Welding Inspection Q and Ans.

Name: ______________________ Multi -Choice Question Paper (MSR-WI-1)

1. Which of the following butt-weld preparations is usually the most susceptible to lack of sidewall fusion 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 (equal leg 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 welding inspector 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 following welding positions will deposit the most weld metal. 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 root b. 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 from welding. 9. The strength of a fillet weld is primary controlled 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 crack d. Star crack. 11. Which of the following welding processes/technique is likely to be used for the repair welding of localised porosity in a butt weld? a. MMA, PG position. b. Mechanised MAG. c. Submerged arc. d. All of the above. e. None of the above.

Date: ___________

12. Which of the following welds would be considered in a situation where two plates are to be 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 the following is most likely to be caused by a welder with a poor technique? a. Deep weld craters/crater cracks. b. Copper inclusions c. Hydrogen cracks d. 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 of a 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, the specification makes no mention of the requirements for visual inspection, in this situation what 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 following do you consider to be duties of a welding inspector? a. The supervision of welders. b. Procedure writing. c. Qualifying welders

d. All of the above. 18. Which of the following is most likely to cause a burn through a. Root gap too small. b. Travel speed too fast. c. Root face too small d. All of the above. 19. In an arc welding process, which of the following is the correct term used for the amount of 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 has undergone 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, which defect (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 due to: 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 speeds b. Improper electrode angle c. Hot shrinkage. d. Improper joint design.

25. On a single-V butt weld, the distance through the centre 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 mm b. 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 speeds c. The use of a larger welding electrode. d. All of the above. 28. Which of the following butt weld preparations is most likely to be considered for the welding of a 6mm 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 should cover: a. Before, during and after welding. b. Before welding activities only. c. After welding activities only. d. None of the above. Multi -Choice Question Paper (MSR-WI-2) 1. Defects outside the permissible limits of the applicable 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 can be 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 an arc welding process is termed: a. Arc deviation. b. Arc misalignment. c. Arc blow. d. Stray arc. 4. A crack type most associated with the submerged 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 metals plastically? a. Friction welding. b. Resistance welding. c. Arc welding. d. Plasma welding. e. All of the above. 6. What type of power source characteristic is required 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 current types may be used for the TIG welding of nickel and 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 fusion d. Entrapped hydrogen, a reduction in carbon content and lack of fusion.

9. The main reason for using a back purge when welding 18-8 stainless steel with the TIG welding process is to: a. Improve positional welding. b. Prevent the possibility of porosity. c. Prevent excessive root penetration d. Prevent the formation of a dense oxide layer forming in the root. 10. The possible effects of having a travel speed too fast: 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 laps d. Low toughness, poor fusion and slag inclusions. 11. If arc blow exists when welding with the MMA welding process, this can be best reduced or eliminated 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 the submerged arc welding process the presence of centre line porosity may be due to: a. Damp flux. b. Contamination on the weld preparations. c. Incorrect flux depth d. All of the above. 13. The inclusion of an inductance in the welding circuit when using MIG/MAG welding process is to: 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 oxide residue, 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 most likely to be used for the welding of a small diameter stainless steel pipe, 6mm-wall thickness? a. GTAW b. SMAW. c. Submerged arc welding. d. GMAW. 16. When considering the tungsten arc welding process 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 hardening 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. local

18. In a semi-automatic welding process, which of the following shielding gas/gas mixtures would normally 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.

19. In a MMA welding process, which of the following statements are false? a. An arc gap, which remains almost constant even if as usual the welder varies the position of 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 the weld is completed normally requires a post weld heat treatment to restore toughness values ~ a. ESW. b. MMA. c. MAG. d. All completed welds require a post heat treatment, regardless of welding process. 21. Which of the following current types would you expect to be used for the welding of aluminium with the TIG welding process? a. DC -ve. b. DC +ve. c. AC d. 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 is fast freezing. b. DC electrode positive is used for the MAG welding of steel plate. c. The word calcium carbonate means limestone d. All of the above 23. When considering hydrogen, which of the following welding process would produce the lowest levels in the completed weld (under controlled conditions) a. MMA. b. SAW. c. TIG. d. FCAW. 24. Pre heat prior to the welding of a carbon steel butt weld: 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 heat treatment is to follow d. None of the above. 25. In steel the element with the greatest effect on hardness is: a. Chromium. b. Manganese. c. Carbon. d. Nickel. 26. For a given voltage and current settings on a MMA welding plant, when the arc length is shortened, which of the following will be most affected. 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 semiautomatic 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 welding plant. c. Both travel speed and arc gap is controlled by the welding plant d. All of the above. 28. What is purpose of a rectifier in a welding sets electrical circuit? a. To keep the arc stable when using low current settings b. 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 welding plant, 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.

