1.

Typical temperature used for normalizing a C-Mn steel plate are

A. 600-650°C
B. 1000-1100°C
C. 700-800°C
D. 880-920°C
2. Which of the following is a suitable shielding gas for FCAW of stainless steels?
A. 100% Argon
B. 70% Argon +30% He
C. Argon+5% Hydrogen
D. Argon+20% CO2
3. A suitable gas/gas mixture for GMAW for aluminium is
A. 100% CO2
B. 100% Ar
C. 80% Ar+20% CO2
D. 98% Ar+2% O2
4. A C-Mn steel is being welded by MMA and the electrode run-out lengths that have been used are much shorter
than specified by the WPS. This deviation may give
A. Increased risk of hydrogen cracking
B. Increased risk of solidification cracking
C. Lower values of HAZ toughness
D. Higher values of HAZ toughness
5. Initiation of a TIG arc using high frequency spark may not be allowed because it
A. Often causes tungsten inclusions
B. Can damage electric equipment
C. Is an electrical safety hazard
D. Often causes stop/start porosity.
6. For GMAW the burn-off rate of the wire is directly related to
A. Stick-out length
B. Wire feed speed
C. Arc voltage
D. Travel speed
7. What is the term given for the area of a welded joint outside the weld metal that has undergone microstructural
changes?
A. Heat affected zone
B. The weld zone
C. Fusion zone
D. All the above terms may be used.
8. In an arc welding process which of the following is the correct term for the amount of weld metal deposited per
minute?
A. Filling rate
B. Deposition rate
C. Weld deposition
D. Weld duty cycle
9. What is meant by the term crater pipe:
A. Another term for concave root.
B. Another term given for a burn through.
C. A type of gas pore found in the weld crater.
D. A shrinkage defect found in the weld crater.
10. Under most conditions which of the following welding positions will deposit the most weld metal.
A. PG
B. PE

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 C. PC
D. PA

11. Compound welds:-

A. Always contain butt and fillet welds
B. Joints which have combination of welds made by different welding processes.
C. Combination between two different weld types.
D. All of the above
12. A singular gas filled cavity that is ≥ 1.6mm in diameter is termed
A. Cavity
B. Cluster porosity
C. Blow hole
D. Rounded porosity
13. When hyper-eutectoid steel is quenched at above its upper critical, the predominant structure will be:
A. Austenite
B. Martensite
C. Troostite
D. Sorbite
14. A metal is said to have ____________ when it regains its original shape when stress acting upon it is removed.
A. Ductulity
B. Plasticty
C. Malleability
D. Elasticity
15. Hydrogen is excluded from the weld metal in order to prevent the weld from:
A. Cracking
B. Cooling slowly
C. Cooling quickly
D. Expanding
16. The arc length is most likely to be affected by what during CO 2 welding
A. The wire diameter
B. The current returns connections
C. The gas flow rate
D. The torch to work angle
17. Select the correct statement from the following:
A. Preheating increases hardness
B. Preheating increases cooling
C. Preheating increases dilution
D. Preheating increases shrinkage stress.
18. What does BS 499 specify regarding the drawing dimension quoted for a fillet weld according to UK practice?
A. Leg length
B. Throat thickness
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 C. Weld width
D. Actual throat thickness
19. Which amongst the following is going to result in a more severe effect on the load bearing capacity of a weld?
A. Porosity
B. Cracking in the weld area
C. Undercut for fillet welds
D. Lack of fusion
20. In which welding process is it possible to change from constant voltage to constant current?
A. TIG
B. SAW
C. MAG
D. MMA
21. The most common type of defect found in a structure when it is undergoing service is
A. Weld decay
B. Fatigue cracking
C. Crystallation
D. Stress fracture
22. You have a macro section of a ‘T’ butt joint that shows a step-like defect lying outside the visible HAZ. What
would this defect possible signify?
A. Lamination
B. Toe cracking
C. HAZ cracking
D. Lamellar tearing
23. An Izod impact machine is used to give indication of the --------------of a material.
A. Ductility
B. Tensile strength
C. Hardness
D. Yield strength
24. The tough laminated structure that is formed on slow cooking of ferrite and iron carbide (cementite) is called----
A. Trootsite
B. Martensite
C. Austenite
D. Pearlite
25. Proof stress is used when non-ferrous metals are undergoing tensile tests to determine the equivalent Yield
strength.
26. Which physical test is more likely to reveal HAZ embrittlement?
A. All weld tensile
B. Charpy impact
C. Transverse tensile
D. Root bend
27. Quenching a carbon or low alloy steel will result in an increase in hardness and an increase in ductility.
28. Sulphur and phosphorus are not alloying elements. They are impurities.
29. All things contain imperfections, but is only when they fall outside the level of acceptance they should be
termed
A. Discontinuity
B. Defect
C. Mechanical damage
D. Welding imperfection
30. In considering the shielding gases argon, helium and carbon dioxide. Which of the following is true about
GMAW Process?
A. They can produce spray transfer

