* rwi ae ‘THE WELDING INSTITUTE Welding Inspection, Steels - WIS 5 a xe Multi —- Choice End of Course Assessment ] Question Paper (MSR-AWI-1) Name: ....P20), .NUEAGKON, J =2e- Answer all questions Few 1. What is the ratio between the leg length and the design throat thickness on a mitre fillet weld with equal leg lengths a 41 a ed @ 1414:1.74% d, _Itdepends on the fillet welds dimensions and fit up requirements. 2. Which of the following charpy test pieces form a carbon manganese stee! weld, welded with a high heat input is likely to have the lowest toughness value? ae BO Test piece taken from parent metal. b. Test piece taken from weld metal. © Test piece taken from HAZ. d. _ Allof the above values will be the same. 3. Whyis the arc shielded, when using an arc welding process? To eliminate hydrogen from the arc. To retard the cooling rate of the solidifying metal. To excluded the atmosphere from the arc region. / a@go The arc is not always shielded when using an arc welding process. at WHICH Tap ris foletote TC Aue A Rerteas oor Aglguny, (peti Ao tHe Pelee Cress qpidayurg & + Geman Ragire Oem Redving Carton Cratent WIS 5 End of course assessment Qu paper MSR-AWI-1 1of8 issue 4 Date: 05/06/03,THE WELDING INSTITUTE 4 Which of the following is applicable for a none planar defects? a. They are always repaired. ©. Their existence will result in the removal of the entire weld. c. W They are not usually as significant as planar defects. d. They can only be detected using radiography. a Lamellar tearing is: 7a A product defect caused during the manufacturing of certain steels kL SX — Acrack 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 hat 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. Which of the following additions to an electrode flux acts as a stabilizer? > a G’% Sodium silicate. £ ® Silicon ¢. Phosphorous. d. Sulphur. 7. Which of the following elements if present in significant quantities in steet may lead to cold shortness. Sulphur. Phosphorous. Silicon. a0 @e Copper. WIS 5 End of course assessment Qu paper MSR-AWI-1 20f8 issue 4 Date: 05/06/03TWI es THE WELDING INSTITUTE 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. 6 Welding to be carried out on site (field weld). d. The weld must be subjected to NDT. vv 9. Austenitic stainless steel can be readily identified by: 6 Lack of magnetic attraction. v b. Its extreme hardness. c. Very shinny appearance. d. None of the above, Which of the following is likely to be considered an essential variable on a welder qualification test? a. A change from an electrode classified to AWS E6011 to an electrode £6012. b. __ Achange in preheat temperature from 50°C to 100°C. ¢.” A change in welding position from PA to PF @® _— Allofthe above 11. Which of the following is applicable if the heat input is tarhigh during the deposition of a weld made using the MMA welding process? @ —_Lowtoughness. ~~ b. High susceptibility to hydrogen entrapment. c. High hardness. d. High susceptibility to tack of fusion. WIS 5 End of course assessment Qu paper MSR-AWI-1 30f8 issue 4 Date: 05/06/03,* TW CLM. 12. Which of the following will influence the amount of distortion on a component during and after welding? THE WELDING INSTITUTE a. Heat input. b. Lack of restraint. c. Material properties. d. Botha and b. © — Alllof the above. Y When welding with the MIG welding pracess using pure argon as the shielding gas on carbon steel, which of the following problems are likely to occur? 8. Copper inclusions and excessive cap heights. b. _ Excessive root penetration and porosity. c. Slag inclusions and crater pipe. d. 17 Lack of fusion and poor cap profiles. 14, {tis:a requirement to excavate a crack in a low carbon steel welded component; the defect is at least 25 mm in depth, which of the following would you expect to be done to remove the defect? a. Arcair, ground finish and check with DP! b. Thermal gouging, ground finish and check with MP! Oxy-gas cutting, ground finish and checked with crack detection Both a and b.v €. Allo the above we The heat affected zone associated with a fusion weld: a. Usually has the highest tensile strength. - ® Always exists in a fusion-welded joint. c is usually the area of a welded joint that is the most susceptible to. HICC? d. ¥ Allof the above. 2 WIS 5 End of course assessment Qu paper MSR-AWI-1 40f8 issue 4 Date: 05/06/03‘ Twi THE WELDING INSTITUTE PO 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 ¢. Manual metal arc. @ Plasma are. Va Awelding process where the welding plant controls the travel speed and are gap, but under a constant supervision using a shielding gas mixture of 80% argon — 20% carbon dioxide is termed as: @ — Amanual MAG process. b. Asemi automatic MAG process. c. Amechanised MIG process. 3) Amechanised MAG process 18. The purpose of normalising steel: @ To modity the grain structure by making it more uniform in order to improve mechanical properties. b. To soften a material for extensive machining. ©. To reduce fracture toughness. d. To reduce ductility 19. Hot cracking in steel weld ments occurs: Along the fusion line In the last metal to solidify. Weld centre line ao @o In the area of lowest dilution. : WIS 5 End of course assessment Qu paper MSR-AWI-1 Sof8 issue 4 Date: 05/06/0320. 