ai TWI certification & Tra ia Welding Inspection, Steels — WIS 5 Multi — Choice Question Paper (MSR-WI-1) Name: .L22DIMESH.K UMAR... Answer all questions 1. Which of the following butt-weld preparations is usually the most susceptible to lack of sidewalll fusion during the manual metal arc process? a. A double-U butt. b. Asingle-V butt c. Adouble-V butt, d. _ Itis not normally a defect associated with the MMA welding process. 2. What is the leg length of a fillet weld? a. The distance from the toe to face. b. The distance from the root to face centre. ¢. The distance from the root to the toe. d. The distance from toe to toe. 3. Whats the throat thickness of a fillet weld (equal leg leng‘hs)? 2. The distance from the toe to the face. b. , The distance from the root to the face centre. c. The distance from the root to the toe. d. The distance from toe to toe. Lap joints contain: s a Fillet welds. b. Corer joints. c. Buti-welds. d. Single-bevel butts. nef MSR-'XT-L issue 1 Date: 8/1/02TLWI certification & Training a a d A duty not normally undertaken by a welding inspector is to Check the condition of the parent material. Check the condition of the consumables. Measure residual stress. Check calibration certificates 6. Under most conditions, which of the following welding positions will deposit the Most weld metal. a. b. a9 Vertical down. Overhead. Horizontal-vertical. Flat (down hand) 7. What meant by the term crater pipe: a b. ° Another term for concave root Another term given for a burn through A type of gas pore, found in the weld crater. A shrinkage defect, found in the weld crater. 8. What is meant by the term weld junction? 2. The area containing the HAZ and the weld metal , The weld metal and parent metal. ©. The boundary between the fusion zone and the HAZ d. The part of the weld, which has undergone metallu-gical changes due to the heat from welding. 9. The strenzth of a fillet weld is primary controlled by = Leg length. ©. Throat thickness. ¢. Weld thickness. d. —Allof the above. WIS 5 Qu paper MSR-WI- issue I Date: $"1/02TWI centiteation & Training Ue 10. in 12. 13. WIS $ Ou paver MERAUTT 5 A crater crack may also be termed a. Cold crack b. Tearing, c. Fatigue crack d. Star crack. Which of the following welding processes/technique is likely to be used for the repair welding of localised porosity in a butt weld? 2 a MMA, PG position. b. Mechanised MAG. ©. Submerged arc. d. All of the above. e. None of the above. Which of the following welds would be considered in a situation where two plates are to be joined that overlap (assume no external assess). a Afillet weld. b. Asingle-bevel butt weld. c. Aplug weld. dg. Asingle-U butt weld 'n the MMA welding process, which of the following is most likely to be caused by a welder with a poor technique? a. Deep weld craters/crater cracks b. Copper inclusions c.. Hydrogen cracks Gd. Allof the above.TLWI certitcation & Tr ad 15. 16. 17. Root concavity is caused by a. Excessive back purge pressure and entrapped gas b. Excessive back purge pressure and very high heat inputs c. Excessive root grinding and a slow travel speed d. Excessive root grinding and excessive back purge pressure. When inspecting a critical component, the toes of a weld must be: a. Always ground flush. b, Must always overlap at least 1.5 mm onto the parent material c. Must always be inspected using a crack detection method (MPI, DPI). d. None of the above can be selected ~ specification requirements unknown. When carrying out visual inspection, the specification makes no mention of the requirements for visual inspection, in this situation what should you do? a. Carry out normal visual inspection. b. Seek advice from higher authority. ¢. Carry out no visual inspection. d. _ Re-write the requirements of the specification Under most circumstances, which of the following do you consider to be duties of a welding inspector? a. The supervision of welders. b. Procedure writing c. Qualifying welders d. . Allof the above. WIS 5 Qu paper MSR-WI-L issue 1 Date: 8/1/02 sor?TWI certitication & Training ie 18. 19. 20. 21 22 Which of the following is most likely to cause a burn through a. Root gap too small b. Travel speed too fast C, Root face too small dg. Allof the above. In an arc welding process, which of the following is the correct term used for the amount of weld metal deposited per minute? a. Filling rate. b. Deposition rate. Weld deposition. d. Weld duty cycle. What is the term given for the area of a welded joint just outside the weld metal that has undergone microstructural changes? a Heat affected zone. b. The weld zone. ©, Fusion zone. d. Allo the above terms may be used. When carrying out visual inspection, which defect (s) is likely to be missed? 2. Linear misalignment. b. Cap undercut, © Porosity. d. Lack of fusion (inter run), Cold lapping is another term for: 2. Lack of fusion at the toe of a weld b. Lack of fusion between weld metal and weld metal c. Undercut at the toe’of a weld dé. Botha and b. WIS 5 Qu paper MSR-WL-1 issue I Date: $/1/02 Sof?TWI certification & Training it 23. _ Incomplete root penetration is most likely due to: 2. — Welding speed too slow. b. Welding current too high Root gap too small ° d. Electrode diameter too small 24. + Crater cracks are caused mainly by’ a. Excessively fast welding speeds b. Improper electrode angle c. Hot shrinkage. d. Improper joint design. 25. Ona single-V butt weld, the distance through the centre of the weld from root to face is called: a. Reinforcement. b. Penetration. c. Throat thickness. d. None of the above. 26. The throat thickness of a % inch fillet weld is? a. 27.5mm b. 24mm. c 13.5 mm. d 12.5 mm. 27. The feed for pre-heat for steel will increase if The material thickness reduces » b. Faster welding speeds c. The use of a larger welding electrode d. Allo the above WIS $ Qu paper MSR-WE-L issue 1 Date: $/1/02. 6of7TLWI certification & Training ay 28. 29. 30. Which of the following butt weld preparations is most likely to be considered for the welding of a 6mm thick plate? a. Double-V butt b. Asymmetrical double-V butt c. Single-U butt d. — Single-V butt Awelding inspectors main attributes include: a. Knowledge. 5. Honesty and integrity. Good communicator. 4. Allof the above. A code of practice for visual inspection should cover: Before, during and after welding. a. b. Before welding activities only. ©. a. None of the above, After welding activities only, WIS 5 Qu paper MSR-WI-I issue | Date: 8/1/02 For?TWI certitication & 1 ae Welding Inspection, Steels - WIS 5 Multi - Choice Question Paper (MSR-WI-2) Name: ULM ESH. KUMAR... Answer all questions 1. Defects outside the permissible limits of the applicable specification should be: a. _The decision is up to the welding inspector. b, Repaired. c. Always double checked using NOT. d. All of the above. 2, Electrodes used in manual metal arc welding can be grouped into three main types, these are: a Oxidising, basic and rutile. b, Cellulose, basic and acidic. c. Granular, rutile and basic. d. — Rutle, basic and cellulose 3. Movement of the arc by magnetic forces in an arc welding process is termed a. Arc deviation. b. — Aremisalignment cc. Arcblow. dé. Stray are c welzing process is 4. Acréick type most associated with th @ Hydrogen cracking in the HAZ b. Solidification cracking c Lamellar tearing ¢. Fatigue crackingTWI cevtincaion & training wy 5 © Which of the following processes joins metals plasticali b. iG d. e. Friction welding, Resistance welding Arc welding Plasma welding All of the above What type of power source characteristic is required for 2 manual process? a. b. c 4 Constant voltage. Flat characteristic. Drooping characteristic. None of the above. Which of the following electrodes and current types may be used for the TIG welding of nickel and its alloys? a. b. c. ‘ Cerium electrode, DC -ve. Zirconium electrode, AC. Thorium electrode, OC +ve. All of the above may be used. What are the possible results of having a heat input to lox:? An increase in hardness, lower yield strength anc iack of fusion A reduction in toughness, hydrogen entrapment ed an increase in hardness. k of fusion Entrapped hydrogen, an increase is hardness an : Entrapped hydrogen, a reduction in carbon conte~: and lack of fusion.fication & Training ss steel 9. The main reason for using a back purge when welding 18-8 with the TIG welding process is to: Improve positional welding, b. Prevent the possibility of porosity. Prevent excessive root penetration d. Prevent the formation of a dense oxide layer forming in the root 10. The possible effects of having a travel speed too fast: a. Low toughness, slag inclusions and cap undercut b. High hardness, slag inclusions and a narrow thin weld bead. c. High hardness, excessive deposition and cold laps d. Low toughness, poor fusion and slag inclusions. 