WELDING INSPECTION TECHNOLOGY Sample CWI Fundamentals Examination THIRD EDITION Published By American Welding Society Education Department American Welding SocietyQR CERTIFICATION AWS Certicetions | Accredited Test Facilities BODY OF KNOWLEDGE To help you prepare further .. . This is the breakdown of the Bo category and the approximate percentage of questions drawn fr FUNDAMENTALS. Welding Processes Heat Control and Metallurgy Weld Examination Welding Performance Definitions and Terminology ‘Symbols - Welding & NDT ‘Test Methods - Nondestructive Reports and Records Destructive Tests Conversions and Calculations PRACTICAL APPLICATIONS Procedure and Welder Qualifications Mechanical Test and Properties Welding Inspection and Flaws Nondestructive Tests rom each, lumber of Te ns, 16 12 14 14 23 15 12 10 7 4 12 1 Number of Total Questions dy of Knowledge for the CWICAW!FA F2 F3 Fa FS Fe Welding inspection Tecnmeiegy Suinple CW! Fundamentals Sxamination co ieatly cut w High-carbon steel b, low-carbon stee! ¢. steel d. cast iron e. © and d above Electrical conductivity of a parts the primary requirement for which NDE method? a ET b UT. c PT 4 RT © none of the above ‘The melting point of carbon steel is approximately: a -2250°F b. 23759F c. 2780°F d. 3005°F & 3333°F | Decibel is a term associated with which NDE method? a. UT bo oORT © MT 4 Pr 6. ET Which type of GMAW metal transfer results in the least amount of penetration? a globular b. short circuiting ©. spray d. pulsed spray globular spray ‘Which of the following gases is not commonly used as a shielding gas for GIAW? argon carbon dioxide helium argowhelium none of the above peaogeFe F9 FAO Fil F12 tion "wenn aiogy 2is Examination ro be ace & change the origina! juspection report to indicate the par’s acceptance b. mark directly on the part © fill out a second inspection report 4 e tell the foreman ta have the part moved to its next operation none of the above When a metal is alloyed, how ate the atoms of the alloy incorporated into the original metal lattice structure? by inclusion substitutionally interstitially aorb above borcabove eaogp A wire IQI is used in which NDE method? a UT b ET ec RT 4. MT e PT Which of the following is not used as a semiautomiatic process? a GMAW b. FCAW c OAW a sw ® cand d above none of the above Crater cracks are most often the result oft a. improper technique b. improper filler metal ©. improper base metal 4. all of the above none of the aboveF13 Fig Fis FI6 FI7 Fis cing Ing Sample CW! Fundamentais Ea: The til ofa welding symbol 4. denoting weld! ». denoting welding 2 requirements © denoting welding electrode requirements 4. denoting welding specification requirements e. all of the above During tempering, as the temperature increases, which of the following are correct? hardness increases hardness decreases elongation decreases a and above b andic above peoee In GMAW, the distance from the end of the contact tube to the are is: a arc length b. electrode extension c. stickop 4. aandb above © band c above Of the following, which is not a type of metal transfer in GMAW? a spray b. short circuiting globular 4. pulsed are © open circuiting traviolet light may be used with which NDE method? VT Ul a. b Pr © MT d— aandbabove @ band above The technique which does not aid in reducing residual stress is: a peening b. vibratory stress relief ¢. thermal stress relief 4d. external restraint preheating ection TechnolegyF20 Fat F23 Faq ° Paere es all of the above Part dimensions can be determined using which of the following? a MT b oUT ec ET 4. aand ¢ above e. band ¢ above OF the following tests, which are used forth actual determination ofa material's toughness? a. Charpy test MT chemical analysis all of the above none of the above sans Which of the following elements are used as alloying elements with tungsten to produce GTAW electrodes? a zirconium b. thorium ¢. — columbjum @. aorb above @ bore above For single bevel-groove weld symbols, the line of the AWS weld symbol running perpendicular to the reference line is always drawn on which side? & on the right b. onthe left © on either side, depending on company policy 4. on the side in which the straight side actually appears in the joint €. does not matter The surface between two pieces to be joined that lie in parallel planes is called: weld interface faying surface weld edge groove face none of the above SaneF26 Fo7 F28 F29 F30 2 t09 slow S welding electrode too large d. improper electrode manipulation © use of electrode in a position other than that for which it was designed NDE technicians are usually qualified in accordance with the requirements of: a AWS DII b. API1104 ¢. ASNT SNT-TC-1A d. ASME Section VI e. ASME Section IX ‘Which factor listed below has the least effect on the amount of residual stress and distortion that results from welding? a heat input b. phase changes ©. welding position 4. tensile strength © coefficient of thermal expansion Capillary action plays a role in which NDE method? ET Ur RT PT MT Spogp Ifa welder is continually tuming outrejectable work, the welding inspector should: a. inspect his work mote critically b. ask that the welder be fired ©. require that the welder be retested for qualification 4. instruct the welder in the proper techniques €. ask that the welder use another process