%- MULTICHOICE PAPER ONE I. 2. 3. 4. 5. 6. 7. 8. --· ( \ 0 · .,.."- t.'-i\ C.\.'4'- (i' ..;,, l,/.}>1- \ ' .... ';{..<>(ll . i'i"f- . tl''e'>f 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 You would certainly recognise a hydrogen controlled flux covered electrode from its: a. Colour b. Length c. Trade name d. BS639/AWS code letter When manual metal arc welding is being carried out on an open construction site, which group of welders are most likely to require continuous monitoring? a. Concrete shuttering welding teams b. Pipe welding teams c. Plater welders d Plant maintenance welders 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 metal composition may be wrong d The wire is too short 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 The steel composition in a structural contract is changed from 0.15% carbon 0.6% manganese, to 0.2% carbon 1.2% manganese. This might influence the incidence of: a. Porosity b. Cracking in the weld area c. Undercut for fillet welds d. Lack of fusion defects 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 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 96 97 9. Pre-beating 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 10. In UK practice, BS499 specifies that the drawing dimension quoted for a fillet weld is the: a. Leg length b. Throat thickness c. Weld width d. Actual throat thickness For open site manual metal welding the following equipment is available. Which would 11. you choose for safe site working? a. Single operator transformer b. Multi operator transformers c. AC/DC composite power unit d. Diesel engine driven motor generator 12. Hsubmerged arc welding is 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 During C02 welding, the arc length is most likely to be affected by: 13. a. The wire diameter b. The current return connections c. The gas flow rate d. The torch to work angle Preheating for arc welding applies to: a. Assembly welding only b./ Assembly and tack welding c. Joints over 25 mm thick only d. Cruciform welds only Which one of the following statements is correct? 15. a. Preheating increases hardness b. Preheating increases cooling c, Preheating increases dilution d. Preheating increases shrinkage stress You see a welder using an oxy-acetylene flame with a long feathered inner cone.What !6. would be the effect of this on a carbon steel? a. The weld would be hard and brittle b. The weld could be too soft c. There will be no effect on the weld d. The weld will have undercut I 7. 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 97 98 18. 20. 21. 22. 23. 24. A fabricating procedure calls for fillet welds to be 'blended in' by grinding. This influences: a. HAZ. cracking b. Fatigue life c. Residual stress d. Yield strength Bend test specimens have been taken from a 25 mm thick carbon steel butt weld.Which would show lack of inter-run fusion? a. Sidebend b. Rootbend c. Face bend d. Guided bend 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 examination 4. It would not have been found by any inspection method Yon are to oversee the arc welding of some machine fittings and find that 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 One of the reasons for excluding hydrogen from the weld metal is to prevent the weld from: a. Cracking b. Cooling slowly c. Cooling quickly d. Expanding When a metal regains its original shape when a stress acting upon it is removed, the metal is said to have: a. Ductility b. Plasticity c. Malleability d. Elasticity Proof stress is used when non-ferrous metals are undergoing tensile tests to determine the equivalent: a. Tenacity b. Elasticity c. Yield strength d. Tensile strength 98 99 25. 26. 27. 28. 29. To test a component for vibrational loading, a suitable mechanical test would be: a. Impact b. Tensile c. Compressive d. Fatigue The main reason for pre-beating medium and high carbon steels before cutting by oxy fnel gas technique is to: a. Improve the quality of the cut b. Increase the cutting speed c. Refine the grain structure d. Prevent hardening and cracking One purpose of a microscopic examination of a weld is to establish the: a. Strength of the weld b. Number of alloying elements c. Grain size d. Number of runs used The predominant structure of an byper-eutectoid steel that has been quenched at above its upper critical point will be: a. Austenite b. Martensite c. Troostite e. Sorbite When weld metal refinement takes place in a multi-run deposit, it is known by the term: a. Weld annealing b. Weld refining c. Weld normalising d. Weld recrystallisation One advantage of metal gas arc shielded welding is: a. Can be used in draughty locations without protection b. Produces a deposit low in hydrogen content c. Any welding position can be welded with spray transfer d. Fine spatter at nozzle restricting gas flow ---------.-------- X 1\ ----------/'\:-------"-. "'- /\ ..) The use of flux with gas shielded metal arc welding allows: a. Voltage b. Welding speed c. Iron powders in tbe coating d. Wbicb of tbe following symbols indicates tbe deptb of weld penetration required on tbe joint? a b.. !Ov '\. MULTICHOICEPAPER TWO BS499 communicates by tbe use of symbols tbe type of joint preparation to be used. 2. wV d. Aluminium to be welded d. v '\. c. Current 100 . Less dilution oftbe weld by the parent metal In MMA welding what parameter is used for control of penetration into tbe base material? a. Sheet metal to be welded b. b.100 I. d. A stable arc when using high current densities c. c. 3. \. 4. Wbicb of tbe following symbols would indicate tbat a weld bas to be finished on tbe 'otber' side of tbe weld? a.. Titanium d. DC generator Which of the following tests would indicate the toughness of weld metal/parent metal HAZ? a. 10. Flat characteristic c. Wire stick-out length b. All of the above 6. Charpy vee notch Degreasing components is essential for quality welding but some agents may: a. Iron powders with the flux coating d. The core wire b. the slags produced can be varied to suit the welding position. Amperage c. Molybdenum b. 11. Which type of slag would be required for welding in the HV position? a. Fluid b. Drooping characteristic d. Carbon In MAG/C02 welding which parameter gives the greatest control of weld appearance during dip transfer or short-circuiting welding? a. None of the above The weld metal deposit of MMA electrodes achieves its mechanical strength through: a. Leave residues d. Cause corrosion problems b. Macro b. Wire feed speed d. 8 9. Nick break c. What type of power characteristic is required for manual welding? a. Give off phosgene gas c. Semi t1uid d. Root face b. None of the above . 12. Viscous c.101 In the welding of a butt joint from one side. 7. Rootgap d. Hardness d. Bevel angle c. Chromium c. All the above Which of the following elements has the greater effect on the hardenability of a steel plate? a. Inductance In MMA welding. the profile of the root bead is controlled by: a. The flux coating c. Constant voltage b. Prevent oxidation of the root bead d. Shorter arc length can be obtained 102 . Fine grained steel In submerged arc welding the use of excessively high voltage would result in: a. IQI indicator c. Ductility b. Higher arc voltage can be obtained d. Toughness c. Had control of chemical composition b. 18. Density of the film b. Mechanical strength In the welding of austenitic pipework the bore is usually purged with argon to: a. KVA available d. Fatigue strength d. Eliminate the formation of hydrogen In X-ray work the quality of the radiographic image is assessed by the: a. Insufficient flux melting b. Prevent bum-through in the root run c. Been quality tested d. There are iron powders in the electrode c. 17. Rimming steel d. Semi killed steel c. Been vacuum melted Wbich one of the following types of steel would give rise to the formation of porosity when autogenously welded with an arc process? a. Calcium carbonate 14. 19. 16. Calcium fluoride c. Iron powders b. Stand-off distance A steel described as QT will have improved tensile properties because it has: a. Welds made with high heat inputs show a reduction in which ofthe following properties? a. Silicon e. Fully killed steel b. Cellulosic electrodes are often used when welding the root pass of pipes in the field because: a. Slag removal difficulties d. Hydrogen control is needed b. Excessive t1ux melting c. Prevent formation of porosity in the weld b. Spatter 15. Wbat constituent is needed in the coating of an electrode to prevent tbe formation of porosity in the welding of a rimming steel? a.102 13. 20. Been heat-treated c. To improve mechanical properties in the weld 25. Electron beam welding d. High beat inputs would: a. Carbon 24. Plastic state d Elastic state () Welding procedures may require welds to be deposited at a controlled rate of heat input. Solid state c. 23. 22. Fused and agglomerated In a steel tba_t bas improved creep properties at elevated temperatures. Shows a reduction in size b. Friction welding b. Sintered and agitated b.The reason for this is to prevent: a Cracking in the heat affected zone b. The fonnation of chromium carbides c. Prevent hardening in the HAZ c. Tungsten b. Cracking in the weld metal d.103 21. the electrode and plate material can be purchased with low carbon contents. Distortion Submerged arc fluxes can be supplied in two forms. Have poor profile b. Diffusion bonding c. Liquid state b. Have high hardness in the HAZ d. Autogenous TIG welding 26. Breaks at 45° to the load 1::1 . Which of the following processes uses the 'keyholing' system of fusion? a. Manganese c. In a tensile test a brittle material would be indicated if the fracture surface: a. Is flat and featureless c. Agitated and fused c. In the welding of austenitic stainless steels. Prevent the fonnation of carbides d. Molybdenum d.45 would require preheating to: a. which one of tbe following elements helps in this improvement? a. Breaks in the parent material d. Sintered and agglomerated d. Welding a steel plate with a CE of 0. In friction welding the metal at the interface is in the: a.These are: a. Have low elongation properties 28. Prevent the fonnation of sulphides b. Have larger grain size c. Side bend test c. Excessive penetration b. Change in weld metal composition c.104 29. Nick break b. Charpy impact test d. Narrow weld width d. Excessive bead profile 104 . What destructive test would be required to ascertain the likelihood of cracking in the heat affected zone of a weld? a. 30. Macro test In submerged arc welding excessive arc voltage may cause: a. Submerged arc welding d. Corrosion b. Welding position c. All of the above Wben visually inspecting a completed single vee butt weld cap. Cap height b. Low current setting d. Differing root face widths d. Overlap type defects d. This is most likely caused by: a. Manual metal arc b. Toe blend c. Before welding activities only c. during and after welding activities b. BS4870 d. Weld width d. Linear misalignment b. Both A and C Incomplete root fusion would certainly be caused by: a. All the above 105 106 . Excessive travel speed d. Excessive travel speed d. All the above You notice a very 'veed' ripple shape. Both A and C Undercut is principally caused by: a. 2. you would certainly assess: a. Before. 