mw | AMER Lt 243 CI. ‘THE WELDING INSTITUTE Welding Inspection, Steels — WIS 5 Assessment Question Paper (MSR-AWI-1 05) Name: Answer all que: What is the Arc energy for the following welding process parameters? Amps 140, Volts 21, Travel speed 250mm/min. b. 0.6 KJ/mm, c. 0.01 KJ/mm d. 0.7 Jimm In an all weld metal tensile test, the original test specimens gauge length of 50mm After testing the gauge length increased to 72mm, what is the elongation percentage. DuACENCE 22 So 225 Bom = -44% b. 144%. c. 69.4% d. 2.27% e. The elongation is not normally tested in this tensile test. What is the ratio between the leg length and the design throat thickness on a mitre fillet weld with equal leg lengths a, 1to1 b. 2to1 d. All of the above it depends upon the leg length size. The toughness and yield strength of steel is reduced by: a. Reducing the grain size c. Reducing the heat input. (lof, hardness increase,narrow haz) d. Both a and b. WIS 5 Qu paper MSR-AWI-+4 Rev 5 Date: 11-11-10 Page 1 of 7TWI CME. ‘THE WELDING INSTITUTE 5. Which of the following statements is true if applicable to a charpy vee notch impact test b. d. It's a static test used to determine materials toughness in the notch region. 6. How can you tell the difference between an EN/ISO weld symbol and a BS weld symbol? a. The EN/ISO weld symbol will always have the arrow side weld at the top of the reference line. ° The » EN/ISO symbol has a fillet weld leg length identified by the letter “a”. The EN/ISO symbol has a fillet weld throat thickness identified by the letter ‘2’. Both b and d. 2 e. 7. Whatis the possible effect of having the heat input too low during welding? a. Low toughness, entrapped hydrogen and low hardness. ° Entrapped hydrogen, low toughness and high ductility |. Lack of fusion, low toughness and a reduction in ductility 2 8. An MMA electrode classified as E7018 is: b. A rutile electrode containing iron powder. c. Acellulose electrode suitable for welding in all positions. WIS 5 Qu paper MSR-AWI-+1 Rev § Date: 11-11-10 Page 20f 710. 1 12. TWI LLM. The number 135 is placed at the end of the reference line on a weld symbol According to ISO 2553 what does this number indicate? THE WELDING INSTITUTE a. The welding process is stated as MMA (il MA b, The welding process is stated as TIG (21 SAW c. The welding process is stated as SAW Vi MiG d. NDT is to be carried out after welding (35 MAG Which of the following is the most likely to be considered an essential variable for a welder qualification test? a. Acchange from an electrode classified to BS EN 499 as an E46 3 INI B to an electrode classified to AWS A5.1 as an E7018. A change of pipe wall thickn ast 18 c. Acchange in pre-heat temperature from 50°C to 100°C. d. Achange from PC welding position to PA welding position. e. All of the above What would be a typical appearance of a ductile fracture surface? Rough randomly torn and ‘Smooth fracture surface displaying beach marks -fatigue Step like appearance. —lamellar tearing Bright crystalline fracture with very litle reduction in area. - brittle Both a and b. e@aog In EN 499, what does the number 50 represent in the following electrode classification? E 503 1Ni B 160015. a. A minimum of 50 Nimm2 yield strength b. Aminimum of 500 Nimm2 tensile strength. c. Aminimum of 50000 psi yield strength d. Aminimum of 50000 psi tensile strength WIS 5 Qu paper MSR-AWI-1 Rev 5 Date: 11-11-10 Page 3 of 713. 14. 15. 16. 17, TwI CMT. Which of the following under typical conditions using the MMA welding process would give the deepest penetration. THE WELDING INSTITUTE a. DC -ve ce. AC d. Both a and b €. Allof the above would give the same depth of penetration. Which of the following is applicable for the HAZ on a C/Mn steel weld if the heat input increases: a. Both hardness and width is increased. c. Both hardness and width decreases. d. Hardness increases, width decreases. ‘What is the main reason for the application of pre-heat a. To change the chemical composition of the weld and parent material. c. To remove residual stresses. — stress relieving d. Both a and b. e. Allof the above Which of the following is most likely to increase the chance of solidification cracking? a. Reduction in sulphur content of the parent material Increase in weld hydrogen content from 15 ml/100 g to 25 m/l100 g. - HICC Poor through thickness ductility in the materials being welded. — Lamellar tearing e. Botha and b. What is the effect of full annealing compared to normalizing? a. Areduction in grain size. - quenching An increase in grair annea c. Anincrease in toughness - QT d. The grain size will not be affected None of the above WIS 5 Qu paper MSR-AWI-1 Rev 5 Date: 11-11-10 Page 4 of 718, 19. 