WELDING INSPECTION, STEEL WIS 5

MULTI CHOICE QUESTION PAPER ( MSR WI 4)

Answer all question

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 gages
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. Minimize 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 NDT methods can only detect surface breaking defects?
a. MPI
b. DPI
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 the 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
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 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 line 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. Min post weld heat treatment applied to a weld
b. Min stress relief tem
c. The lowest tem to be used during preheat
d. The lowest tem 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 NDT methods would be the least effective on an austenitic steel butt weld
a. UT
b. RT
c. DPI
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 time
c. It depends on the welder
d. It depends on the specification requirements
18. The usual method of assessing the sensitivity and density of a radiograph is by mean
a. Densitometer and dosimeter
b. Penetrameter and a densitometer
c. IQI and a dosimeter
d. IQI and fluxmeter
19. In the submerged arc welding process, the use of excessive high voltages would result in?
a. Insufficient flux melting
b. Excessive flux melting
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 c. Slag removal difficulties
d. Excessive spatter
20. Which of the following welding process uses a resistive heating system to achieve weld metal
deposition
a. NMA
b. Resistant spot welding
c. Electro-slag
d. Friction welding
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. What does the 70 represent on an E70 10 AWS A5.1 classified electrode?
a. 70 n//mm2 min UTS
b. 70 joules min impact strength
c. 70,000 P.S.I min yield strength
d. 70,000 PSI min UTS
23. Basic electrode provided in a standard packaging
a. Should be baked as to manufactures recommendations prior to used.
b. The backing 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 position
24. 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, hydrogen contents>15 ml per 100g of weld metal deposited
and should be never baked
c. Large volumes of shielding gas, high spatter contents and hydrogen levels < 15 ml per 100g of
weld metal deposited
d. High spatter contents ,high deposition and large volumes of gas shield
25. From the following electrode coding E50 4 B 160 20 H5, the compulsory part is:
a. E50 4 b 160 20 h5
b. B 160 20 h5
c. E50 4 B
d. None of the above

26. Which of the following is applicable to electrode efficiency?

a. The mass of metal deposited as a percentage of the mass core wire melted
b. Iron powder electrodes have efficiencies above 100%
c. Electrodes of high efficiencies tend to procedure welds of a smooth flat profile
d. Both a and b
e. All of the above
27. A fatigue cracks fracture surface is:
a. Rough randomly torn
b. Smooth
c. Step like appearance
d. Bright crystalline
28. E6014 electrode would most probably used for welding
a. Low pressure pipework
b. High- pressure pipework
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 c. Vertical down welding on storage tanks
d. In a situation where low hydrogen welds are specified
29. Which element in steel if present in significant amounts may lead to hot shortness
a. Phosphorus
b. Manganese
c. Silicon
d. Sulphur

MULTI CHOICE END OF COURSE ASSESSMENT

QUESTION PAPER (MSR-AWI-1)

1. What is the ratio between the 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 center
c. The distance from the root to the toe
d. The distance from the 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 cause 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. Phosphorus
c. Silicon
d. Copper
8. A black triangular flag used in conjunction with a weld symbol as to en 22553 means:
a. 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)
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 d. The weld must be subjected to NDT
9. Austenitic stainless steel can be ready 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 tem from 50oc to 150oc
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 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 inclusions and excessive cap heights
b. Excessive root penetration and porosity
c. Slag inclusions and crater pipe
d. Lack of fusion and poor cap profiles
13. It is a requirement to excavate a crack in a welded component; the defect is at least 25 mm 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
14. 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
15. 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
16. A welding process where the welding plant controls the travel speed and arc gap, but under the
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 mechanized MIG process
d. a mechanized MAG process
17. The purpose of normalizing steel
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 a. To modify the grain structure by making it more uniform on order to improve mechanical
properties
b. To soften a material for extensive machining
c. To reduce fracture toughness
d. To reduce ductility
18. Which of the following destructive tests would show the results in joules?
a. Tensile test
b. Charpy test
c. Bend test
d. Hardness test
19. 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
20. 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
21. 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
c. Magnetic particle
d. It could not be found by any testing method
22. 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 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
25. On a single V butt weld, the distance through the center of the weld from root to face is called:
a. Reinforcement
b. Penetration
c. Throat thickness
d. None of the above
26. Which of the following flame types would you expect to be used for the cutting of mild steel?
a. Carburising flame
b. Oxidizing flame
c. Reducing flame
d. Neutral flame
27. The need for the pre-heat for steel will increase if :
a. The material thickness reduces
b. Faster welding speeds
c. The use of the larger welding electrode
d. All of the above
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28. The main reason for toe blending on certain welded steel components is :
a. Corrosion considerations
b. Fatigue life
c. Appearance
d. All of the above
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

MSR-WI-1
1. which of the following butt-weld preparations is usually the most susceptible to lack of sidewall fusion during
the metal arc process ?
a. a double-u butt
b. a single-V butt
c. a double V butt
d. it is 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 the toe to toe
3. what is the throat thickness of a fillet weld ( equal leg length ) ?
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 the toe to toe
4. lap joints contain :
a. fillet weld
b. corner joint
c. butt-weld
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 certificated
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 mean by the term crater pipe :
a. another term for concave root
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 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 mean by the term weld junction ?
a. the area containing the HAZ and the weld metal
b. the weld metal and the parent metal
c. the boundary between the fusion zone and the HAZ
d. the part of the weld, which has undergone metallurgical change due to the heat from welding
9. the strength if the 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 localized
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

12. . which of the following welds would be considered in a situation where two plate 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
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
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 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 welder
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 welder joint just outside the weld metal that has undergone micro
structural change ?
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 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 crack is 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 center 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. 27.5mm
b. 24mm
c. 13.5mm
d. 12.5mm
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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

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 tem 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 applied 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. tenstile
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
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 c. elongation
d. penetration
7. which of the following steel types would give rise to the formation of porosity when autogenously weld 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, tem above 200 oC and a slow cooling rate
c. hydrogen, a grain structure susceptible to cracking, strees and a tem below 200oC .
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 100oc.
b. is generally significant for carbon for manganese steels and is certainly not to be taken into
consideration for preheat tem.
c. Is high for carbon manganese steels and may require a preheat tem over 300oc as to avoid
cracking
d. Is calculated from the heat input formula.
e. 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 interpass tem ?
a. min post weld heat treatment applied to a weld
b. min stress relief tem
c. the lowest tem allowed during welding and between weld passes
d. the lowest tem to be used during preheat
14. which of the following heat treatments on steel cools down in air from the austenite region ?
a. normalizing
b. annealing
c. tempering
d. stress relieving
15. what is the purpose of microscopic exam 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
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 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 tem
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 tem to be increase ?
a. an increase in travel speed
b. a reduction in a 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 value in excess of 400 HV
c. a very tough and a 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 steel
c. martensitic stainless steel
d. forging steel
22. which of the following NDT method 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 mechanized 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 2.0mm
c. single-U butt backing
d. none of the above can be used for mechanized 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. 2.16kj/mm
b. 0.036 kj/mm
c. 2160kj/mm
d. 3.6kj/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 tenstile strength material
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 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 multipass MMA butt weld made on a 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 a grain refinement
b. a lower heat input and a coarse grain structure
c. a lower amount of distortion and a higher degree of a grain refinement
d. a higher amount of distortion and a lower degree of a 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 weld ability
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.

MCQ 001
A1. 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
2. you would certainly recognize a hydrogen controlled flux covered electrode from its :
a. colour
b. length
c. trade name
e. AWS/BS639 code letter
3. 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
f. pipe welding team
b. plater welders
c. plant maintenance welders
4. 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
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 b. the wire would be too thick
g. the weld metal composition may be wrong
c. the wire is too short
5. 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
h. electrode storage
c. day tem
6. 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 incident of :
a. porosity
i. cracking in the weld area
b. undercut for fillet welds
c. lack of root fusion defects

7. one of the following alloys is non magnetic. Which

a. 4.0% chromium molybdenum
b. 12.0% chromium
j. austenitic stainless steel
c. 9.0% nickel steel
8. when the TIG welding austenitic stainless steel pipe, argon gas backing is called for. This is to :
k. prevent oxidation
a. prevent under bead cracking
b. prevent porosity
c. control the penetration bead shape
9. pre-heating the carbon steel manual metal arc welding is carried out to minimize the risk of :
a. scattered porosity
b. worm hole porosity
l. parent metal cracking
c. lack of penetration
10. in UK practice, BS499 Part 2 specifies that the drawing dimension quoted for a fillet weld is the ;
m. leg length
a. actual throat thickness
b. weld width
11. for open site manual welding the following equipment is available. Which would you choose for safe
working ?
a. single operator transformer
b. multi operator transformer
c. AC/DC composite power unit
n. Diesel engine driven motor generator
12. if submerged arc welding is to be used to make butt welds, which would you most critical of :
o. the root gap tolerance
a. the angle of preparation
b. the root face width
c. the gas cut finish
13. during CO2 welding, the arc length is most likely to be affected by :
a. the wire diameter
p. the current return connections
b. the gas flow rate
c. the torch to work angle
14. pre-heating for arc welding applies to :
a. assembly welding only
q. assembly and tack welding
14
 b. joints over 25mm thick only
c. cruciform welds only
15. 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.
r. the weld could be hard and brittle
a. the weld metal could be too soft
b. there will be no effect on the weld
c. the weld will have undercut

16. a welder qualification test is to verify

s. the skill of the welder
a. the quality of the materials
b. the non-destructive test procedures
c. the manufacturing methods
17 a fabricating procedure calls for fillet welds to be blended in by grinding. This is to influence :
a. HAZ cracking
t. Fatigue life
b. Residual stress
c. Yield strength
18. bend test specimens have been taken from a 25mm thick carbon steel butt weld. Which would show lack of
inter-run fusion :
u. side bend
a. root bend
b. face bend
c. guided bend
19. lamellar tearing has occurred in a steel fabrication. BEFORE welding could it have been found by :
a. X-ray exam
b. Dye penetrant
c. Ultrasonic inspection
v. It would not have been found by any inspection method
20. you are to oversee the arc welding of some machined fittings and find they are cadmium plated. Would you
:
a. permit to proceed
b. permit to proce4ed with fume extraction
w. stop the operation at once
c. advise the welder to drink milk and proceed

MCQ 004
1. Movement of the arc by magnetic forces in MMA welding is termed :
a. arc deviation
b. arc misalignment
x. arc blow
c. arc eye
2. a metallurgical problem most associated with submerged arc welding is :
a. hydrogen cracking in the HAZ
y. solidification cracking in the weld metal
b. hydrogen cracking in the weld metal
c. lamellar tearing in the weld metal
3. oxy pressure and nozzle size would influence what in flame cutting :
a. the tem require for cut initiation
b. the ability to cut stainless steels
z. the depth of cut obtainable
c. none of the above
4. the main usage of arc cutting/gouging processes is in :
15
 a. the cutting of single bevel preparations
aa. the removal of deposited welds
b. the cutting of single U-type preparations
c. the cutting/gouging of none-ferrous materials only
5. which of the following processes joints metals plastically
bb. friction welding
a. resistance welding
b. plasma welding
c. all of the above
6. which electrode classification would be relevant to AWS A5.1-81 :
cc. E 6013
a. E 5133
b. E 7018 G
c. Fleet weld 5
7. which of the following coatings is associated with stove welding
a. rutile
b. cellulosic
c. basic
d. 0xidising
8. a common gas/mixture used in MIG welding nickel alloys to combine good levels of penetration with good
arc stability would be :
dd. 100% CO2
a. 100% argon
b. 80% argon 20%CO2
ee. 98% argon 2% oxygen
9. the type of SAW flux is more resistant to moisture absorbtion:
a. fused
b. agglomerated
c. basic
d. all of above the same resistance
10. the flame tem of oxy/acetylene mixture gas is given as :
a. 3200oc
b. 2300oc
c. 5000oc
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 tem 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 steel
b. stainless steels
c. micro alloyed steels (HLSA)
16
 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. consumable 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 inclusion 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. normalizing
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. inter granular corrosion
d. stress corrosion cracking

MCQ 003
1. the British code for Visual Inspection Requirements is :
a. BS 4872
b. BS 499
c. BS 4870
d. None of the above
2. a code of practice for visual inspection should cover the following
a. before, during and after welding activities
b. before welding activities only
c. after welding activities only
d. none of the above
3. 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 and c
4. incomplete root fusion would certainly be caused by
a. linear misalignment
b. incorrect tilt angle
17
 c. differing root face widths
d. all of the above
5. when visually inspecting a completed single vee butt weld cap you would certainly assess
a. cap height
b. toe blend
c. weld width
d. a, b and c
6. you notice a very veed ripple shape. This is most likely caused by :
a. poor consumable choice
b. welding position
c. excessive travel speed
d. all of the above
7. toe blending is important as it may affect
a. corrosion
b. fatigue life
c. overlap type defects
d. all of the above
8. slag inclusions would occur with
a. manual metal arc
b. metal inert gas
c. submerged arc welding
d. both a and c
9. undercut is principally caused by
a. excessive amps
b. excessive volts
c. excessive travel speed
d. all of the above
10. undercut is normally assessed by
a. its depth
b. its length
c. its blending
d. all of the above
11. a welding procedure is useful to :
a. give information to the welder
b. give information to the inspector
c. give confidence to a product
d. all of the above
12. an essential variable may :
a. 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
13. a magnifying glass may be used during visual inspection but BS 5289 states that its magnification should
be :
a. up to 5
b. 2-2.5
c. 5-10
d. none of the above
14. when visually inspecting a fillet weld, it would normally be sized by :
a. the leg length
b. the actual throat thickness
c. the design throat thickness
d. both a and c
15. a planar defect is
18
 a. incomplete fusion defects
b. slag inclusion
c. incomplete penetration
d. both a and c
16. penetrate inspection and magnetic particle inspection are mainly used to
a. aid visual inspection
b. because the application standard says so
c. to confirm visual uncertainties
d. all of the above
17. defects outside of the limits specified in a standard should always be :
a. repaired
b. reported to a senior person
c. assessed along with other defects
d. all of the above
18. MIG welding tends to be susceptible to lack of fusion problems. This is because of :
a. poor maintenance of equipment
b. incorrect settings
c. poor interun cleaning
d. all of the above
19. manual metal arc electrodes can be grouped into three main types. These are
a. basic cellulocis and rutile
b. neutral cellulosic and rutile
c. basic cellulosic and neutral
d. none of the above
20. ther main causes of porosity in welded joints are
a. poor access
b. loss of gas shield
c. dirty materials
d. all of the above
21. cracks in welds may be due to
a. solidification problems
b. hydrogen problems
c. excessive stresses
d. all of the above
22. a weave technique may give rise to
a. better profiles
b. improved toe blending
c. improved ripple shape
d. all of the above
23. with reference to a root penetration bead, you could certainly assess
a. root fusion and penetration
b. root concavity
c. burn through
d. all of the above
24. a fatigue failure is characteristic by the appearance of the fracture surface. It would be :
a. rough and torn
b. chevron like
c. smooth
d. none of the above
25. 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
19
26. overlap in welds could be influenced by
a. poor welding technique
b. welding process
c. welding position
d. all of the above
27. flame cut preparations may, during welding, increase the likelihood of
a. cracking
b. misalignment problems
c. inclusions
d. all of the above
28. macroscopic exam requires any specimen to be inspected
a. once, after etching
b. twice, before and after etching
c. using a microscope
d. none of the above
29. which of the following may be classed as a more serious defect
a. slag inclusions
b. fusion defects (interun)
c. fusion defects (surface )
d. porosity
30. 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