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. Multi -Choice Question Paper (MSR-WI-3) 1. The likelihood of a brittle fracture in steels will increase 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 to occur 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 would indicate the toughness value of the weld metal/parent metal and HAZ? a. Macro. b. Nick break. c. Tensile. d. Charpy Vee notch. 5. What constituent is needed in a coating of an electrode to prevent the formation of porosity when welding rimming steel? a. Iron powder. b. Potassium silicate. c. Silicon d. Calcium carbonate. 6. Welds made with high heat inputs show a reduction 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 when autogenously welded with an arc welding process a. Fully killed steel. b. Semi killed steel. c. Rimming steel. d. Balanced steel. 8. Which of the following elements, which may be added to steel, has the greatest affect on creep strength. 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 produce hydrogen 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 below 200C. d. Hydrogen, existing weld defects, stress and a 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 100C b. Is generally significant for carbon for manganese steels and is certainly not to be taken into consideration for preheat temperatures. c. Is high for carbon manganese steels and may require a preheat temperature over 300C as to avoid cracking d. Is calculated from the heat input formula.

12. In a martensitic grain structure what would you expect to increase? a. Ductility. b. Hardness. c. Toughness. d. All of the above. 13. What do you understand by the term minimum inter-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 examination of 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 tensile specimen 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, material thickness, carbon equivalent and the welding parameters to be the same, which of the following joint types would normally require the highest preheat temperature. a. Edge joint. b. Lap joint. c. Butt joint (single-V). d. Tee joint (fillet welded).

18. Austenitic stainless steels are more susceptible to distortion when compared to ferritic steels this is 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 require the preheat temperature to be increased? a. An Increase in travel speed. b. A reduction in material thickness c. An increase in electrode diameter. d. None of the above 20. Which of the following properties may be applicable to a carbon steel weld (CE 0.48) welded without preheat? a. Narrow heat affected zone and hardness value in excess of 400 HV. b. Broad heat affected zone and hardness values 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 considered to be the easiest to weld? a. Mild steel. b. Medium carbon steels. c. Martensitic stainless steel d. Forging steel. 22. Which of the following NOT methods would be best suited for the detection of surface breaking defects on an austenitic stainless steel pipe a. 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 welding process a. 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.

24. Which is the correct heat input for the following parameters, amps 350, volts 32 and the travel speed 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 makes no mention of arc strikes, what would you expect to do as a welding inspector if arc strikes were found on a component made of a high tensile strength 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 carbon steel consists of 5 passes deposited using a 6mm diameter electrode. A 12-pass weld made on the same joint deposited using a 4mm diameter electrode on the same material will have: a. A lower heat input and a higher degree of grain refinement. b. A lower heat input and a coarse grain structure. 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 material c. To measure the yield strength of a material d. All of the above. 28. Which of the following mechanical tests can be used 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 applying preheat? 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 of hydrogen entrapment. d. Increase the ultimate tensile strength values and increase overall weldability. 30. Which of the following are true with regards to a Charpy test. a. Its a static test used to determine a materials notch toughness in the weld region. b. Its a dynamic test used to determine a materials notch toughness in the weld region. c. Its a destructive test to give a measurement of through thickness ductility. d. None of the above. Multi -Choice Question Paper (MSR-WI-4) 1. Degreasing components are essential for quality welding. but when welded some agent may: a. Cause corrosion problems. b. Leave residues c. Give off toxic gases. d. All of the above. 2. Cellulose electrodes are often used for the deposition of a root pass on pipes welded in the field. 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, the electrode and plate materials are often specified to 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 carbides c. To prevent cracking in the weld. d. Minimise distortion.

4. With regards to a welding procedure, an essential variable 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 only detect surface breaking defects? a. MPI b. OPI. c. UT d. RT. e. Both a and b. 6. Which of the following defects would show up as light 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 most likely to contain the largest quantity of combustible 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 be used for a pipe to pipe weld (circumferential seam), 610mm diameter with no internal access? a. SWSI. b. DWSI. c. DWDI. d. SWSI-panoramic.

