R.MURAU/SBTIS/Mca-1/REV.01 5. WELDING PROCEDURE& WELDER QUALIFICATION ANSWERS 1A 2.B' 3.D 4.D SA 6.D 7A. 9: 8: C- . Gie JOA 11.B 12D 13.B 144A 15.A 163 17D - 18D 19.C 20.C- 21.0 eo» 24.4 25.B 26.C cd 1.6. PRE-HEAT&PWHT ranganese steel is normally done to avoid 1. Applying preheat when welding carbon A. Siag inclusions B. Hydrogen cracking « ©. Lack of side wall fusion D. Porosity 2. Stress relief is not hetpfut A B c. ©. ne OF the following cases? Which one? In improving resistance to stress corrosion cracking In dmensional stability after machining improving In lowering the peak residual stress in softening the steel, + ri S metal are welding is carried out to minimizeithe risk of? Pre-heating a carbon steel ma A. Scatiored porosity polRMURALI/SETIS/MCQ-1/REV-01 B. Wormhole porosity C. Parent metal cracking « D. Lack of penetration. (See question No --1) 4. Pretheating for aro welding applies to? A Assembly welding only B. Assembly and tack welding C. Joint over 25mm thick only « D. Circumference welds only. 5. Welding a steot plate of CE of 0.45 would require preheating t APH -vent the formation of sulphides B. Prevent hardening inthe HAZ C. Prevent the formation of carbides . To Improve mechantcal properties in the weld 6. Thi pias cr saat Use Ps son prea ck os ad Following processes? A. Annealing : eee x, & Hartering » SSO : 9, Stress relie 3 | scat nth i A. They can with stand creep lalla, “8. They may suffer re-heat cracking problems ©. They may suffer loss of toughness D. Allofthe above 8. Past heat treatment? A. Must be applied to welds if a crack free weld is required B, Should never exesed 300°C « ©. May stress rolieve D. Must always is applied using Gas flames. 9. Precheating prior to welding (or) pre-heat prior to the welding of carbon stect butt-welds? A. Must always be carried out B. Need not be carriod if post heat treatment is to follow welding ©. Is always carried out using Gas flame D. None of the above . E. All of the above, 10. What does preheat or Lo weldfing have aan effect on? lozR-MURAU/SBTIS/MCQ-4/REV-01 A. Harden ability B. Weld ability C. Cooling rate * D. All of the above E. None of the above 11. Fluctrating load is cyclic stresses, below the uts on a weld component may leait to? A. Tensile failure B. Yield failure C. Fatigue failure ~ D. Shear failure. 12. Which of this PWIT temperature is likely to procedure best combina strength, toughness, and residual stress in a omm steel Joint? A. 500°C 8. 600'C" ©. 700°C D. B00'C 4, ee eS D. All of the above 4147 Which of the following are consideration A. Carbon equivalent, joint design, welding process type and plate material quality. B. Alljoints over 2‘imm thick, hydrogen levels, welding process, and carbon equivalen n Of Properties of for the selection of a pre-heat temperature? C. ARC energy material D. All of the above are consideration for the selection of a pre-heat temperature. ‘ickness, hydrogen scale, and carbon equivalent. 15. Which of the following will most likely require the pre-heat temperature to be increased? A. An increase In travel speod vi B. A reduction in material thickness G. An increase in electrode diameter. D. None of the above. - 16. Which of the following are reasons for applying pre-heat? A. The removal of résidual stress 2 . To aid slows cooling and reduces the carbon content. * G. To reduce the chance of a brittle grain structure and to reduce the chance of hydrogen entrapmentRIMIURAL/SBTIS/MCCLA/REV-O1 D. Increase the ultimate tensile strength values and increase overall weld ability. 17. What is the main reason for the apptication of pre-heat? A B_The control the hydrogen and prevent cracking « ro change the chemical composition of the weld and parent material, G. To removal residual stresses. D. Both A and B E, All cf the above. (See question No: 1) 18. Which of the following defects would be likely to occur if the specified preheating temperatures are not adhered to when carbon manganese steels? A. Slag inclusion B. Delay cracking or cold cracking CC. Lack of side wall fusion D. surface porosity - 19: The use of pro-Keat will tond to? A. Resullin a wider heat affected zone B. Produce 2 lower heat- affected Zone ee C. Slow down the cooling rate. - ‘ Be D. Reduce the tendency of producing rae ite Iii heat affected Zone. E. All of the above ¢ ? 