Welding Bits

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1. Pinch effect in welding is the result of?

(A). Electromagnetic forces
(B). Electrostatic forces
(C). Magnetic forces
(D). Electric forces
Answer: a
Explanation: Pinch effect in welding gives narrow and long flame which
is concentrated on the desired part and is achieved by an induction coil,
which results in electromagnetic forces.
2. The junction between weld face and base metal is known as?
(A). Throat
(B). Toe
(C). Root
(D). Puddle
Answer: b
Explanation: The junction of the weld face and the base metal is known
as ‘toe’. For a better weld, the junction should be as small as it can be in
size.
3. The junction between two workpieces and weld face is known as?
(A). Throat
(B). Toe
(C). Root
(D). Puddle
Answer: a
Explanation: The throat of a weld is the distance from the centre of the
face to the root of the weld. Typically, the depth of the throat should
be at least as thick as the thickness of the metal we are welding.
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4. The portion at which two workpieces are at the nearest distance is
called?
(A). Throat
(B). Toe
(C). Root
(D). Puddle
Answer: c
Explanation: The weld root is the point at which the back of a weld
intersects with the base metal surfaces. It determines the weld
penetration and fusion to form a rigid joint.
5. The portion of weld joint that is melted by the heat of melting is

called as ______________
(A). throat
(B). toe
(C). root
(D). puddle
Answer: d
Explanation: The arc spot or “puddle” weld is started by striking an arc
on the deck surface, causing a hole to form in the deck. The weld
operation then continues by depositing electrode material on the beam
or joist and allowing the molten “puddle” to engage the penetrated
deck.
6. Small weld used to temporarily hold the two pieces is called as

______________
(A). crater
(B). base metal
(C). tack weld
(D). penetration
Answer: c

Explanation: Tack welds are essentially temporary welds that help to
hold two metals in place. The main purpose of the tack weld is to hold
the two pieces of metal in place while we apply the actual, final weld.
7. What is the function of a torch?

(A). It controls fuel rate
(B). It mixes fuel and oxygen and controls delivery
(C). It controls oxygen rate
(D). It mixes fuel and hydrogen
Answer: b
Explanation: Torch mixes fuel and oxygen and controls delivery. It has
two control valves, one for controlling the flow of acetylene and the
other of oxygen, entering a chamber called mixing chamber where the
two gases are mixed in a correct proportion.
8. The depth up to which, the filler material is mixed up with base metal
is called?
(A). Deposition
(B). Reinforcement
(C). Penetration
(D). Fusion depth
Answer: c
Explanation: The depth up to which the filler material is mixed up with
base metal is called as penetration. Penetration can be increased by
increasing temperature and appropriate flux.
9. Weld pass is associated with the movement of __________

(A). torch
(B). metal
(C). flux
(D). electrode
Answer: a

Explanation: A single progression of welding or surfacing along a joint
or substrate. The result of a pass is a weld bead.
10. The raised potion from the parent metal in welding is known as
__________
(A). deposition
(B). fusion depth
(C). penetration
(D). reinforcement
Answer: d
Explanation: Weld metal in excess of the quantity required to fill a joint.
This can be machined for a good surface finish.
1. Which of the following process involves metallurgical fusion?

(A). Forming
(B). Welding
(C). Forging
(D). Extrusion
Answer: b
Explanation: Welding joins metals by melting and fusing them together,
typically with the addition of a welding filler metal.
2. In welding, two parts are joined by bringing them to a temperature

of?
(A). Above melting point temperature
(B). Below melting point temperature
(C). Equal to melting point temperature
(D). Equal to Curie temperature
Answer: a

Explanation: In welding one needs to melt the base metals to fuse
them.
3. In welding the strength of the joint piece could be?

(A). Equal to that of parent metal
(B). Greater than that of parent metal
(C). Equal or Greater than that of parent metal
(D). Is lesser than the parent metal
Answer: c
Explanation: The strength of perfectly welded joint is more than the
parent metal, due to the formation of alloy. The alloy formation at the
welded portion makes it the strongest portion while the nearby zones
where uncontrolled cooling take place because of heat is the weakest
zone (heat affected zone). In general we can say that on the basis of
strength: welded portion > parent material > heat affected zone.
4. Which of the following is a type of welding joint?

(A). Tee joint
(B). Lap joint
(C). Corner joint
(D). All of the Mentioned
Answer: d
Explanation:Different types of welding joints are depicted below:
5. The oil substances are removed from the interface by using which of
the following organic solvent?
(A). Acetone
(B). Carbon tetrachloride
(C). Acetone & Carbon tetrachloride
(D). Ethylene glycol
Answer: c
Explanation: Both acetone and carbon tetrachloride are used to remove
the oil substances from the interface.
6. Which of the following does not require fluxes to eliminate the

oxides present in them?
(A). Mild steel
(B). Copper
(C). Aluminium
(D). Magnesium
Answer: a
Explanation: Mild steel does not require flux to eliminate the oxides,
due to the fact that iron oxide has relatively low melting point when
compared to other non-ferrous metals given.
7. The heavier oxide films are removed by using?

(A). Basic flux
(B). Emery
(C). Organic solvents
(D). Neutral flux
Answer: b
Explanation: Oxide films should be removed before welding. Heavier
oxide films may be removed by acid pickling, emery or by wire brusing.
8. In which of the following welding process no filler material is added

during joining?
(A). Autogenous
(B). Homogenous
(C). Heterogenous
(D). Either homogenous or heterogenous
Answer: a
Explanation: In autogenous welding process no filler material is added
during joining, the filler material can be supplied by melting the base
metal.
9. Which of the following is a type of autogenous welding?