10. A balanced welding technique for example back step 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 the following properties. a. High mechanical properties may be used to produce welds of high deposition rates and to produce welds of low hydrogen content. b. Friable slag, high mechanical strength, and to produce welds of a low hydrogen content. c. Low hydrogen content welds, good stop/start properties and high strength. d. Low carbon content welds, friable slag and high strength. 12. On a radiograph, the most likely appearance of lack 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 root d. 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 plate lamination a. They are best detected by radiography. b. They are mainly caused by hydrogen entrapment. c. They originate in the parent material. d. They are caused when welding stresses act parallel with the rolled direction of the parent plate.

15. Which of the following NOT methods would be the least effective on an austenitic stainless steel butt 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 have taken 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 to cool 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 welder d. It depends on the specification requirements. 18. A tee joint on a support bracket is to be welded both sides using a 5 mm leg length fillet weld, each weld is to be intermittent 50 mm in total length, the gap between each weld is to be 25 mm. Which of the fallowing is the correct symbol in accordance with ISO 2553?

a. b. c. d.

Insufficient flux melting. Excessive flux melting Slag removal difficulties. 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 a resistive heating system to achieve weld metal deposition? a. MMA b. Resistant spot welding. c. Electro-slag. d. Friction welding. 23. What does the 70 represent on an E70 10 AWS A5.1 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 standard packaging: 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 following properties? a. Viscous slag, large volumes of shielding gas and UTS values above 90,000 psi. b. Large volumes of shielding gas, high spatter contents and hydrogen levels < 15 ml per 100g of weld metal deposited c. Large volumes of shielding gas, hydrogen contents> 15 ml per 100g of weld metal deposited and should be never baked. d. High spatter contents, high deposition and large volumes of gas shield.

19. The usual method of assessing the sensitivity and density 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 of excessive high voltages would result in?

26. From the following electrode coding E50 4 B 160 20 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 electrode efficiency? 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. b. c. d.

Rough randomly torn. Smooth. Step like appearance. 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 significant amounts 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 questions 1. Movement of the arc by magnetic forces in d) The cutting/gouging of non-ferrous materials MMA welding is termed: only a) Arc deviation b) Arc misalignment 5. Which of the following processes joins metals c) Arc blow plastically: d) Arc eye a) Friction Welding b) Resistance Welding 2. A metallurgical problem most associated with c) Plasma Welding submerged arc welding is : d) All of the above a) Hydrogen cracking in the HAZ b) Solidification cracking in the weld metal 6. Which electrode classification would be c) Hydrogen cracking in the weld metal relevant to AWS A5.1 81: d) Lamellar tearing in the weld metal a) E6013 b) E 5133 3. Oxy pressure and nozzle size would influence c) E7018G what in flame cutting: d) Fleetweld 5 a) The temperature required for cut initiation b) The ability to cut stainless steels 7. Which of the following coatings is associated d) V The depth of cut obtainable with Stove welding: d) None of the above a) Rutile b) Cellulosic 4. The main usage of arc cutting/gouging c) Basic V processes is in: d) Oxidising a) The cutting of single bevel preparations 8. A common gas/mixture used in MIG welding b) The removal of deposited welds nickel alloys to combine good levels of c) The cutting of single U-type preparations penetration with good arc stability would be:

a) 100% Carbon dioxide b) 100% argon c) 80% argon 20% Carbon dioxide d) 98% argon 2% oxygen 9. The type of SAW flux is more resistant to moisture absorption: a) Fused b) Agglomerated c) Basic d) All of about the same resistance 10. The flame temperature of oxy/acetylene mixture gas is given as: a) 3200C b) 2 300 C c) 5000C d) None of the above 11. A large grain structure in steels is said to produce: a) Low ductility values b) Low fracture toughness values c) High fracture toughness values d) High tensile strength 12. The likelihood of brittle fracture in steels will increase with: a) A large grain formation b) A reduction of in-service temperature to sub zero levels c) Ferritic rather than austenitic steels d) All the above 13. Repair welding is often more difficult than production due to: a) The material being ingrained with in-service contaminates b) Restricted access within the repair area c) The possible position of the weld repair d) Any of the above 14. Hydrogen cracking in the weld metal is likely when welding: a) Carbon manganese steels b) Stainless steels c) Micro alloyed steels (HSLA) d) Low carbon steels