20. 24 TWI CMT. Which of the following elements may cause cold shortness Sulphur. ~ hot short THE WELDING INSTITUTE zo c. Manganese.- element for toughness at low temp. Silicon - deoxidiser a. When considering the advantages of site radiography over conventional ultrasonic inspection which of the following applies? b. A permanent record produced, good for the detection of all surface and sub- surface defects and assessing the through thickness depths of defects. id d. No controlled areas required on site, a permanent record produced and good for assessing pipe wall thickness reductions due to intemal corrosion e. All of the above Lamellar tearing is a. A product defect caused during the manufacturing of certain steels atérial due to weld ion of c. A type of hot crack associated with impurities (sulphur, carbon and phosphorous). d. A type of crack that occurs in the weld or parent material due to cyclic stresses. WIS 5 Qu paper MSR-AWI-1 Rev 5 Date: 11-11-10 Page Sof 722. 23. 24. 25. TWI ZH. Which of the following statement maybe considered correct when dealing with agglomerated fluxes? THE WELDING INSTITUTE They're less hygroscopic than other types - fused Flaky appearance -fused MANA Less dust tendency - fused B. wer 1 and 3 are correct C. Answer 4 and 5 are correct D. Statements 1, 2,4 and 5 are correct Which of the following is applicable to the heat treatment process of normalising carbon-manganese steel a. It is always carried out below the lower critical limit. - SR, Tempering, PHR b. Itis carried out to ensure the material has maximum tensile strength. - Quenching c. It is carried out to ensure the material is of maximum ductility and malleabilty in preparation for extensive cold working operations. - annealing In the AWS standard for welding symbols which of the following is true. a. The elementary welding symbol is always place below the reference line to indicate a site weld. b. The elementary welding symbol is always placed above the reference line to indicate a weld made on the arrow side, c. The elementary welding symbol can be placed above or below the reference line to indicate a weld made on the otherside d. The elementary welding symbol is placed on the broken reference line above or below the solid reference line to indicate a weld made on the otherside Austenitic stainless steel can be identified by a. Very shiny appearance. b. Lack of magnetic att c. Its extreme hardness. d. None of the above WIS 5 Qu paper MSR-AWI-1 Rev 5 Date: 11-11-10 Page 6 of 726. 27. 28. 29. 30. TWI CLM. One reason why Ultrasonic testing is preferable to radiographic testing is: THE WELDING INSTITUTE a. Its ability to detect all defects. b. Lower amount of operator skill required, c d. Its ability to detect both sub-surface and surface defects in Austenitic stainless. steel Which of the following flame types would you expect to be used for the cutting of mild steel? a. Carburising flame. JO MUCH GAS b. Oxidising flame. TO much OFF c. Reducing flame. ObfiouwS Neutral flame The heat affected zone of a carbon steel fusion weld a. Usually has the highest tensile strength and highest toughness values c. Is usually gamma iron phase and cannot be avoided - austenite d. Botha and c. e. Allof the above Awelding process where the but under constant supervision using a shielding gas mixture o carbon dioxide is termed a. Amanual MAG process. b. A semi-automatic MAG process. c. Amechanised MIG process. The main reason for toe blending on certain welded components is: a. Corrosion considerations. b c. Appearance. d. Allofthe above WIS 5 Qu paper MSR-AWI-1 Rev 5 Date: 11-11-10 Page 7 of 7TWI CLM THE WELDING INSTITUTE Welding Inspection, Steels - WIS 5 Multi — Choice Question Paper (MSR-WI-1) Name: Answer all questions 1. Which of the following butt-weld preparations is usually the most susceptible to lack of sidewall fusion during the manual metal arc process? a b. — Asingle-V butt. c. Adouble-V butt. d. It is not normally a defect associated with the MMA welding process. 