5. 7 8. All the above Slag inclusions would occur with: a. Excessive root face width b.MULTICHOICE PAPER THREE 1. Excessive root gap size c. Metal inert gas c. Excessive amps b. After welding activities only d. BS 4872 b. Excessive volts c. BS499 c. Fatigue lite c. None of the above A code of practice for visual inspection should include the following: a. 4. None of the above Incomplete root penetration in a butt joint could be caused by: a. All the above Toe blending is important as it may affect: a. Incorrect tilt angle c. 105 The British code for visual inspection requirements is: a. Poor consumable choice b. Undercut is normally assessed by: a. Incomplete penetration d. Its depth b. but BS 5289 states that its magnification should be: )...s f\ a. Incomplete fusion defects b. All the above A magnifying glass may be used during visual inspection. Up to 50 I. Require re-approval of a weld procedure d.pector c. 16. _ 'l. None of the above When visually inspecting a fillet weld it would normally be sized by: a. Change the properties of a weld b. Incorrect settings c. Influence the visual acceptability c. Give information to the in. 14. 17. The actual throat thickness c. This is because of: a. To confirm visual uncertainties d. Both A and C A planar defect is: a. Slag inclusion c. Assessed along with other defects d. 18. All the above Defects outside the limits specified in a standard should always be: a.106 II. The design throat thickness d. Repaired b. Its length c. Give information to the welder b. 12. Reported to 'a senior person' c. It's blending d All the above A welding procedure is useful to: a. Give confidence to a product d. The leg lengths b. Poor inter-run cleaning d. 2 to2. Poor maintenance of equipment b..5 0 c. Because the application says so c. All the above MIG welding tends to be susceptible to lack of fusion problems. 15. 5to 100 d. All the above .. To aid visual inspection b. All the above An essential variable may: a. Both A and C Penetrant inspection and magnetic particle inspection are mainly used a. b. It may reduce the thickness dimension of a component b. All the above 107 . Basic. during welding. All the above In a fatigue failure the appearance of the fracture surface is characteristic. It would be: a. Solidification problems b. Root concavity c. 'Dirty' materials d. Burnthrough d. It may cause hard zones d. Poor access b. It may cause loquation cracks c. Hydrogen problems c. Improved toe blending c. Inclusions e. cellulosic and neutral d. increase the likelihood of: a. b. 26. 23. 22. Poor welding technique b. All the above A weave technique may give rise to: a. Loss of gas shield · c. 21. Smooth d. MMA electrodes can be grouped into three main types. cellulosic and rutile a. Rough and tom b. cellulosic and rutile c. All the above Cracks in welds may be due to: a. Excessive stresses d. None of the above Stray arcing may be regarded as a serious defect because: a. 'Chevron'-like c. Welding position d. Better profiles b. Cracking b. All the above Overlap in welds could be influenced by: a. Root fusion and penetration b. These are: Basic. Misalignment problems c. All the above Flame cut preparations may. Neutral. Welding process c. All the above With reference to a root penetration bead you would certainly assess: a.107 @ 20. Improved ripple shape d. None of the above The main cause of porosity in welded joints is: a. . before and after etching c. Fusion defects (inter-run) c. Macroscopic examination requires any specimen to be inspected: a. Using a microscope d. A set of rules for manufacturing a specific product c. Slag inclusions b. None of the above Which of the following may be classed as a more serious defect: a. Once. b. Porosity A code of practice is: a.108 30. after etching b. A standard for workmanship only . Levels of acceptability of a weldment d. None of the above 108 . Fusion defects (surface) d. Twice. The ability to cut stainless steels c. The temperature required for cut initiation b. Arc eye A metallurgical problem most associated with submerged arc welding is: a. 80% argon and 20% C02 d. Movement of the arc in MMA welding by magnetic forces is called: a. Fleetweld 5 Which of the following coatings is associated with stove welding? a. None of the above The main usage of arc cuttingfgouging processes is: a. Cellulosic c. Hydrogen cracking in the HAZ b. 5. E 5133 c. The removal of deposited welds c. The cutting of single bevel preparations b. E 7018 -G d. Arc misalignment c. The cutting/gouging of non-ferrous materials only Which of the following processes joins metals plastically? a.I-81? a. 8. Aic deviation b. Solidification cracking in the weld metal c. to combine good levels of penetration with good arc stability would be: a. The depth of the cut obtainable d. Hydrogen cracking in the weld metal d.109 MULTICHOICE PAPER FOUR I. 100% C02 b. E 6013 b. The cutting of single U type preparations f. All the above Wbich electrode classification would be relevant to AWS AS. . Oxidising A common gas mixture used in MIG welding nickel alloys. Resistance welding c. 100% argon c. Plasma welding d. Rutile b. Lamellar tearing in the weld metal Oxy pressure and nozzle size in flame cutting would influence: a. 7. Basic d. 4. Arc blow d. 98% argon and 2% oxygen !09 . ). Friction welding b. .I J. None of the above A large grain structure in steels. d. High fracture value values d. 17. sooo•c d. Restricted access within the repair area c. The possible position of the weld repair d. b. 13. Carbon manganese steels b. is said to produce: a Low ductility values b.110 9. 11 0 . Welding equipment. Micro alloyed steels (HSLA) d. type of SAW flux is more resistant to moisture absorption? Fused Agglomerated Basic All the above have the same resistance (§)/The flame temperature of oxy/acetylene mixture gas is given as: a. 23oo•c c. All the above Hydrogen cracking in the weld metal is likely when welding: a. None of the above 18. All the above Repair welding is often more difficult than production welding due to: a. Welding procedure approval d. What type of test is being carried out? a. A root bend test b. Entrapped metallic inclusions in the solidifYing weld g. Low fracture toughness values c. A reduction of in-service temperature to sub zero temperatures c. 3200°C b. Entrapped slag in the solidifYing weld b. A face bend test d. High tensile strength The likelihood of brittle fracture in steels will increase with: a A large grain formation b. None of the above In a bend test the face of the specimen is in tension and the root is in compression. The material being ingrained with in-service contaminants b. 16. A side bend test c. c. c. Entrapped gas in the solidifYing weld c. Low carbon steels EN 288 standard would refer to which of the following: a. Which a. Stainless steels c. Welder approval testing b. Consumables for welding Porosity is caused by: a. Ferritic rather than austenitic steels d. 20. Overlap Tempering is often carried out to regain toughness after which of the following processes? a. Surface undercut c. Open circuit voltage When MMA welding low carbon steel which electrode will give the greatest deposition rate? a. Rutile d. Stress corrosion cracking Austenitic stainless steel electrodes are generally smaller in length than mild steel electrodes because: a.Ultr ason ic testi ng 19. Stress relieving The presence of iron sulphide in the weld metal is most likely to produce which of the following upon contraction ofthe weld? a. High amperage is used b. Mains supply voltage b. Acoustic waves b. DC with straight polarity Gamma rays and X-rays are part of a family of waves called: a. 22. Hardening d. is more advantageous in detecting which of the following weld imperfections. over Ill other NDT methods? a. Shelflife will be decreased c. AC with a suppressor b. They are more expensive The voltage necessary to maintain an arc during metal arc welding is termed: a. Hydrogen cracking c. Iron powder Inherent rectification of the electrical output is produced in the arc when TIG welding using: a. Annealing b. Solidification cracking b. AC without a suppressor c. Their electrical conductivity is less than that of steel d. Arc current c. Normalising c. Lack of sidewall fusion b. Incompletely filled groove d. Cellulosic c. Arc voltage d. Hydrogen controlled b. lntergranular corrosion d. Transverse waves 111 . Light waves c. DC with reverse polarity d. Electromagnetic waves d. 112 26. It bas a high sensitivity to planar flaws d. 29. At right angles to the lines of flux b. The prevention of cracking c. A measure of the accuracy of a radiograph as an NDT tool is given by its: a. Parallel to the lines of flux c. All the above Under normal contract conditions weld procedure approval tests for pipework are: a. All the above The advantage of ultrasonic non-destructive testing for the examination of weldments is: a. It can be used to size flaws c. Dependant upon the contractor's confidence in his procedures d. Only required when MMA welding is used Hydrogen controlled electrodes were developed principally for: a. Density c. The prevention of porosity b. A surface breaking crack will be detected during a magnetic particle inspection if it is: a. It can be used to locate flaws b. Dependant on site and weather conditions c. Mandatory b. 30. Sensitivity d. . Intensity b. Their ease of arc starting 28. At 25° to the lines of flux d. Exposure 27. The enhancement of arc voltage d. All the above. Tbe correct term for 'cap height' is: a. d. d. A 'set of rules' for the manufacture of a product. b. a code of practice is: a. c. Stress. 2. Honesty and integrity. Ultrasonics. Full penetration required. Literacy. c. b. c. Both band c. Re-qualification of the weld procedure. d. Thin material. Tee joints. MPI. b. II . c. Possible changes in the mechanical properties. b. c. c. 5. 7. Weld on 'arrow' side. d. Knowledge and experience. A tensile test will assess: a. Penetrant inspection. A standard. c. a change in essential variable means: a. Impact values. Lamellar tearing. Cobalt as an isotope would generally be used on: a. d. All the above. f All the above. Cap profile height. All the above. b. c. 8. All the above. 3. A welding inspector's main attributes include: a. b. 4. d. None of the above. Weld on site. 6. d. Possible changes in the weld's microstructure. Weld on 'other' side. d. c. Solidification cracking. 