WELDING INSPECTION TECHNOLOGY Sample CWI Fundamentals Examination THIRD EDITION Published By American Welding Society Education Department American Welding SocietyCertifion: We'cin inspect <> CERTIFICATION AWS Certifications | Accredited Test Feailties BODY OF KNOWLEDGE To help you prepare further ... This is the breakdown of the Body of Knowledge for the CWI/CAWI category and the approximate percentage of questions drawn from each, FUNDAMENTALS of Te 1S. Welding Processes 16 Heat Control and Metallurgy 12 Weld Examination 14 Welding Performance 14 Definitions and Terminology 23 ‘Symbols - Welding & NDT 15 ‘Test Methods - Nondestructive 2 Reports and Records 10 Duties and Responsibilities 7 Safety 4 Destructive Tests 12 Conversions and Calculations 1 PRACTICAL APPLICATIONS Number of Ta tions Procedure and Welder Qualifications 15 Mechanical Test and Properties 7 Welding Inspection and Flaws 7 Nondestructivel Tests 7FA F2 FS Fa FS Fe ion Tecanelogy amination hecarbon steel b. tow-carbon stee © stainless steel d. castiron @ cad d above Electrical conductivity of a pert isthe primary requirement for which NDE method? a ET b UT PT 4 RT none of the above ‘melting point of carbon steel is approximately: 2250°F 2375°F 2780°F 3005°F 3333°F papera Decibel is a term associated with which NDE method? a UT b RT ce MT a PT e ET Which type of GMAW metal transfer results in the least amount of penetration? globular short circuiting spray pulsed spray globular spray Sao ep Which of the following gases is not commonly used as a shielding gas for GTAW? & argon b. carbon dioxide c. helium 4. argon/helium e none of the aboveFe F9 F10 Fil F12 near roegy 21s Examination Weld has been repaired. x should a lhe origina! inspection report to indicate the pan’s acceptance b. mark directly on the p: © fill out a second inspection report ¢. tell the foreman to have the part moved to its next operation © none of the above When a metal is alloyed, how are the atoms of the alloy incorporated into the original metal lattice structure? a by inclusion b. substitutionally . — interstitially 4. orb above € — borcabove A wire IQI is used in which NDE method? 35899 Which of the following is not used as a semiautomatic process? GMaw FCAW oAWw sw cand d above Saooe The performance of which of the: following test methods is least affected by high part temperatures? a ET b =oRT ce PT a UT @ none of the above Crater cracks are most often the result of: a. improper technique b. improper filler metal ¢. improper base metal 4. all of the above none of the aboveF13 F14 Fis F16 FI7 F18 °g Inspaction Yechnetogy Fundamentals Examination rozess requirements denoting welding proced are requirements denoting welding electrode requirements Senoting welding specification requitements all of the above i During tempering, asthe temperature increases, which of the following are correct? hardness increases hardness decreases elongation decreases a and.c above bandic above paoee In GMAW, the distance from the end of the contact tube to the are is: a arelength b. electrode extension ©. stickour 4. aandb above © bande above the following, which is not a type of metal transfer in GMAW? spray short circuiting globular pulsed are open circuiting Saar Ultraviolet light may be used with which NDE method? a VT . & PT c MT da aandb above @ bande above ‘The technique which does not aid in reducing residual stress is: Peening vibratory stress relief thermal stress relief external restraint preheating pao geF20 F21 F23 Faq * ay he detected with Part dimensions can be determined using which of the following? a MT b UT ce ET d. aand ¢ above e. band ¢ above a, b. ¢. chemical analysis d. all of the above €. none of the above Which of the following elements are used as alloying elements with tungsten to produce GTAW electrodes? a zirconium b. thorium © columbium ¢. aorb above & — borcabove 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 on the left on either side, depending on company policy on the side in which the straight side actually appears in the joint does not matter Spoge ‘The surface between two pieces to be joined that lic in parallel planes is called: 2. weld interface b. faying surface & weld edge 4. groove face € none of the aboveF26 Fo7 F28 F29 F30 ‘se of electrode in a position other than that for which it was designed NDE technicians are usually quilitied in accordance with the requirements of: a AWS DII b. API 1104 ¢. ASNT SNT-TC-1A d. ASME Section VII ©. ASME Section IX Which factor listed below has the least effect on the amount of residual stress and distortion that results from welding? &. heat input b. phase changes welding position 4. tensile strength ©. coefficient of thermal expansion Capillary action plays a role in which NDE method? a ET b oUT ce RT a PT e MT If welder is continually tuming out rejectable work, the welding inspector should: a. inspect his work more 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? a. nick break b. side bend © face bend 4 radiography e. —allof the aboveFa2 F33 F34 F35 F36 Pe Workized (ground) Welding at the end of @ joint welding in comers all of the above eae ing gases used for GMAW can include: carbon dioxide argon helium oxygen all of the above Pao ren Developing is one of the steps in which NDE method? a UT RT Pr aand b above band c above Pees Which discontinuity below will provide the sharpest MT indication? surface porosity surface crack subsurface porosity subsurface crack indications will be identical for all of the above Pao gp In SMAW, an increase in arc length results in: a increased current; increased voltage b. decreased current; increased voltage c. increased current; decreased voltage 4. decreased current; decreased voltage © none of the above Weld inspection reports should always: be completed in ink, or typewritten and signed be done in pencil so mistakes can be easily corrected be maintained only if the weld is rejectable by filled out by a clerk so that everything is readable include the welder’s identification saogpF38 F39 F40 Fat F43, havtagy ts Examination which ef the followin a ob b. toughness ¢. tensile strength c. fatigue strength & — ductitity In GMANY, the type of metid wransfer requiring a special power source is: spray. globular pulsed arc short circuiting none of the above pees Which of the following is truly a volumetric test method? RT UT ET MT none of the above Saogp Use of preheat will result in: a faster cooling rate and wider heat-affected zone a faster cooling rate and narrower heat-affected zone 4 slower cooling rate and wider heat-affected zone a slower cooling rate and narrower heat-affected zone none of the above Speep Which of the following methods is most likely to use a cathode ray tube for the presentation of flaws? a RT bOET ce UT 4 aand b above € bande above For plain carbon Steels, how are hardness and tensile strength related? increase hardness; decrease tensile strength increase hardness; increase tensile strength decrease hardness; increase tensile strength | aand ¢ above | hardness and strength are not related Spoee‘eteing Sample OW Fury Fag Fag F45, Fag Fa7 Fas coon oy amination In GMAW soitage coment 4. stickout © nome of he above Welibiny variabie controlled by the ‘The welding variables used to calculate heat input are: & voltage and current b. current and travel speed ©. voltage, current end travel speed 4. travel speed, preheat temperature and voltage © voltage, current and preheat temperature As temperature increases: @ tensile strength increases b. tensile strength decreases ©. ductility increases d. aandb above ®& bande above Which of the following provides the best protection from radiation? a. lead shielding b. steel shielding ©. concrete shielding 4. copper shielding © maximize distance from radiation Welding inspection should be performed: before welding begins during welding afier welding is completed all of the above only when there is a problem Saogp 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 d. PW, CAB, RSW all of the above An E7016 SMAW electro: a bits which of the following characteristics? 4 iron powder blow hydrogen; AC and DCEP ©, low hydrogen; AC and DCEP; iron powder d. rutile, DCEP ._mutile; DCEP; iron powder Piezoelectricity is a material property used by which NDE method? a UT bo OET ce RT 4. aand b above e band c above A thermal treatment that follows quenching and restores some of the metal’s ductility is referred toas. 2. stress relief b. tempering c. hardening 4. normalizing ©. postheat ‘Which of these methods is most often used to reduce the high residual stress created by welding? prebending shot blasting quenching rapidly after welding postweld heat treating none of the above paogp The physical principle that permits the migration of liquid penetrants into very fine surface discontinuities is: 2, magnetic permeability b. optical fluorescence ©. capillary action 4. emulsification € none of the aboveF56 FS7 Fs F59 Feo * The b © 4. €. Which of the following conteins ferrous base metal specifications? a. b c. a e. retin jantenials Eran process whe Ee gap is filted with bra torch brazing ate brazing braze welding ip brazing flow brazing AWS DLI ASME Section II, Part C AWS A5.1 ASME Section IX ASME Section II, Part A Which of the following is not considered to be a Satisfactory method of magnetization when conducting a magnetic particle test to a specification? a ACcoil b. ACyoke & DC coil 4 DC prod ©. residual magnetism Advantages of MT include: Ppoep In ger a b ° 4. e. the detection of surface flaws both AC and DC methods the detection of surface flaws tightly closed ‘by carbon, slag or contaminants the fact that it is faster than PT. all of the above neral, an increase in the carbon equivalent of a carbon steel will result in an increase in its: ductility hardness strength aand b above band c above A welding process commonly used to join light gage stainless stee! tubing for critical ‘applica- tions a b ©, a e is: sMAW GMAW GTAW OFW none of the above 10Fe1 F62 F6é3 Fes Fes F66 91 Teck nology 5 Exumination vier weld metal ca b t ©. incomplete penetration 4. porosity & band d above Which of the follow: ing cea result when hydrogen is introduced into the molten weld pool? a porosity b. weld cracking c. delayed cracking d. all of the above ©. none of the above Entrapped slag can result when using: a SMAW b’ SAW ©. FCAW 4 ESW all of the above b. toughness ©. tensile strength fatigue strength ©. none of the above ‘The presence of paint on the surface of a Part will most greatly affect the results of which NDE method? . a PT b oT c MT 4. all of the above © none of the above If no information appears to the left of a groove weld symbol, this means: & no weld is required on that side b. the weld is to be complete joint penetration ©. the weld is to be continuous for the entire length of the joint 4. no weld joint preparation is required €. none of the above "Fer Fes Feo F70 F71 F72 of the follow: 2 jamination &- _lght incomplete fusion at a bevel angle of 350 degrees Sa crack with its depth parallel to radiation beamn & — aandc above Dwell time is a term associsted with which NDE method? a MT ’ PT ec RT da ET © none of the above ‘The material property expressed in terms of an endurance limi a fatigue strength b. toughness c. tensile strength 4 e. ductility hardness Fracture toughness results will often be expressed in terms of: breaking energy tensile strength percent elongation endurance limit reduction of area Saoge Shielding of the molten pool in OFW is accomplished by: @ a granular flux b. achemical reaction ©. an inert gas d.avacuum chamber & aflux paste The welding inspector is usually responsible for which of the following? a. checking for proper electrode storage b. verification of a welder's qualification ©. witnessing all repairs d, aand b above ¢. band c above 2¢. the recommended type of current 6. the degree of penetration e. all of the above F74 ET can be used to detect which of the following? a material’s conductivity b. a material's hardness ¢. a thin material's thickness d. a material's heat treatment €. all of the above F75 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 spose F76 property of a material that best relates to its resistance to impact loading is: endurance limit + fatigue strength fracture toughness tensile strength ductility pesee a F77 Of the following discontinuities, which is least likely to be the result of an improper welding technique? : porosity lamination undercut crack none of