15. EN standard 288 would refer to which of the following: a) Welder approval testing b) Welding equipment c) Welding procedure approval d) Consumables for submerged arc welding 16. Porosity is caused by: a) Entrapped slag in the solidifying weld b) Entrapped gas in the solidifying weld c) Entrapped metallic inclusions in the solidifying weld d) None of the above 17. In a bend test, the face of the specimen is in tension and root is in compression; the type of test being carried out would be: a) A root bend test b) A side bend test c) A face bend test d) None of the above 18. Ultrasonic testing is of advantage in detecting which of the following weld imperfections over other NDT methods: a)Lack of side wall fusion b) Surface undercut c) Incompletely filled groove d) Overlap 19. The process of tempering is often carried out to regain toughness after which of the following processes: a) Annealing b) Normalising c) Hardening d) Stress relieving 20. The presence of iron Sulphide in the weld metal is most likely to produce which of the following upon contraction of the weld: a) Solidification cracking b) Hydrogen cracking c) Intergranular corrosion d) Stress corrosion cracking 21. When "hydrogen control" is specified for a manual metal arc welding project the electrode would normally be:

a) Cellulosic? b) Iron oxide? c) Acid? d) Basic? 22. You would with certainty recognise a hydrogen controlled flux covered electrode from its: a) Colour? b) Length? c) Trade Name? d) AWS/BS639 Code Letter? 23. When manual metal arc welding is being carried out on an open construction site, which group of welders are the most likely to require continuous 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, for TIG 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 in metal arc welds is brought to your attention. What would you investigate? a) Electrode type? b) Power plant type? c) Electrode storage? d) Day temperature? 26. The steel composition in a structural contract is changed from 0.15% carbon, 0.6% manganese, to 0.2% carbon, 1.2% manganese. Might this influence 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-magnetic Which? a) 4.0% Chromium molybdenum b) 12.0% Chromium c) Austenitic Stainless Steel d) 9.0% Nickel Steel 28. When TIG welding Austenitic stainless steel pipe, 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 arc welding 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 that the drawing dimension quoted for a fillet weld is the: a) Leg length? b) Actual throat thickness? / c) Weld width? 31. For open site manual metal welding the following equipment is available. Which would you 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 to make butt welds, which would you be most critical of: a) The root-gap tolerance? b) The angle of-preparation? c) The root face width? d) The gas cut finish?

33. During CO2 welding, the arc length is most likely 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-acetylene flame 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 welds to be "blended in" by grinding. This is to influence: a) H.A.Z. cracking? b) Fatigue life? c) Residual stress? d) Yield strength? 38. Bend test specimens have been taken from a 25mm thick carbon steel butt weld. Which would show lack of inter-run fusion: a) Side bend? b) Root bend? c) Face bend? d) Guided bend? 39. Lamellar tearing has occurred in a steel fabrication. BEFORE welding could it have been found by : a) X-ray examination? b) Dye penetrant?

c) Ultrasonic inspection? d) It would not have been found by any inspection method? 40. You are to oversee the arc welding of some machined fittings and find they are cadmium plated. 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 and cooling in air would be defined as --------. a) Annealing b) Normalizing c) Sub-critical annealing d) Stress relieving 42. The welding inspectors duties should include. a) Verification of base material b) The verification of a weld filler metal type c) The development of weld repair procedures d) a and b above e) b and c above 43. A fatigue failure is characteristic by the appearance of the fracture surface. It would be: a) Rough and torn b) Cheveron like c) Smooth d) None of the above 44. A change in supplementary essential variables requires requalification, when notch- toughness is a consideration. a) True b) False 45. The term used to describe lack of fusion in a casting is ------------. a) Chill b) Fin c) Cold shut d) Shrinkage cavity 46. In the welding of austenitic stainless steels, the electrode and the plate material can be

purchased with low carbon contents. The reason for this is to prevent? a) Cracking in the HAZ b) The formation of chromium carbides c) Cracking in the weld metal d) Distortion 47. The marking of a reject able weld should. a) Be clear and understandable to all involved b) Be made with a steel impression stamp c) Note the proper repair procedure d) Always be in red e) Always include the welders identification. 48. You see a welder using an oxy-acetylene flame 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 metal d) The weld will have undercut 49. Oxygen pressure and nozzle size would influence what in flame cutting a) the temperature required for cut initiation b) the ability to cut stainless steels c) the depth of cut obtainable d) all of the above 50. An austenitic stainless steel may suffer : a) Weld decay b) Sensitization c) Solidification cracking d) All of the above 51. In the construction of a welding symbol, the basic element is the. a) Arrow b) Reference line c) Weld symbol d) None of the above 52. The steel composition in a structural contract is changed from 0.15% carbon, 0.6% manganese, to 0.2% carbon, 1.2% manganese. Might this influence the incidence of ----------------. a) Porosity b) Cracking in the weld area c) Undercut for fillet welds