9. Plate thicknesses greater than 25 mm. Hydrogen cracking. b. b. b. Weld symbols placed on a dotted line in accordance with ISO requirements means: a. Generally the most suitable method of detecting lack of sidewall fusion would be: a. Reinforcement. Radiography. Related to welder and weld procedure approval. Hot shortness is a term used to indicate: a. Technically. Excess weld metal. In welding procedure terms.113 MULTICHOICE PAPER FIVE I. Strain. A basic electrode would normally: a. Argon + 20% carbon dioxide. b. d. Submerged arc utilises: a. Have superior mechanical properties. Crack sensitivity aspects. 13. c. d. Lower skill requirement c. Weld decay. Argon+ 1% oxygen. When referring to TIG welding. Both a and c. the shielding gas would be: a. None of the above. d. Flat (PA) welding only. All the above.114 12. Planar. the shielding gas could be: a. c. c. . 18. All the above. d. All the above. Carbon equivalent values are useful to determine: a. None of the above. The important point of bigb temperature steels is that: a They can withstand creepfailure. Not be used on low carbon steels. b. c. Weldability aspects. Argon and hydrogen. Ability to find most defects. Ultrasonics would be preferred over radiography due to: a. b. d. b. b. Argon and helium. c. b. d. d. They may suffer re-heat cracking problems. Deep penetration characteristic. Both a and b. Cracks. d. 17. High deposition rates on DC+. 15. An austenitic stainless steel may suffer: a. b. Typical mechanical properties. c. Require baking before use. b. Lack of fusion. Sensitisation. All the above. Solidification cracking. When referring to MIG welding. All the above. Argon. d. Argon and nitrogen. They may suffer loss of toughness. c. Ability to detect laminations. b. c. The most serious defect types are: a. HAZ cracks. b. Which of the following defects would you not expect to find by visual inspection of welds? a. Tungsten inclusions. Porosity. Which of the following is likely to give the highest impact strength in ferritic weld metal? a. Weld metal cracks. c.What NDT method would you use to check this? a. c. Rutile electrodes. Lamellar tearing. d. d. d. Tungsten inclusious. Linear misaligmnent. b. Penetrant iuspection.115 19. Cellulosic electrodes. b. Lowering the peak residual stress. Which of the following defects is more common to welds deposited by C02 welding than welds deposited by MMA? a. Basic coated MMA electrodes. Lack of sidewall fusi9n. Undercut b. c. Linear misaligmnent. b. b. @. Cellulosic electrodes. b. Which of the following can arise from copper inclusions in a fe rritic steel . d. 24. You suspect that ferritic steel plates contain cracks in the prepared edges. d. c. Excess penetration. weld? a. Which defect would you expect to get in TIG welds in non-deoxidised steel? a. Iron powder electrodes. Softening the steeL I I5 . Linear slag inclusions. d. MMA welding of low alloy steels is more likely to be performed with: a. c. c. Ultrasonic flaw detection. Undercut. Magnetic particle inspection. Stress relieving is not helpful in which of the following cases? a. Slag inclusions. b. Radiography. Basic hydrogen controlled electrodes. d. c. Overlap. c. d. Improving resistance to stress corrosion cracking. Porosity. Improving dimensional stability after machining. Spray transfer C02 welding. Submerged arc with acid flux. . QT steel. 350 DPHv. c. The overall length of a pipeline can be affected by: a. J. QV What effect does mid thickness laminations in steel plate normally have when they are located within a weld beat affected zone? a Cause lamellar tearing. c. d.--_ 750 DP Hv. Transverse shrinkage.]]6 27. Copper. 29. lOODPHv. 500DPHv. Low carbon steel. The permanent backing material for MMA welding of low carbon steel should be made from: · · a. d. Affect the weld metal composition. b. b. c. Circumferential shrinkage. b. 116 . Cause internal tearing on a micro scale. Fuse together to form a bond. What is the maximum hardness usually recommended for the heat-affected zone of a medium strength ferritic steel weld? a. Longitudinal shrinkage. b. c. Cast iron. d. Angular shrinkage. 7. Stress relieving. d. Low pre-heat temperatures. b. c. Addition of more manganese to the steeL d. c. Called Iedeburite. d. b. All the above. Brittle fracture. 9. The electrodes for welding low alloy steels should be: a. Width of bead. d. c. notches and undercut is: a. Welder qualification tests are designed to: a. Normalising. c. Prove the weldability of the parent materiaL d. d. 6. Regulate excessive expansion. 5. Test the correctness of the welding procedure. Low alloy steels having a higb carbon equivalent before welding will require: a. Leg length. · Annealing. Retard rapid cooling. Refine grain structure. b. c. b. The weld dimension used to indicate the minimum strength of a fillet weld is: a. Weld decay in stainless steels can be avoided by: a. The most common type of failure associated with sharp fillets. Slow cooling after welding. Addition of titanium to the steeL An eutectoid mixture in steel is: a. Crystallisation. Used for welding in the flat position only. c. A reduction in carbon content b. Test the welder's skilL c. Relieve internal stress.117 MULTICHOICE PAPER SIX 3. One size larger than for general purpose electrodes. High pre-heat temperatures. Fatigue. c. A mixture of ferrite and austenite. A mixture comprising a substitutinal solid solution. d. The purpose of pre-beating low alloy steel pipes before electric arc welding is to: a. Heated in a drying oven before use. Throat thickness. No pre-heating. c. 117 . b. b. 8. Stress relieving. Used with a low current value. Quench and tempering. d. Called pearlite. d. b. Length of weld element An electroslag weld requires what heat treatment to improve the grain structure? a. b. Corrosion. . Yon have a macro section of a 'T' butt joint that shows a step-like defect lying outside the visible HAZ. In lowering the peak residual stresses. d. d. Avoid porosity in the root. Weld metal cracks. d. c. HAZ cracks.118 10. Rutile. . d. b. Which of the following can arise from copper inclusions in a mild steel weld? a. b. Stress relief is not helpful in which of the following cases? a. d. c. b. 12. b. Advise them to increase the voltage. II. Leave a poor surface finish. 16. c. Stray arc strikes are undesirable since they: a. Ask for a new welding team. What would this defect possibly signify? a. Suggest the use of a smaller diameter electrode. Obtain full fusion. Reduce corrosion resistance. In improving dimensional stability after machining. d. Cause weld metal cracking. welders are having difficulty in obtaining good capping profiles when welding in the overhead position. Obtain full penetration. b. 17. Which electrode deposits weld metal with ·the greatest ductility and resistance to cracking? a. Lamination. 13asic. In softening the metal. c. Use of double 'V' weld prep using balanced welding technique. Toe cracking. d. In positional MMA welding on pipework. c. Changing from a single 'V' prep for thick material. Advise them to increase the current. c. Which one of the following is not helpful in minimising angular distortion during welding? a. & 15. Lack of fusion. Lamellar tearing. Cause local hardening and cracking in the parent material. Cellulosic. In improving resistance to stress corrosion. Pre-setting of work piece. Porosity. Applying post weld heat soak. b. c. b. d Obtain a satisfactory weld surface finish. Oxidising. c. Argon purging on the root side is necessary in the TIG welding of stainless steel to: a. Would you: a. HAZ cracking. b. 5%? a. d. d. Tensile stress. c. Ductility. Being rolled_ 119 . 21. Shear stress.18. b. When depositing weld metal. when added to steel as an alloying elemen. 20. What happens to the mechanical properties of steel if the carbon content is increased to 0. c. has the effect of making the alloy more: a.t. c. c. c. When a longitudinal load is put on a lap joint. Percentage elongation of a metal undergoing a tensile test is a measure of: a. b. Malleability. b. d. d. The rate of cooling is too fast b. 24. Cold cracking is most likely to occur in a weldment if: a. It lacks ductility at high temperatures. The rate of cooling is too slow. b. Hardenable. Tensile failure. 25. Impurities are present at its grain boundaries. b. Cold. Absorption. Elasticity. Yield failure. Migration. Residual stress. This alloying effect is known as: a. d. b. Plastic. d. c. Ductility is increased. Malleable. Losing heat. The tensile strength is increased_ d. which eventually can result in structural breakdown known as: a. 23. Dilution. The material becomes softer. fusion will take place at the sides of the joint resulting in an admixture between weld metal and parent metal. Columnar growth takes place when a metal is: a. c. a condition of cyclic stressing can be set up. Being heated. Ductile. Compressive stress. the stress set up is normally: a. Shear failure. Malleability is increased. c. b. . Fatigue failure. When a metal is subjected to a fluctuating load. Diffusion. d. Plasticity. 119 Chromium. 27. Sulphur. May cause excessive pipe wear. Can contaminate the liquid. b. c.120 ® If a low carbon steel pipe has to carry a liquid. The type of crystal normally found in a single run arc weld in the as welded condition is: a. Austenite. Phosphorous. Small crystal grains. 28. Manganese. Large crystal grains. c. c. Sorbite. Dendritic. When a steel suffers hot shortness. Pearlite. d. d_ Distorted crystal grains. Reduces the flow rate of the liquid. Equi-axed. When a steel is heated to above its upper critical temperature. Silicon. b. Columnar. 30. b. c. care must be taken when making the butt welds to ensure penetration is not excessive because it: a. May increase the rate of corrosion. Polycrystalline. b. d. it is mostly due to the presence of: a. b. c. . d. 29. Martensite. Elongated crystal grains. d. the structure produced is: a. The first sub-zone in the heat affected zone of the parent metal nearest the weld deposit will consist of: a. A low hydrogen electrode. Elongation and fracture appearance. Ductility and fracture appearance.121 MULTICHOICE PAPER SEVEN I. 2. Tensile strength and fracture appearance. A root bend test is used to test the amount of weld: a. Lack of fusion and penetration. Too long a pause in the down cycle of the weave. d. according to BS 639. Each bead appears to be distinctly separated from the adjoining beads. Penetration. What would be observed if a fillet weld were sectioned and macro-etched? a. Hardness. The different grain structure between the weld deposit and the base metal can be determined by: a. A hardness test. American Petroleum Institute. b. Too high a travel speed. Less than 25 ml of hydrogen per I 00 grams of deposited weld metal. State governments. insurance companies. No hydrogen. Less than 15 ml of hydrogen per I 00 grams of deposited weld metal. d. The purpose of a nick break specimen is to provide a test for: a. c. Welding operators. b. Construction unions. The second run in a three run butt weld using the stovepipe technique is known as the: j _ 121 . The penetration and fusion into the root is very deep. The grain structure remains the same in all passes. b. c. Pipe welding codes are set up by: a. c. 9. b. A root bend test. American National Standards Institute. Too high a current setting. The grain of the other beads is coarser than the final bead. would contain: a. d. A face bend test. Ductility. d. c. d. b. c. 6. American Welding Society. d. c. societies. d. What is the most common cause of failure in root bend tests? a. Between 15 ml and 25 ml of hydrogen per I 00 grams of deposited weld metal. 