the above Snoop F78, Which of the following is considered to be an advantage of VI? discontinuities can be located and noted when they occur it is capable of detecting subsurface discontinuities it can be done very economically aand ¢ above none of the above saoge 13Feo F81 Fe2 Fes Fea sion 5 responsibility to the public? ed factual in the pel of his duties signing only for inspections that he has personally performed G. reporting all nonconformities to the news media ©. none of the above Which of the following cannot be done in the overhead position? a SAW b ESW c. GTAW d. all of the above e. aandbabove ‘No information appearing to the right of a 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 epoop The welding process that typically uses a tubular electrode is: a SMAW b= GMAW ce FCAW a SAW e ESW The property relating to a metal’s resistance to indentation is: 2. tensile strength b. ductility ©. hardness 4. toughness ©. fatigue strength ET is the abbreviation for: a. eddy current testing 6. environmental testing ©. emissive testing da aand b above @ band c above 4Fas c 6. aand b above & bande above F86 The flux covering on an SMAW electrode Provides which of the following? a. 28 shielding for the molten poo! b. are stabilization ©. alloying 4. deoxidation e. all of the above F87 = When a weld Joint preparation is found to be defective, the inspector should: a b @ ePort the deficiency to the proper supervisory personnel 4. require that the parts be disassembled and Properly assembled €. none of the above F88 The orientation of the probing energy source with Tespect to that of a flaw is considered to be a Significant variable for which NDE method? a RT b& oUT c ET 4 MT. €. all of the above F89 Information that appears to the 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 F980 — Which process uses a ‘granular flux? 7 a SAW b GTAW ce ESW G. aand b above © aandc above 15Fo2 F93 Fo4 Fo5. Foe d below, th d. austenite & pearlite raciography, the image on the film of a completely through-cracked weld will: In 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 low 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: percent elongation b. percent reduction of area c. tensile strength 4. aandb above bande above ‘Who is responsible for the qualification of welding procedures? a. independent test lab b. contractor ¢. welding inspector d. ~ architect . _ engineer ‘What MT technique could be'used for the discovery of longitudinal flaws? a head shot b.° circular magnetization ¢. longitudinal magnetization 4. aandb above €, band ¢ above Which code gives prequalified status to certain weld joint configurations? APL 1104 AWS DL.I ASME Section IX ANSI B31.1 none of the above epogp 16Fs8 Fog F100 F101 F102 iosy that appears to the 158 to he used type of electrode to be tise ©. length of weld required 4. size of weld requized © required joint configuration When a clerical mistake is made while completing an inspection report, the inspector shoulds & erase the error and fill in the correct information b, cross out the error and supply the proper information © Hine out the exror with a single line, supply the proper information, and initial and date the ‘occurrence in ink . attach a note to the report explaining the reason for the change © none of the above The rapid quenching of a high earbon steel from the austenitizing range will resuit in the formation of: a pearlite b. martensite c. cementite @. ferrite e austenite When an austenitized carbon steel is cooled to room temperature, an increase in the cooling rate will result in: an increase in hardness and a decrease in ductility an increase in tensile strength and a decrease in hardness a decrease in tensile strength and an increase in hardness an increase in ductility and a decrease in hardness a decrease in hardness and an increase in ductility Seaogp The surface finish of the specimen affects the test results for which of the following? a tensile strength b. fatigue strength ©. impact strength 4. allof the above © aandc 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 ». annealing © normalizing 4. tempering ©. austenitizing 7ea Tenn oamenta Jeast amov f cuctitiny? ce cd aand b above © band c above F104 ‘When a weld has been by a qualified NDE technician, the welding inspector should: a review the test results and maintain the test record b. reinspect to verify the defect © accept the weld if its visual appearance is in compliance with the applicable code or specification require another inspection by a third party €. accept the weld since it is in a low stress region a F105 Equal thicknesses of steel, cast iron, aluminum, lead, and copper are radiographed using the same exposure conditions. Which material will result in the darkest radiograph? a. lead Db. steel c. aluminum 7 4. copper | €. —castiron F106 The welding process that uses a nonconsumable electrode is: | GMAW | SAW GTAW FCAW SMAW | Spaogp F107 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 still air is referred to as: | a austenitizing b. normalizing ¢. annealing 4. quenching tempering F108 Ina guided bend test, the bend radius is: a, always 5 inches b. as specified in the appropriate code or specification c OSinch 4. 0.65 inch ©. none of the above 8FII0 Fit1 F112 F113 Flia rede designation is for which weld FOAW SMAW GMAW 8 none of the above The AWS Centfied Welding inspector must be capable of. 2 welding b. performing PT ¢. performing chemical analysis 4. supervising welding ©. none of the above A break in the arrow line has what significance? a. Welding must first be done on the arrow side b. Welding must first be done on the other side ¢. Welding must be done alternately on both the arrow and the other sides d. The broken arrow line segment points to that member which receives some preparation © none of the above It is discovered that a GMAW mild steel weld was produced with a shielding ges containing excess moisture. To determine the extent of the surface and subsurface Porosity that resulted, which NDE method would be most effective? MT 2. tempering b. austenitizing ©. stress relieving normalizing © preheating 19Pris F116 FII7 Fig F119 F120 The position on & metal’s stre ic to plas % modulus of elasticity © endurance limit ¢. transformation temperature © Young’s Modulus Low-hydrogen electrodes can be properly stored where? in a natural gas oven in an electric oven ina vented electric oven in a vented gas oven None of the above Spogp All welding symbol information refering to the arrow side of the Joint is found: a in the tail above the reference line below the reference line where the inspector decides none of the above gaoe 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 steel 2 and b above band c above farerR Sao op Of the welding processes listed below, the one most commonly having the highest deposition Tate is: a ESW b FCAW c SAW da SMAW @ GMAWFiat F122 F123 F124 F125 F126 ‘The 2 b. reduce the p. Q of hydrogen cracking ©. result in the formation of martensite d. aand b above e band ¢ above ‘The tensile test can be used to provide values for which of the following? a yield point b. ultimate tensile strength ¢. modulus of elasticity elastic limit €. _allof the above ‘Which of the following is not an acceptable method for control of raw materials? color coding alpha-numeric coding first in, first out location segregation bar coding Saoge The welding inspector's duties should typically include: a, the acceptance/rejection of welds b. the verification of a weld filler metal type c. . the development of weld repair procedures a aand b above band c above All welding symbols require which of the following basic elements in their construction? a. reference line, arrow and tail b. reference line and arrow ©. "reference line, arrow, weld symbol 4." reference line, arrow, weld symbol, dimensions and supplementary data reference line only is not important smaw cannot be determined directly from the symbol can be determined from the symbol all of the above The size of the weld represented in Figure 1: | a b. « 4 €. none of the above Figure 1 aarsingtion ation provided in Figure 1 requizey let weld use of shielded metal are welding ll of the above paon F128 A SMAW weld was produced in which the welder feiled to properly clean between passes in a multipass weld. Which nondest-votive test would best reveal the flaws that may be present in the completed weld? a RT b& «VT c MT a PT e EF F129 SMAW can be used in which type of application? a. semiautomatic b machine © manual d. alll of the above © none of the above RESTRICTION RING rest wep was F130 What position is depicted in Figure 2? 6G 56 oF 6GR 7 none of the above Figure 2 Sao ge F131 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, b 47in. c. 0.0047 in, dQ 47in, e 47.2in, F132 Underbead cracking is primarily caused by: a source of hydrogen restraint excessive preheat all of the above none of the above ope eeFI33 F134 F135 F136 F137 F138 wits ota temperature below 803°F ‘an be Gove in an inert gas atmosphere ies on capillary action 8, c,and d abo aand b above band c above als a, c. 4 e. ‘The first operation required by the symbol in Figure 3 2. ultrasonic inspection of the base metal b. visual inspection of joint preparation © welding a V-groove from the other-side of the joint G. _ welding a backing weld from the arrow-side of the joint & back gouging and back welding from the arow-side ofthe joint Figure 3 For Figure 3, ultrasonic inspection is to be performed: on the back weld only b. on the entire length of the other side weld ©. on 10% of the weld length 4. from the arrow side © -bandd above » Which of the following discontinui thickness direction of thick plate? are associated with shrinkage stresses in the through a crater cracks b. lamellar tears __ ©. toe éracks d. root cracks ©. none of the above Rhich 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? 2 semiautomatic b. manual ©. machine 4. automatic ®& none of the aboveF140 F141 F142 F143 eRe ee a V-groove weld @ devel groove weld made one-half the w: 4 V-groove weld arrow-side with the root finished to a convex contour ie AN orbersige \ Figure 4 allowed b: je followed by row-side with melt-through around the diameter of a pipe Which of the following symbols correctly describes the Joint configuration shown in Figure 5? 4a TAs) aT ans (ug 776 (i 44 (7/18 Ge Wai none of the above The width of the cut produced during a cutting process is refered to as: For the 2G position in pipe welding: 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 the axis of Saegp During operation, the heat for electrosiag welding is provided by: the are Seogp a. root opening b kerf bevel 4d. -bevel angle e. chamfer none of the above the electrical resistance heating of the molten slag the consumable guide tube aand b above | band c above not fixed the pipe and the plane ofthe weld are at 45 degree angles with the vertical planeFi4g F145, F146 F147 Fras F149 n Technology s Examination 7 version factor sot per ewe (ofh) for a flow re ded in the chan on page 40, de f 22 titers per minute vine the approx. & 66 eth b. 46.6 cth c. 10.38 off 103.8 cfh e. 4.66 eth It is suspected that a GMAW weld was produced in an area where there was an excessive draft Which nondestructive tesi would best reveal the intemal discontinuities which may have resulted? a PT bo MT c RT ad UT €. none of the above The size of the arrow side weld in Figure 6 is: a V4 inch b. 5/16inch fet c linch d. 2 inches 7 ©. none of the above aes The length of the other side weld in Figure 6 is: a Linch db. 6 inches” c. 2 inches a. 4 inches €. 