END OF COURSE MULTI CHOICE PAPER (MCQ.002)

1.
2.
3. What two functions in arc welding must be in equilibrium to enable a stable arc to be established?
a. Arc voltage
b. Current
c. Wire-electrode feed rate
d. Metal burn- off rate
4. In MMA welding, what parameter is used for the control of penetration into the base material
a. Voltage
b. Welding speed
c. Iron powders in coating
d. Current
5. In the welding of a butt joint made from one side, which of the following controls the profile of the root bead?
a. Root face
b. Bevel angle
c. Root gap
d. None of the above
6. What type of power source characteristic is require for manual welding?
a. Constant voltage
b. Flat characteristic
c. Drooping characteristic
d. Motor generator
7. Which one of the following destructive tests wo8ld indicated the toughness of weld metal HAZ
a. Marco
b. Nick break
c. Hardness
20
 d. Charpy Vee Notch

8. Degreasing components are essential for quality welding but some agents may
a. Cause corrosion problem
b. Give off phosgene gas
c. Leave residues
d. All of the above
9. Which of the following chemical elements has the greater effect on the harden ability of a steel plate/
a. Molybdenum
b. Chromium
c. Titanium
d. Carbon
10. In mag/co2 welding, which parameters give the greatest control of weld appearance during dip transfer or
short circuiting welding?
a. Wire stick-out length
b. Amperage
c. Wire feed speed
d. Inductance
11. In MMA welding, the slag produced can be varied to suit the welding position; which type of slag would be
required for welding in the HV position?
a. Fluid
b. Viscous
c. None of the above
d. Semi fluid
12. The weld metal deposit of manual metal arc electrodes achieves its mechanical strength through?
a. The core wire
b. The flux coating
c. Iron powders with the flux coating
13. What constituent is needed in a coating of an electrode to prevent the formation of porosity in welding of a
rimming steel?
a. Iron powders
b. Calcium fluoride
c. Silicon
d. Calcium carbonate
14. Welds made with high heat inputs show a reduction in one of the following properties?
a. Ductility
b. Toughness
c. Fatigue strength
d. Mechanical strength
15. In the welding of austenitic pipe work, the bore is usually purged with Argon to ?
a. Prevent formation of porosity in the weld
b. Prevent burn-through in the root run
c. Prevent oxidation of the root beat
d. Eliminate the formation of H2
16. In x-ray work, the quality of the radiographic negative is assessed by the ?
a. Density of the film
b. IQI indicator
c. KVA available
d. Stand-off distance
17. A steel described as qt will have improved tensile properties because it has?
a. Had control of chemical composition
b. Been heat-treated
c. Been quality tested
21
 d. Been vacuum melted
18. Which one of the following type of steels would give rise to the formation of porosity when autogenously
welded with an arc process?
a. Fully killed steel
b. Semi killed steel
c. Rimming steel
d. Fine grained steel
19. In submerged arc welding, the use of excessively high voltage would result in?
a. Insufficient flux melting
b. Excessive flux melting
c. Slag removal difficulties
d. Spatter
20. The use of cellulose electrodes is often made when welding the root pass of pipes in the field. This is
because?
a. Hydrogen control is needed
b. Iron powders in the electrode
d. Higher arc voltage can be obtained
e. Shorter arc length can be achieved
21. In the welding of austenitic stainless steels, the electrode and the plate material can be purchased with low
carbon contents. The season for this is to prevent?
a. Cracking the HAZ
b. The formation of chromium carbides
c. Cracking the weld metal
d. Distortion

22. Submerged arc fluxes can be supplied in two forms; these are?
a. Sintered and agitated
b. Agitated and fused
c. Crushed and agglomerated
d. Fused and agglomerated
23. In the steel which has improved creep properties at elevated tem, which one of the following elements
helps in this improvement?
a. Tungsten
b. Manganese
c. Molybdenum
d. Carbon
24.Welding a steel plate of a CE of .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 improve mechanical properties in the weld
25. Which of the following processes uses the KEYHOLING system of fusion?
a. Friction welding
b. Diffusion bonding
c. Electron beam welding
d. Autogenously TIG welding
26. In friction welding, is the metal at the interface in the?
a. liquid state
b. Solid state
c. Plastic state
d. Elastic state
27. Welding procedures may require welds to be deposited at a controlled rate heat input. High heat input
would?
22
 a. Have poor profile
b. Have larger grain size
c. Have high hardness in the HAZ
d. Have low elongation properties
28. In a tensile test, a brittle material would be indicated if the fracture surface?
a. Shows a reduction in size
b. Is flat and featureless
c. Breaks in the weld metal
d. Breaks in the parent metal
29. What destructive test would be required to ascertain the likelihood of cracking in the HAZ of a weld?
a. Nick break
b. Side bend test
c. Charpy impact
d. Marco test
30. In submerged arc welding, excessive arc voltage may cause?
a. Excessive penetration
b. Change in weld metal composition
c. Narrow weld width
d. Excessive bead profile

WELDING INSPECTION, STEELS- WIS 5

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 NDT
d. all of the above
2. electrodes used in manual metal arc welding can be grouped in to three main types, these are :
a. oxidizing, 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 joints 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
23
 b. flat characteristic
c. drooping characteristic
d. none of the above
7. which of the following electrodes and current type 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 toughness, 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 center 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 patter in the dip transfer mode
b. it enables the welder to weld in position with the spray transfer mode
c. it allow for thicker fillet wires to be used ( 2.6-3.6 mm diameter )
d. it allow full control over droplet size in the spray transfer mode
14. an undesirable property of aluminum oxide residue, when welding is that it :
a. decrease weld pool fluidity
b. require more heat to melt it when compared to aluminum
c. cause the welder to travel to quickly
d. the presence of the oxide makes aluminum 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. GMAW
d. Submerged arc welding
16. when considering the tungsten arc welding process what is the purpose of the down-slope (slope-out )
control
a. ensure good penetration
24
 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 local 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
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 give the same depth in penetration
19. in 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 require 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 aluminum with the TIG
welding process
a. DC ve
b. DC+ ve
c. AC
d. All of the above
22. . which of the following statement 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 carbon steel butt weld :
a. must always to carried out
b. is always carried out using a gas flame
c. need not be carried out if post weld heat treatment if 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
25
 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 semi-automatic welding process ?
a. the welder is responsible for the maintaining the arc gap and travel speed
b. the welder is responsible for travel speed only; arc gap is kept constant by the welding plant
c. both travel speed and arc gap is controlled by the welding plate
d. all of the above
28. what is purpose of a rectifier in a welding sates 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 mechanized MAG welding plant, which of the following applies (WSF = 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 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

FINAL ASSESMENT MULTIPLE-CHOICE QUESTION

CSWIP 3.1 WELDING INSPECTOR COURSE
Mfy- 001
ALL THE QUESTIONS TO BE ATTEMPTED
EXAM TIME : 30 MINUTES

1.which of the following does not contribute to hydrogen cracking :

a. external forces on the weldment
c. amount of hydrogen in the weld
d. residual stresses in the weld
e. size and length of linear discontinuities

2. for the arc air carbon cutting process the air is

a. Use for cooling the electrode only
c. produced through the chemical reaction of the electrode and the base metal
d. supplied through air ports in the electrode holder and directed along the electrode
e. supplied by another torch also by other operator
3. acetylene hoses are distinctly difference from oxygen hoses. Why ?
a. because the internal diameters of the two are different.
b. because of operating pressure differences between fuel gas and oxygen
c. acetylene attacks the materials used in oxygen hoses
26
 d. to prevent accidental interchange
4. which of the following can result in a hard and brittle condition resulting from rapid cooling
a. arc strikes
b. excessive weld reinforcement
d. excessive spatter
e. slag inclusion
5. DC negative when use for MIG/ MAG can give the smooth arc
a. true
b. false
6. in which of the following process is the use of pressure required to successfully joint the materials:
a. TIG
b. MMA
c. SAW
d. Stud welding
7. which of the following will contribute significantly to lack of fusion
a. incorrect joint design
b. incorrect welding technique
c. heavy scale on the joint surface
d. all of the above
8. which of the following process used loose granular flux
a. FCAW
b. SAW
c. GTAW
d. SMAW
9. Crack Tip Open Displacement test is used to measure
a. strength of the material being tested
b. hardness of the material
c. the toughness of the materials, resistance to crack extension and the acceptable flaw size all
d. ductility of the material being tested
10. The pulsed MIG/MAG mode of transfer is a variation of a spray transfer mode that make used of a low
background current with a higher, rapidly pulsing current superimposed on it
a. false
b. true
11. the iron carbon diagram is used by metallurgists and other to see how
a. adding nickel changes the corrosion resistance of steels
b. adding carbon changes the response of the steel tem changes
c. adding molybdenum increases the toughness of steel
d. adding chromium improve corrosive resistance
12. the main purpose of a developer is to :
a. assist in the development of the test procedure
b. provide a clean surface for the penetrate indication
c. assist in the development of the penetrate indication from a defect
d. assist in the drying of the penetrate
13. overlap in a fillet weld would occur:
a. at some point in the weld throat
b. only on the face of the weld
d. at the toe of the weld
e. at the root of the weld
14. in the TIG welding process, gas shielding of the weld pool maybe provided by which gas.
a. carbon dioxide
b. argon and oxygen
d. argon and helium
e. oxygen and helium
15. welding flux :
27
 a. helps on control the tem of the pieces being welded
b. crates a temporary bond between the pieces being welded
d. protects from the atmosphere and removes the oxide film on the surface
c. makes it easier to move the electrode
16. increasing the carbon content of steel allows a given level of hardness to be achieved :
a. at a higher cooling rate
b. without consideration of the cooling rate
c. without adding chromium to the steel
d. at a lower cooling rate
17. which is not a factor that should be considered in selecting the best shielding gas mixture for a given
application :
a. weld appearance and acceptable spatter level
b. thickness joint design and penetration requirements
c. the welders personal requirement
d. transfer mode
18. which of the following is not considered to be cause of incomplete fusion
a. welding current exceeding that specified on a WPS
b. using too large an electrode for a narrow Vee
c. improper manipulation of the electrode
d. using the wrong type of electrode
19. which is an advantage of an argon/ hydrogen gas mixture in TIG of stainless steel
a. lower heat input
b. improved toughness
c. faster travel speed
d. improved mechanical properties
20. some MMA electrodes for the welding of stainless steel have a low carbon steel core wire and the alloying
elements in the covering. This is because :
a. the core wire offer lower resistance to the passage of the welding current
b. the manufacturer can more conveniently include alloying elements in the covering than produce
special core wires
c. both for reason a and b above
d. for some reason not listed above
21. sulphur is sometimes added to steel to improve
a. the impact properties of the welded joint
b. provide higher impurities levels
c. toughness of the parent materials
d. machining properties characteristics of the steel
22. slow cooling of liquid metal from high tem promotes the growth of
a. medium grains
b. large grains
c. small grains
d. a combinations of large and small grain
23. a defect can best be described as ;
a. all type of flaw in a weld regardless of size
b. meaning exactly the same thing as a discontinuity
c. any type of weld flaw
d. a discontinuity judged to possibility interfere with the fit for purpose of the weld

24. ACC ( Drooping arc ) power source is suitable for

a. MMA-TIG
b. MIG/MAG FCAW welding process
c. SAW MIG/MAG
d. MMA MIG/MAG
25. In Gas Metal Arc Welding ( GMAW ) , spray Transfer may be achieved using shielding gases containing
28
 a. more than 85% argon
b. less than 50% argon
c. 100% carbon dioxide
d. less than 75% argon
26. when welding with a weave technique the heat input using the same welding parameters( amps and volts )
as those used for stringer bead will be
a. lower than that for the stringer bead
b. unaffected because techniques has no influence on the heat input
c. will the higher than the stringer bead because the travel speed wiil be lower
d. the same as that for the stringer bead
27. welding in cold weather conditions is mostly commonly associated with increased risk of
a. undercut
b. porosity
c. slag inclusion
d. cracking
28. hydrogen trapped in the weldment can cause hydrogen cracking if the contents of hydrogen are too high.
What is the other name commonly used to describe hydrogen cracking?
a. fissure cracks
b. hot cracks
c. supercritical cracks
d. cold cracks
29. steel is often heat treated after it is made at the steel mill. When a steel is normalized what is the primary
objective of this process ?
a. to increase the hardness
b. to decrease the amount of carbon in the steel
c. to increase the low tem toughness of a steel
d. to improve the tensile strength
30. travel speed is the rate at which the welding gun progress along the joint. As the travel speed increases :
a. the penetration is increased
b. the heat input into the joint decreased and the penetration is decreased
c. the penetration is decreased and the weld bead becomes higher and wider
d. the heat input into the joint is increased
31. the recommended drying tem and time required producing a condition below 5 ml H2/100 grams of weld
metal when using basic electrodes would be :
a. below 150oc for 1 hour
b. 250oc for 1 hour
c. over 350c for 1 hour
d. 600c for 1 hour

MFY OO2

1. Why is the generally good practice to aim at using the least amount of consumable materials and keep joint
preparations to a minimum?
a. to increase beneficial residual stresses
b. improved strength
c. smaller welds generally look better
d. to reduce costs and with less weld matel there is the prop ability of fewer weld faults
2. in general, the MIG/MAG mode of transfer best suited for the welding thin sheet is :
a. short- circuiting transfer
b. globular transfer
c. spray transfer
d. should not use MIG?MAG for welding thin sheet
3. in general. The MIG/MAG mode transfer best suited for welding thin sheet is dip transfer
29
 a. true
b. false
4. which of the following maybe difficult to detect with the radiographic inspection method?
a. incomplete penetration
b. discontinuities pendicular to the radiation beam
c. slag inclusion
d. porosity
5. The pulsed MIG/MAG process is only suitable for welding in the flat position
a. True
b. False