3. Associations. b. c. manufacturers and the military. b. 5. d. c. b. 7. American Society of Mechanical Engineers. Elongation. 8. Soundness and fracture appearance. An etching test. Which organisation publishes the most commonly used code for boiler and pressure vessel welding? a. QJ_ . d. In submerged arc welding. Too large a root gap. Slow down the cooling rate after welding. Sealing run.38%. b. d. 16. Too high a heat input d. Submerged arc welds made with re-cycled flux are liable to: a. b. c. Carbon equivalent ofless than 0. c. c. Day temperature. Incomplete penetration. which of the following width to depth ratios would be likely to result in solidification cracking? a. Too small a root gap. c. Power source. c.122 a. Incomplete penetration in a single 'V' butt joint could be caused by: a. 10. Which type of electrode coating gives the most voluminous gas shield? a Rutile. BS 639 coding. Electrode storage. IL 12. 15. Aiding fusion. b. Intermediate run. C. 13. d. Course grain size. A large incidence of porosity has been reported in recent welding. Which of the following steels is likely to be more susceptible to hydrogen cracking? a. 1 :3. Reducing hydrogen content of weld preparation prior to welding. Colour. 3: I.43%.35%. d. b. Carbon equivalent of0. Oxidising. Hotpass.25 %. d. d. Preheating and interpass heating are used primarily for: a. Trade name. 17. Carbon equivalent of 0. Undercut d. b. Too small a root face. c. You are responsible for controlling welding on site. BS 499 coding. c. 14. Would you investigate? a. b. Carbon equivalent of0. b. Basic. b. b. Porosity. The electrode type. I :I. You could determine that an electrode is cellulosic by its: a. Filling run. . 2: J. c. Cellulosic. d. Ensure a fine grain size. Which physical test is more likely to reveal HAZ embrittlement? a. Reduction of the weld deposit is prevented. Micro cracks. transformer. Low hydrogen. The most common type of defect found in a structure when it is undergoing service is: a. C. b. The speed of welding is increased. c. d. D. Alternator. Excessive penetration. All weld tensile. c. Carbon pick-up. which electrode covering will give the greatest degree of penetration? a. Weld decay. b.123 The main reason why all adhering scale should be removed when the pipe end preparation is made by oxy-gas cutting is? a. 21. b. Argon. d. c. macro etching may reveal: a. MMA welds made with damaged electrode coatings are subject to: a. d. Oxidisation of the weld metal is minimised. Constant potential rectifier. When manual metal arc welding low carbon steel. Crystallisation. c. d. b. Excessive bead height. Rutile. Weld decay. Fatigue cracking. Lack of inter-run penetration. c. which one of the following should be used? a. 19. Transverse tensile. c. b. 20. A C. In the examination of a welded aluminium joint. Porosity. b. generator. 25. Cellulosic. d. Carbon dioxide. Nitrogen. When tungsten arc gas shielded welding stainless steel. 22. Stress fracture. d. d. b. Argon/carbon dioxide mixture. Which gas shroud should be used when TIG arc gas shielded welding aluminium alloys? a. Charpy impact. 24. Pipe bore alignment is made easier. 23. d. Iron powder. . c. b. Undercut c. Root bend. . d. b. d. Aid better penetration at the join-up. Macro examination. c. Open square preparation. Reduce the overall consumable consumption. are to be butt welded using the TIG process. c. The included bevel angle will have to be reduced. which of the following preps is most suitable? a. 27. Closed square preparation. The gap setting will have to be changed. Lack of root penetration. A correctly made tack weld should slope from the middle to the ends in order to: a. d. b. Impact tests. Open single Vee. 150mm diameter and 6mm wall thickness. 12 8 . Incorrect gap setting. Fracture tests. b. d. Reduce the electrode size required. d. H pipe bores are not matched correctly it can result in: a. To ensure a full strength joint. Which ofthe following destructive tests is not normally required for welder approval? a. c. Root fusion may be difficult to obtain. Overheating during welding. b. c. Excessive root faces. c. Prevent porosity at the join-up.124 26. 28. Excess reinforcement profile will be difficult to obtain. 29. Bend tests. Too large a diameter of filler rod should not be used to make a welded joint because: a. Two low carbon steel pipes. Open single bevel. b. _ sections and still have the same strength. Sulphur and phosphorus are not alloying elements. The ability of a material to withstand a load pulling it apart is called its 2. 16. The ability of a material to be stretched out without breaking is called . Lack of ductility is called 6. _ carbon. Low carbon steel contains less than . When carbon percentage increases. An alloy that contains a high percentage of chromium and nickel would have resistance to _ 15. The tough laminated structure that is formed on slow cooling of ferrite and iron carbide (cementite) is called _ 18. mechanical and physical properties of a steel. Increase in carbon content causes an 8. This is called 20. Low ductility in a weld metal could result in _ 11. Quenching a carbon or low alloy steel will result in an in ductility.>. the structure may be improved by reheating to 200-300°C. The property of a metal to return to its original shape is called 7. Alloying allows designers to use 14. Alloying is used to 12.125 PROPERTIES OF MATERIALS 1. Small percentages of chromium will increase the strength and percentage of nickel will increase _ in hardness and a _ _ and the percentage . The ability to withstand indentation is called 5. I 0.o.d jll. _ of a material. The hard constituent that results when steel is quenched is called 17. An Izod impact machine is used to give indication of the 4. H0v1. The amount of martensite formed depends on the speed of of _ 19. they are 13. there is a decrease in 9.-V' _ _ in strength and hardness. After quenching. while a small 125 . . Toughness.2% 13.. 4. 8.. 9..Toughness.. Hardness.Carbon. Increase. Increase.Tempering. Corrosion. 0. 6. 19. 10.Brittleness. 20. II. 3. 7. . Cooling. Hardness.!. 5.Increase. Smallerffhinner. 15.. Impurities. Cracking. Ductility. Tensile Strength.Decrease 18. 12.Pearlite. 14.127 PROPERTIES OF MATERIALS 1. 16.Martensite. Elasticity... 2.. Ductility. 17. . c b 7. c 22. 19. c c c b 7. a 19.>. b 18. c 30. 10. c 13. 27.126 ANSWERS PAPER ONE 1. 16. . 13. d 2. a -. d 29. b PAPER SIX 1. d 30.). a 17. b 14. a 13. b -. PAPER THREE 1. c 15. a 7. d b c c 5. d 25. 22. 26. 11. c b b c 6. d 12. 20. a 17. 25. b d d b 6. a 30. 13. 23. a 25. 20. c a 2. a d b d b c b 4. ca 22. d PAPER FIVE 1.16. c 8. d 20. c 5. . 10. a d b a a b a a c a c d a d c d c c d b c c b a d a dt . d 16. d d 7. a 3. d d c d 6. b 9. d b b b 3. b 25. c 21. 10. 19. 9.J. 14. a 27. b 20. b d d d b PAPER FOUR 1. 10. 17. b 29. c 6. d 11. 29. d d d a 5. a -. b d d b . 15. b 5. 22. c b 17. b 19. 18. d 12. 15. c 26. 24. 16. 25. c 12. 15. a c a b PAPER TWO 1. b b c c a 5. 19. d 21. b d b b 4.J. d 13.. 29. d 15. d 30. 4. 11. b 18. 15. d d d d 5. 27. 21. d 2. 14. 15. c 21. d 6. b 3. b 8. b 3. a 16. 8. 21. b 16. a 28.>. 17. d 27. b 11. 20. c 20. b 4. d 24. c 24. d 9. 26. a 8. c 28. 21. c 4. c 14. d 23. 18. 10. 22. d 19. 17 7. c 27. . 12.-. b 10. a 6. 19. 24. c 9. 26. c 2. PAPER SEVEN 7 1. 29. a 14. 12. 22. 18.J. 12. d 18. c 28. 28. d d b c 4. c 26. 24. 8. c . 24. c 28. 11. d 16. 13. 17. b b 10. a c 9. b 21. 18. 25. c 11. 11. b 9. 6. 28. 25. 30. a 22. 20. 14. b d d 7. 23. 30. 8. a 14. 29.J. b 2. b 9. 12. b 8. d 5. c d a a b 7. 13. a 2. 26. a 26. 17. 28. a 24. c d d b b 4. 27. 29. 30. 3 ']- . .. c vD B root face bevel angle root gap included angle Undercut may need to be assessed according to .. A 6. The principle purpose of a welder qualification test is . 1) Please return this paper unmarked 1... Middlesbrough . nick break side bend Charpy impact a face bend test depth length sharpness/profile/blend all of the above When visually inspecting the root bead of a single-vee-butt weld it should be checked for .. A/ B lack of root penetration HAZ hardness C tungsten inclusions D all of the above TWI North..... to test the skill of the welder to assess the weldability of the materials to decide which NDT methods to use to give the welder practice before doing production welding A fabrication procedure calls for the toes of all welds to be "blended in" by grinding.. HAZ and parent material ? A macro B C nick break hardness Charpy impact Dv 2. A Bv C make the weld suitable for liquid (dye) penetrant inspection improve the fatigue life reduce residual stresses D improve the general appearance of the welds For full penetration single-sided butt joints... Which mechanical test can be used to measure the toughness of weld metal.........Welding Inspection: Multi-Choice Questions Paper 1 (Rev..... The most likely reason for doing this is to ......... root bead penetration and profile are mainly influenced by .. Which is the best destructive test for showing lack of side-wall fusion in a 25mm thick butt weld? A BV"'" C D 3.... 5. Av' B C D 4. A B C DV 7... ./" A a standard for workn1anship quality only c a set of rules for manufacturing a specific product D a specification for the finished product all of the above TWI North. A burn-through may occur if . A Bc nv""' an excessive root face an excessive root gap the current setting being too low both A and C 1'2. 1) Please return this paper unmarked 8.. A B C D v before......... A the current is too low B C/ D the root face is too large the root gap is too large all of the above 15. for a high integrity application.. A Code of Practice is .. A linear misalignment B the root gap being too large cnv root faces being too small all of the above 13. ... ......... . A B C Dv' EN 288 EN 499 EN 287 EN970 10. The strength of a fillet weld is determined by A B [)v" 9.......Welding Inspection: Multi-Choice Questions Paper 1 (Rev.. When visually inspecting the face of a finished weld it should be assessed for . Incomplete root penetration in a single-vee-butt joint may be caused by . A maximum excess weld metal height B C toe blend inter-run blend all of the above DV 14. II'........ should cover inspection activities ... Visual inspection of a fabricated item.. leg length weld profile C weld width throat thickness The European Standard for NDE of fusion Welds by Visual Examination is .. Incomplete root fusion in a single-vee butt weld may be caused by .. Middlesbrough 2 . during and after welding before welding only after welding only during welding and after welding only 11. ....... Middlesbrough 3 . A B c/ D a root bend a side bend a face bend a longitudinal bend 20. Heavy porosity on the-surface of some MMA welds made on a construction site is most likely to be caused by .... A manual metal arc welds B metal inert gas welds submerged arc welds both A and C c n/ 22..-""' D use of the wrong class of electrodes the use of excessive current moisture pick-up in the electrode covering a bad batch of electrodes 21. the test is called . A Bv"' C D throat thicknesses leg lengths penetration depths bothA&C 19.... Which group of welders is most likely to require continuous monitoring by a welding inspector? A B '..... A B C \.. Slag inclusions may be present in .. it is normal practice in the UK & USA to measure ... The main cause of undercut is .. when the face of the specimen is in tension and root is in compression.Welding Inspection: Multi-Choice Questions Paper 1 (Rev... In a bend test.. A solid inclusion in a weld may be .....P C D concrete shuttering welders overland pipeline welders tack welders maintenance welders TWI North.. I) Please return this paper unmarked 16........ Which of the following is a planar imperfection ? A B v C D a lack of sidewall fusion a slag inclusion linear porosity root concavity 18. A\/" B C D entrapped slag entrapped gas lack of inter-run fusion all of the above 17. For fillet welds.. A B C DV excessive amps excessive volts excessive travel speed all of the above 23. BS EN 970 allows the use of a magnifying glass for visual inspection but recommends that the magnification is .8mm 3....4mm 27... back purging is not required Dv all welder qualification tests are done on small diameter pipe it requires more skill and increases the welder's qualification range c TWI North.. The majority of welder qualification tests are carried out using an unbacked joint.... If a Welding Inspector detects a type of imperfection not allowed by the Application Standard he must always. A V" B c4/f D request further NDE reject the weld prepare a concession request only reject the weld if he considers it to be harmful 29.. A typical included angle for MMA welding of a full penetration pipe butt joint is . A fillet weld has an actual throat thickness of 8mm and a leg length of 7mm. What is the excess weld metal ? A B cv D 2.. 1) Please return this paper unmarked 24.lmm 1.... A B it is quicker... A BV' C D x2 x2 to x5 x5toxl0 not greater than x20 30.Welding Inspection: Multi-Choice Questions Paper 1 (Rev... Middlesbrough 4 ... if back-gouging is not required if the welding process is not TIG... the the the the boundary between the weld metal and HAZ boundary between individual weld runs depth of root penetration boundary between the HAZ and parent material 28. The fusion boundary of a fillet weld is .. and WPS)? A B C Dv 8 nm1 actual throat 7 nun leg + 2 mm excess weld metal mitre fillet with lOmm leg concave fillet with llmm leg ':/ 7 25. This is because .lmm 1..... and cheaper. Which of the following fillet welds is the strongest (assuming they are made using the same material. A BV"' c D 35° 70° 90° dependent on the pipe diameter 26. . cellulosic and neutral rutile. This should not be allowed because .. that can make welding difficult to control... lmv hydrogen and basic A WPS may specify a maximum width for individual weld beads (the 'weave' width) when welding C-Mn sreels because if this is exceeded it will cause . is commonly known as . I) Please return this paper unmarked 1. 3. AV 5. cellulosic and rutile basic.Welding Inspection: Multi-Choice Questions Paper 2 (Rev. with the flux covering remoYed. A 6... A B cV D 7.../ C D lack of inter-run fusion a reduction in HAZ toughness lack of sidewall fusion all of the above You notice that MMA electrodes. are being used as filler rods for TIG welding. rutile cellulosic high recovery rutile all of the above The three main types of MMA electrodes used for welding C & C-Mn steels are . arc blow it is wasteful the rod diameter be too large the weld metal composition may be wrong the rod is too short For TIG welding......... A arc initiation B arc misalignment c/ D 2.. basic.. Deflection of the arc by magnetic forces.. what benefit does a current slope-out device have? A-/ B C D it reduces Tungsten spatter it reduces the risk of crater cracking it reduces the risk of arc strikes it reduces the interpass temperature . A E 38 3 R BV C E6013 E7018-G D E 51 33 B Which of type of electrode is used for "stove-pipe welding" for overland pipelines construction ? B C D B·. arc constriction Which of the following electrodes is classified to BS EN 499? A B v' C D 4. cellulosic and rutile neutral..... .. A B cv D prevent linear porosity prevent burn-tlnough prevent oxidation of the root bead eliminate moisture pick-up in the root bead 11.# the core wire composition B'v"" additions in the flux coating c iron powder in the flux coating D dilution from the base material 12......... When low hydrogen MMA electrodes are specified for what type of covering will they have ? cellulosic rutile acid basic TWI North....<.{ """"""i . According to AWS 2....4 a weld symbol for the 'other' side is placed .:: f N\ '(1 $. A B arc voltage nv ferro-silicon in the electrode coating c welding speed current 10.. A.... in order to give . AV deoxidation B impro\·e strength C improYe toughness D more resistance to hydrogen cracking .. A .... 13.... I) Please return this paper unmarked 8... Silicon is added to steel) and the covering ofMMA electrodes..Welding Inspection: Multi-Choice Questions Paper 2 (Rev. A B CV D above the dashed line below the dashed line above the solid line below the solid line 15.. Which type of power source characteristic is normally used for manual welding? A B Cv' D 9. penetration is principally controlled by . Pipe bores of some materials must be purged with Argon before and during TIG welding in order to .« '-<fY' ? reduce porosity B give controlled root penetration C avoids the need for a back purge all of the above Dv 14.. constant voltage flat characteristic constant current a motor generator In MMA welding... Middlesbrough 2 """'" "'4 1\.... A fusible insert for TIG welding helps to . The chemical composition of the weld metal deposited by a C-Mn steel electrode is usually controlled by ...\ = '1"'--e:.... Which of the following units is used to express Heat Input? A B c D/ Joules 2 N/mm 2 J/mm kJ/mm 19.._j - --. T /------'0-------· B cv / D / -----..Welding Inspection: Multi-Choice Questions Paper 2 (Rev... According to BS EN 22553 which of the following symbols means that the weld toes must be smoothly blended on the 'other side'? / A ----- v_ - -. AV EN code letter (or AWS code number) B electrode length C Trade Name D colour of the covering 17.. Which one of the following elements is added to steel to give resistance to creep at elevated service temperatures? A Nickel B Manganese cv" Molybdenum D Aluminium 20.. Nick break and fillet fracture tests are used for A B C V assessing weld quality assessing weld metal ductlity assessing weld metal toughness TWI North._/ ---- LM. A hydrogen controlled MMA electrode can always be recognised by the .. 18..------· 1\ _v '--. I) Please return this paper unmarked 16. Middlesbrough 7 . Middlesbrough 2 .D all of the above TWI North. . A it will cause copper contamination B it may cause hard spots cDv it may give cracking of both B & C 25....l Mo 9%Ni 22.. Middlesbrough 9 . A qualified Welding Procedure Specification is used to ... Weld spatter during MMA welding is most likely to be caused by A excessive current c D·/ incorrect baking and storage of electrodes a bad batch of electrodes all of the above B 23..Welding Inspection: Multi-Choice Questions Paper 2 (Rev..... A B give instruction to the welder c Dv give information to the welding inspector give confidence that welds will have the specified properties all of the above 24.. is . The polarity used for TIG welding of all materials..... except aluminium and magnesium... A there is a reduction in cross-section at the position of fracture C D the fracture surface is flat and featureless but has a rough surface fracture occmTed in the weld metal the fracture face shows beach marks Bv 26..------< the WPS Number the welding process a filler material the acceptance standard 141 28... What does the number 141 refer to on this drawing symbol ? A BV c D /------{!.. Which of the following steels is non-magnetic? AV B C D 18%Cr....... An arc strike (stray flash) on a steel component is regarded by some codes as unacceptable because . 1) Please return this paper unmarked 21.. A B cv D be rough and tom have sharp chevron markings be smooth have shear lips 27...8%Ni 13% Cr 9%Cr.. A B C D v DC negative DC positive AC any polarity can be used TWI North. The surface of a fatigue fracture will . brittleness would be indicated if .... In a transverse tensile test. 1) Please return this paper unmarked 29. but the current and voltage remain the same.Welding Inspection: Paper 2 Multi-Choice Questions (Rev./ B C D be reduced by 50% be increased by a factor of two be about the same be reduced by approximately 25% 00000 . A typical temperature range for baking low hydrogen electrodes is A B cv D 0 000 0 000 0 150 to 200°C 200 to 250°C 300 to 350°C 400 to 450°C 30. If welding travel speed is doubled. the heat input will A.. Middlesbrough 2 (Rev.... A low ductility c high toughness high tensile strength Bv D 3. service low carbon steels for cryogenic service A D 7....... A the HAZ microstructure D the weld metal microstructure all of the above BV c overlap TWI North.. A... B c Dv cv D yield strength c co-efficient of thermal expansion elastic modulus co-efficient of electrical conductivity Which of the following is a suitable shielding gas for FCAW of stainless steels? A BV C D 100% Argon 70% Argon+ 30% He Argon+ 5% Hydrogen Argon+ 20% C02 The presence of iron sulphides in a weld bead may cause . low toughness ASTRA test is used to measure ... austenitic stainless steels low alloy steels for elevated temp.. the tensile strength of the welded joint the level of residual stress in butt joints the fracture toughness of the HAZ the through thickness ductility of a steel plate (the 'Z' direction) The risk of hydrogen cracking is higher when MMA welding of . may have ./' agglomerated cr... Bv/ 6./ B C D 8. 