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 Peoge 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 d. band c above e aand b aboveF151 F152 F153 F154 F155 somination learn the ex: ovation jaw in thiee directions YE method 2 BT bo OMT © PT a UT e ET ‘The phrase, “that surface of a member included in the groove” best describes: a. root opening b. groove angle c. weld interface d. groove face © none of the above Crater cracks can be the result of: a poor welding technique restraint : We : Comet Tube te c. shrinkage 4. e Bectrode Motten Fix. Fiala tp, from Hopper underfill of crater all of the above ; Fo Blanket Figure 7 depicts which welding process? a SAW es Mata &SMaW etal tee <4 GMAW Oirecno Tavs! ———a= e. FCAW Figure 7 ‘The boundaries indicated by “A” in Figure 8 are: a. fusion line > b. depth of fusion A c. weld interface . weld size and root penetration ©. depth of fusion da e partial joint penetration incomplete joint penetration | » The dimension “B” in Figure 9 is referred to as: a. joint penetration b. root penetration ¢. root reinforcement d. aandb above e. band aboveF163 F164 F165 F166 the following is nora iype of wel lap When using SMAW, wet clectrodes will most likely cause: a. b. c. a. e, undercut overlep underfill, porosity all of the above Which ofthe following is considered 10 be an acceptable way to Provide backing for a V-groove Weld in a carbon steel butt joint? a b ce 4. e A welder deposits an average of 12 pounds of weld metal er hour, Using the appropriate con- Version factor provided in the chart on page 40, determine the approximate kilograms of weld Volt x Amperage x60 _ Travel Speed (in./min) Sao ep copper backing bar ceramic backing flux backing backing weld all of the above that will be deposited in 6 hours of continuous welding. 2,400 Jin. 1,152,000 Jin. 1.44. 105 Jin, 110,000 J/in, 14,400 Jin,PIS? Fi6s F169 F170 FI71 F173 convex pro- a 2 it, since tis a aonzelevant indicotion b. reject the weld c. Correct the excess convexity and retest 4 e accept the weld none of the above ‘The pipe welding test position ia which the pipe is horizontal and rotated so that welding takes lace at or near the top is designated as: a 2G b oF oF 4 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 a theory of failure that cannot be supported by actual laboratory testing Are strikes are discontinuities most commonly associated with: ; a ESW F b SAW c SMAW d. aand babove e band 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 eS paogpF174 F175 FI76 F177 F178 2 process Is depicied in gure 10. FCAW GMAW c SMAW a SAW ff vets oxo e. SW soup Uf. oaoritts we ge Light-colored areas within the weld ee LLB semen zone in a radiograph could represent: Me ee METAL 2 porosity b. tungsten inclusions DIRECTION OF WELDING ———_» © meltethrough eee 4 aandb above ®& bande above A single-groove joint always requires: a. special welding processes b. back gouging ©. abacking bar 4. no root opening ©. none of the above The substance used in UT to aid in the transmission of sound from the search unit to the work- piece and back is called: 2 solvent b. attenuation © couplant d cable € transducer Using the appropriate conversion factor from the chart on page 40, determine-the approximate Kilogram weight of 2 30 pound roll of welding wire. a 136kg 66 kg 136 kg 66.15 kg 13.6 kgclegy bxomination # Fuuidament F178 ons we best raver e ET F180 Porosity in GMAW can be caused by: a drafts b. contamination ©. too little shielding gas flow 4. too much shielding gas flow e. all of the above F181 The overhead fillet position is designated as: a SF &B 4E c 3F 4 2F e IF F182 The radiograph in Figure 11 shows: a. cracks b. incomplete fusion ©. incomplete joint penetration 4. slag inclusions bo) © none of the above a F183. The welding process depicted in aaa Figure 12 is: aaeeee a GMAW NY exgcrrooe b SAW LEAD < SMAW rape ‘oe fats wane eas Nozze NONCONSUMABLE TUNGSTEN Haan fuer a MOLTEN: ARG ‘SOLIDIFIED vation wean Figure 12 31F185 F186 F187 F188 F189 13 shows: tdefeers tanigsten inch as © porosity 4. longitud e. undercut eas How many micrometers ere in one meter’? a 1,000,000 b 1,000 c. 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 e 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 porosit 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 2G c 2F 4 3G 2 66F130 Figt F192 F193 Fis4 Figs on faction pohes per minw: faed speed 83 ipm 283 ipm 2,834 ipm 5.076 ipm $0.76 ipm Spee ‘The defect noted in the radiograph in Figure 15 a incomplete penetration b. actack ©. incomplete fusion 4. Porosity © none of the above ‘The “A” dimension in Figure 16 is referred to as: a. weld throat b weld size c weld leg a. aand babove € — bandc above in Figure 16 points to: the root penetration the weld penetration the weld root the joint root none of the above dimension “C” in Figure 16 shows: the theoretical throat the actual throat the effective throat aand b above band c above dimension “D” in Figure 16 is called: the theoretical throat the effective throat the actual throat aand b above band ¢ above a, ’. c. a e The a be c a. e. The a b. c a e Figure 16Figg F197 F198 Fog F200 F201 One common cause of centerline weld cracks is a Pees ‘Which NDE method will best reveal subsurface porosity? a b © 4. e discontinuity? a b. c 4. e pain {he conversion factors provided in the chart on page 40, determine the approximate MPa for a tensile strength of 63,000 psi. Saege in Figure 16 vefers to: throat host the theoretical throat 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 2.871 x 103 psi 2.871 x 104 psi 4,136 psi 41.36 psi 2,871 psi RT PT MT UT none of the above intermittent sharper 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F202 F203 F204 F205 F206 F207 discontip ¢ discontinnity? sharper less distinct MT cannot detect a subsurface flaw 1 inch below the surface none of the above peers Which of the following conditions can cause slag inclusions in a weld? poor welder technique b. careful interpass cleaning ©. insufficient preheat 4. aand b above & — bandc above To be most effective, visual inspection must be conducted: a. before welding b. during welding c. after welding d. —allof the above €. bande above The dimension “B” in Figure 17 is: a. the weld leg Db. the weld size c. point of tangency da. aandc above ® - aandb above The dimension “A” in Figure 17 is the: 4. convexity b. concavity ©, face reinforcement a. aandc above e, bande above Figure 17 ‘The dimension “C” in Figure 17 is: the actual throat the effective throat the theoretical throat aand b above band c above ppoeeF208 The dimeyston “1” in Figure 17 is: a. the actual throa! b eifective thro. © theoretical thr d. aand b above © bande above F209 Where should the preheat temperature be measured? a. in the weld groove b, 12inches from the weld groove ¢. where the are will be initiated a. e. 2-3 inches from the weld groove Figure 17 reheat temperature need not be measured F210 A discontinuity is: a. always rejectable b. sometimes rejectable c. always a defect d. sometimes a defect @ band d above F211 What weld discontinuity is shown in the radiograph in Figure 18? crack b. incomplete joint penetration ©. bum through da e Pp holiow bead | tungsten inclusions Figure 18 F212 An oxygen regulator is set for 40 psi. Using the appropriate conversion factor from the chat on | page 40, determine the pressure in kPa. a 2,758 | b. 27,580 © 2,758 | 4. 27.58 | 2 & 2158 | | F213 Which of the following discontinuities can be caused by poor welding technique? a incomplete fusion b. porosity undercut 6. overlap e. all of the above ae 36F215 F216 F217 F218 F219 2 spect his work bask tus che welder be terminated © require requalification ¢. instruct the welder in proper techniques © ask that the welder use another process Which of the following discontinuities is seldom discovered during VT? crack incomplete penetration on plate surface porosity tungsten inclusion none of the above seo ge pector showld 1 Pethnotagy inction Which discontinuity occurs in the heat-affected zone and can result from excess moisture in the weld zone? throat crack b. crater crack c. underbead crack 4 porosity €. centerline crack A megapascal is equal a 1,000 Pa b. 1,000,000 Pa c. 1,000 kPa d. aand b above @ bande 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 b. slag inclusions ©. tungsten inclusions 4. porosity @ undercutF222 F223 F224 a, bd. & 5.65 Pa a e b ©. tungsten inclusions ..- da e. convert a travel speed of Load (pounds) i i = Te Area of Specimen (square inchy ~ PeMsile Strength (psi) 565 Pa 565 MPa 565 kPa 5,650 kPa Porosity @and b above aand c above Cannot inspect critical weldments | Performs inspections the same as a CWI | all of the above | NDE technicians are certified in accordance with: a b. c a e AWS D1. API 1104 ASNT SNT-TC-1A ASME Section VI j ASME Section IX |ANSWER KEY FL a a b b © e c c a a e b db e e d e e a d b b b ec c d © e é e e b b a a c bd c e b © c e e E47 Fag F49 F50 F51 F52 F53 F54 FSS F56 FS7 F58 F59 F60 F61 F62 F63 F64 F6S F66 F67 voces Te RTP OO AMO NAF OATOCOOReRETOTH OO AS OO On enn aeD FO FIL FII2 FU3 Flid FLS FIG FL7 FU8 FLI9 F120 F121 F122 F123 F124 F125 F126 F127 F128 F129 F130 FI31 F132 F133 F134 F135 F136 F137 F138 a F152 FSS F156 FS7 FIS8 F159 F160 FI61 F162 F163 F164 F165 F166 F167 F168 Fi69 F170 FIT] FI72 F173 FI74 FIIS F176 FI77 F178 F179 F180 Fi81 F182 F183 F184 > ’ a b b c b c b d d d e a d © db b b ¢ a b c d e b c ce e a b c 4 c e e © e d a e b c a a ries F186 F187 F188 F189 FI90 Fi91 F192 F193 F194 F195 F196 F197 F198 F199 F201 F202 F203 F204 F205 F207 F208 F209 F210 F2i1 F212 F213 F214 F215 F216 F217 F218 F219 F220 F221 F222 F223 F224 peciicn Technology Examination a a a e e b d b a a e e b b a a c a a d e a c b d © e e e © d c e © b b b e b ©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Weid.ng siapeciien Teehnat Sample CW! Funcanenta's @aninadon Welding Usaga Conversion Chart—-U.S. Customary and SI Property* To Coover: Frem: To: Multiply By: area dimensions . vin? MME eee BBO 102 mn I 1.880 x 108 cument density 2... Ain? AME eee eee 18802104 Aimme Ain? ed 6.452% 108 deposition rate... ‘bar < kglht 0.454 kghhr tbr - 2205 flow rate eh. ce min. 2719x104 Amin fm 22119 heat input oe. vin. . 3937 dim + 254x102 (ieverserevserere BA mm fe 3997 x 102 : : 3.048 x 102 3.281 x 104 + 0454 + 2.205 6.895 6.895 x 10% oe O45 + 1450 x 102 = 1450 69x 107 temperature. ~32)/18 20x18) +32 tensile strength .. 6.895 x 10° 4.450 x 102 travel speed... so indmin 4233x104 . mms 2362 VACUUM ee eerste Pa. + 7501x109 Wwire feed speed ......... inJin + 0.423 mms = 2.362pangs Qu-3 sao ge Qu4 panos Of is considered an important duty of the welding inspector? It is a welding inspector's responsibility to judge the quality of the product in relation to some form of written specification. A welding inspector functions as a judicial representative of an organization. A welding inspector must be able to interpret the specification limitations and intent. all of the above none of the above Of the following, which is not considered an important attribute of a welding inspector? welding experience inspection experience professional attitude engineering experience ability to be trained What document describes the important requirements of the AWS Certified: Welding Inspector program? AWS D1.1 AWS A5.1 AWS QC 1 AWS D14.1 none of the above Asa welding inspector, must you know how to weld? yes, according to AWS D1.1 yes, according to AWS QC 1 yes, if inspecting highway bridges no, according to AWS D1.1 not mandatory, according to AWS QC 1QL-6 QU7 pao oP 1 maiters cf public policy? When may you, inspector, sp when paid by on interested party or parties nylire, 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Ql cording te the requ rar ints of the AWS CWI pregram, what is the necessary i cfa welding jaspector? 