d) Lack of root fusion defects 53. What constituent is needed in a coating of an electrode to prevent the formation of porosity in welding of rimming steel? a) Iron powder b) Calcium fluoride c) Silicon d) Calcium carbonate 54. Which of the following alloys is nonmagnetic? a) 4.0% chromium molybdenum b) 12.0% chromium c) Austenitic stainless steel d) 9.0% nickel steel 55. When welding aluminum with the GTAW process, what type of welding current is most commonly used? a) DCEP b) DCEN c) AC d) Both a & b above 56. Ultraviolet light is utilized with which NDT method? a) VT b) PT c) MT d) b and c above 57. Solidification cracks occur most commonly in which part of weld? a) Parent material b) HAZ c) Weld centre line d) Any of the above 58. As tempering temperature increase: a) hardness increases b) hardness decreases c) elongation decreases d) b and c above 59. Brazing differs from welding in that. a) No tiller metal is used b) An oxyfuel flame is used c) The base metal is not melted

d) All of the above 60. What type of power source characteristic is required for SMAW? a) Constant Voltage b) Flat characteristic c) Drooping characteristic d) Motor generator 61. The size of the a spot weld is determined by its: a) depth of fusion b) spot diameter c) depth of penetration d) thickness 62. The carbon content approximately. a) 1% b) 2% c) 0.5% d) 3% of cast iron is

c) Not enough information given d) Yes, if properly heat treated 66. Which of the following is used for position welding in MIG / MAG welding? a. Spray Transfer b. Globular Transfer c. Dip Transfer d. Pulse Transfer 67. What you will do when you notice that the job you are inspecting is coated with Cd? a. Stop the welding at once b. Continue inspection and allow welding c. 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 welding when the Carbon and manganese content are changed from 0.15 & 0.6 to 0.2 & 1.2? a. more chances of porosity b. more chance of HAZ cracking c. more under cut d. concave cap profile 69. Which of the following NDT method is most effective to find out a surface crack in austenitic stainless steel? a. RT b. UT c. MT d. PT 70. Which of the following process produces more heat input? a. MMA b. MIG / MAG c. SAW d. TIG 71. Which of the following NDT method is best suited to detect lamination defects? a. RT b. UT c. MT d. PT

63. For concave fillet weld, which throat dimensions is the same? a) theoretical and effective b) effective and actual c) theoretical and actual d) none of the above 64. When hydrogen control is specified for a SMAW project the electrode would normally be ----------. a) Cellulose b) Iron oxide c) Acid d) Basic 65. A repair organization has a WPS which states it is qualified for P-8 to P-8 material welded with either E308, E308L, E309, E316 electrodes (SMAW process). The PQR, supporting this WPS, states the weld test coupons were SA-240 type 304L materials, welded with E308 electrodes. Is the WPS properly qualified for the base material listed? a) Yes b) No

72. What will be the result of using excessive voltage in SAW process? a. excessive spatter b. high penetration c. over deposition d. burn through 73. In SAW process bulk porosities are formed due to _____. a. dampened flux b. contamination in the bevel c. high level flux d. misalignment 74. Which of the following elements when added into steel provides corrosion resistance? a. Carbon b. Manganese c. Magnesium d. Chromium 75. Which of the following position requires highest welder skill? a. Plate down hand b. Fillet weld with plate axis fixed vertically c. Pipe rotated d. Pipe axis fixed horizontally 76. The bend test performed with root facing tension side is called ______.

a. side bend test b. face bend test c. root bend test d. nick break test 77. A low Carbon steel specimen is heat treated to achieve which of the following? a. minimize the mechanical damage caused by further machining b. to reduce chance of hydrogen cracking c. to reduce stress d. to minimize the distortion 78.What you will do as an inspector when the specification does not specify about the visual inspection requirement? a. do visual inspection as usual b. dont do visual inspection and accept all c. report to higher authorities and ask advise d. write visual inspection procedure 79. When the specification does not give any criteria for arc-strike, what will be your action if you find arc-strikes? a. accept all b. reject all c. 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 the design throat thickness on a mitre fillet weld with equal leg lengths a. 1:1 b. 2 : 1 c. 1.414 : 1. d. It depends on the fillet welds dimensions and fit 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 arc welding process? a. To eliminate hydrogen from the arc. b. To retard the cooling rate of the solidifying metal. c. To excluded the atmosphere from the arc region. d. The arc is not always shielded when using an arc welding process.

