CSWIP Set Question.

1. Why is it generally good practice to aim at using the least amount of consumable materials and
keep joint preparation to a minimum?
 To reduce costs and with less weld metal there is the probability of fewer weld faults.

2. In generally, MIG/MAG mode of transfer. Best suited for welding thin material sheet is;
 Short Circuiting transfer & Dip transfer ( Welding thin material & low voltage & low Amp)

Note;
 Globular transfer (mode transfer between dip transfer and spray transfer & produce
excessive spatter)
 Spray transfer (must used Argon & Helium gas for shielding)
 The pulsed transfer MIG/MAG process also can welding flat & overhead position.

3. Following maybe difficult to detect with the RT method?

 Discontinuities perpendicular to the radiation beam. i.e. Lamerlatering

4. When welding GMAW (also known as MIG/MAG) process, straight argon may be successfully
used as a shielding gas when welding material?
 Aluminium

5. The primary advantage of a 75% Ar, 25% CO2 gas mixture over pure CO2 in the FCAW process
is;
 Very significant reduction in weld spatter.

6. What is cause of inadequate penetration could;

 Incorrect joint preparation.
 Incorrect joint design.
 Incorrect welding technique.

7. Following is a method of increasing the hardness of steel.

 Heat Treatment
 Casting
 Introducing alloying elements.

8. Welding change the properties of solid steel through.

 Heating and cooling cycles associate with the welding arc and weld metal deposit.

9. Tension result are used;

 To select material for engineering application.
 10. Following may contribute to the formation of porosity in the weld deposit;
 Low welding current
 Contamination of the weld joint surfaces.
 Use of contamination electrodes, damp flux.
 Air entrapment in gas shielding.
 High arc voltage, arc length.
 In correct / insufficient dioxide in electrode, filler or parent metal.

11. when using GMAW process for welding of aluminum, the liner should made of;
 Nylon or Teflon.

Note;
 For welding steel used the steel liner.

12. when preparing bend test specimens it is important to;

 Prevent stress raiser by radius all edges of the specimen.

13. Steels that have intentional additions of suphur, lead or selenium to improve machinability.
 Can develop liquation crack in HAZ after being welded.

14. In TIG process an arc is formed between.;

 The tungsten electrode and the works piece.

15. Oxygen and suphur in steels form non metallic inclusion during the rolling process and can lead to
what during and after welding?
 Lamellar tearing ~ solid inclusion linking up under influence of welding.

16. Smaller and finer grain structure in steel usually provide;

 Higher Hardness & Brittle.

17. Arc energy of weld heat is a function of;

 Arc voltage, arc current and travel speed.

18. The fully transform heat effected zone located next to the fusion boundary in the weldment is the
area?
 With the highest tendency to form hydrogen cracks.

19. Heat treating steel consists of 3 basic steps.

 Heating the steel to specific temperature.
 Maintaining (Holding/Soaking) the steel at the specific temperature for certain period time.
 Cooling the steel at the specific rate.
20. In MMA the molten metal is protected by;
 Gases created from the composition of the electrode covering.

21. In the GMAW process, the electrical current is transferred to the electrode via the;
 Contact tip

22. The effective throat thickness of an complete joint penetration groove weld is;
 Less than the thickness of base metal.

23. When the base metal is melted away and not replace with weld metal. This is referred to as;
 Undercut

24. Defect is a term which is used to be best describe;

 Only discontinuities that has been classed as unacceptable.

25. An excessive large root face on a weld joint preparation;

 Can prevent penetration to desire depth.