20. mere A. Decrease the cooling rate aind inciease the like hood of cracking problems B. Decrease the cooling rate and decrease the like hood of cracking problems. C. Increase the cooling rate and increase the like hood of cracking problems D. Increase the Cooling rate and decrease the like hood of.cracking problems. - » E. None of the above 21. Why is pre heat sometimes carriod out on stec!? A. To remove moisture from the weld preparation B. To retard the cooling rate of the weld ©. To aid fusion between weld metal and parent material “ D. All of the above. - @. How many temperature indi ting Crayons would be required to ensure a pre-heat temperature was hing within a specified range? AA eae eerie ——f-64yR.MURALI/SGTIS/MCQ-1/REV-O1 D. As many as possible. + 23. Which post wold heat ‘reatritent process uscd on steels cool down in air from the austenite region? A. Normalizing B. Annealing + ©. Quenching D. Tempering . 24. When Considering the heat treatment process of tempering? ‘A. This is achieved by slowly heating the material to a temperature between 200C -650C and slow cooling in air. + 4 B. This achieved By heating the material to around 200°C and soaking for approximately 10-12' hours and cooling down in air. C. Very fast cooling from the austenite region. D. All of the above could give a temper. 25. Most metals expand when heated; the change In length Is expressed as? A. Thermal conductivity B! Modulus of elasticity « C. Coefficient D. Yielding 26, Pre-heating prior to welding on, ‘ee strength materials applies to which of the Following? A. Oily on joints over 25mm thickness. B. Production welding only . Pre-heat is not required if post weld heat treatment is to be carried out. D. Production welding and tack welding. 27. Which of the following materials would require the most pre-teat, assuming the thickness to be the same? A. Mild ste! B. Low carbon steel wi ©. Stabilized austenitic stainless ste! D. Carbon manganese steel « m All of the above require the same pre-heat 28. A typical minimum preheat temperature for an MMA weld mace on steel with a carbon content of 0.23% and manganese content of 1.3%2¢ A. Pre-heat would not normally be required B. Less than 50°C ee : {05 - .R.MURALI/SBTIS/MCQ-1/REV-01 C. Aminimumof 190'C + D. Above 280'C 29. Which of the followityg is the most likely reason for the use of pre-heat for flame cutting of high tensile strength materials? A. In order to use a cooler fuel Gas. B. To improve the cut edge « C. To increase the cutting speed D. To avoid hardening and cracking 30. The Main reason for using a pre-heat on medium and high carbon steels before cutting by oxy uel Gas technique is to? A. tenprove the cut quality B. Increase the cutting speed C. Refine the grain structure of the cut edge + D. Frew ant hardening and potential of cracking. 1.6. PRE-HEAT&PWHT ANSWERS SS LB 2B AQ 5 558, 6.C 7 eee 9E 10.D 11.11 12B 13.B 14.6 15.B 16. ©2173 S188 19.E 20.B 21.D. 292A - 93.4 QA 25.C 26.D 2715 28.C ~ 29.D 30.D 106 : 'RMURALY/SBTIS/MCO-1/REV-01 1.7. PROPERITIES OF MATERIALS [STEEL] 1. Which one of the following elements is added to steel to give resistance to creep at elevated service temperatures? . Nicket > Manganese « Molybdenum ‘Aluminum: poos . Which of the following steels is non magnetic? 18% Cr, 8% NI + 13% Cr 9% Cr, 1%MO 9% NI 3. The chemical composition of the weld metat deposited by a c. usually controlled by in emn steel? ce composition . o DO p> steel MMA electrode Is The core v | Alange sain size, in the HAZ ofa Ay Low toughness poo p> fd joint, may have? i o p> .. High toughness High tensile strength The property of a material that has the Greatest influence on welding distortiza is the? ~ Yield strength : . CO-Efficient of thermal expansion - prego Elastic modulus Co-Efficient of electrical conductivity me the presence of iron sulphides in a weld bead may cause? g9 > Solidification cracking.