6. When using Gas Metal Arc Welding ( GMAW ) process, straight argon may be successfully used as a
shielded gas when welding the following
a. steel or aluminum
b. Aluminum
c. Straight argon is never used
d. Steel
7. The primary advantage of a 75% Ar,25% co2 gas mixture over pure co2 in the FCAW process is :
a. increase in welding speeds
b. very significant reduction in weld spatter
c. increase the heat input
d. decrease in welding speeds
8. A cause of inadequate penetration could :
a. Incorrect joint preparation
b. Incorrect joint design
c. Incorrect welding technique
d. All of the answer provided are possible cause
9. which of the following is not a method of increasing the hardness of a steel ?
a. heat treatment
b. casting
c. mechanical deformation
d. introducing alloying elements
10. welding changes the properties of solid steel through ;
a. mechanical changes caused by rolling
b. changing the final appearance of the steel
c. heating and cooling cycles associated with the welding arc and weld metal deposit
d. metallurgical effects as a results of micrographs
11. tension test results are used :
a. soundness of the materials being tested
b. to select material for engineering applications
c. fracture toughness of the materials being tested
d. fatigue capability of the material being tested
12. which of the following may contribute to the formation of porosity in the weld deposit :
a. all of the answer provided is a contributing factor
b. low welding current
c. contamination of the weld joint surfaces
d. use of contaminated electrodes

13. When using the GMAW process for the welding of aluminium, the liner should made of :
a. Nylon
b. Graphite
c. Steel
30
 d. A liner should not be used
14. When preparing bend test specimens it is important to :
a. use a proper etching
b. prevent stress raisers by radius all edges of the specimen
c. ensure the reduced section is of the correct dimensions
d. accurately place the notch in the correct position
15. steels that have intentional additions of sulphur, lead or selenium to improve machine ability :
a. can develop liquation crack in the HAZ after being welded
b. are used for trucks axles only
c. do not require approved procedures to be welded
d. can not be welded
16.
Ticking by Mr. Duong (response and explain by Green Word)
QA/QC POS

SPECIMEN WRITTEN EXAMINATION QUESTIONS

CSWIP 3.1

1.1 Part A and Part A2

Candidates are required to tick, or otherwise indicate, the corrective answer in the section provided.
There is only one correct answer for each question.
18-5-2012
1 Applying preheat when welding carbon manganese steel is normally done to avoid:
a) Slag inclusions (not related to preheat, main cause of slag inclusion is insufficient
cleaning between passes, contaminated weld preparationR)
b) Hydrogen cracking (with steels, carbon equivalent is high hence needing preheat to
prevent hydrogen cracking)
c) Lack of sidewall fusion (not concerned any more)
d) Porosity (moisture in preparation before welding is cause porosity happening, so before
welding preheat also prevents to reduce porosity but it is not enough to say is main
answer)

2 Which of following mechanical properties of a weld in carbon manganese steel is most affected
if the heat input per unit length of weld is excessively high?

a) Elongation
b) Tensile strength
c) Hardness
d) Toughness
No explain for this question, the response is by experienced.
3 You observe centerline cracking a weld that as been made one of five work stations each
making similar components. The first action to take is:

a) Impound (tch thu) all welding consumables ( this is not responsibility of welding
inspector)
b) Report the occurrence to high authority
c) Stop all welding
d) Call for full NDT checks

4 Which of the following defects is unlikely to be found by visual inspection?

a) Linear misalignment
b) Undercut
c) Overlap
31
 d) Linear slag inclusion (inside weld)

5 Which of the following welding processes uses a resistive heating system to achieve weld metal
deposition?

a) Manual metal arc welding

b) Submerged-arc welding
c) Electro slag welding (Welding is achieved by resistance heating a molten conductive
slag to a sufficiently high temperature to melt the electrode, consumable guide, and
faying surfaces of the base metal)
d) Resistance spot welding
6 Which of the following units could Charpy V notch energy be measured in?

a) Pounds per square inch

b) Joules
c) Newtons per square millimeter
d) None of the above

7 The usual method of assessing the sensitivity of radiograph is by means of a:

a) Dosimeter
b) Fluoroscope
c) IQI ( Penetrameter)
d) Clinometer

8 Under normal contract conditions, weld procedure approval tests for pipe work are:

a) Mandatory
b) Depend upon site and weather conditions
c) Dependent upon the contractors confidence in his procedures
d) Only required when CO2 welding is to be used.

9 Which of the following destructive tests is not normally required for welder approval test for mild
steel?

a) Bend test (
b) Macro examination
c) Impact tests
d) Fracture tests

10 Hydrogen controlled electrodes were developed principally (ch yu) for:

a) The prevention of porosity

b) The prevention of cracking
c) The enhancement (s tng) of arc voltage
d) Their ease of arc starting

11 For which of the following is pre-heating most likely to be required?

a) Austenitic stainless steels

b) High strength alloy steels
c) Low and medium strength steels ( same plain carbon steel SMTS<600MPA)
d) Low carbon steels

32
12 Manual metal arc welding of low alloy steels is more likely to be performed with:

a) Rutile electrodes
b) Cellulosic Electrodes
c) Iron powder electrodes
d) Basic hydrogen controlled electrodes

13 which of the following defects is more common to weld deposited by the CO-2 welding process
than weld deposited by manual metal arc?

a) Slag inclusion
b) Excess penetration
c) Lack of side fusion
d) Tungsten inclusions

14 Which defect would you expect to obtain in TIG welds in non-deoxidized (cha kh oxi) steel?

a) Under cut
b) Porosity
c) Tungsten inclusions
d) Linear misalignment

15 Which of the following can arise (bt ngun) from copper inclusions is a ferrite steel weld?

a) Weld metal cracks

b) HAZ cracks
c) Lamellar tearing (by deduced)
d) Porosity

16 Which of the following is likely to give the highest impact strength in ferritic weld metal?

a) Cellulosic electrodes
b) Submerged arc with acid flux (basic have better metal properties YS, CVN, UTS)
c) Spray transfer Co-2-welding (spray transfer can not use CO2)
d) Basic coated normal metal arc electrodes

17 Which of the following methods of NDT would be most likely to detect lack of side fusion in
ferritic steel welds?

a) Penetrants
b) Magnetic particles
c) Radiography
d) Ultrasonic flaw detector

18 You suspected (nghi ng) that ferritic steel plates, which have been edge, prepared contain
crack in the prepared edges. Which NDT method would you use to check this?

a) Radiography
b) Magnetic particle
c) Penetrants
d) Ultrasonic flaw detector
33
19 Which of the following defects do you not expect to find by visual examination of completed
welds?

a) Linear slag inclusions

b) Under cuts
c) Overlap
d) Linear misalignment

20 Stress relief is not helpful in one of the following cases. Which one?

a) In improving resistance to stress corrosion cracking D S

b) In dimensional stability after machining improving D S
c) In lowering the peak residual stress D S
d) In softening the steel S D

21 What is the maximum hardness usually recommended for the HAZ of a medium strength ferritic
steel weld?

a) 100 DP Hv
b) 350 DP HV (DP is ball symboy)
c) 500 DP Hv
d) 750 DP Hv

22 What effect to midthickess lamination in steel plate normally have when they are located within
a weld HAZ?

a) Cause lamellar tearing

b) Fuse together to form a bond
c) Affect the weld metal composition
d) Cause internal tearing on a micro-scale

23 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

24 You would with certainty recognize a hydrogen controlled flux covered electrode from its:

a) Color
b) Length
c) Trade name
d) AWS/BS639 Code Letter

25 When manual metal arc welding is being carried out on an open construction site, which groups
of welder are most likely to require continuous monitoring?

a) Concrete shuttering welding team

b) Pipe welders
c) Plater welders
d) Plant maintenance welders
34
26 You noticed manual metal arc welding electrodes, stripe 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

27 When open site working, serious (nghim trng) porosity in manual metal arc welding is brought
to your attention. What would you investigate?

a) Electrode type
b) Power plant type
c) Electrode storage
d) Day temperature

28 The steel composition in structural contract is changed form 0.15% carbon, 0.6% manganese,
to 0.2% carbon, 1.2% manganese. Might this influence the incidence (phm vi nh hng) of:

a) Porosity
b) Cracking in the weld area
c) Under cut for fillet welds
d) Lack of root fusion defects

29 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
30 When the TIG welding Austenitic Stainless Steel pipe. Argon gas backing is called for. This is
to:

a) Prevent oxidation
b) Prevent under bead cracking
c) Prevent porosity
d) Control the penetration bead shape

31 Pre-heating a carbon steel manual metal arc welding is carried out to minimize the risk of

a) Scattered porosity
b) Worm hole porosity
c) Parent metal cracking
d) Lack of penetration

32 IN UK practice, BS 499 Part2 specifies that the drawing dimension quoted for a fillet weld is the:

a) Leg length
b) Actual throat thickness
c) Weld width
35
33 For open site manual metal arc 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

34 If submerged welding to be used to make butt welds, which would you be most critical of:

a) The root gap tolerance

b) The angle of penetration
c) The root face width
d) The gas cut finish

35 During CO-2 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

36 Pre heating for arc welding applies to:

a) Assembly welding only

b) Assembly and tack welding
c) Joint over 25 mm thick only
d) Cruciform welds only

36 You see a welder using oxy-acetylene flame with along 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 the weld
d) The weld have under cut

37 A welder qualification test is o verify:

a) The skill of the welder

b) The quality of the materials
c) The non-destructive procedures
d) The manufacturing methods

38 A fabricating procedure calls for fillet welds to be blended in by grinding. This is to influence:

a) HAZ cracking
b) Fatigue life
c) Residual stresses
d) Yield strength

36
 39 Bend test specimens have been taken from a 25 mm 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

40 Lamellar tearing has been occurred in 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

41 You are to oversee arc welding of some machine fittings and find they are cadmium plated.
What 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

42 What two functions in arc welding must be in equilibrium to enable a stable arc to be
established?

a) Arc voltage
b) Current
c) Wire/electrode feed rate
d) Metal burn-off rate
19-5-2012

43 In MMA welding, what parameter is used for the control penetration into the base material?

a) Voltage
b) Welding speed
c) Iron powders in the coating
d) Current

44 In the welding of butt joint from one side, which of the following controls the profile of the root
bead?

a) Root Face
b) Bevel Angle
c) Root Gap
d) One of the above

45 What type of power source characteristic is required for manual welding?

a) Constant voltage
37
 b) Flat Characteristic
c) Drooping Characteristic
d) Motor Generator

46 Which of the following destructive tests would indicate the toughness of weld metal/parent metal
HAZ.

a) Macro
b) Nick break
c) Hardness
d) Charpy vee notch

47 Degreasing components are essential for quality welding but some agents may:

a) Cause corrosion Problems

b) Give off Phosgene Gas
c) Leave Residues
d) All of the Above

48 Which of the following chemical elements has the greater effect on the harden ability of a steel
plate?

a) Molybdenum
b) Chromium
c) Titanium
d) Carbon

49 In MAG/CO2 welding, which parameters give the greatest control of weld appearance during dip
transfers or short-circuiting welding?

a) Wire sick-out length

b) Amperage
c) Wire feed speed
d) Inductance

50 In MMA welding, the slag produced can be varied to suit the welding position; which type of slag
would be required for welding in the HV position?

a) Fluid
b) Viscous
c) None of the above
d) Semi fluid
Cellulosic electrode with slag fluid, de-slag is difficult, all position but prefer to vertical down, (specially for root
run), poor bead profile

Rutile electrode with viscous slag, easily removable slag, all position but suitable for welding fillet joints in the
horizontal/vertical (H/V) position, good bead profile

Basic electrode with more fluid than rutile, slag removes difficultly, all position but suitable welding in the
vertical and overhead position because of fast-freezing, more poor than bead profile cellulosic

51 The weld metal deposits of manual metal arc electrode achieves its mechanical strength
through?

38
 a) The core wire
b) The flux coating
c) Iron powder with the flux coating

Iron powder electrodes are mainly used in the flat and H/V positions to take advantage of the higher deposition
rates

52 What constituent is needed in coating of electrode of an electrode to prevent formation of

porosity in welding of rimming steel?

a) Iron powder ( Fe) ( are mainly used in flat and H/V position take advantage of higher
deposition rate t l in kim loi vo mi hn sau mi que hn tnh theo Kg/h, fusion-
kh nng lm tan chy kim loi que hn va kim loi c bn, penetration-
b) Calcium fluoride (CaF2) (was included basic flux electric with slag former, H2 removal
because CaF2 will generates fluorine F on dissociation in the heat of arc, after F + H2
HF )
c) Silicon (Si) (de-oxidant)
d) Calcium carbonate (CaCO3) (arc stable, slag former)

53 Welds made with high heat inputs show a reduction in one of the following properties?

a) Ductility
b) Toughness
c) Fatigue strength
d) Mechanical strength

54 In the welding of Austenitic pipe work, the borer is usually purged with Ar to?

a) Prevent formation of porosity in the weld

b) Prevent burn-through in the root run
c) Prevent oxidation of the rood bead
d) Eliminate the formation of H2

55 In X-ray the quality of the radiograph negative is assessed by the?

a) Density of the Film D

b) IQI indicator
c) KVA available
d) Stand-off (s xa cch) distance

56 A steel described, as QT will have improved tensile properties it has?

a) Had control of chemical composition

b) Been heat treated
c) Been quality tested
d) Been vacuum melted

57 Which one of the following steels would give rise to the formation of porosity when autogenously
welded with an arc process?

a) Fully killed steel

b) Semi killed steel
c) Rimming steel
39
 d) Fine grained steel

58 In submerged arc welding, the use of excessively high voltage would result in?

a) Insufficient flux melting

b) Excessive flux melting
c) Slag removal difficulties
d) Spatter

59 The use of cellulosic electrode is often made when welding the root pass of pipes in the field.
This is because?

a) Hydrogen control is needed

b) Iron powder in the electrode
c) Higher arc voltage can be obtained
d) Shorter arc length can be achieved

60 In the welding of Austenitic stainless steels, the electrode and plate material can be purchased
with low carbon contents. The reason for this is to prevent?

a) Cracking I the HAZ

b) The formation of chromium carbides
c) Cracking in the weld metal
d) Distortion

61 Submerged arc fluxes can be supplied in two forms; theses are?

a) Sintered and agitated

b) Agitated and fused
c) Crushed and agglomerated
d) Fused and agglomerated

62 In a steel, which has improved creep properties at elevated temperature, which one of the
following elements helps in this improvement?

a) Tungsten
b) Manganese
c) Molybdenum
d) Carbon

63 Welding a steel plate of 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 improve mechanical properties in the weld

64 Which of the following processes uses the keyholing

system of fusion?

a) Friction welding
b) Diffusion bonding
c) Electron beam welding
40
 d) Autogenous TIG welding

