HKWIP TEST PAPER –chapter 5

(Specific Questions)

1. When using the TIG (GTAW) process which of the following defects would
you typically expect?

(a) Root concavity

(b) Slag inclusions
(c) Tungsten inclusions
(d) Transverse cracks

2. When you enter the welding area you find that the basic coated electrodes
are being used directly from their cardboard packets. Which weld defect would
you expect to find?

(a) Slag inclusions

(b) Porosity
(c) Undercut
(d) Tungsten inclusions

3. Post weld visual inspection should be done

(a) In a darkened room

(b) Immediately after welding
(c) After slag removal
(d) After NDT

4. Laminations are only visible

(a) At the root pass

(b) Adjacent to the cap
(c) On the plate surface
(d)On the plate edge

5. Arc strikes should be

(a) Always permitted

(b) Disregarded
(c) Unavoidable
(d) Reported

6. Arc Blow may cause

(a) Lack of root fusion

(b) Porosity
(c) Slag inclusions
(d) Cap undercut

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7. Slag inclusions are caused by

(a) Low amperage

(b) Windy conditions
(c) Lack of preheat
(d) Incorrect electrodes

8. Longitudinal cracks are caused by

(a) Improper electrode angle

(b) Excessive preheat
(c) Too long welding cables
(d) Internal stresses

9. The bevel in a butt joint is for

(a) Ventilation
(b) Slag removal
(c) Preventing porosity
(d) Allowing lower welding current

10. In butt welding, misalignment of the joint can result in

(a) Lack of root fusion

(b) Lack of side fusion
(c) Slag inclusions
(d) Overlap

11. In MMA (SMAW) welding porosity can be caused by

(a) Too long arc length

(b) Windy conditions
(c) Low amperage
(d) All of the above

12. At which stage should a weld be inspected

(a) At fit up
(b) During welding
(c) After welding is complete and the joint has been cleaned
(d) All of the above

13. When repairing a weld defect the defect should be removed

(a) As stated in the weld procedure

(b) By grinding
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 (c) By arc air gouging
(d) By mechanical chipping

14. In MIG (GMAW) welding excessive stickout causes

(a) Slag inclusions

(b) Porosity
(c) Cold cracking
(d) Burnthrough

15. In MMA(SMAW) welding the use of damp electrodes can lead to

(a) Slag inclusions

(b) Hydrogen embrittlement
(c) Overlap
(d) Burnthrough

16. Poor earth contact to the workpiece may cause

(a) Arcing
(b) Porosity
(c) Linear slag inclusions
(d) Excess penetration

17. During MIG/MAG (GMAW) welding the contact tip touches and arcs at the
weld bevel. This results in a

(a) Copper Inclusion

(b) Lack of penetration
(c) Slag inclusion
(d) Tungsten inclusion

18. A single pass fillet weld in the flat position has undercut along one toe of
the weld. The probable cause is

(a) Too long arc length

(b) Too high amperage
(c) Incorrect electrode angle
(d) Too slow welding speed

19. In a MMA (SMAW) 2 pass but weld in 6mm plate there was excessive
reinforcement. The probable cause was

(a) Electrode diameter to large

(b) Travel speed to slow
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 (c) Amperage to high
(d) Any of the above

20. Which of the following defects would more likely occur while doing
different thickness joint (transition thickness).
(a) Slag Inclusion
(b) Burn through
(c) Misalignment
(d) Porosity

21. Which of the following are essential factors for lamellar tearing?

a. High residual stresses, poor through thickness ductility, existing plate

laminations.
b. Poor through thickness ductility, fusion face parallel with rolled direction of
parent plate, most commonly occurs in butt welds.
c. Stress, poor through thickness ductility, fusion face parallel with rolled
direction of parent material.
d. Tensile stress, deoxidised parent plate, poor through thickness ductility.

22. What is another term for suckback?

a. Concave root.
b. Elongated porosity in the rot area of a weld.
c. Lack of root penetration.
d. None of the above.

23.Root concavity may be caused by which of the following:

a. Excessive back purge pressure and very high heat inputs.

b. Excessive back purge pressure and entrapped gas.
c. Excessive root grinding and a slow travel speed.
d. Excessive root grinding and excessive back purge pressure.

24. Assuming that the specification makes no reference to arc strikes, what
would you do if you found arc strikes on a high tensile strength material?

a. Have the welders re-approved.

b. Reject all the areas where the arc strikes occur.
c. Check the area for cracking.
d. If the specification makes no reference to arc strikes ignore them.

25. What are the possible results of having a lower heat input from the
approved procedure?

a. An increase in hardness, lower yield strength and lack of fusion.

b. A reduction in toughness, hydrogen entrapment and an increase in
hardness.
c. Entrapped hydrogen, an increase in hardness and lack of fusion.
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 d. Entrapped hydrogen, a reduction in carbon content and lack of fusion.

26. Which of the following methods would be the best suited for the detection
of lamellar tearing in a fabrication?

a. Radiography.
b. Ultrasonics.
c. Dye penetrant.
d. Magnetic particle

27. Planar defects may be best described as :

a. Linear from at least on direction.

b. Rounded indications.
c. Linear from at least one direction with volume.
d. May be classed as all of the above.

