DOC NO: 5Q&A-002-SA2ABN 69 003 696 526

Revision: 0 Date of Issue: 23 May 2011 Page 1 of 12

Management System Manual

QUALIFICATION & CERTIFICATION BOARD

IIW International Welding Specialist (IWS) Sample Questions and Anwers SA2 MATERIALS AND THEIR BEHAVIOUR DURING WELDING

QUESTION 1 The following questions have multiple-choice answers and are worth 2 marks each. Only one answer is correct. Tick only one. If more than one box is ticked, no marks will be awarded. 1.1 The basic reason for a bend test is: a. b. c. d. 1.2 Measure the resistance to local penetration by a harder substance. To determine the soundness of weld metal and HAZ, and to give an indication of the ductility of welded joints. The resistance to bending under the application of a point load. None of the above.

What would be the reason for using a nick break test? a. b. c. d. To test if the fillet weld is strong enough. To use as a substitute for a Charpy impact test. To find lack of root penetration. To expose porosity, lack of fusion, slag inclusions, and cold lap.

1.3

What would be the approximate minimum chromium content be in a steel to be stainless? a. b. c. d. 11% 8% 20% None of the above

1.4

The term t8/5 is used to describe: a. b. c. d. The time taken for a weld zone to cool from the post weld heat treatment temperature to room temperature The time taken during cooling for a weld run and the HAZ to pass through the temperature range of 800C to 500C The time taken during heating for the HAZ to pass through the temperature range of 500C to 800C. None of the above

1.5

What problems could arise when welding a leaded brass alloy? a. b. c. d. There are no problems. Zinc and lead fume, cracking, and porosity. These structures are not normally welded. The cost of re-applying the galvanised layer.

1.6

Galvanic corrosion can result if: a. b. c. d. Two dissimilar materials are joined in the presence of an electrolyte If similar materials are joined in the presence of an electrolyte If carbon steel and stainless steel are joined together in chlorinated water a and c above.

1.7

When welding a 304L stainless steel to grade 250 carbon steel: a. b. c. d. An austenitic stainless steel weld metal should be used. A general purpose electrode should be used. A silicon bronze alloy weld metal should be used. Options b or c can be used.

DOC NO: 5Q&A-002-SA2ABN 69 003 696 526

Revision: 0 Date of Issue: 23 May 2011 Page 2 of 12

Management System Manual

QUALIFICATION & CERTIFICATION BOARD

IIW International Welding Specialist (IWS) Sample Questions and Anwers SA2 MATERIALS AND THEIR BEHAVIOUR DURING WELDING

1.8

When welding ferritic stainless steels, why must heat input be controlled? a. b. c. d. To avoid lack of fusion. To limit grain coarsening in the HAZ In order to prevent excessive hardening of the weld metal. To ensure the correct welding parameters are used.

1.9

Why is pickling and passivation of a weld joint important? a. b. c. d. To improve the aesthetic appearance of a welded structure. It is normally a client requirement. To restore the passive film on copper. To restore corrosion resistance to stainless steel in the weld zone.

1.10

The weldability of quenched and tempered steel is mainly affected by: a. b. c. d. Its hardenability and the presence of hydrogen The presence of a passive film. The correct choice of welding consumable. The amperage used for welding.

1.11

Which of the four following samples correspond to a steel: a. b. c. d. 0.2 % C 2.4 % C 6.4 % C 12.0 % C

1.12

A tensile test of parent material and weld metal enables: a. b. c. d. Determination of the tested materials resistance to impact stress. Determination of the tested materials creep strength. Determination of the tested materials hardness. Determination of the tested materials ultimate strength.

1.13

Sulphur is known to have many bad effects on steel. Which of the following statements is not correct with respect to Sulphur (S) in an unalloyed steel?? a. b. c. d. Increases the risk of hot cracking Eases the process of turning and milling Decreases the risk of lamellar tearing Leads to poor weldability when present in significant amounts

1.14

A steel of 0,2% C is heated over A3 temperature and is then cooled slowly. What constituents are present in the steel at room temperature? a. b. c. d. Ferrite Austenite Martensite Ferrite and pearlite

1.15

The t8/5 cooling rate can be a significant parameter for welding: a. b. c. d. Quenched and tempered steels SAF 2205 type steels. Managing post weld heat treatments. Austenitic stainless steels.

