‘ Vertical traverse (for electro-slag only). : " Water cooled copper shoes: Consumables, Electrode wires are similar to those used for submerged are welding, and supplied on standacd spools weighing 25 - 75 kg. Consumable guides may be in the form of tubes or specially made hollow sections according to the particular application. The composition of both wires and guides must be chosen to suit the parent material and with reference to required weld metal properties. Fluxes are specially formulated and resemble submerged are welding fluxes. Materials. Steels. ‘Typical Applications. Thick pressure vessels. Thick civil engineering fabrication. Shipbuilding. Overall Advantages. Fast completion of joints in thick plate. Overall Limitations. Only for vertical or near vertical joints. Welds have poor impact properties unless heat treated. Safety. Molten metal spillage must be considered. O— HMA NeLbiniG MULTICIIOICE PAPER ONE, CE) When ‘hydrogen control’ is specified for a manual metal are welding project the electrode would nonnally be: Cellulosic Iron oxide Acid Basic 2, You would certa jrode from its:a . 7 105 Colour 60. Length Trade name . BS639/AWS code letter(F) ~ @ __ When manual metal are welding is béing carried out on an open construction site, which group of welders are most likely to require continuous monitoring? ‘A Concrete shuttering welding teams 2 Pipe welding teams © Plater welders Dp Plant maintenance welders“ = + ~ untenayie @ — Younotice manual metal arc electrodes; stripped of flux, are being used as filler wire for TIG welding. You would object because: Tt is too expensive The wire would be too thick ‘The metal composition may be wrong, Je, The wire is too short CO) When spensite working, sesious porosity in metal arc welds is brought to your attention, What would you investigate? Electrode type Power plant type Electrode storage - .. Day temperature 6. ‘The stecl composition ina stmctural contract js changed from_0.15% carbon 0.6% manganese, to 0.2 n 1.2% manganese, This might influence the incidence of Porosity . ee 4 Cracking in the weld area ~ Undercut for fillet welds i sate Lack of fusion defects 7. One of the following alloys is non-magnetic - which? 4.0% cheomism malybdenam . 12.0% chromium Austenitic stainless steel - 9.0% nickel steel 8 When TIG welding austenitic stainless steel pipe, argon gas backing is called for. This is to: Prevent oxidation Prevent underbead cracking Prevent porosity Control the penetration bead shape Oo Pesccating a carbon steel manual metal are welding is carried out to, minimise the tisk of: Scaltered porosity a Wor hy iLack of penetration 10. _In UK practice, BS499 specifies that the drawing dimension quoted for a fillet weld is the: Teg length- 9 12, 13, 14, _Preheating for arc welding applies to: tiresee! 1 Poy ‘Assembly welding only A 15. 16. 7. ‘Throat thickness rk ‘Weld width aK ‘Actual throat thickness For open site manual metal welding she following equipment is availabl Which would you choose for safe site working? ‘Single operator transforiner ‘Multi operator transformers “” ‘AC/DC composite power unit Diesel engine driven motor generator If submerged arc welding is used to make butt welds, which would you be most critical of? ‘The root gap tolerance ‘The angle of preparation oS We ‘The root face width f The gas cut finish Ne During CO2 welding, the arc length is most likely to be affected by: ‘The wire diameter ‘The current return connections The gas flow rate The torch to work angle Assembly and tack welding- oa Joints over 25 mm thick only Cruciform welds only Which one of the following statements is correct? . Preheating increases hardness 20° Preheating increases cooling *~ Preheating increases dilution . _ Preheating increases shrinkage stress You ssea weldecusing anaxv.acetslene ame with along feathered inner cone, What would be the effect of this on a carbon stecl? The weld would be hard and brittle The weld could be too soft —~ There will be no effect on the weld The weld will have undercut A veolder qualification testis to verify: The skill of the welder > Thy qualixy of the materials Tiss non-destructive test proceduresi 18. 19. 20. 21. 22. 23. 107 ‘The manufacturing methods A fabricating procedure calls for fillet welds to be ‘blend inding, This influences: HAZ. cracking Fatigue life Residual stress A “Yield strength a Bend test specimens have been taken from 2 25 mm thick ca butt weld. Which ‘would show lack of inter-run fusion?” “Side bend- Root bend Face bend Guided bend ‘found by: X-ray examination : Dye penetrant hep Ultrasonic examination At would not have been found by any inspection method ‘You are to oversee the are welding of some machine fines and find that they are cadmium. -plated. Would you: Permit it to proceed Permit it to proceed with fume extraction ‘Stop the operation at once~ . Advise the welder to drink milk and progeed Cobrwesoer G08 pareono-4 One of the seasons for éxcludine hydrogen from the. weld metal is to prevent the weld from: Cracking ~ Cooling slowly Cooling quickly Expanding When a metal regains its original shape when a stress acting upon it is removed, the metal is, Fae “tet fas pene Plasticity Yb het Mallcability Elasticity ” Proof sicess is used when non-ferrous metals are undeigoing tensile tests to determine the equivalent: ~25, 27. 