(Engineering / General Engineering) a transient column of vapour or plasma formed during the welding or
cutting of materials, using high energy beams, such as lasers

65 In friction welding, is the metal at the interface in the?

a) Liquid state
b) Solid state
c) Plastic state
d) Elastic state

66 Welding procedures may require welds to be deposited at a controlled rate heat input. High heat
inputs would?

a) Have poor profile

b) Have larger grain size
c) Have high hardness in the HAZ
d) Have low elongation properties

67 In a tensile test, a brittle material would be indicated if the fracture surface?

a) Shows reduction in size

b) Is flat and featureless
c) Breaks in the weld metal
d) Breaks in the parent material

68 What destructive test would be required to ascertain the likelihood of cracking in the HAZ of a
weld?

a) Nick break
b) Side bend test
c) Charpy input
d) Macro test

69 In submerged arc welding, excessive arc voltage may cause?

a) Excessive penetration
b) Change in weld metal composition S
c) Narrow weld width S
d) Excessive bead profile

70 The British code for visual inspection requirements is:

a) BS4872
b) BS499
c) BS4870
d) None of the above

71 A code of practice for visual inspection should cover the following:

a) Before, during and after welding activities

b) Before welding activities only
41
 c) After welding activities only
d) None of the above

72 Incomplete 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

73 Incomplete root fusion weld certainly be caused by:

a) Linear misalignment
b) Incorrect tilt angle
c) Differing root face widths
d) All of the above

74 When visually inspecting a completed single vee butt weld cap you would certainly assess:

a) Cap height
b) Toe blend
c) Weld width
d) A, B & C

75 You notice a very veed ripple shape. This is most likely caused by:

a) Poor consumable choice

b) Welding position
c) Excessive travel speed
d) All of the above

76 Toe blending is important as it may affect:

a) Corrosion
b) Fatigue life
c) Overlap type defects
d) All of the above

77 Slag inclusion would occur with:

a) Manual metal arc

b) Metal inert gas
c) Submerged arc welding
d) Both A & C

78 Undercut principally caused by:

a) Excessive amps
b) Excessive volts
c) Excessive travel speed
d) All of the above

42
79 Undercut normally assessed by:

a) Its depth
b) Its length
c) Its blending
d) All of the above

80 A welding procedure is useful to:

a) Give information to the welder

b) Give information to the inspector
c) Give Confidence to a product
d) All of the above

81 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

82 A magnifying glass may be used during visual inspection but BS 5289 states that its
magnification should be:

a) Up to 5
b) 2 2.5
c) 5 10
d) None of the above

82 When visually inspecting a fillet weld, it would normally be sized by:

a) The leg lengths

b) The actual throat thickness
c) The design throat thickness
d) Both A & C

83 The planar defect is:

a) Incomplete fusion defects

b) Slag inclusion
c) Incomplete penetration
d) Both A & C

84 Penetrant and Magnetic particle inspection are mainly used to:

a) Aid visual inspection

b) Because application standard says so
c) To confirm visual uncertainties
d) All of the above

43
85 Defects outside of the limits specified in a standard should always be:

a) Repaired
b) Reported to a senior person
c) Assessed along with other defects
d) All of the above

86 MIG welding tends to be susceptible to lack of fusion problems. This is because of:

a) Poor maintenance of equipment

b) Incorrect setting
c) Poor inter run cleaning
d) All of the above

87 Manual metal arc electrodes can be grouped into three main types. Thses are:

a) Basic cellulosic and rutile

b) Neutral cellulosic and rutile
c) Basic cellulosic and neutral
d) None of the above

88 The main causes of porosity in welded joints are:

a) Poor access
b) Loss of gas shield
c) Dirty materials
d) All of the above

89 Weave technique may give rise to:

a) Better profiles
b) Improved toe blending
c) Improved ripple shape
d) All of the above

90 Cracks in welds may be due to:

a) Solidification problems
b) Hydrogen problems
c) Excessive stresses
d) All of the above

91 With reference to a root penetration bead, you could certainly assess:

a) Root fusion and penetration

b) Root concavity
c) Burn-through
d) All of the above

92 A fatigue failure characteristic by the appearance of the fracture surface. It would be:
a) Rough and torn
b) Cheveron like
c) Smooth
44
 d) None of the above

93 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 (mainly is low cohesion between the grains boundaries in
the HZA, HZA under an opposing contraction stress cracks may now occur parallel to
the weld in the HZA such as F/S in the HZA)
c) It may cause hard zones
d) All of the above
Stray arcing or arc strike or stray flash is same called

94 Overlap in welds could be influenced by:

a) Poor welding technique

b) Welding process
c) Welding position
d) All of the above

95 Flame cut preparations may, during welding, increase the likelihood of:

a) Cracking
b) Misalignment problems
c) Inclusions
d) All of the above

96 Macroscopic examination requires any specimen to be inspected:

a) Once, after etching

b) Twice, before and after etching
c) Using a microscope
d) None of the above

97 Which of the following may be classes as a more serious defect:

a) Slag inclusions
b) Fusion defects (interun)
c) Fusion defects (surface)
98 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

99 Movement of the arc by magnetic forces in-MMA welding is termed:

a) Arc deviation
b) Arc misalignment
c) Arc blow
d) Arc eye
20-5-2012

100 A metallurgical problem most associated with submerged arc welding is:
45
 a) Hydrogen cracking in HAZ
b) Solidification cracking in the weld metal
c) Hydrogen cracking in the weld metal
d) Lamellar tearing in the weld metal

101 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

102 The main uses 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

103 Which of the following processes joins metals plastically:

a) Friction welding
b) Resistance welding
c) Plasma welding
d) All of the above

104 Which electrode classification would be relevant AWS A 5.1-81:

a) E 6013
b) E 5133
c) E 7018 G
d) Fleet weld 5
105 Which of the following coating is associated with Stove welding;

a) Rutile
b) Cellulosic
c) Basic
d) Oxidizing

106 A common gas mixture used in MIG welding nickel alloys to combine good levels of penetration
with good arc stability would be:

a) 100% CO2
b) 100% argon
c) 80% argon 20% CO2
d) 98% argon 2% oxygen

107 The type of SAW flux is more resistance to moisture absorption:

a) Fused
b) Agglomerated
c) Basic
d) All of about the same resistance
46
108 The flame temperature of oxy/acetylene mixture gas is given as:

a) 3200 C
b) 2300 C
c) 5000 C
d) None of the above

A common propane/air flame burns at about 3,630 F (2,000 C), a propane/oxygen flame burns at
about 4,530 F (2,500 C), and an acetylene/oxygen flame burns at about 6,330 F (3,500 C).

109 A large grain structure in steels is said to produce:

a) Low ductility values S

b) Low fracture toughness values
c) High fracture toughness values
d) High tensile strength

110 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 of the above

111 Repair welding is often more difficult than production due to:

a) The material being ingrained with in-service contaminates

b) Restricted access with the repair area
c) The possible position of the weld
d) Any of the above

112 Hydrogen cracking in the weld metal is likely when:

a) Carbon manganese steels

b) Stainless steels
c) Micro alloyed steels (HSLA)
d) Low carbon steels

113 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

114 Porosity is caused by:

a) Entrapped slag in the solidifying weld

b) Entrapped gas in the solidifying weld
47
 c) Entrapped metallic inclusions in the solidifying weld
d) None of the above

115 In 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

116 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

117 The process of tempering is often carried out to regain (ly li) toughness after which of the
following processes:

a) Annealing
b) Normalizing
c) Hardening
d) Stress relieving

118 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 (Fe/S)

b) Hydrogen cracking (H2)
c) Intergranular corrosion (Cr/C)
d) Stress corrosion cracking (stress and corrosion)

119 Generally the most suitable method of detecting lack of sidewall fusion would be:

a) Ultrasonic
b) MPI
c) Radiography
d) Penetrants

120 Hot shortness term is used to indicate:

a) Lamellar tearing
b) Solidification cracking
c) Hydrogen cracking
d) None of the above

121 The use of cobalt as an isotope would generally be used on:

a) Thin materials
48
 b) Tee joints
c) Plate thickness greater than 25mm
d) None of the above

122 In welding procedure term, a change in essential variable means

a) Re-qualification of the welding procedure

b) Possible change in the welds microstructure
c) Possible change in t he mechanical properties
d) All of the above

123 Weld symbol placed on a dotted line in accordance with ISO requirements means:

a) Weld on arrow side

b) Weld on other side
c) Weld on site
d) Full penetration required

124 A welding inspectors main attribute includes:

a) Knowledge and experience

b) Literacy
c) Honesty and integrity
d) All of the above

125 The correct term for a joint prepared on one component only is:

a) A bevel butt
b) A J butt
c) A K butt
d) All of the above

126 Technically a code of practice is:

a) A standard
b) A set of rules for the manufacture of a product
c) Related to welder and weld procedure approval
d) All of the above

127 The correct term for cap height is:

a) Reinforcement
b) Cap profile height
c) Excessive weld metal
d) All of the above

128 A tensile test will assess

a) Impact values
b) Stress
c) Strain
d) Both a) & c)
49
129 The important point if high temperature steel is that:

a) They can withstand creep failure

b) They may suffer re-heat cracking problems
c) They may suffer loss of toughness
d) All of the above

130 An austenitic stainless steel may suffer:

a) Weld decay
b) Sensitization
c) Solidification cracking
d) All of the above

131 Carbon equivalent values are useful to determine:

a) Weld ability aspects

b) Crack sensitivity aspects
c) Typical mechanical properties
d) All of the above

132 A basic electrode would normally:

a) Have superior mechanical properties

b) Require baking before use
c) Not be used on low carbon steels
d) Both a) and b)

133 When referring to TIG welding, the shielding gas could be:

a) Argon + Hydrogen
b) Argon + Helium
c) Argon + Nitrogen
d) All of the above

134 When referring to MIG welding, the shielding gas could be:

a) Argon
b) Argon + 1% Oxygen
c) Argon + 20% CO2
d) None of the above

135 Submerged arc utilities:

a) Deep penetration characteristic

b) High deposition rate on DC+
c) Flat (P.A.) welding only

136 Ultrasonic would be prefer over radiography due to:

50
 a) Ability to find more defects
b) Lowest skill requirements
c) Ability to detect laminations
d) Both a) and c)

137 The most serious defects

a) Planar
b) Cracks
c) Lack of fusion
d) All of the above

138 The weldability of a material may be affected by:

a) Temperature of the component

b) The C.E. % of the material
c) The elements in the material
d) All of the above

139 Post heat treatment:

a) Must be applied to welds if a crack free weld is required1

b) Should never exceed 300 dg C
c) May stress relieve
d) Must always be applied using gas flames

140 Which of the following welding processes may be described, as a low hydrogen process in
comparison with general MMA welding:

a) TIG
b) MIG
c) MAG
d) None of the above
e) All f the above

141 Which form of NDT could be used on a fillet weld on aluminum?

a) Dye penetrant testing

b) Ultrasonic testing
c) Radiography
d) MPI
e) a, b and c
f) D only
g) All of the above

142 Which of the following NDT methods would not detect sub-surface defects?

a) MPI
b) Dye penetrant testing
c) Ultrasonic testing
d) Radiography
e) All of the above would detect sub-surface defects

51
143 Why have a high O.C.V. with MMA welding

a) To initiate the arc

b) To obtain penetration
c) To avoid lack of fusion
d) MMA welding does not have a high O.C.V.

144 What is the purpose of a rectifier in relation to welding plant?

a) To adjust the voltage

b) To adjust the amperage
c) To convert A.C to D.C.
d) To prevent arc strikes

145 Fish eyes, chevron cracks and fissures (ch nt) are:

a) Not associated with welding

b) Types of cracks
c) Only encountered in MMA welds
d) Hydrogen related problems

146 Pre heating prior to welding:

a) Must always be carried out

b) Need not be carried out if post heat treatment is to follow welding
c) Is always carried out using gas flame
d) None of the above
e) All of the above

147 What does pre heat prior to welding have an affect on:

a) Hardenability
b) Weldability
c) Cooling rate
d) All of the above
e) None of the above

148 The toes of the cap on a butt weld:

a) Must overlap on the external surface of a pipe or plate by at least 1.5mm

b) Must be grounded
c) Must never be grounded
d) None of the above

149 Which of the following butt-weld preparations is generally most susceptible to lack of side wall
fusion during MMA welding?

a) A U preparation
b) A V preparation
c) A double V preparation
d) Lack of side wall fusion does not exist with MMA

150 What is the leg length of a fillet weld?

52
 a) The distance from the toe to the face
b) The distance from the root and to the face center
c) The distance from the root to the toe
d) The distance from toe to toe

151 What is throat thickness of the fillet weld?

a) The distance from toe to the face

b) The distance from the root to face center
c) The distance from the root to the toe
d) The distance from toe to toe

152 Quality assurance is:

a) The inspection of a product or service

b) A management system designed only to ensure material compatibility
c) Not solely related to planning and inspection
d) The implementation (s thc hin y ) of quality control

153 Which welding process is considered the most versatile (bin i linh hot)?

a) SAW
b) TIG
c) MIG/MAG
d) MMA

-thit b
-con ngi
-phm vi
-vt liu
-chiu dy
-tnh di ng
-gi thnh
.,R..
154 Quality assurance:

a) Is an other term for inspection

b) Related to all activities and functions concerned with the attainment of quality
c) Is the activity of ensuring documents relating to specific contracts are in order
d) Is the activity of carrying out quality control

155 Which NDT method would never be use on a 6 aluminum pipe weld?

a) Radiography
b) Magnetic particle inspection
c) Ultrasonic testing
d) Dye penetrant testing

156 Why is hot pass so-called?

a) Because it is applied at a high amperage

b) Because it is applied when the root is still hot
c) Because it could cause hot shortness
53
 d) Because it heat treats the root

157 Generally speaking a welding inspector, as a minimum requirement:

a) Must have at a thorough(ton din) knowledge of NDT

b) Must know how to interpret radiographs
c) Must have a thorough knowledge of welding metallurgy
d) None of the above
e) All of the above

158 Which of the following is not an inert gas?

a) Argon
b) Xenon
c) Carbon dioxide
d) Helium

159 Why is welding is shielded?

a) To eliminate hydrogen
b) To retard the cooling rate of the weld
c) To eliminate the atmosphere
d) To ensure maximum heat input

160 The primary duty of welding inspector:

a) Is ensure welds are defect free

b) Is to ensure the weld is free from residual stresses
c) Is to write job specifications
d) Is to ensure all welding and associated activities are carried out in accordance with the
procedure(s)

161 Which of the following welding processes is most susceptible to lack of fusion?

a) Submerged arc
b) CO2 (metal active gas) (Dip transfer)
c) Manual metal arc
d) Tungsten inert gas

