CLF. THE WELDING INSTITUTE Welding Inspection, Steels ~ WIS 5 Assessment Question Paper (MSR-AWI-1 05) \Z /s Z LE... DIN. THUY. Answer all questions Name: 1. What is the Arc energy for the following welding process parameters? Amps 140, Volts 21, Travel speed 250mmimin. VY Ya. 0.7 Kum b. 0.6 Ki/mm c. 0.01 Kuimm 4. 0.7 Jimm 2. What is the effect of tempering after quenching a. Toughness and strength are increased. b. Toughness and strength are reduced. c. Toughness reduced and strength increased 4, Toughness increased and strength reduced 9 . Toughness increased and hardness increased 3. What is the ratio between the leg length and the design throat thickness on a mitre fillet weld with equal leg lengths a ito b. 2to1 Vo. 1414101. Sf 4d. Allof the above it depends upon the leg length size. WIS 5 Qu paper MSR-AWI-1 05 issue5 Date; 10/02/05 lorsTWI MT. ‘THE WELDING INSTITUTE 4. The toughness and yield strength of steel is reduced by: a. Reducing the grain size b. Increasing the heat input. “ec. Reducing the heat input. 4. Botha andb. = 5. Which of the following statements is true if applicable to a charpy vee notch impact test a. It's a destructive test used to assess materials ductility in the weld zone. b. It's a mechanical test used to determine a welds resistance to creep. ve. It's a dynamic test, which is used to give a measure of notch toughness. - +l It's a static test used to determine materials toughness in the notch region. 4 fe Bothaandc. VW 6. How can you tell the difference between an EN/ISO weld symbol and a BS weld symbol? a. The EN/ISO weld symbol will always have the arrow side weld at the top of the reference line. Vb. The EN/SO symbol has the welds elementary symbol placed on a dashed line |, lying above or below the solid reference line to indicate a weld on the other side. The EN/ISO symbol has a fillet weld leg length identified by the letter ‘a’ d. The EN/ISO symbol has a fillet weld throat thickness identified by the letter "2". e. Both b and d. 7. What is the possible effect of having the heat input too low during welding? ‘a. Low toughness, entrapped hydrogen and low hardness. ~b. High hardness, lack of fusion and entrapped hydrogen. ©. Entrapped hydrogen, low toughness and high ductility. d. Lack of fusion, low toughness and a reduction in ductility. WIS 5 Qu paper MSR-AWI-1 05 issues Date: 10/02/05 2009TWI CLM 8 An MMA electrode classified as E7018 is: yu Abasic low hydrogen electrode containing iron powder. ~ b. Arutile electrode containing iron powder. ©. Acellulose electrode suitable for welding in all positions. ‘THE WELDING INSTITUTE FE 4 Abbasic electrode depositing weld metal with yield strength of a least 70,000 psi ve. both aand d. 9. The number 135 is placed at the end of the reference line on a weld symbol. According to iSO 2553 what does this number indicate? a. The welding process is stated as MMA . The welding process is stated as TIG The welding process is stated as SAW |, NDT is to be carried out after welding . None of the above Y 4 10. Which of the following is the most likely to be considered an essential variable for a welder qualification test? a. Achange from an electrode classified to BS EN 499 as an E46 3 INI B to an electrode classified to AWS AS.1 as an E7018, Wo. A change of pipe wall thickness by atleast 15mm. V// A change in pre-heat temperature from 50°C to 100°C. ‘A change from PC welding position to PA welding position e. All of the above, 11 What would be a typical appearance of a ductile fracture surface? Ya. Rough randomly torn and a reduction in area. wa b. Smooth fracture surface displaying beach marks ©. Step like appearance. \ d. Bright crystalline fracture with very little reduction in area. \ e, Botha andb. WIS 5 Qu paper MSR-AWI-1 05 issueS Date: 10/02/05 3.009TWI CLT. ‘THE WELDING INSTITUTE 42. In EN 499, what does the number 50 represent in the following electrode classification? 503 1NiB 16001 HS. a. Aminimum of 50 N/mm? yield strength. vb. A minimum of 500 N/mm2 tensile strength. A minimum of 50000 psi yield strength A minimum of 50000 psi tensile strength e. None of the above. 