26. Following would be considered the most serious structural discontinuity;

 Crack

27. A code of practice for visual inspection should cover the following;
 Before, During & After welding activities.

28. Incomplete root penetration in the butt joint could be cause by;
 Excessive root face width.
 Low current setting.

29. Incomplete root fusion would certainly be cause by;

 Linear misalignment
 Incorrect tilt angle
 Differing root face widths

30. When visually inspecting a completed single vee butt weld cap. You would certainly access;
 Cap height
 Toe blend
 Weld width

31. A very “ VEED” ripple shape. This is most likely cause by;
 Excessive travel speed.
32. “Toe Blending” is important as it may effect;
 Corrosion
 Fatigue life
 Overlap type defect

33. Slag inclusion would occur with;

 MMA
 SAW

34. Undercut is principally caused by;

 Excessive amps
 Excessive volts
 Excessive travel speed

35. Undercut is normally assessed by;

 Its depth
 Its length
 Its blending

36. A welding procedure is useful to;

 Give a information to a welder
 Give a information to the inspector
 Give a confident to the product

37. An essential variable may;

 Change the properties of the weld
 Influence the visual acceptability
 Require re-approval of a weld procedure.

38. A magnifying glass may be used during visual inspection. But BS 5289 states that magnification
should be;
 2 - 2.5diameter.

39. When visually inspecting a fillet weld, it would normally be “sized” by.
 The leg length.
 The design throat thickness.

40. A PLANAR defect is;

 Incomplete fusion defect.
 Incomplete penetration.
41. Penetration inspection and magnetic particle inspection are mainly used to;
 Aid visual inspection.

42. Defect outside of the limits specified in the standard should always be;
 Reported to “ a senior person “

43. MIG welding tends to be susceptible to lack of fusion problem. This is because of;
 Poor maintenance of equipment.
 Incorrect setting.
 Poor inter run cleaning.

44. MMA electrode can be grouped into 3 main type.

 Basic
 Cellulose
 Rutile

45. The main causes of porosity in welded joint are;

 poor access
 loss of gas shield
 dirty material

46. Crack in welds may be due to;

 Solidification problem
 Hydrogen problem
 Excessive stresses

47. A “weave technique” may give rise to;

 Batter profile
 Improved toe blending
 Improved ripple shape

48. With reference to a root penetration bead, you could certainly assess;
 Root fusion and penetration
 Root concavity
 Burn through

49. A fatigue failure is characteristic by the appearance of the facture surface. It would be;
 Smooth

50. “Stray Arcing” may be regarded as a serious defect. This because;

 It may reduce the thickness dimension if a components.
 It may cause liquation crack.
 It may cause hard zones.
51. Overlap is weld could be influence by;
 Poor welding technique
 Welding process
 Welding position

52. Flame cut preparation may, during welding, increased the like hood of;
 Cracking
 Misalignment problems
 Inclusion

53. Macroscopic examination require any specimen to be inspected;

 Twice, before & after etching

54. Which of the following may be classes as a “more serious defect”;

 Fusion defect (surface)

55. A code practice is;

 A set of rules for manufacturing a specific product

56. When “Hydrogen Control” is specified for a MMA welding. The electrode would normally be;
 Basic

57. You would certainly recognize a hydrogen controlled flux covered electrode from its;
 AWS / BS639 Code Letter

58. When MMA welding is being carried out on open construction site. Which group welder is likely
to require continues monitoring.
 Pipe welding team

59. You notice MMA electrode, stripped of flux, are being used as a filler wire, for TIG welding.
Would you object because;
 The weld metal composition may be wrong.

60. When open site working, serious porosity in metal arc welds is brought to your attention. What
would u investigate?
 Electrode storage

61. The steel composition in structure contrast is changed from 0.15% carbon, 0.6% manganese, to
0.2% carbon , 1.2% manganese. Might this influence the incidence of;
 Cracking in the weld area.
62. Following alloys is non-magnetic;
 Austenitic stainless steel.

63. When TIG welding Austenitic stainless pipe, Argon gas backing is called for;
 Prevent oxidation

64. Pre-Heating carbon steel. MMA welding is carried out to minimize the risk of;
 Parent metal cracking

65. In UK practice, BS499 Part 2 specified that the drawing dimension quoted for fillet weld is the;
 Leg length

66. For open site, MMA welding the following equipment is available and choose for safe working
area.
 Diesel engine driven motor generator

67. If SAW is to be used to make butt weld, which would you be most critical of;
 The root gap tolerance

68. During CO2 welding, the arc length is most likely to be effected by;
 The current return connections

69. Preheating for arc welding applies to;

 Assembly and tack welding.