162 Fillet welds are

a) Preferable to butt welds due to high strength S

b) Difficult to assess with Non Destructive Testing in comparison with butt (grove) welds
c) Used only for appearance purposes
d) Only feasible (posiable) on steels S
e) All of the above

163 API stands for

a) Associated Pipeline Industries

b) American Pipe Institute
54
 c) American Pipeline Institute
d) American Petroleum Institute

164 When welding using the MMA process, varying the arc length will give the most variation of:

a) Voltage
b) Amperage
c) Polarity
d) None of the above

165 Lap joints contain:

a) Fillet welds
b) Corner joints
c) Butt welds
d) Single bevel butt welds

166 Which arc welding process utilizes a non-consumable electrode?

a) MIG
b) TIG
c) MMA
d) SAW
e) All of the above

167 A welding Inspector:

a) Must know how to interpret radiographs

b) May be required to interpret radiographs on certain contracts
c) Should be able to weld
d) Both b and c
e) All of the above

168 Which electrodes are very susceptible to causing porosity in the deposited welds if long arc
employed?

a) Basic
b) Cellulosic
c) Rutile
d) None of the above

169 What do you understand by the term minimum interpass temperature

a) Minimum pre heat temperature

b) Minimum stress relieve temperature
c) The lowest temperature to be used when normalizing
d) The lowest temperature allowed during welding and between passes

55
170 Is it permissible to allow a single V butt weld to cool down passes?

a) It is solely (duy nht) the decision of the welder S

b) It depends on the requirement of the procedure and specifications
c) It is solely the decision of the welding inspector
d) No, all welds should be completed before dropping the temperature to ambient

171 What is the problem with restraint during welding?

a) It does not cause a problem S

b) It may lead to cracking, especially with small welds between large components
c) It causes distortion
d) Restraint is term not used in relation to welding S

172 Which mechanical test (s) can b e used to make an assessment of surfacing breaking defects?

a) Bend test
b) Nick break test S
c) Macro test S
d) None of the above
e) All of the above

173 What is the purpose of a tensile test?

a) To assess tensile strength

b) To assess ductility
c) To assess yield strength
d) All of the above could be assessed

174 When a metal returns to its original shape after an applied load has been removed, the metal is
said to have:

a) Plasticity
b) Ductility
c) Elasticity
d) Malleability

175 Fluctuating load is: cyclic stresses, below the UTS on a weld component may lead to:

a) Tensile failure
b) Yield failure
c) Fatigue failure
d) Shear failure

176 Stress is equal to:

a) Stress
b) Load divided by cross sectional area
c) Extension of gauge length divided by original gauge length
d) Toughness

177 Strain is equal to:

a) Stress
56
 b) Load divide by cross sectional are
c) Extension of gauge length divided by the original gauge length
d) Toughness

178 Stress can be measured in:

a) N/mm
b) PSI
c) mm
d) Both a and b

179 What is a crater pipe?

a) An oval tube
b) Another term for burn through
c) A type of porosity
d) A shrinkage defect

180 Which British standard relates to welding term and symbols

a) BS 639
b) BS 638
c) BS 18
d) BS 499

181 How could you accurately measure the root radius of a charpy or Izod specimen?

a) With a machine called shadowgraph

b) With a rule
c) With a vernier caliper
d) With a densitometry

182 Herringbone porosity is:

a) A particular pattern (kiu mu) of porosity

b) Made up of wormholes
c) Made up of piping
d) All the above are correct
e) None of the above

183 A crack is a weld zone:

a) Is repairable
b) Always results in s cut out and complete reweld
c) Is acceptable up to 2mm in length
d) May be repaired or cut out depending on specification requirements.

184 If the amperage were too low during the welding of a root bead the possible result would be:

a) Lack of penetration
b) Lack of fusion
57
 c) The freezing of the electrode
d) All of the above

185 Stress acting in the opposite direction of compressive stress is known as:

a) Residual stress
b) Shear stress
c) Hoop stress
d) Tensile stress

186 Distortion may be affected by:

a) Restraint
b) Heat input
c) Material properties
d) Material thickness
e) All of the above

187 Distortion:

a) Is plastic deformation
b) Is elastic deformation
c) Is another term for stress
d) May be elastic or plastic deformation
e) All of the above

CSWIP 3.1 (WELDING INSPECTOR) MULTIPLE CHOICE QUESTIONS

01. When H2 control is specified for a manual metal arc welding project, the electrode would normally
be:

(a) Cellulose
(b) Iron oxide
(c) Acid
(d) Basic

02. You would with certainty recognize a hydrogen controlled flux covered electrode from its:

(a) Colour
(b) Length
(c) Trade Name
(d) AWS / BS639 Code Letter

03. 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

04. You notice manual metal arc electrodes, stripped of flux, are being used as filler wire for TIG welding.
You would object because:
58
 (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

05. 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

06. The steel composition in a structural contract is changed form 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

07. One of the following alloys is non-magnetic. Which?

(a) 4% Chromium Molybdenum

(b) 12% Chromium
(c) Austenitic Stainless Steel
(d) 9% Nickel Steel

08. When TIG welding Austenitic Stainless Steel pipe, Argon gas baking is called for. This is to:

(a) Prevent oxidation

(b) Prevent under bead cracking
(c) Prevent porosity
(d) Control the penetration bead shape

09. Pre-heating a carbon steel manual metal arc welding is carried out to minimize the risk of:

(a) Scattered porosity

(b) Worm hole porosity
(c) Parent metal cracking
(d) Lack of penetration

10. 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 length

11. For open site manual metal arc welding the following equipment is available. Which would you
choose for safe working?

(a) Single operator transformer

(b) Multi operator transformer
59
 (c) AC / DC composite power unit
(d) Diesel engine driven motor generator

12. 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

13. During CO2 welding, the arc length is most likely to be affected by:

(a) The wire diameter

(b) The current return connection
(c) The gas flow rate
(d) The torch to work angle

14. 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

15. 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

16. A welder qualification test is to verify:

(a) Skill of the welder

(b) The quality of the materials
(c) The non-destructive test procedures
(d) The manufacturing method

17. 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

18. 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

19. Lamellar tearing has occurred in a steel fabrication. Before welding could it have been found by:
60
 (a) X-ray examination
(b) Dye penetrant
(c) Ultrasonic inspection
(d) It would not have been found by any inspection method

20. 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

21. The unit of Joules would be used to measure:

(a) Tensile strength

(b) Impact energy
(c) Hardness
(d) Electrical resistance

22. Submerged arc welding is a process that generally gives:

(a) Slag free welds

(b) Low penetration
(c) Low dilution
(d) High heat input

23. Which of the following does not require baking or drying:

(a) E 6010
(b) E 7018
(c) Sub are flux with Basicity Index of 2
(d) Sub are flux with Basicity Index of 3

24. A welder and procedure re-qualification would be required:

(a) When the run out date of the procedure has been reached
(b) Every Year
(c) When changing from day to night shift work
(d) When there is a change in an essential variable

25. Tensile strength can be increased in steel by:

(a) Annealing (use for making steel softness and ductility)

(b) Galvanising
(c) Addition of carbon
(d) Casting

26. Which of the following always occurs in the parent material:

(a) Hydrogen cracks

(b) Laps and laminations
(c) Center line cracks
61
 (d) Porosity

27. To prevent the hardening and cracking of High Carbon Steel plate when flame cutting it is advisable
to:

(a) Pre-heat the plate

(b) Soak the plate in oil
(c) Cool the plate quickly after cutting
(d) Increase the cutting Oxygen pressure

28. Re-crystallization during annealing is used to make steel:

(a) Softer
(b) Harder
(c) Tougher
(d) Stronger

29. You should always refer to a higher authority for guidance when:

(a) Cracks appear during welding

(b) The welder will not follow your instructions
(c) Instructions are missing in the specification or contract documents
(d) All of the above

30. Spatter may be finely controlled during MIG / MAG welding by:

(a) Adjusting the inductance control

(b) Using CO2 gas
(c) Increasing the arc voltage
(d) Welding with no gas

31. Fatigue testing is used to test welds:

(a) Under cyclic loading

(b) Under creep stress loading
(c) Under impact loading
(d) Under static loading

32. Argon + 2% Oxygen is used when welding:

(a) High carbon steels

(b) Austenitic stainless steels
(c) Aluminum
(d) Marten site stainless steels

33. In BS 639 and BSEn 499 the first digits of the electrode classification indicate:

(a) Tensile and yield strength

(b) Toughness
(c) Electrode coating
(d) Electrode efficiency

34. Cellulosic coatings are generally used because of:

62
 (a) Their low hydrogen content
(b) Their high penetration characteristic
(c) Their high strength weld deposit
(d) Their high weld toughness values

35. Porosity would mostly occur in which of the following:

(a) When MMA welding semi de-oxidized steel

(b) When MIG / MAG welding fully de-oxidized steel
(c) When welding TIG welding non de-oxidized steel
(d) When Sub Arc Welding semi killed steel

63
36. When welds have a depth to width ration of higher than 2:1 it is possible that:

(a) Centerline cracks may appear

(b) The fusion boundary will be outside the HAZ
(c) The HAZ will be too narrow
(d) The weld will be non magnetic

37. On which of the following would you not use MPI inspection?

(a) A low carbon steel butt welded joint

(b) An Austenitic Stainless steel fillet welded T joint
(c) A medium carbon steel fillet welded lap joint
(d) All of the above

38. Increasing the arc energy input of a welded joint will:

(a) Increase the strength of the joint

(b) Increase the toughness of the joint
(c) Increase the grain size of the weld and HAZ
(d) Decrease the width of the HAZ

39. In Sub Arc Welding, excessive flux melting will result from:

(a) Increasing the arc voltage

(b) Decreasing the arc voltage
(c) Increasing the travel speed
(d) Increasing the wire feed speed

40. To BS 499 part 2, which of the following is true for a welding symbol:

(a) This or arrow side of the joint goes on top of the reference line
(b) This or arrow side of the joint goes below the reference line
(c) This or arrow side of the joint goes in the middle of the reference line
(d) All of the above

41. Internal lack of fusion defects can be normally found by using:

(a) Penetrant testing

(b) Impact tests
(c) Side bend test
(d) Hardness test

42. Which of the following steel structures has the highest hardness:

(a) Martensite
(b) Austenitic
(c) Ferritic
(d) All have the same hardness

43. An IQI would be used in radiography to assess:

(a) Image quality

(b) Type of steel
(c) Density of graph
64
 (d) Type of welding process used

44. Poor penetration would be found in MIG / MAG welded steels when using:

(a) Argon + 20% CO2

(b) CO2
(c) Pure Argon
(d) Argon + 5% CO2

45. In which of the following steels are you most likely to find H2 induced weld metal cracking after
welding:

(a) Low carbon steel

(b) High strength low alloy steel
(c) Austenitic stainless steels
(d) 1% Nickel steel

46. Silicon is added to electrode coating as:

(a) A slipping agent

(b) A slag former
(c) A de-oxidant
(d) A colouring agent

47. The main reason degreasing agents should always be dried from metals prior to welding, is because
they are likely to:

(a) Increase the arc voltage

(b) Produce hazardous fumes
(c) Slow down the welding speed
(d) Produce lack of fusion defects

48. Which of the following processes would be most prone to lack of fusion defects:

(a) Pulsed arc MIG

(b) Spray transfer MIG
(c) Dip transfer MIG
(d) Submerged arc

49. Adjusting the inductance control in dip transfer MIG / MAG welding, will control:

(a) The pulse rate

(b) The gas flow rate
(c) The amount of spatter
(d) The arc voltage

50. Which of the following is an inspection point in Sub Arc Welding?

(a) Flux mesh size

(b) Gas type
(c) Tungsten size
(d) Gas flow rate

51. Why is Hot Pass so called?

65
 (a) Because it is applied to a high amperage
(b) Because it is applied when the root is still hot
(c) Because it could cause hot shortness
(d) Because it heat treats the root

52. Which of the following is not inert gas?

(a) Argon
(b) Xenon
(c) Carbon dioxide
(d) Helium

53. Why is a welding arc shielded?

(a) To eliminate hydrogen

(b) To retard the cooling rate of the weld
(c) To eliminate the atmosphere
(d) To ensure maximum heat input

54. Which welding process is considered to be the most versatile (linh hot)?

(a) SAW
(b) TIG
(c) MIG / MAG
(d) MMA

55. The HAZ associated with a weld is:

(a) The melted portion (phn chia) of the parent plate

(b) The area immediately adjacent to the weld which has undergone a micro structural change
(c) The weld area plus the parent plate which has undergone a micro structural change
(d) The are in the weld region with the lowest tensile strength

56. A crack in a weld zone:

(a) Is repairable
(b) Always results in a cut out and complete re-weld
(c) Is acceptable up to 2mm in length
(d) May be repaired or cut out depending on specification requirements

57. If the amperage is too low during the welding of a root bead, the possible result would be:

(a) Lack of penetration

(b) Lack of fusion
(c) The freezing of the electrode
(d) All of the above

58. Pre-heating prior to welding:

(a) Must always be carried out

(b) Need not be carried out if post heat treatment is to follow welding
(c) Is always carried out using gas flames
(d) All of the above
66
 (e) None of the above

59. Cold lap in another term for:

(a) Lack of fusion

(b) Low amperage
(c) Undercut
(d) Hydrogen cracking

60. When a medium to high carbon steel is quenched:

(a) It becomes malleable

(b) Its hardness increases
(c) It becomes ductile
(d) The plasticity is increased

61. The TIG welding process utilizes an electrode that is:

(a) Cellulosic
(b) Non consumable
(c) Consumable
(d) None of the above

62. Another name for Suckback in the root of a weld is:

(a) Concavity
(b) Convexity
(c) LORP
(d) Root undercut

63. One of the advantages of a multi-pass MMA weld is that it generally produces a:

(a) High tensile strength

(b) High degree of ductility
(c) Coarse grain structure
(d) Fine grain structure

64. A Normalising heat treatment process is carried out by:

(a) Heating the metal just above 650*C

(b) Taking the metal above the re-crystallization temperature and allowing to air cool
(c) Taking the metal above the re-crystallization temperature and allowing to furnace cool
(d) Taking the metal above the re-crystallization temperature and quickly cooling by immersing

65. The extent of the changes in microstructure will depend on the following:

(a) Material composition

(b) Heat input
(c) The rate of cooling
(d) All of the above

66. The British code for visual inspection requirements is:

(a) BS 4872
67
 (b) BS 499
(c) BS 4870
(d) None of the above

67. A code of practice for visual inspection should cover the following:

(a) Before, During and After welding activities

(b) Before welding activities only
(c) After welding activities only
(d) None of the above