- B. Hydrogen cracking C. Lamellar tearing. D. Weld decay a 7. Typical temperatures used for normalizing a ©, MN steel plate ai A.600' 10 650C.RIMURALI/SBTIS/MCQ-1/REV-01 B.1000 to 100°C €.700" to 800'C D.880 ‘to 920°C + ler to improve resistance to service failure caused by cyclic loading i is good practice A. Use low heat input welding » 8. Use steel with a low CEV ©. Ensure there is no features that give high stress concentration D. All of the above 9. The use of low carbon austenitic stainless steels and stabilized stects will minimize the risk of : AHAZ cracking « B. Weld decay C. Weld metal cracking D. Distortion 10. Carbon manganese steel is being welded by MMA and the electrode run-out lengths that have been used are much shorter than specified by WPS2,This deviation may give? A. An increased risk of hydrogen cracking + .<. B. An increased risk of soli cation craghing Ca pes, 44. Transfer of material identification’ by hard stamping is sometimes not allowed for high integrity applications because? C. Lower values of HAZ toughness D Higher values of HAZ hardness A. ttis too slow B. It canbe a safety hazard . It may be damaging to the material D. Allofthe above - 12. When'welding thin plate, A. Using back-step welding 1 can be minimized by? B. Minimizing weld volume . Using Bridge takes D.Allofthe above + 13. Which element has the greatest effect on the HAZ hardness of carbon-manganese steel? A. Molybdenum B. Chromium G/ Titanium D. Carbon + 108R.MURALI/SISTIS/MCQ-1/REV-01 14, Pre-heating a steel plate with a carbon equivalent value (CEV) of 0.48 may be requined in Order to? A. Drive out moisture from the plate B. Prevent excessive harening in the HAZ n of carbides: C. Prevent the form: D. Improve the mechanical propbrties of the weld metal. m 15, Which of the following cutting methods is suitable for cutting stainless stee!? A.Plasma , B. OXY-acetylene C. OXY propane , D. Allof the above 16, Exceeding the maximum interpass temperature spe give? A. Excessive porosity B, Burn through steel weld joint may ©. Lower toughness - ie rs q en. Ova te db aon) 17. Wiewrererensette tnenginiows creak ee WE ae ee true? A. They are all non magnetic « 6B. They all require 100% Ar for GM) . They alll have very high thermal conductivity D. Only certain grades can be used for service at very low temperatures 18. Carbon equivalent values (CEV) are used to determine the how to avoid the risk of? A. Hydrogen cracking a B. Lamellar tearing ©. Solidification cracking - D. Weld decay me 19. One of the following alloys is nonmagnetic which? [See question no-2) A. 4.0% chromium molybdenum B, 12.0% chromium, C. Austenitic stainless steel D, 1.0% nickel. ° 20, The steel composition in structural contract is changed tro Manganese to 0.2% carbon 1.2% manganese. Thi 0.15% carbon 0.6% ce of A. Porositytrea ee enna B.MURALI/SBTIS/MCQ-1/REV-01 B. Cracking in the weld area ©. Under cut forifillet welds D. Lack of fusion defects. 24. The Predominant structure of hyper-cutectoid steel that has been quenched at above its upper critical point will be? A. Austenite B. Marton site. ©. Troostite D. Sorlite 2 A multi run deposi 22. When weld metal refinemont takes plac is known by the term? A. Weld annealing + B. Weld refining ©. Weld normalizing « D. Weld recovery stylization 23. Which-of-the following clements has the greater effect on hardenability of steel plate? OR which of tho following element which may be adgei to stee! has the great effect on creep strengin? A. Molybdenum B. Chromium ©. Titanium - D. Carbon 24. A steel described as QT ‘A. Had contro! of chemical composi B, Been heat (reated. il have inipfoved teasile properties because it has? C. Been quality to steel. D. Been vacuum melted 5. Welding Stecl plate with a CE of 0.45 would require pre heating? A. Prevent the formation of sulphides B. Prevent harciening in the HAZ « C. Prevent the formation of carbides 1D. To improve