Cswip 3

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Introduction
Gas metal arc welding (GMAW) is a welding process that has been commercially available for around 60 years. The basic operation of the GMAW
process occurs when an electrical arc is established and maintained between a base material and a continuously feed wire electrode. The molten weld
pool is shielding from the atmospheric conditions by an envelope of shielding gas that is flowed continuously around both the wire filler metal feeding in
the weld pool and the weld pool itself.
The heat of the electrical arc serves to locally melt the base metal as well as melt the wire filler metal that is being fed into the weld. There are two
entities at play in the GMAW process:
1. Burn Rate: This refers to the rate, inches/minute (in/min) or meters/minute (m/min), at which the wire filler metal is melted or consumed by the
thermal energy of the welding arc. The primary variables that control the thermal energy of the arc are the welding current, welding voltage, and
shielding gas composition.
2. Feed Rate: This simply refers to the rate, again in in/min or m/min, that the wire filler metal is feed into the weld.
For a stable welding arc, the burn rate and feed rate need to equal each other. For instance, if the burn rate is higher than the feed rate, the wire filler
metal would melt back to the contact tip and cause issues. With the exception of short circuit metal transfer, if the feed rate is higher than the burn rate,
the wire filler metal would feed into the molten weld pool, again, causing issues.
There are four main variables of the GMAW process that affect both the penetration profile into the base material and weld bead profile above the base
material for a given weld:
1. Welding Current
2. Welding Voltage
3. Contact To Work Distance
4. Travel Speed
The information below observes thevery basic effects that the welding current and welding voltage variables have on the weld penetration profile in the
base material and the weld bead profile that lies above the base material. The base material used in for the following welds is cold rolled 1018 bar
stock and the shielding gas is 90% Argon – 10% CO2.
GMAW with Constant Voltage Power Supply
The GMAW process commonly uses a constant voltage power source (GMAW-CV) that allows for a relatively constant welding voltage output over a
range of welding currents. For GMAW-CV the welder selects the wire feed speed (WFS) on the wire feeder unit and an appropriate voltage on the
welding power supply. The internal circuitry of the power source then supplies an appropriate amount of welding current necessary to maintain a stable
arc. The GMAW process variables of current and wire feed speeds are interrelated so one cannot be independently adjusted without affecting the other
byjust altering the WFS selector setting on the power supply itself.
Welding Current
The variable of welding current primarily controls the amount of weld metal that is deposited during welding. As discussed earlier, the process variables
of WFS and current are directly related so as one increase so does the other and vice versa. Welds 1-5 demonstrate this relationship, Figure 1 & 2.
Holding all other variable constant, the WFS was incrementally increased from Weld 1 through Weld 5 which consequently increased the welding
current. Remember, the welder sets the WFS not the current level on a GMAW-CV power supply, so the primary way of adjusting current is by
adjusting the WFS. Table 1 show the welding data from these welds.
The welding current also affects the weld penetration profile. Holding all other variables constant, as the welding current increases the further the weld
will penetrate into the base material. This increase in weld penetration is seen in Welds 1-5, Figure 1. The driving force behind the fingerlike
penetration in Welds 3-5 is that the metal transfer mode in the welding arc was spray metal transfer mode. This metal transfer mode typically
transitions from globular to spray mode transfer above approximately 190 amps of welding current for certain metal and shielding gas combinations.
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Figure 1: Cross Sectional View of Welds 1-5. Red outline better displays the penetration profile.
Figure 2: Topside View of Welds 1-5
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Table 1: Welding Current Data
Welding Voltage
Welding voltage primarily controls the arc length which is the distance between the molten weld pool and the wire filler metal at the point of melting
within the arc. As the voltage is increased, the weld bead will flatten out more and have an increasing width-to-depth ratio. Welds 7-11 in Figure 4 show
this widening of the weld beads as the voltage is increased. Table 2 shows the weld data for these welds.
Note that the penetration remained relatively constant for Welds 7-9. Despite the change in voltage, the welding current did not change therefore weld
penetration did not appreciably change. Welds 10 & 11 both exhibited an increase in fingerlike penetration as well as in increase in welding current. As
the arc length increases proportional to an increase in voltage, the electrode extension, distance from the contact tip to the point where the welding
wire is melting in the arc, consequently decreases, Figure 3.
Figure 3: Electrode Extension and Arc Length Diagram

As the electrode extension decrease so also does the resistance to the welding current flowing through that portion of the wire. Using Ohm’s law and
holding the voltage constant, the welding current would consequently increase. The current was indeed increased and enough so to change the
transfer mode from globular to spray which is evidenced by the increase in fingerlike penetration. This phenomenon will be further explained in the
next blog that will look at the affect of the variables of contact to work distance (CTWD).
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Figure 4: Cross Sectional View of Weld 7-11. Red outline better displays the penetration profile.
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Table 2: Welding Voltage Data
Next time we will look at the variables of contact to work distance (CTWD) and travel speed and observe how they affect the weld bead profile and
base material penetration.
For any questions on the basic operating principles of GMAW, please contact Jason Rausch, Applications Engineer, via email at jrausch@ewi.org or
via phone at 614-688-5204.
Introduction
In the first blog of this series, a general description was given of the basic operation of the gas metal arc welding (GMAW) process. To get up to speed
please look at the following link to the this blog:
There are four main variables of the GMAW process that affect both the penetration profile into the base material and weld bead profile that lies above
the base material for a given weld:
1. Welding Current
2. Welding Voltage
3. Contact To Work Distance
4. Travel Speed
The first blog discussed the how variations in both welding current and welding voltage affect the penetration profile and bead profile of a weld. In this
blog installment, the variables of travel speed and contact to work distance (CTWD) will be discussed in the same fashion.
Travel Speed
In most cases, weld penetration into a base material is increased when the travel speed of a weld is increased, and vice versa. At slower travel
speeds, the arc is directly above the center of the molten weld pool. Consequently, the metal that is transferred from the melting filler metal to the weld
pool is deposited into the center of the weld pool. When the metal transfer happens in this centered fashion, the weld pool acts as a large cushion to
the incoming metal droplets and reduces the degree to which the droplets penetrate into the base material.
Conversely, at faster travel speeds, the arc is typically at the leading edge of the weld pool resulting in the metal transfer droplets directly impacting
some of the base material instead of just the weld pool. This more direct impacting into the base material results in deeper weld penetration as it limits
the cushioning effects of the weld pool.
The welds show in Figure 1 & 2 show the relationship between travel speed and weld penetration into the base material. The welds were made at
incrementally increased travel speeds yet at the relative same heat input. This was done in attempt to keep the weld deposit size of each weld bead
relatively the same. Weld 30 through Weld 34 had increased travel speeds and consequently increased penetration into the base metal. The weld
data for these welds is shown in Table 1.
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Slower travel speeds result in a solidification pattern that is circular or oval. Faster travel speeds result in a solidification patter that is circular on the
leading edge but v-shaped on the trailing edge of the weld pool. Note the variation in solidification pattern of each bead outlined in red on Figure 2.
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Table 1: Travel Speed Data
Contact To Work Distance

It was established in the first blog of this series that the GMAW process commonly uses a constant voltage power source (GMAW-CV) that allows for a
relatively constant welding voltage output over a range of welding currents. For GMAW-CV the welder selects the wire feed speed (WFS) on the wire
feeder unit and an appropriate voltage on the welding power supply. The internal circuitry of the power supply then supplies an appropriate amount of
welding current necessary to maintain a stable arc. The GMAW process variables of current and wire feed speeds are interrelated so one cannot be
independently adjusted without affecting the other by just altering the WFS selector setting on the power supply itself.
One common way to independently manipulate the welding current from the WFS is by adjusting the contact to work distance (CTWD). This
phenomenon understood by applying Ohm’s law, V=IR (V=voltage, I=current, and R=resistance), to the electric extension segment of the welding wire,
Figure 3.
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Figure 3: Electrode Extension, Arc Length, and Contact To Work Distance Diagram
Since we want to see the effect of CTWD variations on welding current, let’s rearrange the equation to I=V/R. Assuming the use of a constant voltage
power supply the V (volts) will remain a constant in this equation. The diagram on the left of Figure 4 suggests a baseline CTWD. If then, the CTWD is
increased the electrode extension will also increase since the constant voltage power supply will maintain a consistent arc length despite the change in
the CTWD. The increase in electrode extension length has an associated increase in resistance as the effective ‘conductor’ length has increased.
According to Ohm’s law, assuming a constant voltage, current and resistance are inversely proportional to each other so the increase in resistance will
result in a decrease in current.
Figure 4: CTWD Variation Diagram

This is exactly what was seen in Welds 13 – 18. As the CTWD was incrementally increased for each weld, the welding current decreased, all the while
maintaining the same WFS. The weld data from these trials is shown in Table 2.
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Table 2: Contact To Work Distance Data
For any questions on the basic operating principles of GMAW, please contact Jason Rausch via email at jrausch@ewi.org or via phone at 614-688-
5204.
CSWIP 3.1: Question with Answer and Explanation – Part 21
Date: April 7, 2018Author: Thanh ( QC ) Nguyen Le0 Comments

1) When ‘hydrogen control’ is specified for a manual metal arc welding project the electrode
would normally be:
a. Cellulose
b. Iron oxide
c. Acid
d. Basic ( answer )
MMA have 3 type of electrode covering:
+ cellulose ( hydrogen content is 80-90 ml/100 g of weld metal )
+ rutile ( hydrogen content is 25-30 ml/100 g of weld metal )
+ basic ( have the lowest level of hydrogen (less than 5 ml/100 g of weld metal). Need Careful
control of baking and/or issuing of electrodes is essential to maintain low hydrogen status and
avoid risk of cracking.
2) You would certainly recognise a hydrogen controlled flux covered electrode from its:
a. Colour
b. Length
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c. Trade name
d. BS639/AWS code letter ( answer)
+ Example AWS electrode flux types:
 Cellulosic: flux-ends in 0 – 1
Examples: E6010, E6011, E7010, E8011
 Rutile: flux-ends in 2 – 3 – 4
Examples: E5012, E6012, E6013, E6014
 Basic: flux-ends in 5 – 6 – 7 – 8
Examples: E6016, E7017, E8018, E9018
+ BS639:
3) When manual metal arc welding is being carried out on an open construction site, which
group of welders are most likely to require continuous monitoring?
a. Concrete shuttering welding teams
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b. Pipe welding teams ( answer )
c. Plate welders
d. Plant maintenance welders
Notes: Welders who are working in high pressure work environments like pressure vessels,
Boilers, Piping and Pipeline.
4) You notice manual metal arc electrodes, stripped of flux, are being used as filler wire for
TIG welding. You would object because:
a. It is too expensive
b. The wire would be too thick
c. The metal composition may be wrong ( answer )
d. The wire is too short
Note: Function of the Electrode Covering:
 – To facilitate arc ignition and give arc stability

 – To generate gas for shielding the arc & molten metal from air contamination
 – To de-oxidise the weld metal and flux impurities into the slag
 – To form a protective slag blanket over the solidifying and cooling weld metal
 – To provide alloying elements to give the required weld metal properties
 – To aid positional welding (slag design to have suitable freezing temperature to support
the molten weld metal)
 – To control hydrogen contents in the weld (basic type)
5) When open site working, serious porosity in metal arc welds is brought to your attention.
What would you investigate?
a. Electrode type
b. Power plant type
c. Electrode storage (answer)
d. Day temperature
Note: Causes porosity:
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 Excessive moisture in flux or preparation
 Contaminated preparation
 Low welding current
 Arc length too long
 Damaged electrode flux
 Removal of gas shield
6) The steel composition in a structural contract is changed from 0.15% carbon 0.6%
manganese, to 0.2% carbon 1.2% manganese. This might influence the incidence of:
a. Porosity
b. Cracking in the weld area ( answer )
c. Undercut for fillet welds
d. Lack of fusion defects
Notes:
The weldability of steel is mainly dependant on carbon & other alloying elements content.
With above changing: from 0.15%C & 0.6% Mn to 0.2%C & 1.2% Mn: it means change
from Carbon steel to Carbon Manganes steel
Carbon-Manganese Steels:
 Manganese up to ~ 1.6%
 Carbon steels with improved toughness due to additions of Manganese
Carbon (C): Major alloying element in steels, a strengthening element with major influence on
HAZ hardness. Decreases weldability. typically < ~ 0.25%
Manganese (Mn): Secondary only to carbon for strength, toughness and ductility,

secondary for de-oxidiser and also reacts with sulphur to form manganese sulphides. typically<
~0.8% is residual from steel de-oxidatio,up to ~1.6% (in C-Mn steels) improves strength &
toughness.
The weldability of the material will also be affected by the amount of alloying elements
present.
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Carbon equivalent (CE) Weldability
Up to 0.35 Excellent
0.36–0.40 Very good
0.41–0.45 Good
0.46–0.50 Fair
Over 0.50 Poor
7) One of the following alloys is non-magnetic – which?

a. 4.0% chromium molybdenum
b. 12.0% chromium
c. Austenitic stainless steel ( answer )
d. 9.0% nickel steel
In stainless steel group, only Austenitic stainless steel is non-magnetic.
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8) When TIG welding austenitic stainless steel pipe, argon gas backing is called for. This is to:
a. Prevent oxidation ( answer )
b. Prevent underbead cracking
c. Prevent porosity
d. Control the penetration bead shape
Notes: back purging is done to prevent the formation of oxides inside of the pipe, which are
caused by the presence of oxygen.
9) Pre-heating a carbon steel manual metal arc welding is carried out to minimise the risk of:
a. Scattered porosity
b. Worm hole porosity
c. Parent metal cracking ( answer )
d. Lack of penetration
Note: are used to increase weldability, by reducing sudden reduction of temperature, and

control expansion and contraction forces during welding.
Advantages of preheat:
 Slows down the cooling rate, which reduces the risk of hardening
 Allows absorbed hydrogen a better opportunity of diffusing out, thereby reducing the
risk of cracking
 Removes moisture from the material being welded
 Improves overall fusion characteristics
 Lowers stresses between the weld metal and parent material by ensuring a more
uniform expansion and contraction

10) In UK practice, BS499 specifies that the drawing dimension quoted for a fillet weld is the:
a. Leg length ( answer )
b. Throat thickness
c. Weld width
d. Actual throat thickness
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The UK has traditionally used BS 499 Part 2. This standard has now been superseded by BS EN
22553, however in many welding and fabrication organisations there will be old drawings used
that make reference to out of date standards such as BS 499 Pt 2.
https://www.twi-global.com/technical-knowledge/job-knowledge/a-review-of-the-application-
of-weld-symbols-on-drawings-part-1-064/
https://www.twi-global.com/technical-knowledge/job-knowledge/a-review-of-the-application-
of-weld-symbols-on-drawings-part-2-065/
11) For open site manual metal welding the following equipment is available. Which would
you choose for safe site working?
a. Single operator transformer
b. Multi operator transformers
c. AC/DC composite power unit
d. Diesel engine driven motor generator ( answer )
There are four basic types of power source:
 AC transformer
 DC rectifier
 AC/DC transformer-rectifier
 DC generator
AC electrodes are frequently operated with the simple, single phase transformer with current
adjusted by means of tappings or sliding core control.
DC rectifiers and AC/DC transformer-rectifiers are controlled electronically, for example by

thyristors. Modern power sources called inverters use transistors to convert mains AC (50Hz) to
a high frequency AC (typically 50 kHz) before transforming down to a voltage suitable for
welding and then rectifying to DC. Because high frequency transformers can be relatively
small, principal advantages of inverter power sources are undoubtedly their size and weight
when the source must be portable.
12) If submerged arc welding is used to make butt welds, which would you be most critical
of?
a. The root gap tolerance ( answer )
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b. The angle of preparation
c. The root face width
d. The gas cut finish
Root Gap is very importance for accessibility joint.
13) During CO2 welding, the arc length is most likely to be affected by:
a. The wire diameter
b. The current return connections ( answer )
c. The gas flow rate
d. The torch to work angle
The reaction of the magnetic field that surrounds the MIG wire tip and the current flow in the
plate to the current return cable can be sufficient to deflect the arc plasma and weld bead.
Reducing the arc current magnetic field deflection can be reduced by positioning the current
return cable so that welding is always towards or away from the ground clamp.
http://www.weldreality.com/arcblowarticle.htm
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14) Preheating for arc welding applies to:
a. Assembly welding only
b. Assembly and tack welding ( answer )
c. Joints over 25 mm thick only
d. Cruciform welds only
Preheat are used to increase weldability, by reducing sudden reduction of temperature, and
control expansion and contraction forces during welding.
15) Which one of the following statements is correct?

a. Preheating increases hardness
b. Preheating increases cooling
c. Preheating increases dilution ( answer )
d. Preheating increases shrinkage stress
The end!
Date: October 26, 2017Author: Thanh ( QC ) Nguyen Le1 Comment

1) Cast and Helix are terms that refer to:
a. Ingredients in the flux covering
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b. Bead deposition techniques for distortion control
c. ( answer ) Quality of the welding wires
d. Sources from which wires are drawn
2) A MMA electrode which is classified as an E7024 (according to AWS) is a:
a. Basic type
b. Cellulosic type
c. Rutile type
d. ( answer ) Thick coated iron powder

We use “Exclusion principle”
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3) An electrode is classified to BS EN ISO 2560 as E 35 3 B. What does 35 signify?
a. ( answer ) 350 N/mm2 yield strength
b. 35 Joules -30oC
c. 35 N/mm2 tensile strength
d. 35ksi tensile strength
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Pls take note:
 With BS EN ISO 2560: it is classified follow yield strength

 With AWS A5.1 & A5.5: it is classified follow TENSILE STRENGTH
4) A large diameter pipe with a wall thickness of 10mm is to be used for a cross-country
pipeline. Which electrode type could be used to combine high welding speed and deep
penetration?
a. Basic covered
b. ( answer ) Cellulosic covered
c. Rutile covered
d. Iron powder loaded
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Cellulosic Electrode compositions are only available for welding low carbon non-alloyed steels
although nickel additions may be made to improve notch toughness. Charpy-V values of around
27J at -20°C are possible in the unalloyed electrodes. The high hydrogen level means that any
steel welded with these electrodes should be selected to have a very high resistance to
hydrogen induced, cold cracking. They should not be used without giving due consideration to
the steel composition, restraint and the need for preheat. The characteristics of deep
penetration, high deposition rates and the ability to be used vertically down means that the
main use for these electrodes is for cross country pipelining although they are used to a more
limited extent for welding storage tanks.
Cellulosic electrodes contain a high proportion of cellulose in the coating and are characterised
by a deeply penetrating arc and a rapid burn-off rate giving high welding speeds. Weld deposit
can be coarse and with fluid slag, deslagging can be difficult. These electrodes are easy to use in
any position and are noted for their use in the ‘stovepipe’ welding technique.
5) Which of the following electrode types would produce the highest levels of hydrogen?
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a. Basic electrode when baked correctly
b. ( answer ) Cellulosic in a sealed tin
c. Rutile
d. Heavy rutile
 Cellulosic electrodes: hydrogen content is 80-90 ml/100 g of weld metal.