DOC NO: 5Q&A-002-SA2ABN 69 003 696 526

Revision: 0 Date of Issue: 23 May 2011 Page 3 of 12

Management System Manual

QUALIFICATION & CERTIFICATION BOARD

IIW International Welding Specialist (IWS) Sample Questions and Anwers SA2 MATERIALS AND THEIR BEHAVIOUR DURING WELDING

1.16

Quenching is a heat treatment that tries to reach: a. b. c. d. Maximum hardness and strength. Maximum hardness and minimum strength. Minimum hardness and maximum strength. Minimum hardness and strength.

1.17

When welding a mild steel, multi-pass welding allows: a. b. c. d. An improvement of the mechanical characteristics of the joint A saving of filler metal. An improvement of productivity. None of the above

1.18

Which of the following microstructures will give the highest toughness values? a. b. c. d. Large grained, coarse martensite. Fine grained martensite. Large grained, coarse tempered martensite. Fine grained tempered martensite.

1.19

Lamellar tearing of the parent plate can be countered by: a. b. c. d. Increase in yield strength of the weld metal. Improving through-thickness ductility of the parent plate. Increasing impact resistance of the weld metal. Reducing the nitrogen content in both parent plate and weld metal

1.20

Which are the three necessary conditions for cold cracking to occur? a. b. c. d. Presence of hydrogen, tensile stresses, austenitic weld metal Presence of nitrogen, tensile stresses, susceptible microstructure. Presence of inclusions, tensile stresses, T-joints. Presence of hydrogen, susceptible microstructure, tensile stresses.

1.21

What of the following is the most likely imperfection when welding quenched and tempered steel? a. b. c. d. Hot cracking. Cold cracking. Lamellar tearing. Lack of fusion.

1.22

The basic property of steel required to successfully work in very low temperature is: a. b. c. d. Strength. Resistance to brittle cracking Hardness. Creep resistance.

1.23

To be considered corrosion resistant, steels have to include minimally: a. b. c. d. 11 % of Cr. 18% of Cr 6% of Cr. 3% Cr.

DOC NO: 5Q&A-002-SA2ABN 69 003 696 526

Revision: 0 Date of Issue: 23 May 2011 Page 4 of 12

Management System Manual

QUALIFICATION & CERTIFICATION BOARD

IIW International Welding Specialist (IWS) Sample Questions and Anwers SA2 MATERIALS AND THEIR BEHAVIOUR DURING WELDING

1.24

Generally speaking, aluminium alloys have wide solidification temperature ranges, and therefore they are prone to: a. b. c. d. Hot crack. Cold crack. Form non-metallic inclusions. Form blowholes.

1.25

What can be seen on macroetch sample? a. b. c. d. Microstructure . Carbides on grain boundaries. Appearance of weld metal and HAZ. Grain size. is where it is used. 3 marks

1.26

Describe what metallography

Metallography is a systematic method to examine the microstructure of materials. Important uses of metallography include process control and qualification of welds, examination of defects that appear in finished or partly finished products and studies of parts that have failed in service. Investigations for these purposes usually require that the specimen be removed from a large mass of material, and often involve more than one sectioning operation. 1.27 Explain the term Carbon Equivalent 1.28 3 marks

Different elements increase the hardenability of a steel to varying degrees. The Carbon Equivalent equates each elements hardenability against that of Carbon and by adding the effect of each element on hardenability together, one arrives at an equivalent hardenability to Carbon. The higher the carbon equivalent the greater is the difficulty in welding the steel.

Find the Combined Joint Thickness for the joint given below assuming that the welds indicated in black already exist. 4 marks 12 mm 50 mm

80 mm

All dimensions are in mm

50 mm

16 mm

Weld here

60 mm

T = 12 +

50 x16 50 x16 12 x60 + + = 42.9mm 75 75 75

DOC NO: 5Q&A-002-SA2ABN 69 003 696 526

Revision: 0 Date of Issue: 23 May 2011 Page 5 of 12

Management System Manual

QUALIFICATION & CERTIFICATION BOARD

IIW International Welding Specialist (IWS) Sample Questions and Anwers SA2 MATERIALS AND THEIR BEHAVIOUR DURING WELDING

QUESTION 2 2.1 Explain the term Weldability 5 marks

Weldability is a measure of how easy it is to: Obtain crack free welds Achieve adequate mechanical properties Produce welds resistant to service degradation.