70. What will effected on the carbon steel, when welder using an oxy-acetylene flame with a long
feathered inner cone;
 The weld could be hard and brittle

71. A welder qualification test is to verify:

 The skill of the welder

72. A fabrication procedure calls for fillet weld to be “blended in” by grinding. This is to influence;
 Fatigue life

73. Bend test specimen has been taken from 25mm a thick carbon steel butt weld. Which would show
lack of inter run fusion;
 Side bend
 74. Lamellar tearing has occurred in steel fabrication. Before welding could it have been found;
 It would not have been found by any inspection method

Note: It only found after welding and form when welding stress act it the short transverse direction of the
material.

75. You are overseeing the arc welding of some machined fitting and find they are cadmium plated.
What your action;
 Stop the operation at once

76. Movement of the arc by magnetic force in MMA welding is termed;

 Arc blow

77. A metallurgical problem most associated with SAW is;

 Solidification cracking in the weld metal

78. Oxy pressure and nozzle size would influence what in flame cutting;
 The depth of cut obtained

79. The main usage of arc cutting / gouging process is in;

 The removal of deposit welds

80. Following process joint metals plastically;

 Friction welding

81. The electrode classification would be relevant to AWS A5.1-81;

 E7018-G

82. Which of the following coating is associated with “ Stove” (vertical down) welding;
 Basic

83. A common gas / mixture used in welding MIG welding nickel alloy to combine good level of
penetration with good arc stability would be;
 100% Argon

84. The type of SAW flux is more resistance to moisture absorption;

 Fused

Note; Agglomerated flux ~ to avoid high H2 level granular.

 85. The flame temperature of oxy / acetylene mixture gas is given as;
 3200˚C

86. A large grain structure (annealing & normalizing) in steels said to produce;
 Low fracture toughness value

87. The like hood of brittle fracture in steels will increase with;
 A reduction of in-service temperature to sub zero levels (Fast cooling)

88. Repair welding is often more difficult than production due to;
 The material being ingrained with in-service contaminates
 Restricted access within repair area
 The possible position of the weld repair

89. Hydrogen cracking in the weld metal is likely when welding;

 Micro alloyed steel (HSLA)

90. EN standard 288 would refer to the;

 Welding procedure approval

91. The process of tempering is often carried out to to regain toughness after which of the following.
 Hardening.

92. The present of Iron Sulphide in the weld metal is most likely to produce which of the following upon
contraction of the weld.
 Solidification cracking.

93. Defect outside permissible limits of the applicable specification should be;
 Repair

94. Movement of the arc magnetic forces in an arc welding process is termed;
 Arc Blow.

95. A crack type most associated with the submerged arc welding process is;
 Solidification cracking.

96. Electrode and current type used for the TIG welding nickel and alloys.
 Cerium electrode, DC –ve

97. What are the possible result of having a heat input to low and high.
 LOW HEAT INPUT ~ entrapment hydrogen, increased hardness and lack of fusion.
 HIGH HEAT INPUT ~ low toughness, reduction in strength.
98. Main reason using back purge. When welding stainless steel with TIG;
 Prevent the formation of the dance oxide layer forming in the root.

99. Possible effect when Travel speed to fast;

 High hardness, slag inclusions and narrow thin weld bead.

100. If ARC BLOW exist when welding with MMA welding process, this can be reduce or eliminate by;
 A change from DC to AC current.

101. The inclusion of inductance in the welding circuit. When using MIG / MAG welding process is to;
 Control the rate of spatter in the dip transfer mode.

102. An undesirable property of aluminium oxide residue, when welding is;

 Requires more heat to melt it, when compare to aluminium.

103. When considering the TIG welding process. What is the purpose of the down slope / up slope (slope
out / slope in) control?
 SLOPE OUT ~ to help prevent the formation of crater pipe and possible cracking.
 SLOPE IN ~ to prevent burn through.