28. 29. 30. i Yield strength” Tensile strength To test a component for vibrational loading, a suitable mechanical test would be: Impact Tensile Compressive Fatigue - ‘The main reason forpre-hetine medium and hh carbon stetls before cutting by oxy-fuel gas technique is to: Improve the quality of the cut Increase the cutting speed Refine the grain structure Prevent hardening and cracking- ‘One purpose of a microscopic examjnation of a weld is to establish the: Strength of the weld ‘Number of alloying elements Grain size Number of runs used Macteale . ‘an hyper-uitectoid steel that has been quenched at above its Austenite Martensite ~ Troostite Sorbite ‘When weld metal refinement takes place in a multi-run deposit, it is known by the term: Weld annealing Weld refining - Weld normalising Weld recrystallisation One advantage of metal gas arg shielded welding is: Can be used in draughty locations without protection Produces a deposit low in hydrogen content — Any welding position can be welded with spray transfer Fine spatter at nozzie restricting gas flow MULTICHOICE PAPER TWO B59) conuaunicusss by the use of symbols the type of joint preparation to be use Which of Cie foitowing symbols indicates the depth of weld petietration required on the joint? L E109 finished on the ‘other’ The use of flux with gas shielded metal arc welding allows; ‘Shect metal to be welded Asstable are when using high current densities ~ Aluminium to be welded + Less dilution of the weld by the parent metal In MMA welding what parameter is used for contr tration into the base material? Voltage Welding speed Iron powders in the coating Current” In the welding ofa butt joint from one side, the profile of the ropt bead is controlled by: 7 Root face Bevel angle Root gop- All of the above Wnt pe of power charmcteristic is required (or niaaual welding?: Constant voltage . Flat characteristic Drooping characteristic - DC generator 7. Which of the following tests would indicate the toughness of weld metal/parent metal - HAZ? 5 ‘Macro Nick break Hardness 1 _— Charpy vee notch - 8. Degreasing components is essential for quality welding but some agents may: Cause corrosion problems Give off phosgene gas Leave residues All the above - 9. Which of the following elements has the greatec effect on the hardenability of a stecl plate? Molybdenum Chromium Titanium Carbon - 10, In MAG/CO2 welding which parameter gives the greatest control of weld appearance during, dip transfer or short-cirouiting welding? Wire stick-out length Amperage Wire feed speed Inductance - @ 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 HV position? Fluid Viscous - Semi fluid None of the above @ The weld metal deposit of MMA electsades achieves its mechanical strength through: The core wire The Mux coating’ Iron powders with the flux coating None of the above 13. What constituent is needed in the coating ofan elsctrode to prevent the formation of porosity in the welding of a rimming steel? roa powders cium Auoride uo2 Silicon ~ \ Calcium carbonate 14. Welds mode with hish heat inputs show s'reduetion in which of the following properties? Ductility Toughness ~ Fatigue strength Mechanical strength 15. In the welding of austenitic pipework the bore is usually purged with argon to: Prevent formation of porosity inthe weld a Prevent bum-through in the root run Prevent oxidation of the root bead- Eliminate the formation of hydrogen 16. In.X-ray work the quality of the radiographic image is assessed by the: Density of the film IQL indicator - KVA available Stand-off distance 17. _ A steel described as QT will have improved tensile properties because it has: Had control of chemical composition Beenbesttrestel” gy tad grad boepevd Been quality tested eee aaa Been vacuum melted ven 18. Which ont of the following tyncs of stecl would give rise to the formation of porosity when utoncnous! ‘ith an arc process? Fully killed steel Semi killed steel Rimming steel - Fine grained ste! 19, In submerged arc welding the use of excessively high voltage would result in: Insufficient flux melting Excessive flux melting Slag removal difficulties Spatter 20. Cellulosic elverodes are oftey used when welding the root pass of pipes in the field because Hydrogen control is needed There are iron powders in the electrode te ge can be o! thy can be obtained Higher are volt Shonter are beng) 23. 24, 25. 26. 