(A). Arc
(B). Gas
(C). Brazing
(D). Resistance
Answer: d
Explanation: Resistance welding is inherently autogenous as there is no
convenient way to apply a filler material.
10. In which of the following joining process, the filler material used is
the same as the parent material?
(A). Autogenous
(B). Homogenous
(C). Heterogenous
Answer: b
Explanation: In homogenous joining process the filler material used is
the same as the parent material.
11. In which of the following joining process the filler material used is
different as the parent material?
(A). Autogenous
(B). Homogenous
(C). Heterogenous
Answer: c
Explanation: In heterogenous joining process the filler material used is
different as the parent material.
12. Which of the following is a type of homogenous welding?

(A). Gas
(B). Solid phase
(C). Brazing
(D). Resistance
Answer: a
Explanation: Gas metal arc welding (GMAW), manual metal arc welding
(MMAW), flux cored arc welding (FCAW), etc. always use consumable
filler material and thus can be performed in homogenous mode.
13. Which of the following is a type of heterogeneous welding?

(A). Gas
(B). Solid phase
(C). Arc
(D). Soldering
Answer: d
Explanation: Certain welding processes such as plasma arc welding,
friction stir welding, laser beam welding, etc. can be performed in
heterogenous mode.
14. When two insoluble materials such as iron and silver are supposed
to join, which of the following joining process is used?
(A). Autogenous
(B). Homogenous
(C). Heterogenous
Answer: c
Explanation: When two insoluble materials such as iron and silver are
joined then heterogenous joining process is used.
15. For joining two insoluble materials such as iron and silver which of
the following filler material is used?
(A). Cobalt
(B). Tin
(C). Aluminium
(D). Zinc
Answer: b

Explanation: Tin is used for joining two insoluble materials such as iron
and silver because it is soluble in both the parent material (i.e. silver
and iron).
1. Which of the following is also called “gas welding”?

(A). Oxy fuel gas welding
(B). Metallic welding
(C). Arc welding
(D). Fuel gas welding
Answer: a
Explanation: Gas welding is also known as oxy fuel gas welding. In gas
welding, fuel gases are used to generate high amount of heat and melt
the metal.
2. How many types of flames are there in welding?

(A). 1
(B). 2
(C). 3
(D). 4
Answer: c
Explanation: There are three basic flame types: neutral (balanced),
excess acetylene (carburizing), and excess oxygen (oxidizing) as shown
below.
3. In which of the following type of flame, oxygen is of same proportion

with acetylene?
(A). Neutral flame
(B). Oxidizing flame
(C). Carburizing flame
(D). Both oxidizing flame and carburizing flame
Answer: a
Explanation: In neutral flame oxygen is in the same proportion with
acetylene. Neutral welding flames are commonly used to weld: mild
steel, stainless steel, cast iron, copper, aluminium, etc.
4. In which of the following type of flame, oxygen is in excess

proportion with acetylene?
(A). Neutral flame
Answer: b
Explanation: Oxidizing welding flames are produced when slightly more
than one volume of oxygen is mixed with one volume of acetylene.
Oxidizing welding flames are commonly used to weld zinc, copper,
manganese steel, cast iron, etc.
5. In which of the following type of flame, oxygen is deficient in

proportion with acetylene?
(A). Neutral flame
Answer: c
Explanation: The carburizing flame has excess acetylene then oxygen.
Reducing flame is used for the welding of low carbon and alloy steel.
6. Which of the following flame is harmful to steel?

(A). Neutral flame
Answer: b
Explanation: Oxidizing flame is harmful to steel. An oxidizing flame
should not be used for welding steel because the deposited metal will
be porous, oxidized and brittle. This flame will ruin most metals and
should be avoided.
7. For brazing, soldering and flame hardening which of the following

flame is used?
(A). Neutral flame
Answer: c
Explanation: For brazing, soldering and flame hardening carburizing
flame is used.
8. The inner cone of the flame in welding has the following nature?
(A). Highest temperature
(B). Coldest temperature
(C). Moderate temperature
(D). Uncertain
Answer: a
Explanation: The inner cone of the flame has the highest temperature
(3500°C). The outer flame has the lowest temperature.
9. The oxy acetylene gas welding is a type of?

(A). Endothermic reaction
(B). Exothermic reaction
(C). Neutral reaction
(D). Both endothermic reaction and exothermic reaction
Answer: b
Explanation: The oxy acetylene gas welding is a type of exothermic
reaction. 1 mole of acetylene can produce KJ/mol of heat.

10. The chemical formula of acetylene is?
(A). C2H4
(B). C2H6
(C). C2H5OH
(D). C2H2
Answer: d
Explanation: The chemical formula of acetylene is C2H2. 1 mole of
acetylene can produce KJ/mol of heat.
1. Amount of time during which the transformer will be used for

welding under normal loading condition is known as?
(A). Hold time
(B). Off time
(C). Weld time
(D). Duty cycle
Answer: d
Explanation: Amount of time during which the transformer will be used
for welding under normal loading condition is known as the duty cycle.
2. Amount of voltage required to generate the arc under no load

condition is called?
(A). Open circuit voltage
(B). Closed circuit voltage
(C). Short circuit voltage
(D). Arc voltage
Answer: a
Explanation: Amount of current required to generate the arc under no
load condition is called short circuit current (SCC).