mechanical properties in the weld, said to produce? [see question no-4) 26. A large grain structure in ste! A. Low éustilily values. « B. Low fracture toughness values C. High fracture value values ? — D.High tensile strength . hoR.MURALI/SBTIS/MCQ-1/REV-O1 27. The likelihood of brittle fracture in stec! will Increase widths? ‘A. Alarge grain formation + B. A reduction of in service temperature to sub zero temperature C. Ferrite rather than austenitic stee! D. All of the above 28, The important point of high temperature stee! is t ‘A. They Can with stand creep failure B. They may stiffer re heat cracking problems C. They may suffer loss of toughness D. All of the above 29. An austenitic stainless steel may suffer? A. Weld decay B. Sensitization C. Solidification cracking D. Allof the above + ocr ment oe watt gn A. Weld ability aspect NY C. Typleal mechenice! propertos 0. Allofthe above Yd tat 81, The permeant backing materi MA welding of low carbon stect should be made from? A. Copper B. Low carbon steel + C. QT steel 0. Cast iron 22. Weld decay In staintess ste! can avoided by? A. Stress relieving a B. Slow cooling after welding C. Addition of more manganese: to the steel - D. Addition of titanium to the steel 33. Low Alloy steels having a high carbon equivalent before welding will require? A. A reduction in carbon ccntent B. High pre-heat temperature C. Low pre-heat temperatures D. No pre-heatingR.MURALI/SOTIS/MCQ-2/REV-O1 84. Chromium, when added to steel as an alloying element has the effect of making the alloy A. Dustile + B, Plastic C. Harde 1 able D. Malleable 35. If a tow carbon steel pipe has to carry a liquid care must be taken when making the butt ‘welds to ensure penetration is not excessive because it? A, Reduces the flow rate of the liquid - B, May increase the rate of corrosion C. Can contaminate the liquid D. May cause excessive pipe wear 36. When steel suffers hot shortness, it is mostly due to the presence of? A. Sulphur B. Phosphorous ©. Silicon + D. Manganese 47. Wiwen steet heated to above its upper ae the structure produced Is? A. Martensite B. Austenite - Y C. Partite Cc D. Sorbite atl 38. The need for pre heat for steel will increase ‘A. The material thickness reduces B. Faster welding speed + C. The use of a larger welding electrode D. All of the above 29. Pre-heat prior to the w ng of a carbon steel butt weld? A. Must always be carried out B. Is always carried out using a Gas flame + C. Need not to be carried out if post welds heat treatment to follow D. None of the above 40. in steel the element with the greatest effect on hardness is? A. Chromium, B. Manganese - ©. Carbon D.Nicket 41, Ina martensit 1 structure what woutd you exp A. Duel 442R.MURALI/SBTIS/MCC.1/REV-O1 B. Hardness C. Toughness D. Allof the above 42. Which of the following heat treatments on steel cools down in air from the aust region? ‘ A. Normalizing B. Annealing ©. Tempering D. Stress relieving 43. Austenitic Stainless steels are more susuptible to distortion when compared Lo fersite Stects this is because? A. High coefficient, low thermal conductivity B. High coefficient, high thermal conductivity « C. Low coefficient, high thermal conductivity D. Low coefficient, low thermal conductivity 1h of the following properties may be applicable to a carbon steel weld (CE 0.48) weld pre-heat? ‘A. Narrow heat affected zone and hardness value inf excess of 400HV B. Broad heat affected zone and hardness valugSig excess of 4OOHV C. A very tough and narrow heat affected 24 D. Narrow heat affected zone and low hardgess Values. 