41. If arc blow exists when welding with the MMA welding process, this can be best reduced or eliminated by: a. Achange from AC to DC current. b. — Achange from DC to AC current. c. Achange from DC +ve to DC ~ve. dg. Achange from DC -ve to DC +ve. 12. When welding a double-V butt weld with the submerged afc welding process the presence of centre line porosity may be due to: a. Damp flux. b. Contamination on the weld preparations. c. Incorrect flux depth d. 2 Allof the above.TWI cevineasin 6 tevining We 15. The inclusion of an inductance in the welding circuit wh=> using MIG/MAG welding process is to: a. Control the rate of spatter in the dip transier moc b. tenable the welder to weld in position with the :2ray wansfer mode. c. _ Itallows for thicker filler wires to be used (2.6-3.6~m diameter). 6. Itallows full control over droplet size in the spray «"snsfer mode. An undesirable property of aluminium oxide residue, whe welding is that it Decrease weld pool fluidity. b. Requires more heat to melt it when compared to ekuminium. Causes the welder to travel to quickly. d. The presence of the oxide makes aluminium impcssible to weld Which of the following welding process is most likely to be used for the welding of a small diameter stainless steel pipe, 6mm-wall thickness? a GTAW b. SMAW, c. Submerged arc welding, dé. GMAW, When considering the tungsten arc welding process wha: s the purpose of the down-slope (slope-out) control? Ensure good penetration To prevent arc striking on the parent materia! c. Tohelp prevent the formation of crater gip2 d. > Tohelp prevent tungsten inclusions during weldineTLWI centiteion s Testing 7 18, 20, reduced by When considering thermal cutting loce! hardening can Increasing the cutting speed » b. The use of propane as a fuel gas Pre heating the material to be cut ° d. All of the above. In a semi-automatic welding process, which of the follow:ng shielding gas/gas mixtures would normally give the deepest penetration o> stee!?_ a. 100% argon. b. 100% CO2. c. 75% argon + 25% COz d. _Allof the above would give the same depth in peretration In 2 MMA welding process, which of the following statements are false? a, Anarc gap, which remains almost constant even if as usual the welder varies the position of the electrode. b. Avoltage, which remains almost constant even if as usual the welder, varies the arc gap. s usual the welder, c. Accurrent, which remains almost constant even if varies the arc gap. d.— Aandb. e. — Allof the above. Which of the following welding process, sfter the weld is completed normally requires 2 post weld heat trez:ment to restore toughness values a ESW. b> MMA c RAG. ¢. Ak completed welds rezwi sgaidiess of welding processTWI cer ae tion & Training 21. Which of the following current types would you expect to 92 welding of aluminium with the TIG welding process? a OC -ve b. DC +ve. ©. AC d. Allof the above. 22, Which of the following statements is false? a. Inthe MMA welding process electrode DC + produces a deep narrow weld pool, which is fast freezing. b. DC electrode positive is used for the MAG welding of steel plate. c. The word calcium carbonate means limestone d. Allo the above 23. When considering hydrogen, which of the following welding process would produce the lowest levels in the completed weld (under controlled conditions) a MMA b. SAW. c. TIG. 4. FCAW. 24, Pre heat prior to the welding of a carbon steel butt weld @. Must always be carried out b. Is always carried out using a gas flame c. Need not be carried out if post weld heat treatme~ s to ‘ollow d. > None of the above.TWI certification & Training ae 26. 27. 28. In steel the element with the gr a b. c. 4. ‘est effect on hardness is: Chromium. Manganese. Carbon Nickel. For a given voltage and current settings on a MMA weldag plant, when the arc length is shortened, which of the following will be m a. b. ©. d. st affected The current will increase. The current will decrease The voltage will decrease. The voltage will increase. Which of the following best describes a semi-automatic welding process? a. e The welder is responsible for the maintaining the erc gap and travel speed. The welder is responsible for travel speed only; arc gap is kept constant by the welding plant. Both travel speed and arc gap is controlled by the wvelding plant All of the above. What is purpose of a rectifier in a welding sets electrical ¢ rcuit? a To keep the arc stable when using low current set ngs To convert AC current to DC current To convert DC current to AC current To initiate the arc at start uo.TW certification & Training # 29, 30. When calibrating a mechanised MAG welding plant, «hich of the following applies (WFS = Wire feed speed)? Check — WES, current, volts and wire diameter fe and \ b. Check ~ WES, joint set-up, gas flo: Check ~ Gas flow rate, stick out length, WFS anc d. All of the above, The main usage of the arc air process is: - 2. The cutting of a weld preparation. b. The removal of defective welds. c. For the cutting of non-ferrous materials only d. For the cutting of ferrous materials only.DWI certincation & Training Welding Inspection, Steels - WIS 5 Multi — Choice Question Paper (MSR-WI-3) Name: .L1.2dMES4.. KUMAR. Answer all questions 1 The likelihood of a brittle fracture in steels will increase with a. The formation of a fine grain structure. b, A reduction in-service temperature to sub-zero conditions. c. Aslow cooling rate. dg. Allof the above. 2. Hydrogen cracking in a weld zone is most likely to occur when welding: a. Carbon manganese steels. b. Austenitic stainless steel. ©. Micro alloyed steel (HSLA). d. Low carbon steel. 3. Preheating for arc welding applies to: @. Assembly and tack welding only. b. Joint over 25 mm thick only. ° Assembly welding only. When using the MMA welding process only. e Bothaandb. ess value of Which of the following destructive tests would indice"3 the oughn the weld metal/parent metal and HAZ? @ Macro, b. Nick break c. Tensile, 6. Charpy Vee notch. __TLWI centiication & Training ie What constituent is needed in a coating of an electrode to prevent the formation of porosity when welding rimming steel? a, Iron powder. b. Potassium silicate. c Silicon d. Calcium carbonate. Welds made with high heat inputs show a reduction in one of the following properties? 2 a. Duetilty. b. Toughness. c. Elongation. d. Penetration, Which of the following steel types would give rise to the formation of porosity when autogenously welded with an arc welding process a Fully killed steel b. Semi killed steel. Rimming steel ° d. Balanced steel. Which of the following elements, which may be added to steel, has the greatest affect on creep strength. - . a. Tungsten. b. Manganese. ©, Carbon. ¢.* Molybdenum.TW certitication & Training 8 10. 11. The HAZ associated with 2 fusion weld 2 Can not be avoided. b. Usually has the highest tensile strength c. Is usually martensitic. 4 Both a and b. €. — Allof the above. What four criteria are necessary to produce hydrogen induced cold cracking? a. Hydrogen, moisture, martensitic grain structure and heat. b. Hydrogen, poor weld profiles, temperatures above 200°C and a slow cooling rate. c. Hydrogen, a grain structure susceptible to cracking, stress and a temperature below 200°C. d. Hydrogen, existing weld defects, stress and a grain structure susceptible to cracking, A carbon equivalent (CE) of 0.5%: a. _ Is high for carbon manganese steel and may require a preheat over 100°C b. Is generally significant for carbon for manganese steels and is certainly Not to be taken into consideration for preheat temperatures. ¢. __ Is high for carbon manganese steels and may require a preheat temperature over 300°C as to avoid cracking d. Is cafculated from the heat input formula. In 2 martensitic grain structure what would you expect to increase? a. | Duetility b. Hardness. © Toughness. ¢._ Allof the above.TWI ceriitication & Training ie 13. 