Which of the following tests can be used to judge weld soundness? nick break side bend face bend radiography all of the aboveF32 F33 F34 F35, F36 <. Welding at the end of e joint d. welding in comers © all of the above Shielding gases used for GMAW can include: & carbon dioxide b. argon helium oxygen €. all of the above Developing is one of the steps in which NDE method? UT RT PT aand b above band c above Spogp Which discontinuity below will provide the sharpest MT indication? @ surface porosity b. surface crack ©. subsurface porosity 4. subsurface crack €. indications will be identical for all of the above In SMAW, an increase in arc length results in: a. increased current; increased voltage b. decreased current; increased voltage ©. increased current; decreased voltage 4. decreased current; decreased voltage ®. none of the above Weld inspection reports should always: 2 be completed in ink, or typewritten and signed b. be done in pencil so mistakes can be easily comected ©. be maintained only if the weld is rejectable 4. by filled out by a clerk so that everything is readable © include the welder's identificationFa7 F38 F39 F40 Fat Fag hastagy by Examination ‘owing properties amet harduess b toughness ©. tensile strength 4. fatigue strength & ductility In GMANY, the type of metil transfer requiring a special power source is: & spray b. globular ©. pulsed are 4. short circuiting ©. none of the above Which of the following is truly a volumetric test method? a RT & UT ce ET d. MT €. none of the above Use of preheat will result in: a faster cooling rate and wider heat-affected zone 2 faster cooling rate and narrower heat-affected zone a slower cooling rate and wider heat-affected zone a slower cooling rate and narrower heat-aifected zone none of the above Seep Which of the following methods is most likely to use a cathode Tay tube for the presentation of flaws? a RT bo OET e« UT d. aand b above 7 | © bande above For plain carbon steels, how are hardiness and tensile strength related? increase hardness; decrease tensile strength increase hardness; increase tensile strength decrease hardness; increase tensile strength aand c above hardness and strength are not related Snoopfelciing inspucson Tas! Sainple OW Fury Fag Fa4 Fas Fag. Fa7 Fag y amination welding variable controtied by t tickout one of the above ‘The welding variables used to calculate heat input are: voltage and current current and travel speed voltage, current and travel speed travel speed, preheat temperature and voltage voltage, current and preheat temperature Sao gp ‘As temperature increases: . tensile strength increases D. tensile strength decreases ©. ductility increases 4. aand b above €. bande above Which of the following provides the best protection from radiation? . lead shielding steel shielding concrete shielding copper shielding maximize distance from radiation p Pao Welding inspection should be performed: . before welding begins during welding after welding is completed all of the above only when there is a problem Paogp If the weld symbol straddles the reference line, it means: weld both sides weld arrow side first Weld other side first weld has no side significance none of the aboveFas F50 F51 F52 F53 F54 b.-BCAW, GTAW, PAW ©. ESW, LBW, FW a. PW, CAB, RSW e. all of the above An E7016 SMAW electrode exhibits which of the following charac 2 low hydrogen; AC only; iron powder b. low hydrogen; AC and DCEP ©. low hydrogen; AC and DCEP; iron powder d. rutile; DCEP €. rutile; DCEP; iron powder Piezoelectricity is a material property used by which NDE method? a UT b OET «RT 4. aand babove e. band c above A thermal treatment that follows quenching and restores some of the metal’s ductility is referred to as: 2, stress relief b. tempering c. hardening d. normalizing €—postheat Which of these methods is most often used to reduce the high residual stress created by welding? a. prebending b. shor blasting © quenching rapidly after welding 4. postweld heat treating ©. none of the above The physical principle that permits the migration of liquid penetrants into very fine surface discontinuities i 2. magnetic permeability b. optical fluorescence ¢. capillary action 4. emulsification enone of the aboveF56 F57 F5s Fs9 Feo * are brazing braze welding ip brazing flow brazing be © 4. e. ‘Which of the following contzins ferrous base metal specifications? a AWSD11 b. ASME Section HI, Part C e AWSAS1 d. ASME Section IX e. ASME Section I, Part A Which of the following is not considered to be a satisfactory method of magnetization when conducting a magnetic panticle test to a specification? AC coil AC yoke DC coil DC prod residual magnetism Saogee Advantages of MT include: a. the detection of surface flaws b. both AC and DC methods ¢- the detection of surface flaws tightly closed by carbon, slag or contaminants 6. the fact that itis faster than PT ©. all of the above 1h general, an increase in the carbon equivalent of a carbon steel will result in an increase in its: a ductility b hardness strength 4 aandb above € bande above A welding process commonly used to join light gage stainless steel tubing for critical applica- tions is: a SMAW b. =GMAW c. GTAW da OFW © none of the above 10Fe1 F62 Fes F64 F6s F66 91 Teck nology 5 Examination Sample CWE her weld metal ca eerking incomplete