2. Whatis the leg length of a fillet weld? a. The distance from the toe to face. b. The distance from the root to face centre. C The distance from the root to the to d. Its 0.7 of the design throat thickness. e Both c and d 3. Whats the throat thickness of a fillet weld (equal leg lengths)? a. The distance from the toe to the face The d e from the > al c. The distance from the root to the toe. d. The distance from toe to toe. 4, Compound welds a. Always contain butt and fillet welds b. Joints, which have combinations of welds made by different welding processes. c. x d. _ Allof the above. 5. Aduty not normally undertaken by a welding inspector is to: a. Check the condition of the parent material, b. Check the condition of the consumables oc OM e residual stress, d. Check calibration certificates. WIS 5 Qu paper MSR-WI-1 Rev 5 Date: 11-11-10 Page 1 of7es THE WELDING INSTITUTE 6. Under most conditions, which of the following welding positions will deposit the most weld metal. Pa Fuser De HorRiZosTAL QE QVECHEAD 0G \eracae Dov) 7. What meant by the term crater pipe: a. Another term for concave root b. Another term given for a burn through. c.__Atype of gas pore, found in the weld crater. A shrink 8. What is meant by the term weld junction? a. The area containing the HAZ and the weld metal b. The weld metal and parent metal. The boundary en the fusion zone d. The part of the weld, which has undergone metallurgical changes due to the heat from welding 9. The strength of a fillet weld is primary controlled by: a. Leg length. b. c. Actual throat thickness. d. All of the above. 10. 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 d, They can only be detected using radiography 11. Which of the following welding processes/technique is likely to be used for the repair welding of localised porosity in a butt weld? a MMA, PG position. b. Mechanised MAG c. Submerged are. WIS 5 Qu paper MSR-WI-1 Rev 5 Date: 11-11-10 Page 2 of 7TWI LIM. 12. When measuring the welding parameters with the MMA welding process for the purpose of approving a welding procedure, the Welding Inspector should measure the voltage: THE WELDING INSTITUTE b. Anywhere along the welding cable. c. Always from the voltmeter on the welding plant. d. As near to the welding terminals as possible. 43. _ In the MMA welding process, which of the following is most likely to be caused by a welder with a poor technique? a j b. Copper inclusions c. Hydrogen cracks d. — Allof the above. 14. Root concavity is caused by’ a. Excessive back purge pressure and entrapped gas. b. Excessive back purge pressure and loss of shielding gas. c. Excessive root grinding and a slow travel speed 15. When inspecting a critical component, the toes of a weld must be: a. Always ground flush. b. Must always overlap at least 1.5 mm onto the parent material. c. Must always be inspected using a crack detection method (MPI, DPI) 16. _ When carrying out visual inspection, the specification makes no mention of the requirements for visual inspection, in this situation what should you do? a. Carry out normal visual inspection: b advice from higher aut c. Carry out no visual inspection. d. Rewrite the requirements of the specification 17, Under most circumstances, which of the following do you consider to be duties of a welding inspector? a. The supervision of welders. b. Procedure writing. d. — Allof the above. WIS 5 Qu paper MSR-WI-1 Rev 5 Date: 11-11-10 Page 3 of 7TWI CLM. 18. Which of the following is most likely to cause a burn through a. Root gap too small. b. Travel speed too fast. THE WELDING INSTITUTE d. — Allof the above. 19. In an arc welding process, which of the following is the correct term used for the amount of weld metal deposited per minute? a. Filling rate c. Weld deposition, d. Weld duty cycle. 20. —Whatis the term given for the area of a welded joint just outside the weld metal that has undergone microstructural changes? The weld zone. vo ©. Fusion zone. d. All of the above terms may be used. 21. When carrying out visual inspection, which defect (s) is likely to be missed? a. Linear misalignment b. Cap undercut. c. Porosity. Lack of fusion (ir 22. Cold lapping is another term for: a 1 b. Lack of fusion between weld metal and weld metal. ¢. Undercut at the toe of a weld. d. Botha and b. 23. _ Incomplete root penetration is most likely due to: a. Welding speed too slow. b. Welding current too high d. Electrode diameter too small. WIS 5 Qu paper MSR-Wi-i Rev 5 Date: 11-11-10 Page 4 of 7TWI VT 24. — Crater cracks are caused mainly by: THE WELDING INSTITUTE a. Excessively fast welding speeds b. __ Improper electrode angle d. Improper joint design. 