21. Pr TWI C/MT. THE WELDING INSTITUTE Generally the most suitable method of detecting lack of sidewall fusion on a single-V butt weld (30° to 35° bevel angles) would be: ® _ Ultrasonic testing. v b. Radiographic testing c. Magnetic particle testing d. Bothaand b. e. Allof the above Ultrasonic testing is preferable to radiographic testing due to: a. Ability to find all defects. b. Lower amount of operator skill required © Ability to detect laminations. d. None of the above cet ee wt Lamellar tearingthas occurred in a steel fabrication BEFORE welding, which of the following test methods could have detected it? a. Radiographic testing. © Ultrasonic testing. c. Magnetic particle testing, Ox It could not be found by any testing method a In x-ray radiography, if the kilo voltage is increase: a The radiographic sensitivity will increase. b. The depth of penetration will reduce. o) YZ, The depth of penetration will increase d. Kilo voltage has very litle effect on penetration. WIS 5 End of course assessment Qu paper MSR-AWI-1 60f8 issue 4 Date: 05/06/03,Twi CLM. ; You are to oversee the arc welding of some machined fittings and find that they are cadmium plated. What would you do in this situation? THE WELDING INSTITUTE a. Permit the welding to proceed. b, Permit the welding to proceed with fume extraction. /Z_ Stop the operation at once. ® Advise the welders to drink milk then proceed. 25. On a single-V butt weld, the distance through the centre of the weld from root to face is called: Reinforcement, Penetration. Throat thickness. “ eos o 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. . Oxidising flame. = —~ ene - c. Reducing flame. @ Neutral flame. % 27. The need for pre-heat for steel will increase if: a. ‘The material thickness reduces. 6. Faster welding speeds ~ c. The use of a larger welding electrode 4. All of the above. WIS 5 End of course assessment Qu paper MSR-AWI-I 70f8 issue 4 Date: 05/06/03TWI UM 28. The main reason for toe blending on certain welded steel components is: THE WELDING INSTITUTE Corrosion considerations. Fatigue life. Appearance. ao@oe All of the above. 29. Which of the following welding process require a drooping characteristic power source ®@ = -TIGand MMA. b. — MIG/MAG and MMA. ¢. IG and SAW (less than 500 amps) 7 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. © Spray transfer. ~~ d. Globular transfer. WIS 5 End of course assessment Qu paper MSR-AWI-1 8 of8 issue 4 Date: 05/06/03i SH Gay. * TWI LLM. THE WELDING INSTITUTE Welding Inspection, Steels - WIS 5 28 os Multi — Choice Question Paper (MSR-WI-4) “3p Answer all questions Name: ... 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. QV Allof the above. 2.v Cellulose electrodes are often used for the deposition of a roct 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. @ The hydrogen gas produced in the flux increases the arc voltage. d._— Allof 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. ® To prevent the formation of chromium carbides c.. To prevent cracking in the weld. d. Minimise distortion. ‘WIS 5 Qu paper MSR-WI-4 1of8 issue 3 Date: 28/05/03,TWI CH. THE WELDING INSTITUTE 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. @./ Allofthe above 5.“ Which of the following NDT methods can only detect surface breaking defects? a. MPI ®v OPI. c. UT a Lie 2 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. ©v’ Tungsten inclusions and excessive root penetration. ¢. 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? BO Basic, b. Acidic. c. Rutile. 5 @ Cellulose. ye wleptyin work tt WIS 5 Qu paper MSR-WI-4 20f8 issue 3 Date: 28/05/03- TWI es THE WELDING INSTITUTE 8. ¥ Lamellar tearing is 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. £@ Botha andb. Ba All of the above. 9, V’ 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 O” ows! c. DWI d. SWSI-panoramic. 10. ¥ A balanced welding technique for example back step welding is most often used for: : a a. Controlling lamellar tearing. ° 36 SG b. Increasing weld toughness. - Reducing weld zone hardness. @v' Reducing distortion. 11. V/ Basic coated electrodes have which of the following properties. (9.” 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. WIS 5 Qu paper MSR-WI-4 30f8 issue 3 Date: 28/05/03- TWI VIM. THE WELDING INSTITUTE 12. Ona radiograph, the most likely appearance of lack of root fusion on a single- V butt weld is: @/ A dark straight line with a light root. b. dark root with straight edges. c. _ Adark 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. b. c. OY Minimum post weld heat treatment applied to a weld. Minimum stress relief temperature The lowest temperature to be used during preheat. The lowest temperature allowed during welding and between weld passes. 44. Which of the following is applicable to a plate lamination They are best detected by radiography. They are mainly caused by hydrogen entrapment. They originate in the parent material. They are caused when welding stresses act parallel with the rolled direction of the parent plate. 