28. Which of the following statement is true regarding serious undercut?

a. Located along the weld toe.

b. Too high the welding current used.
c. Arc blow occurring when welding in DC polarity.
d. All of the above

29.What type of planar defect might likely be induced in the weld when
welding run has the large width-depth ratio?

a. Lack of penetration.
b. Lack of fusion.
c. Hydrogen crack.
d. Centre crack.

30.What type of defect would likely be induced if too fast to remove the
welding arc from molten pool without weld return?

a. Lack of fusion.
b. Group porosity.
c. Crater crack.
d. Slag inclusion.

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Answer the following questions from 31 to 45 referring to BSEN970

31. The minimum Illuminance required at the surface of welded

specimen for examination is
a. 500 lx
b. 300 lx
c. 350 lx
d. Any of the above

32. This standard covers visual examination for

a. Fusion welds in steels
b. Resistance Welds in steels
c. Fusion welds in metallic materials
d. All of the above

33. In normal condition the examination is performed on the weld

a. Before, during & after welding
b. Before welding only
c. In as welded condition
d. Any one of the above

34. Which of the following information are correct while using direct
inspection
a. The subject shall be placed from the eye greater than
600mm & examined at an angle not less than 30
b. The subject shall be placed from the eye less than
300mm & examined at an angle greater than 30
c. The subject shall be placed from the eye within 600mm
& to be examined at an angle not less than
approximately 30
d. None of the above answers are correct

35. Personnel performing visual examination shall be examined for

their eye
a. Every 3 months
b. Every 12 months
c. Every 24 Months
d. Only once

36. Which of the following document shall be referred when visual

examination is required prior to welding
a. Welding standards
b. BS EN 970
c. Welding procedure specification
d. BS EN 25817

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 37. Which of the following defects would be expected during welding
process & care shall be taken as an visual Inspector
a. Cracks
b. Undercut
c. Overlap
d. All of the above

38. Which of the following standards shall be referred as acceptance

criteria corresponding to this standard
a. BS EN 288 -2
b. BS EN 25817
c. BS 5135:1984
d. BS 5289

39. Which of the following are incorrect for finished weld

examination
a. there are no tool impressions or blow marks
b. the fusion faces and adjacent surfaces are cleaned
c. the surface of the weld is regular
d. All of the above

40. Which of the following defects shall be expected in a finished

welding
a. Incomplete Penetration
b. Root concavity
c. Cracks
d. All of the above
e. A & C above

41. Which of the following not refers to examine a repaired weld

which is partially removed
a. The shape and dimensions of the weld preparation
meet the specified requirements
b. Excavation is sufficiently deep and long
c. The width and profile of the cut is adequate access for
re-welding
d. None of the above

42. Which of the following tools shall be carried out by a visual

Inspector
a. Straight edge
b. Vernier calliper
c. Feeler gauge
d. All of the above
e. None of the above

43. It has been noticed few visual inspectors use Magnifiers while
inspecting welds, In accordance with this standard what shall be
magnification used
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 a. Less than 2X
b. 10X
c. 5X to 10X
d. 2X to 5X

44. Which of the following tools shall be used for visual inspection of
welds with limited accessibility
a. Mirrors
b. Endoscopes
c. Boroscopes
d. All of the above

45. In accordance with this standard each repaired welds

a. Shall be examined with stringent requirements
b. Not necessary to be re-examined
c. Shall be examined to the same requirements
d. None of the above

46. When temporary attachments were welded to the object to

facilitate production or assembly, which of the following method
are correct
a. The attachment shall be removed so that the object is
not damaged.
b. The area where the attachment was fixed shall be
checked to ensure freedom from cracks
c. Any under cut is within the limit
d. A & B above
e. B & C above

47. Which of the following best practice while dressing a weld is

required
a. Overheating shall be avoided
b. Grinding marks shall be avoided
c. Uneven finish shall be avoided
d. All of the above

48. Which of the following method shall be adopted for the record of
a visual examination
a. Photographs
b. Accurate sketches
c. A & B above
d. None of the above

49. What are best qualities for a personnel performing visual

examination
a. Familiar with standards
b. Informed about welding procedure
c. Have good vision
d. All of the above
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The hard copies shall be destroyed after discussion if any.
 50. After performing visual examination few doubt arises which are
the good practice in accordance to this standard
a. Perform a Radiographic Inspection
b. Perform a Destructive testing
c. Retest with visual examination
d. Supplement other NDT for surface Imperfections.

