WELDING IMPERFECTIONS

1, When visually inspecting the root bead of a slngle-vee-butt weld it should be checked for.
a. lack of penetration
b. HAZ hardness
c. tungsten inclusion
d. all of the above

2. When visually inspecting the face of a finished weld it should be assessed for
a. maximum excess weld metal height
b. toe blend
C.inter-run blend
d. all of the above

construction site is most likely

3. Heavy porosity on the surface of some MMA welds made on a

to be caused by..
a. use of the wrong class of electrodes
b. the use of excessive current
C. moisture pick-up in the electrode covering
d. a bad batch of electrodes

4. Slag inclusions may be present in..

a. MMA welds
b.MIGwelds
C. SA welds
d. both a &c

5. What is hollow bead?

a. concave root
b. elongated porosity in the root
C. lack of penetration
d. a slag line above the root

most susceptible to lack of sidewal

6. Which of the following butt weld preparations is generally
fusion during MMA welding?
a. a "U" preparations
b. a "V" preparations
C. a "double V" preparations
d. lack of sidewall fusion does not exist with MMA welding

7. Which of the following processes is most susceptible to lack of fusion

a. MMA
b. TIG
C. SAW
d. Co2 (metal active gas)

8. Which of the following butt-weld preparations is usually the most susceptible to lack of sidew
fusion during the maual metal arc process?
a. a double U butt
b. a single V butt
c. a double V butt
d. it is not normally a defect associated with the MMA welding process
9. What is meant by the tem crater
pipe
a. Another term for concave root
b. Another term given for a burm
through
C. A type of gas pore, found in the weld crater
d. A shrinkage defect, found in the weld crater

10. Which of the following welding processestechnique is likely to be used for the repair weldin
localized porosity in a butt weld?
a. MMA, PG position
b. mechanized MAG
c. submerged arc
d. all of the above
e. none of the above

11. Which of the following is

applicable for none planar defects?
a. they are always repaired
b. their existence will result in the removal of the entire weld
c. they are not usually as significant as planar defects
d. they can only be detected using
radiography
12. Inthe MMA welding process, which of the following is most likely to be caused bya welder
with a poor technique?
a. deep weld craters/crater cracks
b. copper inclusions
c. hydrogen cracks
d. all of the above

13. Root concavity is caused by:

a. excessive back purge pressure and entrapped gas
b. excessive back purge pressure and very high heat inputs
c. excessive root grinding and a slow travel speed
d. excessive root grinding and excessive back purge pressure

14. When inspecting a critical component, the toes of a weld must be:
a. always ground flush
b. must aways overlap at least 1.5mm into the parent metal
c. must aways be inspected using a crack detection metthod (MPI, DPI)
d. none ofthe above can be selected - specification requirements unknown

15. Which of the following is most likely to cause a bum through

a. root gap too small
b. travel speed too fast
c. root face too small
d. all the above

16. When carying out visual inspection, which defect is likely to be missed
a. linear misalignmet
b. cap undercut
C. porosity
d. lack of fusion (inter run)
 17. Cold lapping is another term for:
a. lack of fusion at the toe of the weld
b. lack of fusion between weld metal and weld metal
C.undercut at the toe of the weld
d. both a&&b

18. Incomplete root penetration is most likely due to:

a. welding speed too slow
b. welding current too high
C. root gap too small
d. electrode diameter too small

19. Crater cracks are caused mainly by:

a. Excessively fast welding speeds
b. Improper electrode angle
c. Hot shrinkage
d. Improper joint design
20. A fabrication procedure calls for the toes of all welds to be blended smooth by grinding
The most likely reason for doing this is t o .
a. make the weld suitable for liquid (dye) penetrant inspection
b. improve the fatigue life
C. reduce residual stress
d. improve the general appearance of the welds

21. For a full penetration single V butt joint, control of root bead penetration is mainly
influenced by the....
a. root face
b. bevel angle
C. root gap
d. included angle

22. Acceptance standards for undercut may be based on..

a. depth
b. length
C. sharpness/profile/blend
d. all of the above

23. When the root bead of a single-V-butt weld is visually inspected it should be checked for..
a. lack of root penetration
b. HAZ hardness
C. tungsten inclusions
d. all of the above

24. Incomplete root penetration may be caused by..

a. an excessive root face
b. an excessive root gap
c. the current setting being too slow
d. both a 8&c

25. Incomplete root fusion in a single V butt weld may be caused by..
a. linear misalignment
b. the root gap being too large
C. root faces being to0 small
d. all of the above
26. When visually inspecting the face of a finished weld it should be a[sessed for...
a. excess weld metal height
b. toe blend/ profile
c. inter-run blend/profile
d. all of the above