145 Which of the following NDT methods would be the least effective on an austenitic stainless steel butt weld. a b. G ® UT. RT. DPI. MPI. WIS 5 Qu paper MSR-WI-4 4of8TWI Ls THE WELDING INSTITUTE 46. v The hardest part of a multi-pass welded joint, assuming no post weld heat treatment has have taken place is: @/ The HAZ of the cap. b. The HAZ of the root. CG The root.: d. — Thecap. 17. a |s it permissible to allow a single pass butt weld to cool down between weld 18.~ passes? a. It should be up to the welding inspector. b. No the weld must be kept hot at all times. ©. It depends on the welder © Itdepends on the specification requirements. A tee 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? 5 5 x 50 (25) 5 5 x 50 (25) a ve wuganer Lire doe to ti Gide Bayete 5 25 (50) 5x 50 (25) WIS 5 Qu paper MSR-WI-4 5of8 issue 3 Date: 28/05/03~ TWI es THE WELDING INSTITUTE 19.1 The usual method of assessing the sensitivity and density of a radiograph is by means of: a. Densitometer and dosimeter. (8. Penetrameter and a densitometer. c. [Ql and a dosimeter. ) d, IQland a fluxmeter. 20.,/ In the submerged arc welding process, the use of excessive high voltages would result in? a, _ Insufficient flux melting, © e Excessive fldx melting c. Slag removal difficulties. d. Excessive spatter. 21. Welding a stee! plate with a CE of 0.45 would require preheating to? a. Prevent the formation of sulphides. {B. Prevent hardening in the HAZ. ¢. Prevent the formation of carbides. d, 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 b. Resistant spot welding. OV Electro-slag. 4. Friction welding. WIS 5 Qu paper MSR-WI-4 60f8 issue 3 Date: 28/05/0323. What does the 70 represent on an E70 10 AWS AS.1 classified electrode? a. 70. N/mm? minimum UTS. THE WELDING INSTITUTE b. 70 joules minimum impact strength. ©. 70,000 p.s.i. Minimum yield strength. Oy 70,000 psi minimum UTS. | provided in a standard packaging: @®V Should be baked as to manufactures recommendations prior to use. b. The baking conditions depend upon the welder. ¢. Are recommended for use where porosity free welds are required. 4. Are only suitable for welding in the flat, vertical, and down hand positions. 250 Cellulose electrodes have which of the following properties? JF Viscous slag, large volumes of shielding gas and UTS values above 90,000 psi. b. Large volumes of shielding gas, high spatter contents and hydrogen levels < 15 mi per 100g of weld metal deposited 6 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. 26. From the following electrode codin 160 20 HS, the compulsory part is: i a. £504 B 160 20 HS. Len + gprieeat. b. B 160 20H5. © E5048. d. None of the above. WIS 5 Qu paper MSR-W1-4 70f8 issue 3 Date: 28/05/03nnn THE WELDING INSTITUTE 27. Which of the following is applicable to electrode efficiency? a. Y The mass of metal deposited as a percentage of the mass of core wire melted. b. / fron powder electrodes have efficiencies above 100%. ¢. Electrodes of high efficiencies tend to produce welds of a smooth’ flat profile. © — Bothaandb. e. — Allof the above. 28. A Fatigue cracks fracture surface is: a. Rough randomly torn. ® c. Step like appearance. +> lasmutees U4 d. Bright crystalline Smooth. 29.0’ £6013 electrode would most probably used for welding: ®v Low pressure pipework. b. High-pressure pipework. c. Vertical down welding on storage tanks. d. V_Inasituation where low hydrogen welds are specified. 30. Which element in steel if present in significant amounts may lead to hot shortness? a. Phosphorus. > Cp Qécernort b. Manganese. c. Silicon. @ sulphur re tor Cement WIS 5 Qu paper MSR-WI-4 80f8 issue 3 Date: 28/05/03TWI CLI. THE WELDING INSTITUTE. Welding Inspection, Steels - WIS 5 Multi - Choice Question Paper (MSR-WI-3) Paps, NURAtertMAaD s - 2e Answer all questions Name: .. 1. V The likelihood of a brittle fracture in steels will increase with: (4.4) ao@oe The formation of a fine grain structure. A reduction in-service temperature to sub-zero conditions. A slow cooling rate. All of the above. 2. v_ Hydrogen cracking in HAZ is most likely to occur when welding: (22.4) @ b. c. d. Carbon manganese steels. Austenitic stainless steel. Micro alloyed steel (HSLA). Low carbon steel. Preheating for arc welding applies to: A@Y Assembly and tack welding only. & 4 e. Joint over 25 mm thick only. Assembly welding only. When using the MMA welding process only. 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 b, c. Macro. Nick break. Tensile. @ Charpy Vee notch. ‘WIS 5 Qu paper MSR-WI-3 10f8 issue 3 Date: 28/50/03,TWI ZHI. 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. © 7 Silicon Ane te media d. Calcium carbonate. THE WELDING INSTITUTE 6. Welds made with high heat inputs show a reduction in one of the following properties? a. Duetility. © Toughness. ©. Elongation. d. Penetration. 