3. Amount of current required to generate the arc under no load
condition is called?
(A). Open circuit current
(B). Closed circuit current
(C). Short circuit current
(D). Arc current
Answer: c
Explanation: Amount of current required to generate the arc under no
load condition is called short circuit current. It is represented by SCC.
4. If the open circuit voltage is 60 volt and the short circuit current is 20
amperes. Then determine the voltage required for welding if the
current required during welding is 10 amperes?
(A). 30 V
(B). 60 V
(C). 20 V
(D). 40 V
Answer: a
Explanation: Voltage = OCV – (\\(\\frac{I}{SCC}\\))×OCV, where “OCV” is
open circuit voltage, “SCC” is short circuit voltage and “I” represents
the current in amperes.
5. How does the arc voltage V depends upon the length of arc L?
(A). V = f(L)
(B). V = 1/f(L)
(C). V = f(L2)
(D). V = f(√L)
Answer: a
Explanation: V= A+BL, where ‘V’ is the arc voltage and ‘L’ is the length
of arc in cm, A & B are constants.
6. What is the function of flux in submerged arc welding?

(A). To completely cover the welded zone
(B). To prevent oxidation of joint
(C). To prevent spattering of molten metal
(D). To prevent sticking of molten metal
Answer: d
Explanation: Flux is used to completely cover the welded zone. It
prevents oxidation of weld joint and spattering of molten metal.
7. In which of the following gas welding process a non-consumable

electrode is used?
(A). Submerged arc welding
(B). Tungsten inert gas welding
(C). Stud welding
(D). Gas metal arc welding
Answer: b
Explanation: In tungsten inert gas welding process a non-consumable
electrode is used, which is made of tungsten.
8. What is the only difference between Plasma arc welding and TIG
welding?
(A). Flux is not used
(B). Construction of torch is different
(C). Gas is not used
(D). Tungsten electrode is not used
Answer: b
Explanation: Construction of the torch is the only difference between
Plasma arc welding and TIG welding. Both the TIG and PAW are uses
tungsten electrodes.
9. In plasma arc welding the gas is?

(A). Ionized
(B). Heated
(C). Magnetized
(D). Vaporized
Answer: a
Explanation: In plasma arc welding the gas is ionized. Electrode used is
made of tungsten and filler metal is used addition to it.
10. If the heat transfer efficiency is 0.5 and the melting efficiency is 0.6,
then the overall efficiency will be?
(A). 0.83
(B). 0.03
(C). 0.30
(D). 0.12
Answer: c
Explanation: ηtotal = ηmelting * ηheat transfer, where η denotes
efficiency. There are two types of efficiencies, one is melting efficiency
and another is heat transfer efficiency.
11. The deflection of the arc in arc blow is by?

(A). Electric field
(B). Magnetic field
(C). Combination of both
(D). Hydrostatic field
Answer: b
Explanation: The deflection of the arc in arc blow is by a magnetic field.
Electric field, hydrostatic field does not affect the deflection of the arc.
12. If the total efficiency is 0.35 in arc welding. Then what is the welding
speed in mm/sec if the cross-sectional area is 5mm2, welding power is
2 kW and the heat required in melting the metal is 100 J/mm3.
(A). 1.4
(B). 14
(C). 1400
(D). 140
Answer: a

Explanation: N = (P×total efficiency)/(Q×A), where P represents power,
q represents heat transfer, and A represents the cross-sectional area.
13. Which of the following gas welding process uses constant voltage?
(A). Submerged arc welding
(B). Tungsten inert gas welding
(C). Stud welding
(D). Gas metal arc welding
Answer: d
Explanation: Gas metal arc welding uses constant voltage. Tungsten
inert gas welding does not use constant circuit voltage.
14. Which of the following inert gas is used with DC power supply only?
(A). Argon
(B). Helium
(C). CO2
(D). Nitrogen
Answer: c
Explanation: Co2 is used only in DC power supply. It cannot be used in
AC power supply. Argon and helium can be used with AC supply.
15. In order to prevent oxidation and retain molten metal in stud

welding which of the following is used?
(A). Ceramic rings
(B). Metal rings
(C). Non-metal rings
(D). Flux
Answer: a
Explanation: In order to prevent oxidation and retain molten metal in
stud welding ceramic rings are used.

1. Which of the following is not true about fusion welding?

(A). It depends upon the characteristics of heat source.
(B). It depends upon the nature of deposition of the filler material
(C). It does not depend upon the heat flow characteristics in the joint
(D). It depends upon the gas metal or slag metal reaction
Answer: c
Explanation: Fusion welding depends upon the heat flow characteristics
in the joint. The quantity of heat required to melt a given volume of
metal depends on: (1) The heat to raise the temperature of the solid
metal to its melting point, (2) The melting point of the metal, (3) The
heat to transform the metal from solid to liquid phase at the melting
point.
2. Which of the following is not used to produce heat during welding?