27. In the welding of austenitic stainless steels, the electrode and plate material can be purchased With low carbon contents, The reason for this is to prevent: Cracking in the heat affected zone ‘The formation of chromium carbides - Cracking in the weld metal Distortion Submerged arc fluxes can be supplied in two forms. These are: Sintered and agitated Agitated and fused Sintered and agglomerated Fused and agglomerated - Ina steel that has improved creep properties at elevated temperatures, which one of the allo} is improvement? Tungsten ‘Manganese Molybdenum: Carbon, Welding a stec! plate with a CE of 0.45 would require preheating to: Prevent the formation of sulphides Prevent hardening in the HAZ. Prevent the formation of carbides To improve mechanical properties in the weld Which of the following processes uses the 'keyholing’ system of fusion? Friction welding Diffusion bonding Electron beam welding, “\ Autogenous TIG welding In friction welding the metal at the interface is in the: Tiquid state Solid state Plastic state- Elastic state Welding procedures may require welds to be deposited at a controlled rate of heat input. High heat inputs would: Have poor profile Have larger grain size Have high hardness in the HAZ Have low elongation properties Ya ugsllotat a biule matesial would be indicted jhe fracture sueface Sivows a reduction i fs flat and & uretess -29. 30. * 3 Breaks in the parent material Breaks at 45° to the load seo ‘Whet destructive test would be required to ascertain the likelihood of cracking in the heat, afféated zone of a weld? : ! fos ve Nick break: ro0! pened Side bendtest I= le ne Charpy impact test boy 7 Macro test. Crack, eS yaad orett bow In submerged arc welding excéssive aro voltage may cause: Excessive penetration. Change in weld metal composition ‘Narrow weld width Excessive bead profile MULTICHOICE PAPER THREE ‘The British code for visual inspection requirements is: BS 4872 BS 499 BS 4870 None of the above - A code of practice for visual inspection should include the following: i Before, during and after welding activities - Before welding activities only After welding activities only None of the above Incomplete reat penetration jn a butt joint could be caused by: Excessive root face width Excessive root gap size Low current setting Both A and C~ Jacomplete root fusion would certainly be caused by: Linear misalignment Incorrect tilt angle Differing root face widths A\l of the above ~ visually inspecting a completed single vee butt weld cap, you would certainly assess: Cap height Toe blend Weld width All above is4 6 & 10. i. 12. 3 nee You notice a very ‘veed' ripple shape. This is most likely caused by: Poor consumable choice Welding position Excessive travel speed — All the above ‘Toe blending is important as it may affect: Corrosion Fatigue life “ Gverlap type defects All the above Slag inclusions would occur with: ‘Manual metal arc@\u™ Metal inert gas a Submerged arc welding 5" Both A and C- ‘Undercut is principally caused by: Excessive amps Excessive volts Excessive travel speed Ali the above~ Undercut is normally assessed by: Its depth Its length It's biending All the above - A welding procedure is useful to: Give information to the welder Give information to the inspector Give confidence to a product All the above 7 Anessential variable may: ‘Change the properties ofa weld Influence the visual acceptability Require re-approval of a weld procedure All the above A magnilying glass may be used during visual inspection. but BS 5289 states that its magnification should be: Uptos a 2929 Ge 5t010D14, 15. 16. 7. 18, 20. ai. us None of the above When visually inspecting a fillet weld it would normially be sized by: The leg lengths : ‘The actual throat thickness ‘The design throat thickness Both A and C ~ A planar defect is: v= Incomplete fusion defects = ~Slaginclusion Incomplete penetration Both A and C - B inspection and magnetic particle inspection are mainly used: ‘To aid visual inspection Because the application says so To confirm visual uncertainties All the above ” Defects outside the limits specified in a standard should always be: Repaired Reported to'a senior person” Assessed along with other defects All the above welding tends to pe susceptible so lack of fusion problems. This is because of: Poor maintenance of equipment Incorrect settings Poor inter-run cleaning All the above, MMA electrodes can be grouped into three main types. These are: Basic, cellulosic and rutile”. ~ Neutral, cellulosic and rutile Basic, cellulosic and neutral None of the above ‘The mai rosity in. welded joints is: ‘Poor access Loss of gas shicld ‘Dirty’ materials Allie above Cracks in welds may be due to: Solidification problems Hydrogen problen E s116 | 22. Ayweave technique may give rise to: Better profiles oe Improved toe blending . - . Improved ripple shape + All the above ~ 23. With zeference to a root penetration bead you would certainly assess: Chee Root fusion and penetration Root concavity — a ‘Burnthrough All the above 24, Ina fatigue failure the appearance of thie