20/20 natural s 20/20 corrected vision 20/40 natural vision 20/40 corrected vision 20/40 natural or corrected vision Which of the following could be considered essential knowledge for a welding inspector? nondestructive testing welding symbols welding processes destructive testing all of the above When a weld requites repair due to some deficiency, to whom should your inspection report be directed? to the welder whose mark is on the weld to another welder, better trained to the project engineer to the welding engineer to the welding foreman or supervisor What professional aitribuies are most helpful in performing inspection duties? being informed, impartial and consistent in your decisions being close friends with welders and superiors being a former welder being a non-union employee being a nondestructive examination technician as well as CWIan 14 sao 15 eae gE ing inspector communic during the performance of his welding engine welding foreman welders inspection supervisor all of the above What document defines the proper terminology for use by the CWI? AWS QC 1 AWS A3.0 AWS D1.1 AWS AS.1 none of the above With regard to drawings and specifications, the CWI must: be familiar with engineering drawings and able to understand specifications, memorize the content. memorize those portidns of these documents applicable to a particular job. all of the above none of the aboveas Q2-3 Of those listed below, which is an acceptable way to correct an error on an inspection report? Draw a line through the incorrect portion of the report. Erase the incorrect word or words. Throw away the report. Line out the error, make the correction, and initial and date the correction. none of the above What records should you keep as a CWI? copies of reports of ail inspections you perform copies of reports relevant to your areas of responsibility (material test reports, welder qualification paperwork, procedure qualification paperwork, etc.) even though you didn’t prepare them copies of sales literature describing welding equipment both a and b all of the above When a particular type of weld is consistently marginal, with rejects occurring, what action would be appropriate for you as the inspector? Tell the welder what you want. Bring the problem to the attention of engineering personnel in order for corrective action to be taken, if possible. Simply continue to accept or reject the welds according to specified criteria [no more action is appropriate for inspectors]. all of the above none of the aboveA specification for a weld joint which must be immediately accepted or rejected lacks detailed information about that particular joint. Who should rule on the meani intent of the specification? the designer the welding engineer the project engineer or quality assurance personnel [if their approval is required by contract] you, as the CWI none of the above How can you identify an individual low hydrogen electrode which a welder is already consuming to make a weld? Read the classification numbers painted on the covering near the stub end of the electrode. Ask the welder what itis. Ask the welding foreman. Look at the completed weld and identify the type of electrode by the visual appearance of the weld deposit. Look on the drawing or specification to determine what type of electrode is required for that weld. How should low hydrogen electrodes be stored before use? in their original unopened containers in ovens held at a temperature Which assures the maintenance of their low moisture content in tool room cribs, properly labeled, ready for quick distribution either a orb all of the above~ ‘What joint fit should you insist on? within tolerances specified on drawings or specifications Groove welds should have minimal root openings to reduce distortion. root openings greater than 1/8” to assure complete penetration Fillet welds should heve root openings so that the resulting weld’s effective throat will be greater. none of the aboveneem as Q28 a. b, c. 4. e. Q29 a. b. c. a. e. Q2-10 a. b. ©. 4. e. Q2-11 a. b. ce. a. ee en Which welders ave allowed to work on a “code” job? only those’ with certiticarien papers from former jobs only those tested by the “abricator for this particular job only those qualified in accordance with job specifications only those you have requalified for this job all of the above How should low hydrogen electrodes out of their original containers be stored? in their original resealed containers in heated storage ovens in open tool crib shelves in individual welders’ electrode pouches none of the above How can a CWI verify that the specified material is used on the job? : For code jobs, cach piece of material must be correctly marked with its identity. Perform a quick carbon analysis with a field test kit. Material must be scrapped if no identification is evident. Once the material leaves the storage area, the CWI no longer has to verify it none of the above Ifa mill product has imperfections such as splits, tears or surface irregularities, what action should you as the inspector take? Reject any imperfect materials. Judge whether or not the imperfections meet acceptance criteria according to applicable job specifications. Ignore the irregularities if not in the immediate vicinity of the weld joint. Wait until the welder finishes the weld to see if any cracking occurs before making any judgment, none of the aboveURCEEALEYLATH TEST TLT PUREE TELAT T ES PEEL DEL EOOITS 249 ditions below s a. One of the welders seers «¢ hav grade of steel being usec b. Every Monday, five of the welders make poor welds, but the rest of the week all goes well. One of the welders produces undercut with welding in the vertical position, | Cracking is repetitive when welding a certain steel alloy, €. none of the above Q212 Whi inordinete trouble meking a sovnd weld on the ae Q213 Which of the following is a welding inspector's responsibility prior to welding? Check joint fit. Check preheat temperature. | Check interpass temperature. aand b above band c above Sao gp G14 A 1/4” fillet weld is specified on the drawing. When the CWI inspects the weld, it is measured to be 3/8.” What should be done? Reject the weld for being oversize. Accept the weld if no weld size tolerances are specified, Ask for an engineering review of the design, band c above none of the above Paes Q2-15. Fillet welds should be measured using what tolerance? a. +1/16" b. + 1/32” c. -1/16" d. -1/32" ¢. no tolerance2 g 8 8 A Peres do ono oe ed pang Paogp Job quality requirements can be found i codes standards specifications text books ad&b only Of the following documents, which may be c codes specifications recommended practices aand b above all of the above ‘onsidered a “standard”? The type of document which has legal status is: code standard Specification both a and b above ail of the above That type of document which describes the re component is referred to as: code standard Specification aandb above band c above ‘quirements for a particular object orstandards - specifications drawings none of the above The code which covers the welding of steel structures is: ASME Section IX ANSIB31.1 API 1104 AWS D1.I none of the above The code which covers the design and fabrication of unfired Pressure vessels is: ASME Section IX ~ ASME Section VIII ASME Section II API 1104 AWS D1.1 The specification covering the requirements for welding electrodes are designated as: AWS DLX AWS D14.X AWS ASX ASTM A53 ASTM A36 The standard describing the requirements for welding of crosscountry AWS DL1 ASME Séction VII ” ASME Section IX API 1104 none of the aboveQ44 Sao gp Spore butt T fillet comer edge Which of the following is not considered a type of joint? The type of joint formed when the two pieces to be joined lie in parallel planes and their edges overlap is called: corner T edge lap butt ‘That portion of the joint where the two Pieces to be joined come closest together is referred to as the: bevel joint root groove angle root face bothb &d In a single-V-groove applied are called: root face . joint root groove face groove angle bevel angle weld, the sloped surfaces against which the weld metal isQs sae ee Q4-6 Q4-7 Q48 gaege Q4-9 Sao ep paoge eaose ripasre: elongated hele in an overleppiag member slot weld none of the above ‘The type of weld having a generally triangular cross section and which is applied to either a T-, corner or lap joint is called a: flange weld flare weld fillet weld slot weld spot weld The type of weld used to build up thinned surfaces, provide a layer of corrosion Protection, provide a layer of abrasion-resistant material, etc. is referred to as a: edge weld : flare weld flange weld slot weld surfacing weld The type of weld applied to the opposite side of a joint before a single- V-groove weld is completed on the near side of a joint is called a: melt-through weld backing weld back weld root weld none of the above In a completed groove weld, the surface of the weld on the side from which the welding was done is called the: crown weld reinforcement weld face root none of the aboveQs-10 paoge Q4-41 gp aogp Q4-12 sage 04-13 gaege Q4-14 epoge tea between the weld hi a copipleted weld, the ji © ond the base metal is ed th weld edge weld reinforcement leg weld toe The height of the weld above the base metal in a groove weld is called the: crown buildup face weld reinforcement none of the above Ina fillet weld, the leg and size are the same for what type of configuration? equal leg concave convex unequal leg oversize | When looking at the cross section of a completed groove weld, the difference between the fusion face and the weld interface is called the: depth of fusion depth of penetration ! root penetration joint penetration effective throat For a concaye fillet weld, which throat dimensions are the same? theoretical and effective actual and effective theoretical and actual all of the above none of the aboveQ415 sae ge Q4-16 PRO ee 4-17 Spose Q4-18 PRoge Q4-19 SRO ee ceLreraeresae Ina pardal penewation siale dint roct ‘0 the weld re joint pereiration effective throat foot penetration depth of fusion weld interface The size of a spot weld is determined by its: depth of fusion Spot diameter depth of penetration thickness none of the above In the performance of a vertical Position weld, the type of weld progression having a side-to-side motion is called: stringer bead technique stagger bead technique weave bead technique unacceptable none of the above. Which of the following is only found in a single-welded groove? weld face weld root weld toe root reinforcement face reinforcement ‘The technique used to control distortion of a long joint where individual passes are applied in a direction opposite the general progression of welding in the joint is called: backstepping boxing staggering cascading blockingalock sequense box sequence cascade sequence backstep sequence stagger sequence 44 | ced ine am « weld deposit where each successive leyer is | | | paege Questions Q4-21 through Q4-28 refer to Figure 1 below: ; top Q4-21, The weld face shown in Figure 1 is labeled: aol bo 2 a 3 d. 6 e 7 Q4-22 The weld root shown in Figure 1 is labeled: eRoge yaone Q4-23. The type of weld shown in Figure 1 is a: a. double-bevel-groove single-bevel-groove ' double-V-groove single-V-groove none of the above SaosgS asge ye 4-25 saegp 4-26 Sao op 4-27 sae rp 4-28 Saoge ba wd er fircemer in Figure 1 is abi ait i 3 6 7 The weld toe shown in Figure 1 is labeled: yawNe Number 6 shown in Figure 1 is the: weld root fusion face groove face weld interface depth of fusion Number 5 (between arrows) shown in Figure } is the: weld root fusion face groove face weld interface depth of fusion Number 4 shown in Figure 1 is the: weld size joint penetration actual throat theoretical throat aand b abovee 2 below: 5 Q429 throng Q4 A) eer ay ~ Q4-29 pao 4-30 spe ge Q4-31 sao ee 24-32 aos 2 The weld face shown in Figure 2 is labeled: 7 8 6 ll 10 The weld root shown in Figure 2 is labeled: wWoUAD The welds shown in Figure 2 are: concave fillets conical fillets convex fillets T-fillets fillet of fish ‘The actual throat shown in Figure 2 is labeled: 1 2 3 10 9 seen SP ease eumThe wel 7 8 10 7 both a and d ‘Number 6 shown in Figure 2 is the: weld root fusion face groove face weld interface depth of fasion Number 9 shown in Figure 2 is the: weld root fusion face groove face Weld interface cepth of fusion Number 5 shown in Figure 2 is the: weld root fusion face groove face weld interface depth of fasion Number 4 shown in Figure 2 is the: weld root fusion face groove face weld interface depth of fusion stown in Figure 2 is labeled: 421Q4-33 Number 2 shown i a. weld size bd. effective throat ¢. actual throat 4. e. theoretical throat aand b above Q4-39. Number 3 shown in Figure 2 is the: weld size effective throat actual throat theoretical throat aand b above sapgee Q4-40 Number 10 shown in Figure 2 is the: weld size and leg size weld size Jeg theoretical throat actual throat pong Questions Q4-41 through Q4-45 refer to Figure 3 below: Q4-41 The groove angle shown in Figure 3 is labeled: eae gp UrenQ4.52 Pao Q4-43, paoge Q4-44 ep aogp Q4-45 ep aogp Tho bevel angie show in Figure 3 is Upwene Number 3 shown in Figure 3 is the: groove angle bevel angle groove face fusion face cand d above Number 6 shown in Figure 3 is the: groove'face fusion face bevel face root face bevel Number 5 shown in Figure 3 is the: fusion face groove face root opening root face weld rootQuestions Q4-46 through Q4-54 refer to Figure 4 below: Q4-46 The weld faces shown in Figure 4 are labeled: a 8&2 b. 9&7 c 7&4 d. 1&6 e 3&9 Q4-47. The weld root shown in Figure 4 is labeled: al b-2 a 3 a7 e. aandc above Q4-48 The weld shown in Figure 4 includes a: a. backing weld b. back weld c. double-V-groove d. double-bevel-groove e. none of the above Q4-49 The weld size shown in Figure 4 is labeled: 9 8 7 2 none of the aboveQ4-51 eaegp Q4-52 epee Q4-53 eSaos 24-54 Sao Number 6 shown in Figure 4 is the: weld root. fusion face groove face weld interface depth of fusion Number 5 shown in Figure 4 is the: weld root fusion face groove face weld interface depth of fusion Number 4 (between arrows) shown in Figure 4 is the: weld root fusion face groove face weld interface - depth of fasion Number 2 shown in Figure 4 is the: root surface fusion face weld face weld interface depth of fusionQ4-55, Q4-57 a. b ©. a. e. 4-58 a. b © da © The bevel angle shown in Figure 5 is labeled: ts 2 a 4 cand d above The joint root shown in Figure 5'is labeled: RODE none of the above The groove face shown in Figure 5 is labeled: 1 2 3 4 cand d above ‘The root face shown in Figure 5 is labeled: ReEwe none of the above$ Q4-59 thrcugh QS.69 refer to Figure 6 belov: eee Faun Q4-59 The weld face shown in Figure 6 is labeled: aol b 4 ee a 3 e 2 Q4-60 The weld root shown in Figure 6 is labeled: a 6 v 4 a 5 da 9 e. 10 Q4-61 The welds shown in Figure 6 are: a. concave fillets conical fillets convex fillets T-fillets fillets of fish eae Q4-62 The actual throat shown in Figure 6 is labeled: a 9 b. 10 ce 3 do 2 e 5Q4-63 ‘The weld toe show: igure 6 is labeled: aol bO8 ec. 10 ad 7 €. both aand d above Q4-64 Number 6 shown in Figure 6 is the: a. weld root b. fusion face c. groove face 3 4. weld interface : e. depth of fusion Q4-65 Number 8 shown in Figure 6 is the: weld root fusion face groove face weld interface depth of fusion pRogp Q4-66 Number 5 shown in Figure 6 is the: a. weld root b. fusion face ©. toe 4. weld interface ¢. depth of fusion Q4-67 Number 2 shown in Figure 6 is the: weld size leg size Jeg and weld size theoretical throat actual throat rae eeCREEP ED IS Stree eee EEE Een S Number 3 shewa ir Figue €is the: veld size leg leg and weld size theoretical throat actual throat Number 9 shown in Figure 6 is the: a. effective throat b. weld size c leg d..