. a30. d

1. c2. b

3. c4. b5. a6. a7. b8. b9. a10. a11. b12. d13. d14. c

15. c16. b17. c18. a19. c20. a21. d22. d23. b24. c25. c26. b

27. c28. a29. c30. a31. d32. a33. b34. b35. a36. a37. b38. a

39. d40. c

41. D42. D

43. C44. A45. C46. B47. A48. D49. D50. D51. A52. B53. C54. C

55. B56. D57. C58. B59. C60. B61. D62. B63. B64. D65. B66. C

67. A68. B69. D70. C71. B72. A73. A74. D75. D76. C77. A78. C

79. C

1. c2. c

3. c4. c5. b6. a7. b8. c9. a10. d11. a12. e13. d14. d

15. d16. b17. d18. a19. b20. a21. c22. d23. c24. c25. c26. d

27. b28. b29. a30. c

welding inspection q and ans

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