14, 18. 16. What do you understand by the term minimum interpass temperature? a Minimum post weld heat treatment applied to 2 weld. b. Minimum stress relie? temperature. c. The lowest temperature to be used during preheat. d. The lowest temperature allowed during welding and between weld passes. Which of the following heat treatments on steel cools down in air from the austenite region? a. Normalising. b. Annealing, Tempering. ° d. Stress relieving. What is the purpose of microscopic examination of a weld? a. To determine the number and type of defects present. : b. To determine the grain size. c. To determine the strength of the weld. d. Both a and. €. All of the above. Which of the following units could a tensile specimen be measured iri? a. Pounds per square inch. b. Newton per square inches. c. . Joules. d. * BothaandbL ig WI certification & Training Assuming that the welding process, material thickness, carbon equivalent and " the welding parameters to be the same, which of the following joint types would normally require the highest preheat temperature a. Edge joint. b. Lap joint c. Butt joint (single-V). d. Tee joint (fillet welded), 18. Austenitic stainless steels are more susceptible to distortion when compared to ferritic steels this is because: a. High coefficient, low thermal conductivity. b. High coefficient, high thermal conductivity. c. Low coefficient, high thermal conductivity. d. Low coefficient, low thermal conductivity, 19. _ Which of the following will most likely require the preheat temperature to be increased? a, An Increase in travel speed. b. A reduction in material thickness c. Anincrease in electrode diameter. d. None of the above 20. Which of the following properties may be applicable to a carbon steel weld (CE 0.48) welded without preheat? a. Narrow heat affected zone and hardness valve in excess of 400 HV. 5. Broad heat affected zone enc hardness values in excess of 400 HV c. > Avery tough and narrow heat affected zone. 5. Nerrow heat affected zone and low hardness -alues.TWI cerineation & Training ie 24 22. 23, WIS 5 Qu naner MERAH Which of the following materials is considered to be the easiest to weld? a Mild steel b Medium carbon steels. c, Martensitic stainless steel d. Forging steel. Which of the following NDT methods would be best suited for the detection of surface breaking defects on an austenitic stainless steel pipe a MPI. b. UT. ©. DPI. d. All of the above can be used. Which of the following butt weld preparations would be considered for a mechanised welding process 2 Single-V butt, root gap 2.5 mm (welded from on side only). b. Double-V butt-welded both sides, root gap 2.0 mm. ©. Single-U butt with backing. G. None of the above can be used for mechanised weldina Which is the correct heat input for the following parameters, amps 350, volts 32 and the travel speed 310 mm/minute (MMA welding process)? a 2.16 kJ/mm. b. 0.036 kJ/mm. © 2160 kd/mm. d. 5 3.6 kJimm.TLWI certification & Training We Assuming that the applicable specification makes no mention of arc strikes, ‘at would you expect to do as 2 welding inspector if arc strikes were found 02 2 component made of a high tensile strength material Have the welder re-qualified. eS Ignore them, ©. Have the area checked for possible cracking 6 Cut out the entire weld where the arc strikes exist. 26. A multi-pass MMA butt weld rade on carbon steel consists of 5 passes Geposited using a 6mm diameter electrode, A 12-pass weld made on the seme joint deposited using a 4mm diameter electrode on the same material will have: A lower heat input and a higher degree of grain refinement. » A lower heat input and a coarse grain structure A lower amount of distortion and a higher degree of grain refinement. ao A higher amount of distortion and a lower degree of grain refinement. 27. Whats the purpose of a tensile test? @. To measure ultimate tensile strength. b. To measure the elongation of a material © To measure the yield strength of a material d. All of the above. 28. Which of the following mechanical tests can be used to give a quantitative mezsurement of weld zone ductility? a. Tensile test. b. = Bend test. c.” Charpy Vaotch test e All of the above. WIS 5 Qu pares MSR-WL3 issue | Date: 9/1/07TWI certincaton & Tesinng ae 29. Which of the following are reasons for applying preheat? a. The removal of residual stress. b. To aid slow cooling and reduce the carbon content ¢. To reduce the chance of a brittle grain structure and to reduce the chance of hydrogen entrapment d. Increase the ultimate tensile strength values and increase overall weldability. 30. Which of the following are true with regards to a charpy test a, It's a static test used to determine a materials notch toughness in the weld region. b. It's a dynamic test used to determine a materials notch toughness in the weld region. ©. * It's a destructive test to give a measurement of through thickness ductility. d. None of the above. WIS 5 Qu paper MSR-WI3 issue I Date: 9/1/02ay TWI certification & Traini Welding Inspection, Steels — WIS 5 Multi — Choice Question Paper (MSR-WI-4) Name: ..(/..Q/MESH.& OMAR. - Answer all questions 1. Degreasing components are essential for quality welding but when welded some agent may: Cause corrosion problems. Leave residues Give off toxic gases. Allof the above. 2. Cellulose electrodes are often used for the deposition of a root pass on pipes welded in the field. This is because? a. Hydrogen control is required. b. The high deposition rate due to the iron powder content c. The hydrogen gas produced in the flux increases the arc voltage. d. — Allof the above. 3. _ Inthe welding of austenitic stainless steels, the electrode and plate materials are often specified to be low carbon content. The reason for this: a. To prevent the formation of cracks in the HAZ. b. To prevent the formation of chromium carbides c. To prevent cracking in the weld d. Minimise distortion. WIS 5 Qu paper MSR-WI-4 issue | Date: 9/1/02 1of8TWI certification & Training A 4. With regards to a welding procedure, an essential variable may: a b. Change the properties of the weld Influence the visual acceptance Require re-approval of a weld procedure All of the above 5. Which of the following NDT methods can only detect surface breaking defects? a MPI b. DPI -c. UT d RT. e Both a and b. 6. Which of the following defects would show up as light indications on a radiograph? a. b. c. d. Slag inclusions and copper inclusion. Tungsten inclusions and excessive root penetration. Cap undercut and root piping Excessive cap height and incomplete root penetration 7. Which of the following electrodes is the most likely to contain the largest quantity of combustible organic compounds? a. b. c. Basic. Acidic, Rutile, Cellulose. WIS 5 Qu paper MSR-WI-4 issue | Date: 9/1/02 2ofstion & Training 8. Lamellar tearing is best prevented by: a. The use of plate materials containing low levels of impurities. b, The use of buttering runs c. Post weld stress relief, dé. Botha andb e. — Allof the above, 9. When considering radiography using X-ray, which of the following techniques is most likely to be used for a pipe to pipe weld (circumferential seam), 610mm diameter with no internal access? a b, ©. d. swsl. ows! DWDI. SWSI-panoramic 10. A balanced welding technique for example back step welding is most often used for: a b. ©. 4. Controlling lamellar tearing Increasing weld toughness. Reducing weld zone hardness. Reducing distortion 11. Basic coated electrodes have which of the following properties a High mechanical properties may be used to produce welds of high deposition rates and to produce welds of low hydrogen content. Friable slag, high mechanical strength, and to produce welds of a low hydrogen content. Low hydrogen content welds, good stop/start properties and high strength Low carbon content welds. friable slag and high strength. WIS 5 Qu paper MSR-WI-4 issue 1 Date: 9/1/02 3 ofTWH certification & Training a 12. Ona radiograph, the most likely appearance of lack of root fusion on a single- V butt weld is: a b c. d A dark straight line with a light root. A dark root with straight edges. A dark uneven line following the edge of the root None of the above lack of root fusion can not be seen on a radiograph. 