fracture surface is characteristic. It would be: Rough and tom ‘Chevron'-like ' Smooth ‘None of the above Age Sree 25. Stray arcing may be regarded as a serious defect because: Tt may reduce the thickness dimension of a component Temay cause loquation cracks Tt may cause hard zones All the above 26. Overlap in welds could be influenced by: Poor welding technique Welding process Welding position Alll the above ~ 27. Flame cut preparations may, during welding, increase the likelihood of: () : 4 Cracking Misalignment problems Inclusions All the above ~ 28. Macroscopic examination requires any sp ‘Once, after etching Twice, before and after etching” Using a microscope \ None of the above 29. Which of the following may be classed as a more serious defect: ‘Slag inclusions Fusion defects (inter ron) Fusion detects (surface) en to be inspected:0. 30. ‘A standard for workmanship only A set of rules for manufacturing a specific product Levels of acceptability of a weldment None of the above MULTICHOICE PAPER FOUR, doucm in MMA welding by magnetic forces is called: ‘Are deviation Are misalignment Arc blows Are eye A metallurgical problem snost associated with submeried are welding i: Hydrogen cracking in the HAZ 5 ‘Solidification cracking in the weld metal - 9 ** a Hydrogen cracking in the weld metal ~ pisin 1" ‘Lamellar tearing in the weld metal ~ Oxy pressure and nozzle size in flame cutting would influence: ‘The temperature required for cut initiation The ability to cut stainless steels ‘The depth of the cut obtainable - None of the above + ‘The mainusage of arc cuttine/gouging processes is: The cutting of single bevel preparations The removal of deposited welds~ ‘The cutting of single U type preparations ‘The cutting/gouging of non-ferrous matezials only ‘Which of the following processes joins metals plastically? Friction welding Resistance welding Plasma welding All the above Which glectrode classification would be relevant to AWS AS.1-81? EGOLy ESU33 E70IS-G Fleeoweld 5 7 Ww10. ML 12. 3B. re} Which of the following fated with stove welding? A common gasimixture used in MIG welding nicke] alloys, to combine good levels of Rutile Cellulosic~ Basic Oxidising Benetation with good are stability would ‘be: 100% CO2 = Yeargon~ “ie 80% argon and 20% CO2 98% argon and 2% oxygen ‘Which type of SAW flux is more resistant to moisture absorption? Fused ~ Agglomerated Basic All the above have the same resistance The flame temperature of oxy/acetylene mixture gas is given as: 320°C 2300°C 5000°C None of the above A large grain structure in stecls is said to produce: Low ductility values Low fracture toughness values High fracture value values High tensile strength ‘The likelihood of brittle fracture jn steels will increase with: “All the above- Repair welding is often more difficult than production welding duc to: A large grain formation A reduction of in-service temperature to sub zero temperatures Ferritic rather than austenitic steels The material being ingrained with in-service contaminants Restricted access within the repair area The possible position of the weld repair -All the above thefveld metaljis likely when weldin; Carbon manganese steels Stainless steels Micro alloyed stecls (HSLA)~ Low carbon steels16. 7. 18, 19. 20. 9 EN 288 standard would refer to which of the following: ‘Welder approval testing Welding equipment - Welding procedure approval Consumables for welding Porosity is caused by: Entrapped slag in the solidifying weld Entrapped gas in the solidifying weld~ Entrapped metallic inclusions in the solidifying weld ‘None of the above In abend test the face of the specimen is in tension and the root is in compression. What type of test is being carried out? y Arroot bend test 7 Aside bend test A face bend test“ None of the above Ultrasonic testing is more advantageous in detecting which of the following weld imperfections, over othe ds? Lack of sidewall fusion~ Surface undercut Incompletely filled groove Overlap pecs ater spreereae ts Homes is often cassie regain toughness after which of the following processes? ‘Annealing Normalising Hardening, Steess relieving ‘The presence of iron sulphide in the weld metal is most likely to produce, which of the following upon contraction of the weld? Solidification cracking ~ Hydrogen cracking Intergranular corrosion Stress corrosion cracking Austonttic stainless steel clectrodes are generally smaller in Jength thanild steel electrodes because: —— High amperage is used Shelf life will be decreased Their electrical conductivity iy less thaa They are more exp24. 25. 26. 21. 2s. ‘The voltage necessary to maintain an arc during metal arc welding is termed: Mains supply voltage ‘ Are current Are voltage Open circuit voltagee ‘When MMA welding low catbon steel which electrode will “Hydrogen controlled Cellulosic. 