7.5¢ Which of the following steel types would give rise to the formation of porosity when autogenously welded with an arc welding process il Fully killed steel. Semi killed steel. ZR 6 Rimming steel. Balanced steel. of (90 exidoser ” Which of the following elements, which may be added to steel, has the greatest affect on creep strength. a. Tungsten. b. Manganese. cc Carbon. @./ Molybdenum. WIS 5 Qu paper MSR-WI-3 issue 3 Date: 28/50//03,' TWI CM. 9. ¥ The HAZ associated with a fusion weld: THE WELDING INSTITUTE a. Cannot be avoided. b. Usually has the highest tensile strength. c. _ Isusually martensitic. @ — Bothaandb. e. — Allof 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, temperatures above 200°C and a slow cooling rate. Ov 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. 11. A carbon equivalent (CE) of 0.5%: @¥ _Ishigh for carbon manganese steel and may require a preheat over 100°C b. Is generally significant for carbon for manganese steels and is certainly not to be taken into consideration for preheat temperatures. c. Is high for carbon manganese steels and may require a preheat temperature over 300°C as to avoid cracking d. 1s calculated from the heat input formula. 12. Ina martensitic grain structure what would you expect to increase? a. Duality, @ V Hardness. c. Toughness. d. _Allof the above. WIS 5 Qu paper MSR-WI-3 30f8 issue 3 Date: 28/50/03Twi ee ncneceems THE WELDING INSTITUTE 13. / What do you understand by the term minimum interpass temperature? a. Minimum post weld heat treatment applied to a weld. b. Minimum stress relief temperature. c. The lowest temperature to be used during preheat. @ v The lowest temperature allowed during welding and between weld passes. 14.7 Which of the following heat treatments on steel cools down in air from the austenite region? . @. V Normalising. b. Annealing, c. Tempering. d. Stress relieving. 15 What is the purpose of microscopic examination of a weld? a. 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. e. All of the above. 16.¥ Which of the following units could a tensile specimen be measured in? ® v’ Pounds per square inch. b. Newton per square inches. c. Joules. d. Botha andb. WIS 5 Qu paper MSR-WI-3 4of8 issue 3 Date: 28/50//03,‘TWI CM. 17. Assuming that the welding procese: 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. THE WELDING INSTITUTE a. Edge joint. b. Lap joint. c. Butt joint (single-V). @~ Tee joint (fillet welded). 18. Austenitic stainless steels are more susceptible to distortion when compared to ferritic steels this is because: AQ High coefficient, low thermal conductivity. b. High coefficient, high thermal conductivity. — Atye swe QV Low coefficient, high thermal conductivity. 4. 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. — Areduction in material thickness c. Anincrease 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? @+ Narrow heat affected zone and hardness value in excess of 400 HV. b. Broad heat affected zone and hardness values in excess of 400 HV. c. — Avery tough and narrow heat affected zone. Narrow heat affected zone and low hardness values. WIS 5 Qu paper MSR-WI-3 50f8 issue 3 Date: 28/50/03‘TWI CZF. 21.¥ Which of the following materials is considered to be the easiest to weld? @ v Mild steel. b. Medium carbon steels. THE WELDING INSTITUTE c. Martensitic stainless steel d. Forging steel 22../ Which of the following NDT methods would be best suited for the detection of surface breaking defects on an austenitic stainless steel pipe a. MPI DS Oy @v oP. d. —_ Allof the above can be used. 23. Which of the following butt weld preparations would 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. @v _ Single-U butt with backing. d. None of the above can be used for mechanised 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)? @Y 2.46 kdimm. ee eo b. 0.036 kJ/mm. 7 ho 2160 ku/mm. 4. 3.6 kd/mm. WIS 5 Qu paper MSR-WI-3. 6of8 issue 3 Date: 28/50//03‘TWI CZF. 25. V’ 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 tensile strength material THE WELDING INSTITUTE a. Have the welder re-qualified. b. Ignore them. @©V Have the area checked for possible cracking. d. Cutout the entire weld where the aro strikes exist. 26. ~ A multi-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. A lower heat input and a coarse grain structure. c. Alower amount of distortion and a higher degree of grain refinement. 4. Ahigher amount of distortion and a lower degree of 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 @v allofthe above. 28. Which of the following mechanical tests can be used to give a quantitative measurement of weld zone ductility? ® _ Tensile test. b.v Bend test. cc. Charpy V notch test. d. Allofthe above. WIS 5 Qu paper MSR-WI-3 70f8 issue 3 Date: 28/50//03,Twi CZ. THE WELDING INSTITUTE 29. V Which of the following are reasons for applying prehgat? a, b. Ov d. The removal of residual stress. To aid slow cooling and reduce the carbon content. To reduce the chance of a brittle grain structure and to reduce the chance of hydrogen entrapment. Increase the ultimate tensile strength values and increase overall weldability. 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. © __ It's a dynamic test used to determine a materials notch toughness in the weld region. ¢. 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 8of8 issue 3 Date: 28/50//03,TWI UM. THE WELDING INSTITUTE Welding Inspection, Steels — WIS 5 Multi — Choice Question Paper (MSR-WI-2) 2° x we § ‘Answer all questions Ge 4 = ver? 1 a Defects outside the permissible limits of the applicable specification should be: The decision is up to the welding inspector. Repaired Always double checked using NDT. All of the above. 