25. Ona single-V butt weld, the distance through the centre of the weld from root to face is. called a. Reinforcement. b. Penetration. c. d. None of the above 26. The throat thickness of a % inch fillet weld is? a. 27.5mm b. (24mm. esis = [Tm KX OF = (3-3 mm d. 12.5 mm. 27. The need for pre-heat for steel will increase if: a. The material thickness reduces b a 3) fast speed fast cooling c. The use of a larger welding electrode d. — Allof the above. 28. Which of the following butt weld preparations is most likely to be considered for the welding of a 6mm thick plate? a. Double-V butt b. Asymmetrical double-V butt. c. _ Single-U butt. 29. Awelding inspectors main attributes include: a. Knowledge. b. Honesty and integrity. WIS 5 Qu paper MSR-Wi-1 Rev 5 Date: 11-11-10 Page 5 of 7TWI ¢ ZHI 30. A code of practice for visual inspection should cover: THE WELDING INSTITUTE Before welding activities only. c. After welding activities only. d. None of the above. 31. When manual metal are welding is being carried out on an open construction site, which group of welders are the most likely to require continuous monitoring? a. Pipe welders b. ‘Structural welders c. Welder fitters e. All of the above 32. When open site working, serious porosity in metal arc welds is brought to your attention. What would you investigate? a. Electrode type este c. Day temperature d. Power plant type All of the above. 33. What is the maximum allowable HI/LO for 8mm material if the code states the following. ‘Linear misalignment is permissible if the maximum dimension does not exceed 10% of t up toa maximum of 2mm” 0. 2mm 8mm d None of the above, insufficient information provided m 34. When conducting a visual inspection on a butt weld you notice an excessive “Veed” cap ripple on the cap. This may indicate which of the following a. Incorrect electrode c. Incorrect pre-heat applied d. All of the above. WIS 5 Qu paper MSR-WI-1 Rev § Date: 11-11-10 Page 6 of 7TWI LMF. 35. 36. 37, 38. 39. 40 THE WELDING INSTITUTE Toe blending is generally carried out: b. To improve the toughness of the welded joint c. To increase the Ultimate Tensile Strength of the welded joint 4. Alllof the above. When visually inspecting a fillet welded Tee piece, which of the following is normally measured to determine the fillet welds size. a. Leg length b. Throat thickness c. Design throat thickness d What is the maximum lack of root fusion permitted a. 30mm in any continuous length c. Lack of root fusion is permitted regardless of length d. None of the above. Defects outside the permissible levels of the applicable specification/standard requirements should always be: b. The action taken depends on the welding inspector. accepted Radiography and Ultrasonic carried out again regardless of the initial inspection methods carried out. Are strikes associated with a welded joint may be considered a serious defect. Because a. The presence of arc strikes may lead to hardening of the parent material b. The presence of arc strikes may lead to cracking c. The are strike may cause a reduction in parent material thickness. d. Bothaandb él Alllof th Which of the following defects would usually be considered the most serious. a. _ Lack of interun fusion. b. Slag inclusions. » Porsor WIS 5 Qu paper MSR-WI-1 Revs Date: 11-11-10 Page 7 of 7TWI CLM. Ture 2 THE WELDING INSTITUTE Welding Inspection, Steels — WIS 5 Multi - Choice Question Paper (MSR-WI-3) Name: . Answer all questions The likelihood of a brittle fracture in steels will increase with: a. The formation of a fine grain structure. c. — Aslow cooling rate. d. —_Allof the above Hydrogen cracking in HAZ is most likely to occur when welding: b Austenitic stainless steel. c. Micro alloyed steel (HSLA). d. Lowcarbon steel. Which of the following are considerations for the selection of a preheat temperature: a. Carbon equivalent, joint design, welding process type and plate material quality. b. All Joints over 25 mm thick, hydrogen levels, welding process, carbon equivalent. All of the above are considerations for the selection of a preheat temperature. Which of the following destructive tests would indicate