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TWI CMT. T 29. When calibrating a mechanised MAG welding plant, which of the following applies (WFS = Wire feed speed)? %. Check -WFS, current, volts and wire diameter. - THE WELDING INSTITUTE b. Check — WFS, joint set-up, gas flow rate and WFS. . Ske. Check — Gas flow rate, stick out length, WES and current. d. Alll of the above. “T 30. The main usage of the are air process is: e. The cutting of a weld preparation. vf. The removal of defective welds. 9g. For the cutting of non-ferrous materials only. h. For the cutting of ferrous materials only. . WIS 5 Qu paper MSR-WI-2 8 off issue 4 Date: 17/02/05,18/3 TWI CMF. THE WELDING INSTITUTE Welding Inspection, Steels - WIS 5 Multi — Choice Question Paper (MSR-WI-3) cf Answer all questions -T 1. The likelihood of a brittle fracture in steels will increase with: a. The formation of a fine grain structure. vb. A reduction in-service temperature to sub-zero conditions. c. — Aslow cooling rate. d. — Allof the above. F 2. Hydrogen cracking in HAZ is most ikely to occur when welding: ® Carbon manganese steels. b. Austenitic stainless steel. Vc. Micro alloyed steel (HSLA). d. Low carbon steel. T 3. Which of the following are considerations for the selection of a preheat temperature: a. Carbon equivalent, joint design, welding process type and plate material quality. b. All Joints over 25 mm thick, hydrogen levels, welding process, carbon equivalent. vc. Arc energy, material thickness, hydrogen scale and carbon equivalent. d. _Allof the above are considerations for the selection of a preheat temperature. WIS 5 Qu paper MSR-WI-3 1 off issue 4 Date: 17/03/05TWI CMT. 4. Which of the following destructive tests would indicate the toughness value of the weld metal/parent metal and HAZ? ‘THE WELDING INSTITUTE. a. Macro. b. Nick break. c Tensile. vd. Charpy Vee notch. “7 5. What constituent is needed in a coating of an electrode to prevent the formation of porosity when welding rimming stee!? a. Iron powder. b. Potassium silicate. =.» vc. Silicon d. Calcium carbonate. Ts. Welds made with high heat inputs show a reduction in one of the following properties? a. _Dueility. vb. Toughness. c. Elongation. d. Penetration. T ! 7. Which of the following steel types would give rise to the formation of porosity when autogenously welded with an arc welding process ya Fully killed steel. ae Semi killed steel. ve. Rimming steel d. Balanced steel. WIS 5 Qu paper MSR-WI-3 2of8 issue 4 Date: 17/03/05TWI CIM. ‘T 8 Which of the following elements, which may be added to steel, has the greatest affect on creep strength. THE WELDING INSTITUTE a. Tungsten b. Manganese. Carbon. Vd. — Molybdenum. FF 9. The HAZ associated with a fusion weld: Ya. Can not be avoided. Usually has the highest tensile strength 's usually martensitic. ven. Nerd Both a and b. Allof the above. 2@ee “7 10. What four criteria are necessary to produce hydrogen induced cold cracking? a. Hydrogen, moisture, martensitic grain structure and heat. b. Hydrogen, poor weld profiles, temperatures above 200°C and a slow cooling rate. vc. Hydrogen, a grain structure susceptible to cracking, stress and a temperature below 200°C. d. Hydrogen, existing weld defects, stress and a grain structure susceptible to cracking, F 11. Acarbon equivalent (CE) of 0.5%: 2.) Is high for carbon manganese steel and may require a preheat over a “400°C b. Is generally significant for carbon for manganese steels and is certainly not to be taken into consideration for preheat temperatures. Vc. __Ishigh for carbon manganese steels and may require a preheat temperature over 300°C as to avoid cracking d. ts calculated from the heat input formula. WIS 5 Qu paper MSR-WI-3 3 of 8 issue 4 Date: 17/03/05TWI LZ. e 2 13. Tr? Ft ‘THE WELDING INSTITUTE In a martensitic grain structure what would you expect to increase? Va. d. Duotiity, Hardness. Toughness All of the above. in which of the following mechanical tests would you expect to use a comparison from ductile to brittle transition curve. a. “b. Tensile test. Charpy test. Fusion zone test. All of the above Which of the following heat treatments on steel cools down in air from the austenite region? Ya. b. Normatising. Annealing. ‘Tempering Stress relieving What is the purpose of microscopic examination of a weld? a. vb. To determine the number and type of defects present. To determine the grain size c. To determine the strength of the weld. Both a and b. All of the above. WIS 5 Qu paper MSR-WI3 40f8 issue 4 Date: 17/03/05TWI CLM. “7 16. Which of the following units is a tensile specimen usually measured in? ‘THE WELDING INSTITUTE va. — Pounds per square inch. b. Newton per square inches. c. Joules. Both a and b ‘E17. Assuming that the welding process, material thickness, carbon equivalent and the welding parameters to be the same, which of the following joint types would normally require the highest preheat temperature. a. Edge joint, b. Lap joint. Yc. Butt joint (single-V). @ Tee joint (filet welded). 