 Rutile electrodes: hydrogen content is 25-30 ml/100 g of weld metal.
 Basic covering: have the lowest level of hydrogen (less than 5 ml/100 g of weld metal).
6) Which of the following electrode types would produces the lowest levels of hydrogen?
Cellulose coated electrodes sealed in a tin

a.
immediately after manyfature
Basic coated electrodes when baked correctly

b. (answer )
immediately prior to use
Rutile coated electrodes when dried at 150oC prior

c.
to use
Heavy rutile coated electrodes when dried at 150oC

d.
for 2 hours prior to use

7) Basic electrodes are often sold vacuum packed. The reason is:
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They have been packed at the manufactures at a
a. (answer ) hydrogen level less than 5ml per 100g of weld metal
deposited
They are mass produced which makes these

b.
electrodes cheap
They require less baking time after removal from the

c.
packet
They are formulated that once open they will pick up

d.
no more moisture
8) A general terms which of the following would required the highest preheat if all other
factors were the same as per ISO BS EN 1011?
a. ( answer ) MMA weld with cellulosic electrodes
b. MMA weld with rutile electrodes
c. MMA weld with basic electrodes
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d. MAG weld with solid wire

Cellulosic electrodes have highest Hydrogen content and easy lead to Cold crack. So, it to be
required the highest preheat to avoid this cracking type.
Preheat: Preheat, which slows the cooling rate, allows some hydrogen to diffuse away, and
generally reduces the hardness, and therefore susceptibility to cracking, of hard, crack-sensitive
microstructural regions. The recommended levels of preheat for carbon and carbon manganese
steel are detailed in EN 1011-2: 2001 (which incorporates nomograms derived from those in BS
5135: 1984). The preheat level may be as high as 200°C for example, when welding thick section
steels with a high carbon equivalent (IIW CE) value.
Alloyed weld metal where preheat levels to avoid HAZ cracking may be insufficient to protect
the weld metal. Low hydrogen processes and consumables should be used. Schemes for
predicting the preheat requirements to avoid weld metal cracking generally require the weld
metal diffusible hydrogen level and the weld metal tensile strength as input.
9) When welding medium carbon steel plates over 90mm in thickness would the basic
electrode require any pre-treatment before use?
a. (answer ) None if they were in a vacuum pack
b. None if they were used in a factory
c. Heat to 500oC for 2 hours if used outside
d. Baked at 150oC for 4 hours prior to use
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10) When welding medium carbon steel plates over 100mm in thickness would basic
electrodes require any pre-treatment before use?
None if they were in a vacuum pack opened 8 hours

a.
prior to use
None if they were in a sealed vacuum pack prior to

b. ( answer )
use
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Pls see next part:

1) A drawing with symbols to BS EN 22553 will show a 5mm leg filler by which of the following:
a. a5
b. t5
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c. (answer ) z5
d. 5Z
a = Design throat thickness
s = Depth of Penetration, Throat thickness
z = Leg length(min material thickness)
a = (0.7 x z)
2) Which of the following joint designs is preferred in cyclic loading condition?
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a. View A
b. View B
c. View C
d. ( answer ) View D
We need to know:
 The effect of a change in section ( thickness / welding cap / welding toe ), where it can
be seen that the stress is locally raised at the weld toe. The illustration shows a bead-on-
plate run but a full penetration weld will show the same behaviour.
 In addition, misalignment and/or distortion of the joint will cause the applied stress to
be further increased, perhaps by introducing bending in the component, further reducing
the expected fatigue life. A poorly shaped weld cap with a sharp transition between the
weld and the parent metal will also have an adverse effect on fatigue performance.
 Fatigue cracks generally start at changes in section or notches where the stress is raised
locally and, as a general rule, the sharper the notch the shorter the fatigue life – one reason
why cracks are so damaging.
So, the welding cap to be removed when cyclic loading condition is an issue.
“a” lack off penetration issue
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“b” weld cap to be removes as above explanation
“c” at root pass maybe has some undercut –> stress concentrating.
“d”: righ answer.
3) The number 111 is shown at the tail-end of a weld symbol reference line. According to BS EN
ISO 22553, what does this number indicate?
a. ( answer ) Welding process
b. Type of welding electrode
c. Welding position
d. Total weld length
4) According to EN 22553, if the symbol is on the identification line, where does the weld go?
a. On both sides
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b. On the arrow side
c. ( answer ) Opposite arrow side
d. It does not matter
5) According to AWS 2.4, where does the symbol go for welding on the arrow side?
a. ( answer ) Below solid line
b. Above solid line
c. Depends on the joint
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d. Always weld where the arrow is pointing
6) Asymmetrical weld symbols to EN 22553 are:
a. The same both sides of the arrow
b. ( answer ) Different each side of the arrow
c. Show fillet welds only
d. Show butt welds only
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7) While making a symbol for a symmetrical fillet weld ______________________________
a. the size does not need not be mentioned
b. the length can be mentioned to the left of the symbol
c. the finish is assumed to be flat
d. ( answer ) the broken line can be omitted
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8) Which of the following is normally true?
a. Impact energy is specified in N/mm2
b. Heat input is specified in kJ/mm2
c. (answer) Yield strength is specified in N/mm2
d. Diffusible hydrogen is specified in ml
 The ultimate tensile strength in N/mm2, p.s.i or Mpa

 Impact Energy Joules: J
 Heat input: kJ/mm
 Diffusible Hydrogen ( ml/100g ): example – Cellulosic electrodes: hydrogen content is

80-90 ml/100 g of weld metal.
9) An effective weld metal volume reduction can be achieved …
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a. Changing from double V to single V
b. ( answer ) Changing from single V to single U
c. Changing from double U to single V
d. Changing from single J to single V
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10) The typical included angle used for MMA welding of a 15mm thick steel single “V” butt joint
is most likely to be:
a. 30o
b. 120o
c. ( answer ) 70o
d. 90o
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Pls see next part:
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1) Why is it essential to clean the excess weld metal on completion of the production weld?
a. So it can be ready for painting
b. To remove any rust
To ensure it is suitably clean for visual inspection

c. ( answer )
and NDT
d. To remove slag from the undercut
After production weld finished. The surface to be examined shall be free from all dirt, grease,
lint, oil, scale or slag. If it needs do NDT, the excess weld metal to be cleaned suitably for NDT.
2) During root welding, which of the following would be the main cause of excess
penetration?
a. The root gap is too small in accordance with WPS
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b. Preheat not used
c. ( answer ) The current is too high
d. Root face is too large
Arc energy (kJ/mm)= (Volts x Amps) / (welding speed(mm/s) x 1000). It means Amps high –>
HEAT INPUT high –> excess root penetration.
3) At what level is H2 considered to be more critical in cracking?
a. Less than 5ml per 100g of weld metal deposited
Between 5 and 10ml per 100g of weld metal

b.
deposited
Between 10 and 15ml per 100g of weld metal

c.
deposited
d. ( answer ) Over 15ml per 100g of weld metal deposited
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4) With regards to Lamellar tearing, a buttering layer will:
a. ( answer ) Improve ductility
b. Disperse heat
c. Improve toughness
d. Improve hardness
Lamellar tearing occurs when material have Susceptible Microstructure – Poor through

thickness ductility.
The surface of the fracture is fibrous and ‘woody’ with long parallel sections which are
indicative of low parent metal ductility in the through-thickness direction.
a) Buttering the surface of the susceptible plate with a low strength weld metal has been widely
employed. As shown for the example of a T butt weld (Fig. 5) the surface of the plate may be
grooved so that the buttered layer will extend 15 to 25mm beyond each weld toe and be about
5 to 10mm thick.
b) In-situ buttering ie where the low strength weld metal is deposited first on the susceptible
plate before filling the joint, has also been successfully applied. However, before adopting
either buttering technique, design calculations should be carried out to ensure that the overall
weld strength will be acceptable.
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Note: Steel suppliers can provide plate which has been through-thickness tested with a
guaranteed STRA value of over 20%.
5) Lamellar tearing can be detected by which of the following NDE methods?
a. Radiography
b. ( answer ) Ultrasonics
c. Eddy current
d. MPI using AC
If surface-breaking, lamellar tears can be readily detected using visual examination, liquid

penetrant or magnetic particle testing techniques. Internal cracks require ultrasonic
examination techniques but there may be problems in distinguishing / identify lamellar tears
from / with inclusion bands. The orientation of the tears normally makes them almost
impossible to detect by radiography.
6) A fatigue fracture can be identified (from examination of the fracture …):
a. ( answer ) The presence of beach marks
b. The presence of plastic deformation
c. Being rough and torn
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d. Being flat and rough
The surface is smooth and shows concentric rings, known as beach marks, that radiate from the
origin; these beach marks becoming coarser as the crack propagation rate increases. Viewing
the surface on a scanning electron microscope at high magnification shows each cycle of stress
causes a single ripple. The component finally fails by a ductile or brittle overload.
7) A steel designated as “Z” quality will have:
a. ( answer ) Through thickness ductility > 20%
b. Through thickness ductility < 20%
c. Been specially heat treated
d. Zirconium added to improve weldability
Note: Steel suppliers can provide plate which has been through-thickness tested with a
guaranteed STRA value of over 20%.
Two main options are available to control the problem in welded joint liable to lamellar tearing:
-Use clean steel with guarantee through-thickness properties (Z grade)
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-A combination of joint design, restraint control and welding sequence to minimize the risk of
cracking
8) Which of the following types of destructive test is sometimes used for welder qualification
testing:
a. Hardness test
b. ( answer ) Fracture test
c. Charpy V notch impact test
d. CTOD test
 We need to know what is Fracture test?
 Welder qualification – BS EN 287: the fracture test to be done for welder qualification
as below table.
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9) Which one of these tests would most probably be used for welder qualificaiton on a plate
butt weld using 13mm low carbon steel:
a. CTOD
b. ( answer ) Nick break test
c. Fracture fillet test
d. IZOD
 Pls take note this question apply for welder.

 CTOD – Crack Tip Open Displacement: To determine the fracture toughness or
resistance towards crack extension.
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 Nick break test: To permit evaluation of any weld defects across the fracture surface
of a butt weld. This is righ answer for above question.
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 Fracture fillet test: To break open the joint through the weld to permit examination of
the fracture surfaces ( fillet weld ). See previous question.
 IZOD: Izod Impact Test:
10) A transverse tensile test piece from a weld joint will give the:
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a. Tensile strength of the weld
b. Tensile strength of the joint
c. Stress/Strain characteristics of the weld
d. ( answer ) Stress/Strain characteristics of the joint
Transverse Tensile Tests: To measure the transverse tensile strength of a butt joint under a
static load.
Pls see next part: part 3
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This is the excerpt for your very first post.
Date: October 24, 2017Author: Thanh ( QC ) Nguyen Le0 Comments

We will practical CSWIP 3.1 by Welding question with answer & explanation:
1) A code give the acceptance standard for excess weld metal “h” as h ≤ 1mm + 0.1b, max.
5mm, where “b” is the width of the weld cap. For which of the following situations is the
excess weld metal acceptable?
a. b = 15 h = 3.0
b. ( answer ) b = 22 h = 3.0
c. b = 28 h = 4.0
d. b = 40 h = 5.4
from b = 22 –> h<=3.2 < 3.0. So, “b” is righ answer.
2) A long centreline crack has been detected in a submerged arc weld bead this may be due
to:
a. Use of a high manganese filler wire
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b. Use of a damp flux
c. ( answer ) Weld bead is deep and narrow
d. Use of too high voltage
The long centreline crack is Solidification Cracking (hot crack) can occur when:
-Weld metal has a high carbon or impurity (sulphur) content
–The depth-to-width ratio of the solidifying weld bead is large (deep & narrow)
-Disruption of the heat flow condition occurs, stop/start condition
3) Which of the following defects will have the more severe effect on the load-bearing
capacity of a weld?
a. Undercut
b. ( answer ) Incompletely filled groove
c. Irregular width
d. Excess penetration
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Pls understand that: The Cap on the weld is weld filler that does not contribute to the load
bearing structure of the weld.
4) While inspecting a weld on a 100mm thick high carbon steel plate with a … the weld is
visually acceptable, however the parent material has severse … the weld approximately 3mm
deep, what course of action would you …
a. None I am only inspecting the weld
b. Recommend that the area be dressed smooth
Recommend that the area be dressed smooth

c. ( answer )
followed by MPI
High carbon steel is not susceptible to cracking so I

d.
would weld over …
 High carbon steel is susceptible to cracking. So, weld over it to be careful.

 We have to inspect at weldment & parent material ( base metal ) also.
 The defect to be dressed smooth with MPI to make sure that all defect are removed
completely.
Pls take note: All materials arriving on site should be inspected for:
 Size / dimensions
 Condition
 Type / specification
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5) Which of these statements are true concerning Lamellar tearing?
As hydrogen levels increase Lamellar tearing is more

a.
likely
As material thickness increases ductility decreases

b.( answer )
making Lamellar tearing more likely
c. Lamellar tearing occurs in the HAZ
d. Lamellar tearing affects all joint types
What is Lamellar tearing?
LAMELLAR TEARING occurs only in rolled steel products. Cracking occurs in joints where:
-A thermal contraction strain occurs in the thru. thickness direction of steel plate
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-Non-metallic inclusions are present as very thin platelets with their principal planes parallel to
plate surface
Two main options are available to control the problem in welded joint liable to lamellar
tearing:
-Use clean steel with guarantee through-thickness properties (Z grade)
-A combination of joint design, restraint control and welding sequence to minimize the risk of
cracking
Location: Parent metal
Steel Type: Any steel type possible
Susceptible Microstructure: Poor through thickness ductility
 Lamellar tearing has a step like appearance due to the solid inclusions in the parent
material (e.g. sulphides and silicates) linking up under the influence of welding stresses
 Low ductile materials in the short transverse direction containing high levels of
impurities are very susceptible to lamellar tearing
 It forms when the welding stresses act in the short transverse direction of the
material (through thickness direction)
6) Which of the following types of imperfection is generally considered to be the most
serious?
a. ( answer ) Surface breaking planar
b. Root concavity
c. Buried planar
d. Surface breaking non-planar
 Root concavity:
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 Buried planar: the deject stay in side of weld
7) Burn through may occur because the:
a. (answer) Current is too high
b. Root gap is too small
c. Travel speed is too fast
d. Current is too low
Burn Through: a collapse of the weld pool resulting in a hole in the weld
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8) On inspecting a completed 150mm OD pipe weld some small smooth, shallow areas of
undercut have been found < 0.25mm deep. The welder says he can quickly put this right by
depositing a thin narrow bead along the undercut. In this situation would you?
Agree to go ahead with no preheat as the weld is so

a.
small
Only allow the welder to cosmetically blend out the

b. (answer) undercut providing the wall thickness remains within
the specification tolerances
Agree to go ahead with a preheat 50oC above

c.
original
d. Cut out the joint and re-weld
Have 3 type of Undercut defect, they have to be measured in both length & depth. After that
compare with specification / tolerance for assessment.
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9) On inspecting a completed weld which has Charpy impact requirements some small areas
of undercut have been found. The welder says he can quickly put this right by depositing a
thin narrow bead along the undercut. In this situation would you?
Agree to go ahead with no preheat as the weld is so

a.
small
Agree to go ahead with the same preheat as the

b.
original weld
Agree to go ahead with a preheat 50oC above

c.
original
Only allow the welder to cosmetically blend out the

d. ( answer )
undercut
See previous question!
10) Why would visual inspection of the excess weld metal at the bottom of a cross country
pipeline be important?
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a. ( answer ) It is the most difficult area to weld
It is the dirtiest part of the pipe as it is near the

b.
ground
c. Welders always forget to weld the bottom
d. It is the most difficult area to radiograph
What is Cross country pipeline? See below pciture:
At bottom of pipeline is hard to weld.
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1) In a welding procedure transverse joint tensile test the following observations were made.
The specimen CSA was recorded as 25mm x 12mm and the maximum load applied was
recorded as 150kN. What is the UTS?
a. 50kN/mm2
b. 5500N/mm2
c. ( answer ) 500N/mm2
d. 50N/mm2
 Transverse tensile test:
 CSA: cross section area

 UTS: ultimate tensile strength ( N/mm2; p.s.i; Mpa )
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 UTS = (150×1000)/(25×12) = 500N/mm2
 Pls take note for unit of value.
2) In welder qualification testing of 10mm plates, 2 root and 2 face bends were test … what
course of action would you follow?
Accept them as 75% were acceptable, you are

a.
allowed one failure
b. 2 more root bends should be prepared and tested
2 more root and 2 more face bends should be

c.
prepared and tested
d. Retest the welder
 Bend test: To determine the soundness of the weld zone. Bend testing can also be
used to give an assessment of weld zone ductility. There are three ways to perform a
bend test: Face bend, root bend & side bend (Generally for materials above 12mm
thickness).
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 But this question is for Welder.
3) In an all weld tensile test, the original specimen gauge length was 50mm, and after the test
the increased gauge length was 60mm, what is the elongation percentage?
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a. %A is 50
b. %A is 20
c. %A is 29
d. %A is 36
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E= (60-50)*100/50 = 20%. So, righ answer is “b”.
4) Some codes require the excess weld metal (weld cap) on cross weld joint
tensilespecimens to be flush, this is because:
Flushed caps will always break in the weld metal

a.
area
This is to remove any porosity in the excess weld

b.
metal (weld cap)
It is easier to calculate the cross sectional area of

c.
the joint when flushed
Flushed caps have fewer stress raisers and therefore

d. ( answer )
give a more accurate result
to be double check!
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 Cross weld joint tensile = Transverse Tensile Tests
 Transverse Tensile Tests: these result below to be recorded:
– Type of specimen e.g. reduced section
– Whether weld reinforcement is removed
– Dimensions of test specimen
– The ultimate tensile strength in N/mm2, p.s.i or Mpa
– Location of fracture.
5) When transverse tensile testing a welded joint the excess weld metal is often removed.
This action is done to:
Allow the test piece to fit accurately into the

a.
equipment
b. ( answer ) Reduce stress concentrations to the weld toes
Allow strain gauges to be placed over the weld face

c.
area
d. Allow weld metal ductility to be measured
see previous question!
6) In welder qualification testing of 20mm plates, why are side bends used instead of root and
face bends:
a. They are easier to produce
The testing equipment cannot handle thick

b.
root/face bends
Root defects are not important for welder

c.
qualification
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d. ( answer ) They give more accurate indications
B
end test: To determine the soundness of the weld zone. Bend testing can also be used to give
an assessment of weld zone ductility.
Side bend tests are normally carried out on welds over 12mm in thickness.
When make the “Side bend”, 3 area as: root, face & side will be tested. That tests test the full
section thickness. So, it gives more accurate indications.
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Specimens and testing for bend testing for butt joints shall be in accordance with EN 910.
For thicknesses < 12 mm two root and two face bend test specimens shall be tested. For
thicknesses 12 mm four side bend specimens are recommended instead of root and face bend
tests.
7) Mechanical tests are divided into two areas, identify these from the list below:
a. Destructive and non destructive tests
b. ( answer ) Qualitative and quantitative
c. Visual and mechanical
d. Qualitative and visual
Quantitative Tests: For measuring a ‘quantity’ ( a mechanical property )
Qualitative Tests: For assessing joint ‘quality’ (good fusion & free from defects)
The following mechanical tests have units and are termed quantitative tests to measure
Mechanical Properties:
 Tensile tests (Transverse Welded Joint, All Weld Metal)
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 Toughness testing (Charpy, Izod, CTOD)
 Hardness tests (Brinell, Rockwell, Vickers)
The following mechanical tests have no units and are termed qualitative tests for assessing joint
quality:
 Macro testing
 Bend testing
 Fillet weld fracture testing
 Butt weld nick-break testing
8) When examining a completed bend test, the angle of the bend was found to be 175o. The
testing specification calls for the sample to have been formed through 180o.
a. The bends should be considered as falled
b. ( answer ) They should be bent to 180o then re-examined
They should be acceptable as the reduction in angle

c.
is due to material spring back
They should be rejected as the angle is not close

d.
enough to be acceptable
Follow BS EN – 910:
9) Charpy testing is carried out on a welding procedure test plate because?
It gives an indication of the through thickness

a.
ductility (in the Z direction)
The impact test results can be used to verify that

b. ( answer ) the material has not been adversely affected by the
heat of the welding
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It gives an indication of the materials elongation
c.
properties
It gives a quick indication of the weld quality for

d.
welder qualification tests
Some question we need use “exclusion method”.
Charpy testing:
a) It gives an indication of the through thickness ductility (in the Z direction): this for STRA not
Charpy impact test.
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c) It gives an indication of the materials elongation
properties:
d) It gives a quick indication of the weld quality for welder qualification tests: welder
qualification test don’t require Chapry impact test.
b) The impact test results can be used to verify that the material has not been
adversely affected by the heat of the welding: this is correct answer.
10) Charpy impact tests show a 50% rough torn surface and a 50% flat crystalline surface after
the completed test, this would indicate which type of failure?
a. Fatigue to brittle
b. ( answer ) Ductile to brittle
c. Ductile with gross yielding
d. Fatigue to ductile
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Charpy impact test: These tests show that metals can be classified as being either ‘brittle’ or
‘ductile’. A brittle metal will absorb a small amount of energy when impact tested, a tough
ductile metal a large amount of energy.
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Some steels may show transition characteristics in their failure mode from ductile to
brittle gradually as temperature is decreased, which is given in Figure-4 schematically. In this
case different approaches may be used in determining transition temperature but the average
energy concept is the most popular one. Determination of transition temperature can also be
done by examining the fracture surfaces of specimens tested at different temperatures. For
example the temperature, at which the fracture surface consists 50 percent cleavage
(crystalline) and 50 percent ductile (fibrous) types of fracture, is called fracture appearance
transition temperature (FATT). Another common criterion is to determine the transition
temperature on the basis of an arbitrary energy absorbed.
Pls see next part!
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1. Charpy impact test showing a flat through surface after the completed test, this would
indicate which type of faiture?
a. Fatigue
b. Ductile
c. Fatigue to ductile
d. ( answer ) Brittle
See below picture: the Brittle faiture have surface is flat.
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2) A STRA test is carried out to determine which of the following?
A quick indication of the weld quality for welder

a.
qualification tests
The test results can be used to verify that the

b. material has not been adversely mechanically
damage by the heat during welding
c. An indication of the materials’ elongation properties
d. ( answer ) An indication of the through thickness ductility (in
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the Z direction)
3) In a transverse WELD tensile test, if the break was in the Parent material, the sample
would be:
a. Rejected
Acceptable if the UTS is equal to or greater than the

b. ( answer )
specified UTS of the plate
c. Rejected
Acceptable if the UTS is between 80 – 90% of the

d.
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Follow ASME IX: see below – tolerance for this test is not more than 5%.
4) What unit of measurement is used for Charpy impact test …
a. ( answer ) Joules
b. N/mm2
c. kJ
d. VPN
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5) During a transverse tensile test, the first stage the specimen goes through is known as:
a. Plastic stage
b. ( answer ) Elastic stage
c. Deformed stage
d. UTS stage
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a) the tensile strength, also known as the ultimate tensile strength, the load at failure divided by
the original cross sectional area where the ultimate tensile strength (U.T.S.).
b) the yield point (YP), the stress at which deformation changes from elastic to plasticbehaviour
ie below the yield point unloading the specimen means that it returns to its original length,
above the yield point permanent plastic deformation has occurred.
6) Root and Face bends from an 8mm thick butt weld require testing. The specimens are cut
to 20mm wide. The Code calls for a 4t bend. Which one of the following former should be
selected for the testing:
a. 80mm radius
b. 80mm diameter
c. 32mm radius
d. ( answer ) 32mm diameter
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The former diameter depend on thickness of test speciment not wide.
7) Which NDT method is associated with Burmah Castrol strips?
a. Radiographic testing
b. Helium leak testing
c. ( answer ) Magnetic particle testing
d. Ultrasonic testing
We need to know what is Burmah Castrol strips:
Magnetic flux indicator strips (Castrol or Ely Strips) are widely used to indicate the presence of
induced magnetic fields during the magnetic particle inspection method for inspection of
77
ferromagnetic materials. Flux Indicators give evidence of an external field in the air above the
magnetised surface.
8) Which NDT method is associated with the use of a yoke?
This is simple question.
78
9) The penetrating power of an X-ray set is expressed in:
a. Curies
b. ( answer ) kV
c. IQI values
d. The number after the isotope type
79
10) You find out that the contractor has carried out radiography as per the 10% contractual
percentage required by the specification/Code. The specification also insists that an
additional 2 welds are radiographed for every weld that has failed. One of the pipe spools
had an unacceptable defect which the contractor has ignored and radiographed another weld
in its place which is acceptable, what would your course of action be?
As long as the other radiographed butt weld is

a. acceptable its OK as the 10% contractual percentage
required by the specification/Code has been satisfied
This is usual practice as 10% NDT is not really

b.
important
Review the original failed weld and insist that they

c.
have the additional 2 welds radiographed
Review the original failed weld and have it repaired,

d. ( answer ) radiographed. Then I would insist that they have an
additional 2 welds radiographed
The contractor does it wrong.
Pls see next part:
80