the toughness value of the weld metal/parent metal and HAZ? a. Macro. b. Nick break. c. Tensile, ‘What constituent is needed in a coating of an electrode to prevent the formation of porosity when welding rimming stee!? a. Iron powder. b. Potassium silicate. ° (silicon is deoxidizer) d. Calcium carbonate. WIS 5 Qu paper MSR-WI-3 Rev 5 Date: 11-11-10 Page 1of8TWI LMT 6. © 10. THE WELDING INSTITUTE Welds made with high heat inputs show a reduction in one of the following properties? a. Ductility. c. Elongation. d. Penetration. Which of the following steel types would give rise to the formation of porosity when autogenously welded with an arc welding process a. Fully killed steel. b. Semi killed steel. d. Balanced steel. Which of the following elements, which may be added to steel, has the greatest effect on creep strength a. Tungsten HiGU Tem) Sttesaru STLENGTH TOUGHBESS Carbon sresarH HIGH CleEP STRENGTH The HAZ associated with a fusion weld: c. Is usually martensitic. a All of the above. What four criteria are necessary to produce hydrogen induced cold cracking? a 1, moisture, martensitic grain structure and heat. b. oe poor weld profiles, iscyeratii above 200°C and a slow cooling rate. (ati) d. —_ HYBFOGEN, existing weld defects, stféSS and a gfaif/strUcture susceptible to cracking. WIS 5 Qu paper MSR-WI-3 Rev 5 Date: 11-11-10 Page 2 of 8TWI CLM. 44, A carbon equivalent (CE) of 0.5%: 3. Ss high fe THE WELDING INSTITUTE carbon’ b. Is generally significant for carbon for manganese steels and is certainly not to be taken into consideration for preheat temperatures. c. _ Is high for carbon manganese steels and may require a preheat temperature over 300°C as to avoid cracking d. Is calculated from the heat input formula. 12. Ina martensitic grain structure what would you expect to increase? a. Ductility. c. Toughness. d. All of the above. 13. _ In which of the following mechanical tests would you expect to use a comparison from ductile to brittle transition curve. a Tensile test. c test. c. Fusion zone test. d. All of the above 14. Which of the following heat treatments on steel cools down in air from the austenite region? b. Annealing c. Tempering. d. Stress relieving 15. Whatis the purpose of microscopic examination of a weld? a. To determine the number and type of defects present. b. To determine the grain size. c. To determine the strength of the weld. e. All of the above. \WiS 5 Qu paper MSR-WI-3 Rev 5 Date: 11-11-10 Page 3 of &TWI LM. 16. Which of the following units is a tensile specimen usually measured in? THE WELDING INSTITUTE b. Newton per square inches c. Joules. d. Bothaandb. 17. Assuming that the welding process, material thickness, carbon equivalent and the welding parameters to be the same, which of the following joint types would normally require the highest preheat temperature a. Edge joint b. Lap joint. c. Butt joint (single-V) TS joi {d6d). (heat dissipation in 3 way) 18. Austenitic stainless steels are more susceptible to distortion when compared to ferritic steels this is because: , high thermal conductivity Low coefficient, high thermal conductivity, 19 \n In ein A reduction in material thickness c. An increase in electrode diameter. d. None of the above. 20. Which of the following properties may be applicable to a carbon steel weld (CE 0.48) welded without preheat? a rroW heat ated ZONE and HaFAHESS value in excess of 400 HV. WIS 5 Qu paper MSR-WI-3 Rev 5 Date: 11-11-10 Page 4 of 8TWI LMF. 26. 27. 28. 29. 30. THE WELDING INSTITUTE A multipass MMA butt weld made on carbon steel consists of 5 passes deposited using a 6mm diameter electrode. A 12-pass weld made on the same joint deposited using a 4mm diameter electrode on the same material will have: b. A lower heat input and a coarse grain structure. c. A lower amount of distortion and a higher degree of grain refinement. d. — Ahigher amount of distortion and a lower degree of grain refinement. What is the purpose of a transverse tensile test? a. To measure ultimate tensile strength: b. To measure the elongation of a material c. Tomeasure the yield strength of a material a “Allofthe above, Which of the following mechanical tests can be used to give a quantitative measurement of weld zone ductility? b. Bend test c. Charpy V notch test. 4. Allof the above Which of the following are reasons for applying preheat? a. The removal of residual