45. Which of the following materials.is Cbgsidgred to be the easiest to weld? ‘mit stot i) ®. Medium carbon stools C. Martens tic stainless steel D. Forging steel 4G. Th reason for toe blending on certain welded steel components is? A. Corrosion considerations B. Fatigue life C. Appearance D. Allof the above AT. Increasing the carbon content of steel allows # given level of hardness to be actieved? A. Ata higher cooling rate B. Without consideration of the cooling rate C. Without adding chromium to the steel D. Atlower cooting rate 48, Sulphur is sometimes added A. The impact properties of the welded j B. Provide higher impurities levels 10 steel to improve? a C. Toughness of the parent materials ESi F-MURALY/SBTIS/MCO-1/REV-O1 1b. Machining properties characteristics of steel. oo ciow coottas of Hiquid metal {rom high temperature promotes te growth of? A Medium grains 8. Large grains ©. Sinall grains) > D. A combinations of large and small grain. 50. vie importgnt point of high temperature steels is that? A. They can with stand creep failure - B. They may suffer re-heat cracking problems C. They may suffer loss of toughness D. All of the above ei Which element if stect if present in significant amounts may tead (0 hot shortness? A. Phosphorous B. Manganese ©. Silicon D. Sulphur 52, Which of the following elements cold shortness? A. Sulphur B, Phosphorous B. Its extreme hardness C. Very shivery appearance D. None of the above. 4. Which of the following could be used as stabilizes in austenitic stainless stec! A Niobium and nickel B. Titanium aid tungsten : ©. Titaniuim and niobium D. Tungsten and nickel. 55. Which of the following materials has the poorest weld ability? A Austenitic stainless stee! B. Martens tié stainless stee! * C. Carbon manganese D.HSLA steal 56. Which material is most su ceptible to reheat ¢ A High carbon steels B, Killed ste! a p resistant stee! D. Austenitic steelsRAMMURALI/SBTIS/MCOA/REV-01 57. Mf a steel has a cev% of 0.48? ‘A. Post weld heat treatment would always be necessary. ©. itwil probably require a pre-heat temperature above 300°C, prior to welding C. Itwill probably require a pre-heal temperature above 100'C prior Welding: 1D. The heat- affected Zone will be very high. 58. What happens to the mechanical propertic: 0.5% A The material becomes softer B. Malleability increase: C. The tensile strength increase D. Duelility Increase. 59.168 Austenitic stainless steel properties? A. Avery shiny surface B. Good weld ability C. Extreme hardness D. Lack of magnetic attraction GO. What is the purpose of normalizing steel weldments? tro modity the grain structures by making them,sforerugitorm in order fo Improve mechanical properties. ‘ 2 Sa B. To soften material C. To reduce ductility. cy me metals, this can be minimized by? 5 of steel if carbon content i increased to can be readily indent jed by, which of the foffowing D. To increase the grain size in ord! G1. Welding may result in the harde A. Carbonizing © B, Using faster welding spools ©. The use of rutile electrode D. Slow down the cooling rate of the weld. © tensile strength. G2, A good rule so follow when wolding steels of carbon content above 1% Is to? A. Always use pi > heat above 400°C B. The use of atutile coated electrode C. Use pre-heat around 250°C D.(All of the above.R.MURALW/SBTIS/MCQ-1/REV-01 1.7. PROPERITIES OF MATERIALS [STEEL] ANSWERS 1,C 2.D 3.D 4.B 5.B GAS 7D. 8. D 9A 10.C 11.C 12.D z 13.- 14.D 15.4 16.D 17.C 18.A 19.C 20.B 21.B 22.D 23.4, 24.4 25.B 26.B 27.B 28.D 29. D 30.D 31B 32.B 33.D 34.C 35.B : 36.4 37B 38B 39 Sr 41.C 42.0 43.B 44.0 45.B an 47D 48B 49.B 50.D AD 52.B 53.A 54.B 55.B 56.C 57.C 53:6. 69.D 60.A 61.D 62.C 146.———— RAMURALI/SBTIS/MCO-./REV-O2 1.8. MECHNICAL TESTING at can be used to measure the toughness of weld metal, 4. Which mechanical te: Mz, parent Material? A. Macro test B. nick break test C. Hardness test D. Charpy impact test 2. Which is the best destructive test tor showing lack of weld? 1¢ wall fusion in a 250 thick butt A. Nick Break test B. Side bend test ©. Charpy impact test b, A face bend test a. ina bend test, when the face of speci called men is intension and root 1s compressor, the test Is A. Acoot bend test A tao bend teat! m) D. Atongitudinal test >. Gs A, Assessing weld Quality <= B. Assessing weld metal ductility C. Assessing weld metal toughness D. Allof the above 5. A Macro section is particutarty usel A. The HAZ Microstructure ul tor showing? B, Over lap C. The welds metal Microstructure 1D. Allof the above 6. A