18. Austenitic stainless steels are more susceptible to distortion when compared to ferritic steels this is because: Q High coefficient, low thermal conductivity. what 1% Coefei creat b. c d High coefficient, high thermal conductivity. Low coefficient, high thermal conductivity Low coefficient, low thermal conductivity, 19. Which of the following will most likely require the preheat temperature to be increased? An Increase in travel speed. b. A reduction in material thickness c. Anincrease in electrode diameter. vd. None of the above. WIS 5 Qu paper MSR-WI3 Soff issue 4 Date: 17/03/05TWI C/T. 2 20. Which of the following properties may be applicable to a carbon steel weld (CE 0.48) welded without preheat? Ee Narrow heat affected zone and hardness value in excess of 400 HV. « D. Broad heat affected zone and hardness values in excess of 400 HV. THE WELDING INSTITUTE. c. Avery tough and narrow heat affected zone. d. Narrow heat affected zone and low hardness values. 7E. 21. Which of the following materials is considered to be the easiest to weld? @ Mid steel b. Medium carbon steels. c. Martensitic stainless steel ~~ 4d. Forging steel. TT 22. Which of the following test pieces taken from a charpy test on a carbon- . manganese steel weld, welded with a high heat input is most likely to have the lowest toughness a. Test piece taken from parent metal. b. Test piece taken from weld metal. ve. Test piece taken from HAZ. d. —Allof the above values will be the same. “fF 23. Which ofthe following butt weld preparations would normally be considered for a mechanised welding process a. Single-V butt, root gap 2.5 mm (welded from on side only) b. _Double-V butt-welded both sides, root gap 2.0 mm. Vc. Single-U butt with backing. d. None of the above can be used for mechanised welding WIS 5 Qu paper MSR-WI-3 6 of8 issue 4 Date: 17/03/05TWI CIF 24. — Which is the correct heat input for the following parameters, amps 350, volts { _32andtthe travel speed 310 mm/minute (MMA welding process)? Va. 2.16 ku/mm. THE WELDING INSTITUTE Tete 6 2 aj ser cee 1 b. 0.036 kJ/mm. H sant ©. 2460 kiimm, ata 4. 36ksimm. e J 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 ‘ona component made of a high tensile strength material a Have the welder re-qualified. b. Ignore them. 7 vc. — Have the area checked for possible cracking. d. Cut out the entire weld where the arc strikes exist. F 28. Amuiti-pass MMA butt weld made on carbon steel consists of 5 passes deposited using a 6mm diameter electrode. A 12-pass weld made on the same joint deposited using a 4mm diameter electrode on the same material will have: @) Alower heat input and a higher degree of grain refinement. b. — Alower heat input and a coarse grain structure. vc. A lower amount of distortion and a higher degree of grain refinement. d. — Ahigher amount of distortion and a lower degree of grain refinement. 27. Whatis the purpose of a transverse tensile test? @) To measure ultimate tensile strength. b. To measure the elongation of a material c. Tomeasure the yield strength of a material Vd. Allofthe above. WIS 5 Qu paper MSR-WI-3 7of8 issue 4 Date: 17/03/05TWI CML. THE WELDING INSTITUTE oa wg. Which of the following mechanical tests can be used to give a quantitative ov T_ measurement of weld zone ductility? Ya. Tensile test. b. Bend test. Charpy V notch test. All of the above. TT 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. - “ce. To reduce the chance of a brittle grain structure and to reduce the chance of hydrogen entrapment. d. Increase the ultimate tensile strength values and increase overall weldability. Ti 30. Which of the following are true with regards to a charpy test a It's a static test used to determine a materials notch toughness in the weld region. V6. I's a dynamic test used to determine a materials notch toughness in the weld region. i It's a destructive test to give a measurement of through thickness ductility d. None of the above. WIS 5 Qu paper MSR-WI-3 Bof8 issue 4 Date: 17/03/05,22/30 TWI CZF. ‘THE WELDING INSTITUTE Welding Inspection, Steels — WIS 5 Multi — Choice Question Paper (MSR-WI-4) LE DIN HT