stress. b. — Toaid slow cooling and reduce the carbon content. d. Increase the ultimate tensile strength values and increase overall weldability Which of the following are true with regards to a charpy test a. __ It's a static test used to determine a materials notch toughness in the weld region. s a dynamic sed tc mine a materials notch toughness in the c. It's a destructive test to give a measurement of through thickness ductility. d. None of the above. WIS 5 Qu paper MSR-WI-3 Rev 5 Date: 11-11-10 Page 6 of 8TWI CMI. 21. Which of the following materials is considered to be the easiest to weld? b. Medium carbon steels. c. Martensitic stainless steel d. Forging steel, THE WELDING INSTITUTE 22. _ Which of the following test pieces taken from a charpy test on a carbon-manganese steel weld, welded with a high heat input is most likely to have the lowest toughness a. Test piece taken from parent metal. b. Test piece taken from weld metal. Test piece taken from HAZ d. —_Allof the above values will be the same. 23. Which of the following butt weld preparations would normally be considered for a mechanised welding process a. Single-V butt, root gap 2.5 mm (welded from on side only). b. —_ Double-V butt-welded both sides, root gap 2.0 mm. Single-U butt with backing c it g d. None of the above can be used for mechanised welding. 24. — Which is the correct heat input for the following parameters, amps 350, volts 32 and the travel speed 310 mm/minute (MMA welding process)? a 246KIMIM =—-BBO X 32 X60 ~ BIO-c00 v IMC wh b. 0.036 kJ/mm. ©. 2160 ki/mm, 3.6 kim. 25. Assuming that the applicable specification makes no mention of arc strikes, what would you expect to do as a welding inspector if arc strikes were found on a component made of a high tensile strength material. a. Have the welder re-qualified. b. Ignore them. d. Cut out the entire weld where the arc strikes exist. WIS 5 Qu paper MSR-WI-3 Rev 5 Date: 11-11-10 Page S of 8TWI LM. 31. Which one of the following bend tests would be the best suited for the detection of lack of interun fusion on a 25mm thick carbon steel butt weld THE WELDING INSTITUTE Face bend b. ©. Root bend d. Longitudinal bend. 32. Which of the following persons needs access to the welding procedure (WPS) a. Welders b. Inspectors c. NDT tech’s d 33, _ Macro specimens should be inspected: a. After etching b. After cutting and before etching ©. Only through 10X magnification MACRo UNDER XH E nd ib. e. — Alllof the above 34. EN 287 standard refers to what: Welder approval Welding procedure approval c. Visual Inspection of fusion welds d. Welding Inspection Personnel. 35. _ EN 499 standard refers to which of the following. a. Welding Terms and symbols c. Filler wires d. SAW Flux 36. _ Which of the following documents provides instruction to the welder? a pWPS c. WPAR d. All of the above WIS 5 Qu paper MSR-WI-3 Rev § Date: 11-11-10 Page 7 of &TWI LMT. 37. 38. 39 40. THE WELDING INSTITUTE The main reason for qualifying a welding procedure is: a. Determine the welder's ability. b. Check whether the Acceptance criteria specific to the project can be met c. To show that the fabricator has good welding control. e. All of the above. If welding travel speed is doubled but amps and volts remain the same the heat input value will: b. Be increased by a factor of two c. Remain about the same. d. Be reduced by about 25% When two different materials are to be welded, the joint is often referred to as: a. Acomposite joint c. Acompound joint. 4. Alllof the above Which of the following best describes a MIG/MAG welding plant Transformer Flat characteristic Transformer / rectifier / inverter constant current) d. All of the above. WIS 5 Qu paper MSR-WI-3 Rev 5 Date: 11-11-10 Page 8 of 8Ryle S THE WELDING INSTITUTE Welding Inspection, Steels — WIS 5 TWI VT Multi — Choice Question Paper (MSR-WI-2) Name: .. Answer all questions In accordance with BS EN 970, what is the minimum light illumination required for visual inspection: @MNSSOLEX! (min illumination) b. 800 Lux. (normal room illumination) 600 Lux at not less than 30° d 10 Wim? wrong unit) 2. Flux cored wires may be advantages over solid wires because: a. “Higherdeposition, b. Lower hydrogen contents in the deposited welds, i8. (because of flux inside the wire) e. — Allof the above. 