104. When considering Thermal cutting local hardening can be reduce by;
 Pre heating the material to be cut out.

105. Semi- automatic (MIG/MAG) welding process. Following shielding gas would normally give a
deepest penetration on steel.
 100% CO2

106. Following welding process, after weld is completed normally requires a PWHT to restore toughness
values.
 ESW

107. TIG process. When welding of aluminium, following current are used;
 AC

108. When considering hydrogen, following welding process would produce the lowest levels in the
completed weld (under controlled condition)
 TIG

109. In steel the element with the greatest effect on hardness is;
 Carbon

110. MMA welding voltage current setting, when the arc length is shortened & high?
 ARC length shortened ~the voltage will decrease.
 ARC length high ~ the voltage will increase.

111. What is purpose of a rectifier in a welding sets electrical circuit?

 To convert AC current to DC current.
112. When calibrating a mechanized MAG welding plant, which of the following applies (WFS = wire feed
speed)
 Check – gas flow rate, stick out of length, WFS and current.

113. What is effect of Tempering after Quenching;

 Toughness increased and strength reduced.

114. Ratio between leg length & design throat thickness;

 1.414 to 1

115. HEAT INPUT = Amp x Volt x 60

Travel speed mm/sec x 1000

116. The toughness & yield strength of steel reduce by;

 Increasing heat input.

117. Typical appearance of ductile fracture surface.

 Rough randomly torn and reduction in area.

118. Increased carbon;

 Increased hardness, decrease toughness

119. Effect of full annealing compared to normalizing.

 An increase in grain size.

120. Following element may cause hot & cold shortness;

 COLD SHORTNESS ~ phosphorous
 HOT SHORTNESS ~ sulfur

121. Following material most susceptible to HICC in weld zone;

 Carbon manganese steel (also occur in HAZ)
 Micro alloyed steel (HSLA)

122. HAZ of carbon steel fusion weld;

 Low toughness value.

123. The like hood of a brittle fracture in steel will increased with;
 A reduction in-service temperature to sub-zero conditions;

124. Following are consideration for the selection of a preheat temperature;

 Arc energy, material thickness, hydrogen scale and carbon equivalent.

125. Following element, which may added to steel, has the greatest effect on CREEP strength;
 Molybdenum.
126. In a martensitic grain structure, what expected to increase?
 Hardness.

127. Following mechanical test, to use a comparison from ductile to brittle transition curve;
 Charpy test

128. Heat treatment

 Normalizing ~ cools down in air from austenite region.
 Annealing ~ cooling in furnace (large grain structure)
 Quenching ~ (small grain structure).
 Tempering ~ is achieved by slowly heating the hardness steel to temperature between
200~650 c.
 Hardening ~ is achieved by very fast cooling from the austenite region.

129. The purpose of Microscopic examination of a weld;

 To determine the number & type of defect present
 To determine the grain size

130. FCAW & GMAW, when the amperage increased the wire speed will;
 Increase

131. When using MIG/MAG, welding of aluminum. The liner should be made of;
 NYLON

132. Flux of SAW are generally name by the method of manufacturer such as;
 Fused, agglomerated and mechanically type.

133. Travel speed is the rate, which the welding gun processes along the joint. As the travel speed is
increased;
 The heat input into the joint is decreased and the penetration is decreased.

134. Following are one of the methods to initiate the arc GTAW process. This has a potential of
contaminating the electrode and transferring tungsten to the work piece;
 Scratch or touch start method

135. The shielding gas commonly used in FCAW process is;

 Carbon dioxide (CO2)

136. In general, the amount of oxygen in a mixed gas used for (GMAW) should be limited to;
 2% maximum

137. Using GMAW process, straight ARGON may successfully used as a shielding gas when welding;
 Aluminum

138. A 70% duty cycle means that a machine may, at its rated output, run;
 7minute out of every 10minutes

139. In GMAW, spray transfer may achieve using shielding gas containing;
 More than 85% ARGON

140. A constant current power source is suitable for;

 GTAW & Plasma GTAW