- theoretical throat @, actual throatThe primary element of any welding symbol is referred to as the: tail arrow reference line arrow side weld symbol Information appearing above the reference line refers to the: near side arrow side far side other side none of the above The graphical representation of the type of weld is called the: tail welding symbol weld symbol arrow none of the above Which of the symbols below represents the weld shown? ay a. b. c. a. @. none of the aboveQ5-15 gaos fe} Z o B eae se Q5-17 eeoge Dimensions appearing to the right of the weld symbol generally refer to the: weld size root opening depth of preparation weld length/pitch none of the above A weld symbolized by a rectangular box that contains a dimension represents a: plug weld slot weld plug weld in beveled hole partially filled plug weld i plug weld in hole having dimension shown ‘The required spot weld size can be shown as: a dimension to the right of the symbol a dimension of the required nugget diameter a value for the required shear strength aandb above band c above A number appearing to the right of the spot weld symbol refers to: spot weld size spot weld length number of spots required pitch distance between adjacent spots none of the above In the symbol below, the “A” dimension represents: A Bec weld size flange radius flange length depth of penetration none of the aboveQ5-18 1a the syrabol below, the symbol shown on the other side represenis SHEE | back weld backing weld melt-thru weld aand b above band c above paoge Q5-19 The symbol below shows the use of what type of weld? a, single-bevel-groove weld b._ single-V-groove weld c. backing weld d, back weld e. band c above Q5-20 The symbol below shows what type of groove configuration? square groove skewed groove sloped groove scarf none of the above SRogewelding symbol which can be used to convey any additional ich cannct be shown otherwise is referred to as: information w a. the weld symbol b. the arrow c. the reference line d. the tail . none of the above Q5-22 The symbol below shows what type of weld? GTAW a. gas metal arc spot weld b. resistance spot weld ¢. gas tungsten arc seam weld 4. resistance seam weld €. none of the above Q5-23 What nondestructive examination method is to be applied to the arrow side? PT MT a, magnetic particle testing b. eddy current testing ¢. radiographic testing 4. penetrant testing e. none of the above Q5-24 A number in parentheses just outside a test symbol rep: a. the length of weld to be tested b. extent of testing c, the number of tests to perform d. e the type of test to perform noe of the above‘A mamber to the right of a nondestructive examinatica symbol refers to the: number of tests to perform the length of weld to be tested the applicable quality standard the test procedure to use none of the above g a peaogeh 5-26 Which of the symbols represent the weld shown below? ee a b. c, d. e. none of the above _ Q5-27 Which of the symbols represent the weld shown below? a. b. c. d. e. none of the aboveQ5-28 Which of the symbols represent the weld shown helow? | tg D dig a. b. c. d. ©. none of the above , Q5-29_ Which of the symbols represent the weld shown below? om a. cee c. a. @. none of the above Q5-30 Which of the symbols represent the weld shown below? OAS Rs L ae a c d. €, none of the abovea b. c a. e. none of the above Q5-32 Which of the symbols represent the weld shown below? oe e. none of the above Q5-33 Which symbol represents the welds shown? a, to vo 4 N | a b. c. d. , none of the above EE .Q5-34 Which of th: ed by the symbol below? a b. ° a. a b. ° qd. @. none of the above Q5-36 Which of the welds is represented by the symbol below? e. none of the aboveted by the symbol below? of the welds 5-37 W e. none of the above Q5-38 Which of the welds is represented by the symbol below? wa xae)\ a, b. c a insufficient reference or detailing Q5-39 Which of the welds is represented by the symbol below? hy v — EE _GD & a bd. c €. none of the aboveMEQQURE TENET eee eee esented by the symbol below? of the welds > @ | |\ewme ow Cs a. b. c. @. none of the above Q5-41 Which of the welds is represented by the symbol below? @ 67S a be a c e. none of the above Questions Q5-42 through Q5-46 refers to Figure 1 below: 3/8 3-10 14] 7 3-10 FIGURE 1 Q5-42 What is the weld length? a 1/4" b, 3/3" a 3” d. 10” e. none of the aboveWhat is the pitch distaace? 1a” us” 3” 10” none of the above What is the size of the arrow side weld? 1/4” 3/8” 3" 10" none of the above What is the size of the other side weld? a" 3/8" 3 10” none of the above What does the symbol represent? fillet welds on both sides intermittent fillet welds chain intermittent fillet welds staggered intermittent fillet welds none of the aboveDR OnE Pa Sener ETE & Questions Q5-47 through Q5-51 refer to Figure 2 below: ai Wd 6 A 45° FIGURE 2 QS5-47 What is the pitch distance? a 1 b 12" ec. 45” d. e, 6 none of the above t Q5-48 What is the angle of the countersink? a 1° b, 12° c. 45° d 6° e. none of the above Q5-49 What is the depth of filling? ao” b /2" c. 45” a6 e. none of the above Q5-50 What is the weld size? a 1” b 1/2" c 45" da 6” €. none of the above Q5-51 Whet weld is represented by the symbol? a. arrow side slot weld b. other side slot weld c. ammow side plug weld 4d. other side plug weld 2 acreaboveoy [REE OR Suara eam menace a Emenee 56 iefer to Figure 3 belo 114 (3/8) 4/2 (9/16) ‘What is the arrow side depih of preparation? va" 3/8" 2" 9/16" 15/16" What is the other side depth of preparation? 14” 38" 12" one" 15/16” What is the other side weld size? 1/4” 3/8” 1/2” one” 15/16” What is the arrow side weld size? va" 3/8" 172” 9/16” 15/16" What is the total weld size? 4" 3/8” v2" 9/16" 15/16"As a metal is heated: energy is added to the structure. the atoms move farther apart. the atoms vibrate more vigorously. the metal expands. all of the above ‘The state of matter which exhibits the least amount of energy is: solid liquid gas quasi-liquid none of the above A problem occurring in weldments caused by the nonuniform heating produced by the welding operation is: porosity incomplete fusion distortion slag inclusions none of the above All but which of the following will result in the elimination or reduction of residual stresses? vibratory stress relief extemal restraint thermal stress relief peening postweld heat treatment a ne tmentSteel exi HCP FCC BCC aand b above band c above in which of the following crystal arrangements? Rapid cooling of a steel from the austenitic range results in a hard, brittle structure known as: pearlite carbide cementite bainite martensite Very slow cooling of steel may result in the production of a soft, ductile micro structure which has a lamellar appearance when viewed under high magnification. This structure is referred to as; martensite pearlite bainite ferrite cementite When rapid cooling produces a martensitic structure, what non-austenitizing heat treatment may be applied to improve the ductility of the steel? quenching tempering annealing normalizing none of the above ‘The use of preheat will tend to: result in a wider heat affected zone produce a lower heat affected zone hardness slow down the cooling rate reduce the tendency of producing martensite in the heat affected zone all of the abovepaogre QO m xu eaooe When a weld symbol is centered on the reference line, this indicates: that the welder can put the weld on either sidz. that there is no side signi e. that the designer doesn’t know where the weld should go. that the welder should weld in whatever position the weld is in. none of the above The symbol below depicts what type of weld? flare-V-groove flare-bevel-groove edge-flange corner-flange none of the above In the symbol below, the 1/8 dimension refers to what? 418 groove angle root face depth of preparation weld size root opening In the symbol below, the 3/4 dimension refers to what? 3/4 (7/8) weld size effective throat depth of preparation root opening none of the shoveQ5-9 [fapplied toa 1 inch thick weld, the symbol below represents what type of weld? 5/16 (1/2) 5/16 (1/2) a. full penetration double-bevel-groove weld b, full penetration double-V-groove weld c. partial penetration double-bevel-groove weld d. partial penetration double-V-groove weld e, none of the above Q5-10 Dimensions appearing to the left of the weld symbol generally refer to the: a. weld length b. weld size/depth of preparation c. root opening d. radius e. none of the above Q5-11 A triangular-shaped weld symbol represents what type of weld? . bevel-groove b. flare-groove c. flange-groove d. V-groove e. none of the above Q5-12. The symbol below represents what type of weld? 24 24 staggered intermittent fillet weld chain intermittent fillet weld segmented fillet weld intermittent fillet weld none of the above ean geQ6-10 Seep Q6-11 pao gp 06-12 SpRogp Q6-13 pRogp Q6-14 Spee ‘ant the addition or increase in the Which ef the following changes will w. decreased carbon eq! increased carbon equi increased base metal thickness aandc above band c above What heat treatment is characterized by holding the part at the austenitizing temperature for some time and then slow cooling in the furnace? normalizing quenching annealing tempering stress relief What heat treatment is characterized by holding the part at the austenitizing temperature for some time and then slow cooling in still air? normalizing quenching annealing tempering Stress relief Increasing the heat input: decreases the cooling rate and increases the likelihood of cracking problems. decreases the cooling rate and decreases the likelihood of cracking problems. increases the cooling rate and increases the likelihood of. ‘cracking problems. increases the cooling rate and decreases the likelihood of cracking problems. none of the-above Increasing preheat: decreases the cooling rate and incteases the likelihood of cra decreases the cooling rate and decreases the likelihood of cracking problems. increases the cooling rate and increases the likelihood of cracking problems. increases the cooling rate and decreases the likeli none of the above ing problems. eS Se eae aca |the cacbont cen'eat decreases the likeliaved of cracking problems. increases the likeliico 9: cracking problems. has nothing to do with the likelihood of cracking problems, all of the above none of the above Which of the following generally follows quenching? annealing normalizing quenching tempering stress relief Which of the following can be accomplished using either thermal or mechanical techniques? annealing normalizing quenching tempering stress relief, Which of the following results in the softest structure for steel? annealing normalizing quenching cempering stress relief For a steel having the following composition: 0.11 carbon, 0.65 manganese, 0.13 chromium, 0.19 nickel, 0.005 copper, and 0.07 molybdenum, what is its carbon equivalent using the following formula? CE=%C + (%Mn) + (S6Ni) + (96 it) + (%COu) + (%Iio) 6 15 5 14 4 eaeee 0.15 0.23 0.28 0.31 0.42ganese. 