2 Electrodes used in manual metal arc welding can be grouped into three main types, these are: a, b. c. w Oxidising, basic and rutile. Cellulose, basic and acidic. Granular, rutile and basic. Rutlé, basic and cellulose. Forte 3. “ Movement of the arc by magnetic forces in an arc welding process is termed: a b. a d. Arc deviation. Arc misalignment. Arc blow. Stray arc. 4.” Acrack type most associated with the submerged arc welding process is: a2 @p Hydrogen cracking in the HAZ. Solidification cracking. Lamellar tearing Fatigue cracking. WIS 5 Qu paper MSR-WI-2 Lof8 issue 3 Date: 28/50/03,TWI CM. THE WELDING INSTITUTE 5. Which of the following processes joins metals plastically. 6 b. ©. d. e. Friction welding. Resistance welding. Arc welding. Plasma welding. Allof the above. 6./ What type of power source characteristic is required for a manual process? ne Constant voltage. Flat characteristic. Drooping characteristic. / Conan currery None of the above. 7. Which of the following electrodes and current types may be used for the TIG welding of nickel and its alloys? Cerium electrode, DC —ve. Zirconium electrode, AC. Thorium electrode, DC +ve. All of the above may be used. 8.“ What are the possible results of having a heat input to low? An increase in hardness, lower yield strength and lack of fusion. b. Areduction in toughness, hydrogen entrapment and an increase in hardness © _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 2of 8 issue 3 Date: 28/50/03TWI es THE WELDING INSTITUTE 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 @ v Prevent the formation of a dense oxide layer forming in the root 10.“ The possible effects of having a travel speed too fast: uy aunt t a. Low toughness, slag inclusions and cap undercut. @®v High hardness, slag inclusions and a narrow thin weld bead. c. High hardness, excessive deposition and cold laps o 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. Achange from AC to DC current. @v Achange from DC to AC current. ¢, Achange from DC +ve to DC -ve. d. — Achange from DC ~ve to DC +ve. 12. When.welding a doubie-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. Incorrect flux depth @~ Allofthe above. WIS 5 Qu paper MSR-WI-2 30f8 iseue 3 Date: 28/50/03TWI ZU. ‘THE WELDING INSTITUTE 13.V The inclusion of an inductance in the welding clreult when using MIG/MAG welding process isto: @v 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, It allows full control over droplet size in the spray transfer mode. 14.“ An undesirable property of aluminium oxide residue, when welding is that it: Decrease weld poo! fluidity. a oO 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. 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? @v GTAW b. SMAW c, Submerged arc welding. d. GMAW. 46.” 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. ©” Tohelp prevent the formation of crater pipe and possible cracking. d. _ Tohelp prevent tungsten inclusions during welding. WIS 5 Qu paper MSR-WI-2 40f8 issue 3 Date: 28/50/03TWI CTT. THE WELDING INSTITUTE 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 © Pre heating the material to be cut. d. —Allof the above. 18.” ina semi-automatic welding process, which of the following shielding gas/gas mixtures would normally give the deepest penetrati non steel? 100% argon. ~~ Wable kee set a 100% COz. 75% argon + 25% COz ao @e All of the above would give the same depth in penetration. 19.” Ina MMA welding process, which of the following statements are false? a. An are gap, which remains almost constant even if as usual the welder varies the position of the electrode. b. voltage, which remains almost constant even if as usual the welder, varies the arc gap. c. Acurrent, which remains almost constant even if as usual the welder, varies the art gap. @y Aandb. e. — Allof the above. 20.” Which of the following welding process, after the weld is completed normally requires a post weld heat treatment to restore toughness values @ ESW. = dette cue welding b. MMA. c. MAG d. __Allcompleted welds require a post heat treatment, regardless of welding process. WIS 5 Qu paper MSR-WI-2 Sof8 issue 3 Date: 28/5003TWI CMT. 21.7 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. io b. DC He. L Ne @v ac : d. All of the above. 22.Y Which of the following statements is false? @ _ 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. ¢. The word calcium carbonate means limestone d. v Allof the above 23.4 When considering hydrogen, which of the following welding process would produce the lowest levels in the completed weld (under controlled conditions) a. MMA. db. SAW. © 6 d. FAW. 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 @” None of the above. WIS 5 Qu paper MSR-WI-2 6ofs issue 3 Date: 28/50/03Twi neers THE WELDING INSTITUTE 25. ¥ Insteel the element with the greatest effect on hardness is: a. Chromium, : b. Manganese. ©” Carbon. 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. © __ 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. yx [aud @®v/ 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. All of the above. 