1) . in the HAZ of a C-Mn steel weld joint. A large grain size.... Which type of submerged arc welding flux is susceptible to moisture pick-up? A neutral B-... A 4. ....... A B 5. fused they are all about the same solidification cracking hydrogen cracking lamellar tearing weld decay A macro section is particularly good for showing . ..Welding Inspection: Multi-Choice Questions Paper 3 Please return this paper unmarked 1.... C-Mn steels The property of a material that has the greatest influence on welding distortion is the....t' D 2. Welding Inspection: Multi-Choice Questions Paper 3 (Rev.. I 00% Argon 80% Argon + 20% C02 98% Argon + 2% 02 11. multi-pass 1 pass per side 10. measured pore diameter3... s10mm. as near as practical to the arc across the power source terminals prior to arc initiation across the power source terminals during the welding operation all of the above are suitable 14. To measure arc voltage accurately it is recommended that the voltmeter should be cmmected .. Which of the following procedures would be expected to produce the least distortion in 15nnn straight butt weld? A B C TIG weld MMAweld MMAweld SAWweld n·/ single sided.-:...3s. for GMAW of aluminium is .Onun .5mm 13..measuredporediameter 3. 1) Please return this paper unmarked 9. A suitable gas /gas mixture. For which of the following situations is the pore acceptable? A B VC D '=. 15..... Lamellar tearing has occurred in a steel fabrication..s = 20mm. EN ISO 5817 (Level C) specifies that the limit for the diameter (D) of a single pore in a weld is: D :$ 0. multi-pass single sided...5mm :. A sv c D porosity excessive distortion HAZ cracking lack of fusion . multi-pass double sided..4mm where s =material thickness.' s 15mm./ B C D hydrogen cracking in the HAZ solidification cracking in the weld metal re-heat cracking during PWHT lamellar tearing 12.. Pre-heating a low alloy steel prior to welding is done to minimise the risk of . A B C v D 100% CO. but max.0mm 3 s10mm. What technique could have been used to find it before the weld was made ? A B c DV X-ray examination liquid penetrant examination ultrasonic examination it could not have been found by any inspection method. measured pore diameter= S. Which of the following is associated with SAW more often than it is with MMA welds is ? A... measured pore diameter4. . Which type of SAW flux is susceptible to breaking down into fine particles during circulation? G). pre-heat temperature should be checked..........- 600 to 650°C 1000 to 1100°C 700 to 800°C 880 to 920°C 17. For GMAW the bum-off rate of the wire is directly related to .. Middlesbrough 4 ..... For MMA welding of a 60mm wall nozzle to a lOOmm wall vessel shell....... AV B C D the stick-out length wire feed speed the arc voltage the travel speed 18.. 1) Please return this paper unmarked 16. A B C D. A B C 8 D V use low heat input welding use steel with a low CEV ensure there are no features that give high stress concentration all of the above The use of low carbon austenitic stainless steels and stabalised stainless steels will minimise the risk of ...Welding Inspection: Multi-Choice Questions Paper 3 (Rev. The maximum hardness in the HAZ of a steel will increase if the ._/' B C D before welding starts/re-starts on the shell and the nozzle at points at least 75mm from the joint edge all of the above 19.. A heat input is increased c joint thickness is decreased Bv D CEV is increased all of the above TWI North... A B c n/ use of damp flux lack of preheat arc voltage being too high weld bead being too deep and very narrow 20. A crack rwming along the centreline of a weld bead could be caused by ../ B C D fused neutral alloyed agglomerated 23. A......... it is good practice to .. In order to improve resistance to service failure caused by cyclic loading... A B C D HAZ cracking weld decay weld metal cracking distortion 22..... Typical temperatures used for normalising a C-Mn steel plate are ... Initiation of a TIG arc by using a High Frequency spark may not be allowed because .5mm 25. distortion can be minimised by .lb..5 J/mm 5. BS EN ISO 5817 (Level B) specifies the limit for Excess Weld Metal (h) on a butt weld as: h lmm + O.5mrn )....5mm . A carbon manganese steel is being welded by MMA and the electrode run-out-lengths that have been used are much shorter than specified by the WPS.. AV B C D pWPS WPS WPQR WPAR 27.... A B cV" D b 10 b 20 b35 b 45 measured excess measured excess measured excess measured excess weld weld weld weld metal= 2.Welding Inspection: Multi-Choice Questions Paper 3 (Rev... I) Please return this paper unmarked 24....: metal= 5.. ... but max... .... Transfer of material identification by hard stamping is sometimes not allowed for high integrity applications because ... When welding thin plate. A\/""' B C D it often causes tungsten inclusions it can damage electronic equipment it is an electrical safety hazard it often causes stop/start porosity . 5mm.. metal= 3. A B c DV using back-step welding minimising weld volume using bridge tacks all of the above 29. Which of the following would be considered to be high Heat Input welding? A B C Dv 550J/mm 55 J/mm 5.. A B an increased risk of hydrogen cracking an increased risk of solidification cracking D lower values of HAZ touglmess higher values of HAZ hardness cv 26. b weld width...... In which of the following situations is the measured Excess Weld Metal acceptable.... it is too slow A B C D v it can be a safety hazard it may be damaging to the material all of the above 28.! •.0kJ/mm 30.. This deviation may give .. The first procedure that is prepared for a Weld Procedure Qualification test weld is a .5nml 3 metal= 4.. . \Neider approval testing /' welding equipment calibration CV D consumables for submerged arc welding A B time type of isotope C sourcc-to-fllm distance D source strength Which element has the greatest effect on the HAZ hardness of a carbon-manganese steel ? A B Molybdenum Chromium o·/ Titanium Carbon Pre-heating a steel plate \dth a carbon equivalent value (CEV) of0.... A B\/" c D he has not done any welding for a period of 4 months he has been absent from work for a period of 7 months the repair rate for his welds exceeds 1% all of the above TWI North.Welding Inspection: Multi-Choice Questions Paper 4 (Rev.. I) Please return this paper unmarked G Which of these drawing symbols sho\\S weld penetration depth in accordance with BS EN 22553? j/'---\lOss-t------ A /-.....--- BS EN 288 is a specification for..------ B ------..... A driYe out moisture from the plate c preYent excessive hardening in the 1-IAZ preYent the formation of carbides improve the mechanical properties or the weld metal BV D 6._L:A. welding procedure approval What determines the penetrating power of Gamma rays ? c 5.... ---. Middlesbrough ... A B 0 / lOs A welder approval certificate should be withdrawn if ...48 may be required in order to .. 4.------ c V D 2. Ultrasonic testing has an advantage over other NDT methods for the detection of .... A B c ov- the the the the TWI North........ MIG/MAG welding has a tendency to give lack of sidewall fusion when . Av B c @ D lack of side wall fusion root undercut incompletely filled groove root concavity Exceeding the maximum inter-pass temperature specified for a C-Mn steel weld joint... may give A B CV"' D excessive porosity bum through lower toughness all of the above 13. Which of the following would be classed as the most serious type of defect? A B cv D a buried linear slag inclusion buried lack of inter-run fusion surface breaking lack of sidewall fusion surface porosity 11..Multi-Choice Questions Welding Inspection: Paper 4 (Rev.. A B the size of a discontinuity in a weld joint the density of a radiographic film C the degree of film contrast D the quality of the radiographic technique Which of the following cutting methods is suitable for cutting stainless steel? AV plasma B oxy-acetylene C D oxy-propane all of the above 10.... A B cv G 9. the metal at the interface when the joining occurs is described as being in the ... Middlesbrough critical transformation temperature ductility dip temperature bi-modal temperature transition temperature 2 .. I) Please return this paper unmarked 7... A B c DV spray transfer conditions are used 1OO%C02 shielding gas is used pulsed current is used dip transfer conditions are used 14. D liquid state inter-critical state plastic state elastic state A penetrameter is used to measure ... In friction welding.... The temperature range over which a steel goes from having high toughness to low toughness is called . ...o S1 I:)) Ib c7 i$ovn' < c E6013V I 3 1 01 I S b 1 19.. what is the effect of raising arc voltage but keeping with all other parameters the same? A llV'" c D the weld bead width will increase the depth of penetration will increase the weld bead width will decrease the depth of penetration will decrease 16... AV B C D using inductance using 100% C02 using Ar + 30%He increasing the stick-out length 22.... Middlesbrough 3 ....ilc 2 lo 11 --7 (e\\v.. it is heated to the soak temperature at a much higher rate than specified by the procedure.e plant and equipment may be more difficult than making repairs during initial fabrication because A B c o. which of the following statements is true ? A B c DV they are all non-magnetic they all require 100% Ar for GMAW they all have very high thermal conductivity only certain grades can be used for service at very low temperatures 18. Repair welding ofin-servic.... For SAW.. When MAG welding in dip transfer mode (short-circuiting mode) spatter can be reduced by .. Welds made with very high heat input will show a reduction in @ C D tensile ductility notch toughness fatigue strength creep resistance During PWHT of a complex fabrication..... Which of the following AWS A5... Changing an essential variable (beyond the allowed limits) for a qualified welding procedure ..-::r RuJ.Welding Inspection: Multi-Choice Questions Paper 4 (Rev. A B C D cause excessive oxidation not allow sufficient time to relieve stresses introduce excessive compressive stresses cause distortion 21.1 electrodes has a rutile covering . I) Please return this paper unmarked 15..... A E 6010 B E E 7016 7018 oJ \l)li...._\../ the material may be contaminated of restricted access to repair area positional welding may be needed of any of the above TWI North. This may .... With reference to the various grades of stainless steels.. may change the mechanical properties of the joint may adversely affect the quality of the weld will require a new welding procedure to be approved all of the above 17. is used to measure A D the tensile strength of the weld the tensile strength of the joint the stress/strain characteristics of the weld the stress/strain characteristics of the joint / 26.... the recommended isotope is A B cv D'l?' Thulium 170 :=.. A B C DV PB highest. PA lowest PE highest.. PG lowest Quhat type of covering will an electrode have that is suitable for welding 60mm C-Mn steel and can give good eld metal toughness at -50°C? . 