Weldability is not a fixed parameter for a given material, but will depend on joint details, service requirements, and welding processes and facilities available. OR :Metallic material is considered to be susceptible to welding to an established extent with given processes and for given purposes when welding provides metal integrity by a corresponding technological process for welded parts to meet technical requirements as to their own qualities as well as to their influence on a structure they form 2.2 What is stainless steel? List five basic groups of stainless steels used in welded fabrication. 6 marks The term stainless steel is taken to mean any of a large number of steels i.e. iron-carbon alloy, containing a minimum of 11% chromium (Cr). Ferritic Austenitic Duplex Martensitic Precipitation hardening 2.3 Explain the term sensitisation as applied to stainless steel. List one method of preventing it. 4 marks Also known as chromium carbide precipitation, this condition primarily affects the heat affected zone (HAZ) and is dependent upon the level of carbon present in the material and the length of time that the material stays in the critical temperature range of 450C - 850C. The carbon in the steel combines with chromium to form chromium carbides. These carbides form along the grain boundaries and result in the areas immediately adjacent to the precipitates being low in chromium i.e. those areas are no longer stainless. Preferential corrosion attack occurs along these boundaries, resulting in intergranular corrosion or weld decay. PREVENTION

Low carbon grades of stainless steel and filler material of less than 0.03% carbon should be used / use stabilised grades of austenitic stainless steel (321/347). Weld zones should be free of contamination.

DOC NO: 5Q&A-002-SA2ABN 69 003 696 526

Revision: 0 Date of Issue: 23 May 2011 Page 6 of 12

Management System Manual

QUALIFICATION & CERTIFICATION BOARD

IIW International Welding Specialist (IWS) Sample Questions and Anwers SA2 MATERIALS AND THEIR BEHAVIOUR DURING WELDING

2.4

With the aid of a sketch, what would the effect of grain size in a ferritic steel have on mechanical properties? 5 marks

The finer the grain size, the lower the DBTT temperature, hence the greater the impact resistance and ductility of the material, and the greater the yield strength. 2.5 What are the common reasons for carrying out heat treatment on metals. 5 marks

Common reasons for carrying out heat treatments are to: 1. Remove internal (residual) stresses, incurred for example from such previous treatments as hardening, cold forming processes, welding and uneven cooling 2. Refine the grain structure and size, leading to enhanced ductility 3. Soften to permit further working operations e.g. rolling 4. Improve mechanical properties, including hardness, improving wear resistance and machinability 5. Improve uniformity in castings forgings and weldments. 2.6 What is Stress Corrosion Cracking (SCC)? What factors contribute to its occurrence? How can it be controlled? Give two examples of material-environment combination where SCC may occur. 10 marks Stress corrosion cracking (SCC) requires three conditions, a susceptible alloy, tensile stresses, and a specific corrosive environment to occur simultaneously. The necessary tensile stress can be either externally applied or existing in the material due to forming or welding. If one condition is eliminated, SCC will not occur. Some examples are caustic conditions for steel, ammonia for brass, various chloride solutions for certain stainless steel grades. Prevention can be achieved by: Reducing the overall stress level and designing out stress concentrations Selection of a suitable material not susceptible to the environment Design to minimise thermal and residual stresses Developing compressive stresses in the surface the material Use of a suitable protective coating

DOC NO: 5Q&A-002-SA2ABN 69 003 696 526

Revision: 0 Date of Issue: 23 May 2011 Page 7 of 12

Management System Manual

QUALIFICATION & CERTIFICATION BOARD

IIW International Welding Specialist (IWS) Sample Questions and Anwers SA2 MATERIALS AND THEIR BEHAVIOUR DURING WELDING

QUESTION 3 3.1 Discuss the weldability of medium carbon steels in relation to carbon content and risk mitigation techniques to overcome weldability issues. 7 marks