13. What do you understand by the term minimum interpass temperature? Minimum post weld heat treatment applied to a weld. Minimum stress relief temperature. The lowest temperature to be used during preheat. The lowest temperature allowed during welding and between weld passes. 14, — Which of the following is applicable to a plate lamination a b, c. 6. They are best detected by radiography. They are mainly caused by hydrogen entrapment. They originate in the parent material They are caused when welding stresses act parallel with the rolled direction of the parent plate. 15. — Which of the following NDT methods would be the least effective on an austenitic stainless steel! butt weld a b. c Dd UT. RT. OPI. MPI. v WIS 5 Qu paper MSR-WI-4 issue I Date: 9/1/02 4of8TWI certification & Training a 16, 17, 18. The hardest part of a multi-pass welded joint, assuming no post weld heat treatment has have taken place is: a. The HAZ of the cap. b. The HAZ of the root c. The root. d. The cap |s it permissible to allow a single pass butt weld to cool down between weld passes? a. It should be up to the welding inspector. __b. No the weld must be kept hot at all times. co It depends on the welder d. It depends on the specification requirements. A tee joint on a support bracket is to be welded both sides using a 5 mm leg length fillet weld, each weld is to be intermittent 50 mm in total length, the gap between each weld is to be 25 mm. Which of the following is the correct symbol in accordance with ISO 2553? 5 A, sxs0es 5 5 x 0 (25) 50 (25) 50 (25) A 5x50 (25) a Zl J Np WIS 5 Qu paper MSR-WI-4 issue I Date: 9/1/02 Sof8TWI certification & Trainin vm 19. The usual method of assessing the sensitivity and density of a radiograph is by means of: a. Densitometer and dosimeter. b. Penetrameter and a densitometer. c. IQl and a dosimeter d 1QI and a fluxmeter. 20. _ In the submerged arc welding process, the use of excessive high voltages would result in? a. _ Insufficient flux melting _b. Excessive flux melting Slag removal difficulties. d. Excessive spatter. 21. Welding a steel plate with a CE of 0.45 would require preheating to? a. Prevent the formation of sulphides b. Prevent hardening in the HAZ. Cc Prevent the formation of carbides. d. — Toreduce the amount of current required 22. Which of the following welding process uses a resistive heating system to achieve weld metal deposition? a. MMA b. Resistant spot welding c. — Electro-siag. d. Friction welding. WIS 5 Qu paper MSR-WI-4 issue | Date: 9/1/02 6of8TWI certification & Training wa 23. 24, 25. 26. What does the 70 represent on an E70 10 AWS AS.1 classified electrode? a. 70 N/mm? minimum UTS. b. 70 joules minimum impact strength. c. 70,000 p.s.i. Minimum yield strength 70,000 psi minimum UTS. a Basic electrode provided in a standard packaging: a. Should be baked as to manufactures recommendations prior to use. b. The baking conditions depend upon the welder, ° Are recommended for use where porosity free welds are required. d. Are only suitable for welding in the flat, vertical, and down hand positions. Cellulose electrodes have which of the following properties? a. Viscous slag, large volumes of shielding gas and UTS values above 90,000 psi b. Large volumes of shielding gas, high spatter contents and hydrogen levels < 15 ml per 100g of weld metal deposited . ¢ Large volumes of shielding gas, hydrogen contents > 15 ml per 100g of weld metal deposited and should be never baked. d. High spatter contents, high deposition and large volumes of gas shield. From the following electrode coding E50 4 B 160 20 HS, the compulsory part is: a. E503 B 160 20 HS b. B 160 20 HS. c. £5048. d None of the above. WIS 5 Qu paper MSR-WI-4 issue | Date: 9/1 02 7of8TWI certification & Training 7 27. Which of the following is applicable to electrode efficiency? a. The mass of metal deposited as a percentage of the mass of core wire melted. b. Iron powder electrodes have efficiencies above 100% c. Electrodes of high efficiencies tend to produce welds of a smooth flat profile. d Both a and b. e. — Allof the above. 28. A Fatigue cracks fracture surface is: Rough randomly torn. 8 b. Smooth. c. Step like appearance. d Bright crystalline. 29. £6014 electrode would most probably used for welding: a. Low pressure pipework. b. High-pressure pipework. c. Vertical down welding on storage tanks. d. Ina situation where low hydrogen welds are specified 30. Which element in steel if present in significant amounts may lead to hot shortness? a. Phosphorus. b. Manganese. c. Silicon d. Sulphur. WIS 5 Qu paper MSR-WI-A issue | Date: 9/1/02 8of8Al. WELDING INSPECTION STEELS - COURSE REF. WIS 5 MULTIPLE-CHOICE QUESTION PAPER (1MCQ.001) Name : .U:DUIMESELKUMAR.... Answer all questions 21 arc welding project.the When “hydrogen contro!” is specified for a manval m electrode would normally be: (2) Cellulosic ? (b) Iron oxide ? (©) Acid 2 () Basic? You would with certainty recognise a hydrogen controlled flux covered electrode from its : (2) Colour ? (b) Length 2 (©) Trade Name ? (2) AWS/BS639 Code Letter ? When manual metal are welding is being castie¢ ov: cn an open construction site, which group of welders are the most iike!y ‘0 require continuous monitoring ? (2) Concrete: shutiering welding teams ? (0) Pipe welding team 7 ()_ Plater welders ? (6) Plant-maintenance welders ?A > 6. of fux, are being used as filler You notice manuzi metal arc electrodes, strip wire, for TIG welding. You would object bec: (@) It is too exzensive ? (0) The wire would be too thick 2 tal composition may be wong ? (€) The wire is too short ? When open site working, serious porosity in metal attention. What would you investigate ? (2) Electrode type ? (0) Power plani type ? (©) Electrode storage ? (4) Day temperature 7 The steel composition in a structural contract is changed from 0.15% carbon, 0.6% manganese, :0 0.2% carbon, 1.2% mangznese. Might this influence the incidence of : (2) Porosity 2 (b) Cracking in she weld area ? ()_ Undercut for iillet welds 2 (0) Lack of root fusion defects ? loys is non-magnetic. Which 7 One of the followir % Chromium molybdenum {0} 12.0% Chromium ic) Austenitic S:zinless Steel (6) 9.0% Nickel Stee!AB Ag. A10. All. steel pipe, Argon gas backing is called When TIG welding Austenitic stain! or. This is to : (2) Prevent oxidation 7 (bo) Prevent underb: (©) Prevent porosity 2 (4) Control the penetration bead shape ? Pre-neating a Cerbon steel manual metal arc minimise the risk of welding is carried out to (2) Scattered porosity 7 (&) Worm hole porosity 2 (c) Parent metal cracking ? (4) Lack of penetration ? In UK practice, BS499 Part 2 specifies that the drawing dimension quoted for a fillet weld is the (2) Leg length ? (0) Actual throat thickness ? (c) Weld width ? lowing equisment is available. Which For open site manuel metal welding th would you choose ior sef2 working ? 2) Single operator transformer ? (0) Multi opereser trensiormers 7 {c) AC/DC comzosite power unit ? motor generator ? fc) Die:Ala. AIS. elds, which would you erged arc welding is to be usec st critical of : (2) The root gap tolerance 7 (0) The angle of preparation ? {c) The root face width 7 (6) The gas cut finish ? CO, welding, the arc length is mo: (2) The wire diameter ? (2) The current return connections 7 (c) The gas flow rate 2 (d) The torch to work angle 7 Preheating for arc welding applies to : (2) Assembly welding only ? (b) Assembly and tack welding ? (c) Joints over 25mm thick only 2 (6) Cruciform welds only 2 You see a welder using an oxy-acetylene izme wisn a long feathered inner cone, What would be the effect of this on 2 carbon ‘The weld could de hard and brittle ? The weld metal could be too soit ? (¢} There will be no effect on the w (c) The weld will have undercut ?Ai6. A welder qualification iest is to verify (2) The skill of the welder 7 (b) The quality of the materials ? (c) The non-destructive test procecur (6) The manufacturing methods ? ding. This ds to be "blended in” by At7. A fabricating procedure calls for fille is to influence : (a) HAZ. cracking ? (b) Fatigue life 2 (c) Residual stress 7 (d) Yield strength 2 A18. Send test specimens have been taken from 2 25mm thick carbon steel butt weld. Which would show lack of inter-run