68. 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

69. 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

70. You notice a very yeed ripple shape. This is most likely caused by:

(a) Poor consumable choice

(b) Welding position
(c) Excessive travel speed
(d) None of the above

71. Toe Blending is important as it may affect:

(a) Toughness
(b) Fatigue life
(c) Penetration
(d) All of the above

72. Slag inclusions may occur with:

(a) Manual Metal arc

(b) Metal Inert Gas
(c) Submerged Arc Welding
(d) Both A & C

73. Undercut is caused by:

(a) Excessive amps

(b) Excessive volts
(c) Excessive travel speed
(d) All of the above

74. Undercut is normally assessed by:

68
 (a) Its depth
(b) Its length
(c) Its blending
(d) All of the above

75. A welding procedure is useful to:

(a) Give information to the welder

(b) Give information to the inspector
(c) Give Confidence to a product
(d) All of the above

76. An essential variable may:

(a) Change the properties of the weld

(b) Influence the visual acceptability
(c) Require re-approval of the weld procedure
(d) All of the above

77. A magnifying glass may be used during visual inspection by typical magnification would be:

(a) Up to 50
(b) 2 2.5
(c) 50 100
(d) None of the above

78. When visually inspecting a fillet weld, it would normally be Sized by:

(a) The leg lengths

(b) The actual throat thickness
(c) The design throat thickness
(d) Both A & C

79. A planar defect is:

(a) Incomplete fusion defects

(b) Slag inclusion
(c) Incomplete penetration
(d) Both A & C

80. Penetrant inspection and MPI are mainly used to:

(a) Aid visual inspection

(b) Because the application standard says so
(c) To confirm Visual uncertainties
(d) All of the above

81. Defects outside of the limits specified in a standard should always be:

(a) Repaired
(b) Reported to a senior person
(c) Radio graphed
(d) All of the above
69
 82. MIG welding tends to be susceptible to lack of fusion problems. This is because of:

(a) Poor maintenance of equipment

(b) Incorrect settings
(c) Poor inter run cleaning
(d) All of the above

83. MMA electrode can be grouped into three main types. These are:

(a) Basic, Cellulosic and Rutile

(b) Neutral, Cellulosic and Rutile
(c) Basic, Cellulosic and neutral
(d) None of the above

84. The main causes of porosity in welded joints are:

(a) Poor access

(b) Loss of gas shield
(c) Dirty materials
(d) All of the above

85. Cracks in welds may be due to:

(a) Solidification problems

(b) Hydrogen problems
(c) Excessive stresses
(d) All of the above

86. Welding a single V butt with laminations showing on the side wall may give rise to:

(a) Lamellar tearing

(b) Solidification cracking
(c) Martensite
(d) Undercut

87. With reference to a root penetration bead, you could certainly assess:

(a) Root fusion and penetration

(b) Root concavity
(c) Burn through
(d) All of the above

88. 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

Stray arcing may be regarded as a serious defect. This is because:

(e) It may reduce the thickness dimension of a component

(f) It may cause liquation cracks
70
 (g) It may cause hard zones
(h) All of the above

89. Overlap in welds could be influenced by:

(a) Poor welding technique

(b) Welding process
(c) Welding position
(d) All of the above

90. Flame cut preparation may, during welding, increase the likelihood of:

(a) Cracking
(b) Misalignment problems
(c) Inclusions
(d) All of the above

91. Macroscopic examination requires any specimen to be inspected:

(a) Once after welding

(b) Twice once before and once after etching
(c) Using a microscope
(d) None of the above

92. Which of the following may be classed as a More serious defect?

(a) Slag inclusions

(b) Fusion defects (Inter run)
(c) Fusion defects (Surface)
(d) Porosity

93. 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

94. Movement of the arc by magnetic forces in MMA welding is termed:

(a) Arc deviation

(b) Arc misalignment
(c) Arc blow
(d) Arc eye

95. 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

96. Oxy pressure and nozzle size would influence what in flame cutting:

71
 (a) The temperature required for cut initiation
(b) The ability to cut Stainless steel
(c) The depth of cut obtainable
(d) None of the above

97. The main usage of arc cutting / gouging processes is in:

(a) The cutting of single bevel preparation

(b) The removal of deposited welds
(c) The cutting of single U-type preparation
(d) The cutting / gouging of non-ferrous materials only
98. Which of the following processes joints metals plastically:

(a) Friction welding

(b) Resistance welding
(c) Plasma welding
(d) All of the above

99. Which electrode classification would be relevant to AWS A5.1 / 81:

(a) E 6013
(b) E 5133
(c) E 7018
(d) Fleet weld 5

100. Which of the following coatings associated with Stove Welding?

(a) Rutile
(b) Cellulosic
(c) Basic
(d) Oxidizing

101. A common gas / mixture used in MIG welding nickel alloys to combine good levels of penetration
with good arc stability would be:

(a) 100 % CO2

(b) 100% Argon
(c) 80% Argon 20% CO2
(d) 98% Argon 2% Oxygen

102. The type of SAW flux is more resistant to moisture absorption:

(a) Fused
(b) Agglomerated
(c) Basic
(d) All of the above the same resistance

103. The flame temperature of oxy / acetylene mixture gas is given as:

(a) 3200* C
(b) 2300* C
(c) 5000*C
(d) None of the above

72
104. A large grain structure in steels said to produce:

(a) Low ductility values

(b) Low fracture toughness values
(c) High fracture toughness values
(d) High tensile strength

105. 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 of the above

106. 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

107. Hydrogen cracking in the weld metals is likely when welding:

(a) Carbon Manganese steels

(b) Stainless steels
(c) Micro alloyed steels (HSLA)
(d) Low carbon steels

108. 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

109. 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

110. 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

111. Ultrasonic testing is of advantage in detecting which of the following weld imperfection over other
NDT method:

(a) Lack of side wall fusion

73
 (b) Surface undercut
(c) Incompletely filled groove
(d) Overlap

112. 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

113. 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

114. When visually inspecting a completed single V butt cap you would certainly assess:

(a) Cap height

(b) Toe blend
(c) Weld width
(d) A, B & C

115. Generally the most suitable method of detecting lack of side wall fusion would be:

(a) UT
(b) MPI
(c) RT
(d) PT

116. Hot shortness is a term used to indicate:

(a) Lamellar tearing

(b) Solidification cracking
(c) Hydrogen cracking
(d) None of the above

117. The use of cobalt as an isotope would generally be used on:

(a) Thin material

(b) Tee joints
(c) Plate thickness greater than 25mm
(d) None of the above

118. In welding procedure terms, a change in essential variable means:

(a) Re-qualification of the weld procedure

(b) Possible changes in the welds micro structure
(c) Possible changes in the mechanical properties
(d) All of the above
74
119. Weld symbols placed on a dotted line in accordance with ISO requirements means:

(a) Weld on Arrow side

(b) Weld on Other side
(c) Weld on site
(d) Full penetration

120. A welding inspectors main attribute includes:

(a) Knowledge and experience

(b) Literacy
(c) Honesty and integrity
(d) All of the above

121. The correct term for a joint prepared on one component only is:

(a) A bevel butt

(b) A J butt
(c) A K butt
(d) All of the above

122. The correct terminology in the preceding question (7) is:

(a) -
(b) -
(c) -
(d) -

123. Technically, a code of practice is:

(a) A standard
(b) A Set of rules for the manufacture of a product
(c) Related to welder and weld procedure approval
(d) All of the above

124. The correct term for cap height is:

(a) Reinforcement
(b) Cap profile height
(c) Excess weld metal
(d) All of the above

125. A tensile test will assess:

(a) Impact values

(b) Stress
(c) Strain
(d) Both B & C

126. The important point of high temperature steels is that:

(a) They can withstand creep failure

(b) They may suffer re-heat cracking problems
75
 (c) They may suffer loss of toughness
(d) All of the above

127. An austenitic stainless steel may suffer:

(a) Weld decay

(b) Sensitisation
(c) Solidification cracking
(d) All of the above

128. Carbon equivalent values are useful to determine:

(a) Weldability aspects

(b) Crack sensitivity aspects
(c) Typical mechanical properties
(d) All of the above

129. A basic electrode would normally:

(a) Have superior mechanical properties

(b) Require baking before use
(c) Not be used on low carbon steels
(d) Both A & B

130. When referring to TIG welding, the shielding gas could be:

(a) Argon + Hydrogen

(b) Argon + Helium
(c) Argon + Nitrogen
(d) All of the above

131. When referring to MIG welding, the shielding gas could be:

(a) Argon
(b) Argon + 1% oxygen
(c) Argon + 20% CO2
(d) None of the above

132. Submerged arc utilizes:

(a) Deep penetration characteristic

(b) High deposition rates on DC +
(c) Flat (PA) welding only
(d) None of the above

The amount of welding material deposited per unit of time, expressed in pounds per hour.

133. Ultrasonic would be preferred over radiography due to:

(a) Ability to find most defects

(b) Lower skill requirement
(c) Ability to detect lamination
(d) Both A & C

76
134. The most serious defect types are:

(a) Planar
(b) Cracks
(c) Lack of fusion
(d) All of the above

135. Which of the following discontinuities could be as a primary processing discontinuity often found in
cast material?

(a) Fatigue crack

(b) Stress corrosion crack
(c) Porosity
(d) Lack of penetration

136. Which of the following discontinuities could be classified as a service induced discontinuity?

(a) Fatigue crack

(b) Porosity
(c) Machining tear
(d) Lap

137. Which of the following contamination could affect the sensitivity of penetrant?

(a) Acid
(b) Water
(c) Salts
(d) All of the above

138. Which of the following is a discontinuity that might be found in a forging?

(a) Shrinkage cracks

(b) Laps
(c) Cold shuts
(d) Insufficient penetration

139. The prime purpose of the black light (n cc tm) for fluorescent (hunh quang) penetrant
inspection:

(a) To magnify indications

(b) To make the indications visible
(c) To develop indications
(d) To speed up inspection

140. In accordance with BS 5135 which of the following is applicable for scale C with regards to
hydrogen content per 100g of deposited weld metal?

(a) > 15 ml
(b) > 15 ml < 25 ml
(c) > 10 ml < 15 ml
(d) > 5 ml < 10 ml
Scale A High: >15 ml
Scale B Medium: 10 ml - 15 ml
Scale C Low: 5 ml - 10 ml
77
 Scale D Very low: 3 ml - 5 ml
Scale E Ultra-low: < 3 ml

141. Which is the correct heat input if the amps are 350, volts 32 and travel speed 310 mm / s?

(a) 2.16 kJ / mm
(b) 0.036 kJ / mm
(c) 2160 kJ / mm
(d) 36 kJ / mm

142. In accordance with BS 5135 what is the minimum distance the pre heat shall be applied from the
joint preparation?

(a) 100 mm
(b) 25 mm
(c) 75 mm
(d) Not specified

143. In accordance with BS 5135 what is the recommended minimum time allowed for the pre heat
temperature to equalize?

(a) 2 Min for each 25 mm of parent material thickness

(b) 5 Min for each 25 mm of parent material thickness
(c) 2 Min for each 50 mm of parent material thickness
(d) 5 Min for each 50 mm of parent material thickness

144. Which of the following best describes the elastic limit?

(a) The resistance to fracture under impact loading

(b) The maximum stress to which a material can be subjected without permanent deformation
(c) The amount of stress at which point the material will continue to elongate without an increase in
force applied
(d) The ability of the material to stretch and become permanently deformed without breaking or
cracking

145. In accordance with BS 2901 which of the following is classified as triple de-oxidized filler wire?

(a) A 17 wire
(b) A 18 wire
(c) A 15 wire
(d) All of the above

146. In BS 639 an electrode classified as E51:

(a) Has an UTS value of 51,000 psi, minimum yield strength of 330 N/mm
(b) Has an UTS value of 430 to 550 N/mm, minimum yield strength of 360 N/mm
(c) Has an UTS value of 510 to 650 N/mm, minimum yield strength of 360 N/mm
(d) Has an UTS value of 510 to 650 N/mm, minimum yield strength of 330 N/mm

147. An E80 electrode would normally be classified in which standard:

(a) BS EN 499
78
 (b) BS 639
(c) AWS A5.5
(d) AWS A5.1

148. What is an active flux?

(a) A material used to clean surfaces of the joint through continued chemical reaction
(b) A material used to protect the molten weld pool during welding
(c) A material used to aid fusion
(d) All of the above

149. Which of the following is most likely to reduce the chances of arc blow?

(a) A change from ac current to dc current

(b) A change from dc current to ac current
(c) A change from dc electrode +ve to de electrode ve
(d) A change from dc electrode ve to dc electrode +ve

150. If a steel has a Ceq % of 0.48%:

(a) PWHT would always be necessary

(b) It will probably require a pre-heat temperature above 300*C prior to welding
(c) It will probably require a pre-heat temperature above 100*C prior to welding
(d) The heat affected zone will be very tough

151. When welding a double V butt joint with SAW process the presence of centerline porosity may be
due to:

(a) Damp flux

(b) Contaminated joint preparation
(c) Incorrect stick out lengths
(d) All of the above

152. When considering the advantages of site RT over UT which of the following applies?

(a) A permanent record produced, good for detecting defects which do not have significant depth in
relation to axis of the X-ray beam and defect identification
(b) A permanent record produced, good for detecting all surface and sub-surface defects and
assessing the through thickness depths of defects
(c) A permanent record produced, defect identification not so reliant on operator skill
(d) No controlled areas required on site, a permanent record produced and good for assessing the
extent of pipe wall thickness reductions due to internal corrosion

153. When ac only is required for welding, the power supply unit is almost always:

(a) A transformer, rectifier and a means to change the current

(b) A transformer, inverter and a means to change the current
(c) A rectifier, alternator and a means to change the current
(d) A transformer or alternator and a means to change the current

154. The HAZ associated with a fusion weld on steel has up to how many separate regions of micro
structure?

(a) 4
79
 (b) 6
(c) 1
(d) 2

155. The possible effects of having a travel speed too fast:

(a) Low toughness, slag inclusions and 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

156. What five parameters would be checked when calibrating welding equipment for mechanized MAG
welding?

(a) Joint set up, flux coating, polarity, travel speed and amps / volts
(b) Amps / volts, WFS, gas flow rate, polarity and travel speed
(c) Amps / volts, WFS, wire diameter, polarity and travel speed
(d) Electrode stick out, WFS, amps / volts, polarity and wire diameter

157. Which of the following statements is true when using a flat characteristic power source?

(a) The electrode is always dc ve

(b) The shielding is always pure argon
(c) The wire feed speed remains constant
(d) The electrode extension will have no effect on weld quality

158. Which of the following will vary the most, when varying the arc length?

(a) Voltage
(b) Amperage
(c) Polarity
(d) None of the above

159. Which of the following statement is true?

(a) The core wire in a MMA electrode has a higher melting point than the flux
(b) Electrode dc +ve is used when welding with the MIG / MAG welding process
(c) The HAZ of a carbon manganese steel weld usually has a lower ultimate tensile strength than
the weld
(d) All of the above are true

160. A multi run MMA butt weld made on C/Mn steel consists of 5 passes using 6mm electrodes. A 12
pass weld made on the same joint using 4mm electrodes on the same material will:

(a) Have a lower heat input and a higher degree of grain refinement
(b) Have a lower heat input and a coarser grain structure
(c) Have a lower amount of distortion and a higher degree of grain refinement
(d) Have a higher amount of distortion and a lower degree of grain refinement

161. The main reason for using a back purge when welding 18-8 stainless steel with the TIG welding
process is to:

(a) Control the root penetration

80
 (b) Prevent root bead porosity
(c) Improve positional welding
(d) Prevent the formation of a dense oxide layer on the root

162. A typical minimum preheat temperature for an MMA weld made on steel with a carbon content of
0.23% and manganese content of 1.3%:

(a) Preheat would not normally be required

(b) Less than 50*c
(c) A minimum of 100*c
(d) Above 280*c

163. Which is often the hardest part of a multi run weld made using MMA?

(a) The HAZ of the root

(b) The HAZ of the cap
(c) The root
(d) The cap

164. The HAZ of fusion weld:

(a) Usually has the highest tensile strength

(b) Cannot be avoided
(c) Is usually martensite
(d) Both A & B
(e) All of the above

165. Which of the following welding processes would you expect to use a collet:

(a) TIG / TAG

(b) MIG / MAG
(c) MMA
(d) All of the above

166. Which of the following may be used for the TIG / TAG welding of austenitic stainless steel?

(a) Lathanum electrode dc ve S

(b) Cerium electrode dc ve
(c) Zirconium electrode ac
(d) Thorium electrode dc ve

167. Which of the following standards is entitled electrode wire and fluxes for submerged arc welding
process of carbon steel and medium tensile steel?