27. A burn-through may occur if.

a. the current is too slow
b. the root face is too large
c. the root gap is too large
d. all ofthe above

28. A solid inclusion in a weld may be..

a. entrapped slag
b. entrapped gas
c. lack of inter-run fusion
d. all of the above

29. Which of the following would be classed as a planar imperfection?

a. a lack of side wall fusion
b. a slag inclusion
c.linear porosity
d. root concavity

30. Heavy porosity on the surfaces of some MMA welds made on a construction site is most
likely to be caused by.
a. use of the wrong class of electrodes
b. the use of excessive current
c. moisture pick-up in the electrode covering
d. a bad batch of electrodes

31. Slag inclusion may be presentin..

a. MMA welds
b. MIG/MAG welds
c. SAW welds
d. both a &c

32. The main cause of undercut is..

a. excessive amps
b. excessive volts
C. excessive travel speed
d. all of the above

33. If a Welding Inspector detects a type of imperfection not allowed by the Application Standare
he must always.
a. request further NDT
b. rejectthe weld
C. prepare a concession request
d. only reject the weld if he considers it to be hamful

34. Which of the following is a non-planar imperfection?

a. A weld centerline crack
b. A HAZ crack
C. A Crater crack
d. Linearporosity
 likely appearance of lack of root fusion on a single-V-butt weld is:
44. On a radiograph, the most
a. a dark straight line with a light root
b. a dark root with straight edges
C. a dark uneven line following the edge of the root
d. none of the above lack of root fusion can not be seen on a radiograph

should be:
45. Defects outside the permissible limits of the applicable specification
a. the decision is up to the welding inspector
b. repaired
C. always double checked using NDT
d. all of the above
steel with the TIG
46. The main reason for using a back purge when welding 18-8 stainless
welding process is to:
a. improve positional welding
b. prevent the possibility of porosity
C. prevent excessive root penetration
root
d.prevent the formation of a dense oxide layerforming in the
process the presence
47. Whenwelding a double V butt weld with the submerged arc welding
ofcenter line porosity may be due tot
a. damp flux
b. contamination on the weld preparations
c. incorrect flux depth
d. all of the above
the shielding gas on carbo
48. When welding with the MIG welding process using pure argon as
steel, which of the following problems are likely to occur?
a. Copper inclusions and excessive cap heights
b. excessive root penetration and porosity
c. slaginclusions and crater pipe
d. lack of fusion and poor cap profiles
49. When considering the tungsten arc welding process what is the purpose of the down-slope
(slope out) control?
a. ensure good penetration
b. to prevent arc striking on the parent material
c. to help prevent the formation of crater pipe and possible cracking
d. to help prevent tungsten inclusions during welding

50. You observe centerline cracking a weld that as been made one of five work stations each

making similar components. The first action to take is:

a. impound all welding consumables
b. report the occurrence to high authority
c. stop all welding
d. call for full NDT checks

51. Which of the following defects is unlikely to be found by visual inspection

a. linear misalignment
b. undercut
C. Overlap
d. linear slag inclusion
 36. For TIG welding, what benefit does a current slope-out devlce have?
a. it reduces tungsten spatter
b. it reduces the risk of crater cracking
c. it reduces the risk of arc strlkes
d. it reduces the interpass temperature

36.When arc welding is being used, which parameter has the greatest effect on penetration?
a. arc voltage
b. welding speed
C.current
d. all of the above

37. Pipe bores of some materials must be purged with argon before & during TIG welding.
This is done order t
a. prevent root concavity
b. prevent burn-through
C. prevent oxidation ofthe root bead
d. prevent moisture pick-up in the root bead

38.
Excessive spatter during MMA welding is most likely to be caused by..
a. excessive current
b. incorrect baking and storage of electrode
C. a bad batch of electrode
d. all of the above

39. An arc strike (stray arc) on a steel component is usually an unacceptable imperfection
because.
a. it may cause contamination by copper
b. it may cause hard spots
c. it may give cracking
d. both b &c

40. Which of the following would be classed as the most serious type of defect?
a. a buried linear slag inclusion
b. buried lack of inter-run fusion
c. surface breaking lack ofsidewall fusion
d. surface porosity

41. Visual examination has revealed the presence of a longitudinal crack running down
the center of a submerged arc weld bead. This could be due to:
a. the use of damp flux
b. the specified pre-heat temperature has not been used
C. the arc voltage used was too high
d. the weld bead was very deep and narrow