1) For ultrasonic testing, which of the following statements is true?
a. It is easy to identify all defects
b. ( answer ) The equipment should be calibrated before use
c. The equipment cannot be automated
d. Sound waves will not travel through copper
UT Disadvantages:
 Trained and skilled operator required

 Requires high operator skill
 Good surface finish required
 Defect identification
 Couplant may contaminate
 No permanent record
 Calibration Required
 Ferritic Material (Mostly)
Why:
Calibration refers to the act of evaluating and adjusting the precision and accuracy of
measurement equipment. In ultrasonic testing, several forms of calibration must occur. First,
the electronics of the equipment must be calibrated to ensure that they are performing as
designed. This operation is usually performed by the equipment manufacturer and will not be
discussed further in this material. It is also usually necessary for the operator to perform a “user
81
calibration” of the equipment. This user calibration is necessary because most ultrasonic
equipment can be reconfigured for use in a large variety of applications. The user must
“calibrate” the system, which includes the equipment settings, the transducer, and the test
setup, to validate that the desired level of precision and accuracy are achieved. The term
calibration standard is usually only used when an absolute value is measured and in many
cases, the standards are traceable back to standards at the National Institute for Standards and
Technology.
2) Which of the following standards is concerned with welder approval?
a. BS EN 499
b. BS EN 288
c. BS EN 22553
d. ( answer ) BS EN 287
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3) The WPS calls for a root gap to be between 2 and 3mm, the actual measured gap is 4mm, …
of action would you like?
a. Accept it as its only 1mm
b. ( answer ) Reject it
c. The welder will decide, if it fails it will be his problem
The welder insists he can weld the butt joint easily so

d.
let him go ahead
Pls understand that:
 With Welding inspector position: We have follow Approved WPS stricly! Any difference
with WPS will be rejected. But:
 With Welding engineer: it can cosider to checked again. For ex: if it is checked follow
ASME IX: root spacing is Nonessential –> can accept.
4) What is the abbreviation for a Welding Procedure Specification that has been written for
the purpose of qualifying a Weld Procedure Test weld?
a. WPS
b. ( answer ) pWPS
c. uWPS
d. pWPT
Pls see attached link: WPS understanding.
83
 pWPS: Some codes, such as AWS D1.1, allow “Prequalified WPS”, whereby it is
established that the WPS written per code will produce welds with correct mechanical and
metallurgical properties. It is NOT NEED to prepare a PQR in such cases. However, the pre-
qualified WPS have a specified range (TABLE 3.X) of parameters under which the weld must
be produced. When welding variables fall outside these ranges, a WPS with supporting PQR
must be prepared.
 PQR: is a record of the weld data used to weld a test coupon. It also contains the test
results of the tested specimens. The completed PQR shall document all the essential when
required supplementary essential variables for each welding process used during the
welding of test coupon. Non essential variables used during the welding of the coupon may
be recorded.
 WPS: is a written document that provides direction to the welder or welding operator
for making production welds in accordance with code requirements. The completed WPS
shall describe all the essential , non essential and when required supplementary
essential variables for each welding process used in the WPS.
One question: between WPS & PQR – which one have first?
 To come out a WPS we need follow these below steps – 5 steps:

 Five Step Process to Qualify a Welding Procedure
1. Understand the intended application for which the WPS will be used
2. Develop a draft procedure
3. Make a qualification weld
4. Test the qualification weld
5. Write up the WPS
 Step No. 2: we can understand it is pWPS ( prequalified WPS )
 Step No. 3: it is PQR
So, between WPS & PQR: PQR have first.
5) How are the lengths of tack welds during assembly and fit up determined?
a. By the welders as they have extensive knowledge
The fabrication specification will give minimum tack

b. ( answer )
length requirements
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c. The fabrication drawing will give all the information
d. Any length of tack weld will do for assembly
For information:
Qualification of tack welds, a topic that is being interpreted differently by various companies.
Tack welds on EXC2, EXC3 and EXC4 components are required to be welded in accordance with
a qualified WPS. Tack welds are to be a maximum length of 4x the thickness of the thicker part
or 50mm “…unless a shorter length can be demonstrated as satisfactory…”.
6) What does the term WPS mean?
a. Weld productivity specification
b. Weld production scheme
c. ( answer ) Welding procedure specification
d. Work productivity standard
Pls see question No. 4
7) What does the term WPQR mean?
a. Weld productivity quality review
b. Weld productivity quality requirements
c. ( answer ) Welding procedure qualification record
d. Work production quantity review
Pls see question No. 4
8) Is it always necessary to preheat the base material before welding?
a. Not on a sunny day
85
b. ( answer ) Only in accordance with the WPS
c. If the equipment is available it must be used
d. If using cellulosic rods these will provide enough heat
It depens on the thickness of material / type of material.
9) Which of the following would not be required to be checked before welding?
a. The welding consumables
b. The weld root gap
c. ( answer ) PWHT temperature range
d. The weld preparation
PWHT: POST WELD HEAT TREATMENT – are used to change the properties of the weld
metal, controlling the formation of crystalline structures.
PWHT is a mandatory requirement when certain criteria are met, the main one being the
thickness. BS EN 13445 and BSPD 5500 require that joints over 35mm thick are PWHT’d, ASME
VII above 19mm. If, however, the vessel is to enter service where stress corrosion is a
possibility, PWHT is mandatory, irrespective of thickness. The soak time is also dependant on
thickness. As a very general rule this is one hour per 25mm of thickness; for accuracy, reference
must be made to the relevant specification.
Post Weld Heat Treatment (PWHT):
So what does the term ‘post weld heat treatment’ mean? To some engineers it is a rather vague
term that is used to describe any heat treatment that is carried out when welding is complete.
To others however, particularly those working in accordance with the pressure vessel codes
such as BS PD 5500, EN 13445 or ASME VIII, it has a very precise meaning. When an engineer
talks of post weld heat treatment, annealing, tempering or stress relief it is therefore advisable.
10) How do we determines what the correct weld preparation (root gap, root face, included
angle) should be?
86
a. ( answer ) By consulting the WPSs
b. The fabrication drawing will give all the information
c. The welder will decide
d. The inspectors will recommend what is suitable
Pls see next part:

1) With which of the following NDE processes is it possible to detect both surface and slight
sub-surface defects up to 2mm below the surface:
a. Visual
b. Dye penetrant
c. ( answer ) Magnetic particle using DC
d. Magnetic particle using AC
See below, you can know why choose “c”:
 Alternating Current (AC). Electric current flows through a conductor in a back and forth
direction at specific intervals. Note: It provides the best sensitivity for the detection
of surface discontinuities only.
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 Direct Current (DC). Electric current flows through a conductor in only one direction at
all times. Note: DC from a battery source has been phased out in favor of rectified forms of
AC for surface and subsurface flaw detection:

– Full-Wave Rectified (FWDC). Electric current flows through a conductor in one direction only
with an increased rate of pulsating surges and drops at specific intervals. Note: FWDC is
recommended for effective surface and subsurface flaw detection when using the wet method
of inspection.
– Half-Wave Rectified (HWDC). Electric current flows through a conductor in one direction only
with pulsating surges and drops at specific intervals-hence the name half wave. Note: It is most
effective for surface and subsurface flaw detection when using the dry powder method of
inspection.
2) For MPI using the prods method, which of the following statements is true:
It may cause arc damage on the specimen material

a. ( answer )
surface
b. It requires fewer operators therefore is easier
c. It can be used with ferritic and non-ferritic materials
d. It is quicker than using a yoke type electromagnet
88
Prods induce a circular magnetic field by sending a high amperage (1000A typically) current
through the testpiece. The high amperage can cause arcing between the electrodes and test
surface. Contact points must be carefully cleaned, and electrode materials chosen to prevent
contamination of the testpiece.
Advantages Disadvantages
 Variable field
 Danger of arcing
strength
 AC or DC fields  Danger of overheating
 Useful in
 Heavy transformer required
confined spaces
 Possible to switch on without

 Low voltages
creating field
 No poles to  Possible contamination of the

attract particles testpiece by the electrode
 Control of
 Must have good electrical contact
amperage
89
 Usually two-man operation
3) With the DPI method of inspection, after the contact time has elapsed the dye should be
removed by:
Spraying the surface with the remover till all dye has
a.
gone then wipe with a clean cloth
b. Spraying with the developer then wiping with a cloth
Wipe clean, using a lint free cloth soaked in a solvent

c. ( answer )
remover
It doesn’t matter how it is done as long as all traces

d.
of dye are removed
DPI: means Liquid Penetrant (PT or Dye-Penetrant). It has 4 steps:
Step 1. Pre-Cleaning: Ensure surface is very Clean normally with the use of a solvent
Step 2. Apply penetrant: After the application, the penetrant is normally left on the
components surface for approximately 15-20 minutes (dwell time). The penetrant enters any
defects that may be present by capillary action.
Step 3. Clean off penetrant: the penetrant is removed after sufficient penetration time (dwell
time). Care must be taken not to wash any penetrant out off any defects present. After the
penetrant has be cleaned sufficiently, a thin layer of developer is applied. The developer acts as
a contrast against the penetrant and allows for reverse capillary action to take place.
Step 4. Inspection / development time: Inspection should take place immediately after the
developer has been applied. any defects present will show as a bleed out during development
time. After full inspection has been carried out post cleaning is generally required.
Above question ask about How to cleaning surface after apply penetration. Penetrant removal:
The method of removal depends upon the type of penetrant used. The main method we are
usually use is Solvent removable penetrants.
90
 The solvent can be applied by spray or by a cloth.
 During the initial inspection stage, after dweel time the excess penetrant should be
removed by applying the solvent to a cloth and then wiping the surface clean.
4) Which of the following commonly used radio active isotopes has the longest half life?
a. Iridium 192
b. ( answer ) Cobalt 60
c. Thulium 170
d. Ytterbium 169
What determines the penetrating power of a gamma ray ? This is:
 the type of isotope (the wavelength of the gamma rays)

GAMMA SOURCES with Isotope Typical Thickness Range:
 Iridium 192: from 10 to 50 mm (mostly used)

 Cobalt 60 > 50 mm
 Ytterbium < 10 mm
 Thulium < 10 mm
 Caesium < 10 mm
We can see Cobalt 60 have Isotope typical thickness range > 50mm. So, it has Haft life
longest ( more than 5 years ).
For more inforation:
 Iridium-192 (symbol 192Ir) is a radioactive isotope of iridium, with a half-life of 73.83 days

 Cobalt-60, is a synthetic radioactive isotope of cobalt with a half-life of 5.2714 years
 Thulium 170: This isotope has a half-life of 128.6 days
 Ytterbium 169: The 169Yb isotope (with a half-life of 32 days)
 Caesium: The isotopes with mass numbers of 129, 131, 132 and 136, have half-lives
between a day and two weeks, while most of the other isotopes have half-lives from a few
seconds to fractions of a second.
91
5) A 300mm diameter pipe, 10mm wall thickness is to be radiographically tested using the
double wall single image technique (DWSI). The source to be used is Iridium 192. Which of
the following statements is true?
It should not be done as the thickness is below that

a.
recommended
It would be better to use a cobalt 60 source in this

b.
instance
c. ( answer ) There is no problem with the technique
Only the double wall, double image technique should

d.
be used with Iridium
We know:
– GAMMA SOURCES with Isotope Typical Thickness Range:
 Iridium 192: from 10 to 50 mm (mostly used)

 Cobalt 60 > 50 mm
 Ytterbium < 10 mm
 Thulium < 10 mm
 Caesium < 10 mm
– Radiographic Techniques:
 Single Wall Single Image (SWSI): film inside, source outside

 Single Wall Single Image (SWSI) panoramic: film outside, source inside (internal
exposure)
 Double Wall Single Image (DWSI): film outside, source outside (external exposure)
 Double Wall Double Image (DWDI): film outside, source outside (elliptical exposure)
– Double Wall Single Image (DWSI):
92
 IQI’s are placed on the film side
 Source outside film outside (multiple exposure)
 This technique is intended for pipe diameters over 100mm
6) What is the greatest disadvantage of radiographic inspection?
a. Its inability to size defects accurately
b. The physical size of the equipment
c. The skill level of the operators
d. ( answer ) The harmful effects of ionising radiation
Disadvantages Expensive consumables:
 Bulky equipment
 Harmful radiation
 Defect require significant depth in relation to the radiation beam (not good for planar
defects)
 Slow results
 Very little indication of depths
 Access to both sides required
7) Half life is a term used to describe:
93
a. The penetrating ability a gamma source
b. Half the total time a gamma source will be useful
The time taken for the gamma source to reduce its

c. ( answer )
strength by half
d. The rate of decay of an X-ray tube
Pls see question No. 4 above first.
Documents for refer:
Half-life (symbol t1⁄2) is the time required for a quantity to reduce to half its initial value.
The term half-life is defined as the time it takes for one-half of the atoms of a radioactive
material to disintegrate. Half-lives for various radioisotopes can range from a few microseconds
to billions of years. See the table below for a list of radioisotopes and each of unique their half-
lives.
8) Which of the following defects are unlikely to be detected by normal radiographic

techniques?
a. ( answer ) Intergranular corrosion cracking
b. Porosity
c. Slag
d. Lack of penetration
We use Exclusion principle to answer this question. The porosity / slag / lack of penetration can
detect by RT. So, “a” is righ answer.
Pls refer to link to know about: Intergranular corrosion cracking
– The principles of radiography:
 Thinner areas and materials of a less density show as darker areas on the radiograph
 Thicker areas and materials of a greater density show as lighter areas on a radiograph
94
– Intergranular corrosion cracking ( weld decay ):
 Intergranular corrosion is sometimes also called “intercrystalline corrosion” or

“interdendritic corrosion“. In the presence of tensile stress, cracking may occur along grain
boundaries and this type of corrosion is frequently called “intergranular stress corrosion
cracking (IGSCC)”or simply “intergranular corrosion cracking“.
 “Intergranular” or ‘intercrystalline” means between grains or crystals. As the name
suggests, this is a form of corrosive attack that progresses preferentially along interdendritic
paths (the grain boundaries). Positive identification of this type of corrosion usually
requires microstructure examination under a microscopyalthough sometimes it is visually
recognizable as in the case of weld decay.
We see that: Intergranular corrosion cracking – Positive identification of this type of corrosion
usually requires microstructure examination under a microscopy. The crack is very small, not
enough to see what difference about density on flim. So, we can not see it ON Flim.
9) Which of the following would be most unlikely to be found in a butt welded butt joint using
… conventional radiographic method of NDT?
Linear elongated slag inclusions in the root (wagon

a.
tracks)
b. Burn through
c. ( answer ) Lack of sidewall fusion
d. An elongated gas cavity
Disadvantages Expensive consumables:
 Bulky equipment
 Harmful radiation
 Defect require significant depth in relation to the radiation beam (not good for planar
defects)
 Slow results
 Very little indication of depths
 Access to both sides required
95
The RT method is not good for Planar defects. So, “c” is righ answer.
10) Who should select the specific welds for NDT, to cover the 10% contractual percentage
required by the Specification/Code?
a. Anyone can select …
b. The welder as he knows which …
c. ( answer ) This will be referenced in the inspection and test plan
Nobody, as welding is always carried out to a high

d.
standard the use of percentage NDT …
This is mimple question. The 10% NDT to be follow ITP ( inspection and test plan ).
Pls see next part:

1. Charpy impact test showing a flat through surface after the completed test, this would
indicate which type of faiture?
a. Fatigue
b. Ductile
c. Fatigue to ductile
96
d. ( answer ) Brittle
See below picture: the Brittle faiture have surface is flat.
2) A STRA test is carried out to determine which of the following?
A quick indication of the weld quality for welder

a.
qualification tests
The test results can be used to verify that the

b. material has not been adversely mechanically
damage by the heat during welding
97
c. An indication of the materials’ elongation properties
An indication of the through thickness ductility (in

d. ( answer )
the Z direction)
3) In a transverse WELD tensile test, if the break was in the Parent material, the sample
would be:
a. Rejected
Acceptable if the UTS is equal to or greater than the

b. ( answer )
c. Rejected
Acceptable if the UTS is between 80 – 90% of the

d.
98
Follow ASME IX: see below – tolerance for this test is not more than 5%.
4) What unit of measurement is used for Charpy impact test …
a. ( answer ) Joules
b. N/mm2
c. kJ
d. VPN
99
5) During a transverse tensile test, the first stage the specimen goes through is known as:
a. Plastic stage
b. ( answer ) Elastic stage
c. Deformed stage
d. UTS stage
100
a) the tensile strength, also known as the ultimate tensile strength, the load at failure divided by
the original cross sectional area where the ultimate tensile strength (U.T.S.).
b) the yield point (YP), the stress at which deformation changes from elastic to plasticbehaviour
ie below the yield point unloading the specimen means that it returns to its original length,
above the yield point permanent plastic deformation has occurred.
6) Root and Face bends from an 8mm thick butt weld require testing. The specimens are cut
to 20mm wide. The Code calls for a 4t bend. Which one of the following former should be
selected for the testing:
a. 80mm radius
b. 80mm diameter
c. 32mm radius
d. ( answer ) 32mm diameter
101
The former diameter depend on thickness of test speciment not wide.
7) Which NDT method is associated with Burmah Castrol strips?
We need to know what is Burmah Castrol strips:
Magnetic flux indicator strips (Castrol or Ely Strips) are widely used to indicate the presence of
induced magnetic fields during the magnetic particle inspection method for inspection of
102
ferromagnetic materials. Flux Indicators give evidence of an external field in the air above the
magnetised surface.
8) Which NDT method is associated with the use of a yoke?
This is simple question.
103
9) The penetrating power of an X-ray set is expressed in:
a. Curies
b. ( answer ) kV
c. IQI values
d. The number after the isotope type
104
10) You find out that the contractor has carried out radiography as per the 10% contractual
percentage required by the specification/Code. The specification also insists that an
additional 2 welds are radiographed for every weld that has failed. One of the pipe spools
had an unacceptable defect which the contractor has ignored and radiographed another weld
in its place which is acceptable, what would your course of action be?
As long as the other radiographed butt weld is

a. acceptable its OK as the 10% contractual percentage
required by the specification/Code has been satisfied
This is usual practice as 10% NDT is not really

b.
important
Review the original failed weld and insist that they

c.
have the additional 2 welds radiographed
Review the original failed weld and have it repaired,

d. ( answer ) radiographed. Then I would insist that they have an
additional 2 welds radiographed
The contractor does it wrong.
Pls see next part:
105

1) When using DC+ve polarity, what is the typical OCV?
a. 20V
b. 50V
c. ( answer ) 90V
d. 240V
106
107
2) When MMA welding what will be the effect on the weld if the electrode was changed from
DC+ve to AC
a. None
It would have been easier for the welder to strike the

b.
arc
c. It would slightly increase the depth of penetration
d. ( answer ) It would give less penetration
3) What would the effect be if the polarity were changed from DC+ve to DC-ve?
a. None
b. ( answer ) Greater deposition rate
c. Greater penetration
d. Less deposition rate
108
Pls see previous question!!!
4) Which of the following processes uses a flat characteristic?
a. ( answer ) MAG (GMAW)
b. Oxy-fuel gas welding
c. Resistance spot welding
d. SAW using more than 1000 amps
109
5) How could arc blow be avoided?
a. ( answer ) Use AC
b. Use DC+
c. Use DC-
d. Increase travel speed
110
6) Which process uses a constant current characteristic?
a. MIG/MAG
b. ( answer ) MMA
c. FCAW
d. All processes use this
111
7) If the maximum inter pass temperature is exceeded in a carbon manganese butt weld …
affected most
a. Hardness
b. ( answer ) Toughness
c. Fusion
d. Penetration
112
8) What is meant by the term duty cycle?
a. How long a welder can weld for in a given period
b. The amount of time the electrode is being used
c. ( answer ) The amount of time a welding machine can be used
d. The amount of electricity being consumed
113
9) The term manual welding is often used when the welder controls:
a. ( answer ) Arc length
b. Wire speed
c. Burn off rate
d. Transfer mode
10) Which welding process develops the lowest level of hydrogen …
a. ( answer ) TIG
b. SAW
c.
d.
Pls see next part:

114
1) When measuring arc voltage, where should the measuring …
a. Across the terminals of the power source
b. Across the arc and as near as practical to the arc
Across the power source positive terminal and earth

c.
cable
d. It does not matter – anywhere in the circuit
 The voltmeter may be connected only across the circuit (to the workpiece and as close
as possible to the electrode!)
 The ammeter may be connected at any point in the circuit.
2) Which of the following is NOT a fusion welding process?
a. ( answer ) Friction welding
b. Gas tungsten arc welding
c. Resistance welding
d. Laser welding
 Rotary friction welding is a solid-state joining process

 Welding is regarded as a joining process in which the work pieces are in atomic
contact.
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 Weld is A permanent union between materials caused by heat, and or
pressure (BS499)
 Friction welding:
3) What is the maximum OCV allowable to initiate an arc when using AC current?
a. 1000V
b. 10V
c. ( answer ) 90V
d. 900V
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4) Why is the OCV capped at this voltage setting?
a. To save electricity
b. To prevent exploding of the consumable
c. Allow smooth transition into welding voltage range
d. ( answer ) To reduce the risk of fatality
See previous question!
The prevention of electrical shock from welding equipment relies on three major principles.
5) A typical minimum OCV requirements for MMA (111) using filler rutile electrode …
117
a. 40V
b. 120V
c. 100V
d. ( answer ) 50V
6) A typical minimum OCV requirements for MMA (111) using basic electrode would be:
a. ( answer ) 70V
b. 40V
118
c. 100V
d. 20V
7) Heat input can be altered from the original procedure according to EN1011, …
a. +10%
b. +20%
c. (answer ) +25%
d. +30%
8) A butt weld has been made by MMA in a 50mm thick impact tested steel plate. The
welding electrode used was a basic type, 5mm diameter. The measured welding parameters
119
for one of the runs was 220 amps, 21 volts, using DC+ve polarity, and a ROL of 270mm per
min. What would be the arc energy?
Insufficient information given to calculate the arc

a.
energy
b. 1.54kJ/mm
c. ( answer ) 1.026kJ/mm
d. 2.82kJ/mm
HI = (220*21) / ( 270/60*1000) = 1.026kJ/mm
Pls note for: what is ROL & Travel speed in MMA?
120
9) A butt weld has been made by MMA in a 50mm thick impact tested steel plate. The
welding electrode use was a basic type, 5mm diameter. The measured welding parameters
for one of the runs was 250 amps, 24 volts, using DC+ve polarity, and a ROL of 180mm per
min. What would be the Arc energy?
Insufficient information given to calculate the arc

a.
energy
b. 1.9kJ/mm
c. 1.87kJ/mm
d. ( answer ) 2.0kJ/mm
HI = (250*24) / ( 180/60*1000) = 2.0kJ/mm
10) When using DC+ve polarity, what is the typical OCV?
a. 10-40V
b. ( answer ) 50-90V
c. 100-140V
d. 200-240V
Pls see next part:

1) Which of the following would not be required to be checked before welding?
121
a. The welding consumable
b. The welder qualification
c. Calibration of the welding equipment
d. ( answer ) The workshop humidity
Pls see below link: Typical Duties of a Welding Inspector
2) Is it permissible to allow a trainee welder to carry out production welding?
a. ( answer ) Never
Yes as long as the supervisor is happy with his

b.
workmanship standard
Yes as long as he has the approved qualification to

c.
cover the intended scopr of work
Yes as long as no NDT is required on the finished

d.
weld
 Before Welding: list of available qualified welders related to WPS’s, certificates are valid

and ‘in-date’.
 During Welding: is approved to weld the joint
3) What information should be recorded as a minimum, on a completed production weld?
a. Size and type of electrode used
b. Welding supervisor’s name
122
c. ( answer ) Welder’s identification, date and weld number
d. Welding inspectors name
After Welding – Weld Identification:
 identified/numbered as required
 is marked with welder’s identity
4) Which standard is used for the basic requirements for visual inspection?
a. ( answer ) BS EN 970
b. API 1104
c. BS EN 7079
d. BS EN 4515
BS EN 970 – Non-destructive examination of fusion welds – Visual examination
5) Which standard is used for European welding procedure qualifications?
a. ASME IX
b. BS EN ISO 4872
c. ( answer ) BS EN ISO 15614
d. BS EN ISO 287
6) A procedure is a document which:
123
a. ( answer ) Specifies the way to carry out an activity or a process
Provides binding legistative rules that are adopted by

b.
an authority
Specifies which resources shall be applied by whom

c. and when, to a specific project, product process or
contract
A written and verbal description of the precise steps

d.
to be followed
7) Which BS EN standard is used for welding symbols on drawings?
a. BS EN 970
b. BS EN287
c. ( answer ) BS EN 22553
d. BS EN 4515
8) A document that is established by consensus and approved by a recognised body and
provides, for common and repeated use, guidelines, rules, characteristics for activities or
their results, aimed at the achievement of the optimum degree of order in a given context is
called:
a. Normative document
b. Regulation
c. Specification
d. ( answer ) Standard
124
 Specification: Document stating requirements. Meaning full data and its supporting
medium stating needs or expectations that is stated, generally implied or obligatory.
 Standard: A document that is established by consensus and approved by a recognised
body. A standard provides, for common and repeated use, guidelines, rules, and
characteristics for activities or their results, aimed at the achievement of the optimum
degree of order in a given context.
9) A fillet weld has a design throat thickness of 8mm. What is the minimum leg length that is
required?
a. 5.6mm
b. ( answer ) 11.2mm
c. 11.8mm
d. It cannot be determined from the information given
125
Design Throat Thickness = Leg Length x 0.7
Leg Length = Design Throat Thickness x 1.4
It means: 11.2mm
10) Which of the following actions can help to prevent the production of spatter during a
welding process:
a. Switch to AC power
b. Use dry electrodes
c. Reduce arc current
d. ( answer ) All of the above
Spatter: small droplets of electrode material can be projected clear of the weld and may be
fused to the parent metal. Cause:
 Excessive current
 Damp electrodes
 Contamination
 Incorrect wire feed speed when welding with the MAG welding process
 Arc blow
Prevention:
 Reduce arc power

 Reduce arc length or swith to AC power
 Modify electrical settings ( but be careful to maintain full fusion )
 Use dry electrodes
Pls see next part:
126
1) Which of the following imperfection types is NOT usually associated with TIG welding?
a. Tungsten inclusion
b. Lack of root fusion
c. Crater pipe
d. ( answer ) Spatter
Most welding defects with TIG are caused by a lack of welder skill, or incorrect setting of the
equipment. i.e. current, torch manipulation, welding speed, gas flow rate, etc.
 Tungsten inclusions (low skill or wrong vertex angle)

 Surface porosity (loss of gas shield mainly on site)
 Crater pipes (bad weld finish technique i.e. slope out)
 Oxidation of S/S weld bead, or root by poor gas cover
 Root concavity (excess purge pressure in pipe)
 Lack of penetration/fusion (widely on root runs)
2) Which polarity is normally used for GTAW welding of aluminium?
a. ( answer ) AC
b. DC electrode negative
c. DC electrode positive
d. It would make little difference which was used
127
3) What is a typical arc voltage setting when welding with the TIG (GTAW) process?
a. 18-20V
b. 24-26V
c. ( answer ) 10-12V
d. 70-90V
 ARC CHARACTERISTICS FOR TIG WELDING is Constant Current.
128
 Constant Current characteristic is:
4) In TIG welding hydrogen is added to argon for the welding of which type of steel?
a. Carbon steel
b. Copper
129
c. Carbon manganese steel
d. ( Answer ) Austenitic stainless steel
Shielding gases for TIG/GTAW welding:
The normal gas for TIG welding is argon (Ar). Helium (He) can be added to increase penetration
and fluidity of the weld pool. Argon or argon/helium mixtures can be used for welding all
grades. In some cases nitrogen (N2) and/or hydrogen (H2) can be added in order to achieve
special properties. For instance, the addition of hydrogen gives a similar, but much stronger
effect as adding helium. However, hydrogen additions should not be used for welding
martensitic, ferritic or duplex grades.
5) Which Tungsten electrode is usually used to weld Aluminium?
a. (answer) Zirconiated
130
b. Thoriated
c. Large diameter
d. Pointed electrodes
6) What may be a reason for using nitrogen gas in TIG welding?
a. To stabilized the arc when welding carbon steel
b. ( answer ) It can be used to weld copper
c. The gas used is always the choice of the welder
d. It is the very best gas to weld Nickel Alloys
131
7) What is the mode of metal transfer for the TIG (GTAW) welding process?
a. Spray transfer
b. Globular transfer
c. Dip transfer
d. ( answer ) None of the above
 The filler metal is added directly to the weld puddle, not transferred across the arc,
but is melted by it.
 The difference between an electrode and a rod is that an electrode carries welding
current and the metal transfers across the arc, but a filler rod is added directly to the weld
puddle without electricity running through it.
8) When MIG/MAG welding, wire feed speed is proportional to:
a. Travel speed
b. (answer ) Welding current
c. Arc length
d. Inductance
132
9) In the MAG welding process which gas type gives good penetration but an unstable arc and
high levels of spatter?
a. (answer) Pure Carbon dioxide
b. Pure argon
c. Argon +5-20% Carbon dioxide
d. Argon +1-2% Oxygen or Carbon dioxide
10) The output characteristic of a typical MAG set is:
a. ( answer ) Constant voltage
b. Constant current
c. Drooping
d. Pulsing
133
Pls see next part:

1) When welding medium carbon steel plates over 90mm in thickness would the basic
electrode require any pre-treatment before use?
a. ( answer ) None if they were in a vacuum pack
b. None if they were used in a factory
134
2) An advantage of the MMA (111) welding process is that if:
a. Has higher current density than SAW (121) welding
Has a very large range of consumable for most

b. ( answer )
welding applications
c. No core wire is lost during the process
Requires a lower skill level than other manual forms

d.
of welding
135
3) Rutile electrodes are often sold packed in a cardboard box covered with a plastic film …
you found they were damp and the ends were rusty what course of action would you …
Use them as rutile electrodes are only for general

a.
purpose welding
b. Re-dry them at 125oC and issue to the shop floor
c. ( answer ) Quarantine them
d. Only use them for tack welding
 Rutile electrodes do not require pre-baking but should be stored in a dry condition.
 Checks should be made to ensure that the correct specification of electrode is being
used, the electrode is the correct diameter and in good condition.
 Rutile electrodes can be dried to lower H2 content but cannot be baked as it
will destroy the coating.
4) Which of the following defects are not associated with the MMA (SMAW) welding process?
a. Isolated pores
136
b. Lack of fusion
c. Undercut
d. ( answer ) Tungsten inclusions
Inclusions – Tungsten:
Causes: Contamination of weld Caused by tungsten touching weld metal or parent metal during
welding using the TIG welding process
5) Slag lines found in MMA welds are usually associated with:
a. The voltage being too low
b. The open circuit current being too high
c. Improper cleaning between weld runs
d. Low open circuit voltage
Inclusions – Slag:
6) When MMA welding what will be the effect on the weld if the electrode was channged
from AC to DC-ve?
a. None
b. Lower deposition rate
It would be less penetration or a slight increase in

c. ( answer )
deposition rate
137
d. The arc would become unstable
7) Which of the following electrodes don’t require re-baking at higher temperature …
a. Cellulosic types
b. ( answer ) Vacuum packed types
c. Hydrogen types
d.
138
8) Using the MMA process, which polarity produces the greatest penetration?
a. AC
b. DC-
c. (answer ) DC+
d. Depends on electrode size
139
9) When welding vertically up with the MMA process weaving is sometimes restricted
diameter, this restriction is mainly applied to:
a. Reduce the overall width of the weld
b. ( answer ) Limit the heat input into the joint
c. Reduce the number of electrodes used in the joint
d. Reduce the time required to finish the weld
The weaving will effect to ROL –> chagne Heat Input.
140
10) A typical baking temperature for basic low hydrogen electrodes is:
a. 120oC
b. (answer) 350oC
c. 500oC
d. 200oC
141

Pls see nect part:

Date: November 2, 2017Author: Thanh ( QC ) Nguyen Le1 Comment

1) Prior to commencing production welding using the MAG (GMAW) you notice the earth
clamp is in a very poor condition, what would you do?
a. Nothing
Insist the welder have it replaced before commencing

b. (answer)
welding
It will not affect the welding so wait untill it

c.
eventually melts of then have it replaced
It will be OK for welding but ensure that nobody

d.
touches it because they may get burnt
ALL the welding current passes through the earth clamp. Without a good earth connection,
the performance of the welder and the welding machine will be compromised… this can only
mean one thing: an inferior quality weld.
142
If the earth clamp is not in good condition, this will cause welding current leakage or
restriction. Or in other words, it will cause a drop in welding output voltage… which is like
someone changing the settings on your welder. (If you are MIG welding, for example, the wire
speed may seem to be creeping up).
2) An advantage of the SAW process is that:
143
a. It can be used in the vertical down (PG) position
b. (answer) Little or no ozone or UV light is produced/emitted
c. It is not affected by arc blow
d. It is not prone to solidification cracking
3) Which type of submerged arc flux can be described as sharp?
a. Agglomerated
b. ( answer ) Fused
c. Basic
d. Neutral
Note: Flaky / sharp is same.
Fluxes may be categorised in two ways: by the method of manufacture (fused or agglomerated)

or by its activity (neutral, active or alloying). Within these broad groupings the fluxes may be
classified further by their constituents, silica, manganese oxide, calcium fluoride etc.
144
4) Standard oxy-fuel gas cutting equipment can be applied to:
a. Aluminium alloys
b. ( answer ) Carbon steels
c. Austenitic stainless steels
d. Copper
145
5) Which of the following alloying elements is used mainly to improve the toughness of steel?
a. Chrome
b. (answer) Managanese
c. Sulphur
d. Carbon
146
6) Weldment in Carbon-Manganese steels, made by low heat input welding may show:
a. Greater ductility
b. Higher distortion
c. Higher dilution
d. (answer) Higher hardness
147
A low heat input leads to rapid cooling as the weld deposited is small in relation to the parent
material and the parent material acts as a heat sink. The toughness can be low in
microstructures that have arisen from rapid cooling rates. In general, very low heat inputs are
to be avoided as they result in hard, crack susceptible microstructures with poor toughness.
Simple is low heat input –> faster cooling rate –> higher hardness
7) Weldments in C-Mn steels, made using a heat input higher than the maximum specified by
the WPS, may show:
a. Higher integrity
b. Lower distortion
c. ( answer ) Lower toughness
d. Higher hardness
148
A high heat input gives slower cooling and the grain size in the HAZ can become very coarse if
the temperature is high enough to promote grain growth prior to transformation. Very large
grain sizes can have poor toughness even when the microstructure is soft.
8) Using a stabilised stainless steel will reduce the risk of:
a. Excessive distortion
b. ( answer ) Weld decay
c. Formation of iron-sulphides
d. Sour service cracking
149
9) Which of the following microstructures is critical to the likely formation of hydrogen
cracks?
a. Austenite
b. Ferrite
c. Pearlite
d. Martensite
150
10) An arc strike on a high carbon steel plate is likely to have the following microstructure
beneath surface:
a. Austenite
b. ( answer ) Martensite
c. Ferrite
d. Pearlite
Pls see next part:
Thanks!!!
151
1) To assess the surface of a weld for direct inspection, the distance from the surface to the eye
should be a maximum of?
a. 200mm
b. ( answer ) 600mm
c. 60mm
d. 6000mm
2) What is the recommended minimum range of illumination required by BS EN 970 for

inspection of a welded surface?
a. 90-125 lux
b. 150-250 lux
c. ( answer ) 350-500 lux
d. 35-50 lux
3) Who should have access to the WPS?
a. NDT operators
b. Inspectors only
c. Welder only
d. ( answer ) Welder and Inspectors
152
4) Who has the responsibility of ensuring the welder is using the correct consumable during
fabrication?
a. The QA department
b. Store man and the welder
c. Welding engineer
d. ( answer ) The welder and the welding inspector
5) Who has the responsibility of ensuring the welder is using the correct polarity during
welding?
a. ( answer ) The welder and the welding inspector
b. Store man and the welder
c. Welding engineer
d. The QA department
6) You notice the welders are adjusting the current on the welding set, is this allowable?
a. Never
b. The welder has the final say on voltage and current
Only if the current is within the range recorded on

c. ( answer )
the WPS
As long as the welder has approval from the welding

d.
foreman
7) Who determines what the correct weld preparation (root gap, root face, included angle)
should be?
a. ( answer ) The welding engineer
b. The welding supervisor
153
c. The welder will decide
d. The inspector will recommend what is suitable
8) What course of action should be taken upon finding a welder using incorrect welding
consumable?
Report the incident and record all relevant

a. ( answer )
information
b. Allow welding to proceed if the workmanship is good
None if the tensile strength of the consumable is the

c.
same as the approved one
Change the electrode for the correct type and

d.
continue welding
9) Who should have access to the WPQRs?
a. NDT operators
b. Inspectors only
c. Welders only
d. ( answer ) Welding engineer
10) Who has the final responsibility of sentencing and accepting a weld on completion?
a. The contractor’s inspector
b. Site manager
c. The welder
d. ( answer ) The client’s inspector or certifying authority
Pls see next part:

CSWIP 3.1: PROPERTIES OF MATERIALS
154
Date: September 16, 2018Author: Thanh ( QC ) Nguyen Le0 Comments
We summary some properties of material as below:
1.The ability of a material to withstand a load pulling it apart is called its tensile strength_.
2. The ability of a material to be stretched out without breaking is called _ductility.
3. An Izod impact machine is used to give indication of the toughness of a material.
4. The ability to withstand indentation is called hardness.
5. Lack of ductility is called brittleness.
6. The property of a metal to return to its original shape is called elasticity.
7. Increase in carbon content causes an increase___ in strength and hardness.
8. When carbon percentage increases, there is a decrease in ductility.
9. Low carbon steel contains less than 0.2%___ carbon.
10. Low ductility in a weld metal could result in __cracking_____.
11. Alloying is used to increase____ mechanical and physical properties of a steel.
12. Sulphur and phosphorus are not alloying elements; they are containmination_/
impurities___.
13. Alloying allows designers to use smaller / thin sections and still have the same strength.
14. An alloy that contains a high percentage of chromium and nickel would have resistance
to corrosion_____.
15. Quenching a carbon or low alloy steel will result in an ___increase____ in hardness and a
___decrease____in ductility
16. The hard constituent that results when steel is quenched is called __martensite____.
17. The tough laminated structure that is formed on slow cooling of ferrite and iron carbide
(cementite) is called ___peartile____.
18. The amount of martensite formed depends on the speed of ___cooling____ and the
percentage of __carbon_____.
19. After quenching, the structure may be improved by reheating to 200-300°C (550-650). This
is called tempering.________.
20. Small percentages of chromium will increase the strength and___hardness____, while a
small percentage of nickel will increase ___toughness____.
Refer document:
+ CSWIP 3.1
Stainless steel material – Part 1: How to check Iron contamination on stainless steel surface!
155
Date: August 28, 2019Author: Thanh ( QC ) Nguyen Le0 Comments
DETECTING FREE IRON
Free iron cannot see on the surfaces of contaminated parts by eye –> it must be converted into
a visible form.
There are at least the following three methods:
+ Moisten the surface, either by spraying with clean water or by immersing the part in clean
water. The water accelerates the reaction of the iron with oxygen to form iron oxide (rust)
which is readily visible. Sometimes, just allowing the part to sit undisturbed for a period of time,
especially in a humid environment will result in the conversion of iron to iron oxide. However,
156
this can take several days or weeks. It is important that the water is clean. If it contains iron
(from iron plumbing) or certain other chemicals, it will give a false indication of iron on the part
surface.
+ Spray the surface with a solution of copper sulfate in water. If free iron is present, a copper
film will form. In this test, the chemical reaction is: Fe + CuSO4 = FeSO4 + Cu. The copper film is
immediately visible.
+ Use the “ferroxyl test.” Spray the surface with a solution of potassium ferricyanide. If free
iron is present, a blue color will appear. This test is extremely sensitive and often gives false
positive results, that is, it gives an indication of iron being present when it really is not. The
ferroxyl solution must be made fresh each day. Both the copper sulfate and the ferroxyl tests
are described in ASTM A380.
157
Document refer:
CSWIP 3.1: What is OCV ( Open Circuit Voltage ) in welding power source?
Date: November 28, 2017Author: Thanh ( QC ) Nguyen Le0 Comments