penetration porosity bandd above “hich of the following cea result when hydrogen is introduced into the molten weld pool? porosity weld cracking delayed cracking all of the above none of the above Entrapped slag can result when using: Saoep SMAW SAW FCAW ESW all of the above ‘The material property that best describes its ability to withstand a static load is: Pao gp method? a PT b oRT ce MT d, all of the above © none of the above if Saogp hardness toughness tensile strength fatigue strength none of the above no information appears to the left of a groove weld symbol, this means: no weld is required on that side the weld is to be complete joint penetration the weld is to be continuous for the entire length of the joint no weld joint preparation is required none of the above 1"Fes Feo F70 Fri F72 lamination porosity Slight incomplete fusion at a bevel angle of 350 degrees 4a crack with its depth parallel to radiation beamn e aand ¢ above Dwell time is a term associsted with which NDE method? a MT b PT ce RT a ET none of the above The material property expressed in terms of an endurance limi a. fatigue strength b. toughness © tensile strength 4 ductility © — hardness Fracture toughness results will often be expressed in tems of: breaking energy tensile strength percent elongation endurance limit reduction of area SaRoop Shielding of the molten pool in OFW is accomplished by: & a granular flux b. achemical reaction can inert gas d. a vacuum chamber €& — aflux paste ‘The welding inspector is usually responsible for which of the following? checking for proper electrode storage verification of a welder’s qualification witnessing all repairs aand b above band ¢ above See ge 2 lineF74 F75 F76 F78. ©. the recommended type of current the degree of penetration e all of the above ET can be used to detect which of the following? a material’s conductivity a material's hardness a thin material's thickness ‘a material's heat treatment all of the above peoge For an SMAW electrode, the next to the last number in the designation refers to: the tensile strength of the weld deposit the positions in which it can be used the type of coating the recommended type of current none of the above Pepe ge ‘The property of a material that best relates to its resistance to impact loading is: endurance limit fatigue strength fracture toughness tensile strength’ ductility papee Of the following ‘discontinuities, which is least likely to be the result of an improper welding technique? 2. porosity b. Jamination ©. undereut d. crack ©. none of the above Which of the following is considered to be an advantage of VT? discontinuities can be located and noted when they occur it is capable of detecting subsurface discontinuities it can be done very economically aand c above none of the above saooe 130 the public? in the perf: of his duties for inspections that he has personally perforined reporting all nonconformities to the news media none of the above paps FO Which of the following cunnot be done in the overhead position? a SAW b ESW ec. GTAW d. all of the above €. aandb above F81 No information appearing to the right of 2 groove weld symbol means: the weld is to be complete joint penetration no weld is required on that side the weld is to be continuous for the entire joint length ‘no weld joint preparation is required none of the above saogp F82 The welding process that typically uses a tubular electrode is: a SMAW b. GMAW c. FCAW a SAW « ESW 83° The property relating to a metal’s resistance to indentation is: a. tensile strength b. ductility ©. hardness 4. toughness ©. fatigue strength F84 ET is the abbreviation for: & eddy current testing “ b. — environmental testing ©. emissive testing 4 aandb above e band above 4Fas Fee F87 Fes. Fsg Foo icing Inspection Sarr 7 c AWS 43.0 ¢. aand b above & band c above The flux covering on an SMAW electrode provides which of the following? a g28 shielding for the molten poo! 6. are stabilization ©. alloying 4. deoxidation all of the above a b a TePart the deficiency to the proper supervisory personnel 4. require that the parts be disassembled and properly assembled © none of the above The orientation ofthe probing energy source with respect to tha ofa flaw is considered to be a significant variable for which NDE method? a RT b oUT c. ET ad MT. €. all of the above Information that appears tothe left of the weld symbol refers to: 2 the weld length b. the weld size © the electrode size 4. the number of passes required ©. none of the above ‘Which process uses a granular flux? a SAW b. «GTAW c ESW G. aand b above ® aand c above 15F9y Fo2 F93 Fo4 F95 Fo6. stituents listed below, the fy austenite Pearlite In radiography, the image on the film of a completely through-cracked weld will; 2. appear as a well-defined, low density lightly shaded, sharp line b. appear as a well-defined, high density, darkly shaded, sharp line © appear as a row of iow density light spots or dots 4. appear as a row of high density dark spots or dots © none of the above A material's ductility is commonly expressed in terms of: a. percent elongation b. percent reduction of area ©. tensile strength 4d. aandb above ©. bandc above Who is responsible for the qualification of welding procedures? & independent test lab b. contractor ©. welding inspector @. > architect engineer ‘What MT technique could be used for the discovery of longitudirial flaws? a. head shot b. circular magnetization ©. longitudinal magnetization d. aandb above € band above ‘Which code gives prequalified status to certain weld joint configurations? a APL1104 b AWS DLAI ¢. ASME Section IX d ANSIB31.1 ©. none of the above 16Fos. Fog F100 Fi01 F102 appears to the "ess to be used) ype of electrode to be used ©. length of weld required size of weld req © required joint configu: 8 When a clerical mistake is made while completing an in Sspection report, the inspector should: a ‘erase the error and fill in the correct information b. cross out the error and supply the proper information © Tine out the error with a single line, supply the proper information, and initial and date the occurrence in ink 4. attach a note to the report explaining the reason for the change e none of the above The rapid quenching of a high carbon steel from the austenitizing range will result in the formation of: a pearlite b. martensite ©. cementite ad ferrite © austenite When an austenitized carbon steel is cooled to room temperature, an increase in the cooling rate will result in: 4 an increase in hardness and a decrease in ductility b. an increase in tensile strength and a decrease in hardness ¢. a decrease in tensile strength and an increase in hardness d. an increase in ductility and a decrease in hardness a decrease in hardness and an increase in ductility The surface finish of the specimen affects the test results for which of the following? a tensile strength b. fatigue strength ©. impact strength 4. all of the above e aand c above The heat treatment in which a carbon steel's temperature is raised to the austenitizing range, held for a prescribed time and then allowed to cool to room temperature while remaining in the furnace is referred to as: a stress relief b. annealing ©. normalizing 4. tempering e. — austenitizing 7F104 F105 F106 F107 F108 When a weld has been ¢ plete of carbon s g Citection f ductiliny? aand b above band c above ted by a qualified NDE technician, the welding inspector should: review the test results end maintain the test record teinspect to verify the defect accept the weld if its visual appearance is in compliance with the applicable code or specification tequire another inspection by a third party accept the weld since itis in a low stress region Equal thicknesses of steel, cast iron, aluminum, lead, and copper are radiographed using the satne exposure conditions. Which material will result in the darkest radiograph? eeoge lead steel aluminum copper cast iron ‘The welding process that uses a nonconsumable electrode is: a b. © a. e GMAW SAW GTAW FCAW SMAW ‘The heat treatment in which the metal’s temperature is raised to the austenitizing range, held for prescribed time and then allowed to cool to room temperature in stil] air is referred to as: a. b e ch e. austenitizing normalizing annealing quenching tempering Ina guided bend test, the bend radius is: a b ce a. e always 5 inches as specified in the appropriate code or specification 0.5 inch 0.65 inch none of the above 18F110 Fi11 F112 F113 Fig Th A a be c a e It excess moisture. To determine the extent of the surface and subsurface Porosity that resulted, which NDE method would be most effective? a b. cs 4. « Saoge ‘The heat treatment for carbon steels in which the metal’s temperature is raised to just below the lower transformation temperature and held for a preseribed time before allowing it to cocl at a controlled rate is referred to as: a papoose FOAW SMAW GMAW none of the above he AWS Centfied Weiding inspecior must be capable of. welding performing PT performing chemical analysis supervising welding none of the above break in the arrow line has what significance? Welding must first be done on the arrow side Welding must first be done on the other side Welding must be done alternately on both the arrow and the other sides The broken arrow line segment points to that member which receives some preparation none of the above is discovered that a GMAW mild steel weld was produced with a shielding gas containing MT RT VT tempering austenitizing stress relieving normalizing preheating | 19Pris F116 FII7 Fig F119 F120 lie position on @ meial’s str plas Yield point 2. modulus of elasiicity © endurance limit transformation temperature © Young’s Modulus Low-hydrogen electrodes can be properly store 2 ina natural gas oven b. inan electric oven © ina vented electric oven d e in a vented gas oven none of the above All welding symbol information referring to the arrow side of the Joint is found: in the tail above the reference line below the reference line where the inspector decides none of the above Spo ge ‘The marking of a rejectable weld should: be clear and understandable to all involved be made with a steel impression stamp note the proper repair procedure always be in red always include the welder’s identification Cannot be used effectively to inspect: austenitic stainless steel welds on carbon steel austenitic stainless steel welds on stainless steel] carbon steel welds on carbon stee] @ and b above band c above PeeorR Spee Of the welding processes listed below, the one most ‘commonly having the highest deposition rate is: a ESW bo FCAW c SAW d SMAW e GMAWFi21 F122 F123 F124 F125 