star Test is used to measure? ‘A. Tensile strength of the welded joint 8. The level of residual stress in butt joints. C. The fracture toughness of the HAZ D. ‘The tough thickness ductility of 4.5 tel plate (2 directions) 4s cow taxens from 26mm tick carbon, tect buttweldy wh Bond test specimens have bi tn srould show Jack of inter ran fusioen en RMURALI/SBTIS/MCQ-1/REV-O1 A, Sida Bend test , Root Bend test ©. Face Bend test D. Guided Bend test 6. Proof stress is used when non ferrous metals are undergoing tensile tests to determine the equivalent? A. Tenacity B. Elesticity ©. Yield Strength D. Tensile strength 9. To test a component for vi ing, a suitable mechanical testing would be? A. Impact 8. Tensile C. Compressive D. Fatigue 10. One purpose of a Microscopic examination of a weld to establish the? A. Strength of the weld B. NuinbecOf Aer yates Ce ©. Grain Size So 2! Nutr of cana teed A 14. tira tonsite test a brittle material wigddlhe indicated of the fracture surface? A Ghana 0 redueior ie a8 SS fs pal arid ule ©. Break In the parame rae. D. Breaks at 45’ to the load 42. What destructive test would be required to ascertain the like hood of cracking in the heat affected Zone of a weld? A. Nick Break B. Side bend test C. Charpy impact test D. Maero test ; 13. Percentage elongation of a metal undergoing a tensile test is a measure of? A. Elasticity B. plastically CC. ductility . D. malleability 14, mates A. There is a reduction in cross section at the position of fracture. 38 would be indicated if? B, The fracture surface is flat and features less but has a rough surface C. Fracture occurred in the weld metalR.MURAL/SBTIS/MCQ-1/REV-O1 D. The fracture face shows beach marks. 45. Which Material property has the greatest joints? A. Yields Strength B. Co-efficient of thermal expansion C. Tensile ductility *D. Co-efficient of electrical conducted 16. The Maximum hardness in the HAZ of stee! wil C.MN steel will tend to increase when? A. Heat input is increased B. CEVis increased C. Joint thickness is decreased D. All of the above, 17. Welds made with very high input will show a reduction in? A. Tensile ductility B. notch toughness C. Fatigue strength D. Creep resistance 18. When a metal regains its original shape when aye 1g upon it is removed, the metal is said to have? 2S B. Plasticity ©. Malleability D. Elasticity 19. Macroscopic exan fluence on distortion that occurs in welded \crease if the? OR (The HAZ harden spected? A. Once after e etching B. Twice, before ard after ¢ etching ©. Using a Micro srope : D. None of the absve 20. A tensile test will assess? A. Impact values B. Stress. strain d. Both A&C 21. The different grain structure between the weld deposit and the base metal determined by? A. A Face bend test B. A root bend testa R.MURAU/SBTIS/MCQ-1/REV-01 ©. Ahardness test D. An etching test 22. A root bend fest is used to test the amount of welds? A. Duetitity 8. Elong: C. Hardness: D. Penetration the most common cause of failure in root bead tests? lion igh @ current setting B. Too long a pause in down cycle of the weave ©. Lack of fusion and penetration D. Too h’gh travel speed 24. The purpose of nick break specimen is to provide a test for? A. Tensile strength and fracture appearance 8. Dustility and fracture appearance 2. Elongation and fracture appearance 9. Soundness and fracture appearance What would be observed if a fillet weld A. The grain of the other beads is coarser, 13. The penetration and fusion into 1 ©. Each bead appears to be distin 0. The grain structure remains the samen all passes. 2%, Avhich physical test is more likely to reveal HAZ embaitlement? fed from the adjoining beads. A Transverse tensile B. All weld tensile ©. Root bend D. Charpy ‘V impact 27. Which of the following destructive test is not normally required for weld r approval? « A. Bend tests, 8. Macre examination 6. Impact tests D. Fracture tests 28. Which of 1h metal/parent ny following destructive tests would indicate the toughness value of the weld fal and HAZ? A. Macro B. Nick Break 120