28.’ What is purpose of a rectifier in a welding sets electrical circuit? a. To keep the arc stable when using low current settings @®~ Toconvert AC current to DC current. ¢.v Toconvert DC current to AC current. d. — Toinitiate the arc at start up. WIS 5 Qu paper MSR-WI-2 7of8 issue 3 Date: 28/50/03TWI CMF. 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 Check ~ WFS, joint set-up, gas flow rate and WES. Check - Gas flow rate, stick out length, WFS and current. All of the above. 2@re 30.7 The main usage of the are air process is: : pe The cutting of a weld preparation. a. ® The removal of defective welds. . For the cutting of non-ferrous materials only. 4. For the cutting of ferrous materials only. WIS 5 Qu paper MSR-WI-2 8of8 issue 3 Date: 28/50/03THE WELDING INSTITUTE Welding Inspection, Steels —WIS 5 Multi — Choice Question Paper (MSR-WI-1) 20 ' Se eee Zo : EMEA R Answer all questions - wed 1.” Which of the following butt-weld preparations is usually the most susceptible to lack of sidewall fusion during the manual metal arc process? Adouble-U butt, w= wiftle fur eo VOTE b. — Asingle-V butt. ©. Adouble-V butt. 4. 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. | © The distance from the root to the toe. i d. The distance from toe to toe. 3. \ What is the throat thickness of a fillet weld (equal leg lengths)? a. ‘The distance from the toe to the face. @ —Thedistance from the root to the face centre. 7 c. The distance from the root to the toe. d. The distance fram toe to toe. 4, “Lap joints contain: Fillet welds. b, Comer joints. c. — Buttwelds. d. _ Single-bevel butts. WIS 5 Qu paper MSR-WI-1 1 0f7 issue 3 Date: 28/0/03,a. Check the condition of the parent material. b. Check the condition of the consumables. © Measure residual stress. x d. Check calibration certificates. 6. v Under most conditions, which of the following welding positions will deposit the jweid metal. a. Vertical down. b. Overhead. c. Horizontal-vertical. @ _ Flat (down hand) 7. Y What meant by the term crater pipe: «> SdidahCaran Creel a. Another term for concave root b. Another term given for a bum through. c. _ Atype of gas pore, found in the weld crater. @__ Ashrinkage defect, found in the weld crater. ao ‘What is meant by the term weld junction? a. The area containing the HAZ and the weld metal. b. The weld metal and parent metal. @ 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. 9. : The strength of a fillet weld is primary controlled by: a. —_Leglength. @ Throat thickness. = Weld thickness. d. All of the above. WIS 5 Qu paper MSR-WI-l issue 3 Date: 28/0/03 20f7es THE WELDING INSTITUTE 10.4 A crater crack may also be termed: a, Ls c. Cold crack. Tearing. Fatigue crack Star crack. por Rey Fase lotarion 11.1 Which of the following welding processes/technique is likely to be used for the repair welding of localised porosity in a butt weld? a9 5 ® © MMA, PG position. Mechanised MAG. ee ee Submerged arc. \ reclve TH Hed Rees J centemanles All of the above. None of the above. kao He peeter 12. ~ Which of the following welds would be considered in a situation where two plates are to be joined that overlap (assume no extemal assess). b. © 4. A fillet weld. Asingle-bevel butt weld. Aplug weld. Asingle-U butt weld. 13, | Inthe MMA welding process, which of the following is most likely to be caused by a welder with a poor technique? @ Deep weld craters/crater cracks. b. Copper inclusions c. Hydrogen cracks 4. Allof the above. WIS 5 Qu paper MSR-WI-1 30f7 issue 3 Date: 28/0/03TWI h_ $@$£$ $< _$____—_ THE WELDING INSTITUTE 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. @ 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). @© _ None of the above can be selected — specification requirements unknown. 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. © _ Seek advice from higher authority. ¢. Carty out no visual inspection. 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. 1—> quent b. Procedure writing, =.» we © Qualifying welders. > yoses Regis weloiwt d Alll of the above. WIS 5 Qu paper MSR-WI-1 40f7 issue 3 Date: 28/0/03,THE WELDING INSTITUTE 18.” Which of the following is most likely to cause a bum through Root gap too small, 4-= tempt tyrmietir Travel speed too fast, ya (nti, ome / Root face too small 2@re 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? Filling rate. Deposition rate. Weld deposition. Weld duty cycle. 2° @p 20.” Whats the term given for the area of a welded joint just outside the weld metal that has undergone microstructural changes? @® Heat affected zone. b. The weld zone. ¢. Fusion zone. d. _Allof the above terms may be used. av When carrying out visual inspection, which defect (s) is likely to be missed? a. Linear misalignment. b. Cap undercut. cs Porosity. @ Lack of fusion (inter run). r> tar rt eater Ace ty a pontine at onfaee 22. Cold lapping is another term for: 6 Lack of fusion at the toe of a weld. ea b. Lack of fusion between weld metal and weld metal. = .