A pronounced change in the weldability of carbon steel takes place when the carbon content is in the 0.30 to 0.50 % range. Steels containing about 0.30 % carbon and relatively low manganese content have good weldability. As the carbon content is increased, the welding procedures must be designed to avoid the formation of large amounts of hard martensite in the heat-affected zone. For most applications, medium carbon steels should be preheated prior to welding. The preheat temperature depends upon the carbon equivalent of the steel, the joint thickness, and the welding procedure. A stress relief heat treatment is recommended immediately after welding, especially with thick sections, high joint restraint, or service conditions involving impact or dynamic loading. If possible, the welded joint should be heated to the stress relief temperature without intermediate cooling to ambient temperature. Low hydrogen welding procedures are mandatory with these steels. Selection of filler metal for arc welding becomes more critical as the carbon content increases. Pick-up of carbon will occur with steels of higher carbon content and this may produce a weld metal of high hardness, susceptibility to cracking and tendency for brittle failure. Dilution can be minimised by depositing small weld beads or using a welding procedure that provides shallow penetration. Low heat input is generally recommended for the first few layers in a multipass weld to limit dilution. 3.2 What are the three conditions required for the onset of brittle fracture in a welded steel structure? 3 marks 3.3 A defect. A tensile stress transverse to the defect. A microstructure which is susceptible at the temperature of interest. 5 marks

Explain briefly what is a TMCP steel and discuss its weldability?

Thermo-Mechanical Control Process (TMCP) steels achieve high strength by a combination of controlled rolling and controlled accelerated cooling. The microstructure is strengthened by mechanisms of precipitation hardening, grain refinement and work hardening, transformation and microstructure that allow for lower carbon contents than common steels. They have relatively good weldability characterised by: Low hardenability (Carbon > 0.1%) Even for thick sections and low temperatures preheat is hardly required 3.4 Define the phenomenon of Creep of a material with the help of Strain/Elongation v/s Time diagram and explain the effect of the main variables. 10 marks

DOC NO: 5Q&A-002-SA2ABN 69 003 696 526

Revision: 0 Date of Issue: 23 May 2011 Page 8 of 12

Management System Manual

QUALIFICATION & CERTIFICATION BOARD

IIW International Welding Specialist (IWS) Sample Questions and Anwers SA2 MATERIALS AND THEIR BEHAVIOUR DURING WELDING

3.5

Discuss the weldability of duplex stainless steels and risk mitigation techniques to overcome weldability issues. 5 marks Increased ferrite levels in both the base metal and weld metal can reduce joint toughness and corrosion resistance. Control over ferrite level is possible through welding consumable selection and heat input control. Welding consumables for duplex stainless steels contain Nitrogen (a strong austenite stabiliser) as an alloying element. Generally heat input should be limited to between 0.5 - 2.5 kJ/mm.

3.6

Comment in general on the weldability of copper and its alloys.

5 marks

In terms of weldability, alloys have quite different welding characteristics. Due to the high thermal conductivity of copper substantial preheat is required to counteract the very high heat sink and avoid incomplete penetration. Copper is often cold worked. Welding softens the HAZ. Tendency for cracking. Precipitation hardened copper should be welded in the annealed condition and then heat treated. Be aware of alloying elements with low melting and boiling point. Welding free machining copper is not recommended.

DOC NO: 5Q&A-002-SA2ABN 69 003 696 526

Revision: 0 Date of Issue: 23 May 2011 Page 9 of 12

Management System Manual

QUALIFICATION & CERTIFICATION BOARD

IIW International Welding Specialist (IWS) Sample Questions and Anwers SA2 MATERIALS AND THEIR BEHAVIOUR DURING WELDING

3.7

Explain the mechanism and causes of reheat cracking with the aid of sketches. How would you avoid it and what materials are susceptible to it? 10 marks Reheat cracking may occur in low alloy steels containing alloying additions of chromium, vanadium and molybdenum when the welded component is subject to: Post weld heat treatment, Multiple welds or To high temperature service (at 350 - 550C). Cracks may occur in the coarse-grained region of the HAZ or sometimes in weld metal Reheat cracking results from embrittlement of the grain boundaries caused by segregation of phosphorus, tin and arsenic