4 WwW 43, Increasing the carbon content of a steel will: a. Increase the hardness and toughness, b. Decrease the hardness and toughness Jc. Increase hardness, decrease toughness = \/ d. Decrease hardness, increase toughness 14. Which of the following is applicable for the HAZ on a C/Mn stee! weld if the heat input increases: Both hardness and width is increased. b. Hardness decreases, width increases. ee c. Both hardness and width decreases. ( Vd. Hardness increases, width decreases. 18. What is the main reason for the application of pre-heat a, To change the chemical composition of the weld and parent material. ~b. The control the hydrogen and prevent cracking. vo ©. To remove residual stresses. d. Both a and b. @. All of the above WIS 5 Qu paper MSR-A\WI-1 05 issueS Date: 10/02/05 40r9Ee TWI CMT. THE WELDING INSTITUTE 16. Which of the following is most likely to increase the chance of solidification cracking? a. Reduction in sulphur content of the parent material ¥ b. Increased restraint on the joint during welding. Vv c. Increase in weld hydrogen content from 15 mi/100 g to 25 m/I100g. d. Poor through thickness ductility in the materials being welded. e, Both a and b. 17. What is the effect of full annealing compared to normalizing? a. Areduction in grain size. vb. Anincrease in grain size. Y ¢. Anincrease in toughness d. The grain size will not be affected. e. None of the above . Which of the following elements may cause cold shortness a. Sulphur. Phosphorous _¥~~ . Manganese. V4. Silicon 19. When considering the advantages of site radiography over ultrasonic inspection Which of the following applies? a. Apermanent record produced, good for detecting lack of sidewall fusion in a single U butt weld and defect identification. b. Apermanent record produced, good for the detection of all surface and sub- surface defects and assessing the through thickness depths of defects. Ve Permanent record produced, good for defect identification and not as reliant upon surface preparation. FE 4. No controlled areas required on site, a permanent record produced and good for assessing pipe wall thickness reductions due to intemal corrosion. ©. Botha andc v WIS 5 Qu paper MSR-AWI-1 05 issues Date: 10/02/05 50f9TWI CLM. 20. Which of the following materials are the most susceptible to HICC in the weld zone ‘THE WELDING INSTITUTE . Carbon Manganese steel Micro alloyed steel (HSLA). Austenitic steel Both a and b v All of the above 21. Lamellar tearing is: Va. Aproduct defect caused during the manufacturing of certain steels b. Acrack type, which occurs in the parent material due to welding strains acting in. | / the short transverse direction of the parent material, Atype of hot crack asso phosphorous). 4) ‘ed with impurities (sulphur, carbon and d. Atype of crack that occurs in the weld or parent material due to cyclic stresses. 22. Which of the following statement maybe considered correct when deating with agglomerated fluxes? ~ Easy addition of additive - They're less hygroscopic than other types + Flaky appearance - Need to bake, prior to their use Less dust tendency oeena Statements 1 & 4 are correct ~ Answer 1 and 3 are correct Answer 4 and § are correct VD. — Statements 1, 2,4 and 5 are correct - OP 23, Which of the following is applicable to the heat treatment process of normalising carbon-manganese stee! a. Itis always carried out below the lower critical limit. b. Itis carried out to ensure the material has maximum tensile strength. ~ . Itis carried out to ensure the material is of maximum ductility and malleability in preparation for extensive cold working operations. V%a. tis carried out at approximately 910°C for the purpose of grain refinement WIS 5 Qu paper MSR-AWI-1 0S issueS Date: 10/02/05 6or9TWI ETT. 24. Atee joint on a support bracket is to be welded both sides using 5 mm leg length fillet welds, each weld is to be intermittent 50 mm in length, and the gap between each weld is fo be 25 mm. In accordance with EN 22553 which of the following symbols gives the correct representation? ‘THE WELDING INSTITUTE “ soe) Ys __ 8 x50(28) sl 50 @5) 5 x50 (25) b. SIX 25. (50) 2 48x50 (25) a 25 (50) 5 x50 (25) 25. Austenitic stainless steel can be identified by: a. Very shiny appearance. wb. Lack of magnetic attraction. 