—» ne Gir i Undercut at the toe of a weld. a. Both a and b. WIS 5 Qu paper MSR-WI-1 Sof? issue 3 Date: 28/0/03TWI UTM. THE WELDING INSTITUTE 23 Incomplete root penetration is most likely due to: a, b. © 4. Welding speed too slow,» vucecr veto te fe Welding current too high. —~ Peeing HF. Ufc. Root gap too small. Electrode diamete/ too small. 24. / Crater cracks are caused mainly by: a b. @ é. Excessively fast welding speeds Improper electrode angle Hot shrinkage. Improper joint design. 25. On a single-V butt weld, the distance through the centre of the weld from root to face is called: a. Reinforcement. b. Penetration. i a © Throat thickness. ——I— d. None of the above. 26.~/ The throat thickness of a % inch fillet weld is? a, b © 4. 27.5mm 24mm. 13.5 mm. 12.5 mm. 27. ~ The need for pre-heat for steel will increase if: a. The material thickness reduces. ® _ Fasterwelding speeds > Lk | c. The use of a larger welding electrode d. Allof the above. WIS 5 Qu paper MSR-WI-1 60f7 issue 3 Date: 28/0/03* TW CLM. 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. © Single-V butt. THE WELDING INSTITUTE 29. ~~ A welding inspectors main attributes include: a. Knowledge. b. Honesty and integrity. c. Good communicator. @ __ Allofthe above. 30. ~~ A code of practice for visual inspection should cover: @ __ Before, during and after welding. b. Before welding activities only. c. After welding activities only. d. None of the above. WIS 5 Qu paper MSR-WI-1 70f7 issue 3 Date: 28/0/03| &) WELDING INSPECTION STEELS - COURSE REF. WIS 5 MULTIPLE-CHOICE QUESTION PAPER (MCQ.001) Name : 2% NDB, Answer all questions. ‘At. When “hydrogen control" is specified for a manual metal arc electrode would normally be: 1g project the (a) Cellulosic? Ho 4 Cor (b) . fron oxide 2 ten. ) Acid ? AL Basic ? wv Lew) 42. Youwould with certainty recognise a hydrogen controlled flux cove from its : (a) Colour ? (0) Length 2° () Trade Name ? vQK AWS/BSB39 Code Letter 2 ~~ A3. When manual metal arc welding is being carried out on an open construction site, which group of welders are the most likely to require continu: us monitaring ? Coner: 4 _ BE Pipe weicing vem? 7 (c) Plater welders ? (4) Plant maintenance welders ?A4- You notice manual metal arc electrodes, stripsed of flux, ere being usec as iti wire, for TIG welding. You would object because : (@) It is too expensive 2 (o) The wire would be tca thick 7 0 may be wrong 7) W~ PK The weid metal compo: (8) The wire is too short ? AS. When open site working, serious gorosity in metal attention. What would you investigate ? welds is broucht to your (2) Electrode type ? (0) Power plant type ? YR Electrode storage? (4) Day temperatuire ? , 46. The steel composition in 2 structural contract is changed from 0.15% carbon, 0.8% manganese, to 0.2% carbon, 1.2% manganase. Might this influence the incidence oi (2) Porosizy 7 BRL Cracking in the weld area ? uw (cY — Undercut for fillet welds 2 (@) Lack of root fusion defects ?: One of the following alloys is non-magnetic. Which ? >“ont A8. When TIG welding Austenitic stainless sizel pipe, Arcon cas backing is caiiec for. This is to: wR Prevent oxidation ? (0) Prevent uncerd (©) Prevent gcrosity ? n bead shape ? {d) Control the pen: AQ, Pre-heating a Carbon steel manual metal arc welding minimise the risk of : (2) Scattered porosity 2 (2) Worm hole porosity 7 oR Parent metal cracking ? vw a (4) Lack of penetration ? \ A10. In UK practice, BS4S9 Par 2 specifies that tne dra’ 2 fillet weld is the : fo) Actual throat (c) Weld width ? Which Ali. For open site manual metal welding the following equipment is availadle. ‘would you choose for safe working ? mer ? (2) Single operator tr.Al2. Als, AIS, lf submerged arc welding is to be used om be most critical of : (2) The rost gap PK The angie of (c) The root face (@) The gas cut uring CO, welding, the arc length is most likaiy :o-be affected (2) The'wire diameter ? (0) The current return connections 2. The gas flow raze ? (c) ey The torch to work angle ? Preheating for arc welding applies to : : (2) Assembly wel BE Assembly and (c) Joints over 25nx only 2 K welding 2 sick only ? (4) Cruciform welds only ? You see a welder using an oxy-. cone. What would be the effect of this on 2 carbon steel” (a) The weld could 52 hard and bristle 7. VW The weld meta! could be teo soi {8 The weld will have undereut 7 cetylene flame with a long feathered iciATB. AIB. Alg. Awelder qualification test is 0 verify : Jal The skill of the welder 2 (0) The quality of the materials 7 () The non-destructive test procedures 2 (d) The manuia methods ? for fillet welds to be “blended in’ by grinci A fabricating procecure cai is to influence (2) HAZ. creck PE Fatigue tie 2 (c) Residual stress 2 (4) Yield strength ? Send test specimens have deen taken from a 25mm thick carson size! but weld, Which would show lack of inter-run fusion : ORI Side bend? (0) Root bend ? (c) Face bend ? (J) Guided bend ? Lamellar tearing nas occurred in a steel fabrication. BEFORE welding could it have been found by (a) (3) Oeycadmium plated. Would you : (a) Permit it to proceed ? 2 (b) Permit it to proceed with fume extraction 7 vel Stop the operation at once 2. W~ (4) Advise the welder to drink miik and proceed ?1 3. Fa lee () WELDING INSPECTION STEELS - COURSE REF. WIS 5 END OF CGURSE MULTIPLE CHOICE PAPER (MCQ.002) Name : .