F126 The vse of pre tem carbon steet wil} of hydrogen cracking ¢. result in the formation of martensite a and b above band ¢ above The tensile test can be used to provide values for which of the following? a yield point >. ultimate tensile strength c. modulus of elasticity 4. elastic limit €. all of the above Which of the following is not an acceptable method for control of raw materials? & color coding b. alpha-numeric coding c. first in, first out d. location segregation €. barcoding ‘The welding inspector's duties should typically include: the acceptance/rejection of welds the verification of a weld filler metal type the development of weld repair procedures aand b above band c above gaoge All welding symbols require which of the following basic elements in their construction? reference line, arrow and tail reference line and arrow reference line, arrow, weld symbol reference line, arow, weld symbol, dimensions and supplementary data reference line only paoge ‘The size of the weld represented in Figure I: a. isnot important smaw b. cannot be determined directly from the symbol ©. can be determined from the symbol d. all of the above e none of the above Figure 1 aF128 F129 F130 F131 F132 asingtion fon provide pure T raguires liet weld the use of shi all of the above metal are welding pRoer A SMAW weld was produced in which the welder failed to properly clean between passes in a multipass weld, Which nondestructive test would best reveal the flaws that may be present in the completed weld? a RT b& VT «MT da PT e ET ‘SMAW can be used in which type of application? semiautomatic a RESTRICTION RING b. machine ©, manual d. alll of the above TEST WELD €. none of the above sas ‘What position is depicted in Figure 2? a 6G be 5G c ° OF d 6GR 7 none of the above Figure 2 Using the appropriate conversion factor provided in the chart on page 40, determine the approx- imate diameter in inches for an electrode that measures 1.2 mm. a 0.047 in, db 47in c. 0.0047 in, dd 47in, e 47.2in, Underbead cracking is primarily caused by: a source of hydrogen restraint excessive preheat all of the above none of the above Sao eEFI33 F134 F135 F136 F137 F138 fection? jamentals & mperatere below 80)°F 6 it can be dove in an inert ‘gas atmosphere dit relies on capillary action e ic, and d above Which weiding process uses a constant current power source? GMAW >’ SMAW c GTAW 4. aandb above band c above ‘The first operation required by the symbol in Figure 3 is: UT ultrasonic inspection of the base metal VT visual inspection of joint preparation welding a V-groove from the other-side of the joint welding a backing weld from the arrow-side of the joint back gouging and back welding from the arow-side of the joint Figure 3 Spogp For Figure 3, ultrasonic inspection is to be performed: @ on the back weld only on the entire length of the other side weld on 10% of the weld length from the arrow side bandd above Saeg Which of the following discontinuities are associated with shrinkage stresses in the through thickness direction of thick plate? 7 crater cracks lamellar tears ._ toe cracks Toot cracks none of the above Pao Which of the welding techniques below describes a welding process in which the filler metal feeding is machine operated while the joint travel speed and guidance are the responsibility of the welder? semiautomatic manual machine automatic none of the above gaosre 4 depicis: followed bya V le followed by Figure 4 id made one-half the w a V-groove weld arrow-side with the root fi around the diameter of a pipe hed to a convex contour F140 Which of the following symbols correctly describes the joint configuration shown in Figure 5? = ane . c Figure § a ‘1/4 (7/16) 174 (7716) © none of the above FIAT The width of the cut produced during a cutting process i referred to as: root opening kerf bevel bevel angle chamfer pRooe F142 For the 2G position in pipe welding: 2 the axis of the pipe is vertical and the plane of the weld is horizontal the axis of the pipe is horizontal and the plane of the weld is vertical the pipe is not fixed Paes one of the above F149 During operation, the heat for electrosiag welding is provided by: . the are the electrical resistance heating of the molten slag the consumable guide tube 2 and b above band above Spo oe 24 the axis of the pipe and the plane ofthe weld are at 45 degree angles with the vetical planeF144 F145, F146 F147 F148 F149 ension factor j he char on page 40, determine the approx ewe ¢off) for a flow ree of 22 titers per minute b. 4e.6 cm 10.38 ofa 4 03.8cfh e. 4.66 eth Its suspected that a GMAW weld was produced in an area where there was an excessive draft, Which nondestructive test would best reveal the intemal discontinuities which may have resulted? a PT b. MT «RT @ UT e. none of the above The size of the arrow side weld in Figure 6 is: a V4 inch b. 5/16inch feet c Jinch a inches ©. none of the above Figure 6 The length of the other side weld in Figure 6 is: a." Vinch b 6 inches ©. 