7 Rutile Iron powder give the greatest deposition rate? Inherent rectification of the electrical output is produced in the arc when TIG welding usin; ‘AC with a suppressor AC without a suppressor, DC with reverse polarity DC with straight polarity Garima rays and X-rays are part of a family of waves called: ‘Acoustic waves Light waves Electromagnetic waves- Transverse waves A measure of the accuracy of a radiograph as an NDT tool is given by its: Intensity Density Sensitivity - Exposure A surface breaking crack will be detected during a magnetic particle inspection if it is: . Atright angles to the lines of flux - Parallel to the lines of flux ‘a All the above o At 25° to the lines of flux ‘The advantage of ultrasonic non-destructive testing for the examination of weldments is: Tecan be tsed to locate flaws Itcan be used to size flaws Ithas a high susitivity to planar flaws All the above, tet conditions weld proced:re approval tests for pipzwork are30. 2 Mandatory - ‘Dependant on site and weather-conditions ‘Dependant upon the contractor's confidence in his procedures Only required when MMA welding is used Hydrogen controlled electrodes were developed principally for: ‘The prevention of porosity ‘The prevention of eracking- ~ ‘Thie enhancement of are voltage case of arc starting MULTICHOICE PAPER FIVE, Generally the most suitable method of detecting lack of sidewall fusion would be: Ultrasoi MPI. Radiography. Penetrant inspection. Hot shortness js a term used to indicate: Lamellar tearing. Solidification cracking- Hydrogen cracking. None of the above. Cobalt as an isotope would generally be used on: Thin material. Tee joints. Plate thicknesses greater than 25 mm. - Alll the above, In welding procedute terms, a change in éssential variable means: Re-qualification of the weld procedure. Possible changes in the weld's microstructu Possible changes in the mechanical properti All the abover na dotted ling in accordance with ISO requirements means: ‘Weld on ‘arrow’ side, Weld on ‘other side.- Weld on site. Full penetration required. A welding inspector's main attributes include: Knowledge and experience. Literacy. Honesty and integrity All theabove. -122 10. Th 12. 13. 14, 15. ically, a code of practice is: ‘A standard. A\'set of rules' for the manufacture of a product Related to welder and weld procedure approval. All the above. ‘The correct term for ‘cap height’ is: Reinforcement. Cap profile height. Excess weld metal. A tensile test will assess: ~~ Impact values. Stress. Strain. Both b and cy ‘The important point of high temperature steels is that: They can withstand creep failure. ‘They may suffer re-heat cracking problems. They may suffer loss of toughness. All the above. - An austenitic stainless steel may suffer: Weld decay. Sensitisation. Solidification cracking, Alll the above values are useful to determine: Weldability aspects. Crack sensitivity aspects. Typical mechanical properties. All the above.- A basic electrode would normally: Have superior mechanical properties. Require baking before use, Not be used on low carbon steels. Botha and by When zeferring to TIG welding, the shielding gas could be: ‘Argon and hydrogen. Azgon and helium. to MIG wel, the shiel gas would be:24, 2s. . Céllulosic electrodes. . «Submerged arc with acid flux. “wp Vibert Spray transfer CO2 welding. *--" Basic coated MMA electrodes. Yoususpect that fertic steel plates codtain cracks in the prepared edges. What NDT method would you use to check this? ‘Radiography. Magnetic particle inspection.” Penetrant inspection. ~ Ultrasonic flaw detection. ‘Which of the following defects would you not expect to find by visual inspection of welds? Linear slag inclusions.” Undercut. Overlap. «Linear misalignment, 26. ‘Sires relieving is not helpful in which of the following cases? 27. 28. Improving resistance to stress corrosion cracking. Improving dimensional stability after machining Lowering the peak residual stress. Softening the steel. ‘What is the maximum, ally recommended for the heat-affected zone of a medium strength ferritic stec] weld? - 100 DP Hv. 350 DP Hv- 500 DP Hv. 750 DP Hv. What effect does mid thickness laminations in steel plate nagnally have when they are located within a weld heat affected zone? -Cause lamellar tearing- Fuse together to form a bond. Affect the weld metal composition. Cause internal tearing on a micro scale. 7 The permanent backing material for MMA welding of low carbon steel should be made from Copper Low carbon steel? QT stevt. Cast i17. 