(a) BS 639
(b) BS 2901
(c) BS 2633
(d) BS 4165

168. Which of the following processes use a constant characteristic?

(a) Sub-arc < 1000 amps, MMA, Electro slag S

(b) TIG / TAG, Sub-arc > 1000 amps, Electro slag S
(c) Sub-arc < 1000 amps, MIG / MAG, Electro slag D
81
 (d) MIG / MAG, Sub-arc > 1000 amps, Electro slag S

169. What are the possible results of having a too lower heat input?

(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

170. What kind of steel is used for making filler rod?

(a) Killed steel

(b) Rimming steel
(c) Carbon steel

171. Which of the following is not related to weld?

(a)

(b)

(c)

172. Which of the following NDT method is not suitable to detect sub surface defect?

(a) UT
(b) PT
(c) RT
(d) MPI

173. SAW in single pass weld will give:

82
 (a) Poor profile
(b) Burn rapidly
(c) Good penetration
(d) None of the above

174. In SAW process if voltage and current is increased and travel speed is decreased, what will be the
effect in the profile?

(a) Wider weld

(b) Higher weld reinforcement
(c) Concave weld surface

175. What change will occur on the HAZ during heating of metal caused by welding?

(a) Change in tensile strength

(b) Change in hardness
(c) Change in grain crystal structure

176. What types of electrodes needs extra treatment?

(a) Basic
(b) Rutile
(c) Cellulosic

177. Applying preheat when welding, carbon manganese steel is normally done to avoid:

(a) Slag inclusions

(b) Hydrogen cracking
(c) Lack of side wall fusion
(d) Porosity

178. Which of the following mechanical properties of a weld in carbon manganese steel is not affected if
the heat per unit length of weld is excessively high?

(a) Elongation
(b) Tensile strength
(c) Hardness
(d) Toughness

179. You observe centerline cracking in a weld that has been made at one of five work station each
making similar components. The first action to take is:

(a) Impound all welding consumables

(b) Report the occurrence to a higher authority
(c) Stop all welding
(d) Call for full NDT checks

180. Which of the following defects is unlikely to be found by visual inspection?

(a) Linear misalignment

(b) Undercut
(c) Overlap
(d) Linear slag inclusions
83
181. Which of the following welding processes uses a resistive heating system to achieve weld metal
deposition?

(a) MMA
(b) SAW
(c) Electro slag welding
(d) Resistance spot welding

182. What two functions in arc welding must be in equilibrium to enable a stable arc to be established?

(a) Arc voltage

(b) Current
(c) Wire / Electrode feed rate
(d) Metal burn off rate

183. In MMA welding, what parameter is used to control the penetration into the base material?

(a) Voltage
(b) Welding speed
(c) Iron powder in the coasting
(d) Current

184. In the welding of a butt joint made from one side, which of the following controls the profile of the root
bead?

(a) Root face

(b) Bevel angle
(c) Root gap
(d) None of the above

185. What type of power source characteristic is required for manual welding?

(a) Constant voltage

(b) Flat characteristic
(c) Drooping Characteristic
(d) Motor generator

186. Which of the following destructive test would indicate the toughness of weld metal and parent metal
HAZ?

(a) Macro
(b) Nick break
(c) Hardness
(d) Charpy vee notch

187. Degreasing components are essential for quality welding but some agents may:

(a) Cause corrosion problems

(b) Give off phosgene gas
(c) Leave residues
(d) All of the above

188. Which of the following chemical elements has the greater effect on the hardenability of a steel plate?
84
 (a) Molybdenum
(b) Chromium
(c) Titanium
(d) Carbon

189. In MIG ? CO2 welding which parameters give the greatest control of weld appearance during dip
transfer or short circuiting welding?

(a) Wire stick out length

(b) Amperage
(c) Wire feed speed
(d) Inductance

85
190. In MMA welding, the slag produced can be varied to suit the welding position. Which type of slag
would be required for welding in the HV position?

(a) Fluid
(b) Viscous
(c) None of the above
(d) Semi fluid

191. The weld metal deposit of MMA electrodes, achieves its mechanical strength through:

(a) The core wire

(b) The flux coating
(c) Iron powders with the flux coating

192. What constituent is needed in a coating of an electrode to prevent the formation of porosity in
welding of a rimming steel?

(a) Iron powders

(b) Calcium fluoride
(c) Silicon
(d) Calcium carbonate

193. Welds made with high heat inputs show a reduction in one of the following properties:

(a) Ductility
(b) Toughness
(c) Fatigue strength
(d) Mechanical strength

194. In X-ray the quality of radiographic negative is assessed by the:

(a) Density of the film

(b) IQI Indicator
(c) KVA available
(d) Stand off distance

195. A steel described as QT will have improved tensile properties because it has:

(a) Had control of chemical composition

(b) Been heat treated
(c) Been quality tested
(d) Been vacuum melted

196. Which one of the following type of steels would give rise to the formation of porosity when
autogenously welded with an arc process?

(a) Fully killed steel

(b) Semi killed steel
(c) Rimming steel
(d) Fine grained steel

197. In SAW, the use of excessively high voltage would result in:

(a) Insufficient flux melting

86
 (b) Excessive flux melting
(c) Slag removal difficulties
(d) Spatter

198. The use of cellulosic electrodes is often made when welding the root pass of pipes in the field. This is
because:

(a) H2 control is needed

(b) Iron powders in the electrode
(c) Higher arc voltage can be obtained
(d) Shorter arc length can be achieved

199. 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

200. Submerged arc fluxes can be supplied in two forms. These are:

(a) Sintered and agitated

(b) Agitated and fused
(c) Crushed and agglomerated
(d) Fused and agglomerated

201. In a steel which has improved creep properties at elevated temperature, which one of the following
elements helps in this improvement?

(a) Tungsten
(b) Manganese
(c) Molybdenum
(d) Carbon

202. Welding a steel plate of 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 improve mechanical properties in the weld

203. Which one of the following processes uses the Key holing system of fusion?

(a) Friction welding

(b) Diffusion welding
(c) Electron beam welding
(d) Autogenous TIG welding

204. In friction welding, is the metal at the interface in the:

(a) Liquid state

(b) Solid state
(c) Plastic state
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 (d) Elastic state

205. Welding procedures may require welds to be deposited at a controlled rate heat input. High heat
input would:

(a) Have poor profile

(b) Have larger grain size
(c) Have high hardness in the HAZ
(d) Have low elongation properties

206. BS 499 part II communicates by the use of symbols the type of joint preparation to be used. Listed
below are four symbols. Which of these indicates the depth of penetration of the weld required on the
joint?

(a)

(b)

10

10

(c)

10

10

(d)

207. In accordance with BS 499 what is the weld junction?

(a) The area containing HAZ and weld metal

(b) The weld metal and parent metal
(c) The boundary between the fusion zone and HAZ
(d) The part of the weld, which undergoes metallurgical change due to heat from welding

208. Which of the following are essential factors for lamellar tearing?

88
 (a) High residual stresses, poor through thickness ductility, existing plate Laminations
(b) Poor through thickness ductility, fusion face parallel with rolled direction of parent plate, most
commonly occurs in but welds
(c) Stress, poor through thickness ductility, fusion face parallel with rolled direction of parent
material
(d) Tensile stress, deoxidized parent plate, poor through thickness ductility

209. In gas welding, leftward welding is described in BS 499 as:

(a) The flame is described towards the welded part and filler material is directed toward un-welded
part of the joint
(b) The flame and filler material both directed towards welded part of the joint
(c) The flame is directed towards the un-welded part and filler material is directed towards welded
part of the joint
(d) The flame and filler material is both directed towards un-welded part of the joint

210. Which of the following is not a fusion welding process:

(a) Thermit welding

(b) Electro slag welding
(c) Laser welding
(d) Friction welding

211. When considering the heat treatment process of tempering:

(a) This is achieved by slowly heating the material to a temperature between 200*c to 650*c and
slow cooling in air
(b) This is achieved by heating the material to around 200*c and soaking for approximately 10 12
hrs and cooling down in air
(c) Very fast cooling form the austenite region
(d) All of the above could give a temper

212. Which of the following are essential variables for PWHT?

(a) Heating rate

(b) Temperature attained
(c) Cooling rate
(d) All of the above

213. Most metals expand when heated, the change in length is expressed as:

(a) Thermal conductivity

(b) Modulus of elasticity
(c) Coefficient
(d) Yielding

214. In TIG welding the nozzle is usually made:

(a) Copper
(b) Aluminum
(c) Ceramic
(d) Copper / Zinc

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215. Which of the following is the odd out?

(a) Neon
(b) Xenon
(c) Argon
(d) Nitrogen

216. The welding arc could be characterized as:

(a) A high current, low voltage arc with a flow of electrons from cathode to anode S
(b) A low current, high voltage arc with a flow of electrons flowing from anode S
(c) A medium current and medium voltage with a flow of electrons and +ve ions flowing from anode
to cathode S
(d) A voltage which always remains constant at a constant potential with a flow of electrons and ve
ions from cathode to anode

217. Which of the following are considered to be HAZ cracks?

(a) Solidification cracks, lamellar tearing and reheat cracks

(b) Reheat cracks, liquation cracks and solidification cracks
(c) H2 cracks, solidification cracks and liquidation cracks
(d) Reheat cracks, liquation cracks and H2 cracks

218. Which of the following standards entitled Visual inspection of fusion welded joints?

(a) BS 4515
(b) BS 5289
(c) BS 5135
(d) BS EN 440

219. In general it is not easy to mechanise the MMA welding process because:

(a) Short electrode length, the control of the arc length and the process uses a flat characteristic
(b) Short electrode length, the control of the arc length and flux coverings
(c) The control of the arc length, stop start problems and short electrode length
(d) Flux coverings, short electrode lengths and relationship between amps and volts

220. Which of the following statements is true?

(a) Oxygen-fuel gas cutting is essentially an oxidization thermal cutting process

(b) Oxygen-fuel gas cutting is essentially a melting process
(c) The only fuel gas used is acetylene
(d) Propane is the preferred fuel gas in oxygen-fuel gas cutting as it produces hotter flame

90
221. Which of the following best describes a semi automatic welding process?

(a) The welder is responsible for the arc gap and travel speed
(b) The welder is responsible for the travel speed only
(c) The welding plant controls both travel speed and arc gap but under constant supervision S
(d) The welding plant controls both travel speed and arc gap, no supervision required S

222. Which sub atomic particle has a +ve charge?

(a) A proton
(b) A photon
(c) An electron
(d) A neutron

223. Which material is the most susceptible to reheat cracking?

(a) High carbon steel

(b) Killed steel
(c) Creep resistant steels
(d) Austenitic steels

224. Three essential factors for producing fusion weld are melting, removal of surface oxide from the joint
surfaces and elimination of atmosphere from the region of the arc. Name the fourth one:

(a) The weld must be free from stress

(b) The filler material must match that of the weld
(c) The completed joint must at lease match the mechanical properties
(d) An arc for a heat surface

225. Which arc welding process technique is likely to be used to repair localized porosity in a weld?

(a) MMA PG position

(b) Mechanised arc welding
(c) Sub Arc
(d) All of the above
(e) None of the above

226. A welder qualified in the PG position would normally be qualified for welding:

(a) All diameters of pipe

(b) Welding positions PA, PG and PF
(c) In position PG only
(d) All pipe wall thickness

227. Name the fourth weld process crack which has a totally different formation mechanism to HICC (H2
induced cold crack), solidification cracking and lamellar tearing:

(a) Liquation cracking

(b) Reheat cracking
(c) Crater cracking
(d) Hot tearing

228. Planar defect are best described as:

91
 (a) Linear from at least one direction
(b) Rounded indications
(c) Linear from at least one direction with volume
(d) May be classed as all of the above

229. Which of the following welding processes is not classed as an arc welding process?

(a) Electro slag welding

(b) Thermit welding
(c) Plasma welding
(d) Both A and B
(e) All of the above

230. Which of the following materials has the poorest weldability?

(a) Austenitic stainless steel

(b) Martensitic stainless steel
(c) Carbon manganese steel
(d) HSLA steel

231. Which of the following in a fusion weld usually has the highest tensile strength?

(a) Weld metal

(b) Parent material
(c) HAZ
(d) Fusion zone

232. Which of the following is an alternative name for a crater crack?

(a) Cold crack

(b) Tearing
(c) Star crack
(d) Fatigue crack

233. What action must the welding inspector request if a lamination is found extending into the bevel
face?

(a) Cut back the material until a lamination free area is found
(b) Accept the bevel unless the lamination exceeds 5mm
(c) Place a sealing run over the lamination and dress flush, then make the weld as normal
(d) Action to take will depend on the agreed specification (or welding engineer/client if specification
does not state the action).