2inches 4 4inches ©. continuous down the length of the joint ‘The pitch of the other side weld in Figure 6 is: 1/4 inch 4 inches 5/16 inch linch 6 inches paogp The process to be used in welding according to Figure 6 above in question 148 is: a. the inspector's choice b. the fabricator's choice ©. not stated dd. bandc above e aand b above 25F151 F152 F153 F154 F156 sonination te a ET BOM? c PT ad UT e ET ‘The phrase. “that surface of a member included in the groove” best describes: a. root opening b. groove angle ¢. weld interface 4. groove face € none of the above Crater cracks can be the result of: a. poor welding technique restraint shrinkage Bectroge, Slap Molten Fix b, ce .— underfill of crater €. all of the above Figure 7 depicts which welding process? a SAW sola SE Welded 4 GMAW © FCAW ‘The boundaries indicated by “ a. fusion line b. depth of fusion c. weld interface d. fusion face €. none of the above ‘The dimension “D” in Figure 8 is referred to as: a. fusion face b. fusion zone c. depth of fusion d. weld interface ml fusion line 26 Contact Tube Nozzle Flaxia from Hopper Fu Blanket Motes Base Metal Weld Metal Path Direction of Trav ——— Figure 7jon Technolo: aC a p> @. none of the above F157 Using the appropriate conversion factor provided in the chart on page 40, determine the approx- imate degrees Celsius for a preheat temperature of 25°F, a 225°C b 107°C ce. 437°C a 107°C e 107°C F158 Which of the following welds is not considered applicable for a butt joint? a. V-groove b plug ©. edge-flange d. U-groove e. Iegroove F159 The dimension “A” in Figure 9 refers to: a. root penetration b. weld penetration cc. depth of fusion d. joint penetration ©. none of the above F160 The dimension “C” in Figure 9 identifies: a. joint penetration and weld size b. weld size and root penetration c. depth of fusion d. partial joint penetration incomplete joint penetration F161. The dimension “B” in Figure 9 is referred to as: joint penetration Toot penetration root reinforcement aand b above band c above eaereF163 F164 F165 F166 moamesstots Ex ination the following is nota iype of wel When using SMAW, wet electrodes will most likely cause: a. underevt b. overtep ©. underfill 4. porosity ©. all of the above Which ofthe following is considered to be an acceptable way to provide backing for a V-groove weld in a carbon steel butt joint? & copper backing bar b. ceramic backing ¢. flux backing d. backing weld ¢. all of the above A welder deposits an average of 12 pounds of weld metal Per hour. Using the appropriate con- version factor provided in the chart on page 40, determine the approximate kilograms of weld ‘metal that will be deposited in 6 hours of continuous welding, a Skg b 33kg cb kg a 26 kg e 37kg A single-wire, submerged arc welding machine is Operating at 32 volts, 600 amps and is travel- ing at 8 inches per minute, Using the formula provided. what is the tert input for this situation? Voltx Amperage x60 _ Sin, ‘Travel Speed (in,/min) 7 2,400 Win, 1,152,000 J/in, 1.44 x 105 Jin, 110,000 Jin, 14,400 Win, saorp 28F187 F168 F169 F170 Fi71 F172 ing Iepestion Te empie #1 Fundementals & nation hibits an ssively convex pro- h fi sprite acto 2 it, since its a aonselevant indicotion b. reject the weld c correct the excess convexity and retest d e secept the weld none of the above ‘The pipe welding test position ia which the pipe is horizontal and rotated so that welding takes place at or near the top is designated as: 2G bo OF 3 a 3G e 1G The design strength of a fillet weld is always based on the throat dimension because: a, thas a columnar microstructure, which is more prone to cracking b, itis the shortest failure path through the weld ¢. itis the location of most defects d. the design calculations cannot be checked ¢. itis theory of failure that cannot be supported by actual laboratory testing Are strikes are discontinuities most commonly associated with: a ESW b SAW ©. SMAW a. aand babove @& bande above Double-groove joints always require: backgouging special welding processes high deposition rate processes weld to be deposited from both sides of the joint a spacer to hold critical root openings Saogeainination 2 process is depicied in b. MAW c SMAW 4, e, SAW ESW sours we F174 Light-colored areas within the weld he zone in a radiograph could represent: 2. porosity tungsten inclusions melt-through aand b above band c above METAL Wo S80, onoPLEtS Peneraanion oem BASE METAL PIRECTION OF WELDING ————a b. < Figure 10 e F175 A single-groove joint always requires: a. special welding processes b. back gouging ©. abacking bar 4. no root opening ©. none of the above FI76 The substance used in UT to aid in the transmission of sound from the search unit to the work: piece and back is called: a solvent b. attenuation © couplant @ cable e transducer FI77 Using the appropriate conversion factor from the chart on page 40, determine-the approximate Kilogram weight of a 30 pound roll of welding wire. a 136 kg b 66 kg e136 kg d 66.15 kg e 136k F178 The junction of the weld face with the exterior surface of the base metal is referred to as the: a” face b. root ce leg 4 toe e. edgeF178 F180 F181 F182 F183 vinations ave best revealed vs «ET Porosity in GMAW can be caused by: a drafts 6. contamination ©. too little shielding gas flow 4. too much shielding gas flow €. all of the above ‘The overhead fillet position is designated as: a SF bd 4E ce 3F 4 2F e IF The radiograph in Figure 11 shows: Inspection T oimciegy damentak, Exomination, a cracks b. incomplete fusion ©. incomplete joint penetration d. slag inclusions ©. none of the above Figure 11 ‘The welding process depicted in ‘Thamovor wanna Figure 12 is: GMAW cet ise SAW SMAW ror GTAW Booy sc PAW ‘COLLET BODY paoge MOLTEN anc WELD METAL Figure 12 31 ELECTRODE: SHIELOING GAs NONCONSUMABLE TUNGSTEN ELECTRODE. SouoirieD, WELD METALF185 F186 F187 F188 Figg re 13 sho) nclusions or soot defects tangsten inehusions porosity longitudinal crack e. undercut aan How many micrometers ere in one meter’? @ 3,000,000 b 1,000 ce. 100 4. 