Material susceptible to reheat cracking: Low alloy steels containing alloying additions of chromium, vanadium and molybdenum e.g. 5Cr 1Mo, 0.5Cr 0.5Mo 0.25V How to avoid: Use appropriate welding procedure Use buttering technique Control heat iinput Produce the maximum refinement of the coarse grain HAZ Eliminating stress concentrations

DOC NO: 5Q&A-002-SA2ABN 69 003 696 526

Revision: 0 Date of Issue: 23 May 2011 Page 10 of 12

Management System Manual

QUALIFICATION & CERTIFICATION BOARD

IIW International Welding Specialist (IWS) Sample Questions and Anwers SA2 MATERIALS AND THEIR BEHAVIOUR DURING WELDING

QUESTION 4 4.1 4.1.1 List two specific weld imperfections that may occur in each of the following: Nickel and Nickel Alloys Porosity Oxide inclusions and lack of inter-run fusion Weld metal solidification cracking Microfissuring Heat treatable Aluminium Alloys Excessive porosity if cleaning not performed correctly Over-aging of the heat affected zone Quenched and Tempered Steels Cold cracking due to high Carbon Equivalent Excessive softening of the HAZ. Ferritic stainless steels for use catalytic convertors Lower toughness due to excessive grain growth. Formation of brittle phases. 2 marks

4.1.2

2 marks

4.1.3

2 marks

4.1.4

2 marks

4.2

What are the recommended steps for welding in planning welding of stainless steels to carbon steels? 5 marks 1. 2. 3. 4. 5. Selecting welding process and its parameter Determine dilution Pre-selection of the filler metal Determine the weld metal composition in the Schaeffler diagram Confirm filler metal, or select another one if the weld metal composition is outside of the safe area

4.3

When joining cladded steels to each other, what are the areas of concern that should be addressed and how would a welding sequence be approached (use sketches)? In the weld joining of the clad steels it is essential to preserve the properties of the cladding at the weld. Otherwise, the desired corrosion resistance, abrasion resistance, or other properties of the clad surface are not continuous. At the same time, it is also essential that the properties of the backing metal be maintained. These two requirements mean that special joint designs and welding procedures are required. In general, the procedure is to weld the backing metal portion of the joint first, followed by welding the clad side. This sequence prevents the formation of hard, brittle areas in the weld.

DOC NO: 5Q&A-002-SA2ABN 69 003 696 526

Revision: 0 Date of Issue: 23 May 2011 Page 11 of 12

Management System Manual

QUALIFICATION & CERTIFICATION BOARD

IIW International Welding Specialist (IWS) Sample Questions and Anwers SA2 MATERIALS AND THEIR BEHAVIOUR DURING WELDING

4.2 .

Discuss the weldability issues of martensitic stainless steels and how to overcome them? 5 marks Martensitic stainless steels are difficult to weld successfully due to the formation of martensite in the HAZ. To reduce the effects of martensite formation, adequate control over pre-heat, interpass temperatures and heat input are essential. Depending on the carbon content, preheat temperatures of between 100 - 300C are commonly recommended to avoid cracking. Post Weld-Heat Treatment (tempering) my be required to improve mechanical properties and reduce welding stresses.

4.3

Explain with the aid of sketches the phenomenon of lamellar cracking and how it may be mitigated. 12 marks A type of crack stretching parallel to rolling surfaces. If rolled products are stressed in the thickness direction, the deformation capacity is often lower than in the longitudinal and transversal direction. The reason for this is the arrangement of non-metallic inclusions in layers parallel to the surface during rolling. Thus the danger of fractures parallel to the surface of the rolled products arises.

There are three conditions that must be satisfied for lamellar tearing to occur: 1. Transverse strain - the shrinkage strains on welding must act in the short direction of the plate i.e. through the plate thickness 2. Weld orientation - the fusion boundary will be roughly parallel to the plane of the inclusions 3. Material susceptibility - the plate must have poor ductility in the through-thickness direction.

DOC NO: 5Q&A-002-SA2ABN 69 003 696 526

Revision: 0 Date of Issue: 23 May 2011 Page 12 of 12

Management System Manual

QUALIFICATION & CERTIFICATION BOARD

IIW International Welding Specialist (IWS) Sample Questions and Anwers SA2 MATERIALS AND THEIR BEHAVIOUR DURING WELDING

Specification of the use of steel tested in the z-direction.