0.25 Q6-20 For asi arbon chromi equivalent sing the following formula? C+ Cn) + (NI) + (%Cn) + (Cu) + (%Mo) 6 415 5 13 4 0.23 0.31 0.34 0.41 0.46 esaogre Questions Q6-21 through Q6-24 refer to the Heat Input formula below: Heat Input (J/in) = Amperage x Voltage x 60 Travel Speed (in/min.) Q6-21 The FCAW process is being utilized to weld a 1 inch thick structural steel member to a building column.’ The welding is being done with a 3/32 inch diameter self- i shielded electrode with a 150° minimum preheat and interpass temperature. The welding parameters are adjusted to 30 volts, 250 amperes and 12 in/min. What is * the heat input? 375 Jfin: 37,500 Jin 375 kI/m aand b above band c above eaoge Q6-22 GMAW (short circuiting) welds are produced at 18 volts, 100 amperes and 22 in/min, What is the heat input? 238 Vin 7333 Jin 4909 Jfin 30 S/in none of the above sapere | |The GMAW pro: against a copp: ISivmin, Wh 650 KV/in 650,000 J/in 165,000 Jin 16,500 J/in none of the above schanized for we ‘The pr heat inpuct rig 18” The GTAW process is being used for welding 1/16" 110 amperes, 15 volts and 6 in/min. What is the hea! 21000 Jin 21 kJ/in 16,500 Hin aand b above band cabove cess is operated at 300 amp ” thick stainte-s stzel sl ests 28, 26 vo'ts end thick titanium using DCEN at it input?Pap ge Which property cannot be determined from a tensile test? ultimate tensile strength Percent elongation percent reduction of area impact strength yield strength ‘The property which describes the ability of a metal to deform or resist some applied load is: strength toughness hardness ductility none of the above ‘The point at which a metal’s behavior changes from elastic to Plastic (onset of permanent deformation) is referred to as: yield strength ultimate tensile strength modulus of elasticity ‘Young’s modulus none of the above Which of the following is an expression for a metal’s ductility? percent elongation percent reduction of area proportional limit aand b above band c aboveQ7-5 eae Sag gp What is the ercea on of a specimen whose criginal gage tength was 2 ler g'b was 2.5 inches? 40% none of the above ‘The property of metals which describes their resistance to indentation is called: strength toughness hardness ductility none of the above The type of testing which is used routinely for the qualification of welding procedures and welders is: tensile strength hardness soundness impact strength all of the above Of the following, which properties can be determined as a result of tensile testing? ultimate tensile strength ductility percent elongation yield strength all of the above The family of hardness tests which uses both a minor and major load is called: Brinell Vickers Rockwell Knoop. none of the aboveWhich a. Rockw b. Vickers c. Knoop a. e. f che folov ing tests ae referred 10 as microhardness tests? aand b above bandc above Q7-11 What type of test uses a weighted pendulum which strikes a notched test specimen? Brinell test fatigue test tensile test crack opening displacement (COD) Charpy impact test Pages Q7-12 Of the following, which is one of the most measurable features of a metal? a, fatigue | b. hardness c. soundness @. “tension e. none of the above Q7-13' Which of the following is not considered a soundness test? a. tensile face bend fillet break root bend nick-break paos Q7-14 The type of testing used to evaluate the type of microstructuré present in a metal is called: tensile hardness toughness metallographic none of the above seertrodes weighs approximately how many kg? €. none of the above Q7-16 Which two metal properties are directly related for many steels? impact strength and fatigue strength tensile strength and ductility tensile strength and hardness toughness and fatigue strength none of the above eae gp Q7-17 What is the wire feed speed which is measured to be 175 in./min? 125 m/s 74 mm/s 7.4 mm/s | aand b above | band.c above Sao gp QU7-18_ The property of metals which describes their ability to carry some type of load is: a, strength b, toughness ©. hardness ' d, ductility €, none of the above Q7-19 For less ductile metals, which method is used to determine the yield strength? drop of beam offset technique Stress-strain curve abrupt yielding none of the above eRe SPQ7-21 Sao gp Q7-22 paegp Q7-23 Pee ee Q7-24 saos D energy is cailed: ductility hardness toughness none of the above A weld joint is measured and found to be 345 mm long. How long is that joint in terms of inches? 135.8 in 13.58 in 8760 in 876 in none of the above Which of the following tests are used to verify the soundness of a weld? nick break fillet break bend test radiographic test all of the above With the SAW process we achieve a deposition rate of 19.7 kg/h. How many Ib/h is this? 434 Ib/h 43.4 Ib/h 87.5 lbh 8.9 Ib/h none of the above Ultimate tensile strength can be determined using which of the following tests? tensile bend Charpy nick break nil-ductility drop-weightQ7-25 eBoge Q7-26 PRO gp Q7-27 faose Q7-28 Sane Q7-29 eae oe Calculation of percent elongation is determined after measuring the change in: percent reduction of area depth of indentation diameter of indentation cross sectional area length between gage marks With the GMAW process we use a wire feed speed of 170 mm/s. How many in/min is this? 40.16 in/min 93.7 in/min 401.6 in/min 537 in/min none of the above With the GTAW process, flow rates are measured at 22 L/min, How many ft/h is this? 10.4 fe" 1.39 fo" 46.6 fon 83.2 f8/n none of the above Calculation of tensile strength is accomplished by dividing the tensile load by: cross sectional area percent elongation percent reduction of area gage length none of the above The metal property describing its freedom from imperfections is: tensile strength soundness impact strength toughness ductilityQ7-30 Paes Q7-31 SaegD 2 7 8 eas ob Q7-33 SROs Q7-34 Sao op -20 Ibf. Tf. metal exhibits a greut deal of elongation prior to falling when a tensile load is epplied is said to have high: tensile strength hardness impact strength toughness ductility A specimen approximately 2” long with a V-notch machined in the center of one of its sides is used for which of the following tests? tensile nil-ductility drop-weight Charpy bend tuck break A heat input of 1,500,000 J/m is how many J/in? 381 fin 3,810 Jin iI 38,100 J/in 381,000 J/in none of the above Which of the following properties can be determined from a tensile test? ultimate tensile strength, yield strength, ductility yield strength, ductility, toughness duetility only toughness only all of the above ‘The force required to bend a steel bar is measured to be 890 N. That is how many Ibf? 200.3 Ibf 2003 Ibf 550 Ibf none of the aboveQ7-35 A coating peasy have a ma 68g 682 0.008 g 08g none of the ‘as removed from a SMAW electrode. After weighing, it was found to | of 2.4 02, That is how many grams? | aboveA poaeoge Ss Roop Who is normally responsible for the qualification of welding procedures aii welders? welder architect welder's employer independent test lab Code body Which of the following destructive testing methods may be used for procedure qualification testing? B tensile nick-break charpy bend all-of the above ‘What is the pipe welding position where the pipe remains fixed with its axis ° * horizontal, so the welder must weld around the joint? 1G 2G 5G : 6G 6GR What is the pipe welding position where the axis of the pipe lies fixed at a 45 degree angle? 1G 2G 5G 6G none of the aboveQS-S What is the necessay pipe position vest for welders to qualify te weld T., K., ahd ¥- connections? a 1G b 2G «. 5G . 66 e. 6GR Q8-6 With relation to procedure and welder qualification, what is the most important part for the welding inspector? watching the welding qualification test identifying samples cutting test specimens testing specimens monitoring production welding pao ep Q8-7 For most codes, if a welder continues to use a particular procedure, how long does his qualification remain in effect? indefinitely 6 months lyear 3 years until he produces a rejectable weld paso Q8-8 What document describes the requirements of welder quelification in accordance with ASME? ASME Section I ASME Section IJ, Part A ASME Section IX ASME Section XI ASME Section V gS aogP Q8-9 Qualification to weld cross country pipelines is normally done in accordance with: a, ASMB Section I AWS D1.1 AWS D14.3 . APL 1104 API 650 Ca | eaeQ9-1 Of the following, which is not a necessary requirement for a welding process? a. source of energy electricity means of shielding molten metal base material none of the above Q9-2 Which of the following are functions of the flux coating of a SMAW electrode? : a. insulating ! b. alloying c. deoxidation 2 4. shielding ‘ e. all of the above Q9-3 In the AWS system of SMAW electrode designations, the next to the last number refers to: a, usability ee b. electrode cpating c. - position strength e. none of the above Q9-4 Which of the following is an incorrect statement about a SMAW electrode designated as an E7024? a.. Itis alow hydrogen type. b. The weld deposit has a minimum: tensile strength of 70,000 psi c. tis suitable for use in the flat and horizontal fillet positions only. d. all of the above e.. none of the aboveeaog Which of the following is not an essential part of a typical SMAW system? constant current power supply wire feeder covered electrode electrode lead work lead Shielding of the molten metal in GMAW is accomplished through the use of: granular flux slag fuel gas and oxygen aand b above inert and reactive gases Which of the following is not considered a type of metal transfer for GMAW? short circuiting spray globular droplet pulsed are Which of the following types of metal transfer in GMAW is considered to be the lowest energy, and therefore prone to incomplete fusion? short circuiting spray globular droplet pulsed arcnee a. SMAW b. GMAW c. FCAW d SAW e. ESW Q9-10 Which of the following is not considered an arc welding process? a SMAW b. GMAW ce. FCAW d. ESW €. none of the above: Q9-11 In the electrode designation system for FCAW, the second number refers to: a. strength b.. position chemical composition d. usability e. none of the above Q9-12 Which of the following is not always an essential element of a FCAW system? constant voltage power supply b. tubular electrode c. wire feeder a, shielding gas e. work (ground) leadWhat aspect of the GTAW and PAW processes is different from the other arc welding processes? nonconsumable electrode power supply shielding all of the above none of the above Shielding for the GTAW and PAW processes is accomplished through the use of: granular flux slag inert gas reactive gas none of the above A green stripe on a tungsten electrode designates: pure tungsten 1% thoriated tungsten 2% thoriated tungsten zirconated tungsten none of the above When welding aluminum with the GTAW process, what type of welding current is most commonly used? DCEP DCEN, AC aand b above’ band c above: SAW and ESW are similar in that: both are arc welding processes both use shielding gases both use a granular flux aand b above, aand c aboveQ9-18 Q9-19 a b. c. d. e. Q9-20 The diagram below depicts what welding process? Solidification cracking due to improper width-to-depth ratio of the weld nugget 2 may be a problem with which welding process? OFW sw SAW all of the above none of the above A welding process done essentially in the flat position with welding progressing from the bottom to top of the weld joint positioned vertically identifies: GMAW SAW ESW aand b abave band c above Which of the following are not common to both GTAW and PAW? nonconsumable tungsten electrode copper constricting nozzle shielding gas nozzle externally-applied filler metal none of the above© What technique is employed with PAW to produce full penetration welds? stringer beads weave beads keyhole backstep none of the above What welding process produces welds in the flat position, in a single pass, with the progression vertically upward along the joint? SAW ESW FCAW aand b above band c above Which of the following is not an advantage of the ESW process? high deposition rate ease of setup capable of joining thick sections no tendency for angular distortion none of the above Which welding process is considered to be a chemical welding process? SMAW ESW SAW oaw none of the above Which