4. Which of the following is applicable for a none planar 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 planar defects. d. They can only be detected using radiography. 5. Lamellar tearing is: a. A product defect caused during the manufacturing of certain steels b. A crack type, which occurs in the parent material due to welding strains acting in the short transverse 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 or parent material due to cyclic stresses. 6. The weld zone associated with a welded joint is: a. Weld metal, HAZ and the parent material in the immediate 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 in significant quantities in steel may lead to cold shortness. a. Sulphur. b. Phosphorous. c. Silicon. d. Copper. 8. A black triangular flag used in conjunction with 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 readily identified 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 be considered an essential variable on a welding procedure a. A change from an electrode classified to AWS E6011 to an electrode E6012. b. A change in preheat temperature from 500C to 1500C. c. A change in welding position from PA to PF. d. All of the above 11. Which of the following is applicable if the heat input is to high during the deposition of a weld 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 the amount of distortion on a component during and after 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 process using pure argon as the shielding gas on carbon steel, which of the following problems are likelY to 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 a welded component; the defect is at least 25 mm in depth, which of the following would you expect to be done to remove the defect? a. Arc air, ground finish and checked with crack detection b. Thermal gouging, ground finish and check with MPI. c. Oxy-gas cutting, ground finish and checked with crack detection. d. Both a and b.

e. All of the above. 15. The heat affected zone associated with a fusion 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 the most susceptible to HICC d. All of the above. 16. Which of the following welding processes would be the most suited for the welding of carbon steel in excess of 100 mm thickness a. Tungsten inert gas b. Electro-slag c. Manual metal arc. d. Plasma arc. 17. A welding process where the welding plant controls the travel speed and arc gap, but under a constant supervision using a shielding gas mixture of 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 it more uniform in order to improve mechanical properties. b. To soften a material for extensive machining. c. To reduce fracture toughness. d. To reduce ductility. 19. Which of the following destructive tests would show the results in joules? a. Tensile test b. Charpy test. c. Bend test. d. Hardness test. 20. Generally the most suitable method of detecting lack of sidewall fusion on a single-V butt weld (30o to 35o bevel angles) would be: a. Ultrasonic testing. b. Radiographic testing c. Magnetic particle testing d. Both a and b.

e. All of the above 21. Ultrasonic testing is preferable to radiographic testing due to: a. Ability to find all defects. b. Lower amount of operator skill required c. Ability to detect laminations. d. None of the above 22. Lamellar tearing has occurred in a steel fabrication BEFORE welding could, which of the following test methods could have detected 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 due to: 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 some machined fittings and find that they are cadmium plated. What would you do in this situation? a. Permit the welding to proceed. b. Permit the welding to proceed with fume extraction. c. Stop the operation at once. d. Advise the welders to drink milk then proceed. 29. Which of the following welding process require a drooping characteristic power source a. TIG and MMA. b. MIG/MAG and MMA. c. TIG and SAW. d. All of the above. 30. When considering the MIG/MAG welding process which of the following metal transfer modes would be the best suited to the welding of thick plates over 25 mm, flat welding position. a. Dip transfer. b. Pulse transfer. c. Spray transfer. d. Globular transfer.

Key 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30.

WI-1

a c b a c d d c b d e c a d d b c c b a d a c c c c b d d a

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30.

WI-2

b d c b a c a c d a b d a b a c c b d a c a c d c c b b c b

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30.

WI-3

b c a d c b c d d c a b d a d a d a a a a c c a c a d a c b

WI-4

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30.

d c b d b b d d b d a a d c d a d b b b b c d a c c e b a d

MCQ004 & MCQ 001 MSR-AWI-1

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40.

c b c b a a b b a a b d d c c b c a c a d d b c c b c a c a d a b b a a b a d c

41. 42. 43. 44. 45. 46. 47. 48. 49. 50. 51. 52. 53. 54. 55. 56. 57. 58. 59. 60. 61. 62. 63. 64. 65. 66. 67. 68. 69. 70. 71. 72. 73. 74. 75. 76. 77. 78. 79.

D D C A C B A D D D A B C C B D C B C B D B B D B C A B D C B A A D D C A C C

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30.

c c c c b a b c a d a e d d d b d a b a c d c c c d b b a c