(A). Electric arc
(B). Chemical flame
(C). Electrical resistance
(D). Acetone flame
Answer: d
Explanation: For welding heating, different kinds of energy are
converted into heat, typically, electrical, beam, chemical and
mechanical energy and also their combinations.
3. In which of the following welding process heat and pressure is

applied on the joint but no filler material or flux is added?
(A). Arc welding
(B). Resistance welding
(C). Gas welding
(D). Thermite welding (i) Resistance of electrode
Answer: b

Explanation: Resistance welding is the method to joint two plain metal
work pieces together by running an electrical current through them. No
filler metal and no flux are needed in this type.
4. Total resistance in welding is composed of:

(A). i
(B). ii, iii and iv
(C). ii and iv
(D). I, ii, iii and iv
Answer: d
Explanation: Total resistance is the equivalent resistance of all
resistances present in the welding circuit during the process of welding.
5. If 20 amperes of current is flowing in a wire for 1 minute of time

having a resistance of 1000 ohm. Then the amount of heat generated in
resistance welding will be (in kilo joules)?
(A). 24000
(B). 240000
(C). 24000000
(D). 2400
Answer: a
Explanation: Heat produced = I2RT, where ‘I’ is the current, ‘R’ is
resistance and ‘T’ is the time in seconds. For the given problem, heat
produced = (202)×(1000)×(1×60)
6. Which of the following is true about electrodes?

(A). Low electrical conductivity and low mechanical strength
(B). Low electrical conductivity and high mechanical strength
(C). High electrical conductivity and low mechanical strength
(D). High electrical conductivity and high mechanical strength
Answer: d
Explanation: To get maximum efficiency, electrodes should have high
electrical conductivity and high mechanical strength.
7. Which of the following is true about resistance welding?

(A). Electrodes of higher resistivity is used for lower resistive piece
(B). Electrodes of higher resistivity is used for higher resistive piece
(C). Electrodes of lower resistivity is used for lower resistive piece
(D). Electrodes of lower resistivity is used for higher resistive piece
Answer: a
Explanation: To get high efficiency, electrodes of higher resistivity is
used for lower resistive piece.
8. According to the joules law?

(A). The poor conductor heats up to a higher degree than a good
conductor
(B). The poor conductor heats up to a lower degree than a good
conductor
(C). The poor conductor heats up to equal degree than a good
conductor
(D). Joules law does not relate to heat
Answer: a
Explanation: Joules law relate power with voltage and current as:
Power (P) = Voltage (V) × Current (I). It conveys that poor conductor
heats up to a higher degree than a good conductor.
9. Which of the following electrode has very high electrical conductivity

but low strength?
(A). Copper chromium alloys
(B). Copper cobalt alloys
(C). Copper beryllium alloys
(D). Copper cadmium alloys
Answer: d
Explanation: Copper cadmium alloys have very high electrical
conductivity but low strength. They produce very less heat during the
current flow.
10. Which of the following electrode has low electrical conductivity but
high strength?
(A). Copper chromium alloys
(B). Copper cobalt alloys
(C). Copper beryllium alloys
(D). Copper cadmium alloys
Answer: a
Explanation: Copper chromium alloys electrode has low electrical
conductivity but higher strength. They generate more heat during the
current flow.
1. Which one of the following is the simplest type of resistance welding

used in making lap welds?
(A). Resistance spot
(B). Resistance seam
(C). Projection
(D). Upset
Answer: a
Explanation: The simplest form of the process is spot welding for lap
welds, where the pressure is provided by clamping two or more
overlapping sheets between two electrodes. Up to a thickness of 12.7
mm we can go for it.
2. The time required for electrodes to align and clamp the work piece
together under them is known as?
(A). Hold time
(B). Off time
(C). Squeeze time
(D). Weld time
Answer: c
Explanation: Squeeze time is the time interval between the initial
application of the electrode force on the work and first application of
current. Squeeze time is necessary to delay the weld current until the
electrode force has attained the desired level.
3. Time of current flow through the work piece till they are heated to
require temperature is known as?
(A). Hold time
(B). Off time
(C). Squeeze time
(D). Weld time
Answer: d
Explanation: Weld time is the time during which welding current is
applied to the metal sheets. The weld time is measured and adjusted in
cycles in cycles of line voltage as are all timing functions.
4. Time, when pressure is maintained on the molten metal without

electric current, is known as?
(A). Hold time
(B). Off time
(C). Squeeze time
(D). Weld time
Answer: a
Explanation: Hold time is the period programmed into the weld
controller, typically between the end of weld time and the command to
open the electrode.
5. The time after which the pressure is released, and metal piece is
removed for next cycle is known as?
(A). Hold time
(B). Off time
(C). Squeeze time
(D). Weld time
Answer: b
Explanation: Off time is the time after which the pressure is released,
and metal piece is removed for next cycle. It begins automatically after
hold time./
6. The spot formed between the interface of work piece, when strong
current and pressure is applied is known as?
(A). Joint
(B). Nugget
(C). Core
(D). Tee
Answer: b
Explanation: The spot formed between the interface of work piece
when strong current and pressure is applied is known as a nugget. It
may be of any shape.
7. In which of the following welding process disc electrodes are used

instead of the cylindrical electrode?
(C). Projection
(D). Upset
Answer: b
Explanation: In resistance seam welding disc electrodes are used
instead of the cylindrical electrode. Disc are rotated for the welding
operation.
8. In which of the following operation embossing is required before

welding?
(C). Projection
(D). Upset
Answer: c
Explanation: In projection, welding embossing is required before
welding. It is non-productive time used in preparation of welding.
9. In which of the following welding operation the pieces are joined by

butt joint?
(C). Projection
(D). Upset
Answer: d
Explanation: Upset welding or resistance butt welding is a welding
technique that produces coalescence simultaneously over the entire
area of abutting surfaces or progressively along a joint, by the heat
obtained from resistance to electric current through the area where
those surfaces are in contact.
10. In which of the following operation it is possible to weld more than

one spot at a given time?
(C). Projection
(D). Upset
Answer: c
Explanation: The advantage of projection welding include flexibility, as
the welder can weld more than one spot at a time. Additionally, the
welder can position welded spots more closely to each other than is
possible with spot welding.