fusion : (a) Side bend ? (0) Root bend ? (c) Face bend 7 (d) Guided bend ? welding could it A19. Lamellar tearing hes occurred in a ste have been found by (2) X-ray examination 7 (0) Dye penetrant ? (©) Ultrasonic inspection ? i) IE would not have bzen found by eny inspectic>s and find they are A20. You are to oversee the arc welding of some cadmium plated. Would you : (2) Permit it to proceed ? (b) Permit it to proceed with tume ex: (c) Stop the operation at once ? (d) Advise the welder to drink miik and proceed >WELDING INSPECTION STEELS ~ COURSE REF. WIS 5 END OF CGURSE MULTIPLE CHOICE PAPER (MCQ.002) Name : U.2(IMESH..KUUMAR. Answer all questions. S499 Part II communicates by the use of symbols the type of joint preparation to be used. Listed below are four symbols; which of these indicates the depth of penetration of the weld required on the joint? o ZK B tok © ek ° Loe Which of the following symbols would indicate that a weld has to be finished flush on the ‘other’ side of the weld? A Ye B © xa ° i librium to enable a stable arc What two functions in arc welding must be in e: to be established? Arc Voltage Current Wire/Electrode feed rate Metal burn-off rate oonIn MMA welding, what parameter is used for the control of penetration into the base material? A Voltage 8 *" Welding Speed ) Iron Powders in the co: o Current hich of the following controls In the welding of a butt joint made from one side, the profile of the root bead? A Root Face B Bevel Angle G Root Gap D None of the above What type of power source characteristic is required for manual welding? A Constant Voltage B Flat Characteristic c Drooping Characteristic D Motor Generator 2 toughness of Which one of the following destructive tests would i weld metal/parent metal ~ haz, A Macro 8 Nick Break ic Hardness oO Charpy Vee Notch8 Degreasing components are essential for quality welding but some agents may A Cause Corrosion Problems 8 * Give off Phosgene Gas Cc Leave Residues o All of the Above 8. Which of the following chemical elements has the greater effect on the hardenability of a steel plate? A Molybdenum B Chromium c Titanium D Carbon 10. In MAG/CO, welding, which parameters give the greatest control of weld appearance during dip transfer or short circuiting welding? A Wire stick-out length B Amperage c Wire feed speed D Inductance 11. 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 SY position? A Fluid 8 Viscous c None of the above Do Semi fluid12. The weld metal deposit of manual metal arc electrodes achieves its mechanical strength through? A The Core Wire B ” The Flux Coating c tron powders with the flux coating 13. What constituent is needed in a coating of an electrode to prevent the formation of porosity in welding of a rimming steel? A Iron Powders 8 Calcium Fluoride . : c Silicon o Calcium Carbonate 14. Welds made with high heat inputs show a reduction in one of the following properties? A Duetiity B Toughness iC) Fatigue Strength D Mechanical Strength 15. In the welding of austenitic pipework, the bore is usually purged with Ar to 7 A Prevent formation of porosity in the weld. 8 Prevent burn-through in the root run. ic) Prevent oxidation of the root bea D Eliminate the formation of H,16. 17. 18. In X-ray work, the quality of the radiogrpahic negative is assessed by the ? A Density of the Film B _ 101 Indicator iS KVA available D Stand-off Distance et co A steel described as QT will have improved tensile properties because it has ? A Had control of chemical composition 8 Been heat-treated ic Been quality tested D Been vacuum melted Which one of the following type of steels would give rise to the formation of porosity when autogenously welded with an arc process? A Fully killed steel B Semi killed stee! c Rimming steel D Fine grained steel would result in? In submerged arc welding, the use of excessively high volt A Insufficient flux melting 8 Excessive flux melting ac Slag removal difficulties D Spatter20. The use of cellulosic electrodes is often made when welding the root pass of pipes in the field. This is because ? A Hydrogen control is needed B ~ Iron powders in the electrode c Higher arc voltage can be obtained D Shorter are length can be achieved 21. — Inthe welding of austenitic stainless steels, the electrode and the piate material can be purchased with low carbon contents. The reason for this is to prevent ? - A Cracking in the HAZ 8 The formation of chromium carbides c Cracking in the weld metal D Distortion 22. Submerged arc fluxes can be supplied in two forms; these are ? A Sintered and agitated B Agitated and fused c Crushed and agglomerated D Fused and agglomerated 23. Ina steel which has improved creep properties at elevated temperature, which ‘one of the following elements helps in this improvement ? 7 A Tungsten B Manganese ic Molybdenum o Carbon24. Welding a steel plate of a CE of .45 would require prehea A Prevent the formation of sulphides _ Prevent hardening in the HAZ a Prevent the formation of carbides ° D To improve mechanical properties in the weld, 25. Which one of the following processes uses the *keyholing” system of fusion? A Friction welding . 8 Diffusion bonding c Electron beam welding D Autogenous TIG welding 26. _ In friction welding, is the metal at the interface in the ? A Liquid state 8 Solid state Cc Plastic state D Elastic state 27. Welding procedures may require welds to be deposited at a controlled rate heat input. High heat inputs would ? A Have poor profile t 8 Have larger grain size G Have high hardness in the HAZ D Have low elongation properties28. Ina tensile test, 29. a brittle material would be indicated ii the fracture surface ? ‘Shows a reduction in size Is fiat and featureless Breaks in the weld metal Breaks in the parent material What destructive test would be required to ascertain the likelihood of cracking in the HAZ of a weld? A 8 Nick break Side bend test Charpy impact Macro test 30. In submerged are welding, excessive arc voltage may cause ? A B Excessive penetration Change in weld metal composition Narrow weld width Excessive bead profile.WELDING INSPECTION, STEELS - WIS 5 MULTI-CHOICE QUESTION PAPER (MCQ.003) Name : .L2. Circle one answer only for each question in 45 minutes The British code for Visual Inspection Requirements is: a) BS 4872 b) BS 499 c) BS 4870 d) none of the above ‘A Code of Practice for Visual Inspection should cover the following: a) Before, during and after welding activities b) Before welding activities only c) After welding activities only d) None of the above Incomplete root penetration in a butt joint could be caused by: a) Excessive root face width b) Excessive root gap size c) Low current setting @) BothA&C Incomplete root fusion would certainly be caused by: a) Linear misalignment b) Incorrect tilt angle c) Differing root face widths d)_ Allof the above When visually inspecting a completed single vee butt weld cap you would certainly assess: a) Cap height b) Toe blend c) Weld width d AB&C10. You notice 2 very “veed" ripple shape, This is most likely caused by: a) Poor consumable choice b) Welding position c) Excessive travel speed d) —_Alllof the above “Toe blending" is important as it may affect: a) Corrosion b) Fatigue life ©) Overlap type defects 4) Allof the above Slag inclusions would occur with: a) Manual metal are b) Metal inert gas ©) Submerged are welding d) BothA&C Undercut is principally caused by: a) Excessive amps b) Excessive volts ©) Excessive travel speed d) All of the above Undercut is normally assessed by: a) its depth b) its length ©) its blending 4d) allof the above A welding procedure is useful to : 2) Give information to the welder b) Give information to the inspector c) Give "confidence" to a product d) —_Alllof the above12 13. 14, 15, 16. 17. An essential variable may: a) Change the properties of the weld b) Influence the visual acceptability c) Require re-approval of a weld procedure ¢) — Allof the above A magnifying glass may be used during visual inspection but BS 5289 states that its magnification should be: a) up to 56 b) 2-256 c) 5-106 d) none of thé above When visually inspecting a fillet weld, it would normally be “sized" by : a) the leg lengths b) the actual throat thickness ©) the design throat thickness d) both A&C A planar defect is: a) Incomplete fusion defects b) Slag inclusion c) Incomplete penetration ad BothA&C Penetrant inspection and magnetic particle inspection are mainly used to : a) Aid visual inspection b) Because the application standard says so c) To confirm “visual uncertancies" ¢)— Allof the above. Defects outside of the limits specified in a standard should always be: 2) Repaired b) Reported to “a senior person" c) Assessed along with other defects ¢) — Allof the above18. 