1,000,000,000 none of the above In a groove-weld cross section, the ‘line’ separating weld metal from base metal is called: a. the fusion face b. the depth of fusion ©. the depth of penetration d. the weld interface ©. none of the above In the radiograph in Figure 14, the arrows point to: a. transverse cracks b. acrater crack ¢. a longitudinal crack d. an underbead crack €. none of the above Figure 14 Incomplete fusion can be caused by: a porosity b. weld joint contamination ©. undercut 4. poor fitup e banddabove In pipe groove welding, the 45 degree fixed position is designated as: a 1G b 26 c 2F d 5G e 66F130 Figt F192 F193 F194 Figs peed i 83 ipa bd. 283 ipm © 2834 ipm 4 5.076 ipm € 50.75 ipm The detect noted in the radiograph in Figure 15 a. incomplete penetration b acrack ©. incomplete fusion 4. porosity ©. none of the above The “A” dimension in Figure 16 is referred to as: weld throat b. weld size cc. weld leg 4. aand b above bande above in Figure 16 points to: the root penetration the weld penetration the weld root the joint root none of the above Figure 16 a. b. ©, 4 e. ‘The dimension “C” in Figure 16 shows: @ the theoretical throat b. the actual throat ¢. the effective throat 4. aand b above & bande above The dimension “D” in Figure 16 is called: a, the theoretical throat b. the effective throat c. the actual throat d. aand b above e. bande aboveF1g6 F197 F198 Fisg F200 F201 One common cause of centerline weld cracks is Sap ee the theoretical throut Jeg and weld size concavity the use of preheat # highly restrained weld joint using the wrong polarity stress relief heat treatment the presence of incomplete sidewall fusion Figure 16 Using the appropriate conversion factor from the chart on Page 40, determine the approximate Pounds per square in. (psi) for a yield strength of 198 MPa’ a b. c a. e. discontinuity? a. b, c 4. e Using the conversion factors provided in the chart on page 40, determine the approximate MPa for a tensile strength of 65,000 psi. a. 2.871 x 103 psi 2.871 x 104 psi 4,136 psi 41.36 psi 2,871 psi intermittent less distinct PT cannot detect a subsurface flaw none of the above 448,000 4.48 x 108 448 9,425,000 | 9.425 x 106pitten F203 F204 F205 F206 F207 sharper Jess distinct MT cannot detect a subsurface flaw } inch below the surface none of the above Which of the following conditions can cause slag inclusions in a weld? poor welder technique careful interpass cleaning insufficient preheat aand b above band ¢ above geaos To be most effective, visual inspection must be conducted: before welding during welding after welding all of the above band ¢ above paneer ‘The dimension “B” in Figure 17 is: athe weld leg b. the weld size c. . point of tangency d. aandc above e aand b above The dimension “A” in Figure 17 is the: a convexity b. concavity ¢. face reinforcement 4 aande above © bande above ‘The dimension “C” in Figure 17 is: the actual throat the effective throat the theoretical throat aand b above band c above epaege Figure 17F208 The dimension “Din F a. the actual throa: fective thn ne theoretical 1 d. aand b above © band above gare 17 is; “ F208 Where should the preheat temperature be measured? in the weld groove 12 inches from the weld groove where the arc will be initiated 2-3 inches from the weid groove Figure 17, reheat temperature need not be measured ¢ Pao op F210 A discontinuity is: a. always rejectable b. sometimes rejectable c. always a defect d. sometimes a defect e. band d above F211 What weld discontinuity is shown in the radiograph in Figure 18? a crack b. incomplete joint penetration © bum through 4 hollow bead | ©. ° tungsten inclusions Figure 18 F212 An oxygen regulator is set for 40 psi. Using the appropriate conversion factor from the chait on | + page 40, determine the pressure in kPa, 2,758 27,580 2.758 27.58 : 2758 | pooge F213 Which of the following discontinuities can be caused by poor welding technique? a. incomplete fusion b. porosity c. undercut: ‘overlap ©. all of the above |F215 F216 F217 F218 F2ig é © require requalitic ¢. instruct the welder in proper techniques ©. ask that the welder use another process Which of the following discontinuities is seldom discovered during VT? crack b. incomplete penetration on plate ¢. surface porosity ¢. tungsten inclusion ©. none of the above throat crack crater crack underbead crack porosity centerline crack A megapascal is equal to: a 1,000 Pa b. 1,000,000 Pa c 1,000 kPa qd. aandb above e band c above Which of the conditions below can cause porosity in a weld? a. welder technique ‘b. damp electrodes ©. oily base metal 4. rainy weather €. all of the above Which of the following discontinuities is not associated with GTAW? lack of fusion slag inclusions tungsten inclusions porosity undercut SP aegeWeidiry insp, Sample Cw) F220 Using the apptopriate con 27 pm to mins, on page 40, vel speed of F221 Pot ann ttsion factor from the chart on page 40, cto are iath in MP2 of e tensile specimen having a ere section of 0.300 at a tensile load of 24,600 pounds, ulate the ultimate tensile square inch which broke Load (pounds) i F = Tensile Strength (ps ‘Area of Specimen (square inch ~ TMsile Strength (psi) 565 Pa 565 MPa 5.65 Pa 565 kPa 5,650 kPa a b. °, 4. e. F222 Which of the following discontinuities ae not associated with GMAW? 2 slag inclusions b. porosity ©. tungsten inclusions ..