1. Which of the following defects occur due to flux employed and
electrode coating?
(A). Inclusion of slag
(B). Inadequate penetration
(C). Incomplete fusion
(D). Porosity
Answer: a
Explanation: Slag inclusions are one of the main weld defects. If we
don’t properly clean the slag from a bead, we run the risk of it
becoming part of the weld when we run the next bead. A good welder
will generally burn it out on the next pass, but if not, there will be a
chunk of slag in the bead which leaves a weak spot. Slag inclusions.
2. Which of the following defects occur when the deposited metal is

not focused on the root of weld?
(D). Porosity
Answer: b
Explanation: Inadequate penetration defects occur when the deposited
metal is not focused at the root of weld. Some part of gap remains
unwelded due to this defect.
3. Which of the following defects occur when weld metal layer fails to
fuse together?
(D). Porosity
Answer: c
Explanation: Incomplete fusion defects occur when weld metal layer
fails to fuse together. It causes discontinuity in weld zone.
4. Which of the following defects occur due to the entrapment of gas

bubbles by the freezing dendrites during the cooling of molten pad?
(D). Porosity
Answer: d
Explanation: Referred to as worm holes, these are gas pockets trapped
in the weld. A couple of reasons would be from not enough shielding
gas in MIG, or moisture in the flux.
5. Which of the following defects occur due to filler material having a

different rate of contraction compared to parent metal?
(A). Undercut
(B). Spatter
(C). Cracking in weld metal
(D). Cold cracking
Answer: c
Explanation: Weld cracking occurs close to the time of fabrication. Most
forms of cracking result from the shrinkage strains that occur as the
weld metal cools. It can be of hot cracks types.
6. Which of the following defects occur due to melting or burning away

of base metal?
(A). Undercut
(B). Spatter
(D). Cold cracking
Answer: a
Explanation: Undercut is the cardinal sin of welding grasshopper!
Cutting into the steel with the force of the arc leaves a cut out groove
in the weld. If this is not filled back in with filler metal, it leaves a weld
defect which is a weak point that can cause the joint to fail. This can
cause property damage, injury and even loss of life.
7. Which of the following defects occur due to scattering of metal

around the vicinity of weld?
(A). Undercut
(B). Spatter
(D). Cold cracking
Answer: b
Explanation: Spatters are the droplets of molten material during GAS
welding or arc welding. A temperature difference and slag
accumulation are the reason of spatter formation. Welding speed is
also one of the main causes of spatter. Type of material used and type
of welding also decide to spatter density.
8. Which of the following defects occur due to incorrect welding

techniques?
(A). Undercut
(B). Hot cracking
(D). Cold cracking
Answer: c
Explanation: Cracking in weld metal defect occur due to incorrect
welding techniques. Sometimes cracking may not be visible by naked
eyes.
9. Which of the following defect is influenced by sulphur and carbon

content of weld metals?
(A). Undercut
(B). Hot cracking
(D). Cold cracking
Answer: b
Explanation: Hot cracks are those that occur at elevated temperatures
and are usually solidification related. It is being influenced by sulphur
and carbon content of weld metals. Sometimes cracking may not be
visible by naked eyes.
10. Which of the following defects occur at a lower temperature?

(A). Undercut
(B). Hot cracking
(D). Cold cracking
Answer: d
Explanation: Cold cracks are those that occur after the weld metal has
cooled to room temperature and may be hydrogen related. These
occurs are lower temperature. Sometimes cracking may not be visible
by naked eyes.
1. Consider a situation in which a welding operation is being performed

with V = 20 volts, I = 200 A, and the cross-sectional area of the weld
bead is 30 mm2. Estimate the welding speed if the workpiece and
electrode are made of (a) aluminum, (b) carbon steel, and (c) titanium.
Use an efficiency of 75%.
(A). 35 mm/s
(B). 34.5 mm/s
(C). 36 mm/s
(D). 46 mm/s
Answer: b
Explanation: For aluminum, the specific energy required is u = 2.9
J/mm3

2. Upon which of the following parameters does the current intensity in
arc welding depend?
(A). Stability of arc
(B). Electrode diameter
(C). Gap between the electrode and parent metals
(D). Thickness of parent metals i) Strength of the deposited weld metal
Answer: b
Explanation: Electrodes for consumable arc-welding processes are
classified according to the following properties:
3. In which of the following welding processes we use two non-

consumable electrodes?
(A). MIG
(B). TIG
(C). Atomic hydrogen
(D). Submerged arc
Answer: c
Explanation: Non consumable electrodes are the ones that are not
consumed during the process of welding. GTAW (Gas Tungsten Arc
Welding)/TIG (Tungsten Inert Gas Welding), AHW (Atomic Hydrogen
Welding), CAW (Carbon Arc Welding) processes use non-consumable
electrodes.
4. Which of the following brazing process is good for mass scale joining?
(A). Furnace
(B). Induction
(C). Dip
(D). Torch
Answer: a
Explanation: Furnace brazing is a semi-automatic used widely in
industries and are best suited to large scale production operations.