4 c. Its extreme hardness. d. None of the above 26. Ultrasonic testing is preferable to radiographic testing due to’ a. Its ability to detect all defects. b. Lower amount of operator skill required. Cc. Its ability to detect laminations. a 4. Its ability to detect both sub-surface and surface defects in Austenitic stainless steel. WIS 5 Qu paper MSR-AWI-I 05 issueS Date: 10/02/05 7089TWI CMT THE WELDING INSTITUTE 27. Which of the following flame types would you expect to be used for the cutting of mild steel? a. Carburising flame. vb. Oxidising flame. — Fe Reducing flame. d. Neutral flame. 28. The heat affected zone of a carbon steel fusion weld a. Usually has the highest tensile strength and highest toughness values vb. Usually has the lowest toughness values and cannot be avoided == Is usually gamma iron phase and cannot be avoided Both a and c. All of the above. ead 29. Awelding process where the welding plant controls the travel speed and the arc gap, but under constant supervision using a shielding gas mixture of 80% argon — 20% carbon dioxide is termed a, Amanual MAG process. b. Asemi-automatic MAG process. ©. Amechanised MIG process. va, Amechanised MAG process. \/ 30. The main reason for toe blending on certain welded components is: a. Corrosion considerations vb. Fatigue lite v Appearance. Allof the above WIS 5 Qu paper MSR-AWI-1 05 issue Date: 10/0205 80f9TWI 2t/so CLM. THE WELDING INSTITUTE Welding Inspection, Steels —- WIS 5 Multi —- Choice Question Paper (MSR-WI-2) wk. -RIMH. THIAY. Answer all questions Name TT 1. Defects outside the permissible limits of the applicable specification should be: a. The decision is up to the welding inspector. vb. Repaired. c. Always double checked using NDT. d. — Allof the above. T 2. Flux cored wires may be advantages over solid wires because: a Higher deposition. b. Lower hydrogen contents in the deposited welds. c. Easy addition of alloying elements. vd. Botha ando. e. All of the above. TT 3. Movement of the arc by magnetic forces in an arc welding process is termed: a. Are deviation. b. Are misalignment. ve. Arc blow. d. Stray arc. T4 A crack type most associated with the submerged arc welding process is: a. Hydrogen cracking in the HAZ. vb. Solidification cracking. Lameliar tearing. Fatigue cracking. WIS 5 Qu paper MSR-WI-2 10f8 issue 4 Date: 17/02/05TWI CLM. THE WELDING INSTITUTE T 5. Which of the following processes joins metals plastically. ya. __ Friction welding. b. Resistance welding. c. Are welding. d. Plasma welding. All of the above. ‘T 6. What type of power source characteristic is required for a manual process? a. Constant voltage. b. Flat characteristic. vo. Drooping characteristic. d None of the above. T 7. Which of the following electrodes and current types may be used for the TIG welding of nickel and its alloys? va. Cerium electrode, DC -ve. b. Zirconium electrode, AC. .- c. Thorium electrode, DC +ve. d. _Allof the above may be used. - T 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. ve. —_ Entrapped hydrogen, an increase in hardness and lack of fusion d. _ Entrapped hydrogen, a reduction in carbon content and lack of fusion. WIS 5 Qu paper MSR-WI-2 20f8 issue 4 Date: 17/02/05TWI VT THE WELDING INSTITUTE “T 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. Prevent the possi ty of porosity. Prevent excessive root penetration Prevent the formation of a dense oxide layer forming in the root 10. The possible effects of having a travel speed too fast: a (Tb. ° vd. Low toughness, slag inclusions and cap undercut. High hardness, slag inclusions and a narrow thin weld bead High hardness, excessive deposition and cold laps Low toughness, poor fusion and slag inclusions. T 11. Ifarc blow exists when welding with the MMA welding process, this can be best reduced or eliminated by: a. Yb. °. a. A change from AC to DC current Acchange from DC to AC current. A change from DC 4ve to DC -ve. A change from DC -ve to DC +ve. -T 12. When welding a double-V butt weld with the submerged arc welding process the presence of centre line porosity may be due to: a Damp