Hhlay. Answer all questions Name: .. J 1. Degreasing components are essential for quality welding but when welded some agent may: a Cause corrosion problems. b. Leave residues c. Give off toxic gases. vd. Allof the above. T 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. \ vo. The hydrogen gas produced in the flux increases the arc voltage. d. — Allof the above. TJ 3. Inthe 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. vb. To prevent the formation of chromium carbides ¢. To prevent cracking in the weld. d. Minimise distortion. WIS 5 Qu paper MSR-WI-4 Lora issue 4 Date: 17/02/05TWI VM. ‘THE WELDING INSTITUTE, T 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. - V4. Allof the above “7 5. Which of the following NDT methods can only detect surface breaking defects? a. MPI vb. DPI. ce UT d. RT. e. Bothaandb. { 6 Which of the following defects would show up as light indications on a radiograph? a, Slag inclusions and copper inclusion. vb. Tungsten inclusions and excessive root penetration. cc. Cap undercut and root piping. d. Excessive cap height and incomplete root penetration ‘T 7. Which of the following additions may be added to an electrodes flux to act as a stabilizer? va Sodium silicate b. Silicon ©. Manganese d. Titanium dioxide. WIS 5 Qu paper MSR-WI-4 2068 issue 4 Date: 17/02/05,TWI CM. Ff 8. Lamellar tearing is best prevented by: HE WELDING INSTITUTE Va, The use of plate materials containing low levels of impurities. b. The use of buttering runs. c. Post weld stress relief. Xd. Both a and b. e. Allofthe above. A 2 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. SWSL. vb. DWSI. c DWDI. d.— SWSt-panoramic. T 10. A balanced welding technique for example back step welding is most often used for: a. Controlling lamellar tearing. b. _ Increasing weld toughness. ¢. Reducing weld zone hardness. Vd. Reducing distortion. T 11. Basic coated electrodes have which of the following properties. Va. 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. Lowhydrogen content welds, good stop/start properties and high strength. d. Low carbon content welds, friable slag and high strength. WIS 5 Qu paper MSR-WI-4 30f8 issue 4 Date: 17/02/05TwI CIM. T 12. Onaradiograph, the most likely appearance of lack of root fusion on a single- V butt weld is: Va. Adark straight line with a light root. b. Adark root with straight edges. c. Adark uneven line following the edge of the root THE WELDING INSTITUTE d. None of the above lack of root fusion can not be seen on a radiograph. “J 13. Which of the following applies to the heat treatment process of tempering a. __ tis always carried out at a temperature above upper critical limit, b. __ Its carried out to increase the strength and toughness of weldments. c. Tempering is generally carried out before quench hardening vd. None of the above ‘J 14, Which of the following is applicable to a plate lamination They are best detected by radiography. b. They are mainly caused by hydrogen entrapment. ~ wc. They originate in the parent material. d. They are caused when welding stresses act parallel with the rolled direction of the parent plate. ‘T 15. _ Which of the following NDT methods would be the least effective on an austenitic stainless steel butt weld. a UT. b. RT. DPI. wd. MPL. WIS 5 Qu paper MSR-WI-4 4088 issue 4 Date: 17/02/05,TWI THE WELDING INSTITUTE 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, vb. The HAZ of the root, c. The root. dé. The cap. J 17. _ |sit permissible to allow a multi-pass butt weld to cool down between weld passes? a. It should be up to the welding inspector. b. No the weld must be kept hot at all times. - c It depends on the welder V4. Itdepends on the specification requirements. I 18, Atee joint on a support bracket is to be welded both sides using a 5 mm leg length fillet weld, each weld is to be intermittent 50 mm in total length, the gap between each weld is to be 25 mm. Which of the following is the correct symbol in accordance with ISO 2553? IS Sa eaee 50 (25) a. meemeonsoetesosbiaasaani 5 5 x 50 (25) 50 (25) 25 (60) 5x50 (25) c. 7 aoa a 8 25 (50) 5x50 (25) WIS 5 Qu paper MSR-WL-4 Soff issue 4 Date: 17/02/05,TWI CMT ‘THE WELDING INSTITUTE. J 19. The usual method of assessing the sensitivity and density of a radiograph is by means of: a. vb. c. 4 Densitometer and dosimeter. Penetrameter and a densitometer. Il and a dosimeter. 