- 4. aandb above e, aandc above F223 The CAWE a B _ inspects weldments only under the dieting ot CWI or SCWI & cannot inspect critical weldments | 4. performs inspections the same asa CWI ; © all of the above | F224 NDE technicians are certified in accordance with: a AWSD1I | He b. APT 1104 | ¢. ASNT SNT-TC-1A d. ASME Section VI €. ASME Section IXANSWER KEY a a b bd © e © © a a e b b e e d e e a a b. b b © c d © e é e e db b a a c b c e b © c e e B47 Fas F49 F50 FSI F52 FS3 F54. FSS FS6 FS7 F58 F59 F60 F61 Fo2 F63 F64 F65 eoasn THO TOO AR ONT EATON TO CReME FATHOM OA OOOO ono aEH F110 Fill FIZ FH3 Fld FS FIG FUT FLU8 FLI9 Fi20 F121 F122 F123. F124 F125 F126 F127 F128 F129 F130 F131 F132 F133 F134 F135 F136 Fi37 F138 a Ro roe eee mor oT race nwa oon oH cao rronRogaAN eon Gora PI3s F140 FI41 Fl42 F143 Flag 14s F146 F147 F148 F149 FiSO FIS1 FIS2 F153 FIS4 FISS F156 FIS7 F158 F159 F160 FI61 F162 F163 F164 F165 F166 F167 Fi68 Fi69 F170 FI71 F172 F173 FI74 FIIS F176 Fl77 F178 F179 F180 Fi81 F182 F183 F184 as peciicn Technology ination Creer ree nooo soars eam acanccoobacarce manWweising inepecti Tect:notogy Fureamen 7 bxamination WIT—Useful Formulae Area of Square or Rectang'e ‘Area=length xwidth or Area = width x thickness Area or Circle Area=mxradiys? or Arse = mx or Area = 0.7854 x diemeter? diameter? 4 Percent Elongation ton = Final Gage Length ~ Original Gage % Elongation alee ont Sa Sogo Lareth ooh x10 Percent Reduction of Area «= Original Area — Final Area 1s Reduction oe = eg x 100 Tensile Strength General uts = Pmax where: P max = load to break specimen * ixrea Area = specimen’s original cross-sectional area Pipe UTS for full section pipe = TOT Yield Strength yg = Load at specified ofset Original cross-sectional area Welding Heat Input. * Une VxAx60 where: J = Joules (energy) “~ Travel Speed (ipm) V = welding voltage A= welding amperage ‘ipm = inches per minute Carbon Equivalent CEs C+ + Bt 44Welding sispeciiea Techno! Sample CW! Funearenta ®acsinedion Welding Usaga Conversion Chart— Property* To Conver: Frem: To: area cimensions . vin? seereeeeee MM, mm? wee Lae in? current éansity ANN Aime? sm ain? deposition rate... ‘bir = kglht kghhr toh. flow rate = fh. rin . min. heatinput 22... dn vn cei mm... fi. linear measure . Wire feed speed... infin $ Customary and $1 Multiply By: +1 M52 x 102 «1550x109 + 1550x109 + 6.452 x 108 ATI9x 104 2119 = 39.37 + 254x102 254 = 3.937 x 102 = 3.048 x 102 = 3.281 x 103 - 6.895, 6.895 x 10-9 oe O45 + 1.450 x 102 = 1450 69x 107 33/18 CC x 1,8) +32 6.895 x 10 1,450 x 102 2383x1071 2.362 = 7.501 x 10% 0.423 «2.362Of the following, which is considered an important duty of the welding inspector? QL-1 a. Itis a welding inspector's responsibility to judge the quality of the product in relation to some form of written specification. b. A welding inspector functions as a judicial representative of an organization. c. A welding inspector must be able to interpret the specification limitations and intent. d. all of the above e, none of the above QI-2 Of the following, which is not considered an important attribute of a welding inspector? a. welding experience . inspection experience c. professional attitude d. engineering experience e. ability to be tained Qi-3 ‘What document describes the important bie aie of the AWS Certified Welding Inspector program? a. AWSDI.1 b. AWS AS.1 c. AWSQC1 d. AWS D14.1 e. none of the above Ql-4 Asa welding inspector, must you know how to weld? a. yes, according to AWS D1.1 b. yes, according to AWS QC i ©. yes, if inspecting highway bridges d. no, according to AWS D1.1 €. not mandatory, according to AWS QC 1Qus b c QL-6 Qu7 paoge When may you, as 4 welding inspector, speak out on maiters cf public policy? when paid by an interested party or parties anytime, if no money interest is involved after disclosing all possible financial connections of the statement, criticism, or argument presented when the statement is based upon adequate facts, upon a background of technical competence pertinent to the subject,and upon honest conviction of the accuracy and propriety of the statement Welding inspectors should never make public statements Which of the following are important ethical requirements for the welding inspector? integrity professional ability good physical condition ‘volunteering public statements regarding an inspection for personal exposure. all of the above Of those attributes considered to be important to the welding inspector, which is probably most influential in his gaining the cooperation and respect of others with which he works? ability to be trained professional attitude ability to complete and maintain inspection records good physical condition ability to interpret drawings and specifications ‘The welding inspector is likely to work in which of the following industries? shipbuilding automotive bridge construction pressure vessel construction all of the above