are’ welding process provides an efficient means of joining attachments to some planar surface? oAW sw GMAW GTAW SMAW9-32 Q9-27 pao Q9-28 Q9-29 Q9-30 gasses Q9-31 sees Brazing differs from welding in that: no filler metal is used. an oxyfuel flame is used. the base metal is not melted. all of the above none of the above For satisfactory results, a braze joint should have: alarge surface area. a small gap between pieces to be joined. a precise bevel. aandb above bandc above Which of the following is not an advantage of brazing? ease of joining thick sections ability to join dissimilar metals ability to join thin sections aandb above band c above Of the following metals, which‘cannot be effectively cut using OFC? high carbon steel Jow carbon steel medium ¢arbon steel Stainless steel none of the above Which of the following gases can be used to perform OFC? MAPP propane acetylene natural all of the aboveQ 19-32 a. b. c. d. e Q9-33 a. b. c d. e. Q9-34 Q9-35 Which of the following cutting processes can be used to cut any metal? OFC CAC-A PAC aand b above band c above The width of a cut is technically referred to as the: gap dross kerf drag none of the above Which process is illustrated below? GMAW PAW GTAW BMAW CAW ESW designates which process? electric slag arc welding electroslag arc welding electric slag welding electroslag welding electric stud welding9-34 Q9-36 Which process is illustrated below? sae ge GMAW PAW GTAW TIG cAW Q9-37 Which process is illustrated below? wo Ne ob peer, a. b. c 4, e.Q9-38 Which process is illustrated below? Q9-39 SMAW designates which process? a. stick metal are welding b. shielded metal are welding c. submerged arc welding d. seam metal are welding e. short cireuiting metal arc welding Q9-40 SW designates which process? stud welding stud arc welding submerged welding stick welding submerged are welding pooge Q9-41 SAW designates which process? stud welding stud are welding submerged welding i stick welding submerged arc welding | eS RogPp9-36 Q9-42, FCAW designates which flux cored arc welding flux centered arc welding furnace controlled arc welding friction arc welding flow are welding pPaege Q9-43 GMAW designates which process? gas machine arc welding gas method are welding gas material are welding gas metal are welding general material arc welding Seaege Q9-44 GTAW designates which process? gas tungsten are welding general tungsten arc welding globular transfer are welding gas torch are welding none of the above eaoge 2 id & a PAW designates which process? plasma are welding pressure are welding plate are welding percussion arc welding none of the above eaoge Q9-46 Which of the following could result in the creation of porosity in the GTAW of | 6061-16 aluminum structural members for an aircraft application? insufficient cleaning of the weld joint contaminated filler metal leak in the shielding gas hose presence of drafts during the welding operation all of the above eae seQ9-47 eaore Q9-48 p Rese Q9-49 wane sao oe ‘An ER70S-6 electrode can be vsed with which of the processes? GTAW GMAW PAW all of the above none of the above ‘A granular flux is a characteristic of which of the following? ESW SAW SMAW both a and b both b and ¢ ‘Which of the classifications listed below produces the strongest weld metal? ERT0S-6 E70T-S E7018 FTA2-EM12K no difference Which process is classified as a chemical welding method? GTAW GMAW ESW PAW OAW Which cutting methods use electricity? PAC CAC-A oac and b above “dc above2-33 Q9-52 eae Q9-53 Sao ge Q9-54 eae ge Q9-55 eae op Q9-56 saoge A tubular electrode is a significant characteristic of which process? SAW ESW FCAW SMAW GMAW Which arc welding process is used very effectively for the welding of various types of attachments to surfaces of plates and structural members? SMAW GMAW FCAW sw ESW Molding shoes is a term associated with which process? SAW GTAW ESW FCAW GMAW Short circuiting metal transfer is a mode of operation for: GTAW FCAW SMAW none of the aboye all of the above The need for electrode holding ovens for some types of its filler metal is a disadvantage of which process below? SMAW FCAW SAW all of the above aenddWhich process uses a catbon electrode? SMAW GMAW GTAW CAC-A PAC EWTh-1 is an electrode designation for which of those processes listed below? GTAW PAW GMAW aand b above, band c above, Of the following which brazing process is preferred when the parts to be brazed can be assembled with the filler metal preplaced near or in the joint? torch induction furnace diffusion none of the above F7P6-EM12 isa filler metal designation for: SMAW GMAW FCAW SAW PAW ‘The ability to perform keyhole welding is a primary advantage of: GTAW PAW SMAW FCAW SAWWhich gases can be used for OFW? MAPP. acetylene natural gas propane all of the above Which gases below can be used for TB? acetylene oxygen natural gas propane ‘ all of the above A ferrule is an item used for shielding in which process below? ESW PAW PAC sw FB When GTAW is used, what type of current results in the greatest amount of * penetration? ‘ dcen deep ac hwac no difference A constricting nozzle is one of the components for which welding process? PAW GTAW SAW GMAW swQ9-67 Q9-68 poos Q9-69 paege Q9-70 eaoge Q9-71 paoee, What gases can be used for GMAW? carbon dioxide ergon 75% argon-25% carbon dioxide 98% argon-2% oxygen all of the above ‘The process \vhich can be used either with or without an external shielding gas is: GMAW SMAW FCAW GTAW PAW. Which of the welding processes below is generally considered to provide the highest deposition rate? sAW ESW FCAW SMAW GMAW When welding carbon steel with the OAW process, the torch should be adjusted to provi an oxidizing flame a carburizing flame a neutral flare aheating flame none of the above Of the following which of the processes make use of water-injected torches to minimize the effect of irregular kerf? PAC CAC-A GTAW aand b above band c aboveQ9-72 The use of a constricting orifice, is the distinguishing feature cf which of th following? GTAW GMAW FCAW PAW none of the above seese Q9-73 Which of the following processes utilize a flux to provide necessary shielding? SMAW SAW GMAW aand b above all of the above Sao seA discontinuity is: always a defect. always a reject. always acceptable. rejectable if it exceeds code limits. none of the above Of the following, which is commonly caused by the presence of hydrogen in a crack suscéptable microstructure subjected to applied stress? Jamellar tearing. delamination. porosity. delayed cracking. none of the above Porosity, o¢curing in the form of large cylindrical pores is called: clustered porosity linear scattered porosity uniformly scattered porosity elongated porosity none of the above Which of the following discontinuities is least likely to be seen. visually? toe crack undercut lamellar tear overlapQu0-5 goo Q10-6 gaoge Q10-7 spore Q10-8 eae gp Underbead cracks can result from which of the following welding practices? use of wet electrodes welding on contaminated steels welding over paint all of the above none of the above ‘The weld discontinuity which results from improper termination of the welding arc is referred to as: undercut overlap crater crack incomplete fusion all of the above All but which of the following processes may result in the presence of slag inclusions in the completed weld? SMAW PAW FCAW SAW none of the above ‘That discontinvity which results from the entrapment of gas within the weld cross section is referred to as: crack slag inclusion incomplete fusion porosity none of the aboveQ10-9 What bebe metal discen traveling too rapicly? underfill undercut incomplete fusion overlap none of the above eied at the weld toe, is caused by the weldeg Sao gp Q10-10 What weld discontinuity results when the welder travels too slowly causing excess weld metal to pour out of the joint and lay on the base metal surface without fusing? undercut underfill overlap 4 incomplete fusion a none of the above SROs QU0-11 What weld metal discontinuity results when the welder fails to completely fill the weld groove? a. underfill b. undercut ©. overlap d. incomplete fusion €. none of the above Q10-12 Excessive weld metal buildup on a groove weld is referred to as: a excess convexity b. excess weld reinforcement c. overfill d. all of the above ©, none of the aboveQ10-13 The weld discon pap ee ation of the welding arc outside esults from the init ity w the weld joint is referred to a3: incomplete fusion undercut overlap scratch start arc strike QU0-14 Of the following, which weld discontinuity shows up as a light region on a Saore radiograph? porosity incomplete joint penetration aand b above tungsten inclusion none of the above QU0-15 What base metal discontinuity results from improper steelmaking practice and is paoge associated with the rolled surface? Jamination delamination. seam crack none of the above18 Questions Q10-16 through Q10-20 refer to the figure on the facing page: Q10-16 What discontinuity is shown by #12b? lengitudinal crack b, transverse crack face crack 4. toe crack €. root crack Q10-17 What discontinuity is shown by #11? a. lamination b. base metal crack c. lamellar tear 4. seam e. Jap QU0-18 What discontinuity is shown by #12g? toe crack incomplete fusion root crack Jameilar tear underbead crack Pao ep Q10-19 What discontinuity is shown by #5? a, undercut b. underfill c. overlap 4. incomplete fusion e. toe crack Q10-20 What discontinuity is shown by #10? 2, lamination! seam c. delamination 4. base metal crack e. incomplete fusionQu-1 eaoge Qu1-2 gaose QU-3 gags Ql1-4 eae op Which of the following nondestructive examination methods do not usually requi electricity? eddy current visible dye penetrant visual aand b above band c above Which of the following nondestructive examination methods is limited to detection of surface discontinuities? visual penetrant magnetic particle all of the above none of the above To be most effective, visual inspection should be performed before welding. during welding. after welding. all of the above none of the above The time during which the penetrant remains on the surface of the part to allow to be drawn into any discontinuities is called: waiting time. penetrating time. soak time. dwell time. none of the aboveQU.-7 Bes ° QUL-8 gaos Qui9 Sao oe ung current provides the best combination of penetrationab lity and pariicle mobility? half-wave rectified DC band c above all of the above What NDE method will most likely reveal subsurface Porosity? PT MT RT UT all of the above Which of the following statements is correct for a radiographic test? A reduction in thickness will produce a light image on the film. A low-density discontinuity will produce a light image on the film. A high-density discontinuity will produce a light image on the film. aand b above band ¢ above Which of the following discontinuities is almost never detected using RT? crack incomplete fusion undercut lamination none of the above What device is used during radiography to indicate the acquired sensitivity of a radiograph? rate meter dosimeter lead screen penetrameter none of the aboveQ11-10 Which pondestructive Boop e QU1-11 The process whereby the ultrasonic indications are related to physical distances j SaBoge aS @ probir nunation method utilizes sound ene: mediura? VT RT | UT PT ET a test standard is referred to as: setup | calibration | standardization | synchronization | none of the above QU1-12 A test probe containing an altemating current coil is used for which NDE method? a, Pees RT UT ET. MT c &dabave QUL-13 Changes in electrical conductivity can be measured using which NDE method? a aos e QU1-14 a b. ET RT MT UT none of the above Which of the following NDE methods are suitable for detecting surface cracks? RT VT ET PT all of the aboveQUL-45 What NDE|methéd is rar a kely to reveal intern: nations in a rolled plate? b. UT c EF d. MT €. none of the above QU1-16 PT is limited to the detection of those discontinuities which are? a, near the test object surface b. open to the test object surface c. clean and open to the test object surface d. all of the above €. none of the above QUI1-17 Visible dye penetrant indications: must be observed under a black light don’t have to be observed under a black light, but are more sensitive if they are must be observed under ultraviolet light must be observed under white light none of the above Sao rE QU1-18 Penetrant’can be applied by: a, brushing b. spraying ©. dipping 4. all/of the above €. none of the above QU1-19 Fluorescent penetrants are