1) Please return this paper unmarked 23...:=rS:mm Cobalt 60 _ 1... from a Weld Procedure Approval Record (WPAR) test plate..Welding Inspection: Multi-Choice Questions Paper 4 (Rev..... A B'" -"' C D by using a densitometer by using an image quality indicator ( IQI ) from the kV A used from stand-off used 25.mt'Yl Iridium 192 _ 1 0_ . A B cv D hydrogen cracking lamellar tearing solidification cracking weld decay 30.. Carbon equivalent values (CEV) are used to determine the how to avoid the risk of . Middlesbrough 4 .. PC lowest PD highest. The highest and lowest heat input positions are considered to be .. PB lowest PF highest. The sensitivity of a radiograph is assessed ... A transverse tensile test.. AV B c D a composite joint a transition joint an autogenous weld all of the above TWI North.. A B rutile basic C cellulosic D choice will depend on the welding position 28. For gamma radiography of a steel weld at 40mm thick.. 1-wwn Ytterbium 169-:= I '2. When 2 different material types are welded together.. The dip transfer mode (or short-circuiting mode) of metal transfer used for MIG/MAG welding is characterised by A giving deep penetration c being suitable for positional welding giving low spatter all of the above sv-'"' D 29.. r -- '"10-t aml'Yl 24.. the joint is referred to as .... 03/03 WELDING INSPECTION TRAINING ONLY MULTl CHOICE PAPER 1 Name: Date: Answer all questions. (ONLY ONE ANSWER PER QUESTION) 1. 2. 3. 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 Page 1 of 8 .WIS 5 M1 Rev. 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 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 When manual metal arc welding is being carried out on an open construction site. You notice manual metal arc electrodes. 7.15% carbon.Rev. 6. 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 When open site working. 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 One of the following alloys is non-magnetic. 03/03 WIS 5M1 4.6% manganese.0% Nickel Steel Page 2 of8 . 1. What would you investigate ? (a) Electrode type (b) Power plant type (c) Electrode storage (d) Day temperature The steel composition in a structural contract is changed from 0. stripped of flux. to 0. 5.2% carbon.0% Chromium molybdenum (b) 12. serious porosity in metal arc welds is brought to your attention.2% manganese.0% Chromium (c) Austenitic Stainless Steel (d) 9. Which? (a) 4. 0. for TIG welding. are being used as filler wire. WIS 5 M1 8. BS499 Part 2 specifies that the minimum drawing dimension quoted for a fillet weld is the : (a) Leg length (b) Actual throat thickness (c) Weld width (d) Depth of penetration For open site manual metal welding the following equipment is available. Rev. 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 Page 3 of 8 . 03/03 When TIG welding Austenitic stainless steel pipe. 10. 11. 9. This is to : (a) Prevent oxidation (b) Prevent underbead cracking (c) Prevent porosity (d) Control the penetration bead shape 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 In UK practice. Argon gas backing is called for. (c) Fused (d) Alkaline ' - During C02 welding. What would be the effect of this on a carbon steel. 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 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 You see a welder using an Oxy-acetylene flame with a long feathered inner cone. What type of flux would you expect this to be: (a) Basic (b) Acid I. 14. The flux being used for a SAW application has been described as sharp or flaky. (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 .Rev. 15. / 13. 03/03 WIS 5M1 12. 19.carbon steel butt weld. Before welding could it have been detected by: (a) X-ray examination (b) Dye penetrant (c) Ultrasonic inspection (d) It would not have been found by any inspection method . 17. This is to: (a) Remove Hydrogen cracking (b) Improve fatigue life (c) Remove undercut (d) Improve yield strength Bend test specimens have been taken from a 25mm thick. 03103 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 A fabricating procedure calls for fillet welds to be "blended in" by grinding.WIS 5M1 16. 18. Which would show lack of inter-run fusion: (a) Side bend (b) Root bend (c) Face bend (d) Guided bend Lamellar tearing has occurred in a steel fabrication. Rev. Rev. 23. measurable from the surface. of a mitre fillet weld having equal 20mm leg lengths will be: (a) 25mm (b) 17mm (c) 14mm (d) It cannot be determined form the information provided . 22. 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 What is the leg length of a fillet weld? (a) The distance from the weld face to the penetration (b) The distance between the two toes (c) The distance from the original root to the toe (d) The distance from penetration to the weld toe The term duty cycle normally refers to: (a) The shift pattern of inspection staff (b) A monthly occurrence involving outage time (c) Output capability of a welding plant (d) Component life expectancy The throat dimension. You are to oversee the arc welding of some machined fittings and find they are cadmium plated. 03/03 WISS M1 20. 21. when specified? · (a) To reduce component weight (b) To remove all defects in the cap region (c) To reduce the risk of Hydrogen cracking (d) To reduce the likelihood of fatigue failure . Which of the following abbreviations is "the odd one out"? (a) GTAW/ (b) MM. A pipeline girth weld has been made in the 5G position. 03/03 WIS 5M1 24.Rev. 25. 27.A :>cc!' (c) SMAW (d) GMAW A typical included angle for MMA welding 15mmt carbon steel. In which region would you expect to find the highest heat input? (a) PA (b) Flat (c) PB (d) PF What is the main reason for grinding flush single V butt welds. single V butt joints would be: (a) 35° (b) 30° (c) 70° (d) 26. 8mm (b) 0.Rev. Plug welds are normally used to weld plates that: (a) Overlap (b) Have holes through both plates (c) Are to be 100% watertight (d) Have "P" shaped lifting lugs attached Which of the following is a non planar defect: (a) Spheroidal graphite (b) Lack of penetration (c) Lamination (d) Slag inclusion .J What is a typical diameter range for basic electrodes for all positional MMA Welding (a) 2.2mm (c) 3. 03103 WIS 5M1 28.4mm (d) Size really does not mater Page 8 of 8 v .5. 29.25.8 -1. 2. 3. 1. Movement of the arc by magnetic forces in MMA welding is termed: (a) Arc deviation (b) Arc misalignment (c) Arc blow (d) Arc eye A metallurgical problem most associated with submerged arc welding is: (a) Hydrogen cracking in the HAZ (b) Solidification cracking in the weld metal (c) Hydrogen cracking in the weld metal (d) Lamellar tearing in the weld metal Oxy 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) None of the above Page 9 of8 .WIS 5M2 Rev03/03 WELDING INSPECTION TRAINING ONLY MULTl CHOICE PAPER 2 Date: Name: Answer all questions. The main usage of arc cutting/gouging processes is in: (a) The cutting of single bevel preparations (b) The removal of deposited welds (c) The cutting of single U-type preparations (d) The cutting/gouging of non-ferrous materials only Which of the following processes is not a fusion welding process: (a) Friction welding (b) Resistance welding (c) Plasma welding (d) All of the above Which electrode classification would be relevant to AWS A5. 5. 7. 6.R (d) E22553 Which of the following MMA electrode coatings is associated with "Stove" welding: (a) Rutile (b) Cellulosic (c) Fused (d) Pipelex .Rev03/03 WIS 5M2 4.1-81: (a) E6013 (b) E5133 (c) E 433N. (a) Fused (b) Agglomerated (c) Basic (d) All of about the same resistance The flame temperature of oxygen/acetylene gas mixture is given as: 11. Rev03/03 A common gas/mixture used in MIG welding nickel alloys to combine good levels of penetration with good arc stability would be: (a) 100% C02 (b) 100% argon (c) 80% argon 20% C02 (d) 98% argon 2% oxygen The type of SAW flux is more resistant to moisture absorption is: 10.WIS5 M 2 8. Rev03/03 The likelihood of brittle fracture in steels will increase with: (a) Page 11 of8 A large grain formation . 9. (a) 3200°C (b) 2300°C (c) 5000° (d) None of the above 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 WIS5 M 2 12. (b) A reduction of in-service temperature to sub zero levels (c) Ferritic rather than austenitic steels (d) All of the above 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 Hydrogen cracking is most likely when welding: (a) Carbon manganese steels (b) Stainless steels (c) Micro alloyed steels (HSLA) (d) Low carbon steels EN standard 288 would refer to which of the following: (a) Welder approval testing (b) Welding equipment (c) Welding procedure approval (d) Weld symbols on drawings Page 3 of 8 . 15. 14.13. 17. 18. the face of the specimen is in tension and root is in compression. 19. RevOJ/03 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 In a bend test.WIS 5M2 16. 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 Ultrasonic testing is of advantage in detecting which of the following weld imperfections over other NOT methods: (a) Lack of side wall fusion (b) Surface undercut (c) Incompletely filled groove (d) Overlap 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 Page 5 of 8 . (d) None of the above SMAW welding equipment is said to have an output characteristic that is: (a) (b) Constant current (c) Constant voltage (d) 23. Flat Either b or c Which of the following materials is most likely to require the highest levels of cleaning immediately prior to welding: (a) Low carbon steel (b) Carbon manganese steel (c) Austenitic stainless steel (d) All about the same . 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) lntergranular corrosion (d) Stress corrosion cracking A welding procedure that has yet to undergo testing is referred to as: (a) WPS (b) WPRT (c) WPSut. 22.Rev03/03 WIS SM 2 20. 21. Rev03/03 WIS 5M2 24. The code you are using gives the following formula for the maximum penetration allowance: h $ 1mm + 0. (a) You must have the pipe radiographed (b) Sentencing may only be performed by a qualified radiographic interpreter (c) It should be rejected (d) You should accept.6 b up to a maximum of 4mm .The application standard you are using contains the following statement: "Root concavity shall be acceptable provided the density of the radiographic image does not exceed that of the parent material" Which of the following is correct: 26. in a single V butt. What is the maximum allowable HI/LO for 8mm material if the code states the following"Linear misalignment is permissible if the maximum dimension does not exceed 10% oft up to a maximum of 2mm" (a) 2mm (b) 8. as there is no radiograph to view Which of the following statements is correct regarding gas welding low carbon steel: (a) It will give a low heat input (b) Acetylene or propane are normally used as fuel gasses (c) A low skill level is required to produce sound welds (d) It may be used for autogenous welding WIS5 M 2 27.5 mm . which has a depth of 0.8mm (c) 0.8mm (d) I could not sentence this defect as an incorrect term has been used When visually inspecting the root of a pipe weld. You have identified root concavity. 