20. at. 23. MIG welding tends to be susceptible to lack of fusion problems. This is because of: a) Poor maintenance of equipment b) Incorrect settings c) Poor interun cleaning d) _Allof the above- Manual! metal are electrodes can be grouped into three main types. These are: a) Basic cellulosic and rutile b) Neutral cellulosic and rutile c) Basic cellulosic and neutral d) None of the above The main causes of porosity in welded joints are: a) Poor access b) Loss of gas shield ©) "Dirty" materials d) — Allof the above. Cracks in welds may be due to: a) Solidification problems b) Hydrogen problems c) Excessive stresses d) _Allof the above. A ‘weave technique" may give rise to: a) Better profiles b) Improved toe blending ©) Improved ripple shape dg) All of the above With reference to a root penetration bead, you could certainly assess: 2 ) Root fusion and penetration ) Root concavity ) Burnthrough ) All of the above ao24. 26. 27. 28. 29. 30, A fatigue failure is characteristic by the appearance of the fracture surface. It would be a) Rough and torn b) — “Cheveron"=like ) Smooth d) None of the above “Stray arcing’ may be regarded as a serious defect. This is because: a) It may reduce the thickness dimension of a component b) It may cause liquation cracks c) It may cause hard zones d) All of the above. Overlap in welds could be influenced by: a) Poor welding technique b) Welding process ©) Welding position d) Allo the above. Flame cut preparations may, during welding, increase the likelihood of: a) Cracking b) Misalignment problems c) Inclusions d) _Allof the above Macroscopic examination requires any specimen to be inspected: a) Onee, after etching b) Twice, before and after etching c) Using a microscope d) None of the above. Which of the following may be classed as a “more serious defect": a) Slag inclusions b): Fusion defects (interun) c) Fusion defects (surface) d) Porosity. A code of practice is: a) A standard for workmanship only b) A set of rules for manufacturing a specific product c) Levels of acceptability of a weldment d) __None of the aboveWELDING INSPECTION, STEELS - WIS 5 MULTI-CHOICE QUESTION PAPER (MCQ.004) arterla Answer all questions Name Movement of the arc by magnetic forces in MMA welcing is termed: a) Arc deviation b) Are misalignment c) Are blow d) Arceye ‘A metallurgical problem most associated with submerged arc welding is : a) Hydrogen cracking in the HAZ b) Solidification cracking in the weld metal ©) Hydrogen cracking inthe weld metal d) Lamellar tearing in the weld metal Oxy pressure and nozzle size would influence what in flame cutting a) The temperature required for cut initiation b) The ability to cut stainless steels c) The depth of cut obtainable d) None of the above The main usage of arc cutting/gouging processes is in a) The cutting of single bevel preparations b) The removal of deposited welds c) The cutting of single U-type preparations d) The cutting/gouging of non-ferrous materials only. ——- -1-Which of the following processes joins metals plastically a) Friction Welding b) Resistance Welding c) Plasma Welding d) —_Allof the above Which electrode classification would be relevant to AWS AS.1-81: a) £6013 - b) 5133 °c) E7018-G d) — Fleetweld 5 Which of the following coatings is associated with"Stove* welding: a) Rutile b) Cellulosic ©) Basic d) Oxidising A common gas/mixture used in MIG welding nickel alloys to combine good levels of penetration with good arc stability would be: a) 100% CO, b) 100% argon ©) © 80% argon 20% CO, @) 98% argon 2% oxygen© The type of SAW flux is more resistant to moisture absorbtion: a) Fused b) — Agglomerated ©) Basic - 4) Allof about the same resistance The flame temperature of oxy/acetylene mixture gas is given as: a) 3200°C b) —-2300°C ) — 5000°C d None of the above Allarge grain structure in steels is said to produce: a) Low ductility values b) Vy Low fracture toughness values ©) High fracture toughness values d) High tensile strength The likelihood of brittle fracture in steels will increase with: a) Alarge grain formation b) A reduction of in-service temperature to sub zero levels ©) FeNitic rather than austenitic steels d) All the aboye7 14, 15. 16. Repair welding is often more difficult than production due to : a) The material being ingrained with in-service contaminates b) Restricted access within the repair area c) The possible position of the weld repair d) Any of the above Hydrogen cracking in the weld metal is likely when welding: a) Carbon manganese steels b) Stainless steels ©) Micro alloyed steels (HSLA) d) Low carbon steels EN standard 288 would refer to which of the following: a) Welder approval testing 2* b) Welding equipment ) Welding procedure approval d) Consumables for submerged arc welding Porosity is caused by: a) Entrapped slag in the solidifying weld b), _ Entrapped gas in the solidifying weld ©) _Entrapped metallic inclusions in the solidifying weld d) None of the abovex 18, 19. 20. In a bend test, the face of the specimen is in tension and root is in compression; the type of test being carried out would be: 2) Aroot bend test b) Aside bend test <) A face bend test d) None of the above Ultrasonic testing is of advantage in detecting which of the following weld imperfections over other NDT methods: a) Lack of side wall fusion b) Surface undercut c) __Incompletely filled groove 4) Overlap ‘The process of tempering is often carried out to regain toughness after which of the following processes: a) Annealing b) —_Normalising c) Hardening d) Stress relieving ‘The presence of iron sulphide in the weld metal is most likely to produce which of the following upon contraction of the Weld: a) Solidification cracking b)” Hydrogen cracking ¢) Intergranular corrosion ¢) Stress corrosion crackingLWI certification & Training Welding Inspection, Steels — WIS 5 Multi — Choice End of Course Assessment Question Paper (MSR-AWI-1) Answer all questions What is the ratio between the leg length and the design throat thickness on a mitre fillet weld with equal leg lengths a 4 b. 2:1 Co 1.41421 d. It depends on the fillet welds dimensions and fit up requirements. 2. Whatis the leg length of a fillet weld? @. The distance from the toe to face. b. The distance from the root to face centre. The distance from the root to the toe. ao The distance from toe to toe. Why is the arc shielded, when using an arc welding process? To eliminate hydrogen from the arc. a b. To retard the cooling rate of the solidifying metal @ To excluded fhe atmosphere from the arc region. d. The arc is not always shielded when using an arc welding process. 4. Which of the following is applicable for a none planar defects? x a. They are always repaired. 5. Their existence will result in the removal of the entire weld (G) ‘They are not usually as significant as planar defects. 4, They can only be detected using radiography. WIS 5 End of course assessment Qu paper MSR-AWL-I issue 1 Date: 8/1/02 10f8TWI certification & Training Vf 5. Lamellar tearing is: 2. b. 6. a b. é d. 7. ™ a (i c da. “42 A product defect caused during the manufacturing of certain steels A crack type, which occurs in the parent material due to welding strains acting in the short transverse direction of the parent material. A type of hot crack associated with impurities (sulphur, carbon and phosphorous). A type of crack that occurs in the weld or parent material due to cyclic stresses. The weld zone associated with a welded joint is: Weld metal, HAZ and the parent material in the immediate vicinity. Weld metal only. The weld metal plus parent material. HAZ and parent material. Which of the following elements if present in significant quantities in steel may lead to cold shortness. . Sulphur. Phosphorous. Silicon. Copper. A black triangular flag used in conjunction with a weld symbol as to EN 22553 means: b. A specific welding process is required The weld is to be made under constant supervision of a qualified welding inspector. Welding to be carried out on site (field weld). The weld must be subjected to NDT. WIS 5 End of course assessment Qu paper MSR-AWI-I issue 1 Date: 8/1/02 2of8TWI certitication & Training Ga 9. Austenitic stainless steel can be readily identified by: a, b. ©, 6. 