18. ai. 123 Argon Argon + 1% oxygen, ‘Argon +20% carbon dioxide. None of the above. Deep penetration characteristic. High deposition rates on DC#. Flat (PA) welding only. None of the zbove. Ultrasonics would be preferred over radiography due to: Ability to find most defects. Lower skill requirement. Ability to detect laminations. Both a and c.7 ‘The most serious defect types are: Planar. Cracks. Lack of fusion. All the above. eq!" MMA welding of low alloy steels is more likely to be performed with: Rutile electrodes. Cellulosic electrodes. Iron powder electrodes. Basic hydrogen controlled electrodes. Which of the following defects is more common to welds deposited by CO2 welding’than welds deposited by MMA? Slag inclusions. Excess penetration. Lack of sidewall fusion- Tungsten inclusions. Which defect would you expect to get in TIG welds in fion-deoxidisedisteel? Undercut. a Porosity.” : ‘Tungsten inclusions. . “ Linear misalignment. oly ‘Which of the following can arise from Copper inclusion? in a ferritic steel weld? Weld metal cracks” HAZ cracks, Lamellar tearing. Porosity. of the following i4. 6. ‘The overall length of a pipeline can be affected by: Transverse shrinkage. . Longitudinal shrinkage. Angular shrinkage. Circumferential shrinkage. MULTICHOICE PAPER SIX ‘The weld dimension used to indicate the Leg length. ae Throat thickness.” ih +r mumn strength of a fillet weld is; - Width of bead. Length of weld element. An electroslag weld requires what heat treatment to improve the grain structure? Annealing. Stréss relieving, ; ANormalising, #15 Goa cose Quench and tempering. The most common type of failure associated with sharp fillets, notches and undercut is: Crystallisation. Fatigue. Corrosion. Brittle fracture, Weld decay in stainless steels can be avoided by: Stress relieving. Slow cooling after welding. Addition of more manganese to the stee Addition of titanium to the steel. (sal sig aretoe 4 asa a An culectoid mixture in stect is: A mixture of ferrite and austenite. ‘A mixture comprising a substitutinal solid solution. Lalled pearlite. 3 Yo! 2494 Called ledeburite, ste ‘Low alloy stecls having a high carbon equivalent before welding will require: ‘A reduction in carbon content. High pre-heat temperatures. Low pre-heat temperatures No pre-heating. ‘The electrodes for welding love alloy steels should be: 125\ uM. 12. 13. 14, Used with a low current value, One size larger than for general Used for welding in the flat position only. Heated in a drying oven before use.~ ‘The purpose of pre-heating low alloy steel pipes before electric arc welding is to: Refine grain structure. Relieve internal stress, 7 ‘Retard rapid cooling. 1? babies: Li Arte of __-Regulate excessive expansion... - = - Welder quelification tests are designed to: Test the correctness of the welding procedure. «Test the welders skill. Prove the weldability of the parent material. All the above. In positional MMA welding on pipework, welders are having difficulty in obtaining good capping profiles when welding in the overhead position, Would you: ‘Advise them to increase the current. Advise them to increase the voltage. Ask for a new welding team. Suggest the use of a smaller diameter electrode. You have a macro section of a'T* butt joint that shows a s visible HAZ. What would this defect possibly signify? HAZ cracking. Toe cracking. Lamination, Lamellar tearing. Which electrode deposits weld metal with the greatest ductility and resistance to cracking? Rutile. Cellulosic. Basic.’ Oxidising. Which one of the following is no, helpful in minimising angular distortion during welding? Use of double 'V" weld prep using balanced welding techi Pre-setting of work piece, “Applying post weld heat soak. ‘Changing from a single 'V" prep for thick material. Argon purging on the root side is necessary in the TIG welding of stainless stec! to: Obtain full penctration, Obtain full fusion. ANoid porosity in the root Obtain a satisfactory weld surface fini sh el weld? Which of the following can arise from copper inclusions in a nsild16. 7. 18. 19. 20. ai. ‘Weld metal cracks c HAZ cracks. Lack of fusion. Porosity. Stress relief is not helpful in which of the following cases? In improving resistance to stress corrosion. ; In improving dimensional stability after machining.~ In lowering the peak residual stresses. In softening the metal, Stray are strikes are undesirable Leave a poor surface finish. Cause weld metal cracking. Reduce corrosion resistance. Cause local hardening and cracking in the parent material.“ ce they: Cold cracking is most likely to occur in a weldment if: ‘The rate of cooling is too fast. “ ‘The rate of cooling is too slow. It lacks ductility at high temperatures. Impurities are present at its grain boundaries, Chromium, when added to steet as an alloying element, has the effect of making the alloy more: Ductile. Plastic. -Hardenable.~ Malleable. ae eat Uf ga When depositing weld metal, fusion will take place at the sides of the joint resulting in an admixture between weld metal and parent metal. This alloying effect is known as: Diffusion. Absorption. - Dilution. Migration. Percentage elongation of a metal undergoing a tensile testis a measure of a. y. ; b. Plasticity. L Yad dud . ¢. - Ductility” d.— Malleability, When a longitudinal load is put on a lap joint, the stress set up is normally: a. ‘Shear stressv b. Tensile stress. c. Compressive st e Residuat ress. 127 ,“,. 128 23. 