generally more sensitive than visible dye penetrants because: a. ” they can flow into smaller cracks b. fluorescent indications are better seen by the human eye ¢, they are subject to greater capillary action d. aandc above e. bande aboveQU1-20 Which of the following cause decreased sei a. too heavy application of the developer b. oily or greasy test objec c, improper penetrant removal d. all of the above e. none of the above Q11-21 PT is limited to test objects which: a. are metallic b, are-porous c. are magnetic 4. e are nonporous have subsurface discontinuities Q11-22 MT will discover: a. surface discontinuities b. slightly subsurface discontinuities c, underbead cracking d. aand babove : e. all of the above Q11-23 MT is most sensitive to those discontinuities which are: a. within 45° of perpendicular to the lines of flux b. within 45° of parallel to the lines of flux c. perpendicular to the lines of flux d. parallel to the lines of flux e. none of the above QU1-24 MT is limited to test objects which: a. are metallic b. are porous c. are ferromagnetic d. are nonporous e, have subsurface discontinuities Q11-25 UT is most sensitive to those discontinuities which are: a, within 45? of perpendicular to the sound waves b. within 45? of parallel to the sound waves c. perpendicular to the sound waves d, ‘parallel to the sound waves e. none of the aboveQU1-26 UT uses freque below the range of human hearing within the range of human hearing above the range of human hearing beside the range of human hearing none of the above eS aose QU1-27 In UT the horizontal axis of the CRT screen gives information about: a. the distance the sound has traveled in the part . the amount of sound energy reflected c. the type of discontinuity discontinuity orientation discontinuity cause eo QU1-28 RT shows areas of lower density as: a. dark regions gn the film b._ light regions on the film c. light or dark regions on the film d. all of the above €, none of the above QU1-29 RT shows areas of less thickness as: a. dark regions on the film b._ light regions oh the film ¢. light or dark regions on the film d. allof the above €. none of the above QU1-30 RT shows areas of incr ‘eased transmission as: a. dark regions on the film b. light regions on the film light or dark regions on the film all of the above, da €. none of the aboveQU1-31 Tungsten inclusions generally appear in RT as a, dark régions on tha §'m blight régions on the film light or dark regions cn the film d. all of the above €. none of the above Q11-32 Cracks generally appear in RT as: dark lines on the film light lines on the film light or dark lines on the film all of the above none of the above Spo ge QUI-33 Weld reinforcement generally appears as: a. dark regions on the film b. light regions on the film ¢. light or dark regions on the film d. all of the above none of the above QUI-34 Porosity generally appears in RT as: a. dark regions on the film b. light regions on the film ¢. light or dark regions on the film d. all of the above 2 none of the above QU1-35 Shallow surface cracks can best be detected in 308 stainless by: a UT b. MT c. RT d. PT , all of the aboveQUL-36 Uncerbecd cracks cay dest QU1-37 Porosity ur a b. c. d. e. eRe op ET MT UT PT all of the above MT RT PT all of the above de detected by: in ESW can best be detected by: QU1-38 The vertical axis of the UT CRT screen represents: a. Paes Sao ge distance time reflector size! none of the above all of the above object? aand b above band c above QU1-39 What NDE method(s) rely on the transmission of sound energy through the test QU1-40 What NDE method(s) often rely on the application of a hydrostatic pressure to a Pao gp vessel? pressure tests leak tests proof tests all of the above none of the abovei $ a. b. c d. e a. Saeg rpmoeas ferrite test UT QU1-42 Application of a vacuum box t form of which test below? VT PRT LT all of the above none of the above Q11-43 FN is a unit of measurement with which test below? RT PRT feitite test UT PT QU1-44 NDE personnel are normall ASME Section V AWS D1.1 ANSI SNT-TC-1A, ASNT SNT-TC-1A ASME SNT-TC-1A. lied to determine the metallurgical effects of Welding fo the inside surface of a Steel storage tank is one YY qualified in accordance witheRogp QU2-2 eae Q12-3 saos Q12-4 sees Once inspections are completed, what important aspect of the inspector's job mus| be accomplished? RS tell the foreman that the weld is acceptable tell the supervisor that the inspection is complete fill out an inspection report detailing his findings all of the above none of the above Which of the following is not normally required of inspection reports? inspector's signature an indication of only those parts which were acceptable they should be clear and concise they should be filled out in ink none of the above “What authorship is attached to inspection report forms? the inspector’s signature the weldér’s signature the welding supervisor's signature Forms are anonymously presented. Forms are not signed. i ‘What handy report forms are available from AWS? Appendix E of AWS D1.1 Appendis I of AWS D1.1 Appendix O of AWS D1.1 AWS QC1 ASME N+1 FormQI2-5 You have made ar misiake oa a report form, How should it be corrected? ctor will use a pencil so such errors can be erased and An experienced in corrected, As an inspector-in-training, such errors need not be corrected. To keep the report legal and"credible, the error should be crossed out and the correction added adjacent to the error and noted complete with initials and date of correction. The report must be completely rewritten. none of the above How are errors in writing corrected in written reports? crossed out erased with an ink eraser entire page must be rewritten crossed out, corrected, initialed and dated none of the above Who is authorized to sign off ASME data report forms? the authorized inspector who performed inspection an authorized keeper of the code stamp an officer or manager of the company any of the above both a and b above How are opinions on workmanship or stiggestions for repair usually reported? Comments are written in chalk on the work. by unstructured reports Provisions for such comments are contained in structured reports. Inspectors are forbidden to offer such comments. none of the aboveChapter 1 Qu Qu2 a3 Qu4 Qs Quis Qu-7 gre Qo QUI0 Qrile Qn12 a Ql-13 e Quid b QUIS a eecgzaeoan Chapter 2 Qi ¢ Q22 4 Q23 b Qr4 a Q25 a Q6 4 Q7 a Q2-8 c Qo db Q-10 2 Qi db Q212 d Q213 d Q214 b Bis Chapter 3 Bid Q3-2 3 Q3-4 G5 Q3-6 Q3-7 3-8 Q3-9 aocacone Chapter 4 eI Qa2 Q4-3 44 Q4-5 Q4-6 2 = Ss BOTo THR OoMOTeO ano oO Q4-24 Q4-25 a Q4-26 d. Q427 € Q4-28 € Q4-29 b- Q4-30 b Q431 ¢ Q4-32 a 33 & Q4-34 b Q4-35 & Q4-36 d 4-37 a Q4-38 b 4-39 d Q4-40 a Q441 a Q4-42 b. Q4-43 c Qa-44 d Q4-45 ¢ Q4-46 a Q4-47 a 448 b Q4-49 e Q-50 sid Q4-52 b Q453 € Q4-54 Q4-55 b Q456 d Q4-57 4-58 d 4-59 b- Q4-60 a. Q4-61 Q4-62 b Q4-63 € Q4-64 a Q4-65 d Q5-66 b Q4-67 b Q4-68 a 4-69 d Chapter 5Q5-28 ax 5-29 dv Q5-30 bu Q5-31 ev Q5-32 a 5-33 b’ 5-34 a Q5-35 b 5-36 ©, Q537 by Q5-38 e. GS-39 ¢, Q5-40 b QS-41 c/ Q5-42 Q5-43 dv 5-44 a, Q5-45 bi Q5-46 av Q5-47 d Q5-48 c, 5-49 b. 5-50 a Q5-51 cY Q5-52 05-53. a 5-54 bs GS-54 Q5-56 & Chapter 6 Gl ev Q6-2 ay 3 c Q6-4 bi 65 © 6-6 e Q6-7 db: QBS 59 or QE1O €> QE cr Q6-12 av Q6-13 b« Q6-14 bY Q6-15 bY Q6-16 d 06-17 & Q6-18 aX Q6-19 ex Q6-20 ev Q6-21 b Q6-22 © Q6-23 6.24 Chapter 7 Quid Q7-2 O73 + Qhd Qs 6 QT Q78 Q7.9 Qr0e Ql e, Qri2 a QB a Qrid d Qr-15 ¢ Qrl6 & Qri7 b QU-18 a Qz-19 b Q7-20 d Q7-21 b Q7-22 Q7-23 b Q7-24 a Q7-25 e.- Q1-26 Qr27¢ QU-28 a Q7-29 b- Q7-30 e- Q731 ¢ 7-32 « Q7-33 a Q7-34 ev Q7-35 av Chapter Q8-1 cw Q8-2 Q33 Q8-4 Q8-5 Q8-6 Q8-7 Q88 Q8-9 aonegace Chapter 9 QW-1 b. Q9-22 ¢ Q9-23 > Q9-24 9-25 9-26 99-27 99-28 9-29 9-30 Q9-31 99-32 9-33 99-34 9-35 99-36 Q9-37 9-38 9-39 9-40 Q9-41 9-42 Q9-43 9-44 9-45 9-46 € Q9-47 d Q9-48 d Q9-49 € Q9-50 & Q9-51 4 Q9-52 9-53 d Q9-54 © Q9-55 € Q9-56 & Q9-57 4d Q9-58 d 9-59 ¢ Q9-60 4 Q9-61 b Q9-62 b Q9-63 € Q9-64 4 pepareosceoncgacrceenspancadChapter 9c Q9-65 a QB-65 a Q-57 ¢ 9-68 ¢ Q9-69 b Q9-70 71a @-n2e Q-73 d Chapter 10 Quo a QU0-2 4 Q10-3 d Q10-4 Q10-5 4 Q10-6 ¢ QU0-7 b Q10-8 ¢ Q10-9 b Q10-10 ¢ QU0-11 a QU0-12 b Q10-13 € Q10-14 b QUO-15 ¢ QU0-16 b 0-17 ¢ QU0-18 & Q10-19 a 10-20 b Chapter 11 Qil-le Qll-2 d Qu3 a Qua d Quis c QIL6 QUT c Qu8 d Qu-9 “d QUI-10 ¢ Quest b Qil-i2e QUAi3 a Qu-14e QUIS b QUI-16 c QUIT d QU-18 d QII-19 b QU1-20 d Quaid Qi1-22 ad QU1-23 ¢ QU1-24 c QUL-25 € QUi-26 ¢ QU1-27 a QU1-28 a QU-29 a QU1-30 a QU-3r b QU1-32 a Q11-33 b QUI-34 a QU-35 d QUL-36'¢ QU1-37 ¢ QU-38 QU-39 e QU-40 4 QUL-4i c QU-42 QU1-43'¢ Qu1-44 a Chapter 12 Qa Qi2.-2 Q12-3 Q12-4 Qi2-5 Qu2-6 2-7 2-8 cr aonecaé CERTIFICATION MANUAL FOR WELDING INSPECTORS THIRD EDITION Published By American Welding Society Education Department Tow 6, BA MAR. 3 LAJADIA R31, 2600 American Welding SocietyDISCLAIMER The American Welding Society, Inc. assumes no responsibility for the information | contained in this publication. An independent, substantiating investigation should be made prior to reliance on or use of such information. TOWL G, BALAJADIA MAR 31 , 2000 International Standard Book Number: 0-87171-421-3 Copyright © 1993 by American Welding Society, Miami, Florida, Third Edition 1993 Revised 10/95 Allrights reserved. No part of this book may be reproduced in any form or by any means, electronic or mechanical, including photocopying, recording, or by any information storage or retrieval system, without permission in writing from the publisher. Printed in the United States of AmericaIn 1976, the American Welding Society introduced a much needed certification program specificelly for those individuals who perform visual welding inspection. Shortly thereafter, the AWS Qualification and Certification Committee initiated the development of a single publication which could serve as a valid reference for those individuals interested in becoming qualified as a Certified Welding Inspector. Prior to the initial publication of Certification Manual for Welding Inspectors in 1977, relevant information on the subject could be found scattered among Various documents such as Welding Inspection and Guide to Nondesiructive Testing of Welds. Dr, Hallock C, Campbell was selected to organize existing information on the topic in a manner that would be most helpful to those individuals who wished to become better prepared for both the certification ‘examination as well As their jobs as welding inspectors. Dr. Campbell's ability to present this technical information in a form that inspectors of many different backgrounds could easily comprehend ha$ made the Certification Manual for Welding Inspectors one of the most utilized documents on the subject. The initial printing was followed by a revised second printing in 1979, and finally a Second Edition, released in 1980. This is, I feel, adequate proof of the publication's value to the industry. ince that time, humerous changes have occurred in both the AWS Certified Welding Inspector program end examination as well as the technology related (0 welding inspection. Consequenily, the AWS Continuing Education Committee sought to update the information contained in the Certification Manual ‘Much of the information contained herein was drawn from other AWS publications, including: Welding Inspection, Second Edition, Welding Inspection Technology, AWS BH.11-88, Guide for the Visual Inspection of Welds, and AWS B1.10-86, Guide for the Nondestructive Inspection of Welds. The reader is encouraged to review these and other documents for even more detailed descriptions of much of the information contained in this new edition. ‘As Dr. Campbell pointed out in previous editions, welding inspectors are employed in 2 variety of industries, As a result, their duties will differ somewhat from one situation to the next. This Manual has been developed under the assumption that a welding inspector will be performing quality control duties of a general nature, Some inspectors, for example, may be working at a field construction site where he or she is in charge of overall welding quality. At the other extreme, in a large organization, a quality assurance department may make many of the decisions that the Manvel assigns solely to the inspector. As noted by Dr. Campbell, in either case, the welding inspector will always perform a key role. The individual inspector's specific role in the quality control activity must therefore mesh with many other ac- tivities and personnel, 2s outlined in the pages which follow.