In this topic we will talk about OCV in welding power source. We need to solve some question
to clear this topic:
 What is OCV?
 Types of static characteristic of power source?
 How to identify?
 How to know which welding process use what type of it ( CC or CV )?
 …
1) What is it?
Open circuit voltage (or potential) is voltage which is not connected to any load in a circuit.
158
As you can see, open circuit voltage is disconnected and does not form a complete circuit. This
is why it is called open. It is open and not connected to a form a complete electrical path.
The highest voltage is the open circuit voltage of the power source.
2) Types of static characteristic of power source:
Static characteristic of a welding source shows the trend of variation in voltage with current
when power source is connected to a load. This variation may be of three types:
 constant current (CC)

 constant voltage (CV)
 rising voltage (RV): will be discussed later.
a) Constant current / Amperage characteristic ( called CC ):
159
It is easy to understand it when add the arc length curve.
160
The volt ampere output curves for constant current power source are called ‘drooper’. With a
change in arc voltage, the variation in welding current is small and, therefore, with a
consumable electrode welding process, electrode melting rate remains fairly constant even
with a minor change in arc length.
These power sources are required for processes that use relatively thicker consumable
electrodes which may sometimes get stuck to work pieces or with non-consumable tungsten
electrode where touching of electrode with base metal for starting of arc may lead to damage
of electrode if current is unlimited. Under these conditions, the short circuiting current shall be
limited which would provide safety to power source and the electrode.
In constant current power source, variation in welding current with arc voltage (due to
fluctuations in arc length) is very small therefore welding current remains more or less constant
despite of fluctuations in arc voltage / length. Hence, this type of power source is also
found suitable for all those welding processes where large fluctuation in arc length is likely to
take place e.g., MMA and TIG welding ( importance note )!!!
b) Constant Voltage characteristic ( called CV ):
161
In CV power sources, a small variation in arc voltage (due to fluctuations in arc length) causes
significant change in welding current. Since arc voltage remains almost constant during welding
despite of fluctuations in arc length therefore this type of power source is called constant
voltage type.
Moreover, the constant voltage power sources do not offer true constant voltage output as
current voltage relationship curve shows slightly downward or negative slope. This negative
slope is attributed to internal electrical resistance and inductance in the welding circuit that
causes a minor droop in the output volt-ampere characteristics of the power source.
This type of power sources is found more suitable for all those welding processes
where fluctuation in arc length during welding is limited like in semiautomatic welding process
MIG, SAW, PAW.
162
This feature gives us what is known as a “self-adjusting arc” where changes in arc length,
voltage and current are automatically returned to the required values, producing stable welding
conditions. This makes the welder’s task somewhat easier when compared with MMA or TIG
welding. Although in principle it may be possible to use a constant voltage characteristic power
source for MMA welding it is far more difficult for the welder to judge burn-off rate than arc
length so arc instability results and the method is not practicable in MMA welding & GTAW
also.
3) How to identify?
Setting up of correct open circuit voltage is important for stability of welding arc especially
when AC is used.
The selection of an optimum value of OCV (50-100V) depends on the type of base metal,
composition of electrode coating, type of welding current and polarity, type of welding process
etc.
Base metal of low ionization potential (indicating ease of emitting free of electrons) needs
lower OCV than that of high ionization potential metal. Presence of low ionization potential
elements such as K, Na and Ca in electrode coating/flux in optimum amount reduces OCV
setting required for welding.
163
AC welding needs higher OCV compared with DC owing to problem of arc stability as in case of
AC welding current continuously changes its direction and magnitude while in case DC it
remains constant.
In the same, GTAW needs lower OCV than GMAW and other welding processes like SMAW and
SAW because GTAW uses tungsten electrode which has good free electron emitting capability
by thermal and field emission mechanism. Abundance of free electron in GTAW under welding
conditions lowers the OCV needed for having stable welding arc.
Too high OCV may cause electric shock. OCV is generally found to be different from arc voltage.
Arc voltage is potential difference between the electrode tip and work piece surface when
there is flow of current. Any fluctuation in arc length affects the resistance to flow of current
through plasma and hence arc voltage is also affected.
Increase in arc length or electrode extension increases the arc voltage. Further, electrical
resistance heating of electrode increases with electrode extension for given welding
parameters.
4) Summary:
Below table is Welding process comparisons about electrical characteristic:
164
We can divide 2 group of welding process for easy identify what electrical characteristic is used:
 Group 1: is for welding process where fluctuation in arc length during welding is

limited like in semiautomatic welding process MIG, MAG, FCAW, SAW, PAW –> it needs CV.
 Group 2: is for welding process where large fluctuation in arc length is likely to take
place e.g., MMA and TIG, SAW welding…—> it needs CC.
MMA, TIG and submerged arc power sources are therefore designed with what is known as a
drooping output or constant current static characteristic, MIG/MAG and FCAW power sources
with a flat or constant voltage static characteristic.
Finished!!!
Thanks!!!
Date: November 11, 2017Author: Thanh ( QC ) Nguyen Le1 Comment

1) Which of the following processes is most prone to solidification cracks?
165
a. MMA with basic coated electrodes
b. MMA with rutile coated electrodes
c. TIG
d. ( answer ) SAW
Solidification also referred as Hot Cracking.
Solidification Cracking (hot crack) can occur when:
-The depth-to-width ratio of the solidifying weld bead is large (deep & narrow)
-Disruption of the heat flow condition occurs, stop/start condition
2) Which of the following could be used to minimise the occurrence of solidification cracks in
steels welds?
a. Increase sulphur levels to a minimum of 0.5%
166
b. ( answer ) Reduce the dilution into the base metal
c. Increase carbon content in the weld metal
d. Reduce the manganese content in the weld metal
3) Hydrogen cracking is considered a cold crack as it will not form till the weldment cools to
below:
a. 500oC
b. ( answer ) 300oC
c. 300oF
d. 730oC
300oF = 149oC
167
400oF = 205oC
HYDROGEN INDUCED CRACKS: As know cold cracking, delayed cracking or underbead/toe

cracking.
4) In a heavy plate fabrication where S is residual @0.3%, which may cause problems in the
welded joint, additions of Mn may be added to prevent:
a. Laminations in the plate through thickness
b. Stress corrosion cracks
c. Manganese sulphides (MnS)
d. ( answer ) Solidification cracking
Solidification Cracking (hot crack) can occur when: Weld metal has a high carbon or impurity
(sulphur) content.
Precautions for controlling solidification cracking:
168
Add Manganese to the electrode to form spherical Mn/S which form between the grain and
maintain grain cohesion.
As carbon increases the Mn/S ratio required increases exponentially and is a major factor.
Carbon content % should be a minimised by careful control in electrode and dilution.
5) Inspection for hydrogen cracking is often specified to be done between 48 to 72 hrs after
completion of the weld, this is because?
a. The stress level will have reduced by then
It is the maximum time it taken for all the H2 to

b. ( answer )
diffuse out of the weld
c. Usually after 48 hrs such cracking is unlikely to occur
It is to ensure the weld has property cooled down to

d.
ambient temperature
Typically, hydrogen-induced cracking occurs at temperatures below 600 degrees Fahrenheit

(more commonly around or below 300 degrees Fahrenheit) and within 48 hours of completing
the weld. In some cases, it can occur as much a week after welding.
In applications with greater contributing factors — highly restrained joints; high levels of
hydrogen; or rapid cooling after weld completion — hydrogen-induced cracking can occur much
sooner, even immediately.
6) Preheats are used on steel joints of high hardenability mainly to:
a. ( answer ) Slow the cooling rate of the steel
b. Remove surface moisture from the joint
c. Reduce the formation of surface oxides
d. Increase the diffusion rate of hydrogen into the HAZ
There are four primary reasons to utilize preheat:
169
(1) it lowers the cooling rate in the weld metal and base metal, producing a more ductile
metallurgical structure with greater resistant to cracking
(2) the slower cooling rate provides an opportunity for any hydrogen that may be present to
diffuse out harmlessly without causing cracking
(3) it reduces the shrinkage stresses in the weld and adjacent base metal, which is especially
important in highly restrained joints and
(4) it raises some steels above the temperature at which brittle fracture would occur in
fabrication. Additionally, preheat can be used to help ensure specific mechanical properties,
such as notch toughness.
7) Sensitisation is a term applied to the formation of which intermetallic compound at the

grain boundaries in the HAZ of austenitic stainless steels?
a. ( answer ) Chromium carbide
b. Titanium carbide
c. Niobium carbide
d. Molybdenum carbide
Crack type: Inter-granular corrosion
Location: Weld HAZ. (longitudinal)
Steel types: Stainless steels
Microstructure: Sensitised grain boundaries*
Occurs when:
An area in the HAZ has been sensitised by the formation of chromium carbides. This area is in
the form of a line running parallel to and on both sides of the weld. This depletion of chromium
will leave the effected grains low in chromium oxide which is what produces the corrosion
resisting effect of stainless steels. If left untreated corrosion and failure will be rapid*
170
8) When comparing the properties of plain carbon steels and austenitic stainless steels …
which of the following statements is true?
a. ( answer ) Carbon steels have better thermal conductivity
b. Stainless steels have low expansion and contraction
Carbon steels have higher expansion rates in the Z

c.
direction
d. Stainless steels have lower chromium
Austenitic stainless steels have high ductility, low yield stress and relatively high ultimate tensile
strength, when compare to a typical carbon steel.
Plain Carbon Steels:
 Low Carbon Steel 0.01 – 0.3% Carbon

 Medium Carbon Steel 0.3 – 0.6% Carbon
 High Carbon Steel 0.6 – 1.4% Carbon
Plain carbon steels contain only Iron & Carbon as main alloying elements, but traces of Mn, Si,
Al, S & P may also be present.
Austenitic Grades:
 Non-magnetic
 Low thermal conductivity (‘hold’ the heat during welding)
 High coefficient of expansion – more distortion during welding
9) Weld decay occurs in which of the following steel types:
a. Carbon Manganese
b. Low alloy
c. Any stainless steels
d. ( answer ) Austenitic stainless steels
171
Inter-Granular Corrosion Also known as Weld Decay
 Location: Weld HAZ. (longitudinal

 Steel Type: Austenitic stainless steels
 Susceptible Microstructure: Sensitised HAZ grain boundaries
10) Which of the following materials is most susceptible to hydrogen cracking?
a. Low carbon steel
b. Austenitic stainless steel
c. (answer) High strength low alloy steel
d. Aluminium
Pls see next part:

Thanks!!!
CSWIP 3.0 / 3.1 / 3.2 , WELDING FIELD

1) Austenitic stainless steels are not susceptible to HICC becausse:
172
a. They are non-magnetic
b. They are stainless and contain chromium
c. ( asnwer ) They don’t harden during heating and cooling
d. They are highly ductile
HICC is Hydrogen Induced Cold Cracking
Susceptible Microstructure: Hardness Greater than 400HV Vickers (Martensite)
300 Series austenitic stainless steel has austenite as its primary phase (face centered

cubic crystal). These are alloys containing chromium and nickel, and
sometimes molybdenum and nitrogen, structured around the Type 302 composition of iron,
18% chromium, and 8% nickel. 200 Series austenitic stainless steels replace the majority of their
nickel content with manganese to reduce cost. Austenitic steels are not hardenable by heat
treatment.
173
2) The higher the alloy content of steels:
a. The lower the tendency for HICC to occur
b. ( answer ) The higher the tendency for HICC to occur
c. High alloy steels do not influence HICC susceptible
d. None of the above
174
3) Which one of these statements is true concerning solidification cracking?
a. Only occurs in MMA welding
b. ( answer ) Increased depth to width ratio will increase stress
c. Never occurs in MIG/MAG welding
d. All of the above
Solidification Cracking (hot crack) can occur when:
-The depth-to-width ratio of the solidifying weld bead is large (deep & narrow)
4) A solidification crack normally occurs where?
a. Through the HAZ
b. (answer) Longitudinal through the weld centre line
c. Transverse through the weld
175
d. Can occur anywhere
5) Weld decay is caused by the formation of a compound with carbon. The other element in
this compound is:
a. Manganese
b. Sulphur
c. (answer) Chromium
d. Nickel
Occurs when:
An area in the HAZ has been sensitised by the formation of chromium carbides. This area is in
the form of a line running parallel to and on both sides of the weld. This depletion of chromium
will leave the effected grains low in chromium oxide which is what produces the corrosion
resisting effect of stainless steels. If left untreated corrosion and failure will be rapid.
6) The directions of shrinkage in a welded joint are:
a. Transverse and diagonal
b. Transverse, short transverse and conical
176
c. (answer) Transverse, short transverse and longitudinal
d. Angular, diagonal and transgranular
7) In a single pass weld, the width of the zone in which longitudinal residual stresses are …
a. Independent of the weld width
b. Narrower than the weld metal
c. The same width as the weld metal
177
Wider than the weld metal and the heat affected
d. ( answer )
zone
8) What does the term “back-step” refer to during welding?
a. A QA term referring to inspection points
b. Use of step wedges on the root of the joint
c. Use of step wedges for radiography
d. (answer) A weld run sequence
9) Sequential welding is referred to with reference to which of the following?
a. (answer) Distortion
b. Residual stress
c. Fatigue life
d. Not associated with any of the above
178
10) A typical temperature for stress relieving C-Mn steel weldmet is:
a. (answer) 580oC – 620oC
b. 5000oC – 6200oC
c. 75oC – 80oC
d. 1500oC – 1800oC
179
11) A typical temperature for normalising C-Mn steel is:
a. Approximately 200oC
b. Approximately 300oC
c. (answer) Approximately 900oC
d. Approximately 1200oC
12) A maximum interpass temperature is generally given to control:
a. High HAZ hardness
b. Low HAZ toughness
c. Lack of inter-run fusion
d. Excess levels of penetration
180

Pls see next part:

Thanks!!!

1) During post weld heat treatment what is the sequence for the PWHT chart?
Restricted heating rate, soak time, unrestricted

a.
cooling rate
181
Unrestricted heating rate, restricted heating rate,
b. ( answer ) soak time, restricted cooling rate, unrestricted
cooling rate
Unrestricted heating rate, soak time, restricted

c.
cooling rate
Restricted heating rate, unrestricted heating rate,

d. soak time, unrestricted cooling rate, restricted
cooling rate
Variables for heat treatment process must be carefully controlled
Recommendations:
 Provide adequate support (low YS at high temperature!)

 Control heating rate to avoid uneven thermal expansions
 Control soak time to equalise temperatures
 Control temperature gradients – NO direct flame impingement!
 Control furnace atmosphere to reduce scaling
 Control cooling rate to avoid brittle structure formation
182
Below 427 degree, it is no need restricted heating.
2) After PWHT, it has been noticed that a repair must be carried out. How should this be
done?
a. With the minimum amount of heat input
b. ( answer ) Welded, checked and PWHT again
Defect removed via non-thermal process then

c.
checked
d. Welded and allowed to cool in air
The PWHT depends on the thickness of the repair. If the thickness of the repair welding is equal
to or higher of the minimum base metal thickness which requires PWHT then you shall perform
PWHT after completion of the repair.
3) Preheating may not be necessary during welding in which of the following material?
a. Welding of cast iron
b. Welding of low alloy steels
183
c. Welding of martensitic stainless steels
d. (answer) Welding of austenitic stainless steels
4) The main problem with solution treatment of stainless steels is that:
a. Controlling the rate of the temperature use
b. Controlling the cooling rate
c. The length of the soak period
d. ( answer ) High risk of distortion
 High coefficient of expansion – more distortion during welding

5) When would you measure the interpass temperature?
184
The highest temperature recorded in the weld joint
a. ( answer )
immediately prior to depositing the next runs
b. Immediately prior to commencing the first pass
c. When the welding is complete
Only required if the heat input is lower than that

d.
specified in WPS
6) If pre heating is decreased, which of the following would be most greatly affected?
a. Impact value
b. ( answer ) Hardness
c. Tensile strength
d. Toughness
Pre-heat treatments: are used to increase weldability, by reducing sudden reduction of

temperature, and control expansion and contraction forces during welding
 Preheat controls the formation of un-desirable microstructures that are produced from
rapid cooling of certain types of steels. Martensite is an undesirable grain structure
very hard and brittle it is produced by rapid cooling form the austenite region.
7) Assuming the same materials and welding procedure were used, which of the following is
the highest preheat?
185
a. Butt weld in 35mm plate
b. Cruciform joint in 25mm plate
c. Tee joint butt welded in 30mm plate
d. Tee joint fillet welded in 20mm plate
8) Why is it sometimes necessary to preheat the base material before welding?
a. Remove oil and grease
b. Remove moisture from the inside of the material
c. ( answer ) Prevent the possible risk of cracking
Not required if using cellulosic electrodes, as these

d.
will provide enough heat
186
9) Ultraviolet and infrared radiation, produced during arc welding, may:
a. Make arc striking easier
b. Be used for weld testing
c. Increase the welding speed
d. (answer) Cause skin burns
10) Who is responsible for site safety?
a. Site engineer
b. Welding supervisor
c. An approved inspector
d. (answer) Everyone
11) Is it permissible to allow welding to be carried out in bad weather?
187
a. Never
Yes as long as there is adequare protection from the

b. ( answer )
poor weather conditions
Yes as long as basic low hydrogen welding electrodes

c.
are used
Yes as long as the welder is prepared to work in the

d.
rain
Pls see next part:

Thanks!!

1) One of the following alloys is non-magnetic. Which?
 4% Chromium Molybdenum
 12% Chromium
 Austenitic Stainless Steel (answer)
 9% Nickle Steel
188
2) When TIG welding Austenitic Stainless Steel pipe, Argon gas baking is called for. This is to:
 Prevent oxidation ( answer )

 Prevent under bead cracking
 Prevent porosity
 Control the penetration bead shape
3) The principal purpose of a welder qualification test is to:
 Test the skill of the welder. ( answer )

 Assess the weldability of the materials.
 Decide which NDT methods to use.
 Give the welder practice before doing production welding.
189
4) A fabrication procedure calls for the toes of all welds to be blended in by grinding. The
reason for doing this is to:
 Make the weld suitable for liquid (dye) penetrant inspection.

 Improve the fatigue life. (answer)
 Reduce residual stresses.
 Improve the general appearance of the welds.
5) For full penetration single-sided butt joints, root bead penetration and profile are mainly
influenced by:
 Root face.
 Bevel angle.
 Root gap. ( answer )
 Included angle.
Pls take note the “profile” in question.
190
191
6) Which of the following would be cause for rejection by most fabrication standards when
inspecting fillet welds with undercut, a small amount of:
 Depth
 Length
 Width
 Sharpeness (answer)
The size effect is reflected by the loss of cross-sectional area which is insignficant when
compare to the shape effect.
192
7) When visually inspecting the root bead of the single V-butt weld it should be checked for:
 Lack of root penetration. ( answer )

 HAZ hardness.
 Tungsten inclusions.
 Slag
Because this is “visual inspection”. So we can’t check hardness / internal slag / tungsten
insclucions.
8) The strength of a fillet weld is determined by:
193
 Leg length.
 Weld profile.
 Weld width.
 Throat thickness. (answer)
9) The European Standard for NDE of fusion welds by visual examination is:
 EN 288.
 EN 499.
 EN 287.
 EN 970. ( answer )
194
10) Visual inspection of a fabricated item for a high integrity application should cover
inspection activities:
 Before, during and after welding. ( answer )

 Before welding only.
 After welding only.
 During and after welding only.
11) Incomplete root penetration in a single V butt joint may be caused by:
 Excessive root face.

 Excessive root gap.
 The current setting being too low.
195
 Both a and c. ( answer )
Below is summary why lack of penetration:
196
Current: The current used will be determined by the choice of electrode, electrode diameter
and material type and thickness. Current has the most effect on penetration.
12) Incomplete root fusion in a single V butt weld may be caused by:
 Linear misalignment. (answer)

 Root gap being too large.
197
 Root faces being too small.
 Welding current too high.
Refer above question!
13) When visually inspecting the face of a finished weld which of the following flaws would
be considered to be the most serious:
 Excess weld metal height.

 Start porosity.
 Spatter
 Arc strikes. ( answer )
198
Arc strikes: easy lead to crack due to cooling down too fast.
14) A burn-through may occur if the:
 Current is too low.

 Root face is too large.
 Root gap is too large.
 Arc voltage is too high. (answer)
199
Arc voltage is more than effect.
15) A Code of Pratice is a:
200
 Standard of workmanship quality only.
 Set of rules for manufacturing a specific product. (answer)
 Specification for the finished product.
 Code for the qualification of the welding procedures and welders qualifications.
Pls see next part!!!

Thanks!!!

1) A solid inclusion in a welder may be:
1. Entrapped slag. (answer)

2. Entrapped gas.
3. Lack of inter-run fusion.
4. None of the above.
This is “solid” not gas!
2) Which is the following is a planar imperfection?
1. Lack of sidewall fusion. (answer)

2. Slag inclusion.
201
3. Linear porosity.
4. Root concavity.
3) For fillet welds it is normal practice in the UK and USA measure:
1. Throat thickness.
2. Leg lengths. ( answer )
3. Penetration depths.
4. Both 1 and 3.
Measure “Leg lengths” is easy checking on site.
4) Heavy porosity on the surface of some MMA welds made on a construction site is most
likely to be caused by :
1. Use of the wrong class of electrodes.