24. 25. 26. 27. 28. 29. ‘When a metal is subjected to a fluctuating load, a condition of cyelie stressing can be set up, which eventually cen result in structural breakdown known as: Tensile failure. Fatigue failurey Yield failure! Shear failure, ‘What happens to the mechanical properties of steel if the carbon contents iicfeased to 0.5%? The material becomes softer.. ‘Malleability is increased:-~ The tensile strength is increased.” Ductility is increased, Columnar growth takes place when a metal is: Cold. Losing heat.” Being heated. Being rolled. Ifa low carbon steel pipe has to carry a liquid, care must be taken when making the butt ‘welds to ensure penetration is not excessive because it: Reduces the flow rate of the liquid May increase the rate of corrosion. Can contaminate the liquid. May cause excessive pipe wear. Whena steel suffers hot shortness, it is mostly due to the presence of: Sulphur. Phosphorous. Silicon. Manganese. When a steel is heated to above its upper critical temperature, the structure produced is: Martensite, bs SES Austenite. A fee porn Pearlite, Sorbite. The type of crystal normally found in a single run arc weld in the as welded condition is: Equi-axed, Polycrystalline Dendritic, -Aolunnar. 4129 consist Large crystal grains. 7 Small crystal grains. Blongated crystal grains. Distorted crystal grains. MULTICHOICE PAPER SEVEN Pipe welding codes are set up by: “Welding operators. State governments. “Associations, societies, insurance companies, manufacturers and the military + Construction unions. ‘The different grain structure between the weld deposit and the base metal can be determined by: : A face bend test. A root bend test. Avhardness test. “An etching test.- yee A root bend testis used to test the amount of weld: Ductility- Elongation. Hardness. a Penetration. ‘What would be observed if a fillet weld were sectioned and macro-etched? The grain of the other beads is coarser than the final bead. The penetration and fusion into the root is very deep. wt Each bead appears to be distinctly separated from the adjoining beads. ‘The grain structure remains the same in all passes. ‘What is the most common cause of failure in root bend tests? Too high a current setting, Too long a pause in the down cycle of the weave. Lack of fusion and penetration Too high a travel speed. ‘The purpose of a nick break specimen is to provide a test for: Tensile strength and fracture appearance. Ductility and fracture appearance. Elongation and fracture appearance. +Soundness and fracture appearance.10. ML. 12. 13. 1, ‘Which organisation publishes the most commonly used code for boiler and pressure vessel welding? ‘American Welding Soci¢ty. American Society of Mechanical Engineersv. American Petroleum Institute. ‘American National Standards Institute, A low hydrogen electrode, according to BS 639, would contain: No hydrogen. . * “Less than 15 ml of hydrogen per 100 grams of deposited weld metal. Between 15 ml and 25 mil of hiydrogen per 100 grams of deposited weld metal. Less than 25 ml of hydrogen per 100 grams of deposited weld metal. ‘The second run in a three run butt weld using the stovepipe technique is known as the: Filling run. Hot pass- Intermediate run. Sealing run. You could determine that an electrode is cellulosic by its: BS 639 coding- Colour. - Trade name. BS 499 co iB. Which type of electrode coating gives the most voluminous gas shicld? Rutile. Basic. Oxidising. Cellulosic. Which of the following steels is likely to be more susceptible to hydrogen cracking? Carbon equivalent of less than’ 0.25 %. Carbon equivalent of 0.35%. Carbon equivalent of 0.38%. Carbon equivalent of 0.43% Preheating and interpass heating are used primarily for: Aiding fusion, Reducing hydrogen content of weld preparation prior to welding. Ensure a fine grain size. Slow down the cooling rate after welding. Submerged are welds made with re-cycled flux are liable to: Porosity Course grain size. Undercu Incompl 13016. 17. 18. 20. 2. : 131 Incomplete penetration in a single 'V! butt joint could be caused by: Too large a root gap. ‘Too small a root gap. - Too high a heat input. : Too small a root face. ees . In submerged arc welding, which of the following width to depth ratios would be likely to result in solidification cracking? — Ase depthiwidtn 3?! lL 2:1. lsh. ‘You are responsible for controlling welding on site. A large incidence of porosity has been reported in recent welding. Would you investigate? . ‘The electrode type. Power source. Electrode storage. ~ Day temperature, ‘The main reason why all adhering scale should be removed when the pipe end preparation is made by oxy-gas cutting is? 7 Oxidisation of the weld metal is minimised. ‘The speed of welding ig increased. Pipe bore alignment is made easier. Reduction of the weld deposit is prevented. When manual metal are welding low carbon steel, which clectrode covering will give the greatest degree of penetration? +. -Iron powder. Rutile. Cellulosic. Low hydrogen. ided welding stainless steel, which one of the following should ‘When tungsten arc gas s! be used? Altemator. A.C, tcansformer. 