flux. ~ b. Contamination on the weld preparations. c. Incorrect flux depth Vd. Allof the above. WIS 5 Qu paper MSR-WI-2 30r8 issue 4 Date: 17/02/05TWI CMT. T 13, The inclusion of an inductance in the welding circuit when using MIG/MAG. welding process is to: THE WELDING INSTITUTE. va, Control the rate of spatter in the dip transfer mode, b. _ It enables the welder to weld in position with the spray transfer mode. It allows for thicker filler wires to be used (2.6-3.6mm diameter). d. _Itallows full contro! over droplet size in the spray transfer mode. “T 14. Anundesirable property of aluminium oxide residue, when welding is that it: a. Decrease weld pool fluidity. 4b. Requires more heat to melt it when compared to aluminium, c. Causes the welder to travel to quickly. d. The presence of the oxide makes aluminium impossible to weld 7 15. 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? e. Copper inclusions and excessive cap heights f. Excessive root penetration and porosity. g. _ Slag inclusions and crater pipe. « vh. Lack of fusion and poor cap profiles. 4-16. When considering the tungsten arc welding process what is the purpose of the down-slope (slope-out) control? a. _ Ensure good penetration b. . To prevent arc striking on the parent material, wc. Tohelp prevent the formation of crater pipe and possible cracking. d. To help prevent tungsten inclusions during welding, WIS 5 Qu paper MSR-WI-2 4of8 issue 4 Date: 17/02/05TWI CMT. THE WELDING INSTITUTE. ‘T 17. Whenconsidering thermal cutting local hardening can be reduced by: a. __ Increasing the cutting speed. b. The use of propane as a fuel gas. vc. Pre heating the material to be cut. da Alll of the above. “18. Ina semi-automatic welding process, which of the following shielding gas/gas mixtures would normally give the deepest penetration on steel? a 100% argon. vb. 100% CO2. c. 75% argon + 25% COz, d. —_ Allof the above would give the same depth in penetration. - T 19. Ina MMA welding process, which of the following statements are false? a. Anarc gap, which remains almost constant even if as usual the welder v varies the position of the electrode. b. — Avoltage, which remains almost constant even if as usual the welder, varies the arc gap. cc. Acurtent, which remains almost constant even if as usual the welder, varies the arc gap. vd. Aandb. e. — Allofthe above. F 20. 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. vb. Pulse transfer. © Spray transfer. d. Globular transfer. WIS 5 Qu paper MSR-WI-2 Soff issue 4 Date: 17/02/05TWI CMT. TT 21. Which of the following current types would you expect to be used for the welding of aluminium with the TIG welding process? THE WELDING INSTITUTE a DC-~ve. b. DC +ve. vc. AC d. — Allofthe above. T 22, Which of the following statements is false? a. __ Inthe 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. cc. _ In the MAG welding process the wire feed speed remains constant , during the welding operation d. — Allof the above “T 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. ve TIG. d. FCAW. T 24. Pre heat prior to the welding of a carbon steel butt weld: a. Must always be carried out, b. _ Is always carried out using a gas flame c. Need not be carried out if post weld heat treatment is to follow vd. None of the above. ‘WIS 5 Qu paper MSR-WI-2 6of8 issue 4 Date: 17/02/05TWI VT. T 25. _ Insteel the element with the greatest effect on hardness is: THE WELDING INSTITUTE a. Chromium. b. Manganese. ve Carbon. 4. Nickel ‘T 26. For agiven 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. » vc. The voltage will decrease. - Xd. The voltage will increase. - T 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. Vb. The welder is responsible for travel speed only; arc gap is kept constant by the welding plant c. Both travel speed and arc gap is controlled by the welding plant d. Allof the above. F 28. Whats purpose of a rectifier in a welding sets electrical circuit? a. Tokeep the arc stable when using low current settings « @) —Toconvert AC current to DC current. c. To convert DC current to AC current. vd. To initiate the arc at start up. WIS 5 Qu paper MSR-WI2 7068 issue 4 Date: 17/02/05