51. Which of the following standard supersedes BS5289-1976 for

visual inspection of fusion welds
a. BS 5289-1980
b. BSEN970: 1997
c. BSEN288-3: 1992
d. BSEN287-1: 1992

52. Which of the following are not clearly spelled out in BS 5289
compared to the current visual standard
a. Scope
b. Examination conditions
c. Reporting
d. Repair

53. Which of the following are correct when comparing BS5289 with
current standard
a. BS 5289 list out the imperfections
b. Personnel requirements are not spelled out
c. Examination equipments are detailed
d. A & B above
e. B & C above

54. Which of the following best practice shall be done before

welding
a. Check welding procedures
b. Check condition of welding equipment
c. Check weld preparations
d. Check joint fit up
e. All of the above

55. The requirement of preheating shall be verified when

a. Before welding
b. During welding
c. After welding
d. Any of these stages above.

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 Answer Questions Referring to BS EN25817: 1992

56. What is the dimension of throat thickness when the leg length of fillet weld
is 15mm?

a. 15mm
b. 10.6mm
c. 7.5mm
d. 21.2mm

57. What is the max. length of imperfection(s) specified as short imperfection

allowed when the length of weld is 50mm only?

a. 25mm
b. 6.25mm
c. 12.5mm
d. 18.75mm

58. What is the max. dimension of an isolated porosity in a 20mm thick butt
weld when quality level B is applied?

a. 6mm
b. 4.2mm
c. 3mm
d. 5mm

59. What is the max. dimension of lack of penetration in a butt weld with 80mm
long and 10mm thick allowed when quality level C is applied?

a. 25mm in length and 1.5mm in height

b. 20mm in length and 1.6mm in height
c. 25mm in length and 2.0mm in height
d. 20mm in length and 1.0mm in height

60. What is the max. gap between two plates allowed for a T-fillet weld with leg
length 6mm when quality level B is applied?

a. 2mm
b. 0.5mm
c. 0.92mm
d. 1mm

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61. What is the max. depth of undercut allowed when quality level C is
applied?

a. 0.5mm with smooth transition

b. 1.0mm with smooth transition
c. 1.5mm with smooth transition
d. 2.0mm with smooth transition

62. What is the max. height of weld reinforcement on a 12mm thick butt weld
allowed
when the weld cap is 20mm in width and quality level C is applied?

a. 3mm
b. 4mm
c. 5mm
d. 7mm

63. What is the max. height of excessive convexity on a fillet weld when weld
width is 10mm and quality level C is applied?

a. 2.5mm
b. 3mm
c. 4mm
d. 5mm

64. What is the max. dimension of insufficient throat thickness allowed when a
10mm throat thickness fillet weld was welded and quality level C is
applied?

a. 0.4mm
b. 1mm
c. 1.3mm
d. 2mm

65.What is the max. height of excessive penetration on a butt weld when weld
width at root is 5mm and quality level C is applied?

a. 2.5mm
b. 3mm
c. 4mm
d. 5mm

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66. What is the max. height of linear misalignment on a butt weld in plate with
plate thickness is 20mm and quality level B is applied?

a. 2mm
b. 3mm
c. 4mm
d. 5mm

67. What is max. height of linear misalignment on a butt circumferential weld

with pipewall thickness is 20mm and quality level B is applied?

a. 2mm
b. 3mm
c. 4mm
d. 5mm

68. What is the max. depth of incompletely filled groove on a butt weld with
plate thickness is 10mm and weld width is 15mm when quality level C is
applied?

a. 0.5mm with smooth transition

b. 0.75mm with smooth transition
c. 1mm with smooth transition
d. 1.5mm with smooth transition

69. What is the max. dimension of unequal leg length allowed when an 10mm
throat thickness fillet weld was welded and quality level B is applied?

a. 1.5mm
b. 2mm
c. 3mm
d. 3.5mm

70. What is the max. depth of root concavity on a 10mm thick butt weld
allowed when quality level C is applied?

a. 0.5mm with smooth transition

b. 1mm with smooth transition
c. 1.5mm with smooth transition
d. 2mm with smooth transition

This Question Bank is for use within WG-HKISC & shall not be copied or reproduced or
circulated to any members of public other than welding group committee members in any form
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71. What is the max. total height of multiple imperfections in any cross-section
of a 20mm thick butt weld allowed when quality level C is applied?

a. 2mm
b. 3mm
c. 4mm
d. 10mm

72. What is the max. height of weld reinforcement on a 20mm thick Butt weld
allowed
when the weld cap is 30mm in width and quality level D is applied?

a. 7mm
b. 7.5mm
c. 8.5mm
d. 10mm

73. Generally, what thickness range is covered by this international standard?

a. 3mm and above

b. 3mm-63mm
c. Not thicker than 63mm
d. No restriction on thickness range.

74. What is the max. dimension of a copper inclusion in a 10mm thick butt
weld allowed when quality level C is applied?

a. Max. 25mm in length and 2mm in height

b. Max. 25mm in length and 3mm in height.
c. Not permitted.
d. Max. 25mm in length and 1.5mm in height.

75. What is the max. dimension of a wormhole in a 12mm thick butt weld
allowed when quality level C is applied?

a. Max. 25mm in length and 3mm in height / width.

b. Max. 25mm in length and 3.6mm in height / width.
c. Max. 25mm in length and 2mm in height / width.
d. Max. 25mm in length and 4.8mm in height / width.

(Prepared by Andy/ Eden/SKB)

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