5. For grey cast iron, which of the following welding methods is
preferable?
(A). MIG
(B). Submerged arc
(C). Gas flame
(D). Electric arc
Answer: a
Explanation: As the percentage of carbon in grey cast iron is less,
therefore MIG welding is preferable.
6. Due to which of the following reasons, flux is not used in atomic

hydrogen welding?
(A). The burning hydrogen shields the molten metal
(B). Two electrodes are coated which gradually release the flux
(C). The filler rod is coated with flux
(D). One of the two electrodes is coated which releases the flux
Answer: a
Explanation: Separate flux/ shielding gas is not required in atomic
hydrogen welding. The hydrogen envelop itself prevents oxidation of
the metal and the tungsten electrode.
7. In resistance welding, between the electrodes, the nature of current

and voltage parameters being used?
(A). high current, high voltage
(B). low current, high voltage
(C). low current, low voltage
(D). high current, low voltage
Answer: d
Explanation: High current produces more heat. When we use a low
voltage power source, it allows a welder to have some reasonable over
the small lighting bolts we use to fuse metal together.

8. Which of the following welding process in which heat is produced for
welding by a chemical reaction?
(A). Resisting welding
(B). Thermit welding
(C). Forge welding
(D). Gas welding
Answer: b
Explanation: The thermite process is a chemical reaction in which a
metal oxide (preferably molten) is displaced by another molten metal
which is more reactive than the metal in the metal oxide, releasing a lot
of heat. Example:
9. The maximum diameter of electrodes being used in submerged arc

welding?
(A). 30 mm
(B). 20 mm
(C). 15 mm
(D). 10 mm
Answer: d
Explanation: A consumable electrode can be used by the submerged arc
welding which is a loop of bare round wire with 1.5 mm to 10 mm
diameter. It can be fed routinely throughout the welding gun, and the
submerged arc welding electrode composition depends on the welded
material.
10. In arc welding, arc is created between the electrode and work by?
(A). Contact resistance
(B). Flow of voltage
(C). Flow of current
(D). Electrical energy
Answer: d
Explanation: All arc welding utilizes the transfer of electrical energy to
heat energy. An arc is a sustained electric discharge through this
ionised gas column called plasma between the two electrodes. In order
to produce the arc, the potential difference between the two
electrodes (voltage) should be enough to allow them to move across
the air gap. The larger air gap requires higher potential differences. If
the air gap becomes too large for the voltage, the arc may be
extinguished.
11. The coating material used for the electrode is termed as?
(A). Flux
(B). Slag
(C). Protective layer
(D). Deoxidiser
Answer: a
Explanation: Flux is a substance used to prevent the formation of oxides
and the other unwanted contaminations, or to dissolve them and
facilitate removal. During welding the flux melts and becomes a liquid
slag, covering the operation and protecting the molten weld metal the
slag hardens upon cooling and must be removed later by chipping or
brushing.
12. Which of the following welding process in which two pieces to be

joined are overlapped and placed between two pointed electrodes?
(A). Seam welding
(C). Projection welding
(D). Spot welding
Answer: d
Explanation: Spot welding is the simplest and most used resistance
welding process. Welding may be performed by means of single (most
common) or multiple pairs of electrodes (as many as a hundred or
more), and the required pressure is supplied through mechanical or
pneumatic means.

13. Which of the following gases are used in Tungsten inert gas
welding?
(A). Helium and neon
(B). Hydrogen and oxygen
(C). Argon and helium
(D). Carbon dioxide and hydrogen
Answer: c
Explanation: In the TIG welding process the arc is formed between a
pointed tungsten electrode and the workpiece in an inert atmosphere
of argon or helium.
14. Which of the following materials necessitates preheating in

welding?
(A). Copper
(B). Aluminium
(C). Cast iron
(D). Stainless steel
Answer: c
Explanation: As the weldability of cast iron usually decreases as the
amount of free carbon in cast iron increases, so it is preheated to a dull
red and then welded.
15. The temperature, in arc welding, is of the order of?

(A). 30000°C
(B). 55000°C
(C). 20000°C
(D). 70000°C
Answer: c
Explanation: One of the main functions of the arc is to produce heat.
The heat of the arc melts the surface of the base metal and the end of
the electrode. The electric arc has a temperature that ranges from 3000
to 20,000°C.

1. Which of the following is used to generate Acetylene gas?

(A). Calcium
(B). Carbon
(C). Calcium carbonate
(D). Calcium carbide
Answer: d
Explanation: Acetylene is a hydrocarbon consisting of two carbon atoms
and two hydrogen atoms. The simplest process reacts calcium carbide
with water to produce acetylene gas and a calcium carbonate slurry,
called hydrated lime. The chemical reaction may be written as CaC2 +
2H2O → C2H2 + Ca (OH)2.
2. Striking voltage as compared to a voltage during arc welding is?

(A). less
(B). same
(C). more
(D). can’t say
Answer: c
Explanation: The minimum voltage enough to arc across a given gap is
called as the striking voltage. It is more than the arc voltage in arc
welding.
3. How many zones are there in a carburising flame?