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 B. They are all suitable for all position welding
C. They all produce heavy spatter in DC+
31. In GMAW welding, which mode of metal transfer uses high and low current cycles?
A. Spray transfer
B. DIP transfer
C. Globular transfer
D. Pulse transfer
32. For which of the following types of NDT does the term prod related?
A. MPI
B. PT
C. UT
D. RT
33. Which of the following statement is true regarding lamellar tearing?
A. As material gets thicker the resistance to lamellar tearing improves
B. As material gets thicker the ductility improves
C. As material gets thicker the ductility decreases.
D. Thick material don’t suffer from lamellar tearing
34. The similarities between EN ISO 22553 and AWS A2.4 in depicting welding symbols are:
A. Both have the same rule for depicting “Sequence and operation”
B. Both have the same rule for depicting “other side”
C. Both have the same method
D. Both have the same rule for depicting “weld all around”
35. Which test from below measures the material property known as fracture toughness?
A. Nick break test
B. Fillet weld fracture test
C. Hardness
D. CTOD
36. A weld all around symbol is not required
A. Indicating circumferential joint
B. Indicating a nozzle to shell weld
C. Indicating a pipe to pipe butt weld
D. All of the answers indicated
37. When welding medium carbon steel plate over 100mm in thickness would basic electrodes used any pre-
treatment before use?
A. None if they were in a sealed vacuum pack immediately prior to use
B. Heat to use 5000C for 2 hours if use outside.
C. Baked at 1500C for 4 hours prior to use
D. None if they were in a vacuum pack opened 8 hours prior to use.
38. Why essential to clean the surrounding parent metal adjacent to weld metal made by MMA which is to be
ultrasonic testing?
A. Sound wave will not travel through paint
B. Remove any dust
C. Spatter could impact contact of the probe with the parent metal surface.
D. Spatter will reflect the back wall echo signal and give spurious
39. Which if the following will help to reduce distortion?
A. Using the minimum number of runs
B. Welding by a manual method
C. Using the maximum number of runs
D. Using very high heat input
40. Which is the most accurate method of ensuring that the correct preheat is applied
A. Using calibrated digital thermometer

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 B. Measure it with heat sensitive crayon (temple stick)
C. Temperature measuring paint
D. Using heat treatment equipment with thermocouples attached and a chart recorder.
41. In a fillet weld fracture test the specimen is broken with
A. Suitable machining
B. The fillet weld in compression
C. The fillet weld in tension
D. No specific method needs to be adopted
42. During PWHT what is the sequence for PWHT chart?
A. Unrestricted heating rate, restricted heating rate, soak time, restricted cooling rate and unrestricted cooling
rate.
B. Unrestricted heating rate, soak time, restricted cooling rate
C. Restricted heating rate, soak time, unrestricted cooling rate
D. Restricted heating rate, unrestricted heating rate, soak time, unrestricted cooling rate, restricted cooling
rate
43. A standard radiographic film test cannot adequately detect:
A. Lamination in rolled plate adjacent to the weld
B. Slag inclusion in the weld
C. Lack of root penetration in a weld
D. Porosity in the weld volume
44. The melting rate on the wire in the GMAW and FCAW process depend on
A. Current density
B. Ampere per unit length of the wire
C. Voltage per unit length
D. Shielding gas flow rate
45. Thoriated tungsten electrodes have the major disadvantages of
A. It used for thick plates
B. Having lower melting point
C. Being radioactive in nature
D. Being very costly.
46. Charpy impact tests showing a rough torn surface after the completed test would indicate which type of failure?
A. Ductile
B. Brittle:-Flat and featureless
C. Fatigue:-smooth
D. Fatigue to Ductile
47. Which of the following may cause distortion
A. Stress
B. Heating
C. Contraction
D. All if the above can cause distortion
48. For a bend test which of the following is not true?
A. A 4T bend is more severe than 2T bend
B. It reveals defect like lack of fusion and porosity
C. The outer surface if the bend specimen is examined
D. It given indication of the ductility of the welded joint and wed metal
49. Which of the following inspection point is most critical to arc conditions for the spray transfer MAG welding
process?
A. Gas flow rate
B. Electrode coating type
C. Inductance setting
D. All electrical connections and contacts