42. To reduce the risk of crater cracks in TIG welds the welder could:
a. make the weld pool freeze more quickly by rapid withdrawal of the filler wire
b. make the weld pool freeze more quickly by rapid arc extinction
C. use a current slope-out device
d. use all of the above techniques

43. Which of the following defects would show up as light indications on a radiograph?
a. Slag inclusions and copper inclusion
b. Tungsten inclusions and excessive root penetration
c.cap undercut and root piping
d. excessive cap height and incomplete root penetration
 52. Which of the following defects is more common to weld deposited by the GO2 welding proce
than weld deposited by MMA
a. slag inclusion
b. excess penetration
C. lack of side fusion
d. tungsten inclusion

53. Which defect would you expect to obtain in TIG welds in non-deoxidized steel?
a. undercut
b. porosity
C. tungsten inclusion
d. linear misalignment

54. Which of the following can arise from copper inclusions is a ferrite steel weld?
a. weld metal cracks
b. HAZ cracks
c. lamellar tearing
d. porosity
65. Which of the following defects do you not expect to find by visual examination of completed
welds?
a. linear slag inclusion
b.undercuts
C. overlap
d. linear misalignment

56. When open site working, serious porosity in MMA welding is brought to your attention.
What would you investigate?
a. electrode type
b. power plant type
c. electrode storage
d. day temperature

57. When the TIG welding austenitic stainless steel pipe. Argon gas backing is called for.
This is to:
a. prevent oxidation
b. prevent under bead cracking
C. prevent porosity
d. control the penetration bead shape

58. In the welding of austenitic pipe work, the borer is usually purged with argon to?
a. prevent formation of porosity in the weld
b. prevent burn-through in the root run
c. prevent oxidation of the root bead
d. eliminate the formation of H2

59. Incomplete penetration in a butt joint could be caused by:

a. Excessive root face width
b. Excessive root gap size
c. Low current setting
d. Both a &c

60. Incomplete root fusion weld certainly be caused by:

a. linear misalignment
b. incorrect tilt angle
 c. differing root face widths
d. all of the above

61. When visuallya completed single V butt weld cap you would certainly assess:
a. cap height
b. toe blend
C. weld width
d. a, b & c

62. You notice a very "veed" ripple shape. This is most likely caused by:
a. poor comsumable choice
b. welding position
C. excessive travel speed
d. all of the above

63. Toe blending is important as it mey affect:

a. corrosion
b. fatigue life
C. overlap type defects
d. all of the above

64. Slag inclusion would occur with:

a. MMA
b.IMIG
c. SAW
d. both a &6

65. Undercut principally caused

by:
a. excessive amperesS
b. excessive volts
C. excessive travel
speed
d. all of the above

66. Undercut normally assessed by:

a. its depth
b. its length
c. its blending
d. all of the above

67. The planar defect is:

a. incomplete fusion defects
b. slag inclusion
C. incomplete penetration
d. both a &c

68. Defects outside of the limits specified in the standard should always be:
a. repairedd
b. reported to a senior person
C. assessed along with other defects
d. all of the above

C. :' s ' o * ., o !ck of ucdoa pc'.lc:s. This is because of:

a. poor maintenance of equipment
b. incorrect setting
c. poor inter-run cleaning
d. all of theabove
 70. The main
causes of porosity in welded joints are:
a. poor access
b. loss of gas shield
C. dirty materials
d. all of the above

71. Weave technique may give rise to:

a. better profiles
b. improved toe blending
C. improved ripple shape
d. all ofthe above

72. With reference to a root penetration bead, you could certainly assess:
a. root fusion & penetration
b. root concavity
c. burn through
d. all of the above

73. Stray arcing may be regarded as a serious defect. This is because:

a. It may reduce the thickness dimension of a component
b. It may cause liquation cracks
C. It may cause hard zones
d. all ofthe above

74. Overlap in welds could be influence by:

a. poor welding technique
b. welding process
C. welding position
d. all ofthe above.

75. Flame cut preparations may, during welding, increase the likelihood of:
a. Cracking
b. Misalignment problems
C. Inclusions
d. All ofthe above

76. Which of the following may be classes as a more serious defect:

a. slag inclusion
b. fusion defects (interun)
c. fusion defects (surface)

77. Porosity is caused by:

a. Entrapped slag in the solidifying weld
b. Entrapped gas in the solidifying weld
C. Entrapped mettalic inclusions in the solidifying weld
d. none of the above

78. The most serious defects

a. planar
b. cracks
c. lack of fusion
d. All of the above

79. What is crater pipe?

a. an oval tube
 b. another torm for burm through
.atype of porosity
d. a shrinkage defect

80. Herringbone porosity t

.particular patten of poroeity
b.made up of wormholes
6. made up
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