(A). one
(B). two
(C). three
(D). four
Answer: c
Explanation: If the oxygen is insufficient for full combustion, the flame
is known as a reducing, or carburizing, flame. The temperature of a
reducing flame is lower; hence, such a flame is suitable for applications
requiring low heat, such as brazing, soldering, and flame-hardening
operations.
4. Due to which of the following reasons distortion in welding occurs?

(A). Oxidation of weld pool
(B). Use of high voltage
(C). Improper clamping
(D). Use of high current
Answer: c
Explanation: As if the clamping is improper the weld will not be at the
right place.
5. In reverse polarity welding _____________

(A). work piece is connected as negative, and holder is earthed
(B). electrode holder is connected to negative and work piece to
positive
(C). electrode holder is connected to positive and work piece to
negative
(D). both electrode holder and work piece are connected to negative
Answer: c
Explanation: In direct current reverse polarity (DCRP) or direct current
electrode positive (DCEP), when base metals relate to the negative
terminal of the power source and electrode relates to the positive
terminal.
6. Where does maximum flame temperature occur?

(A). Next to inner cone
(B). At the inner cone
(C). At the tip of the flame
(D). At the outer cone
Answer: b

Explanation: Maximum flame temperature occur at inner cone. As
flame moves from inner to outer temperature drop takes places.
7. In which of the following welding processes, electrode gets

consumed?
(A). TIG welding
(C). Thermit welding
(D). Arc welding
Answer: d
Explanation: As in arc welding, welding is totally dependent on
electrode, so it will be consumed.
8. Which of the following statements about welding is incorrect?

(A). Increased corrosion resistance
(B). Even materials like stainless steel and aluminium can be welded
(C). No flux required
(D). High welding speed
Answer: c
Explanation: Flux is mainly used for the following purposes: (a) It
prevents the oxidation o the surface of the weld which can contaminate
the welded potion, (b) It helps in forming alloy at the welded portion
which improves the strength, (c) In arc welding the flux coating helps in
directing the spark that’s why the electrode is kept concave in shape so
that spark can be precisely directed towards the cavity where welding
has to be performed.
9. Where is half corner weld used?

(A). where efficiency of the joint should be 50 percent
(B). where longitudinal shear is present
(C). where severe loading is encountered, and the upper surfaces of
both pieces must be in the same plane
(D). For welding materials heavier than 12 gauge
Answer: d
Explanation: The half-open corner joint is used for welding materials
heavier than 12 gauge.
10. Which of the following percentage of carbon in steel is most

weldable?
(A). 0.15
(B). 0.25
(C). 0.35
(D). 0.8
Answer: a
Explanation: Low carbon steel is typically the most readily welded steel
in a room temperature environment.
11. In which of the following metals does the phenomenon of ‘weld

decay’ occurs?
(A). stainless steel
(B). cast iron
(C). carbon steel
(D). bronze
Answer: a
Explanation: Weld decay is a form of intergranular corrosion, usually of
stainless steels or certain nickel-base alloys, that occurs as the result of
sensitization in the heat-affected zone during the welding operation.
12. On which of the following principles does the ‘positive pressure

type torch’ work?
(A). equal volume
(B). positive pressure
(C). equal pressure
(D). equal flow
Answer: c

Explanation: There are two types of welding and cutting torches
commonly used. They are the positive-pressure type (also known as an
equal pressure type or medium type pressure type torch), and the
injector type.
13. Why is post cleaning necessary at brazed joint?

(A). to avoid corrosion
(B). to avoid slagging
(C). to avoid oxidation
(D). to avoid scaling
Answer: a
Explanation: Depending on the brazing process, we may need to
perform post-braze joint cleaning to remove residual flux. This step is
crucial for several reasons; including the corrosive nature of most fluxes
and the possibility that excess flux could contribute to joint failure. The
most common cleaning methods involve water-specifically
soaking/wetting and quenching.
14. While welding, which of the following material welding, neutral

flame is not used?
(A). cast iron
(B). steel
(C). copper
(D). zinc
Answer: d
Explanation: The neutral flame has a one-to-one ratio of acetylene and
oxygen. A neutral flame is named neutral since in most cases will have
no chemical effect on the metal being welded. Neutral welding flames
are commonly used to weld: mild steel, stainless steel, cast iron,
copper, aluminium, etc.
15. Which of the following statements about “projection welding” is

correct?
(A). It is multi spot welding process
(B). It is an arc welding process
(C). It is a continuous spot-welding process
(D). It is a process used for joining round bars
Answer: a
Explanation: Projection welding is a modification of spot welding in
which the weld is localized by means of raised sections, or projections,
on one or both workpieces to be joined. This is high-production
process, and multiple projection welds can be arranged by suitable
designing and jigging.
1. In which welding process the electric energy required for welding is

stored in the capacitor?
(A). Percussion welding
(B). Explosion welding
(C). Diffusion welding
(D). Thermit welding
Answer: a
Explanation: In percussion welding, two pieces are welded by a high
intensity short duration arc followed by very rapid or percussive
impacting of the workpieces. There are three different methods of arc
initiation in percussion welding viz., low voltage with drawn arc, high
voltage breakdown, and ionising by a fusing tip. With each method, the
energy source is a bank of capacitors which is charged by a variable
voltage transformer cum rectifier unit.
2. In which welding process pressure is applied by detonating a layer of