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50. A transverse tensile test was carried out on a welding procedure. The cross sectional area was 30mm wide and
15mm thick. The maximum load applied was 170KN. What is the ultimate tensile strength value?
A. 300 N/mm2 Maximum load applied
B. 600 N/mm2 UTS= CSA
2
C. 377 KN/mm = 170X1000 = 377 N/mm2
2
D. 377 N/mm 30X15
51. In GMAW process the use of pulsed current usually result in between:
A. Spray and dip transfer
B. Spray and globular transfer
C. Globular transfer and dip transfer
D. None of the answer given are correct
52. When reviewing the WPS during welding the maximum interpass stated is 250°C. What would be the minimum
interpass temperature?
A. The preheat temperature
B. Any temperature above 250°C would be acceptable
C. The welder would decide this.
D. The interpass temperature is never stated on a WPS
53. At what level is the hardness value a problem when trying to minimize the risk of HAZ cracking?
A. 300 to 350 HV
B. 160 to 200 HV
C. 270 to 290 HV
D. 100 to 150 HV
54. Weld decay is caused by the formation of a compound with carbon. The other element in this compound is
A. Chromium
B. Sulphur
C. Nickle
D. Manganese
55. What heat treatment is used to create a high strength but brittle microstructure?
A. Quenching hardening
B. Stress relieving
C. Normalizing
D. Annealing
56. Usually liquid penetrant is applicable at temperature range of approximately?
A. 50 to 60°C
B. 0 to 100°C
57. Hydrogen cracking is considered a cold crack as it will not form until the weldment cool to below
A. 300°C B. 300°F C. 500°C D.660°C
58. In SAW at higher currents or in the case of multiple electrode system, AC is often preferred to:
A. Avoid the problem of dilution
B. Avoid the problem of excess of penetration
C. Avoid the problem of arc blow
D. Avoid the problem of lack of fusion
59. Which of the following defect are the most difficult to size correctly when ultrasonically testing a weld?
A. Clustered porosity
B. Isolated pore>3mm diameter
C. Slag
D. Lack of root penetration
60. A tensile test was 120mm long before testing and after testing the length was 135mm long, which is the
percentage elongation?
A. 12.5% Increase of gauge lengthX100
B. 20% Elongation%= Original gauge length

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 C. 11% = 15X100 = 12.5
D. 15% 120
61. Which of the following are considerations for selection of preheat temperature:
A. Carbon equivalent, joint design, welding process type and plate material quality
B. All joint over 25mm thick, hydrogen levels, welding process, carbon equivalent
C. Arc energy, material thickness, hydrogen scale and carbon equivalent
D. All of the above are considerations for the selection of a preheat temperature
62. Which of the following fillet welds is the strongest assuming they are all made of the same material and welded
using the same WPS.
A. 8mm throat of a mitre fillet
B. 7mm leg+2mm excess weld metal
C. Mitre fillet with 10mm leg
D. Concave fillet with 11mm leg
63. In the martensitic grain structure what would you expect to increase?
A. Ductility
B. Hardness
C. Toughness
D. All of the above
64. Tensile strength can be increased in steel by:
A. Annealing
B. Galvanising
C. Addition of carbon up to 0.83%
D. Casting
65. Which of the following always occurs in the parent material?
A. Hydrogen cracks
B. Laps and laminations
C. Centre line cracks
D. Porosity
66. In BS 639 and BSEN 499 the first digits of the electrode classification indicate:
A. Tensile and yield strength
B. Toughness
C. Electrode coating
D. Electrode efficiency
67. Increasing the arc energy input of a welded joint will:
A. Increase the strength of the joint
B. Increase the toughness of the joint
C. Increase the grain size of the weld and HAZ
D. Decrease the width of the HAZ
68. Which of the following processes would be most prone to lack of fusion defects?
A. Pulsed arc MIG
B. Spray transfer MIG
C. Dip transfer MIG
D. Submerged arc
69. Pre-heating prior to welding:
A. Must always be carried out
B. Need not be carried out if post heat treatment is to follow welding
C. Is always carried out using gas flames
D. All of the above
E. None of the above
70. When a medium to high carbon steel is quenched:
A. It becomes malleable
B. Its hardness increases
C. It becomes ductile