1Ql and a fluxmeter. F 20. Inthe submerged arc welding process, the use of excessive high voltages would result in? a vo. ° Insufficient flux melting Excessive flux melting Slag removal difficulties. Excessive spatter. T 21. Welding a steel plate with a CE of 0.45 would require preheating to? a %. ° Prevent the formation of sulphides. » Prevent hardening in the HAZ. Prevent the formation of carbides. To reduce the amount of current required 22. Which of the following welding process uses a resistive heating system to achieve weld metal deposition? a MMA vb, Resistant spot welding. (P — Electro-slag d. Friction welding WIS 5 Qu paper MSR-Wi-4 6or8 issue 4 Date: 17/02/05,TWI CMT ‘THE WELDING INSTITUTE 23. What does the 70 represent on an E70 10 AWS A6.1 classified electrode? va. 70 N/mm? minimum UTS. b. 70 joules minimum impact strength ¢ 70,000 p.s.i. Minimum yield strength. (@ 70,000 psi minimum UTS. F 24. Hot cracking in steel weldments occurs: a. Along the fusion line (©) inthe jast metal to solidity Ve. Weld centre line d.__ Inareas of the lowest dilution. T 25, Cellulose electrodes have which of the following properties? a. Viscous slag, large volumes of shielding gas and UTS values above 90,000 si. b. Large volumes of shielding gas, high spatter contents and hydrogen levels, < 15 ml per 100g of weld metal deposited vc. Large volumes of shielding gas, hydrogen contents > 15 ml per 100g of weld metal deposited and should be never baked. d, High spatter contents, high deposition and large volumes of gas shield. F 26. From the following electrode coding in BS EN 499, E50 3 1NiB 14004H5, what does the 3 represent a. Aminimum charpy value of a 30 joules. vb. Aminimum impact value of 47 Joules. (&) — Aminimum impact temperature of -30°C at a given Joule value. 4. None of the above. WIs 5 Qupaper MSR-WI-4 Toft issue 4 Date: 1740208‘THE WELDING INSTITUTE 2 27. Which of the following is applicable to electrode efficiency? a. The mass of metal deposited as a percentage of the mass of core wire melted b. Iron powder electrodes have efficiencies above 100%. Electrodes of high efficiencies tend to produce welds of a smooth flat profile dg. Both a and b. @ All of the above. “T 28. A Fatigue cracks fracture surface is: a. Rough randomly torn. vb. Smooth. Step like appearance. Xd. Bright crystalline. F 29. E6013 electrode would most probably used for welding (2) Low pressure pipework we High-pressure pipework. m0) vc. Vertical down welding on storage tanks. Nin, d. Ina situation where low hydrogen welds are specified 30. Which element in stee! if present in significant amounts may lead to hot shortness? a. Phosphorus. b, Manganese. Silicon vd. Sulphur. WIS 5 Qu paper MSR-WES sors issue 4 Date: 17/02/0522/30 2 13% TWI LM. THE WELDING INSTITUTE Welding Inspection, Steels —- WIS 5 Multi - Choice Question Paper (MSR-WI-1) LE. DIN H THUY, Answer all questions Name 1. Which of the following butt-weld preparations is usually the most susceptible to lack of sidewall fusion during the manual metal arc process? a) — Adoubie-U butt. “b. — Asingle-V butt. ie A double-V butt. vd. tis not normally a defect associated with the MMA welding process. 2. Whatis the leg length of a fillet weld? a. The distance from the toe to face. b. The distance from the root to face centre. “6. The distance from the root to the toe. d. Its 0.7 of the design throat thickness. e. Both c and d FF 3. Whatis the throat thickness of a fillet weld (equal leg lengths)? va. The distance from the toe to the face. b,) The distance from the root fo the face centre. ~c. The distance from the root to the toe. d. The distance from toe to toe. WIS 5 Qu paper MSR-WI-1 lors issue 4 Date: 17/02/05TWI CTT. ‘THE WELDING INSTITUTE T 4. Compound welds: (a) Always contain butt and fillet welds b. Joints, which have combinations of welds made by different welding processes. ve. Combinations between two different weld types d. —Allof the above, T 5. Aduty not normally undertaken by a welding inspector is to: a, Check the condition of the parent material. b. Check the condition of the consumables. vc.) Measure residual stress. d. Check calibration certificates. T 6. Under most conditions, which of the following welding positions will deposit the most weld metal a. PG. b. PE. c PC. vd. PA eee What meant by the term crater pi a. Another term for concave root b. Another term given for a bum through. ¢. _ Atype of gas pore, found in the weld crater. ¥d.’ — Ashrinkage defect, found in the weld crater. WIS 5 Qu paper MSR-W1-1 20f8 issue 4 Date: 17/02/05TWI CIMT. T 8. Whatis meant by the term weld junction? THE WELDING INSTITUTE a. The area containing the HAZ and the weld metal. ‘b. The weld metal and parent metal. vc. The boundary between the fusion zone and the HAZ. d. The part of the weld, which has undergone metallurgical changes due to the heat from welding 7.9. The strength of a fillet weld is primary controlled by: a. Leg length. vb. —_ Design throat thickness. c. Actual throat thickness. d. Allof the above. — 10. Which of the following is applicable for none planar defects? a. They are always repaired. b. Their existence will result in the removal of the entire weld. @ They are not usually as significant as planar defects. vd. They can only be detected using radiography. 111. Which of the following welding processes/technique is likely to be used for the repair welding of localised porosity in a butt weld? a. MMA, PG position b. Mechanised MAG. c. Submerged are. All of the above. ve. None of the above. WIS 5 Qu paper MSR-WI-1 30f8 issue 4 Date: 17/02/05TWI ME. { 12, When measuring the welding parameters with the MMA welding process for the purpose of approving a welding procedure, the Welding Inspector should measure the voltage: Ya. — Asclose to the welding arc as possible THE WELDING INSTITUTE b. Anywhere along the welding cable. c. Always from the voltmeter on the welding plant. d. — Asnearto the welding terminals as possible. F 13. _ Inthe MMA welding process, which of the following is most likely to be caused a welder with a poor technique? ‘a Deep weld craters/crater cracks. b. Copper inclusions Hydrogen cracks vd. _Allof the above. T 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. Ww. Excessive root grinding and excessive back purge pressure. -T 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). vd. None of the above can be selected — specification requirements unknown. WIS 5 Qu paper MSR-WI-I 4of8 issue 4 Date: 17/02/05TWI CMT ‘THE WELDING INSTITUTE T 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. vb. Seek advice from higher authority. c. Carry out no visual inspection. d. — Re-write the requirements of the specification. T 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. ve. Qualifying welders d. Alll of the above. -f 18. Which of the following is most likely to cause a burn through a. Root gap too small. b. Travel speed too fast. Ye. Root face too small d. — Alllof the above. © 19. _ Inan arc welding process, which of the following is the correct term used for the amount of weld metal deposited per minute? Filling rate. Deposition rate. c. Weld deposition. d. Weld duty cycle WIS $ Qu paper MSR-W1-1 issue 4 Date: 17/02/05 S0f8TWI VM T 20. Whatis the term given for the area of a welded joint just outside the weld metal that has undergone microstructural changes? Ya. Heat affected zone. THE WELDING INSTITUTE b. The weld zone. ©. Fusion zone. d. _ Allof the above terms may be used. T 21. When carrying out visual inspection, which defect (s) is likely to be missed? a. Linear misalignment. b. Cap undercut. c. Porosity. vd. Lack of fusion (inter run). F 22. Cold lapping is another term for: @ Lack of fusion at the toe of a weld, /b. Lack of fusion between weld metal and weld metal c. —_Undercut at the toe of a weld. d. Both aandb. T 23. Incomplete root penetration is most likely due to: a. Welding speed too slow. b. Welding current too high Yc. Root gap too small. d. Electrode diameter too small. T 24, Crater cracks are caused mainly by: a. Excessively fast welding speeds b. Improper electrode angle vc. Hot shrinkage. d. Improper joint design. WIS 5 Qu paper MSR-WI-1 6 ors issue 4 Date: 17/0205TWI CT. T 25. Ona single-V butt weld, the distance through the centre of the weld from root to face is called: a b. ve. 4. Reinforcement. Penetration. Throat thickness. None of the above. F 26. The throat thickness of a % inch fillet weld is? a. b. © vd. a. vb. ©. d. TT 28. Which of the following butt weld preparations is most likely to be considered 27.5mm 24 mm, 13.5 mm, 12.5 mm. T 27. The need for pre-heat for stee! will increase if: The material thickness reduces. Faster welding speeds ‘The use of a larger welding electrode All of the above. for the welding of a 6mm thick plate? a b. ©. Ya. Double-V butt. Asymmetrical double-V butt. Single-U butt. Single-V butt. T 29. Awelding inspectors main attributes include: a. b. c. vd Knowledge. Honesty and integrity. Good communicator. Alll of the above. WIS 5 Qu paper MSR-WI-1 issue 4 Date: 17/02/05 THE WELDING INSTITUTETWI CH. ‘THE WELDING INSTITUTE F 30. Acode of practice for visual inspection should cover: @ Before, during and after welding. b. Before welding activities only. vc. After welding activities only. d. None of the above. WIS 5 Qu paper MSR-WI-1 80f8 issue 4 Date: 17/02/05