2. Use of excessive current.
3. Moisture pick-up in the electrode covering. ( asnwer )
4. A bad batch of the electrodes.
202
5) Slag inclusion may be present is:
1. Manual metal arc welds. (answer)

2. Metal inert gas welds.
3. Metal active gas welds.
4. All welds.
203
6) The main cause of undercut is:
1. Excessive amps. (answer)

2. Excessive OCV.
3. Excessive travel speed.
4. Current too low.
204
7) Which group of welders is most likely to require continuous monitoring by a welding
inspector?
1. Concrete shuttering welders.

2. Overland pipeline welders. ( answer )
3. Tack welders.
4. Maintenance welders.
8) Which of the following fillet welds is the strongest assuming they are all made using the
same material and welded using the same WPS?
205
1. 8mm throat of a mitre fillet. ( answer )
2. 7mm leg + 2mm excess weld metal. ( throat thickness: 7*0.7=4.9mm, excess weld metal
is not effect to strength of weld )
3. Mitre fillet with 10mm leg. ( throat thickness: 10*0.7=7mm )
4. Concave fillet with 11mm leg. ( throat thickness: least )
Throat thickness is direct effect to the strength of weld.
9) A typical included angle for MMA welding a full penetration pipe butt is:
1. 350 .
2. 700. ( answer )
3. 900.
4. Dependent on the pipe diameter.
206
10) A fillet weld has an actual throat thickness of 8mm and a leg length of 7mm, what is the
excess weld metal?
1. 2.1mm
2. 1.8mm
3. 3.1mm ( answer )
4. 11.4mm
207
From leg length 7mm –> design throat thickness is 7*0.7 = 4.9mm
So, excess weld metal is 8 – 4.9 = 3.1mm
11) The fusion boundary of a fillet weld is the:
208
1. Boundary between the weld metal and HAZ. ( answer )
2. Boundary between individual weld runs.
3. Depth of root penetration.
4. Boundary between the HAZ and parent material.
It is same with butt weld:
12) If the Visual Welding Inspector detects a type of imperfection not allowed by the
application Standard he must:
209
1. Request further NDE.
2. Reject the weld. ( answer )
3. Prepare a concession request.
4. Reject the weld only if he considers it to be harmful.
13) BS EN 970 allows the use of a magnifying glass for visual inspection but recommends that
the magnification is:
1. X2
2. X2 to X5. ( answer )
3. X5 to X10.
4. Not greater than X20.
14) The majority of welder qualification tests are carried out using unbacked joints, because:
1. It is quicker and cheaper if back-gouging is not required.

2. If the welding process is not TIG back purging is not required.
3. All welder qualification tests are done on small diameter pipe.
4. It requires more skill and increase the welders’ qualification range (answer )
210
15) If submerged arc welding is to be used to make butt welds, which would you be most
critical of?
1. The root gap tolerance ( answer )

2. The angle of preparation
3. The root face width
4. The gas cut finish
Root Gap is very importance for accessibility joint.
211
Pls see next part:
Thanks!!!

1. You see a welder using an oxy-acetylene flame with a long feathered inner cone. What
would be the effect of this on carbon steel?
a. The weld would be hard and brittle ( answer )
b. The weld could be too soft
c. There will be no effect on the weld
d. The weld will have undercut
Notes: The high intensity of heat and rapid cooling will cause hardening in low alloy and
medium/high C steels Ù they are thus pre-heated to avoid the hardening effect.
2. A welder qualification test is to verify:

a. The skill of the welder ( answer )
b. The quality of the materials
c. The non-destructive test procedures
d. The manufacturing methods
Notes:
Question:
What is the main reason for qualifying a welder ?
Answer:
To show that he has the skill to be able to make production welds that are free from defects
Note: when welding in accordance with a Qualified WPS
3. A fabricating procedure calls for fillet welds to be ‘blended in’ by grinding. This influences:
a. HAZ. cracking
b. Fatigue life ( answer )
212
c. Residual stress
d. Yield strength
Notes:
 Most codes quote the weld toes shall blend smoothly

 This statement is not quantitative and therefore open to individual interpretation
 The higher the toe blend angle the greater the amount of stress concentration
 The toe blend angle ideally should be between 20o-30o
4. Bend test specimens have been taken from a 25 mm thick carbon steel butt weld. Which
would show lack of inter-run fusion?
a. Side bend (answer)
b. Root bend
c. Face bend
d. Guided bend
Note:
+ Side bend tests are normally carried out on welds over 12mm in thickness
+ Below approximately 12mm material thickness transverse specimens are usually tested with
the root or face of the weld in tension. Material over 12mm thick is normally tested using the
side bend test that tests the full section thickness.
+ The transverse face bend specimen will reveal any defects on the face such as excessive
undercut or lack of sidewall fusion close to the cap. The transverse root bend is also excellent at
revealing lack of root fusion or penetration. The transverse side bend tests the full weld
thickness and is particularly good at revealing lack of side-wall fusion and lack of root fusion in
double-V butt joints. This specimen orientation is also useful for testing weld cladding where
any brittle regions close to the fusion line are readily revealed.
213
5. Lamellar tearing has occurred in a steel fabrication. BEFORE welding could it have been
found by:
a. X-ray examination
b. Dye penetrant
c. Ultrasonic examination
d. It would not have been found by any inspection method ( answer )
Notes:
Lamerllar teaing:
+ Lamellar tearing can occur beneath the weld especially in rolled steel plate which has poor
through-thickness ductility.
+ Lamellar tearing has a step like appearance due to the solid inclusions in the parent material
(e.g. sulphides and silicates) linking up under the influence of welding stresses.
Lamination:
+ Plate lamination defect is one of the primary processing discontinuity that originates during
hot or cold forming processes and is considered as a serious metal plate defect.
+ All the metals contain discontinuities at micro and macro levels. These discontinuities, when
above the acceptance level, are termed as defects. The discontinuities in metal are classified
according to the stage of manufacturing in which they initiate.
214
+ Plate lamination defect can be defined as flat and thin subsurface separations present inside
metal plate, parallel to the surface of the plates. The sources of this defect are inherent
discontinuities present in metal such as inclusion and porosity, which are flattened during the
rolling process.
6. You are to oversee the arc welding of some machine fittings and find that they are
cadmium plated. Would you:
a. Permit it to proceed
b. Permit it to proceed with fume extraction
c. Stop the operation at once ( answer )
d. Advise the welder to drink milk and proceed
Note: Cadmium coatings are applied to iron, steel, brass and aluminium and give excellent
resistance to corrosion in most conditions and especially in marine and alkaline environments.
Cadmium, like zinc, also provides sacrificial protection to a substrate such as steel by being
preferentially corroded when the coating is damaged and small areas of the substrate are
exposed.
Welding on some plated or painted metals may be especially hazardous. Cadmium is often used
as a coating on steel to prevent rust. However, cadmium in welding fumes causes the lung
disease, emphysema, as well as kidney failure.
CADMIUM WELDING HAZARDS. Fumes and dust accumulating in the air during welding
of cadmium plated metals are major health hazards. Whenever it is necessary to weld
cadmium plated parts adequate local exhaust ventilation will be provided.
In many instances it will be easier and safer to remove cadmium from the parts, accomplish
welding, and re-cadmium plate to restore the original corrosion resistance.
Cadmium plated metals can be confused with other electroplated metals. When there is
doubt about the composition of a metal to be welded (including the plating) a sample shall be
submitted to a metallurgical or chemical laboratory for qualitative analysis. Welding will not
be performed until the metal/plating is properly identified.
7. One of the reasons for excluding hydrogen from the weld metal is to prevent the weld
from:
a. Cracking
215
b. Cooling slowly
c. Cooling quickly
d. Expanding
Note: Hydrogen Induced Cold Cracking:
Also known as HCC, Hydrogen, Toe, Underbead, Delayed, Chevron Cracking. Occurs in:
–Carbon Steels
–Carbon-Manganese
–Low, Medium and High Alloy Steels:
 Mainly in Ferritic or Martensitic steels.

 Very rarely in Duplex stainless steels,
 Never in Nickel or Copper alloys.
216
8. When a metal regains its original shape when a stress acting upon it is removed, the metal
is said to have:
a. Ductility
b. Plasticity
c. Malleability
d. Elasticity ( answer )
217
218
9. Proof stress is used when non-ferrous metals are undergoing tensile tests to determine the
equivalent:
a. Tenacity
b. Elasticity
c. Yield strength ( answer )
d. Tensile strength
219
10. To test a component for vibrational loading, a suitable mechanical test would be:
a. Impact
b. Tensile
c. Compressive
d. Fatigue ( answer )
11. The main reason for pre-heating medium and high carbon steels before cutting by oxy-
fuel gas technique is to:
220
a. Improve the quality of the cut
b. Increase the cutting speed
c. Refine the grain structure
d. Prevent hardening and cracking ( ANSWER )
Note: The high intensity of heat and rapid cooling will cause hardening in low alloy and
medium/high C steels. They are thus pre-heated to avoid the hardening effect.
12. One purpose of a microscopic examination of a weld is to establish the:

a. Strength of the weld
b. Number of alloying elements
c. Grain size ( ANSWER )
d. Number of runs used
Note: Macro examination is used to check number of runs used.
13. The predominant structure of an hyper-eutectoid steel that has been quenched at above
its upper critical point will be:
a. Austenite
b. Martensite ( answer )
c. Troostite
d. Sorbite
14. When weld metal refinement takes place in a multi-run deposit, it is known by the term:
a. Weld annealing
b. Weld refining (answer )
c. Weld normalising
d. Weld recrystallisation
15. One advantage of metal gas arc shielded welding is:

a. Can be used in draughty locations without protection
b. Produces a deposit low in hydrogen content ( answer )
221
c. Any welding position can be welded with spray transfer
d. Fine spatter at nozzle restricting gas flow
Note: Shielding gas will protect weld pool & prevent hydrogen content.
Dip Transfer: (Voltage < 22) / (Amperage < 200)
 Thin materials positional welding

Globular Transfer: Between Dip & Spray Transfer
 Limited commercial, Used only in some mechanised MAG process using CO2 shielding
gas
Spray Transfer: (Voltage > 27) / (Amperage > 220)
 Thicker materials, limited to flat welding positions, high deposition

Pulse Transfer: Both spray and dip transfer in
 one mode of operation, frequency range 50-300 pulses/second

 Positional welding and root runs

222
The end!
Date: April 12, 2018Author: Thanh ( QC ) Nguyen Le1 Comment

1) BS499 communicates by the use of symbols the type of joint preparation to be used. Which
of the following symbols indicates the depth of weld penetration required on the joint?
Answer: B
It is same with below picture.
223
2) Which of the following symbols would indicate that a weld has to be finished on the
‘other’ side of the weld?
Answer: A ( weld on other side of the weld is weld on both side ).
224
We can confuse with D ( but D is symbol indicate for 1 side only ).
3) The use of flux with gas shielded metal arc welding allows:
a. Sheet metal to be welded
b. A stable arc when using high current densities ( answer )
c. Aluminium to be welded
d. Less dilution of the weld by the parent metal
Note:
Electrode:
Various accessories for SMAW:

The choice of electrode for SMAW depends on a number of factors, including the weld material,
welding position and the desired weld properties. The electrode is coated in a metal mixture
called flux, which gives off gases as it decomposes to prevent weld contamination, introduces
deoxidizers to purify the weld, causes weld-protecting slag to form, improves the arc
stability, and provides alloying elements to improve the weld quality.
4) In MMA welding what parameter is used for control of penetration into the base material?
a. Voltage
b. Welding speed
c. Iron powders in the coating
d. Current ( answer )
225
5) In the welding of a butt joint from one side, the profile of the root bead is controlled by:
a. Root face
b. Bevel angle
c. Root gap ( answer )
d. All of the above
6) What type of power characteristic is required for manual welding?

a. Constant voltage
b. Flat characteristic
c. Drooping characteristic ( answer )
d. DC generator
Note: Constant Current Power Source = Drooping Characteristic
7) Which of the following tests would indicate the toughness of weld metal/parent metal-
HAZ?
a. Macro
b. Nick break
c. Hardness
d. Charpy vee notch ( answer )
226
CVN test:
 measuring impact strength in different weld joint areas

 assessing resistance toward brittle fracture
8) Degreasing components is essential for quality welding but some agents may:
a. Cause corrosion problems
b. Give off phosgene gas
c. Leave residues
d. All the above ( answer )
9) Which of the following elements has the greater effect on the hardenability of a steel
plate?
a. Molybdenum
b. Chromium
c. Titanium
d. Carbon ( answer )
Iron (Fe):
Main steel constituent. On its own, is relatively soft, ductile, with low strength.
Carbon (C):
Major alloying element in steels, a strengthening element with major influence on HAZ
hardness. Decreases weldability. typically < ~ 0.25%
10) In MAG/CO2 welding which parameter gives the greatest control of weld
appearance during dip transfer or short-circuiting welding?
a. Wire stick-out length
b. Amperage
227
c. Wire feed speed
d. Inductance
+ There are 3 principle modes of droplet transfer, namely
 dip transfer (short-circuiting)

 spray transfer
 pulsed transfer
+
Maximum inductance:
 reduced spatter
 Hotter arc –> more penetration
 More fluid weld pool Ù flatter and smoother weld
 Recommended on thicker materials and stainless steels
Minimum inductance:
 Colder arc –> used only for arc stability when welding wide gaps
 Convex weld, more spatter
228
 Improved weld pool control
 Recommended on thin materials
11) In MMA welding, the slags produced can be varied to suit the welding position. Which
type of slag would be required for welding in the HV position?
a. Fluid
b. Viscous ( ANSWER )
c. Semi fluid
229
Notes: HV position have got PB & PD.
12) The weld metal deposit of MMA electrodes achieves its mechanical strength through:
a. The core wire
b. The flux coating ( ANSWER )
c. Iron powders with the flux coating
Notes: Function of the Electrode Covering:
 To facilitate arc ignition and give arc stability

 To generate gas for shielding the arc & molten metal from air contamination
 To de-oxidise the weld metal and flux impurities into the slag
 To form a protective slag blanket over the solidifying and cooling weld metal
 To provide alloying elements to give the required weld metal properties
 To aid positional welding (slag design to have suitable freezing temperature to
support the molten weld metal)
 To control hydrogen contents in the weld (basic type)
Welding consumables for MMA:
 Consist of a core wire typically between 350-450mm in length and from 2.5-6mm in
diameter
 The wire is covered with an extruded flux coating
 The core wire is generally of a low quality rimming steel
 The weld quality is refined by the addition of alloying and refining agents in the flux
coating
 The flux coating contains many elements and compounds that all have a variety of
functions during welding
13) What constituent ( thanh phan ) is needed in the coating of an electrode to prevent the
formation of porosity in the welding of a rimming steel?
a. Iron powders
b. Calcium fluoride
230
c. Silicon (answer)
d. Calcium carbonate
Notes:
+ What is rimming steel?
Rimmed steel is a low-carbon steel. This steel contains an amount of iron oxide such that
continuous generation of carbon monoxide during solidification is not inhibited. Rimmed steel
is virtually free from voids, and is easily bendable and cleanable.
Most rimmed steels contain less than 0.1% carbon. Rimmed steel has an excellent, defect-free
surface which gives it advantages over other types of steel. Steel sheets and plates are
produced from rimmed steel.
+ Explains Rimmed Steel:
Rimmed steel is different from other steels in terms of chemical composition across the section
and from top to bottom of an ingot. It requires partial deoxidization before casting. This de-
oxidization allows a rim, containing mostly iron, to form in the steel. The concentration of
carbon, sulfur and phosphorus in rimmed steel is lower than average for an ingot in the outer
rim and higher in the core of the rim. Fine gas bubbles form in the body of the ingot after
solidification of the outer rim which help to protect solidification shrinkage. The rim’s internal
voids are removed during rolling and forging, but it remains in the clean outer rim. This clean
surface enhances the quality of the steel surface.
Steels made with 0.15 percent carbon are rimmed steel. This steel is valued more for its easy
work ability than its strength and durability.
This steel is not as hard as other steels. Therefore, easily machinable or bendable products can
be made of rimmed steel. Since it is easily rolled, cold-bent and cold-formed, it shows high
aesthetic properties and low roughness. In hot-bending and other hot processes this steel can
be problematic.
+ Silicon (Si):
231
Residual element from steel de-oxidation. typically to ~0.35%
14) Welds made with high heat inputs show a reduction in which of the following properties?
a. Ductility
b. Toughness ( answer )
c. Fatigue strength
d. Mechanical strength
Note:
+ High heat input – slow cooling:
 Low toughness (grain growth)

 Reduction in yield strength
+ Low heat input – fast cooling:
 Increased hardness
 Hydrogen entrapment
 Lack of fusion
15) In the welding of austenitic pipework the bore 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 ( answer )
d. Eliminate the formation of hydrogen
232
THE END!!!

1. In X-ray work the quality of the radiographic image is assessed by the:
a. Density of the film
b. IQI indicator ( ANSWER )
c. KVA available
d. Stand-off distance
Note:
Density – relates to the degree of darkness
Contrast – relates to the degree of difference
233
Definition – relates to the degree of sharpness
Sensitivity – relates to the overall quality of the radiograph
2. A steel described as QT will have improved tensile properties because it has:

a. Had control of chemical composition
b. Been heat-treated ( ANSWER )
c. Been quality tested
d. Been vacuum melted
Note: quenching and tempering (Q-T) process:
QT steels are low Carbon(lower than for N steel of same strength level),low alloyed
(Mn,B,Cr,Mo,Ni….), high purity
• Oil, spray or water quenching gives a fine grain bainitic to martensitic hard microstructure
(ferritic for N steels)
• Tempering makes the microstructure softer, tougher and improves the homogeneity of
mechanical properties over the thickness
• Tempered martensite gives the best compromise for strength and toughness
• Yield/Strength ratio is of 0.8(upper baintite) to 0.95 (martensite) compared to about 0.6/0.7
for ferrite
• Good weldability is achieved with low carbon and high purity
3. Which one of the following types of steel would give rise to the formation of porosity when
autogenously welded with an arc process?
a. Fully killed steel
b. Semi killed steel
c. Rimming steel (answer)
d. Fine grained steel
Notes:
+ What is rimming steel?
234
Rimmed steel is a low-carbon steel. This steel contains an amount of iron oxide such that
continuous generation of carbon monoxide during solidification is not inhibited. Rimmed steel
is virtually free from voids, and is easily bendable and cleanable.
Most rimmed steels contain less than 0.1% carbon. Rimmed steel has an excellent, defect-free
surface which gives it advantages over other types of steel. Steel sheets and plates are
produced from rimmed steel.
+ Explains Rimmed Steel:
Rimmed steel is different from other steels in terms of chemical composition across the section
and from top to bottom of an ingot. It requires partial deoxidization before casting. This de-
oxidization allows a rim, containing mostly iron, to form in the steel. The concentration of
carbon, sulfur and phosphorus in rimmed steel is lower than average for an ingot in the outer
rim and higher in the core of the rim. Fine gas bubbles form in the body of the ingot after
solidification of the outer rim which help to protect solidification shrinkage. The rim’s internal
voids are removed during rolling and forging, but it remains in the clean outer rim. This clean
surface enhances the quality of the steel surface.
Steels made with 0.15 percent carbon are rimmed steel. This steel is valued more for its easy
work ability than its strength and durability.
This steel is not as hard as other steels. Therefore, easily machinable or bendable products can
be made of rimmed steel. Since it is easily rolled, cold-bent and cold-formed, it shows high
aesthetic properties and low roughness. In hot-bending and other hot processes this steel can
be problematic.
4. In submerged arc welding the use of excessively high voltage would result in:
a. Insufficient flux melting
b. Excessive flux melting ( answer )
c. Slag removal difficulties
d. Spatter
235
Welding voltage:
 welding voltage controls arc length

 increase in voltage produce a flatter and wider bead
 increase in voltage increase flux consumption
 increase in voltage tend to reduce porosity
 an increased voltage may help bridging an excessive root gap
 an increased voltage can increase pick-up of alloying elements from an alloy flux
5. Cellulosic electrodes are often used when welding the root pass of pipes in the field
because:
a. Hydrogen control is needed
b. There are iron powders in the electrode
c. Higher arc voltage can be obtained ( answer )
d. Shorter arc length can be obtained
Cellulosic electrodes:
236
 covering contains cellulose (organic material).
 produce a gas shield high in hydrogen raising the arc voltage.
 Deep penetration / fusion characteristics enables welding at high speed without risk of
lack of fusion.
 generates high level of fumes and H2 cold cracking.
 Forms a thin slag layer with coarse weld profile.
 not require baking or drying (excessive heat will damage electrode covering!).
 Mainly used for stove pipe welding
 hydrogen content is 80-90 ml/100 g of weld metal.
Note:
Another consequence of the hydrogen content of the gas shield is the requirement for a higher
voltage (around 70V).
However, the high hydrogen content in the shielding gas is also this electrode’s main drawback.
It causes a high level of diffusible hydrogen in the weld, which is one of the parameters
influencing hydrogen cracking (also called cold cracking) if good practices are not followed and
preventive actions are not taken.
The high hydrogen level means that any steel welded with these electrodes should have a very
high resistance to hydrogen-induced cold cracking. These electrodes are mainly used on low-
carbon, non-alloyed steel. They should be used only with due consideration of the steel
composition, restraint and need for preheat.
One other advantage of cellulosic electrodes is their ability to weld in the stove piping (or
vertical down) position. E6010 electrodes are sometimes called ‘stove pipe electrodes’. This
position can enhance the weld and helps to improve efficiency and productivity, thanks to quick
cooling of the slag.
Refer: https://www.twi-global.com/technical-knowledge/job-knowledge/comparison-of-the-
use-of-rutile-and-cellulosic-electrodes-142/
6. In the welding of austenitic stainless steels, the electrode and plate material can be
purchased with low carbon contents. The reason for this is to prevent:
237
a. Cracking in the heat affected zone
b. The formation of chromium carbides ( answer )
c. Cracking in the weld metal
d. Distortion
Notes: Precautions against Weld Decay
 Using low carbon grade stainless steel e.g. 304L, 316L, as the amount of free carbon in
solution is sufficiently low to ensure that Cr carbide formation is minimal and therefore that
sensitisation is not usually of practical significance during welding.
7. Submerged arc fluxes can be supplied in two forms. These are:

a. Sintered and agitated
b. Agitated and fused
c. Sintered and agglomerated
d. Fused and agglomerated ( answer )
Note:
A flux is supplied separately via a flux hopper in the form of either fused or agglomerated.
8. In a steel that has improved creep properties at elevated temperatures, which one of the
following elements helps in this improvement?
a. Tungsten
b. Manganese
c. Molybdenum (answer )
d. Carbon
Note:
+ Chromium (Cr) Corrosion resistance and resistance to elevate temp. (secondary only to Mo

in creep resistance)
+ Molybdenum (Mo) 1% is for Creep resistance
238
9. Welding a steel plate with a CE of 0.45 would require preheating to:
a. Prevent the formation of sulphides
b. Prevent hardening in the HAZ
c. Prevent the formation of carbides
d. To improve mechanical properties in the weld
Notes: C-Mn, medium carbon, low alloy steels (CE 0.4 to 0.5)
 Thin sections can be welded without preheat but thicker sections will require low
preheat levels and low hydrogen processes or electrodes should be used
 Hardness: Preheat-reduces cooling rate which reduces the risk of Susceptible
Microstructure
 Preheat may help: – to slow down cooling rate
 We can preheat metals and alloys when welding for a number of reasons. Primarily we
use most pre-heats to achieve one or more of the following:
 To control the structure of the weld metal and HAZ on cooling
 To improve the diffusion of gas molecules through an atomic structure.
 To control the effects of expansion and contraction.
 Preheat controls the formation of un-desirable microstructures that are produced from
rapid cooling of certain types of steels. Martensite is an undesirable grain structure very
hard and brittle it is produced by rapid cooling form the austenite region.
10. Which of the following processes uses the ‘keyholing’ system of fusion?
a. Friction welding
b. Diffusion bonding
c. Electron beam welding ( answer )
d. Autogenous TIG welding
Note:
Keyhole – When welding an open butt, or open groove weld JOINT with STICK, MIG or TIG, a
“keyhole” will open up. When the sides of the plate burn away on each side of the WELD POOL
a hole is formed which allows for good TIE IN and PENETRATION.
239
The keyhole must not be allowed to grow too large or the WELD POOL will waterfall out the
back of the joint.
If the keyhole grows too large, stop welding immediately, let the plate cool and make the
proper adjustment to correct the problem. (Too much heat, wrong rod angle, or staying too
long in the puddle may be the cause.)
refer: http://www.keenovens.com/articles/welding-terms.htm
240
11. In friction welding the metal at the interface is in the:
a. Liquid state
b. Solid state
c. Plastic state (answer )
d. Elastic state
Note: Friction Welding
 Because no fusion – can join wide variety of dissimilar materials

 Sound joints produced
 HAZ degradation minimised
241
 Many variants being developed for different shapes/applications
Friction surfacing is a process derived from friction welding where a coating material is applied
to a substrate. A rod composed of the coating material (called a mechtrode) is rotated under
pressure, generating a plasticised layer in the rod at the interface with the substrate. By
moving a substrate across the face of the rotating rod a plasticised layer is deposited between
0.2–2.5 millimetres (0.0079–0.0984 in) thick depending on mechtrode diameter and coating
material.
12. Welding procedures may require welds to be deposited at a controlled rate of heat input.
High heat inputs would:
a. Have poor profile
b. Have larger grain size (answer )
c. Have high hardness in the HAZ
d. Have low elongation properties
Notes:
High heat input – slow cooling:
 Low toughness (grain growth)

 Reduction in yield strength

Low heat input – fast cooling:
 Increased hardness
 Hydrogen entrapment
 Lack of fusion
13. In a tensile test a brittle material would be indicated if the fracture surface:
a. Shows a reduction in size
b. Is flat and featureless ( answer )
c. Breaks in the parent material
d. Breaks at 45° to the load
242
14. What destructive test would be required to ascertain the likelihood of cracking in the heat
affected zone of a weld?
a. Nick break
b. Side bend test
c. Charpy impact test
d. Macro test (answer )
Notes:
+ Purpose:
To examine a particular region of the weld or HAZ in order to:-
 To examine the microstructure

 Identify the nature of a crack or other imperfection
+ Will Reveal:
243
 Weld soundness
 Distribution of inclusions
 Number of weld passes
 Metallurgical structure of weld, fusion zone and HAZ
 Location and depth of penetration of weld
 Fillet weld leg and throat dimensions
15. In submerged arc welding excessive arc voltage may cause:

a. Excessive penetration
b. Change in weld metal composition
c. Narrow weld width
d. Excessive bead profile (answer )
Note: Welding voltage:
 welding voltage controls arc length

 increase in voltage produce a flatter and wider bead
 increase in voltage increase flux consumption
 increase in voltage tend to reduce porosity
 an increased voltage may help bridging an excessive root gap
 an increased voltage can increase pick-up of alloying elements from an alloy flux
244

The end!!!

1. The British code for visual inspection requirements is:
a. BS 4872
b. BS 499
c. BS 4870
d. None of the above ( answer )
Note:
BS EN 970: Non – destructive examination of fusion welds – visual examination
2. A code of practice for visual inspection should include the following:
245
a. Before, during and after welding activities ( answer )
b. Before welding activities only
c. After welding activities only
Note: Stages of Visual Inspection (to BS EN 970)
Extent of examination and when required should be defined in the application standard or by
agreement between the contracting parties
For high integrity fabrications inspection required throughout the fabrication process:
+ Before welding
+ During welding
+ After welding
3. Incomplete root 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 and C ( answer )
Note: Causes
 Too small a root gap

 Arc too long
 Wrong polarity
 Electrode too large for joint preparation
 Incorrect electrode angle
 Too fast a speed of travel for current
4. Incomplete root fusion would certainly be caused by:
246
a. Linear misalignment
b. Incorrect tilt angle
c. Differing root face widths
d. All of the above ( answer )
Note: Causes
 Too small a root gap

 Arc too long
 Wrong polarity
 Electrode too large for joint preparation
 Incorrect electrode angle
 Too fast a speed of travel for current
5. When visually inspecting a completed single vee butt weld cap, you would certainly assess:
a. Cap height
b. Toe blend
c. Weld width
Note:
Features to Consider:
+ Butt welds – Profile
+ Butt welds – Toe Blend
+ Butt welds – Weld Width
6. You notice a very ‘veed’ ripple shape. This is most likely caused by:
a. Poor consumable choice
b. Welding position
247
c. Excessive travel speed (answer )
d. All the above
Note: Travel speed too fast:
+ Narrow thin weld bead
+ Fast cooling weld pool
+ Slag inclusion
+ Poor fusion/ penetration
7. Toe blending is important as it may affect:

a. Corrosion
b. Fatigue life (answer )
c. Overlap type defects
d. All the above
Note:
 Blend the weld profile: reduce stress concentration at the toes of the weld
 Most codes quote the weld toes shall blend smoothly
 This statement is not quantitative and therefore open to individual interpretation
 The higher the toe blend angle the greater the amount of stress concentration
 The toe blend angle ideally should be between 20o-30o
8. Slag inclusions would occur with:

a. Manual metal arc
b. Metal inert gas
c. Submerged arc welding
d. Both A and C (answer )
Note: MMA & SAW have slag after welding
248
9. Undercut is principally caused by:
a. Excessive amps
b. Excessive volts
c. Excessive travel speed
d. All the above (answer )
Note: Causes:
+ Excessive welding current
+ Welding speed too high
+ Incorrect electrode angle
+ Excessive weave
+ Electrode too large
10. Undercut is normally assessed by:

a. Its depth
b. Its length
c. It’s blending
Note: refer to ASME IX
11. A welding procedure is useful to:

a. Give information to the welder
b. Give information to the inspector
c. Give confidence to a product
d. All the above (answer )
249
12. An essential variable may:
a. Change the properties of a weld
b. Influence the visual acceptability
c. Require re-approval of a weld procedure
13. A magnifying glass may be used during visual inspection, but BS 5289 states that its
magnification should be:
a. Up to 5 ∅
b. 2 to 2.5 ∅ (ANSWER )
c. 5 to 10 ∅
Note:
+ Aids to Visual Inspection (to BS EN 970):
 magnifying lens (if magnification lens used it should have magnification between X2 to

X5)
+ BS 5289:
250
14. When visually inspecting a fillet weld it would normally be sized by:
a. The leg lengths
b. The actual throat thickness
c. The design throat thickness
d. Both A and C (answer )
251
15. A planar defect is:
a. Incomplete fusion defects
b. Slag inclusion
c. Incomplete penetration
d. Both A and C ( answer )
Note: Defects can be grouped under three main classifications:
1. Planar defects: linear from at least one direction
 + Cracks
 + Lack of fusion/ penetration
2. Linear Volumetric defects: linear in length with volume.
 + Slag lines
 + Lack of fusion with associated slag.
 + Piping.
3. Non-planar defects: rounded indications without significant length
 + Slag inclusions
 + Gas pores/ blow holes
 + Other metallic and non-metallic inclusions.
252
The end!

16. Penetrant inspection and magnetic particle inspection are mainly used:
a. To aid visual inspection
b. Because the application says so
c. To confirm visual uncertainties
+ Four basic NDT methods:
 Magnetic particle inspection (MT)

 Dye penetrant inspection (PT)
 Radiographic inspection (RT)
 Ultrasonic inspection (UT)
+ Surface Crack Detection:
 Liquid Penetrant (PT or Dye-Penetrant)

 Magnetic Particle Inspection (MT or MPI)
17. Defects outside the limits specified in a standard should always be:
a. Repaired
b. Reported to ‘a senior person’ ( ANSWER )
c. Assessed along with other defects
d. All the above
In cases where extensive rectification would be required to meet code requirements,

experience has shown that considerable savings in both cost and time can be obtained if the
significance of the defects present is assessed on a fitness for purpose basis. This involves
calculation of the maximum growth of defects under fatigue loading and the required
toughness levels of weld metal, parent plate and HAZ to avoid brittle fracture during the peak
loadings of a structure. The application of fitness for purpose criteria has in some cases
resulted in some inspection authorities accepting defects that exceed the limits of code
requirements.
253
18. MIG welding tends to be susceptible to lack of fusion problems. This is because of:
a. Poor maintenance of equipment
b. Incorrect settings
c. Poor inter-run cleaning
Note: Most welding imperfections in MIG/MAG are caused by lack of welder skill, or incorrect
settings of the equipment:
 Worn contact tips will cause poor power pick up, or transfer
 Bad power connections will cause a loss of voltage in the arc
 Silica inclusions (in Fe steels) due to poor inter-run cleaning
 Lack of fusion (primarily with dip transfer)
 Porosity (from loss of gas shield on site etc)
 Solidification problems (cracking, centerline pipes, crater pipes) especially on deep
narrow welds
19. MMA electrodes can be grouped into three main types. These are:
a. Basic, cellulosic and rutile ( ANSWER )
b. Neutral, cellulosic and rutile
c. Basic, cellulosic and neutral
Note:
The three main electrode covering types used in MMA welding:
 Cellulosic – deep penetration/fusion

 Rutile – general purpose
 Basic – low hydrogen
20. The main cause of porosity in welded joints is:

a. Poor access
254
b. Loss of gas shield
c. ‘Dirty’ materials
Note:
Causes:
+ Excessive moisture in flux or preparation
+ Contaminated preparation
+ Low welding current
+ Arc length too long
+ Damaged electrode flux
+ Removal of gas shield
21. Cracks in welds may be due to:

a. Solidification problems
b. Hydrogen problems
c. Excessive stresses
Note:
+ Solidification Cracking (hot crack)
+ Hydrogen Induced Cold Cracking
255
22. A weave technique may give rise to:
a. Better profiles
b. Improved toe blending
c. Improved ripple shape
23. With reference to a root penetration bead you would certainly assess:
a. Root fusion and penetration
b. Root concavity
c. Burnthrough
24. In a fatigue failure the appearance of the fracture surface is characteristic. It would be:
a. Rough and torn
b. ‘Chevron’-like
c. Smooth ( answer )
25. Stray arcing may be regarded as a serious defect because:

a. It may reduce the thickness dimension of a component
b. It may cause location cracks
256
c. It may cause hard zones
26. Overlap in welds could be influenced by:

a. Poor welding technique
b. Welding process
c. Welding position
27. Flame cut preparations may, during welding, increase the likelihood of:
a. Cracking
b. Misalignment problems
c. Inclusions
d. All the above (answer)
28. Macroscopic examination requires any specimen to be inspected:

a. Once, after etching
b. Twice, before and after etching ( answer )
c. Using a microscope
29. Which of the following may be classed as a more serious defect:

a. Slag inclusions
b. Fusion defects (inter-run)
c. Fusion defects (surface) ( answer )
d. Porosity
30. A code of practice is:

a. A standard for workmanship only
b. A set of rules for manufacturing a specific product ( answer )
c. Levels of acceptability of a weldment
257
CSWIP 3.1: QUESTION with answer and explanation! part 27
Date: May 30, 2019Author: Thanh ( QC ) Nguyen Le0 Comments

1 – If a steel has a Ceq % of 0.48%, then what?
i) It will probably require a pre-heat temperature above 100°C prior to welding (answer)
ii) It will probably require a pre-heat temperature above 300°C prior to welding
iii) PWHT would always be necessary
iv) The heat affected zone will be very tough
 C-Mn, medium carbon, low alloy steels (CE 0.4 to 0.5): Thin sections can be welded
without preheat but thicker sections will require low preheat levels and low hydrogen
processes or electrodes should be used.
258
2 – What is the cause of the presence of centerline porosity when welding a double V butt
joint with SAW process?
i) Contaminated joint preparation (answer)

ii) Damp flux
iii) Incorrect stick out lengths
iv) All the Above
Common causes of porosity are:
1. Contamination of joint surfaces with oil, paint, grease, hydrated oxides, etc. These
decompose in the arc to give gaseous products which can cause elongated ‘wormhole’
porosity often located along the centreline of the weld.
2. Damp flux: flux should be kept dry. It is good practice to dry all fluxes before use and
store them in a heated hopper. The manufacturer’s recommendations regarding drying
temperatures should be observed. Note that if a flux recovery unit, driven by compressed
air, is used the compressed air should be dried thoroughly.
3. Insufficient flux burden can expose the arc and molten weld pool to atmospheric
contamination.
https://www.twi-global.com/technical-knowledge/faqs/faq-what-are-the-common-causes-of-
porosity-in-sa-submerged-arc-welds
3 – Which one of the following applies, when considering the advantages of site RT over UT?
i) A permanent record produced, good for detecting all surface and sub-surface defects and
assessing the through thickness depths of defects
ii) A permanent record produced, defect identification not so reliant on operator skill
( answer )
iii) A permanent record produced, good for detecting defects which do not have significant
depth in relation to axis of the X-ray beam and defect identification
iv) No controlled areas required on site, a permanent record produced and good for assessing
the extent of pipe wall thickness reductions due to internal corrosion
259
Note: good for detecting defects which do not have significant depth in relation to axis of the X-
ray beam: it means is planar defect!
4 – When AC only is required for welding, the power supply unit is almost always:
i) A rectifier, alternator and a means to change the current

ii) A transformer or alternator and a means to change the current
iii) A transformer, inverter and a means to change the current (answer )
iv) A transformer, rectifier and a means to change the current
 Transformer: AC-AC ( thay đổi điện áp – biến áp )

 Inverter: máy biến tần ( thay đổi tần số của AC hoặc là biến 1 chiều thành xoay chiều )
 Rectifier: AC-DC ( bộ chỉnh lưu )
 Alternator: máy phát điện xoay chiều
welding are transformers (which transform mains AC-AC suitable for welding), transformer-
rectifiers (which rectify AC-DC), diesel or petrol driven generators (preferred for site work) or
inverters (a more recent addition to welding power sources).
260

5 – The HAZ associated with a fusion weld on steel has up to how many separate regions of
micro structure?
i) 1
ii) 2
iii) 4 ( answer )
iv) 6
It has total 4 zones. The fusion boundary is too small. So, it is not a zone!
END!
Document refer:
+ TWI
261

1 – What are the possible effects of having a travel speed too fast?
i) High hardness, excessive deposition and cold laps

ii) High hardness, slag inclusions and a narrow thin weld bead (answer)
iii) Low toughness, poor fusion and slag inclusions
iv) Low toughness, slag inclusions and undercut
Note: Travel speed too fast–> heat input (HI) reduce –>fast cooling–> hardness increase / slag
inclusion / narrow thin weld bead!
262
2 – When calibrating welding equipment for mechanized MAG welding, what are the five
parameters that would be checked?
i) Amps / volts, WFS, gas flow rate, polarity and travel speed (answer)
ii) Amps / volts, WFS, wire diameter, polarity and travel speed
iii) Electrode stick out, WFS, amps / volts, polarity and wire diameter
iv) Joint set up, flux coating, polarity, travel speed and amps/volts
Note: question ask about Welding for equipment, the Wire diameter doesn’t belong to welding
plan!
3 – Which one of the following statements is correct when using a flat characteristic power
source?
i) The electrode extension will have no effect on weld quality

iii) The electrode is always DC –ve
iii) The wire feed speed remains constant (answer)
iv) The shielding is always pure argon
Note: electrode extension high effect to weld quality. Flat / CV characteristic has use DCEP such
as MIG/MAG/SAW(<1000A). Except Ar, it has some other shielding gas as: CO2, He…
4 – When varying the arc length which one of the following will vary the most?
i) Amperage
ii) Polarity
263
iii) Voltage ( answer )
iv) None of the above
Note: arc length = arc gap = arc voltage
5 – Which one of the following statements is correct?
i) Electrode dc +ve is used when welding with the MIG / MAG welding process
ii) The core wire in an MMA electrode has a higher melting point than the flux
iii) The HAZ of a carbon manganese steel weld usually has a lower ultimate tensile strength than
the weld
iv) All the above are true ( answer )
Note:
+ MIG/MAG: use dcep: ok
+ Flux has melting lower than core wire, burn first to protect weld pool!
+ In HAZ: It has 4 zones with difference properties.
264
END!
Document refer:
+ TWI

1 – A multi run MMA butt weld made on C/Mn steel consists of 5 passes using 6mm
electrodes. What will have a 12-pass weld made on the same joint using 4mm electrodes on
the same material?
i) Have a higher amount of distortion and a lower degree of grain refinement

ii) Have a lower amount of distortion and a higher degree of grain refinement
iii) Have a lower heat input and a coarser grain structure
iv) Have a lower heat input and a higher degree of grain refinement ( answer )
265
Note: more pass / layer with smaller electrode lead to: lower HI (heat input), higher distortion,
higher degree of grain refinement!
2 – What is the main reason for using a back purge when welding 18-8 stainless steel with the
TIG welding process?
i) Prevent the formation of a dense oxide layer on the root (answer)

ii) Control the root penetration
iii) Improve positional welding
iv) Prevent root bead porosity
Note: easy question: backing gas to avoid:
It is necessary to protect the back of the weld from excessive oxidation during TIG welding,
achieved by using a purge gas, usually pure argon. For pipe welding spools it is relatively easy to
purge the pipe bore, but for plate/sheet welding it is necessary to use a purge channel or
sometimes another operator positions and moves a back purge nozzle as the weld progresses.
For purging large systems soluble dams or bungs are required and can it can be a complex
operation.
3 – What does a typical minimum preheat temperature for an MMA weld made on steel with
a carbon content of 0.23% and manganese content of 1.3%?
i) Above 280°c
ii) A minimum of 100°c ( answer )
iii) Less than 50°c
iv) Preheat would not normally be required
Note: this is C-Mn steel ( has Mn up to 1.6% ):
Types of weldable C, C-Mn and low alloy steels:

+ Carbon steels:
 Carbon contents up to about ~ 0.25%.
 Manganese up to ~ 0.8%.
 Low strength and moderate toughness.
+ Carbon-manganese steels:
266
 Manganese up to ~ 1.6%.
 Carbon steels with improved toughness due to additions of manganese.
C-Mn, medium carbon, low alloy steels (CE 0.4 to 0.5):