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 D. The plasticity is increased
71. One of the advantages of a multi-pass MMA weld is that it generally produces a:
A. High tensile strength
B. High degree of ductility
C. Coarse grain structure
D. Fine grain structure
72. Stress can be measured in:
A. N/mm2
B. Psi
C. mm
D. both a & b
73. What is the ratio between the leg length and the design throat thickness on a miter fillet weld with equal leg
lengths
A. 1 to1
B. 2 to 1
C.  1.414 to 1
D.  All of the above
74. Stress acting in the opposite direction of compressive stress is known as:
A. Tensile stress
B. Shear stress
C. Hoop stress
D. All of the above
75. Fillet welds are:
A. Preferable to butt welds due to high strength
B. Difficult to assess with NDT in comparison with butt (groove) welds
C. Used only for appearance purposes
D. All of the above
76. Which one of the following statements is correct?
A. Preheating increases dilution
B. Preheating increases cooling
C. Both 1 & 2
D. Neither 1 & 2
77. 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
D. Number of runs used
78. Submerged arc welds made with re-cycled flux are liable to:
A. Porosity
B. Underfill and spatters
C. Incomplete fusion
D. All of the above
79. 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 1 and 3
80. Gamma rays and X-rays are part of a family of waves called:
A. Acoustic waves
B. Light waves
C. Electromagnetic waves
D. Transverse waves
81. A surface breaking crack will be detected during a magnetic particle inspection if it is:
A. At right angles to the lines of flux
B. Parallel to the lines of flux

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 C. At 25° to the lines of flux
D. All the above
82. 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. Magnetic Particle using DC
D. Magnetic Particle using AC
83. For MPI using the prods method, which of the true:
A. It may cause arc damage on the specimen material surface.
B. It requires fewer operators therefore is easier
C. It can be used with ferritic and non-ferritic material.
D. It is quicker than using a yoke type electromagnet
84. Which of the following commonly used isotopes has the longest half life?
A. Iridium 192
B. Cobalt 60
C. Thulium 170
D. Ytterbium 169
85. What determines the penetrating power of gamma ray?
The type of isotope (the wavelength of the gamma rays)
A. Iridium 192- from 10 to 50mm (mostly used)
B. Cobalt 60 >50mm
C. Ytterbium <10mm
D. Thulium <10mm
E. Caesium <10mm
86. Radiographic techniques:
A. Single wall single image (SWSI):- Film inside & source outside
B. Single wall single image (SWSI) Panoramic:- Film outside & source inside (Internal exposure)
C. Double wall single image (DWSI):- Film outside & source outside (external exposure or multiple exposure)
D. Double wall double image (DWDI):- Film outside source outside (elliptical Exposure)
87. Double wall single image:-
A. IQI’s placed on the film side
B. This technique is intended for pipe diameter over 100mm.
C. The 10% NDT to be follow as per ITP ( inspection and test plan)
88. 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 Ductile fracture
B. Ductile to brittle Brittle feacture
C. Ductile with gross yielding
D. Fatigue to Ductile
89. To weld a carbon steel which electrode will give the greatest deposition rate in SMAW?
A. 2% Hydrogen
B. Cellulosic
C. Iron powder (Low-hydrogen electrodes have about 30% iron powder in the coating and this is why they
have a higher deposition rate.)
D. Rutile
90. A root bend test is used to test the amount of weld:
A. Ductility
B. Degree of freedom
C. Hardness
D. Crack orientation
91. The most common type of failure associated with sharp fillets, notches and undercut is
A. Cree
B. Fatigue
C. Corrosion

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 D. Sudden bend
92. Submerged arc welding is a process that generally gives:
A. Slag free welds
B. Low penetration
C. Low dilution
D. High heat input
93. When steel is heated to above its upper critical temperature, the structure produced is:
A. Martensite
B. Austenite
C. Pearlite
D. Ferrite
94. Toughness test-The notch may be machined either in the weld metal, fusion zone or HAZ depending on which
area/zone is to be evaluated during the test.
95. Manganese of up to 1.6% positive effect on improving the toughness of plain ferritic steels at cryogenic
temperatures. Nickel also has a very positive effect on low temperature toughness of steels, however nickel is a
very expensive metallic element and is only used where low temperatures are severe. Steels containing 5 to 9%
nickel have excellent low temperature toughness with fully austenitic stainless steels having measurable
toughness down to -270°C. A fine grain structure will increase the toughness values of a steel. Welding fluxes
containing high amounts of basic compounds will give much higher toughness values.
96. MMA covered electrode:- E 46 3 1Ni B 54 H5
Compulsory: - E 46 3 1Ni B
Optional: - 54 H5
97. Dip transfer can be used in all positions.
98. The predominant structure of an hyper-eutectoid steel that has been quenched at above its upper critical point
will be
A. Austenite
B. Martensite
C. Troosite
D. Sorbite

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