pre-heating most likely to be required?

High strength alloy steels

sensitivity of radiograph is by : IQI ( Penetrameter)

The weld metal deposits of manual metal arc electrode achieves its mechanical strength
through- The flux coating

To weld a carbon steel which electrode will give the greatest deposition rate in SMAW - Iron
Powder

The use of cellulosic electrode is often made when welding the root pass of pipes in the field.
This is because- Higher arc voltage can be obtained

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?
The formation of chromium carbides

Steel heated to above its critical temperature , the structure produced is - Austenite

The higher the alloy content of steels: High alloy steels do not influence HIC susceptibility

Ar+O2 for stainless steel

Code & Standard

BS 5289 @ 17637- Visual Inspection
15614 @ 288-WPS
9606 @ 278 - WQT
22552 @2553 - WELDING SYMBOL
2560 - MMA Welding Consumable
499 - Covered Electrode (MMA)
BS EN 26520- imperfections in Metallic fusion welds with explanation

Code of practice - a set of rule for manufacturing a specific product

A procedure is a document which:

-Specifies the way to carry out an activity or a process
Cellulosic - Exxx0-1 Rutile - Exxx2-3-4 Basic - Exxx5,6,7,8
H2 80-90ml/100gram H2 25-30ml/100gram H2 <5ml/100gram
1. No bake. 1. Can be dry to lower H2 but no 1. Bake 350oC 2Hours
2. High arc Volt. bake. 2. Used for high pressure
3. Deep penetration 2. Used mainly on general work,thick section steel
&fusion characteristics purpose. & high strength steel.
enable welding at high 3. Use for low pressure pipe 3. High toughness & low
speed without risk of work. hydrogen content, low
lack of fusion. crack tendency
4. All position.
5. Large volume shielding
gas.
6. Use for stove pipe
welding.
TIG
Zirconiated-Al
Ceriated-
Lanthiated-

Vertex
DC-sharp
AC-ball type after chamfer & ignite

Type of transfer mode

spray dip globular pulse
High current Low heat input Undesirable mode Lower HI < spray
Used for thick Used for thin 3-6mm Used for steel
section section >1mm
>6mm steel <3.2mm
>3mm Al
Max penetration Lack of fusion PA position only Good fusion, high
productivity

Normalised
Heating material to an elevated temperature 880~920oC then allowed to cool in air to ambient
temperature. optimize strength and toughness
Reduce hardness and increase ductility.

Applied to : C-Mn steel and some low alloy steels.

Quenching & Tempering (QT)

Heated to ~900oC then cooled as quickly as possible by quenching in water or oil. After
quenching, steel must be tempered (softened) to improve the ductility (reheat to tempering
temperature, soak and air cool)

Applied to : some alloy steels to give higher strength toughness or wear resistance.
Solution Annealed
Steel heated to ~1100oC (100% austenite), rapid cool cooling by quenching in water or oil

Applied to austenitic stainless steel

Annealed
Heating a material to an appropriate temperature for a certain period of time and then slowly
cooling with furnace

Reduce strength and toughness

Low hardness
improve ductility

Classification of steel

Alloy steel are considered the type of steel that predominant contain extra alloying element
other than Iron (Fe) and Carbon (C)

Carbon (C) - Strength

Manganese (Mn) - Toughness
Silicone (Si)- <0.3% Deoxidiser
Aluminium (Al)- Grian Refiner
Chromium (Co)- Corrosion resistance
Molybdenum (Mo) - 1% for creep resistance
Vanadum (V)- Strength
Nickel (Ni)- Low temperature application
Copper (Cu) - Used for weathering steels (corten)
Sulfur (S)- Impurities element cause hot shortness
Phosphorous (P)- Impurities element cause cold shortness

Low Alloy steel <7% alloying element

Steel for elevated temperature service.

Cr and Mo additional give improved strength at high temperature ,corrosion and good creep
resistance

2.25% Cr (Chromium) + 1% Mo (Molybdenum)

9% Cr + 1% Mo

Steel for low temperature service

Ni (Nickel) additional give good toughness at low temperature
Steel may referred to as cryogenic steels.

3.5% Ni steel
9% Ni steel

High Alloy steel >7% alloying element

Type of stainless steel
Austenitic Grades
Alloyed with Cr and Ni
18% Cr + 8% Ni (304 & 316)
Main phase is austenite
Wide range application because:
 Very low temperature services (cryogenic)-Ni
 High temperature service - Cr
Moderate corrosion resistance
NON-MAGNETIC
HIGH COEFFICIENT THERNAL EXPANSION(more distortion)
LOW THERMAL CONDUCTIVITY (hold heat)

Ferritic & Martensitic Grades

Alloyed with Cr but have or no Ni

Example - 13% Cr (Ferritic) 13% Cr + 4% Ni
Ferritic grades have ferrite as main phase and so can be Magnetic
martensitic grades have martensitic as main phase
Similar characteristic to C & Mn steel but with improve corrosion resistance
Not suitable for very low temperature but some Ferritic grades used to good resistance to
scaling at high temperature.