10. Which of the following is likely to be considered an essential variable on a Lack of magnetic attraction Its extreme hardness. Very shinny appearance. None of the above. _- welding procedure V- ~ a 11. Which of the following is applicable if the heat input is to high during the A change from an electrode classified to AWS E6011 to an electrode £6012. A change in preheat temperature from 500C to 1500C. ‘A change in welding position from PA to PF. All of the above a deposition of a weld made using the MMA welding process? / @ Low toughness. b. High susceptibility to hydrogen entrapment. c. ° High hardness d. High susceptibility to lack of fusion. 12. — Which of the following will influence the amount of distortion on a component x during and after welding? a. b. @ Heat input. Lack of restraint. Material properties. Both a and b. Alll of the above. WIS 5 End of course assessment Qu paper MSR-AWE-I issue | Date: 8/1/02 30f8TWI certification & Training ca 13. When welding with the MIG welding process using pure argon as the shielding gas on carbon steel, which of the following problems are likely to occur? a. b. c. 4. Copper inclusions and excessive cap heights. Excessive root penetration and porosity Slag inclusions and crater pipe. Lack of fusion and poor cap profiles, 14, __ Itis a requirement to excavate a crack in a welded component; the defect is at a b. ~~~ least 25 mm in depth, which of the following would you expect to be done to remove the defect? Arc air, ground finish and checked with crack detection Thermal gouging, ground finish and check with MPI. Oxy-gas cutting, ground finish and checked with crack detection. Both a and b. All of the above 15. The heat affected zone associated with a fusion weld: LK“ a b. c. Usually has the highest tensile strength. Always exists in a fusion-welded joint. |s usually the area of a welded joint that is the most susceptible to HICC? All of the above. 16. / Which of the following welding processes would be the most suited for the we welding of carbon steel in excess of 100 mm thickness a. b, c. Tungsten inert gas Electro-slag Manual metal arc. ’ Plasma arc. WIS 5 End of course assessment Qu paper MSR-AWI-I issue | Date: 8/1/02 4of8TWI certification & Trai a 17. Aweiding process where the welding plant controls the travel speed and arc gap, but under a constant supervision using a shielding gas mixture of 80% argon - 20% carbon dioxide is termed as a b. c d A manual MAG process. A semi automatic MAG process. A mechanised MIG process. A mechanised MAG process. 18. The purpose of normalising steel To modify the grain structure by making it more uniform in order to improve mechanical properties. To soften a material for extensive machining. To reduce fracture toughness. To reduce ductility. 19. Which of the following destructive tests would show the results in joules? 4a b. c, a. Tensile test Charpy test. Bend test. Hardness test. 20, Generally the most suitable method of detecting lack of sidewall fusion on a a. b. c. single-V butt weld (30° to 35° bevel angles) would be: Ultrasonic testing. Radiographic testing Magnetic particle testing Both a and b. All of the above WIS 5 End of course assessment Qu paper MSR-AWI-I issue | Date: 8/1/02 5of8TWI certification & Tra el 21. Ultrasonic testing is preferable to radiographic testing due to: a. Ability to find all defects. b. Lower amount of operator skill required c. Ability to detect laminations. d. None of the above Which of the following is never a reason for applying post weld heat treatment. Hydrogen release. a. b. Stress relieving. Grain refinement. d. Reducing carbon contents. 23, Lameliar tearing has occurred in a steel fabrication BEFORE welding could, \ which of the following test methods could have detected it? a. Radiographic testing. b. Ultrasonic testing. 9 Magnetic particle testing a It could not be found by any testing method. 2h. y Incomplete root penetration is most likely due to: ~~ a. Welding speed too slow. b. Welding current too high. ¢. Root gap too small. gd. Electrode diameter too small. WIS 5 End of course assessment Qu paper MSR-AWI-I issue 1 Date: 8/1/02 bors,Certification & Training 2° You are to oversee the arc welding of some machined fittings and find that they are cadmium plated. What would you do in this situation? a. b, ae Permit the welding to proceed. Permit the welding to proceed with fume extraction Stop the operation at once. Advise the welders to drink milk then proceed. 26. Ona single-V butt weld, the distance through the centre of the weld from root _to face is called: \ a. b. c. d. Reinforcement. Penetration. Throat thickness. None of the above. 24. Which of the following flame types would you expect to be used for the cutting a. b. c. d of mild steel? Carburising flame Oxidising flame. Reducing flame. Neutral flame. 28, The need for pre-heat for steel will increase if a b. 9 The material thickness reduces. Faster welding speeds The use of a larger welding electrode All of the above. WIS 5 End of course assessment Qu paper MSR-AWI-I issue ! Date: 8/1/02 Tof8TWI certification & Training ey 24 The main reason for toe blending on certain welded steel components is a. Corrosion considerations. Fatigue life. Appearance. ¢. Allof the above. 3 Which of the following welding process require a drooping characteristic power NS source nan (@) TIG and MMA, b. MIG/MAG and MMA. c TIG and SAW d. . Allof the above. 34. When considering the MIG/MAG welding process which of the following metal transfer modes would be the best suited to the welding of thick plates over 25 x mm, flat welding position, a. Dip transfer. b. Pulse transfer, . B Spray transfer. Globular transfer. WIS 5 End of course assessment Qu paper MSR-AWI-I issue 1 Date: 8/1/02 8 ofCandidate: _U -pew€SH_ KUMAR Date: .29-/0-2003 FINAL ASSESMENT MULTIPLE ~ CHOICE QUESTION CSWIP 3.1 WELDING INSPECTOR COURSE MFY - 001 ALL QUESTIONS TO BE ATTEMPTED, EXAMINATION TIME : 30 MINUTES 1, Which of the following does not cont jute to hydrogen cracking: a External forces on the weldment b. Amount of hydrogen in the weld ¢. Residual stresses in the weld d. Size and length of linear discontinuities. 2. For the are air carbon cutting process the air is a. Use for cooling the electrode only b. Produced through the chemical reaction of the electrode and the base metal Vv ¢. Supplied through air ports in the electrode holder and directed along the electrode d. Supplied by another torch also by other operator 3. Acetylene hoses are distinetly difference from oxygen hoses . Wh: A Because the internal diameters of the two are different Vv B Because of operating pressure differences between fuel gas and oxygen ¢. Acetylene attacks the materials used in oxygen hoses K To prevent accidental interchange4. Which of the following can result in a hard and brittle condition resulting from rapid cooli (Aare strikes ¥ B. Excessive weld reinforcement cc Excessive spatter d. Slag inclusion 5. DC negative when used for MIG/MAG can give smooth are. AA. True x (@Fatse 6. Inwhich of the following pr successfully joint the mat. ess is the use of pressure required to Is: A. TIG MMA SAW d. Stud welding 7. Which of the following will contribute significantly to lack of fusion (Aimeorrect joint design / B. Incorrect welding technique ~ c. Heavy scale on the joint surface «YAM of the above8. Which of the welding process used loose granular flux: A. FCAW B. SAW c. GTAW d. SMAW 9, Crack Tip Open Displacement test is used to measure A. Strength of the material being tested /B, Hardness of the material ~ (The toughness of the materials, resistance to crack extension and the acceptable flaw size all d. Ductility of the material being tested 10. The pulsed MIG/MAG mode of transfer is a variation of a spray transfer mode that make used of a low background current with a higher, rapidly pulsing current superimposed on it. A. False Vv AB. True 11. The iron carbon diagram is used by metallurgists and others to see how: a. Adding nickel changes the corrosion resistance of steels v Adding carbon changes the response of the steel to temperature ‘changes ¢. adding molybdenum increases the toughness of steel d. adding chromium improves corrosive corrosion resistance12, The main purpose of a developer is to : a. Assist in the development of the test procedure b. Provide a clean surface for the penetrant indication VY €. Assist in the development of the penetrant indication from a defect 4d. Assist in the drying of the penetrant 13. Overlap in a fillet weld would occur : a. At some point in the weld throat b. only on the face of the weld Vv 4 At the toe of the weld d. At the root of the weld 14, In the TIG welding process, gas shielding of the weld pool maybe provided by which gas (es ) a. carbon oxide b. argon and oxygen Vv argon and helium 4. oxygen and helium 15. Welding flux : a. Helps on control the temperature of the pieces being welded D. Crates a temporary bond between the pieces being welded V Protects from the atmosphere and removes the oxide film on the surface e. Makes it easier to move the electrode16. Increasing the carbon content of steel allows a given level of hardness to be achieved : a. ata higher cooling rate b. without consideration of the cooling rate ¢. without adding chromium to the steel x 4. At lower cooling rate, / 17. Which is not a factor that should be considered in selecting the best shielding gas mixture for a given application a, weld appearance and acceptable spatter level b. thickness, joint design and penetration requirements /&. the welder’s personal requirements d. Transfer mode 18. Which of the following is not considered to be cause of incomplete fusion 4. Welding current exceeding that specified on a WPS b. Using too large an electrode for a narrow Vee x ¢. Improper manipulation of the electrode Using the wrong type of electrode 1”19. Which is an advantage of an argon/hydrogen gas mixture in TIG of stainless steel a. Lower heat input b. Improved toughness c. Faster travel speed v d. Improved mechanical properties 20. Some MMA electrodes for the welding of stainless steel have a low carbon Steel core wire and the alloying elements in the covering. This is because :- a. The core wire offer lower resistance to the passage of the welding current ) The manufacturer can more conveniently include alloying elements in the covering than produce special core wires c. Both for reasons a and b above e. For some reason not listed above 21. Sulphur is sometimes added to steel to improve: a. The impact properties of the welded joint by Provide higher impurities levels ¢. Toughness of the parent materials lachining properties characteristics of the steel 22. Slow cooling of liquid metal from high temperature promotes the growth of : a. Medium grains ~ B. Large grains vw ¢. Small grains d. A combinations of large and small grain22. A defect can best be described as : Alll types of flaw in a weld regardless of size b. Meaning exactly the same thing as a discontinuity ¢. Any type of weld flaw @ A discontinuity judged to possibility interfere with the fit for purpose of the weld // 23. A CC ( Drooping are ) power source is suitable for a.MMA-TIG. b. MIG/MAG - FCAW welding process v ¢. SAW— MIG/MAG d. MMA - MIG/MAG 24, In Gas Metal Are Welding (GMAW ) , spray Transfer may be achieved using shielding gas containing :~ A. More than 85 % argon b. Less than 50% Argon ©. 100 % carbon dioxide d. Less than 75% argon25. When welding with a weave technique the heat input using the same welding parameters( amps and volts ) as those used for stringer bead will b a. Lower than that for the stringer bead b.. Unaffected because techniques has no influence on the heat input / c. Will be higher than the stringer bead because the travel speed will be 1 lower d. The same as that for the stringer bead 26. Welding in cold weather conditions is mostly commonly associated with increased risk of : a. Undereut b. porosity vo ¢. Slag Inclusion vi Cracking 27. Hydrogen trapped in the weldment can cause hydrogen cracking if the contents of hydrogen are too high. What is the other name commonly used to describe hydrogen cracking? a. Fissure cracks b. Hot cracks 4 ¢. Supercritical cracks Cold cracks28. — Steel is often heat treated after it is made at the steel mill. When a steel is normalized what is the primary objective of this process ? a. To increase the hardness b. To decrease the amount of carbon in the steel c., To increase the low temperature toughness of the steel 4d. To improve the tensile strength 29. Travel speed is the rate at which the welding gun progress along the joint. As the travel speed increased : a. The penetration is increased v b.. The heat input into the joint decreased and the penetration is decreased c. The penetration is decreased and the weld bead becomes higher and wider 4, The heat input into the joint is increased 30, The recommended drying temperatures and time required producing a condition below 5 ml H; / 100 grams of weld metal when using basic electrodes would be :- a. Below 150° C for 1 hour b. 250°C for 1 hour VY 6 Over 350° C for 1 hour + . 600° C for 1 hour 9Candidate: Date: Lo/eJoces D ~— CHOICE QUESTION CSWIP 3.1 WELDING INSPECTOR COURSE. MFY ~ 003 ALL QUESTIONS TO BE ATTEMPTED EXAMINATION TIN E: 30 MINUTES 1. Which of the following mechanical properties of a weld made in carbon — manganese steel is most affected, if the heat input per unit length is excessively x high: - a. Tensile strength ® Toughness ¢. Brittleness d. Elongation A steel is intended for non load carrying service in air at 800° C - 900° YL ‘C.What single alloying element would you almost certainly find in order that . scaling is minimised a. Nickel b. Chromium ©. Cooper A. Molybdenum x The effective or design throat thickness of a complete joint penetration butt weld is a, Equal to the thickness of the base metal thickness if welded from both sides b. Considered to be equal to the thickness of the base metal thickness less 1.0mm ¢. Considered to be equal to the thickness of the base metal thickness less 3.0mm AG. Equal to the thickness of the base metal4. The three main modes of transfer encountered in Gas Metal are Welding (GMAW) are: - a. Spray, globular and drooping b. Spray, high ~ are and drooping ¢. High -are, globular and short - circuiting Al. Spray, globular and short - circuiting 5. Weld joints di yaterial. Why? igned with J preparations are usually used only on very thick \_% preparations are more difficult to fit than other preparations y< J preparations require least amount of weld filler metal for a given joint thickness ¢. J preparation are expensive because they must usually be machined 4. J preparations affords limited access to the root of the joint Which of the following situations is most likely to produce the greatest amount wai the direct and reflected ultraviolet light? a. Submerged are welding b. Gas Metal Arc Welding aluminium plate ¢. Brazing d. Resistance welding two thin sheet steel 7. Which of the following conditions must be present for the oxyfuel gas cutting process to be effective: a. The temperature of the metal’s oxides should be above that of the metal b. The metal must be brought up to its melting temperature c. The kindling temperature of the material must be above its melting temperature (@)™e melting temperature of the materials must be above its kindling temperature8. Slow cooling of liquid metal from high temperature promotes the growth of ; X a. Small grains b. A combination of large and small grains c. Medium grains Al. Large grains 9. Dimensional discontinuities become dimensional defects when: wa a. Specified by the welding inspector b. Specified by the engineer ~ Their dimensions have been found to exceed the set limits of a specifications or code d. There is no difference since the terms mean the same 10. The CTOD toughness depends on the following four items @ Thickness,temperature of the specimen,loading rate and microstructure b. Loading rate,microstructure,notch location and temperature ©. Bending radius, weld size, hardness and width of specimen d. Notch location, weld size, thickness of specimen and temperature 11, The shielding gas that is commonly used with Flux cored Are Welding process is: a. Argon J Carbon dioxide . Helium d. Hydrogen