3. Movement of the are by magnetic forces in an arc welding process is termed a. Are deviation b. Are misalignment. c. Arc blow. d. Stray are. 4. Acrack type most associated with the submerged arc welding process is: Hydrogen cracking in the HAZ. 5, Solidification eracking c. Lamellar tearing d. Fatigue cracking. 5, Which of the following processes joins metals plastically. Resistance welding. Arc welding. Plasma welding b. ©. d. ‘WIS 5 Qu paper MSR-WI-2 Rev § Date: 11-11-10 Page Lof 8TWI LLM. THE WELDING INSTITUTE 6. What type of power source characteristic is required for a manual process? a. Constant voltage. b. Flat characteristic. d. None of the above. 7. Which of the following electrodes and current types may be used for the TIG welding of nickel and its alloys? b. Zirconium electrode, AC. c. Thorium electrode, DC +ve. d. __Allof the above may be used 8. Whatare the possible results of having a heat input to low? a. Anincrease in hardness, lower yield strength and lack of fusion. b. Areduction in toughness, hydrogen entrapment and an increase in hardness. en, an increase in hardness anc of fusion d. _ Entrapped hydrogen, a reduction in carbon content and lack of fusion. 9. The main reason for using a back purge when welding 18-8 stainless steel with the TIG welding process is to: a. _ Improve positional welding b. Prevent the possibility of porosity. c. Prevent excessive root penetration 10. The possible effects of having a travel speed too fast a. Low toughness, slag inclusions and cap undercut. c. High’hatdness, excessive deposition and cold!laps d. Low toughness, poor fusion and slag inclusions. 11. Ifare blow exists when welding with the MMA welding process, this can be best reduced or eliminated by: a. Achange from AC to DC current. A change from DC to AC cu \ tt. c. Achange from DC +ve to DC -ve. d. — Achange from DC -ve to DC +ve. WIS 5 Qu paper MSR-WI-2 Rev 5 Date: 11-11-10 Page 2 of 8TWI LMI. 12. 13, 14 15. 16. 17, THE WELDING INSTITUTE When welding a double-V butt weld with the submerged arc welding process the presence of centre line porosity may be due to: The inclusion of an inductance in the welding circuit when using MIG/MAG welding process is to’ b. __Itenables the welder to weld in position with the spray transfer mode. c. __ Itallows for thicker filler wires to be used (2.6-3.6mm diameter). d. It allows full control over droplet size in the spray transfer mode. An undesirable property of aluminium oxide residue, when welding is that it: a. Decreases weld pool fluidity c. Causes the welder to travel to quickly. d. The presence of the oxide makes aluminium impossible to weld. When welding with the MIG welding process using pure argon as the shielding gas on carbon steel, which of the following problems are likely to occur? a. Copper inclusions and excessive cap heights b. Excessive root penetration and porosity. c. Slag inclusions and crater pipe. 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 are striking on the parent material. help: ormation o} F pipe and pi d. To help prevent tungsten inclusions during welding. When considering thermal cutting local hardening can be reduced by: a. _ Increasing the cutting speed. b. The use of propane as a fuel gas d. — Allof the above. WIS 5 Qu paper MSR-WI-2 Rev 5 Date: 11-11-10 Page 3 of 8TWI MI. THE WELDING INSTITUTE 18. Ina semi-automatic welding process, which of the following shielding gas/gas mixtures would normally give the deepest penetration on steel? a. 100% argon. (3) a c. 75% argon + 25% COz (2) d. All of the above would give the same depth in penetration. 49. Ina MMA welding process, which of the following statements are fals6? c. Accurrent, which remains almost constant even if as usual the welder, varies the arc gap. (constant welding current, between 20-30V of voltage) e. All of the above. 20. When considering the MIG/MAG welding process which of the following metal transfer modes would be the best suited to the welding of thick plates over 25 mm, flat welding position, a. Dip transfer. b. Pulse transfer. (fastest, but only suit the PA position) d. Globular transfer. 