¥ADL... CANDIAMAKN Answer all questions. S499 Part fi 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? 5 0 Wt > toK ik 7 x VS Which of the following symbols wouid indicate that a weld has to be finished flush on the ‘other’ side of the weld? A oa What two functions in arc welding must be in equilibrium to enable a stable arc to be established? Are Voltage Current Wire/Electrode feed rate Metal burn-off rate4. InMMA welding, what parameter is used for the control of penetration into the base material? . A : Voltage K =” Welding Speed c Iron Powders in the coating . x 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 aS Root Gap ° None of the above 6 What type of power source characteristic Is required for manual welding? A Constant Voltage B | =. i: mM Drooping Characteristic MMA, TIE w Kw D> wow Auge D Motor Generator 7. Which one of the following destructive tests would indicate the toughness of weld metal/parent metal ~ haz. A Macro ars vituag telvaner Ub mts Seer - B Nick Break —-~ moons fie game c Hardness as ty wurewing utara. stl aq entane K Charpy Vee Netch8. Degreasing components are essential for quality welding but some agents may : A Cause Corrosion Problems B =" Give off Phosgene Gas c Leave Residues m All of the Above : 9. Which of the following chemical elements has the greater effect on the hardenabilty of a steel plate? A Molybdenum aa thardanatilihy , life ore @renget B Chromium = tareteneracanes | bard we c Titanium Ls Meabiuaed 3 Cot % HELA K Carbon ne ere feet 10. In MAG/CO, welding, which parameters give the greatest control of weld appearance during dip transfer or short circuiting welding? : A Wire stick—out length = / peessiien g Cearvrde B Amperage S ur fost c Wire feed speed mw Inductance pone TORR frootanee pases - In MMA welding, the slags produced can be varied to suit the welding position; which type of slag would be required for welding in the 47 Position? an 3G verweac uprie A K vaca RK ” None of the above D ‘Semi fluid12. The weld metal deposit of manual metal arc electrodes achieves its mecha strength through? x The Core Wire m xe *" The Flux Coating c Iron powders with the flux coating a " (13.) What constituent is needed in a coating of an electrade to prevent the formation \*" of porosity in welding of a rimming steel? pe A Iron Powders B Calcium Fluoride 1x Silicon so koxgdiger' D Calcium Carbonate 14, _ Welds made with high heat inputs show a reduction in one of the following properties? ea A Duetility VK Toughness c Fatigue Strength D Mechanical Streigth 15. In the welding of austenitic pipework, the bore is usually purged with Ar to 7 A Prevent formation of porosity in the weld. 8 Prevent burn-through in the root run. Oe Prevent oxidation of the root bead D _ Eliminate the formation of H,,16. _ In X-ray work, the quality of the radiogrpahic negalive is assessed by the ? Density of the Film x OG > ¥—,. 101 Indicator a c | KVAavailable D Stand-off Distance . 17. Asteel described as OT Will have improved tensile properties because it has ? A Had control of chemical composition * Been heat-treated c Been quality tested 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 : A | Fully killed steel i Semi killed steel B mK Rimming steel D Fine grained steel 19. Insubmerged arc welding, the use of excessively high voltage would result in? | Insufficient flux meiting Excessive flux melting ~~ Slag removal difficulties oo XK Spatterbts ea 23. The use of cellulosic electrodes is often made when welding the root pass of pipes in the field. This is because ? A Hydrogen control is needed 8 Iron powders in the electrode v om Higher arc voltage can be obtained D Shorter arc length can be achieved 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 a The formation of chromium carbides ns wale deta Cc Cracking in the weld metal D Distortion Submerged arc fluxes can be supplied in two forms; these are 2 A Sintered and agitated B Agitated and fused c Crushed and agglomerated ae Fused and agglomerated ve ina steel which has improved creep properties at elevated temperature, which one of the following elements helps in this improvement ? A Tungsten gm Hiqh Heap. Changtn B Manganese «> pyurbiry - : KK Molybdenum ~~ D Carbon Hordneee24, Welding a steel plate of a CE of .45 would require preheating to 7 Bh ben al A aK rele ML gC Hea fend. ee D Prevent the formation of sulphides Ce © 04 tome =~ Prevent hardening in the HAZ CE Oa ~ oe ratte : Ce you Puoltt Prevent the formation of carbides To improve mechanical properties in the weld. 25. — Which one of the following processes uses the “keyholing" system of fusion? A on ax vO Friction welding Diffusion bonding Electron beam welding Autogenous TIG welding --—~ 26. _ In friction welding, is the metal at the interface in the ? A x Liquid state i Solid state Plastic state 9 (\“ Elastic state 27. Welding procedures may require welds to be deposited at a controlled rate heat ~ _ input. High heat inputs would ? 7 A 54 Have poor profile Have larger grain size / Have high hardness in the HAZ Have low elongation properties