25. with the cap ground flush. (a) h = 0.5mm b = 5.8mm b= 4.6mm b = 6. 29.0mm (b) h = 4.0mm (d) None of the above Which of the following statements is correct: (a) Copper inclusions are usually grouped with slag and other Solid inclusions for sentencing purposes (b) Undercut lengths at both weld toes in the same longitudinal Location are added together for sentencing purposes (c) A measurement for maximum penetration height is always specified in Application standards (d) None of the above According to BS 499 a weld on the "other side" is shown by a symbol: (a) 30. On the dotted line (b) Below the reference line (c) On the solid line (d) Above the reference line What defect would appear as "bright white specks" on a radiograph? (a) Gas pores (b) Slag inclusions (c) Tungsten inclusions (d) Undercut Rev03/03 .0mm (c) h = 3.(Where "h" is the penetration height and "b" is the penetration width) Which of the following root heights is acceptable? 28. 1. during and after welding activities (b) Before welding activities only (c) After welding activities only (d) None of the above Incomplete root penetration in a butt joint could be caused by: (a) Excessive root face width (b) Excessive root gap size (c) Low current setting (d) Both A & C Page 9 of 8 . 3.WIS5 M3 Rev. 03/03 WELDING INSPECTION TRAINING ONLY MULTl CHOICE PAPER 3 Date: Name: Answer all questions. The BS EN code for welder approvals is: (a) BS EN 4872 (b) BS EN 499 (c) BS EN 287 (d) None of the above A Code of Practice for Visual Inspection should cover the following: (a) Before. 2. Incomplete root fusion would certainly be caused by: (a) Linear misalignment (b) Incorrect tilt angle (c) Differing root face widths (d) All of the above Which of the following tests would you normally expect a test house to use for the assessment of HAZ hardness. 5. 03/03 WIS 5M3 4. Vickers You notice a very "veed" ripple shape.Rev. for procedure approval in the UK: (a) Rockwell (b) CTOD (c) Brinell (d) 6. 7. This may indicate: (a) Poor consumable choice (b) The use of a fully automated welding process (c) Excessive travel speed (d) Both b and c "Toe Blending" is important as it may affect: (a) Toughness (b) Fatigue life (c) Penetration (d) All of the above . 11.45 (d) Low carbon steel The abbreviation PQR is otherwise known as: (a) Provisional Qualification Record (b) WPAR (c) Personnel Qualification Record (d) WQT . Slag inclusions may occur with: (a) Manual Metal arc (b) Metal Inert gas (c) Submerged arc welding (d) Both A & C Undercut may be caused by: (a) Excessive amps (b) Excessive volts (c) poor weaving technique in vertical position with MMA (d) All of the above Which of the following materials would be considered to represent the greatest problem from a weldability aspect when using SMAW: (a) Carbon Manganese with CE of 0. 10.Rev. 03/03 WIS 5M3 8. 9.28 (b) Free machining steel (c) Carbon Manganese with CE of 0. An alteration of an essential variable may: (a) Change the properties of the weld (b) Influence the visual acceptability (c) Require re-approval of a weld procedure (d) All of the above Weld samples prepared for micro examination would typically require a finish to which of the following levels: (a) 1200 grit (b) 500 grit (c) 3000 grit (d) 3 micron When visually inspecting a fillet weld. 03/03 WIS 5M3 12. 14. it would normally be "sized" by: (a) The leg lengths (b) The actual throat thickness (c) The design throat thickness (d) Both A & C Which of the following relate to the term "planar defect": (a) A lamination (b) A serious defect likely to lead to failure of the product (c) Slag inclusion (d) Both a and b Page 4 of 8 .Rev. 15. 13. Penetrant inspection and magnetic particle inspection are mainly used to: (a) Aid visual inspection (b) Because the application standard says so (c) To confirm "visual uncertancies" (d) All of the above Defects outside of the limits specified in a standard should always be: (a) Repaired (b) Reported to "a senior person" (c) Radiographed (d) All of the above When MIG welding aluminium alloy in the overhead position which current type would normally be expected to be used: (a) AC (b) DC negative (c) Drooping (d) DC positive Manual metal arc electrodes can be grouped into three main types. These are: (a) Basic. agglomerated and basic .Rev. 19. cellulosic and neutral (d) Fused. 03/03 WIS 5M3 16. 18. cellulosic and rutile (c) Basic. cellulosic and rutile (b) Neutral. 17. Gas poor 1.Rev. 22.5mm 0 Cracks in welds may be due to: (a) Solidification problems (b) Hydrogen problems (c) Excessive stresses (d) All of the above Welding a single V butt with laminations showing on the sidewall may give rise to: (a) Lamellar tearing (b) Solidification cracking (c) Martensite (d) Undercut With reference to a root penetration bead. 23. 03/03 WIS5 M3 20. you could certainly assess: (a) Root fusion and penetration (b) Toe blend (c) Overlap (d) All of the above . Which of the following defects would normally be considered to be not detectable by Radiography: (a) 2 mm deep/4mm long centreline cracking in weld root (b) 200 mm long Lamination (c) 10 mm deep lack of sidewall fusion on a single U butt (d) 21. Rev. 03/03 WIS 5M3 24. 25. 26. 27. A welded product has failed in service. This has been confirmed as being caused by material overload due to a design fault. What would you expect the appearance of the fracture surface to be? (a) Rough and torn (b) Flat and crystalline (c) Flat and very smooth (d) Showing beach marks "Stray arcing" may be regarded as a serious defect. This is because: (a) It may reduce the thickness dimension of a component (b) It may cause liquation cracks (c) It may cause hard zones (d) All of the above Overlap in welds is : (a) A non planar defect (b) Where the 2 plates to be joined are overlapping (c) Lack of fusion defect found in the root or cap region (d) Another name for linear misalignment Flame cut edges would normally be required to be ground back to a distance specified in a procedure because: (a) If the HAZ is left on the prep it may result in weld decay In service (b) The HAZ would have become sensitised (c) There is a strong potential for hardening in this region (d) To reduce weight loading on the completed structure WIS 5M3 28. M Page 8 of 8 acroscopic examination requires any specimen to be inspected: 29. (a) Once, after etching (b) During preparation and after etching (c) Using a microscope (d) By penetrant inspection Which of the following may be classed as a "more serious defect": (a) (b) Fusion defects (interun) (c) Fusion defects (surface) (d) 30. Slag inclusions Porosity A code of practice is: (a) A standard for workmanship only (b) A set of rules for manufacturing a specific product (c) Levels of acceptability of a weldment (d) None of the above Page 7 of 8 Rev. 03/03 WIS 5 M4 WELDING INSPECTION TRAINING ONLY MULTI CHOICE PAPER 4 20 questions total Date: Name: Answer all questions. 1. Which of the following would be a typical MAG, individual pass, heat input (a) (b) (c) (d) 2. The term "Skip" refers to what in welding/fabrication terms ? (a) (b) (c) (d) 3. A production scheduling term A secure location for quarantined goods An Australian marsupial A run sequence A prod may be used for which NOT process (a) (b) (c) (d) 4. 1.2 j/mm 65 kj/mm 6.5 kj/mm 1.2 kj/mm Eddy current Radiography Ultrasonic testing. Magnetic particle inspection Which of the following is a typical electrode classified as E7016 according to AWS5.1 (a) (b) (c) (d) Page 9 of4 Iron powder electrodes Rutile electrode Cellulosic electrode Basic electrode WIS5 M4 5. During TIG welding the arc voltage is controlled by: a. b. c. d. 6. Which one of the following statements is correct: (a) (b) (c) (d) 7. SMAW may use either AC or DC GTAW may use either AC or DC SAW may use both AC and DC All of the above Suckback is a commonly slang term used to describe: (a) (b) (c) (d) B. The welder The voltage control on the power source The power source giving out a constant voltage The electrode polarity Lack of penetration Root concavity Underfill Incomplete root penetration A typical temperature specifically for hydrogen removal for a carbon manganese weldment is: (a) 150°C (b) 600°C (c) 350°C (d) goo0c 9. A typical angle of bevel used for MAG welding 12mm carbon steel could be: (a) 120° (b) 35° (c) 70° (d) goo 10. In arc welding processes, excess weld metal profile is mostly affected by: (a). (b). (c). (d). Arc length Open circuit voltage Amperage Root gap "Autogenous welding" basically means: (a) (b) (c) (d) 12. _ (b) b. According to ISO 2553 which of the following symbols represents a permanent backing strip:- (a) a. Fully automated process Fusion welding Fully mechanised process Welding without filler wire Gamma Cobalt 60 Thorium Iridium 192 Which submerged arc flux may be described as "powdery" or "ball like"? (a) (b) (c) (d) Page 11 of 4 Basic Fused Agglomerated Acid .WIS 5 M4 11. _ (d) 13. None of the above d. _ (c) c. _ Which of the following radioactive terms do we not normally associate with NOT (a) (b) (c) (d) 14. For which of the following stages would you consider your closest scrutiny to be required? (a) (b) (c) (d) 19.I WlS 5 M4 15. Current Travel speed Arc length lnterpass temperature You are the only welding inspector overseeing 4 welding stations. Concave Convex Mitre Not able to be determined MMA using basic type electrodes SAW using correctly treated flux Electron Beam MIG Which of the following tests would you normally not expect to be performed during a welder approval test? (a) (b) (c) (d) Bend Nick break Macro Tensile . The weld profile is: (a) (b) (c) (d) 16. Completion of capping run Cleaning of completed weld Radiography Root pass deposition Which of the following processes would be potentially most capable of producing weldments that are low in H2 (a) (b) (c) (d) 20. producing circumferential single V butt welds on a pipeline. During visual inspection of a fillet weld with even leg lengths of 15mm and a throat measurement of 9mm . Which of these statements relating to carbon steels is false : (a) (b) (c) (d) 17. A cross section is not available. High heat input results in high hardness High heat input may result in large grains Loss of toughness may result from weaving Toughness may be restored by normalising Which of the following parameters presents the welding inspector with the greatest difficulty to monitor during fully manual welding operations? (a) (b) (c) (d) 18.
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