7D. C. generator. Constant potential restificr. ee Which gos'shroud should be used when tungsten arc gas shielded welding aluminium alloys? Nitrogen. Carbon dioxide. Argowearbou dioxide mixture. vAgon. ast23. 25. 26. 27. 28. 29. ‘The most common type of defect found in a structure when it is undergoing service is: Fatigue cracking. : Crystallisation. ‘Weld decay. Stress fracture. In the examination ofa welded aluminium joint, macro etching may reveal: 1'Si5(: -Lack of inter-run penetration’ Carbon pick-up. ‘Weld decay. aa Micro cracks. MMA welds made with damaged electrode coatings are subject to: Porosity. Undercut. Excessive penetration, Excessive bead height. Which physical test is more likely to reveal HAZ embrittlement? ‘Transverse tensile. All weld tensile. Root bend. ~Charpy impact. Which of the following destructive tests is not normally required for welder approval? Bend tesis. Macro examination. Impact tests. Fracture tests. Too large a diameter of filler rod should not be used to make a welded joint because: Excess reinforcement profile will be difficult to obtain. The included bevel angle will have to be reduced. -Root fusion may be difficult to obtain. ‘The gap setting will have to be changed. IEpipe bores are not matched correctly it can result in: + Lack of root penetration, Incorrect gap setting. Excessive root faces. Overheating during welding. A correctly made tack weld should slope from the middle to the ends in order to: “Aid better penetration at the join-up. Prevent porosity at the join-up. Reduce the electeode size requited ali consumable const:10. te 12, 13. 14. 15 133 ‘Two low carbon stee! pipes, 150mm diameter and 6mm wall thickness, ere to be butt welded using the TIG process. To ensure a full strength joint, which of the following preps is most suitable? i Open single bevel. Open single Vee.~ Open square preparation Closed square preparation, PROPERTIES OF MATERIALS ‘The ability of a material to withstand a load pulling it apart is called its“ ‘The ability of a material to be stretched oist without breaking is called___. ‘An Izod impact machine is used to give indication of the__ of a material. ‘The ability to withstand indentation is called Lack of ductility is called The property of metal to return to its original shape iscalled +. Increase in carbon content causes an_- in strength and hardness. ‘When carbon percentage increases, there is a decrease in Low carbon steel contains less than _":_ carbon, Low ductility in a weld metal could result in Alloying is used to___ mechanical and physical properties of a stecl. Sulphur and phosphorus are not alloying elements; they are Alloying allows designers to use_--_ sections and still have the same strength. Analloy that contains a high percentage of chromium and nickel would have resistance to 5 Quenching a carbon or low alloy steel will result in an in hardness and a in ductility. ‘The hard constituent that results when steel is quenched is called The tough laminated structure that is formed on slow cooling of ferrite and iron carbide (cementite) is called , ‘The aniount of mat“i34 of, 19. After quenching, the structure may be improved by reheating to 200-300°C. This is called 20. Small percentages of chromium will increase the strength and , While a small percentage of nickel will increase ANSWERS PAPER ONE bed 2 3b 4. 5. 6 b oe 8 oa 96 10, a IL d 12. a 13. b 14. b 15, ¢ 16. a Wa 18. b 19. a 20. d 2 22. a 23. d 24. 6 25. d 26. 4 27. ¢ 28. b 29. b 30. b PAPER TWO Lob Ba oan) 4. 4 Sc 6 © 1d & od 90d 10. d lb 12 b 1B. 4. b 15. ¢ 16. b 172 b 18. 19. b 20. ¢ 2. b 2.4 23. ¢ 24. b 25. ¢ 26. ¢ 27. b 28. b 2. d 30. b PAPER THREE Lod Roa 3d 4.4 5d 6 6 Lob 8 od 9d 10. d Mid 12d 13. b 14. d 15. 4 16. d 172 18, d 19. a 20.4 21. d 22.4 23.4 24, ¢ 25. 4 26. 4 2d 28. b 29. ¢ 30. b PAPER FOUR Loe 2b 3. 4. b oo aa) Qo Lob & ob % a 10. a Mb 12d 13. d 4. ¢ 15. ¢ 16. b We 18, a 19. ¢ 20, a 21 22. ¢ 23.4 24. b 25. ¢ 26. ¢ 2a 28. d 29. a 30. b PAPER FIVE Loa 2b 3 oe =) a 7. 8 oc ied to. d ia! d ed ia 16, 3 ec od Be Mob18 228 23. b 24. b 25. 4 26. 27. b 2. a 29. b 30. b PAPER SIX Lob Bo b 4.4 mG 6 b oa 8B 9b 10. d ud 1 Boe 4c 15. a 16. b 17.4 18. a 19. ¢ 20. ¢ 2c 22. a 23. b 24. ¢ 25. b 26. a 27. a 28. b 29. 4 30. a PAPER SEVEN ie 2 a 3a Ac 5 6 a mob & b 9% b 10. a ld Id 13. b 14, a 15. b 16, a ine 18. a 19. ¢ 20. ¢ 2. d 22. a 23. a 24. a 25. 4 26. ¢ 27. © 28. 2 29. a 30. b PROPERTIES OF MATERIALS 1. Tensile Strength. 2. Duetility 3. Toughness. 4, Hardness. S.Britleness. 6. Elasticity. 7. Increase, 8. Ductili 9.0.2% 10. Cracking. 11. Increase. 12, Impurities. 13, Smaller/Thinner. 14, Corrosion. 15.Increase.... Decrease 16.Martensite. 17 Pearlite. 18. Cooling... Carbon 19,Tempering. 20, Hardness...-Toughness.