 Thin sections can be welded without preheat but thicker sections will require low preheat
levels and low hydrogen processes or electrodes should be used.
4 – Often, which is the hardest part of a multi run weld made using MMA?
i) The Cap
ii) The HAZ of the cap ( answer )
iii) The HAZ of the root
iv) The Root
267
5 – The HAZ of fusion weld:
i) Cannot be avoided ( answer )

ii) Is usually martensite
iii) Usually has the highest tensile strength
iv) All the above
Note:
+ can not be avoid: correct
+ highest tensile strength is not total correct (see part 28 – question 5)
+ usually martensite: same above (see part 28 – question 5)
268
In case: iv – change to: i & iii are correct. We will choose iv!
END!
Document refer:
+ TWI

1 – Which of the following welding processes would you expect to use a collet?
i) MIG/MAG
ii) MMA
iii) TIG/TAG ( answer )
iv) All the above
269
2 – Which of the following may be used for the TIG / TAG welding of austenitic stainless
steel?
i) Cerium electrode DC –ve ( answer )

ii) Lathanum electrode DC –ve
iii) Thorium electrode DC –ve
iv) Zirconium electrode AC
Note: cerium & thorium are ok with austenitic SS but Thorium has slight radiation. So, Thorium
is not good!
3 – Name the standard which is entitled electrode wire and fluxes for submerged arc welding
process of carbon steel and medium tensile steel.
i) BS 2901
ii) BS 639
270
iii) BS 4165 ( answer )
iv) BS 2633
4 – Name the process which uses SAME a constant characteristic?
i) MIG / MAG, Sub-arc > 1000 amps, Electro slag

ii) Sub-arc < 1000 amps, MIG / MAG, Electro slag ( answer )
iii) Sub-arc < 1000 amps, MMA, Electro slag
iv) TIG / TAG, Sub-arc > 1000 amps, Electro slag
5 – What are the possible results of having a too lower heat input?
271
i) A reduction in toughness, hydrogen entrapment and an increase in hardness
ii) An increase in hardness, lower yield strength and lack of fusion
iii) Entrapped hydrogen, a reduction in carbon content and lack of fusion
iv) Entrapped hydrogen, an increase in hardness and lack of fusion ( ANSWER )
End!
Document refer:
+ TWI
Date: June 1, 2019Author: Thanh ( QC ) Nguyen Le0 Comments

1 – For making filler rod what kind of steel is used?
272
i) Carbon steel
ii) Killed steel
iii) Rimming steel ( answer )
iv) None of All
Welding consumables for MMA consist of a core wire typically 350-450mm length and 2.5-6mm
diameter but other lengths and diameters are available. The core wire is generally of low
quality rimming steel as the weld can be considered a casting so can be refined by the addition
of cleaning or refining agents in the extruded flux coating. This coating contains many elements
and compounds which have a variety of jobs during welding. Silicon is mainly added as a de-
oxidising agent (in the form of ferro-silicon), which removes oxygen from the weld metal by
forming the oxide silica. Manganese additions of up to 1.6% will improve the strength and
toughness of steel.
2 – Name the NDT method that is not suitable to detect sub surface defect?
i) PT ( answer )
ii) MPI
iii) RT
iv) UT
3 – What will the SAW in single pass weld give?
i) Burn Rapidly
ii) Good Penetration ( maybe )
iii) Poor Profile
iv) None of the above
Note: if ask high deposited or high dilution is easier!
4 – In SAW process if voltage and current is increased and travel speed is decreased, what will
be the effect in the profile?
i) Concave weld surface

ii) Higher weld reinforcement
iii) Wider weld ( answer )
273
Note: Vol & Amper increase & travel speed reduce –> HI increase
+ High heat input process allow a larger root face, less weld metal required, less distortions,
higher productivity
+ High heat input process allow a larger root face, less weld metal required, less distortions,
higher productivity ( cause of Over lap )
5 – What change will occur on the HAZ during heating of metal caused by welding?
i) Change in grain crystal structure

ii) Change in hardness
iii) Change in tensile strength
iv) All the Above ( answer )
Note:
+ High heat input – slow cooling:

 Low toughness (grain growth).
 Reduction in yield strength.
+ Low heat input – fast cooling:
 Increased hardness.
 Hydrogen entrapment.
 Lack of fusion.
+ https://www.twi-global.com/technical-knowledge/faqs/faq-what-is-the-relationship-
between-hardness-microstructure-and-toughness-in-steel-heat-affected-zones
+ https://www.twi-global.com/technical-knowledge/faqs/what-is-the-heat-affected-zone
6 – What types of electrodes that need extra treatment?
i) Cellulosic
ii) Basic (answer)
iii) Rutile
iv) None of All
274
7 – During welding while applying preheat, carbon manganese steel is normally done to avoid
what?
i) Lack of side wall fusion

ii) Porosity
iii) Slag inclusions
iv) Hydrogen cracking ( answer )
Note: Standards such as BS EN 1011: Recommendations for welding of metallic materials for
guidance on selection of preheat temperature ranges based on CEV, material thickness, arc
energy/heat input and the lowest level of diffusible hydrogen required.
8 – If the heat per unit length of weld is excessively high, which of the following mechanical
properties of a weld in carbon manganese steel is not affected?
i) Elongation ( answer )
ii) Toughness
iii) Hardness
iv) Tensile strength
9 – You observe centerline cracking in a weld that has been made at one of five work station
each making similar components. What is the first action to take?
275
i) Report the occurrence to a higher authority ( answer )
ii) Call for full NDT checks
iii) Impound all welding consumables
iv) Stop all welding
10 – What are the defects that are unlikely to be found by visual inspection?
i) Linear misalignment
ii) Linear Slag inclusions ( answer )
iii) Overlap
iv) Undercut
Note: slag inclusion will be found by RT
+ https://www.twi-global.com/technical-knowledge/job-knowledge/defects-imperfections-in-
welds-slag-inclusions-043
11 – Name the welding process that uses a resistive heating system to achieve weld metal
deposition?
i) Electro slag welding (ANSWER)

ii) MMA
iii) Resistance spot welding
iv) SAW
Electroslag welding (ESW) is a highly productive, single pass welding process for thick (greater

than 25 mm up to about 300 mm) materials in a vertical or close to vertical position. (ESW) is
similar to electrogas welding, but the main difference is the arc starts in a different location. An
electric arc is initially struck by wire that is fed into the desired weld location and then flux is
added. Additional flux is added until the molten slag, reaching the tip of the electrode,
extinguishes the arc. The wire is then continually fed through a consumable guide tube (can
oscillate if desired) into the surfaces of the metal workpieces and the filler metal are then
melted using the electrical resistance of the molten slag to cause coalescence.
+ https://en.wikipedia.org/wiki/Electroslag_welding
276
12 – What are two functions in arc welding that must be in equilibrium to enable a stable arc
to be established?
i) Current
ii) Arc Voltage ( ANSWER )
iii) Metal burn off rate
iv) Wire/Electrode feed rate
Note: arc voltage / arc length / arc gap
13 – What parameter is used to control the penetration into the base material in MMA
welding?
i) Iron powder in the coating

ii) Voltage
iii) Current ( answer )
iv) Welding speed
Current (amperage):
The flow of electrons through the circuit is the welding current measured in amperes (I).
Amperage controls burn-off rate and depth of penetration. Welding current level is determined
by the size of electrode and manufacturers recommend the normal operating range and
current.
+ Amperage too low:
Poor fusion or penetration, irregular weld bead shape, slag inclusion unstable arc, arc stumble,
porosity and potential arc strikes.
+Amperage too high:
Excessive penetration, burn-through, undercut, spatter, porosity, deep craters, electrode
damage due to overheating, high deposition making positional welding difficult.
14 – WHICH OF THE FOLLOWING CONTROL THE PROFILE OF THE ROOT BEAD IN THE
WELDING OF A BUTT JOINT MADE FROM ONE SIDE?
i) Bevel Angle
ii) Root Face
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iii) Root Gap ( answer )
iv) None of the Above
15 – WHAT TYPE OF POWER SOURCE CHARACTERISTIC IS REQUIRED FOR MANUAL

WELDING?
i) Drooping Characteristic ( answer )

ii) Constant Voltage
iii) Flat Characteristic
iv) Motor Generator
Note: MMA: Droop = CV
16 – Name the destructive test that would indicate the toughness of weld metal and parent
metal – HAZ?
i) Charpy vee notch ( ANSWER )

ii) Hardness
iii) Macro
iv) Nick Break
17 – Degreasing components are essential for quality welding, but some agents may:
i) Give off phosgene gas

ii) Cause corrosion problems
iii) Leave residues
iv) All the above ( answer )
18 – Name the chemical element that has the greater effect on the hardenability of a steel
plate?
i) Carbon ( answer )
ii) Chromium
iii) Molybdenum
iv) Titanium
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+ https://www.sciencedirect.com/topics/engineering/hardenability
19 – In MIG CO2 welding, which parameters give the greatest control of weld appearance
during dip transfer or short-circuiting welding?
i) Amperage
ii) Inductance ( answer )
iii) Wire Feed Speed
iv) Wire Stick out Length
20 – In MMA welding, the slag produced can be varied to suit the welding position. Which
type of slag would be required for welding in the HV position?
i) Fluid
ii) Semi fluid
iii) Viscous ( answer )
iv) None of All
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21 – The weld metal deposit of MMA electrodes, achieves its mechanical strength through
which of the following?
i) Iron powders with the flux coating

ii) The core wire
iii) The flux coating ( answer )
iv) None of All
280
22 – What is the constituent that needed in coating of an electrode to prevent the formation
of porosity in welding of a rimming steel?
i) Calcium fluoride
ii) Calcium carbonate
iii) Iron powders
iv) Silicon ( answer )
Note: see above question!
23 – Which one of the following properties shows a reduction when welds are made with
high heat inputs?
i) Ductility
ii) Fatigue strength
iii) Mechanical strength
iv) Toughness ( answer )
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24 – In X-ray, by which one of the following the quality of radiographic negative is assessed?
i) KVA available
ii) Density of the film
iii) Stand – off distance
iv) IQI Indicator ( answer )
282
25 – A steel described as QT will have improved tensile properties because it has which of the
following?
i) Been heat treated

ii) Been quality tested
iii) Been vacuum melted
iv) Had control of chemical composition
CHECK ANSWER
26 – Name the steels that would give rise to the formation of porosity when autogenously
welded with an arc process?
i) Fine grained steel

ii) Fully killed steel
iii) Semi killed steel
iv) Rimming steel ( answer )
283
27 – What would result the use of excessively high voltage in SAW welding?
i) Excessive flux melting ( answer )

ii) Insufficient flux melting
iii) Slag removal difficulties
iv) Spatter
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28 – The use of cellulosic electrodes is often made when welding the root pass of pipes in the
field. This is because of what?
i) Shorter arc length can be achieved

ii) H2 control is needed
iii) Higher arc voltage can be obtained ( answer )
iv) Iron powders in the electrode
285
29 – In the welding of austenitic stainless steels, the electrode and the plate material can be
purchased with low carbon contents. The reason for this is to prevent of what?
i) Cracking in the HAZ

ii) Cracking in the weld metal
iii) Distortion
iv) The formation of chromium carbides ( answer )
End!
Document refer:
+ TWI
CSWIP 3.0 / 3.1 / 3.2 , WELDING FIELD
286
CSWIP 3.1: What is OCV ( Open
Circuit Voltage ) in welding
power source?
In this topic we will talk about OCV in welding power source. We need to solve some question to clear this topic:
 What is OCV?
 Types of static characteristic of power source?
 How to identify?
 How to know which welding process use what type of it ( CC or CV )?
 …
1) What is it?
Open circuit voltage (or potential) is voltage which is not connected to any load in a circuit.
As you can see, open circuit voltage is disconnected and does not form a complete circuit. This is why it is called
open. It is open and not connected to a form a complete electrical path.
The highest voltage is the open circuit voltage of the power source.
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2) Types of static characteristic of power source:
Static characteristic of a welding source shows the trend of variation in voltage with current when power source is
connected to a load. This variation may be of three types:
 constant current (CC)
 constant voltage (CV)
 rising voltage (RV): will be discussed later.

a) Constant current / Amperage characteristic ( called CC ):
It is easy to understand it when add the arc length curve.
288
The volt ampere output curves for constant current power source are called ‘drooper’. With a change in arc voltage,
the variation in welding current is small and, therefore, with a consumable electrode welding process, electrode
melting rate remains fairly constant even with a minor change in arc length.
These power sources are required for processes that use relatively thicker consumable electrodes which may
sometimes get stuck to work pieces or with non-consumable tungsten electrode where touching of electrode with
base metal for starting of arc may lead to damage of electrode if current is unlimited. Under these conditions, the
short circuiting current shall be limited which would provide safety to power source and the electrode.
In constant current power source, variation in welding current with arc voltage (due to fluctuations in arc length) is
very small therefore welding current remains more or less constant despite of fluctuations in arc voltage / length.
Hence, this type of power source is also found suitable for all those welding processes where large fluctuation in
arc length is likely to take place e.g., MMA and TIG welding ( importance note )!!!
b) Constant Voltage characteristic ( called CV ):
289
In CV power sources, a small variation in arc voltage (due to fluctuations in arc length) causes significant change in
welding current. Since arc voltage remains almost constant during welding despite of fluctuations in arc length
therefore this type of power source is called constant voltage type.
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Moreover, the constant voltage power sources do not offer true constant voltage output as current voltage
relationship curve shows slightly downward or negative slope. This negative slope is attributed to internal electrical
resistance and inductance in the welding circuit that causes a minor droop in the output volt-ampere characteristics
of the power source.
This type of power sources is found more suitable for all those welding processes where fluctuation in arc length
during welding is limited like in semiautomatic welding process MIG, SAW, PAW.
This feature gives us what is known as a “self-adjusting arc” where changes in arc length, voltage and current are
automatically returned to the required values, producing stable welding conditions. This makes the welder’s task
somewhat easier when compared with MMA or TIG welding. Although in principle it may be possible to use a
constant voltage characteristic power source for MMA welding it is far more difficult for the welder to judge burn-
off rate than arc length so arc instability results and the method is not practicable in MMA welding & GTAW also.
3) How to identify?
Setting up of correct open circuit voltage is important for stability of welding arc especially when AC is used.
The selection of an optimum value of OCV (50-100V) depends on the type of base metal, composition of electrode
coating, type of welding current and polarity, type of welding process etc.
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Base metal of low ionization potential (indicating ease of emitting free of electrons) needs lower OCV than that
of high ionization potential metal. Presence of low ionization potential elements such as K, Na and Ca in electrode
coating/flux in optimum amount reduces OCV setting required for welding.
AC welding needs higher OCV compared with DC owing to problem of arc stability as in case of AC welding
current continuously changes its direction and magnitude while in case DC it remains constant.
In the same, GTAW needs lower OCV than GMAW and other welding processes like SMAW and SAW because
GTAW uses tungsten electrode which has good free electron emitting capability by thermal and field emission
mechanism. Abundance of free electron in GTAW under welding conditions lowers the OCV needed for having
stable welding arc.
Too high OCV may cause electric shock. OCV is generally found to be different from arc voltage. Arc voltage is
potential difference between the electrode tip and work piece surface when there is flow of current. Any fluctuation
in arc length affects the resistance to flow of current through plasma and hence arc voltage is also affected.
Increase in arc length or electrode extension increases the arc voltage. Further, electrical resistance heating of
electrode increases with electrode extension for given welding parameters.
4) Summary:
Below table is Welding process comparisons about electrical characteristic:
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We can divide 2 group of welding process for easy identify what electrical characteristic is used:
 Group 1: is for welding process where fluctuation in arc length during welding is limited like in

semiautomatic welding process MIG, MAG, FCAW, SAW, PAW –> it needs CV.
 Group 2: is for welding process where large fluctuation in arc length is likely to take place e.g., MMA
and TIG, SAW welding…—> it needs CC.
MMA, TIG and submerged arc power sources are therefore designed with what is known as a drooping output or
constant current static characteristic, MIG/MAG and FCAW power sources with a flat or constant voltage static
characteristic.
Finished!!!
Different types of steel!

Date: June 14, 2018Author: Thanh ( QC ) Nguyen Le0 Comments
293
According to the American Iron and Steel Institute (AISI), steel can be broadly categorized into four groups based
on their chemical compositions:
1. Carbon Steels
2. Alloy Steels
3. Stainless Steels
4. Tool Steels
1) Carbon steels:
Plain Carbon Steels:
 Low Carbon Steel 0.01 – 0.3% Carbon
 Medium Carbon Steel 0.3 – 0.6% Carbon
 High Carbon Steel 0.6 – 1.4% Carbon

Plain carbon steels contain only Iron & Carbon as main alloying elements, but traces of Mn, Si, Al, S & P may also
be present.
Note:
Carbon Steels:
 Carbon contents up to about ~ 0.25%
 Low strength and moderate toughness

Carbon-Manganese Steels
 Carbon steels with improved toughness due to additions of Manganese

2) Alloy Steels:
 Low Alloy Steels <7% alloying elements
 High Alloy Steels >7% alloying elements
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Alloy Steels are considered the type of steels that predominantly contain extra alloying elements other than Iron &
Carbon
3) Stainless steel:
Stainless steels generally contain between 10-20% chromium as the main alloying element and are valued for high
corrosion resistance. With over 11% chromium, steel is about 200 times more resistant to corrosion than mild steel.
These steels can be divided into 5 groups based on their crystalline structure:
 1 & 2: Ferritic and martensitic alloys
 3: Austenitic stainless steels
 4. Duplex stainless steel
 5. Precipitation-hardened materials
4) Tool steel:
Tool steels contain tungsten, molybdenum, cobalt and vanadium in varying quantities to increase heat resistance and
durability, making them ideal for cutting and drilling equipment.
Steel products can also be divided by their shapes and related applications:
 Long/Tubular Products include bars and rods, rails, wires, angles, pipes, and shapes and sections.
These products are commonly used in the automotive and construction sectors.
 Flat Products include plates, sheets, coils, and strips. These materials are mainly used in automotive
parts, appliances, packaging, shipbuilding, and construction.
 Other Products include valves, fittings, and flanges and are mainly used as piping materials.
295
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Figure 2: Topside View of Welds 1-5

Figure 3: Electrode Extension and Arc Length Diagram

Figure 5: Topside View of Welds 7-11

Contact To Work Distance

Figure 4: CTWD Variation Diagram

Figure 6: Topside View of Welds 30-34

CSWIP 3.1: Question with Answer and Explanation – Part 21

Date: April 7, 2018Author: Thanh ( QC ) Nguyen Le0 Comments

MMA have 3 type of electrode covering:

+ cellulose ( hydrogen content is 80-90 ml/100 g of weld metal )

+ rutile ( hydrogen content is 25-30 ml/100 g of weld metal )

+ Example AWS electrode flux types:

Note: Function of the Electrode Covering:

 – To facilitate arc ignition and give arc stability

Manganese (Mn): Secondary only to carbon for strength, toughness and ductility,

0.36–0.40 Very good

Over 0.50 Poor

7) One of the following alloys is non-magnetic – which?

In stainless steel group, only Austenitic stainless steel is non-magnetic.

Note: are used to increase weldability, by reducing sudden reduction of temperature, and

There are four basic types of power source:

DC rectifiers and AC/DC transformer-rectifiers are controlled electronically, for example by

Root Gap is very importance for accessibility joint.

15) Which one of the following statements is correct?

CSWIP 3.1: Question with Answer and Explanation – Part 12

Date: October 26, 2017Author: Thanh ( QC ) Nguyen Le1 Comment

a. Ingredients in the flux covering

c. ( answer ) Quality of the welding wires

d. Sources from which wires are drawn

2) A MMA electrode which is classified as an E7024 (according to AWS) is a:

d. ( answer ) Thick coated iron powder

a. ( answer ) 350 N/mm2 yield strength

c. 35 N/mm2 tensile strength

d. 35ksi tensile strength

 With BS EN ISO 2560: it is classified follow yield strength

b. ( answer ) Cellulosic covered

d. Iron powder loaded

b. ( answer ) Cellulosic in a sealed tin

 Cellulosic electrodes: hydrogen content is 80-90 ml/100 g of weld metal.

Cellulose coated electrodes sealed in a tin

Basic coated electrodes when baked correctly

Rutile coated electrodes when dried at 150oC prior

Heavy rutile coated electrodes when dried at 150oC

 Cellulosic electrodes: hydrogen content is 80-90 ml/100 g of weld metal.

They are mass produced which makes these

They require less baking time after removal from the

They are formulated that once open they will pick up

a. ( answer ) MMA weld with cellulosic electrodes

b. MMA weld with rutile electrodes

c. MMA weld with basic electrodes

 Cellulosic electrodes: hydrogen content is 80-90 ml/100 g of weld metal.

a. (answer ) None if they were in a vacuum pack

b. None if they were used in a factory

c. Heat to 500oC for 2 hours if used outside

d. Baked at 150oC for 4 hours prior to use

None if they were in a vacuum pack opened 8 hours

None if they were in a sealed vacuum pack prior to

c. Heat to 500oC for 2 hours if used outside

d. Baked at 150oC for 4 hours prior to use

Date: October 24, 2017Author: Thanh ( QC ) Nguyen Le1 Comment

a = Design throat thickness

s = Depth of Penetration, Throat thickness