explosive?
(A). Percussion welding
(B). Explosion welding
(C). Diffusion welding
(D). Thermit welding
Answer: b
Explanation: In explosion welding, a compression force created by
detonation of explosives is used to join overlapping metal sheets. The
joining parts are arranged toward each other at an angle of 1-15°,
depending on the material and method, and are prepared with a layer
of explosive on the top.
3. In which welding the surfaces of two components are subjected to

static normal force and oscillating shear stress?
(A). Diffusion welding
(C). Laser beam welding
(D). Ultrasonic welding
Answer: d
Explanation: In ultrasonic welding (USW), the faying surfaces of the two
members are subjected to a static normal force and oscillating shearing
(tangential) stresses. The shearing stresses are applied by the tip of a
transducer similar to that used for ultrasonic machining.
4. In which welding the strength of the weld results due to diffusion

and plastic deformation of the flying surface?
Answer: a
Explanation: In diffusion welding, the bond strength is achieved by
pressure, temperature, time of contact, and cleanness of the surfaces.
The strength of the bond is primarily due to diffusion rather than any
plastic deformation.

5. In Thermit welding the heat generated is due to the mixing of?
(A). Aluminum and copper
(B). Aluminum and iron
(C). Aluminum oxide and iron
(D). Aluminum and iron oxide
Answer: d
Explanation: Thermite welding is a welding process in which the
workpiece is joined with the help of molten metal by means of an
exothermic reaction. Thermite mixture consists of a metal oxide
(usually iron oxide) and aluminum powder. The major application of
thermite welding is to weld railway tracks. It is also used to weld heavy
machinery.
6. Which of the following welding is also known as arc and gas welding?
(A). Electro slag welding
(B). Atomic hydrogen welding
Answer: b
Explanation: Atomic hydrogen welding, also known as AHW, is an arc
welding technique that uses an arc which is located between two
tungsten electrodes and a hydrogen shielding gas.
7. Which of the following welding is used for welding vertical section in

one pass?
(A). Electro slag welding
(B). Atomic hydrogen welding
(D). Electro gas welding
Answer: d
Explanation: Electro gas welding (EGW) is an vertical positioned arc
welding process, is used for welding the edges of sections vertically and
in one pass with the pieces placed edge to edge (butt joint).
8. Electron beam welding is carried in?

(A). Inert atmosphere
(B). Partially filled chamber
(C). Vacuum
(D). Partially vacuum
Answer: c
Explanation: In electron beam welding process, electrons are emitted
from the heated filament called electrode. This is done under vacuum
conditions to prevent dissipation of the electron beam.
9. Which of the following welding process the weld joint is obtained by

means of filler material and not by melting?
(C). Electroslag welding
(D). Brazing
Answer: d
Explanation: A brazed joint is made in a completely different manner
from welded joint. The big difference is in temperature-brazing does
not melt the base metals. This means that brazing temperatures are
invariably lower than the melting points of the base metals. It joins
base metals by creating a metallurgical bond between the filler metal
and the surfaces of the two metals being joined. The principle by which
the filler metal is drawn through the joint to create this bond is capillary
action.
10. Which of the following statements is not true?

(A). Brazing occurs at a temperature above 450°C
(B). Soldering occurs at a temperature below 450°C
(C). Epoxy resins are used to join metals, ceramics etc
(D). Epoxy resins are not used to join metals, ceramics etc
Answer: d

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1. Pinch effect in welding is the result of?

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5. The portion of weld joint that is melted by the heat of melting is

6. Small weld used to temporarily hold the two pieces is called as

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7. What is the function of a torch?

9. Weld pass is associated with the movement of __________

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1. Which of the following process involves metallurgical fusion?

2. In welding, two parts are joined by bringing them to a temperature

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3. In welding the strength of the joint piece could be?

4. Which of the following is a type of welding joint?

6. Which of the following does not require fluxes to eliminate the

7. The heavier oxide films are removed by using?

8. In which of the following welding process no filler material is added

9. Which of the following is a type of autogenous welding?

12. Which of the following is a type of homogenous welding?

13. Which of the following is a type of heterogeneous welding?

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1. Which of the following is also called “gas welding”?

2. How many types of flames are there in welding?

3. In which of the following type of flame, oxygen is of same proportion

4. In which of the following type of flame, oxygen is in excess

5. In which of the following type of flame, oxygen is deficient in

6. Which of the following flame is harmful to steel?

7. For brazing, soldering and flame hardening which of the following

9. The oxy acetylene gas welding is a type of?

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1. Amount of time during which the transformer will be used for

2. Amount of voltage required to generate the arc under no load

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6. What is the function of flux in submerged arc welding?

7. In which of the following gas welding process a non-consumable

9. In plasma arc welding the gas is?

11. The deflection of the arc in arc blow is by?

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15. In order to prevent oxidation and retain molten metal in stud

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1. Which of the following is not true about fusion welding?

2. Which of the following is not used to produce heat during welding?

3. In which of the following welding process heat and pressure is

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4. Total resistance in welding is composed of:

5. If 20 amperes of current is flowing in a wire for 1 minute of time

6. Which of the following is true about electrodes?

7. Which of the following is true about resistance welding?

8. According to the joules law?

9. Which of the following electrode has very high electrical conductivity

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1. Which one of the following is the simplest type of resistance welding

4. Time, when pressure is maintained on the molten metal without

7. In which of the following welding process disc electrodes are used

8. In which of the following operation embossing is required before

9. In which of the following welding operation the pieces are joined by

10. In which of the following operation it is possible to weld more than

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