Duplex Grades

Alloyed with Cr and Ni

Example - 22% Cr + 5% Ni & 25% Cr + 7% Ni
Call duplex because 2phases - 50% Ferrite + 50% austenite
Present ferrite - can be magnetic
Stronger than austenitic 304 & 316 and good resistance to certain type of corrosion
Not suitable for low temperature or very high temperature service

HICC

H2-More than 15ml/100gram of weld metal

Moisture on the electrode,water vapour in the air or in the shielding gas, oxide or grease on the
plate
TIG <3ml
MIG <5ml
ESM <5ml
MMA <5ml
SAW <10ml
FCAW <15ml
Stress-more than 1/2 yield stress
Design,balanced welding

Temperature-<300oC
Hydrogen entrapped inside weld meta,HAZ cant diffusion below 300oC

Susceptible Microstructure-Hardness >400HV Vicker (Martensite)

Preheat reduces cooling rate which reduces the risk of susceptible microstructure

Weld Decay

Service failure problem-cause by corrosion may be long time in service

Crack type : inter granular corrosion

Location : Weld HAZ(longitudinal)
Steel type : Stainless Steel
Microstructure : sensitised grain boundaries (formation chromium carbides)
Precaution: use low carbon grade stainless steel eg 304L,316L free carbon in solution to ensure
Cr Carbides formation is minimal, use stabilized grade stainless steel eg 321,347, 348 ,PWHT

Weld decay may be minimized by adding elements called stabilisers. These may be:
Titanium/ Niobium

MIG
Usually Ar shielding
Can be Ar+He mix
Used for non-ferrous alloy eg. Al,Ni

MAG
Has oxidation gas shield
Can be 100% for Ferritic steel
Often Ar+12-20% CO2
Ar+O2 for stainless steel

What mean by ferritic

What element not change if weld use high HI
Elongation??

Why hot pass so called??

Fuse Flux
Acid type
Flaky appearance (sharp)
Lower weld quality
Low moisture intake
Low dust tendency
Good re-cycling
Very smooth weld profile

Agglomerated flux
Basic type (baked)
Granulated appearance
High weld quality
Tendency to absorb moisture
Additional of alloy
Low consumption
Easy slag removal
Smooth weld profile

Dont answer ALWAYS

NON porous DPI

Stress-N/mm load per unit length?
Strain-elongation ?Extension of gauge length divided by original gauge length

Proof stress is used when non-ferrous metals are undergoing tensile tests to determine the
equivalent:
c. Yield strength

One advantage of metal gas arc shielded welding is:

b. Produces a deposit low in hydrogen content

3. The use of flux with gas shielded metal arc welding allows:
b. A stable arc when using high current densities

What destructive test would be required to ascertain the likelihood of cracking in the heat
affected zone of a weld?
d. Macro test

Which electrode classification would be relevant to AWS A5.1-81?

a. E 6013

The likelihood of brittle fracture in steels will increase with:

a. A large grain formation
b. b. A reduction of in-service temperature to sub zero temperatures
c. c. Ferritic rather than austenitic steels
d. d. All the above

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

When MMA welding low carbon steel which electrode will give the greatest deposition rate?
Iron powder

Inherent rectification of the electrical output is produced in the arc when TIG welding using:
b. AC without a suppressor

Gamma rays and X-rays are part of a family of waves called:

c. Electromagnetic waves

Cap height - excess weld metal?

An austenitic stainless steel may suffer:
a. Weld decay.
b. Sensitisation.
c. Solidification cracking.
d. All the above.

Which defect would you expect to get in TIG welds in non-deoxidised steel?
b. Porosity.

Fish – eyes, chevron cracks and fissures are:??

A typical minimum OCV requirement for MMA(111) using either rutile or cellulosic electrode
would be;
D) 50 Volts

A common gas mixture used in process 131 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

An 80 mm diameter pipe, 10 mm wall thickness is to be radiographed using the double wall

single imagine technique. The source to be used is iridium. Which of the following statements
is true?
A) It should not be done as the thickness is below that recommended
B) It would be better to use a cobalt 60 source in this instance
C) There in no problem with the technique
D) The preferred method is the double wall, double image technique

A 300mm diameter pipe, 10mm wall thickness is to be radiographically tested using the double
wall single image technique (DWSI). the source to be used is Ir192. Which of the following
statements is true?
A) It should not be done as the thickness is below that recommended
B) It would be better to use a cobalt 60 source in this instance
C) There is no problem with the technique
D) Only the double wall, double image technique should be used with Iridium

Voltage and amperage meters have been removed from GMAW equipment making calibration
invalid, the equipment should be:
A) Quarantined
B) Only used for tack welds
C) Only used if validated
D) Monitored closely by the welding inspector for amperage and voltage

The purpose of a hot pass is to:

A) Improve fusion
B) Improve profile
C) Remove hydrogen
D) Remove Sulphur

Strain is equal to:

Stress
Load divide by cross – sectional are
Extension of gauge length divided by the original gauge length-??
Toughness

A document that is established by consensus and approved by a recognized body and provides,
for common and repeated use, guidelines, rules, characteristics for activities or their results,
aimed at the achievement of the optimum degree of order in a given context is called:

Normative document
Regulation
Specification
Standard

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

 Voltage
 Welding speed
 Iron powders in the coating
 Current-??
 1. When hydrogen control is specified for a manual metal arc-welding project the electrode would
normally be:

 Cellulosic
 Iron oxide
 Acid
 Basic-?

When MMA welding what will be the effect on the weld if the electrode was changed from DC-
ve to AC?
A) None-??
B) Higher deposition rates
C) There would be more penetration or a slight decrease in deposition rate
D) The arc would become unstable

Is it permissible to allow a welder to carry out a MMA (SMAW) welding procedure test if he is
not qualified?
A) No
B) Yes as long as the Welding Engineer is happy to allow it-??
C) Yes as long as he has a TIG (GTAW) qualification
D) Yes as long as no NDT is required on the finished weld

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

Homogeneous joint: welded joint in which the weld metal and parent metal have no significant
differences in mechanical properties and/or chemical composition.

Heterogeneous joint: welded joints in which the weld metal and parent materials have
significant differences in mechanical properties and/or chemical composition.

Dissimilar material joint: welded joint in which the parent materials have significants

Autogenous weld: A fusion weld made without filler metal by TIG, plasma, electron beam,
laser or oxy-fuel gas welding.