234. The deviation of the arc during arc welding due to external magnetic influences is known as:

(a) Arc strike

(b) Arc blow
(c) Paramagnetic interference
(d) Diamagnetic interference

235. The weldability of a material may be affected by:

(a) Temperature of the component

(b) The Ceq % of the material
92
 (c) The elements in the material
(d) All of the above

236. Which of the following heat treatment processes would be used for grain refinement?

(a) Annealing
(b) Normalizing
(c) Quenching
(d) H2 release

237. A repair has been made using MMA on a double V butt weld on a 10 m diameter tank. The defect
repaired was lack of inter-penetration and it had been excavated with a disc grinder prior to repair.
After repair it was determined that the wrong electrodes had been used. What action should the
inspector take:

(a) Have the repair area ground and re-repair

(b) Accept the work if the electrodes were the same flux type
(c) Heat treat the area
(d) Consult the senior inspector or welding engineer if the specification or procedure does not cover
the course of action

238. Which one of the following statements is false?

(a) Surface breaking defects are usually more detrimental to a weld in comparison with sub-surface
defects
(b) The HAZs of a steel weld usually have h higher tensile strength than the weld metal
(c) Lameller tearing may occur within the fusion zone of large fillet welds
(d) PWHT may stress relieve D

239. What is the possible cause of too mush restraint of the parent material during welding?

(a) Restraint is always desirable

(b) It may lead to cracking, especially with small welds between large components
(c) It will cause too much distortion
(d) It will cause lamellar tearing if it is present on a corner joint

240. Fluctuating loads ie cyclic stresses below the u.t.s on a weld component may lead to:

(a) Tensile failure

(b) Yield failure
(c) Fatigue failure
(d) Shear failure

241. Which of the following is a method to accurately measure the root radius of a charpy or izod
specimen?

(a) Use a machine called a shadowgraph

(b) Use pyrometer
(c) Use a vernier caliper
(d) Use a densitometer

242. Which of the following statements is true?

(a) Fillet welds are preferable to butt welds due to high strength
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 (b) Fillet welds are normally difficult to assess with NDT in comparison with butt welds
(c) Fillet welds are only made on steels
(d) All of the above are true

243. Which of the following is not an inert gas at welding temperature?

(a) Argon
(b) Neon
(c) Carbon dioxide
(d) Helium

244. Which arc welding process uses a non consumable electrode?

(a) MIG
(b) TIG
(c) SAW
(d) None of the above

245. Which of the following welding processes is not a fusion welding process?

(a) Electro slag welding

(b) Oxy-gas welding
(c) Forge welding
(d) TIG welding

246. Which of the following current types would be used for welding aluminum with the TIG welding
process?

(a) Ac
(b) Dc +ve electrode
(c) Dc ve electrode
(d) All of the above could be used successfully

247. Which of the following statements is true?

(a) Electrode dc +ve always produces a narrow deep weld pool

(b) The word Rutile means calcium carbonate S
(c) Porosity is always repairable S
(d) Dc electrode +ve is used for the MAG welding of steel

248. What four criteria are necessary to produce HICC?

(a) Hydrogen, moisture, martensite and heat S

(b) Hydrogen, poor weld profile, temperature above 200*c and slow cooling S
(c) A grain structure susceptible to cracking, stress, hydrogen and a temperature below 200*c
(d) Weld defects, pearlite, hydrogen and a temperature above the melting point for the material

249. How many temperature indicating crayons would be required to ensure the preheat temperature was
lying within a specified range?

(a) 1
(b) 2
(c) 3
(d) As many as possible
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250. A carbon equivalent of 0.48%:

(a) Is hig for a C-Mn steel and may require a preheat temperature over 100*c
(b) Is insignificant for a C-Mn steel and preheat will not be required
(c) Is calculated from the heat input formula
(d) Is not a consideration for determining preheat temperature

251. A martensite grain structure:

(a) Is always present in welds on steel

(b) Is brittle grain structure
(c) Is obtained when the preheat temperature exceeds 200*c
(d) All of the above

252. Which of the following is not a type of crack?

(a) Fissure
(b) Lamellar tear
(c) Fish eye
(d) Reheat crack

253. What do you understand by the term minimum interpass temperature?

(a) Minimum post heat temperature

(b) Minimum stress relief temperature
(c) The lowest temperature to be used when normalising
(d) The lowest temperature allowed during welding and between passes

254. Which of the following welding processes may be described as a low H2 process in comparison with
MMA welding?

(a) TIG
(b) MIG
(c) MAG
(d) All of the above

255. Which of the following standards is entitled imperfections in Metallic fusion welds with explanation:

(a) BS EN 25817
(b) BS EN 26520
(c) BS EN 22553
(d) BS EN 24165

256. Which of the following could cause root concavity?

(a) Excessive back purge pressure and very high heat input
(b) Excessive back purge pressure and entrapped gas
(c) Excessive root grinding and a slow travel speed
(d) Excessive root grinding and excessive back pressure

257. High Phosphorous contents in carbon steels may cause:

(a) Cold shortness

95
 (b) Hot shortness
(c) An increase in ductility
(d) An increase in malleability

258. If arc strikes are found on carbon steel (C eq of .5%), what undesirable grain structure may be
present?

(a) Perlite
(b) Martensite
(c) Bainite
(d) All of the above are undesirable grain structures in constructional steels

259. How do you convert psi to N/mm2?

(a) Divide by 144.9

(b) Multify by 25.4
(c) Divide by 14.7
(d) Multify by 14.7

260. How many Mpa are equal to 1 N/mm2?

(a) 144.9
(b) 25.4
(c) 14.7
(d) 1.

261. What is the UTS of a material?

(a) The proof stress

(b) The maximum load a specimen can withstand
(c) The limit of proportionality
(d) The point of plastic deformation

262. What is a charpy test used for?

(a) To measure the ductility of a material

(b) To test the tensile strength of a material
(c) To test the notch toughness of a material
(d) To measure crack propagation speed

263. What is a Vickers Pyramidal Indentor used for?

(a) To measure indentation toughness

(b) To measure ductility
(c) To measure hardness
(d) All of the above

264. What is the main constituent of a rutitle electrode flux?

(a) Cellulosic
(b) Titanium dioxide
(c) Calcium carbonate
(d) Asbestos

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265. What does the 70 represent on a E 7010 AWS classified electrode?

(a) 70 N/mm2 minimum uts

(b) 70 N/mm2 minimum impact strength
(c) 70,000 psi minimum uts
(d) 70,000 psi minimum impact strength

266. Basic coated electrodes provided in standard packaging:

(a) Are deep penetrating electrodes

(b) Should be heated prior to welding to obtain a low H2 content in the weld
(c) Should be heated to totally eliminate H2 in the weld
(d) Should not be preheated as this will detrimentally effect welding performance

267. Sodium silicate in an MMA electrode flux:

(a) Stabilizes the arc

(b) Binds the ingredients of the flux
(c) Forms slag
(d) All of the above

268. Which electrodes are very susceptible to causing porosity in the deposited welds if long arc
employed?

(a) Basic
(b) Cellulosic
(c) Rutitle
(d) None of the abobe

269. What is the purpose of a rectifier?

(a) To adjust the voltage

(b) To adjust the amperage
(c) To covert ac to dc
(d) To reduce the chance of arc strike

270. A welding process using equipment with a flat characteristic:

(a) Will require a permanent or temporary backing to be pre placed on the root side of the welds
(b) Has the advantage of being able to use any type or size of electrode
(c) Is likely to be using an electrode less than 2 mm dia.
(d) Is likely to be using an electrode more than 2 mm dia.

271. Which of the following best describes the duty of a welding inspector?

(a) To carry out inspection and NDT in order to find all weld flaws present
(b) To attempt to ensure that all welding and any associated actions are carried out in accordance
with agreed specification
(c) To carry out welding inspection and radiography interpretation with agreed procedure for the
work being undertaken
(d) To make sure that all the welds are defect free

272. Which of the following butt weld preparation is usually the most susceptible to lack of side wall fusion
during MMA welding?
97
 (a) A double sided U preparation
(b) A single V preparation
(c) A double sided V preparation
(d) It is not possible to induce lack of side wall fusion during MMA welding

273. What is the leg length of a fillet weld?

(a) The distance from the toe to the face

(b) The distance from the root to the face center
(c) The distance from the root to the toe
(d) The distance from the toe to the toe

274. What is the throat thickness of a mitre fillet weld equal leg length?

(a) The distance from the toe to the face

(b) The distance from the root to the face center
(c) The distance from the root to the toe
(d) The distance from the toe to the toe

275. Which of the following will vary the most when varying the arc length using the MMA process?

(a) Voltage
(b) Amperage
(c) Polarity
(d) None of the above

276. What is a possible result if the amperage is too low during the welding of a root bead using an arc
welding process with a consumable electrode?

(a) Incomplete root penetration

(b) Lack of root fusion
(c) The freezing of the electrode to the work piece
(d) All of the above

277. Why have a high OCV with MMA welding?

(a) To initiate
(b) To obtain penetration
(c) To avoid lack of fusion
(d) MMA welding does not have a high OCV

278. What is another term for suck back?

(a) Concave root

(b) Elongated porosity in the root
(c) Lack of penetration
(d) A slag line above the root pass

279. A center line crack in a fillet weld:

(a) May be repaired if the welding engineer for the client says so
(b) May be related to a poor setup
(c) May be related to the way the grains solidify
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 (d) All of the above

280. What is lamellar tearing?

(a) Strain cracking at the edge of bend test specimen S

(b) A type of crack occurring in the parent material is associated with poor through thickness
ductility especially when large fillet welds or tee butt joints are made on the material
(c) A type of crack found in welds which have undergone several thermal cycles either during
welding or PWHT
(d) It is another name for a plate lamination caused during plate or pipe manufacture S

281. What is a crater pipe?

(a) Another term for concave root

(b) Another term for a burn through
(c) A type of gas pore found in the weld crater
(d) A shrinkage defect which may be found in a weld center

282. Why is a weld procedure qualification test necessary?

(a) To ensure the welder is able to make sound welds meeting the requirements of the agreed
welding procedure
(b) To ensure the welder satisfies the NDT and mechanical requirements of the specification
(c) To give maximum confidence that the variables used for welding are compatible and will
produce sound welds meeting the requirements of the agreed specification
(d) To give a guarantee that defect free welds are going to be produced

283. Which of the following is not specified on a typical written welding procedure?

(a) To make sure the welder can weld

(b) To make sure the weld is able to withstand stress
(c) To give maximum confidence that the welder can produce welds to meet the requirements of
the specifications(s)
(d) To make sure the welder can produce a weld free from discontinuities

284. A welder qualified in the 6G position would normally be qualified for welding:

(a) All diameter pipes

(b) All metals
(c) In all positions for the butt welds and fillet welds
(d) All of the above

285. Non-planar defects associated with a weld:

(a) Are not significant

(b) Must be removed
(c) Are not usually as significant as planar defects
(d) Only exit sub-suface

286. Lamellar tearing:

(a) Only occurs in the rolled direction of a parent material

(b) Is a HAZ type of type of crack
(c) Is another term for a lamination
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 (d) All of the above

287. Cold lapping is another term for:

(a) Lack of fusion at the toe of a weld

(b) Low amperage
(c) Undercut
(d) Hydrogen cracking

288. Which of the following sentences applies to the use of basic MMA electrodes?

(a) They are used to deposit weld metal in the vertical position only
(b) They are used where deep penetration is a primary requirement
(c) They are usually used to deposit weld metal of low hydrogen content
(d) Basic electrodes are chosen when ease of use is of importance

289. Which of the following would show as light indications on a radiograph?

(a) Slag inclusions and copper inclusions

(b) Tungsten inclusions and excessive penetration
(c) Cap undercut and root piping
(d) Excessive cap height and incomplete penetration

290. Which of the following welding processes does not use a consumable electrode?

(a) SAW
(b) MMA
(c) TIG
(d) ESW

291. The hardest grain structure capable of being produced when welding C/Mn steel is:

(a) Bainite
(b) Austenite
(c) Pearlite
(d) Martensite

292. The presence of too much hydrogen when welding C/Mn steels would be to cause the formation of:

(a) Porosity
(b) Lack of fusion
(c) Crack
(d) undercut

293. What term applies if a carbon steel weldment is heated up to a temperature which creates austenitic
grain growth and then is allowed to cool in air?

(a) Normalizing
(b) Annealing
(c) Quenching
(d) Tempering

294. Why is stress relief (PWHT) some times carried out on weldments?

100
 (a) To dissolve entrapped hydrogen
(b) To remove residual stresses
(c) To fuse planar defects
(d) All of the above

295. When welding a double V butt with the SAW process the presence of center line porosity may be due
to:

(a) Damp flux

(b) Incomplete penetration
(c) Contaminated weld preparation
(d) Atmospheric contamination
296. MIG welding tends to be susceptible to lack of fusion problems. This is because of:

(a) Poor maintenance of equipment

(b) Incorrect settings
(c) Poor inter run cleaning
(d) All of the above

297. Welding a single V butt with laminations showing on the side wall may give rise to:

(a) Lamellar tearing

(b) Solidification cracking
(c) Martensite
(d) Undercut

Stray arcing may be regarded as a serious defect. This is because:

(e) It may reduce the thickness dimension of a component

(f) It may cause liquation cracks
(g) It may cause hard zones
(h) All of the above

298. Which of the following statement is true?

(a) The core wire in a MMA electrode has a higher melting point than the flux
(b) Electrode dc +ve is used when welding with the MIG / MAG welding process
(c) The HAZ of a carbon manganese steel weld usually has a lower ultimate tensile strength than
the weld
(d) All of the above are true

299. In general it is not easy to mechanise the MMA welding process because:

(a) Short electrode length, the control of the arc length and the process uses a flat characteristic
(b) Short electrode length, the control of the arc length and flux coverings
(c) The control of the arc length, stop start problems and short electrode length
(d) Flux coverings, short electrode lengths and relationship between amps and volts

300. Which material is the most susceptible to reheat cracking?

101
 (a) High carbon steel
(b) Killed steel
(c) Creep resistant steels
(d) Austenitic steels

301. Name the fourth weld process crack which has a totally different formation mechanism to HICC (H2
induced cold crack), solidification cracking and lamellar tearing:

(a) Liquation cracking

(b) Reheat cracking
(c) Crater cracking
(d) Hot tearing

302. Which of the following welding processes is not classed as an arc welding process?

(a) Electro slag welding

(b) Thermit welding
(c) Plasma welding
(d) Both A and B
(e) All of the above

303. Which of the following materials has the poorest weldability?

(a) Austenitic stainless steel

(b) Martensitic stainless steel
(c) Carbon manganese steel
(d) HSLA steel

304. A center line crack in a fillet weld:

(a) May be repaired if the welding engineer for the client says so
(b) May be related to a poor setup
(c) May be related to the way the grains solidify
(d) All of the above

102