21. Which of the following current types would you expect to be used for the welding of aluminium with the TIG welding process? a. DC -ve. b. DC +ve. 22. b. DC electrode positive is used for the MAG welding of steel plate. In the MAG welding process the wire feed speed remains constant during the welding operation d. — Allof the above WIS 5 Qu paper MSR-WI-2 Rev § Date: 11-11-10 Page 4 of 8TWI CLM. THE WELDING INSTITUTE 23. When considering hydrogen, which of the following welding process would produce the lowest levels in the completed weld (under controlled conditions) a. MMA. (2) b. SAW. (4) (1) d. FCAW. (3) 24. Pre heat prior to the welding of a carbon steel butt weld a. Must always be carried out b. Is always carried out using a gas flame c. Need not be carried out if post weld heat treatment is to follow 25. _ Insteel the element with the greatest effect on hardness is: a. Chromium, 4 b. Manganese. d. Nickel 26. For a given voltage and current settings on a MMA welding plant, when the arc length is shortened, which of the following will be most affected. a. The current will increase. The current will decrease. b c (low gap low voltage, high gap high voltage) d The voltage will increase. 27, Which of the following best describes a semi-automatic welding process? a. The welder is responsible for the maintaining the arc gap and travel speed. only! it) c. Both travel speed and arc gap is controlled by the welding plant d.—Allof the above. 28. What is purpose of a rectifier in a welding sets electrical circuit? a. To keep the arc stable when using low current settings c. To convert DC current to AC current. d. __Toinitiate the arc at start up. WIS 5 Qu paper MSR-WI-2 Rev 5 Date: 12-11-10 Page 5 of 8TWI LMT. 29. 30. 31. 32. 33. 34. THE WELDING INSTITUTE When calibrating a mechanised MAG welding plant, which of the following applies (WFS = Wire feed speed)? a. Check ~ WS, current, MEN and wire'iameter. b. Check — 4 — gas flow rate and WFS. c. and current. d. All of the above. The main usage of the arc air process is: a. The cutting of a weld preparation. b is c. For the cutting of non-ferrous materials only. d. For the cutting of ferrous materials only Which of the following fillet welded Tee Joints would have the highest resistance to fatigue fractures, assuming material, welding process, filler material to be the same. a. Aconvex fillet weld throat thickness 8mm b. — Amitre fillet weld throat thickness 8mm d. Both a and b (throat thicknesses dimension the same). You notice TIG welding being carried out using MMA electrode striped of flux being used as filler wires. You would certainly report this issue and file a non-conformance report. What would be the main reason why? a. Because of the additional cost incurred b. The wire would have been too thick. d. The welder would not be qualified. The main reason for grinding the capping passes flush is: To increase the chances of fatigue cracking To improve visual appearance d. To reduce the components weight. Duplex Stainless steel can be sometimes referred to as: a. Martensitic Stainless Steel c. 316L Stainless Steel d. — Allof the above. WIS 5 Qu paper MSR-WI-2 Rev 5 Date: 11-11-10 Page 6 of 8TWI CLM. THE WELDING INSTITUTE 35. Weld centre line longitudinal cracks in welded butt joints may have resulted from which of the following e, All of the above 36. Which of the following would be considered a typical heat input reading with the MIG/MAG welding process (normal welding heat input) b. 12KJ/mm (super high) ©. 1.2Jouls/mm (too low) dg. 6.5KJ/mm (heat input high) 37. During the visual inspection of a fillet weld with even leg lengths of 15mm, the throat thickness is measured at 8.5mm, what is the fillet welds profile. a. Convex b. Mitre 15a Seam & Concave - d. Botha andb VSem 38. Which of the following welding parameters are the most difficult to control during the welding operation using a manual arc welding process. a. Travel speed b. Voltage. c. Current di Are length 39. You are the only welding inspection on a cross country gas supply pipeline project. Which of the following welding/fabrication stages would you consider the most important stage for your closest scrutiny b. Post weld cleaning. ¢. Fillers and capping pass welding d. Radiography. WIS 5 Qu paper MSR-WI-2 Rev 5 Date: 11-11-10 Page 7 of 8TWI LLM. 40. Which of the following is the best way to identify hydrogen controlled electrodes for the MMA welding process. a. The colour of the flux covering b. The electrodes classification code on the box c. The electrodes classification code stamped on to the electrode d. The electrodes trade/manufacturers name. All of the above. ‘THE WELDING INSTITUTE WIS 5 Qu paper MSR-WI-2 Rev 5 Date: 11-11-10 Page 8 of 8